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March 2013_Layout 1 2/14/13 4:00 PM Page 3

CONTENTS
32

March 2013 Volume 92 Number 3

AWS Web site www.aws.org

Features

Departments

32

Repair of a Hull 15 m below the Waterline

Follow the repair procedure through all its stages from
accident to finish
U. Aschemeier and K. Peters

40

Minimizing Risk in Offshore Submerged Arc Welding

The influences of welding procedures and practices on
avoiding the risks of hydrogen buildup are explained
B. Schaeffer and T. Melfi

Editorial ............................4
Press Time News ..................6
News of the Industry ..............8
International Update ............12
Stainless Q&A ....................14
Letters to the Editor ............20
RWMA Q&A ......................22
Technology........................24
Product & Print Spotlight ......28
Coming Events....................44
Certification Schedule ..........50
Society News ....................53
Tech Topics ......................55
Errata: D9.1M/D9.1:2012, Sheet
Metal Welding Code
Guide to AWS Services ......66
Conferences ......................70
Personnel ........................72
The American Welder
Learning Track ..................94
Fact Sheet ......................98
Classifieds ......................100
Advertiser Index ................101

The American Welder

76

76

How to Become a Commercial Diver and Weld Underwater

Take a look at the profession and its demands and decide
whether it is for you
T. M. Brown

80

Family Business Shines in Sunny Florida

See the growth of a company from a small fabricating shop to
a major player in the South Florida construction industry
M. R. Johnsen

88

Navigating Welding Standards

Help is on the way to sort out the confusion that codes and
standards sometimes cause
M. J. Skinkle

92

Welding Students Bring Steel Sculptures Roaring to Life

Artistic expression and welding skills go together at the
Robert Morgan Educational Center
K. Campbell

Welding Research Supplement

57-s

88

Transient Liquid Phase Diffusion Brazing of Stainless

Steel 304
A copper interlayer was used in brazing austenitic stainless
steel to address the concerns of brittle intermetallic compound
formation
M. Mazar Atabaki et al.

64-s

Porosity, Element Loss, and Strength Model on

Softening Behavior of Hybrid Laser Arc Welded
Al-Zn-Mg-Cu Alloy with Synchrotron Radiation Analysis
A new model was developed after analyzing weld softening
produced with a hybrid welding system on age-hardened alloys
S. C. Wu et al.

72-s

Fabrication and Characterization of Graded Transition

Joints for Welding Dissimilar Alloys
A dual-wire gas tungsten arc welding system was used in this
experiment in joining ferritic low-alloy steels to austenitic alloys
G. J. Brentrup and J. N. DuPont

80-s

Effect of Postweld Heat Treatment on the Toughness of

Heat-Affected Zone for Grade 91 Steel
Recommendations are offered on procedures to improve heataffected zone toughness in Grade 91 ferritic steels
B. Silwal et al.

Welding Journal (ISSN 0043-2296) is published

monthly by the American Welding Society for
$120.00 per year in the United States and possessions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and
$10.00 per single issue for nonmembers and
$14.00 single issue for international. American
Welding Society is located at 8669 Doral Blvd., Ste.
130, Doral, FL 33166; telephone (305) 443-9353.
Periodicals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address
changes to Welding Journal, 8669 Doral Blvd.,
Suite 130, 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 articles, provided customary acknowledgment of
authors and sources is made. Starred (*) items
excluded from copyright.

On the cover: A diver removes metal from the hull of a tanker that was damaged while taking on cargo at a loading facility in Venezuela. (Photo courtesy
of Uwe Aschemeier.)

WELDING JOURNAL

Editorial March 2013_Layout 1 2/14/13 4:24 PM Page 4

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

Focusing on Students
Over the past year or so, there has been one overriding theme in the financial sections
of the media the world has a very large shortage of skilled workers to fill immediate
job needs, and this condition is expected to get worse before enough people are trained
to meet the demand. The experts also agree that the lack of skilled workers is having a
direct impact on the economic recovery.
The American Welding Society is working diligently on efforts to develop the skilled
personnel needed to fill the openings in the numerous occupations involved in the fields
of welding and materials joining. A prime example of this activity is the work of the AWS
Foundation through its various scholarship programs. Providing funds to enable men
and women to attend schools and training facilities so they may develop new skills and
enter the workforce is an essential function of the Foundation, and these programs have
aided hundreds of people who are now employed in the welding industry.
Other segments of AWS are also playing a role in this workforce development activity. The Membership Committee is working to better define the membership benefits
that are attractive to students and that will lead to their participation in Society activities
as well as enhance their skills and knowledge to better enable their entry into the workforce. To this end, AWS held two student focus group meetings this past fall. A focus
group meeting is an event for which a limited number of people with expected common
interests are invited and asked to freely share their thoughts in a safe environment. Just
as the field of welding is extremely broad, so too are the interests of our student members. Recognizing that students learning the skills required to enter the workforce as a
welder may require different benefits than those seeking an engineering career, AWS
held a focus group for each of these interests.
As expected, the needs of each student group were different, but they had much in
common. The number one benefit each group requested was job related. The details
built into the recommendations were different, but it is apparent that both groups are
focused on their careers and employment opportunities.
Examples of the recommendations included the following:
Assistance with rsum writing
Assistance with the interview process
A request for potential employers to better define the skill set they need for a welder
rather than just the generic welder wanted
Opportunities for summer intern work
Sending student-specific information through social media that can be accessed from
smart phones and tablets
Provide examples of how to tips for real-world applications.
The Membership Committee has received the information from the focus groups and
is planning to incorporate as many recommendations as possible into new member benefits. Also, the committee is discussing having one or more focus group meetings in 2013
to collect additional thoughts regarding other benefit needs or concerns.
One of the committees objectives this year is to establish a minimum of two new
member benefits that, while possibly of interest to others, are specifically aligned with
the recommendations of our student membership.
We truly appreciate the input from the students who attended the focus meetings.
The meetings were held afterhours and this did
impose some scheduling challenges. I also invite everyone who has suggestions or recommendations for new
benefits that would impact our students to e-mail them
to AWS at rhenda@aws.org or cburrell@aws.org. The
Membership Committee will be pleased to accept and
consider your thoughts.

Officers
President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Well-Dean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society

Directors
T. Anderson (At Large), ITW Global Welding Tech. Center
U. Aschemeier (Dist. 7), Miami Diver
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
R. E. Brenner (Dist. 10), CnD Industries, Inc.
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1)
D. A. Flood (At Large), Tri Tool, Inc.
S. A. Harris (Dist. 4), Altech Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (Dist. 17), The Harris Product Group
W. A. Komlos (Dist. 20), ArcTech, LLC
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Engineering
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), Desert Rose H.S. and Career Center
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
J. A. Willard (Dist. 13), Kankakee Community College
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.

Lee G. Kvidahl
AWS Past President and Chair, Membership Committee

MARCH 2013

victor_FP_TEMP 2/11/13 2:14 PM Page 5

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PTN March 2013_Layout 1 2/14/13 4:15 PM Page 6

PRESS TIME
NEWS
Robotics Market Sets New Sales Records
The North American robotics market has recorded its strongest year ever in 2012,
according to new statistics from Robotic Industries Association (RIA), Ann Arbor, Mich.
A total of 22,598 robots valued at $1.48 billion were sold to companies in North America last year, beating the previous record of 19,337 robots sold in 2011. When sales by
North American robot suppliers to companies outside North America are included, the
totals are 25,557 robots valued at $1.66 billion.
Compared to 2011, North American orders were up 17% in units and 27% in dollars. Sales were up in metalworking industries. Also, increases were seen in assembly,
spot welding, arc welding, coating and dispensing, and material handling.
The fourth quarter of 2012 was the strongest quarter ever recorded by RIA in terms
of units ordered, with 6235 robots sold to North American companies.
It is promising to see such positive growth in robotics despite the tumultuous manufacturing environment throughout 2012, said Jeff Burnstein, RIA president.

Van-Rob Plans to Create 530 Jobs in Michigan

Van-Rob, Inc., through its Michigan subsidiaries including Lenawee Stamping Corp.,
a producer of metal stamping, welded fabrications, and autobody assemblies, is considering adding programs at its facility in the city of Tecumseh and a new facility in Michigan. The company plans to invest $30.7 million and create 530 jobs, resulting in a $5.3
million Michigan Business Development Program performance-based grant.
Governor Rick Snyder recently announced the Michigan Strategic Funds approval
of state incentives to support 14 business expansions expected to generate more than
$1.1 billion in investments and add 4590 jobs in Michigan.

AWS President Nancy Cole Receives STEP Award

Nancy Cole, 2013 president of the American Welding
Society (AWS), has been selected as an honoree for the inaugural Women in Science, Technology, Engineering and
Production (STEP) Award from The Manufacturing Institute, in partnership with Deloitte, University of Phoenix,
and the Society of Manufacturing Engineers.
The award celebrates womens achievements at all levels of manufacturing and was launched to honor industry
women through leadership, research, and recognition.
On February 5, the honorees were recognized at an event
in Washington, D.C. The keynote speaker, Karen Gilgenbach of Airgas USA, is an AWS Certified Welding Inspector and a past chair of the AWS Milwaukee Section.
Nancy Cole
Not only am I honored to receive a STEP Award, but I
am so grateful to The Manufacturing Institute and its partners for recognizing the role that women play in this industry, said Cole. As the industry continues to grow and advance, it is more important than ever to attract and retain
women in manufacturing.
Cole, the first female to graduate with a degree in metallurgical engineering from
the University of Tennessee, began her career at Oak Ridge National Laboratory. Currently, she runs her own welding engineering consulting firm in Fernandina Beach, Fla.

Weld-Ed Reveals Professional Development Workshops

The National Center for Welding Education and Training (Weld-Ed), located at Lorain County Community College, Elyria, Ohio, recently announced its 2013 professional
development workshop series. Welding educators are offered a broad selection of affordable, interactive training conducted throughout the summer at teaching facilities
around the United States, including Hawaii and Alaska.
The five modules encompass welding metallurgy; joining and cutting processes; design, assembly, and robotic welding; weld quality and inspection; welding codes, specifications, and safety; and laser welding.
For descriptions, locations, and registration details, visit www.bit.ly/WeldEd2013.

Publisher Andrew Cullison

Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
Associate Editor Howard M. Woodward
Associate Editor Kristin Campbell
Editorial Asst./Peer Review Coordinator Melissa Gomez
Publisher Emeritus Jeff Weber
Design and Production
Production Manager Zaida Chavez
Senior Production Coordinator Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
National Sales Director Rob Saltzstein
Advertising Sales Representative Lea Paneca
Advertising Sales Representative Sandra Jorgensen
Senior Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Tabetha Moore
tmoore@aws.org
American Welding Society
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
American Welding Society
D. Brown, Weiler Brush
T. Coco, Victor Technologies International
L. Davis, ORS Nasco
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. F. Saenger Jr., Consultant
S. Smith, Weld-Aid Products
D. Wilson, Well-Dean Enterprises
N. C. Cole, Ex Off., NCC Engineering
J. N. DuPont, Ex Off., Lehigh University
L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems
D. J. Landon, Ex Off., Vermeer Mfg.
S. P. Moran, Ex Off., Weir American Hydro
E. Norman, Ex Off., Southwest Area Career Center
R. G. Pali, Ex Off., J. P. Nissen Co.
N. Scotchmer, Ex Off., Huys Industries
R. W. Shook, Ex Off., American Welding Society
Copyright 2013 by American Welding Society in both printed and electronic formats. The Society is not responsible for any statement made or
opinion expressed herein. Data and information developed by the authors
of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the
part of potential users.

MEMBER

MARCH 2013

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NI March 2013_Layout 1 2/13/13 2:51 PM Page 8

NEWS OF THE
INDUSTRY

AWS Accredited Test Facility to Launch at Great Falls College

Jim and Debbie Filipowicz of Steel Etc.,
Great Falls, Mont., a steel/recycling business providing support services for welding and construction companies statewide,
recently donated $20,000 to Great Falls
College Montana State University (GFC
MSU) for supporting the expanding needs
of its welding program. The contribution
will be used to establish an American Welding Society (AWS) Accredited Test Facility
(ATF).
It is rewarding to witness the impact
your donation makes, said Debbie Filipowicz, who played a role in the GFC
MSU deans advisory council she was appointed to last year by former Gov. Brian
Schweitzer.
Great Falls College Montana State University started the application process to
become an AWS ATF last December. Following a satisfactory review of the colleges
application, an on-site audit will be conducted. It is anticipated the process will be
complete by May. Once accredited, students and the public can take AWS certification tests there.

Not only is Great Falls College increasing the

capacity of its welding program to satisfy
workforce needs in north-central Montana,
but it is also in the process of becoming an
AWS Accredited Test Facility.

T. J. Snow Adds Second Airplane for

On-Call Resistance Welding Service
To facilitate response time for in-plant service calls, T. J. Snow
Co., Chattanooga, Tenn., a resistance welding equipment

provider, recently added a second single-engine airplane to its

transportation fleet to service locations throughout the eastern
two-thirds of the United States. The company has five pilots
among its 75-person staff.
Many of its customers supply welded sheet metal parts to automobile manufacturing plants on a just-in-time basis, so both
are on call to quickly transport service technicians, specialized
troubleshooting instruments, and spare parts during emergency
breakdowns. Two of the service technicians are instrument-rated
private pilots as well, so they can fly themselves as needed.

Tulsa Welding School Starts Shipfitting

and Steel Fabrication Program

T. J. Snow flies a Mooney Ovation and Beechcraft Bonanza. From

left are pilots Ray Michelena, service technician; Tom Snow, chief
executive officer; James Dillard, vice president, engineering; and
Randy Darby, service technician.
8

MARCH 2013

Tulsa Welding Schools location in Jacksonville, Fla., is offering a new shipfitting and steel fabrication program. Students will
learn welding, structural drawings, layout, and fitup skills that
could lead to careers building military, commercial, and fishing
vessels. The program also prepares graduates for entry-level positions as a fabricator, layout mechanic, quality technician, sheet
metal fabricator, shipfitter, and steel fabricator.

NI March 2013_Layout 1 2/13/13 2:52 PM Page 9

We are excited to expand our career training to include the

nine-month shipfitting and steel fabrication program to our list
of training offerings. This is a program that has both local and
national career opportunities, said Dr. Jim Vernon, campus
president.
For more information, visit www.weldingschool.com.

National Network for Manufacturing

Innovations Initial Design Plans Revealed

The Jacksonville, Fla., location of Tulsa Welding School has a new

shipfitting and steel fabrication program for its students.

The Obama Administrations National Science and Technology Council (NSTC) recently released National Network for Manufacturing Innovation: A Preliminary Design (http://manufacturing.gov/docs/NNMI_prelim_design.pdf) based on the input of
nearly 900 stakeholders. Developed by the NSTCs Advanced
Manufacturing National Program Office, it was previewed at a
Huntsville, Ala., workshop.
Also, the report proposes the Institutes of Manufacturing Innovation preliminary activities include applied research, development, and demonstration projects that reduce the cost and risk
of developing and implementing new technologies in advanced
manufacturing; education and training at all levels; development
of methods and practices for increasing the capabilities and capacity for supply chain expansion and integration; engagement
with small- and medium-sized manufacturing enterprises as well
as large original equipment manufacturers; and access to shared
facility infrastructure with the goal of scaling up production from
lab demos and making technologies ready for manufacture.

For info go to www.aws.org/ad-index

WELDING JOURNAL

NI March 2013_Layout 1 2/13/13 2:52 PM Page 10

Mechanized Plate Edge-Preparation Tool

to Reduce Navy Shipbuilding Costs
To improve the plate edge-preparation process because
during ship fabrication, rust and primer must be removed from
the weld joint areas of steel plates prior to welding the Navy
Metalworking Center, Johnstown, Pa., has developed a mechanized tool to increase production rates.
The project identified and developed prototype concepts for
abrasive tools. Test results demonstrated two abrasive configurations disc and drum can be used effectively.
General Dynamics Bath Iron Works tested the prototype tools
on sample and production plates. It processed at least 1500 ft of
plate edges on DDG 51 Class hulls.
The team estimates a 230% increase in production rate is possible with the potential of saving as much as $6 million on the
cost of a modern surface combatant. In addition, it estimates savings of approaching $10 million may be possible across several
hulls in various stages of completion.

U.S. Armys Blackhorse Regiment Installs

Jet Edge Waterjet System
The U.S. Armys 11th Armored Calvary Regiment installed a
Jet Edge waterjet cutting system at its home base in Fort Irwin,
Calif. The Mid Rail Gantry waterjet system is operated by the
Service & Recovery Section, a support section within the Regiments Maintenance Troop, Regimental Support Squadron. The

SPC Roberts and PFC Adams program and build a part with
SigmaNEST software. (Photo courtesy of the U. S. Army 11th
Armored Calvary Regiment.)
20-soldier section machines and welds fabricated parts as well as
provides recovery support to the regiment.
We decided to purchase this equipment specifically to assist
in expediting our work requests, said Chief Warrant Officer Two
Alphonso L. Ash Jr. He added the decision to incorporate this
waterjet into shop operations was based solely on daily workload.
It has also helped to expedite work requests and allows the section to fabricate parts with a long shipping date and/or high cost.
Within the first month of installation, many parts were built,

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MARCH 2013