AWS Welding Journal September 2012

PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
September 2012

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3 WELDING JOURNAL
CONTENTS
26 Good Design Plus Early Inspection Equals High Productivity
There is an inspection method that puts weld quality
determination at the start of the fabricating process, and
not at the end, when it is too late
J. Noruk and J.-P. Boillot
32 Choosing a Surface Coating Technology
Two surfacing technologies, high-velocity oxyfuel spray and
laser cladding, are compared
T. Peters and T. Glynn
36 Phased Array Testing of Resistance Spot Welds
Inspection technology takes on the challenge of determining
spot weld integrity in advanced high-strength steels
J. K. Na
41 Thermal Spray Wins as a Green Technology
Restoring parts to like-new condition with thermal spray
conserves materials and energy that would be used to
produce a brand-new component
R. S. Brunhouse, P. Foy, and D. R. Moody
46 The Welding Journal: Digitized and Ready to Travel
There are more ways to enjoy reading the Welding Journal
now
C. Guzman
Welding Journal (ISSN 0043-2296) is published
monthly by the American Welding Society for
$120.00 per year in the United States and posses-
sions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and
$10.00 per single issue for nonmembers and
$14.00 single issue for international. American
Welding Society is located at 8669 Doral Blvd.,
Doral, FL 33166; telephone (305) 443-9353. Peri-
odicals postage paid in Miami, Fla., and additional
mailing offices. POSTMASTER: Send address
changes to Welding Journal, 8669 Doral Blvd.,
Doral, FL 33166. Canada Post: Publications Mail
Agreement #40612608 Canada Returns to be sent
to Bleuchip International, P.O. Box 25542,
London, ON N6C 6B2
Readers of Welding Journal may make copies of
articles for personal, archival, educational or
research purposes, and which are not for sale or
resale. Permission is granted to quote from arti-
cles, provided customary acknowledgment of
authors and sources is made. Starred (*) items
excluded from copyright.
Departments
Editorial ............................4
Press Time News ..................6
News of the Industry ..............8
International Update ............14
Stainless Q&A ....................16
RWMA Q&A ......................18
Product & Print Spotlight ......20
Conferences ......................52
Coming Events....................54
Certification Schedule ..........58
Society News ....................59
Tech Topics ......................60
Guide to AWS Services ........75
Personnel ........................78
American Welder
Learning Track ..................93
Fact Sheet ......................98
Thermal Spray Profiles ........100
Classifieds ......................104
Advertiser Index ................105
237-s Study on Vacuum Brazing of Glass to Kovar Alloy with
Cu-Ni-Sn-P
The best time and temperature combination for optimum shear
strength was determined
Z. Zhong et al.
241-s Selecting Processes to Minimize Hexavalent Chromium
from Stainless Steel Welding
Different welding processes were studied to see which offered the
least exposure to hexavalent chromium
M. Keane et al.
247-s Estimating the Cooling Rates of a Spot Welding
Nugget in Stainless Steel
A way to determine the cooling rate will relate directly to weld
nugget shape and mechanical properties
Y. Zhang et al.
252-s Design Considerations of Graded Transition Joints for
Welding Dissimilar Alloys
Models were developed to help predict the performance of
dissimilar welds between ferritic and austenitic alloys using a
composite material in the joint
G. J. Brentrup et al.
Features
Welding Research Supplement
The American Welder
26
87
32
September 2012 Volume 91 Number 9
AWS Web site www.aws.org
On the cover: High-velocity oxyfuel appli-
cation of tungsten carbide to a lumber roll.
(Photo courtesy of Sulzer Metco Coating
Services.)
81 Spot and Projection Welding Basics
This overview helps in the understanding of resistance welding
L. H. McDevitt
87 Building Demand for Tradeswomen
A program founded in 1981 provides support and training to
women to help them enter trades traditionally held by men
EDITORIAL
It is currently projected that the United States will need an additional 238,000 weld-
ing-related professionals by 2019. Since 2007, when AWS made welder workforce devel-
opment a strategic direction and aligned it with the AWS Foundations scholarship activ-
ity, the Society has continued to develop programs to enhance the image of welding and
is focused on recruiting welders to ease this national shortage. These efforts have includ-
ed the use of national spokespersons; student recruitment collateral; a careers Web site
at www.CareersInWelding.com; a job-search Web site at www.JobsInWelding.com; profes-
sional development events for career counselors; workforce development grants for edu-
cation/industry partnerships; a Careers in Welding mobile exhibit; and more. We have
collaborated with Weld-Ed, the National Center for Welding Education & Training,
under a grant funded by the National Science Foundation, as well as with the National
Association of Manufacturers (NAM) and its portable, stackable certification program.
A collaborative effort undertaken late last year was organization of The State of the
Welding Industry Workforce Roundtable. This event cosponsored by AWS, AWS
Foundation, and Weld-Ed included 16 executive panelists and some 70 audience partic-
ipants. I served as the moderator for the morning panel discussion, which included industry
representatives from Caterpillar, Vermeer, Huntington-Ingalls, Bechtel, Westinghouse,
RoMan Engineering, AWISCO, ESAB, Lincoln, ITW, and education representatives from
UA Local 597, Texas State Technical College, Lorain County Community College, and
University of Alberta. The AWS and NAM were also part of the executive panel.
The panelists shared challenges their organizations face in recruiting, training, and
retaining welding professionals, as well as organizational impacts from new technologies,
advancements in welding, and globalization. Ideas and frameworks for pilot projects that
address the stated challenges were formulated in later small group discussions. A report
on the roundtable centered around three main priorities: Build Enthusiasm for Welding,
Expand Industry/Education Collaboration, and Flexibility in Education and Training.
Building upon this successful event, AWS has identified seven priority projects on
which it is focusing its efforts for future welder workforce development initiatives,
including the following:
Branding of the profession and messaging specific to each market segment including
young students (K12), young adults (1826 and military), incumbent workforce (transi-
tioning workers), gender-specific strategies, new Americans (being mindful of language
barriers)
Fast Track Program for Military enlisted and transitioning
Focus on Women of Gases & Welding
SkillsUSA and World Skills increased recognition
Collaboration with existing career exploration networks
Master Certification designation program with all NAM-Endorsed Manufacturing
Skills Certification system partners.
Activities are well underway for several of these initiatives. Meetings with branches of
the military have resulted in a plan to implement SENSE Level 1 and the Certified
Welder programs at the Armys Fort Lee training facility. In addition, the militarys
COOL and CERT Web sites have been updated to provide the current certification
information for active and transitioning service people. Women of Gases & Welding, a
joint initiative between AWS and GAWDA, was formed last fall. A luncheon featuring
AWS Vice President Nancy Cole as the keynote speaker was held at GAWDAs Spring
Management Conference in April. A strategic plan-
ning committee has been formed and a networking
event is being planned for FABTECH this November.
Your AWS will continue to focus its initiatives on
these priorities. We will look for new collaborations as
well as expand our current ones. Working together, we
can and must address the welding skills shortage and
ensure our industry is well positioned for growth and
success for the future.
SEPTEMBER 2012 4
Officers
President William A. Rice Jr.
OKI Bering
Vice President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Vice President David J. Landon
Vermeer Mfg. Co.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
T. Anderson (At Large), ITW Global Welding Tech. Center
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
J. C. Bruskotter (Past President), Bruskotter Consulting Services
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
D. A. Flood (Dist. 22), Tri Tool, Inc.
R. A. Harris (Dist. 10), Total Quality Testing
D. C. Howard (Dist. 7), Concurrent Technologies Corp.
J. Jones (Dist. 17), Victor Technologies
W. A. Komlos (Dist. 20), ArcTech, LLC
R. C. Lanier (Dist. 4), Pitt C.C.
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Engineering
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
D. L. McQuaid (At Large), DL McQuaid & Associates
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. R. Polanin (Dist. 13), Illinois Central College
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), Desert Rose H.S. and Career Center
N. S. Shannon (Dist. 19), Carlson Testing of Portland
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
Founded in 1919 to Advance the Science,
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Addressing the Welding
Skills Shortage
Dean R. Wilson
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PRESS TIME
NEWS
Lincoln Electric Announces Leadership Transition
Lincoln Electric Holdings, Inc.,
Cleveland, Ohio, recently announced
that effective Dec. 31, John M. Stropki
Jr., who has been chairman, president,
and chief executive officer since 2004,
will become executive chairman of the
board, and Christopher L. Mapes will
be named president and chief execu-
tive officer of the company.
As executive chairman, Stropki
will work closely with Mapes to en-
sure a seamless transition for Lincoln Electrics shareholders, global employee base, key
customers, industry associations, and community and government relationships. Mapes
has been serving as chief operating officer of the company since September 1, 2011, and
has been a member of the board of directors since February 2010.
This leadership transition is a direct result of the boards and Johns conscientious
focus on developing a deep, talented, and experienced management team at Lincoln Elec-
tric, said Harold L. Adams, lead director and chair of the nominating and corporate gov-
ernance committee. He added, Chris has demonstrated outstanding leadership skills,
strategic insight, and operational expertise during his time as a director and as a member
of the companys executive management team, with responsibility for all of Lincolns global
businesses and product development initiatives.
AWS Reveals Matching Gift Program for Endowed
Scholarships and Expands International Services
The American Welding Society (AWS), Doral, Fla., recently announced that, for a lim-
ited time, all donations to existing Named Scholarships or new Named Scholarships will be
matched dollar for dollar. The AWS Board of Directors approved the matching program
to provide more students with the opportunity to cover their welding education tuition.
The AWS matching gift program provides an excellent opportunity for businesses and
individuals to make a donation that will benefit the future of the welding industry, said
Sam Gentry, executive director, AWS Foundation. This is an excellent program to estab-
lish a scholarship in your name, your companys name, or your District or Sections name.
Since 1991, the AWS Foundation has awarded more than $5.3 million in scholar-
ships, and this year will award 400 students with more than $390,000. To learn more,
visit www.aws.org/foundation or contact Sam Gentry at sgentry@aws.org.
In other news, with international membership on the rise, AWS has launched a series of
country-specific Web sites known as microsites for members to access information in their
native languages. Multilingual microsites are now live for Mexico at www.aws.org/mexico,
China at www.aws.org/china, and Canada at www.aws.org/canada. They feature information
on services offered by AWS in each specific country, membership benefits, exposition in-
formation, online education, and access to AWS publications and technical standards. Other
countries will continue to be added.
Over the past few years, AWS has seen a significantly increasing interest from across
the globe in attaining AWS certifications, standards, and membership. Weve launched a
global initiative that will allow us to better serve the international welding community, and
the country-specific Web sites are just one of the steps that we are taking to become more
accessible to our members wherever they are, said Ray Shook, executive director, AWS.
Manufacturing Day Slated for October 5
The Fabricators & Manufacturers Association, Intl, U.S. Commerce Departments
Hollings Manufacturing Extension Partnership, Wisconsin MEP, and Illinois Manufac-
turing Extension Center are launching Manufacturing Day on October 5. It will high-
light the importance of manufacturing to the nations economy and draw attention to
these available high-skill jobs. Through open houses, public tours, career workshops,
and other events held at participating facilities on that day, the sponsors hope to intro-
duce as many people as possible to the role played by manufacturing in local communi-
ties and the nation. To learn more, visit www.mfgday.com. Also, organizations wanting
to become involved as official sponsors should e-mail info@mfgday.com.
SEPTEMBER 2012 6
MEMBER
Publisher Andrew Cullison
Publisher Emeritus Jeff Weber
Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
Associate Editor Howard M. Woodward
Associate Editor Kristin Campbell
Editorial Asst./Peer Review Coordinator Melissa Gomez
Design and Production
Production Manager Zaida Chavez
Senior Production Coordinator Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
National Sales Director Rob Saltzstein
Advertising Sales Representative Lea Paneca
Senior Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Sylvia Ferreira
sferreira@aws.org
8669 Doral Blvd., Doral, FL 33166
(305) 443-9353 or (800) 443-9353
Publications, Expositions, Marketing Committee
D. L. Doench, Chair
Hobart Brothers Co.
S. Bartholomew, Vice Chair
ESAB Welding & Cutting Prod.
J. D. Weber, Secretary
T. Birky, Lincoln Electric Co.
D. Brown, Weiler Brush
J. Deckrow, Hypertherm
D. DeCorte, RoMan Mfg.
J. R. Franklin, Sellstrom Mfg. Co.
F. H. Kasnick, Praxair
D. Levin, Airgas
E. C. Lipphardt, Consultant
R. Madden, Hypertherm
D. Marquard, IBEDA Superflash
J. Mueller, Victor Technologies International
J. F. Saenger Jr., Consultant
S. Smith, Weld-Aid Products
N. C. Cole, Ex Off., NCC Engineering
J. N. DuPont, Ex Off., Lehigh University
L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems
S. P. Moran, Ex Off., Weir American Hydro
E. Norman, Ex Off., Southwest Area Career Center
R. G. Pali, Ex Off., J. P. Nissen Co.
R. Ranc, Ex Off., Superior Products
W. A. Rice, Ex Off., OKI Bering
R. W. Shook, Ex Off., American Welding Society
D. Wilson, Ex Off.
Copyright 2012 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 in-
tended for use without independent, substantiating investigation on the
part of potential users.
Christopher L. Mapes John M. Stropki Jr.
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SEPTEMBER 2012 8
NEWS OF THE
INDUSTRY
SkillsUSA Competitors Earn Medals
at 2012 Championships
The welding winners of the annual SkillsUSA Championships
were revealed on June 27 at the award session of the national
leadership and skills conference held in Kansas City, Mo.
The high school welding medalists were Dillon Belair, Pio-
neer Technology Center, Ponca City, Okla. (gold); Cole Witte,
Pike Central High School, Petersburg, Ind. (silver); and Kurtis
Rice, Jefferson Scranton High School, Jefferson, Iowa (bronze).
The following college/postsecondary students also won weld-
ing medals: Tanner R. Tipsword, Eastern Wyoming College, Tor-
rington, Wyo. (gold); Jacob Hughes, Jefferson College ATS, Hills-
boro, Mo. (silver); and Simon Rowe, Cuesta Community Col-
lege, San Luis Obispo, Calif. (bronze).
The welding competitors received contest drawings and a set
of Welding Procedure Specifications. All drawings, welding sym-
bols, and welding terms conformed to American Welding Soci-
ety (AWS) standards.
Contestants were tested on various aspects, including meas-
uring weld replicas, using weld measuring gauges; laying out a
plate and using oxyacetylene equipment to cut several holes that
would be checked for accuracy and quality; gas metal arc weld-
ing on steel in which they made welds in various positions using
pulse transfer; and using a combination machine capable of pro-
viding the correct welding current for shielded metal arc and gas
tungsten arc welding. Competitors completed the steel project
Airbus will establish a manufacturing facil-
ity in the United States to assemble and
deliver A320 family aircraft. Located at the
Brookley Aeroplex in Mobile, Ala., it will be
the companys first U.S.-based production
facility.
A319, A320, and A321 aircraft will be as-
sembled there. Construction of the assembly
line is expected to begin next summer. Aircraft
assembly is planned to start in 2015, with first
deliveries from the Mobile facility beginning
in 2016. The company further anticipates the
facility will produce between 40 and 50 aircraft
per year by 2018.
The time is right for Airbus to expand in
America, said Fabrice Brgier, Airbus presi-
dent and CEO. He added the United States is
the largest single-aisle aircraft market in the
world with a projected need for 4600 aircraft
over the next 20 years.
Alabama Governor Robert Bentley said,
This project will create 1000 stable, well-
paying jobs that the people of this area need
and deserve.
Airbus already operates an Engineering
Center in Mobile as well as a military customer
services operation supporting U.S. Coast
Guard aircraft.
Airbus to Establish U.S. Assembly Line
Airbus President and CEO Fabrice Brgier (left) is joined by Alabama Governor
Robert Bentley after announcing the decision to create an A320 family final assem-
bly line at Mobiles Brookley Aeroplex. (Photo Airbus S.A.S 2012.)
Shown are the welding winners and some of the technical commit-
tee members at the 2012 SkillsUSA Championships: (front row,
from left) national technical committee member, Nick Peterson;
high school medalists Cole Witte (silver), Dillon Belair (gold), and
Kurtis Rice (bronze); plus national technical committee members,
including AWS Education Services, Director, Operations Martica
Ventura, Paul Cleveland, and Ed Norman. Also shown (back row,
from left) are national technical committee member, Branden
Muehlbrandt; postsecondary/college medalists Jacob Hughes (sil-
ver), Tanner Tipsword (gold), and Simon Rowe (bronze); along
with national technical committee member, Steve Theesen. (Photo
courtesy of Clay Allen, SkillsUSA photographer.)
9 WELDING JOURNAL
and welded a stainless steel project in various positions using a
variety of filler metals.
Judges were provided by the AWS Kansas City Section. Con-
testants were judged while assembling and welding the project.
Certified Welding Inspectors judged the completed project. In-
spection methods included visual and liquid penetrant techniques.
To view a video of the events welding competition, visit
http://tinyurl.com/7pft6dr. In addition, awards were presented in
categories for welding fabrication and welding sculpture.
WorldSkills Germany will host the 42nd WorldSkills Compe-
titions in Leipzig, Germany, July 27, 2013, at the Leipzig Trade
Fair and Exhibition Center.
New Welders at Sabre Industries to
Benefit from Customized Training
Western Iowa Tech Community College has partnered with
Sabre Industries, Inc., a tower, pole, and shelter manufacturer,
to provide customized training for nearly 200 new jobs being cre-
ated by the companys expansion plans in Sioux City, Iowa.
The welding program, created as a training opportunity for
Sabres new welders, is four weeks long and features an orienta-
tion plan strong in blueprint reading and safety.
The company revealed its multiphased expansion in the citys
new Southbridge Business Park earlier this year. The initial phase
will include approximately 200 new jobs added to the 208 exist-
ing employees and an $18 million capital investment. Additional
phases anticipate a total investment of $28 million and 532 jobs.
Sabres Sioux City operations will include positions in weld-
ing, manufacturing, executive management, administration, sales,
operations, human resources, and shipping/receiving. Its Web
site provides employment details at www.sabreindustries.com.
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SEPTEMBER 2012 10
SmithCo Awards Contract to Manufacture
Side-Dump Trailer Components
Radius Steel Fabrication SOO Tractor, Sioux City, Iowa, has
recently been awarded an agreement by SmithCo Mfg. Co., Le
Mars, Iowa, to build steel components for trailers to meet pay-
load requirements for the Canadian mining industry. The steel
fabrication, welding, and blast/paint technologies provider will
manufacture large components for the side-dump trailers.
I see this project as an opportunity to not only support U.S.
manufacturing, but to create jobs for Americans, said Ida Covi,
CEO of Radius Steel.
Radius Steel SOO Tractors owner, Allen Mahaney, with
the companys engineering department, designed a custom weld
fixture that will attach to the hydraulic roll-over positioner. It re-
duces the welding time of each component by more than 2 h and
takes into consideration the workers ergonomic position.
Miller Launches Job Weld Done Giveaway
Miller Electric Mfg. Co., Appleton, Wis., launched the Job
Weld Done Giveaway. Those interested can review the official
rules and enter at MillerWelds.com/win once monthly until Dec.
31, 2012, to increase chances of winning. Among the prizes are
welding machines. Also, three individual grand prize packages
will be awarded in January 2013, including a custom-built EPIC
chopper, NASCAR trip to Bristol, Tenn., and a trip to Las Vegas
including an inside look at the SEMA Show. Ten winners will be
awarded a Miller t-shirt during each monthly entry period as well.
North American Robotics Industry
Posts Best Quarter Ever
North American robotics companies sold more industrial ro-
bots in the second quarter of 2012 than any previous quarter in
history, according to new statistics released by the Robotic In-
dustries Association, Ann Arbor, Mich.
A total of 5556 robots valued at $403.1 million were sold to
North American companies, a jump of 14% in units and 28% in
dollars over the same quarter in 2011. Orders in the first half of
2012 totaled 10,652 robots valued at $747 million, increases of
20% in units and 29% in dollars over the same period last year.
Orders for spot welding robots, used primarily in automotive
solutions, jumped 68% in the first half of 2012. Other large jumps
were seen in coating and dispensing, arc welding, and assembly.
Radius Steel Fabrication SOO Tractor has been awarded an agree-
ment by SmithCo to build steel components for trailers to meet pay-
load requirements for the Canadian mining industry. As shown
above, welders use a roll-over positioner.
The Tweco Tradition of Creating
Pewter Figurines Continues
Ray Townsend, founder of the Townsend Welding Equipment
Co., better known as Tweco, began a pewter figurine tradition
that started at the 1975 convention in San Francisco, Calif., for
the National Welding Supply Association, which later became
GAWDA. Figurines are created each year to represent a histori-
cal person or icon of the host city; the first one commemorated
the miner/49er to pay homage to the California Gold Rush of
1849.
The pewter figurines have become collectable items for at-
tendees with 700 to 1200 produced annually. The attraction stems,
in part, from the craftsmanship of the Soldier Factory. For the
2011 GAWDA Annual Convention in New York City, a first re-
sponders figurine was created. Most recently, a bear figurine was
built for the 65th Annual Assembly & International Conference
of the International Institute of Welding in Denver, Colo.
Central McGowan Provides Welding
Supplies to Local Career Academy
Central McGowan, Inc. (CMI), a distributor of welding and
cutting equipment, along with industrial gases and MRO sup-
plies in central Minnesota, recently fulfilled a request from Cen-
tral Minnesota Jobs and Training Services, Inc., Monticello,
Minn., for welding supplies and other equipment needed to run
its 2012 Central Minnesota Career Academy.
For the second year in a row, Jeff Skumautz, CMIs president,
committed welding wire, contact tips, and safety glasses. He also
appointed two employees, Erin Brum and Dean Kiffmeyer, to
represent the company and ensure a successful academy experi-
ence. In addition, CMI involved a business partner to help sup-
port this event. Kiffmeyer reached out to Midsota Manufactur-
ing, Inc., in Avon to secure welding coupons.
The academy offers an opportunity for youth, ages 16 to 21,
who have an interest in manufacturing but have not yet decided
11 WELDING JOURNAL
/ Battery Charging Systems / Welding Technology / Solar Electronics
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the electrode and the work piece. With each spot, the process tape indexes one step forward; its like
welding every spot with a brand new electrode, making the quality 100% predictable. Join aluminum
to aluminum or steel to steel, even dissimilar metals.
Want to know more? Check out: www.fronius-usa.com

This custom-designed, pewter bear figurine was made for the 65th
Annual Assembly & International Conference of the International
Institute of Welding held July 813 in Denver, Colo.
their career path. Attendees try a manufacturing career through
hands-on projects on the shop floor and in a college classroom;
tour manufacturing companies and college campuses; learn from
industry specialists; and use equipment. They experience weld-
ing, metals and plastics machining, laser programming, computer-
aided design, electronics, and basic automotive technology.
Raybel Compres Named Outstanding
Welder of the Year at U.A. Graduation
Raybel Compres, a resident of Silver Spring, Md., and an
American Combustion Industries (ACI) employee for more than
five years, has been named Outstanding Welder of the Year at
the United Association (U.A.) Mechanical Trade School gradu-
ation, Local 602.
To earn this honor, Compres completed more than 1100 class-
room hours and 10,100 h of on-the-job training at ACI. He also
earned nine welding qualifications and spent most of his appren-
ticeship working under one of the companys most distinguished
journeymen, Ray Cary. Primarily, Compres worked on large-scale
heating, ventilation, and air-conditioning projects at construc-
tion sites and for existing customer facilities. He maintained
a 96.46 GPA, ranking him 13th in a graduating class of 109
steamfitters.
TMK Breaks Ground on New Facility
TMK IPSCO has begun developing a new 69,000-sq-ft facility
in Odessa, Tex. Consisting of two main buildings, the facilities
will host ULTRA premium connection manufacturing, includ-
ing both pipe preprocessing and threading. It is expected several
skilled labor jobs will be created. The site is projected to be fully
operational by the end of the year.
In addition, the 37-acre site will streamline the companys
operations, which are currently spread out. Consolidating these
SEPTEMBER 2012 12
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Raybel Compres earned the
Outstanding Welder of the
Year title at the United Asso-
ciation Mechanical Trade
School graduation, Local
602. (Photo courtesy of Amer-
ican Combustion Industries.)
Central Minnesota Career Academy students Derek Rivers and
Tessia Silbernagel proudly display their new welding skills.
continued on page 80
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INTERNATIONAL
UPDATE
TRUMPF Opens Disk Laser Facility in Japan
The TRUMPF Group, a manufacturer of sheet metal fabrica-
tion machinery and industrial lasers, recently opened a production
facility for disk lasers in Yokohama, Japan, its third worldwide.
One hundred twenty people attended the official inauguration
of the latest TruDisk production location on June 1, 2012. Accord-
ing to the company, the new location will not only contribute to the
expansion of disk laser technology in the Japanese market, but will
allow customers to observe TRUMPFs production processes and
products first-hand.
Dr. Christof Lehner, general manager of TRUMPF Laser
Technology Center in Plymouth, Mich., said, Disk lasers are in
high demand, especially when integrated into our TruLaser Cell
8030 multiaxis laser cutting system, which was designed specifi-
cally for the hot formed cutting market. In the United States, we
continue to add employees and grow in an effort to meet this de-
mand. Increased global manufacturing capacity will help to ease
delivery constraints and allow us to better serve the North Amer-
ican market.
Wall Colmonoy Opens Machine Shop in Wales
Wall Colmonoy, a materials engineering group of companies
engaged in the manufacturing of surfacing and brazing products,
castings, and engineered components, recently opened a state-
of-the-art machine shop in Pontardawe, Wales. The 23,500-sq-ft
facility was inaugurated by Carwyn Jones, M.P., First Minister of
Wales.
According to the company, the new machining site will add
capacity, advanced processes, and equipment while increasing
the quality, speed, and efficiency of production. Jones said, The
decision to expand here in Pontardawe is a great boost for man-
ufaturing in Wales.
Women Who Weld Program Launched in
Queensland
The Women Who Weld program, an initiative to encourage
young women to take up a welding apprenticeship, launched on
July 24th in Queensland, Australia. Women from their late-teens
to mid-30s, and a range of backgrounds, are participating in the
pilot program held at Atlas Heavy Engineerings facility at
Narangba. They will be attending orientation workshops focused
on the engineering trades. Upon completion of the course, they
will be presented with a Statement of Achievement.
Women Who Weld is a partnership between the Australian
Industry Group, QMI Solutions, and Atlas Heavy Engineering.
The alliance was formed on International Womens Day 2012 to
give young women an opportunity to experience welding and
other engineering trades in a real-world manufacturing setting.
Jim Walker, CEO of QMI Solutions, said, This program will
venture into Queensland schools to seek out young women who
might be intereted in pursuing a trade as a welder but didnt quite
know how to kick off the process.
Hydrex Performs Several On-Site Ship
Repairs
Over the last few months, Hydrex divers and technicians have
been sent to perform vessel repairs in Belgium, The Netherlands,
and Cameroon. Repairs were carried out according to the Hy-
drex class approved procedure for the welding of inserts in a ves-
sels shell plating while afloat.
In Zeebrugge, Belgium, a 560-mm crack in the bottom shell
plating of a 203-m roll-on-/roll-off vessel needed repairing. The
Hydrex team, upon inspection of the onboard and water-side
shell plating, installed a cofferdam over the affected area. They
then cut the shell plating and secured a new insert plate with a
complete-joint-penetration weld.
In Amsterdam, a leak in one of the ballast tanks of a 144-m
tanker was stopped by inserting a round plug with a diameter of
300 mm. The diver and technician team then also installed a cof-
ferdam over the rack, and installed a new insert with a complete-
joint-penetration weld.
In Douala, Cameroon, similar repairs were performed on a
228-m tanker. The cavitated area on the flat bottom in the bal-
last tank was removed, and a new insert plate was installed and
welded.
These permanent repairs meant no further attention to the
hull cracks was required, and because of the on-site teams, the
vessels did not need to go to drydock, and were able to continue
their schedules.
Dr. Peter Leibinger, vice chairman of TRUMPF GmbH+ Co. KG
and president of the laser technology and electronics division,
speaks at the inauguration of the companys new facility in Japan.
Wall Colmonoys its new machining facility in Pontardawe, Wales.
SEPTEMBER 2012 14
A Hydrex technician performs an on-site weld repair on a vessel.
STAINLESS
Q&A
BY DAMIAN J. KOTECKI
Q: We have done some cladding with
stainless steel covered electrodes of AWS
A5.4 class E309LMo-16. Recently, for the
first time, we purchased stainless steel
wire for submerged arc cladding that was
advertised as ER309LMo. But when our
incoming material inspection took place,
the wire was rejected on the ground that it
did not meet AWS A5.9 Class ER309LMo
composition requirements. In particular,
the chromium was low (a little more than
21%) and the nickel was high (around
15%). Subsequently, we tried to find an-
other source that met ER309LMo re-
quirements, but were not successful. It
seems that every product we can find that
is advertised as ER309LMo fits this same
pattern of low chromium and high nickel.
What is going on here, and what can we do
to find real ER309LMo?
A: Unless you purchase metal-cored
EC309LMo, I doubt that you can find sub-
merged arc wire (or gas metal arc welding
wire, for that matter) on the market that
meets AWS A5.9 ER309LMo composi-
tion requirements. This situation is driven
by market economics. That requires some
explaining. First, you should realize that
the covered electrodes of the E309LMo-
16 class are not made from 309LMo core
wire. They are most likely made from 309L
core wire, or even from a leaner alloy
than 309L, and a lot of alloy is found in the
coating.
There are two main reasons for want-
ing to use ER309LMo as specified in AWS
A5.9. The first is to obtain a rather high
calculated ferrite content in undiluted
weld metal (typically 20 to 30 FN using the
WRC-1992 Diagram) in order to allow for
a lot of dilution in a dissimilar metal joint
or cladding on carbon steel or low-alloy
steel. The high calculated wire ferrite con-
tent permits solidification of the diluted
weld metal in the primary ferrite solidifi-
cation mode, which provides for high re-
sistance to solidification cracking. The sec-
ond reason is to provide for some molyb-
denum in the diluted first layer of cladding
so that a second layer, deposited with
ER316L, can achieve the 2% minimum
Mo of a 316L weld metal.
The economic problem with
ER309LMo is that the high-ferrite com-
position is difficult to draw into wire, or
even to roll into rod stock prior to drawing
into wire. The material behaves more like
a duplex stainless steel than an austenitic
stainless steel, which makes it rather ex-
pensive to produce. It requires more fre-
quent and more careful annealing than or-
dinary austenitic stainless steel composi-
tions. The more frequent annealing is due
to the high strength and rapid work hard-
ening of the higher-ferrite material, and
the care in annealing is due to need to con-
trol temperatures to avoid sigma phase
formation in the rod or wire as it is being
reduced in diameter. Europe, Japan, and
others reacted to this situation by produc-
ing wire of the sort that you purchased and
rejected. Since chromium promotes fer-
rite while nickel promotes austenite, the
lower-chromium and higher-nickel results
in a lower calculated ferrite content for the
wire, on the order of 15 FN as calculated
from the WRC-1992 Diagram. This modi-
fied composition is less resistant to exces-
sive dilution and resulting solidification
cracking tendencies than the AWS A5.9
SEPTEMBER 2012 16
ER309LMo composition, so it requires
more limitation on dilution, the first rea-
son for specifying ER309LMo. But, it
serves the second reason well, because it
provides for the molybdenum in a first
cladding layer to help achieve 2% Mo min-
imum in a second layer deposited using
ER316L.
Until now, the AWS A5.9 specification
has not embraced this modified composi-
tion. It can be found in the current ISO
14343 specification and in the older
EN12072 specification. The AWS A5
Committee on Filler Metals and Allied
Materials, through its A5D Subcommit-
tee, seems to be on a path to adopting ISO
14343 as AWS A5.9 in the not very distant
future. This step will put the modified
composition into the AWS A5.9 specifica-
tion and ultimately into the ASME Code
if all proceeds according to plan.
Table 1 provides a comparison of the
composition of the AWS A5.9 ER309LMo
composition requirements with those of
the ISO 14343 S 23 12 2 L. This latter com-
position is, almost certainly, what you ac-
tually purchased and rejected.
You can see that there is a great deal of
overlap in the two sets of composition
ranges. In fact, the ER309LMo composi-
tion range is entirely inside of the S 22 12
2 L composition range. You might think
that the two alloys are basically the same.
However, you need to appreciate that
stainless steel melting no longer uses mid-
range targets for individual alloy elements
as it once did. If the S 22 12 2 L rod stock
were melted to mid-range, it would also be
very high in ferrite. But todays suppliers
invariably aim for the low end of the
chromium range and the high end of the
nickel range in these alloys, to reduce the
need both for the number of anneals and
for care in annealing as the cast material is
processed into rod stock and eventually
into wire. So these two alloys are really not
the same in practice.
If you can limit dilution, and if you can
convince your customer to accept use of
the modified composition, then you
should be able to use the modified com-
position of the S 22 12 2 L classification in
ISO 14343 in place of the current AWS
A5.9 class ER309LMo.
If you cannot do these things, then your
only alternative, I believe, is to purchase
AWS A.9 Class EC309LMo metal cored
wire. Metal cored wire, in this composition
range for submerged arc welding, is likely
to be produced from low-carbon mild steel
strip, with all of the alloying elements
present in the core. In smaller diameters,
as for GMAW, it is likely to be produced
from 304L or 316L strip, with the remain-
ing alloy elements in the metal core. If the
metal cored wire is produced from mild
steel strip, the wire will be quite soft and
have very different feeding characteristics
from those of solid stainless steel wire.
You are likely to need U-grooved gear-
drive rolls to avoid crushing or flattening
the wire, and low drive roll pressure. The
fragility of high-alloy metal cored wire
made from mild steel strip requires some
tenderness in handling and feeding the
wire. On the other hand, if you find
EC309LMo wire made from 304L or 316L
strip, it will be considerably less fragile and
will require less care in feeding. Also, be
aware that deformation of metal cored
high-alloy wires is likely to lead to fill leak-
age, which can wear contact tips and, in
the extreme, can result in low alloy content
in the weld metal.
17 WELDING JOURNAL
DAMIAN J. KOTECKI is president,
Damian Kotecki Welding Consultants, Inc.
He is treasurer of the IIW and a member of
the A5D Subcommittee on Stainless Steel
Filler Metals, D1K Subcommittee on Stain-
less Steel Structural Welding; and WRC
Subcommittee on Welding Stainless Steels
and Nickel-Base Alloys. He is a past chair of
the A5 Committee on Filler Metals and Al-
lied Materials, and served as AWS president
(20052006). Send questions to damian@
damiankotecki.com, or Damian Kotecki,
c/o Welding Journal Dept., 8669 Doral
Blvd., Doral, FL 33166.
Table 1 Comparison of AWS A5.9 Class ER309LMo and ISO 14343-A Class S 22 12 2 L
Class Composition (wt-%) (single value is a maximum)
C Mn P S Si Cr Ni Mo Cu
ER309LMo 0.03 1.02.5 0.03 0.03 0.300.65 23.025.0 12.014.0 2.03.0 0.75
S 22 12 2 L 0.03 1.02.5 0.03 0.02 1.0 21.025.0 11.015.5 2.03.5 0.75
SEPTEMBER 2012 18
RWMA
Q&A
BY ROGER HIRSCH
Q: We keep blowing fuses on a 100-kVA
single-phase press welding machine. After
the fuse is replaced and a weld is made,
a loud metallic growling noise comes from
the welding machine. Even when we in-
crease weld heat in the control, weld
strength is very low.
A: The following two conditions can cause
all of your problems.
Weld Control Problem: The control on
your welding machine is designed to al-
ternately fire the positive and negative
voltage from your power line in equal lev-
els through the silicon-controlled rectifier
(SCR) contactor (solid-state switch) in-
side the control. If the SCR contactor is
not firing these half-cycles in balance, the
welding transformer will saturate and be-
come less of an inductor and more of a
very low resistance. This will greatly in-
crease the current on the incoming power
lines and, at the same time, lower the
welding machines secondary current. Re-
pair or replacement of the welding con-
trol should solve this problem.
Transformer Problem: Welding trans-
formers can internally ground to frame.
This can cause both high primary current
as well as loss of welding strength. In ex-
treme cases, this can cause the trans-
former to be partially turned on all the
time and cause electrodes to melt together
when they close.
The transformer can only be checked
by use of a hi-pot tester. Companies that
repair transformers and motors will have
this device. A typical reason why a water-
cooled welding transformer fails in this
way is lack of proper cooling water flow-
ing through the transformer.
Air-cooled welding transformers typi-
cally fail when they are being used beyond
their design ability.
Q: The indirectly water-cooled SCR con-
tactor on our welding control shorted re-
cently. The manufacturer of the SCR con-
tactor checked the shorted switch and said
it looked like the amperage through the
switch was too high. At that time, the weld-
ing machine was doing very light welding.
We replaced the SCR contactor and after
a few days this new one also shorted. Any
advice?
A: If you were getting good welds before
the failure, and the current this SCR is
switching is within the manufacturers
range, then you probably do not have
proper water flow going through the heat
sink in the SCR contactor. Install a sim-
ple mechanical in-line water flow indica-
tor and be sure there is good flow. Check-
ing to see if there is water pressure on one
hose going into the switch will not guar-
antee that water is flowing since there can
be either a blockage in water passage of
the cooling base, or there might be high
backpressure on the water line.
Q: We are able to make very good spot
welds, but trying to make good weld nut
welds is driving us crazy. We are using a
30-kVA rocker arm welding machine and
are trying to weld 20 thread weld nuts
that have four projections. We can get one
or two projections to weld all right most
of the time, but never all four. Increasing
the weld time seems to make it worse be-
cause the threads change pitch and will
not pass the thread go/no-go test.
A: First, you are using the wrong machine
for the job. Consistent welding of weld
nuts requires the welding electrodes to be
absolutely parallel and rigid. This is not
possible on a rocker arm welding machine
since the electrodes are closed on an arc.
Second, successful welding of all four
projections requires that you have high
current, high force, and short time. For a
20 thread weld nut with four projec-
tions, you will need about 1200 lb of force,
20,000 A, and a weld time of 4 cycles.
Move the project to a short-throat
press welding machine and use these set-
tings. You should get really great welds on
all four projections.
Q: I tried to use the welding schedules
in the RWMA Resistance Welding Manual,
4th edition, and am having a problem
with the settings. I am trying to weld
0.078-in. low-carbon steel, and the chart
calls for 1100 lb of force. But when I try
to set the air pressure to get this elec-
trode force, my offset electrodes bend a
lot and slide on the part. I get poor welds
and a lot of sparks.
A: You have found the limitation in using
offset electrodes. The more the offset, the
less force you can put on them. For some
applications, you can use solid forged off-
set electrodes, but you should be aware
they will not allow good water cooling and
will have limited electrode life.
Try to use the absolutely smallest off-
19 WELDING JOURNAL
set possible for the part being welded. If
the welding chart force is still too high for
the offset electrode, you will have to find
an alternate welding schedule. Table 7.3
in the RWMA Resistance Welding Manual,
4th edition, has Class A, B, and C
weld setups that might help you.
For 0.078-in. low-carbon steel, the
Class A schedule calls for 1100 lb of
force, 21 cycles of weld time, and 13,300
A of welding current. The Class B sched-
ule calls for 650 lb of force, 36 cycles weld
time, and 10,400 A of welding current.
The Class C schedule calls for 325 lb of
force, 58 cycles of weld time, and 7900 A
of welding current.
You could use the B or C schedules,
but know that the weld strength (average
tensile shear strength) will be 3225 lb for
the Class A schedule, 3025 lb for the class
B schedule, and 2900 lb for the Class C
schedule. Also, using much longer weld-
ing time will decrease electrode life and
require electrode dressing more often.
Q: I am installing a 100-kVA, 230-V, sin-
gle-phase resistance welding machine and
need to operate it from a 440 to 220-V step-
down transformer. My electrician said I
need a 100-kVA step-down transformer.
Is that correct?
A: There is often confusion about resist-
ance welding machine transformer rat-
ings. If you look closely, you will see that
the transformer, if built to RWMA stan-
dards, is rated at 100 kVA but at 50%
duty cycle. This means the transformer
can be used at the maximum thermal out-
put for up to 30 s every min. The step-
down transformer is rated at 100% duty
cycle, which means it can operate contin-
uously at the rated kVA without over-
heating the windings.
To size a power line or step-down
transformer, multiply the kVA of the
welding machine by the square root of
the duty cycle. In this case, the calcula-
tion would be:
Step-down transformer = 100 kVA
0.50 = 100 kVA 0.707 = 70.7 kVA.
Therefore, a 75-kVA transformer will
work fine.
Minimum wire primary amps of the
welding machine can be calculated by di-
viding this kVA by the machines line
voltage.
For wires going into the welding ma-
chine transformer, the calculation is
70,700/220 = 321 A.
For wires going from the power source
into the input of the step-down trans-
former, the calculation is
70,700/440 = 161 A.
The required minimum wire size can
be found in the RWMA Resistance Weld-
ing Manual, 4th edition, Table 21.2.
ROGER HIRSCH is immediate past
chair of the Resistance Welding Man-
ufacturing Alliance (RWMA), a stand-
ing committee of the American Weld-
ing Society. He is also president of Uni-
trol Electronics, Inc., Northbrook, Ill.
Send your comments and questions to
Roger Hirsch at roger@unitrol-elec-
tronics.com, or mail to Roger Hirsch,
c/o Welding Journal, 8669 Doral Blvd.,
Doral, Fl 33166.
PRODUCT & PRINT
SPOTLIGHT
Video Camera Contains
Built-in Borescope Coupler
The Luxxor portable video camera
quickly attaches to any Hawkeye rigid
or flexible borescope and most other
major borescope brands. It allows users
to view internal visual inspection images
on portable/benchtop video monitors or
on laptop/desktop computers. Video
footage and still photos can be viewed live
as well as saved, documented, and e-
mailed. Also, the camera has a
1
4-in. color
CCD; built-in, 25-mm borescope coupler;
768 494 pixel resolution; and can be at-
tached to the Luxxor portable video mon-
itor or to any computer or video monitor.
Gradient Lens Corp.
www.gradientlens.com/lpc
(585) 235-2620
Light Source Useful
for NDE
The Spectroline EK-3000 Eagle-
Eye UV-A/white-light LED inspection
kit (patents pending) is for fluorescent
magnetic particle and penetrant testing
along with other uses. It features the palm-
sized, cool-running EagleEye inspection
lamp with two ultrahigh-intensity UV-A
(365-nm) LEDs useful for NDE, plus a
three-LED white-light assembly. An ad-
justable strap allows the lamp to be worn
on a hard hat or on the head. A lamp
mount/sprayer attachment permits the
lamp and a spray can to be mounted for
single-handed fluorescent yoke inspec-
tion. The lamp produces a nominal steady-
state UV-A intensity of 4500 W/cm at
15 in. The kit comes with a lanyard, two
replacement splash guards with integral
particulate filters, three spare batteries, a
battery charging cradle with AC and DC
cord sets, and UV-absorbing spectacles.
Components come in a soft carrying case.
Spectroline
www.spectroline.com
(800) 274-8888
Oxyfuel Safety DVD Offered
in English and Spanish
A 36-min-long video, titled Oxy-Fuel
Safety: Its Your Responsibility, and supple-
mental training materials are designed to
SEPTEMBER 2012 20
Weld Inspection Scanner Offers High Probability of Detection
The portable, time-of-flight-diffraction in-
spection system allows users to view weld qual-
ity quickly. It positions two angle beam trans-
ducers facing each other to transmit and receive
the diffraction of ultrasonic waves generated in
this technique. The hand-held scanner needs
only one person to operate and is sensitive
enough that an external preamplifier is not
needed. Used with the companys Pocket UT
TM
battery-operated, hand-held, C-scan acquisition
system, users can display the scan, plus store
and measure indications in terms of height,
length, and position. The B-scan image best rep-
resents the real-time data captured for evalua-
tion. Additional benefits include a high proba-
bility of detection, hand-held magnetic wheel
scanner, touch-screen operation, multiple lan-
guage results, auto data file saving, adjustable
probe center separation, and ports to UTWin
advanced weld inspection technique.
MISTRAS Group, Inc.
www.mistrasgroup.com
(609) 716-4000
21 WELDING JOURNAL
support safety programs in schools, tech-
nical colleges, and industry. Included are
a leaders guide to facilitate group discus-
sions and a participants guide with review
questions and helpful resources. The
DVD and all contents are available in
English or Spanish. The topics include
safety and personal responsibility, gases,
regulators and hoses, torches, lighting the
torch, and a cutting demonstration. The
video displays the proper methods to in-
spect, set up, light, and safety shut down
an oxyfuel system using acetylene and al-
ternate fuels such as propylene. While the
video uses the companys torches and
EDGE regulators, it is nonpromotional
and the techniques shown can be applied
to any equipment brand. The entire video
may be viewed online on YouTube. Search
for Victor Gas. The DVD and training
materials may be obtained from your local
company representative or inquire at your
gases and welding supply distributor.
Victor Technologies International
www.victortechnologies.com
(800) 426-1888
Wires Meet D1.8 Seismic
Code Requirements
The company offers 16 metal-cored
and flux-cored (gas- and self-shielded)
wires that meet AWS D1.8/D1.8M, Struc-
tural Welding Code Seismic Supplement
for demand critical welds in seismic mo-
ment frame welded connections. These
filler metals have been three-lot tested in
accordance with AWS D1.8/D1.8M:2009
testing requirements and meet the re-
quirements specific for their diameter and
shielding gas (where applicable). They are
considered prequalified for seismic appli-
cations and can be used by contractors
without additional filler metal testing. The
extra testing also ensures the deposited
weld metal has adequate strength and
toughness at the specified heat input en-
velope for the low and high heat inputs
according to individual diameter sizes. In-
cluded in the offering are the Hobart
Fabshield XLR-8 self-shielded flux-
cored wire, Tri-Mark Metalloy Van-
tage metal-cored wire, and Hobart
FabCO Hornet gas-shielded flux-cored
wire.
Hobart Brothers
www.hobartbrothers.com
(800) 532-2618 (technical department)
Metal Analyzers Include
UV Probe for Arc Operation
The Spectrotest mobile metal analyz-
ers offer an ergonomic design, plasma
generator, and intelligent calibration logic
system that monitors the correct state of
the measuring system independently from
external influences. In addition, company
engineers designed a pluggable probe with
an integrated UV optic that can be used
for spark and arc excitation. By incorpo-
rating a lightweight transport trolley, de-
sign engineers cut the instruments weight

The all new S1 TITAN

hhsales@Bruker-Elemental.net
s Positive Material Identication
s Fast alloy ID and chemistry
s Completely non-destructive
s Prevents material mix-up
s Lightweight only 1.44kg / 3.17 lbs,
including battery

e all new S1
ight and ex
nition of Pr
ceptionally accur
TIT

recision
ceptionally accurate
TA TAN

Innovation with Integrity

o
r
hhsales@Bruk uker.com/s1titan
y of virtually any alloy.
y analyzer which provides grade ID and element
Handhel d XRF

uk r- er-Elemental.net
vides grade ID and elemental
Handhel d XRF
SEPTEMBER 2012 22
in half. The analyzer further features a 15-
in. display. The software only shows the
user the context-dependent functions re-
quired for the current operation; and it is
suited for identifying low-alloy steels using
the carbon content in the rapid arc exci-
tation mode.
Spectro Analytical Instruments
www.spectro.com
(800) 548-5809
Pipe Milling End-Prep Tool
Features One Mandrel
The Commander MILLHOG pipe
milling end-prep tool can perform any
angle of weld prep, including compound
and multiangle preps on stainless steel,
superduplex, P-91, and other hard alloyed
pipes. Featuring one mandrel and seven
sets of clamps for the 3.75-in. ID to 14-in.
OD range of the tool, it pulls a thick chip
without cutting oils. Available with pneu-
matic or hydraulic motors, it is built for
fabricating and maintaining high-temper-
ature and high-pressure piping systems.
Standard features include dual-opposed
tapered roller bearings and oversized
clamps with six contact points.
Esco Tool
www.escotool.com
(800) 343-6926
New Video Showcases
CNC Plasma Technologies
A 3-min video presents new CNC
plasma technologies. This Impact Movie,
being distributed worldwide, showcases
the companys technologies, including
For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index
Precision Hole Technology, Smart Volt-
age Height Control, and SmartCycle.
Viewers can watch the film at the follow-
ing link.
ESAB Cutting Systems
esabna.com/cncmovie
(800) 372-2123
Brazing Technology
Spanish Site Launched
The companys Global Brazing Solu-
tions has launched a Spanish version of
its corporate Web site in recognition of
the companys growing need to provide
Spanish language support for Latin Amer-
ica. Spanish is the third language the Web
site has been translated to and all sites
contain the same information.
Lucas-Milhaupt, Inc.
www.lucasmilhaupt.com/es-MX/
(414) 769-6000
Grinding Tool Prepares
Tungsten Electrodes
The Sharpshooter grinds tungsten
electrodes to exacting tolerances in an en-
closed chamber while quietly and safely
storing all dust. Also, it recently received
a listing from ETL Intertek after under-
going rigorous safety evaluations and test-
ing associated with earning a listing from
a nationally recognized testing laboratory.
To the best of the companys knowledge,
the product is the only listed tungsten
grinding tool in the world.
Pro-Fusion Technologies
www.pro-fusiononline.com
(800) 747-9353
Vacuum Lifter Protects
Heavy Pipe and Tube
The VPFL4 vacuum lifter for heavy
pipe and tube features nylon centering
guides and oval rubber suction cups to
prevent anything other than nylon or rub-
ber from touching the load. Designed to
compensate for unevenly packed loads
with staggered rows, it has a 500-lb capac-
ity and can pick up two, three, or four
pipes or tubes from the top simultane-
ously. Eliminating hooks, slings, and ex-
cessive handling that can cause damage,
the lifter is offered in air-powered or elec-
tric units that only need 8 in. of headroom.
Standard features include an all-welded
23 WELDING JOURNAL
steel frame, adjustable handle with built-
in controls, a vacuum gauge, and audio-
visual vacuum leakage detector system.
Anver Corp.
www.anver.com
(800) 654-3500
Cutoff Wheel Suited for
Thin-Walled Railing
The A 60 TZ Special, a fast and smooth
ultrathin cutoff wheel, utilizes a hard bond
for extended life and a burr-free cut, while
its cool cut reduces the risk of contamina-
tion and prevents discoloration. It is most
useful in stainless steel applications and
cutting thin-walled tube, pipe, and railing.
The wheel is available in Type 1 (flat) and
Type 27 (depressed center) forms in 4
1
2 or
5 in. diameter and 0.045 in. thick.
Klingspor
www.klingspor.com
(800) 645-5555
Gun Available with Optional
Dual Schedule Switch
The Dura-Flux self-shielded flux-
cored arc welding (FCAW-S) gun with re-
placeable power cable liner provides op-
erators 350 A of welding capability at a
60% duty cycle. Its handle design helps
reduce downtime associated with user fa-
tigue. In addition, it is available with an
optional dual schedule switch that allows
easy wire feed speed adjustment while
welding. The trigger absorbs less heat to
increase arc-on time, lower heat input,
and extend component life. Extra features
include a rotatable Hi-Viz neck to im-
prove weld pool visibility, and the com-
panys Quik Tip series consumables de-
signed with a threaded taper lock that in-
creases contact tip life.
Bernard
www.bernardwelds.com
(800) 946-2281
Welding Line Detailed in
Brochure
An 80-page, full-color brochure, The
Ultimate Welding Combo, features the
companys full line of professional-qual-
ity welding machines and accessories. In-
SEPTEMBER 2012 24
SEPTEMBER 2012 26
W
hen you hear the words we
need to improve our weld qual-
ity, the following are a few of
the things that typically come to mind:
We will need to do more inspection
and so will need to hire more people
Improving quality will most likely
reduce productivity, increase costs, and
take more time
There will be a mountain of extra
paperwork and reports required.
Utilizing a weld quality management
methodology will erase these concerns
by improving the overall productivity and
quality of welding fabrication. Such a
methodology utilizes the following tools:
1. Design for Manufacturing (DFM)
for upfront planning to ensure the prod-
uct can be manufactured effectively and
efficiently with the processes planned for
the production floor.
2. Total cost of quality, which meas-
ures the four cost categories of preven-
tion, analysis, repair, and scrap.
3. Overall equipment effectiveness
(OEE) , which tracks uptime, productiv-
ity, and quality for actual production
monitoring, control, and continuous im-
provement.
Prevention Is Key
The typical quality control function
utilized today for determining weld qual-
ity requirements and assessing whether
they have been met starts at the end of
the overall manufacturing process. That
is totally backward because it means that
most of the work has been put into in-
spection, rework/repair, and managing
scrap rather than into preventing a bad
product from being made in the first
place. The focus needs to be reversed so
that most of the planning is put into pre-
venting defects and analysis of historical
data so that work can be done up front to
establish robust processes that will be able
to handle as much variation in manufac-
turing as possible. Figure 1 shows the typ-
ical breakdown of costs in industry today
and how this cost breakdown would look
in a pro-active world. It is a fact that
the cost to fix a defect in a product in-
creases exponentially the farther it
proceeds through the manufacturing
process.
Looking specifically at welding oper-
ations, we can use DFM methodology to
improve productivity and quality by pre-
venting, or at least identifying, a prob-
lem as early in the process as possible.
Specifically, DFM is used for
1. Ensuring the product is designed to
be efficiently manufactured. In addition,
we should strive to design whenever pos-
sible for a high level of automation be-
cause this reduces the variability inher-
ent with human involvement.
2. Facilitating the gathering of histor-
ical process capability data of the same
or surrogate welding processes to deter-
mine what level of productivity (like
travel speed, cycle time) and quality
(first-pass yield, parts per million) can be
expected with the methods, people, and
equipment planned.
3. With the knowledge from Nos. 1
and 2, we can now look at what new tech-
nology can be introduced to improve the
status quo.
Variability: A Challenge
and an Opportunity
Today, most testing and prove-out of
what a weld process can do is performed
in the perfect world of a lab. Welding pro-
cedure specifications (WPSs) are done
under controlled conditions and then we
reach the real world and everything is dif-
ferent than expected, which adversely af-
fects both productivity and quality. Why
does this occur? Two reasons:
1. Poorly understood upstream vari-
ability that is not reflected in the weld-
ing procedure specification.
2. Not using the right technology to
overcome the limitations present in your
product manufacturing.
Lets walk through the seven weld
quality assurance steps shown in Fig. 2.
Step 1: Benchmarking
Existing Welding
Operations.
A portable laser scanning weld in-
spection system can be used at the point
Good Design Plus Early
Inspection Equals
High Productivity
JEFF NORUK
(j.noruk@servorobot. com) is
President, Servo-Robot Corp.,
Milwaukee, Wis.
JEAN-PAUL BOILLOT
(jp.boillot@servorobot.com) is
CEO, Servo-Robot Group, St-
Bruno, PQ, Canada.
This quantitative method ties the
welding process quality results to
the actual welding parameters used
BY JEFF NORUK AND
JEAN-PAUL BOILLOT
27 WELDING JOURNAL
where the parts are stamped, cut, or ma-
chined to determine whether the proper
edge preparation is present, which affects
downstream fitup quality. From there,
you can check every fixtured or tacked
part presented to the welding operation
to determine how well the joints conform
to what they should be. If you are doing
robotic welding, simply hook up an au-
tomatic laser scanning weld inspection
system to the face plate of the robot as
shown in Fig. 3 and then measure the
complete variability of the weld joints
and welds. Information about the joint
includes variability of fitup (root open-
ing, mismatch, etc.), as well as the vari-
ability of the joint in space, which is com-
posed of part and fixture changes. This
benchmarking gives you an understand-
ing as to the level of the incoming vari-
ability, which then can be used when you
make the test samples for the WPS. Like-
wise, for weld inspection and measure-
ment, you can determine the variability
in the geometry and presence of defects
that are typical in production (see Fig. 4,
which shows an inspector performing a
part-to-part weld quality audit). Finally,
you can use this information to deter-
mine what the main problems are for
example, undersized welds, undercut
and then dig even deeper to determine
why, where, who, etc.
Step 2: Continuous
Improvement.
With the information from step one,
you can decide whether new methods,
techniques, equipment, people, or
processes need to be developed or uti-
lized. This may even involve doing some
development to improve an existing
process or introduce a whole new weld-
ing method. A portable laser scanning
weld inspection system can quickly and
efficiently help gauge whether any of
these changes and/or improvements
raised the quality level because it is easy
to link the process change with its effect
on weld quality.
Typically, you can get to a certain point
with your variation reduction effort on
your existing process where no more im-
provement is possible. If this level is ac-
ceptable, then you are good to go. How-
ever, if the actual production require-
ments are higher than you can now
achieve, then you need to look at the next
level of technology.
For example, instead of living with the
joint variability, which will always keep
you from being able to optimize the
process, you can now add technology
such as vision to overcome this limita-
tion. Figure 5 shows an example of laser
vision joint tracking, which can be used
to negate most of the inherent excessive
variability in the manufacturing opera-
tion. This is accomplished by giving the
Fig. 1
Cost of quality today and in a Six
Sigma world.
Fig. 2
Seven weld quality assurance steps.
Fig. 3
Automated weld inspection.
1
2
3
robot eyes so it will always follow the
joint to maintain optimum weld wire po-
sition and stickout. Going one step fur-
ther, adaptive welding methods can be
utilized to automatically change the
welding parameters (current, travel
speed, etc.) to accommodate variation
greater than what can be handled with a
fixed weld schedule. Figure 6 shows how
a change in root opening is handled using
adaptive welding techniques so produc-
tivity and quality are optimized.
Step 3: Welding Procedure
Specification
Development.
Because you have the information
needed to simulate real-world conditions
and to determine how the inputs affect
the welding process, you can now de-
velop a robust welding process capable
of managing anticipated inputs. All the
information, including test plate joint
fitup, welding parameters, and inspec-
tion results, can be combined to provide
a complete record of the WPS work. Fig-
ure 7 shows the process inputs and out-
puts and how they are related to the end
goal of optimizing the welding.
Step 4: Training,
Qualification, and
Certification of Personnel.
The people aspect of the welding op-
eration is equally important to that of the
technology and equipment used.
Whether it is manual or automated weld-
ing, you need an efficient and timely
means of determining whether the peo-
ple involved are qualified to run the
equipment to maximize performance.
The portable laser scanning weld inspec-
tion system can be used to help select
people to be trained as welders, it can as-
sist in the training by giving actual scores
on their performance, and it can even be
used to help welders who need some re-
medial training to improve their skills.
Likewise, the same-type system can be
used in a manual or robotic auditing
mode to determine if the robots have
been programmed correctly and whether
this level is being maintained.
Step 5: From Robot Cell
Design to Integrator
Runoff.
An important step associated with
purchasing new automated welding
equipment to improve the existing weld-
ing operation is to understand what the
real baseline is, so that you can determine
whether the improvement required is
achievable, and once installed, achieved.
This relates to the previously discussed
benchmarking phase where you can get
real data on what level of productivity
and quality is presently being achieved in
the factory. This information needs to be
supplied to the integrators quoting on
new automation so they know how to
properly design and build the system and
what the realistic cost will need to be.
Then, during the runoff at the integrator,
you have real metrics to compare to so
you know if the goal was achieved. At this
stage, the integrator can use simulation
to determine when the weld inspection
needs to occur in the production cycle to
keep the process in control.
Step 6: Production Runoff
in Customer Factory.
This runoff is done to ensure the au-
tomated system can produce an accept-
able level of quality parts when faced with
all the variability that will occur on a reg-
ular basis. A laser scanning weld inspec-
tion system can be used either manually
or on a robot to inspect every part in the
early runoff stages to establish the actual
process capability and the parts per mil-
lion defect rate. Figure 8 shows a typical
auditing exercise showing an inspection
report developed through the use of a
WikiScan/Robo portable laser scanning
weld inspection system from Servo-
Robot Corp.
Step 7: Ongoing Quality
Audits of Production.
Periodic auditing makes sure the qual-
ity level is okay, and if not, helps deter-
SEPTEMBER 2012 28
Fig. 4
Automated vs. old-fashioned
manual inspection.
Fig. 5
Real-time laser vision joint tracking.
mine where the problem is and how best
to get to the root cause.
While it is best to prevent any poten-
tial defect from being planned into the
overall manufacturing process, the weld
quality assurance methodology plans for
ongoing inspection in the factory. How-
ever, there is good/effective inspection
and bad/ineffective inspection. Lets re-
view the latter first.
How many times have you walked
through a factory and seen either a man-
ual or automated inspection station at the
end of the production line? No matter
how sophisticated or automated this sta-
tion may be, it is really just an attempt to
keep bad products from leaving the fac-
tory and getting to the final customer.
Any repair (sometimes called rework to
make it sound like some value is being
added) at this point is extremely expen-
sive and disruptive to Just-in-Time (JIT)
efforts and delivery schedules. The worst
part of this inspection, especially if done
manually, is that it is extremely subjec-
tive and can even result in repairing a
product that is actually acceptable. No
one wants to be held responsible for a bad
product leaving the factory so people
overinspect and thus force more weld re-
pair to occur.
Now lets look at the characteristics of
effective weld inspection that actually
pays for itself. These include the
following:
Inspection is done at the point of
welding, or as close as possible, so imme-
diate feedback to the operator, or process
itself, occurs resulting in a minimum
29 WELDING JOURNAL
Fig. 6
Adaptive welding techniques.
Fig. 7
Weld process inputs/outputs.
Fig. 8
Robotic weld inspection.
7
8
6
quantity of bad welds being made. Figure
9 shows a robot cell where any of the weld-
ing robots can decide to pick up a weld
inspection system to check the weld qual-
ity before proceeding to make the next
weld or put in the next layer. This emu-
lates a welder lifting his helmet and look-
ing at the weld or pulling out his gauge to
check the size and quality of the weld.
The inspection is automated as
much as possible so there is minimal
human interference and it is done as
quickly as possible.
Inspection is done by actually meas-
uring the weld geometry directly so that
not only go/no-go results are available
but there is also the ability to store the
data and analyze it to see why there is
variability. From there you can develop
ways to reduce the variability.
The results are available to be fed
back into the planning cycle for product
improvement and future new products.
This means the real data can be used to
develop the next WPS, as well as to plan
for new technology Fig. 10.
The information is readily available
to everyone from the welder or operator
to the president of the company, if
needed. It is even possible to connect to
any laser scanning weld inspection sys-
tem from your smart tablet device and
see the latest quality assessment or down-
load the results and look for trends and
evaluate the process capability.
Summary
While weld quality assurance method-
ology is not radical or perhaps even new,
it is simply the right way to manage weld
quality. Historically, it has been difficult
for people to achieve the desired results
due to the lack of a quantitative method
to tie the welding process quality results
to the actual welding parameters used
whether in the R&D area, welding pro-
cedure development phase, or in produc-
tion out in the factory. This methodology,
combined with new tools, helps to turn
raw data into actionable information.
SEPTEMBER 2012 30

Manufacturing
Flux Cored
Welding Wire
COBALT

NICKEL

HARDFACE

STAINLESS

ALLOY STEEL

TOOL STEEL

MAINTENANCE

FORGE ALLOYS

CUSTOM ALLOYS

COR-MET, INC.
12500 Grand River Rd.
Brighton, MI 48116
PH: 800-848-2719
FAX: 810-227-9266
www.cor-met.com
sales@cor-met.com

COBALT LT
Welding W
Flux Cored
Manufacturin

elding Wire
Flux Cored
uring

TA STAINLESS
HARDFACE
NICKEL

INLESS
E

FORGE ALLO
MAINTENAN
TOOL STEE
ALLOY Y STEEL

OYS
CE
EEL
EEL

12500 Grand River Rd.
MET, INC. - COR
CUSTOM ALLOYS
FORGE ALLO

and River Rd.
, INC.
OYS
OYS

met.co - sales@cor
met.com - ww www.cor
9266 - 227 - FA FAX: 810
27 - 848 - PH: 800
Brighton, MI 481

t.com
t.com
9266
719
116
Fig. 9 Robot arm with weld inspection system.
Fig. 10 Comprehensive on-board inspection report.
SEPTEMBER 2012 32
W
hen various surface technolo-
gies have many similarities, it
can be difficult to choose the
most appropriate for specific jobs.
This occurs frequently when deciding be-
tween laser cladding and thermal spray,
specifically high-velocity oxyfuel spray
(HVOF).
Once considered radically different,
both technologies have advanced to the
point that either is suitable for certain
applications. High-velocity oxyfuel coat-
ings are growing thicker, while laser
cladding coatings are becoming thinner.
Additionally, HVOF has reduced poros-
ity to levels that verge on being consid-
ered fully dense.
Still, the technologies behind HVOF
and laser cladding and the majority of
applications remain fundamentally
distinct. Coating with HVOF involves
spraying the material at a high velocity
and temperature, which softens the par-
ticles and forms a mechanical bond with
the roughened substrate. In contrast,
laser cladding melts both the material
being applied and the surface of the sub-
strate to form a metallurgical bond.
Functional Similarities
Both laser cladding and HVOF will
continue to converge for the next two to
five years, which will then create a shift
in commercial assessment. Presently,
HVOF is the only technology for thinner
Choosing a
Surface
Coating Technology
HVOF application of tungsten carbide
applied to a lumber roll using a DJ-
2600 spray gun. Coating is for
abrasion and corrosion resistance.
33 WELDING JOURNAL
coatings, such as 200 to 300 m (0.008 to
0.012 in.). However, despite HVOF ad-
vances in producing thicker coatings in
excess of 0.5 mm (0.02 in.), laser cladding
is preferred over HVOF for thicker coat-
ings Fig. 1.
Another area of convergence is poros-
ity. The fundamental principle behind
thermal spray necessitates that particles
are softened by heating and compacted
in a solid state, leaving small spaces be-
tween them that result in a porous coat-
ing. Porosity levels for HVOF have been
reduced to less than 0.5%, which is nearly
fully dense. Still, these pockets can cause
penetration of the coating when parts are
exposed to high-pressure environments
or long-duration tests. Despite HVOFs
decreasing porosity levels, laser cladding
is a completely dense surfacing solution.
Both coating technologies can create
residual stress on the substrate, distort-
ing it and potentially forming cracks in
the coating and/or the substrate. When
a laser cladding material is heated,
melted, and solidified, it shrinks, and
these temperature fluctuations cause in-
ternal stresses that can warp a thin part.
Though laser cladding has advanced to
minimize distortion levels, HVOF still
causes less stress and distortion risk be-
cause the material is neither fully melted
nor metallurgically bonded. The internal
stresses in HVOF coatings are what limit
the thickness.
Difference in
Application
One major application difference be-
tween these two technologies has to do
with how the coatings adhere to the sub-
strate. High-velocity oxyfuel creates a
mechanical bond between the coating
and substrate surface, allowing manufac-
turers to use any material. Laser cladding
creates an intermetallic alloy in the in-
terface zone between substrate and coat-
ing material and, as a result, is limited by
being able to bond only to materials that
are weldable. Manufacturers should en-
sure that the selected materials will cre-
ate a successful metallurgical bond, such
as a nickel deposit to iron substrate to
create a nickel-iron alloy. Materials that
are not compatible, such as titanium and
iron, could result in a weak intermetallic
layer that can easily crack.
Additionally, laser cladding has a
small melt pool, meaning the application
process can take longer than HVOF.
Thus, extra time for the application of
laser cladding materials can offset other
cost savings. High-velocity oxyfuel still
has a significantly higher deposition rate
but adds time with the increasing thick-
ness of the coating.
Surface Conditions
The parts surface conditions play a
role in determining the appropriate coat-
ing. High-velocity oxyfuels limited bond
strength is less ideal for parts that will be
subjected to high stress or impact load-
ing. The mechanical bond may cause the
coating to shatter or spall if subjected to
too much stress, particularly point-
loaded stresses such as with a hammer.
The stress may weaken laser claddings
alloyed coating but will likely not cause
it to debond.
The same rule of thumb can be ap-
plied to parts that will endure many ther-
mal cycles. Fluctuating temperatures
cause different metals to expand and con-
tract independently. This thermal shock
Fig. 1 Key surface enhancement
processes.
Knowing the strengths and
weaknesses of high-velocity
oxyfuel thermal spray and
laser cladding will help you
choose the right process
for your application
THOMAS PETERS is project
manager, Business Development
Laser Cladding, Sulzer Metco,
and THOMAS GLYNN
(thomas.glynn@sulzer.com) is
product line manager, Metals
and Alloys, Sulzer Metco,
Westburg, N.Y. Photo courtesy of
Sulzer Metco Coating Services.
BY THOMAS PETERS AND
THOMAS GLYNN
can stress and weaken the HVOF bond
interface, but this is not the case with
laser cladding because it creates a met-
allurgical bond.
Corrosion
Coatings are also vulnerable to corro-
sion, which can be aggravated by poros-
ity. Despite advances in HVOF, the lin-
gering pores if interconnected, render
the coating vulnerable to environmental
pressures that deteriorate the surface.
For example, a valve coated with the min-
imally porous HVOF would eventually
succumb to harsh seawater leaking
through the coating, causing corrosion at
the interface.
Such high-pressure environments
often necessitate laser cladding to pro-
duce a fully dense coating but these are
limited to materials that are weldable.
Manufacturing
Environment
Both coating technologies also have
different requirements in regard to man-
ufacturing environments. Compared to
laser cladding, HVOF covers a larger
spray area but is less precise. The rela-
tive velocities of the spray gun and part
need to be moved quickly or the coating
will accumulate too rapidly, which will
create excessive residual stress and bond
failure.
While thermal spray can be applied
both manually and via automated tech-
nology, laser cladding requires an auto-
mated factory environment for safety
reasons and because of the application
precision. Each weld track has to be po-
sitioned with tolerances below 1 mm
(0.04 in.), necessitating a robot to apply
the coating. With such a small coverage
area, what laser cladding gains in preci-
sion it loses in application time. Compar-
ing the two technologies, laser coatings
are applied in a narrow but relatively
thick layer while HVOF uses many wider
but thinner layers.
However, because HVOF is applied
in fine layers to mitigate the stress and
shrinkage issues, care must be exercised
to properly cool the part during the spray
process or the substrate may overheat.
This is not typically a concern with laser
cladding. With some HVOF coatings re-
quiring 50 passes, this process can de-
crease efficiency. Laser cladding may
also require a waiting period for the part
to cool as the materials are heated locally
beyond the melting temperature.
As mentioned previously, the differ-
ences in deposition rates, or material
mass per unit of time, are notably large
with HVOF having a significantly higher
rate. Though HVOF coatings can reach
0.5 mm (0.02 in.), laser cladding tends to
be more efficient often only one layer
is required.
When both technologies are auto-
mated and implemented using standard
industrial robots, the comparison be-
comes more apples to apples. Laser
cladding previously required compli-
cated manipulation using copper mirrors.
Now it uses the more simplified fiber-
optic bundles to control the laser beams.
On the other hand, a thermal spray gun
can easily be mounted at the end of a
robot or manually manipulated.
Thermal spray also requires speedy
manipulators and when covering a large
area, a large robot. However, this pres-
ents a paradox as a very large robot is also
slower.
Safety
When incorporating such potent tech-
nologies, safety is at the forefront of con-
sideration. Both laser cladding and
HVOF have their respective safety pre-
cautions for workers and are always en-
closed in an isolated cell. Laser cladding
requires compliance with general laser
regulations, such as protecting eyes with
special glasses, shielding the workers,
and safeguarding against welding fumes
and laser light wavelength.
With HVOF generating heat loads up
to 1 million BTUs, thermal spray booths
typically require large volumes of air ex-
change to keep temperatures within rea-
sonable limits. Another requirement is a
dust collector with closed-circuit air fil-
ters to vacuum the dust generated from
sub-25 m particles. The gun also gener-
ates extremely high temperatures and a
piercing noise that registers above safe
levels, so workers need to wear appropri-
ate protective gear if manually applying
the coating.
Energy and Material
Efficiency
Both technologies consume energy
and materials at different rates. Laser
cladding was previously a notorious en-
ergy consumer with an efficiency of less
than 10%. For example, a 5-kW laser
would demand 50 kW to power it. Fortu-
nately, laser cladding is now 30% effi-
cient, a radical enough improvement to
be considered power efficient.
Because of the energy-intensive gas
stream needed to heat the particles,
HVOF spray is considered less efficient
than laser cladding.
From a material standpoint, laser
cladding is more than 90% efficient, out-
performing thermal sprays 40 to 60% ef-
ficiency. This is due to the imprecision
of the HVOF spray cone, which does not
project some of the particles at a fast-
enough velocity. As a result, many parti-
cles bounce off the substrate and fail to
bond.
Though laser cladding and HVOF use
powder-based materials at similar price
points and availability, the particle sizes
differ. Laser cladding particles are
coarser and heavy enough that no filtra-
tion device is needed. Thermal sprays
finer particles are light enough to become
airborne, necessitating the dust collector
and air filters. Another component of
HVOF overspray waste is that some par-
ticles are so lightweight, they blow away
and never reach the substrate.
Application Equipment
The thermal spray gun can be easily
moved up, down, and into awkward
corners while the target part remains
stationary. If the part has a more compli-
cated design, the HVOF gun can be eas-
ily maneuvered to cover all contours. In
addition to manual application, HVOF
is versatile in that it can be also used with
an automated system. Because thermal
spray essentially blankets an area with a
continuous coating, the automated
programming is relatively simple in most
applications.
On the other hand, laser cladding is
much more complex. Each weld track in-
volves a repeated start-stop approach
where the laser starts and stops. As men-
tioned previously, each laser application
is comparably precise. Thus, the pro-
gramming effort is much more sophisti-
cated and requires the precise location
and dimensions of the part. Crucial to re-
ducing this time-consuming process,
offline programming tools are needed.
Access
Both technologies are line-of-sight
processes with different distance require-
ments. While the laser cladding powder
nozzle needs to be less than 25 mm (1 in.)
from the substrate for HVOF, a typical
distance range from 150 to 300 mm (6 to
12 in.) is common. When coating the
small space inside of a tube, thermal
SEPTEMBER 2012 34
spray can turn to the plasma spray
process as specialized internal spray guns
can be easily placed into a 100-mm part.
However, this is another area of conver-
gence as laser heads are continually be-
coming smaller and can presently fit in-
side a 3-in. bore.
Both guns operate at extremely high
temperatures, which affect the applica-
tion processes. Laser cladding creates
local temperatures above the melting
point of the material.
When laser cladding, the powder noz-
zle must be cooled because one-third of
the laser light is reflected toward the pro-
cessing head and not absorbed by the
melting process. The closer the powder
nozzle is located to the substrate, the
greater the risk of harming it.
The HVOF gun uses air and/or water
cooling to dissipate the heat of combus-
tion from the internal gun components.
Maintenance
With typical use, the laser itself is
durable enough to operate without main-
tenance for several months. There are
neither moving parts nor sensitive opti-
cal components. Because of the robots
movement, the fiber-optic cables even-
tually need replacement but that is often
measured in years. Depending on the ma-
terial being used, powder nozzles may
need to be replaced after 100500 hours.
With HVOF, the extremely high tem-
peratures and velocities cause the com-
ponents to wear quickly, measuring noz-
zle life in hours. Though frequent, noz-
zle replacements are simple and quick.
The materials used also determine the
change-out frequency. Abrasive materi-
als such as carbides are applied at a much
higher velocity, making the HVOF bar-
rels and nozzles wear out sooner than
with metallic materials, with which the
nozzles last several days.
Conclusion
There are many factors to enter into
the equation of whether to use HVOF or
laser cladding. Some are obvious choices,
such as if a thick and fully dense coating
is needed or if material compatability is
a concern. As these technologies con-
tinue to evolve, their applicability will
broaden. In the meantime, it is critical
that users work with material and equip-
ment suppliers that are knowledgeable
about both technologies to ensure a suc-
cessful coating application with the most
efficient and cost-effective surface
solution.
35 WELDING JOURNAL
SEPTEMBER 2012 36
T
o reduce vehicle weight and im-
prove fuel efficiency, advanced
high-strength steels (AHSS) have
been introduced to the automotive in-
dustry. Advanced high-strength steels
continue to gain momentum in the in-
dustry as a result of initiatives to increase
body rigidity (driving performance), im-
prove crash ratings, and improve fuel
economy (reduce weight to meet CAF
legislation requirements). These steels
have challenged manufacturing practices
in a variety of ways, from forming to join-
ing to inspecting.
A major issue with these higher-
strength, thinner materials is integrity of
spot welds. Typically, there are between
4000 and 7000 resistance spot welds on
U.S. manufactured automobiles, and the
reliability of the structure and safety of
passengers relies heavily upon sound
welds. It has been found that the stress
state at the weld, fracture toughness of
the weldment, and presence of pores,
cracks, and embrittled regions in AHSS
are driving factors that result in differ-
ing failure modes from conventional
steels, especially interface-type failures
(Ref. 1). It has been recognized that tra-
ditional resistance spot weld (RSW) de-
structive test methods (pry-bar or chisel
check and peel test, see Fig. 1) are costly
and inaccurate when applied to AHSS.
The automotive industry dictates for bet-
ter nondestructive means to be devel-
oped as a replacement for current de-
structive testing in order to ensure safe
implementation of AHSS steels.
Some advanced nondestructive exam-
ination (NDE) techniques that can pro-
vide solutions to the automotive market
already exist in other markets. Unfortu-
nately, a rapid technology transfer of
NDE techniques, already used in the
aerospace and power generation indus-
tries, to the automotive industry is lim-
ited because of fundamental differences
between these markets (Ref. 2). There
is still a gap to validate and correlate
NDE technique findings. The desired
status is to reduce the time for valida-
tion and increase the confidence in cor-
relation methodology with less engineer-
ing and laboratory time. To reduce the
repeatability gap, the automotive indus-
try desires improved robustness of NDE
techniques and little or no operator de-
pendence (Ref. 2).
These problems have been addressed
by using ultrasonic matrix pulsed array
An ultrasonic, 3-D matrix phased array probe
has been designed and tested for performing
nondestructive examination of resistance spot
welds on automotive chassis
JEONG K. NA (jna@ewi.org)
is technology leader, NDE
Group, Edison Welding Institute,
Columbus, Ohio.
Phased Array Testing of
Resistance Spot Welds
BY JEONG K. NA
Fig. 1 Destructive testing meth-
ods for resistance spot welds on
thin sheet metals: A Drive test;
B peel test.
1A
1B
37 WELDING JOURNAL
(MPA) technology as an alternative to de-
structive testing of AHSS. Initially, a two-
dimensional MPA probe was designed and
tested for validation purposes for the tech-
nology in terms of sizing weld nuggets and
locating flaws in the weldments. By shap-
ing the probe surface that fits to the gen-
erally concave shape of resistance spot
welds, it was found that the total number
of elements and operating frequency could
be lowered. This, in turn, helps to lower
the cost of the probe and electronics.
A New High-Frequency
MPA Probe
To reduce the cost and time for devel-
oping a reliable high-frequency MPA
probe with an appropriate delay line that
provides an optimum propagation dis-
tance for the ultrasonic beam to be
steered and focused onto a spot weld,
computational modeling and simulations
were performed upfront. A commercially
available CIVA modeling package was
used for this work.
Probe Modeling and
Simulations
It was necessary to define parameters
such as material thickness and spot weld
diameter for which the probe would be
used. A literature review and discussions
with clients in the automotive industry
revealed that the majority of spot weld
applications are for materials in the
thickness range of 0.7 to 2 mm having a
nominal weld diameter of 5 to 7 mm.
Some initial beam modeling calculations
were done to determine general param-
eters for a probe that would be capable
of inspecting spot welds in the targeted
range. Consideration was also given to
current MPA instrumentation capabili-
ties. Many MPA instruments on the mar-
ket today have a maximum limit on the
number of elements in the order of 128.
Figure 2 shows a schematic of a 2-D MPA
probe element with some probe param-
eters evaluated using the beam modeling
tools. The same probe parameters apply
to 3-D probes with additions of curvature
shape and radius.
To achieve good focusing at a depth
of 0.7 to 2 mm, it was necessary for the
probe to have a physical delay distance
between the probe element and the part
surface. Since water can offer the ability
to conform to surface deformations
Fig. 2 Schematic of a 2-D matrix
phased array probe element.
Fig. 3 Modeling results of the
water path length dependence at the
water and metal interface.
Fig. 4 Modeling results of water
path lengths at the interface of two
2-mm metal sheets.
2
3
4
SEPTEMBER 2012 38
caused by the welding electrodes, the
delay line tip was assumed to be filled
with water. The images in Fig. 3 show
beam profile results using a 3 3 aper-
ture at different water path lengths as the
sound passes through the water and
metal interface. By observing these im-
ages, it can be seen that a water path
length of 18 mm produces a narrow beam
with minimum side lobes. Quality of the
ultrasonic beam within the metal sheets
was also simulated for different water
path lengths with a 3 3 aperture. As
shown in the images in Fig. 4, at the water
path length of 18 mm, the best beam fo-
cusing effect was achieved with small side
lobes.
Based on the two modeling results
shown in Figs. 3 and 4, a hand-held probe
was designed and fabricated with a water
delay line cavity at the end of the probe.
A subsequent modeling investigation for
a 64-element probe with 8 8 matrix
configuration operating at a frequency
of 12 MHz proved that the same water
delay line could be used. In this case, the
probe element was shaped to have a con-
vex curvature with a radius of 50 mm. The
modeling result of beam quality and a
schematic drawing of the 3-D MPA probe
are shown in Fig. 5.
NDE and Statistical
Validation
Resistance Spot Welded
Sample Preparation
Two sets of spot weld samples with two
sheet stackups having thicknesses at the
theoretical lower limit (0.7-mm-thick
sheet metal) of the probe design were
prepared. Two rows of nine spot welds
were made on test sample No. 1. For this
sample, a constant current of 6 kA was
applied for all welds while the number of
cycles was varied from 1 to 9 at an incre-
ment of 1 cycle for each weld. For the
sample set No. 2, weld current was ad-
justed such that three welded conditions
were obtained: stuck weld, where there
was localized melt and resolidification of
the zinc coating; a small nugget condi-
tion, where the button pulled was smaller
than the generally accepted 4 t in di-
ameter; and a good weld condition,
where the button pulled was larger than
4 t in diameter. Spot welds on both sam-
ple sets were tested using the MPA in-
spection system and then destructively
examined to determine the actual weld
condition and to measure the weld
Fig. 5 CIVA modeling result for
the ultrasonic beam quality and
schematic drawing of a 3-D MPA
probe. A Beam quality of 3-D
MPA probe; B schematic of a 3-D
probe.
Fig. 6 Images of resistance spot
welds of both test sample sets. A
Resistance spot weld NDE sample
No. 1; B example spot welds of
test sample set No. 2.
5A
5B
6A
6B
nugget size just for the sample set No. 2.
The test sample set No. 1 and an exam-
ple piece of sample set No. 2 are shown
in Fig. 6.
Test Results and
Discussions
The MPA ultrasonic inspection results
for the sample set No. 1 are shown in Fig.
7. The number in the upper-left corner
of each image indicates the number of
electric current cycles used to form the
weld nuggets. In both upper and lower
rows, a good acceptable size spot weld
was measured after four cycles. The left
and right numbers shown in the upper
portion of each ultrasonic image indicate
nondestructively estimated nugget diam-
eter and area, respectively. It was noticed
that the nugget size did not improve as
much after five cycles. For both rows, the
overall increase in nugget size was less
than 10% after five cycles. Each inspec-
tion took less than 10 s.
The welds in sample set No. 2 were
examined first with the MPA inspection
system before the planar metallography
technique where one of the welded
sheets was ground away to reveal the
weld nugget was used to estimate the
nugget size destructively. This method
provided a full planar view of the weld
region without distorting the weld but-
ton. The NDE results are plotted against
the destructively measured data as shown
in Fig. 8.
The test result of set No. 2 in Fig. 8
shows a good correlation with the actual
nugget size. The dotted line in the graph
indicates the 95% safety limit against un-
dersizing (LUS), which is a combined pa-
rameter between systematic (average)
error and standard deviation. A slight un-
dersizing trend (positive false call) is ob-
served from these data and the calculated
LUS was approximately 1 mm. This LUS
value in the range of 1 mm is considered
to be a good NDE reliability.
Conclusions
A high-frequency, ultrasonic, 3-D
MPA probe designed to perform nonde-
structive examination of resistance spot
welds on automotive chassis has been de-
veloped and tested. The NDE results of
spot welds made on two 0.7-mm metal
sheets with different cycle numbers at a
constant electrical current level showed
that a good weld nugget with an accept-
able diameter and area can be formed
after four or five cycles. This means that
the number of cycles currently used on
automotive chassis could be reduced to
save time and cost without overwelding
with extra numbers of cycles. The PoD in-
vestigation performed on the two 0.7-mm
stackups showed a tight nugget size dis-
tribution between 4 and 6 mm with a good
correlation between the NDE results and
the destructive results with an undersiz-
ing factor of 1 mm. Additional benefits
obtained from a 3-D MPA probe design
are thought to be lowering the operating
frequency and total number of elements,
which can play major roles in reducing
the costs of probe and electronics.
References
1. Gould, J., and Peterson, W. 2005.
Advanced materials require advanced
knowledge Understanding resistance
spot weld performance on AHSS. The
Fabricator Vol. 35, No. 8.
2. Hopkins, D., and the USAMP NDE
Steering Committee. 2007. Reliability in
high volume manufacturing: An automo-
tive perspective. Materials Evaluation.
39 WELDING JOURNAL
Fig. 7 Ultrasonic images of spot
weld nuggets for sample set No. 1.
A Upper row; B lower row.
Fig. 8 Probablity of detection
(PoD) result for test sample set No. 2.
7B
8
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T
hermal spraying is not usually re-
garded as a green technology
that helps to conserve the environ-
ment and natural resources. Yet, the
process has been at the forefront of con-
servation of materials and energy since it
was first developed in the early 1900s. For
example, thermal spray has provided a
second or green life to products by
restoring or remanufacturing damaged
parts associated with everything from
aerospace to zoos.
Thermal spraying is defined (Ref. 1)
as a group of processes in which finely
divided metallic or nonmetallic surfacing
materials are deposited in a molten or
semimolten condition on a substrate to
form a thermal spray deposit. The sur-
facing material may be in the form of
powder, rod, cord, or wire.
Remanufacturing is defined (Ref. 2)
as an industrial process in which worn-
out products are restored to like-new
condition. In contrast, a repaired prod-
uct normally retains its identity, and only
those parts that have failed or are badly
worn are replaced or serviced.
When to Remanufacture
There are several green reasons to
consider remanufacturing, including the
following:
41 WELDING JOURNAL
Thermal Spray
Wins as a
Green Technology
Remanufacturing worn parts using thermal spray
technologies can be a lucrative business that can
conserve materials, energy, and time
BY RICHARD S. BRUNHOUSE,
PETER FOY, AND
DALE R. MOODY
RICHARD S. BRUNHOUSE, PETER FOY, and DALE R. MOODY (DaleRMoody@aol.com) are with Plasma Powders and Systems,
Inc., Marlboro, N.J.
Thermal spray was used at the
Xiaolangdi Power Dam site in China
to cover welds with tungsten car-
bide to protect them from the abra-
sive sand in the Yellow River.
1. The reuse of the core or base ma-
terials conserves natural resources.
2. A significant portion of the energy
consumed to configure the original part
is conserved.
3. Reduced cycle time. For thermal
spray operations, the time to remanufac-
ture a part is significantly less than the
time needed to order and receive a re-
placement part.
Remanufacturing can be considered a
win-win-win situation compared with
manufacturing: the customer pays less,
the remanufacturer earns more, and the
environment is protected (Ref. 3). These
points are illustrated in Fig. 1 (Ref. 4).
For thermal spray operations, there is
an additional element to the life-cycle di-
agram. That has to do with specialized
machinery for thermal spray; for exam-
ple, chambered or controlled-atmos-
phere thermal spray systems. Often,
these specialized systems are recycled
to the remanufacturer for a second life.
In Fig. 1, note that remanufacturing is
the most labor-intensive operation of the
three Rs (Reuse, Remanufacture, Recy-
cle). It has been estimated that the re-
manufacturing process is, in general,
three to five times more labor-intensive
than manufacturing of the same product.
The stripping, cleaning, inspection, and
sorting are activities that are not present
in manufacturing. Also, the batch sizes
are much smaller and the degree of au-
tomation is lower than in manufacturing.
Therefore, the core value has to be high
for remanufacturing to be cost-effective.
Typical Thermal
Spray Cycle
A typical thermal spray remanufactur-
ing cycle is diagrammed in Fig. 2. The
steps shown in the figure may differ from
the those associated with other remanu-
facturing operations. In many remanu-
facturing procedures, cleaning is done
prior to inspection in order to reveal de-
fects. For thermal spray, cleaning typi-
cally follows inspection since faults that
would cause rejection of the core are usu-
ally apparent before cleaning, and the
thermal spraying is usually performed on
a freshly cleaned (grit-blasted) part to en-
sure coating integrity.
A number of studies have been carried
out to gain a better understanding of re-
manufacturing and its implementation
(Refs. 58). An objective of this article is
to apply and expand some of those find-
ings to the thermal spray industry, specif-
ically, what is needed to put into practice
the recommendations from these studies.
Types of
Remanufacturers
These studies considered three types
of remanufacturers: original equipment
manufacturers, contracted remanufactur-
ers, and independent remanufacturers.
Original Equipment Manufacturers
(OEMs) may remanufacture their own
components. Many diesel engine and gas
turbine manufacturers (such as Caterpil-
lar and GE) perform their own remanu-
facturing. The OEM remanufacturer has
the advantage of having detailed infor-
mation regarding the thermal spray
process needed for the component. The
OEM may also have access to specialized
machinery such as controlled-atmos-
phere thermal spray systems. In addition,
by carrying out their own remanufactur-
ing, the OEM maintains control of any
proprietary materials and processes. The
distribution is also easier since, in many
cases, the OEM has a direct relationship
with the end user. The disadvantage that
the OEM remanufacturer has is usually
higher overhead resulting in higher
prices for the remanufactured product.
One engine manufacturer indicated that,
despite its higher overhead, it attributed
its competitiveness to factory methods
carried over from the OEM, resulting in
higher worker productivity. This com-
pany also claimed higher efficiencies re-
garding use of equipment, facilities, and
energy (Ref. 6).
Contracted remanufacturers include
companies that have an established con-
tract to remanufacture components for
an OEM. Some gas turbine manufactur-
ers have set up separate companies for
this purpose in order to maintain control
of the remanufacturing without conflict-
ing with their own OEM operations. The
OEM-owned or controlled remanufac-
turer usually has less restrictive business
requirements compared to the OEM and,
therefore, can hold the costs down.
SEPTEMBER 2012 42
Fig. 2 Diagram of the
remanufacturing steps for
thermal spray.
Fig. 1 Diagram of a product
life cycle.
Receive Inspect Clean Spray Machine Inspect Ship
Independent remanufacturers for
thermal spray operations are typically job
shops that remanufacture components
supplied to them by their customers. In a
few cases, the thermal spray job shop may
purchase the cores from one party and
then sell the remanufactured component
to another company. The operations usu-
ally have very limited association with the
OEM but a close relationship with the
customer. A good example of this type of
remanufacture is the thermal spray oper-
ation serving the pulp and paper industry.
It is often preferable to thermal spray and
machine large calendar rolls, boilers, and
digesters in situ to avoid the time and ex-
pense of removing and shipping them.
The independent thermal spray opera-
tors serving the pulp and paper industry
are able to provide this service since they
have the portable equipment required to
make the repairs.
End-User Operations
In addition, thermal spray has a fourth
type of remanufacturer not discussed in
these studies, the owner or end user. The
owner or end user, including many air-
lines such as American, Delta, and
United, have their own thermal spray
shops for remanufacturing aircraft com-
ponents. This arrangement is feasible be-
cause the airlines are closely associated
with the aircraft manufacturer from the
conception of an aircraft, and therefore
can plan on and control the remanufac-
turing requirements (design for remanu-
facturing). Airlines often need a quick
turnaround of parts and must avoid the
delays associated with shipping the parts
to another shop. Airlines need to be fa-
miliar with the equipment for mainte-
nance and safety, and therefore are posi-
tioned to remanufacture the parts.
Airlines have a significant number of air-
craft to justify maintaining a stock of re-
manufactured parts.
This airline-aircraft association has
been beneficial to the ecosystem in an-
other respect. It was this association that
led to the Hard Chrome Alternatives
Team (HCAT) program that developed
(green) alternatives for using hard-
chrome coatings on landing gear struts
and other components. This environmen-
tally friendly process also allows for rapid
turnaround of these critical parts.
Use by Power Companies
Some land-based power companies
attempted to follow this same business
model but ran into many problems when
they tried to bring the remanufacturing
of turbine engine components in-house.
For example, the company had relatively
few gas turbines from a number of differ-
ent manufacturers (see point 4 in the fol-
lowing list). The company had limited
knowledge of the manufacturing meth-
ods, many of which were proprietary (see
point 3 in the following list). The com-
pany did not have the specialized equip-
ment needed for a number of the reman-
ufacturing operations (see point 3 in the
following list).
Conditions for Success
The following is a list of conditions
that are necessary to ensure the success
of any remanufacturing operation.
1. Availability of a core that has value
and can be reused.
2. The cost to remanufacture the core
must be significantly less than the value
of the end product.
3. The technology is available to re-
store the core to as-new condition.
4. The part can be mass-produced in a
factory environment (unless it is a high-
value part such as a calendar roll).
5. The value of the remanufactured
part is close to the value of a new part.
6. The part is not prone to obsoles-
cence.
The studies also noted several obsta-
cles encountered by independent reman-
ufacturers, including the following.
1. The OEM usually has to deal with
only a few models at any given time. On
the other hand, the remanufacturer often
has to deal with numerous models or vari-
ations extending over a period of time.
2. Special components or materials
may not be available to the independent
remanufacturer.
3. The need for long-lead-time or
custom materials imposes delays.
Other problems encountered in re-
manufacturing are poorly defined acces-
sibility to used products to be remanu-
factured, and a poorly defined, variable
remanufacturing process.
Advantages of Using
Thermal Spray
Remanufacturing using thermal spray
has several advantages compared to
other remanufacturing operations. Most
components to be remanufactured using
thermal spray operations generally do
not experience rapid obsolescence.
Moreover, thermal spray is a mature
process that does not experience a high
rate of technical innovations. In fact,
some thermal spray operators success-
fully use equipment that is 50 years old.
Therefore, some level of technical fore-
casting is possible.
The Three Main Concerns
The three main challenges that a ther-
mal spray remanufacturer faces are core
collection, the labor-intensive process,
and redistribution.
Core collection for thermal spray op-
erations is often voluntarily performed by
the end user due to the high value of the
core. The main problem for the remanu-
facturer is to identify the end users and
develop a relationship for acquiring the
cores. A remanufacturing firm typically
has a large number of core sources,
meaning they have to bring together a
large number of small-volume flows that
increases the collection complexity.
Controlling the quality, quantity, and
timing of the returned products is key for
creating a profitable remanufacturing
operation.
The labor-intensive thermal spray
process is exacerbated by the stripping
and special cleaning (grit blasting) oper-
ations normally not present in other man-
ufacturing processes. In addition, special
quality assurance requirements, such as
spraying, preparing, and evaluating test
coupons, may be necessary.
The uncertainty in core quality also
adds challenges to the thermal spray re-
manufacturing process. Two returned
products that are identical except for
quality might require two different sets of
remanufacture programs, which make
planning and control more difficult. Also,
when looking at one type of product
within the same remanufacturing facility,
the processing steps are, to a large de-
gree, dependent on the condition of the
product. Unlike manufacturing, remanu-
facturing does not have a fixed sequence
of production steps.
Redistribution. A typical remanufac-
turing firm serves a number of small mar-
kets and uses a variety of products and
strategies to serve these markets. These
are often different from each other. Also,
the recovered products often are distrib-
uted to a large number of customers.
Complications can be caused by many
different products being in the same sup-
43 WELDING JOURNAL
ply chain and in different phases of the
product life-cycle. In one study (Ref. 4),
Cummings OER, a Toronto remanufac-
turer of gasoline engines, was evaluated.
With its association with the OEM oper-
ations, Cummings OER was able to pro-
vide flexibility to market demands with a
quality product.
Entering the Business
Anyone thinking about entering or ex-
panding into the remanufacturing busi-
ness should start with a detailed business
finance model. This model can start with
a business plan overview and then be de-
veloped over the three remanufacturing
divisions previously discussed. When
considering entering several different
markets, it would be well to develop a
separate plan for each market.
Begin with a mission statement as to
which market to pursue (i.e., remanufac-
turing of printing rollers). Include a
statement as to where you plan on posi-
tioning your organization in the market
(price, responsiveness, quality demon-
strated by offering a warranty, etc.). This
would be a place to identify the competi-
tion along with estimates regarding quan-
tities, market share, and pricing. Include
the OEM as a competitor.
The plan should also include a state-
ment regarding business readiness; are
any permits needed, is the required ther-
mal spray equipment available, are qual-
ified operators in place, are any special
quality control or lab services needed?
Other considerations include the follow-
ing areas listed below.
Collection. How do you plan to collect
the cores (printing rollers is being used as
an example). This would include the fol-
lowing: Where are the cores when re-
tired? How many, how often? Who owns
the cores following retirement? If you
own them, how will they be inventoried,
stored, etc.? Is there anything your or-
ganization can do to encourage collec-
tion of the cores? For example, provide a
prepaid shipping container. What are the
conditions of the cores when shipped?
For example, are the bearings in place on
the rollers? What protection is needed
for the cores during shipment? Is there a
need to maintain the identity of each
core?
Process. The process steps must be
detailed and correlated to the machines
and the operators. The process starts
with the receipt of the cores through the
delivery of remanufactured cores. It
needs to include stripping of the old coat-
ing, examination of the part prior to coat-
ing, postcoating machining or polishing,
and replacing other elements, such as the
bearings on a printing roll.
Redistribution. How will the remanu-
factured part be distributed: placed in
stock for later sale, or sent directly to the
customer? Will there be any follow-up
items such as commissioning or running
in the part?
Once developed, the business model
should be reviewed, revised, and kept
up to date as a true reflection of the
business.
Conclusions
Remanufacturing can be a win-win-
win situation. It can make your customer
happy, the environment cleaner, and
your bank balance healthier. This article
references several studies that include in-
terviews with successful remanufacturers
who present ideas that should be consid-
ered by everyone contemplating entering
the remanufacturing business.
References
1. AWS A3.0M/A3.0:2010, Standard
Welding Terms and Definitions. 2010.
American Welding Society. Miami, Fla.
2. The Association for Operations
Management (APICS). www.apics.org.
3. Lundmar, P., et al. Industrial chal-
lenges within the remanufacturing sys-
tem. Linkping University.
4. Nasr, N., et al. Remanufacturing: A
key enabler to sustainable product sys-
tems. Rochester Institute of Technology.
5. Sundi, E. Product and process de-
sign for successful remanufacturing.
Linkping Studies in Science and Technol-
ogy. Dissertation No. 906.
6. Adler, D. P., et al. 2007. Comparing
energy and other measures of environ-
mental performance in the original man-
ufacturing and remanufacturing of en-
gine components. Proceedings of the 2007
International Manufacturing Science and
Engineering Conference.
7. Subramoniam, R., et al. 2009. Re-
manufacturing for the automotive after-
market-strategic factors: Literature re-
view and future research needs. Journal
of Cleaner Production 17: 11631174.
8. Subramoniam, R., et al. 2010. Af-
termarket remanufacturing strategic
planning decision-making framework:
Theory and practice. Journal of Cleaner
Production 18: 15751586.
SEPTEMBER 2012 44

Decal Series
By
The Welding Journal:
Digitized and Ready to Travel
SEPTEMBER 2012 46
N
ot since the introduction of desktop publishing in the 1980s
has the world of publishing been revolutionized so pro-
foundly as with the popularization of smart phones and
tablets. Current mobile devices have changed the way we purchase
and consume reading material from magazines and newspapers
to books and encyclopedias and the digital publishing revolution
is here to stay.
Although printing is still alive and well in most magazine cate-
gories, digital editions are on the rise and growing in tandem with
the steady increment in smart phones and, especially, tablet sales.
The American Welding Society (AWS) is pleased to present the
new digital edition of the Welding Journal. For those of you who may
not know, the digital edition has been offered (for desktop reading)
The new digital edition of the Welding Journal offers an
enhanced reading experience both on desktop computers
and mobile devices, and Apple iOS users get a dedicated
reading app for the iPad and iPhone
BY CARLOS GUZMAN
(cguzman@aws.org) is editor,
Welding Journal en Espaol.
Fig. 1 Some of the features of the reading window are adjustable page zooming, highlighted active Web links and email addresses,
and jumping to a specific page by entering the page number.
Fig. 2 The menu in the upperright corner offers
the following functions:
1. Show table of contents
2. Save issue to your desktop for offline reading
3. Print
4. Help using the reading window, menus, and options
5. Access and search the archives
6. Full screen mode
7. Download as a PDF.
1 3 2 4 5 6 7
On the Go with Mobile Web
Browsers
One of the niftiest features of the new
digital edition comes to life when the is-
sues are accessed through a mobile de-
vice (smartphone or tablet), which auto-
matically detects and formats the
browser to add functionality similar to
the reading window of the desktop digi-
tal edition. The mobile browser Web app
gives you direct access to the archives
(dating back to December 2011), lets you
highlight any active links in the page, and
gives you the option to save the issue in
your mobile device as a PDF file for of-
fline reading Fig. 3. The Web app is
compatible with mobile browsers in iOS
devices (iPad and iPhone), Android (2.2,
2.3, or 4.0), Blackberry OS 6, and Ama-
zon Kindle Fire.
47 WELDING JOURNAL
Fig. 3 The Web app automatically rec
ognizes that the issue is being accessed
through a mobile browser (A) and adds
functions such as page navigation (B).
to all international and student members since 2009, mainly to
save trees, fuel, and the expense of printing and mailing hard
copies. However, AWS recently switched to a new digital pub-
lishing vendor that offers a greatly improved reading interface
on desktop and particularly a highly functional Web app
that runs within most mobile browsers (more on this later), so it
has been decided to expand the distribution of this new and im-
proved digital edition to all AWS members.
If you want to receive this new digital edition, do nothing:
Youve probably already received a notification via e-mail in-
troducing you to this news. But if you havent received a notifi-
cation, it means that either we dont have your e-mail address
on file, or your e-mail system is filtering our e-mail notifications.
Please be sure to include the e-mail address info@american-
weldingsociety.org in your safe list, and get in touch with our
membership department to update your records in case you
havent received the notification [(800) 443-9353, ext. 480, or e-
mail rhenda@aws.org]. If youd rather not receive the digital edi-
tion, simply hit the unsubscribe link at the bottom of the e-mail
notification. Domestic members will continue receiving the hard
copy as usual.
We also are pleased to introduce our new Apple iOS reading
app for iPad and iPhone. If you own one of these devices, we are
sure you will appreciate the added convenience of a reading app.
The Welding Journal iOS app is available through iTunes by typ-
ing in the search window the words welding journal, or you
may have received our e-mail notification already with the
direct link. Read on for more details about these new reading
platforms.
Reading in Your Desktop: A Great Experience
Digital publishing of magazines has been around since the
1990s, and although it has not developed into the revolution that
mobile publishing has created, it is an important media that of-
fers a lot of practicality to the experience of reading a magazine.
Beside the fact that some of us find our computer screen irre-
sistible to look at, reading a magazine on your desktop offers
some unique advantages, such as a global search that can include
one or all the issues in the archive, and a convenient way to keep
all your issues handy in one place. It is also a great research tool,
as having a library of the Welding Journal available at your fin-
gertips can save you time, and the active Web and e-mail links
allow you to easily interact with the content Figs. 1 and 2.
A
B
iPad, iPhone Users Rejoice
Available free to all members through
Apples iTunes Store, The Welding Jour-
nal app lets you read the issues online, or
you may download them for offline read-
ing, which comes in handy when traveling
and an Internet connection is unavailable
Fig. 4. The app is free to download, but
it requires your member ID and pass-
word. If you have logged in to the AWS
Web site before, you have probably
known that by default, your zip code is
your password, or you may have created
a new password already. The app will
grant you access when using your pass-
word or zip code, and additionally, you
may also use your last name as a password
Fig. 5. Feel free to change it to a per-
sonalized password following the instruc-
tions in the login window, or through the
AWS Web site. Please get in touch with
our membership department should you
encounter any problems logging in.
What the Future Holds
Everything indicates that the mobile
device market will continue to explode as
technologies improve and prices de-
crease, and tablets offer an especially ap-
pealing platform for reading magazines.
Whether you choose to use the iOS app
on your iPad, or to view it online through
an Android device, mobile publishing
sure brings fun and convenience to the
reading experience. In the same manner,
desktop magazine reading also is on the
rise, and we think it will continue to so-
lidify itself as a ubiquitous platform for
magazine reading. AWS hopes you find
these new reading options for the Welding
Journal valuable, as we strive to further
expand your member benefits.
SEPTEMBER 2012 48
Fig. 4 The Apple app allows you to read
the issues online (see the Read button in
the middle of the page) or download for
offline reading (Download button). The
archive dates back to December 2011, and
new issues are added to the catalog
around the first day of every month.
Fig. 5 The Welding Journal iPad and
iPhone app is free to download, but it
requires login to access the content. By
default, your password is your zip code or
your last name.
Whether you choose to
use the iOS app on your
iPad, or to view it online
through an Android
device, mobile publishing
sure brings fun and
convenience to the
reading experience.
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Hosted by:
Earn PDHs toward your AWS recertification or renewal when you attend the conference!
For the latest conference information, visit our website at
www.aws.org/conferences or call 800-443-9353, ext. 264.
September 20 21, 2011
Fort Lauderdale, Fla.
Attendee Registration
AWS Members: $550
Nonmembers: $680
Exhibitor Registration
AWS Members: $750
Nonmembers: $880
At this conference, a distinguished panel of aluminum-industry experts will survey the state of the art in aluminum
welding technology and practice. The 14th Aluminum Welding Conference will also provide several opportunities
for you to network informally with speakers and other participants, as well as visit an exhibition showcasing products
and services available to the aluminum welding industry.
Hosted by:
A distinguished panel of aluminum-industry experts will survey the state of the art
in aluminum welding technology and practice during this two-day conference.
September 18
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Register today
Members $675 / Non-Members $805
For the latest conference information and registration visit our web site at
www.aws.org/conferences or call 800-443-9353, ext. 264.
Earn PDHs toward your AWS recertification when you attend the conference.

September 18

I i H
th
- 19
th
September 18

e I t t a e S n o t I


.aws.org/conference

or call 800-443-9353, ext. 264. .aws.org/conference

or call 800-443-9353, ext. 264.


Earn PDHs toward your

WS recertification when you attend the conference. A Earn PDHs toward your
.aws.org/confe ww. ww

WS recertification when you attend the conference.
or call 800-443-9353, ext. 264. s .aws.org/conference

or call 800-443-9353, ext. 264.


Welcome and Overview
Tony Anderson, Conference Committee Chair
The Aluminum Designation System
Frank Armao, The Lincoln Electric Co.
Aluminum Welding Metallurgy
Bruce Anderson, MAXAL International
Design and Performance of Aluminum Welds
Bruce Anderson, MAXAL International
Filler Alloy Selection Primary Characteristics
Patrick Berube, MAXAL International
Metal Preparation for Aluminum Welding
Greg Doria, The Lincoln Electric Co.
Gas Metal Arc Welding of Aluminum Alloys
Frank Armao, The Lincoln Electric Co.
The Fundamentals of GTAW Welding of Aluminum
Brent Williams, Miller Electric Mfg. Co.
Aluminum Weld Discontinuities: Causes and Cures
Tony Anderson, ITW Welding North America
Application of the AWS D1.2 Structural Welding CodeAluminum
Thom Burns, AlcoTec Wire Corp.
Friction Stir Welding and Processing of Aluminum Alloys
Christopher B. Smith, Friction Stir Link Inc.
Technology Advancements and Automation in the Aluminum Welding Industry
Kevin Summers, Miller Welding Automation
Increasing Performance and Production in Aluminum GMAW Welding
Thom Burns, AlcoTec Wire Corp.
Welding Aluminum for Marine Applications
Jerry Mirgain, AlcoTec Wire Corp.
Low Heat Input GMAW of Thin-Gauge Aluminum Structures
Mike Ludwig, Fronius USA
Real Welds, Real Problems, Real Solutions
Rob Krause, AlcoTec Wire Corp.
Techniques for Soldering Aluminum Alloys
Dr. Yehuda Baskin and William Avery, Superior Flux & Mfg. Co.
Engineering Design and Strength Assessment of Aluminum Weldments
for Static and Cyclic Loading
Mike Weaver, Weaver Engineering
The Fundamentals of GT
Armao, Frank
Metal Arc Gas
Greg Doria,
Metal Preparation for
Patrick Be
elding of W W AAW ndamentals of GTTA
The Lincoln Electric Co. Armao,
of Aluminum Alloys elding W Metal Arc
The Lincoln Electric Co. Greg Doria,
Aluminum W Metal Preparation for
International erube, MAXAL
Aluminum elding of
of Aluminum Alloys
elding Aluminum W
Thom Bur
Friction Stir W
Thom Bur
Application of the
Anderson, ITW W ony TTo
Aluminum W
ec Wire Corp
elding and Processing of Friction Stir W
ec Wire Corp. AlcoT AlcoTTe Te rns, rns
WS D1.2 Stru AAW Application of the
America elding North erson, ITW WWe
eld Discontinuities: Causes and Cures Aluminum W
elding CodeAluminum
Alloys Aluminum elding and Processing of
WS D1.2 Structural W
America
eld Discontinuities: Causes and Cures
elding of
Alloys
elding CodeAluminum
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Advancements and logy
Aluminum W Automation in the
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CONFERENCES
Conference on U.S. and European Welding
Standards: Structural, Pressure Piping,
Pipelines, Railroad, NDT
October 22, 23
Munich, Germany
The American Welding Society has partnered with Ger-
manys Gesellschaft fr Schweitechnik International (GSI)
to deliver this conference, in which U.S. and European weld-
ing standards will be presented, compared, and discussed. With
increased globalization and complexity of supply chains, more
companies have realized the need to be knowledgeable about
multiple national and international fabrication codes and stan-
dards. Engineers, inspectors, supervisors, and quality control
personnel who are familiar with one set of standards, but who
need to know more about the other set of standards, will find
this of benefit. The conference will be conducted in English.
The format will be that one expert presentation on the U.S.
standards will be followed by an expert presentation on the com-
parable European standards for each topic.
FABTECH 2012,
November 1214
Las Vegas, Nev.
North Americas largest metal forming, fabricating, welding,
and finishing event heads to the Las Vegas Convention Center. If
your job requires you to look for new ways to work smarter, oper-
ate leaner, and boost productivity, then you and your team need to
attend FABTECH. Make plans now to attend your industrys main
event where youll find the products, resources, and ideas to
strengthen your business and achieve your manufacturing goals.
Following are conferences to be offered at the Show.
Activity Picks up in Underwater Welding
November 12
Installations in the Gulf of Mexico in particular are increas-
ing and the divers in those areas are making sure that everything
is okay in all of the welds connected to the offshore platforms.
Uwe Aschemeier will be on hand to discuss the performance of
wet welding electrodes as well as tell you about some underwa-
ter repair work.
Covering the Many Aspects in
Health and Safety
November 13
As industry awaits the next ruling on fumes from manganese,
companies have their work cut out for them in such areas as the
control of radiation, ventilation, welder comfort and visibility,
plasma cutting, and the light from lasers. There is much to keep
tabs on. This conference will focus on many of the solutions.
What Are Some of the New Wrinkles in
Nondestructive Testing?
November 14
Such processes as alternating current field measurement
(ACFM), time of flight diffraction (TOFD), computed radiogra-
phy, and the many types of phased array methods are moving more
and more into critical inspection lines. This conference will also
provide information on the new technologies that are being ap-
proved for use in the demanding work under the ASME Code.
For more information, please contact the AWS Conferences
and Seminars Business Unit at (800) 443-9353, ext. 264, or e-
mail zoliva@aws.org. You can also visit the Conference De-
partment Web site at www.aws.org/conferences for upcoming
conferences and registration information.
SEPTEMBER 2012 52
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COMING
EVENTS
GAWDA Annual Convention. Sept. 912. The Broadmoor, Col-
orado Springs, Colo. Gases and Welding Distributors Assn.
www.gawda.org.
IMTS 2012, Intl Manufacturing Technology Show. Sept. 1015.
McCormick Place, Chicago, Ill. Association for Manufacturing
Technology. www.IMTS.com.
6th Intl Quenching and Control of Distortion Conf. Sept. 1013.
Radisson Blu Aqua Hotel, Chicago, Ill. ASM International Heat
Treating Society. www.asminternational.org/content/Events/qcd/.
15th Annual Aluminum Welding Conf. Sept. 18, 19, Seattle,
Wash. Industry experts will survey the state of the art in aluminum
welding technology and practice. American Welding Society.
www.aws.org/conferences.
ICALEO, 31st Intl Congress on Applications of Lasers and
Electro-Optics. Sept. 2327. Anaheim Marriott Hotel, Anaheim,
Calif. Laser Institute of America. www.icaleo.org.
8th Annual Northeast Shingo Prize Conf.: Learning to Share.
Sept. 25, 26. DCU Center, Worcester, Mass. (617) 287-7630;
www.neshingoprize.org.
2nd Intl Conf. Welding Trainer 2012, The Future of Education.
Sept. 26, 27. GSI, Duisburg, Germany. www.weldingsimulation.
eu/en/home/.
Northern Welding Trade Show. Sept. 26, 27. Materials Joining In-
novation Centre, Northern College, Kirkland Lake, Ont.,
Canada. www.northernweldingtradeshow.com.
2012 Intl Conf. on Advances in Materials Science and Engineer-
ing. Sept. 27, 28. Bangkok, Thailand. Singapore Society of Me-
chanical Engineers. www.smss-sg.org/amse2012/index.htm.
Sheet Metal Welding Conf. XV. Oct. 25, VisTaTech Center,
Livonia, Mich. This is the premier conference dedicated to ad-
vancing the science and technology of sheet metal welding. Spon-
sored by the AWS Detroit Section. www.awsdetroit.org.
2nd Intl Welding and Joint Technologies Congress and 19th
Technical Welding Sessions. Oct. 35. Civil Engineering School,
Polytechnic University of Madrid, Spain. Sponsored by the Span-
ish Welding Association. www.cesol.es/jornadas2012.htm.
2nd Intl Conf. on Mechanical Materials and Manufacturing En-
gineering. Oct. 5, 6. Dalian, China. www.icmmme-conf.org.
TITANIUM 2012, 28th Annual Conf. and Expo. Oct. 710. Hilton
Atlanta Hotel, Atlanta, Ga. International Titanium Association.
www.titanium.org.
METALCON Intl 2012. Oct. 911. Donald E. Stephens Conven-
tion Center, Chicago, Ill. www.metalcon.com.
NOTE: A DIAMOND ( ) DENOTES AN AWS-SPONSORED EVENT.
SEPTEMBER 2012 54
55 WELDING JOURNAL
Aluminum Week 2012. Oct. 1518. Renaissance Chicago Down-
town Hotel, Chicago, Ill. Co-locating events for The Aluminum
Assn., Aluminum Extruders Council, and Aluminum Anodizers
Council. www.aluminum.org.
AWS/GSI Conf. on U.S. and European Welding Standards:
Structural, Pressure Piping, Pipelines, Railroad, NDT. Oct. 22,
23, Munich, Germany. www.aws.org/conferences.
EuroBLECH 2012, 22nd Intl Sheet Metal Working Technology
Exhibition. Oct. 2327. Hanover Exhibition Grounds, Hanover,
Germany. www.euroblech.com.
LME 2012, Lasers for Manufacturing Event. Oct. 23, 24, Renais-
sance Schaumburg Convention Center Hotel, Schaumburg, Ill.
Laser Institute of America. www.lia.org/lmesd.
Manufacturing with Composites. Oct. 23, 24, Charleston Con-
vention Center, North Charleston, S.C. Society of Manufactur-
ing Engineers. www.sme.org/mfgcomposites.
National FFA Convention and Expo. Oct. 2427. Indianapolis,
Ind. Future Farmers of America. www.ffa.org.
ASNT Fall Conf. Oct. 29Nov. 2. Rosen Shingle Creek Resort, Or-
lando, Fla. American Society for Nondestructive Testing.
www.asnt.org/events/conferences/fc12.htm.
EXPO IAS 2012, 6th Conf. on Uses of Steel, 19th Rolling Conf.
Nov. 68. City Center, Rosario, Santa Fe, Argentina. www.siderur-
gia.org.ar/conf12/Home.html.
Fischers Feritscope
FMP30
is the ideal solution for fast,
precise measurement of ferrite
content of constructional steels,
welded claddings, austenitic
stainless steels and duplex steels.
Non-destructive measurement
in the range of 80% Fe or 0-120
WRC number.
Battery or AC powered
Large, backlit display
Automatic probe recognition
Statistical evaluation
USB interface
Multiple application memories
FISCHER DataCenter Software
1-800-243-8417 1-860-683-0781 Fax: 1-860-688-8496
www.Fischer-Technology.com info@fischer-technology.com
Measurement
of the Ferrite Content in Austenitic
and Duplex Steel
FERITSCOPE
FMP30
SEPTEMBER 2012 56
Welder training and qualification coupons
Destructive test equipment
Full testing services

SERIOUS AIR FOR SERIOUS PLACES
sales@schaeferfau.com 1.800.779.82G7 www.schaeferfau.com
0ualit] aud luuovatiou 8iuce 1951
A powerhouse ventilator
for the toughest jobs.
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00r|og aod 0ry|og
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20th National Quality Education Conf. Nov. 11, 12. Hyatt Re-
gency Louisville, Louisville, Ky. American Society for Quality.
(800) 248-1946; www.asq.org.
Advanced Visual Inspection Workshop. Nov. 12. Las Vegas Con-
vention Center, Las Vegas, Nev. American Welding Society.
www.fabtechexpo.com; www.aws.org/conferences; (800/305) 443-
9353, ext. 264.
ASME Section IX Code Clinic. Nov. 12, 13. Las Vegas Conven-
tion Center, Las Vegas, Nev. American Welding Society.
9353, ext. 264.
Brazing Symposium. Nov. 12. Las Vegas Convention Center,
Las Vegas, Nev. American Welding Society. www.fabtechexpo.
com; www.aws.org/conferences; (800/305) 443-9353, ext. 264.
FABTECH. Nov. 1214. Las Vegas Convention Center, Las
Vegas, Nev. This exhibition is the largest event in North America
dedicated to showcasing the full spectrum of metal forming, fab-
ricating, tube and pipe, welding equipment, and myriad manufac-
turing technologies. American Welding Society. www.fabtech-
expo.com; www.aws.org/conferences; (800/305) 443-9353, ext. 264.
Thermal Spray Basics Conf. Nov. 12. Las Vegas Convention
Center, Las Vegas, Nev. American Welding Society. www.fabtech-
Underwater Welding and Cutting Conf. Nov. 12. Las Vegas Con-
9353, ext. 264.
D1.1 Code Clinic (Spanish). Nov. 13. Las Vegas Convention
Center, Las Vegas, Nev. American Welding Society. www.fabtech-
Friction Stir Welding and Solid-State Processes. Nov. 13. Las
Vegas Convention Center, Las Vegas, Nev. American Welding So-
ciety. www.fabtechexpo.com; www.aws.org/conferences; (800/305)
443-9353, ext. 264.
RWMA Resistance Welding School. Nov. 13, 14. Las Vegas Con-
9353, ext. 264.
Underwater Welding and Cutting Conf. Nov. 13. Las Vegas Con-
9353, ext. 264.
D1.5 Bridge Code Clinic. Nov. 14. Las Vegas Convention Cen-
ter, Las Vegas, Nev. American Welding Society. www.fabtech-
Trends in Nondestructive Testing Conf. Nov. 14. Las Vegas Con-
9353, ext. 264.
Welding Stainless Steel (Avoiding Weld Defects). Nov. 14. Las
Vegas Convention Center, Las Vegas, Nev. American Welding So-
ciety. www.fabtechexpo.com; www.aws.org/conferences; (800/305)
443-9353, ext. 264.
57 WELDING JOURNAL
Indian Industrial Trade Fairs. Nov. 2124. India Expo Centre,
Delhi, India. Hannover Messe/CeMAT. www.cemat-india.com.
Power-Gen Intl Show. Dec. 1113. Orange County Convention
Center, Orlando, Fla. www.power-gen.com.
Intl Conf. on Advanced Material and Manufacturing Science
(ICAMMS 2012). Dec. 20, 21. High-Tech Mansion BUPT, Beijing,
China. www.icamms-conf.org.
Intl Conf. on Frontiers of Mechanical Engineering, Materials,
and Energy (ICFMEME 2012). Dec. 20, 21. Beijing, China.
www.icfmeme.org. Conference general contact is Dr. Zheng,
icfmeme@163.com.
The Automate 2013 Show and Conf. Jan. 2124. McCormick
Place, Chicago, Ill. Robotics Industries Assn., Advancing Vision
+ Imaging, and Motion Control Assn. www.automate2013.com.
LAM 5th Annual Laser Additive Manufacturing Workshop.
Feb. 12, 13, 2013. Hilton Houston North Hotel, Houston, Tex.
American Welding Society is a cooperating society in this event.
AWS members receive discounted registration. www.lia.org/con-
ferences/lam.
ILSC Intl Laser Safety Conf. March 1821, 2013. Doubletree
by Hilton, Orlando, Fla. Laser Institute of America.
www.lia.org/ilsc.
AeroDef Manufacturing Expo and Conf. March 1921, 2013.
Long Beach Convention Center, Long Beach, Calif. Society of
Manufacturing Engineers. www.sme.org; (800) 733-4763.
JOM-17, Intl Conf. on Joining Materials. May 58, 2013. Kon-
ventum Lo Skolen, Helsingr, Denmark. Institute for the Joining
of Materials (JOM) in association with the IIW. Cosponsored by
AWS, TWI, Danish Welding Society, Welding Technology Insti-
tute of Australia, University of Liverpool, Cranfield University,
Force Technology, and ABS (Brazilian Welding Assn.). E-mail
Osama Al-Erhayem at jom_aws@post10.tele.dk; www.jominsti-
tute.com/side6.html.
ASM Heat Treating Society Conf. and Expo. Sept. 1618, 2013. In-
diana Convention Center, Indianapolis, Ind. www.asminterna-
tional.org/content/Events/heattreat/.
WESTEC. Oct. 1517, 2013. Los Angeles Convention Center, Los
Angeles, Calif. The Society of Manufacturing Engineers.
www.westeconline.com; (800) 733-4763.
Educational Opportunities
First Wall Colmonoy India-based Brazing School. Sept. 11, 12.
Pune Marriott Hotel and Convention Centre, Pune, India.
Contact Lucy Williams, Wall Colmonoy, Marketing Manager,
Europe, lucywilliams@wallcolmonoy.co.uk,+44 (0) 1792 860251.
EWI/TMS Workshop: Applying ICME to Solve Manufacturing
Challenges. Sept. 19, 20, Edison Welding Institute, Columbus,
Ohio. www.ewi.org.
Fundamentals of Brazing Seminar. Sept. 19, Sheraton Chicago
OHare Airport Hotel, Chicago, Ill.; Sept. 2527, Wyndham
continued on page 260-s
CERTIFICATION
SCHEDULE
Certified Welding Inspector (CWI)
LOCATION SEMINAR DATES EXAM DATE
Corpus Christi, TX Exam only Sept. 8
Houston, TX Sept. 914 Sept. 15
St. Louis, MO Sept. 914 Sept. 15
New Orleans, LA Sept. 914 Sept. 15
Miami, FL Sept. 914 Sept. 15
Anchorage, AK Exam only Sept. 22
Miami, FL Exam only Oct. 18
Tulsa, OK Oct. 1419 Oct. 20
Long Beach, CA Oct. 1419 Oct. 20
Newark, NJ Oct. 1419 Oct. 20
Nashville, TN Oct. 1419 Oct. 20
Portland, OR Oct. 2126 Oct. 27
Roanoke, VA Oct. 2126 Oct. 27
Detroit, MI Oct. 2126 Oct. 27
Cleveland, OH Oct. 2126 Oct. 27
Atlanta, GA Oct. 28Nov. 2 Nov. 3
Corpus Christi, TX Exam only Nov. 3
Dallas, TX Oct. 28Nov. 2 Nov. 3
Sacramento, CA Oct. 28Nov. 2 Nov. 3
Spokane, WA Oct. 28Nov. 2 Nov. 3
Shreveport, LA Nov. 49 Nov. 10
Las Vegas, NV Exam only Nov. 14
Syracuse, NY Dec. 27 Dec. 8
Houston, TX Dec. 27 Dec. 8
Reno, NV Dec. 27 Dec. 8
Los Angeles, CA Dec. 27 Dec. 8
Miami, FL Dec. 27 Dec. 8
Certified Welding Supervisor (CWS)
Miami, FL Sept. 1014 Sept. 15
Norfolk, VA Oct. 1519 Oct. 20
CWS exams are also given at all CWI exam sites.
9Year Recertification Seminar for CWI/SCWI
For current CWIs and SCWIs needing to meet education
requirements without taking the exam. The exam can be taken
at any site listed under Certified Welding Inspector.
Denver, CO Sept. 1015 No exam
Dallas, TX Oct. 1520 No exam
New Orleans, LA Oct. 29Nov. 3 No exam
Miami, FL Nov. 26Dec. 1 No exam
Certified Radiographic Interpreter (CRI)
Chicago, IL Sept. 1014 Sept. 15
Pittsburgh, PA Oct. 1519 Oct. 20
The CRI certification can be a stand-alone credential or can
exempt you from your next 9-Year Recertification.
Certified Welding Sales Representative (CWSR)
CWSR exams will be given at CWI exam sites.
Certified Welding Educator (CWE)
Seminar and exam are given at all sites listed under Certified
Welding Inspector. Seminar attendees will not attend the Code
Clinic portion of the seminar (usually the first two days).
Certified Robotic Arc Welding (CRAW)
WEEKS OF, FOLLOWED BY LOCATION AND PHONE NUMBER
Nov. 9 at
ABB, Inc., Auburn Hills, MI; (248) 3918421
Dec. 3 at
Genesis-Systems Group, Davenport, IA; (563) 445-5688
Oct. 22, Oct. 26 at
Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Oct. 15 at
OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
Sept. 10, Nov. 5 at
Wolf Robotics, Fort Collins, CO; (970) 225-7736
On request at:
MATC, Milwaukee, WI; (414) 297-6996
Certified Welding Engineer (CWEng) and Senior Certified
Welding Inspector (SCWI)
Exams can be taken at any site listed under Certified Welding
Inspector. No preparatory seminar is offered.
International CWI Courses and Exams Schedules
Please visit www.aws.org/certification/inter_contact.html.
SEPTEMBER 2012 58
IMPORTANT: This schedule is subject to change without notice. Applications are to be received at least six weeks prior to the semi-
nar/exam or exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application deadline
dates by visiting our website www.aws.org/certification/docs/schedules.html. Verify your event dates with the Certification Dept. to con-
firm your course status before making travel plans. For information on AWS seminars and certification programs, or to register on-
line, visit www.aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars. Apply early to avoid
paying the $250 Fast Track fee.
AWS Certification Schedule
Certification Seminars, Code Clinics, and Examinations
SOCIETYNEWS SOCIETYNEWS
59 WELDING JOURNAL
Leadership Symposium Presented in Doral
The 14th annual AWS Leadership Symposium was held July
29Aug. 1 at AWS headquarters in Doral, Fla. Leaders represent-
ing 21 of the 22 AWS Districts participated in the training.
The purpose of the symposium is to develop leadership and
communication skills to enhance each attendeess effectiveness
in the performance of their Section duties.
Listed here are the District number, attendees name, and Sec-
tion. 1) Steve Goodrow, Connecticut; 2) Kenneth Temme, Philadel-
phia; 3) Kenneth Ring, Washington, D.C.; 4) David Kincaid, SW
Virginia; 5) Bob Guenther, South Florida; and Jennifer Skyles,
N. Central Florida; 6) no attendee; 7) Nolan Allbritain, Colum-
bus; 8) George Smith, NE Mississippi; 9) Michael J. Zoghby Jr.,
Mobile; 10) Paul Revolinsky, Cleveland; 11) James Koster, W.
Michigan; and Dan Wellman, Detroit; 12) Anni Van Dyke, Mil-
waukee; 13) Marle Yarno, J.A.K.; 14) Jon Stephens, Mississippi
Valley; David Beers, St. Louis; and Bud Merrill, Louisville; 15)
Randall Washenesky, Arrowhead; 16) Jason Miles, Kansas City;
and Eric Nordhues, Nebraska; 17) Donnie Williams, North Texas;
18) Justin Gordy and Alejandro Alvarez, Houston; 19) Chris
Vrolyk, Alberta; and Ken Johnson, Puget Sound; 20) Gerald Hen-
derson, New Mexico; and Joe Stavinoha, Idaho/Montana; 21)
George Moore, San Diego; and 22) Pat Linggi and Kerry Shatell,
Sacramento.
The Leadership Symposium is conducted each year by Ron
Gilbert, senior partner and principal management consultant for
Gilbert Education & Management Systems, www.gilbertems.com,
and a professor of management in the Chapman Graduate School
of Business at Florida International University.
Assisting Dr. Gilbert again this year was Lee Kvidahl, an AWS
past president, and manager of welding/manufacturing engineer-
ing at Huntington Ingalls Industries, Pascagoula, Miss. The par-
ticipating AWS staff members included Cassie Burrell, deputy
executive director; Rhenda Kenny, director, Member Services
Dept.; and Alfred Nieves, coordinator, Member Services.
BY HOWARD WOODWARD
woodward@aws.org
The Annual Meeting of the members
of the American Welding Society will be
held on Monday, Nov. 12, 2012, begin-
ning at 9:00 AM at the Las Vegas Con-
vention Center, Las Vegas, Nev.
The regular business of the Society will
be conducted, including the election of
officers and nine members of the Board
of Directors. Any business properly
brought before the membership will be
considered.
Notice of Annual Meeting, American Welding Society
AWS Life Members are urged to take
advantage of their complimentary free
admission to the upcoming FABTECH
show plus free registration to the entire
Professional Program (a $325 value),
scheduled for Nov. 1214, 2012, at the
Las Vegas Convention Center in Las
Vegas, Nev.
The free Professional Program regis-
tration entitles AWS Life Members to at-
tend any of the technical sessions occur-
ring during the three-day period. Regis-
tration forms are available in issues of
the Welding Journal, as well as in the Ad-
vance Program that was mailed to mem-
bers previously. You may request a form
from the Membership Dept. (305/800)
443-9353, ext. 260. To obtain your free
registration, mark AWS Life Member:
Free Registration at the top of your Reg-
istration Form. Then FAX both sides of
the form to (305) 443-5647, Attention:
Rhenda Kenny, membership director, or
mail the form to Rhenda Kenny, Ameri-
can Welding Society, 8669 Doral Blvd.,
Doral, FL 33166.
AWS Life Members Offered Free Registration for Professional Program
SEPTEMBER 2012 60
Tech Topics
New Standard Projects
Development work has begun on the
following revised standards. Affected in-
dividuals are invited to contribute to the
development of these standards. For in-
formation, contact the staff engineer
listed with the document. Participation
on AWS Technical Committees and Sub-
committees is open to all persons.
D3.6M:20XX, Underwater Welding
Code. This document covers the require-
ments for underwater welding of struc-
tures or components in both dry and wet
environments. Clauses 16 constitute the
general requirements and clauses 79
contain the special requirements appli-
cable to three individual classes of welds:
Class A Comparable to above-water
welding; Class B For less critical ap-
plications; and Class O To meet the re-
quirements of another designated code
or specification. Stakeholders: Underwa-
ter welding industry associates. B. Mc-
Grath, ext. 311.
D8.1M:20XX, Specification for Auto-
motive Weld Quality-Resistance Spot Weld-
ing of Steel. This document contains both
visual and measurable acceptance crite-
ria for resistance spot welds in steels. The
information contained herein may be
used as an aid by designers, resistance
welding equipment manufacturers,
welded product producers, and others in-
volved in the automotive industry and re-
sistance spot welding of steels. Stake-
holders: Member of the resistance weld-
ing and automotive communities E.
Abrams, ext. 307.
Standards for Public Review
AWS was approved as an accredited
standards-preparing organization by the
American National Standards Institute
(ANSI) in 1979. AWS rules, as approved
by ANSI, require that all standards be
open to public review for comment dur-
ing the approval process. The following
standards are submitted for public review
with the expiration dates shown. A draft
copy may be obtained from R. ONeill,
roneill@aws.org, ext. 451.
A5.8M/A5.8:2011-AMD1, Specification
for Filler Metals for Brazing and Braze
Welding. $30. 9/17/12.
A5.10/A5.10M:20XX (ISO 18273:2004
MOD), Welding Consumables Wire Elec-
trodes, Wire and Rods for Welding of Alu-
minum and Aluminum Alloys Clas-
sification. $66. 9/3/12.
C2.25/C2.25M:20XX, Specification for
Thermal Spray Feedstock Wire and Rods.
Revised. $25. 8/20/12.
D15.2/D15.2M:20XX, Recommended
Practices for Welding of Rails and Related
Rail Components for Use by Rail Vehicles.
Revised. $38.50. 8/27/12.
D17.2/D17.2M:20XX, Specification for
Resistance Welding for Aerospace Applica-
tions. Revised. $32.50. 8/27/12.
G2.1M/G2.1:20XX, Guide for the Join-
ing of Wrought Nickel-Based Alloys.Re-
vised. $36.50. 9/10/12.
Technical Committee Meetings
All AWS technical committee meet-
ings are open to the public. To attend a
meeting, contact the committee secretary
as listed below. Call (800/305) 443-9353
at the extention shown. Visit www.aws.
org/technical/jointechcomm.html to learn
more about what technical committees
do, membership requirements, and to
apply for membership online.
Sept. 12, C1 Committee on Resistance
Welding. Dearborn, Mich. Contact E.
Abrams, ext. 307.
Sept.12, J1 Committee on Resistance
Welding Equipment. Dearborn, Mich.
Contact: E. Abrams, ext. 307.
Sept. 19, 20, B4 Committee on Me-
chanical Testing of Welds. Charleston,
S.C. Contact B. McGrath, ext. 311.
Sept. 25, B2D Subcommittee on Stan-
dard Welding Procedure Specifications.
Coraopolis, Pa. Contact A. Diaz, ext. 304.
Sept. 26, B2A Subcommittee on Braz-
ing Qualifications. Coraopolis, Pa. Con-
tact A. Diaz, ext. 304.
Sept. 26, B2B Subcommittee on Weld-
ing Qualification. Coraopolis, Pa. Con-
tact A. Diaz, ext. 304.
Sept. 26, B2C Subcommittee on Ma-
terials. Coraopolis, Pa. Contact A. Diaz,
ext. 304.
Sept. 26, B2E Subcommittee on Sol-
dering Qualifications. Coraopolis, Pa.
Contact A. Diaz, ext. 304.
Sept. 27, B2 Committee on Procedure
and Performance Qualifications.
Coraopolis, Pa. Contact A. Diaz, ext. 304.
Oct. 35, A2 Committee and Subcom-
mittees on Definitions and Symbols.
Wheeling, W.Va. Contact S. Borrero, ext.
334.
Oct. 23, 24, D15 Committee and Sub-
committees on Railroad Welding. Miami,
Fla. Contact S. Borrero, ext. 334.
Thermal Spray
C2 Committee on Thermal Spraying
seeks educators, general interest, and
users seeks members to help update its
documents. E. Abrams, eabrams@aws.org;
ext. 307.
Robotic and Automatic Welding
The D16 Committee on Robotic and
Automatic Welding seeks general interest
and educators to help revise its documents.
B. McGrath, bmcgrath@ aws.org; ext. 311.
Soldering; Joining Nickel Alloys
The G2C Subcommittee on Nickel Al-
loys seeks members to help review
B2.3/B2.3M, Specification for Soldering
Procedures and Performance Qualification.
S. Hedrick, steveh@ aws.org; ext. 305.
Local Heat Treating of Pipe Work
The D10P Subcommittee for Local
Heat Treating of Pipe seeks members. B.
McGrath, bmcgrath@aws.org; ext. 311.
Magnesium Alloy Filler Metals
A5L Subcommittee on Magnesium
Alloy Filler Metals seeks members to as-
sist in updating its document. R. Gupta,
gupta@aws.org, ext. 301.
Oxyfuel Gas Welding and Cutting
C4 Committee on Oxyfuel Gas Welding
and Cutting seeks general interest and ed-
ucators to help revise its documents. E.
Abrams, eabrams@aws.org; ext. 307.
Surfacing Industrial Mill Rolls
D14H Subcommittee on Surfacing and
Reconditioning of Industrial Mill Rolls
seeks members to help revise AWS D14.7,
Recommended Practices for Surfacing and
Reconditioning of Industrial Mill Rolls. A.
Davis, adavis@aws.org, ext. 466.
Automotive Welding
The D8 Committee on Automotive
Welding seeks members to help prepare
standards on all aspects of welding in the
automotive industry. E. Abrams,
eabrams@aws.org; ext. 307.
Resistance Welding Equipment
The J1 Committee on Resistance Weld-
ing Equipment seeks educators, general
interest, and users to help develop its doc-
uments on controls, installation, mainte-
nance, calibration, and resistance welding
fact sheets. E. Abrams, eabrams@aws.org;
ext. 307.
Welding Handbook
Volunteers with experitse in welding
copper, lead, zinc, and titanium are
sought to help update Welding Handbook.
A. OBrien, aobrien@ aws.org; ext. 303.
Opportunities to Contribute to AWS Welding Standards and Codes
NOTE: LEARN MORE ABOUT TECHNICAL COMMITTEES AND APPLY FOR MEMBERSHIP ONLINE AT www.aws.org/technical/jointechcomm.html.
61 WELDING JOURNAL
Membership Winners Named
The Houston Section, District 18, has
been awarded the Henry C. Neitzel Na-
tional Membership Award for the great-
est net numerical increase in membership
for the year 20112012.
The winner of the Henry C. Neitzel Na-
tional Membership Award for the great-
est net percentage increase for 20112012
is the Reading Section, District 3.
Following are Sections in each District
that achieved the greatest percentage in-
crease in membership for the year.
District No. Section Name
1 Maine
2 New York
3 Reading
4 Northeastern Carolina
5 Columbia
6 Twin Tiers
7 Cincinnati
8 Western Carolina
9 Birmingham
10 Stark Central
11 Central Michigan
12 Racine-Kenosha
13 Chicago
14 Indiana
15 Saskatoon
16 Siouxland
17 Central Arkansas
18 Sabine
19 Inland Empire
20 Colorado
21 Arizona
22 Sierra Nevada
District 14 Awards Announced
Robert Richwine, District 14 director,
has nominated the following members for
this award:
Rick Ferguson Indiana
Eric Cooper Indiana
Tim Atchley Mississippi Valley
Jon Stephens Mississippi Valley
Bobby Wilson Mississippi Valley
Keith Cusey Sangamon Valley
Tim Neubauer Sangamon Valley
Eric Gleason Sangamon Valley
David Beers St. Louis Section
Mike Arand Louisville
Joyce Kent Louisville
Brent Wright Tri-River
Karl Watson Lexington
Coy Hall Lexington
Gordon Holl Lexington
This award provides a means for Dis-
trict directors to recognize individuals and
corporations who have contributed their
time and effort to the affairs of their local
Section and/or District.
The AWS Weldmex, FABTECH Mexico, and Metalform Mexico event was recently named the
winner of Best Event of the Year, Best Industrial Show, and Best Industrial Show Organizers.
Cintermex made the announcements at a special awards-presentation program held at the
Cintermex Expo Center in Monterrey, Mexico.
Weldmex Show Wins Three Prestigious Awards
Member-Get-A-Member Campaign
Listed are the members participating in
the 20122013 Member-Get-a-Member
campaign. Standings are as of July 20, 2012.
See page 65 of this Welding Journal for a
complete list of rules and a prize list, or
visit www.aws.org/mgm. Call the AWS
Membership Dept. at (800) 443-9353, ext.
480, with any questions about your mem-
ber-proposer status.
Winners Circle
Listed below are the sponsors of 20 or
more Individual Members per year, since
June 1, 1999. The superscript denotes the
number of years the member has earned
Winners Circle status if more than once.
E. Ezell, Mobile
9
J. Compton, San Fernando Valley
7
J. Merzthal, Peru
2
G. Taylor, Pascagoula
2
L. Taylor, Pascagoula
2
B. Chin, Auburn
S. Esders, Detroit
M. Haggard, Inland Empire
M. Karagoulis, Detroit
S. McGill, NE Tennessee
B. Mikeska, Houston
M. Pelegrino, Chicago
W. Shreve, Fox Valley
T. Weaver, Johnstown/Altoona
G. Woomer, Johnstown/Altoona
R. Wray, Nebraska
Presidents Roundtable
Sponsored 919 new members
R. Fulmer Twin Tiers 10
A.Tous Costa Rica 9
Presidents Club
Sponsored 38 new members
W. Komlos Utah 7
C. Becker Northwest 5
A. Bernard Sabine 3
D. Jessop Mahoning Valley 3
Presidents Honor Roll
Sponsored 1 or 2 new members
E. Norman Ozark 2
A. Sam Trinidad 2
Student Member Sponsors
R. Munns Utah 18
S. Lindsey San Diego 17
E. Norman Ozark 16
R. Udy Utah 7
G. Siepert Kansas 4
R. Zabel SE Nebraska 4
J. Boyer Lancaster 3
G. Von Lunen Kansas City 3
American Welding Society members
will receive a discounted fee to attend the
Laser Institute of America (LIA) 5th An-
nual Laser Additive Manufacturing Work-
shop to be held Feb. 12, 13, 2013, at Hilton
Houston North Hotel in Houston, Tex.
The two societies have signed a cooperat-
ing society agreement wherein AWS is
listed as a Cooperating Society for the
event and AWS members receive the LIA
member discount. For complete informa-
tion, visit www.lia.org/conferences/lam.
AWS Members Offered Discounted Fee for Laser Additive Manufacturing Workshop
SEPTEMBER 2012 62
Thirty-eight Colorado-area Boy Scouts
received their welding merit badges, July 9,
10, in Denver during the 65th Annual Inter-
national Institute of Welding Assembly. The
Scouts spent four hours with the merit badge
counselor going through safety procedures,
demonstrating care of equipment, discussing
what they learned from the Welding Merit
Badge pamphlet, and describing the advan-
tages and limitations of two welding
processes. Each scout selected a process and
set up the equipment, which was inspected
and approved by the counselor. Then, each
scout performed several experiments. Fi-
nally, the scouts discussed the role of the
American Welding Society in the welding
profession and described three career oppor-
tunities in the welding field.
Assisting the scouts were Steve Bruce,
Tom Kienbaum (Colorado Section), Gordon
Reynolds (Utah Section), Russell Rux
(Wyoming Section), and Robert Ulibarri
(New Mexico Section). On site for the event
were the Miller Road Show and the Careers
in Welding Mobile Exhibit.
The welding merit badge and the Careers
in Welding trailer are both part of recent ef-
forts by AWS to bring attention to the criti-
cal shortage of welders in the United States.
An analysis of projected data gathered
through Weld-Ed, a National Science Foun-
dation funded center, shows that by 2019,
there will be a shortage of more than 238,000
new and replacement welding professionals.
Welding is such an important part of our
nations growth and stability, said Janice
Downey, senior innovation manager, Boy
Scouts of America. The welding merit badge
is a good fit with preparing Scouts for their
future and offers them a fun way to explore
skills that can grow into a hobby or career.
There was significant enough interest shown
in a youth interest survey to add a welding
merit badge to the more than 120 merit
badges currently in the series.
Boy Scouts Earn Welding Merit Badges during IIW in Denver
AWS Distinguished Members Tony Brosio
(left) and Gary Dugger.
Tony Brosio and Gary D. Dugger, vet-
eran members of the Indiana Section,
have attained the status of Distinguished
Member for their participation in the So-
cietys leadership and professional-devel-
opment programs and member-recruit-
ing achievements.
To qualify for Distinguished Member
status, applicants must accrue a minimum
of 35 points from these four categories:
National AWS leadership, local AWS lead-
ership, professional development, and
AWS member recruitment. If you believe
you qualify for Distinguished Member sta-
tus, contact Rhenda Kenny, AWS Mem-
bership Dept., rhenda@aws.org, (800/305)
443-9353, ext. 260.
November 5, 2012, is the deadline for
submitting nominations for the 2013 Prof.
Koichi Masubuchi Award.
This award is presented each year to
one person, 40 years old or younger, who
has made significant contributions to the
advancement of materials joining through
research and development. Nominations
should include a description of the candi-
dates experience, list of publications, hon-
ors, and awards, and at least three letters
of recommendation from fellow re-
searchers. This award is sponsored by the
Dept. of Ocean Engineering at Massachu-
setts Institute of Technology (M.I.T.), this
award includes a $5000 honorarium.
E-mail your nomination package to
Todd A. Palmer, assistant professor,
The Pennsylvania State University,
tap103@psu.edu.
Two Attain Distinguished Member Status in Indiana Section
M.I.T. Award Candidates Sought
63 WELDING JOURNAL
SECTIONNEWS
NEWS
District 1
Thomas Ferri, director
(508) 527-1884
thomas_ferri@victortechnologies.com
Participants at the District 3 conference were (from left) Steve Hill, Mike Schweinberg, Tracy Davenport, District 3 Director Mike Wiswesser,
AWS staff representative Monica Pfarr, Ken Ring, Merilyn McLaughlin, Justin Heistand, John Ganoe, and Mike Sebergandio.
Tom Ferri (right), District 1 director, and
Doug Desrochers are shown at the District
1 conference in May.
Shown at the Maine Section event are (from left) Joel Stanley, Tom Millet, Pat Kein, and
Dave Hartley.
Shown at the Green & White Mountains Sec-
tion event are Rob Coulstring (left) and
Geoff Putnam.
District 1 Conference
MAY 9
Activity: Tom Ferri, District 1 director,
conducted the meeting at Fireside Inn and
Resort in West Lebanon, N.H. Service cer-
tificates of appreciation were presented to
Ray Henderson, chair, Green & White
Mts.; and Doug Desrochers, Central Mass.
and R.I. Section treasurer and secretary.
GREEN & WHITE MTS.
JULY 2
Activity: The Section members met at Tri-
angle Engineering in Hanover, Mass., to
present an appreciation award for the com-
panys continued support of the SkillsUSA
welding competitions and donations of test
coupons.
MAINE
JUNE 18
Activity: Pat Kein, vice chair, hosted a
send-off event for Tom Millet, the state of
Maine SkillsUSA welding representative,
to compete in the national contest. At-
tending were Joel Stanley of FASTCO
Corp. and David Hartley, welding instruc-
tor at Northern Penobscot Technical High
School.
JUNE 8
Speaker: Monica Pfarr, AWS corporate di-
rector, workforce development
Topic: AWS Foundation, national events
Activity: The meeting, conducted by Mike
Wiswesser, District 3 director, was held at
the Heritage Hills Conference Center in
York, Pa.
District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com
District 3
Michael Wiswesser, director
(610) 820-9551
mike@welderinstitute.com
SEPTEMBER 2012 64
District 4
Roy C. Lanier, director
(252) 321-4285
rlanier@email.pittcc.edu
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
District 7
Don Howard, director
(814) 269-2895
navigatorlost@hotmail.com
District 6
Kenneth Phy, director
(315) 218-5297
kenneth.phy@gmail.com
READING
APRIL 25
Speaker: Mike Wiswesser, Dist. 3 director
Affiliation: Welder Training Institute
Topic: AWS update, awards presentations
Activity: The Section hosted its awards
banquet at Dutch Way Restaurant in My-
erstown, Pa. Patricia Davenport and Bryan
Shenk served as emcees. Thomas Daven-
port received a $750 Section scholarship
from Scholarship Chair Allen Quigg to
continue his studies at LeTourneau Uni-
versity. Awards were presented to the stu-
HOLSTON VALLEY
MAY 10
Activity: Matthew Thompson, the gold
medalist in the Tennessee SkillsUSA weld-
ing contest, received funds to travel to
Kansas City, Mo., to compete in the Na-
tional SkillsUSA welding competition. The
award was presented by Dale Hicks, a
welding instructor at Tennessee Technol-
ogy Center in Elizabethon, Tenn.
dents participating in the March welding
contest, headed by the three first-place
winners Frank Mohr, Zach Trimble, and
Dan Moldovan. Other award winners in-
cluded Joseph Markle, Jan Roldan, Austin
Wohlfeil, John Van Rohr, Diego Jimenez,
Taylor Kunkel, Corey Appleby, Jamie
Bange, Elyjahwuan Blake, Ryan Achey,
and Brian Kuhn. Tracy Davenport re-
ceived an award for his services as chair,
presented by past chair David Hibshman.
Thomas Davenport (right) receives a Read-
ing Section scholarship from Allen Quigg.
Reading Section Chair Tracy Davenport
(right) is shown with David Hibshman.
Tom Sparschu (left) is shown with speaker
Steve Sciatto at the Detroit Section in May.
Welding gold medalist Matthew Thompson
(left) is shown with Dale Hicks at the Hol-
ston Valley Section program.
Felix Bevilacqua displays the AWS Gold
Member Certificate presented to him by the
Mahoning Valley Section.
Shown at the Reading Section are the three first-place welding contest winners (from left)
Frank Mohr, Zach Trimble, and Dan Moldovan.
District 8
Joe Livesay, director
(931) 484-7502, ext. 143
joe.livesay@ttcc.edu
67 WELDING JOURNAL
District 9
George Fairbanks Jr., director
(225) 473-6362
ts@bellsouth.net
MAHONING VALLEY
JUNE 29
Activity: Felix Bevilacqua received his Life
Member Certificate for 50 years of serv-
ice to the Society during a special awards
luncheon held for him at Stonebridge
Grille & Tavern in Boardman, Ohio.
Bevilacqua was a part owner of Northeast
Fabricators in Youngstown, Ohio.
MILWAUKEE
JUNE 20
Activity: The Section announced it has es-
tablished the John Hinrichs Memorial En-
dowment with $110,000 with AWS Foun-
dation matching funds. The memorial is
expected to provide $5000 in scholarships
annually. Hinrichs, who died June 5, was
the founder of the National Robotic Arc
Welding Conference and a mentor of many
in the engineering and robotics disciplines.
DETROIT
MAY 17
Speaker: Steve Sciatto, manager
Affiliation: Roush Industries
Topic: The growth of welding at Roush
Activity: Following the talk, a team of
Roush welding experts answered questions
posed by the 86 attendees. The event con-
cluded with visits to the companys mu-
seum and gift shop and demonstrations
from Miller and Lincoln Electric. John
Bohr and Mike Palko received District 11
Meritorious Awards. The event was held
at Roush Industries in Livonia, Mich.
JUNE 9
Activity: The Section hosted an executive
committee meeting to recognize those who
contributed their efforts to the Sections
support. Don Maatz, outgoing chair, in-
troduced incoming Chair Mike Palko.
Maatz received a certificate of apprecia-
tion for his services as chair from Mike
Karagoulis, a past chair. Other past chairs
in attendance were Tom Sparschu, Bernie
Bastian, Fred Ellicott, Richard Du
Charme, Carl Hildebrand, Paul DAngelo,
David Beneteau, James Osborne, and Ken
Kramer.
Detroit Section past chairs are shown at the June 9 event. From left are Tom Sparschu, Bernie Bastian, Fred Ellicott, Richard DuCharme,
Carl Hildebrand, Paul DAngelo, David Beneteau, James Osborne, Mike Karagoulis, Don Maatz, and Ken Kramer.
District 10
Richard A. Harris, director
(440) 338-5921
richaharris@windstream.net
Mike Rotary (left) is shown with Mike Palko
at the Detroit Section program.
Shown at the Detroit Section June 9 program are (from left) Mike Karagoulis, Chair Don
Maatz, and Mike Palko, incoming chair.
District 11
Robert P. Wilcox, director
(313) 949-3676
rwilcox1@ford.com
District 12
Daniel J. Roland, director
(715) 735-9341, ext. 6421
daniel.roland@us.ncantieri.com
SEPTEMBER 2012 68
District 13
W. Richard Polanin, director
(309) 694-5404
rpolanin@icc.edu
District 14
Robert L. Richwine, director
(765) 378-5378
bobrichwine@aol.com
RACINE-KENOSHA
JUNE 20
Activity: The Section members toured
Racine Flame Spray, Inc., in Racine, Wis.,
to see its machine shop, sound-attenuated
booths, 8-axis robots, and specialized roll
equipment led by Peter Patterson, prod-
uct development manager. Dr. Patterson
demonstrated spray and coating applica-
tions using the HVOF, plasma arc, and
thermal spray technologies.
JULY 14
Speaker: Dan Crifase, Racine-Kenosha
Section chair
Affiliation: Ark Welding Inspection Serv-
ices
Topic: Careers in welding and inspection
Activity: Crivase made his presentation to
students and welding instructor Ben
Sorensen at Plum City High School in
Plumb City, Wis.
rector, hosted the meeting at Kroc Com-
munity Center in Quincy, Ill. The AWS
staff representative was Fernando Tun,
controller. Chosen to attend the Leader-
ship Symposium were Jon Stephens, Mis-
sissippi Valley Section; David Beers, St.
Louis Section; and Bud Merrill, Louisville
Section as Section-sponsored representa-
tives. See the Leadership Symposium story
and group photo on the first page of Soci-
ety News (page 59).
ST. LOUIS
JUNE 4
Activity: The Section hosted its annual golf
outing at Fox Creek Golf Course in Ed-
wardsville, Ill. The top performers were
Tom Graham, Kent Zimmer, Lyle Shorkey,
Vic Shorkey, Larry Closterman, Beau
Vuagniaux, James Coleman, John
Mageiro, Jeff Palazzolo, Eric Bischof,
Jerry Hilf, and Craig Johnson.
CHICAGO
JULY 6
Activity: The Section held a board meet-
ing at Hackneys Restaurant in Palos Park,
Ill. Attending were Chair Craig Tichelar,
Cliff Iftimie, Peter Host, and Eric Purkey.
Shown during the Racine-Kenosha Section June 20 tour are (from left) presenter Peter Patterson, Anders Farr, Ken Karwowski, Joe Kaw-
czynski, Renee Karwowski, Annette Crifase, and Chair Dan Crifase.
Dan Crifase (far right), Racine-Kenosha Section chair, discussed welding-related careers for Plum City High School class in July.
JUNE 2
Activity: Robert Richwine, District 14 di-
69 WELDING JOURNAL
Shown at the Chicago Section board meeting are (from left) Chair Craig Tichelar, Cliff
Iftimie, Peter Host, and Eric Purkey.
Shown at the District 14 conference are (from left) District 14 Director Bob Richwine, Dave Jackson, Gary Tucker, Gary Dugger, Bennie
Flynn, Jon Stephens, Keith Cusey, Coy Hall, Karl Watson, Tully Parker, and Fernando Tun.
St. Louis Section members queue up for their annual golf outing June 4.
TRI-RIVER
JUNE 14
Activity: The Section hosted its past chair-
mens night event at Bosse Field to watch
the Evansville Otters baseball game.
Tully Parker (left) and Vic Shorkey are
shown at the St. Louis golf outing.
Jeff Palazzolo (left) and Eric Bischof were
among the best St. Louis Section golfers.
Tri-River Section Past Chairs Steve Eidson
(left) and Earl Young cheered for the Evans-
ville Otters at the ballpark.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
SEPTEMBER 2012 70
District 17
J. Jones, director
(940) 368-3130
jjones@victortechnologies.com
OKLAHOMA CITY
JUNE 19
Activity: The Section held its annual golf
outing at Cimarron National Golf Club in
Guthrie, Okla. First-place team honors
went to Dustin Andrews, Dillon Andrews,
Dakota Andrews, and Dan Andrews. Sec-
ond- and third-place team honors went to
Terry Morse, Randy Morse, Brennan,
Morse, Joe Cansler, Ray Adams, Jessie
Loyd, Sammie Ramos, and Jamie
Williams. Last place was secured by Mike
Heinrichs, Robby Hageman, Matt Terell,
and Scott Bivins.
MAY 5
Activity: The Houston Section hosted the
meeting at the Hyatt at Market Street, The
Woodlands, Tex., for 20 participants. Dis-
trict 18 Director John Bray conducted the
program. Special guests were District 14
Director Bob Richwine and Sam Gentry,
AWS Foundation executive director.
CORPUS CHRISTI
MARCH 22, 23
Activity: The Section participated in the
state SkillsUSA welding competition at
Craft Training Center of the Coastal Bend
in Corpus Christi, Tex. The judges included
Dan Jones, Barney Burks Jr., and John
Bray, District 18 director. Section appre-
ciation certificates were presented to Chair
Chris Long, Misty Ralls, Oscar Medina,
and Jim Miller.
The Oklahoma City Section golf champs are (from left) Dustin Andrews, Dillon Andrews,
Dakota Andrews, and Dan Andrews.
Scored high, but had fun anyway; the Oklahoma City Sections last-place team members
are (from left) Mike Heinrichs, Robby Hageman, Matt Terell, and Scott Bivins.
Shown at the District 18 conference are (standing, from left) Derek Stelly, Barney Burks Jr., Houston Section Chair Dennis Eck, John Hus-
feld, Alex Alvarez, District 18 Director John Bray. Seated is Justin Gordy, incoming Houston Section chair.
Shown at the Corpus Christi Section event are (from left) Misty Ralls, Oscar Medina, Chair
Chris Long, Jim Miller, and John Bray, District 18 director.
District 18
John Bray, director
(281) 997-7273
sales@afliatedmachinery.com
71 WELDING JOURNAL
District 18 delegates are shown at the annual conference in May.
Houston Section golf experts are (from left) Calvin Nolen, District 18 Director John Bray,
Bob Ashlock, and Homer Ballard.
Shown at the Lake Charles Section event are (from left) Terry Buxton, Chris Caldarera,
James Bobo, Drew Fontenot, Chair Tac Edwards, and Kermit Babaz.
Shown at the Houston Section May 4 event are (from left) Brian Suarez, Andrew Lilley, Tara Napolillo, Barney Burks, Albert Stredney,
Event Chair Dan Jones, Andre Horn, Justin Kirby, and Tripp Fulmer.
HOUSTON
APRIL 16
Activity: The Section held its golf outing
at Black Horse Golf Club in Cypress,
Tex. Dennis Eck chaired the event for 64
participants.
MAY 4
Activity: The Houston Section held its stu-
dent welder certification day at San Jac-
into College in Pasadena, Tex., for 98 weld-
ing students from the greater Houston
area. Dan Jones (Gas and Supply) chaired
the event. CWIs Barney Burks (Sowesco)
and Brian Suarez (Matheson Gas) per-
formed the visual inspections and Scott
Witkowski (Maverick Laboratories) did
the bend testing. Others participating were
Andrew Lilley, Tara Napolillo, Albert
Stredney, Andre Horn, Justin Kirby, Tripp
Fulmer, and San Jacinto College staff
members Hector Carmona, Juan Con-
teras, and Tiburcio Parras.
MAY 11
Activity: The Houston Section held a fam-
ily night out to watch the Sugar Land
Skeeters baseball team play at the new Con-
stellation Field in Sugar Land, Tex.
SEPTEMBER 2012 72
District 19
Neil Shannon, director
(503) 201-5142
neilshnn@msn.com
District 20
William A. Komlos, director
(801) 560-2353
bkoz@arctechllc.com
District 21
Nanette Samanich, director
(702) 429-5017
nan07@aol.com
District 22
Dale Flood, director
(916) 288-6100, ext. 172
d.ood@tritool.com
LAKE CHARLES
APRIL 18
Activity: The Section held its annual craw-
fish boil event in Lake Charles, La., for 75
attendees. Chair Tac Edwards and John
Bray, District 18 director, presented
awards to Chris Caldarera (Section Mer-
itorious), Aaron Toups (Section Educa-
tor), Terry Buxton (Section CWI), and
James Bobo (District Director). Tac Ed-
wards received an appreciation certificate
for serving as District 18 deputy director.
RIO GRANDE VALLEY
APRIL 11
Activity: John Bray, District 18 director,
presented awards to Richard Salinas
(Section Educator), Fernando Garcia
(Section Meritorious), and Hector Ren-
don (District Director Award). The meet-
ing was held at Casa Del Taco in Weslaco,
Tex.
SABINE
APRIL 17
Activity: The Section members toured
the Trinity Industrial Services facility in
Beaumont, Tex. Matthew Jowett, shop
manager, conducted the program for 23
attendees.
Attendees are shown the Rio Grande Valley Section program in April.
Shown at the Rio Grande Valley program are (from left) John Bray, District 18 director, Fer-
nando Garcia, and Hector Rendon.
Sabine Section Chair John McKeehan (left) is shown with Mike Smith (center) and Charles
Bales.
SAN ANTONIO
APRIL 10
Speaker: Christopher Wright
Affiliation: Trinity Specialty Products, Inc.,
plant manager
Topic: Trinitys welding and safety pro-
grams
Activity: John Bray, District 18 director,
presented District Director Awards to
Chair Cornelio Ontiveros, Clifton Rogers,
and Tom Settle. The meeting was held at
Don Pedro Mexican Restaurant in San An-
tonio, Tex.
L.A./INLAND EMPIRE
JUNE 19
Activity: The meeting was held at Multi-
plaz LLC welding and cutting facility in
Santa Monica, Calif.
73 WELDING JOURNAL
Sabine Section members are shown at the April program.
Shown at the San Antonio Section are (from left) John Bray, District 18 director, Chair Cornelio Ontiveros, Clifton Rogers, and Tom Settle.
Chair Cornelio Ontiveros (left) is shown with
speaker Christopher Wright at the San An-
tonio Section program.
George Rolla (left), L.A./Inland Empire
Section chair, is shown with Oscar Garcia.
GERMANY
Annual Meeting Notice
Sept. 18. The Section will hold its an-
nual planning meeting from 12:30 to 1:30
PM during the DVS Annual Conference
in Saarbruecken, Germany. Contact
Christian Ahrens, e-mail at ahrens@gsi-
slv.de.
Sept. 26, 27. Intl Conf. Welding Trainer
2012, Duisburg, Germany.
Oct. 22, 23. AWS/GSI Intl Conf. on
U.S. and European Welding Standards.
Munich, Germany. For complete informa-
tion, visit www.aws.org/w/a/conferences/
index.html.
SAUDI ARABIA
JUNE 24
Activity: The Section held its election of
officers and planning meeting in Khobar,
Saudi Arabia. Officers include Khaled Ali,
chair; Osama Khalil, first vice chair; In-
ayat Koya, secretary and second vice chair;
Mazen Melhem, publicity chair; and Ab-
dullah Alhuzaim, technical representative.
Shown at the Saudi Arabia Section meeting are (from left) Mazen Melhem, Osama Khalil,
Chair Khaled Ali, Inayat Koya, and Abdullah Alhuzaim.
International
Sections
SEPTEMBER 2012 74
New AWS Supporters
Sustaining Members
Ammonia Refrigeration Service, Inc.
2509 Wigle Creek Rd., Homer, NE 68030
Representative: Larry Bledsoe
www.ammoniarefrigeration.com
Ammonia Refrigeration Service, estab-
lished in 1972, designs, installs, and services
industrial refrigeration systems. It offers
competitive pricing on all equipment and
parts.
HAKS Engineers, Architects &
Land Surveyors P.C.
40 Wall St., 11 Fl., New York, NY 10005
Representative: Fereshtech Hayihassani
www.haks.net
HAKS is a multidisciplined special in-
spection agency and engineering firm.
Formed in 1991 in New York City, most of
its more than 400 employees are licensed
professionals and certified inspectors. Its
highly trained field staff are certified to con-
duct all special inspections.
Oscar J. Boldt Construction
2525 N. Roemer Rd., Appleton WI 54912
Representative: Nathan Jacobson
www.theboldtcompany.com
The Boldt Company provides facilities
solution services to customers in a variety
of industrial, institutional, healthcare, com-
mercial, and renewable-energy markets. It
is renowned as a sustainable (green) con-
struction and integrated Lean Project De-
livery. It has 13 offices nationwide.
Supporting Companies
3M - Abrasive Systems Div.
3M Center, Bldg. 223-6N-01
Saint Paul, MN 55144
Bender U.S.
2150 E. 37th St., Vernon, CA 90058
Byron Products
3781 Port Union Rd., Fairfield, OH 45014
Donaldson Torit
MS #365, 9250 W. Bloomington Freeway
Bloomington, MN 55431
Ellison Surface Technologies
8093 Columbia Rd., Ste. #201
Mason, OH 45040
F.W. Gartner Thermal Spraying
25 Southbelt Industrial Dr.
Houston, TX 77047
Ferrothermal Spray Coating
Avenida San Nicolas 3500 Norte
Colonia Vidriera
Monterrey, NL 64520, Mexico
Fujimi
126 East Wing St. # 279
Arlington Heights, IL 60004
Genie Products, Inc.
Old Hwy. 64 E., POB 1028
Rosman, NC 28772
Green Belting Industries Ltd.
381 Ambassador Dr.
Mississauga, ON L5T 2J3, Canada
HAI Advanced Material Specialist, Inc.
1688 Sierra Madre Cir.
Placentia, CA 92870
Harper Corp. of America
POB 38490, Charlotte, NC 28278
Hausner Hard-Chrome
3090 Medley Rd., Owensboro, KY 42301
Haynes International
158 N. Egerton Rd.
Mountain Home, NC 28758
Hayden Corp.
333 River St.
West Springfield, MA 01089
Plasma Technology, Inc.
1754 Crenshaw Blvd., Torrance, CA 90501
PM Recovery, Inc.
106 Calvert St., Harrison, NY 10528
Saint-Gobain Ceramic Materials
One New Bond St., POB 15008
Worcester, MA 01615
Savoy Technical Services, Inc.
4301 Hwy. 27 S., Sulphur, LA 70665
Thermal Spray Technologies, Inc.
515 Progress Way, Sun Prairie, WI 53590
Affiliate Companies
BGI Contractors
PO Box 22077, Beaumont TX 77720
Brookville Equipment Corp.
175 Evans St., Brooksville, PA 15825
L-3 Unidyne
3835 E. Princess Anne Rd.
Norfolk, VA 23502
Partogarane Sanate Khayyam Welding
Besat Blvd., Front of 32nd Besat St.
Neyshabur 9314735456, Iran
PT Welding & Fabricating
28500 Calvert Rd., Tomball, TX 77377
Sisneros Bros. Mfg.
2300 Roldan Dr., Belen NM 87002
Temp Control Mechanical Corp.
4800 N. Channel Ave., Portland, OR 97217
United Marine Shipyard LLC
PO Box 22077, Beaumont, TX 77720
Educational Institutions
Academy of Welding Technology
Dalia Complex, Palaithazham Rd.
Kalpetta, Kerala 673121, India
Baraka Middle East Inspection
& Quality Services
Office #5, 10th Fl., W. 14th St.
Borj Bldg. Kianpars Ave.
Ahwaz, Khuzestan 6155865537, Iran
Canyon Independent School District
8800 Valleyview Dr., Amarillo, TX 79118
Magnolia High School
POB 428, 14350 FM 1488
Magnolia, TX 77354
Magnolia West High School
POB 426, 42202 FM 1775
Magnolia, TX 77354
Mercer County Technical School
1085 Old Trenton Road
Trenton, NJ 08690
Middlesex County Vo-Tec School
112 Rues Ln., East Brunswick, NJ 08816
WQC Institute of NDT
and Inspection Technology
Arjun Tower, Cusat Rd., Cusat Po,
Pin 682022, South Kalamassey
Ernakulam, Kerala 682022, India
AWS Member Counts
August 1, 2012
Grades
Sustaining ......................................539
Supporting.....................................354
Educational ...................................604
Affiliate..........................................473
Welding Distributor........................52
Total Corporate ..........................2,022
Individual .................................59,210
Student + Transitional ...............10,280
Total Members.........................69,490
75 WELDING JOURNAL
Guide to AWS Services
8669 Doral Blvd., Doral, FL 33166; (800/305) 443-9353; FAX (305) 443-7559; www.aws.org
Staff extensions are shown in parentheses.
AWS PRESIDENT
William A. Rice
brice@oki-bering.com
1411 Connell Rd.
Charleston, WV 25314
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246)
Chief Financial Officer
Gesana Villegas.. gvillegas@aws.org . . . . . .(252)
Executive Assistant for Board Services
Gricelda Manalich.. gricelda@aws.org . . . . .(294)
Administrative Services
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214)
IT Network Director
Armando Campana..acampana@aws.org . .(296)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
Human Resources
Director, Compensation and Benefits
Luisa Hernandez.. luisa@aws.org . . . . . . . . .(266)
Director, Human Resources
Dora A. Shade.. dshade@aws.org . . . . . . . . .(235)
International Institute of Welding
Senior Coordinator
Sissibeth Lopez . . sissi@aws.org . . . . . . . . .(319)
Liaison services with other national and international
societies and standards organizations.
GOVERNMENT LIAISON SERVICES
Hugh K. Webster . . . . . . . . .hwebster@wc-b.com
Webster, Chamberlain & Bean, Washington, D.C.,
(202) 785-9500; FAX (202) 835-0243. Monitors fed-
eral issues of importance to the industry.
CONVENTION and EXPOSITIONS
Director, Convention and Meeting Services
Matthew Rubin.....mrubin@aws.org . . . . . . .(239)
ITSA International Thermal
Spray Association
Senior Manager and Editor
Kathy Dusa.kathydusa@thermalspray.org . . .(232)
RWMA Resistance Welding
Manufacturing Alliance
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
Brazing and Soldering
Manufacturers Committee
GAWDA Gases and Welding
Distributors Association
Executive Director
John Ospina.. jospina@aws.org . . . . . . . . . .(462)
Operations Manager
Natasha Alexis.. nalexis@aws.org . . . . . . . . .(401)
INTERNATIONAL SALES
Managing Director, Global Exposition Sales
Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . .(297)
Corporate Director, International Sales
Jeff P. Kamentz..jkamentz@aws.org . . . . . . .(233)
Oversees international business activities involving cer-
tification, publication, and membership.
PUBLICATION SERVICES
Department Information . . . . . . . . . . . . . . . . .(275)
Managing Director
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
National Sales Director
Rob Saltzstein.. salty@aws.org . . . . . . . . . . .(243)
Society and Section News Editor
Howard Woodward..woodward@aws.org . .(244)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
MARKETING COMMUNICATIONS
Director
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . .(416)
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
Section Web Editor
Henry Chinea...hchinea@aws.org . . . . . . . . .(452)
MEMBER SERVICES
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between Section members and AWS
headquarters.
CERTIFICATION SERVICES
Managing Director
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472)
Oversees all certification activities including all inter-
national certification programs.
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
scoring.
Director, Certification Programs
Linda Henderson..linda@aws.org . . . . . . . .(298)
Oversees the development of new certification pro-
grams, as well as AWS-Accredited Test Facilities, and
AWS Certified Welding Fabricators.
EDUCATION SERVICES
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
Director, Education Development
David Hernandez.. dhernandez@aws.org . . .(219)
AWS AWARDS, FELLOWS, COUNSELORS
Senior Manager
Wendy S. Reeve.. wreeve@aws.org . . . . . . . .(293)
Coordinates AWS awards, Fellow and Counselor
nominees.
TECHNICAL SERVICES
Managing Director
Andrew R. Davis.. adavis@aws.org . . . . . . .(466)
International Standards Activities, American Coun-
cil of the International Institute of Welding (IIW),
Structural Welding, Machinery, and Equipment
Director, National Standards Activities
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Manager, Safety and Health
Stephen P. Hedrick.. steveh@aws.org . . . . . .(305)
Metric Practice, Safety and Health, Joining of Plas-
tics and Composites, Welding Iron Castings, Welding
in Sanitary Applications, Personnel and Facilities
Qualification
Senior Manager, Technical Publications
Rosalinda ONeill.. roneill@aws.org . . . . . . .(451)
AWS publishes about 200 documents widely used
throughout the welding industry.
Senior Staff Engineer
Rakesh Gupta.. gupta@aws.org . . . . . . . . . .(301)
Filler Metals and Allied Materials, International Filler
Metals, UNS Numbers Assignment, Arc Welding and
Cutting Processes
Staff Engineers/Standards Program Managers
Efram Abrams.. eabrams@aws.org . . . . . . . .(307)
Thermal Spray, Automotive Resistance Welding, Oxy-
fuel Gas Welding and Cutting
Stephen Borrero... sborrero@aws.org . . . . .(334)
Brazing and Soldering, Brazing Filler Metals and
Fluxes, Brazing Handbook, Soldering Handbook,
Railroad Welding, Definitions and Symbols
Alex Diaz.... adiaz@aws.org . . . . . . . . . . . . . .(304)
Welding Qualification, Sheet Metal Welding, Aircraft
and Aerospace, Joining of Metals and Alloys
Brian McGrath .... bmcgrath@aws.org . . . . .(311)
Methods of Inspection, Mechanical Testing of Welds,
Welding in Marine Construction, Piping and Tubing,
Friction Welding, Robotics Welding, High-Energy
Beam Welding
Notes: Official interpretations of AWS standards may
be obtained only by sending a request in writing to An-
drew R. Davis, managing director, Technical Services,
adavis@aws.org. Oral opinions on AWS standards
may be rendered, however, oral opinions do not con-
stitute official or unofficial opinions or interpretations
of AWS. In addition, oral opinions are informal and
should not be used as a substitute for an official in-
terpretation.
AWS FOUNDATION, INC.
www.aws.org/w/a/foundation
General Information
(800/305) 443-9353, ext. 212, vpinsky@aws.org
Chairman, Board of Trustees
Gerald D. Uttrachi
Executive Director, Foundation
Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . (331)
Corporate Director, Workforce Development
Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . (461)
The AWS Foundation is a not-for-profit corporation es-
tablished to provide support for the educational and scien-
tific endeavors of the American Welding Society.
Promote the Foundations work with your financial sup-
port. Call (800) 443-9353 for information.
PERSONNEL
SEPTEMBER 2012 78
TRUMPF Names Managers
TRUMPF, Inc., Farmington, Conn., has
appointed Shane Simpson regional man-
ager of machine tool sales for the mid-
Atlantic region of the United States, and
Tom Bailey product manager, TruBend
Product Group in North America. Simpson,
with the company for 17 years, will manage
sales of the companys laser cutting, punch-
ing, combination punch-laser, and press
brake technologies. Bailey, who previously
served as a sales engineer for laser machine
tools, will now manage the TruBend and
BendMaster product lines.
Battelle Names Director
Battelle, Columbus, Ohio, an independ-
ent scientific research and technology de-
velopment organization, has elected Frank
L. Douglas to its board of directors. Dou-
glas is president and CEO of Austen BioIn-
novation Institute, a collaboration of five
leading medical and educational institu-
tions based in Akron, Ohio.
RMT Robotics Names
Customer Care Manager
RMT Robotics, Grimsby, Ont.,
Canada, a Cimcorp Oy company, has ap-
pointed Andrew Bell customer care man-
ager. New to the customer care team, Bell
formerly worked for five years as a project
manager.
Robotics Sales Engineer
Appointed at PRE-TEC
PRE-TEC, a division of Willamette
Valley Co., Eugene, Ore., has hired Shawn
Loftus as a sales engineer, robotics. In this
capacity, Loftus, with more than 20 years
of experience in the field, will serve to
bridge the link between customers and the
companys engineering group. Based in
Ohio, he will be responsible for customer
support throughout the eastern half of the
United States. Loftus previously worked
with Motoman Robotics and other robotic
integrators, most recently with a packag-
ing systems house in Spokane, Wash.
Wagner Companies Hires
Sales Representative
The Wagner Companies, Milwaukee,
Wis., a manufacturer of metal products for
architectural and industrial applications,
has appointed Connie Knaak outside sales
representative for the southwestern
United States. With the company for 24
years, Knaak most recently served as man-
ager of employee development. She will
be based in Austin, Tex.
GreenWizard Hires
Renewable Energy Pro
GreenWizard, Charleston, S.C.,
a cloud-based product management and
project collaboration solution that simpli-
fies building efficient and sustainable
buildings, has hired Greg Kats as a strate-
gic advisor. Kats, an authority in renew-
able energy, green buildings, and the
LEED standard, is president of Capital
E, a clean energy and investment advisory
firm. He also served five years as director
of financing for Energy Efficiency and Re-
newable Energy at the U.S. Department
of Energy.
Coleman Cable Announces
Organization Changes
Coleman Cable,
Inc., Waukegan,
Ill., has appointed
Kathy Jo Van exec-
utive vice presi-
dent, distribution
group, with an ex-
panded role for the
companys indus-
trial and electrical
distribution busi-
nesses in the
United States and Canada. With the com-
pany since 2000, she previously served as ex-
ecutive vice president, retail business. Dave
Oriatti has been named vice president,
product development, including oversight
for distribution of welding, industrial,
HVAC, and irrigation products. Gene Stang
has assumed the new position of vice presi-
dent, customer supply chain. Stangs role in-
cludes serving as the primary liaison be-
tween customers and the companys engi-
neering, manufacturing, and distribution
teams. During his 26 years with the com-
pany, he has served in a variety of sales and
manufacturing roles.
Shane Simpson Tom Bailey
Dave Oriatti
Kathy Jo Van
Gene Stang
Obituaries
Edward J. Nittiskie Jr.
Edward Joseph Nittiskie Jr., 54, died
July 8 at his home in Gainesville, Va. An
AWS member since 1999, he was affiliated
with the Washington, D.C., Section. Nit-
tiskie was born in Poughkeepsie, N.Y. He
served in the United States Air Force for
nine years where he began as a flight line
hydraulics mechanic and then advanced to
flight simulation. After leaving the Air
Force in 1985, he continued in the flight
simulation field. He held many roles in
this field for Sperry Unisys, Hughes, NLX,
and Rockwell Collins, including engineer,
programmer, and electrical designer. Nit-
tiskie was a private pilot, a certified
welder, and a hunter safety instructor. He
enjoyed skiing, golfing, rifle matches,
mountain climbing, and repairing cars. He
is survived by his wife Leslie, his mother,
two brothers, and two nephews.
Briggs Smith
Briggs Smith, 53, died July 23 in Chat-
tanooga, Tenn.,
where he was a
lifelong resident.
He was a member
of the AWS Chat-
tanooga Section
and an active
member of the
AWS Education
Committee. Smith
graduated from
the University of
Tennessee at
Knoxville then earned his masters degree
in administration and eduction from the
University of Tennessee at Chattanooga.
He was a teacher in the Bradley County
School System and served as director of Ca-
reer and Technical Education in Bradley
County. He later became director of Career
and Technical Education for Hamilton
County Schools. Smith was recognized as
Chattanoogas Father of the Year, Teacher
of the Year for Bradley County Schools, and
most recently the SkillsUSA Administrator
of the Year.
William P. Stevenson
William (Bill) Stevenson, 68, died June
27 in Centreville,
Va. An AWS
member since
1979, he served
on the executive
committee of the
Wa s h i n g t o n ,
D.C., Section.
Following high
school, Steven-
son worked in
the construction
industry. He en-
tered the U.S. Navy in 1964 where he par-
ticipated in Operation Deep Freeze in
Antarctica. Following active duty, he at-
tended Spartan College of Aeronautics
and Technology in Tulsa, Okla. He subse-
quently worked as a helicopter mechanic
servicing oil rig platforms in the Gulf of
Mexico. He later worked in the Marine
Corps Museum for a short period before
joining the Smithsonian National Air and
Space Museum (NASM) where he worked
as a welder and fabricator restoring mu-
seum artifacts for many years. Stevenson
is survived by his wife, Thalia, and a
brother. Donations may be made to
NASM, Udvar-Hazy Collections Div.,
Restoration Shop, 14390 Air & Space
Museum Pkwy., Chantilly, VA 20151.
Briggs Smith
William Stevenson
79 WELDING JOURNAL
cluded is information on the Versa-Cut
plasma arc cutting machine and acces-
sories. Product categories include paint-
ing, specialty coatings, rust solutions,
abrasive blasting, body and fender, pow-
der coating, and metal fabrication. To re-
quest a catalog, order online or call.
Eastwood Co.
www.eastwood.com
(800) 345-1178
Abrasive Products Pictured
in Catalog
The 20122013 Time Saving Solutions
Catalog illustrates the companys nonwo-
ven cotton-fiber abrasive products, grind-
ing wheels, cut-off wheels, mounted
points, and other products. Featured are
abrasive products for weld removal and
blending, edge-breaking, grinding, finish-
ing, and cutting stainless steel and alu-
mium. Included are an easy-to-use index,
product photos, descriptions, specifica-
tions, and primary applications for each
product. This 30-page catalog can be
downloaded at the Web site shown, or a
hard copy may be requested from the fol-
lowing contact information.
Rex-Cut Abrasives
www.rexcut.com
(800) 225-8182
SEPTEMBER 2012 80
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PRODUCT & PRINT
SPOTLIGHT
continued from page 24
operations will provide improved production and reduced response times. The high-
tech equipment will include quality labs, laser length measuring systems, a bar code
pipe tracking system, climate-controlled operations, and modern employee amenities.
The site will also have three pipe threading lines and one tubing line, which will con-
tinue to cover the Odessa plants current capabilities of 2
3
8 to 13
3
8 in. size range.
Industry Notes
Jet Edge, Inc., St. Michael, Minn., became one of the first U.S. companies to take
advantage of the United States new free trade agreement with South Korea, ship-
ping two containers of industrial ultrahigh-pressure waterjet equipment valued at
more than $700,000 to the Republic of Korea.
Tech Air, Danbury, Conn., a distributor of industrial, medical, and specialty gases and
related welding supplies, is acquiring Pennsylvania-based Dressel Welding Supply.
Based on its recent analysis of the computed radiography inspection systems mar-
ket, Frost & Sullivan recognized Carestream NDT with the 2012 Global Frost &
Sullivan Award for Product Differentiation Excellence.
Northeast Iowa Community College, Iowa Workforce Development, and area com-
panies are introducing a new welding certificate program in Cresco. Alum-Line,
Featherlite, and McNeilus partnered with the college to create a curriculum.
Matheson, Basking Ridge, N.J., acquired the assets and business of US Airweld,
Inc., Phoenix, Ariz., and also opened a new facility in Joplin, Mo., with 1400-sq-ft
of sales display and demo space to replace the structure lost in the tornado.
Rolled Alloys intends to open a facility in South Carolina. The 33,000-sq-ft service
center will feature an inventory of stainless and alloy bar products and processing
equipment.
Tormach LLC, Waunakee, Wis., launched TeachSTEMNow.com, an online resource
that promotes Science Technology Engineering and Mathematics in education.
Laboratory Testing, Inc., expanded its accreditation with The American Associa-
tion for Laboratory Accreditation. Many testing services under the umbrellas of
mechanical as well as chemical testing have been added.
NEWS OF THE INDUSTRY
THE AMERICAN WELDER
81 WELDING JOURNAL
I
t is essential to grasp the fundamen-
tals of resistance spot and projection
welding to better perform these
processes. In doing so, users can
improve in the key areas of production,
supervision, engineering, quality control,
and maintenance. This article features
an overview of the factors to take into
consideration.
Reviewing Modern
Welding Practices
From its discovery, metal has been
valued for its strength, durability, and
ability to perform tasks under the influ-
ence of heat and pressure. It can be
formed into shapes, welded together,
and joined using heat and force. This is
the method used by blacksmiths when
they heated metal with coal-fired forges
and made welds by applying pressure
with hammer blows.
Modern resistance welding is still
achieved using pressure and heat. A
modern resistance welding machine
applies pressure with an air cylinder sup-
ported by a steel frame and compressed
air causing a ram to apply pressure on
the two pieces of metal to be welded.
Electricity is passed through a trans-
former also supported in the same frame
that supports the air cylinder. The elec-
trical current creates the heat required
to make the welds. Secondary voltage
and current are controlled with tap
switches mounted remotely or on the
transformer. The welding current is con-
trolled by turning a solid-state switch
(silicon-controlled rectifier or SCR) on
and off. The current is passed through
copper secondary conductors, welding
arms, and the welding electrodes.
In the past, ignitron tubes were used
before the invention of SCRs. Todays
modern midfrequency DC welding
machines use diode packs built into the
transformers and insulated gate bipolar
transistors in the controls to control the
current and convert it into direct current.
How to Create
Satisfactory Welds
All the parameters required to make
satisfactory welds today are run with a
solid-state, digitally operated weld con-
trol that turns the switch (SCR or igni-
tron tube) on and off.
Most basic controls set the time and
welding amps, and the air pressure is set
with the remote regulator on the welding
machine. An option for most modern
weld controls is a built-in force monitor,
and with the addition of a programmable
regulator, the weld force can be set as
Spot and Projection
Welding Basics
Presented is a detailed look at these two
methods, plus the various types of
machines offered for making these welds
BY LARRY H. MCDEVITT
LARRY H. McDEVITT
(larry@wsiweld.com) is an application
engineer with Weld Systems
Integrators, Inc., Cleveland, Ohio.
Fig. 1 A Heres an example
of a direct weld featuring
balanced electrodes and a good
weld nugget position;
B direct weld showing
imbalanced electrodes and a
poor weld nugget location.
A B
THE AMERICAN WELDER
SEPTEMBER 2012 82
part of the weld schedule. Controls can
be set to fire based on time, or for fast
production times and with the force
option, they can be programmed to fire
when the weld force is reached.
The four elements required to make a
satisfactory weld are heat (H) in the
workpiece, electrical current (I) in the
workpiece, resistance (R) of the metal
being welded, and time (T). The com-
mon formula for weld development is H
= IRT. You can vary the heat by chang-
ing any of the elements in the formula.
Evaluating the Categories
of Basic Resistance
Welding
Basic resistance welding is generally
broken into four methods: spot, projec-
tion, seam, and flash welding.
Which method is best for a particular
application is based on the shape of the
parts, weld strength required, and econ-
omy. For instance, an example of econo-
my is making spot and projection welds
on similar machines so it would be more
cost effective to make multiple projec-
tion welds in one hit vs. the same num-
ber of single welds.
Spot Welding Characteristics
When making a spot weld, the area
being welded is the area clamped
between the two electrodes. The size and
shape of the electrodes will determine
the size of the weld nugget. The weld will
form in the interface between the elec-
trodes. With the same size and shape
electrodes, the nugget will form equally
in both sheets of the same thickness
metal. The weld nugget can be located
closer to one electrode or the other by
changing the diameter or the shape of
the electrodes. There may be cases where
you want the nugget to form closer to one
interface than the other, and you can do
this by changing the electrodes.
A flat electrode on one side and a
domed electrode on the other will give a
cleaner, less visible weld on the side
backed up with the flat electrode. You
can also use this combination of large
and small electrode diameters when
welding dissimilar thicknesses to move
the nugget so that it will be located at the
interface between the two metal thick-
nesses. This method is often used when
the appearance of one of the sheets is
more critical than the other.
Exploring Direct, Series, and
Indirect Welding
Direct welding, where the current
passes from the transformer to a top
electrode directly through the material
into a bottom electrode and back to the
transformer, is the most commonly used
process Fig. 1A, B.
When we are unable to back up the
workpiece or the size or shape of the
workpiece dictates using a flat backup
shunt bar, it is suggested the series weld-
ing process be used Fig. 2. In this
case, the two electrodes are connected to
the opposite poles of the transformer,
and the current passes through the trans-
former, the one electrode through the
workpiece into a copper backup shunt
bar, then back out to the second elec-
trode and back to the transformer.
Series welding is recommended for
joining only 18-gauge and thinner materi-
als. Thicker materials may not allow the
current to reach the weld interface and
can cause undesirable surface heating.
When the material thickness is over 16
gauge, indirect welding is recommended.
With indirect welding, the two elec-
trodes are connected to the opposite poles
of the transformer, and the current passes
through the transformer to one electrode
through the workpiece into a copper back-
up shunt bar and back out to a contact gun
and back to the transformer Fig. 3.
A Focus on Press Style,
Rocker Arm, and Multigun
Welding Machines
Typical press-style welding machines
recommended for direct and series spot
welding use are size 02 press welding
machines providing weld forces from 250
to 3600 lb Fig. 4. The maximum second-
ary current ranges from 20,000 to 65,000 A.
Rocker arm welding machines used
typically for sheet metal welding range
from 250 to 1500 lb force and provide up
to 25,000 A maximum secondary current
Fig. 5.
For many automotive applications,
multigun welding machines are used.
They can be designed for high-produc-
tion applications in both sheet metal and
assembly applications, and fitted with
many different sizes of double and triple
air or air over oil operated guns and
compact fixture style transformers.
Multigun welding machines can be
designed and set up for direct welding,
series welding, and indirect welding.
The guns can also be programmed to
do single or multiple welds in cascade or
in sequence. Cascade welding is when all
the weld guns are energized at the same
time, and they are fired by a control with
multiple SCRs one at a time. Sequential
welding is when the guns are energized
and the SCRs are fired one at a time.
Cascade welding usually offers the fastest
cycle time of all the methods available.
For projection welding applications,
Fig. 2 This series weld
displays a good weld nugget.
Fig. 3 An indirect weld (left)
and the ground pad are
presented.
2
3
THE AMERICAN WELDER
83 WELDING JOURNAL
the same welding machines can be fitted
with tooling to locate the parts and sized
properly for the projection welding
process.
Projection Welding Details
While with spot welding the electrode
faces determined the size and shape of
the welds, in projection welding, the size
and shape of the workpiece are the
determining factors.
Embossed projections provide the
smallest cross-sectional area in the cir-
cuit. This creates the greatest resistance
to the flow of current, causing the tem-
perature rise to begin at the projection,
ensuring that the weld interface will
develop at that point between the work-
pieces. Several projections may be weld-
ed at the same time because similar pro-
jections require the same weld force and
current.
Because the geometry of the parts to
be welded can vary considerably, the fol-
lowing projections can be designed for
various styles: button, elongated, chisel,
line, and edge. Another method of pro-
jection welding is cross wire welding
when the wire diameter as the projection
is used. Ring, shoulder ring, chamfer
ring, and domed projections are the
standard projection styles commonly
used; a majority can be welded using
standard projection welding machines
with special tooling for most projection
welding applications.
The height of the projections will be
determined by material thickness.
Handbooks published by the Resistance
Welding Manufacturing Alliance and
American Welding Society should be
consulted when designing projections.
Many manufacturers will supply data
that can be used for projection design.
Typical tooling used for projection weld-
ing will be platen mounted, water-cooled
copper blocks with welding die inserts
and parts locators.
A key to successful projection weld-
ing is proper fitup of the parts to be
welded. It is imperative that the tooling
be square and parallel, and the clear-
ances and tolerances are correct to pre-
vent shunting, which will affect the qual-
ity of the weld. Proper setup of the weld-
ing dies is especially important when-
welding multiple projections because
equal current and pressure are required
to make quality welds. Ring projections
should be within 0.001 in. parallelism
when a hermetic seal is required.
Fig. 4 A press-style welding
machine works for creating
direct and series spot welds.
Fig. 5 A rocker arm welding
machine makes welds on sheet
metal.
4 5
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November 12-14, 2012 | Las Vegas Convention Center
FABTECH.
North Americas Largest Metal Forming,
Fabricating, Welding and Finishing Event
Follow us: Cosponsors:
CONNECT.
LEARN.
COLLABORATE.
Experience the dynamic learning environment of FABTECH 2012 a place
where you can exchange best practices and discover new ideas and trends
to take your business to the next level. Network with peers, learn from
top industry experts and be inspired by the 100+ targeted educational
sessions. Teres nothing else like it!
THE ONE EVENT TO GAIN CRITICAL KNOWLEDGE
AND ENHANCE YOUR TECHNICAL EXPERTISE.
FABTECH 2012.
PREVIEW OF AWS EDUCATIONAL PROGRAMS AT FABTECH
Conferences and Symposium
Underwater Welding and Cutting (Nov. 12)
Thermal Spray Basics: Putting Coatings to Work (Nov. 12)
Brazing Symposium (Nov. 12)
Health and Safety in the Welding Environment (Nov. 13)
Thermal Spray Technology: High-Performance Surfaces (Nov. 13)
Trends in Nondestructive Examination (Nov. 14)
Resistance WeIding SchooI
RWMA Emmet A. Craig Resistance Welding School (Nov. 13-14)
Seminars
Metallurgy Applied to Everyday Welding (Nov. 12)
Advanced Visual Inspection Workshop (Nov. 12)
API 1104 Code Clinic (Spanish) (Nov. 12)
ASME Section IX, B31.1 & B31.3 Code Clinic (Nov. 12-13)
D1.1 - Code Clinic (Spanish) (Nov. 13)
The Why and How of Welding Procedure Specifications (Nov. 13)
Understanding Welding Symbols (Nov. 13)
Welding of Stainless Steel (Basics) (Nov. 13)
Welding of Stainless Steel (Avoiding Weld Defects) (Nov. 14)
D1.5 Bridge Code Clinic (Nov. 14)
Corrosion of Welds: Causes and Cures (Nov. 14)
Free for Educators
AWS Educational Sessions (including Plummer Lecture) (Nov. 12-14)
ProfessionaI Program
Session 1: Welding Metallurgy (CIMJSEA) (Nov. 12)
Session 2: Arc Welding Studies (Nov. 12)
Session 3: Weld Microstructure and Properties (Nov. 12)
Session 4: Keynote Address: Dr. Peter Mayr (Nov. 13)
Session 5: Modeling (CIMJSEA) (Nov. 13)
Session 6: Friction Stir Welding & Solid State Processes (Nov. 13)
Session 7: Welding Metallurgy (Nov. 13)
Session 8: Sensing Applications (Nov. 13)
Session 9: Weldability (CIMJSEA) (Nov. 13)
Session 10: Applied Technology (Nov. 13)
Session 11: Keynote Address: Prof. Philip Withers (Nov. 14)
Session 12: Applications of Weld Modeling (Nov. 14)
Session 13: Weldability (Nov. 14)
Register at fabtechexpo.com
Welding Fundamentals
AWSs American Welding Online is introducing a self-paced online seminar designed to
provide technical knowledge and insight to non-welders who work in the welding and
fabricating industry.
Welding Fundamentals is an approximately 14-hour course that can be taken at your own
speed and convenience. The course provides a fundamental overview of welding, focusing
on the most widely used welding processes. Fundamental instruction is presented on
welding theory, equipment, safety, weld design, metallurgy, welding inspection, and quality
control.
Professional Development Hours and a certificate of completion will be provided upon
completion.
For more information, visit American Welding Online at
www.aws.org
New online course

THE AMERICAN WELDER
87 WELDING JOURNAL
C
hicago Women in Trades (CWIT)
improves womens economic equi-
ty by increasing their participation
in well-paid, skilled trade jobs traditional-
ly held by men and eliminating the barri-
ers that deter women from entering and
succeeding in these fields.
To accomplish these goals, CWIT pro-
vides support, advocacy, and education to
tradeswomen; works to increase training
for women and girls to enter nontradi-
tional jobs; provides technical assistance
to employers, unions, and other service
providers; documents trends in the non-
traditional workplace; and advocates for
improved policies and practices that sup-
port womens access to and retention in
nontraditional training and jobs.
Founded by tradeswomen in 1981,
CWIT celebrated its 30th anniversary last
year. Today, it is the only organization in
Illinois working consistently on issues
concerning equitable employment condi-
tions and policies for women in the con-
struction trades and other nontraditional
occupations. This article not only details
its vast training opportunities but also
looks into the personal stories of four suc-
cessful participants.
Features of the Technical
Opportunities Program
Outreach and Career Education
Chicago Women in Trades conducts
weekly information sessions and two to
three orientation/career fairs annually to
introduce women to careers in the con-
struction trades and other nontraditional
occupations.
Building Demand for Tradeswomen
At a Chicago-based organization, women
prepare for nontraditional careers in welding
and construction to help fill current shortages
Article contributed by the Chicago
Women in Trades.
For more information, visit
www.chicagowomenintrades.org.
The Chicago Women in Trades weld-
ing training program offers SMAW,
GMAW, GTAW, and oxyfuel cutting
instruction. Pictured above is gradu-
ate Charlita Mason.
THE AMERICAN WELDER
SEPTEMBER 2012 88
Also, the program provides free
career education materials, training,
technical assistance, and on-site presen-
tations to community colleges and other
organizations seeking to inform and pre-
pare women for construction careers.
Preapprenticeship Tutorial
Established in 1987, the technical
opportunities program (TOP) offers a
free 190-h course designed to prepare
women to compete for and succeed in
apprenticeship programs and other
skilled blue-collar occupations.
The curriculum includes math and
test preparation, workplace readiness,
physical conditioning, and basic con-
struction skills/hands-on experience in a
variety of trades. The full curriculum can
be viewed at www.chicagowomenintrades.
org/top/top_home.html.
Welding
Formal welding training began at
CWIT in 2009 to prepare women to
meet the projected shortage of skilled
welders in the construction and manu-
facturing industries.
The program provides approximately
100 h of instruction in shielded metal arc
welding (SMAW), gas metal arc welding
(GMAW), and gas tungsten arc welding
(GTAW) as well as oxyfuel cutting.
Training can also be customized to respond
to specific employment opportunities.
Employment Services
The CWIT connects aspiring and
experienced tradeswomen to apprentice-
ship programs, contractors, and other
nontraditional employers. In addition, it
maintains a large database of qualified
applicants, including preapprenticeship
graduates, qualified welders, and
tradeswomen.
Employers may contact the organiza-
tion to list job announcements and/or
request to interview prescreened appli-
cants to meet specific job requirements.
Policy and Advocacy
Complementing its direct service pro-
grams, the organization serves as a voice
for tradeswomens issues through policy
and advocacy initiatives.
The goals of CWITs policy work are
to remove institutional barriers and
redress the persistent discrimination
that maintains womens poverty and
exclusion from high-wage, nontradition-
al careers. It promotes policies and pro-
vides models for preparing and connect-
ing women to these careers, building
demand for tradeswomen in the work-
place, and supporting their long-term
retention in the construction industry.
Welding Training Program
Details
The basic welding training program
at CWIT is a ten-week session focusing
on SMAW. The end goal is to have par-
ticipants certify in the 3F position on -
in. plate. The program has been modi-
fied to include procedures used in the
Pipe Fitters, Ironworkers, and Sheet
Metal Workers training programs. It also
uses ideas from the American Welding
Societys (AWS) Schools Excelling
through National Skill Standards
Education (SENSE) training program.
As with most training programs, safe-
ty and generally accepted industry prac-
tices are stressed. Being prepared to
enter the workforce with an understand-
ing of what employers expect is essential.
The basic training program also
includes blueprint welding symbols, use
of measuring tools, layout and fitup
practices, and practical application of
welded joints. Participants are given a
broad overview of oxyfuel torch usage
with a demonstration in oxyfuel gas
welding, brazing, and soldering tech-
niques. Daily practice occurs with cut-
ting mild steel to specific dimensions,
including holes of various sizes.
Currently, its facility is not equipped
with a plasma arc cutting device, so
training in this process will be incorpo-
rated when one is acquired.
Todays economy has left a reduced
opportunity for the organizations par-
ticipants to join various construction
unions, but fortunately, the manufactur-
ing segment is rebounding. As a conse-
quence, it is revising the curriculum to
include GMAW training specific to this
opportunity.
In addition, CWIT is working with the
National Association of Manufacturers
to train participants in the skills manu-
So far this year, CWIT has seen two
candidates complete the Pipe Fitters
hybrid welding training program.
Sonia Valdes, a 38-year-old single
mother of four children, graduated from
the Local Union 597 Chicago Pipe
Fitters and finished the program with
two qualifications Fig. 1. She is now
an apprentice pipe fitter with A.M.S.
Mechanical, Burr Ridge, Ill.
Darlene Munoz, who has a BA in lib-
eral arts, also accomplished two qualifi-
cations Fig. 2. Currently, she is an
apprentice pipe fitter for Meccon
Industries, Inc., Lansing, Ill.
While waiting to get into the Pipe
Fitters program, another participant,
Arlena Tucker-Hampton, a 40-year-old
single mom, was drafted by Caterpillar
as a production worker. She is now in
the Sheet Metal Workers apprentice
program, works as a sheet metal pre-
apprentice with F. E. Moran, and is a
member of Local Union 73 Fig. 3.
Tucker-Hampton started her welding
career with Freedman Seating, Chicago,
Ill., and further developed her skills
while working with Interlake Metallux,
Pontiac, Ill.
Charlita Mason is waiting on deck
for the next opening in the Pipe Fitters
hybrid welding program while employed
as a production gas metal arc welder
see lead photo and Fig. 4.
Networking has been a key ingredient
in the eventual success of CWITs candi-
dates. Tucker-Hampton was one of its
first welding program graduates to get a
job as a production gas metal arc welder
with Freedman Seating on the west side
of Chicago. While at Freedman, she met
Valdes and told her about the organiza-
tions training. Valdes joined CWITs
technical opportunities program, com-
pleted welding training, and was accept-
ed immediately to the Pipe Fitters hybrid
welding program. The opening left at
Freedman by Valdes was filled by anoth-
er technical opportunities program and
welding program graduate, Charlita
Mason. Because Mason was not finan-
cially ready to enter the next hybrid weld-
ing opening, another technical opportu-
nities program graduate, Munoz, took
this entry and finished the hybrid welding
program at the top of her class.
Recent Success Stories
THE AMERICAN WELDER
89 WELDING JOURNAL
Fig. 1 Sonia Valdes, a single
mother of four children, serves as
an apprentice pipe fitter with A.M.S.
Mechanical, Burr Ridge, Ill.
Fig. 2 Darlene Munoz enjoys op-
erating as an apprentice pipe fitter
for Meccon Industries in Lansing, Ill.
Fig. 3 Arlena Tucker-Hampton is
shown welding and with her daugh-
ter. She is a sheet metal preappren-
tice with F. E. Moran.
Fig. 4 Charlita Mason presently
works for Freedman Seating and
awaits an opening to the Pipe Fitters
hybrid welding program.
Sonia Valdes Darlene Munoz
Charlita Mason
Arlena Tucker-Hampton
THE AMERICAN WELDER
SEPTEMBER 2012 90
facturers require. It hopes to establish an
internship program where clients will
receive on-the-job training while contin-
uing to learn in its facility to improve
their knowledge and skills. This could
potentially end in a win/win situation for
everyone. Employers will get employees
trained for free and the organizations
participants will receive a position with
an employer who recognizes and values
their skills.
Successful candidates would then be
eligible for additional training at
CWITs facility in GTAW. For the
employer, this would raise their employ-
ees skill levels at no training cost to
them. Ideally, a contractual agreement
similar to armed forces recruiting could
secure employment for participants and
ensure continuing improvement in skills
for employers.
Looking to the Future
The state of our current economy,
and the ever-looming threat of cutbacks
in funding, puts CWITs program in a
tentative position. While most would
agree that training and education are
imperative to a productive workforce,
who should fund them is debatable.
From the return-on-investment view-
point, most employers could not provide
the training it provides at a lower cost. It
also frees up their operations from
including a program they dont need
continuously. Employers have a larger
pool of candidates to select from with
measurable skills to meet their needs.
With continued funding, trade pro-
grams can expand and be continually
modified to provide the talent required
to meet the needs and changes in our
blue collar world. Partnering with indus-
try would foster the original idea of the
trades. A person would get a basic edu-
cation in a skill (apprentice); move on to
develop, improve, and refine their skills
(journeyman); and eventually become a
master craftsperson. The master could
then be the instructor for the next gener-
ation of tradespeople. This practice
needs to be revisited to at least maintain
our workforce, if not improve it.
The welding profession has a large
number about to retire, and new welders
are needed to take up their legacy. It is
valuable for these master craftspeople to
repay the success they have enjoyed and
instill the ethic that they lived by.
Who Will Take up the
Legacy?
Chicago Women in Trades believes
the breeding ground of our future lies in
elementary education. It is important for
females to be exposed and cultured in the
ways of industrial workplace operations.
Education for all students needs to
include math, measurement, mechanical
operation, verbal comprehension, logic,
and problem-solving skills. People who
come prepared with these primary abili-
ties will progress at a much quicker and
easier pace, be comfortable in their
training, and enjoy their work. Those
who are uncomfortable with their train-
ing see it as a struggle they wish to avoid.
Conversely, those comfortable in their
training embrace the challenge and excel
in their development.
Women are considered a minority in
the workforce, especially the trades. The
reality is that they outnumber males
throughout the world. Women in the
trades are considered nontraditional,
meaning that these are jobs women do
not normally seek or aspire to. The
organization believes it is time to remove
this gender-based stigma and let the best
qualified and most enthusiastic give the
world what it needs and deserves.
Many other careers show the validity
of women in the workplace. Female doc-
tors, lawyers, physicists, and engineers
are making great contributions to our
society and the welfare of all mankind.
The only thing keeping women from a
welding career is their ability to know it
is available to them and the training nec-
essary to do the job.
Acknowledgment
John Leen, who has been instrumen-
tal in the success of CWITs program
both in getting candidates approved and
supplying practice materials, and the
Local Union 597 Chicago Pipe Fitters
are gratefully acknowledged.
THE AMERICAN WELDER
LEARNING TRACK
93 WELDING JOURNAL
N
orthern College School of
Welding Engineering Technology
(SWET), located in Kirkland
Lake, in northeastern Ontario, Canada,
provides students with a balanced blend
of practical skills and theoretical knowl-
edge and a low student-teacher ratio that
permit graduates to perform exceptional-
ly well as engineering team members.
The optional industry-supported co-
op program allows students to earn while
they learn and put into practice the the-
ory and skills acquired in class.
Additionally, they gain valuable work
experience and business contacts. The
challenging curriculums provide gradu-
ates with solid foundations in mathemat-
ics, science, metallurgy, and welding
process technology.
The colleges welding engineering
technology program, established in 1970,
boasts more than 90% of its two- and
three-year program graduates are
employed in a related field. The college
notes that about 70% of its technology
students have jobs waiting for them
when they graduate in the automotive,
aerospace, construction, manufacturing,
petrochemical, and power industries.
The faculty members have working rela-
tionships with employers and other job-
placement contacts enabling them to
help students find employment.
The welding course materials are
reviewed by an Advisory Committee
comprised of representatives from aca-
demia, private consulting firms,
Canadian Welding Bureau, Lincoln
Electric, ESAB, CANMET, Canadian
Institute of Steel Construction, National
Research Council of Canada, and Rofin-
Baasel, Inc., who ensure the courses are
updated and pertinent to the current
needs of industry. The welding curricu-
lum is recognized by the Ontario
Association of Certified Technicians and
Technologists. Graduates may apply for
accreditation after two years of work
experience and use the professional des-
ignations C.Tech and CET, respectively.
The general descriptions of the weld-
ing courses currently offered in the
SWET welding program follow.
The Welding Fitter Program
A welding fitter interprets blueprints
in order to cut, fit, assemble, and weld
metal components while meeting code
requirements. The training is presented
as a two-semester, full-time course that
awards an Ontario College Certificate.
The subjects include applied blueprint
reading, trade practices, weld theory,
welding quality, welding and cutting,
trade mathematics, welding skills, and
communications. The program requires
completion of several practical hands-on
projects to ensure graduates are ready to
work in industry.
Northern College Grads Find
Rewarding Jobs in Welding
HOWARD M. WOODWARD
(woodward@aws.org) is associate
editor of the Welding Journal.
Fig. 1 The Northern College weld-
ing technology faculty members are
(from left) Josh Fuller, Abdul
Hameed, and David Rogalsky.
BY HOWARD M. WOODWARD This Canadian college boasts 90% of its graduates
are employed in a welding-related field and 70% of
technology majors have jobs waiting for them
when they graduate
THE AMERICAN WELDER
SEPTEMBER 2012 94
Welding Engineering
Technician Inspection
This program is a four-semester, full-
time course that awards an Ontario
College Diploma. It provides a back-
ground in science and technology related
to welding to enable graduates to inter-
act with engineers and scientists while
maintaining the practical skills necessary
to supervise trades personnel. Stressed
are weldment design, welding variables,
materials engineering, and the various
welding processes. The courses include
computer applications, mathematics,
welding drafting, welding electrical fun-
damentals, inspection codes and stan-
dards, materials joining, mechanic/stat-
ics, computer-aided fixture design, mate-
rials preparation, strength of materials,
nondestructive examination, and weld-
ing processes. Graduates may opt to
enter the workforce or continue their
studies for an additional two semesters
in the Welding Engineering Technology
program.
Welding Engineering
Technology
This six-semester program builds on
the previous course of study awarding
graduates an Ontario College Advanced
Diploma. The additional studies include
courses in welding physics, robotic weld-
ing and automation, calculus, principles
of statistical process control and failure
analysis, and business management and
organizational behavior. Some students
opt to take advantage of the co-op, nine-
semester, work-study program to earn
while they learn and further enhance
their experience and skills. Students
learn to develop, qualify, and implement
welding procedures, and design and
inspect welded structures using their
knowledge of welding, metallurgy,
mechanics, and electrical engineering.
International Welding
Design
The International Welding Design
Certificate program prepares graduates
for an international career by qualifying
them to write the exam for either the
International Welding Technologist
Diploma or the International Welding
Engineer Diploma, depending on the
applicants previous studies. The admis-
sion requirement for this program is an
Ontario College Advanced Diploma
from an engineering technology pro-
gram, such as mechanical, manufactur-
ing, civil, structural, or electrical, or an
equivalent credential. The three-semes-
ter course includes studies in welding
processes and equipment, metallurgy,
construction and design, and applica-
tions engineering, and is supported by
the International Institute of Welding.
Welding Staff
Josh Fuller is a professor and Jack
Pacey is technical advisor at the
Materials Joining Innovation Centre.
Fuller teaches the mathematics
courses for the welding engineering pro-
grams, and also acts as coordinator.
Recently, SWET alumnus David
Rogalsky took over the responsibilities
of instructing core welding technology
courses from Jack Pacey. Six years ago,
Abdul Hameed joined the full-time staff,
bringing with him a wealth of industrial
and international experience and a
strong background in metallurgy and
nondestructive examination Fig. 1.
The Training Facilities
The welding facilities occupy about
10,000 sq ft. The fully equipped welding
shop features 24 welding booths (Fig. 2),
a metallurgy lab with specimen-prepara-
tion equipment, industrial-size shears,
press brake, rolls, punch, etc., as well as
a microscopy suite, and heat-treatment
ovens. The Nondestructive Examination
Lab is outfitted with a variety of inspec-
tion technology including X-ray, ultra-
sonic inspection units, a magnetic parti-
cle bench, and liquid dye penetrant sup-
plies. The Robotics Lab provides an edu-
Fig. 2 A student hones his gas
metal arc welding skills using a metal
cored electrode.
Fig. 3 A welding student adjusts the
settings on a Lincoln NA-5 automatic
wire feeder for a submerged arc weld-
ing assignment.
2
3
THE AMERICAN WELDER
95 WELDING JOURNAL
cational welding robot and an industrial-
size welding robot. The Welding
Processes Lab is equipped with power
sources to facilitate resistance welding,
GMA, GTA, FCA, SA, and SMA weld-
ing Figs. 3, 4. The Materials Testing
Lab features a 400,000-lb-capacity ten-
sile testing machine, Charpy V-notch
impact testing machine, and associated
tools.
Student Success Centers
A valuable resource offered by the
college is the Student Success Centers
provided to offer quiet environments for
studying, peer tutoring, and faculty men-
toring. The services include specific
course assistance and access to profes-
sors and student tutors in all courses and
programs of study. Students can apply
online to request a tutors services or to
submit an application to serve as a tutor.
Living on Campus
A professionally managed co-ed resi-
dence with furnished semiprivate and
private rooms designed specifically for
students is available at the Northern
College Kirkland Lake campus. The
facility includes common areas fitted
with a kitchen, snack shop, cable TV,
high-speed Internet, utilities, coin-oper-
ated laundry, and telephone service to
call anywhere within the United States
and Canada. Security is maintained with
surveillance cameras, staffed front desk,
and locked entry. The reasonably priced
rooms may be booked online by the
semester or for short term.
More Money Matters
The Welding Engineering Technology
program tuition including all fees for
local students for the 20122013 year is
about $3325, plus $250 for the co-op
option. International students pay about
$12,072, plus $250 for the co-op option.
The college has an Employment
Center on campus to assist students
locating co-op jobs, part-time jobs, and
full-time careers upon graduation.
Students normally do not work part-
time jobs since they make substantial
money during co-op placements. There
is a high demand for the students. The
recent co-op employers include General
Dynamics Land Systems, Babcock &
Wilcox, Lincoln Electric, MAGNA, and
Chicago Bridge & Iron. In cases where
students need a part-time job, there are
often opportunities to work as peer
tutors, or to work at the campus library
during evenings.
Financial assistance is available from
several sources. The Canadian Welding
Bureau awards ten scholarships annual-
ly, each valued at $2000, to outstanding
students who wish to pursue a career in
welding fabricating. Candidates submit a
faculty recommendation and a 1000-
word technical essay related to welding
or the welding industry in general.
Northerns students generally base their
submissions on their technical report, a
culminating project in the third year of
the program.
College Open to Changes
In 2008, the college helped launch the
Materials Joining Innovation Centre
(MaJIC), an independent, not-for-profit
research center located at the colleges
Kirkland Lake Campus. MaJIC offers a
complete range of services in welding
procedure development, code interpre-
tation, applied research, materials char-
acterization, welder qualifications test-
ing, and specialized training. The college
has access to these facilities Fig. 5.
The SWET is North Americas first
Authorized Training Body for the
International Institute of Welding (IIW).
Certification as an International
Welding Technologist through the
Canadian Welding Bureau (CWB), the
Authorized National Body for the IIW,
provides its technology graduates with
job opportunities in 56 IIW-member
countries worldwide.
Fig. 4 A welding process lab assign-
ment requires students to regulate a
pulsed gas metal arc welding setup
using computer-controlled waveform
technology.
Fig. 5 At the Northern College
Materials Joining Innovation Centre, an
MTS 647 hydraulic testing machine is
used to evaluate basic metal properties.
4
5
Jack Pacey, with 34 years of teaching
experience in Northerns programs, has
been committed to the implementation
of IIW standards.
Its a passport to opportunity, said
Pacey. It will help promote uniformity
in Canadian credentialing. We need con-
sistency in welding credentials across the
spectrum from welder to engineer.
During his years with Northerns
welding program, Pacey has witnessed a
lot of changes. In the 1970s, the pro-
gram focused primarily on heavy-plate
fabrication for structural applications,
pressure vessels, and shipbuilding, in
support of heavy industry, he said. The
program has since evolved to place
increased emphasis on fabrication using
lighter-gauge materials and automation,
in support of the industrial changes.
A Historical Summary
Originating in 1970 as a three-year
welding engineering technology pro-
gram, SWET introduced the two-year
welding engineering technician (inspec-
tion) program in 1979 and optional co-
op programs for both diplomas in 1995.
The president of Lincoln Electric
Canada together with leaders at
Dominion Bridge and other industries,
were members of the founding Program
Advisory Committee.
Current Lincoln Electric Canada
President Joe Doria, an alumnus of the
program, said, Because there was such
a need, Northern had the vision to
develop this program. We supported and
continue to support that vision. Our sole
interest is the joining, welding, and cut-
ting of metals. We need the technology
to ensure that welding, as a key compo-
nent of virtually all manufactured prod-
ucts, is considered the best choice to
lower costs and build our economy.
A strong engineering concentration
has been the foundation of the technol-
ogy programs since inception. The pro-
grams instructors are professional engi-
neers and certified engineering technol-
ogists who draw upon engineering prin-
ciples and practices. The criteria of the
curriculums are analysis, critical think-
ing, problem-solving, and team building
in the design of welding procedures and
inspection of welded structures, with a
constant regard for the cost-quality
equation.
The co-operative learning option,
introduced in 1995, is a win-win-win addi-
tion to the SWET program. First, stu-
dents have the opportunity to reinforce
their classroom learning and laboratory
experiences during work terms within the
welding industry. Work provides students
with income, practical experience, indus-
trial contacts, and exposure to the diver-
sity of professional careers in the welding
industry. Second, the college benefits by
learning from the co-op students and
their employers about improvements that
could be made to program offerings.
Third, employers benefit by verifying the
effectiveness of the college program by
observing how well the students perform
on the job. After graduation, the students
are often well positioned to be hired by
the company.
Accommodating the varied abilities
of co-op students can be a challenge, but
for those industries that make the time,
its worth the effort. We see it as col-
laborative relationship, said Anthony
Long, senior weld engineer at
Multimatic Structures and Suspension
Inmet division in Richmond Hill, Ont.
We have enjoyed an excellent experi-
ence with Northern College. A Northern
College student brings enthusiasm and
dedication toward learning and making
an impact in the welding industry. Long
explained, Our involvement in the pro-
gram allows us to influence its develop-
ment to better support our needs. In
addition, we have the opportunity to
donate equipment to Northerns pro-
gram, which better prepares students for
our work environment. In the long run,
Northerns co-op program will save us
time and money.
Alumnus Corby Nicholson, working
for MDS Nordion, said, The skills and
knowledge gained at Northern have
resulted in a very challenging and
rewarding career. The welding technolo-
gist plays an important role in the
Canadian welding industry, often serv-
ing to bridge the gap between the design
office and the shop floor or job site.
The Locale
Prior to World War II, Kirkland Lake
was a bustling open-pit gold-mining
region nicknamed The Mile of Gold
and the Hub of the North. Today,
although gold is still mined to a lesser
degree in the area, the town (population
8133 in 2011), surrounded by a mixed
boreal forest with clean lakes, is better
known as a place where students can
pursue myriad disciplines while enjoying
the best of the great outdoors.
Northern College, via its four cam-
puses, provides learning opportunities to
a region the size of France, and to an
even wider area via its satellite-based
learning centers.
THE AMERICAN WELDER
SEPTEMBER 2012 96
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140 Government Rd. E.
Kirkland Lake, ON P2N 3L8, Canada
www.northernc.on.ca/welding
welding@northern.on.ca
Phone: (705) 567-9291, ext. 3750
FAX: (705) 567-8186
www.AmericanWeldingOnline.com
Online Welding Safety Certificate Course
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Three-hour self-paced course covers electric shock, vision and skin protection,
ventilation, fire protection, handling of gases, and much more.
Sample seminar at awo.aws.org/seminars/safety
OSHAestimates that
4 out of every 1,000
welders will
experience a fatal
injury or accident over
their working lifetime
Online W g Safety Certificate Course eldin Online W g Safety Certificate Course
experience a fatal
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THE AMERICAN WELDER
SEPTEMBER 2012 98
FACT SHEET
Sprayed coatings applied to enhance
or extend performance in severe ther-
mal, wear-intensive, or corrosive envi-
ronments remain the mainstay of the
thermal spray industry. The thickness of
the deposited layer for applications typi-
cally is in the range of 0.1251.0 mm
(0.0050.040 in.). Much thicker spray
deposits of more than 25 mm can be pro-
duced with some spray materials, and
thermal spraying sometimes is used to
make freestanding shapes. For example,
injection molding dies can be produced
by spraying onto removable patterns or
mandrels.
In a generic thermal spray process,
electrical or chemical energy is used to
create small molten or semimolten
droplets from powder, wire, rod, or cord
feedstock. The droplets are propelled
onto a workpiece surface (the substrate)
by a subsonic or supersonic stream of gas
Fig. 1. On impact, the droplets spread
out and quickly solidify, cooling at rates
ranging from 10
4
deg per second to 10
8
deg per second. The solidified droplets,
called splats, randomly stack up on one
another (much like randomly stacked
playing cards) to form the layered or
lamellar microstructure that is charac-
teristic of most thermal-spray-deposited
materials. Note that, technically, only
the first layer lands on the substrate;
subsequently deposited material actually
lands on previously deposited material.
The quality of the interfaces between
the solidified splats, called splat bound-
aries, strongly influences the physical
and mechanical properties of the spray-
deposited material, much like grain
boundaries influence the properties of
cast or wrought materials. Deposition
rates vary widely with different process-
es, materials, and applications.
Thermal spraying is commonly car-
ried out in an ambient air environment,
and a major advantage is the ability to
spray-coat very large items in place.
Table 1 shows some examples of applica-
tions for thermal spray.
Table 1 Some Representative Examples of Industrial Thermal Spraying Applications
Industry Application Coating Purpose Spray Process Coating
Automotive Seam welds Filler Arc Silicon-bronze
Piston cylinders Wear resistance Plasma Steel
Piston rings Wear resistance Plasma Molybdenum
Shift forks Wear resistance Flame Molybdenum
Oxygen sensors Thermal barrier Flame Spinel
Heat exchangers Corrosion resistance Arc Zinc
Pulp and Paper Yankee dryer rolls Wear resistance Arc FeCrBSi
Center press rolls Wear resistance Plasma Chrome-oxide
Calendar rolls Wear resistance High-Velocity Oxyfuel (HVOF) Chrome-carbide
Boiler tubes Wear, corrosion resistance Arc Nickel-chrome
Corrugated rolls Wear resistance HVOF Tungsten-carbide
Digesters Wear, corrosion resistance Arc Alloy 625
ID fans Wear resistance HVOF Tungsten-carbide
Aerospace Aircraft engines Thermal barrier Plasma Yttria-zirconia
Aircraft engines Abradable clearance control Flame Aluminum-polyester
Aircraft engines Wear resistance HVOF Tungsten-carbide
Aircraft engines Dimension restoration Arc Nickel-aluminum
Landing gear Wear, corrosion resistance HVOF Tungsten-carbide
Airframe Conductivity Flame Aluminum
Airframe Flap tracks HVOF Tungsten-carbide
Petrochemical Ball valves Wear, corrosion resistance HVOF Tungsten-carbide
Gate valves Wear, corrosion resistance HVOF Tungsten-carbide
Choke stems Wear, corrosion resistance HVOF Tungsten-carbide
Piston rods Wear resistance Flame Chrome-oxide
Offshore oil rigs Corrosion resistance Flame Aluminum
Pump housings Dimension restoration Arc Aluminum-bronze
Compressor cylinders Dimension restoration Arc 420 stainless steel
Processing tanks Corrosion resistance Flame Aluminum
Thermal Spray Basics
Excerpted from the Welding Handbook, Vol. 3, ninth edition.
Fig. 1 Generic thermal spray device with
close-up view of spray deposit.
Welding Alloys USA acquired ST Alloys, Mobile, Ala. It adds
five employees to Welding Alloys 50 in Florence, Ky. The
company plans to hire five more for the Mobile facility and
spend about $300,000 on equipment improvements/upgrades.
Victor Technologies, St. Louis, Mo., recently acquired all of
the capital stock of Robotronic Oy, the parent company of
ProMotion Controls, Inc., a maker of intelligent CNC con-
trollers used in shape-cutting machines.
EWI, Columbus, Ohio, has been selected to win a 2012 R&D
100 Award for AcousTech Machining, its patent-pending
ultrasonic-assisted machining technology.
The CNA Foundation, Chicago, Ill., is donating $15,000 to
Nuts, Bolts and Thingamajigs, the educational foundation
of FMA, in support of its summer manufacturing camps.
Praxair Canada, Inc., acquired Canadian Cylinder & Gases,
Inc., Prince George, British Columbia, an independent dis-
tributor of industrial/specialty gases and welding equipment.
A new manufacturing training program, Mobile Outreach
Skills Training (M.O.S.T), that includes welding is launch-
ing in Philadelphia. It begins with an employer commitment
to hire individuals completing an initial two-week training.
Coxreels is moving to a new location not far from its current
facility and will remain in Tempe, Ariz. Fabrication, machine,
and welding departments have already relocated and are
functional.
EDAC Technologies Corp., Farmington, Conn., acquired
EBTEC Corp., Agawam, Mass., a provider of manufacturing
processes and fabrication systems, for approx. $11 million.
The Michigan Economic Development Corp. revealed the
Michigan Strategic Fund approval of loans. RWC, Inc., a de-
signer and producer of manufacturing systems that also per-
forms welding, received $1,247,500 in loan enhancement and
plans to hire an additional 24 workers over the next five years.
The Harris Products Groups Mason, Ohio, facility received
the 2011 Environmental Health Safety Chairmans Award by
its parent company, Lincoln Electric, for maintaining a safe
and environmentally conscious manufacturing environment.
Caster Concepts, Inc., Albion, Mich., acquired the assets
and select liabilities of Larcaster/Owl Welding, Selkirk,
Manitoba.
Hobart Brothers, Troy, Ohio, received the European Con-
formity Mark for its TM-881K2 and TM-791 gas-shielded
flux-cored wires in 1.2 mm diameters.
Rentapen, Inc., a specializer in reducing weld fixtures costs
for manufacturers, achieved certification as a Woman-Owned
Business Enterprise through the State of Wisconsin Depart-
ment of Administration.
99 WELDING JOURNAL
NEWS OF THE INDUSTRY
The AWS Careers in Welding Trailer offers many at-
tractive features to get young people excited about weld-
ing industry careers.
In particular, the mobile exhibit showcases the
following:
Five of The Lincoln Electric Co.s VRTEX 360
welding simulators that feed computer-generated data
with a virtual welding gun and helmet equipped with in-
ternal monitors;
Interactive educational exhibits, including a display
wall featuring 11 industry segments with trivia questions,
fun facts, and industry artifacts;
Day in the Life of a Welder exhibit with videos
depicting real-life environments in which welders work;
Life-size welder highlighting welding as a safe
profession;
Social media kiosk; and
Welding scholarship information.
The 53-ft, single expandable trailer designed and built
by MRA experiential tours and equipment covers 650-
sq-ft of exhibit space.
It is expected the trailer will be on the road for 1824
weeks in 2012. To learn more and view its schedule, visit
www.explorewelding.com.

$6450.
3&13*/54 5 / * 3 1 & 3
. 0 5 4 6 $

4 5
.

sales@fosterprinting.com
Call 866.879.9144 or

AWS Debuts Careers in Welding Trailer

ABC Testing Incorporated
Founded 1981
ABC Testing Incorporated was founded by
Carleton A. Richardson out of his home in
Bridgewater, Massachusetts. The business
has remained in the family with his son
Bruce taking over in 2003. He is a 1982
Northeastern University graduate with a
degree in mechanical engineering, ASNT
certified level III, AWS certified welding
inspector (CWI), and NYDOT certified
ultrasonic inspector. We celebrated our
30th year in business in 2011. Our number 1
commitment is customer service. ABC Test-
ing Incorporated is certified as ASNT SNT
TC 1A, level III in ultrasonic, radiography,
magnetic particle, liquid penetrant, and
visual. We have several AWS certified
welding inspectors on staff. We can provide
inspectors certified by the NYDOT in ultra-
sonic testing. We are also certified by ABS
to perform ship hull thickness surveys. We
are Veriforce certified for inspection of gas
pipelines. Visit our web site to see what
we have to offer or contact us with any
questions you may have.
ABC Testing Incorporated
95 First Street
Post Office Box 868
Bridgewater, MA 02324
(508) 697-6068
Fax: (508) 697-6154
www.abcndt.com
Ardleigh Minerals, Inc.
Founded 1994
Ardleigh Minerals is a specialty recycler pro-
viding one-stop recycling services. Ardleigh
can ship all your recyclables on one truck, at
one time. Since 1994 Ardleigh has been
specializing in the recycling of raw materials
generated in thermal spray preparation and
processing, including aluminum oxide,
silicon carbide, glass, plastic, bicarb blast
media, metal chips, solids, grindings, turn-
ings, steel, stainless, zinc shot/dust, thermal
spray, plasma spray, cold spray, and HVOF
overspray powders, dusts, solids, and sludge
containing chromium, cobalt, copper,
indium, molybdenum, nickel, rhenium and
tungsten carbide. Ardleigh proudly serves
the aerospace, automotive, catalytic,
electronic, and thermal spray industries.
Ardleighs corporate offices are located
in Beachwood, Ohio. Ardleigh also has
facilities in Cleveland, Charlotte, Houston
and Phoenix.
Bay State Surface
Technologies
Founded 1968
Make Bay State your complete source for
thermal spray equipment, materials, and
services. We've been in business for more
than 40 years and we are known for our high
quality and affordable plasma spray systems,
power feeders, twin wire arc metallizing
equipment, thermal spray powder, and
wire. We offer turnkey solutions and a
broad array of auxiliary equipment.
AS9100/ISO 9001 registered and award win-
ning quality and service. Check out our new
40-kw plasma system, which is value priced
for those companies that are just starting
out with plasma spraying. See special offers
online.
201 Washington Street
Auburn, MA 01501
(508) 832-5035
jkapur@aimtek.com
www.baystatesurfacetech.com
CenterLine (Windsor) LTD.
Founded 1957
CenterLines Supersonic Spray Technology
Division (SST) supplies patented low-
pressure cold gas dynamic spray (Cold
Spray) metal coating equipment and
supplies to the aerospace, defense, glass and
automotive industries. Cold spray is a cost
effective, practical process that applies
extremely machine-able, high density, metal
coatings to a variety of substrates. Cold
Spray technology is fast becoming a pre-
ferred coating choice for many applications
since it is performed at much lower temper-
atures than thermal spray. This solid state
metal coatings technology offers the ability
to restore and rebuild worn, corroded and
abused metal, as well as many composite
surfaces, without significant heat input into
the parts and little to no masking/prep
requirements. CenterLine offers several
cold spray equipment choices ranging from
portable and manual to fully automated
turnkey production systems. As well, SST
components products such custom powders,
nozzles, spray guns and powder feeding
systems are also available.
(519) 734-8464
info@cntrline.com
www.supersonicspray.com
THERMAL SPRAY PROFILES(advertisements)
SEPTEMBER 2012 100
Fisher Products LLC
Founded 1965
Fisher products robotic hard coating
processes: JP5000 HVOF, plasma spray and
PTA. Other processes: spray and fuse, oxy
fuel rod weld and metalized coatings.
Precision machined: pump shafts, wear
rings, sleeves, bushings, stage pieces and
plungers. Under pressure with premature
wear on parts and you need them to last
longer! Call our technical sales support
team today.
Quick turnaround shop
available upon request.
ISO 9001:2000
FAA Repair Station # IF2R896K
1320 West 22nd Place
Tulsa, OK 74107
(918) 582-2204
sales@fisherproductsllc.com
www.fisherproductsllc.com
Hayden Corporation
Founded 1919
Hayden Corporation's expertise in wear
protection spans three generations and multi-
ple industries. Our experience with the
strictest tolerances and standards (military,
aerospace, proprietary applications, etc.)
helps us solve clients' engineering challenges,
not just their service needs. Specialized capa-
bilities make Hayden a unique resource in the
Northeast: 1) Our own metallurgy lab; 2)
In-the-field thermal spray service, eliminating
time and shipping expenses; and 3) CNC-
guided laser cladding services for intricate
wear surfaces. In addition to the full
range of thermal spray coating processes,
Hayden also has in-house machining capability
for preparing and finish grinding customer
components.
333 River St.
West Springfield, MA 01089-3603
(413) 734-4981
Fax: (413) 785-5052
www.haydencorp.com
Hausner Hard-Chrome
HHC Inc. business is providing surface
modifications that will enhance component
performance, increase life and repair
damage. Along with our core competency of
hard chrome plating, we provide alternatives
such as thermal spray coatings and brush
plating both in-house and onsite. A new
Hausner Hard Chrome business unit, HHC
On-Site Services, was established in 2010.
This new on-site service provides thermal
spray, brush plating, welding machining,
grinding and polishing services. HHC is fully
committed to addressing your industry
needs throughout the world.
3094 Medley Road
Owensboro, KY
(270) 684-2279
670 Greenleaf Ave.
Elk Grove Village, IL 6007
(847) 439-6010
www.hausnerinc.com
International
Thermal Spray Association
Founded 1947
The International Thermal Spray Association is
a professional organization dedicated to
expanding the use of thermal spray technologies
for the benefit of industry and society. Once
known as Metallizing Service Contractors, the
association has been closely tied to almost all
major advances in thermal spray technology,
equipment and materials, industry events,
education, standards, and market development
in North and South America. ITSA member-
ship represents a broad spectrum of thermal
spray markets throughout the world. Contact us
for copies of our What Is Thermal Spray? and
SPRAYTIME newsletter publications.
For more information, contact
Kathy Dusa
(440) 357-5400
Fax: (440) 357-5430
P.O. Box 1638
Painesville, OH 44077
itsa@thermalspray.org
www.thermalspray.org
101 WELDING JOURNAL
SEPTEMBER 2012 102
Plasma Technology Inc.
The Surface Engineering Co.
When it comes to advanced thermal Spray
coatings, the worlds toughest customers come
to PTI, a recognized leader in the coating
field. We have two modern, state-of-the-art
facilities, with 24 fully operational spray
booths equipped with advanced robotic
systems for precise uniform application of
HVOF, Plasma, Arc and Flame Spray coat-
ings, machining, diamond grinding and super
finishing, and laboratory testing. PTI is
approved by NADCAP, FAA, JAA, the US
military and over 100 of the largest aerospace
and industrial companies. PTI applies over
300 different coatings for surface engineering
solutions such as Wear Protection, Thermal
Barriers, Corrosion/Oxidation Protection,
Dielectric, Conductive, EMI Shielding, etc.
PTI also offers thin film PVD coatings for
aerospace and automotive applications.
1754 Crenshaw Blvd.
Torrance, CA 90501
(310) 320-3373
Fax: (310) 533-1677
70 Rye Street
South Windsor, CT 06074
(860) 282-0659
Fax: (860) 528-2631
www.ptise.com
Polymet Corporation
Polymet is a world-class manufacturer of
high-performance welding, hardfacing and
thermal spray wire. Our manufacturing
processes include a patented hot extruded
forged wire process, rolling, die drawing,
and alloy cored wire fabrication. Polymets
multiple wire processing capabilities allows
it to be an innovator in problem solving. The
high quality products provide protection
against abrasion, corrosion, impact and
high temperature application for the
aerospace, automotive, chemical, petro-
chemical, cement, mining, lumber, power
generating, and other industries.
Progressive Surface
Founded 1968
Progressive Surface is a full service thermal
spray equipment supplier that develops
coating processes and turnkey systems for
the thermal spray community. Our 100HE
coating system can achieve significantly
higher particle velocities and deposition
rates, which enhances the capabilities and
efficiency of the spray process. We continue
to advance the thermal spray field through
ongoing projects researching the emerging
technologies of solution and suspension
plasma spraying.
4695 Danvers Drive SE, Grand Rapids,
Michigan 49512-4018 USA
(800) 968-0871 or (616) 957-0871
Fax: (616) 957-3484
sales@progressivesurface.com
www.progressivesurface.com
Saint-Gobain
Founded 1920
Saint-Gobain is a world class manufacturer
of equipment and consumables for the
thermal spray coatings industry. Our
expansive equipment experience dates back
to 1920 with the development of the first
oxy-acteylene flame wire gun followed by
Rokide Spray Systems, Plasma Spray
Systems, PTA and many innovative materi-
als. We offer a wide range of consumables
in the form of powder, flexible cords,
Rokide rods and wire for use in many
different applications and industries. We
supply our own raw materials and this
enables us to develop a product to meet your
exact needs.
Visit our website at
www.coatingsolutions.saint-gobain.com.
1 New Bond Street
Worcester, MA 01615
(800) 243-0028
(508) 795-2380
coatingsolutions@saint-gobain.com
www.coatingsolutions.saint-gobain.com
Stronghold Coatings
Founded 1920
Stronghold Coatings LTD. provides custom
polymeric products and process development
for thermal spray coating applications,
including ARC, Plasma and HVOF. We
specialized in complex problem-solving
involving issues of wear, friction, adhesion,
and corrosion. Metallic and ceramic coatings
developed by Stronghold are applicable up to
thick; the heat and pressure inherent in
our processes produces a finish that is excep-
tionally hard, smooth and low in porosity.
Standard Stronghold coatings include
Dichtol, a capillary sealer that impregnates
micropores and hairline cracks on any alloy
without vacuum pressure, and a high-perfor-
mance hex chrome replacement. Advanced
met lab; technical programs, R&D and
expert on-site training available. Specialists
in commercial, aviation and military projects.
For ultimate performance, get a Stronghold
Solution! A veteran-owned business
8634 Lesourdsville W C Rd.
West Chester, OH 45069
(937) 746-7632
www.strongholdone.com
Sulzer Metco
Sulzer Metco is the worldwide leader for ad-
vanced thermal spray materials, integrated
systems, and equipment for all thermal spray
processes, specialized coating and surfacing
services, high quality braze and weld hard-
facing materials, and global customer
support services. Contact Sulzer Metco to
unravel your toughest surface engineering
and joining applications.
Sulzer Metco (US) Inc.
1101 Prospect Ave.
Westbury, NY 11590
(516) 334-1300
Fax: (516) 338-2414
www.sulzermetco.com
HAI Inc.
HAI is a recognized leader in the thermal
spray industry and a leading supplier of
thermal spray equipment and consumables
since 1979. Our products are used by
hundreds of companies, worldwide in the
aerospace, airline, automotive, printing,
textile, petro-chemical, pulp and paper, semi-
conductor and electronics industries for
extending product life, increasing product
performance and reducing production and
maintenance costs. We offer a wide selection
of pure metal, metal alloys, ceramic, carbide
and speciality metal powders and wires along
with plasma, twin-wire arc, combustion and
HVOF equipment and replacement parts.
We are committed to partnering with you to
provide a coating solution for your complete
thermal spray operation. Whether you need
to equip a basic thermal spray shop or a
complete high production advanced technol-
ogy thermal spray cell, HAI can analyze your
requirements and match them up with
the proper systems to optimize your
production. In addition, our staff of highly-
trained material science engineers can
provide on-site training, engineering services,
metallurgical evaluations, and system
integration. Visit us on the web at
www.haiinc.com for more information or call
1-877-411-8971.
Visit us at Fabtech, Nov. 12-14,
in Las Vegas, booth N2319.
1688 Sierra Madre Circle
Placentia, CA 92870
(877) 411-8971
Fax: (877) 411-8778
www.haiinc.com
103 WELDING JOURNAL
ATTENTION
THERMAL SPRAY MARKETEERS
We would like to thank you for
advertising in the fourth thermal
spray profile that the AWS Welding
Journal has published.
If you would like more information
on how to include your company
in the next Thermal Spray profile,
please contact us by email at
salty@aws.org or lea@aws.org.
You can also call us at 1-800-443-
9353 ext. 243 or 220.
Put Your Products and
Services to Work in
January 2013
Generate new sales leads by show-
casing your full-color product photo
with a product description or other
sales literature, along with your com-
pany contact information. The Welding
Marketplace reaches 80,000 qualified
buyers. Its great exposure for just
pennies per contact.
Then double down at no extra cost
and reach thousands more when
we place it on our AWS Web site
with active links to your web site at
no extra cost and email it to our
AWS Members.
Closing date is
November 15, 2012
Call the AWS sales team at:
(800) 443-9353
Rob Saltzstein at ext. 243
salty@aws.org
Lea Paneca at ext. 220
lea@aws.org
SERVICES
Oxygen Analyzers,
Purge Dams, Flow Meters

www.OrbitalWelding.com
for Pipe Welding
408-567-0232
EQUIPMENT FOR SALE OR RENT
For sale or rent
The worlds very
best portable end
prep tools and
abrasive saws
800-343-6926
www.escotool.com
SEPTEMBER 2012 104
CLASSIFIEDS
The world's first and only completely
online NDT & CWI training program!
NDT Training to meet global standards
including SNT-TC-1A, ISO 9712, etc.
Visit www.worldspec.org today and save
$100 instantly by entering the discount
code: aws59c2
Call toll free: 1-877-506-7773
CERTIFICATION
& TRAINING
CWI PREPARATORY
Guarantee Pass or Repeat FREE!
80+ HOUR COURSE
MORE HANDSON/PRACTICAL APPLICATIONS
Pascagoula, MS Sept. 1021 & Nov. 25Dec. 7
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Pascagoula, MS Sept. 1721 & Dec. 37
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Test follows on Saturday at same facility &
includes additional self study for weekend
FOR DETAILS CALL OR E-MAIL:
(800) 489-2890
info@realeducational.com
Also offering: 9Year CWI Recertification,
RT Film Interpretation, MT/PT/UT Thickness,
Welding Procedure Fundamentals,
CWS, SCWI, Advanced Inspection Courses
2012
Place Your
Classified Ad Here!
Contact Frank Wilson,
Senior Advertising
Production Manager
(800) 443-9353,
ext. 465
fwilson@aws.org
JOE FULLER LLC
We manufacture tank turning rolls
3ton through 120ton rolls
www.joefuller.com
email: joe@joefuller.com
Phone: (979) 277-8343
Fax: (281) 290-6184
Our products are made in the USA
EQUIPMENT FOR SALE OR RENT (contd)
105 WELDING JOURNAL
MITROWSKI RENTS
Made in U.S.A.
Welding Positioners
1-Ton thru 60-Ton
Tank Turning Rolls
Used Equipment for Sale
www.mitrowskiwelding.com
sales@mitrowskiwelding.com
(800) 218-9620
(713) 943-8032
ADVERTISER
INDEX
ArcOne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
www.Arc1Weldsafe.com . . . . . . . . . . . . . . . .(800) 223-4685
Arcos Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . .IBC
www.arcos.us . . . . . . . . . . . . . . . . . . . . . . . . .(800) 233-8460
Atlas Welding Accessories, Inc. . . . . . . . . . . . . . . . . . . . .90
www.atlaswelding.com . . . . . . . . . . . . . . . . .(800) 962-9353
AWS Education Services . . . . . . . . . . . . . . . . .5051, 86, 97
www.aws.org/education/ . . . . . . . . . . . . . . . .(800) 443-9353
AWS Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7677
www.aws.org/foundation/ . . . . . . . . . . . . . . .(800) 443-9353
AWS Membership Services . . . . . . . . . . . . . . . . .53, 91, 92
www.aws.org/membership/ . . . . . . . . . . . . . .(800) 443-9353
Bay State Surface Technologies, Inc. . . . . . . . . . . . . . . . .10
www.baystatesurfacetech.com . . . . . . . . . . .(800) 772-0104
Bruker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
www.bruker.com/s1titan . . . . . . . . . . . . . . . .(978) 439-9899
Camfil Farr Air Polution Control . . . . . . . . . . . . . . . . . . .2
www.camfilfarrapc.com . . . . . . . . . . . . . . . .(800) 479-6801
Champion Welding Alloys . . . . . . . . . . . . . . . . . . . . . . . .78
www.championwelding.com . . . . . . . . . . . . .(800) 321-9353
Commercial Diving Academy . . . . . . . . . . . . . . . . . . . . . .35
www.commercialdivingacademy.com . . . . .(888) 974-2232
Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
www.cor-met.com . . . . . . . . . . . . . . . . . . . . .(800) 848-2719
Diamond Ground Products, Inc. . . . . . . . . . . . . . . . . . . .19
www.diamondground.com . . . . . . . . . . . . . .(805) 498-3837
Divers Academy International . . . . . . . . . . . . . . . . . . . . .17
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Introduction
Glass-to-metal seal technology is ap-
plied to fabricate heat receivers, which con-
vert solar energy into thermal energy. A
glass-to-metal seal requires a certain me-
chanical strength and excellent gas tightness
under a high-vacuum condition, which be-
come key factors in a parabolic trough solar
thermal power system (Ref. 1).
The methods for glass-to-metal sealing
can be classified into fusion sealing and
diffusion welding. Oxidation treatment of
the metal is often done for the two meth-
ods to promote the glass-to-metal adhe-
sion, which can provide a transition layer
between the metal and the glass (Refs.
24). The two following conditions are
necessary for a glass-to-metal seal: 1) The
coefficients of thermal expansion (CTE)
of the metal and glass should be as close
as possible in order to reduce thermal
stress generated during the cooling from
the joining temperature to room tempera-
ture, and 2) the metal should have excel-
lent surface wettability with the glass to
provide good mechanical adhesion and
gas tightness.
Anodic bonding, successfully realized
for the first time in 1969 by Wallis and
Pomerantz, is a typical diffusion sealing
method to seal an alkali-rich glass to any
metal. It has been used to join glass and
metal by applying a voltage between two
samples (Refs. 5, 6). However, the bond-
ing strength and gas tightness of the joints
formed using two sealing processes were
not good enough to be used in the para-
bolic trough solar thermal power system
(Ref. 7).
Therefore, it is very important to im-
prove the shear strength between the glass
and metal. In this research, a vacuum braz-
ing process was used to improve the joint
strength and simplify the sealing process.
The shear strength of the joints was meas-
ured. Scanning electron microscopy
(SEM) and X-ray diffraction (XRD) were
applied to analyze the microstructure of
the joint interface.
Experimental
Material
The glass and metal were joined to-
gether using vacuum brazing technology.
The experimental materials used in this in-
vestigation were borosilicate glass 3.3 and
Kovar(iron-nickel-cobalt alloy) because
of their similar CTE (Ref. 8). Meanwhile,
borosilicate glass has characteristics of
chemical stability and anticorrosion at
high temperature (Ref. 9). The amor-
phous Cu-7wtNi-9wtSn-6wtP filler
metal with the solidus temperature 833 K
and the liquidus temperature 913 K was
used. Filler metal foils with 50-m thick-
ness and 6-mm width were fabricated
using a rapid solidifying technique (Ref.
10). Tables 1 and 2 show the composition
of Kovar alloy and borosilicate glass, re-
spectively. Table 3 lists the mechanical
properties of the alloy and glass.
Process
Both borosilicate glass and Kovar
alloy were cut into samples with dimen-
sions of 60 20 4 mm and 60 20
1.5 mm, respectively. The joining surface
of the Kovar was ground flat by grit paper
and cleaned in ethanol and acetone solu-
tion (Ref. 11). The joining surface of the
borosilicate glass was electroless plated
with a thin copper layer. Before the elec-
troless plating, the glass surface was
roughened by sand blasting to improve the
adhesive ability between the glass sub-
strate and copper layer (Ref. 12). The soft-
ening point of borosilicate glass is about
1097 K.
The borosilicate glass, Cu-Ni-Sn-P
foils, and Kovar alloy were assembled as
shown in Fig. 1. The mating surfaces of
samples were kept in contact by a specially
designed clamp, and pressure was applied
along the longitudinal direction to en-
hance the interfacial reaction. The speci-
mens were placed into a vacuum brazing
furnace. The vacuum was maintained at 4
10
2
Pa during the brazing process.
SUPPLEMENT TO THE WELDING JOURNAL, SEPTEMBER 2012
Sponsored by the American Welding Society and the Welding Research Council
Study on Vacuum Brazing of Glass to Kovar
Alloy with Cu-Ni-Sn-P

The optimum brazing time and temperature were sought to improve the shear
strength and hermetic seal in the fabrication of a solar power system
BY Z. ZHONG, J. ZHOU, X. SHEN, AND X. LING
KEYWORDS
Glass-to-Metal Adhesion
Vacuum Brazing
Microstructure
Shear Strength
Cu-Ni-Sn-P Brazing
Alloy
Z.ZHONG, J. ZHOU, X. SHEN, and X. LING
are with School of Mechanical and Power Engi-
neering, Nanjing University of Technology, Nan-
jing, China.
ABSTRACT
A vacuum brazing process of borosilicate glass to Kovar alloy was carried out at
943~973 K using Cu-Ni-Sn-P brazing alloy. The shear strength was tested after vacuum
brazing, and the microstructural evaluation of the glass-to-metal brazed joints was per-
formed by scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS),
and X-ray diffraction (XRD). The results showed that the maximum shear strength of the
brazed joint was 1.6 MPa when the brazing temperature was 953 K and the brazing time
was 10 min. The fracture location of the brazed joint was near the side of the glass. Many
microcracks occurred along the interface of the glass, and then extended to the center of
the interface. Cu
3
P and Ni
2
P intermetallic compounds, -Cu, and Cu
x
Sn
y
layer form at
the interface of the brazed joint. The compounds Cu
3
P and Ni
2
P are harmful for the
strength of the brazed joint.
237-s WELDING JOURNAL
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Then, the specimens were heated to the
brazing temperatures of 933, 943, 953, 963,
and 973 K, respectively, and the heating
rate was 10 K/min. The brazing times were
5, 10, 15, 20, and 30 min, respectively. In
order to reduce the brazed residual
stresses, the samples were cooled at the
rate of 3 K/min from the joining tempera-
ture to 573 K and then cooled to room
temperature in the furnace. The tempera-
ture change during the vacuum brazing ex-
periment is shown in Fig. 2.
After vacuum brazing, shear strengths
of five samples were measured at a con-
stant speed of 0.5 mm/min in the MTS
testing machine. The average value of five
samples was taken as the shear strength.
The microstructure of the brazed joint was
examined using SEM and XRD to investi-
gate the phase composition in the area of
the brazed joint. Meanwhile, the element
distribution on the interface was measured
using energy-dispersive spectroscopy
(EDS).
Results and Discussion
Shear Strength of the Brazed Joint
To obtain the mechanical property of
the brazed joint, the shear strength was
measured by means of a digital press test-
ing machine. The relationship between the
brazing temperature and shear strength is
shown in Fig. 3. It can be seen that the
brazing temperature has a marked effect
on shear strength of the joint. The shear
strength gradually increases from 6 to 11.6
MPa when the heating temperature in-
creases from 933 to 953 K. The main rea-
son is that the atom diffusion near the
interface can be sufficient to form an ex-
cellent metallurgical combination at ele-
vated temperatures. However, shear
strength decreases due to coarseness of
the microstructure when the brazing tem-
perature continually increases.
The relationship between the brazing
time and shear strength is shown in Fig. 4.
As shown in Fig. 4, the shear strength of
the joint brazed at 953 K rapidly increases
with an increase in brazing time, and a
brazed joint with a shear strength of 11.6
MPa can be obtained at 953 K for 10 min.
However, the shear strength of the brazed
joint reduces when the brazing time is
longer than 10 min. The brazing time has
an important effect on the shear strength
of the joint. If the brazing time is shorter
than 10 min, the brazing filler metal just
melts, and the diffusion of the brazing
filler metal and base metal isnt uniform,
which leads to the low shear strength of
the joint. If the brazing time is longer than
10 min, the brazing filler metal is easily
lost and forms brittle compounds, which
SEPTEMBER 2012, VOL. 91 238-s
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Fig. 1 Map of the glass-to-metal brazing setting.
Fig. 2 Technical requirement graph of the vacuum brazing ex-
periment.
Fig. 3 Relationship between the brazing temperature and shear strength. Fig. 4 Relationship between the brazing time and shear
strength.
Table 1 Chemical Composition of Kovar Alloy (wt-%)
C P S Mn Si Cu Cr Mo Ni Co Fe
0.03 0.02 0.02 0.5 0.3 0.3 0.2 0.2 28.5~29.5 16.8~17.8 base
Table 2 Chemical Composition of Borosili-
cate Glass (wt-%)
SiO
2
B
2
O
3
Na
2
O Al
2
O
3
CaO
80.9 12.7 4 2.3 0.1
make the shear strength of the joint de-
crease. Therefore, it is necessary to con-
trol the brazing time to ensure the
diffusion of the brazing filler metal and
base metal is complete while avoiding the
formation of brittle compounds during the
vacuum brazing of the borosilicate glass
and Kovar alloy.
Figure 5 shows the typical fracture pat-
tern of a sample measured using the ten-
sile test. Figure 6 shows the rupture path
of the brazed joint. The results indicate
that the fracture occurs near the glass, and
the shear rupture is cleavage fracture with
little brittle fracture. Most microcracks
propagate along the interface near the
side of the glass, and sometimes micro
cracks are close to the center of the inter-
face. A similar situation occurs in samples
using other sealing processes (Ref. 13).
Large shear stress induced at the interface
suppresses the crack propagation along
the interface (Ref. 14). Residual thermal
stresses within the joint are induced due to
the CTE mismatch and different re-
sponses of the glass and the metal, which
could weaken the brazed joint strength.
Generally, the lower the thermal residual
stresses are, the higher the allowable stress
to the fracture of the joint (Ref. 15).
Microstructure of the Brazed Joint
The cross-section microstructure of the
brazed joint is shown in Fig. 7. The cross
section is divided into three regions
marked by E, F, and G. The EDS analyses
of the three regions are shown in Figs. 8, 9,
and 10, respectively. As shown in Fig. 8,
region E is near the copper-coated glass,
which mainly consists of the elements Cu,
Ni, Sn, and P. There is a zone enriching Cu
and Sn near region F and region G Fig.
9. However, P is not found. Therefore, Cu
and Ni are prevented from forming Cu
3
P
and Ni
2
P due to the decrease of P. As
shown in Fig. 10, Au is found in the EDS
analysis because of the gold spraying on
the surface of the sample before EDS
analysis, and region G is composed of Cu,
Sn, Fe, and Ni. As we know, P can reduce
the melting point of Cu filler metal and
have a self-cleaning effect on the surface
of metal. Phosphorus will react with the
oxidation layer of the Kovar alloy and
form P
2
O
5
near the Kovar alloy side.
Meanwhile, P has a high-vapor pressure
and evaporates during brazing, which
leads to enriching Cu and Sn near Regions
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Fig. 5 Macromorphology of shear crack on a brazed joint.
Fig. 7 Microstructure of the joining interfaces for glass/braz-
ing alloy/Kovar alloy.
Fig. 6 Map of rupture crack path of a brazed joint.
Fig. 8 EDS analysis of a small area component of the
glass-to-brazing alloy interface (Region E).
Table 3 Thermal and Mechanical Properties of Borosilicate Glass and Kovar Alloy
Material Temperature Youngs Modulus Poissons Ratio CTE Yield Stress
(K) (GPa) (10-6/K) (MPa)
Borosilicate 64 0.20 3.3 35~120
Glass
293 134 0.37 6.5 340
Kovar Alloy 473 141 0.37 5.9 200
(4J29) 673 155 0.37 5.1 110
240
Cu
C
o
u
n
t
s
0
0.100
C
C
keV 10.340
Cu
Cu
Sn
Ni
F and G. However, P also diffuses with Cu
near the copper-coated glass and forms
Cu
3
P and Ni
2
P, besides partly evaporating.
Cu
3
P and Ni
2
P are brittle compounds that
reduce the mechanical strength of the
brazed joints.
It can be seen that the metal element
does not react with the glass. A reaction
layer is necessary for adequate wettability
of the filler metal on the copper-coated
glass. However, the negative effect of the
excessive growth of the reaction layer
should also be considered. The formation
of a brittle intermetallic in the condensed
zone usually reduces the mechanical
strength of the joint. The reaction layer
should be thin and dense to inhibit further
interaction between the reactive metals of
the filler metal and the Kovar alloy as a
diffusion barrier, which limits the forma-
tion of brittle phases.
According to XRD results (Fig. 11), the
reaction products are mainly composed of
-Cu, Ni
2
P, Cu
2
P (or Cu
3
P) and Cu
x
Sn
y
.
The mechanism of interface formation in-
volving metallized glass differs from that of
active filler metals. In metallized glass, Cu
is already in contact with the glass surface,
whereas the use of active filler metal re-
quires the migration of Cu from the alloy to
the glass.
Conclusions
Glass to metal was
brazed at 943~973 K
using Cu-Ni-Sn-P filler
metal in vacuum, and
shear strength tests and
microstructure analyses
were performed. The
brazing process was opti-
mized successfully. The
main results are as fol-
lows:
1) The shear strength
of the brazed joint de-
pended on the brazing
temperature and the
brazing time. The shear
strength reached 11.6
MPa when the brazing
temperature and the
brazing time were 680 K
and 10 min, respectively.
2) The shear test results indicated that
the fracture location of the brazed joint
was near the side of the glass. Many mi-
crocracks occurred along the interface of
the glass, then extended to the center of
the interface.
3) It was determined that Cu
3
P and
Ni
2
P intermetallic compounds, -Cu, and
Cu
x
Sn
y
layer formed at the interface of the
brazed joint. The brittle compounds Cu
3
P
and Ni
2
P are mainly responsible for low-
ering the strength of the brazed joints.
Acknowledgments
The authors gratefully acknowledge
the financial support rendered by the Na-
tional Natural Science Foundation of
China (Grant No. 10672072) and Hi-Tech
Research Program Foundation of Jiangsu
(Grant No. BG 2006040) in carrying out
this investigation.
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nal of Materials Processing Technology 91: 9094.
11. Wang, Y., Feng, J. C., Zhang, L. X., He,
P., and Zhang, J. H. 2007. Microstructure of alu-
mina ceramic/Ag-Cu-Ti brazing alloy/Kovar
alloy joint. Materials Science and Technology
23(3): 320323.
12. Song, Y. W., Zhao, B., and Sun, C. X.
1999. Electroless copper plating and its appli-
cation to glass industry. Glass & Enamel 27(5):
4751.
13. Selcuk, A., Atkinson, A., and Senerver-
atne, D. 1999. Mechanical strength of glass-to-
metal joints. Metal Abstract 32: 202206.
14. Bartlett, A., Evans, A. G., and Ruhle,
M. 1991. Residual stress cracking of metal/ce-
ramic bonds. Acta Metallurgica et Materialia
39(7): 15791585.
15. Park, J. W., Mendez, P. F., and Eagar, T.
W. 2002. Strain energy distribution in ceramic-
to-metal joints. Acta Materialia 50(5): 883899.
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Fig. 9 EDS analysis of a small area component of the braz-
ing alloy (Region F).
Fig. 11 XRD patterns of the fracture interface.
Fig. 10 EDS analysis of a small area component of the braz-
ing alloy-to-Kovar interface (Region G).
200 Cu
C
o
u
n
t
s
0.100
0
keV
10.340
Cu
Cu
Au
Sn
Ni
200
C
o
u
n
t
s
0
0.100
Cu
C
Au Sn
Ni
keV
Fe
Cu
Cu
10.340
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Introduction
Welding is a major occupational activ-
ity in the United States and worldwide,
and includes workers in manufacturing,
construction, and a number of other in-
dustrial sectors. In excess of 462,000 U.S.
workers do some welding as part of their
duties (Ref. 1), and about two-thirds of
these workers are in manufacturing indus-
tries. Welding produces a number of haz-
ards during operation, including fumes,
gases, and physical agents such as heat and
ultraviolet and infrared radiation. Occu-
pational health studies indicate a number
of occupationally related adverse health
effects, such as lung disease (Ref. 2). Most
welding operations are performed on low-
alloy or high-carbon steels, but stainless
steel may account for up to 5% of welding
(Ref. 3), and is an important segment of
some industries, such as food processing
equipment manufacturers, chemicals
manufacturing, and shipbuilding.
However, welding on stainless steel
presents an additional occupational-risk
exposure; the known carcinogens hexva-
lent chromium (Cr
6+
) and nickel (Ni) have
been identified in stainless steel welding
fumes (Ref. 4). A review by the Interna-
tional Agency for Research on Cancer
(Ref. 3), along with an additional Envi-
ronmental Protection Agency review
(Ref. 5) found a very wide range of Cr
6+
concentrations; this suggested that differ-
ent welding processes and conditions
could account for the 20:1 range of Cr
6+
concentrations. The general purpose of
this study was to identify the welding
process that minimizes exposure to Cr
6+
by determining its concentration in a
range of common welding processes.
Common Welding Configurations
Analysis of welding-based hazards is
dependent on an understanding of the
range of welding processes and condi-
tions. More than 80 different welding
processes (Ref. 6) are commonly found,
but most welding is done with electrical
arc welding processes. The most preva-
lently used variations, based on materials
usage, are shielded metal arc welding
(SMAW) ~ 45%; gas metal arc welding
(GMAW), ~34%; and flux cored arc
welding (FCAW), ~17% (Ref. 5).
The SMAW process has the simplest
equipment requirements: a power supply,
an electrode holder, welding rods, and a
ground clamp. The welding rods have a
coating over the filler metal rod that pro-
vides a shielding environment to minimize
degradation of the weld by atmospheric
oxygen or nitrogen. The GMAW process
uses more complex equipment; besides a
power supply, it uses a gas-shielded gun
and the electrode is a consumable wire of
the desired filler metal fed by a motorized
feeder. The shielding gas is externally sup-
plied from cylinders. Shielding gases
range from the completely inert argon
(Ar), helium (He), and their mixtures to
so-called active gases, which include car-
bon dioxide (CO
2
), Ar mixtures with CO
2
or oxygen (O
2
), and other gas mixtures.
These gases may have chemical interac-
tions with the weld or fume. The FCAW
process uses equipment similar to
GMAW, but the wire electrode has an in-
ternal flux material for weld shielding; the
process may be used with or without an ex-
ternal shielding gas.
Selecting Processes to Minimize Hexavalent
Chromium from Stainless Steel Welding
Eight welding processes/shielding gas combinations were assessed for generation
of hexavalent chromium in stainless steel welding fumes
BY M. KEANE, A. SIERT, S. STONE, B. CHEN, J. SLAVEN, A. CUMPSTON, AND J. ANTONINI
ABSTRACT
Eight welding processes/shielding gas combinations were assessed for generation
of hexavalent chromium (Cr
6+
) in stainless steel welding fumes. The processes exam-
ined were gas metal arc welding (GMAW) (axial spray, short circuit, and pulsed spray
modes), flux cored arc welding (FCAW), and shielded metal arc welding (SMAW).
The Cr
6+
fractions were measured in the fumes; fume generation rates, Cr
6+
genera-
tion rates, and Cr
6+
generation rates per unit mass of welding wire were determined.
A limited controlled comparison study was done in a welding shop including SMAW,
FCAW, and three GMAW methods. The processes studied were compared for costs,
including relative labor costs. Results indicate the Cr
6+
in the fume varied widely, from
a low of 2800 to a high of 34,000 ppm. Generation rates of Cr
6+
ranged from 69 to
7800 g/min, and Cr
6+
generation rates per unit of wire ranged from 1 to 270 g/g.
The results of field study were similar to the findings in the laboratory. The Cr
6+
(ppm)
in the fume did not necessarily correlate with the Cr
6+
generation rate. Physical prop-
erties were similar for the processes, with mass median aerodynamic diameters rang-
ing from 250 to 336 nm, while the FCAW and SMAW fumes were larger (360 and 670
nm, respectively). Conclusion: The pulsed axial spray method was the best choice of
the processes studied based on minimal fume generation, minimal Cr
6+
generation,
and cost per weld. This method is usable in any position, has a high metal deposition
rate, and is relatively simple to learn and use.
M. KEANE (mjk3@cdc.gov), S. STONE, B.
CHEN, A. CUMPSTON, and J. ANTONINI are
with National Institute for Occupational Safety
and Health (NIOSH), Health Effects Laboratory
Div., Morgantown, W.Va. J. SLAVEN is with
NIOSH and Indiana University, Indianapolis,
Ind. A. SIERT is with Xcel Energy, Denver, Colo.
KEYWORDS
Hexavalent Chromium
Stainless Steel
Gas Metal Arc Welding
(GMAW)
Flux Cored Arc Welding
(FCAW)
Shielded Metal Arc Welding
(SMAW)
Welding Fume
242-s
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Metal Transfer Modes in GMAW
Gas metal arc welding differs from
other arc welding processes in that more
than one mode of metal transfer from the
electrode into the weld pool is possible. At
relatively low applied voltage, the process
is called short-circuit gas metal arc weld-
ing (GMAW-S). The end of the electrode
wire is in direct contact with the weld pool,
and a portion melts and is transferred into
the weld pool. The melting breaks the
short circuit, and the arc forms. The arc is
intermittent (up to 200 times/s), and not
perfectly stable; this may generate spatter,
where relatively large droplets may be re-
leased outside the weld bead.
When the voltage is increased above
the short circuit range, another mode of
operation known as globular transfer oc-
curs. The wire end melts, forming large
drops that typically are larger than the
wire diameter. The droplets fall by gravity
into the weld pool. This limits usage to flat
or horizontal welding positions; this mode
is generally avoided because of severe
spatter problems.
With shielding gases containing high
percentages of Ar, there is a transition to
axial spray (AXS) transfer mode as the ap-
plied voltage is increased. Metal leaves the
electrode wire tip and is transferred as a
very fine spray into the weld pool. This
produces a high-quality weld with lower
spatter. The technique is used primarily in
flat or horizontal applications; overhead
or vertical use may have drip problems. A
variation of spray transfer is pulsed spray
transfer (GMAW-P), where current pulses
are added to a steady-state background
current. This allows the total current to
periodically exceed the required transition
current and permit spray mode. This pro-
duces high-quality welds in any position
with lower heat input, and a low fume-
generation rate.
The study objectives were to assess a
wide spectrum of arc welding processes
for fume generation and Cr
6+
generation
rates, and identify the best choice or
choices one could select to minimize Cr
6+
exposures at the source.
Methods and Materials
The basic welding system included a
multiprocess welding machine (an MP350
from The Lincoln Electric Co., Cleveland,
Ohio) with a wire feeder capable of rates to
300 in./min (762 cm/min). Welding was con-
ducted in a conical chamber based on an
American Welding Society (AWS) design
for a chamber to measure fume-generation
rates (Ref. 7). A photograph of the cham-
ber in operation is shown in Fig. 1. The test
chamber was validated to AWS perform-
ance standards and met the performance
criteria. Aerosols were drawn from the
chamber with a pump at 200 L/min. The ap-
proximate chamber aerosol concentration
was monitored with a DataRAM 4000
(Thermo Electron, Franklin, Mass.). Stain-
less steel welding wire was AWS A5.9 Class
ER308LSi 0.045 in. (1.14 mm) in diameter,
fed from an 11.4-kg (25-lb) reel. The
GMAW samples analyzed for Cr
6+
in this
study were sampled from a single lot of wire.
The manufacturers nominal composition
of the wire is 2% Mn, 1925% Cr, 1013%
Fig. 1 American Welding Society-type welding chamber in use. Fig. 2 Welding fume-generation rates for eight welding processes, in mg/min.
Fig. 3 Hexavalent chromium content in welding fumes from eight
processes, in mg/kg.
Fig. 4 Hexavalent chromium generation rates for eight welding processes, in
g Cr
6+
/min.
SEPTEMBER 2012, VOL. 91
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Ni, and the remainder Fe. Flux cored arc
welding used AWS A5.22 Class E308LT0-1
wire, while SMAW generation used AWS
A5.4 Class E308L-16
3
16-in. (4.8-mm) rods.
Shielding gas was taken from pressure-
regulated cylinders at a flow rate of 19
L/min. The welding material in the base-
plates was -in.- (12.7-mm-) thick 304
stainless steel, 22-in.- (56-cm-) diameter
disks. Operation with all shielding gases
and welding process types used similar
conditions, but was adapted to good weld-
ing practice, generally as recommended by
welding machine manufacturers. All weld-
ing operations were adjusted for good
bead appearance with good penetration of
the base plates and good toe wetting and
without undercut. Baseplates were ro-
tated at the desired rotary speed to pro-
vide a travel rate compatible with good
welds. A commercial welding turntable
was modified for external control by the
Labview (National Instruments, Austin,
Tex.) program; rotary speed was detected
by an encoder on the output shaft and
input to the program, and the travel rate
displayed continuously during operation.
Welding machine operation was initiated
under program control to precisely con-
trol arc time.
Operating variables are
shown in Table 1.
Sampling Strategies
Fumes from the weld area
were sampled through a 102-
mm filter at the top of the
chamber at 200 L/min. The
filter material was
Hollingsworth and Vose
(East Walpole, Mass.) elec-
trostatic medium (PE
13060NA), cut to fit the filter
housing. The flow was measured with a
mass flow meter (TSI, Shoreview, Minn.)
before sampling. After sampling was com-
pleted, filters were removed from the
housing, folded inward, weighed to the
nearest 0.1 mg, and put in sealed antista-
tic polyethylene bags.
Sample Recovery and Processing
Welding fume particulate matter was
recovered from the filters by gentle suc-
tion onto a 47-mm, 0.8-m polycarbonate
filter. The 47-mm stainless steel filter
hous-
ing had a short piece of 6-mm ID silicone
tubing, cut at 45 deg on the inlet end, and
a house vacuum was connected to the out-
let end. Using a gentle blotting action,
most of the particulate fume was removed
from the filter. Sufficient quantity was col-
lected for analysis of Cr
6+
and other met-
als, but quantitative recovery was not nec-
essary. After completion, the
polycarbonate filter was removed from the
housing over a tared 75 75-mm weigh-
ing boat, and material brushed from the
filter and housing interior with a #3
artists brush. The fume was treated with
an antistatic device at this point to prevent
losses. The dust was then ground in a
metal-free apparatus to homogenize the
sample for replicate analyses. Preliminary
results indicated large differences be-
tween replicate samples weighed from
material recovered from filters and subse-
quently analyzed, with coefficients of vari-
ation typically >20% for replicate sam-
ples. The process below resulted in much
better precision for replicate samples,
with coefficients of variation of typically
510%. The system used was a disposable
13-mm-diameter 25-mm-long polyeth-
ylene vial with two 3.2-mm (
1
8-in.) silicon
nitride coated ceramic balls, shaken for 30
s in a Wig-L-Bug grinder. After grinding,
the material was antistatic treated again,
Table 1 Operating Variables for Generated Welding Fume Samples
Shielding Gas Gas Flow Weld Mode Wire Feed Voltage (V) Current (A)
cm/min
Ar/CO
2
99%/1% 19 L/min Short circuit 320 1718 120
Ar/O
2
99%/1% 19 L/min Short circuit 320 1718 125
He/Ar/CO
2
90%/7.5%/2.5% 19 L/min Short circuit 320 19.5 100
Ar/CO
2
99%/1% 19 L/min Axial spray 760 25 200
Ar/O
2
99%/1% 19 L/min Axial spray 760 23 200
Ar/O
2
98%/2% 19 L/min Pulsed spray 760 0.9 V trim (pulsed)
Ar/CO
2
75%/25% 19 L/min FCAW 760 26 160
none none SMAW 361
(a)
~20 150
(a) Equivalent wire feed speed based on an equal mass consumption rate.
Fig. 5 Hexavalent chromium generation rates for eight welding processes, in
g Cr
6+
/g of welding wire consumed.
Fig. 6 Hexavalent chromium exposures inside welders helmets in
g Cr
6+
/m
3
for five welding processes.
and weighed into 20-mL scintillation vials
with PTFE-lined caps. Storage in the vials
was at room temperature, in air, and vials
remained sealed unless samples were re-
moved for analysis. A previous study (Ref.
8) indicated samples were stable after
three-months storage using this proce-
dure. For Cr
6+
analysis, 5.0-mg samples
were weighed into 15-mL polycarbonate
centrifuge tubes.
Field Study
The controlled comparison study was
done in a large welding shop using bead-on-
plate welding on 0.25-in. 309 stainless steel
in the flat position, to maximize exposures.
Welding was kept at 50% arc time for all
processes tested, which included SMAW,
FCAW, and GMAW (short-circuit, spray,
and pulsed spray modes). There were 8 ob-
servations for SMAW, 16 for FCAW, 6 for
GMAW-SC, 8 for GMAW-spray, and 7 for
GMAW-pulsed spray modes. All welders
did each type of welding in the study. Sam-
ples were collected inside the welding hel-
mets, and the welders wore half-face respi-
rators with P100 filters during welding.
Short-term trials were conducted to main-
tain 8-h time-weighted average exposure
levels below the OSHA Cr
6+
permissible ex-
posure level (PEL).
Analysis for Cr
6+
Samples were treated and analyzed
using NIOSH Physical and Chemical
Analysis Method 7605, Hexavalent
Chromium by Ion Chromatography (Ref.
9). The estimated limit of detection is 0.02
g, and the method range is 0.05 to 20 g
of Cr
6+
. Five mL of extraction solution
(3% Na
2
CO
3
/2% NaOH) were added to
each 5-mg sample, and the tubes sonicated
in a bath for 30 min. This procedure ex-
tracts both soluble and insoluble Cr
6+
present in the fumes. Samples were re-
moved and centrifuged for 15 min at 3500
g. The supernatant was transferred to
25-mL volumetric flask and diluted with
H
2
O. Samples were analyzed by ion chro-
matography using a Dionex HPIC-AS7
column with 250 mM (NH
4
)
2
SO
4
/100 mM
NH
4
OH mobile phase and a postcolumn
reagent (2.0 mM diphenylcarbazide/10%
methanol/1N H
2
SO
4
) with absorbance de-
tection at 540 nm. Four concentrations of
standards were made from a certified Cr
6+
solution, covering a range of 0.44 g/mL.
Particle Size Distributions
Particle size distributions of different
welding fumes were determined by using
two Micro-Orifice Uniform Deposit Im-
pactors (MOUDI and Nano-MOUDI,
MSP Models 110 and 115; MSP Corp.,
Shoreview, Minn.). By combining the two
impactors, the particles were size-classi-
fied and collected into 15 fractions rang-
ing from more than 18 m down to 10 nm.
Besides the special feature of being able to
classify nano-size particles, the MOUDI
has rotating stages to obtain a nearly uni-
form particle deposit on the collection
substrates, which reduces particle bounce
and improves subsequent analysis. The
total flow rate for the impactors was 30
L/min, and they were operated for 4 min
total sampling time.
Statistical Approaches
The data did not follow a normal dis-
tribution, and were extremely skewed.
Therefore, the Kruskal-Wallis nonpara-
metric test was used to look for statistically
significant differences between groups.
Statistical results were considered signifi-
cant at a p-value of 0.05.
Results
Fume-generation rates for four runs
are displayed graphically in Fig. 2. The re-
sults in Figs. 25 are presented as arith-
metic means standard error of the
mean. Results range from 16 mg/min
(GMAW-P) to 228 mg/min (SMAW). The
Cr
6+
fractions in the fume, in mg/kg (ppm)
are displayed in Fig. 3. The results are the
arithmetic means standard error of
three replicate samples for each of the
four welding runs. Results range from
2800 ppm (GMAW-S using He/Ar/CO
2
shielding gas) to 34000 (SMAW). The
Cr
6+
generation rates were calculated as
the product of the fume-generation rate
and the Cr
6+
fraction in the fume, and are
displayed in Fig. 4. Additionally, some of
the differences in total fume-generation
rate and Cr
6+
generation rates were influ-
enced by the different wire-feed rates nec-
essary to maintain optimal welds. The nor-
malized generation rate is related to a
welders exposure for any given weld,
since the weld is not complete until suffi-
cient metal is deposited to meet the re-
quirements of that weld. Therefore, the
generation rates were renormalized with
respect to wire feed rates; results are
shown in Fig. 5. The results normalized for
wire-feed rates were calculated as the
product of the Cr
6+
generation rate and
the reciprocal of the wire-feed rate in
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Table 2 Mass Median Aerodynamic Diameters (MMADs) and Geometric Standard
Deviations (GSDs) of Welding Fumes for Different Shielding Gases and Processes, from MOUDI
Data
Shielding Gas Process MMAD (nm) GSD
Ar/CO
2
99%/1% Short circuit 340 1.46
Ar/O
2
99%/1% Short circuit 280 1.53
He/Ar/CO
2
Short circuit 330 1.47
90%/7.5%/2.5%
Ar/CO
2
99%/1% Axial spray 260 1.23
Ar/O
2
99%/1% Axial spray 250 1.37
Ar/CO
2
98%/2% Pulsed spray 320 1.58
Ar/CO
2
75%/25% FCAW 363 1.35
SMAW 600 1.34
Fig. 7 Particle size distribution of a typical welding fume in this study using a MOUDI device.
g/min. The SMAW rod-consumption rate
was converted to a wire feed rate by relat-
ing the masses consumed per unit time,
after measuring the rod lengths and den-
sity. The GMAW-P results were signifi-
cantly smaller than all other processes for
fume-generation rate, Cr
6+
generation
rate, and Cr
6+
generation rate per gram of
wire, p< 0.0004, but not for Cr
6+
compo-
sition in the fume (ppm).
The results of the field-controlled com-
parison study in a welding shop are shown
in Fig. 6. The results are shown as box
plots of the observed exposure concentra-
tions in g/m
3
, with the median identified
and the box spanning the 25th to 75th per-
centile, and the whiskers encompassing
the entire range of observations.
A typical particle size distribution is
shown in Fig. 7, including the curve for the
best-fit unimodal model. All of the
processes also included substantial mass
in the large, nonrespirable fractions >10
m, most likely associated with micro-
spatter from the welding processes. Sum-
mary data on geometric mean particle
sizes and respective geometric standard
deviations are shown in Table 2.
Discussion
The results showed a wide range of
fume-generation rates (a 14:1 ratio over-
all, and 4:1 for GMAW), demonstrating
there are clearly some best and worst
choices for minimizing total fume expo-
sures. The results were somewhat greater
than those found in similar studies (Refs.
8, 10, 11). A probable explanation is that
the chamber used in this study was highly
efficient with low losses and a minimal res-
idence time. Evidence for this includes the
observation of very little loss of fume to
the interior of the chamber (< 1% of the
collected mass for a given run), and the
presence of substantial masses of large
(>10 m and > 18 m) fractions in the
MOUDI sampler; these are easily lost by
sedimentation in large systems with long
residence times and extended sampling
lines.
The Cr
6+
fractions (mg/kg or ppm) in
the fumes were comparable to those in
previous studies (Refs. 8, 10, 11):
230034,000 ppm overall, and 23006100
ppm for GMAW processes. Hexavalent
chromium generation rates were again el-
evated relative to earlier findings, which
was consistent with the higher fume-
generation rates of the current study. The
Cr
6+
generation rates did not necessarily
correlate with the Cr
6+
content of the
fume, especially for the very low fume-
generating processes such as GMAW-P.
The controlled comparison field study
confirmed the laboratory findings in gen-
eral, but the very wide range of exposure
concentrations found suggests that fac-
tors other than generation of Cr
6+
at the
source are critically important in deter-
mining exposures. While all of the
welders in the small group welded in the
same shop on the same materials, the re-
sults indicate that a single observation for
each process was dramatically higher
than the remaining exposures, for both
GMAW-spray and GMAW-P modes.
There was no obvious explanation for
these anomalies, but some factor of work
practice is probably responsible.
There have been a number of success-
ful approaches to reducing Cr
6+
in weld-
ing, including altered fluxes for SMAW
and FCAW (Refs. 12, 13), secondary
shielding gases for GMAW (Ref. 14), non-
Cr-containing welding alloy wires and
rods (Ref. 15), and chemical fume reac-
tants (Ref. 16). This study concentrated on
reducing generation of Cr
6+
at the process
level, and could be used along with some
of those other methods, such as Cr-free
welding wire, fume reactants, and a sec-
ondary shielding gas.
The various welding processes have
multiple associated cost factors that are an
important issue in selecting a welding
process. Costs that need to be considered
include consumables (welding wire, rods,
shielding gases, etc.), equipment costs,
and labor costs per completed weld.
Table 3 presents relative costs in a non-
quantitative way, based on consumables
costs from typical industrial suppliers, and
manufacturers suggested prices on weld-
ing equipment that have similar current
capacities, but different process capabili-
ties. Comparisons in equipment costs are
at best imperfect, and some process capa-
bilities are available only in dedicated
units, while others can be added to exist-
ing units.
In general, most welders will not be
eager to change welding practices, espe-
cially for familiar tasks. Most welders are
very skilled and confident in their abilities,
and have completed training and certifi-
cation testing for multiple types of weld-
ing. They know very well what works and
how to solve problems, while this may not
be the case for GMAW-P and other
GMAW processes. Additionally, the work
sequence is different when changing from
SMAW to any of the GMAW techniques.
For example, a typical SMAW sequence
would be to prepare the area for welding,
weld until the rod is consumed, put down
the electrode holder (stinger) and go back
and chip off the slag from the weld, inspect
the weld and prepare any suspect areas for
rewelding. Then, typically, they would
mount a new rod and repeat the sequence.
Gas metal arc welding work patterns
would typically include preparation and
then welding continuously as long as the
torch cable can reach, unless obstacles,
etc., are present. This may result in more
fatigue, especially for vertical and over-
head positions. Some training and testing
may be necessary, but most GMAW
processes, including GMAW-P, are not es-
pecially difficult to learn or use.
Some suggestions for easing adoption
would be to replicate the timing intervals of
current practice and keep welding rates
(time for completion of a typical weld) sim-
ilar at the outset, even though GMAW
processes are often easier and faster than
SMAW.
Recommendations
For fume-generation rate, Cr
6+
gener-
ation rate, and Cr
6+
generation rate per
unit of wire in this study, pulsed spray
GMAW was clearly the best of the
processes evaluated. A previous study in
multiple industrial plants (farm machinery
manufacturing) confirms the clearly lower
fume exposures in those facilities (Ref. 17)
when using pulsed spray welding. The
method has multiple practical advantages
in addition to the minimal Cr
6+
and total
fume-generation rates: It is usable in any
position, has low heat input that mini-
mizes warping, the high metal deposition
rate lowers labor costs, it is relatively sim-
ple to learn and use, it has a noncritical
working distance and good visibility, and is
only modestly more expensive than GMA
welding machines with similar capacities.
While there will be situations where
pulsed spray mode may not be suitable, it
would be a good choice in many applica-
tions, especially where Cr
6+
exposures
may be difficult to reduce by local exhaust
ventilation or similar measures.
245-s
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Table 3 Relative Cost Ratios for Stainless Steel Welding
Shielding Gas Weld Mode Wire Costs Equip. Costs Gas Costs Labor/Weld
Ar/CO
2
99%/1% Short circuit + ++ + ++
Ar/CO
2
99%/1% Short circuit + ++ + ++
He/Ar/CO
2
Short circuit + ++ ++ ++
Ar/CO
2
99%/1% Axial spray + ++ + +
Ar/O
2
99%/1% Axial spray + ++ + +
Ar/O
2
98%/2% Pulsed spray + +++ + +
Ar/CO
2
75%/25% FCAW ++ ++ ++ +
none SMAW ++ + none ++
WELDING JOURNAL
Disclaimer
The findings and conclusions in this
paper are those of the author and do not
necessarily represent the views of the Na-
tional Institute for Occupational Safety
and Health. The mention of any company
names or products does not imply an en-
dorsement by NIOSH or the Centers for
Disease Control and Prevention, nor does
it imply that alternative products are un-
available, or unable to be substituted after
appropriate evaluation.
References
1. Bureau of Labor Statistics, U.S. Depart-
ment of Labor: Welding, soldering, and brazing
workers. Occupational Outlook Handbook,
2006-07 [Online] at www.bls.gov/oco/ocos
226.htm.
2. Antonini, J. M. 2003. Crit. Rev. Toxicology
33(1): 61103.
3. IARC. 1990. Monographs on the evalua-
tion of carcinogenic risks to humans, Volume 49:
Chromium, nickel, and welding. Lyon, France.
4. NIOSH. 2005. Pocket Guide to Chemical
Hazards, DHHS (NIOSH) Publication 2005-
149.
5. U.S. Environmental Protection Agency:
Chapter 12: Metallurgical Industry. AP 42, Section
12.19: Development of Particulate and Hazardous
Emission Factors for Electric Arc welding. [Online]
at www.epa.gov/ttn/chief/ ap42/index.html.
6. NIOSH. 1988. Criteria for a Recom-
mended Standard: Welding, Brazing, and Ther-
mal Cutting, DHHS (NIOSH) Publication No.
88-110 (Cincinnati, Ohio), or available at
www.cdc.gov/niosh/topics/hexchrom/.
7. AWS F1.2, Laboratory Method for Meas-
uring Fume Generation Rates and Total Fume
Emission of Welding and Allied Processes. 2006.
Miami, Fla.: American Welding Society.
8. Keane, M., Stone, S., Chen, B., Slaven, J.,
Schwegler-Berry, D., and Antonini, J. 2009. J.
Env. Mon. 11: 418424.
9. NIOSH Analytical Methods Manual, 4th
edition, Method 7605, Hexavalent chromium
by ion chromatography; available at
www.cdc.gov/niosh/nmam/default.html.
10. Moreton, J., Smars, E. A., and Spiller, K.
R. 1985. Metal Construction 17: 794798.
11. Yoon, S. Y., Paik, N. W., and Kim, J. H.
2003. Ann. Occ. Hyg. 47: 671680.
12. Dennis, J. H., French, M. J., et al. 2002.
Ann. Occup. Hyg. 46(1): 3342.
13. Kimura, S., Kobayashi, M., Godai, T.,
and Minato, S. 1979. Welding Journal 58: 195-s
to 203-s.
14. Dennis, J. H., French, M., Hewitt, P.,
Mortazavi, S., and Redding, C. 2002. Ann. Occ.
Hyg. 46: 4348.
15. Sowards, J. W., Liang, D., Alexandrov, B.
T., Frankel, G. S., and Lippold, J. C. 2011. Weld-
ing Journal 90: 63-s to 76-s.
16. Topham, N., Kalivoda, M., Hsu, C.-Y.,
Oh, S., and Cho, K. 2010. J. Aerosol Sci. 41:
326330.
17. Wallace, M., Landon, D., Song, R., and
Echt, A. 2001. Appl. Occ. Environ. Hyg. 16:
9397.
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Introduction
Resistance spot welding utilizes the in-
herent resistance of metal pieces to join
two or more sheets of metal by the flow of
electrical current, which passes through
the metal sheets and generates the weld-
ing heat. As a traditional welding tech-
nique, resistance spot welding is a major
metal-connecting method in the automo-
tive, consumer electronics, and aircraft in-
dustries (Ref. 1).
For resistance spot welding, its cooling
crystallization of liquid metal in a nugget
is consistent with the general rules of a so-
lidification process; the nugget shape or
structure after solidification is closely re-
lated to the cooling rate of the solidifica-
tion of the liquid metal and directly deter-
mines the performance of the spot welded
joint (Ref. 2).
However, it is currently impossible to de-
termine the cooling rate directly with nor-
mal test methods, such as thermocouple,
optical temperature measurement, or high-
speed photography, which have been widely
used in the research field of rapid solidifi-
cation. The reason behind this is the nugget
crystallization of spot welding is instanta-
neously completed in a closed plastic ring,
and the spot weld nuggets in sheet metals
are usually small. Therefore, there are few
open publications in this field to directly de-
termine the cooling rate of a spot welding
nugget. It was reported that under spot
welding conditions, the cooling rate of low-
carbon steel had been roughly inferred from
the phenomenon of hardened martensite in
the welding nugget (Ref. 3). In addition, by
using an X-ray, Elmer (Ref. 4) observed the
solidification and cooling processes of stain-
less steel spot welding.
According to the secondary dendrite
arm spacing method, a cooling rate could
be indirectly determined based on the cor-
relation between the cooling rate and di-
mensional characteristics of microstruc-
ture after rapid solidification (Ref. 5).
This method is widely and successfully ap-
plied in the research area for rapid solidi-
fication technology (Refs. 68).
Due to the fact that the crystallization
temperature range in stainless steel is rel-
atively narrow and its dendrites can grow
fully, it is relatively easy to measure their
secondary dendrite arm spacing. As such,
1Cr18Ni9Ti stainless steel was taken as
the research material. Based on the meas-
urement of the secondary dendrite arm
spacing in the spot welding nugget of this
material, the cooling rates in different
areas of the nugget were estimated ac-
cording to rapid solidification theory.
The Test Material, Equipment,
and Method
The test material was a rolled stainless
steel 1Cr18Ni9Ti sheet with a specimen
size of 100 20 1 mm. Its chemical com-
position is shown in Table 1. Figure 1 il-
lustrates the microstructure of the base
metal showing equiaxed austenite grains.
The spot welding machine used was a
DN-200-4 equipped with type KD(T)-4
spot welding microcomputer controller.
The upper and lower electrodes of the ma-
chine were made of chrome-zirconium-cop-
per alloys in a truncated cone shape with a
tip diameter of 5 mm, which were cooled in-
side by room-temperature circulating water
with a flow rate of 0.02 m
3
/min. A single im-
pulse procedure was used in this spot weld-
ing machine simply because the austenitic
stainless steel can be spot welded in high
quality without any special technical treat-
ments. The welding parameters used were
as follows: welding current 6 kA, welding
time 0.14 s, and electrode force 3800 N.
After welding, the weld nugget was cut
in the center for metallographic examina-
tion. The etching solution was made from 5
mL hydrochloric acid, 10 mL nitric acid, 10
g ferric chloride, and 100 mL water. The
measurement of nugget dendrite arm spac-
ing was carried out using an Olympus
PMG3 optical microscope. To reduce meas-
uring errors of the secondary dendrite arm
spacing, the selected measure points should
be away from the dendrite tips. Further-
more, the third dendrite arms were ignored
during the distance measurement of a sec-
ondary dendrite to its primary dendrite for
the sake of consistency. The average of mul-
tiple measurements was taken as the meas-
uring result.
Secondary Dendrite Arm
Spacing Model
The secondary dendrite arm spacing
(SDAS) is a distance between the second-
ary dendrite arms. Based on Ficks law and
Gibbs-Thompsons equation, Furer and
Wunderlin proposed the SDAS theoreti-
Estimating the Cooling Rates of a
Spot Welding Nugget in Stainless Steel
In this study, the projected results show the cooling rate from the nugget edge
to nugget center decreases gradually from 10
5
to 10
4
K/s
BY Y. ZHANG, T.-J. MA, H.-X. XIE, Y.-M. TAN, AND P.-Y. LI
KEYWORDS
Spot Welding
Nugget
Cooling Rate
Secondary Dendrite Arm
Spacing
1Cr18Ni9Ti Stainless Steel
Y. ZHANG (hjzhyong@nwpu.edu.cn), T.-J. MA,
H.-X. XIE, Y.-M. TAN, and P.-Y. LI are with the
Shaanxi Key Laboratory of Friction Welding Tech-
nologies, Northwestern Polytechnical University,
Xian, China.
ABSTRACT
Cooling rates at different areas of a spot welded nugget in a 1Cr18Ni9Ti stain-
less steel material were investigated based on the rapid solidification theory and
Furer-Wunderlin secondary dendrite arm spacing (SDAS) model. In the calcula-
tion of the cooling rates by using a SDAS method, only the diffusion of carbon
atoms, which spread rapidly as a solute element in the solid phase, was consid-
ered. The experimental results show that the SDAS values in a 1Cr18Ni9Ti spot
welded nugget exhibited significant variation even for those on the same primary
dendrite axis. The estimated cooling rate from the nugget edge to nugget center
decreased from an order of magnitude 10
5
to 10
4
K/s.
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cal model (Ref. 9).
Furer and Wunderlin suggested that
with remelting of small secondary den-
drites, the distance or spacing of the bigger
secondary dendrite arms will increase, as
shown in Fig. 2, where
2
is the SDAS. The
coarsening mechanism assumed that the
finer second dendrite arms would be
melted while the other bigger branches
would become thicker. Whenever a fine
secondary arm is melted, the local second-
ary dendrite spacing will be doubled. The
driving force of this process is the differ-
ence of interfacial energy between grains
with different curvatures. Based on this as-
sumption, the following Furer and Wun-
derlin equation is obtained:
2
= 5.5(At
f
)
1
3 (1)
Where
2
is secondary dendrite arm spac-
ing (m); t
f
is local solidification time (s);
and A is coarsening coefficient (s/K).
Here, the coarsening coefficient A
could be calculated by following formula:
A = D
L
ln(C
L
/C
0
)/m
L
(1 k)(C
0
C
L
) (2)
Where is Gibbs-Thompson coefficient
(Km); D
L
is diffusion coefficient of solute
in liquid phase; C
L
is liquid concentration
(wt-%); C
0
is the original concentration of
the liquid alloy (wt-%); m
L
is liquidus
slope; and k is distribution ratio at
equilibrium.
In Equation 1, the local solidification
time t
f
is defined as the time when each
dendrite arm contacts the liquid phase,
which is a function of the growth rate, tem-
perature gradient, and alloy compositions.
The following formula can be used for cal-
culating the local solidification time t
f
, i.e.,
t
f
= T /|| = T /GV (3)
Where T is nonequilibrium solidification
temperature range (K); G is temperature
gradient (K/m); V is dendrite growth veloc-
ity (m/s); and || is the cooling rate. The
product of G and V equals to the cooling
rate , so that Equation 3 can also be ex-
pressed as the following:
t
f
= T /|| = T / (4)
Cooling Rate Calculation of
1Cr18Ni9Ti Nugget Solidification
Determination of the Secondary Dendrite
Microstructures and Solute Elements for
Calculating the Cooling Rate
Secondary Dendrite Microstructures of
1Cr18Ni9Ti Spot Welding Nugget
Figure 3AC shows the dendritic mi-
crostructures of 1Cr18Ni9Ti spot welding
nugget, respectively, in the areas from
nugget edge to nugget center. In each
image, there is an arrow pointing to the
position where the secondary dendrite
segment is selected for the SDAS meas-
urement. As soon as the welding current is
turned off, the welding zone will begin to
cool down due to no more heat generation
to compensate the heat loss; as a result,
crystallization will start from the partial
melting crystalline grains around the edge
of the nugget. This crystallization occurs
in a form of dendrite, and this dendrite
grows toward the center core along the op-
posite direction of heat dissipation.
If the axis direction of the dendrite
branch is the same as the axis of heat dis-
sipation, then the heat flow will be better
and the dendritic growth will also be
faster; consequently, the best direction for
the dendritic growth is along the elec-
trodes of the spot welding machine. The
growth of these dendrites will usually be
sufficient due to no external electromag-
netic stirring behavior during the crystal-
lization (Refs. 10, 11).
The SDAS measured from Fig. 3 is gen-
erally between 1~5 m, the dendrite arm
spacing is small, and each of them is differ-
ent. From the edge to the core of the weld
nugget, the average dendrite arm spacing
increases. One reason is that the crystalliza-
tion at spot welding begins generally from at
the partial melting zone around the nugget
with a lower temperature and better cooling
condition, where the crystallization temper-
ature can be reached first, i.e., it begins from
the nucleus of the partial melting grain sur-
face with lowest surface energy. These den-
drites grow in the opposite direction of heat
dissipation. Due to the relatively small ther-
mal conductivity of stainless steel, the latent
heat of crystallization released during the
solidification process will lower the temper-
ature gradient in the nugget as the dendrites
approach the nugget center. The lower tem-
perature gradient and lower cooling rate
near the nugget center make the dendrites
grow slower, and thus, smaller average den-
drite arm spacing.
Determination of Solutes for Calculating the
Cooling Rate
It is difficult to accurately determine
the thermodynamic parameters for a com-
plicated alloy system like 1Cr18Ni9Ti
stainless steel with many alloy elements.
Only three alloy elements Fe, Cr, and
Ni will be considered in the calculation
of physical parameters. For the calculation
of cooling rate, the following parameters
need to be known: the liquidus tempera-
ture, the solidus temperature, and the liq-
uidus slope for each precipitated single el-
ement. Under normal cooling conditions,
the thermal diffusion rate of a casting part
is about in an order of magnitude 10
6
m
2
/s,
but for a solute atom in an alloy liquid, its
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C
H
Fig. 1 Microstructure of the base metal 1Cr18Ni9Ti stainless
steel.
Fig. 2 Secondary dendrite arm spacing.
Table 1 Chemical Composition of 1Cr18Ni9Ti Stainless Steel (wt-%)
Material C Si Mn P S Cr Ni N
1Cr18Ni9Ti 0.052 0.465 1.26 0.0005 0.0028 19.6 8.54 0.06
diffusion coefficient will be only about 10
9
m
2
/s. Especially in an alloy solid-phase, its
diffusion coefficient is only about 10
12
m
2
/s. Thus, a solute diffusion process can
be seen far behind a solidification process
(Ref. 12). At a given temperature, the dif-
fusion coefficients of C, Cr, and Ni atoms
in -Fe are, respectively, in an order of
magnitude as follows: 10
4
, 10
9
, and 10
9
.
The diffusion coefficients of these solute
elements will be even lower as the cooling
rate increases.
In addition, Cr and Fe have similar
atom diameters (2.54 vs. 2.56 ) and close
electronegativity (1.8 vs. 1.6) (Ref. 13).
According to the solid solution theory,
they could form a continuous solid solu-
tion, but due to BCC crystal structure of
Cr and FCC structure of -Fe, it is impos-
sible for Cr and Fe to form such a contin-
uous solid solution. At 1100C, the diffu-
sion coefficient of Cr in the -Fe phase is
still about 10
9
, while the spot welding time
is short; generally, there will not be
enough time for Cr atoms to diffuse in Fe
matrix. Consequently, in our calculation
of the cooling rate, the diffusion of Cr will
not be taken into account.
The study (Ref. 14) showed that for
1Cr18Ni9Ti, when C and Ni were respec-
tively used as a single added element to
calculate the cooling rate, the values of
their coarsening coefficient A in Equation
1 were similar. As can be seen from Equa-
tion 1, the effect of the coarsening coeffi-
cient A on the SDAS
2
is just propor-
tional to its cube root value; therefore, the
SDAS
2
barely varies with the variation of
the coarsening coefficient A in compari-
son with the unavoidable deviation extent
of the measured values. For this reason, in
the estimation of the cooling rate for a
spot welding nugget, only the diffusion of
the C atom, which diffuses relatively rap-
idly in the solid phase, will be considered.
The Cooling Rate in Case of Single
Element Carbon Diffusion
Determination of Parameters
1. The Gibbs-Thompson coefficient
and diffusion coeffi-
cient D
L
of solute in liq-
uid phase and D
L
for
1Cr18Ni9Ti can be
found from the physical
properties manual of
an iron alloy (Ref. 15):
= 1.9 10
7
(K m)
and D
L
= 2 10
8
(m
2
/s).
2. Distribution ratio
k and liquidus slope
m
L
.
From the Fe-C
phase diagram in Fig. 4
(Ref. 16), the equilib-
rium distribution ratio
k and the liquidus slope
m
L
can be calculated. To simplify the
mathematical treatment of the solidifica-
tion process, the liquid phase line and the
solid phase line of the phase diagram are,
respectively, assumed as straight lines.
Hence, the liquidus slope m
L
and the dis-
tribution ratio k can be considered as
constants.
According to the theory of solute re-
distribution, the equilibrium distribution
ratio k is calculated as follows:
k = C
S
/C
L
= 0.057/0.39 = 0.15
where C
S
and C
L
is solid concentration
(wt-%) and liquid concentration (wt-%),
respectively.
As shown in Fig. 4, the liquidus slope
can be calculated as follows, when T
L
=
1806 K and T
S
= 1780 K:
m
L
= T
L
T
S
/C
L
C
0
= (1806 1780/0.39 0.057) = 82.2
3. Local solidification time
The nonequilibrium crystallization
temperature range T in Equation 3 can
be calculated in this way:
T = m
L
(C
l
* C
l
m
) (5)
where C
l
* is the concentration of the den-
dritic tip, and in most cases, C
l
* is similar
to C
0
(Ref. 15). C
l
m
is the liquid concen-
tration of the final phase. C
l
m
equals to the
eutectic concentration C
E
, if it is in an eu-
tectic transformation system. Otherwise,
the value of C
l
m
is difficult to determine.
For an equilibrium solidification sys-
tem, the liquid concentration of the final
phase could be determined by using the
lever law, i.e., C
l
m
= C
0
/k, but for most of
solutes in practice, it is almost impossible
to determine the liquid concentration of
the final phase because of their small dif-
fusion coefficient. However, there are also
a few important exceptional cases. For ex-
ample, for interstitial solid solutions, es-
pecially for those with open locations in
their crystal structures and for solidifica-
tions in small zones (such as dendritic seg-
regation of C in the -Fe), the diffusion co-
efficient could be so great that Fourier
number could be over 100 (Ref. 15).
For a nonequilibrium solidification sys-
tem, Kurz and Fisher introduced the fol-
lowing calculation equation (Ref. 15):
C
l
m
= C
0
(2k)
p/u
(6)
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H
A
B
C
Fig. 3 Microstructures of 1Cr18Ni9Ti austenite stainless steel spot weld-
ing nugget. A Edge of nugget and HAZ; B middle region of nugget;
C nugget center.
Where u = 1 2k, p = 1 k, and is
the reverse diffusion parameter and a
function of t
f
.
= [1 exp (1/)]
1/2 exp (1/2) (7)
in Equation 7, is the dimensionless time
(Fourier number) and can be obtained as
follows:
= D
S
t
f
/L
2
= 4D
S
t
f
/
2
(8)
The parameter has the following
characteristics (Ref. 13): When the value
of is less than 0.1, then = ; when
value is greater than 50, then = 0.5.
Based on the experiential data, it can be
estimated roughly that the value of in
Equation 8 is quite big. When = 0.5, C
l
m
can be obtained as C
l
m
= 0.33. Therefore,
in this paper only, the effect of a C atom
on the solidification process will be con-
sidered, and the solidification is assumed
in equilibrium. Hence, T can be
achieved as follows:
T = m
L
(C
l
* C
l
m
)
= 82.2 (0.057 0.39) 27C
Calculation of Cooling Rate
From the measurement of the dendrite
segments indicated by the arrow in Fig. 3,
the average values of SDAS can be ob-
tained at different areas in a weld nugget
as listed in Table 2. Putting the SDAS av-
erage values and the afore-calculated pa-
rameters , D
L
, k, m
L
, T into Equations
14, the solidification time t
f
, and the cool-
ing rate C
R
, can consequently be obtained
and listed in Table 2. As shown in Table 2,
for 1Cr18Ni9Ti spot nugget solidification,
the cooling rates from nugget edge to
nugget center decrease gradually from an
order of magnitude 10
5
K/s at the nugget
edge to 10
4
K/s at the middle region and
the nugget center.
Discussion
Measuring the secondary dendrite arm
spacing enables gaining information on
the local solidification in a nugget. Figure
5 shows the morphology of local second-
ary dendrite in the middle region of the
nugget. The significant difference of the
secondary dendrite arm spacing can be
seen for those secondary dendrites from
different primary dendrites in the same
area. A few secondary dendrite arms can
obviously be observed with a clear shape
of dendrites, while others are so fine that
it is difficult to distinguish their dendrite
arm spacing. In addition, Fig. 5 shows that
the secondary dendrite arms on a primary
dendrite have different lengths. This is be-
cause a secondary dendrite will always
grow up as long as its length is less than
half the length of a primary dendrite arm
spacing, and at the same time, these sec-
ondary dendrites will also devour each
other. Once the growing tip of a secondary
dendrite meets that of a neighboring den-
drite, the growth of the secondary den-
drite will be stopped.
As can be clearly seen in Fig. 5, values
of the secondary dendrite arm spacing on
a given primary dendrite also have a rela-
tively big variation due to the difference
on the release of the latent heat during
crystallization and the behavior of solute
elements in dendrite interactions. Figure
6A presents the measuring results for each
segment of secondary dendrite arm spac-
ing for the location marked in Fig. 5. The
estimated corresponding cooling rates are
plotted in Fig. 6B.
As can be observed from Fig. 6, sec-
ondary dendrite arm spacing values ex-
hibit a significant variation from 0.97 to
3.7 m. Accordingly, the cooling rate
varies from about 1 10
4
to 10 10
4
K/s.
The big variation of cooling rates may be
related to the solidification process of the
welding nugget. Due to the release of the
latent heat of crystallization, the tempera-
ture between dendrites will rise. As a re-
sult, a few relatively small secondary arms
in two adjacent secondary dendrites will
melt and disappear to promote the growth
of a few big dendrite branches. Further-
more, unlike the primary dendrite arm
spacing in the solidification process, the
secondary dendrite arm spacing depends
largely on the gradual cooling process dur-
ing their growth (Ref. 9).
Conclusions
The cooling rates at different areas of
the spot welding nugget for 1Cr18Ni9Ti
were estimated by using the secondary
dendrite arm spacing method as well as
considering the characteristics of the spot
welding process and the situation of an
atoms diffusion (atom C was selected as
an independent solute in solvent Fe). The
estimated results show that the cooling
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Table 2 The Values of Cooling Rate in Only Considering C Diffusion
Average SDAS Solidification Time Cooling Rate
Position SDAS in Fig. 3
2
/m t
f
/s C
R
/K/s
Nugget edge and HAZ 1.29 1.5 10
4
4.19 10
5
Middle region of nugget 2.151 7.07 10
4
9.05 10
4
Nugget center 3.036 1.9 10
3
3.22 10
4
Fig. 4 Fe-Fe3C phase diagram. Fig. 5 Section of local secondary dendrite arm microstructure.
rate from the nugget edge to nugget cen-
ter decreases gradually from an order of
magnitude 10
5
to 10
4
K/s.
For the 1Cr18Ni9Ti spot welding
nugget, there are a lot of variations for the
secondary dendrite arm spacing; it largely
depends on the relative location in the
nugget for its primary dendrite and loca-
tion inside the primary dendrite. The sec-
ondary dendrite arm length on a given pri-
mary dendrite changes with the location,
and their secondary dendrite arm spacing
will vary consequently.
Acknowledgment
The authors would like to thank the fi-
nancial support from the 111 Project
(B08040).
References
1. Cho, Y., and Rhee, S. 2002. Primary cir-
cuit dynamic resistance monitoring and its ap-
plication to quality estimation during resist-
ance spot welding. Welding Journal 81(6): 104-
s to 111-s.
2. The Resistance Council of the Chinese
Welding Society. 1994. The theory and practice
of resistance welding. Beijing, China. Machine
Press.
3. Bi, H. Q. 1981. Welding methods and
equipments. Beijing, China. Machine Press.
4. Elmer, W. J. 2000. In-situ observations of
phase transformations during solidification and
cooling of austenitic stainless steel welds using
time-resolved X-ray diffraction. Scripta Materi-
alia 43: 751757.
5. Zhou, Y. H. 1998. Solidification technol-
ogy. Beijing, China. Machine Press.
6. Cheng, M. T., Tang, Z. H., and Ni, M. S.
1993. Relationship between cooling rate and
secondary dendrite arm spacing for steel No.
45. Journal of Iron and Steel Research 5(4): 14.
7. Turhal, M. S., and Savaskan, T. 2003. Re-
lationships between secondary dendrite arm
spacing and mechanical properties of Zn-40Al-
Cu alloys. Journal of Materials Science 38:
26392646.
8. Zhang, D. F., Lan, W., Zeng, D. D., and
Zhang, B. P. 2008. Quantitative relationship be-
tween secondary dendrite arm spacing and so-
lidification cooling rate of AZ31 magnesium
alloy. Heat Treatment of Metals 33(3): 13.
9. Li, H. X., Guo, T. M., Li, R. D., Li, R. X.,
and San, J. C. 2004. Research on secondary den-
drite arm spacing. Foundry 53(12): 10111014.
10. Alcini, W. V. 1990. Experimental meas-
urement of liquid nugget heat convection in
spot welding. Welding Journal 69(5): 177-s to
180-s.
11. Li, Y. B., Lin, Z. Q., Lai, X. M., Chen,
G. L., and Zhang, K. 2010. Induced electro-
magnetic stirring behavior in a resistance. Sci-
ence China Technological Sciences 53(5):
12711277.
12. Pen, G. W., Liu, J., Li, L., and Zeng, B.
2005. Progress of technic and theory of direc-
tional solidification. Research Studies on
Foundry Equipment (4): 4447.
13. Xiao, J. M. 1983. The metallography
problems of the stainless steel. Beijing, China.
Metallurgical Industry Press.
14. Li, P. Y. 2011. Cooling rate calculation
and microstructure characterization on spot
welding nugget of stainless steels. Masters dis-
sertation. Xian, China. Northwestern Poly-
technical University.
15. Kurz, W., and Fisher, D. J. 1987. Solidi-
fication Theory. Xian, China. Northwestern
Polytechnical University Press.
16. Dai, Y. N. 2009. Binary alloy phase dia-
gram. Beijing. China Science Press.
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Fig. 6 The curves of secondary dendrite arms and cooling rate in Fig. 5. A The curve of the second arm spacing; B the curve of the cooling rate.
A
B
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Introduction
Many engineering components today
have service conditions that require the
properties to vary with position (Ref. 1).
Differing stresses, temperatures, and en-
vironments necessitate a range of material
properties that often cannot be achieved
in a component with a single composition.
One solution is to replace these compo-
nents with functionally graded materials
(FGMs), which are composite materials
engineered with different phases whose
composition changes gradually with posi-
tion (Ref. 2). In FGMs, abrupt changes in
composition or properties that can act as
stress concentrations are eliminated, de-
creasing the possibility of failure (Ref. 1).
Unfortunately, graded materials are not
regularly integrated into industrial com-
ponents because the design and manufac-
turing processes include many unresolved
challenges. In terms of design, optimiza-
tion routines must be developed to iden-
tify the gradient in properties that pro-
vides superior component performance
for a given set of service conditions. The
component then needs to be manufac-
tured correctly to produce the microstruc-
tural gradient leading to the predeter-
mined property gradient.
Functionally graded materials can also
be useful for joining dissimilar alloys that
have large differences in thermal and me-
chanical properties. For example, dissimi-
lar metal welds (DMWs) between ferritic
low-alloy steels and austenitic alloys are
commonly used in fossil-fired power
plants. The less-expensive, low-alloy steels
are used in the low-temperature regions of
the plant, while the higher temperatures in
the superheater regions require the supe-
rior corrosion resistance and greater creep
strength of more expensive austenitic al-
loys. A typical power plant can contain
thousands of DMWs. The DMWs are
prone to premature failure due to sharp
gradients in chemical composition, ther-
mal expansion, and creep strength be-
tween the two alloys (Refs. 3, 4). Prema-
ture failure of these DMWs can result in
forced plant outages that can cost a power
company up to $850,000 per day in lost
revenue (Ref. 5). A transition joint that
gradually changes from the pure
austenitic alloy to the pure ferritic steel
could replace the one dissimilar weld with
two similar welds. By continuously grading
the joint composition, the sharp changes
in microstructure and properties of tradi-
tional DMWs would be eliminated, thus
improving the high-temperature
performance.
The different microstructures of
DMWs in the as-welded condition are due
to a sharp chemical concentration gradi-
ent across the weld interface that sepa-
rates the ferritic and austenitic alloys. The
DMW will contain two different weld in-
terfaces one separating the (primarily
austenitic) fusion zone and ferritic alloy,
and another separating the austenitic fu-
sion zone and austenitic alloy. The weld
interface between the fusion zone and fer-
ritic alloy is of primary interest in DMWs
and is discussed throughout this article.
During fusion welding, the combination of
the high alloy content of the austenitic
filler metal and fast cooling rate produce
a hard martensite band along the weld in-
terface (Refs. 4, 6, 7). The partial mixing
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Design Considerations of Graded Transition
Joints for Welding Dissimilar Alloys
Models were developed and utilized for designing functionally graded transition
joints for joining ferritic to austenitic alloys
BY G. J. BRENTRUP, B. S. SNOWDEN, J. N. DUPONT, AND J. L. GRENESTEDT
KEYWORDS
Dissimilar Metal Welding
Functionally Graded Materials
Finite Element Models
Thermodynamic and Kinetic
Models
G. J. BRENTRUP and J. N. DUPONT
(jnd1@lehigh.edu) are with Dept. of Materials
Science & Engineering, Lehigh University,
Bethelehem, Pa. B. S. SNOWDEN and J. L.
GRENESTEDT are with Dept. of Mechanical
Engineering, Lehigh University, Bethelehem, Pa.
ABSTRACT
Functionally graded materials have potential for joining dissimilar materials in
many applications. In this work, models have been developed and utilized for design-
ing functionally graded transition joints for joining ferritic and austenitic alloys. Finite
element (FE) models were used to optimize the graded length and geometry of the
transition joint in order to minimize stresses due to thermal expansion mismatch.
Thermodynamic and kinetic models were used to determine the length of grade
needed to reduce chemical potential gradients and carbon migration. Results from the
FE simulations of a conventional dissimilar weld demonstrate that localized stresses
as high as ~ 240 MPa can exist at 650C when a nominal tensile stress of ~ 32 MPa is
applied. The high local stress is due primarily to coefficient of thermal expansion
(CTE) mismatch between the ferritic and austenitic alloys. Mechanical property mis-
match between the two alloys plays a much smaller role. Similar FE model results from
graded joints demonstrate that these local stresses can be reduced significantly to
~ 50 MPa for a 120-mm grade length that consists of at least 30 layers within the tran-
sition zone. Further stress reduction down to ~ 40 MPa is possible by increasing the
wall thickness of the transition joint in high stress locations. Thermo-Calc model re-
sults of the chemical potential of carbon in a T22-Alloy 800-347 graded transition show
that the chemical potential gradient is steepest between the T22 and Alloy 800, and is
due to the large differences in chromium content between the two materials. Results
from kinetic simulations demonstrate that a 25-mm grade length should significantly
reduce carbon migration at 500C. Higher operating temperatures will require in-
creased joint lengths to provide similar reductions in carbon migration. These results
are useful for fabricating optimized graded transition joints to replace failure-prone
dissimilar metal welds (DMWs) in the power-generation industry.
in the liquid state results in a high harden-
ability leading to the formation of the
martensite layer (Ref. 4). Microhardness
results (Ref. 8) show that the heat-
affected zone (HAZ) and base metal have
similar hardness, but the weld interface is
harder than either of the base metals. The
martensite and a high carbon concentra-
tion both lead to the hardness gradients in
DMWs. The martensite layer occurs re-
gardless of whether a stainless steel or Ni-
based filler metal is used (Ref. 9). The
hardness gradients that exist directly after
welding due to the presence of martensite
can be nearly eliminated with a properly
designed postweld heat treatment
(PWHT) as shown by Laha et al. (Ref. 10).
High temperatures encountered during
either PWHT or service provide the activa-
tion energy for carbon diffusion to occur
down the chemical potential gradient from
the ferritic steel toward the austenitic alloy,
leading to formation of carbon-enriched
and depleted zones, as well as nucleation
and growth of carbides on the austenitic
side that have very high hardness (Refs. 3,
813). The chemical potential gradient
arises from either concentration gradients
or differences in solid solubility (Ref. 11),
both of which are present in dissimilar metal
welds. Reports published to date have
shown (Refs. 8, 12, 1416) the majority of
DMW failures exhibit the carbon-depleted
zone in the ferritic steel and the carbon-en-
riched zone in the stainless steel or Ni filler
metal (Refs. 8, 13).
The primary driving force for carbon
migration is the chemical composition dif-
ference between the ferritic and austenitic
steels (Ref. 12), specifically chromium.
The austenitic filler metals contain signif-
icantly more chromium than the low-alloy
ferritic steels. Additionally, the changing
chromium concentration, due to the re-
moval of chromium from solution and the
precipitation of chromium carbides, af-
fects the solubility, and therefore the dif-
fusion rate, of carbon (Ref. 10).
The carbon that has migrated into the
austenitic material sets up a concentration
gradient that extends from the weld inter-
face (high C) into the austenitic fusion
zone (low C). This concentration gradient
promotes further diffusion away from the
weld interface and into the austenitic ma-
terial (Ref. 12). As carbon migrates to the
high-alloy side of the fusion zone, the car-
bon concentration increases up until the
solubility limit. Once the solubility limit is
reached, carbide precipitation will occur
(Ref. 12). Precipitation of M
23
C
6
and
M
7
C
3
on the austenitic side of the weld in-
terface has been commonly observed
(Ref. 10). The difference in hardness
across the weld interface increases with in-
creasing aging time due to nucleation and
growth of the interfacial carbides.
These large differences in microstruc-
ture and hardness occur over very short
distances across the weld interface
(~50100 m) (Refs. 4, 8, 15). At the same
time, stresses develop in the DMW from
the differences in creep strength and ther-
mal expansion coefficients of the steels.
Austenitic stainless steels have a coeffi-
cient of thermal expansion approximately
40% higher than the ferritic steels. The
differing expansions will induce high local
stress at the HAZ-weld metal interface
(Ref. 14). The thermal stresses generated
from the CTE mismatch are created from
the numerous startups and shutdowns that
occur in the lifetime of a power plant (Ref.
17). The number of thermal cycles varies
for each plant and controls the failure
mechanism. Additionally, austenitic stain-
less steel can have creep strength two to
three times higher than ferritic steel (Refs.
1820). As a consequence of the hardness
and strength gradients, these stresses are
concentrated in the weak carbon-depleted
zone near the weld interface (as discussed
previously), generating creep voids
around carbides that lead to eventual
creep rupture (Refs. 14, 21).
It is important to note that microstruc-
tural changes due to carbon diffusion,
combined with high localized stresses due
to CTE mismatch, are primary factors that
contribute to premature failure of DMWs.
Each of these factors can be significantly
minimized with graded transition joints.
This paper describes the development and
use of models to determine the optimal
gradients in composition and geometry for
design of graded transition joints that can
be used for joining ferritic alloys to
austenitic alloys. Finite element models
are used to optimize the grade length and
geometry in order to minimize stresses
due to thermal expansion mismatch, while
thermodynamic and kinetic models are
used to identify grade lengths needed to
reduce chemical potential gradients and
carbon migration.
Procedure
Stress Analysis
Stress analysis was first conducted on a
conventional DMW design commonly
used in fossil-fired power plants. These re-
sults served as a baseline in order to assess
the effectiveness of a graded transition
joint for minimizing stresses due to CTE
mismatch. The DMW design is shown in
Fig. 1. The CAD file and dimensions of
the DMW are shown in Fig. 1A and B, re-
spectively. A total of 2845 elements were
used in the mesh, and 1000 were in the
transition zone. A total of 9000 nodes were
used, with approximately 3000 in the tran-
sition zone. The joint is approximately 160
mm in length and joins a section of ASTM
A213 T22 (2.25Cr-1Mo) steel with a sec-
tion of AISI 347H (18Cr-12Ni-Nb) stain-
less steel with an interlayer of Incoloy
Alloy 800. The two sections of tube vary in
both their inner and outer diameters. The
stainless section has an inside diameter
(ID) of 25.8 mm and outside diameter
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Fig. 1 A CAD model of the original DMW joint utilized for FEA modeling; B original DMW joint
shown with pertinent dimensions; C mesh used in the transition zone.
A
B C
160.020
67.948
C
25.781
38.100
24 68.072
44.450
19.685
SECTION C-C
C
(OD) of 38.1 mm, while the low-alloy steel
section has an ID of 19.7 mm and an OD
of 44.5 mm. High-temperature material
property data for the Alloy 800, T22 low-
alloy ferritic steel, and 347 stainless steel
were found in the literature and imple-
mented in the model (Refs. 18, 19). The
nominal compositions of these alloys can
be found in Table 1. As a first approxima-
tion, the mechanical properties of the
graded region were modeled as a linear in-
terpolation between the three known
materials.
Finite element (FE) models of the con-
ventional DMW and graded transition
joints were created using the ANSYS fi-
nite element software (version 11.0) to de-
termine the Von Mises stress distribution
in the joints. The joints were assumed to
be stress free at 0C. Residual stresses
from welding were ignored. The joints
were assumed to be operating at 650C,
and the stress from the weight of the tubes
was simulated by application of a 20,000-
N tensile load to one end while holding the
other end fixed. The rotational symmetry
allowed a 2D model to be made for the 3D
geometry. The hatch-marked face in Fig.
1A shows the shape of the actual FE
model. The mesh in the transition region
is shown in Fig. 1c. The sizes of the two
tubes on either side of the joint were fixed
for this optimization. A joint composed of
a single homogeneous material of T22
steel with identical geometry to the DMW
joint was also chosen for stress analysis in
order to separate the effects of changes in
geometry and materials on the resultant
stress distribution.
Stress distributions in the graded joints
were determined by modeling the system
as a layered structure. In this case, the joint
is made up of a series of layers in which the
properties within each layer are constant,
but the properties vary continuously from
layer to layer within the joint. A reduction
of the layer thickness (which is analogous
to an increase in the number of layers
within the joint) has the effect of smooth-
ing out the mismatch in material proper-
ties and thus reducing the stress. This ap-
proach is justified based on the expected
features of actual transition joints that
have recently been fabricated by dual-wire
gas tungsten arc welding (Ref. 22) in which
the composition (and therefore proper-
ties) of each layer within the joint are con-
stant. As shown by the results in the next
section, this also permits stress minimiza-
tion by control of the layer thickness. The
length of the transition joint was held fixed
at 120 mm, and the number of layers was
varied from 10 to 120. The element size
was held at 1 mm, so the element size was
never larger than the layer thickness. This
was shown to be sufficient to produce con-
vergence in the stress analysis.
For the graded transition joints, the Op-
trix program (Ref. 23) was used to minimize
the Von Mises stress within the joint. Optrix
is an optimization platform capable of lo-
cating a minimum to a problem by observ-
ing how design variables affect an objective
function. In this case, the design variables
were the number of material layers and
physical dimensions of the joint. The objec-
tive function here is the maximum Von
Mises stress within the joint. Optrix begins
by slightly perturbing each design variable
to determine its influence on the output (in
this case, the Von Mises stress), essentially
finding approximations for the first deriva-
tive of the objective function with respect to
the design variables. Based on the values of
the objective function and their derivatives,
an approximate optimization problem is
formulated and solved. The design variables
are then updated and the new joint is ana-
lyzed. This continues iteratively until there
is essentially no change in the objective
function. The number of iterations required
for convergence in this work varied between
3 and 15. The converged solution is not
guaranteed to be a global optimum. How-
ever, in all cases the optimization greatly re-
duced the maximum Von Mises stress in the
joint relative to the original DMW.
Physical constraints were imposed on
the transition joint geometry in order to
produce practical results. First, the cross
sections at each end of the optimized joint
matched those of the ends of the DMW.
Second, the inner diameter was held con-
stant at the smaller of the two inner diam-
eters of the DMW (19.7 mm) in order to
avoid flow restriction in the tube. Third,
the outer diameter could not be increased
beyond 44.5 mm, the largest size in the
DMW joint. Last, the length of the entire
transition joint was held constant at 120
mm. These constraints essentially ensure
that at any location where a DMW joint of
this type is presently used, a graded tran-
sition joint could be installed without sig-
nificant modification to the existing tubes.
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Fig. 2 Results from simulation of a uniform tube model with 100% T22
material showing the Von Mises stress distribution for a 20,000-N applied
tensile load at 650C.
Fig. 3 Results from original DMW joint model showing Von Mises stress dis-
tribution with 20,000-N applied tensile load at 650C.
Table 1 Nominal Compositions (wt-%) of the Alloys Used in this Research
Material C Cr Fe Mo Ni
T22 0.050.15 1.92.6 Bal 0.871.13
Alloy 800H 0.060.10 1923 Min 39.5 3035
347H Stainless 0.040.10 1720 Bal 913
Carbon Diffusion Modeling
Thermo-Calc thermodynamic software
(Ref. 24) with the TCFE5 database were
utilized to model the chemical potential
gradient of C across the graded transition
joints (Refs. 14, 21, 25, 26). A linear com-
position profile was assumed in grading
between the three alloys. Calculations
were performed at ten equally spaced in-
tervals along the graded joint, where the
composition at point 1 was the nominal
T22 composition, point
5 was the nominal Alloy
800 composition, point
10 was the nominal 347
composition, and all
other points were a
mixed composition
based on the linear
grading. In an addi-
tional simulation, the Cr
composition within
Alloy 800 was hypothet-
ically reduced to 10 wt-
% to determine the effect of Cr composi-
tion on the C chemical potential gradient.
Carbon diffusion as a function of time
and temperature was modeled using
DICTRA kinetic software (Ref. 27). The
model used here is similar to that de-
scribed in the literature (Refs. 28, 29). The
system was modeled with fcc as a continu-
ous matrix phase and bcc, M
23
C
6
, M
7
C
3
,
and sigma phases as second-phase spher-
oidal particles. The homogenization func-
tion within DICTRA (Ref. 30), which sim-
ulates long-range diffusion through a
multiphase mixture, was employed with a
rule of mixtures to approximate the local
kinetics. The composition, operating time,
and temperature were input as variables
to determine the length of the graded re-
gion necessary to minimize carbon migra-
tion from the T22 low-alloy steel to the
Alloy 800. The temperatures studied were
500, 550, 600, and 650C, with a simu-
lated operating time of 0 to 20 years. A lin-
ear composition gradient was used as a
first approximation. The TCFE5 and
MOB2 databases were used (Refs. 32, 33).
Results and Discussion
Stress Analysis Results
Figure 2 shows the Von Mises stress
distribution for a joint of the dimensions
shown for the DMW in Fig. 1, but with uni-
form material of T22 steel. As with all the
stress analyses, the joint was assumed to
be stress free at 0C. In Fig. 2, the stress
distribution is shown when the tempera-
ture is raised to 650C and a 20,000-N ten-
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Fig. 4 Results from simulation of original DMW joint shown with vary-
ing tensile loads (0, 4000, 12,000, and 20,000- N) applied at 20C.
Fig. 5 Results from simulation of original DMW joint shown at varying
temperatures (20, 200, 400, and 650C), with no tensile load applied.
Fig. 6 Results from FEA model of linear grading scheme shown for vary-
ing number of grade layers with 20,000-N applied tensile load at 650C.
Fig. 7 Plot of the maximum Von Mises stress in a graded joint as a function
of the number of layers, which illustrates a decrease in maximum stress as the
number of layers increases.
sile load is applied. The maximum stress
shown in Fig. 2 occurs in the thinner-
walled tube and is 36 MPa. This stress is
slightly higher than the 32.4 MPa esti-
mated by simply dividing the total load
(20,000 N) by the room-temperature
cross-sectional area of the thinner-walled
tube. The slight increase is due to the ta-
pered geometry of the joint. (It should be
noted that the surface irregularity shown
in the transition region of Fig. 2 (and Fig.
3 below) is associated with the pro-
grammed shape used in ANSYS to repre-
sent the transition area. Midway through
the transition zone, there is a small hori-
zontal component used to mimic the ac-
tual irregular shape of the weld. The
image pixels tend to exaggerate this fea-
ture, but the actual deviation is very
small.)
Figure 3 shows the stress distribution in
the DMW. Note that high Von Mises
stresses form around the dissimilar mate-
rial interfaces and reach a maximum value
of ~ 240 MPa. As previously described, it
is well known that DMWs fail at the weld
interface between the ferritic and
austenitic alloys. The FE results shown in
Fig. 3 are consistent with these observa-
tions, since the stress is highest at this
location.
Figure 4 shows the stress distribution
obtained when the load is increased to
20,000 N while holding the temperature
fixed at 20C. (Note that the top figure
shows a small amount of stress generated
at no load and 20C. This occurs because
the weld was assumed to be stress free at
0C. Thus, the small stress shown at 20C
is due to CTE mismatch.) Figure 5 shows
the opposite case in which the tempera-
ture is increased to 650C while no load is
applied. The maximum stress is only ~ 33
MPa with the application of just the load.
In contrast, the maximum stress due to
CTE mismatch caused by the increased
temperature is nearly 240 MPa, which is
similar to the effects from the combined
load and temperature increase that was
shown in Fig. 3. This result highlights the
significance of CTE mismatch in produc-
ing high local stresses in DMWs.
The stress concentrations exhibited in
Fig. 4 occur due to changes in mechanical
properties and geometry. Coefficient of
thermal expansion mismatch is not opera-
tive here since the temperature was not
changed. The pertinent mechanical prop-
erties are Youngs modulus (E) and Pois-
sons ratio (v). A homogeneous tube of
uniform cross section (A) loaded by a ten-
sile force (F) will experience a stress (
y
)
in the axial direction (y-direction) given
simply by
y
= F/A
The axial stress will generate an axial
strain (
y
) along the y-direction that is
given by
y
=
y
/E
The elongation along the length of the
joint is not of particular interest for this
application. However, the transverse
strain (
x
) is very important, as two differ-
ent materials will tend to contract differ-
ently. The Poissons ratio (v) defines the
relationship between axial strain and
transverse strain in a given material as
x
= v
y
In this case, the low-alloy steel (AS) has a
Poissons ratio of 0.29 while the stainless
steel (SS) has a Poissons ratio of 0.27. By
combining the previous equations, it is ap-
parent that Poissons ratio and the modu-
lus of elasticity of each material determine
whether they will contract by the same or
different amounts. If
E
AS
/E
SS

AS
/
SS
then the two materials will try to contract
different amounts and stress concentra-
tions occur. Similar to the thermal effects
outlined above, the difference in expan-
sion between the two materials can only be
taken up by each imparting a force on the
other, generating additional stress. These
differences, in combination with changes
in geometry, produce the stresses shown in
Fig. 4.
Figure 6 shows the stress distribution
for several graded transitions with various
numbers of layers in the joint. The total
length of the joint is fixed at 120 mm.
Thus, the individual layer thickness is
given simply by the total joint length (120
mm) divided by the number of layers in the
joint. Note that the maximum stress within
the graded joint decreases as the number
of layers increases. Figure 7 plots the max-
imum Von Mises stress as a function of the
number of layers within the joint. There is
a significant reduction in stress down to
~50 MPa relative to ~ 240 MPa for the
DMW joint exposed to the same condi-
tions (650C, 20,000-N tensile load).
These results are also significant in that
most of the stress reduction occurs when
the number of layers is increased to ~ 30,
with very little improvement observed for
additional layers.
It is possible to provide further reduc-
tions in stress level by locally increasing
the wall thickness in high-stress locations.
This can be done by allowing the width of
each layer to also vary within Optrix,
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Fig. 8 Results from FEA simulation of a fully op-
timized joint. A volume reduction of 50% and stress
reduction of 80% were realized when comparing this
design to a standard dissimilar metal weld joint.
Fig. 9 Results from Thermo-Calc model of T22-Alloy 800-347H graded transition
joint with a linear change in composition at 500C. Notice steep gradient between T22-
Alloy 800, the region of interest.
which effectively represents a local in-
crease in wall thickness. The result of this
optimization is shown in Fig. 8 and further
minimizes the stress to ~ 40 MPa, which is
close to the materially homogenous joint
(Fig. 2) of ~ 36 MPa. Also note that the
high stress levels are distributed through-
out the joint along its length, rather than
confined to small concentrated areas.
Carbon Diffusion Modeling Results
The chemical potential of carbon as a
function of position in the graded joint is
shown in Fig. 9. The results shown are for
a transition joint that is graded between
T22 ferritic steel, Alloy 800, and 347H
stainless steel, with a linear composition
gradient. The chemical potential gradient
controls the rate of carbon migration. By
reducing this gradient, carbon migration
can be reduced, thus minimizing the un-
desirable microstructural changes that
lead to the formation of a creep-suscepti-
ble microstructure. The results demon-
strate that the largest gradient in the
chemical potential is between T22 and
Alloy 800, indicating that the focus should
be on minimizing the gradient in this re-
gion of the joint. Because there is no sig-
nificant gradient between Alloy 800 and
347 (due to the similar Cr contents), this
region is not as significant.
It is known that the Cr content has a
strong effect on the C chemical potential
gradient (Refs. 3, 8, 11, 12, 15). Thus, the
simulation was repeated with a hypotheti-
cal Cr content of 10% in the Alloy 800 in
an attempt to reduce the chemical poten-
tial gradient. As seen in the top curve in
Fig. 9, the gradient between T22 and Alloy
800 is reduced significantly for the lower
Cr composition. For example, the gradient
within the first three mm (where the gra-
dient is the steepest) is reduced by ap-
proximately 50%. A new gradient devel-
ops between the Alloy 800 and 347
stainless steel due to the large differences
in Cr content. However, this should not
pose a problem since this area represents
a transition between two austenitic alloys,
and these alloys are commonly joined
without problems of premature failure.
These results demonstrate that Cr has a
major effect on the C chemical potential
gradient, and controlling the Cr content
could be one possible solution for reduc-
ing carbon migration in DMWs and
graded joints.
The T22/Alloy 800 interface exhibits
the steepest C chemical potential gradient
and is therefore most susceptible to car-
bon migration. This result is consistent
with that observed in practice, where car-
bon diffusion is most rapid across the fer-
ritic/austenitic weld interface, and this is
the region where failure occurs (Refs. 8,
11, 12, 15, 21, 31). Thus, this area was con-
sidered for the kinetic calculations. In
order to determine a baseline for compar-
ison, a simulation was conducted for T22
(left side) to Alloy 800 (right side) with a
linear composition gradient. The operat-
ing temperature of 500C and exposure
times of 2 and 20 years were implemented
as variables to simulate carbon migration
over a distance of 1 mm, which is observed
in traditional DMWs. The results are
shown in Fig. 10, where T22 is on the left
side of the plot and Alloy 800 is on the
right side. Thus, the T22/Alloy 800 inter-
face begins at the 0-mm position. Note
that after 20 years at 500C, the carbon
content of the T22 drops from 0.12 to less
than 0.04 wt-%. In addition, in Fig. 10A
there is a spike in carbon content at ~0.3
mm with the carbon concentration in-
creasing from ~ 0.115 to ~ 0.135 wt-% in
the intermediate section of the weld. This
carbon peak corresponds to a peak in the
M
23
C
6
mol fraction plotted in Fig. 10B.
This trend is consistent with that observed
in practice, where a carbon-
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Fig. 10 Results from DICTRA simulation of a DMW between T22 and Alloy 800 after 0, 2, and 20 years of simulated service at 500C showing the follow-
ing: A How the carbon concentration changes across the weld; B the evolution of M
23
C
6
carbides; C the phase fraction.
A B C
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0.14
0.12
0.1
0.08
0.06
0.04
0.02
0
0.035
0.03
0.025
0.02
0.015
0.01
0.005
0
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1
0 0.2 0.4 0.6 0.8 1
Time = 20 years
Time = 2 years
Time = 0
Time = 0
Time = 2 years
Time = 20 years
Distance (mm)
Distance (mm)
Distance (mm)
M
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M
2
3
C
6
sigma
fcc
bcc
Fig. 11 Results from DICTRA simulations of T22-Alloy 800 graded joint at 500C: A Plot of the
carbon concentration profile at 0 and 20 years for a 5-mm joint; B plot of the carbon concentration
profile at 0 and 20 years for a 25-mm joint.
A
B
B
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Distance (mm)
Distance (mm)
0 1 2 3 4 5
0 5 10 15 20 25
0.14
0.13
0.12
0.11
0.1
0.09
0.08
0.14
0.13
0.12
0.11
0.1
0.09
0.08
Time = 0
Time = 0 Time = 2 years
Time = 20 years
Time = 20 years
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0 5 10 15 20 25
0 20 40 60 80 100
0.14
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0.1
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0.08
0.14
0.13
0.12
0.11
0.1
0.09
0.08
Time = 0
Time = 0
Time = 0
Time = 2 years
Time = 20 years
Time = 20 years
Distance (mm)
Distance (mm)
A
depleted region forms along the weld in-
terface in the ferritic material and a car-
bon-enriched band of carbides forms
along the weld interface in the austenitic
material (Refs. 9, 10, 21, 31). The plot in
Fig. 10C shows the relative amounts of
bcc, fcc, and sigma phases across the weld.
As expected, the T22 composition on the
left end is almost 100% bcc. The fcc phase
starts to form at a distance of ~0.25 mm
and increases until ~0.7 mm, at which
point sigma phase starts to form, leading
to a final 0.90 fcc + 0.10 sigma mi-
crostructure in the Alloy 800 on the right
side of the joint. The phase fraction and
carbide plots are representative of those
observed for all of the graded joint simu-
lations as well.
Figure 11 shows the C concentration
profile for a transition joint that is graded
between T22 ferritic steel and Alloy 800.
Figure 11A shows results for a 5-mm joint
length in which there is carbon migration
at 500C after 20 years. The C content de-
creases from 0.12 to less than 0.09 wt-% in
the T22 material. Most importantly, Fig.
11B shows that increasing the joint length
to 25 mm significantly minimizes carbon
migration. This is attributed to the re-
duced carbon chemical potential that oc-
curs with the larger grade length.
As the temperature increases, a corre-
sponding increase in carbon diffusion
should be observed. This is demonstrated
in Fig. 12A where a 25-mm grade length is
no longer sufficient to prevent carbon mi-
gration when the temperature is increased
to 550C. As shown in Fig. 12B, the joint
length must be increased to 100 mm to re-
duce carbon migration. Results for simu-
lations conducted at 600 and 650C (Figs.
13, 14) exhibit similar trends, where the re-
quired joint length to minimize carbon mi-
gration increases to a total length of 200
mm for 600C and 500 mm at 650C. For
joints of at least 500 mm, no carbon-de-
pleted zone forms, and the carbon-
enriched region is smaller and is enriched
to a lower overall composition. Addition-
ally, the fraction of sigma phase present on
the Alloy 800 side of the joints continues
to decrease from 0.1 down to ~0.01 with
increasing temperature.
The kinetic results are summarized in
Fig. 15, where the transition length required
to reduce carbon migration to less than 10%
for a given temperature is shown. Many
joints made between ferritic steels and
austenitic alloys are made with an operating
temperature of ~ 500C, which is set by the
safe operating temperature for the ferritic
steel. For this temperature, a joint length of
~100 mm significantly reduces the carbon
migration problem.
Conclusions
Model calculations have been pre-
sented for designing and optimizing func-
tionally graded transition joints based on
minimization of mechanical stresses and
carbon diffusion. The following conclu-
sions can be drawn from the results:
1. Localized stresses as high as ~240
MPa are expected in conventional DMWs
at 650C when a nominal tensile stress of
~32 MPa is applied. The high local stress
is due primarily to CTE mismatch be-
tween the ferritic and austenitic alloys;
mechanical property mismatch between
the two alloys plays a much smaller role.
2. Similar FE model results from
graded joints demonstrate that these local
stresses can be reduced significantly to
~50 MPa for a 120-mm grade length that
consists of at least 30 layers within the
transition zone, and further stress reduc-
tion down to ~40 MPa is possible by in-
creasing the wall thickness of the transi-
tion joint in high-stress locations.
3. Thermo-calc models show that the
carbon chemical potential gradient is
steepest between the T22 and Alloy 800
materials, providing the greatest driving
force for carbon migration in this region.
Chromium was shown to play a crucial
role in the chemical potential gradient,
which ultimately controls the carbon
diffusion.
4. For a 650C operating temperature,
a 500-mm transition joint was shown to re-
duce carbon migration to less than 10%
after 20 years of simulated service. For a
reduced temperature of 500C, the transi-
tion joint length can be reduced to 100 mm
with the same effect.
Acknowledgments
The authors gratefully acknowledge fi-
nancial support through National Science
Foundation Grant No. CMMI-0758622,
PPL Corp., Contract 00474836, and the
Pennsylvania Infrastructure Technology
Alliance. Useful technical discussions with
Ruben Choug and Robert Schneider of
PPL Corp. are also gratefully appreciated.
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Fig. 15 Plot showing the length of graded joint
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20 years of simulated service for temperatures be-
tween 500 and 650C.
A
A
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Call for Papers
You are invited to submit papers for the 17th JOM International Conference on the Joining
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Machine Safeguarding Seminars. Rockford Systems, Inc.; (800)
922-7533; visit www.rockfordsystems.com.
Machining and Grinding Courses. TechSolve, www.TechSolve.org.
NACE Intl Training and Certification Courses. National Assoc.
of Corrosion Engineers; (281) 228-6223; www.nace.org.
NDE and CWI/CWE Courses and Exams. Allentown, Pa., and
customers locations. Welder Training and Testing Institute, (800)
223-9884; www.wtti.edu.
NDT Courses and Exams. Brea, Calif., and customers locations.
Level I and II and refresher courses in PA, UT, MP, radiation
safety, radiography, visual, etc. Test NDT, LLC; www.testndt.com;
(714) 255-1500.
COMING EVENTS
When critical welding conditions necessitate
performance without compromise, you can depend
on Arcos to provide you with a comprehensive line
of premium quality high alloy, stainless and nickel
electrodes to conform to your stringent requirements.
You can be assured of our commitment to superior
welding products because Arcos quality meets or
exceeds demanding military and nuclear application
specications. Arcos dedication to excellence has
earned these prestigious certications:
- ASME Nuclear Certicate # QSC448
- ISO 9001: Certied
- Mil-I 45208A Inspection
- Navy QPL
We Can Meet Yours, Too!
To learn more about the many reasons you should
insist on Arcos high alloy, stainless and nickel
electrodes for your essential welding applications,
call us today at 800-233-8460 or visit our website
at www.arcos.us.
Arcos Industries, LLC
39- Arcos lrivc - \t C+rmcl, lA 17S1
lnonc (70) 339-200 - l+x (70) 339-20o
Arcos Electrodes
Meet Exacting Military
and Nuclear Standards.
AR11-96 The Lincoln Electric Co. All Rights Reserved. www.||nco|ne|ectr|c.com/safety
Welding products and solutions that meet the
most demanding requirements Yours.

AWS Welding Journal September 2012

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AWS Welding Journal September 2012

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

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