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I N F A C T, W E’R E I N V E N T I N G I T R I G H T N O W

Some say welding

is a static industry –
that there’s nothing to
learn about joining metal
with metal. But at Lincoln
Electric, we think there will
always be new ways to improve
productivity. That’s why we spend
more on research and development
than any other company in welding.
Our view is long range: we plan to
stay No. 1 in arc welding and cutting.
And we’ll keep inventing the new tech-
nologies that drive your business forward.
• Over 400 Exhibitors
• Sneak Preview of What's New and Hot at the 2004 Exposition
• 34th International Brazing and Soldering Symposium
• Automatic Welding Conference:
Getting the Most Out of Your Automatic Welding Investment
• Professional Program: Peer-Reviewed Papers
• $2,500 First Prize for Best Welder in the
First AWS Professional Welders Competition
• World-Class Bookstore with Thousands of Titles
• Robotic Arc Welding Course
• AWS D1.1/D1.1M:2004 Courses
• Essentials of Steel Weldment Design Short Course
• Advanced Commercial Development Session
• Brazing and Soldering
• Gas Suppliers
• GAWDA Single-Day Pavilion
• Job Shop Interests
• Laser Welding and Cutting
• Nondestructive Examination
• Resistance Welding
• Computer Security
• Interview with Authority on Weld Design
• Trans-Alaska Pipeline
• Valdez Marine Terminal
• World Trade Center Tragedy
A Quick Guide to the AWS Welding Show 2004
Age restriction on Exposition floor . . . . . . . . . . . . . . . . . Page 6 Fuel cells – Advanced commercial development session . . Page 31
Aluminum welding – Professional Program . . . . . . . . . Page 18 Gas metal arc welding – Professional Program . . . Pages 18, 19
Arc welding and power sources – Seminar . . . . . . . . . Page 27 Guests – Registration . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Army exhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11 Hotels
Automatic Welding Conference . . . . . . . . . . . . . . . . . . Page 28 Location map . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 35
Awards ceremony and luncheon . . . . . . . . . . . . . . . . . Page 10 Reservation form . . . . . . . . . . . . . . . . . . . . . . . . Page 32
Brazing and soldering – 34th International Symposium . . Page 22 Reservations information . . . . . . . . . . . . . . . . . . . . Page 7
Competitive events Laser beam welding – Professional Program . . . . Pages 19, 20
Poster Session . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11 Lectures
Professional Welders Competition . . . . . . . . . . . . Page 11 Comfort A. Adams (free) . . . . . . . . . . . . . . . . . . . Page 10
Continuing education – Conferences and Seminars . . . Page 26 Plummer Memorial Education (free) . . . . . . . Pages 10, 25
D1.1/D1.1M:2004, Structural Welding Code—Steel Materials – Professional Program . . . . . . . . . . . . . . . . Page 18
Seminars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 27 Navy research – Professional Program . . . . . . . . . . . . Page 20
Days and hours (Convention and Exposition) . . . . . . . . . Page 6 Planning for cost-effective welding – Seminar . . . . . . . Page 27
Design Professional Program – By day and session . . . . . . . . . Page 18
Steel weldment design (free) . . . . . . . . . . . . Pages 24, 26 Quality management – Seminar . . . . . . . . . . . . . . . . . Page 28
Introduction to Design of Weldments seminar . . . . Page 31 Reception – AWS Officers’ . . . . . . . . . . . . . . . . . . . . . Page 10
Education Program Registration
Education sessions . . . . . . . . . . . . . . . . . . . . . . . Page 25 By mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 33, 34
Plant tours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26 On-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 33, 34
Plummer Memorial Education Lecture (free) . . . Pages 10, 25 On-site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Student Day (College Careers in Welding) . . . . . . . Page 26 Seminar registration form . . . . . . . . . . . . . . . . . . Page 33
Electron beam welding – Professional Program . . . . . . Page 20 Student . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Exhibitors VIP Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 34
Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12 Robotic arc welding – Seminar . . . . . . . . . . . . . . . . . . Page 30
What’s New and Hot . . . . . . . . . . . . . . . . . . . . . . Page 15 Solid-state joining – Professional Program . . . . . . . . . . Page 20
Exposition Stainless steel welding – Seminar . . . . . . . . . . . . . . . . Page 31
Days and hours . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6 Travel
Opening ceremony . . . . . . . . . . . . . . . . . . . . . . . Page 10 Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
VIP Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 34 Car rental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
FCAW/SMAW – Professional Program . . . . . . . . . . . . . Page 18 Local in Chicago . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
Forensics and weld performance – Professional Program . . Page 18 Week at a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
Foundation Weldability – Professional Program . . . . . . . . . . . . . . . Page 19
Recognition luncheon . . . . . . . . . . . . . . . . . . . . . Page 10 Welding procedure specifications – Seminar . . . . . . . . Page 30
Silent auction . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
Free sessions
Advanced commercial development session . . . . . Page 31
College Careers in Welding . . . . . . . . . . . . . . . . . Page 26
Comfort A. Adams Lecture . . . . . . . . . . . . . . . . . . Page 10
Computer Procedures, Policies, and Security . . . . Page 25
Education Program . . . . . . . . . . . . . . . . . . . . . . . Page 25
Field construction/repair . . . . . . . . . . . . . . . . . . . Page 24
Hydrocarbon Vapor Collection at
Valdez Marine Terminal . . . . . . . . . . . . . . . . . . . Page 25
Interview with Dr. Omer Blodgett . . . . . . . . . Pages 24, 26
Maintenance Welding on the
Trans-Alaska Pipeline . . . . . . . . . . . . . . . . . . . . Page 24
Manufacturability of fuel cell products . . . . . . . . . Page 31
Plummer Memorial Education Lecture . . . . . . Pages 10, 25
World Trade Center tragedy . . . . . . . . . . . . . . . . . Page 24

About Membership AWS Foundation
AWS serves nearly 50,000 individual members and Established in 1989 to support research and education
1,100 corporate members worldwide. Individual members in welding and related technologies, the AWS Foundation
comprise engineers, scientists, educators, researchers, is committed to awarding more than $300,000 annually
welders, inspectors, welding supervisors, company execu- in undergraduate scholarships and graduate research
tives and officers, and sales associates. Corporate members fellowships. In addition, the Foundation hosts other
include welding manufacturers, independent welding shops, programs, such as the Engineering Your Future instruc-
distributorships, end users, and educational institutions. tors’ guide, a student loan program, and career promo-
tional videos such as the award-winning Welding:
Member interests include automatic, semiautomatic,
So Hot, It’s Cool (downloadable from
and manual welding; brazing and soldering; cutting;
ceramics; lamination; robotics; lasers; and welding
AWS Certification
inspection, safety, and health.
AWS maintains the National Registry of all certified or
AWS Magazines accredited professionals and entities related to weld-
ing. The testing facilities used to conduct the qualifi-
The Welding Journal – a major monthly magazine specifi-
cation procedures are AWS accredited, and AWS also
cally serving the welding, brazing, soldering, allied joining
develops customized welder qualification programs
and cutting, and manufacturing industries – is mailed to all
for other organizations, including private companies.
AWS members. The publication includes authoritative arti-
cles that can help your business and professional develop- The AWS Certified Welding Inspector (CWI) program
ment, as well as news, "how-to" stories, research reports, has been in effect since 1979. To date, over 47,000
advertisements, and much more. Winner of more than 65 people have been certified. CWIs help ensure the
editorial and design awards. highest quality of welding.
In addition, Inspection Trends – the magazine for In 1989, the AWS Certified Welder Program was launched
materials inspection and testing personnel – is mailed to to certify the qualifications of welders nationwide.
individuals and facilities certified by AWS, including all Welding instructors can earn an important credential
Certified Welding Inspectors. through the AWS Certified Welding Educator program,
established in 1991.
Technical Publications AWS offers a nationally and internationally recognized
AWS offers over 300 books, charts, CDs, replicas, and portable certification for nondestructive testing profes-
proceedings, as well as software. In addition, AWS has sionals. Other AWS programs include the Senior Certified
developed more than 200 codes, recommended practices, Welding Inspector and Certified Welding Engineer.
and guides, produced under strict American National New certification programs in development are the Certifi-
Standards Institute (ANSI) procedures. They include one of cation for Radiographic Interpreters, Certification of Robotic
the most consulted codes in the world, AWS D1.1/D1.1M, Process Operators and Technicians, Certified Welding
Structural Welding Code—Steel. We publish a free Supervisors, and Certified Steel Structure Inspector.
annual 40-page, full-color catalog. You can download
this catalog from the AWS Welding Store Online at Also visit the AWS
Book Store, managed by Global Engineering Documents,
at the 2004 AWS Welding Show. Members receive a
25 percent discount on publications produced by AWS.

Education Programs
AWS education programs include international,
national, and local conferences; seminars; individual cor-
porate programs; and study guides. Subjects range from
the basics to the most recent advances in technology. AWS
offers the award-winning S.E.N.S.E. (Schools Excelling
through National Skills Education) program to all qualified
U.S. welding educational groups.
Compete Through Smarter Welding 5
McCormick Place Air Travel
The 2004 AWS Welding Show, International Exposition Special Air-Fare Savings
and Annual Convention will be at McCormick Place The American Welding Society has appointed One-Stop
Lakeside Center, 2301 South Lake Shore Drive, Chicago, Chicago/ITS as the official air-travel coordinator for the
Illinois 60616. McCormick Place is 23 miles from O'Hare 2004 Welding Show. Save time and money when you book
International Airport and 10 miles from Midway Airport. your air travel on-line.
For further information, contact McCormick Place at
One-Stop Chicago provides attendees with airline reservations
312-791-7000, fax 312-791-6543,
at the lowest available published fare and best journey
time. The service fee per ticket issued is $20, or $15 if you
Exposition Hours book on-line. Go to and click on Travel.
Call One-Stop Chicago toll-free at 1-800-621-1083. Outside
Tuesday, April 6 9 AM–5 PM the USA and Canada, call 847-940-1176 Monday through
Wednesday, April 7 9 AM–5 PM Friday, 8 AM to 5 PM (Central Time).
Thursday, April 8 9 AM–3 PM Fly on the official airlines – American, Delta, and ATA –
and save!
Registration Hours American offers 10 percent off the lowest applicable
On-site registration at McCormick Place: published fare when you book and ticket 30 days or more
before travel. Save five percent when you book within 29
Monday, April 5 8 AM–5 PM
days of travel. Or take advantage of American’s zone fares
Tuesday, April 6 8 AM–5 PM for savings on midweek travel to the meeting. Two-day
Wednesday, April 7 8 AM–5 PM minimum stay; no Saturday-night stay required. Zone
fares are fully refundable, less service fee. Discounts are
Thursday, April 8 8 AM–2 PM based on round-trip applicable published fares. Applicable
restrictions must be met.
Spouse/Guest Registration
Delta offers 10 percent off the lowest applicable published
All spouses and guests accompanying Exposition or
fare when you book and ticket 60 days or more before
Convention attendees must register and receive a badge to
travel. Save five percent when you book within 59 days
visit the exhibit area.
of travel. Booking classes A, D, I, U, and T are not eligible
for the meeting discount. Or take advantage of Delta’s
Student Registration
zone fares for savings on midweek travel to the meeting.
AWS offers complimentary registration to the Welding Two-day minimum stay; no Saturday-night stay required.
Show for student groups accompanied by their instructor. Zone fares are fully refundable, less service fee. Discounts
Student Day at the 2004 AWS Welding Show is Thursday, are based on round-trip applicable published fares.
April 8. Instructors are encouraged to register their groups Applicable restrictions must be met.
before March 12, 2004. For Advance Student Registration
ATA flies into Midway Airport and offers a 10 percent discount
Forms, please call 800-443-9353, ext. 256.
off its published fares. Valid travel dates are April 5 through 9,
2004. Blackout dates are April 3, 4, 10, and 11, 2004.
Exposition Visitor
Age Requirements To call the official airlines directly:
Age requirements for Exposition visitors: Persons under 16 American Airlines: 800-433-1790,
years of age are not allowed on the show floor at any time; Reference file number: A9444AE
those 16 to 18 years of age must be accompanied by an Delta Air Lines: 800-241-6760,
adult at all times. Although extensive safety measures have Reference file number: 199821A
been taken to protect visitors, these precautions are aimed ATA: 877-726-0815. Tell the reservations agent you are
at individuals who have attained a certain age and height. with the AWSWES group and refer to convention code
Please help us safeguard your youngsters by observing 040608 and ticket designator code AWSWES.
this rule.

Advance registration—See pages 33 and 34.

Airport Transportation Hotel Information
Chicago O’Hare International Airport Hotel rooms for the 2004 AWS Welding Show, International
Taxis – Available curbside on the lower level of each Exposition and Annual Convention are available to attendees
terminal. A ride from O’Hare to downtown Chicago costs at discounted rates. Make your reservation through the
about $38 and takes about 30 minutes, depending on traffic. AWS Welding Show Housing Bureau by March 5, 2004,
to ensure negotiated rates.
Passenger Vans – Continental’s Airport Express ticket
counters are across from baggage claim areas. A van ride To reserve hotel rooms, please go to our Web site at
from O’Hare to downtown Chicago costs $21 per person or complete the hotel reservation form
one way, $39 round trip. Telephone: 773-247-1200. and send it to AWS Welding Show/ONE-STOP CHICAGO/ITS.
Sending the housing form to AWS headquarters will
Chicago Transit Authority (CTA) – Trains take 40 minutes
delay your hotel reservation.
between O’Hare and downtown, and cost $1.50. Trains
The telephone numbers are:
leave from inside the terminal on the lower level every 10
800-424-5248 (toll free, U.S./Canada) or
minutes during day and evening hours.
847-940-2152 (outside U.S./Canada).
Telephone: 312-836-7000.
FAX 800-521-6017 (toll free, U.S./Canada) or
Midway Airport 847-940-2386 (outside U.S./Canada).
Midway Airport has three terminals, A, B, and C.
All vehicle pick-up services are in the main lobby at the Getting To McCormick Place
center entrance of the airport. Complimentary shuttle bus service will be provided April 5
Taxis – Available in front of the main terminal. A ride from through April 8 from all official hotels to McCormick Place.
Midway Airport to downtown Chicago costs $20 to $25 and Hours of operation will be posted in each hotel lobby.
takes 20 to 30 minutes, depending on traffic. Alternate transportation is available on the METRA electric
Passenger Vans – Continental’s Airport Express desk is commuter railroad’s direct service to and from downtown
across from the Southwest Airlines ticket counter. A van Chicago. For further information, call 312-836-7000.
ride from Midway Airport to downtown Chicago costs $16 Taxis are plentiful, with more than 5,800 in service. Check
per person one way, $30 round trip. the directional signs to see which gates are designated for
Telephone: 773-247-1200. drop-off and pick-up. Taxis to the downtown area usually
Chicago Transit Authority (CTA) – Trains take 30 minutes are available beginning two hours before the show closes.
between Midway Airport and downtown Chicago, and cost Ask the taxi starter or any McCormick Place Security
$1.50. Trains leave from a station connected to the east Officer for assistance.
side of the airport. Telephone: 312-836-7000.

Car Rental Discounts

Hertz is the official car rental agency for the 2004 AWS
Welding Show. Save $5 a day (up to $25 per week), PLUS
get your AWS Member discount, when you rent with Hertz
to attend the AWS Welding Show. To reserve on-line, go to and click Travel. To reserve by telephone,
call 800-654-2210. Mention CDP# 75641 and PC# 946746
to take advantage of this offer.

Eight thousand parking spaces are available in lots and
garages near McCormick Place. Rates are $14 per entry.

Compete Through Smarter Welding 7



MONDAY, 8 AM–5 PM Registration 9 AM–11 AM Opening Session and

Annual Business
APRIL 5 11 AM–Noon Comfort A. Adams
6:30 PM–8 PM AWS Officers'

TUESDAY, 8 AM–5 PM Registration 8:45 AM Exposition Opening

9 AM–Noon
Session 1: Aluminum Welding
9 AM–5 PM Exposition
APRIL 6 9 AM–5 PM Poster Session Noon–2 PM AWS Awards/AWS
Session 2: Forensics and Weld
(authors available
noon–2 PM) Recognition Luncheon Session 3: GMAW Ferrous 1
9 AM–5 PM Silent Auction
9 AM–5 PM AWS Book Store 2 PM–5 PM
9 AM–5 PM Press Room Session 4: FCAW/SMAW
12:30 PM–4:30 PM Professional Welders Session 5: GMAW Ferrous 2
Competition Session 6: Materials
1 PM–5 PM Gases and Welding
(GAWDA) Pavilion

WEDNESDAY, 8 AM–5 PM Registration 7:30 AM–8:30 AM Prayer Breakfast 9 AM–Noon

Session 7: GMAW Non-Ferrous
9 AM–5 PM Exposition
APRIL 7 9 AM–5 PM Poster Session Session 8: Laser Beam Welding 1
9 AM–5 PM Silent Auction Session 9: Weldability
9 AM–5 PM AWS Book Store
9 AM–5 PM Press Room 2 PM–5 PM
Session 10: Electron Beam Welding
12:30 PM–4:30 PM Professional Welders
Competition Session 11: Laser Beam Welding 2
Session 12: Solid State Joining

THURSDAY, 8 AM–2 PM Registration 1 PM Professional Welders

Competition -
9 AM–Noon
Session SP1: Current Research
9 AM–3 PM Exposition
Announcement of Topics in the U.S. Navy
APRIL 8 9 AM–3 PM Poster Session Winners
9 AM–3 PM Silent Auction
9 AM–3 PM AWS Book Store
9 AM–3 PM Press Room

Gases and Welding Distributors
Association: GAWDA University’s Spring
Management Conference
Manufacturer Hospitalities

8:30 AM–4:30 PM GAWDA

Road Map through the 2004 D1.1, 7 AM–8 AM
Structural Welding Code—Steel Welcome Breakfast and President’s
8:30 AM–4:30 PM Address
Planning for Cost-Effective Welding 8 AM–Noon
Seminar Business Sessions
Noon–1 PM
Networking Lunch
1 PM–3 PM
Business Session
3:30 PM–7PM
Networking Contact Program and
President’s Reception

34th International Brazing and Education Session 1: 8:30 AM–4:30 PM GAWDA

Soldering Symposium: 9 AM–10 AM Inspection to the 2004 D1.1, 7 AM–8 AM
9 AM–Noon Plummer Memorial Educational Lecture Structural Welding Code—Steel Breakfast and Closing Address
Session BS1 10:10 AM–10:40 AM 8:30 AM–4:30 PM 8 AM-10 AM
Brazing and Soldering—Filler Metal Integrating Technology into the Classroom: Arc Welding and Power Sources Seminar Business Session
and Process Technology The Modernized Welding Program at New 8:30 AM–4:30 PM 1 PM-5 PM
2 PM–5 PM Horizons Regional Education Center Welding Fabricator Quality Management GAWDA Pavilion at AWS Exposition
Session BS2 10:45 AM–11:15 AM System Working Seminar
Brazing and Soldering Expert Panel Session Education and Training Strategies for
Advanced Welding Technology
11:20 AM–11:50 AM
A Model for Industry and Technical School
Cooperation: Helping Students Transition
from the Classroom to the Workplace

Education Session 2
1:30 PM–2 PM
S.E.N.S.E. Questions and Answers: A Guide
to the Changes in AWS Welding Curriculum
2:05 PM–2:35 PM
The Education and Training of Welding
2:45 PM–3:45 PM
Panel Discussion: Attracting Students to
the Welding Industry
34th International Brazing and 10 AM–11:30 AM 8:30 AM–4:30 PM Free Sessions
Soldering Symposium: Interview Session with Dr. Omer Blodgett Welding Fabricator Quality Management 8 AM–9:30 AM
9 AM–12:15 PM Noon–4 PM System Working Seminar Emmanuel E. Velivasakis, P.E.: Structural
Session BS3 Plant Tour (Pre-Registration Required) 9 AM–4:10 PM Engineer Response to the World Trade
Brazing Processes, Testing, and Properties The Automatic Welding Conference: Center Tragedy
Getting the Most Out of Your Automatic 9 AM–2 PM
Welding Investment Field Construction and/or Field Repair
8:30 AM–4:30 PM Sponsored by the AWS Welding Industry
Certified Robotic Arc Welding Technician Network (WIN)
and Operators Seminar 10 AM–11:30 AM
8:30 AM–4:30 PM An Interview with the World’s Leading
The Why and How of Welding Procedure Welding Design Expert, Dr. Omer Blodgett
Specifications 2:30 PM–3:30 PM
8:30 AM–4:30 PM Challenges of Maintenance Welding on the
Welding of Stainless Steels (Basics) Trans-Alaska Crude Oil Pipeline and Fuel
Gas Line Repairs
3:30 PM–4:30 PM
Removing Dangerous Gases from Ships
Loading Crude Oil at Valdez

Education Session 3 9 AM–11:30 AM Free Session

9 AM–11:15 AM The Automatic Welding Conference: 8 AM–10:30 AM
Student Day: College Careers in Welding Getting the Most Out of Your Automatic Computer Procedures, Policies, and
Welding Investment Security
9 AM–9:30 AM
Higher Education in Welding Engineering 8:30 AM–4:30 PM
Certified Robotic Arc Welding Technician
9:35 AM–10:05 AM and Operators Seminar 9 AM – Noon
Welding Engineering Education under a Advanced Commercial Development -
Manufacturing Engineering Program 8:30 AM–4:30 PM Manufacturability of Fuel Cell Products
Welding of Stainless Steels (Avoiding
10:10 AM–10:40 AM Weld Defects)
Graduate Research and Engineering Career
in Welding - Perspectives of a Metallurgical 8:30 AM–Noon
Engineer Introduction to Design of Weldments
10:45 AM–11:15 AM
You Want Me to Do What? - Relating My 9
Education to My Internship Experience
Monday, April 5, 2004 Tuesday, April 6, 2004
9 AM–11 AM 8:45 AM–9 AM
American Welding Society Convention Exposition Opening Ceremony
Opening Session and Annual McCormick Place
Business Meeting A short, symbolic ribbon-cutting ceremony opens the
McCormick Place Exposition’s extravaganza of welding and fabricating
FREE TO ALL REGISTRANTS equipment to Welding Show participants. Hosted by
incoming AWS President James E. Greer.
11 AM–Noon
The Comfort A. Adams Lecture 9 AM–10 AM
McCormick Place Plummer Memorial Educational Lecture
Named after Comfort A. Adams, founder and first president McCormick Place
of AWS, this lecture is one of the welding industry's most The Plummer Lecture was created to celebrate the contri-
prestigious recognitions. The presenter of the 2004 butions of Fred L. Plummer to education and to recognize
Comfort A. Adams Lecture is Harry Bhadeshia, professor his service to the American Welding Society as president
of physical metallurgy, University of Cambridge Department from 1952 to 1954 and executive director from 1957 to 1969.
of Materials Science and Metallurgy, United Kingdom. AWS established the lecture to recognize an outstanding
His topic is Reliability of Weld Microstructure and Property individual who has made significant contributions to
Calculations. welding education and training. The lecture is delivered
annually at the AWS Convention as the plenary lecture in
6:30 PM–8 PM the Education Program.
AWS Officers’ Reception This year’s topic will be Welder Training: What Can We
Hilton Chicago Learn From the Cockpit? by Byron May, manager, repair,
This stylish annual party is open to all registrants and is a process and materials engineering, United Air Lines, San
great opportunity to get together. Meet the AWS officers, Francisco, CA.
new friends, new members, and new prospects in an
elegant setting. Cash bar, complimentary hors d'oeuvres Noon–2 PM
buffet. Evening business attire, please. AWS Awards/AWS Foundation
Recognition Ceremony and Luncheon
McCormick Place
The first AWS award, the Samuel Wyllie Miller Memorial
Medal, was presented to Comfort A. Adams in 1927. As
the Society and the industry it serves have grown, so has
the need to recognize outstanding scientists, engineers,
educators, and researchers. Join an assembly of distinguished
award presenters, recipients, and guests for a well-paced
ceremony and a delicious lunch. Tickets: $30

1 PM–5 PM
GAWDA Pavilion
McCormick Place
The Gases and Welding Distributors Association (GAWDA),
as part of its Spring Management Conference, will mount a
special pavilion within the AWS Exposition.

Tuesday, April 6, and Daily—Show Hours
Wednesday, April 7, 2004 AWS Foundation – Silent Auction
12:30 PM–4:30 PM McCormick Place
Professional Welders Competition To help those entering the welding industry achieve their
McCormick Place career goals, place your bid on an array of products and
Compete for cash and prizes in the AWS Professional prizes. All proceeds go to welding scholarships.
Welders Competition to be held on the Expo floor during
Poster Session
the 2004 AWS Welding Show.
McCormick Place on Exposition floor
Contestants will create a multipass horizontal fillet weld
Graphic displays of technical achievements for close,
using shielded metal arc welding on low-carbon steel.
first-hand examination. Posters present welding results
A panel of certified welding inspectors will evaluate
and related material that are best communicated visually,
weldments based on speed, weld length, and quality.
and research results that call for close study of photo-
To be eligible, contestants must be professional welders micrographs, tables, systems architecture, or other
over the age of 19, and must pay a $10 entrance fee. illustrative materials.
On-line preregistration at begins This year’s posters appear in four categories:
December 1, 2003. On-site registration (and check-in for • Two-year degree or certificate student level
preregistrants) will begin Tuesday, April 6, and continue • Four-year degree student level
through Wednesday morning, April 7. Competitive welding • Graduate degree student level
will begin on Tuesday afternoon, April 6, and continue on
• Professional/commercial level
Wednesday afternoon, April 7.
Poster competition authors will be available on Tuesday,
The first-place winner will receive a $2,500 prize and a April 6, 2004, from noon to 2 PM to answer questions.
custom-painted welding helmet. The second-place winner Results will be available Wednesday, April 7.
will receive $1,000; the third-place winner will receive
$500. Each of the top 10 welders will receive an AWS Special U.S. Army Exhibit
duffel bag. Each participant will receive an official AWS McCormick Place on Exposition floor
Professional Welders Competition T-shirt.
Welding experts from the Army's Aberdeen Proving
Winners will be announced on Thursday, April 8, at 1 PM. Grounds will be on hand to demonstrate through lecture,
All contestants are encouraged to attend the award video, and actual equipment—including a mobile welding
presentation. lab—how battle damage to weapons is assessed and
For more information on the Professional Welders repaired. The exhibit will essentially replicate an actual
Competition, contact the AWS Education Department, field site used during combat. Aberdeen Proving Grounds
800-443-9353, ext. 229. has one of the world's largest teaching labs, with 147
booths housed in an $18 million facility.
Wednesday, April 7, 2004
7:30 AM–8:30 AM
Prayer Breakfast
McCormick Place
Fellowship and inspiration to start your day. Tickets: $20

Compete Through Smarter Welding 11

Bold = AWS Sustaining Member

A Colorado School of Mines Hitco Carbon Composites, Inc.

Colorado Vision Systems Hobart Institute of Welding Technology
AAF International
Comeq, Inc. Hobart Welders
Abicor Binzel
Computer Engineering, Inc. Hougen Manufacturing, Inc.
Abmast Abrasives Corp
Computer Weld Technology, Inc. Huys Industries Ltd.
Ace Industrial Products
Computers Unlimited HVQ BRYD
Agfa NDT, Inc.
Cooper Crouse-Hinds Molded Products Hyd-Mech Group Limited
Air Liquide America L.P.
Corex-ITW Hobart Brothers Company Hypertherm, Inc.
Airflow Systems
Cor-Met, Inc.
AlcoTec Wire Corporation
Alfa Tools div. of Alfa Manufacturing Industries
Coxreels I
Cryo Gas International
Allied Flux Reclaiming Ltd./Harbert's Products IBEDA Superflash Compressed Gas Equipment
Cryogenic Industries
aMAESing Tools Manufacturing, Inc. Impact Engineering, Inc.
Amercable Industrial Machine Trader
Americ Corporation Industrial Market Place
Cyl-Tec, Inc.
America Fortune Company Innovation, Energy & Technology, LLC
American Laser Enterprises, Inc. Innov-x Systems, Inc.
American Machining Specialties
D Institute of the Ironworking Industry
American Society for Nondestructive Testing D. L. Ricci Integro
American Torch Tip Company Dataweld Incorporated Intercon Enterprises, Inc.
American Welding Society DAVI Inweld Corporation
(Membership, Certification, Education) Delphi Technologies, Inc. IRT-Scanmaster Systems, Inc.
AMET Inc. Direct Wire and Cable ITW Conference Room
Andrew J. Chobot Doringer Cold Saws ITW Dykem/Dymon
Antenen Research Drahtzug Stein Wire & Welding ITW Hobart Bros. Company
Aquasol Corporation DVS-German Welding Society
Arc Machines, Inc. J
Arc One E Jackson Products, Inc.
Arcon Welding LLC Eagle Bending Machines, Inc. James Morton, Inc.
ATI Industrial Automation Edison Welding Institute Jancy Engineering Company
Atlas Welding Accessories, Inc. Edwards Manufacturing Company JAZ USA, Inc.
Auburn Manufacturing, Inc. Elco Enterprises, Inc. Jetline Engineering, Inc.
AWS Foundation, Inc. Electric Heating Systems
Axxair U.S.A. Electron Beam Technologies, Inc. K
Environmental Air Solutions
B K & K Welding
ESAB Welding & Cutting
Keystone Fastening Technologies, Inc.
Bacou-Dalloz Essen Trade Shows
Kobelco Welding of America, Inc.
Behringer Saws, Inc. Ezee Roll Manufacturing
Kohler Engines
Beijing Advanced Metal Materials Koike Aronson, Inc.
Beijing Metals & Minerals Import & Export Corp. F Kordyne International
Bellman-Melcor, Inc. F&M Magazine KS Electron Technologies
Bernard Welding F.W. Winter Inc. & Company
Bluco Corporation Ferris State University L
Bonal Technologies, Inc. FSH Welding Group
Bosch Power Tools LACO Industries/Markal
Flame Technologies, Inc.
Boss Manufacturing Company Lapco Manufacturing, Inc.
Frommelt Safety Products
Broco, Inc. Lasag Industrial Lasers
Bug-O Systems G LeTourneau University
Bullard Abrasives, Inc.
Garryson, Inc. Lev-co
Gas & Air Systems, Inc. Liburdi Automation
C Genstar Technologies Company, Inc. Liburdi Dimetrics Corporation
C & G Systems, A Thermadyne Company Georg Fischer, Pipe Tools Division, USA Lincoln Electric Company, The
C H Symington Goodweld Corporation Longxing Group
Campbell's Port-A-Cool Goss Incorporated Lucas-Milhaupt, Inc.
Carell Corporation Gulf Wire Corporation Lyall's Labors Ltd.
Centerline (Windsor) Ltd. Gullco International, Inc.
Cerbaco Ltd. M
CGW-Camel Grinding Wheels, USA H M. Braun, Inc.
Changzhou Wujin Nanxiashu
H & S Tool, Inc. Mag Man Bags
Welding & Cutting Tools Plant
Hangzhou Three New Machinery & Magnaflux (Division of ITW)
Chicago Protective Apparel
Electronic Research Institute Magnatech Limited Partnership
CK Worldwide
Harper Trucks, Inc. Magnetic Products and Services, Inc.
CM Industries, Inc.
Harris Calorific, Inc. MAN - Modern Applications News
HE & M Saw Mannings U.S.A., Inc.
COB Industries, Inc.
12 Heck Industries Mathey Dearman, Inc.
Mauritzon, Inc. Robin Subaru Tri Tool, Inc.
MBNA America Roman Engineering Services Trimark-ITW Hobart Brothers Company
McKay - ITW Hobart Brothers Company Roman Manufacturing, Inc. Triple Crown Products, Inc.
Meridian Laboratory, Inc. Trumpf, Inc.
Metabo Corporation S Trumpf, Inc. Laser Technology Center
MetalForming Magazine Saf-T-Cart Tweco/Arcair, A Thermadyne Company
Metorex, Inc. Sanc Materials
Michelle & Andy Heath Sandvik Materials Technology U
Miller Electric Manufacturing Scotchman Industries, Inc. Unibraze Corp.
MIM Industries, Inc. Sellstrom Manufacturing Company United
MK Products, Inc. Servo-Robot, Inc. Unitek Miyachi Corporation
Morgan Advanced Ceramics - Wesgo Metals Sherwin, Inc. Uniweld Products, Inc.
Products Sigmatek Corporation U.S Weld Trials
Motoman, Inc. Sinoweld a/k/a Chiefstone C&T
Multiquip, Inc. SKM Industries, Inc. V
Mutual Industries Smith Equipment Valtra, Inc. (Strong Hand)
Southwestern Illinois College Victor Equipment Company, A Thermadyne Company
N Special Metals Welding Products
National Standard Company Spectronics Corporation W
National Steel Bridge Alliance Stanco Manufacturing, Inc.
National Torch Tip Steiner Industries Wachs Company, E. H.
Navy Joining Center, The Stellite Coatings, Inc. Wall Colmonoy Corp.
Nelson Stud Welding, Inc. Stillwater Technologies Walter, J., Inc.
Nippert Company, The Stoody Company, A Thermadyne Company Watts Specialties
Niton LLC Stork Materials Technology Weartech International, Inc.
NLF Protective Products, Inc. Strong Hand by Valtra, Inc. Weiler Corporation
North American Hoganas Sulzer Metco (US), Inc. Weld Engineering Company, Inc.
Norton Abrasives Sumner Manufacturing Company, Inc. Weld-Aid Products
Superior Products, Inc. Weldas Company
O Sure Flow Products Weldcoa (Welding Company of America)
Systematics, Inc. Weldcraft
Ogden Welding Systems, Inc. Welding Design & Fabrication
Ohio State University, The-Welding Engineering Weldsale Company div. of J.A.Cunningham
OKI Bering, Inc. T
Omni Technologies Corporation Tec Torch Weldship Corporation
Otos Company, Ltd. Techalloy Company, Inc. Wentgate Dynaweld, Inc.
Oxford Alloys Tempil Western Enterprises
OXO Welding Equipment Company Tennessee Rand Company Wilson Industries, Inc.
Termmei Industry & Commerce Company, Ltd. Winner Tungsten Products Company, Ltd.
P Texas State Technical College Wisconsin Wire Works, Inc.
Pac-Mig, Inc. Thermacut WMH Tool Group (Jet-Wilton)
Panametrics Thermadyne Industries
Panasonic Factory Automation Company Thermal Arc, A Thermadyne Company Z
PCI Energy Services LLC Thermal Dynamics Corp., A Thermadyne Company
3M Occupational Health & Environmental Safety ZJ Industries, Inc.
Perks Manufacturing Engineering Company
Permadur Industries, Inc. Tillman Company, John
Tregaskiss Welding Products (Exhibitors as of November 6, 2003)
Pferd, Inc.
Phoenix International
Piddler Tool Company
Pillar Induction
Plazma Cutting Eqpt. Pvt Ltd.
Practical Welding Today/The Fabricator
Precitec, Inc.
Preco Laser Systems, LLC
Preston-Eastin, Inc.
Prince & Izant Company
Protem U.S.A.
Proteus Industries, Inc.

R/D Tech
Rankin Industries, Inc.
Ready Welder Corporation
Redtail International
Resistance Welder Manufacturers Association
Revco Industries, Inc.
Rex-Cut Products, Inc. 13
Compete Through Smarter Welding
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• Pre-qualification of Welding Procedure Specifications
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• Latest restrictions on pre-qualified FCAW and GMAW
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• Adjusts pre-qualification figure details
• Latest revision of the pre-qualified base metal list

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We asked some of the industry’s leading
companies what new products they plan to
introduce at the 2004 Exposition. Their answers
fall into two main categories: ergonomics and
computerization. New welding equipment is
being designed with operator comfort, efficiency,
and safety in mind, while digital technology
enhances precision and productivity on the job.
Here are some of the innovative new products
you will see at the 2004 Welding Show:

Motor in the Cable are adaptable to most laser power source manufacturers.
The product range includes mirrors, lens covers, fiber-optic
To make push-pull welding more comfortable and
cables, and a wide range of peripheral equipment.
convenient for the operator, ABICOR Binzel Corp. in
Frederick, MD, will introduce its new ABICONDA™ series In addition, ABICOR offers the new Highyag Hybrid welding
of push-pull MIG welding guns. The innovative ABICONDA head, which combines the proven MIG process with
350 ampere air-cooled and 500 ampere water-cooled modern laser welding, producing a quality weld through
push-pull guns house the motor in the cable instead of increased tolerances and processing speeds. Highyag
at the front end of the gun, making the ABICONDA much products are modular and easily adaptable to different
lighter in weight and easier to use. processing requirements.
Instead of a pistol-grip handle, the ABICONDA guns have
the popular ALPHA-style handle, with the trigger readily Variable-Speed Foot Control
accessible on the bottom for added comfort. This natural Variable-speed foot control on a welding positioner gives
hand grip puts less strain on the fingers and wrist. the operator maximum control of the rotation of the posi-
On both the air-cooled and water-cooled models, the tioner table top, saving time and increasing productivity. At
front end of the gun and torch cable can be removed and the 2004 Exposition, Genstar Technologies Co., Inc., of
replaced easily. The power cable, water hoses, and con- Chino, CA, will introduce a variable-speed industrial-style
duits have a sturdy outer sheathing for easier maneuver- foot-control option for all of its GENTEC welding positioners
ability. They are available in 10-, 15-, and 25-foot lengths. from 200 pounds to 45,000 pounds.
For better inventory control, the air-cooled ABICONDA This variable-speed unit supports all of the standard
consumables are interchangeable with ALPHA Mig-Guns, control features: on/off, contactor control, speed, and
and the water-cooled ABICONDA consumables are inter- time. Optional control features include variable speed,
changeable with ABIMIG Mig-Guns. weld travel control, and sequencer.
A potentiometer for wire speed control is optional on the The foot control operates like a gas pedal over the full
handle. The ABICONDA does not require an integrated speed range. A light touch moves the part at the slowest
wire drive unit and will fit any commercially available imaginable speed, giving the operator the exact speed
wire drive unit fitted with an ABICOR Binzel adaptor kit. required for a weld with a minimum of effort in manipulat-
This reduces capital investment when the ABICONDA is ing the welding torch. At full speed, the operator can index
used with existing equipment. or jog the part rapidly into the next area to be welded.
ABICOR Binzel Corp. also will introduce, in conjunction with With Genstar’s variable-speed foot-control kits, users
Highyag Lasertechnologie GmbH, advanced tools for laser can employ variable speed for manual welding applica-
welding and cutting. Highyag welding and cutting heads tions, or reconfigure the welding positioner into hundreds

Compete Through Smarter Welding 15

of different applications within minutes. With do-it-your- Digital Communication & Control
self accessory packages, various stages of automation up As welding technology shifts from analog to digital control,
to fully automatic welding systems can be achieved. The Lincoln Electric Company of Cleveland, OH, is position-
ing itself in the forefront of that shift. Lincoln has incorpo-
Consumer-Loyalty Program rated the latest developments in its Nextweld™ technolo-
You’ve heard of frequent-flyer, frequent-shopper, and gies and processes into its newest Power Wave™ power
frequent-stay programs that build consumer loyalty. Now sources and Power Feed™ wire feeders. These highly
comes the first such program in the welding industry, engineered components are designed to work together
JUMP™ (Jackson Upgrade Mastery Program), which in a sophisticated software-driven welding system.
Jackson Products of Belmont, MI, will introduce at the These products reflect the latest Nextweld thinking from
2004 Exposition. Lincoln in digital communication and Waveform Control
JUMP’s goal is to increase welding safety. It provides end- Technology™. For example, they are equipped to allow
users with upgrade incentives, rebate offers, sneak-peeks fast, flexible component communications using Lincoln’s
at Jackson’s latest welding technologies, and up-to-date ArcLink® communications protocol. They also feature new
information about the firm’s top-of-the-line EQC welding process- and production-monitoring capabilities with real-
helmets. Each welding helmet package includes a product- time feedback on arc current, voltage, wire-feed speed,
specific JUMP card that gives the consumer a personal arc time, and other machine-status conditions. At the
"Thank You" along with rebate offers and JUMP registra- 2004 Exposition, Lincoln will demonstrate networked
tion/warranty opportunities. Consumers simply fill out and remote monitoring and control of welding systems via
mail the postage-paid JUMP registration card in the package. Ethernet Web connections.
JUMP’s Welding Instructor Program also encourages Lincoln also will introduce a new level of welding flexibility
students to use Jackson helmets and register for JUMP. for industrial environments with its new “M” version modu-
Instructors can keep track of student-enrollment totals lar power sources and wire feeders. Fabricators may
and receive free Jackson EQC welding helmets. For every change interface modules as their needs change to gain
40 students who enroll in JUMP, a registered instructor added networking capability, using DeviceNet or Ethernet
will receive a Journeyman® auto-darkening helmet. for remote system diagnostics, weld mode selection, data
Instructors may continue building their enrollment to 80 logging, and other functions. They will save time download-
students to receive a Master Variable auto-darkening ing or transferring weld parameters using the infra-red port
helmet, or to 120 students to receive a NexGen™ EQC® with a Palm® OS-based hand-held computer.
auto-darkening helmet. JUMP instructors also will In the welding consumables realm, Lincoln will introduce
receive follow-up correspondence with updated student Innershield® flux-cored self-shielded electrodes with
JUMP enrollment totals, welding-safety information, MicroFlux™ Technology. This proprietary fill technology
promotions, and product literature. packs smaller particles of more uniform size into the
JUMP instructor packets have been sent to more than electrode core to deliver a more forgiving arc and higher
6,200 welding instructors in grade schools, high schools, deposition rates while minimizing gas marking.
community colleges,vocational/technical schools, and Also, Lincoln SuperArc® MIG wire electrode, with
universities across the country. MicroGuard™ Ultra surface-engineering technology,
Jackson plans to expand JUMP with additional elements, benefits from a proprietary surface treatment. It guards
such as personalized newsletters and JUMP Bags for against poor feedability, and contains arc-enhancement
students containing basic accessories that every beginning agents that contribute to a smooth, stable arc.
welder needs.
Jackson also will debut its new Huntsman® Solera™ solar- Flexible Multi-MIG System
powered auto-darkening filter. The Solera features two New multi-MIG welding systems that employ flexible
solar panels, two sensors, and a two-year warranty, at a welding software to provide the perfect arc for every
distributor price 30 % lower than the previous Solex 2100. MIG welding process will be introduced at the 2004
The new Solera lens will be available in the Huntsman line Exposition by Miller Electric Mfg. Co. of Appleton, WI. The
as a cartridge or in the 981P helmet, and as a running processing power of Miller’s new Axcess 450 and Auto-
change under the Jackson Apprentice name. Axcess 450 (the latter for automated applications) solves
these complex physics problems with a simple interface
that prompts operators to enter the wire type, wire diame-

ter, gas combination, and process desired. Then Axcess arc even if primary power varies when welding. It over-
provides the best solution. After that, the operator selects comes “dirty” power, a common problem in rural areas or
desired wire feed speed; the system maintains a constant on construction sites.
arc length throughout the appropriate welding range. The Maxstar 150 is available in three models:
Software is available for steel, stainless steel, and alumin- • S, for stick-only welding with E6013 and E7018
um wires; 100 percent CO2 and 98/2, 95/5, 90/10, and electrodes.
75/25 argon/CO2 gas mixtures; and MIG, pulsed MIG, • STL, for stick or TIG output and Miller’s Lift-Arc™ starting
metal cored, Accupulse™ (a hybrid, pulsed spray transfer method, which provides inclusion-free TIG arc starts
process that cools the weld puddle and adapts to the without the use of high frequency.
joint condition), and RMD™ (Regulated Metal Deposition, • STH, with all features of the other machines, plus built-
an ultra-low-heat input, low-spatter, hybrid short-circuit in high-frequency noncontact arc starting and pulsing
transfer MIG welding process ideal for filling gaps and controls to eliminate tungsten or material contamination.
welding thin materials or root passes on pipe). For other
welding applications and custom programs, operators Precision Process Control Delivers
can fine-tune an existing program using Miller’s optional
Advances in high-definition plasma technology are bring-
WaveWriter™ graphical software on a standard M series
ing precision cutting to ever-thicker materials. The process
Palm® PDA.
is increasingly controlled by computers, and refinements in
The Axcess 450 and Auto-Axcess 450 will have an output torch technology are achieving arc densities (amperage
of 450 amperes/38 volts at 100 percent duty cycle and per square inch) two to three times higher than standard
maximum output of 600 amperes/38 volts at 60 percent plasma.
duty cycle. Voltage range in the constant voltage (CV)
At the 2004 Exposition, Thermal Dynamics, a Thermadyne
mode is 10 to 44 volts with 85 volts DC maximum open-
company located in West Lebanon, NH, will debut its
circuit voltage. They accept any primary power from 208
Ultra-Cut™ 150, the first fully computerized high-definition
volts through 575 volts, single-phase or three-phase, 50
plasma arc cutting system with consumables conveniently
hertz or 60 hertz. Their dimensions are 22 in. x 15.5 in. x
contained in a cartridge instead of the torch head. To
28.5 in. Each weighs 175 pounds.
change applications, an operator now can simply change
New Lightweight Inverters cartridges in a matter of seconds.
For maximum portability and arc quality in shielded metal Gas selection, flow, and power-supply amperage are all
arc welding and gas tungsten arc welding of steel and digitally controlled. The cutting process now is more
stainless steel, Miller also will introduce its new Maxstar“ consistent, forgiving, and user-friendly, delivering an
150 Series of inverters offering the most output per pound exceptionally wide window of parameter adjustment to
of any inverters available. provide precise cuts free of dross and slag.
Miller’s revolutionary Fast Switch technology enables the Another innovative feature is a closed-loop feedback system
Maxstar 150 to weigh just 13.7 pounds (five to 10 pounds using mass flow meters for very precise gas flow. Unlike
lighter than competitive units), have a five-ampere to orifices with pre-measured settings, or ball-type flow
150-ampere welding range on 115 to 230 volts AC primary meters that provide approximate measures, a mass flow
power, and provide outstanding arc performance. meter counts gas molecules to calculate continuously the
exact flow of both the plasma and shield gases. The
All Maxstar 150 models have stick output of 150 amperes Thermal Dynamics Ultra-Cut automatic gas control provides
at 30 percent duty cycle using 230 volts AC power. This real-time readings to a computer, which responds by adjust-
enables nearly unlimited welding with a 1/8-in. diameter ing the aperture as the work proceeds, yielding uniform cuts.
stick electrode, suitable for 80 percent of all stick applica-
tions. Operators in the maintenance/repair, construction, The Ultra-Cut 150 is the first in a new family of products –
mechanical contractor, food/beverage/dairy/restaurant, some higher in amperage, others lower – to be introduced
shipboard welding, experimental aircraft, and farm/ranch during 2004. All will employ Thermal Dynamics’ new
industries all will benefit. XT™-300 torch, using technology that automatically
self-aligns the consumables. The firm says that Ultra-
Through its Auto-Line™ feature, the Maxstar 150 automati- Cut’s rigorous control of consumables alignment,
cally connects to 115 through 230 volts AC single-phase amperage, and gas flow will achieve economies by
power, ± 10 percent, so operators can plug it in and begin making the consumables last longer, and will enhance
welding without delay. Auto-Line also maintains a steady the system’s work performance.

Compete Through Smarter Welding 17

Tuesday, April 6, 2004 SESSION 3 D. 3:45 PM Modeling of Fe-C-Al-Mn
GMAW Ferrous 1 Steel Weld Microstructure, by
MORNING SESSIONS: S. S. Babu, S. A. David, and J. M.
A. 10 AM In Situ Weld Pool
9 AM–Noon Vitek, Oak Ridge National Laboratory,
Measurement Using Stereovision,
Oak Ridge, TN; J. W. Elmer, Lawrence
by C. Debrunner, T. Vincent,
SESSION 1 Livermore National Laboratory,
J. P. Steele, and F. Al-Baiya,
Livermore, CA; and M. Quintana, The
Aluminum Welding Colorado School of Mines, Golden, CO
Lincoln Electric Co., Cleveland, OH
A. 10 AM Variable Polarity Arc B. 10:35 AM Characterizing
E. 4:20 PM Optimization of SMA
Welding Studies on 6061/A1203/10w, Adaptive Arc Length Control Methods
Weld Metal Composition,
by T. Lienert, Los Alamos National for Pulsed Gas Metal Arc Welding,
by M. Marimuthu, S. S. Babu, and
Laboratory, Los Alamos, NM by B. Baughman and D. Harwig,
S. A. David, Oak Ridge National
B. 10:35 AM Aluminum Flux Cored Edison Welding Institute, Columbus,
Laboratory, Oak Ridge, TN
Wire Development, by G. J. Atkins OH; and R. Richardson, The Ohio
and D. L. Olson, Colorado School of State University, Columbus, OH
Mines, Golden, CO C. 11:10 AM Influence of Procedure GMAW Ferrous 2
C. 11:10 AM Electrical Resistance Variables on C-Mn-Ni-Mo Metal
Cored Wire Ferritic All-Weld Metal, A. 2 PM Heat Transfer Fluid Flow
Hot Upset Welding of Aluminum Alloy
by M. R. de Rissone, Facultad Regional and Solidified Surface Profile
5454, by F. Feng, Alcan International
San Nicolas UTN; H. Svoboda, During Gas Metal Arc Fillet Welding,
Limited, Kingston, ON, Canada
Facultad de Ingenieria UBA; E. S. Surian, by W. Zhang, C. H. Kim, and T.
FR San Nicolas UTN; and L. de Vedia, DebRoy, Pennsylvania State
SESSION 2 University, University Park, PA
UNSAM, CIC (Buenos Aires, Argentina)
Forensics and Weld Performance
B. 2:35 PM Determination of
A. 10 AM Forensic Study of the AFTERNOON SESSIONS: Unknown Welding Parameters for
Steel in the World Trade Center, 2 PM–5 PM GMA Fillet Welding Using a Smart
by T. Siewert, F. Gayle, R. Fields, Model, by A. Kumar and T. DebRoy,
D. McColskey, and C. McCowan, SESSION 4 Pennsylvania State University,
National Institute of Standards and FCAW/SMAW University Park, PA
Technology, Boulder, CO
A. 2 PM Hydrogen Reduction C. 3:10 PM The Humping
B. 10:35 AM Fitness-for-Service in FCAW Steel Weld: Metal Phenomenon in High Speed GMA
Evaluation of Bulkheads, by C. Tsai, Spectroscopic Monitoring of Arc Welds, by T. C. Nguyen, D. C.
The Ohio State University, Columbus, During Deposition, by J. Chandler, Weckman, D. A. Johnson, and H. W.
OH; G. Jung, Edison Welding Institute, C. Clasper, S. Liu, and G. Edwards, Kerr, University of Waterloo, Waterloo,
Columbus, OH; and P. W. Sauser, U.S. Colorado School of Mines, Golden, CO ON, Canada
Army Corps of Engineers, Saint Paul, MN
B. 2:35 PM Fluoride and Yttrium D. 3:45 PM Robotic Out-of-Position
C. 11:10 AM A Thermal Method Additions in Steel Welds: Effects on GMAW Welding Downhill: A Study
to Reduce Buckling Distortion, by Hydrogen and Weld Metal Properties, of Performance and Parameters,
R. Dull, Edison Welding Institute, by C. Clasper, J. Chandler, G. Edwards, by J. P. Steele, T. Vincent, and
Columbus, OH and S. Liu, Colorado School of Mines, C. Debrunner, Colorado School of
D. 11:45 AM Weld Repair of the Golden, CO Mines, Golden, CO
U. S. Capitol Dome, by T. Siewert and C. 3:10 PM Characterization of
C. McCowan, National Institute of Microconstituents in Welds Using SESSION 6
Standards and Technology, Boulder, FCAW-S Consumables, by J. Major Materials
CO; K. Hildebrand, AoC, Washington, and S. Liu, Colorado School of Mines, A. 2 PM Stray Grain Formation
DC; R. Bushey, ESAB Welding & Golden, CO; and M. Quintana and C. During Welding of Single Crystals,
Cutting Products, Hanover, PA; and Dallam, The Lincoln Electric Co., by J. M. Vitek, S.S. Babu, S. A. David,
D. Kotecki, The Lincoln Electric Co., Cleveland, OH and J. W. Park, Oak Ridge National
Cleveland, OH
Laboratory, Oak Ridge, TN

B. 2:35 PM Deformation Strains B. 9:35 AM Fundamental Studies C. 10:10 AM Radial Alignment of
in Single Crystal Alloy Welds, by on the Relationship Between Plastic Photonic Packages with Sequential
O. M. Barabash, J. A. Horton, Jr., S. S. Strains and Distortion in Fillet Welded Laser Spot Welds, by P. W.
Babu, R. I. Barabash, and S. A. David, T-Joints, by G. Jung, Edison Welding Fuerschbach, J. T. Norris, and
Oak Ridge National Laboratory, Oak Institute, Columbus, OH; and C. Tsai, J. E. Bernal, Sandia National
Ridge, TN The Ohio State University, Columbus, OH Laboratories, Albuquerque, NM
C. 3:10 PM Topological Features C. 10:10 AM Liquation, Cracking, D. 10:45 AM Analysis of Welding
of Grains in the HAZ, by S. Mishra and Backfilling in Partial-Penetration Induced Submicron Movements
and T. DebRoy, Pennsylvania State Welds of Aluminum Alloys Comparing in Laser Micro-Welding of
University, University Park, PA Alloys 2024, 6061, and 7075, by Optoelectronic Packages, by Z. Feng,
D. 3:45 PM Direct Metal Deposition S. Kou, C. Huang, and G. Cao, Oak Ridge National Laboratory, Oak
of Copper onto Steel Using a Nickel University of Wisconsin, Madison, WI Ridge, TN; and J. Lu, Luxtera, Inc., Lake
Interlayer, by F. F. Noecker II and D. 10:45 AM Gas Metal Arc Forrest, CA
J. N. DuPont, Lehigh University, Welding of Titanium: Producing Full E. 11:20 AM A Coupled Thermal
Bethlehem, PA Penetration, Contaminant-Free Welds, and Microstructure Model for Laser
E. 4:20 PM Fluxless Plasma by G. M. Chirieleison and Processing of Ti-6Al-4V, by S. M.
Soldering of Lead-Free Solders, by S. Liu, Colorado School of Mines, Kelly, S. S. Babu, S. A. David, and
J. P. Jung and Y. N. Zhou, University of Golden, CO; M. Wells, Naval Surface T. Zacharia, Oak Ridge National
Waterloo, Waterloo, ON, Canada; J. K. Warfare Center, West Bethesda, MD; Laboratory, Oak Ridge, TN; and S. L.
Moon, LG Electronics Institute, Seoul, and S. Luckowski, US Army ARDEC, Kampe, Virginia Polytechnic Institute
Korea; and K. I. Kang and J. S. Lee, Picatinny Arsenal, NJ and State University, Blacksburg, VA
University of Seoul, Seoul, Korea E. 11:20 AM Contact Models of
GMAW Wire Liner Friction: An Inverse SESSION 9
F. 4:55 PM The Microstructure
Characterization of Synchronous Photoelastic Solution, by T. Padilla, Weldability
Vibratory Welding, by C. W. Kuo J. R. Berger, and D. R. Munoz, A. 9 AM Repair Weldability of Heat-
and W. Wu, National Chung Hsing Colorado School of Mines, Golden, Resistant Alloys, by S. Shi and J. C.
University, Taichung, Taiwan, Republic CO; T. P. Quinn, National Institute of Lippold, The Ohio State University,
of China Standards and Technology, Boulder, Columbus, OH; and J. Ramirez,
CO; and R. A. L. Rorrer, University of Edison Welding Institute, Columbus, OH
Colorado, Denver, CO
B. 9:35 AM Development of a
Modified Cast-Pin Tear Test, by
Wednesday, April 7, 2004 SESSION 8 D. Ryan and J. C. Lippold, The Ohio
Laser Beam Welding I State University, Columbus, OH
MORNING SESSIONS: A. 9 AM A Novel Approach to C. 10:10 AM The Effect of C, Nb,
9 AM–Noon Laser Weld-Bonding Al Autos, by and Ti Additions on Ductility-Dip
R. W. Messler, Jr., E. A. Johnson, and Cracking in Austenitic Stainless
SESSION 5 J. Y. Levene, Rensselaer Polytechnic Steels, by A. J. Ramirez, J. W. Sowards,
GMAW Non-Ferrous Institute, Troy, NY; L. Chen, University and J. C. Lippold, The Ohio State
A. 9 AM Distortion Control in of Rochester, Rochester, NY; and University, Columbus, OH
Welding Aluminum GIS Vessel, by S. Bohnenstiehl, Montana Technical
D. 10:45 AM Ranking the
C. Tsai, The Ohio State University, University, Butte, MT
Resistance of Wrought Superalloys
Columbus, OH; D. S. Chou, IWTRL, B. 9:35 AM Effect of Temporal Pulse to Strain Age Cracking, by M. Rowe,
Taipei, Taiwan, Republic of China; Shaping on Cracking Susceptibility of Haynes International, Inc., Kokomo, IN
S. S. Lin, Chung-Hsing E&M Ltd., AA 6061-T6 Aluminum Alloy, by
E. 11:20 AM The Effect of
Taipei, Taiwan, Republic of China; J. Zhang, D. C. Weckman, and
Chromium on the Weldability and
and G. Jung, Edison Welding Institute, Y. N. Zhou, University of Waterloo,
Corrosion Behavior of Fe-Al Weld,
Columbus, OH Waterloo, ON, Canada
by J. R. Regina, J. N. DuPont, and
A. R. Marder, Lehigh University,
Bethlehem, PA

Compete Through Smarter Welding 19

F. 11:55 AM *Analysis of Crack B. 2:35 PM Alloying Element E. 4:20 PM Modeling Resistance
Formation in the Longitudinal Vaporization during Laser Spot Spot Welding Electrode Life, by
Varestraint Test, by C. V. Robino, Welding of 304 Stainless Steel, by S. S. Babu and M. L. Santella, Oak
G. A. Knorovsky, and M. Reece, X. He and T. DebRoy, Pennsylvania Ridge National Laboratory, Oak Ridge,
Sandia National Laboratories, State University, University Park, PA; TN; and W. Petterson and J. E. Gould,
Albuquerque, NM; J. N. DuPont, and P. W. Fuerschbach, Sandia Edison Welding Institute, Columbus, OH
Lehigh University, Bethlelem, PA; National Laboratories, Albuquerque, NM
and Z. Feng, Oak Ridge National C. 3:10 PM Identifying Uncertain
Laboratory, Oak Ridge, TN Material Parameters in Weld Pool by Thursday, April 8, 2004
Integrated Modeling, by A. De,
IIT Bombay, Mumbai, India; MORNING SESSIONS:
AFTERNOON SESSIONS and T. DebRoy, Pennsylvania State 9 AM–Noon
2 PM–5PM University, University Park, PA
D. 3:45 PM *Laser and E-Beam
SESSION 10 Current Research Topics
Joining Unusual Fe-Base, Ni-Base,
Electron Beam Welding in the U.S. Navy
and Refractory Alloys, by
A. 2 PM *Electron Beam Sponsored by the U.S. Navy
D. O. MacCallum, B. M. Nowak-Neely,
Diagnostics and Weld Transfer, by G. A. Knorovsky, and F. M. Hooper, A. 9 AM Shielding Gas Dewpoint
T. Palmer, J. W. Elmer, and P. Terrill, Sandia National Laboratories, Study for Titanium Welding, by
Lawrence Livermore National Albuquerque, NM K. N. Tran, M. E. Wells, and
Laboratory, Livermore, CA; and D. R. Forrest, Naval Surface Warfare
E. 4:20 PM Optimization of a Laser+
K. Nicklas and T. M. Mustaleski, Center, West Bethesda, MD
GMAW Hybrid Welding Process,
BWXT Y-12 Plant, Oak Ridge, TN by P. Kinney, Robert W. Hunt Co., B. 9:35 AM Friction Stir Processing
B. 2:35 PM Effect of HED Welding Pittsburgh PA; and D. Farson, The of Nickel Aluminum Bronze, by
on the Microstructural Development Ohio State University, Columbus OH J. P. Nguyen, M. Posada, J. J. DeLoach,
of Superaustenitic Stainless Steels, R. S. Fielder, and W. A. Palko,
by M. J. Perricone and J. N. DuPont, SESSION 12 Naval Surface Warfare Center, West
Lehigh University, Bethlehem, PA Solid-State Joining Bethesda, MD
C. 3:10 PM *The Role of Pressure A. 2 PM Inertia Welding for High- C. 10:10 AM The Effects of Tandem
in Welding (and Cutting) Processes: Pressure Hydrogen Storage, Submerged Arc Welding Process
Comparing Pressure Effects of Heat by M. C. Balmforth, G. K. Hicken, Parameters on HAZ Toughness in
Sources for Various Weld Processes, and J. D. Puskar, Sandia National HSLA-65: Numerical and Experimental
by G. A. Knorovsky and D. O. MacCallum, Laboratories, Livermore, CA Simulations, by D. R. Forrest,
Sandia National Laboratories, J. J. DeLoach, and R. J. Wong,
Albuquerque, NM B. 2:35 PM *Microstructural Naval Surface Warfare Center, West
Characterization of Inertia Welded Bethesda, MD
D. 3:45 PM *Controlled Scanning 2l-6-9 Stainless Steel, by J. D. Puskar,
Electron Beam Micro-to-Nano B. P. Somerday, D. K. Balch, C. H. D. 10:45 AM Weldability of
Welding: Micro-to-Nano Electron Cadden, and M. C. Balmforth, Sandia Dissimilar High Strength Steel
Beam Welding via Adapted National Laboratories, Livermore, CA Weldments, by J. Kalp and
Scanning Electron Microscopy, by J. P. Nguyen, Naval Surface Warfare
B. M. Nowak-Neely, D. O. MacCallum, C. 3:10 PM Prediction of Residual Center, West Bethesda, MD
and G. A. Knorovsky, Sandia National Stresses and Property Distributions
in Friction Stir Welds of Aluminum E. 11:20 AM A Neural Network
Laboratories, Albuquerque, NM Analysis of HSLA Weld Wire: A New
Alloy 6061-T6, by Z. Feng, X. Li Wang,
and S. A. David, Oak Ridge National Weld Metal Composition for 100 ksi
SESSION 11 Weld Wire, by E. A. Metzbower,
Laboratory, Oak Ridge, TN
Laser Beam Welding 2 US Naval Research Laboratory,
D. 3:45 PM Effects of Ti-C Coating Washington, DC; and J. J. DeLoach,
A. 2 PM *Beam Profiling of a on Electrode Degradation: Tip Life
3.3kw CW Cd:YAG Laser, by Naval Surface Warfare Center, West
Improvement for RSW With HDG Bethesda, MD
T. Lienert and R. W. Carpenter, Steel, by K. R. Chan, S. J. Dong,
Los Alamos National Laboratory, Y. N. Zhou, and Y. Ding, University of *Paper sponsored by the U.S. Department
Los Alamos, NM Waterloo, Waterloo, ON, Canada of Energy/Interagency Manufacturing
Operations Group/Subgroup on Joining

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Tuesday, April 6, 2004 Tuesday, April 6, 2004



Brazing and Soldering—Filler Brazing and Soldering Expert Panel Session
Metal and Process Technology At the Expert Panel Session, each presenter will address the audience with
A. 9 AM Brazing Copper Tube introductory remarks of five to 10 minutes. Then members of the audience may
Faster and Better, by W. Sperko, direct questions to a particular panel member or to the panel as a whole.
Sperko Engineering Services, Inc.,
Greensboro, NC Session II—Brazing and Soldering Panel Discussion
B. 9:30 AM Stainless Steel Brazing, Moderator: Carmen Paponetti, Sr., Hi TecMetal Group, Inc., Cleveland, OH
by S. L. Feldbauer, Abbott Furnace
C. 10 AM The Science (and Art) Gary Becka Honeywell, Federal Hand Soldering
of Making Brazing and Soldering Manufacturing and Technologies, Guidelines
Powders, by D. Fortuna, Sulzer Metco Kansas City, MO
(US), Inc., Troy, MI
R. L. Peaslee Brazing Consultant, Braze Joint Design
BREAK Royal Oak, MI
10:30 AM–11 AM J. L. Schuster Omni Technologies, Inc., Aluminum Brazing
Eppins, NH (Furnace and Torch)
D. 11 AM Challenging Solders
for Microjoints: Developments in B. Henson J. W. Harris Company, Inc.,
the Field of Active Solders and Mason, OH Brazing and Soldering
Transient Liquid Phase Systems, Filler Metals
by E. Lugscheider and S. Fortuna, T. Oyama WESGO Metals, Division of
Aachen University, Aachen, Germany Morgan Advanced Ceramics,
Hayward, CA
E. 11:30 AM Experimental
Technique for the Investigation of R. L. Hall Copper Development Association Brazing and Soldering
Liquid Filler Metal Flow Process (CDA), Loganville, GA of Copper
Through a Braze Gap and Fillet
Formation, by J. C. Madeni and
S. Liu, Colorado School of Mines, Wednesday, April 7, 2004
Golden, CO; F. M. Hosking, Sandia
National Laboratories, Albuquerque, 9 AM–12:15 PM
NM; and C. H. Cadden, Sandia
National Laboratories, Livermore, CA SESSION BS3
Brazing Processes, Testing, and Properties
A. 9 AM Hermetic Joints between Alumina and Kovar™ by Active Brazing
Process, by T. Oyama and A. Demmons, WESGO Metals, Division of Morgan
Advanced Ceramics, Hayward, CA
B. 9:30 AM Orientation Effects in Metal/Ceramic Brazing Using Active Filler
Metals, by C. Cadden, N. Yang, and N. R. Moody, Sandia National Laboratories,
Livermore, CA; F. M. Hosking, Sandia National Laboratories, Albuquerque, NM;
and M. Kennedy, Washington State University, Pullman, WA

Wednesday, April 7, 2004

C. 10 AM Effect of Brazing on
Formation of Non-Equilibrium Phases
during Diffusion Brazing of Inconel
738 Superalloy, by M. C. Chaturvedi,
O. A. Ojo, S. M. Crouch, and
N. L. Richard, University of Manitoba,
Winnipeg, Canada

10:30 AM–10:45 AM

D. 10:45 AM Flexure Testing of

Alumina Ceramic and Silver-Based
Active Filler Metal Braze Joints, Special Show discounts up to
by F. M. Hosking, J. J. Stephens,
T. Headley, and R. E. Loehman,
75 PERCENT OFF regular prices will be
Sandia National Laboratories, offered on a wide variety of AWS
Albuquerque, NM
E. 11:15 AM Elevated Temperature
publications at the AWS Book Store.
Mechanical Properties of the
62Cu-35Au-2Ti-1Ni (“Nicoro+2%Ti”)
Braze Alloy, by J. J. Stephens,
D. T. Schmale, J. B. Caris, F. M. Hosking,
and P. F. Hlava, Sandia National
Laboratories, Albuquerque, NM
F. 11:45 AM Optimization and
Characterization of Tool Steel
Assemblies Obtained by Ag-Cu
Brazing, by A. Nafi, O. Mercier, and
P. Revirand, Ecole Des Mines D’Albi,
Albi, France

Grab a Coke® and a code at the AWS Book Store,

where convenience and bargains will meet.

The 2004 AWS Book Store, operated by Global Engineering

Documents, will display literally thousands of titles —
publications you can review either on-line or skim through
at the Book Store. The Book Store will be open for business
during normal Show hours.

Compete Through Smarter Welding 23

Because the following sessions at of the AWS D1 Structural Welding workers. Twenty-eight years later, it
McCormick Place are free and likely to Committee and chair of the D1L remains the largest and most expen-
attract a large audience, on-line Seismic Issues Subcommittee. He is sive privately funded construction
preregistration is advisable. To manager of The Lincoln Electric project ever undertaken. Seventeen
preregister, go to Company’s Welding Technology Center percent of America’s oil moves through
after December 1, 2003. and a welding-design consultant for the 48-inch-diameter pipeline as it
the firm. winds 800 miles under and above
Wednesday, April 7, 2004 the ground through the nation’s most
Wednesday, April 7, 2004 environmentally sensitive land.
8 AM–9:30 AM The risk of damage to the pipeline
Structural Engineer Response to the 9 AM–2 PM Field Construction during welding maintenance and
World Trade Center Tragedy and/or Field Repair Sponsored by the repairs is increasing as a reduction
Emmanuel E. Velivasakis, P.E., the AWS Welding Industry Network (WIN) in the flow of crude oil causes the
lead forensic investigator at the World 9 AM–9:45 AM Field Welding pipeline’s operating temperature to
Trade Center, participated and directed Repair – Common Problems and decrease.
some 300 engineers in securing Their Solutions, by Keynote Speaker Bill Bruce, principal materials section
Ground Zero for safe search-and- Dave McQuaid, D. L. McQuaid & engineer at Edison Welding Institute
rescue efforts in the hours and days Associates, Inc., Bethel Park, PA in Columbus, Ohio, and Alan Beckett,
following the World Trade Center
9:45 AM–10:30AM Automated welding program steward at Alyeska
tragedy. In this presentation, he will
Ultrasonic Inspection Applications Pipeline Service Company in Anchorage,
discuss his team’s assessment,
on Field-Erected Tanks and Vessels, Alaska, will share the alternative
demolition, and temporary stabilization
by Ron Kruzic, Chicago Bridge & procedures that researchers have
efforts at the disaster site. A question-
Iron, Plainfield, IL devised to avoid weld cracking.
and-answer period will follow.
10:30 AM–11:15 AM Production In addition, they will discuss the safety
Mr. Velivasakis is president and
Welding of Alloy 59 Material for methods they use to make in-service
managing principal of LZA Technology,
Corrosion-Resistant Applications, repairs to the gas transmission
a division of The Thornton-Tomasetti
by Mark Butts, Chicago Bridge & pipeline supplying fuel to the north-
Group in New York City.
Iron, Plainfield, IL ern pump stations on TAPS.
10 AM–11:30 AM
11:15 AM–Noon Welding Symbols An audience question-and-answer
An Interview with the World’s
for a Global Manufacturing period will follow their presentation.
Leading Welding Design Expert
Environment, by Jerry Warren, Seating is limited. Please preregister
Omer Blodgett, Sc.D., P.E., is recognized
C & H Global, Burr Ridge, IL on-line at for the
throughout the world for his knowledge
free session with Bill Bruce and Alan
of welded design and his outstanding
Noon–1 PM Beckett.
ability to communicate, dramatize,
LUNCH ON YOUR OWN The presentation will focus on find-
and illustrate it. Dr. Blodgett was
among the notables inducted in the ings discussed in the white papers,
1 PM–1:45 PM Welding of the Review and Requalification of
first Class of AWS Fellows in 1991.
International Space Station Procedures for Maintenance Welding
He continues to present his Essential
Thermal-Control Units – Keeping on the Trans-Alaska Pipeline,
Elements of Steel Weldment Design
Cool in Space, by Ernest Levert, co-authored by Bruce; Mike Rosenfeld,
for Manufactured Products course
Lockheed Martin Missiles & Fire Kiefner & Associates, Columbus,
for The Lincoln Electric Company,
Control, Dallas, TX Ohio; and Beckett; and Trans-Alaska
Cleveland, OH, where he is the senior
design consultant. (See program Pipeline Fuel Gas Line In-Service
2:30 PM–3:30 PM Repairs, by Beckett; Frank Caito,
schedule for Thursday, April 8).
Challenges of Maintenance Welding Veco Engineering, Fairbanks, Alaska;
Another well-known welding expert, on the Trans-Alaska Crude Oil and Kurt Helms, Houston Nana JV,
Duane Miller, Sc.D., P.E., will act as Pipeline and Fuel Gas Line Repairs Fairbanks, Alaska.
the interviewer and will moderate Construction on the Trans-Alaska
an audience question-and-answer Pipeline System (TAPS) spanned two
period. Dr. Miller serves as vice chair years, and involved more than 30,000

3:30 PM–4:30 PM
Removing Dangerous Gases from Thursday, April 8, 2004
Ships Loading Crude Oil at Valdez
As tanker ships take on crude oil at 8 AM–10:30 AM
the Valdez Marine Terminal, the desti- Computer Procedures, Policies, and
nation of the Trans-Alaska Pipeline Security: Is Your Computer, Network,
System, stainless-steel arms capture Intranet, or Internet Safe from
flammable hydrocarbon vapors. FMC Mischief, or Worse, Mayhem?
Energy Systems in Sens, France, a Did you know that a $20 software
subsidiary of FMC Technologies, Inc., program that automates the process worked or higher system, you must
fabricated these devices, which are of computer forensics enables anyone attend this session.
the world’s first duplex stainless-steel to retrieve and view e-mails, por-
nography, and other secrets from a Security experts from Information
marine vapor-collection arms. Handling Services, Englewood, CO,
computer, even if the files were creat-
Tony Balowski, a welding engineer ed years ago? In today’s atmosphere will provide hints, tips, and insider
from the Alyeska Pipeline Service of spiraling litigation, no company or information to help you secure your
Company at Valdez Marine Terminal, consultancy, large or small, can afford computer operations.
will share insider details of the just to cross its fingers and hope it This free session will cover:
extensive research and testing that won’t be the victim of a virus, hacker, • Data protection, including
created this revolutionary develop- or disgruntled former employee. encryption, data erasers, and
ment in welded fabrication. secure USB drives.
If you don’t know that every click you
The presentation will focus on make on the Windows 98 Start Menu • Communications protection,
findings discussed in the white paper, is logged and permanently stored on including anti-virus tools, firewalls,
Fabrication of World’s First Duplex a hidden encrypted database; if you wireless security, secure e-mail,
Stainless Steel Loading Arms, think that deleting “Internet cache anti-spam, anti-spyware, and
by Balowski and Chuck Strub, and history” will protect you; or if secure browsing.
Alyeska Pipeline Service Company, you’re planning to upgrade to a net- • Physical protection, including
Anchorage, Alaska. laptops, surveillance, and
hardware authentication.


Tuesday, April 6, 2004 Classroom to the Workplace, by G. A. Roy, Northrup
Grumman Newport News, Newport News, VA; J. C. Barto III
EDUCATION SESSION 1 and L. T. Saylor, Training Modernization Group, Inc.,
Chesapeake, VA; and E. Dupree, New Horizons Regional
9 AM–10 AM 2004 Plummer Memorial Educational
Education Center, Hampton, VA
Lecture Welder Training: What Can We Learn From the
Cockpit? by Byron May, manager, repair process and
materials engineering, United Air Lines, San Francisco, CA
10:10 AM–10:40 AM Integrating Technology into the EDUCATION SESSION 2
Classroom: The Modernized Welding Program at New
1:30 PM–2 PM S.E.N.S.E. Questions and Answers:
Horizons Regional Education Center, by E. Dupree,
A Guide to the Changes in AWS Welding Curriculum
New Horizons Regional Education Center, Hampton, VA;
Guidelines, by Ed Norman, Southwest Area Career Center,
J. C. Barto III and A. D. Robertson, Training Modernization
Monett, MO
Group, Inc., Chesapeake, VA; and G. A. Roy, Northrup
Grumman Newport News, Newport News, VA 2:05 PM–2:35 PM The Education and Training of
Welding Technicians, by James R. Hannahs, P.E., Edison
10:45 AM–11:15 AM Education and Training Strategies
Community College, Piqua, OH
for Advanced Welding Technology, by Dr. W. R. Polanin,
Illinois Central College, East Peoria, IL 2:45 PM–3:45 PM Panel Discussion Attracting Students
to the Welding Industry
11:20 AM–11:50 AM A Model for Industry and Technical
School Cooperation: Helping Students Transition from the 25
Compete Through Smarter Welding
Wednesday, April 7, 2004 Thursday, April 8, 2004
The Education Committee encourages everyone to 9 AM–11:15 AM Student Day: College Careers in Welding
attend An Interview with the World’s Leading Welding This session is free to all registered attendees.
Design Expert, featuring Dr. Omer Blodgett. (See page 24
9 AM–9:30 AM Higher Education in Welding Engineering,
for details.)
by Yoni Adonyi, LeTourneau University, Longview, TX
Noon–4 PM Plant Tour
9:35 AM–10:05 AM Welding Engineering Education
Registration available on-site; see for
under a Manufacturing Engineering Program, by Leijun Li,
more information.
Utah State University, Logan, UT
10:10 AM–10:40 AM Graduate Research and Engineer-
ing Career in Welding - Perspectives of a Metallurgical
Engineer, by Greg Chirieleison, The Colorado School of
Mines, Golden, CO
10:45 AM–11:15 AM You Want Me to Do What? –
Relating My Education to My Internship Experience,
Caleb Roepke, LeTourneau University, Longview, TX

The nonmember conference fee includes a two-year Ken Coryell, a welding quality consultant based near
membership in the American Welding Society. Cleveland in Burton, OH, has been an AWS faculty member
for over 17 years. His experience includes over 30 years of
About the Instructors welding quality assurance, quality control, nondestructive
examination, and welding engineering for the electric utility,
Ed Bohnart (SCWI, CWE, CRAW-T, and former Certified petrochemical, aerospace, shipbuilding, and structural indus-
Welder) of Winneconne, WI, is president of Welding tries. He is an AWS SCWI, an ASNT Level III certificate holder
Education & Consulting. He launched his consulting in radiography and liquid penetrant testing, and a Registered
practice, with offices in Florida and Wisconsin, after a Professional Engineer. He earned bachelor’s and master’s
successful career directing Miller Electric Manufacturing degrees in Welding Engineering from The Ohio State Univer-
Company’s training operations. Prior to joining Miller sity. His professional affiliations include AWS, ASNT, ASME,
Electric, he was welding instructor at Father Flanagan’s ASM, and the National Society of Professional Engineers.
Boys Home, Boys Town, NB. He is an AWS Distinguished Eugene G. Hornberger of Hampton, VA, is a welding
Member and Past President. Bohnart remains active with consultant for Richmond, VA-based Arcet Equipment
the SkillsUSA organization and chairs the AWS Skills Company. Previously, he was in charge of welder training
Competition Committee, which conducts the U.S. Open for Newport News Shipbuilding. Within AWS, he has served
Weld Trials to select the U.S. competitor for the World Skills on the board of directors and has chaired the AWS
Competition. For six years, Bohnart chaired the AWS C5 Education Committee. He has written and edited several
Committee on Arc Welding and Cutting Processes, and he books, including Welding Processes and Practices, coau-
remains active on the committee as an advisor. thored with AWS Fellow (Class of 1993) August Manz.
Dr. Richard Campbell of Purity Systems, Inc., Louisville, He was the editor for the new AWS publication, Design
CO, is an expert on welding stainless steels and and Planning Manual for Cost Effective Welding, and is
nickel alloys. He serves on the AWS Gas Tungsten Arc working on several other publication projects for the
Welding and Sanitary Applications Committees and on Society. Hornberger teaches welding and troubleshoots for
ASME’s BioProcessing Equipment Standards Materials Arcet’s customers, and as a senior instructor he leads AWS
Joining Subcommittee. He holds a B.S. degree from seminars on preparing for the CWI examination.
LeTourneau University and a Ph.D. from Rensselaer
Polytechnic Institute.
Professional Development Hours • What types of defects and discontinuities may we encounter?
• Is nondestructive examination (NDE) required?
Sessions offer one Professional Development
What does it tell us?
Hour (PDH) for each hour of instruction. PDHs can
Attendees will receive a copy of the Design and Planning Manual
be used toward an AWS recertification or other
for Cost-Effective Welding, a $68 value.
educational requirement. Professional Development Hours: See box on this page.
Monday, April 5, 2004 Tuesday, April 6, 2004
8:30 AM–4:30 PM 8:30 AM–4:30 PM
Road Map through the D1.1/D1.1M:2004, Inspection to the AWS D1.1/D1.1M:2004,
Structural Welding Code—Steel Structural Welding Code—Steel
Instructor: Ken W. Coryell Instructor: Ken W. Coryell
Fees: Member: $345, Nonmember: $470 Fees: Member: $345, Nonmember: $470
This one-day program provides a comprehensive overview of the This one-day course is devoted to inspection of structural steel
AWS D1.1/D1.1M:2004, Structural Welding Code—Steel. Each of welds. Inspector qualifications and the responsibilities of inspec-
the code sections, including General Requirements, Design of tors and contractors will be covered. Procedures and techniques
Welded Connections, Prequalification, Qualification, Fabrication, for visual, liquid penetrant, magnetic particle, radiographic, and
Inspection, Stud Welding, and Strengthening and Repair of ultrasonic inspection are highlighted as a prelude to a detailed
Existing Structures, will be summarized with emphasis on their review of the inspection acceptance standards. Test method fun-
interrelationships and usage. In addition, the role of mandatory damentals will be covered, where necessary, to understand the
and nonmandatory annexes will be reviewed, along with tips on more in-depth tables and criteria, along with tips on what to look
using the code Commentary. for in inspection reports.
Who Should Attend: Who Should Attend:
This program will benefit managers, engineers, supervisors, Supervisors, engineers, inspectors, and auditors will gain a better
inspectors, and other decision-makers who need comprehensive understanding of weld quality from this presentation.
understanding of what is, and what is not, covered by AWS
D1.1/D1.1M:2004 to improve their job effectiveness. Topics covered:
• General inspection requirements, including basis of
Attendees must bring their own copy of AWS D1.1/D1.1M: inspector qualifications, inspection of materials,
2004, Structural Welding Code—Steel. Order it on-line at inspection of Welding Procedure Specifications (WPSs), or call IHS/Global Engineering at and equipment, inspection of qualifications, and
800-854-7179. inspection of work and records
Professional Development Hours: See box on this page. • Acceptance criteria, including visual, liquid penetrant,
magnetic particle, radiographic, and ultrasonic test
Monday, April 5, 2004 methods for all design loading conditions
8:30 AM–4:30 PM • NDE procedures, including personnel qualification,
Planning for Cost-Effective Welding radiographic testing, ultrasonic testing, magnetic particle
Instructor: Eugene G. Hornberger testing, and liquid penetrant testing
Fees: Member: $345, Nonmember: $470
Attendees must bring their own copy of AWS D1.1/D1.1M:
Get a better understanding of what is required to fabricate a 2004, Structural Welding Code—Steel. Order it on-line at
product. This course provides the background needed by engi-, or call IHS/Global Engineering at
neers, supervisors, and senior technicians who have welding- 800-854-7179.
management responsibilities. It covers often-overlooked aspects Professional Development Hours: See box on this page.
of accepting the job and examining the requirements for fabricat-
ing the product, and reviews the best methods for building the Tuesday, April 6, 2004
product. 8:30 AM–4:30 PM
The course will cover basic welding processes, safety, nondestruc- Arc Welding and Power Sources
tive examination, welding metallurgy, weld discontinuities, and Instructor: Edward R. Bohnart
calculating weld costs. Fees: Member: $345, Nonmember: $470
Anyone with these questions should attend: Veteran welder Ed Bohnart has poured 30 years of hands-on
• How does a pre-bid review group work? What is its experience into this much-needed and highly demanded program
makeup? What does it do? from AWS. This isn't an advanced course inflated with theory. It's
• What are capabilities of the welding processes? a primer directed at engineering professionals with evolving
What are their advantages or disadvantages? responsibilities in welding, or for the ambitious senior technician.
• What are the safety aspects involved with the welding If extracting the most from power sources has been a constant
operation? problem, if you need to know the ins and outs of set-up and smooth
• What changes occur to the metals structure when welded? operation, or if this facet of welding is a new job responsibility, then
• What are some of the effects that fatigue has on life of take advantage of this opportunity. The program will benefit profes-
the weldment? What can we do to eliminate or minimize
detrimental effects?

Compete Through Smarter Welding 27

sionals who specify arc welding equipment and processes, such THE AUTOMATIC WELDING CONFERE
as engineers, technicians, welders, supervisors, and set-up and
maintenance personnel. Purchasers will particularly benefit. Wednesday and Thursday, April 7 and 8, 2004
Topics include: Wednesday 9 AM–4:10 PM, Thursday 9 AM–11:30 AM
• Equipment operating precautions Getting the Most Out of Your Automatic Welding Investment
• Equipment and process fundamentals for GTAW, SMAW, Fees: Member: $550, Nonmember: $675
GMAW, FCAW, and CAC; voltage, amperage, and metering The time has come to reduce your welding costs. Automatic
• Power sources welding is the way to do it. Engineers have been discussing
• Controls automatic welding for decades, but many of these discussions
• Problems and troubleshooting have not really hit the bull’s-eye – cost-effectiveness. More than
• Common misunderstandings ever, industry must pay more attention to automatic welding. If a
• How to get more performance from your existing equipment company is not using it, why not? And, if a company is using it,
• Why your electric power bill is the most commonly then what can be done to improve the process? How can the
overlooked expense quality of the weldment be improved? As the quality is improved,
• How to use product specifications to select the power the cost will be driven down. This conference will examine the
source with the right features improvements to conventional automatic-welding processes, and
Attendees will receive the following American Welding Society present some of the newer methods such as laser welding, fric-
publications, valued at $176: tion stir welding, magnetic forge welding, and hybrid welding.
You also will hear about monitors, vision systems, joint tracking
— The Professional's Advisor on Arc Welding Power Sources
systems, robotics, and laser cameras.
— Recommended Practices for Gas Tungsten Arc Welding
Professional Development Hours: See box, page 27.
— Recommended Practices for Gas Metal Arc Welding
Professional Development Hours: See box, page 27.

Tuesday and Wednesday, April 6 and 7, 2004

Wednesday, April 7
8:30 AM–4:30 PM
Welding Fabricator Quality Management System
Working Seminar 9 AM–12:10 PM
Instructors: Terry Logan and Anna Petroski WELCOME
Fees: Member: $550, Nonmember: $675 Robert Irving, consultant, Yardley, PA
Conference Chair
This two-day event is focused on small to medium-sized organiza-
tions. Participants will review the elements of a quality-management 1. Systems Approach to Welding Automation,
system and how it can be applied effectively to a welding fabrica- by Donald L. Lynn, Welding and Joining Management Group,
tor’s business in an inspiring and entertaining way. The event will Dayton, KY
teach you the value of the effective implementation of procedures
that manage the entire business. It is not just QA and QC that can Productivity in automated welding begins with a systems
have a profound effect on business improvement. approach to potential welding applications. A systems approach
will identify the best production candidates for automated weld-
Welding fabricators also will benefit from participating in group ing, and ensure the highest productivity once the automated
discussions where they will learn about the direction and experi- welding begins.
ences of other fabricators in the quest for improved quality.
Attendees will learn to apply the requirements of the AWS 2. The AWS A9.4 Network Specification for Weld Cell Integration,
Welding Fabricator qualification, as well as related codes and by William G. Rippey, National Institute of Standards and
standards. Technology, Gaithersburg, MD
Topics Covered: This presentation describes functional and technical details of
• Quality personnel requirements the CAN-based protocol, A9.4, being developed by the AWS A9
• Management support and organization committee. This network technology is replacing point-to-point
• Quality document and procedure control electronic links to connect power sources, wire feeders, gas
• Quality records controllers, and other devices for hard automation and robotic arc
• Material control welding, and will make integration of weld cell devices more
• Welding procedures efficient and effective.
• Filler materials
• Welder performance qualification Refreshment Break
• Inspection
• Nonconformance
• Measuring and testing equipment 3. Optimizing the GMAW Process Using Digital Technology,
• Quality audits by Randy Broadwater, Miller Electric Manufacturing/ITW,
Appleton, WI
Attendees will receive a copy of the AWS B5.17:2000, Specifi-
cation for the Qualification of Welding Fabricators, valued at $24. The use of digital waveform control technology with modern power
Professional Development Hours: See box, page 27. conversion platforms opens opportunities for developing hybrid
welding process and arc transfer modes. Now a choice of arc

transfer modes is available from a single power source, opening Refreshment Break
the possibility of applying a specific mode to the joint at hand to
optimize welding performance. Now travel speeds, deposition 9. Trends in Transgun Resistance Spot Welding,
rates, spatter reduction, and gap filling can be optimized. Digital by Mark Siehling, RoMan Manufacturing Co., Grand Rapids, MI
network technology also opens up the ability to communicate, The increasing application of transguns for resistance spot-
store, and retrieve data on robot controllers, palm handhelds, and welding operations is having a positive effect on cost and quality.
PCs, and to send weld programs via e-mail. Reducing robot payloads and increasing system reliability have
made dramatic improvements in flexible automation.
4. Development of a Portable Laser-Guided Welding Travel
Carriage, by Ed Celesti, Bug-O Systems, Pittsburgh, PA 10. Friction Stir Welding of Aluminum for Automotive
A consortium that includes Bug-O Systems and MEL Mikroelectronik Applications, by Arthur P. Scafe, Tower Automotive, Inc.,
GmbH has developed a portable, fully-integrated, laser-guided Rochester Hills, MI
three-axis travel carriage. The unit reads the weld joint and will Friction stir welding (FSW) now is in use on automotive compo-
adapt its travel and oscillation speed according to the fit-up. nents for vehicles produced in America. With this new joining
Preprogramming of root fill and cover passes is possible. The technology, the industry must learn how to apply the technology
machine can perform multi-layer, multi-pass welds on butt joints, in both current and future designs. This presentation will focus
T-joints, and lap joints. on the parameters and the design considerations in FSW, and
will cover potential applications on suspensions, body structures,
5. Robotic Metal Cored Robotic Arc Welding with cradles and frames, and the future of FSW in steel products.
Small Diameter Wires, by Chris Anderson, Motoman, Inc.,
Carrollton, OH
At a given current level, metal cored wires provide higher deposi- Thursday, April 8
tion than solid wires. This can be used to increase weld travel
speeds or fill gaps in thinner sheet metal components. In addition, SESSION III
powdered chemical agents added to the core can improve weld- 9 AM–11:30 AM
ability with coated materials or mechanical properties of the weld.
11. Networked Welding: Information for the Future,
12:10 PM–1:10 PM LUNCH ON YOUR OWN by Chris Bailey, The Lincoln Electric Co., Cleveland, OH
A new generation of digital welding equipment is designed to
SESSION II harness the economic power of the Net in an increasingly com-
1:10 PM–4:10 PM petitive global market. Embedded networking capability inside
welding equipment allows inter-connectivity of power sources and
6. Automated Laser Processing and Impact on Manufacturing associated machinery in a production environment. The resulting
Costs, by Paul Denney, Edison Welding Institute, Columbus, OH economy of scale of standard network components and software
can dramatically drive down the cost of the development, deploy-
Laser processing (welding, cutting, drilling, and cladding) has ment, and user training for such networks.
made a major impact in manufacturing. Although they are capital-
intensive, lasers have been put into operation in industries as
diverse as medicine, electronics, and shipbuilding. The presenta- 12. Shielding Gas Selection and Its Impact on Automated
tion will give an overview of how lasers are being used and justi- Welding Quality, Productivity, and Cost, by Kevin A. Lyttle,
fied. Praxair, Inc., Tonawanda, NY
When the shielding gas blend is tailored to the application,
7. Use of Models to Improve the Cost and Quality of Welds, significant improvements in quality and productivity can result in
by Dr. Gordon Clark, The Ohio State University, Worthington, OH reduced welding cost. Examples of carbon and stainless steel
The paper presents three models. The cost model includes a applications show savings of at least 10 percent when the best
general approach to estimating cycle time in automated systems. gas blend is selected.
Two quality models use data from a small number of welds to
estimate the probability of covering a joint and the yield from Refreshment Break
welds subject to porosity.
13. An Overview of Hybrid Welding, by Christian Walz, Center for
8. How Robotics Can Reduce Overall Manufacturing Costs, Coatings and Laser Applications, Plymouth, MI
by Richard Monaco, Wrayco Industries, Inc., Stow, OH Hybrid welding, a combination of laser beam welding and a
American manufacturing is faced with fierce global competition. conventional arc welding process such as GMA welding or GTA
Automated welding can be a successful process to reduce labor welding, is one of today’s hot topics in the laser industry. How does
cost and improve quality. The speaker will share his experience in it work? What are the advantages? What are potential applica-
the transformation of a welding shop from primarily manual weld- tions? These are some of the questions asked in most discussions
ing to robotics. Understand how automated welding can enhance about this “new” process. The presentation tries to answer these
your company’s growth even in difficult economic times. questions and shows some current applications of the process.

Compete Through Smarter Welding 29

THE AUTOMATIC WELDING D16.3/D16.3M:2001, Risk Assessment Guide for Robotic
D16.4:1999, Specification for Qualification of Robotic Arc
14. Reintegration or New Equipment, by Harlon Neumann, Welding Personnel
Genesis Systems Group, Davenport, IA QC19:2002, Standard for AWS Certification of Robotic Arc
A neutral look at what considerations can affect your decision Welding—Operators and Technicians
to purchase new robotic arc welding equipment or to use ARE-10, Monitoring and Control of Welding and Joining
existing assets: Processes
• Product characteristics ARE-11, Mechanized, Automated, and Robotic Welding
• Program volumes and life Professional Development Hours: See box, page 27.
• Workcell design
• Safety Wednesday, April 7, 2004
• Maintenance 8:30 AM–4:30 PM
• Floor space The Why and How of Welding Procedure Specifications
• Head-to-head comparisons and calculations Instructor: Ken W. Coryell
Professional Development Hours: See box, page 27. Fees: Member: $345, Nonmember: $470
If you are responsible for planning a welding operation, which
of the following items are the most critical: base metal, welding
Wednesday and Thursday, April 7 and 8, 2004 process, filler metal, current and range, voltage and travel speed,
8:30 AM–4:30 PM joint design tolerances, joint and surface preparation, tack weld-
Certified Robotic Arc Welding Technician and Operators Seminar ing, welding position, preheat and interpass temperature, or
Instructor: Edward R. Bohnart shielding gas? This course provides the answers.
Fees: Member: $550, Nonmember: $675
The instructor, Ken Coryell, uses his 25 years of international and
This new AWS credential signifies that the robotic arc welding oper- domestic experience in weld quality to shed light on the most
ator or technician has demonstrated the capability of working common problems, misunderstandings, and mistakes. Coryell
safely and effectively in the arc welding cell. Because proof of offers insider advice, hints, and tips on optimum use of the
active practice or re-examination is required every three years, Procedure Qualification Record (PQR) and the Welding Procedure
certification also signifies that the operator or technician is current Specification (WPS).
with the welding industry’s standards.
This program will benefit owners, managers, engineers, and
AWS is offering a two-day training seminar to cover the central supervisors who must qualify, write, or revise their own welding
requirements that will be tested if the participant wishes to procedure specifications to satisfy codes and contract documents.
proceed on to credentialing. Professionals needing a broad
Topics Covered:
overview of automation and robotics issues also should attend.
• Proper preparation and qualification of welding procedure
The topics covered in this seminar include: specifications
• Weld equipment setup • Selecting and documenting welding variables
• GMAW plus other gas-shielded processes • Documenting standard procedure qualification testing
• Weld examination for commonly used processes for joining ferrous plate
• Terms and definitions and pipe materials
• Symbols – welding and robotics
You Can Learn To:
• Safety
• Specify essential and non-essential variables commonly
• Destructive testing
used in sample AWS, ASME, and API code formats
• Conversion and calculations
• Use standards when preparing procedures
• Robot programming
• Document welding variables and qualification tests
• Welding procedures
• Avoid the pitfalls in revising previously qualified procedures
• Programming logic
• Kinematic concepts Attendees will receive a copy of the AWS B2.1:2000,
• Robot arc welding cell components Specification for Welding Procedure and Performance
• Review of AWS D16.4:1999, Specification for Qualification, valued at $120.
Qualification of Robotic Welding Personnel
• Review of AWS QC19:2002, Standard for AWS Certification of
Robotic Arc Welding—Operators and Technicians
• Requirements for the AWS performance portion of the
certification text
Attendees will receive a copy of the following American Welding
Society publications, valued at $236:
D16.2/D16.2M:2001, Guide for Components of Robotic
and Automatic Welding Systems

Wednesday and Thursday, April 7 and 8, 2004 Thursday, April 8, 2004
8:30 AM–4:30 PM 8:30 AM–Noon
Welding of Stainless Steels (Basics and Avoiding Weld Defects) Introduction to Design of Weldments
Instructor: Richard Campbell Instructor: Dr. Omer Blodgett, Senior Design Consultant,
Two-Day Fee: Member: $550, Nonmember: $675 The Lincoln Electric Company, Cleveland, OH
Single Day Fee: Member: $345, Nonmember: $470 Course Fee (includes materials): $125
This seminar has two independent parts: Learn what 15,000 other engineers have been told: how to save
Part 1 - The Basics (Wednesday, April 7), and money through efficient design of welds. Attend this half-day
Part 2 - Avoiding Defects (Thursday, April 8). course and get cost-reduction ideas from the world’s foremost
You may register for either day or for both days. authority, Omer Blodgett, Sc.D., P.E., a world-renowned
(See Seminar Registration Form, page 33.) structural-design engineer, lecturer, and author of Design of
Weldments and Design of Welded Structures.
Part 1: The Basics This wide-ranging course also includes:
This course is designed for engineers and technicians who work • Instruction on mechanical properties of welded connections
with stainless steels and could benefit from a greater understanding • Overview of welding processes
of the special considerations necessary to weld these alloys. The • Determining what size weld is needed
program focuses on the basic weldability of all types of stainless • Basics of fracture mechanics
steels. If you need a comprehensive look at the weldability of stain- • Design for fatigue and shock welding
less steels, particularly the 300 series, this course is for you. • Nondestructive examination (NDE)
Topics Covered: • Control of distortion
• Why alloys are "stainless" Attendees will receive custom handouts and the “Design for
• Stainless steel differences Welding” chapter from Welding Handbook, 9th Ed., Volume 1,
• Selecting a stainless for use Welding Science and Technology.
• Mechanical properties
• Properties after welding Thursday, April 8, 2004
• Heat treatment factors 9 AM–Noon
• Selecting filler metals Advanced Commercial Development – Manufacturability of
• Gas vs. flux shielding Fuel Cell Products
• Code requirements Moderators: Wangen Lin, Ph.D., and Frank E. Jakob, P.E.,
You Can Learn: Edison Welding Institute, Columbus, OH
• Five stainless steel types This session will examine the manufacturing challenges facing
• The effects of welding on all types of stainless steels the fuel cell power industry as the science behind fuel cells
• Why some stainless steels require preheat and others matures, the engineering of fuel cell devices proceeds, and the
prohibit it design of fuel cell products finds markets willing to pay the early,
• Answers to your questions about selecting and welding relatively high price points of current products.
stainless steels
Part 2: Avoiding Defects • Manufacturability of fuel cell products (overview)
This program is designed for individuals who possess a basic • Materials in fuel cell products (metals, graphite, plastics)
understanding of stainless steels. It focuses on defects, special • Portable (small) fuel cell product manufacturing (batteries)
problems, and typical applications associated with welding all • Stationary (medium) fuel cell product manufacturing (buildings)
types of stainless steels. • Transportation (large) fuel cell product manufacturing
Topics Covered:
• Specific weld defects
• Sensitization
• Penetration problems
• Weld hot cracking
• Weld cold cracking
• Excessive grain growth and other embitterment concerns
• Welding dissimilar metals
You Can Learn:
• The most-encountered welding problems for each of
the five stainless steel types
• Methods to reduce or eliminate hot cracks and sensitization
• Answers to your questions about the application of
different stainless steels to avoid weld defects
Attendees will receive the following American Welding Society
publications, valued at $192:
• PASS, The Professional's Advisor on Welding Stainless Steels
• D1.6-98, The AWS Structural Welding Code—Stainless Steel
Professional Development Hours: See box page 27. Compete Through Smarter Welding 31
April 5-8, 2004 APPLICATION DEADLINE: MARCH 5, 2004
McCormick Place, Chicago, IL


Choose one of four convenient ways to reserve a room:

1. On-Line: 3. Fax: 800-521-6017 (U.S./Canada)
or 847-940-2386 (Outside U.S./Canada)
2. Mail: AWS/One-Stop Chicago/ITS
P.O. Box 825 4. Call (for five or fewer rooms only):
108 Wilmot Road, 4th Floor Phone: 800-424-5248 (U.S./Canada) or
Deerfield, IL 60015-0825 847-940-2152 (Outside U.S./Canada)
From 8AM – 5PM CST
Confirmations will be sent out from ONE-STOP CHICAGO/ITS by e-mail, fax, or mail. Do not expect a confirmation from the
hotel. Send confirmation to (please print or type):

Check One: Attendee Exhibitor

First Name________________________________________________Middle Initial_______Last Name ______________________________________

Company __________________________________________________________________________________________________________________

Address_____________________________________________________________________City __________________________________________

State/Province_______________________________________Zip+4____________________________Country ________________________________

Phone_______________________________Fax_______________________________E-mail ______________________________________________

Hotel Preferences – Rooms are assigned on a first-come first-serve basis. If your hotel choices are not available, you will be assigned to the next available
hotel in your preference. Rates do not include tax, which is currently 14.9% in Chicago (subject to change).

See page 35 for official hotel map and rates. List hotel choices in order of preference below.
1. ________________2. ________________3. ________________4.________________
Headquarters Hotel is the Hilton Chicago.

Guest Name (Brackets if Sharing) # In Room Room Type* Arrival Departure Non-Smoking Physical
Day/Date Day/Date Challenges**

* Single ( 1 Person); Double (2 Persons); Triple (3 Persons); Quad (4 Persons) ** Please attach written request for special needs.

Deposits – A $175 deposit is required for each room, $350 for a 1BR suite and $525 for a 2BR suite. Reservations cannot be processed without a deposit.
Deposits may be paid by credit card or check. Credit cards will be charged immediately. Checks must be made payable to One-Stop Chicago in U.S. dollars
and drawn on a U.S. bank. All reservations, changes, and cancellations must be made through One-Stop Chicago through March 18, 2004. Beginning March
23, contact the hotels directly. Cancellations made after March 5 are subject to $16.50 processing fee by the hotels. Please review your assigned hotel’s
individual cancellation policy, which will be stated on your hotel confirmation from One-Stop Chicago

Bill my credit card: Amex MasterCard Visa Discover Diners Club

Card Number: ______________________________________________Exp. Date: ________________________________

Card Holder’s Name: ________________________________________Signature: ________________________________
Check Enclosed: Money Order Enclosed:
(Payable to One-Stop Chicago in U.S. dollars and drawn on a U.S. bank):$ ________________________________________

April 5-8, 2004 IMPORTANT: Please fill out sections B through K
McCormick Place, Chicago, IL on the reverse side of this form.


A. General Information (Required) (No one under 16 admitted. Those under 18 years of age must be accompanied by an adult at all times.)
First Name________________________________________________Middle Initial_______Last Name ______________________________________
Company __________________________________________________________________________________________________________________
Address_____________________________________________________________________City __________________________________________
State/Province_______________________________________Zip+4____________________________Country ________________________________
Phone_______________________________Fax_______________________________E-mail ______________________________________________


AWS Awards / AWS Foundation Recognition Luncheon 6-Apr Noon 2:00p 11 $30 $30
Prayer Breakfast 7-Apr 7:30a 8:30a 13 $20 $20

(Incl. 34th International Brazing and Soldering Symposium) CODE MEMBER NON-MBR*
Complete Professional Program 6-8-Apr 9:00a 5:00p 25 $225 $350
Author/Presiding Officer in Professional Program 6-8-Apr 9:00a 5:00p 26 $50 $125
Single Day Professional Program Tue(28), Wed(29), Thu(30) $150 $275
Education Program 6-Apr 9:00a 5:00p
31 Free Free
7-8-Apr 9:00a 11:30a
Student Professional Program 5-8-Apr 9:00a 5:00p 32 $30 $45**
Abstracts Only 33 $75 $75


The Automatic Welding Conference: 7-Apr 9:00a 4:10p
40 $550 $675
Getting the Most Out of Your Automatic Welding Investment 8-Apr 9:00a 11:30a

Road Map Through the 2004 D1.1 Code 5-Apr 8:30a 4:30p 41 $345 $470
Planning for Cost-Effective Welding 5-Apr 8:30a 4:30p 42 $345 $470
Inspection to the 2004: D1.1 Code 6-Apr 8:30a 4:30p 43 $345 $470
Arc Welding and Power Sources 6-Apr 8:30a 4:30p 44 $345 $470
Welding Fabricator Quality Management System 6-Apr 8:30a 4:30p
45 $550 $675
7-Apr 8:30a 4:30p
Certified Robotic Arc Welding Technician and Operators 7-Apr 8:30a 4:30p
47 $550 $675
8-Apr 8:30a 4:30p
Why and How of Welding Procedure Specifications 7-Apr 8:30a 4:30p 49 $345 $470
Welding of Stainless Steel Part 1 - The Basics 7-Apr 8:30a 4:30p 50 $345 $470
Welding of Stainless Steel Part 2 - Avoiding the Defects 8-Apr 8:30a 4:30p 51 $345 $470
Welding of Stainless Steel Parts 1 and 2 7-8-Apr 8:30a 4:30p 52 $550 $675
Design of Weldments 8-Apr 8:00a Noon 53 $125 $125


Cash (accepted only at show) Check enclosed (made payable to The American Welding Society)
Bill my credit card: Amex MasterCard Visa Discover Diners Club

Card Number: ______________________________________________Exp. Date: ________________________________

Card Holder’s Name: ________________________________________Signature: ________________________________
* Nonmember price includes a two-year AWS Individual Membership (except codes 11, 13, 26, 31, 32, 33, and 53). Member benefits include a subscription
to the Welding Journal, a 25% discount on AWS publications, simultaneous membership in a local Section, and more.
** Nonmember Student Professional Program price includes a one-year AWS Student Membership.

Compete Through Smarter Welding 33

April 5-8, 2004 receive your credentials by mail. After March 12,
bring this registration form to the Expo for free admission.
McCormick Place, Chicago, IL


A. General Information (Required) (No one under 16 admitted. Those under 18 years of age must be accompanied by an adult at all times.)
First Name________________________________________________Last Name ________________________________________________________
Title_____________________________________________________Spouse/Guest ______________________________________________________
Company ❏ Headquarters ❏ Division___________________________________________________________________________________________
Address ❏ Company ❏ Home____________________________________________________________________ ____________________________
City_______________________________________________State/Province__________Zip+4_______________Country ________________________
Phone_______________________________Fax_______________________________E-mail ______________________________________________

B. Are you a member of ?: 14 ❏ Automotive (sub-categorize if applicable) 03 ❏ Electrogas/Electroslag

❏ AWS 141 ❏ Industrial Tractor, Trailer 04 ❏ Electron Beam
❏ GAWDA 142 ❏ Heavy Duty Truck & Bus Body 05 ❏ Friction Welding
❏ Neither 143 ❏ Motor Vehicle Body & Frame 06 ❏ GMAW Automatic
144 ❏ Motor Vehicle Parts 07 ❏ GMAW Manual
C. Are you, or is your company, a distributor?
15 ❏ Aerospace 08 ❏ Hardfacing/Surfacing
❏ Yes (if “yes” call for more VIP Passes)
16 ❏ Railroad Rolling Stock Mfg. 09 ❏ Laser Beam Welding
❏ No
17 ❏ Shipbuilding & Repair 10 ❏ Oxyacetylene Welding
D. Primary Function (check one) 18 ❏ Wholesale Trade 11 ❏ Pipe Welding
01 ❏ Owner, President, CEO 19 ❏ Architectural, Engineering, R&D 12 ❏ Plasma Arc Welding
02 ❏ Management 20 ❏ Education Services 13 ❏ Plasma Arc Cutting
03 ❏ Engineering 21 ❏ Commercial/Industrial Equipment Repair & 14 ❏ Plastic Welding Equipment
04 ❏ Manufacturing Maintenance (except Automotive & Electric) 15 ❏ Positioners, Manipulators
05 ❏ Welder, welding operator 22 ❏ Heavy Construction 16 ❏ Power Supplies GMAW
06 ❏ Purchasing 23 ❏ Water, Sewer, Pipeline 17 ❏ Power Supplies GTAW
07 ❏ Marketing/Sales 24 ❏ Structural Steel Erection 18 ❏ Power Supplies SMAW
08 ❏ Educator 19 ❏ Power Supplies SAW
G. Type of Company (check one)
09 ❏ Other 20 ❏ Resistance Welding & Controls
01 ❏ Contract manufacturer/job shop
E. Purchasing Authority (check one) 21 ❏ Robots (Arc)
02 ❏ End product manufacturer/OEM
01 ❏ Recommend 22 ❏ Robots (Resistance)
03 ❏ Non-manufacturing
02 ❏ Specify 23 ❏ Soldering
04 ❏ Other (specify) ____________________
03 ❏ Approve 24 ❏ Spot Welding & Controls
H. Total Employees at this Location (check one) 25 ❏ Stud Welding & Controls
F. Company’s Primary Field 01 ❏ 1-19 26 ❏ Submerged Arc (Automatic)
or Market (check one) 02 ❏ 20-49 27 ❏ Submerged Arc (Manual)
01 ❏ Electric Utility 03 ❏ 50-99 28 ❏ Thermal Spraying
02 ❏ Construction 04 ❏ 100-249 29 ❏ Ultrasonic Welding
03 ❏ Pulp & Paper Processing 05 ❏ 250-499 30 ❏ Weld Joint Tracking Systems
04 ❏ Chemical Manufacturing 06 ❏ 500-999 31 ❏ Weld Seamers
05 ❏ Petrochemical Manufacturing 07 ❏ 1,000+ 32 ❏ Weld Sensors
06 ❏ Primary Metals Manufacturing 33 ❏ Other Welding Equipment
I. Processes Performed by Your Company
07 ❏ Steel Product Manufacturing
011 ❏ Arc Welding K. Industrial Gases and Related Equipment
08 ❏ Fabricated (Plate) Metal Products
012 ❏ Resistance Welding 01 ❏ Fuel Gases
09 ❏ Prefabricated Metal Buildings
013 ❏ Laser/Electron Beam Welding 02 ❏ Shielded Gases
10 ❏ Fabricated Structural Metal
014 ❏ Brazing & Soldering 03 ❏ Cryogenic Pumps
11 ❏ Steel Metal Work
015 ❏ Other: __________ 04 ❏ Cylinder Coatings
12 ❏ Other:_______________
13 ❏ Machinery Mfg. 05 ❏ Gas Cylinders
02 ❏ Assembly
(sub-categorize if applicable) 06 ❏ Gas Generating Equipment
03 ❏ Automation
131 ❏ Agriculture 07 ❏ Gas Regulators
04 ❏ Finishing
132 ❏ Construction 08 ❏ Handling Equipment
J. Welding Equipment Used by Your Company 09 ❏ Storage & Distribution Equipment
133 ❏ Mining Machinery
01 ❏ Brazing 10 ❏ Other Industrial Gases/Related
134 ❏ Oil & Gas Field Equipment
02 ❏ Controls Equipment__________________


Professional Programs, Conferences, Seminars
Presentations from leading experts on the latest technical FOUR EASY WAYS TO REGISTER:
and management developments.
❏ YES! Please send more information FAX: 708-344-4444
PHONE: 877-868-5290 (toll free)
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require special assistance. P.O. Box 581, Brookfield, IL 60513-0581

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