Aws WJ 201501

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January 2015
WELDING JOURNAL VOLUME 94 NUMBER 1 JANUARY 2015

PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
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For Info, go to www.aws.org/adindex
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CONTENTS
January 2015 Volume 94 Number 1
FEATURES
28
The Case for Using LowHydrogen Covered Electrodes

Here is why low-hydrogen electrodes work so well
for many applications L. Byall
32
FABTECH 2014 Heats up Atlanta

FABTECH was filled with events and products that
appealed to just about everyone A. Cullison et al.
40
Creating a LeakTight Aircraft Relay Switch

Copper-nickel alloy and low-carbon steel were
successfully joined for a reliable high-performance
switch R. Trillwood
28
32
40
WELDING RESEARCH SUPPLEMENT

1s
8s
Primary Chromium Carbide Fraction Control with

Variable Polarity SAW
The effect of the fraction of time in electrode
positive was examined for AC hardfacing with
chromium-carbide alloys S. D. Borle et al.
Preliminary Investigation on RealTime Induction
HeatingAssisted Underwater Wet Welding
A unique induction heating-assisted underwater wet

welding process was investigated H. T. Zhang et al.
16s Gas Metal Arc Welding of Magnesium Alloys:

Oxide Films, High Crowns, and Fingers
Gas metal arc welding using controlled short circuiting
was studied as a means of limiting porosity in joining
magnesium X. Chai et al.
JANUARY 2015 / WELDING JOURNAL 3
Welding Filler Metals for

Lasting Connections
voestalpine Bhler Welding

www.voestalpine.com/welding
Welding Filler Metals for

Lasting Connections
voestalpine Bhler Welding

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DEPARTMENTS
6
8
10
14
16
18
20
24
44
Editorial
Press Time News
News of the Industry
Business Briefs
International Update
Stainless Q&A
RWMA Q&A
Product & Print Spotlight
Coming Events
48
50
52
55
56
75
76
86
88
Certification Schedule
Conferences
Welding Workbook
Society News
Tech Topics
Guide to AWS Services
Personnel
Classifieds
Advertiser Index
On the cover: At the AWS U.S. Invitational
Weld Trials held during FABTECH 2014, Cody
Fojtik performs shielded metal arc welding.
OFFICERS
President David Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Vice President John R. Bray
Affiliated Machinery, Inc.
Vice President Dale Flood
Tri Tool, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
DIRECTORS
T. Anderson (At Large), ITW Welding North America
U. Aschemeier (Dist. 7), Subsea Global Solutions
R. E. Brenner (Dist. 10), CnD Industries, Inc.
D. J. Burgess (Dist. 8), Alstom Power
N. C. Cole (Past President), NCC Engineering
D. L. Doench (At Large), Hobart Bros. Co.
T. A. Ferri (Dist. 1), Victor Technologies
K. Fogleman (Dist. 16), Consultant
P. H. Gorman (Dist. 20), Sandia National Laboratories
S. A. Harris (Dist. 4), Altec Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Knapp (Dist. 17), Gas and Supply
M. Krupnicki (Dist. 6), Mahany Welding Supply
T. J. Lienert (At Large), Los Alamos National Laboratory
S. Lindsey (Dist. 21), City of San Diego
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
S. P. Moran (At Large), Weir American Hydro
W. R. Polanin (At Large), Illinois Central College
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Airgas USA, LLC,
NorthCentral Region
4 WELDING JOURNAL / JANUARY 2015
R. W. Roth (At Large), RoMan Manufacturing, Inc.

M. Sebergandio (Dist. 3), CNH America
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
M. Skiles (Dist. 9), Consultant
J. Stoll (Dist. 18), The Bohler Welding Group U.S.
H. W. Thompson (Dist. 2), UL, Inc.
R. P. Wilcox (Dist. 11), Consultant
J. A. Willard (Dist. 13), Kankakee Community College
WELDING JOURNAL
Publisher Andrew Cullison
Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
Associate Editor Howard M. Woodward
Associate Editor Kristin Campbell
Editorial Asst./Peer Review Coor. Melissa Gomez
Publisher Emeritus Jeff Weber
D. Levin, Airgas
R. Madden, Hypertherm
D. Marquard, IBEDA Superflash
J. F. Saenger Jr., Consultant
S. Smith, WeldAid Products
D. Wilson, Welldean Enterprises
J. N. DuPont, Ex Off., Lehigh University
L. G. Kvidahl, Ex Off., Northrop Grumman
Ship Systems
D. J. Landon, Ex Off., Vermeer Mfg.
S. P. Moran, Ex Off., Weir American Hydro
E. Norman, Ex Off., Southwest Area Career Center
R. G. Pali, Ex Off., J. P. Nissen Co.
N. Scotchmer, Ex Off., Huys Industries
R. W. Shook, Ex Off., American Welding Society
8669 NW 36 St., # 130, Miami, FL 331666672
(305) 4439353 or (800) 4439353
Design and Production

Production Manager Zaida Chavez
Sr. Production Coordinator Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
Sr. Advertising Sales Exec. Sandra Jorgensen
Sr. Advertising Sales Exec. Annette Delagrange
Manager of Sales Operations Lea Paneca
Sr. Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Danielle Garcia
Danielle@aws.org
PUBLICATIONS, EXPOSITIONS,
MARKETING COMMITTEE
D. L. Doench, Chair, Hobart Brothers Co.
S. Bartholomew, Vice Chair, ESAB Welding
& Cutting Prod.
J. D. Weber, Secretary, American Welding Society
D. Brown, Weiler Brush
T. Coco, Victor Technologies International
C. Coffey, Lincoln Electric
D. DeCorte, RoMan Mfg.
S. Fyffe, Astaras, Inc.
Welding Journal (ISSN 00432296) is published monthly by

the American Welding Society for $120.00 per year in the United
States and possessions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and $10.00 per single
issue for nonmembers and $14.00 single issue for international.
American Welding Society is located at 8669 NW 36th St., # 130,
Miami, FL 331666672; telephone (305) 4439353. Periodicals
postage paid in Miami, Fla., and additional mailing offices. POST
MASTER: Send address changes to Welding Journal, 8669 NW
36th St., # 130, Miami, FL 331666672. Canada Post: Publications
Mail Agreement #40612608 Canada Returns to be sent to
Bleuchip International, P.O. Box 25542, London, ON N6C 6B2,
Canada.
Readers of Welding Journal may make copies of articles for
personal, archival, educational or research purposes, and which
are not for sale or resale. Permission is granted to quote from arti
cles, provided customary acknowledgment of authors and sources
is made. Starred (*) items excluded from copyright.
Copyright 2015 by American Welding Society in both
printed and electronic formats. The Society is not responsible for
any statement made or opinion expressed herein. Data and infor
mation developed by the authors of specific articles are for infor
mational purposes only and are not intended for use without inde
pendent, substantiating investigation on the part of potential users.
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EDITORIAL
A Triple Pass of the Torch
David J. Landon
AWS President
While the technol

ogy is impressive, I
believe (superhero)
movies appeal to us
for another reason.
Theyre full of heroes,
and we need heroes
in our lives.
Dr. Ken Ham of the Institute of Creation

Research has a quote I love. It is not a matter of whether one is biased or not. It is really a question of which bias is the best bias
with which to be biased. Everyone has their
own bias. Because I have the privilege of
leading the welding engineering team at Vermeer Corp., I am biased toward manufacturing. It is the world in which I live; therefore,
whenever Im asked to give a presentation, I
always try to do it from that perspective.
Vermeer manufactures agriculture, construction, and industrial equipment that
provide solutions for the forage, environmental, underground pipeline, and specialty
excavation market segments. Because of the
breadth of our product line, we weld steel
that ranges from 16 gauge to 3 in. thick.
Therefore, it is important for our welders to
master multipass welds, the most common
being a triple pass. Here are my thoughts
on another sort of triple pass.
One of my favorite pastimes is watching
movies. While I really enjoy the old Hollywood classics, over the past few years, just
like millions of others around the world, another genre has captured my attention: superhero movies! The first thing that attracts
me to superhero movies is the technology
the characters use.
I have had the privilege of being a member of the American Welding Society for
more than 30 years. When I first became a
member of AWS, a career in welding was
considered to be dark, dirty, and dangerous. That has changed over the years. Today, the technology we use in manufacturing, and specifically in welding, is right out
of a superhero movie. As the first pass of
the torch, let me give you some examples.
Autodarkening welding hoods are considered commonplace today, but when you
think about it, the technology is really
amazing. A protective lens that allows the
user to see clearly, then changes at the
strike of the arc to a dark shade to provide
the protection required during the welding
process, is right out of a superhero movie.
Another superhero technology common
in manufacturing today is the use of robotics. A recent article from the Manufacturing
Institute said 59% of manufacturers today
use some sort of robotics in their operation.
One of the most frequently shown tech-
nologies in superhero movies is the use of

high-intensity light to cut through steel and
other materials. Manufacturing has done
that with lasers for years.
While the technology is impressive, I believe these movies appeal to us for another
reason. Theyre full of heroes, and we need heroes in our lives. In her book Ordinary Heroes,
Flavia Weeden tells us Heroes walk among us.
They appear without a sign, a voice, or a
sound to rescue those in need. From very far
away, they come to comfort, protect, and
touch the lives of known or unknown names
and faces. In our second pass of the torch, I
would like to acknowledge a few of my heroes.
Many heroes work behind the scenes to
sustain our lives and protect our world. They
know that great things come from a series of
small actions. My father, John Landon, was
a structural engineer for Chrysler Corp.
Space Division. He taught me about life and
what it is to be an engineer.
Some heroes wear uniforms, some do
not. But the armor each of them wears is
built of integrity, mercy, and love. The power of such a shield can never be pierced or
broken. My brother, Tom Landon, manager
of Welding Technology and QA with CB&I,
introduced me to welding and a career in
welding engineering.
Our heroes face the world and are able to
continue on when their bodies are more
than tired, because their spirits will not let
them take rest. Bill Kielhorn was my welding engineering professor at LeTourneau
University. He was not only a mentor in
welding engineering, but a mentor in life.
Prof. Kielhorn taught me and countless other welding engineers what it is to be a godly
man. Through my years at LeTourneau,
there was one thing about him that always
impressed me. He never missed a class. In
fact, throughout his 45-year teaching career,
Bill Kielhorn never missed a class.
On the third and final pass of the torch, I
want to ask you, who are you being a hero
to? Whom are you mentoring? To whom are
you passing the gold nuggets you have
learned throughout life?
The next time you take your child or
grandchild to a superhero movie, I invite
you to take the time to share about the exciting technology used in our industry today. It is time to pass the torch! WJ
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PRESS TIME NEWS

SelectArc Opens Facility in Troy, Ohio
A view of SelectArcs building in Troy, Ohio.
Select-Arc, Inc., a manufacturer of welding electrode

products, has purchased the former RevWires building and
is establishing its Troy, Ohio, operations there.
The facility, located at 2015 W. Stanfield Rd., encompasses 79,400 sq ft and will be utilized for manufacturing along
with support functions in conjunction with company headquarters in Fort Loramie, Ohio.
The plant commenced operations in October. Also, the
company has indicated it will require an additional 1520
new employees.
Select-Arc President Dale Stager emphasized the determining factor in purchasing the Troy operations was the
need to better serve our customers to meet their growing
electrode product and service requirements.
Investment of $140 Million to Expand

Manufacturing at the Brooklyn Navy Yard
New York City Mayor Bill de Blasio recently announced
an investment to transform the Brooklyn Navy Yards Building 77 into a modern manufacturing facility generating
3000 good-paying jobs.
This $140 million venture from the city, Brooklyn Navy
Yard Development Corp., Brooklyn Borough President, and
City Council will be used to renovate the vacant building, expanding a project started under the previous administration, and doubling the projected number of facility jobs.
The 1 million-sq-ft building will be upgraded, including
the installation of windows to convert underutilized warehouse space into open areas for active manufacturing and
technology-based businesses.
When completed, Building 77 will increase employment
at the Navy Yard by more than 40%.
In addition, de Blasio mentioned that the city and Brooklyn Navy Yard Development Corp. will expand the yards
Employment Center.
We are jump-starting a new wave of manufacturing and
job creation at the Navy Yard. It will mean more opportunity
for people in this community to not only secure a job, but
also get the skills and upward mobility they need to support
a family, said de Blasio.
InSight Mars Lander Taking Shape

Lockheed Martin, Denver, Colo., has started the assembly, test, and launch operations phase for NASAs InSight
Mars lander spacecraft. This mission will record the firstever measurements of the interior of the red planet, giving
scientists detail into the evolution of Mars and other terrestrial planets. Its scheduled to launch in March 2016.
The InSight mission is a mix of tried and true and new
and exciting. The spacecraft has a lot of heritage from
Phoenix and even back to the Viking landers, but the science
has never been done before at Mars, said Stu Spath, InSight
program manager at Lockheed Martin Space Systems.
The assembly, test, and launch operations is when assembly of the spacecraft starts, moves through environmental testing, and concludes with its launch. Technicians
will install subsystems such as avionics, power, telecomm,
mechanisms, thermal systems, plus guidance, navigation,
and control. Science instruments will also be delivered by
mission partners to Lockheed Martin for spacecraft integration.
Weiler Corp. Makes Multimillion Dollar

Investment, Develops New Brand Identity
Weiler Corp., Cresco, Pa., a provider of power brushes,
abrasives, and maintenance products for surface conditioning, recently revealed a multimillion dollar transformation
to improve customer service and position the company for
future growth. This initiative includes investment in a new
brand identity, facility expansion, increased staffing in key
business areas, as well as new training tools.
Additionally, the company has redesigned its website at
www.weilercorp.com. Highlights include a simplified search
function, products segmented by industry and application,
and a Where to Buy section.
The transformation applies not just to our virtual space,
but also extends into our physical office space, with a complete redesign and expansion of our offices to create a more
open, collaborative working environment, said Chris Weiler, president/CEO.
The change further includes a 60% increase in direct field
sales support, providing market-based applications training
in industry applications.
Shawsheen Valley Tech to Receive

$250,000 Grant for Welding Equipment
Greg Bialecki, secretary of Housing and Economic Development for Massachusetts, has announced a $250,000 capital grant to Shawsheen Valley Technical High School. It will
support purchasing equipment needed to expand the
schools welding and metal fabrication program to help meet
a critical need in advanced manufacturing and construction
trades in Middlesex County.
With new equipment, students will learn the fundamentals of metal fabrication along with joining technologies;
demonstrate using hand/power tools; plus show proper mechanical cutting operations, metalforming techniques, cutting/gouging processes, and welding/joining methods.
Also, this grant supports a collaboration between Shawsheen and Keolis Commuter Services to train new workers
for maintaining and improving rail service throughout the
region. WJ
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Call 800-782-2110 for a free quote on your next project.
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Structural Steel Fabrication

Steel Plate & Sheet Metal Fabrication
Miscellaneous Metals
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Rolling & Forming Services
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Industrial Coatings
Industrial & Electrical Contracting
Crane Rental & Trucking Services
Heat-Bending Services
(AISC Certied for Major Steel
Bridge Fabrication)
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NEWS OF THE INDUSTRY

AWS Names 2014 Image of Welding
Award Winners
Pictured during FABTECH 2014 at the Image of Welding Awards

Ceremony are (from left) Paul Fischer, AWS Milwaukee Section,
AWS Section Award; Dave Lynnes, Lynnes Welding Training, Edu
cational Facility Award; Lloyd Robinson, AWISCO, Distributor
Award; Jerry Warren, CB&I, Large Business Award; George Wer
nette III, Tri Tool, Inc., Small Business Award; Kevin Carter, Educa
tor Award; and (center) Justin Gordy, Individual Award.
The American Welding Society (AWS) and WEMCO, an

association of welding manufacturers, recently announced
the recipients of the 12th Annual Image of Welding Awards.
The following winners, detailed below, were honored at a
ceremony on November 12 during FABTECH in Atlanta, Ga.
Individual Justin W. Gordy, Houston, Tex. Currently the youngest AWS Senior Certified Welding Inspector
in the world, Gordy has an associates degree in welding and
inspection technology, and is an ASNT Level 3 Certified UT
Inspector. Along with his wife, Heather, they operate JTECH Inspections. The AWS Houston Section Justin Gordy
Spirit of Welding Award is also in his honor.
Educator Kevin Carter, Petersburg, Ind. An AWS
Certified Welding Inspector and Educator, Carter has been a
welding instructor at Pike Central High School, Petersburg,
Ind., for the past 32 years. He consistently places students
in apprenticeships or employment. Among his students
achievements are 16 state SkillsUSA champions, 12 Midwest
Team Welding Competition first-place finishes, and seven
top three finishes in the national SkillsUSA Championships.
Educational Facility Lynnes Welding Training,
Fargo, N.Dak. Lynnes Welding Training, the vision of Dave
Lynnes, owner and CEO of the welding school, opened its
doors in 2006 and educates postsecondary school administrators, teachers, guidance counselors, and others in key positions to provide career advice to students of all ages. Staff
speak to local schools and career fairs, plus make presentations. Theyve also collaborated with the North Dakota Boy
Scouts to help host Welding Merit Badge clinics.
Small Business Tri Tool, Inc., Rancho Cordova,
Calif. The company manufactures weld prep machining
equipment. In 1998, it started the Tri Tool, Inc., Sacramento
Section Named Scholarship in conjunction with the AWS

Foundation, providing nearly $50,000 to local students. Recently, the company developed its Pipeline of People committee to reach students in Northern California and Nevada.
Also, it assisted in a local Eagle Scout project to build ramp
handrails and guardrails for the Folsom Sport Complex.
Large Business CB&I, Plainfield, Ill. For more than
125 years, CB&I has provided systems while maintaining a
focus on safety and high standard of quality. Company employees volunteer their time in health, education, and human service organizations in their communities and across
the globe. The company also supports social economic and
cultural development initiatives with many of their projects.
Distributor AWISCO, Maspeth, N.Y. Serving the
New York Metropolitan area since 1979, AWISCO is a distributor of compressed gases, welding, safety, and industrial
equipment and supplies. The company recently invited more
than 100 welding students and their teachers from the New
York area as guests to its annual trade show. In addition, the
company gives demonstrations and presentations at local
schools, and has collaborated with Sussex Technical School
to organize and present workforce development awards.
AWS Section Milwaukee, Milwaukee, Wis. The
Milwaukee Section typically gives more than $5000 in Section scholarships every year. Also, it gives away helmets,
welding kits, and other equipment to students. With the
AWS D16 Committee, the Section hosts a conference every
other year and has used the proceeds to start an endowment, giving out an additional $10,500 to welding engineering students. It is also starting an effort to assist companies
in reaching potential welding-related employees.
Media Heesun Wee, CNBC. Heesun Wee is a features
reporter and editor for CNBC.com where she covers a broad
range of topics. In February 2014, Wee wrote the CNBC.com
article American manufacturing and welding to women: We
want you! highlighting the shortage of welders in the United States and importance of attracting more women into the
industry. View the article at www.cnbc.com/id/101385929.
Nominations for the 2015 awards, which will now be
known as the Excellence in Welding Awards, are open. A Veterans category has been added as well. For more details, visit
www.aws.org/w/a/awards/image.html.
Deadlines Approaching for OSHAs

Hazard Communication Standard
The phase-in dates required under the revised Occupational Safety & Health Administrations (OSHA) Hazard
Communication Standard are as follows:
Employers must comply with all new Hazard Communication Standard requirements by June 1, 2015. By December 1,
2015, chemical distributors must stop shipping containers
with non-GHS labels.
In addition, for employers, the effective completion date
is June 1, 2016, for updating alternative workplace labeling
and hazard communication program as necessary, and providing additional employee training for newly identified
physical or health hazards.
For more information, visit www.osha.gov/dsg/hazcom/
effectivedates.html.
Changing Landscape in Troy, Ohio,

Includes Hobart Brothers History
This historic photograph features the Main Street plant along

with Hobarts garage to the left side. (Image courtesy of The Troy
Historical Society and the Local History Library, Troy.)
A recent article titled Troys changing landscape by

Patrick Kennedy, archivist at the Troy-Miami County Public
Librarys Local History Library in Ohio, for the Troy Daily
News details several area transformations over the years,
including demolition of the old Hobart Brothers factory.
Hobarts roots can be traced to 1904, although the company was incorporated in 1917. During World War I, it operated on West Water St. in the old brewery building. By 1925,
that facility had been outgrown and the Henne Warehouse
on West Main was utilized. Construction then started on a
new, large factory next to the warehouse. The blocks landscape changed again as houses were bought and razed/
moved to other locations.
The first classes of whats now the Hobart Institute of
Welding Technology were held on the buildings third floor.
As the years went on, Hobarts factory expanded a few
times crossing two whole blocks, which was encompassed
between Adams, Water, Elm, and Main Streets later taking in the site on the north side of Water Street and constructing the building later used by Troy Lumber Co.
Also of note are the following factors: This Troy landmark, originally constructed during 192325, covered
500,000 sq ft and for a while served as home to the company offices; 1925 marked the construction year of the first
Hobart arc welding machine; and welding equipment represented the mainstay product but solid wire manufacturing
later took up space. ITW, which purchased Hobart Brothers
Co. in 1996, will leave the property as a green space.
New Program Aims to Connect

Veterans with Industrial Sector Careers
The Guns to Arcs Program is a start up nonprofit, 501c3
organization founded and run by current and former military members. Its mission is to connect unemployed or underemployed veterans with knowledge and assets to pursue
a career in the industrial sector, including welding. These
For info, go to www.aws.org/adindex
soldiers, sailors, airmen, and Marines could revitalize the

nations trade skill industry.
Also, the program seeks industry support to cover tuition
costs, and help spread the word to heroes who serve and
protect this country. For more details, visit the website
www.guns2arcs.org.
Bluegrass Community and Technical

College Offers Welder Helper Certificate
A new Welder Helper Certificate will be offered for the
Spring 2015 session of Bluegrass Community and Technical
Colleges Winchester-Clark County Campus in Kentucky.
Starting January 12, 2015, students enrolled in this program will learn shielded metal arc welding.
The classes will be held on Mondays and Wednesdays at
the Clark County Area Technology Center, 2748 Boonesboro
Rd., Winchester, Ky. The lecture and lab will be offered then
back-to-back with WLD 120 from 4:30 to 5:30 p.m. and
WLD 121 from 5:30 to 8:30 p.m. For more information, visit
www.bluegrass.kctcs.edu.
Coldwater Machine Launches

Solid State Joining Center
Coldwater Machine Co., Coldwater, Ohio, has established
its Solid State Joining Center, a business unit dedicated to

the development of technologies that address the challenges
of joining lightweight and dissimilar materials. Located in
the same building as its parent company, the unit includes a
weld development lab that features five friction welding systems for testing and low-volume production.
In addition, the center has developed friction spin weld
systems and is expanding production systems for the newer
friction spot weld technology.
Industry Notes
The U.S. Department of Commerce has awarded
$100,000 to the University of South Alabama and Mobile Area Chamber of Commerce to implement goals in
the regions application to become a manufacturing community. Lynne Chronister, USA vice president for research
and economic development, added that the grant money
will be used to hire a coordinator and enhance the Gulf
Coasts pipeline for workforce development.
ThyssenKrupp Stahl-Service-Center has added to its
capabilities. A new blanking line at the Mannheim, Germany, steel service center offers options for producing
small blanks. It cuts 0.4- to 3-mm-thick slit strip into
lengths 2002500 mm and widths 80650 mm.
Superior Tube, Collegeville, Pa., is certified to AS9100,
having been assessed by the independent certification organization, Det Norske Veritas. Based on the ISO 9001
series of quality management systems, AS9100 provides a
globally harmonized standard for the aerospace industry.
Futuris Automotive opened a 160,000-sq-ft manufacturing facility/design center in Newark, Calif. It will feature
a design and craftsmanship studio as well as testing, validation, and quality centers; is expected to grow quickly to
circa 400 employees; and will initially be equipped to manufacture product offerings, including welded seat frames.
A check for $20,000 has been presented to Austin Polytechnical Academy, Chicago, Ill., by IMTS The International Manufacturing Technology Show and GIE
Media to advance the schools mission of preparing students for manufacturing/engineering careers. The money
was raised by the Miles for Manufacturing 5K Run/Walk.
Chrysler Group LLCs Indiana Transmission Plant II has
been awarded bronze status for its results in implementing
World Class Manufacturing. This plant produces the fivespeed transmission for various models in the companys
portfolio and received the title just over four years after
adopting the operating system following a two-day audit. WJ
Herr-Voss Stamco recently cohosted a complimentary

slitting seminar at the Detroit Metro Airport Marriott titled The Latest Technologies in Slitting Automotive Materials. Presentations covered many topics, including slitting
high-strength steel. More than 115 people attended.
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adjustment replacing old, hard
to operate rivet. Automatically
shown convexity and concavity
sizes have been predetermined
in accordance with American
Welding Society D1.1
W.T.P.
W.T.
P.S. TYPE GAGE
Measures .010 inch deep
undercut
CAT
AT. NO. 7
TOLERANCES +.0005 inches
Structural Welding Code D1.1,
Underrcut shall be no more than
.010 inches (.25mm) deep when
the weld is transverse to the
primary stress in the part that is
undercut.
CAT
AT. NO. 5
V-WAC Underc
rcut Gage
Also custom gages manufactured
on request.
ADJUSTABLE
ABLE FILLET
WELD GA
AGES
AG
CAT
AT. NO. 3
t For equal and unequal
legged llet welds
t Measures 15 different weld
sizes plus throat thickeness
CAMBRIDGE TYPE GAG

CAT
AT. NO. 4
t Angle of Preparation
APPR
ROVED BY AAR
SKEW-T WELD
t Excess Weld Metal
GAGE/CALCULAT
ATOR
t Depth of Undercut
CAT
AT.
T. NO. 9
t Depth of Pitting
t Replaces all other sets of gages
t Fillet Weld
W Throat Size
used to measure llet or groove
t Fillet Weld
W Length
welds in skewed members at 90O
t Outside Misalignment
t Handy compilation of math ematical relationships between leg
length, throats, skew angles and
inspection dimensions.
HI-LO WELDING GAG

AGES
CAT
AT. NO. 1
For internal misalign in pipe
welds in addition to 6 other crit cal, required measurements.
Patent No. 3,869,801

P.O. BOX 218 STEVENSVILLE, MICHIGAN 49127
P.
PHONE: 269/465-5750 FAX: 269/465-6385
E-mail: info@galgage.com
Website: www.galgage.com
Visa & Mastercard Accepted
7 P.
P C.
C FILLET TYPE GAGE
Accurate
CAT
AT.
T. NO. 8
ALL EDGES DEBURRED
ALL LETTERS AND CHARACTERS
LASER ETCHED
HANDY POCKET CASE
The G.A.L. Fillet Weld gage allows
fast, accurate measurement of 11
llet weld sizes: 1/8, 3/16, 1/4, 5/16,
3/8, 7/16, 1/2, 5/8, 3/4, 7/8, and 1
inch. Includes metric equivalents.
Determine either concave or convex
weld sizes.
BB Jan 2015_Layout 1 12/10/14 3:43 PM Page 14
BUSINESS BRIEFS
Amanda Manufacturing Breaks Ground
in Ohio on Major Expansion
for a strong finish in 2014, said Brad Lawton, chairman of

AMTs cutting tool product group. There is every indication
that the momentum from the fall of 2014 is a harbinger of
continued growth in industrial production and cutting tool
sales for 2015.
The CTMR is important because cutting tools are consumable products used to turn raw materials into intermediate goods and intermediate goods into finished products.
Also, given that tooling needs to be replaced relatively frequently, trends in U.S. cutting tool shipments are a good
measure of overall manufacturing activity.
Solar Atmospheres Expands
Amanda Manufacturings leadership team, along with Ohio

elected officials, get moving on the $5 million expansion.
Amanda Manufacturing, a Deshler Group company in Logan, Ohio, that specializes in metalforming, recently broke
ground on a $5 million expansion and renovation of its facility.
The 130,000-sq-ft building will expand by nearly 40%,
with 54,880 additional square feet of manufacturing plant
space and a 14,000-sq-ft new office and facade improvement. This expansion, expected to be finished by spring
2016, addresses growing international business and entry
into new products/services.
Additionally, the company plans to add new technology
and machinery, including extra engineering and design services; tube forming; and increase the use of lightweight, highstrength steels. The office expansion will include a new facade and office space for engineering and design teams, with
a multimedia conference room.
Adding human resources is critical to our ability to position Amanda Manufacturing as an engineering- and designdriven manufacturing solutions provider for our global customers, said Robert Gruschow, president of the company
and the Deshler Group.
Job opportunities will be announced in early 2015.
We are looking for people with experience, but also are
planning to partner with our local universities and trade
schools to mentor, train, and recruit young talent from
Ohio, added Gruschow.
U.S. Cutting Tool Shipments up 4.6%

The September U.S. cutting tool sales totaled $176.5 million, according to the U.S. Cutting Tool Institute and AMT
The Association for Manufacturing Technology.
This total, as reported by companies participating in the
Cutting Tool Market Report (CTMR) collaboration, was up
4.6% from Augusts total and 7.7% from September 2013.
These numbers, and all data in this report, are based on
the totals actually reported by the companies participating
in the CTMR program. The totals here represent about 80%
of the U.S. market for cutting tools.
The 4.6% increase for Septembers cutting tool shipments was not a surprise as the markets expectations were
Solar Atmospheres Southeast President Steve Prout and

Corporate President Roger A. Jones recently revealed the
site selection process for its expansion into the southeast
has been completed.
The division will be located at 108 Progressive Ct.,
Greenville, S.C. This facility, operational in the near future,
has 54,000-sq-ft of manufacturing space on 14 acres.
This is a major expansion for our companies with an investment in excess of $15 million, including building, property, new vacuum furnaces, and a facility-wide closed-loop
water-cooling system to ensure continuous uptime for our
customers, said Jones.
Prout also noted the ability to find a facility with freespan construction, 40- and 30-ton bridge cranes with 24-ft
clearances for processing large heat treat loads, and space to
support future growth played a part in the decision.
Currently, vacuum furnaces and support equipment are
being scheduled for installation and startup. Furnace sizes
will range from those supporting small production lots and
development work to a 24-ft car bottom furnace.
Lincoln Electric Acquires RealWeld

Systems
The Lincoln Electric Co., Cleveland, Ohio, has acquired
the assets of the privately held live arc welding training system manufacturer, RealWeld Systems, Inc., and associated
intellectual property from EWI, Columbus, Ohio.
Michael Mintun, senior vice president, North America
sales and marketing, noted the RealWeld Trainer system
offers hands-on arc welding training and evaluation.
EWI developed RealWelds technology to advance welding training and help establish industry-accepted credentials
for welders, added Henry Cialone, EWI president.
Bodycote, MessierBugattiDowty Sign

Agreement for Thermal Spray Coatings
Bodycote, Macclesfield, UK, a large thermal processing
services provider, recently announced signing an eight-year
agreement with Messier-Bugatti-Dowty (Safran Group), a
provider of aircraft landing and braking systems.
The company will provide thermal spray coating services
for major commercial and military airframe component programs, including the Boeing 787 and Airbus A350. WJ
otc daihen_FP_TEMP 12/10/14 9:15 AM Page 15
Jan Intl Update_Layout 1 12/10/14 3:51 PM Page 16
INTERNATIONAL UPDATE
Swiftships to Build Patrol Boats for Egyptian Navy
Swiftships, LLC,
Morgan City, La., a
manufacturer of watercrafts built of steel,
aluminum, and fiberglass, has been awarded a contract for construction of six 35-m
The Swiftships 35m patrol boat is
patrol boats (PB) for
constructed of allwelded aluminum
the Egyptian Navy
alloy and its hull includes seven wa
(EN). The vessels are
tertight bulkheads.
part of an extension of
the existing Build, Operate, Transfer program that the Egyptian government and
Swiftships set in place for coproducing four 28-m PBs from
2010 to 2014. Build, Operate, Transfer allows for shipbuilding knowledge and expertise to be transferred to developing
nations.
Technical evaluation performed by an Egyptiangovernment-designated committee determined the Swiftship 35-m PB to have the best platform according to EN requirements. The six boats will be constructed at the Egyptian Ship Building and Repairs Company in Alexandria,
Egypt.
Swiftships has built a total of 23 boats for the Egyptian
Navy, including mine hunters, survey vessels, and steel and
aluminum patrol boats. The 35-m PB hull and superstructure are constructed of all-welded aluminum alloy. The hull
includes seven watertight bulkheads forming eight watertight compartments. The boats can be refueled at sea using
side-by-side procedures, and run on diesel fuel.
Swiftships CEO Shehraze Shah said, The participation of
Swiftships with a public entity and a strong financial arm
can enhance the shipbuilding and ship repair trade. As a result, infrastructure, modernization, and employment can
flourish in the region in which coproduction is applied.
DEKRA Aquires DNV GL Units

DEKRA, Stuttgart,
Germany, a vehicle inspection company, has
taken over the plant integrity, nondestructive
testing, and microscopy operations
from DNV GL, Hvik,
Norway, an international classification society, and is expanding
its industrial operaDEKRAs newly acquired units will
tions in The Nether2
operate in its 14,000m facility in
lands. The three units,
Arnhem, The Netherlands.
employing together 24
workers, operate under
the name DEKRA Material Testing & Inspection in the new DEKRA buildings in
Arnhem, and are concerned with the inspection of capitalintensive and business-critical systems and materials. Cus16 WELDING JOURNAL / JANUARY 2015
tomers include petrochemical, industrial, and energy

companies.
The acquisition of these units is an important step in
DEKRAs global expansion strategy, said Marcel Blinde,
managing director, Service Unit Material and Inspection.
The acquisition is vital in terms of our presence in both Europe and the Middle East as well as being an important addition to our industrial testing operations in the laboratory in
Arnhem.
SKS Welding Systems Expands into Turkey

The German SKS
Welding Systems
GmbH, based in
Kaiserslautern, has
founded a new subsidiary, SKS Welding
Systems Makina
Sanayi ve Ticaret Ltd.
irketi, to serve users
and investors in
Turkey. Its Turkish
subsidiary will allow
SKS to offer its customers professional
advice, individual prodSerdar Arican (left), managing di
ucts, and faster service
rector of the newly founded Turkish
for automated welding.
subsidiary of SKS Welding Systems
With our Turkish
with Dieter Klein, founder of SKS.
subsidiary, we are expanding our international network and thus our customer proximity in important industrial countries. This ensures that our product developments specifically for robot-assisted arc welding
processes and our technical support reach the users and
in-country subsidiaries of our international customers on
site, said SKS Managing Director Marcus Klein.
Solar Atmospheres Extends Contract

with RTI Claro
Solar Atmospheres
of Western Pa., a commercial heat-treating
company, announced
that it has signed a
memorandum of agreement with RTI Claro, a
business unit of RTI
International Metals,
Inc., Laval, Que., CanaSolar Atmospheres will continue to
da, to extend its consupply its seat tracks for Boeing 787
tract for the vacuum
Dreamliner airplanes for another
stress relieving and fluseven years.
orescent liquid penetrant inspection of the
Boeing 787 Dreamliner titanium seat track system until December 2021. The company anticipates the agreement will
include work on more than 1000 of the aircraft. WJ
koike aronson_FP_TEMP 12/10/14 9:14 AM Page 17
KOTECKI January_Layout 1 12/11/14 8:43 AM Page 18
STAINLESS Q&A
BY DAMIAN J. KOTECKI
Q: We make a lot of open root

pipe joints in 304L and 316L
stainless steel using gas tung
sten arc welding (GTAW) for the
root and first fill pass with
ER308L or ER316L filler metal
as appropriate. We might finish
with GTAW or with another
process. Root purging has al
ways been done here with ar
gon (Ar), but a cost reduction
by purging with nitrogen (N2)
has been proposed. I am con
cerned that N2 purging with an
open root will lead to N2 pickup
in the root pass, loss of ferrite,
and solidification cracking. Is
changing to N2 purging a good
idea?
A: The July 2000 Stainless Q&A column cautions against nitrogen (N2)
purging with an open root for the reasons you note. However, your question
reminds me of an axiom emblazoned
on the base of an ancient Riehle tensile testing machine in the University
of WisconsinMadison Mechanical
Engineering Laboratory that impressed me when I saw it as a student
during the 1960s, One test is worth a
thousand expert opinions.
At the time of the July 2000 Stainless Q&A column, I was not aware of
published data that were relevant to
the open root N2 purging question, but
I cautioned against N2 use because of
the possibility of reducing the ferrite
content to the extent that primary
austenite solidification would result,
with its potential for solidification
cracking.
More recently, Bergquist et al. (Ref.
1) examined exactly this situation in
welding 304L stainless steel pipe with
ER308L and manual GTAW. The test
pipe was 150 mm (6 in.) diameter with
Fig. 1 Partially completed gas tungsten arc welded open root pass.
13 mm ( in.) wall thickness. They

used a 70-deg included angle joint
preparation with a 1.5-mm (116-in.)
root face and a 3-mm (18-in.) root
opening, maintained by tack welds, for
all of their tests. Purging was begun 10
min before welding, and a purging
flow rate of 10 L/min (21 ft3/h) was
continued during welding.
For comparison, separate welds
were made with 100% argon (Ar) and
100% N2. A third backing gas, 90% N2
10% hydrogen (H2) was also considered, but that is not discussed herein
because it was not part of the question
raised.
Figure 1 shows a partially completed root pass from that work so that
the openness of the root can be easily
appreciated. After welding, the Ferrite
Number (FN) was measured on the
lightly ground root bead surface and
the full chemical composition, including N2 content, of the root bead was
determined. Table 1 lists the chemical
composition results and FN with the
three backing gases for the root pass
only of each test condition.

There was a repeat weld with Ar
purging and a repeat with N2 purging
to assess reproducibility, and the individual data are included in Table 1.
In addition to the measured FN (average of eight readings), the FN I calculated using the WRC-1992 diagram
and the reported root pass compositions is included in Table 1 for comparison with the measured FN for each
root pass.
Some variation in chromium (Cr)
and nickel (Ni) can be observed in
Table 1. Part of that is likely due to
varying dilution (the pipe composition
is not the same as the filler metal composition) and part of that may be attributable to variability of chemical
analysis. But the important point to be
noticed from Table 1 is that the root
pass N2 content is about 0.06% when
Ar purging is used, and the root pass
N2 content is about 0.11% when N2
purging is used. These results are quite
consistent. So a N2 pickup in the root
of about 0.05% can be attributed to
Table 1 Root Pass Composition, Measured FN, and Calculated FN

Test Weld
Purge Gas
C
First
Second
First
Second
Argon
Argon
Nitrogen
Nitrogen
0.011
0.012
0.014
0.011
Cr
19.1
19.4
19.7
19.3
Composition (wt%)
Ni
Mo
Cu
9.6
10.0
9.6
10.2
0.27
0.10
0.20
0.10
0.19
0.14
0.16
0.13
Measured FN
WRC1992 FN
N
0.063
0.060
0.110
0.110
8.6
6.9
4.4
2.9
9.1
8.2
7.4
3.8
KOTECKI January_Layout 1 12/11/14 8:44 AM Page 19
use of N2 for purging gas under the

conditions of these tests.
The drop in ferrite content from Ar
purging to N2 purging in this instance
did not result in primary austenite solidification or solidification cracking.
Bergquist et al. (Ref. 1) used color etching metallography to establish that the
solidification mode was primary ferrite
in the N2-purged root pass in all cases.
However, they noted that the use of
the N2 purging could have changed the
solidification mode from primary ferrite with Ar purging to primary austenite with N2 purging if the composition
of the filler metal and/or base metal
were less favorable (lower Cr content
and/or higher Ni content). The WRC1992 diagram indicates the solidification mode would change to primary
austenite for the weld compositions
produced if the calculated FN dropped
to less than about 2.
So it is clear that a drop in root pass
weld metal ferrite content can be expected if N2 purging is substituted for
Ar purging. This is not hypothetical.
Whether or not the ferrite content
will drop to a sufficiently low level as
to indicate primary austenite solidification and the potential for solidification cracking will depend upon the
compositions and ferrite potentials of
the base metal and of the filler metal,
the dilution in the root pass (normally
the ferrite potential, as indicated by
the WRC-1992 diagram, is lower for
commercial base metals such as 304L
or 316L than it is for nominally
matching filler metals such as ER308L
or ER316L), and the extent of N2 pickup. The N2 pickup in the root pass is
likely to increase if higher purging gas
flow rates are used, other things being
equal, because more N2 will be pushed
through the open root into the arc
where the diatomic N2 molecule can be
broken into monotonic N ions that
dissolve readily into the weld pool.
Bergquist et al. (Ref. 1) recommend
that, before deciding to employ N2
purging for such welds, one should
check the compositions of the base
metal and filler metal on the WRC1992 diagram, then consider what the
pickup of N2 will do to the weld ferrite
content and solidification mode.
Given that a N2 pickup of about
0.05% seems likely, one can then shift
the calculated root pass ferrite content
according to that amount and observe
if primary ferrite solidification, the
optimum solidification mode for re-
sistance to solidification cracking, can

still be expected. Nitrogen purging is
not without risk, and I agree with
their recommendation. WJ
Reference
1. Bergquist, E.-L., Huhtala, T., and
Karlsson, L. 2011. The effect of purging gas on 308L TIG root-pass ferrite
content. Welding in the World, V55, N34, pp. 5764. International Institute
of Welding, Paris, France.
DAMIAN J. KOTECKI is president, Damian

Kotecki Welding Consultants, Inc., a member
of the A5D Subcommittee on Stainless Steel
Filler Metals, D1K Subcommittee on Stain
less Steel Structural Welding, WRC Subcom
mittee on Welding Stainless Steels and
NickelBase Alloys, past chair of A5 Commit
tee on Filler Metals and Allied Materials, and
AWS president (20052006). Send questions
to damian@damiankotecki.com, or mail to
Dr. Kotecki, c/o Welding Journal Dept., 8669
NW 36 St., # 130, Miami, FL 33166.
RWMA Q&A January 2015_Layout 1 12/11/14 8:43 AM Page 20
RWMA Q&A
BY MURALI TUMULURU
Q: Our fabricating shop manufac

tures resistance spot welded parts
for various industries. We are inter
ested in bidding for jobs that go
into automotive assemblies. The
parts we can fabricate have to be
welded from 590 dualphase steel.
We have no prior experience weld
ing dualphase steels. What are
dualphase steels and what can you
tell us about how to weld them?
A: Dual-phase (DP) steels are classified as advanced high-strength steels

(AHSS) by the World Steel Association (www.worldsteel.org) to distinguish them from the conventional
high-strength steels (HSS). The HSS
types include high-strength, low-alloy
steels and carbon-manganese steels of
tensile strengths up to 440 MPa. The
microstructure of DP steels consists of
martensite in a matrix of ferrite.
Martensite is a hard and brittle phase
whereas ferrite is a soft and ductile
phase. Therefore, due to the presence
of these two phases (hence the name
dual-phase steels), these steels can offer high strength without compromising on elongation Fig. 1. The
amount of martensite in the steel can
vary from about 10% (for 590 MPa
strength level) up to about 45% (for
980 MPa level). Due to the combination they offer of high strength and
high elongation, DP steels are becoming increasingly used in automotive
body-in-white applications.
These steels are available both in
the coated (galvanized/galvannealed)
condition as well as uncoated (or cold
rolled) condition and in commercially
available tensile strengths ranging
from 500 to 1180 MPa. They are typically alloyed with manganese, chromium, molybdenum, and silicon to
achieve the desired strength level.
Coated versions of DP steels generally
contain less than 0.1 wt-% silicon to
prevent problems with coating
adhesion.
Some of the characteristics of dualphase steels include the following:
They achieve strengthening through
a phase transformation, namely the
transformation of austenite to
martensite.
Depending on the strength level,
they contain 10 to 45% martensite
in a soft ferrite matrix.
Fig. 1 Plot of strength and ductility (elongation) relationship for dualphase steels.
Also shown for comparison are the relationships for lowcarbon, highstrength, low
alloy (HSLA), and carbonmanganese (CMn) steels.
To achieve higher strength, more

martensite is required in the steel.
Therefore, as the strength of the
steel increases, the amount of
martensite in the steel increases.
They possess high strength with high
elongation when compared to conventional HSS.
They are bake hardenable (strain aging at elevated temperature). Bake
hardening provides an increase in
strength after the paint bake cycle
that welded automotive bodies
undergo.
Resistance Spot Welding

of DP Steels
Dual-phase steels are readily weldable using the resistance spot welding
process. To successfully weld DP steels,
the World Steel Association offers the
following general guidelines for selecting welding parameters:
Increase the electrode force by 20%
(compared to those used for similar
thickness low-carbon steels) or more
depending on yield strength.
Increase the weld time as appropriate.
Use a multipulse welding schedule
(several pulses of welding current as
opposed to a single pulse).
Use larger tip sizes than those used
for similar thickness low-carbon
steels.
Keep the acceptable minimum weld
size higher than that used for lowcarbon steels.
Dual-phase steels require less cur-
rent to weld compared to low-carbon

or conventional HSLA steels because
they have higher electrical resistivity.
This results from the fact that DP
steels contain more alloying elements
than low-strength steels that increase
base material resistivity. Therefore,
welding current for DP steel should be
reduced to avoid overheating and weld
expulsion (loss of molten metal). Generally, DP steels require about 20%
higher electrode forces compared to
low-strength steels of similar
thickness.
Dual-phase steels have tighter weld
windows (welding parameters that
give acceptable welds) compared to
mild or low-strength steels. However,
these welding windows are large
enough that welds of acceptable quality can be easily obtained over a range
of parameters. AWS specification
D8.9M:2012, Recommended Practices
for Test Methods for Evaluating the Resistance Spot Welding Behavior of Automotive Sheet Steel Materials, provides
starting weld schedules to weld DP
steels. Using these starting schedules,
you can develop appropriate weld
schedules to weld your parts. Depending upon your customers requirements, you may have to perform weld
quality tests, which typically include
weld tensile tests and metallographic
evaluations, to verify the weld schedules selected produce welds of acceptable quality.
Another factor to keep in mind
when welding DP steels is to avoid
weld metal expulsion. Weld metal ex-
RWMA Q&A January 2015_Layout 1 12/11/14 8:43 AM Page 21
pulsion and the current that provides

a certain minimum weld size. In the
automotive industry, it is common to
define the minimum weld size as 4t,
where t is the nominal thickness of the
steel being welded. Figure 2 shows the
welding current ranges for various DP
steels. Select a welding current for
your application that is about 200 A
lower than the expulsion current. By
selecting suitable welding parameters,
you should be able to obtain acceptable weld quality. WJ
Reference
Fig. 2 Welding current range plot for three dualphase steels (Ref. 1).
pulsion (ejection of molten weld metal) occurs when the welding current is
excessive for a given weld time. Expulsion results in loss of weld metal and
smaller weld size. Weld expulsion,
therefore, results in loss of loadbearing area and lower weld strength.
To determine expulsion current
range for a given thickness of DP steel,
the welding current ranges should be

first determined. The procedure for
determining weld current ranges is
provided in D8.9. Basically, welding
current range defines the useful welding current range over which welds of
acceptable size can be produced. The
current range is the difference between the current that produces ex-
1. Tumuluru, M. 2006. Resistance

spot welding of coated high-strength
dual-phase steels. Welding Journal
85(8): 3137.
MURALI TUMULURU is research consultant

Materials Joining, United States Steel Corp.,
Research and Technology Center, Munhall,
Pa. Send your comments and questions to
Murali Tumuluru c/o Welding Journal,
8669 NW 36 St., # 130, Miami, FL 33166, or
via email at mtumuluru@uss.com.
$
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aws wemco convention spread_FP_TEMP 12/9/14 10:15 AM Page 22
Where is the welding

industry headed?
The CEO of Lincoln knows. Economist Alan Beaulieu knows.
Head to WEMCOs
annual meeting
or be left behind.
Non-member executives are encouraged to participate.
aws wemco convention spread_FP_TEMP 12/9/14 10:16 AM Page 23
MEET THE SPEAKERS
An Association of Welding Manufacturers
2015 Annual Meeting

Feb. 2527
Vinoy Renaissance Resort & Golf Club
St. Petersburg, Fla.
Chris Mapes
Chairman, President, and CEO
Lincoln Electric
Chris Mapes was appointed chairman of Lincoln Electric in December 2013, and president
and chief executive officer in 2012. Previously, Chris was Lincolns chief operating officer,
the position he was appointed to when he joined the company in 2011. He was elected
to the Lincoln Board in 2010 while serving as executive vice president of A.O. Smith
Corporation and president of its electrical products unit. Prior to his career at A.O. Smith,
Chris was president, motor sales and marketing of Regal Beloit Corporation and had also
served as president of the Global OEM Business Group of Superior Essex, Inc.
Theme: Welding Industry

Consolidation and Globalization
Jack Keough
Contributing Editor and Associate Publisher
Industrial Distribution Magazine
Jack Keough has been researching and writing about the distribution/manufacturing sector for 30 years. He has served as contributing editor and associate publisher for Industrial
Distribution Magazine of Madison, Wis. for 26 of those years. Jack is also the president
of his marketing and consulting firm, Keough Business Communications, and contributing
editor for Electrical Distributor magazine and its website. He has written extensively
about distribution management, sales and technology issues that have changed industrial
distribution in the past three decades.
he WEMCO Annual Meeting is filled with

unparalleled networking opportunities and
enlightening presentations. Renowned economist
Alan Beaulieu of the Institute for Trend Research will
again be our keynote speaker. Network with additional
speakers such as Lincoln Electric CEO Chris Mapes
and Industrial Distribution Magazines Jack Keough.
Non-members are welcome to attend and

experience the full benefits of networking
with your industry peers!
Register at www.wemco.org. For more

information, please contact Keila DeMoraes at
kdemoraes@aws.org or 800-443-9353, ext. 444
Dave Marquard
Director of Product Management
Integral Ad Science
Dave Marquard is director of product management for an NYC-based advertising
technology startup. For 15 years, he has held leadership roles in product management,
engineering, and marketing at internet technology and enterprise software firms such
as Google, IBM, and Lombardi Software. Dave was an endowed scholar in engineering
at Duke University, earning degrees in electrical engineering and computer science. As
an undergrad, he was a teaching assistant in the Department of Computer Science at
Duke for three years. Later, he returned to Dukes Fuqua School of Business for an MBA.
KEYNOTE SPEAKER: Alan Beaulieu

Economist and President
Institute for Trend Research
One of the countrys most informed economists, Alan Beaulieu is a principal of ITR
Economics, where he serves as president. He is co-author of Make Your Move, a book
on how to increase profits through business cycle changes. He is senior economic advisor
to the NSW, chief forecaster for the European Power Train Distributors Association, and
chief economist for HARDI. Pronouncements from the Institute for Trend Research and/or
Mr. Beaulieu have appeared in/on the Wall Street Journal, New York Times, USA Today,
Knight Ridder News Services, Business Week, Associated Press, Washington Times, CBS
Radio, CNN Radio, Sirius talk radio, KABC, NPR affiliate WLRN, and other outlets.
P and P JAN 2015_Layout 1 12/11/14 2:36 PM Page 24
PRODUCT & PRINT SPOTLIGHT

Portable SMAW Machine
Starts Without Sticking
Weighing 18 lb, the MiniArc

161LTS is a portable, 115- or 230-V,
single-phase machine for GTAW and
SMAW, plus is able to use 6010 electrodes easily. The Automatic Primary
Select function configures to the primary input supplied. When welding in
DC mode, the machine ranges from 5
to 160 A. A fixed hot start function
also allows the operator to strike an
arc without the electrode sticking to
the plate.
ESAB Welding & Cutting Products
www.esabna.com
(800) 3722123
The companys 610 electrode, new

to its line of AWS E6010 covered electrodes, features a concentric design
that provides greater operator control
and ensures even coating along its entire length and consistent arc performance. Designed for use in pipe welding
applications, construction and shipbuilding, maintenance welding, and
general-purpose fabrication, the electrode can be used in all welding positions. It also features quick arc start-
ing, good downhill capabilities, and

provides an easy weld lay-in and
smooth bead appearance with a light
slag for quick and easy cleanup. The
electrode, available in 18- or 532-in. diameters in a 50-lb can, offers tensile
strengths in the range of 78,000
lb/in.2 and yield strengths of approximately 65,000 lb/in.2 It also provides
Charpy V-notch impact values in the
range of 45 ft-lb at 20F to minimize
cracking in low temperatures.
Covered Electrode Increases

Operator Control
Hobart Brothers Co.

www.hobartbrothers.com
(800) 4241543
SMA Welding Glove Made with

Durable Split Cowhide
The 730 Maximus welding glove is
designed to improve comfort and reduce fatigue for shielded metal arc and
pipeline welders. The glove features a
grain pigskin palm for dexterity with
durable split cowhide on the middle
and index fingers to make active wear
areas last longer. The palm is lined

with CushionCore to block heat,
while the back is lined to the cuff with
insulating wool.
Revco Industries, Inc.
www.revcoindustries.com
(800) 5273826
App Provides Alloy Information

for Brazing and Soldering
Brazing and Soldering Selection
Guide, the companys new mobile app
for Apple and Android devices, makes
it easy to find the right alloy for the
job. The app eliminates the need to
flip through catalogs and phone books
when trying to
find materials
for your project
by providing all
of the companys alloy information and a
list of nearby
distributors.
The app features integrated
alloy information, which
means no waiting around for
Internet access,
and how-to videos with important
safety information and lessons on
proper brazing and soldering techniques.
at FABTECH 2014) is a heavy-duty, Vstyle straight cutting torch designed to

cut through metals from 18 to 12 in.
thick with the appropriate tips. It
comes in lengths of 17, 21, and 36 in.,
plus can be used with multiple fuel gases. The Enforcer is a medium-duty oxyfuel torch that can be used for cutting,
welding, brazing, and heating. Prior to
developing these products, the company was known as Cobra Torches, Inc.
Harris Products Group

www.harrisproductsgroup.com
(800) 7334043
Detroit Torch and Mfg. Co.

www.detroittorch.com
(866) 8757066
Industrial Torch Line

Features Two Styles
Dust Collector Offers Mobile

Point of Source Extraction
The Detroiter (pictured on display
The companys new portable explo-
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ORK
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ing technology to prevent edge flaking. Free of contaminants such as iron,

sulfur, and chlorine, the product is
safe to use on surfaces such as stainless steel.
Walter Surface Technologies
www.walter.com
(800) 5220321
New Website Includes

ECommerce Functionality
Model 200 Positioner
Model 1200 Pipemate
sion-proof dust collector features its

FRV DS2-EX series portable vacuums
and NA35 series portable immersion
separation vacuums joined with an exclusive point of source extraction
swing arm system. Designed to safely
collect airborne combustible dusts,
gases, and smoke emitted during manufacturing processes, the dust collector allows for a full range of mobility
on the work floor. It is available in up
to 500 ft3/min and is compliant to
NFPA standards, OSHAs combustible
dust initiative CPL-03-00-008, and
certified to Class 1, Division 1 and 2,
Group D and Class II, Division 1 and 2,
Groups F and G requirements for use
in hazardous locations.
Ruwac
www.ruwac.com
(413) 5324030
Grinding Wheel Contains a

Strong Disc Base/Backing
Designed for demanding grinding
jobs in a range of industry metal fabrication shops, the XCAVATOR grinding
wheel delivers heavy-duty performance and the highest level removal rate
in the companys line of grinding
wheel products. Tested on hard materials including tungsten carbide,
tempered steel, Inconel, Hardox,
and boron steel the wheels feature a
strong disc base/backing and company
patented UHR multilayer manufacturFor info, go to www.aws.org/adindex
The company has launched a new

U.S. website that includes information
on more than 1400 products and features easy navigation to help customers quickly find what they need.
Comprehensive product information is
presented such as features, technical
specifications, high-resolution images,
and references to related products and
accessories. A highlight of the website
is its e-commerce functionality that allows customers to purchase items online directly from the company and
conduct real-time product availability
checks. Other features include an informational instruction video library,
a section devoted to training on the
companys products and application
processes, and the ability for customers to register their product easily
for warranty purposes.
Weller
www.wellertoolsus.com
(800) 6218814
Heated Jacket Line Includes

Womens Gear
The PSJ120 womens heated jacket
offers tailored-fit features and is powered by a 12-V lithium-ion battery
connected to the battery holster. It
not only powers the jacket, but can
keep USB-compatible cell phones and
other electronics charged. The jacket
features three quick warming core heat
zones two chest and one back. The
jackets shell and inner lining are made
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Lincoln feature _Layout 1 12/10/14 1:54 PM Page 28
The Case for Using

Low-Hydrogen
Covered Electrodes
With its versatility, ease of use, and capability
to reduce harmful hydrogen diffusion in the
weld deposit, the low-hydrogen covered
electrode is a wise choice
hile mechanized welding is

seen as the future for a number of applications, shielded
metal arc welding (SMAW) in combination with low-hydrogen electrodes
often can prove to be the best choice.
Low-hydrogen electrodes are the logical choice for a variety of welding applications. Following is a look at what
low-hydrogen electrodes are and why
they work so well.
Low-Moisture Coating =
Hydrogen Control
During welding, the arc and its resultant heat release hydrogen from the
moisture in the coating, the surrounding atmosphere, and from substances
on the base material, among other
sources. Of course, moisture at times
is a good thing without it, forming
and extruding are not possible. But,
sometimes you can have too much of a
good thing. Less moisture in the electrode coating reduces the opportunity
for diffusible hydrogen to be deposited
into the weld metal, which can result
in weld failure from hydrogen-induced
cracking, also known as hydrogen embrittlement or cold cracking.
Low-hydrogen electrodes, most
simply defined, are SMAW consumables that contain less than 0.6% coating moisture compared to 4 to 6%
moisture in traditional cellulosic electrode coatings.
AWS A5.1/A5.1M:2012, Specifica28 WELDING JOURNAL / JANUARY 2015
tion for Carbon Steel Electrodes for

Shielded Metal Arc Welding, states that
low-hydrogen electrodes must have
coating moisture levels of less than
0.6% when tested at 1800F, but many
low-hydrogen electrodes carry much
lower moisture levels. The lower moisture levels correspond to relatively
lower diffusible hydrogen levels in the
deposited weld metal.
Typical AWS classifications for
SMAW electrodes include EXX15-x,
EXX16-x, EXXX18-x, and Exx28-x. Diffusible hydrogen levels, measured in
maximum milliliters of hydrogen per
100 g of weld deposit, are often listed
as optional supplemental designators
Fig. 1 Low-hydrogen electrodes should

be stored in a rod oven (100 to 300F) to
bake out and prevent moisture pickup in
the coatings.
BY LISA BYALL
at the end of the AWS classification

for the electrode. For example, a lowhydrogen electrode may be tested, per
the A5.1 specification, as measuring
no more than 8 mL/100 g. Therefore,
the electrode would carry a designation of H8. Low-hydrogen electrodes
typically measure 16 mL/100 g or less,
with H8 and H4 as common designators. An example of a full AWS classification is E7018 H4.
Certain low-hydrogen electrodes
are manufactured with special moisture-resistant coatings. These electrodes can be identified by the addition of an R to their classification
number. AWS defines the guidelines
for testing electrodes to carry this designation. Low-hydrogen electrodes
having the R designator generally exhibit extended shelf lives and room-air
exposure times, and improved resistance to weld defects such as porosity
and hydrogen-induced cracking.
Generally, the exposure time to
room air for low-hydrogen electrodes
is limited to approximately four hours,
while electrodes with the R designator can potentially be exposed for an
entire work shift, up to nine hours.
There is a limit to how long lowhydrogen electrodes can be exposed to
room air before the coatings pick up
hydrogen from condensation and can
no longer be considered low hydrogen. As a result, it is a recommended
practice to store the electrodes in an
air-tight container at an elevated temperature to prevent condensation. A
Lincoln feature _Layout 1 12/10/14 1:55 PM Page 29
Fig. 2 View of an I-95 corridor bridge interchange. The AWS D1.5, Bridge Welding Code,
and other agency codes specify the use of low-hydrogen electrodes or diffusible hydrogen
levels.
rod oven (Fig. 1) is commonly used to

properly store low-hydrogen electrodes. Electrodes may even require rebaking under strict guidelines if the
stock was exposed to the environment
for a prolonged time.
A Variety of Applications
The low-hydrogen class of electrodes is the most widely used for
SMAW. Common applications include
welding thick metal sections, restrained joints, and making critical
welds for bridge and building construction, offshore, and power generation Fig. 2. Low-hydrogen electrodes are also growing in use for non-
traditional applications to provide an

additional safety measure against weld
defects.
There are many reasons contributing to this widespread use. Most notably, shielded metal arc is considered
the easiest welding method to learn
and employ. In comparison, semiautomatic wire electrode welding demands
more extensive training and higher
initial capital investment. Low-hydrogen covered electrodes also provide a
smooth low-spatter arc that simplifies
welder training.
These versatile electrodes can be
used to weld virtually anything. Consider process piping fabrication Fig.
3. An alternate choice may be mecha-
nized wire electrode welding. However,

given the potential for inconsistent
fitup and constricted space, mechanized welding generally is not a good
option. Manual shielded metal arc
welding, on the other hand, allows for
flexibility in tackling highs and lows
on the pipe weld joint and other poorfitup issues. Covered electrodes can be
bent to permit welding pipe in confined spaces Fig. 4. Often, in these
applications, a manual welder can
maintain a level of productivity that
matches the mechanized processes.
Another benefit of SMAW is its
portability. The covered electrode
eliminates the need for external
shielding gases. When welding is
performed outdoors or in difficult-toaccess spaces, the transport, footprint,
and care required for shielding gas bottles is not a concern Fig. 5.
The AWS E7018 electrode is the
most popular low-hydrogen covered
electrode type in use today. It features
certain characteristics that separate it
from other classes. This class of covered electrode is an ideal choice for allposition welding, with the exception
of downhill welds. They offer smooth,
quiet arc characteristics with low spatter levels and easy slag removal, making E7018 a desirable electrode to use
by welders of all skill levels. They provide weld deposits with medium penetration levels, ensuring good fusion to
the base metal. Another benefit, made
possible with the addition of iron powder in the coating, is a relatively high
deposition rate. The robust deposition
rate can make covered electrode welding cost effective for a wider range of
applications. Finally, under most conditions, these low-hydrogen electrodes
provide good arc starting and restriking capabilities. These start and restrike characteristics minimize starting and striking porosity.
Defense against Cracking
Fig. 3 Covered electrodes can be a good choice for welding pipe in the field.
But why should you specifically

choose low-hydrogen electrodes? The
answer is simple: To avoid cracking.
Low-hydrogen covered electrodes
are ideal for use in crack-sensitive applications since they reduce the risk of
hydrogen-induced cracking.
This phenomenon occurs when elevated levels of hydrogen, which is naturally soluble or diffusible in liquid
metal, becomes trapped in the hardened, highly stressed weld material or
Lincoln feature _Layout 1 12/12/14 7:32 AM Page 30
Fig. 4 Some welders bend electrodes to

facilitate welding in tight spaces. Care
must be taken to use electrodes that resist cracking and loss of coating.
heat-affected zone (HAZ). The trapped

hydrogen seeks an escape route and
eventually produces voids and cracks
in the substrate, ultimately leading to
failures of the welded material. This is
especially true for higher-strength
steels, which are more susceptible to
cracking due to their higher carbon
content.
Today, engineers specify higherstrength steels for a greater number of
applications. Often, a part can be
made from a lighter-weight, thinner
metal if the materials strength is
higher. These thinner materials commonly have lower transport costs and
a reduced volume of weld metal with
fewer weld passes and all of the associated reductions in labor expenses.
In addition, higher strength steels,
correctly used, can hold up well to environmental and force stresses.
Most importantly, weld or HAZ
cracking in high-strength, highcarbon-content steels resulting from
trapped hydrogen is an unacceptable
defect that requires gouging out the
weld and rewelding adding significant cost. Eliminating one variable
that can contribute to cracking, by
specifying low-hydrogen electrodes,
can provide a safety margin in some
applications. Battling diffusible hydrogen levels in higher-strength steels
has led to a marked rise in use of
low-hydrogen electrodes.
Welding Codes Recognize

Low-Hydrogen Benefits
Various welding codes specify the
use of low-hydrogen covered electrodes. Codes and specifications can
refer to hydrogen control by either requiring low-hydrogen covered electrodes or by placing specific limits on
diffusible hydrogen.
Fig. 5 Covered electrodes are favored

for critical welding in tight spaces since
they eliminate the need for separate
shielding gas equipment.
The AWS D1.1/D1.1M:2010, Structural Welding Code Steel, for example, includes several provisions that
use hydrogen designators, such as H8,
and AWS D1.8/D1.8M:2009, Structural Welding Code Seismic Supplement,
specifies the use of low-hydrogen
electrodes when using the SMAW
process for Demand Critical welds. Additionally, the Fracture Control Plan of
AASHTO/AWS D1.5M/D1.5:2010,
Bridge Welding Code, requires the following electrode specs for welding
fracture-critical members: H16, H8, or
H4 when the minimum specified yield
strength is 50 ksi or less; and H8 or
H4 when the minimum specified yield
strength is greater the 50 ksi.
Other agencies, such as the U.S.
military and the American Bureau
of Shipping, have also set limits on
diffusible-hydrogen levels. Both use
limits of 15, 10, and 5 mL/100 g, and
the military specification has a stricter
limit of 2 mL/100 g, or H2, for certain
applications.
The engineer of record can override
these codes to make them more restrictive, but not less. And if the applicable code does not call out for lowhydrogen weld deposits, the engineer
of record can issue that requirement to
provide a safety margin.
Codes and engineers recognize the
value and importance of low-hydrogen
covered electrodes, which is why these
consumables are, and will remain, a
popular choice. WJ
LISA BYALL (www.lincolnelectric.com) is
portfolio manager, Industrial Products,
The Lincoln Electric Co., Cleveland, Ohio.
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Cullison feature January 2015_Layout 1 12/11/14 10:34 AM Page 32
BY ANDREW CULLISON,
KRISTIN CAMPBELL,
CARLOS GUZMAN, AND
MARY RUTH JOHNSEN
FABTECH 2014 Heats up Atlanta

This years exhibition offered a bustling show floor,
high-profile keynote speakers, and abundant
networking and educational opportunities
The American Welding Society and its show
partners packed so many products, professional
development opportunities, and technical talks
into this years FABTECH that the show spread
over all three halls of the Georgia World Congress Center in Atlanta. The show, which took
place November 1113, set records for a
FABTECH Atlanta event with 1477 exhibitors
occupying more than 550,000 sq ft of exhibit
space and drawing in 30,250 attendees. The
welding portion alone drew 456 exhibitors
showcasing their wares in 191,706 sq ft of
space.
The event the largest annual metalforming, fabricating, welding, and finishing event in
North America is sponsored by SME; American Welding Society; Fabricators & Manufacturers Association, International; Precision Metalforming Association; and Chemical Coaters Association International.
AWS Annual Business

Meeting
President Dean Wilson called the
95th annual business meeting to order
November 10. William Pate, president
and CEO, Atlanta Convention & Visitors Bureau, welcomed AWS and its
partners and related how the city has
been a building zone since 2010.
Among the projects he mentioned
were the new College Football Hall of
Fame, which hosted a FABTECH industry event later in the week; the
Center for Civil and Human Rights; an
upscale shopping center in Atlantas
Buckhead neighborhood; an electric
streetcar system; and two new sports
stadiums that will open in 2017. He
He related the establishment of

AWS Weld Link, stackable credentials
to help people earn more over their careers and that will take them from
their first hire through to retirement.
Through Weld Link, he said, Intelligent, user-friendly career development
will be just a click away. Weld Link will
tell users what jobs they are suitable
for because of their knowledge, skills,
and interests, and also send job info to
people who may not have seen the
posting.
Incoming President Dave Landon
(Fig. 1), who leads the welding engineering group at Vermeer Corp. in Pella, Iowa, talked about his interest in
manufacturing, and his penchant for
superhero movies.
What attracts us to superhero
movies? he asked. For me its the
technology, the toys they get to play
with. He cited the advanced welding
technology hes used or been exposed
to during his career. He also discussed
everyones need for heroes in their
lives and mentioned many of the mentors, including his father and brother,
who sparked his interest in welding
and helped him throughout his career.
He then challenged the audience to become mentors themselves. Landon
discusses this in more detail in his
editorial on page 6 of this issue of
Welding Journal.
Adams Lecture
Fig. 1 Incoming President David

Landon emphasized his enthusiasm
for careers in welding and manufacturing technology.
related how important welding and

manufacturing were to those projects
and thanked AWS for continuing to
visit Atlanta.
President Wilson related the Societys successes over the past year and
how he had focused on continuous improvement during his term. He mentioned the Societys stated mission of
advancing the science, technology,
and application of welding and allied
joining and cutting processes and said
this year AWS had informally added
advancing the people of welding to
its mission.
John Goldak (Fig. 2) started his

Adams Lecture with the quip he was
condensing 44 years of experience into
40 minutes. His lecture, titled Four
Decades of Research in Developing
Weld Mechanics at Carleton University, highlighted some of the critical
jobs in which he had been a major participant. Goldak has a PhD in physical
metallurgy and is a Distinguished Research Professor and Lifetime Emeritus Professor at Carleton. He is internationally known and recognized for
the development of a heat source model for arc welds known as the double
ellipsoid weld pool model. He is a
member of the Canadian Academy of
Engineering, and founder of Goldak
Technologies, Inc., a software developer for analysis of welded structures.
His lecture recounted the critical
situation with a nuclear reactor in
Canada that at the time was producing
85% of the worlds medical isotopes.
When a leak was detected in the reac-
Fig. 2 John Goldak presented the

Adams Lecture.
tor vessel wall it had to be shut down,

and Goldak was part of the team called
in to perform the computational
analysis on six proposed weld repairs.
Corrosion at the base of the vessel wall
caused the leak.
The proposed repair entailed using
backing strips and surfacing the area
opposite the corrosion sites. Complete
mockups were constructed to practice
the procedure and validate the repair.
The procedure called for remote robotic welding. A finite element mesh of
the reactor was performed, and a thermal analysis was taken for every millimeter of arc movement. The repair
was complicated further by the fact
that the wall thicknesses at the corrosion sites varied down to 1 mm. Experts indicated this was one of the
most complicated weld repairs they
had ever seen. After extensive analysis
of the corroded areas, thorough stress
and metallurgical analysis, and repeated practice, the repairs were successful.
Goldak told of a repair of a submarine that was also experiencing leaking
due to corrosion. In this instance, the
corroded areas were ground down and
weld surfacing was performed to build
up the area. Because the buildup required multiple passes, it was critical
to predict distortion. Also, a thorough
solidification analysis was done that
showed the microstructure evolution,
and predicted the stress-strain in the
heat-affected zone. Examination of
the repair showed a very close relationship with the predicted results.
Plummer Lecture
Leland Vetter has more than 34
years experience in training, testing,
and inspection. He has been an AWS
member for 32 years and is an AWS
Certified Welding Inspector, Certified
Welding Educator, and Certified Welding Supervisor. His Plummer Lecture,
Training Welders for the Energy Industry Training for the Way I Do
It, was filled with advice for
educators.
When he was growing up in North
Dakota, he was having a hard time in
high school. A friend knew of a blacksmithing job he thought would be
good for Vetter. It would not only
teach him work ethics, but would also
get him out of school for a while.
That changed my life, he said, for
that job turned him in the direction of
welding. After studying welding and
machine tooling at the North Dakota
State College of Science, he went on to
the oil fields in North Dakota, ending
up in the famous Bakken oil basin doing repair welding on large equipment. From there, he knew maintenance and repair welding was going to
be the focus in his life.
Early in his career he was given the
opportunity to start a welding maintenance and repair program at Eastern
Wyoming College, in Torrington, Wyo.
The facility that was provided to start
his program was not the best, and
when he asked the president how
much money had been allocated for
the program, he said $5000. Vetter
told him it might take a little more
than that, and the president obligingly told him to go out and spend what
you need to get going. I ended up
spending $125,000 that year, said
Vetter.
I have always taken pride in meeting with my students before they start
in class, said Vetter. I want them to
know I am there to help them. But
when class starts You should set the
tone immediately. They should know
the proper clothing to wear, the proper attitude to have, and the importance of safety. If they didnt want to
conform, he would send them home.
I was tough on students, and they responded, he said. After a while they
could see the purpose. His classes always taught the basics of being a productive worker: follow instructions,
pay attention to details, stay on track,
do what you are told, and buy in.
He had a class on general welding
Robotic Arc Welding Competition Tests

Programming Skills
This year, Atlanta welcomed the second Robotic Arc Welding Competition.
Twelve contestants raced against the clock to answer as many of the 40 technical
questions as possible in 20 min, and to accurately weld a pretacked steel coupon in
less than 45 min.
Wolf Robotics and Miller Welding Automation provided the robotic welding
cells for the competition, and Servo Robot served as the official judge of the welded coupons. The competition format and structure are designed to emulate the
examination process and testing procedures that the American Welding Society
uses for actual Certified Robotic Arc Welder (CRAW) certification testing.
Prizes for the top three finishers included an AWS duffel bag, an AWS t-shirt,
and medal of recognition. The winner received a complimentary CRAW certification tuition covering training and examination at any Approved Test Center.
Tsukasa Ogihara (left), application engineer at Genesis Systems Group, was

the winner of the 2nd AWS Robotic
Arc Welding Competition. Sam Audia
(right), manufacturing engineer at
Richardson Cooling Packages, claimed
the third position.
Justin Wenning, from The Ohio State

University, claimed the second spot.
Contestants had 45 min to program the robot and weld a pretacked steel coupon.
that started off with oxyfuel welding,

and then moved on to AC welding with
shielded metal arc using 6011, 6013,
and 7014. A lot of people think they
know how to weld, but if they dont
know this, they dont really know
welding. He also has a bit of advice for
instructors. Learn how to weld well;
not just average. When you demonstrate, bring the wow factor to the
student.
The first year of the program, in addition to basic and advanced shielded
metal arc welding, he has classes in inspection, drafting (it teaches relationships, visualization, attention to detail, neatness), print reading, flux
cored arc welding, gas metal arc welding, welding metallurgy, and general
machine shop (it teaches the use of
hand tools, flatness, squareness, layout, measurement).
In the second year, math and writing are part of the studies. I waited to
introduce these in the second year because I knew in my studies if I had
started with these courses at first, I
would have quit. By the second year
they have bought in to what it takes.
Also included in the second year are
gas tungsten arc welding, structural
welding to D1.1, precision machine
tooling (to understand what is occurring when making a cut, how to read a
caliper), and pipe welding uphill with
6010 and 7018, and downhill with
6010 and 7010. A test is given using
6010 with no grinding allowed. He
emphasizes your welding should be
good enough that you dont need to
grind. We are not a grinding school;
we are a welding school. The whole
program is based on sound weld

metal, he said.
Some of Vetters students have
competed in SkillsUSA, but he states,
We are not a competition school. All
students are expected to perform at
this high level. Those who have competed (some have gone on to the international level) have done their preparation after hours. Vetter believes
everyone should be doing his/her best
all the time.
Vetter recently retired, but he,
along with four other instructors, have
built the school into a regional powerhouse that last year instructed 100
full-time students. He left the program in great shape, so much so that a
new $24 million facility is on the
drawing boards.
Keynote Presentations
Cindi Marsiglio, Walmarts vice
president, U.S. manufacturing, presented Creating U.S. Jobs and Bringing Manufacturing Home. During her
talk, she pointed out the companys
commitment to spend $250 billion
over the next decade on U.S.-made
products. In addition, Marsiglio spoke
of working with merchants and their
business strategies, then going to suppliers; the companys recent U.S. Manufacturing Summit and Made in the
U.S.A. open call; reshoring progress;
creating the Walmart U.S. Manufacturing Innovation Fund; and establishing
the Jobs in U.S. Manufacturing Portal
at www.Walmart-jump.com. During a
Q&A session, shortening the supply
chain with U.S.-made products and
New Products
Of course, the stars of FABTECH
are the products on display. Following
are some that caught the eye of the
Welding Journal editors.
The Tweco Velocity consumable was a new introduction at
FABTECH. Meant for medium- and
heavy-duty gas metal arc welding with
Spray Master welding guns, this contact tip (Fig. 3) is uniquely designed to
direct the shielding gas through the
tip, thereby acting as a diffuser as well
as an electrical conduit. The gas flows
through ports in the tip, cooling it,
and in the process extending its work
life. Its design also eliminates a sepa-
Fig. 3 The Tweco Velocity contact tip directs the shielding gas
through the tip, acting as a diffuser as
well as an electrical conduit.
momentum in regard to electronics

manufacturing returning to the United States were discussed.
The last day of FABTECH got started with a stimulating presentation
from Google for Works Head of Manufacturing Mike Walton titled Transforming your Manufacturing Business
for the Digital Age. Google for Work is
designed to help businesses bring
technology to their business so people
can work together, from wherever.
Walton spoke about just that how
the manufacturing sector in particular
could benefit from streamlining their
technology by using the latest Cloud
storage and data-sharing solutions,
and even the use of devices such as the
Google Glass that can, for example, integrate augmented reality in training
and manufacturing. Walton was accompanied by Mike Burak, partner of
PricewaterhouseCoopers (an international consulting and accounting firm),
which recently announced that it is
going Google. Burak explained how
the use of Web and mobile apps contribute to streamlining their business
and enhancing communications with
employees, customers, and vendors all
around the world. They spoke about
how these new tools are part of their
business model, improving services, restructuring supply chains, and optimizing data analysis all of which
help businesses stay innovative. Although Google is just one of the companies offering these technologies to
businesses, it is a good starting point
to see whats available and which tools
can better help your operation (Google
for Work, www.google.com/work).
rate diffuser required in some systems,

making for less parts and fewer
threaded parts to assemble. The handtightened nozzle holds in place the
nonthreaded contact tip. The brass
threads on the nozzle mate with stainless steel threads on the welding gun
for a tight grip. ESAB Welding and
Cutting Products, esabna.com/powerlineup
The ENSIS3015 AJ fiber laser
(Fig. 4) for cutting was a featured
product by Amada. It has a capability
that allows it to cut material of different thicknesses without requiring a
lens change. The beam passes through
a control unit that adjusts it for optimal configuration depending on
whether the material is thin or thick.
This 2-kW machine can cut material

up to 1 in., as well as 1.0-mm sheet
metal. The mechanical and electrical
components are combined and housed
in a single unit, thereby reducing its
size and the floor space required. The
unit has been designed for efficient
energy consumption. Amada North
America, Inc., www.amada.com
Fig. 4 This fiber laser from Amada

can cut material of different thicknesses without the need for a lens
change.
The E-WELD Nozzle from Walter

Surface Technologies is a specially formulated antispatter compound Fig.
5. It prevents spatter adhesion to nozzles for up to eight hours. It can be
used for both semiautomatic and fully
automatic gas metal arc welding, and
it comes with an applicator that is designed to evenly coat the nozzle with
the ceramic-based liquid. A cloth rag is
all that is needed to wipe off spatter
after welding. Gas flow is efficient and
unobstructed when spatter buildup in
the nozzle is eliminated. Walter Surface Technologies, www.walter.com
introduced at FABTECH. This model

can cut a variety of metals up to 19
mm thick. It is not sensitive to back
reflection, making it capable of cutting
reflective metals such as aluminum,
stainless steel, and brass. Its modular
design gives a compact cabinet of 4 ft
H 3.1 ft W 3 D. Panasonic is now
incorporating this model into its metal
cutting systems. It has a wall plug efficiency of 40%. TeraDiode, www.teradiode.com
RoboVent ICE integrates both
dust collection and air conditioning
Fig. 6. This patent-pending, integrated
cooling equipment removes even ultrafine dust from the air workers
breathe and reduces maintenance
since the air going through the coils is
filled to 99.99%. The Vortex system
offers a proprietary design that creates
a circular airflow pattern to capture
and filter ambient air in a plant, no
ductwork required. If a ducted system
is the right selection for your application, the product may also be paired
with the companys Fusion 3 dust collector. RoboVent, www.robovent.com
configured IRB 4400 or IRB 2400 robots are optimized for path performance; the parallel arm design provides
stiffness, plus minimizes resonance
and vibrations affecting the quality of
the laser cutting process. ABB, Inc.,
Robotics, www.abb.com/robotics
Fig. 7 The FlexCutLaserTM provides a

fast and accurate robotic laser cutting system.
The HPRXD short torch with integrated lead has been developed in response to growth in the 3D market, a
segment of which relates to pipe cutting Fig. 8. The shorter length has
been achieved through removing the
quick disconnect feature and replacing
it with a straight torch design. Also,
the main differences between the
standard HPRXD torches and the new
product include the short torch being
194 mm in length (but that will vary a
little based on consumable stackup);
reduction in tin braid coverage from
lead wrap at the torch end; a change in
the coolant path supply line; and insertion of a pass-through connection
box. Hypertherm, Inc., www.hypertherm.com
Fig. 6 RoboVent ICE creates clean,

cool air for the working environment.
Fig. 5 The E-WELD Nozzle prevents

spatter adhesion to nozzles for up to
8 h.
The 2-kW direct diode laser

TeraBlade 2000 from TeraDiode was
The FlexCutLaserTM is a preengineered robotic cell for laser cutting applications Fig. 7. The selfcontained, palletized, and modular design allows for cell transport, minimum setup time, and flexibility in a
limited amount of floor space. RobotStudio Cutting Powerpac enables fast,
accurate offline programming while
Robotware Cutting software means optimized motion control. Also, laser
Fig. 8 The HPRXD short torch offers a tight bend radius for use in 3D
applications.
At just 40 lb, the new Lincoln

Power Mig 210 MP multiprocess
welding machine (Fig. 9) packs a

punch with 210 A, the convenience of
dual voltage inputs (120 and 230 V),
and the ability to weld using three different processes: gas metal arc, fluxcored arc, or shielded metal arc. Targeted for the hobbyist, educator, small
contractor, or small shop, the 210 MP
features push-and-turn digital controls and a color display screen that
make setup and operation intuitive. It
welds up to 38-in. mild or stainless steel
and up to 316-in. aluminum. Lincoln
Electric, www.lincolnelectric.com
Fig. 9 The multiprocess Power Mig

210 MP weighs 40 lb and can plug into
regular 120-V outlets, making it a good
option for smaller jobs where portability is important.
The TruLaser Robot 5020 is a

new laser welding system from
TRUMPF that features easy component compatibility, modular construction, and turnkey installation Fig.
11. Its modular system can clamp
components of different sizes and
shapes, and several components can
be joined in a single processing step
depending on the size of the workpiece. Its able to share a laser source
in a laser network, which provides a
flexible and cost-effective entry into
laser welding. The standard model of
the TruLaser Robot 5020 is fitted with
a hand-operated turntable, with an optional automatic rotational turntable
available. The operator is fully protected from the laser beam and rotational
unit while loading and unloading
parts. The system only rotates when
the internal sensor determines the
area is completely clear. The loadbearing capacity of the rotational unit
is 1650 lb per side, allowing for several
components to be welded simultaneously. TRUMPF, www.us.trumpf.com
Fig. 12 The weldcap combines a

baseball cap hood with an autodarkening welding lens.
The TIG Brush Stainless Steel

Weld Cleaning System uses a combination of electricity, heat, and chemistry to clean welds Fig. 10. Its proprietary, conductive brush applies
cleaning fluid to the work surface, producing an electrochemical cleaning action. The system removes detectable
oxides from the weld zone and returns
chromium content in the surface layer
to original or better levels. Ensitech,
www.tigbrush.com
Fig. 11 The flexibility and component

compatibility of the TruLaser Robot
5020 allows the making of small production batches cost effective.
Fig. 10 The conductive brush of the

TIG Brush system applies cleaning fluid to the work surface, producing an
electrochemical cleaning action.
Shown is the TBE-700 model.
tures a well-defined nose cutout that

allows the goggle-style lens to be
placed closer to the eyes, giving the
welder a tighter fit and greater viewing
area. The user can remove the cap and
wash it in a washing machine, as well
as purchase replacement caps. The helmet lists for $189. Optrel, Inc.,
www.optrel.com
Optrel touts that its new weldcap

is soft where it needs to be for comfort
and hard where necessary for toughness. The product combines a baseball
cap with an autodarkening welding
helmet (Fig. 12), and is designed for
the occasional or hobbyist welder,
not heavy industrial use. It weighs
less than 14 oz, and is made of flameretardant material and plastic. It fea-
Shops that want to implement robotic welding but do not have in-depth
programming knowledge can utilize
Kinetiq Teaching. The sensor
developed by Robotiq in partnership
with Yaskawa Motoman allows the
operator to guide the robot tip by
hand to each weld point for simplified
teaching and faster setup times. At
each weld point, the operator determines the welding parameters through
a touch screen interface, and then
when all the points are recorded, the
operator can play back the programmed trajectory and modify it as
necessary. The icon-based pendant lets
the user intuitively program welding
programs (for example, touching the
turtle icon slows the robot down, the
rabbit speeds it up). The system is useful for small- and medium-sized shops
with high-mix and low-volume welding applications. Robotiq, www.robotiq.com, and Yaskawa Motoman,
www.motoman.com
Designed for the heavy equipment
market and as a replacement for the
companys Axcess line of machines,
the Continuum 500 (Fig. 13) per-
forms semiautomatic gas metal arc

welding, and also offers improved
Accu-Pulse, Regulated Metal Deposition, and high-deposition GMAW capabilities. Features include a new inverter-based power source, new wire
feeder design, and new drive roll system. It offers 500 A of welding power
at 100% duty cycle. An intuitive interface makes the system easier to set up
and adjust. The LCD display shows
complete words, graphics, and numeric values, and it includes memory
buttons that allow welders to quickly
change programs. Miller Electric
Mfg. Co., www.millerwelds.com
Fig. 13 The Continuum 500 offers

a modular design and a control interface that can be located on the power source, feeder, or remote operator
interface.
Welders Spark Up the Competition at AWS U.S.

Invitational Weld Trials
After an intense few days of competing, the top three finalists at the AWS U.S.
Invitational Weld Trials held during FABTECH 2014 were revealed. They are listed
below. A group shot of all the contestants is also shown.
Andrew Cardin from Sutton, Mass., is a graduate of Blackstone Valley Technical High School. He also participated in the preselection process for the 2013
WorldSkills Competition, finishing as runner up; worked multiple welding jobs
over the past two years; and assists his father, as time permits, at his auto repair
shop.
Josiah Mechaelsen from Melrose, Minn., trains at Alexandria Technical and
Community College. He has been a welder at Minnesota Trapline Products, Inc.;
competed in SkillsUSA welding competitions, coming in first at his local and state
competition, then second at the national event in 2013; and served as a machinist
at Melrose Metalworks, Inc.
Jacob Miller from Greers Ferry, Ark., graduated from West Side Schools and
attends ASU-Heber Springs. His SkillsUSA involvement has led to accomplishments such as finishing in the top three in Arkansas in welding for the last three
years. He works at Forge Point Industries.
These welders will advance to the next stages with an AWS TeamUSA finalist
tune-up and AWS/SkillsUSA TeamUSA finals. The winner will represent the United States as its welding competitor at the 43rd WorldSkills Competition in So
Paulo, Brazil, this August. Also, he will earn a $40,000, four-year scholarship from
the AWS Foundation sponsored by Miller Electric Mfg. Co.
The following three welders competed at the weld trials as well: Cody Fojtik
from Grass Lake, Mich. (Washtenaw Community College); Isaiah Gaspar from
Yuma, Ariz. (Arizona Western College); and Drew Swafford from Cedartown, Ga.
(Georgia Northwestern Technical College).
The event, held on the show floor, involved fabricating a pressure vessel; both
aluminum and stainless steel projects; 10-mm groove welds; 12-mm fillet welds;
16-mm test plates; and 6-in., Schedule 40 pipe.
The processes used were flux cored arc, gas shielded flux cored arc, gas metal
arc, gas tungsten arc, and shielded metal arc welding.
Grinding is only allowed on weld starts and stops, and on the face of the root
pass only or in the preparation of welding joints. Testing involved mostly visual
inspection techniques, meeting tight acceptance criteria above whats in welding
codes, plus hydrostatically testing the pressure vessels to 1000 lb/in.2
In addition, three international welding competitors Varaksa Aliaksandr
of Belarus, Thomas Beardsley of the United Kingdom, and Zang Lihuan of
the Peoples Republic of China were invited to compete alongside the U.S.
contestants.
See You Next Year

FABTECH returns to Chicagos McCormick Place November 912. For
more information, visit www.fabtechexpo.com. Links there to Twitter,
LinkedIn, Facebook, YouTube, and Instagram will let you stay connected to
the show all year long. WJ
ANDREW CULLISON (cullison@aws.org) is

publisher, KRISTIN CAMPBELL is associate
editor, and MARY RUTH JOHNSEN is editor of
the Welding Journal. CARLOS GUZMAN is
editor of Welding Journal en Espaol.
Posing for a group picture behind their finished pressure vessels are (from left)
Thomas Beardsley, Drew Swafford, Andrew Cardin, Isaiah Gaspar, Varaksa Aliaksandr,
Cody Fojtik, Jacob Miller, and Josiah Mechaelsen. (Not pictured is Zang Lihuan.)
harris_FP_TEMP 12/10/14 9:10 AM Page 39
Trillwood Layout_Layout 1 12/10/14 4:50 PM Page 40
Creating a Leak-Tight
Aircraft Relay Switch
How welding dissimilar metals, including
copper-nickel and low-carbon steel,
brought this important piece to life
Pure metals and alloys have widely
different constituents, including thermal conductivity, strength, and vapor
pressure. Welding dissimilar metals,
therefore, creates challenges that are
specific to the nature of the combination you are trying to weld. Over the
years, analysis of these combinations
has allowed tabulation of some results
(Table 1).
Benefits of Electron
Beam Welding
Probably the greatest tonnage that
is electron beam welded today, and has
been for many years, is the continuous
strip welding of high-speed steel to a
lower grade steel for manufacturing bimetal saw blades. In all probability, the
hacksaw blade you buy at the hardware
store is a bi-metal blade where the
teeth are high-speed steel welded to a
low-carbon, cheaper steel backing.
In contrast, there are many smaller
volumes of small precision components that rely on the fusion of dissimilar metals the hermetically
sealed relay being just one of them.
While traditional welding techniques can be used to join some dissimilar metals, a complicated project
with heat-sensitive parts in close proximity to the weld requires a precise
welding tool, such as an electron
beam. This process can reduce stress
and distortion and lower heat input.
The beam provides greater control,
reduced stresses, lower heat input, and
reduced distortion as well as the ability to melt one metal preferentially to
ensure optimum strength and reduced
tendency for weld cracking.
Fabricating a Relay Switch

At Electron Beam Engineering, Inc.,
an Anaheim, Calif., welding service
provider that specializes in such projects, one task brought to the company
requiring welding of dissimilar metals
was for a relay switch used in civilian
and military aircraft Fig. 1. This
piece also had to meet class A welding standards and be leak tight.
Hermetically sealed relays are used
in a variety of applications and industries. These high-performance electrical switches are protected from the external environment, except from excessive temperature exposure. In addition, aerospace is a major consumer
because this type of relay is not affected by changes in atmospheric pressure, meaning they will operate at any
altitude. They are compact, plug in,
and if needed, can be interchanged for
servicing or upgrade of the electrical
circuits that they control.
Fig. 1 Making a relay switch, used

in both civilian and military aircraft,
required welding dissimilar metals.
BY RICHARD TRILLWOOD
Working with a Copper-Nickel

Can, Low-Carbon Steel
Header
The materials selected for the relay
switch were a copper-nickel can and
low-carbon steel header. While their
characteristics are widely different,
with the high-energy density of the
small focused spot obtained with
electron beam welding, these differences especially in thermal conductivity are overcome and make the
welding a relatively simple production
process.
The resulting alloy and low stresses
Fig. 2 Helium leak testing, as demonstrated above, takes place on the weld
and other joints in the component.
Fig 1 Alloy Weldability Using Electron Beam Welding Method

Material 1
Welded to Material 2
Notes
Al Alloy 6061
Al Alloy 4047
Al Alloy 6061 is a precipitation hardening aluminum alloy

commonly used in the construction of aircraft structures, such as
wings and fuselages, automotive parts, cans, and scuba tanks.
Al Alloy 4047 is a nonheattreatable wrought alloy type with good
corrosion resistance. It is a ller alloy with a higher silicon content that
prevents cracking during welding to enable 6061 to be welded to itself.
Inconel
Copper
The Inconel alloys oer a superior combination of heat resistance, high

temperature corrosion resistance, toughness, and strength for the most
demanding applications.
Copper has high thermal and electrical conductivities.
Kovar
Hastelloy C22
Kovar alloy, also known as ASTM F15, NILO K, Pernifer 2918, Rodar, and
Dilvar P1, is a controlledexpansion alloy. It is a nickeliron alloy with 29%
nickel, 17% cobalt, and the remaining balance is iron. Popular in
hermetic sealing applications combined with ceramic or glass.
Hastelloy C22 is a versatile nickel chromiummolybdenum
tungsten alloy with improved resistance to both uniform
and localized corrosion as well as a variety of mixed industrial
chemicals. The C22 alloy exhibits superior weldability with electron
beam welding.
Kovar
SS 304L
Kovar alloy (see above information)

304L has a higher chromium and lower carbon content. The lower carbon
minimizes chromium carbide precipitation due to welding and its
susceptibility to intergranular corrosion. In many instances, it can be
used in the aswelded condition.
Molybdenum
Tungsten
Molybdenum, commonly known as moly, has a wide variety of

uses, especially those requiring materials that can withstand high stress,
temperature ranges, and corrosive environments.
Tungstens many alloys have numerous applications, most notably in
incandescent light bulb laments, Xray tubes (as both the lament and
target), electrodes in gas tungsten arc welding, superalloys, and
radiation shielding. Tungstens hardness and high density give it military
applications in penetrating projectiles. Both these metals are known as
refractory or hightemperature metals.
Disclaimer. Some of these material combinations have only been electron beam welded on an experimental basis with variable results. The joint design for the weld
plays an important part for successful electron beam welding results. It is therefore recommended that before chosing a dissimilar metal joint combination you consult
with a specialist at Electron Beam Engineering (EBE), Inc. This information is provided as is and EBE, Inc., makes no warranty of any kind with respect to the subject
matter or accuracy of the information contained herein. EBE, Inc., specically disclaims all warranties, expressed, implied or otherwise, including without limitation, all
warranties of merchantability and tness for a particular purpose. In no event shall EBE, Inc., be liable for any special, incidental, indirect or consequential damages of
any kind or any damages whatsoever resulting from loss of use, data, prots, whether or not advised of the possibility of damage, and on any theory of liability, arising
out of or in connection with the use of the information contained herein. Specialty Metals Corp. owns the trademark names Brightray, Inconel, Incoloy, Monel, Ni
monic, and Nilo. Haynes International is the owner of trade names Hastelloy and Stellite, a trade name of Kennametal Stellite Co., invented by Haynes in the
1900s. Note: This is a partial list only and a more comprehensive data chart is available by request.
are such that it maintains the integrity

of the seal for both of the welds, and
avoids damage to the close by glass-tometal seals. The early problems with
this welding, however, were the apparent overheating of the adjacent glass
seals and leakage at the bond between
the steel and glass. This came up after
successfully welding production batches of parts without problems.
An investigation revealed that the
welding conditions were identical to
previous batches, so a header and can
from an early batch were welded with
no leakage. It was found that the header, although leak tight before welding,
leaked after welding. Further investigation revealed a slightly inferior
glass-to-metal bond, which when corrected, solved the problem.
Performing Various
Welding Processes
In service, the welds experience
temperature and atmospheric pressure
changes, and even a vacuum in space
while the seal ensures that the inter-
nals of the relay are maintained in

their own inert gas can.
With use of more conventional arc
welding, such as gas tungsten arc
welding, the heat input and potential
for seal damage is greatly magnified.
In the case of the aerospace relay,
the dissimilar metals were welded together with a precise ratio at the weld
spot that on analysis showed almost a
one-to-one ratio of copper and steel,
and a ductile joint with no cracking or
leakage.
Electron beam welding can help
control the mixture of the alloying in

the weld zone for optimum weld quality, but there is still much trial and error that takes place to perfect the
process of welding dissimilar metals.
Employing Equipment to
Test for Helium Leaks
All hermetic sealing jobs, including
the relays, are fully tested to ensure
they are leak tight Fig. 2.
This is accomplished using a helium
leak detector to test not only the weld
but any other joints in the component
such as glass-to-metal, metal-to-metal,
and ceramic seals; gaskets; O rings;
and glued joints. The helium molecule
is so small it will find even the minutest leak; thats why helium-filled balloons deflate quickly as the helium
permeates through the rubber
balloon wall.
Two Methods Worth

Following
There are several ways to use helium leak detector equipment, depending on the component configuration.
In the relay case, there are two types in
production; one with a hole in the can
and one without a hole.
Method A: The relay is evacuated
through the hole and is connected to
the helium detector. Helium is sprayed
onto the part and any leakage is detected. After backfilling with inert gas,
usually an argon/helium mix, the
small hole is closed with a resistance
welded ball and, if thought necessary,
Method B can be used as a final test.
Method B: The relay is fully sealed
and a batch of relays are placed into a
pressurized helium container, usually
referred to as a bomb test. After

some hours, the relays are released
from the helium bomb and loaded
into a vacuum container attached to
the detector. Any leakage of the helium that has seeped into the relay will
be detected.
Since the leaking part or parts cannot be identified because its a batch
process, they can either be retested
one at a time or a helium sniffer is
used, which is also connected to the
leak detector, and is operated to sniff
around the relays to locate the leaker.
The percentage of leakers is very low,
so retesting is not often required. WJ
RICHARD TRILLWOOD is CEO

of Electron Beam Engineering, Inc.
(www.ebeinc.com), Anaheim, Calif.
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superflash_FP_TEMP 12/10/14 1:10 PM Page 43
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Self-mixed
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4.2
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$184.80
$29.94
$1,556.72
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$462.00
$74.84
$3,891.79
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$119.75
$6,226.86
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21.1
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$924.00
$149.68
$7,783.58
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31.6
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$1,386.00
$224.53
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C-25
Coming Events Jan_Layout 1 12/11/14 1:55 PM Page 44
COMING EVENTS
AWS-SPONSORED EVENTS
AWS Dissimilar Materials Welding/Joining Workshop. Jan.
25. The Blackwell Inn and Pfahl Conference Center, Columbus, Ohio. This workshop will bring together experts in the
field to share their insight and experience. Topics will include process technology, materials, design, and modeling.
AWS 9th Shipbuilding Conference. April 7, 8. Hampton
Roads, Va.
6th International Brazing & Soldering Conference. April
1922. Long Beach, Calif. Topics will include current research, practical and potential applications, and new developments in these technologies. www.awo.aws.org/2015-ibsc.
AWS Cladding Conference. May 12, 13. Minneapolis, Minn.
AWS 2nd Welding Education, Skills & Certification Confer
ence. July 1416. Chattanooga State Community College,
Chattanooga, Tenn.
AWS High Temperature Steels Conference. August TBA.
Moraine Valley Community College, Chicago, Ill.
AWS 18th Annual Aluminum Conference. Sept. 2224. San
Diego, Calif.
FABTECH 2015. Nov. 912. McCormick Place, Chicago, Ill.

This exhibition is the largest event in North America dedicated to showcasing the full spectrum of metal forming, fabricating, tube and pipe, welding equipment, and myriad
manufacturing technologies. (800/305) 443-9353, ext. 264;
www.fabtechexpo.com.
U.S., CANADA, MEXICO EVENTS

International Thermal Spray Conference colocated with
AeroMat 2015 and Microstructural Characterization of
Aerospace Materials and Coatings. May 1114. Long Beach
Convention & Entertainment Center, Long Beach, Calif.
www.asminternational.org/web/itsc-2015.
INTERTECH 2015. May 19, 20. Downtown Marriott Indianapolis, Indianapolis, Ind. To feature developments and applications for superabrasives in the automotive and other industries. Sponsored by Industrial Diamond Assn. of America. www.intertechconference.com.
INTERNATIONAL EVENTS
2nd Arabia Essen Welding & Cutting. Jan. 1013. Dubai
hypertherm_FP_TEMP 12/10/14 9:13 AM Page 45
Learn more at www.hypertherm.com/quality

From spark to nish, no other brand can cut it
against a Hypertherm Powermax air plasma
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Coming Events Jan_Layout 1 12/11/14 1:56 PM Page 46
Visit our website

e for more
mor information on our
ISO 17025 Accredited
d Test
Te
T Lab Services
COMING EVENTS
continued from page 44
World Trade Center, Dubai, UAE. www.arabia-essen-weldingcutting.com.

International Conference on Testing and Measurement:
Techniques and Applications. Jan. 16, 17. Phuket Island,
Thailand. All papers in English. www.tmta2015.org.
Chemical Analysis
Impact Testing
&%$#"! % #%

Calibration
&%$#"!%!%#%
%%%"
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&%#!
&% """"#%$
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www.wtti.com &%1
1-800-223-9884
International Conference on Power and Mechanical Engi

neering. Feb. 8, 9. Shanghai Olympic Club Hotel, Shanghai,
China. www.icpme2015.org.
EDUCATIONAL OPPORTUNITIES
CWI Courses. Allentown, Pa. CWI Training: Feb. 2327, May
1115, Aug. 1721, Nov. 26; D1.1 Endorsement: Feb. 27,
May 15, Aug. 21, Nov. 6; D1.5 Endorsement: Feb. 20, May 8,
July 28; API Endorsement: May 7, Oct. 30. Bolting Endorsement: Feb. 19, July 27. Welder Training and Testing Institute; (800) 223-9884; www.wtti.edu.
Laser Additive Manufacturing Workshop. March 4, 5. College of Optics and Photonics at the University of Central
Florida, Orlando, Fla. www.lia.org/lam. WJ
For more information on AWS events: www.aws.org/w/a/conferences/index
(800/305) 4439353, ext. 234, belkys@aws.org.
MAVERICK
TESTING
LABORATORIES
Maverick Testing
Laboratories is a full
spectrum, independent,
state-of-the-art ISO
9001 Certified testing
laboratory . We provide a
comprehensive range of
welder performance,
welding procedures,
metallurgical and mechanical
testing services & full welding
consulting services throughout
the TX Gulf Coast.
We provide and sell the Maverick Test
Coupon, a 2.750 OD x 0.688 Wt.,
P-No-1 Material for the ultimate in
unlimited thickness to ASME Sec. IX. See
website for full details.
We have two facilities in Texas to provide a total welding
solutions center for our customers, including mobile on-site
testing capabilities.
Industries Served: Oil & Gas Refining, Offshore, Structural, Power &
Utilities, Pipeline, Petrochemical, and Aerospace.
MAVERICK
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VERICK TESTING LABORATORIES
AT
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visit our web site
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www.m
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T: (281) 888-8210 / www.mavericktestinglabs.com
twi north america_FP_TEMP 12/10/14 9:16 AM Page 47
Jan 2015 Final_Layout 1 12/11/14 11:18 AM Page 48
CERTIFICATION SCHEDULE
Certication Seminars, Code Clinics, and Examinations
Note: The 2015 schedule for all certifications is posted online at

www.aws.org/w/a/registrations/prices_schedules.html.
Certified Welding Inspector (CWI)

Location
Long Beach, CA
New Orleans, LA
Seattle, WA
Waco, TX
Atlanta, GA
Milwaukee, WI
Miami, FL
Mobile, AL
Houston, TX
Kansas City, MO
Norfolk, VA
Boston, MA
Indianapolis, IN
Portland, OR
Rochester, NY
Edmonton, AB Canada
Corpus Christi, TX
Birmingham, AL
Chicago, IL
Dallas, TX
Miami, FL
Springfield, MO
York, PA
Las Vegas, NV
Minneapolis, MN
Syracuse, NY
St. Louis, MO
Nashville, TN
New Orleans, LA
San Francisco, CA
Calgary, Canada
Perrysburg, OH
Miami, FL
Annapolis, MD
Detroit, MI
pus Christi, TX
Albuquerque, NM
Fresno, CA
Miami, FL
Oklahoma City, OK
Corpus Christi, TX
Knoxville, TN
Birmingham, AL
Hutchinson, KS
Spokane, WA
Bakersfield, CA
Pittsburgh, PA
Beaumont, TX
Hartford, CT
Orlando, FL
Memphis, TN
Miami, FL
Corpus Christi, TX
Miami, FL
Cleveland, OH
Seminar Dates
Feb. 813
Feb. 8-13
Feb. 813
Feb. 813
Feb. 2227
Feb. 2227
Exam only
Mar. 16
Mar. 16
Mar. 16
Mar. 16
Mar. 813
Mar. 813
Mar. 813
Exam only
Exam only
Exam only
Mar. 2227
Mar. 2227
Mar. 2227
Mar. 2227
Mar. 2227
Exam only
Mar. 29Apr. 3
Mar. 29Apr. 3
Mar. 29Apr. 3
Exam only
Apr. 1217
Apr. 1217
Apr. 1217
Apr. 1924
Exam only
Exam only
Apr. 26May 1
Apr. 26May 1
Apr. 26May 1
May 38
May 38
May 38
May 38
Exam only
Exam only
May 31June 5
May 31June 5
May 31June 5
June 712
June 712
June 1419
June 1419
June 1419
June 1419
Exam only
Exam only
Exam only
July 1217
Exam Date
Feb. 14
Feb. 14
Feb. 14
Feb. 14
Feb. 28
Feb. 28
Feb. 26
Mar. 7
Mar. 7
Mar. 7
Mar. 7
Mar. 14
Mar. 14
Mar. 14
Mar. 14
Mar. 16
Mar. 21
Mar. 28
Mar. 28
Mar. 28
Mar. 28
Mar. 28
Mar. 28
Apr. 4
Apr. 4
Apr. 4
Apr. 11
Apr. 18
Apr. 18
Apr. 18
Apr. 25
Apr. 18
Apr. 23
May 2
May 2CorMay 2
May 9
May 9
May 9
May 9
May 16
May 23
June 6
June 6
June 6
June 13
June 13
June 20
June 20
June 20
June 20
June 25
June 27
July 16
July 18
Certified Welding Educator (CWE)

Seminar and exam are given at all sites listed under Certified
Welding Inspector. Seminar attendees will not attend the Code
Clinic portion of the seminar (usually the first two days).
Certified Welding Sales Representative (CWSR)

CWSR exams will be given at CWI exam sites.
Certified Welding Supervisor (CWS)

CWS exams are also given at all CWI exam sites.
Location
New Orleans, LA
Minneapolis, MN
Seminar Dates
Mar. 30Apr. 3
July 1317
Exam Date
Apr. 4
July 18
9Year Recertification Seminar for CWI/SCWI

For current CWIs and SCWIs needing to meet education requirements without taking the exam. The exam can be taken at any site listed under Certified Welding Inspector.
Location
Denver, CO
Dallas, TX
Miami, FL
Sacramento, CA
Boston, MA
Charlotte, NC
Pittsburgh, PA
San Diego, CA
Miami, FL
Orlando, FL
Seminar Dates
February 2227
March 0813
March 2227
April 1217
April 25May 1
May 38
May 31June 5
July 1924
July 2631
Aug. 1621
Certified Radiographic Interpreter (CRI)

The CRI certification can be a stand-alone credential or can
exempt you from your next 9-Year Recertification.
Location
Seattle, WA
Houston, TX
Las Vegas, NV
Cleveland, OH
Dallas, TX
Seminar Dates
Feb. 1620
Mar. 30Apr. 3
May 48
June 812
Aug. 1721
Exam Date
Feb. 21
Apr. 5
May 9
June 13
Aug. 22
Certified Robotic Arc Welding (CRAW)

ABB, Inc., Auburn Hills, MI; (248) 3918421
OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Genesis-Systems Group, Davenport, IA; (563) 445-5688
Wolf Robotics, Fort Collins, CO; (970) 225-7736
On request at MATC, Milwaukee, WI; (414) 297-6996
IMPORTANT: This schedule is subject to change without notice. Please ver
ify your event dates with the Certification Dept. to confirm your course sta
tus before making travel plans. Applications are to be received at least six
weeks prior to the seminar/exam or exam. Applications received after that
time will be assessed a $250 Fast Track fee. Please verify application dead
line dates by visiting our website www.aws.org/certication/docs/sched
ules.html. For information on AWS seminars and certification programs, or
to register online, visit www.aws.org/certification or call (800/305) 443
9353, ext. 273, for Certification; or ext. 455 for Seminars.
impact_FP_TEMP 12/10/14 9:13 AM Page 49
Conferences January 2015_Layout 1 12/11/14 10:33 AM Page 50
CONFERENCES
Dissimilar Materials Welding/
Joining Workshop
January 25
Columbus, Ohio
The joining of dissimilar materials can present many
challenges across a number of industry sectors including automotive, petrochemical, power generation, medical products, and microelectronics. Designed to describe the state of
the art in dissimilar joining, the workshop will bring together experts to share their insight and experience. Topics will
include process technology, materials, design, and modeling.
In addition to the technical presentations, the workshop will
feature a panel discussion that will provide attendees the
opportunity to discuss their dissimilar joining problems
with the experts. A tour of the welding laboratories at The
Ohio State University and EWI is included.
9th Shipbuilding Conference

April 7, 8
Hampton Roads, Va.
The technical program will feature presentations on additive manufacturing, automation, new filler materials, and
NDE. Presenters will discuss a newly developed welding electrode that upon cooling does not shrink, which will help re-
duce distortion effects and perhaps negate the need for weld
toe peening required for fatigue life extension. The latest in
aluminum welding will also be discussed. Several presenters
will highlight new methods for automating the welding operations in shipyards. Computed radiography will be discussed as well as the use of artificial intelligence as applied
to NDE. Keynote speaker Johnnie DeLoach, head
of the Materials Division, Naval Surface Warfare Center,
Carderock Division, will kick off the conference.
International Brazing and Soldering

Conference (IBSC)
April 1922
Long Beach, Calif.
Now in its sixth iteration, the IBSC remains the premier
event for the brazing and soldering community. For years,
the IBSC has provided professionals, scientists, and engineers involved in the research, development, and application of brazing and soldering, a unique networking and
idea-exchange forum. This three-day conference provides
cutting-edge education and technical programming for
the brazing and soldering community, as well as peernetworking and exhibit program showcasing the latest
trends, products, processes, and techniques available.
Cladding Conference
May 12, 13
Minneapolis, Minn.
2nd Welding Education, Skills &

Certification Conference
July 1416
Chattanooga, Tenn.
HighTemperature Steels Conference

August (TBA)
Chicago, Ill.
18th Annual Aluminum Conference

September 2224
San Diego, Calif.
For more information, please contact the AWS Conferences and

Seminars Business Unit at (800) 4439353, ext. 234, or email
belkys@aws.org. You can also visit the Conference Department
website at www.aws.org/conferences for upcoming
conferences and registration information.
general corporate_FP_TEMP 12/9/14 9:41 AM Page 51
Welding Workbook January 2015_Layout 1 12/11/14 1:56 PM Page 52
WELDING WORKBOOK
DATASHEET 353
Shielded Metal Arc Welding: Advantages and Disadvantages

5) The dimensions of the SMAW electrodes are ideal for
reaching into areas of limited access (electrodes can be bent,
and with the aid of mirrors, applied in blind spots).
6) The process is suitable for most of the commonly used
metals and alloys.
7) The process is flexible and can be applied to a variety
of joint configurations and welding positions.
8) Optimum results can be readily and reliably obtained.
Process Limitations
Fig. 1 Elements of a typical welding circuit for shielded metal
arc welding.
The shielded metal arc welding (SMAW) process uses an

electrical circuit that supports a welding arc to convert electric line power or fuel into heat. The heat from the welding
arc is intense, extremely concentrated, and immediately
melts a portion of the workpiece and the end of the electrode. The welder maintains the arc length by holding a consistent space between the electrode and the weld pool that
forms on the workpiece. As the arc is removed, the liquid
fuses and the melt solidifies into continuous metal.
The schematic in Fig. 1 shows how the power source is
connected into a circuit with the electrode and workpiece in
series. The welding cable used in the circuit, the electrode
holder, and the connection between the cable and the workpiece are also important elements of the circuit. The power
source has two distinct output terminals. From one terminal, a connection is made to the workpiece; from the other, a
connection is made to the electrode.
Process Advantages
A valuable advantage of SMAW is the large variety of
metals and alloys the process is capable of welding. Procedures and electrodes are available to weld carbon and lowalloy steels, high-alloy steels, coated steels, tool and die
steels, stainless and heat-resisting steels, cast irons, copper
and copper alloys, nickel, and cobalt alloys.
Short welds common to the production of components or
finished products, maintenance and repair work, and field
construction are important areas of application for SMAW.
Other advantages of the process are as follows:
1) The equipment is relatively simple, inexpensive, and
portable.
2) The SMAW electrode provides both the shielding and
the filler metal to make sound welds.
3) Auxiliary gas shielding or granular flux is not required.
4) The process is less sensitive to wind and draft than the
gas shielded arc welding processes.
Metals with low melting temperatures, such as lead, tin,

zinc, and their alloys, are not welded with SMAW. These
metals have relatively low boiling points and the intense
heat of the SMAW arc immediately causes them to vaporize
from the solid state. Because the shielding provided is not
sufficiently inert to prevent contamination of the weld,
SMAW is not suitable for reactive metals such as titanium,
zirconium, tantalum, and niobium.
The SMAW process yields lower deposition rates than the
gas metal arc and flux cored arc welding processes because
the maximum useful current is limited. Because covered
electrodes are produced and used in discrete lengths that
conduct current from the moment the arc is initiated until
the electrode is practically consumed, they are subject to resistance heating. The amount of heat converted by the electrode is a function of the amount of current, the resistance
of the core wire, and the welding time.
If the electrode is too long or the current too high, the
amount of heat generated within the SMAW electrode will
be excessive. After welding has begun, the temperature of
the covering will eventually rise to a range that will cause
the premature breakdown of the covering. That breakdown,
in turn, triggers a deterioration of the arc characteristics
and reduces the level of shielding. Consequently, welding
must stop before the electrode has been fully consumed.
The amount of current that can be used is then limited
within a range that prevents the overheating of the electrode and the breakdown of the covering. The limited useful
current results in generally lower deposition rates than
those obtainable with gas metal arc or flux cored arc
welding.
Another drawback is stub loss. The stub is the grip end of
the electrode that is discarded. Stub loss affects the deposition efficiency, not the deposition rate. Longer stub losses
translate directly into lower deposition efficiency.
The operator factor (i.e., arc time as a percentage of the
welders total labor time) for SMAW is usually lower than
that obtained with a continuous electrode process.
When the weldment requires a large volume of filler metal, the combination of low deposition rates and a lower operator factor detracts from the use of the SMAW process. In
these instances, the weld completion rate may be too slow
and the weld cost relatively high. WJ
Excerpted from the Welding Handbook, 9th Edition, Volume 2, Welding Processes Part 1.
aws educ shipbuilding conf_FP_TEMP 12/9/14 10:12 AM Page 53
aws educ dissimilar metals_FP_TEMP 12/9/14 3:08 PM Page 54
DISSIMILAR
DISSIM
IM
MILAR MATERIAL
MILAR
MA
ATTERIAL
TER WELDING /
JOIN
JOINING
OININ WORKSHOP
JANUAR
JANUARY
JA
RY 26,
2 2015
The Blackwell Inn and Conference Center aatt
The Ohio Sta
te University
State
University,, Columbus, OH
American Welding
Welding Society
www
www.aws.org
.aws.org
The jjoiningg oof dissimilar ma

materials
terials can present man
manyy challenges across a
industryy sectors inc
including
number of indu
ind
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luding automotive, petrochemical, power
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gen
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nedd to
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scrib
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ate-of-the art in dissimilar join
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aterials, design, and modeling. In addition to technical
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presentations
industry,
workshop
feature
presenta
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from academia and industr
y, the works
rkshop will fea
ature
that
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experts
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ng problems.
problems The workshop will
wi also feature
w
feature a tour of
laboratories
State
Welding
the welding labora
tories aatt Ohio
hio Sta
te University
sity and
nd Edison W
elding Institute.
TTime
iime
Event/Speaker
Subject
7:45-8:30
ation & Continental

Breakfast
Registr
Registration
Contin
Co tine
Breakfast
8:30-8:45
John Lippold
old
The Ohio
io Sta
SState
te University
Introductions
8:45-9:30
Johhhnn DuPont
John
Le
Lehigh
University
Tempera
eem
ture Failure
Failure of Austenitic to Ferritic
Ferritic
High Temperature
Welds: Causes and Cures
Dissimilar Metal Welds:
9:30-10:15
Boian Ale
xandrov
Alexandrov
The Ohio Sta
te University
State
Dissimilar Metal Overlays for Oil and Gas

Application
Application
10:15-10
10:15-10:30
-10:30
Br
eak
Break
100:30-11:15
10:3
10:30-11:15
0
Steve McCr
acken
McCracken
Electric PPower
ower Research Institute
Dissimila
laar Metal Joining in the PPower
ower Genera
ation
Dissimilar
Generation
Industr
Industryy
11:15-12:0
11:15-12:00
2:00
Antonio Ram
IrEz
RamIrEz
The Ohio Sta
te University
State
Joining Dissimilar
lar FFe-based
e-based and Ni-based
Materials by FSW
Materials
12:00-1:00
Lunchh
Lunc
1:00-1:45
Jerr
erry Gould
Jerry
Edison
on W
eelding Institute
Welding
Application
ion of Dissimilar Metals
Metal
tals Joining in the
Application
Industry
Automotive Industry
1:45-2:30
Glenn Daeh
ehn
Daehn
The Ohio Sta
te University
Universi
State
Welding Technologies
Teechnologies for Dissimilar
Dissim
ssim
Impact Welding
Materials
Materials
2:30-3:15
Tim Frech
Frech
Tim
Edison W
eelding Institute
tute
Welding
materials joining in the

Dissimilar materials
medical and electronic industries
3:15-3:30
Br
eak
Break
3:30-4:15
W
ei Zhang
Wei
te University
The Ohio Sta
State
Dissimilar Metal Joint of Titanium

Titanium to Stainless
Literature Assessment and Numerical
Steel Literature
Modeling
4:15-5:15
John Lippold
The Ohio Sta
te University
State
Panel Discussion
Panel
Society News Jan 2015_Layout 1 12/10/14 4:25 PM Page 55
SOCIETY NEWS
BY HOWARD WOODWARD woodward@aws.org
National and District Officers Elected for 2015

The American
Welding Society has
elected national and
District officers to
serve terms beginning Jan. 1, 2015.
David Landon was
elected president.
Landon, a Senior Certified Welding InDavid Landon
spector, is manager of
president
welding engineering
and missions support
at Vermeer Mfg. Co., Pella, Iowa. He has
served on many AWS technical committees
and as a Delegate to the IIW Commission
XIV, Welding Education and Training.
David McQuaid was elected to serve a
third term as a vice president. He heads D.
L. McQuaid and Associates, Inc., and has
chaired the AWS D1 Structural Welding
and the Technical Activities Committees.
In 2009, McQuaid received the American
National Standards Institute Finegan Standards Medal for his contributions to industrial standards.
John Bray was elected to serve a second
term as a vice president. He is president of
Affiliated Machinery, Inc., a 25-year AWS
member, past Dist. 18 director, and a former chairman of the Houston Section.
Dale Flood was elected to serve his first
term as a vice president. He is project manager, R&D, at Tri Tool, Inc., served as Dist.
22 director, chaired the Sacramento Valley
Section, and contributes to AWS D10 committee standards for pipe and tube welding. Flood holds five U.S. patents on welding processes.
Tony Anderson was elected a directorat-large. He is director of aluminum technology at ITW Welding North America, an
AWS CWI, CWE, and CWEng, a Fellow of
The British Welding Institute, and chairs
the Aluminum Association Technical Advisory Committee for Welding.
Debra L. Doench was elected a directorat-large. She is manager, marketing communications, at Hobart Brothers Co., chairs the
AWS Publications, Expositions, and Marketing Committee (PEMCO), and serves on the
Gases and Welding Distributor Assn. (GAWDA) Women in Welding Marketing and Industry Partnering Committees.
Michael Sebergandio, a CWI, was elected
Dist. 3 director succeeding Michael Wiswesser. He is a quality and reliability specialist for CNH America, has served as
David McQuaid
vice president
John Bray
vice president
Dale Flood
vice president
Tony Anderson
directoratlarge
Debra Doench
directoratlarge
Michael Sebergandio
Dist. 3 director
Michael Krupnicki
Dist. 6 director
Michael Skiles
Dist. 9 director
Daniel Roland
Dist. 12 director
David Lynnes
Dist. 15 director
John Stoll
Dist. 18 director
Samuel Lindsey
Dist. 21 director
Dist. 3 deputy director, and chair

of the Lancaster Section.
Michael Krupnicki was elected
Dist. 6 director succeeding Kenneth Phy. He is owner and president of Mahany Welding Supply,
executive director of Rochester

Arc + Flame Center, and has
served as a CWI test site supervisor since 1992.
continued on next page
SOCIETY NEWS
continued from previous page
Michael Skiles was elected Dist. 9

director succeding George Fairbanks.
A retired senior account manager for
Airgas, he has chaired the New Orleans and Acadiana Sections and sits
on the advisory committees for six
vo-tech schools.
Daniel Roland was reelected Dist.
12 director. An AWS CWI, he is quality technical coordinator at Marinette
Marine Corp., and teaches welding

classes at Northeast Wisconsin Technical College.
David Lynnes was reelected Dist.
15 director. An AWS CWI and CWE,
with the Northern Plains Section,
Lynnes is part owner of Wild Rice
Mfg. Co. and Lynnes Training in
North Dakota.
John Stoll was elected Dist. 18 director. He is industry segment man-
ager, power and petrochemical, technical services at The Bohler Welding

Group North America. An AWS Life
Member, he is active with the Houston Section.
Samuel Lindsey was elected Dist.
21 director succeeding Nanette
Samanich. He is a CWI and senior
building inspector for the city of San
Diego, Calif., active with the San
Diego Section.
TECH TOPICS
D10 Committees Welding Summit Workshop Meets in Miami
Welding Summit Workshop attendees are shown Oct. 9 at AWS World Headquarters in Miami, Fla.
Presented by the AWS D10 Committee on Piping and Tubing, the

Welding Summit Workshop (WSW),
held Oct. 8, 9, at AWS World Headquarters in Miami, Fla., featured heat
treatment of pipe and nondestructive
evaluation (NDE). The event offered
an innovative approach to the typical
information push seminars. The
speakers intentionally framed their
topics in interesting and assertive
ways to provoke attendees to concur
or argue with their statements based
on their positions and experiences in
the industry.
The previous two workshops
sparked meaningful debate and identified key successes, roadblocks, and the
areas that need attention to obtain
quality welds, workforces, and inspections. This years workshop identified,
among other issues, that those involved in welding need to learn how to
speak the language of the money

people, and in particular, more clearly
understand the welding process variables and approaches that impact the
economic aspects of a job, then be able
to better communicate their findings.
The first day covered preheating,
postweld heat treatment, heating
methods, code applications, and the
Heat Treatment Technician Qualifications that are expected to be rolled out
early this year. Day two covered various forms of direct visual, surface, and
volumetric NDE.
Areas for improvement, especially
in selection and application, became
lively discussion topics. The WSW
closed with a presentation and discussion on welding economy.
The speakers were William Newell
(Euroweld, Ltd.), Mike Lang and Chris
Goocher (Fluor Corp.), Gary Lewis
and John Hainsworth (Superheat
FGH), Daniel Ciarlariello (Analytic

Stress Relieving, Inc.), Scott Witkowski (Maverick Testing Labs), and Jim
Byrne (Miller Electric Co.).
Attending were Andy Mulroy, Bruce
Stewart, Darrell D. Flinn, David L.
Finch, David Schwam, Gustavo A. Zegarra, Henry Skrzypek, Jason D. Becker, Jason M. Cosentino, Jim W. Harrison, Kenneth Arnold, Mary C. Cook,
Patrick T. Blume, Ramon Latorre, Raymond V. Knobbs, Skip Laubach,
Stephen Gillman, Tim Griffin, Ulrich I.
Lopes, Walter Pemberton, William D.
Kashin, and Yong Yang.
The next WSW is tentatively scheduled for presentation in Houston, Tex.
Its topics will feature welding economy
and costs. For more information, contact Belkys Riveron-Raimundez, Education Services, belkys@aws.org.
SOCIETY NEWS
Standards for Public Review
The following revised standards
were submitted for public review with
the expiration dates shown. A draft
copy may be ordered from J. Rosario,
ext. 308, jrosario@aws.org.
AWS was approved as an accredited standards-preparing organization
by the American National Standards
Institute (ANSI) in 1979. AWS rules,
as approved by ANSI, require that all
standards be open to public review
for comment during the approval
process.
B2.1-1/8-010:201X, Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding of Carbon
Steel (M-1/P-1) to Austenitic Stainless
Steel (M-8/P-8), 18 through 10 Gauge,
in the As-Welded Condition, with or
without Backing. $124. 1/12/15.
B2.1-1/8-231:201X, Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding with Consumable Insert Root Followed by Shielded Metal Arc Welding of Carbon Steel
(M-1/P-1, Groups 1 or 2) to Austenitic
Stainless Steel (M-8/P-8, Group 1), 18
inch [3 mm] through 112 inch [38 mm]
Thick, IN309, ER309, and E309-15, 16, or -17, or IN309, E309(L), and
E309(L)-15, -16, or -17, in the As-Welded Condition, Primarily Pipe Applications. $124. 1/12/15.
C2.20/C2.20M:201X, Specification
for Thermal Spraying Zinc Anodes on
Steel Reinforced Concrete. $30.
12/29/14.
C2.21M/C2.21:201X, Specification
for Thermal Spray Equipment Performance Verification. $26. 12/29/14.
D10 Committee Meets in Miami
Members of the D10P Subcommittee on Local Heat Treatment of Pipework met Oct. 6 at
AWS World Headquarters in Miami, Fla. Shown from left are D10 Vice Chair Bill Newell
and D10P members John Hainsworth, Chair Dan Ciarlariello, and Gary Lewis.
Technical Committee Meetings

All technical committee meetings
are open to the public. To attend, contact the staff member listed.
Jan. 12, 13. D20 Committee on
Additive Manufacturing. Miami, Fla.
C. Lewis, ext. 306; clewis@aws.org.
Jan. 14. International Standards
Activities Committee. Miami, Fla. A.
Davis, ext. 466, adavis@aws.org.
Jan. 14. Technical Activities Committee. Miami, Fla. A. Alonso, ext.
299; aalonso@aws.org.
Jan. 28. Committee on Personnel
& Facilities Qualification. Miami, Fla.
S. Hedrick, ext. 305; steveh@aws.org.
Feb. 10. D15 Committee on Railroad Welding. Miami, Fla. J. Rosario,
ext. 308, jrosario@aws.org.
Feb. 10. D15A Subcommittee on
Cars and Locomotives. Miami, Fla. J.
Rosario, ext. 308, jrosario@aws.org.
Feb. 12. D3B Subcommittee on
Underwater Welding. New Orleans,
La. B. McGrath, ext. 311; bmcgrath@
aws.org.
April 710. D1 Committee and

Subcommittees on Structural Welding. Miami, Fla. B. McGrath, ext. 311;
bmcgrath@aws.org.
Candidates Sought for MIT

Masubuchi Award
The Prof. Koichi Masubuchi award,
with a $5000 honorarium, is presented
to one person, 40 or younger, who has
made significant contributions to the
advancement of materials joining
through research and development.
Send a list of your candidates experience, publications, honors, awards,
and at least three letters of recommendation from fellow researchers to Prof.
Todd Palmer, tap103@psu.edu. This
award is sponsored annually by the
Massachusetts Institute of Technology,
Dept. of Ocean Engineering.
Opportunities to Serve on Technical Committees Visit www.aws.org/technical/jointechcomm.html.

Contact the staff member listed for complete information. The Committee designation is shown in parentheses.
Oxyfuel gas welding and cutting
(C4), Friction welding (C6), High-energy beam welding and cutting (C7),
Robotic and automatic welding
(D16), Hybrid welding (C7D).
C. Lewis, ext. 306, clewis@aws.org.
Magnesium alloy ller metals
(A5L). R. Gupta, ext. 301,
gupta@aws.org.
Thermal spraying (C2), Welding
iron castings (D11). J. Rosario, ext.
308, jrosario@aws.org.
Welding practices and procedures

for austenitic steels (D10C), Aluminum piping (D10H), Chromium
molybdenum steel piping (D10I),
Welding of titanium piping (D10K),
Purging and root pass welding
(D10S), Low-carbon steel pipe
(D10T), Orbital pipe welding (D10U),
Duplex pipe welding (D10Y), Reactive
alloys (G2D), Titanium and zirconium
ller metals (A5K), and Committee
on Welding of Sheet Metal. J. Molin,
ext. 304, jmolin@aws.org.
Methods of weld inspection (B1),

Resistance welding (C1), Resistance
welding equipment (J1), Automotive
(D8), Cranes and presses (D14E), Industrial mill rolls (D14H). E. Abrams,
ext. 307, eabrams@aws.org.
Joining of plastics and composites (G1), Mechanical testing of welds
(B4), Safety and Health Committee.
S. Hedrick, ext. 305, steveh@aws.org.
SOCIETY NEWS
MEMBERSHIP ACTIVITIES
Focus Group Meets to Enhance Value of AWS Student Membership
From left are Rhenda Kenny and Cassie Burrell. Welding instructor Tiffany Rivera (frontrow center) and Lee Kvidahl (far right) pose with
Del Mar College welding students during their focus group workshop.
On Monday, Oct. 20, AWS staff

members met with ten students and
welding instructor Tiffany Rivera at
Del Mar College in Aransas Pass, Tex.
The purpose of the focus group was
to get feedback on how the American
Welding Society can better work with
students involved in hands-on welding
in their careers and to improve Student Member benefits.

Three previous focus groups have
been held with both hands-on welding
students as well as engineering students, to obtain similar information.
Lee Kvidahl, AWS Membership
Committee chair and a past AWS pres-
Membership Committee Meets in Corpus Christi

Shown at right are some of the AWS Com
mittee members and guests Oct. 15 in
Corpus Christi, Tex., prior to their business
meeting. Members and others active with
the committee include Chair Lee Kvidahl,
Vice Chair David Trees, Secretary Rhenda
Kenny, Jim Appledorn, Mark Davidson,
Dennis Eck, Dale Flood, Stewart Harris,
Harland Thompson, John Bray, Dean Wil
son, Cassie Burrell, Ellery Francisco, J.
Jones, Bob Pali, Tiffany Rivera, Russ Nor
ris, Bob Tabernik, and ex. officios Tom Bie
dermann, Debbie Doench, and Ray Shook.
AWS Silver Members Recognized

At right, Daniel Galiher (left), Detroit Sec
tion membership chair, presents the Sil
ver Member certificate to Michael Palko
for his 25 years of service to the Society.
The presentation took place during the
Sheet Metal Welding Conference XVI.
At far right, Howard Woodward displays
his Silver Member certificate. During his
career at AWS headquarters, he has
served many years as associate editor of
the Welding Journal and three years as
secretary to the A5 Committees on Filler
Metals and Allied Materials.
ident, facilitated the activity, assisted

by Cassie Burrell, senior deputy executive director, and Rhenda Kenny, director, Member Services. Rivera also
serves on the AWS Membership Committee and is a member of the AWS
Del Mar College/Craft Training Center
Partnership Student Chapter.
SOCIETY NEWS
New AWS Supporters
Sustaining Members
Educational Institutions
Actions of Districts Council
Philtek Services, LLC

8100 N. Hwy. 81, Ste. #2
Duncan, OK 73533
Representative: Jason Phillips
www.philtekservices.com
Argo Community High School

7329 W. 63 St.
Summit, IL 60501
On Nov. 9, after due consideration,

Districts Council approved the charter of the following Student Chapters.
Dist. 4: Tidewater C. C. and Floyd
County H. S. Dist. 15: Tuscaloosa
County School System Welding Technology Program and Mesabi Range
College. Dist. 21: Santa Ana College.
MESCAWS S. C. at Morelia Technical
Institute, Morelia, Mexico.
Approved for disbandment were
Dist. 3: Center of Applied TechnoogyNorth; Dist. 5: Aiken T. C., Savannah
T. C.; Dist. 7: West Virginia
University at Parkersburg; Dist. 10:
Crawford County Area Vo-Tech
School and Northwestern Pennsylvania; Dist. 19: Linn-Benton C. C.; and
Dist. 21: Los Angeles Trade T. C.
Rob and Son Welding, LLC

36285 Cane Market
Denham Springs, LA 70786
Representative: Kaleb Robinson
http://robandsonwelding.com
Weatherford
11909 Spencer Rd.
Houston, TX 77041
Representative: Matthew Palmer
www.weatherford.com
Botetourt Technical Education Center

253 Poor Farm Rd.
Fincastle, VA 24090
Brown Mackie College, Salina
2106 S. 9th St., Salina, KS 67401
Cincinnati State Technical and C. C.
10030 West Rd.
Harrison, OH 45030
Colorado State University
District Energy
6030 Campus Delivery
Fort Collins, CO 80523
Affiliate Members
Affiliated Machinery, Inc.
3008 S. Main St.
Pearland, TX 77581
Emaresa S.A.
Santa Adela 9901
Santiago, Maipu, Chile
Highlands Welding Repair, Inc.
5412 28th Ave. NW
Seattle, WA 98107
NMI Industrial Holdings, Inc.
8503 Weyand Ave.
Sacramento, CA 95828
Naya for Engineering
Services & Training
Al-Waten St., Al Rashed Bldg.
Basra, Iraq
T&C Stainless, Inc.
1016 Progress St
Mount Vernon, MO 65712
Supporting Companies
IWCGroup Tunisia Section

Imm. Marakchi Rue De Bagdad
Route, De Mahdia Km 05,
Sfax 3000, Tunisia
Lake Technical College
2001 Kurt St., Eustis, FL 32726
Libby Public Schools
724 Louisiana Ave.
Libby, MT 59923
Petrotech
Nirmal Arcade, Eranhipalam
Calicut, Kerala 673006, India
Salem High School
400 Sparton Drive
Salem, VA 24153
Universal Welding & Fabrication
Training Centre Ltd.
45 Evo Road, Gra Phase 2
Port Harcourt, River State, Nigeria
Virginia Beach Technical and
Career Education Center
2925 N. Landing Rd.
Virginia Beach, VA 23456
Diamond Technical Services, LLC

9152 Rte. 22
Blairsville, PA 15717
Welding Distributor
Tark, Inc.
420 Congress Park Dr.
Dayton, OH 45459
Weld Specialty Supply Corp.

8929 N. 107th St.
Milwaukee, WI 53224
Raffle Winners Announced

Everyone who joined the American
Welding Society or renewed their AWS
memberships for two years or more at
the FABTECH show in Atlanta, Ga., last
November, received an AWS pen, glass
coffee mug, mouse pad, and a duffle
bag, and were entered into a raffle to
win one of three $100 gift cards. The
raffle winners are:
Blondel Senior, National Steel Car
Ltd., Hamilton, Ont., Canada
Nehemias Burrion, Burox Engineering, Davie, Fla.
Fran Johnston, CTE, Applied Technology, Phoenix, Ariz.
AWS Member Counts

December 1, 2014
Sustaining.................................592
Supporting ...............................351
Educational...............................715
Affiliate.....................................599
Welding Distributor ...................55
Total Corporate ......................2,312
Individual ...........................59,847
Student + Transitional ...........11,014
Total Members ..................70,861
SOCIETY NEWS
MemberGetaMember Update G. Gammill, NE Mississippi 34
Listed are the points members earned
in the campaign that ran from Jan. 1 to
Dec. 31, 2014. Five points and one point
are credited for each Individual and Student Member recruited, respectively.
For campaign rules and a prize list, see
page 65 in this Welding Journal. Standings as of Nov. 21. Call Membership
Dept. (305) 443-9353, ext. 480, for
more information.
J. Morris, Mobile 230
M. Eiswirth, Mobile 74
D. Saunders, Lakeshore 45
M. Pelegrino, Chicago 40
D. Thompson, SW Virginia 38
C. Lariche, Cleveland 35
D. Box, Mobile 33
R. Barber, East Texas 30
R. Richwine, Indiana 29
A. Stute, Madison-Beloit 28
D. Ebenhoe, Kern 25
D. Mandina, New Orleans 25
J. McKenzie, Detroit 25
R. Purvis, Sacramento 25
S. Siviski, Maine 25
E. Donaldson, Cumberland Valley 24
A. Theriot, New Orleans 24
S. Miner, San Francisco 22
R. Zabel, SE Nebraska 22
J. Foley, Pittsburgh 21
C. Bridwell, Ozark 20
S. Hodges, North Texas 20
D. Galiher, Detroit 19
D. Lynnes, Northern Plains 19
R. Munns, Utah 19
M. Haggard, Inland Empire 19
J. Kline, Northern New York 18
G. Smith, Lehigh Valley 17
G. Deem, Columbia 15
R. Farquhar, Cleveland 15
C. Galbavy, Idaho/Montana 15
M. Trute, Atlanta 15
J. Tso, L.A./Inland Empire 15
J. Carney, West Michigan 14
R. Eckstein, Northwest 14
R. Polito, Spokane 14
J. Russell, Fox Valley 14
T. Zablocki, Pittsburgh 14
B. Cheatham, Columbia 13
S. Robeson, Cumberland Valley 13
C. Wolfman, Sacramento 12
R. Bubb, Philadelphia 11
C. Ortega, North Texas 11
Benefits of AWSCorporate Membership Levels Updated

Sustaining Company. As an AWS
Sustaining Company Member, your
company may have up to ten Individual Members ($860 value) listed on
its roster at no additional charge. In
addition, you may choose the AWS
Standards e-Library ($12,000 value)
as the companys primary benefit.
Individual memberships (a $400 value), in addition to a listing on the

Distributor Locator Map on the AWS
website. This listing also provides a
hyperlink that takes visitors directly
to your companys website.
Supporting Company. Members

may have up to five Individual Members ($430 value) listed under the
corporate umbrella.
Educational Institution. Educational Institution Members may have

up to three Individual Members
($258 value) listed on the schools
member roster at no additional
charge.
Welding Distributor. Welding Distributor Members receive up to five
Affiliate Company. Affiliate Company membership includes one Indi-
vidual Member ($86 value).

The Individual Members included
in your companys Corporate Membership receive a subscription to the
Welding Journal, published monthly,
in addition to discounts on all AWS
publications, certification exams, educational seminars, and conferences.
For more information or to obtain AWS Corporate Member application forms, contact Member Services
Dept. (800/305) 443-9353, ext. 260,
e-mail rhenda@aws.org, or visit the
AWS website www.aws.org/w/a/membership/corp.html.
Nominate Your Candidates for These WeldingRelated Awards

The deadline for nominating candidates for the following awards is December 31 prior to the year of the awards presentations. E-mail Wendy Sue Reeve at wreeve@aws.org or call (800/305) 443-9353, ext. 293.
William Irrgang Memorial Award
This award includes a $2500 honorarium to recognize the individual
who has done the most over the past
five years to advance the science and
technology of welding.
International Meritorious
Certificate Award
The award recognizes, in the broadest terms, the honorees significant
contributions and service to the international welding community.
National Meritorious Award

The award includes a $2500 honorarium to recognize the recipients
loyalty, good counsel, dedication to
AWS affairs, and promotion of cordial
relations with industry and other
technical organizations.
Honorary Membership Award
This award recognizes an individual
who has eminence in the welding profession or has made outstanding developments in the field of welding arts.
George E. Willis Award

The award is presented to an individual who has promoted the advancement of welding internationally by fostering cooperative participation in technology transfer, standards rationalization, and promotion of industrial
goodwill for the Society.
SECTION NEWS
LEHIGH VALLEY From left are Vince Facchiano, Dino Forst, Dave Schnalzer, Dist. 3 Director Mike Wiswesser, Melanie Totenbier, Jeff
Buckley, Jeff Wiswesser, Joe Totenbier, and Jason Dieter.
District 1
Thomas Ferri, director
(508) 527-1884
thomas_ferri@victortechnologies.com
BOSTON
November 3
Speaker: David McQuaid, P.E., AWS
vice president
Affiliation: DL McQuaid and Associates
Topic: Problems encountered during
welding in the field
Activity: The event was held in Lexington, Mass.
LANCASTER From left are incoming Dist. 3 Director Mike Sebergandio, Brian Gross,
Chair Justin Heistand, Mark Malone, and John Boyer.
CENTRAL MASSACHUSETTS/
RHODE ISLAND
October 1
Activity: Wayne Cusano, a 30-year
AWS member and a senior welder,
was cited in Rochester, Mass., for his
eight years of dedication and commitment to the Metal Fabrication &
Joining Technology Program Advisory Committee at Old Colony Regional
Vocational Technical High School.
Cusano, a senior welder at CTI Cryogenics, was also instrumental in urging the company to donate $10,000 in
equipment to benefit the schools
welding students.
District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com
District 3
Michael Sebergandio, director
(717) 471-2065
drweld13@gmail.com
BOSTON Speaker Dave McQuaid

(right), an AWS vice president, is shown
with Tom Ferri, Dist. 1 director.
CENTRAL MASS./RHODE ISLAND

Wayne Cusano displays his award.
LANCASTER
LEHIGH VALLEY
October 28
Activity: The Sections board members met to plan for the coming year.
Attending were Chairman Justin Heistand, incoming Dist. 3 director Mike
Sebergandio, Brian Gross, Mark Malone, and John Boyer.
October 18
Activity: The Section members displayed their shooting skills at Lehigh
Valley Sporting Clays in Schnecksville,
Pa.
District 4
Stewart A. Harris, director
(919) 824-0520
stewart.harris@altec.com
SECTION NEWS
FLORIDA WEST COAST Attendees are shown at the November program.
District 5
Carl Matricardi, director

(770) 356-2107
cmatricardi@aol.com
FLORIDA WEST COAST

November 12
Speaker: Corey Aurand, QC manager
Affiliation: AZZ/SMS
Topic: Weld repairs for a P91 header
Activity: Ray Monson received his
Life Member award for 35 years of
service to the Society. The event was
held at Mimis Caf in Brandon, Fla.
FLORIDA WEST COAST At left in both photos, Chair Charles Crumpton III is shown
with speaker Corey Aurand (left photo) and with Life Member Ray Monson at right.
NORTH FLORIDA
October 16
Speakers: Steve Hinote, Frank York
Affiliation: Otto Arc Systems, Inc.
Topic: Orbital gas tungsten arc welding
Activity: The attendees received
hands-on training welding stainless
steel tube and pipe using the orbital
gas tungsten arc process. The event
was held at Plumbers & Pipefitters
Local Union #234 in Jacksonville, Fla.
District 6
Michael Krupnicki, director

(585) 705-1764
mkrup@mahanyweld.com
NORTHERN NEW YORK

November 4
Speakers: Chris Lanese, Mike Toich
NORTH FLORIDA Steve Hinote (far

left) coached members on applying the
orbital GTAW process.
Affiliation: Capital Region BOCES,

welding instructors
Topic: Special features of the schools
welding program
Activity: Following the talks, Lanese
and Toich conducted a tour of the facility located in Colonie, N.Y. Follow-
NORTHERN NEW YORK Vice Chair

Carter Cook (center) is shown with welding instructors Mike Toich (left) and Chris
Lanese.
ing the tour, the Section members

met with welding students to discuss
forming an AWS Student Chapter at
their school and plans for conducting
a Boy Scout welding merit badge
training program.
SECTION NEWS
PITTSBURGH Shown at Chapman Corp. are (from left) Jody Dadum, Ken Broadbent, Chair George Kirk, presenter Ron Delsandro,
Lou Rudi, Matt Wilson, Tom White, John Menhart, and Jack Trettle.
NASHVILLE From left are Andy Afflick, Marion Brown, Mike Ray, Jonathan McDonald, James Donny Cook, John Kahl, Phil Evans,
Ron McCrary, Daniel Stinson, Neil Lambert, James Terry Newton, Scott Bradley, Joey Lloyd, and speaker Jim Hurley.
District 7
District 8
PITTSBURGH
CHATTANOOGA
Uwe Aschemeier, director

(786) 473-9540
uwe@sgsdiving.com
September 30
Speaker: Ron Delsandro, pipe fabrication shop manager
Affiliation: Chapman Corp.
Topic: Welding in the natural gas industry
Activity: More than 60 members and
guests participated in this program
and plant tour, including Jody Dadum, Fab Shop general foreman; Ken
Broadbent, Steamfitters UA Local
449 business manager; Lou Rudi, QA
manager; Matt Wilson, Fab Shop
foreman; Jack Trettle with Matheson
Tri-Gas; Chair George Kirk; Treasurer Tom White; and John Menhart, a
Section past chair.
D. Joshua Burgess, director

(931) 260-7039
djoshuaburgess@gmail.com
October 9
Speaker: Ben Pletcher, technical director
Affiliation: Select Arc, Inc.
Topic: Welding duplex and superduplex stainless steels
Activity: The program was held at the
Komatsu Manufacturing Operation in
Chattanooga, Tenn. Joshua Burgess,
Dist. 8 director, attended the event.
CHATTANOOGA From left are Dist. 8

Director Josh Burgess, speaker Ben
Pletcher, and Chair Thomas Atkinson.
NASHVILLE
November 13
Speaker: Jim Hurley, sales representative
Affiliation: TRUMPF
Topic: Laser welding instruments and

technology
Activity: The event was held at World
Testing, Inc., in Mt. Juliet, Tenn.
SECTION NEWS
District 9
Michael Skiles, director

(337) 501-0304
michaelskiles@cox.net
ACADIANA and
CENTRAL LOUISIANA
October 15
Speakers: Gary Wilson, Ricky Duty
Affiliation: Cameron International
Corp.
Topic: Weld Shop Manager Wilson
presented a talk followed by Director
of Operations Duty who detailed the
welding processes used at the facility.
The two then led a plant tour assisted
by Candace Gerace, HR director. Attending were Acadiana Section Chair
and incoming Dist. 9 Director Mike
Skiles and Don Sanders, Central
Louisiana Section chair.
ACADIANA and CENTRAL LOUISIANA From left are Candace Gerace, presenters
Gary Wilson and Ricky Duty, Acadiana Section Chair Mike Skiles, and Don Sanders, Central Louisiana Section chair.
Lawson State C. C.
Student Chapter
October 24
Activity: Seventeen Chapter members, led by Advisor Roy Ledford,
joined welding students from six colleges to participate in the first annual
Workshop for postsecondary college
welding students. The event was hosted by Bob Kimbrell at Plumber and
Pipefitters Local 372 in Duncanville,
Ala. Representatives from Lincoln
Electric, ESAB, United Association,
and South-Central Pipe Trades presented instruction on welding and
cutting safety and processes.
Lawson State C. C. Student Chapter From left are (kneeling) Ladarious Bledsoe, Advisor Roy Ledford, and Bernard Beal; (standing) DeMarcus Gates, Mason Lusker, Rushton Syphurs, Niya Jackson, Jerome Ambers, Maurice Davis, and Jason Fortenberry.
MOBILE
October 16
Speaker: Bradley Byrne, U.S. Congressman, Alabama Dist. 1
Topic: The need for skilled welders
Activity: Among the 83 attendees
were 31 students representing six
area schools. Scholarships were presented to William Lee, Corey Bonham, Antoine Thurman, Sebe Christian, Jerry Betts, Daryl Jackson, J. C.
Galmiche, Tyler Miller, and Brittney
Pierce.
November 6
Speakers: Steve Day, Steve Yeend
Affiliation: OSHA
Topic: Common workplace accidents
Activity: William Lee, Chandler
Hansen, and Hayden Richards, stu64 WELDING JOURNAL / JANUARY 2015
MOBILE Upper photo: Pensacola State College attendees include (from left) Welding
Career Coach Rafael Deliz, Andrew Cobb, Brandon Cobb, David McCall, Trent Wallace,
Robert Jones, Gilbert Calderon, and Steve Moore, welding instructor. Above photo:
Shown at the scholarship awards presentations are (from left) William Lee, Corey Bonham, Antoine Thurman, Sebe Christian, Scholarship Chair Jerry Betts, Crosby Latham III,
Daryl Jackson, and J.C. Galmiche.
AWS MEMBERSHIP APPLICATION

Join or Renew:

Mail: Form with your payment, to AWS Call: Membership Department at (800) 443-9353, ext. 480
Fax: Completed form to (305) 443-5647 Online: www.aws.org/membership
CONTACT INFORMATION
q New Member q Renewal
q Mr. q Ms. q Mrs. q Dr.
Please print Duplicate this page as needed
Last Name:_______________________________________________________________________________
First Name:___________________________________________________________________ M.I:_______
Birthdate: _____________________________ E-Mail:____________________________________________
Cell Phone (
)__________________________ Secondary Phone (
)______________________
Were you ever an AWS Member? q YES q NO If YES, give year________ and Member #:____________________
Company (if applicable):___________________________________________________________________
Address:________________________________________________________________________________
_______________________________________________________________________________________
City:_____________________________________State/Province:__________________________________
Zip/PostalCode:_____________________Country:______________________________________________
Who pays your dues?: q Company q Self-paid Sex: q Male q Female
Education level: q High school diploma q Associates q Bachelors q Masters q Doctoral
q Check here if you learned of the Society through an AWS Member? Members name:_______________________Members # (if known):________
q Check here if you would prefer not to receive email updates on AWS programs, new Member benefits, savings opportunities and events.
INDIVIDUAL MEMBERSHIP
Please check each box that applies to the Membership or service youd like, and then add the cost together to get your Total Payment.
q AWS INDIVIDUAL MEMBERSHIP (One Year)......................................................................................................$86
AWS INDIVIDUAL MEMBERSHIP (Two Years) SAVE $25 New Members Only....................................$147
q New Member Initiation Fee ...........................................................................................................................................$12
OPTIONS AVAILABLE TO AWS INDIVIDUAL MEMBERS ONLY:

A.) OPTIONAL Book Selection (Choose from 25 titles; up to a $192 value; includes shipping & handling)
q Individual Members in the U.S..................................................................................................................................$35
q Individual Members outside the U.S (includes International shipping)...........................................................................$85
ONLY ONESELECTION PLEASE. For more book choices visit www.aws.org/membership
q Jeffersons Welding Encyclopedia (CD-ROM only) q Design & Planning Manual for Cost-Effective Welding q Welding Metallurgy
Welding Handbook Selections: q WH (9th Ed., Vol. 4) q WH (9th Ed., Vol. 3) q WH (9th Ed., Vol. 2) q WH (9th Ed., Vol. 1)
Pocket Handbook Selections: q PHB-1 (Arc Welding Steel) q PHB-2 (Visual Inspection) q PHB-4 (GMAW / FCAW)
B.) OPTIONAL Welding Journal Hard Copy (for Members outside North America)
q Individual Members outside North America (note: digital delivery of WJ is standard)..............................................$50
INDIVIDUAL MEMBERSHIP TOTAL PAYMENT..................................................................................$_____________
NOTE: Dues include $16.80 for Welding Journal subscription and $4.00 for the AWS Foundation.
STUDENT MEMBERSHIP
Please choose your Student Membership option below.
q AWS STUDENT MEMBERSHIP (One Year)...................................................................................................................$15
Digital delivery of Welding Journal magazine is standard for all Student Members.
q AWS STUDENT MEMBERSHIP (One Year)...................................................................................................................$35

Includes one-year Welding Journal hard copy subscription. Option available only to students in U.S., Canada & Mexico.
STUDENT MEMBERSHIP TOTAL PAYMENT......................................................................................$_____________
PAYMENT INFORMATION
Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card.
q Check q Money Order q AMEX
q Diners Club q MasterCard
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CC#:____________ / ____________ / ____________ / ____________ Expiration Date (mm/yy) ________ / ________

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OFFICE USE ONLY Check #:_______________________________ Account #____________________________________
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Date:_________________________________ Amount:_____________________________________
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FAX (305) 443-5647
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Type of Business (Check ONE only)
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q Contract construction
B
q Chemicals & allied products
C
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q Primary metal industries
E
q Fabricated metal products
F
q Machinery except elect. (incl. gas welding)
G
q Electrical equip., supplies, electrodes
H
q Transportation equip. air, aerospace
I
q Transportation equip. automotive
J
q Transportation equip. boats, ships
K
q Transportation equip. railroad
L
q Utilities
M
q Welding distributors & retail trade
N
q Misc. repair services (incl. welding shops)
O
q Educational Services (univ., libraries, schools)
P
q Engineering & architectural services (incl. assns.)
Q
q Misc. business services (incl. commercial labs)
R
q Government (federal, state, local)
S
q Other
Job Classification (Check ONE only)
01
q President, owner, partner, officer
02
q Manager, director, superintendent (or assistant)
03
q Sales
04
q Purchasing
05
q Engineer welding
20
q Engineer design
21
q Engineer manufacturing
06
q Engineer other
10
q Architect designer
12
q Metallurgist
13
q Research & development
22
q Quality control
07
q Inspector, tester
08
q Supervisor, foreman
14
q Technician
09
q Welder, welding or cutting operator
11
q Consultant
15
q Educator
17
q Librarian
16
q Student
18
q Customer Service
19
q Other
Technical Interests (Check all that apply)
A
q Ferrous metals
B
q Aluminum
C
q Nonferrous metals except aluminum
D
q Advanced materials/Intermetallics
E
q Ceramics
F
q High energy beam processes
G
q Arcwelding
H
q Brazing and soldering
I
q Resistance welding
J
q Thermal spray
K
q Cutting
L
q NDT
M
q Safety and health
N
q Bending and shearing
O
q Roll forming
P
q Stamping and punching
Q
q Aerospace
R
q Automotive
S
q Machinery
T
q Marine
U
q Piping and tubing
V
q Pressure vessels and tanks
W
q Sheet metal
X
q Structures
Y
q Other
Z
q Automation
1
q Robotics
2
q Computerization of Welding
SECTION NEWS
dents at Locklin Tech Career Center,
won the door prizes and raffle. This
Mobile Section meeting was held at
The Original Oyster House in Spanish
Fort, Ala.
NEW ORLEANS
October 21
Speaker: Matt Howerton, sales engineer
Affiliation: The Lincoln Electric Co.
Topic: Welding aluminum
Activity: The Plumbers & Steamfitters UA Local 60 sponsored this event
at Landmark Hotel in Metairie, La.
Representatives included Business
Manager Curtis Mezzic, Al Theriot,
Neal Keller, Dana Colombo, Roy Lerille, and Vernon Delaune.
District 10
Robert E. Brenner, director

(330) 484-3650
MOBILE At left, U.S. Congressman Bradley Byrne (center) poses with Ron Pierce
(left) and Chair Michael Zoghby at the October program. At right, Vice Chair Clay Byron
(left) is shown with speakers Steve Day (center) and Steve Yeend at the November event.
NEW ORLEANS From left are Neal Keller, D. J. Berger, Dana Colombo, Al Theriot,
Roy Lerille, Chair Jimmy Goodson, and Vernon Delaune.
CLEVELAND
October 14
Speaker: Mike Barrett, application
engineer
Topic: Arc welding stainless steels
Activity: The event was held at
Toscana Party Center in Cleveland,
Ohio.
DRAKE WELL
NEW ORLEANS From left are Chair

Jimmy Goodson and Matt Howerton.
CLEVELAND Chair Paul Revolinsky

(left) is shown with Mike Barrett.
MAHONING VALLEY From left are

Homer Swanson, Chair Chuck Moore,
and speaker John Bossone.
LAKESHORE Chair Brian Strebe (left)

is shown with speaker Stephen Berg.
November 13
Activity: The members met to discuss
upcoming events, including a weld-off
on Dec. 5 at Pittsburgh Technical Institute, and a SkillsUSA event in January. The meeting was held at The
Commons at Franklin in Franklin, Pa.
MAHONING VALLEY
November 18
Speaker: John Bossone, consultant
Affiliation: Industrial Quality Services
Topic: Introduction to nondestructive
testing
Activity: Student Chapter Chair
Homer Swanson and Vice Chair Keith
Mohney discussed upcoming Chapter
events. The program was held at
Columbiana County Career Center in
Lisbon, Ohio.
NORTHWESTERN
PENNSYLVANIA
October 8
Speaker: Elliot Ash
Topic: Aluminum gas metal arc welding
Activity: The program was held at
Central Tech High School in Erie, Pa.
November 12
Speaker: Brian Hrinko, instructor
Affiliation: Plumbers and Steamfitters Local 47 Training Facility
Topic: Troubleshooting pipe welding
issues
Activity: The meeting was held at the
training facility in Erie, Pa.
SECTION NEWS
District 11
Robert P. Wilcox, director

(734) 721-8272
rmwilcox@wowway.com
DETROIT
October 2124
Tutorial speaker: Hongyan Zhang, assoc. professor, University of Toledo
Topic: Resistance spot welding of various aluminum alloys
Conference speaker: Alan Taub, CTO,
American Lightweight Materials
Manufacturing Innovation Institute
Topic: Challenges in manufacturing a
multimaterial vehicle
Activity: More than 130 attended the
Sections 16th Sheet Metal Welding
Conference cosponsored by Advanced
Laser Application Workshop, EWI,
and Resistance Welding Manufacturing Alliance. The tutorial was presented at R & E Automated Systems in
Macomb, Mich.; the welding show
and conference were held at Schoolcraft College, VisTaTech Building, in
Livonia, Mich. The Vendor Display
Night event featured equipment
demonstrations provided by Fronius,
R & E Automated Systems, Stanley
Engineered Fastening, and The Lincoln Electric Co. Mike Palko received
his Silver Member certificate for 25
years of service to the Society. See
photo on page 58 of this issue.
District 12
NORTHWESTERN PENNSYLVANIA Upper photo: At the October program are (from

left) Eric Speer, speaker Elliot Ash, Vice Chair Donna Bastian, and Marty Siddall. Above
photo: Shown at the Nov. 12 meeting are (from left) Donna Bastian, speaker Brian
Hrinko, Chair Tom Kostreba, John Fehr, Jason Neff, Eric Speer, and Bob Snyder.
DETROIT Attendees are shown at the Aluminum Welding seminar.
Daniel J. Roland, director

(920) 241-1542
daniel.roland@airgas.com
LAKESHORE
October 9
Speaker: Stephen Berg
Affiliation: Berg Engineering & Sales
Topic: Phased array weld inspections
The program was held at Machuts
Supper Club in Two Rivers, Wis.
MADISONBELOIT
October 3
Activity: The Section celebrated National Manufacturing Day at Madison
Area Technical College with guests
Wisconsin Lt. Gov. Rebecca Kleefisch
and Reggie Newson, secretary, Dept.
of Workforce Development. Previously, Governor Scott Walker had decreed
MADISON-BELOIT Wisconsin Lt. Gov. Rebecca Kleefisch and Workforce Development Secretary Reggie Newson (center) learn about autodarkening helmets from Ben
Newcomb at the Manufacturing Day presentation.
SECTION NEWS
October as Manufacturing Month in

the state of Wisconsin. The state officials visited the welding lab where
Newson donned leathers and hood to
demonstrate his welding skills. The officials talked with instructors Section
Chair Tony Stute and Vice Chair Ben
Newcomb and students about the future of welding education.
October 22
Activity: The Madison-Beloit Section
members participated at the open
house held at Madison Area Technical
College in Madison, Wis. Highlights
included contests using the Lincoln
VRTEX 360 virtual arc welding trainer, and tours of the college facilities.
CHICAGO Top photo: Welding contest participants are shown at Pipefitters Local
Union 597 in October. Above (from left) John Hesseltine, Dolores and Bob Zimny, Erik
Purkey, Pete Host, and Anghelina and Cliff Iftimie are shown at the board meeting.
District 13
John Willard, director

(815) 954-4838
kustom_bilt@msn.com
CHICAGO
October 25
Activity: The Section hosted its fourth
annual welding contest at Pipefitters
Local Union 597 in Mokena, Ill., for
high school and college students.
October 29
Activity: The board members met at
Papa Joes Restaurant in Orland Park,
Ill., for a planning meeting. Attending
were John Hesseltine, Dolores and
Bob Zimny, Erik Purkey, Pete Host,
and Anghelina and Cliff Iftimie.
District 14
Robert L. Richwine, director

(765) 606-7970
rlrichwine2@aol.com
ST. LOUIS John Haake (left, front) receives a speaker gift from Chair Mike
Kamp at the October program.
MADISON-BELOIT Sam Morrison
coaches a student using the virtual arc
welding trainer equipment.
INDIANA
October 23
Activity: Chair David Jackson emceed
the Sections awards-presentation
program. The awardees included Eric
Cooper, David Leapley, past AWS
President Dick Alley, Ricky Ferguson,
Erin Fromson, Josiah Miller, Tony
Brosio, Gary Dugger, Kyle Hutcheson,
Bennie Flynn, and Dave Jackson.
Chair David Jackson; John Bray, AWS
vice president; and Bob Richwine,
Dist. 14 director, participated.
INDIANA Welder-to-be Lincoln Miller

attended the Section meeting with his
award-winning daddy, Josiah.
SECTION NEWS
INDIANA From left are (seated) Eric Cooper, David Leapley, Dick Alley, Ricky Ferguson, and Erin Fromson; (standing) Josiah Miller,
Tony Brosio, Gary Dugger, Kyle Hutcheson, Dist. 14 Director Bob Richwine, Bennie Flynn, Dave Jackson, and Vice President John Bray.
ST. LOUIS Attendees are shown during their tour of Hillsdale Fabricators in November.
IOWA Section members are shown during their tour of Hagie Mfg. Co. in Clarion, Iowa.
KANSAS CITY From left are Chair Tim

Gill, Curt Heinbeck, and Jeb Clement.
NORTH TEXAS From left are Floyd Kiel, Chair Mike Beaton, Donnie Williams, Dist.
17 Director Jerry Knapp, and Paul Stanglin.
SECTION NEWS
ST. LOUIS
October 16
Speaker: John Haake
Affiliation: Titanova Laser, owner
Topic: Laser beam welding
Activity: The program was held at Cee
Kay Supply in St. Louis, Mo.
November 6
Activity: The St. Louis Section members toured Hillsdale Fabricators. The
presenters were Larry Ingram and
Steve Door, directors of estimating
and business development, respectively.
hosted the Welding for the Strength of

America video presentation and spoke
to hundreds of students about welding-related careers. The two-day
event was held at Verizon Arena in
North Little Rock, Ark.
NORTH TEXAS
October 21
Speaker: Michael Beaton, Section
chair
Affiliation: Trinity Industries, Inc.,
Metals Laboratory, director
Topic: Grain structure of welds
Activity: The event was held at
Humperdincks Restaurant and Brewery in Arlington, Tex.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
District 16
Karl Fogleman, director
(402) 677-2490
fogleman3@cox.net
IOWA
November 18
Activity: The Section toured Hagie
Mfg. Co. in Clarion, Iowa, to study its
lean manufacturing methods for producing agricultural machines. David
Landon, AWS president, attended the
tour.
KANSAS CITY
October 16
Activity: The Section toured Paulo
Products Co. to study its metal heattreating operations. Talks were presented by Curt Heinbeck and Jeb
Clement.
District 17
Jerry Knapp, director
(918) 224-6455
jerry.knapp@gasandsupply.com
CENTRAL ARKANSAS
October 15, 16
Activity: Aaron Campbell and Vice
Chair Dennis Pickering attended the
Welsco Welding Expo where they
TULSA
October 28
Speaker: Travis Weber, sales representative, Section technical representative
Topic: Welding stainless steels
Golden Corral in Tulsa, Okla.
November 1
Activity: The Tulsa Section held its
first annual Shoot for Scholarships
outing, headed by Chair Rich Howard
and Tech Rep Travis Weber.
TULSA Chair Rich Howard (left in all

photos) is shown (top photo) Oct. 28
with Travis Weber (center) and Jerry
Knapp, Dist. 17 director; (center photo)
Nov. 1 with Travis Weber; and (bottom
photo) Nov. 18 with Mel Clifford.
November 18
Activity: This Tulsa Section program
addressed advancements in pulsed
gas metal arc waveform technology.
Mel Clifford with OTC Daihen, and
Joe Bagnaro and Andy Harris with
Airgas, made presentations.
District 18
John Stoll, director
(713) 724-2350
John.Stoll@voestalpine.com
BEAUMONT
October 14
Speaker: Ray Shook, AWS executive
director
Affiliation: American Welding Society
Topic: Whats new at AWS
Activity: Ruel Riggs was recognized
for 45 years of service to the Section.
BEAUMONT Chair John McKeehan

(right, both photos) is shown with (top
photo) Ray Shook, AWS executive director; and (bottom photo) Ruel Riggs.
SECTION NEWS
HOUSTON From left are (standing) Jason Durant, Paul McGaughy, Derek Stelly, Ronnie Mercer, speaker Ray Shook, Mark Fahlgren,
Nathan Sumrall, Steve Mize, Cody Morgan, Jeb Baker, John Husfeld, Kyle Robison, Dennis Eck, John Terrell, Marcus Rodriguez, Grant
Peltier, and Brian Cavin, (seated) Barney Burks, Justin Gordy, Justin Kirby, Director-at-Large J. Jones, Vice President John Bray, Terry
Wells, and John Stoll, Dist. 18 director.
HOUSTON
October 15
Speaker: Ray Shook, AWS executive
director
Affiliation: American Welding Society
Topic: Whats new at AWS
Activity: Shook presented Justin
Gordy a letter in appreciation of his
services. The first annual Justin
Gordy Spirit of Welding Award was
announced to recognize a member
who demonstrates consistent support
for the Sections activities during the
previous year.
HOUSTON Justin Gordy (left) and

Ray Shook, AWS executive director, are
shown at the announcement of the first
annual Section Spirit of Welding Award.
ALBERTA (Above) Chair Matthew

Yarmuch (left) is shown with speaker
Garth Stapon; (below) Barry Patchett
displays his Gold Member certificate surrounded by his engineering students.
District 19
Ken Johnson, director

(425) 957-3553
kenneth.johnson@vigorindustrial.com
ALBERTA
September 11
Activity: The Section toured AZZ
Welding Services Intl in Edmonton,
Alb., Canada, conducted by Darren
Barborak. The facility performs overhaul and restoration of boilers,
process towers, reactors, and pressure
vessels.
November 6
Speaker: Garth Stapon
Affiliation: Praxair
Topic: Shielding gases to minimize
hydrogen contamination of welds
Activity: Barry Patchett received his
Gold Member certificate for 50 years
of service to the Society. The event
was held at the University of Alberta.
72 WELDING JOURNAL /JANUARY 2015
BRITISH COLUMBIA From left are Bernard Booth, Rachel Kennedy, Geordie Third,
Ian Sherlock, Simmah Petersen, and Brad Moe.
SECTION NEWS
COLORADO Attendees are shown at the Oct. 9 program (top) and Nov. 13 program (above).
Colorado School of Mines Student Chapter Braving the 7F weather are (from left) Ricky Watts, Rashed Alhajri, Minrui Gao, Grant
Bishop, Pedro Andrade, Jacob Windsor, Jon Watson, Lucas Preuler, Ryan Peck, Paige Stevens, Edwin Supple, Haley Lake, Juan Wei, Allison Loecke, Brittany Boefenkamp, Dan Deveraux, John Moore, Brian Rush, and Prof. Stephen Liu, advisor.
BRITISH COLUMBIA
October 23
Speaker: Kent Hillman
Affiliation: Liaison OSH Consulting
Topic: Impact of new standard for exposure to manganese during welding
Activity: The annual Bruce Third
welding scholarship awards were presented to Rachel Kennedy and Ian
Sherlock by Geordie Third and Brad
Moe, scholarship chair. Attending
were welding instructors Bernard
Booth and Simmah Petersen.
District 20
Pierrette H. Gorman, director

(505) 284-9644
phgorma@sandia.gov
COLORADO
October 9
Speaker: Carlos Rodriguez
COLORADO From left are Lauren Bussey, Josh Heverman, past AWS President Bob
Teuscher, Herb Beaven, and Thompson Tindall.
Affiliation: Rocky Mountain Energy

Forum
Topic: Frackings impact on Colorado
Front Range Community College,
Fort Collins campus.
November 13
Speaker: Brian Wood
Affiliation: Sound Analysis, LLC
Topic: Phased array testing of welds
Activity: The Section joined members
of the local ASNT chapter for this
event, held in Centennial, Colo.
SECTION NEWS
Weber State University Student Chapter Members are shown during their tour of Petersen, Inc., in Ogden, Utah.
ARIZONA Upper photo shows attendees at the Oct. 13 program. Above, from left, (seated) are Gary Gardner and Paul Moreno;
(standing) are John Weber, Jim Benjamin, Chair Brent Boling, Rick Pell, Dist. 21 Director Nan Samanich, AWS President Dean Wilson,
Nicholas Martinez, Andrew Lamer, and Jerry Siko. Fran Johnston took the photo.
Colorado School of Mines

Student Chapter
November 13
Activity: The members toured the
Northwest Pipe Co. in Denver, Colo.
Weber State University

Student Chapter
November 8
Activity: The members toured Petersen, Inc., in Ogden, Utah, to study
the fabrication of heavy-plate pres74 WELDING JOURNAL / JANUARY 2015
sure vessels. Quality and Welding Engineer Tad Dean and Director of Quality Kirk Douglas led the tour.
District 21
Sam Lindsey, director

(858) 740-1917
slindsey@sandiego.gov
ARIZONA
October 13
Speaker: Dean Wilson, AWS president
Affiliation: Welldean Enterprises

Topic: Innovations at AWS
Activity: The event, held at East Valley Institute of Technology in Mesa,
Ariz., attracted 100 members, students, and guests.
District 22
Kerry E. Shatell, director

(925) 866-5434
kesi@pge.com
Guide to American Welding Society Services

8669 NW 36th St., #130
Miami, FL 33166-6672
(800/305) 443-9353; Fax: (305) 443-7559
Phone extensions are in parentheses.
AWS PRESIDENT
David Landon . . . . dlandon@vermeermfg.com
Vermeer Mfg. Co.
2010 Vermeer Rd. E., Pella, IA 50219
ADMINISTRATION
Executive Director
Ray Shook.. rshook@aws.org . . . . . . . . . . . . . .(210)
Senior Associate Executive Directors
Cassie Burrell.. cburrell@aws.org . . . . . . . . . . .(253)
INTERNATIONAL SALES
Managing Director of North American Sales
Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . . .(297)
Corporate Director, International Sales
Jeff Kamentz..jkamentz@aws.org . . . . . . . . . .(233)
Oversees international business activities;
certification, publications, and membership.
PUBLICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . .(275)
Managing Director
Andrew Cullison.. cullison@aws.org . . . . . . . .(249)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . . . .(249)
John Gayler.. gayler@aws.org . . . . . . . . . . . . .(472)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . . .(238)
Chief Financial Officer

Gesana Villegas.. gvillegas@aws.org . . . . . . . .(252)
Society and Section News Editor

Howard Woodward..woodward@aws.org . . . .(244)
Chief Technology Officer

Dennis Harwig..dharwig@aws.org . . . . . . . . .(213)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . . .(303)
Chief Information Officer

Emilio Del Riego..edelriego@aws.org . . . . . . .(247)
Associate Director of Board and
Executive Director Services
Alex Diaz.. adiaz@aws.org . . . . . . . . . . . . . . . .(294)
MARKETING COMMUNICATIONS
Director
Lorena Cora.. lcora@aws.org . . . . . . . . . . . . . .(417)
Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . . .(416)
Administrative Services
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . . .(214)
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . . . .(456)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . . .(287)
Section Web Editor

Henry Chinea...hchinea@aws.org . . . . . . . . . .(452)
HUMAN RESOURCES
Director
Gricelda Manalich.. gricelda@aws.org . . . . . .(208)
MEMBER SERVICES
Senior Associate Executive Director
Cassie Burrell.. cburrell@aws.org . . . . . . . . . . .(253)
Associate Director
Patrick Henry..phenry@aws.org . . . . . . . . . . .( 211)
INTERNATIONAL INSTITUTE OF WELDING
Senior Coordinator
Sissibeth Lopez . . sissi@aws.org . . . . . . . . . . .(319)
Liaison services with other national and international societies and standards organizations.
GOVERNMENT LIAISON SERVICES
Hugh Webster . . . . . . . . . . . . . .hwebster@wc-b.com
Webster, Chamberlain & Bean, Washington, D.C.
(202) 785-9500; F: (202) 835-0243.
Monitors federal issues of importance to the
industry.
CONVENTION AND EXPOSITIONS
Director, Convention and Meeting Services
Matthew Rubin.....mrubin@aws.org . . . . . . . .(239)
ITSA INTERNATIONAL THERMAL
SPRAY ASSOCIATION
Senior Manager and Editor
Kathy Dusa....kathydusa@thermalspray.org . .(232)
RWMA RESISTANCE WELDING
MANUFACTURING ALLIANCE
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . . . .(444)
WEMCO ASSOCIATION OF WELDING
MANUFACTURERS
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . . . .(444)
BRAZING AND SOLDERING
MANUFACTURERS COMMITTEE
Stephen Borrero..sborrero@aws.org . . . . . . . .(334)
Director
Rhenda Kenny... rhenda@aws.org . . . . . . . . . .(260)
Serves as a liaison between members and AWS
headquarters.
CERTIFICATION SERVICES
Senior Associate Executive Director
John Gayler.. gayler@aws.org . . . . . . . . . . . . .(472)
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . . .(470)
Application processing, renewals, and exams.
Director, Accreditation Programs
Linda Henderson..lindah@aws.org . . . . . . . . .(298)
Oversees the development of new certification programs, as well as AWS-Accredited Test
Facilities, and AWS Certified Welding Fabricators.
TECHNICAL SERVICES
Managing Director
Technical Services Development & Systems
Andrew Davis.. adavis@aws.org . . . . . . . . . . .(466)
International Standards Activities, American
Council of the International Institute of Welding
Director, Operations
Annette Alonso.. aalonso@aws.org . . . . . . . . .(299)
Technical Committee Activities, Welding
Qualification
Manager, Safety and Health
Stephen Hedrick.. steveh@aws.org . . . . . . . . .(305)
Metric Practice, Safety and Health, Joining of
Plastics and Composites, Personnel and Facilities
Qualification, Mechanical Testing of Welds
Program Managers II
Stephen Borrero... sborrero@aws.org . . . . . . .(334)
Brazing and Soldering, Brazing Filler Metals
and Fluxes, Brazing Handbook, Soldering Handbook, Definitions and Symbols, Structural Subcommittees on Bridge Welding, Stainless Steel,
and Reinforcing Steel
Rakesh Gupta.. gupta@aws.org . . . . . . . . . . .(301)
Filler Metals and Allied Materials, International Filler Metals, UNS Numbers Assignment,
Arc Welding and Cutting Processes, Computerization of Welding Information
Brian McGrath .... bmcgrath@aws.org . . . . . .(311)
Structural Welding, Welding in Marine Construction
Program Managers
Efram Abrams.. eabrams@aws.org . . . . . . . . .(307)
Automotive, Resistance Welding, Machinery
and Equipment, Methods of Inspection
Chelsea Lewis.. clewis@aws.org . . . . . . . . . . . .(306)
Friction Welding, Oxyfuel Gas Welding and
Cutting, High-Energy Beam Welding, Robotics
Welding, Welding in Sanitary Applications, Additive Manufacturing
Jennifer Molin.. jmolin@aws.org . . . . . . . . . .(304)
Sheet Metal Welding, Welding and Brazing in
Aerospace, Ti and Zr Filler Metals, Joining of
Metals and Alloys, Piping and Tubing
Jennifer Rosario.. jrosario@aws.org . . . . . . . .(308)
Railroad Welding, Thermal Spraying, Welding
Iron Castings, Welding Qualification
AWS FOUNDATION, INC.
www.aws.org/w/a/foundation
General Information
(800/305) 443-9353, ext. 212, vpinsky@aws.org
Chairman, Board of Trustees
William A. Rice.. brice@oki-bering.com
EDUCATION SERVICES
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
Executive Director, Foundation

Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . (331)
Director, Development and Systems

David Hernandez.. dhernandez@aws.org . . . .(219)
Corporate Director, Workforce Development

Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . (461)
AWS AWARDS, FELLOWS, COUNSELORS

Senior Manager
Wendy Sue Reeve.. wreeve@aws.org . . . . . . . .(293)
Coordinates AWS awards and Fellow and
Counselor nominations.
Associate Director of Scholarships

Vicki Pinsky.. vpinsky@aws.org. . . . . . . . . . . . . . . . (212)
The AWS Foundation is a not-for-profit 501(c)(3)
charitable organization established to provide support for
the educational and scientific endeavors of the American
Welding Society. Promote the Foundations work with your
financial support.
Personnel Jan 2015_Layout 1 12/11/14 10:33 AM Page 76
PERSONNEL
Hypertherm Announces
Management Reassignments
Hypertherm, Hanover, N.H., a
manufacturer of plasma, laser, and
waterjet cutting systems, has arranged
for the responsibilities of Carey Chen,
former vice president and general
manager, Light Industrial Businesses,
and CIO, who left the company in December, to be transitioned to two current management team members, Jim
Miller and Mary Bihrle. Miller, current
vice president of operations, assumed
the added responsibilities of vice president and general manager, Light Industrial Businesses. Bihrle, current
CFO, assumed management team responsibility for the companys Information Services function. Chen left
the company to become president and
CEO of Cincinnati, Inc.
Eastwood Names President

The Eastwood Co., Pottstown, Pa.,
a marketer of welding equipment,
tools, and supplies for the repair,
restoration, and modification of cars,
trucks, and motorcycles, has named

Brian Huck president and COO.
With the company
for six years, Huck
previously served
as vice president of
marketing and
sales. He succeeds
Curt Strohacker,
founder and chairBrian Huck
man of the board,
who will continue
as chairman of the board.
CenterLine Fills Two Key Posts

CenterLine (Windsor) Ltd., Windsor, Ont., Canada, a supplier of products and services for welding, metalforming, and cold spray applications
for the automotive, aerospace, and defense industries, has appointed Steve
Renaud vice president of operations
and Jim Komar general manager, Machinery Div. Renaud, with the company for 22 years, most recently served
as general manager, Machinery Div.
Steve Renaud
Jim Komar
Komar with 30 years experience in

the automotive industry, has served
the company for the past three years
as plant manager, Machinery Div.
Laboratory Testing Hires

Sales Representative
Laboratory Testing, Inc., Hatfield,
Pa., an independent, accredited materials testing and
calibration laboratory, has hired Eric
Baum, Towaco,
N.J., as an outside
sales representative. Baum brings
more than ten
Eric Baum
years of business
development experience working with the aerospace,
medical device, and other industrial
markets serviced by the company.
ASTM Selects Next President

ASTM International, West Conshohocken, Pa., board of directors
unanimously selected Katharine E.
Morgan, current vice president of
technical committee operations, to become its next president, succeeding
James A. Thomas who has served in
the post since 1992. During the transition period, Morgan will assume the
position of executive vice president on
March 1, 2015, then work with
Thomas until he retires Feb. 1, 2017.
TaylorWharton Names VP
Taylor-Wharton Cryogenics, LLC,
headquartered in Minnetonka, Minn.,
a manufacturer of a wide range of stationary and portable storage systems
aws wemco image of welding_FP_TEMP 12/9/14 10:14 AM Page 77
buyers guide_FP_TEMP 12/9/14 7:55 AM Page 78
Personnel Jan 2015_Layout 1 12/11/14 10:34 AM Page 79
PERSONNEL
for gas and liquid

applications, has
promoted Chris Kasuba to vice president and general
manager, Cryoindustrial business
unit. Kasuba joined
the company in
2011 as director of
finance for global
operations. PreviChris Kasuba
ously, he served in
senior financial positions at Grede Foundries, Inc., for
nearly 14 years.
tional Institute of
Welding (IIW) and
International Organization for
Standardization
(ISO). He worked
with IIW Commission II to compile
the Catalog of the
International Index
of Welding Filler
Metal ClassificaGiovanni S. Crisi tions, and authored
several technical
articles published in the Welding Journal and other North and South American publications. As a columnist for
the newspaper Fanfulla, he is remembered for his passion for the science of
welding as well as the lectures he presented to various organizations.
Wall Colmonoy Names Director

European Headquarters
William Freed McLaughlin
Wall Colmonoy,
Madison Heights,
Mich., a supplier of
hardfacing and
brazing products,
castings, and engineered components
for the aerospace,
automotive, and
energy sectors, has
announced the appointment of Steph
Steph Curtis
Curtis as managing
director for its European headquarters, based in Pontardawe, Swansea, Wales, UK. Curtis,
who joined the company in 2014, has
30 years of experience in the strategic,
operational, and commercial management fields.
William Freed
McLaughlin, 86,
died Nov. 6 in
Clawson, Mich. A
50-year AWS Gold
Member, he served
on the Detroit Section executive
board for 40 years
and as secretary
19911997.
McLaughlin served
W. F. McLaughlin as a welding engineer for Chrysler
Corp. for more than 30 years, retiring
in 1989. He worked in the companys
welding lab where he developed and
later installed the first automobile assembly plant application of the gas
metal arc welding process. WJ
CAN WE TALK?
The Welding Journal staff encourages an
exchange of ideas with you, our readers. If
youd like to ask a question, share an idea or
voice an opinion, you can call, write, e-mail,
or fax. Staff e-mail addresses are listed
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Publisher
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Ext. 249, Article Submissions
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Ext. 238, Feature Articles
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Obituaries
Giovanni Sebastiano Crisi
Giovanni Sebastiano Crisi, 78, died
April 23 in So Paulo, Brazil, where he
was a professor of mechanical engineering at Mackenzie University. An
AWS member since 2003, he was a frequent contributor to the AWS Welding
Forum where he posted thousands of
entries since 2000. He worked to help
organize ABNT (the Brazilian Technical Standards Association) to bring
Brazils welding filler metal standards
in conformance with those of InternaFor info, go to www.aws.org/adindex
Page 80 Counselor_FP_TEMP 12/10/14 2:48 PM Page 80
Friends and Colleagues:

The American Welding Society established the honor of Counselor to recognize individual
members for a career of distinguished organizational leadership that has enhanced the image
and impact of the welding industry. Election as a Counsel shall be based on an individuals
career of outstanding accomplishment.
To be eligible for appointment, an individual shall have demonstrated his or her leadership in
the welding industry by one or more of the following:
Leadership of or within an organization that has made a substantial contribution to the
welding industry. The individuals organization shall have shown an ongoing
commitment to the industry, as evidenced by support of participation of its employees
in industry activities.
Leadership of or within an organization that has made a substantial contribution to
training and vocational education in the welding industry. The individuals
organization shall have shown an ongoing commitment to the industry, as evidenced
by support of participation of its employees in industry activities.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at
wreeve@aws.org at AWS headquarters in Miami, or simply follow the instructions on the
Counselor nomination form located at http://www.aws.org/awards/fellow_counselor.html.
Please remember, we all benefit in the honoring of those who have made major contributions to
our chosen profession and livelihood. The deadline for submission is July 1, 2015. The
Counselors Committee looks forward to receiving numerous Counselor nominations for 2016
consideration.
Sincerely,
Lee Kvidahl
Chair, Counselor Selection Committee
aws foundation_FP_TEMP 12/9/14 10:13 AM Page 81
Page 82 Fellow_FP_TEMP 12/10/14 2:48 PM Page 82
Friends and Colleagues:

The American Welding Society, in 1990, established the honor of Fellow of the Society to
recognize members for distinguished contributions to the field of welding science and
technology, and for promoting and sustaining the professional stature of the field. Election as a
Fellow of the Society is based on outstanding accomplishment and technical impact of the
individual. Such accomplishments will have advance the science, technology and application of
welding, as evidenced by:
Sustained service and performance in the advancement of welding science and
technology
Publication of papers, articles and books which enhance knowledge of welding
Innovative development of welding technology
Society and Section contributions
Professional recognitions
I want to encourage you to submit nomination packages for those individuals whom you feel
have a history of accomplishments and contributions to our profession consistent with the
standards set by the existing Fellows. In particular, I would make a special request that you
look to the most senior members of your Section or District in considering members for
nomination. In many cases, the colleagues and peers of these individuals who are the most
familiar with their contributions, and who would normally nominate the candidate, are no long
with us. I want to be sure that we take the extra effort required to make sure that those truly
worthy are not overlooked because no obvious individual was available to start the nomination
process.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at
wreeve@aws.org at AWS headquarters in Miami, or simply follow the instructions on the
Fellow nomination form located at http://www.aws.org/awards/fellow_counselor.html. Please
remember, we all benefit in the honoring of those who have made major contributions to our
chosen profession and livelihood. The deadline for submission is August 1, 2015. The Fellows
Committee looks forward to receiving numerous Fellow nominations for 2016 consideration.
Sincerely,
Dr. John Elmer
Chair, AWS Fellows Committee
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Borle 1-15[1]_Layout 1 12/11/14 2:06 PM Page 1
WELDING RESEARCH
SUPPLEMENT TO THE WELDING JOURNAL, JANUARY 2015

Sponsored by the American Welding Society and the Welding Research Council
Primary Chromium Carbide Fraction

Control with Variable Polarity SAW
Increasing the fraction of time spent welding in DCEN compared
to DCEP can increase the amount of primary carbides
BY S. D. BORLE, I. LE GALL, AND P. F. MENDEZ
ABSTRACT
Using alternating current (AC) when welding chromium carbide hardfacing alloys
has a pronounced effect on the resulting welds. To examine exactly the effect of AC
balance (fraction of time in electrode positive) on FeCrC hardfacing, six different
samples were made varying from 50 to 75% balance in 5% increments. The heat
input was found to increase from 3.82 to 4.30 kJ/mm and dilution along the center
line increased from 3.7 to 31.1%. The ultimate consequence of increasing the balance
was a decrease in the volume fraction of primary carbides from 21 to 3% and a de
crease in average diameter of carbides from 30.3 to 21.8 mm with the increase in bal
ance. The increase in the volume fraction of carbides also coincided with
microstructures that had higher percentages of hypereutectic microstructures that
should lead to more uniform wear throughout the height of the hardfacing. The in
crease in volume fraction of carbides as the balance decreases should also increase
the wear resistance. The use of AC waveform with balances near 50% gave mi
crostructures expected to perform the best.
KEYWORDS
Hardfacing Surfacing Cladding Submerged Arc Chromium Carbide
Introduction
In Canada alone, wear is estimated
to cost $2.5 billion a year (Ref. 1). To cut
down on the cost of wear, hardfacing is
employed. Fe-Cr-C hardfacing is a surface treatment aimed at improving the
surface properties of metals, in which a
welded cladding is deposited onto the
surface of a substrate to improve the
parts resistance to wear. There are a
number of different types of material
systems that are employed in surfacing
(Refs. 1, 2). This research focuses on FeCr-C hardfacing.

Fe-Cr-C hardfacing is a surfacing
technique applied to plain carbon
steel and is used in circumstances
where it may be undergoing wear
caused by abrasion, impact, erosion,
and corrosion (Refs. 36). Fe-Cr-C
hardfacing is used in a large number
of industries including mining, mineral processing, cement production,
and pulp and paper manufacturing
(Refs. 79). In oil sands operations its
use includes crusher teeth, sizing

screens, and centrifugal pumps, wearplate for truck bed liners, and slurry
transport pipelines (Refs. 6, 1012).
Fe-Cr-C hardfacing tends to be relatively inexpensive in comparison to
other surfacing types such as tungsten carbide-based and certain polymer liners, which lends them to being
used on the larger scale components
(Ref. 12). This research examines FeCr-C hardfacing produced with the
submerged arc welding (SAW)
process. The main reasons for using
SAW over other processes are its high
productivity and deposition rates
(Ref. 13).
For the optimization of the production of Fe-Cr-C hardfacing, the
use of square-wave alternating current (AC) is attractive because of its
ability to control dilution and decrease heat input. The variables of AC
waves that can be controlled are the
balance, DC offset, and frequency.
This research looks solely at the effect of controlling the balance, which
has been identified as the most important waveform variable controlling dilution (Ref. 14). The balance is
given as a percent of time the arc
spends in electrode positive polarity.
When using a constant-voltage (CV)
implementation of AC welding, the
wire feed speed (WFS) and the voltage are set and held constant while
the machine varies the current (Ref.
14).
S. D. BORLE was a MSc. student at the University of Alberta at the time of this research and is currently at Group Six Technologies. I. LE GALL was a visiting stu
dent at the University of Alberta from Universit de Nantes. P. F. MENDEZ is a professor and director at the Canadian Center for Welding and Joining at the Uni
versity of Alberta, Canada.
JANUARY 2015 / WELDING JOURNAL 1-s
WELDING RESEARCH
Fig. 1 Idealized liquidus surface of the

FeCrC ternary phase diagram.
Table 1 Balance Settings Used in This Work

Sample
Balance
A
B
C
D
E
F
50
55
60
65
70
75
Microstructure of SAW
Chromium Carbide Surfacing
The compositions of the Fe-Cr-C
hardfacing tend to fall in the ranges
of 835 wt-% Cr and 26 wt-% C
(Refs. 3, 13, 15, 16). As shown in the
idealized pseudo ternary in Fig. 1,
this range of compositions encompasses three distinct categories of microstructure: hypoeutectic, eutectic,
and hyper-eutectic. There is a large
difference between the microstructures and the mechanical properties
of the three different categories. Hypereutectic alloys wear resistance is
normally superior (Ref. 2), but corrosion resistance and toughness are
often better in hypoeutectic alloys
(Refs. 13, 17).
Microstructure of hypereutectic alloys consists of primary M7C3 carbides surrounded by a matrix of
eutectic austenite and eutectic M7C3
carbides. The hexagonal M7C3 carbides solidify first, as the composition of the melt approaches the
eutectic line and the temperature decreases, the solidification changes to
eutectic M7C3 carbides and austenite
(Ref. 17). An example of the typical
Fig. 2 Hypereutectic microstructure showing large hexagonal M7C3 primary carbides

surrounded by a matrix of eutectic M7C3 and austenite.
microstructure is shown in Fig. 2. The

size of the primary carbides increases
as the cooling rate decreases or
chromium wt-% increases, while the
addition of carbon increases the volume fraction of carbides while refining them (Refs. 15, 18).
When the composition of the alloy
falls at or close to the eutectic line,
M7C3 and austenite (g) solidify simultaneously as a eutectic microstructure
(Ref. 19). Figure 3 is an example of a
eutectic microstructure in chrome
carbide surfacing. The eutectic can either be a rosseta-like morphology, as
shown in Fig. 3, or it can be fibrous
bundles (Refs. 20, 21).
When the composition is in the
austenite region of the ternary, the
resulting microstructure is hypoeutectic. In this case, the solidification
starts as primary austenite dendrites
and then as a eutectic of M7C3 and
austenite (Refs. 19, 22). The austenite dendrites are surrounded by the
eutectic microstructure of M7C3 carbides and austenite, as seen in Fig. 4.
Previous work has shown there can
be a large variance in the wear resistance within the different microstructures and compositions of Fe-Cr-C
hardfacing; however, it is generally
agreed that as composition varies
from hypereutectic to eutectic to hypoeutectic, the wear resistance decreases (Refs. 2, 1012, 17, 2328). A
significant part of the wear resistance
increase going from hypoeutectic to
eutectic to hypereutectic microstructures is attributed to the increase in
the amount of carbides. In hypereutectic alloys, an increase in the sur-
2-s WELDING JOURNAL / JANUARY 2015, VOL. 94
face fraction of primary carbides increases wear resistance (Ref. 7).

An entirely hypereutectic microstructure is wanted for the best
possible abrasion resistance, but traditional hypereutectic alloys can contain all three microstructures (Refs.
2, 29, 30). Figure 5 is an example of
how the microstructure of a SAW FeCr-C hardfacing can be hypereutectic
at the top, eutectic in the middle, and
hypoeutectic close to the weld interface. This variation is representative
of Fe-Cr-C hardfacings in general, and
it is not typically seen in cast structures of similar compositions. Figure
5 was taken from micrographs of an
unetched sample taken using BSE imaging.
This layering occurs because of differences in composition along the
height of the weld (Ref. 29). However,
it is unclear between solidification,
segregation, diffusion, lack of mixing,
and diffusion what the main cause is.
The issue with the layering is the
wear resistance will not be uniform
throughout the service life of the
hardfacing. Testing protocols address
these variations by specifying a particular depth at which wear testing
must be performed (e.g., 75% of
cladding depth). Current research is
being performed in order to generate
a better understanding of layering,
which has very important practical
consequences. This paper focuses on
how a balance in a square waveform
affects the amount of primary carbides and the physical cause for this
phenomenon.
WELDING RESEARCH
Fig. 3 Eutectic microstructure of austenite and M7C3 .
Fig. 4 Hypoeutectic microstructure of primary austenite dendrites surrounded by eu

tectic M7C3 and austenite.
Table 2 Summary of Dilution and Heat Input for AC Balances between 50 and 75%
Sample
Balance
(%)
Dilution Center
(%)
Dilution Side
(%)
Heat Input
kJ/in. (kJ/mm)
A
B
C
D
E
F
50
55
60
65
70
75
3.7
4.8
19.7
18.7
25.7
31.1
34.0
32.8
47.5
38.6
41.3
41.4
97 (3.82)
100 (3.96)
101 (4.00)
103(4.06)
108 (4.23)
109 (4.30)
Experimental Procedure
When producing Fe-Cr-C hardfacing using SAW, an alloying powder
that contains elements such as
chromium, carbon, manganese, and
molybdenum is placed down in front
of the welding head. The powder used
for the current research was based on
a proprietary blend used to produce
Fe-Cr-C hardfacing industrially. The
main alloying elements were
chromium and carbon with lesser
amounts of manganese, silicon,
molybdenum, and boron added. A

welding gun attached to a weaving
mechanism was used to produce
passes of the desired width. Setups
used to produce Fe-Cr-C hardfacings
resemble the schematic shown in Fig.
6. In the case of the current research,
only a single weld bead was deposited
and the powder was applied evenly by
using a wheel feeder rotating at a constant speed while traveling along the
path of the weld previous to actually
welding. In these experiments, single
weld beads of 1 in. (44.5 mm) width
were made on a 9 12-in. (228 305mm) A36 plate with a thickness of 516
in. (7.94 mm). The sample plate was
clamped to the base plate using bolts
going through 12-in.-thick plates on top
of the sample plates with the bolts
threaded into the base plate to prevent
distortion of the sample plate when
welding.
Typical operating ranges for welding
of Fe-Cr-C hardfacing using SAW are
3040 V and 500700 A. The other operating parameters such as wire feed
speed, alloy powder addition, and weave
are chosen to ensure proper melting of
the powder, a good surface finish, and
slag detachability. The basis of the welding parameters were chosen to replicate
an industrially produced product with
the balance being the only welding variable changing between the samples. The
flux used for these experiments was 1.5
on the basicity index. The experimental
settings were chosen to resemble an industrially produced product and to examine the possibility of process/product
improvement. The welding was done
with constant voltage, constant wire
feed speed, and constant translation velocity, so that the ratio of wire to powder was constant through all the welds.
The offset was not adjusted, the frequency was kept constant at 45 Hz, and
no preheat was applied to the base
metal. The samples and their respective
balance settings are listed in Table 1.
The consumables used were an agglomerated basic flux along with a L61 welding wire (EM12K). A
proprietary blend of powders was used
to produce a weld metal high in
chromium and carbon. The power
source used was an AC/DC SAW machine that allowed for the manipulation of AC waveforms along with data
acquisition through a built-in program. The waveform data collected by
the machine were then used to determine the HI of the welds. HI was calculated by taking the average of the
instantaneous power throughout
welding. Dilutions of the samples were
measured using the formula shown in
Equation 1 and with the areas described in Fig. 7 (Ref. 24).
Dilution(%) = DA/(DA + OA ) 100 (1)
DA is the area of dilution or the
amount of the base metal that was
melted, and OA is the area of the overJANUARY 2015 / WELDING JOURNAL 3-s
WELDING RESEARCH
Fig. 6 Schematic of the experimental SAW setup for the Fe

CrC hardfacing used in this work.
Fig. 5 Microstructure of chromium carbide surfacing showing

a microstructural variation of hypereutectic at the top, eutectic
in the middle, and hypoeutectic at the bottom.
lay that has been added.

To calculate the dilution measurements, samples were taken along the
sagittal plane of the weld at the centerline and 15 mm off to the side, as
shown in Fig. 8, to account for the lack
of uniformity of the welds. The zig-zag
line in Fig. 8 represents the weaving
pattern in the deposition of a single
bead.
Metallographic samples for volume
fraction measurements were made
from along the longitudinal center of
the welds, while dilution measurements were taken from samples taken
from the transverse of the welds. The
samples were hot mounted in Bakelite and then ground and polished
using an automatic polisher with
22.24 N force. For the first step, 60grit rough grinding was carried out for
5 min. After this, multiple other grinding passes down to 1200 grit were carried out at 3 min for each stage. The
samples were then polished using a 1mm diamond suspension for 5 min. All
of the micrographs with exception of
those shown in Fig. 5 were etched for
30 s using a mixture of 20 mL deionized water, 10 mL HCl, 30 mL HNO3,
and 5 g FeCl3.
In order to get a good representa-
Fig. 7 Schematic of transverse cross section of a chromium

carbide surfacing highlighting the cladding area, the dilution
area, and the base metal.
tion of the microstructure, a large

number of photographs was taken of
samples that were then photo merged
together to make large micrographs
across a large width and the entire
height of the weld. The total volume
fraction of carbides was then measured by using Photoshop to select all
of the light areas of the microstructure
in the weld pool with the exception of
the unfused powders, which were not
included in the volume fraction analysis or size analysis. For the samples
where the primary carbides volume
fraction and size were measured,
smaller areas from the large micrograph were examined. The primary
carbides in the smaller areas were then
selected and the total area of the carbides measured using Photoshop. The
average size of the primary carbides in
the individual micrographs was then
calculated by dividing the area by the
number of carbides selected. The average size of primary carbides in the
sample was calculated by taking the
total number of all the carbides that
had been measured throughout the
smaller micrographs divided by the
total area of all of those carbides that
were measured. The diameter given is
the distance between two parallel sides
if the carbides are represented as regular hexagonal shaped.
Results
Figure 9 shows how the profiles
vary when cut transversely across the
samples. The concave weld interface
observed is a result of the weaving,
which has a longer dwell time at the
edges than at the center of the weld.
These cross sections show that the
penetration is increasing throughout
the samples as the balance increases.
The actual dilution measurements
were taken from the longitudinal sections and are tabulated in Table 2
along with the heat input calculations.
Figure 10 shows that the trend for
the heat input and dilution is to increase as the balance increases. The exception is at 60% balance, which
showed exceptionally high dilution
amounts in the experiments performed. The sides are less sensitive to
variations of balance. One possible
reason for this observation is that the
larger depth of molten metal at the
sides reduces the efficiency of cathodic
heating on the weld bead.
The influence of balance in the microstructural inhomogeneity across
WELDING RESEARCH
Fig. 8 Schematic of dilution measure

ment locations taken along the longitudi
nal of the weld hardfacing.
the depth of the hardfacing is illustrated in Fig. 11. For all images, the
top corresponds to the free surface of
the bead, and the bottom corresponds
to the weld interface. For all balances,
a hypereutectic structure is observed
at the top, and often a hypoeutectic
structure near the weld interface. The
white round features correspond to
powders that were not completely
molten, some of which reach a large
size, of the order of 1 mm (seen in the
60% balance image). A steady decrease
in the amount of hypereutectic microstructure at the top was observed
with the increase in balance.
Figure 12 presents a higher magnification image of areas of hypereutectic composition from the cross
sections in Fig. 11. Because of the
small size covered by each image, conclusions about primary carbide fraction were made by direct measurement
over a number of different areas.
The measured volume fraction (VF)
of hypereutectic microstructure, total
carbide VF, VF of primary M7C3 carbide, and the average primary M7C3
size are given in Table 3 and Fig. 13.
Figure 13 illustrates graphically the
trends determined, showing how the
amount of microstructure that is hypereutectic goes from under half to
100% as the balance reaches 50%. The
volume fraction and average primary
carbide size increases as the balance
decreases. The decrease in primary
carbide fraction is consistent with the
increase in dilution.
Discussion
The steady decrease in primary carbide fraction with balance is consistent with the well-known effect of
increased dilution with balance, cou-
Fig. 9 Cross sections of single bead FeCrC hardfacing for AC balance between 50
and 75%.
Fig. 10 Variation of dilution with AC balance.
pled with the understanding of the

thermodynamics of the material system used. The increase in dilution
with balance is due to the metal
spending increasing amounts of time
as a nonthermionic cathode, with the
associate heat input on the surface
(Refs. 32, 33). The reduction in the
amount of primary carbides with a reduction of Cr and C in the system has
been reported previously (Refs. 15, 18,
22). Although no wear tests were performed for the samples prepared, it is
to be expected that the increase in primary carbides should increase the
wear properties of the chromium carbide surfacing (Refs. 11, 15). Another
effect of decreasing the balance was to
increase the volume fraction of the hypereutectic microstructure, which
should make the wear resistance more
uniform throughout the height of the
cladding.
It is not clear at this time why for
the intermediate value of 60% balance
the dilution departed from the general
trend observed. Metallographic measurements of carbide fraction and size

did not show an equivalent departure
in the trends.
The decrease in size of primary carbides with the reduction of balance
was unexpected, and opposite of what
would be expected from welds with
higher heat input. Other experiments
performed with similar alloy systems
showed very little variation in carbide
size for a wide range of heat inputs.
The effect observed here could be because of an increase in the amounts of
Mo and Si caused by the decrease in
the dilution, as both have been found
to reduce the rate of carbide precipitation, which could lead to the larger
carbides (Refs. 29, 31).
This work did not test the effect of
offset and frequency on the microstructure. Based on previous studies (Ref.
14), it is reasonable to expect that offset
will be of secondary importance (with a
slight decrease in fraction of primary
carbides with an offset biased toward
WELDING RESEARCH
Conclusion
Fig. 11 Longitudinal sections of hardfacing with AC balances between 50 and 75%.
Fig. 12 High magnification of hardfacing with AC balances between 50 and 75%. A

50%; B 55%; C 60%; D 65%; E 70%; F 75%.
This work assessed for the first

time the effect of balance on AC waveform in the SAW of Fe-Cr-C hardfacing. The practical implications of the
findings are very significant because
Fe-Cr-C hardfacing is the most commonly used approach to wear protection in ground engagement equipment
in mining, oil, gas, and logging industries.
The amount of primary carbides increases steadily with a decrease in balance. The cases studied indicated a
primary carbide fraction increase from
3% for a 75% balance to 21% for a
50% balance. This effect is directly related to the decrease in dilution as the
balance decreases.
The size of primary carbides also increased with the reduction of balance,
from a characteristic size of 21.8 mm for
75% balance to 30.3 mm for a 50% balance. This work also showed how the
layered structure of Fe-Cr-C hardfacing
is present in a wide range of balances
and how it can be affected by altering
the balance. Balances of 60% and below
resulted in pure hypereutectic microstructures. A hypereutectic structure
throughout the hardfacing thickness is
expected to help make it reliable with
good wear resistance even at advanced
stages of wear.
Acknowledgments
Table 3 Microstructural Characterization Measurements of Carbides

Balance (%) Total VF Carbide (%) VF Hypereutectic (%) VF Pimary M7C3 (%) Average Diameter (m)
50
45.8
100.0
21
30.3
55
42.7
100.0
20
26.7
60
32.8
100.0
18
24.9
65
37.8
84.8
14
23.0
70
31.4
75.6
9
22.7
75
21.0
40.3
3
21.8
DCEP). No effect is expected with frequency changes until frequencies are so

high that the ramp-up and ramp-down
time is of duration comparable to the
hold time. In this case, heat input would
be reduced, likely resulting in lower dilution and higher carbide fraction. Such
high frequencies are not recommended
though because of the difficulty in controlling the process accurately in that
range.
Somewhat similar effects to the
ones reported here are also expected
by varying the contact tip-to-work-
piece distance (CTWD) while keeping

the same voltage and wire feed speed.
Longer CTWD should have a comparable effect to decreased balance, resulting in a higher carbide fraction.
Adjusting CTWD involves mechanical
adjustments that are often undesirable
in the large equipment typically used
in producing a Fe-Cr-C hardfacing.
Balances below 50% were also considered informally in this work, but
the slag system used was too difficult
to remove, and it was considered impractical for industrial use.
The authors want to acknowledge

the support of Wilkinson Steel and
Metal, Lincoln Electric, and NSERC.
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Zhang Supplement January 2015_Layout 1 12/12/14 10:02 AM Page 8
WELDING RESEARCH
Preliminary Investigation on RealTime Induction

HeatingAssisted Underwater Wet Welding
A unique process that combines induction heating and flux cored
arc wet welding to reduce cooling rates in real time was studied
BY H. T. ZHANG, X. Y. DAI, J. C. FENG, AND L. L. HU
ABSTRACT
A novel realtime induction heatingassisted underwater wet welding process was
investigated. The addition of induction heating could reduce the cooling rate of the
joint in underwater wet welding. The macro and microstructures, mechanical prop
erties such as tensile, impact, and bending properties, and Yslit restraint testing
were studied. The results showed the content of martensite (M) and upper bainite
(BU) phases decreased, while the proeutectoid ferrite (PF) and acicular ferrite (AF)
phases increased as the induction heating voltage increased. Mechanical properties
of the joint were improved through addition of induction heating and fracture mor
phology with characteristic uniform dimples belonging to ductile fracture. The crack
ing ratio of Yslit restraint testing was also decreased. Therefore, the susceptibility to
cold cracking of the wet welding joint was improved.
KEYWORDS
Underwater Wet Welding Induction Heating Microstructure
Property
Introduction
Offshore development has accelerated in recent years owing to the fact
that more than 50% of undeveloped
petroleum deposits are located under
the ocean. In the offshore industry
and in underwater oil and gas
pipelines, underwater welding is already a routine activity (Refs. 1, 2).
The demand for underwater welding
processes that can produce quality wet
welds at greater depths, and on a variety of materials, will continue to increase (Ref. 3).
Underwater welding techniques can
be classified as follows: wet welding,
dry welding, and local cavity welding.
Wet welding occurs directly in aqueous
environments with no mechanical barrier between water and welding arc. It

was established that significant cost
savings and simplicity of the process
makes it possible to weld even the
most geometrically complex structures; therefore, underwater wet welding is of increasing importance (Refs.
4, 5). The most commonly used wet
welding techniques are shielded metal
arc welding (SMAW) (Refs. 6, 7) and
flux cored arc welding (FCAW). It was
acknowledged that wet flux cored arc
welding is promising in the future because of much higher production efficiency and applying in the automatic
welding process (Refs. 8, 9).
In order to meet the requirements
for offshore structures, high-strength
steel (yield strength over 350 MPa) is

required. The strength of the steel used
for offshore structures is a very important factor (Ref. 10). Unfortunately,
high-strength low-alloy (HSLA) steels
usually have carbon equivalents greater
than 0.4% and show poorer weldability.
At the same time, an aqueous environment produces a lot of disadvantageous
effects (Ref. 11), such as the cooling effect of the surrounding water, loss of alloying elements, and considerable
amounts of diffusible hydrogen (Ref.
12). The cooling rate in wet welding is
much higher than in dry welding, such
as in the temperature range from 800
to 500C, it can rise sharply from 56 to
415C/s (Ref. 4). This causes brittle
weld microstructures and high amounts
of hydrogen porosity, which can be
causes of crack formation. Susceptibility
to cold cracking is the main problem in
welding of HSLA steels and fabrication
of dissimilar joints.
Many researchers have attempted
to use special methods to avoid these
adverse effects. Many studies utilized
the temper bead technique (Refs.
1315). A full welding procedure qualification without cracking has been
completed for a base plate having a
carbon equivalent of 0.44. However,
this method is only suitable for repair
of underwater structures, which limits
its application. In addition, insulating
materials (Refs. 16, 17) were used to
control cooling rates in underwater
wet welds. The research, taking into
account the insulating material, developed an empirical relationship to predict the optimized cooling rates and
H. T. ZHANG (hitzht@163.com), X. Y. DAI (hitdxy29@gmail.com), J. C. FENG, and L. L. Hu are with the State Key Laboratory of Advanced
Welding and Joining, Harbin Institute of Technology, Harbin, China; Shandong Provincial Key Laboratory of Special Welding Technology,
Harbin Institute of Technology at Weihai, Weihai, China.
Zhang Supplement January 2015_Layout 1 12/11/14 2:15 PM Page 9
WELDING RESEARCH
A
B
Gun
Fig. 1 Schematic of the assembled device.
Table 1 Chemical Composition of Q460 (not more than wt%)

Base Metal
Si
Mn
Ti
Cr
Ni
Cu
Mo
Q460
0.2
0.6
1.8
0.2
0.2
0.3
0.8
0.55
0.2
times for underwater wet welds. Fox

(Ref. 18) and Pope (Ref. 19) investigated the water temperature and water
depth influences on hydrogen-induced
cracking, microstructure, and mechanical properties in underwater wet
welding, and the importance of water
temperature and water depth, quenching, and diffusible hydrogen levels in
underwater wet welding have been
demonstrated. Postweld heat treatment (PWHT) is frequently used to reduce hardened structure and allow hydrogen to diffuse away from the weld
metal and heat-affected zone (HAZ)
(Ref. 20). Szelagowski (Refs. 21, 22)
used a H2-O2 cutting torch and an underwater high-velocity oxyfuel (UWHVOF) thermal spraying device to
serve as PWHT on wet welds. The hydrogen content of the weld metal was
reduced and the bend testing result
showed a higher plastic property.
However, the control of heat input
could not be accurate and efficient.
In this paper, a novel real-time induction heating-assisted underwater
wet welding process was employed for
the first time. Induction heating could
reduce the cooling rates of the joint in
underwater wet welding, especially the
t8/5 (the cooling time range from 800 to
500C) was extended. According to
welding CCT diagrams, it reduced the
hardened and brittle transformation
products. That is, the content of
martensite (M) and upper bainite (BU)
phases decreased as the content of
proeutectoid ferrite (PF) and acicular
ferrite (AF) phases increased. Therefore,
the purpose of this work was to develop
a novel method to obtain an excellent

quality underwater wet welding joint.
Q460 steel (equivalent to Gr. 65 steel
of AST-USA or E460DD steel of 630ISO) delivered as rolled sections with
the dimensions of 300 90 8 mm was
used as the base metal. The single-V
weld groove had a 60-deg included angle
with a 2-mm root face and 1.5-mm root
opening. The chemical composition of
the sheets is shown in Table 1. Prior to
welding, the oxide layers on the surfaces
of the plates were removed by stainless
steel wire brushing and the weld zone
was degreased using acetone. The asreceived plates were welded together
with the gas tungsten arc (GTA) and
flux cored arc (FCA) welding processes.
GTAW was used for the root pass to fix
the plates with 100-A DC and 20 V in
air. Underwater wet FCAW was used for
the fill passes and optimized welding
parameters are listed in Table 2. TiO2CaF2 type flux-cored wire with a diameter of 1.2 mm produced by Paton Welding Institute was chosen.
A schematic of the assembled device is shown in Fig. 1. The device
could be divided into two sections: underwater welding system and induction heating system. The water in the
tank was stationary and the water
depth was 300 mm. A circular, 60-mmdiameter induction coil was installed
behind the welding gun in the welding
direction and below the plates in the
vertical direction. The welding gun
and induction coil were fixed together
and moved at the same speed. The parameter L defined as the distance
between the center of the coil and the
welding gun was constant. The induction heating source had an output
voltage of 70550 V. Changing the induction heating voltage meant changing the output power due to the constant system impedance. Type-K thermocouples with shielding were placed
at different locations from the edge of
the weld groove to measure the temperature profile. Four-channel data
loggers were used to record the temperature measurements with a sampling frequency of 25 Hz. The measurement method of the HAZ temperature field was as follows: weld HAZ
without installed thermocouples was
first identified to be about 2.0 mm
from the weld interface, then the thermocouples located at or near 2.0 mm
from the weld interface were identified as that representing the HAZ
thermal cycle (Ref. 23).
A CCD camera with a frame rate of
2000 frames/s was used to record images of the arc behavior in order to investigate the effect of the induction
magnetic field. The metallographic
specimens of a typical cross section
were prepared vertical to the weld joint
and all specimens were polished with
SiC papers up to grit 1000, and ultrasonically cleaned with acetone to remove oil and other contaminants from
the specimen surfaces. Etching with 5%
nitric acid and alcohol solution for 34 s
was used to reveal the weld beam. The
macro- and microstructure fracture
morphology were observed by optical
microscopy (OM) and scanning electron
microscopy (SEM), respectively. Mechanical property tests such as tensile
testing, impact testing, and bend testing were investigated to build an empirical relationship between induction heating voltages and mechanical properties.
Results and Discussion

Welding Process Stability
A welding arc is an electric discharge between two electrodes and a
heated and ionized gas, called plasma
(Ref. 24). Therefore, the arc stability
could be adversely affected as a result
of the magnetic field of induction
heating and eddy current. Figure 2
shows the captured images of arc
WELDING RESEARCH
A
Fig. 2 Captured images of arc shape: A Without induction heating; B L = 5 mm,

250 V; C L = 5 mm, 450 V; D L = 20 mm, 250 V; E L = 20 mm, 450 V.
Table 2 Optimized Welding Parameters
Welding Voltage (V)
26
Welding Current (A)
Welding Speed (mm/min) Water Depth (mm)
160
shape with parameter L and induction heating voltages. Due to optimum parameters and flux-cored wire,
the welding arc was steady during the
underwater welding process without
induction heating (Fig. 2A). While the
induction coil was installed, the arc
stability was reduced. It was observed
that the parameter L played a major
role in arc stability. When the parameter L was 5 mm, the welding arc was
extremely unstable and even arc interruption appeared in Fig. 3A. At the
same time, when parameter L was increased to 20 mm, the welding arc
shape was stable. Therefore, a continuous and uniform weld could be observed in Fig. 3B. Welding discontinuities, such as incomplete fusion and
undercut, were not found. In addition, the induction heating voltage affected arc stability and the arc stability decreased with increased voltage.
To investigate the influence of voltage on the joint, the parameter L was
fixed as 20 mm in the subsequent
experiments.
CrossSection Macrographs
Q460 sheets were underwater weld-
145
300
ed at a fixed welding parameter (Table

2) and at various induction heating
voltages ranging from 250 to 450 V in
order to clarify the effect of induction
voltage on weld penetration. Crosssectional macrographs of the joints
with different voltages are shown in
Fig. 4. According to the results, weld
penetration and HAZ increased with
the increasing voltage. As was known,
the width of the HAZ depended primarily on heat input. The heat input
was the sum of welding heat input and
induction heating. Therefore, the effect of induction heating was equal to
increasing the welding heat input. In
addition, the induction heating made
the temperature field of the weld zone
relatively more uniform.
Microstructure Characteristics
of the Joints
The HAZ for Q460 delivered as
rolled sections mainly consisted of two
distinct zones: coarse-grained HAZ
(CGHAZ) and fine-grained HAZ (FGHAZ). Typical HAZ temperature vs.
time profiles during the underwater
wet welding are shown in Fig. 5. Ac-
cording to the results, the cooling rate

in wet welding was extremely higher
than in air welding. For instance, the
cooling rate of the temperature range
from 800 to 500C could rise sharply
to 100C/s, which was more than the
critical cooling speed of martensite
formation.
Figure 6 showed the optical microstructure of the weld zone with
various induction heating voltages.
Based on the theory of welding metallurgy, as the austenite phase was
cooled down from high temperature,
ferrite nucleated at the grain boundary at 770680 and then grew inward. This ferrite was proeutectoid
ferrite (PF), which is also called grain
boundary ferrite (GBF). When the
temperature dropped to 500, the
transformation of acicular ferrite
(AF) occurred. The acicular ferrite
phase was a desirable phase because
of the excellent plasticity and toughness characteristics (Ref. 25). As the
cooling rate increased, the transformation product changed to bainite
and martensite phase and reduced
the mechanical properties. The microstructure of the weld zone in air
welding was composed of proeutectoid ferrite and acicular ferrite phase.
As was mentioned previously, the acicular ferrite phase had excellent plasticity and toughness, due to the interlocking nature of the acicular ferrite
and the fine granular size. Therefore,
the mechanical properties were satisfactory. Compared to air welding, the
microstructure of underwater welding was a mixture of lath martensite,
upper bainite, and proeutectoid ferrite Fig. 6A. The bainite sheaf and
martensite lath nucleated and grew
from prior austenite granular boundaries. The formation of lath martensite and upper bainite were detrimental to the weld properties, owing to
the easy crack propagation paths. As
the induction heating voltages increased (Fig. 6 BD), the volume fraction of lath martensite and upper bainite decreased with ferrite phases increasing. Moreover, the lath martensite and upper bainite phase disappeared as the voltage reached 350 V.
The transformation product (Fig. 6C)
could change from upper bainite and
lath martensite to acicular ferrite and
proeutectoid ferrite. Therefore, the
microstructure of the weld metal was
WELDING RESEARCH
A
Fig. 3 Weld appearances: A L = 5 mm, 250 V; B L

= 20 mm, 250 V.
Fig. 4 Crosssectional macrograph of the joints: A 0 V; B 250 V; C

350 V; D 450 V.
Fig. 5 Measured temperature vs. time curves of under

water wet welding without induction heating.
similar to air weld, the only difference

was the morphology of the proeutectoid ferrite. Increased acicular ferrite
content in the microstructure improved cracking resistance, while upper bainite and lath martensite deteriorated the mechanical properties of
the joint. The dimension of the
proeutectoid ferrite was increased
with the increase in the voltage. As
the voltage was 450 V (Fig. 6D), the
morphology of the proeutectoid ferrite was coarsening and a ferrite side
plate (FSP) was found. Because of the
limited output voltage of the induction heating system, the induction
heating was higher than 450 V, and
the microstructural evolution and
mechanism are to be investigated in
the future.
To understand the mechanism of
weld microstructural evolution, temperature vs. time profiles of different
induction heating voltages without being subjected to welding are shown in
Fig. 7. The parameters of t8/5, for a giv-
Fig. 6 The optical microstructure of the weld zone with various induction
heating voltages: A 0 V; B 250 V; C 350 V; D 450 V; E in air.
en hardenability steel, determined the

hardenability of the transformation
products, which should be taken into
consideration to investigate the effect
on susceptibility to hydrogen-induced
cracking. The data of temperature vs.
time curves are shown in Table 3. As
the induction heating voltage was 250
V, the Tmax reached 412C. Therefore,
the microstructure of Fig. 6B was similar to that shown in Fig. 6A because
the t8/5 determined the transformation
products. As the induction heating
voltage was 350 V, the Tmax was increased to 609C and the t8/5 was prolonged at the same time. Therefore,
the transformation products changed
from upper bainite and lath martensite to acicular ferrite and proeutectoid ferrite due to the fact t8/5 was prolonged. A comparison of temperature
curves of 0 and 450 V is shown in Fig.
8. It could be seen that the prolongation of t8/5 was extremely obvious.
Thats the reason for the evolution of
the microstructure of the weld metal.
Figure 9 showed the optical microstructure of the partially melted

zone with and without induction
heating. The red line was the weld interface of the joint. It could be seen
that lath martensite (M) and coarsening Widmansttten (W) structure was
predominant in the coarse-grained
HAZ in Fig. 9A. The ferrite phase precipitated first in the coarse-grained
austenite grain boundary, and then
grew into the austenite in the form of
reticular structure (also called W
structure), resulting in splitting the
matrix structure, even generating the
crack. And the lath martensite composed of vast coarse lath was beneficial for crack initiation and propagation. Therefore, the mechanical properties of the joint were decreased.
However, as the voltage was 350 V,
granular bainite was predominant
and grain coarsening was relieved.
Thus, the tendency to crack was decreased, and the mechanical properties of the joint were increased.
WELDING RESEARCH
Fig. 8 Compared temperature vs. time curves during un

derwater wet welding with various induction heating volt
ages.
Fig. 7 Temperature vs. time profiles of different induc

tion heating voltages without being subjected to welding.
Fig. 9 The optical microstructure of the weld interface: A 0 V; B 350 V.
Table 3 The Data of Temperature vs. Time Curves

Induction Heating Voltages (V)
250
350
450
Mechanical Properties
Tensile Testing and Fracture
Morphology
Five prepared tensile specimens
from each joint were performed using
a fully computerized tensile testing
machine with a loading rate of 1
mm/min at room temperature to evaluate the influence of various induction
heating voltages on the mechanical
properties of the joint. The geometry
of the tensile specimens and tensile
strength vs. voltage curves are shown
in Fig. 10. The thickness of the specimen was 4 mm. The tensile strength
Tmax(C)
t8/5 (s)
412
609
712
0
24
35
of specimens without induction heating was 444 MPa, about 82.2% of the
base metal (540 MPa). The tensile
property increased gradually with increasing voltages. As the voltage was
450 V, the tensile strength reached
532 MPa, about 98.5%, and all the
joints fractured roughly in the HAZ.
Joint efficiency increased from 82.2 to
98.5%.
In order to observe the fracture
mechanism, SEM was carried out to analyze the fracture morphology. Figure
11 shows the typical fracture surface of
specimens with different voltages. It
can be seen that a quasi-cleavage fracture mode was dominant in Fig. 11A,
due to plenty of cleavage plane appear-
Fig. 10 Tensile strength vs. induction

heating voltage curves.
ance. The size of the cleavage plane was

related to the crack path. The large
cleavage planes demonstrated very low
crack propagation energy, while the
small cleavage plane exhibited higher
crack propagation energy (Ref. 26). The
formation of lath martensite and W
structure in the HAZ was detrimental to
tensile property due to the easy crack
propagation paths. Once the crack occurred during the tensile test, it could
propagate along the paths of lath
martensite and W structure rapidly.
Therefore, tensile strength without induction heating was the lowest. The
dimple characteristics became predominant as the voltage was increased in Fig.
11BD. Cleavage planes were in small
proportion while dimples were in large
proportion, as shown in Fig. 11B.
Therefore, the fracture morphology had
the characteristic of ductile fracture.
While the voltage was above 350 V, the
cleavage planes disappeared, instead of
uniform dimples, which was the typical
feature of ductility. Nonmetallic inclu-
WELDING RESEARCH
A
Fig. 12 Impact energy vs. induction heating voltage

curves.
Fig. 11 SEM images of the fractured surface of specimens with

various voltages: A 0 V; B 250 V; C 350 V; D 450 V.
sions phase were disorderly distributed

in the inter-tear edges. Hence, tensile
property of the joints improved to
about 98.9% of the base metal.
Impact Testing and Fracture

Morphology
Charpy V-notch impact tests were
conducted at 20C on an instrumented
drop weight impact tester. The specimens were extracted in the welds perpendicular direction from the middle
thickness of the as-welded specimen
with notches positioned at the center
of the weld metal. The impact energy
of the joints was the average of five
specimens. The geometry of the
Charpy impact V-notch specimens and
impact energy vs. induction heating
voltage curves are shown in Fig. 12.
The thickness of the specimen was 10
mm. The impact energy value of specimens without induction heating was
36 J. As the voltage increased, the impact energy increased consistently. Finally, as the voltage was 350 V, the impact energy could reach 68 J. The results suggested that induction heating
could increase the impact properties
and the toughness of the joint.
For the purpose of observing the
fracture mechanism, SEM was used to
analyze the fracture

C
morphology. Figure 13
shows the SEM micrographs of impact fracture surface morphologies for different voltages. It can be seen that
a cleavage fracture mode
is dominant in Fig. 13A,
due to a network of
Fig. 13 SEM images of the fractured surface of specimens
cleavage steps known as
with various voltages: A 0 V; B 250 V; C 350 V.
a river pattern. Cleavage
was a low-energy fracpresent in large proportion. The apex
ture that propagated along wellof the fan points back to the fracture
defined low-index crystallographic
origin. While the voltage was 350 V,
planes known as cleavage planes. The
the cleavage planes disappeared, inbranches of the river pattern joined
stead of uniform dimples, which was
in the direction of crack propagation.
the characteristic of ductile fracture.
Meanwhile, the formation of lath
Some nonmetallic inclusions phase
martensite and upper bainite was adshowed in a disorderly distribution
verse to the toughness of the joint
and were surrounded by the interdue to the easy crack propagation
tear edges. The reason for these repaths. Once the crack occurred, it rapsults was that the acicular ferrite actidly propagated in a straight line
ed as the crack arrester and increased
along the lath martensite and upper
the crack propagation energy. Therebainite paths. Therefore, the impact
fore, the impact property of the joints
energy value without induction heatwas greatly improved from 36 to 68 J.
ing was the lowest. However, the dimples started to appear and were presBend Testing
ent in small proportion when the
voltage was at 250 V in Fig. 13B.
Longitudinal three-point bend tests
Feather markings, which are a fanwere conducted to measure the bending
shaped array of very fine cleavage
ductility at room temperature. The ansteps on a large cleavage facet, are
WELDING RESEARCH
Fig. 15 Schematic of Yslit selfrestrained cracking test (mm).

Fig. 14 Angle of bending vs. induction heating voltage
curves.
gle of bending for the joints was the average of three specimens. The geometry
of the specimens and angle of bending
vs. induction heating voltage curves are
shown in Fig. 14. The thickness of the
specimen was 5 mm. According to the
results, the angle of bending values of
specimens without induction heating
was 21 deg, which indicated ductility
was very low. At the same time, the angle of bending values increased rapidly
with increasing voltages. Finally, as the
voltage was 450 V, the angle of bending
values reached 88 deg. The results suggested joint ductility had been
increased.
YSlit Restraint Testing

Because of the high quenching rate
caused by the water environment and
because large quantities of hydrogen are
present, hydrogen cracking is one of the
most severe problems in the underwater welding of steel (Ref. 27). The cracking tests were carried out using a Y-slit
restraint test so that the intensity of the
restraint could be related to actual fabricating conditions. The geometry of
specimens subjected to Y-slit restraint
testing and the cracking ratio used as a
measure of the cracking susceptibility
are shown in Fig. 15. This is a ratio of
the height from the root to the tip of
the crack vs. the height from the root to
the surface of the weld metal.
The cracking ratio vs. induction heating voltage curves are shown in Fig. 16.
The carbon equivalent value of Q460
steel was 0.6, which indicated the steel
was particularly sensitive to cracking,
especially in underwater welding.
Therefore, the cracking ratio of specimens without induction heating was

82%. However, as the voltage reached
150 and 250 V, the cracking ratio decreased rapidly to 45% and 22%, respectively. Finally, when the voltage was
above 350 V, the cracking ratio reached
about 10%. Typical weld cross sections
with various induction heating voltages
are shown in Fig. 17. According to the
results, induction heating could reduce
the cooling rate; therefore, the cracking
susceptibility was decreased.
Microhardness Profile
Vickers microhardness measurement
across the fusion zone was carried out
with a load of 100 g and load time of 10
s. Results of hardness measurements
are shown in Fig. 18. The microhardness distribution indicated the microstructural characteristics of the joint.
Increased hardness values of the weld
metal confirmed these microstructural
changes. The location of the HAZ was
determined by metallographic observation and the hardness of the HAZ was
higher than that of the weld metal. The
HAZ and weld metal hardness decreased with increased induction heating voltage. The maximum hardness of
HAZ without induction heating was 425
HV, which was much harder than that
with 250 and 450 V. The hardness values of the weld zone with 250 and 450
V were relatively uniform because the
lath martensite and upper bainite cotent decreased while the acicular ferrite
and proeutectoid ferrite increased. The
results indicated induction heating had
a significant effect on the maximum
hardness. The microhardness profile
across the weld indicated the microstructural characteristics of the joint.

Induction heating made the joint microhardness relatively more uniform.
Conclusion
1) A novel real-time induction heating-assisted underwater wet welding
process was employed. The addition of
induction heating could reduce the cooling rate of the joint in water environment to improve the microstructural
and mechanical properties of the joint.
2) Arc stability was reduced with the
addition of induction heating. The parameter L played a major role in arc stability. As the parameter L increased to
20 mm, the welding arc shape was stable. A continuous and uniform weld
joint could be observed.
3) The content of martensite (M)
and upper bainite (BU) phases decreased while the proeutectoid ferrite
(PF) and acicular ferrite (AF) phases increased as the induction heating voltage
increased. Mechanical properties, such
as tensile, impact, and bending properties, increased as the induction heating
voltages increased.
4) Cracking was examined via a Y-slit
restraint test. The addition of induction
heating could decrease the cracking ratio from 82 to 10%. Therefore, induction heating could make cracking susceptibility decrease.
References
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Science and Technology of Welding and Join-
WELDING RESEARCH
A
Fig. 16 Cracking ratio vs. induction heating voltage

curves.
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heating voltages: A 0 V; B 150 V; C 250 V; D 350 V.
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WELDING RESEARCH
Gas Metal Arc Welding of Magnesium Alloys:

Oxide Films, High Crowns, and Fingers
Sound welds can be made but precautions need to be taken against these defects,
whose mechanisms of formation are established and methods of mitigation demonstrated
BY X. CHAI, Y. K. YANG, B. E. CARLSON, AND S. KOU
ABSTRACT
The use of Mg alloys for vehicle weight reduction has been increasing rap
idly worldwide. Gas metal arc welding (GMAW) has the potential for mass
production welding of Mg alloys. Recently, the University of Wisconsin
demonstrated in beadonplate GMAW of Mg alloys that: 1) the issue of se
vere spatter, which has long delayed the use of GMAW for Mg alloys, can be
eliminated by using controlled short circuiting (CSC), and 2) the issue of
severe hydrogen porosity can be eliminated by removing Mg(OH)2, which
forms on the welding wire surface over time. The present study aimed at ac
tual butt and lap joint welding of Mg alloys by CSCGMAW. The most widely
used wrought Mg alloy AZ31 Mg (~Mg3Al1Zn0.2Mn) was welded by CSC
GMAW. Sound welds were made without spatter and hydrogen porosity,
with butt joint welds approaching 100% of the basemetal strength.
However, three new significant issues were found to occur easily and
degrade the weld quality significantly: 1) formation of oxide films inside butt
joint welds, 2) formation of high crowns on butt joint welds, and 3)
formation of fingers from lap joint welds. These three new issues, like the is
sues of spatter and porosity investigated previously, were caused mainly by
the unusual physical and chemical properties of Mg, rather than the welding
process itself. These properties include the low liquid density, low solid
deformability, low liquid fluidity, and high oxygen affinity of Mg. The mecha
nisms of their formation were established, and the methods for their elimi
nation or reduction were demonstrated.
KEYWORDS
Mg Alloys Gas Metal Arc Welding (GMAW) Controlled Short
Circuiting (CSC) Butt Joint Welds Lap Joint Welds
Introduction
The automotive industry has been
using lighter structural materials including magnesium alloys (Refs. 1, 2)
to reduce vehicle weight, fuel consumption, and emissions. Being one-
third lighter than aluminum (Al), magnesium (Mg) is the lightest metallic
structural material with excellent specific strength (Ref. 3). Due to the rapidly increasing use of Mg alloys (Refs.
13), research interest in Mg welding
has grown rapidly as can be seen in re-
views on recent Mg welding research

(Refs. 47). Spatter has long delayed
the use of gas metal arc welding
(GMAW) for Mg alloys. Spatter is the
metal particles expelled during fusion
welding that do not form a part of the
weld (Ref. 8). It is caused by the expelling of filler metal droplets from
the arc during welding. Severe spattering can result in a messy weld irregular
in shape, with significant variations in
the weld width and penetration depth.
Fifty percent or more loss of the Mg
filler metal by spattering has been reported (Refs. 5, 9).
Lockwood (Ref. 10) pioneered the
GMAW of Mg alloys. He found that
spray transfer at high welding currents
produced too much heat for welding
thin Mg sheets, and globular transfer
was unstable and caused spattering.
So, he used short-circuit transfer to
weld sheets from 1.0 to 3.2 mm (0.04
0.125 in.). The resultant welds showed
rather high crowns. Lockwood (Ref.
11) also tried pulsed-arc welding at intermediate currents, where one small
droplet was transferred per pulse.
Rethmeier et al. (Ref. 12) welded AZ31
Mg and AZ61 Mg alloys by shortcircuiting GMAW, and welds with high
crowns were shown.
Mg alloys have been welded by gas
tungsten arc welding (GTAW) (Ref.
13), laser beam welding (LBW) (Refs.
6, 14), electron beam welding (EBW)
(Ref. 15), friction stir welding (FSW)
(Ref. 16), and double-sided plasma arc
welding (DSPAW) (Ref. 17). Gas tungsten arc welding is slow, LBW and
X. CHAI is a graduate student, Y. K. YANG was a postdoc, and S. KOU is a professor with the Department of Materials Science and Engineering, the University
of Wisconsin, Madison, Wis. B. E. CARLSON is with the Manufacturing System Lab, General Motors Research and Development Center, Warren, Mich.
WELDING RESEARCH
A
A
Fig. 1 Specimen for tensile testing in

the transverse direction of a butt joint
weld. A Top view; B side view.
EBW are not readily available, and

DSPAW can be inconvenient. Friction
stir welding requires rigid clamping
and the use of an anvil, and can be
complicated for making fillet welds.
Gas metal arc welding, if it can be used
for Mg alloys, is readily available, inexpensive and easy to use, and it combines good weld quality, high production rate, and easy automation.
Recently, the University of Wisconsin demonstrated the elimination of
spatter in GMAW of Mg alloys by using controlled short circuiting (CSC)
(Ref. 18). In CSC-GMAW, a process
controller coordinates the feeding and
speed of the wire electrode with the
level of welding current delivered by
the power source (Ref. 19). The controller monitors the voltage between
the electrode and the workpiece to determine if the welding process is in the
arc phase or the short-circuiting phase
at any given time. The controller clears
the short by retracting the wire to the
preset arc length level. Once the arc is
established again, the controller begins feeding the wire toward the weld
pool, and the cycle repeats. CSCGMAW was originally developed and
called CSC-MIG by Miller Electric
Manufacturing Co. and subsequently
manufactured by Jetline Engineering,
Irvine, Calif. This was the first application of CSC-GMAW to Mg alloys.
The mechanism of spatter in conventional GMAW of Mg alloys was established by examining the metal
transfer by high-speed video recording
at 4000 frames/s and analyzing the
waveforms of current and voltage
recorded during welding (Ref. 18). Essentially, the low Mg density makes
the Mg welding wire both fast melting
and difficult to detach by gravity. The
excessively large globule finally touches the weld pool to short circuit. This
Fig. 2 Specimen for tensile testing in

the transverse direction of a lap weld. A
Top view; B side view.
causes a sudden current surge, which

in turn causes the arc to suddenly expand during reinitiation and expel the
large globule as severe spatter. In CSCGMAW, however, the current is always
under tight control, and there is no
current surge to cause spatter.
Severe hydrogen porosity, though
not reported previously in GMAW of
Mg alloys, was observed in both conventional GMAW and CSC-GMAW
(Ref. 18). It was demonstrated that
porosity can be eliminated by cleaning
the Mg welding wire surface with
sandpaper or baking it in air at 380C
for 11 min before welding. The mechanism of porosity formation in Mg
GMAW was also established by using
X-ray diffraction to identify the presence of Mg(OH)2 on the welding wire
that caused porosity and by using the
solubility curve of H in Mg. Essentially, with its large surface area per unit
volume, a welding wire covered with
Mg(OH)2 can carry a significant
amount of Mg(OH)2 into the arc,
where it decomposes by Mg(OH)2
MgO + H2O. The H2O further decomposes to hydrogen to dissolve in Mg(L)
as H. Since Mg(S) can dissolve much
less H than Mg(L), it rejects H to form
a H-rich liquid layer at the solidification front, where the reaction 2H
H2(g) can occur and form hydrogen
bubbles. The low Mg density slows
down the rise of the bubbles to escape
from the weld pool.
The purpose of the present study
was to actually butt and lap joint weld
Mg-alloy sheets together by CSCGMAW. In the previous study (Ref.
18), bead-on-plate welding was used to
demonstrate the elimination of spatter and hydrogen porosity from Mg
welds by CSC-GMAW. As will be
shown, other defects can form in actual butt and lap joint welding of Mg al-
Fig. 3 Waveforms of welding current

and voltage recorded during welding of
weld G011. A Overview; B enlarged.
loys even though spatter and hydrogen

porosity can be eliminated.
Materials
The workpiece was AZ31B-H24 Mg
(~Mg-3Al-1Zn-0.2Mn) sheets 203 mm
long (rolling direction), 76 mm wide,
and 1.6 mm thick (8 by 3 by 116 in.).
They were cut from a larger sheet by
shearing, which is common practice
for preparing metal sheets for welding.
The filler metal was AZ61A Mg (Mg6Al-1Zn-0.33Mn) 1.2 mm in diameter.
The standard welding grade Ar
(99.95% purity) was used as the
shielding gas.
All sheets were welded in the length
direction (203 mm), that is, the rolling
direction. Prior to welding, the surfaces of the workpiece were degreased
with acetone, cleaned with a stainless
steel brush to remove surface oxides,
and then cleaned, including the edges,
with acetone again. The filler metal,
WELDING RESEARCH
on the other hand, was cleaned with
acetone, 240-grit sandpaper followed
by 600-grit sandpaper, and then acetone again (Ref. 18).
Butt Joint Welding

The welding system consisted of a
Miller Electric Invision 456P as the
power source and a Jetline Engineering
CSC-MIG weld process controller. The
welding position was flat and the welding gun was vertical with a distance of
13 mm (12 in.) between the contact tip

and workpiece. Tables 1 and 2 show examples of the values that can be assigned to the parameters defining the
welding current and wire feed speed, respectively (Ref. 18). Tables 3 and 4 show
the values assigned to the parameters
defining the welding current and wire
feed rate for butt joint welds made with
a root opening below 1 mm (0, 0.5, and
0.75 mm). Tables 5 and 6 show similar
values for butt joint welds made with a
root opening of 1 or 1.2 mm.
Table 1 Parameters Related to Welding Current in CSCGMAW
A
R
C
Start
Mid
End
Current (A)
150
310
110
S
H
O
R
T
Start
Mid
End
Current (A)
90
110
90
Rise (A/ms)
Fall (A/ms)
Times (ms)
4.0
20.0
Times (ms)
4.0
8.0
500
500
ms: milliseconds.
Table 2 Parameters Related to Wire Feed Speed in CSCGMAW

18.5
0.0
15.0
0.0
15.0
0.0
0.8
Down WFS (MPM) (Increasing the down WFS will decrease the deposition rate)
Delay before wire down (ms) (Pause time at arc length)
Up 1 WFS (MPM) (Retract WFS until the short is cleared)
Delay before wire up (ms) (Pause time in the short) (Wire stopped)
Up 2 WFS (MPM) (Retract WFS after the short is cleared until the arc length is met)
Arc length (mm) (The distance that the wire will retract after the short has cleared)
Penetration delay (ms) (After a short is detected, the wire continues forward until time out)
As shown in Tables 7 and 8, the travel speeds were 7.6, 11.0, or 14.4 mm/s
(18, 26, or 34 in./min). The groove in
the steel backing plate was 0.44, 0.65, or
1.18 mm deep. The transverse crosssections of the resultant welds were examined by optical microscopy.
Lap Joint Welding

The upper sheet was 76 mm wide
and 203 mm long (rolling direction),
and the lower sheet 92 mm (358 in.) wide
and 203 mm long (rolling direction),
both 1.6 mm thick. The overlapping was
15.88 mm (58 in.). A mild steel plate with
a groove 1.0 mm (0.04 in.) deep and 9.5
mm (0.375 in.) wide was used as a backing plate for welding. All welds were
made with the joint directly on top of
the groove except for weld #031, which
was made on the same backing plate
without a groove. The welding position
was flat and the torch was either vertical or tilted 10 deg to a point toward the
upper sheet, with a distance of 15.88
mm between the contact tip and upper
sheet. The lateral position of the welding wire tip varied from slightly within
the upper sheet to slightly within the
lower sheet. The travel speed was either
7.62 or 10.2 mm/s (18 or 24 in./min).
Similar to butt joint welding, lap joint
welding was conducted along the rolling
direction of AZ31 Mg.
In both butt and lap joint welding,
the waveforms of the welding current
and voltage were recorded using a
computer data-acquisition system together with the software LabView. The
data-sampling rate for each signal was
15,000 Hz. The average power input
was determined by integration of the
product of current and voltage and division over the whole welding time.
Mechanical Testing
Tensile testing of the resultant
WFS: wire feeding speed; MPM: meters per min; ms: milliseconds.
Table 3 Welding Current Settings for Butt Joint Welding with an Opening < 1 mm
Current
Start
Current
Time
(A)
(ms)
Arc Time
Mid
Current
Time
(A)
(ms)
End
Current
Time
(A)
(ms)
50
2.0
60
7.0
50
n/a
Rise Rate of Current (A/ms): 250; Fall Rate of Current (A/ms): 250
ms: milliseconds.
Start
Current
Time
(A)
(ms)
70
2.0
Short Circuit Time

Mid
Current
Time
(A)
(ms)
70
2.5
End
Current
Time
(A)
(ms)
64
n/a
WELDING RESEARCH
C
D
Fig. 4 Tensile test results of sound

butt joint welds.
E
welds was conducted. The purpose was
to understand the effect of various defects on welds instead of documenting
the mechanical properties of Mg
welds. Specimens for tensile testing
were prepared in the transverse direction of the welds, that is, normal to
the rolling direction.
Figures 1 and 2 show sketches of the
butt-joint and lap-joint weld specimens,
respectively. The gauge length for all the
tensile specimens was 80 mm, and all
tensile tests were conducted with weld
crown on. For the purpose of comparison, specimens of 152 by 25.4 by 1.6
mm were also prepared from the same
AZ31B-H24 Mg sheets used for welding, with the length direction (152 mm)
normal to the rolling direction. Thus,
the weld specimens and base-metal
specimens were both pulled normal to
the rolling direction. For all the tests
conducted, the tensile stress was based
on the cross-sectional area of 25.4 by
1.6 mm and the value for each weld was
the average value of three or more tensile test specimens cut from the same
weld. A MTS model Sintech 10/GL tensile testing machine was used. The
crosshead movement speed was set at 5
mm/min (0.2 in./min).
Result and Discussion

Butt Joint Welding
Tables 7 and 8 summarize the welding conditions and tensile testing results of the butt joint welds made in
the present study. Examples of the
Fig. 5 Entrapment of oxide films in weld 002. A Rough edge caused by shearing;
B top view of weld; C transverse cross section of weld; D tensile test curves; E
side views of tensile tested specimens; F fracture surface of specimen 5 showing en
trapped oxide films and air holes.
Table 4 WireSpeed Settings for Butt Joint Welding with a Root Opening < 1 mm
Wire Speed
Down
Wire
Down
Speed
(MPM)
6.8
Delay
before
Wire Down
(ms)
4
Up 1
Up 2
Wire Up 1
Speed
(MPM)
Delay
before
Wire Up (ms)
Wire Up 2
Speed
(MPM)
Arc Length
(mm)
Penetration
Delay (ms)
6.8
6.8
0.0
0.8
MPM: meters per min, ms: milliseconds.
waveforms of the welding current and

voltage are shown in Fig. 3, which
were recorded during the CSC-GMAW
of weld G011.
The current settings are shown in
Tables 3 and 5, the wire-speed settings
in Tables 4 and 6, and the welding conditions in Tables 7 and 8. The welds
were free of spatter as will be shown
subsequently. They were also free of
hydrogen porosity. Hydrogen pores,
when they are present, often reach the

weld top surface as open holes (Ref.
18). This confirms the previous study
based on bead-on-plate welding that
CSC can help eliminate spatter in
GMAW of Mg alloys and that cleaning
the filler metal with sandpaper to remove Mg(OH)2 can help eliminate hydrogen porosity (Ref. 18). As mentioned previously, the workpiece surface in the welding area was also
WELDING RESEARCH
Fig. 6 Assheared edges of 1.6mmthick sheets. A Rough edge of AZ31B Mg (~Mg

3Al1Zn0.2Mn) showing chipping near bottom of edge; B smooth edge of 6061 (~Al
1Mg0.6Si) showing no chipping. Hexagonal closepacked (hcp) structure, with fewer slip
planes available, is less deformable than facecentered cubic (fcc) structure.
strength of a sound weld can be close

to that of the base metal (290 MPa) as
shown in Fig. 4. The compositions of
the welds were calculated based on the
dilution and the compositions of the
workpiece and filler metal. The dilution is defined as the percentage of the
melted base metal in the weld metal,
that is, the extent the filler metal is diluted by the base metal (Ref. 20).
For weld 007, the dilution is about
44%, and the weld metal composition
is thus Mg-4.7Al-1Zn-0.27Mn. As for
weld #008, the dilution is 41% and the
weld metal composition is thus Mg4.8Al-1Zn-0.28Mn. The joint ductility,
about 8 to 9% elongation before failure, is well below that of the base metal (29%). The tensile tested base-metal
specimen showed clear necking (i.e., to
less than the initial width of 25.4 mm)
near the mid length of the specimen.
Obviously, in the weld specimen such
necking is hindered by the top and
bottom reinforcements of the weld. In
fact, the weld and its surrounding area
bent and were no longer flat though
still straight. In the study by Song et
al. (Ref. 21) on butt joint welding of 3mm-thick AZ31 Mg sheets by ACpulsed GMAW, a high strength level
close to that of the base metal was also
reported and the elongation before
failure varied from 6 to 9%.
Although sound butt joint welds
can be made, precautions need to be
taken to avoid two defects that have
not been discussed or even noticed or
observed previously in GMAW of Mg
alloys: 1) entrapped oxide films, and 2)
high crowns. As found in the present
study, they tend to form very easily
and they can degrade the weld quality
significantly, especially the ductility.
These issues and the methods to deal
with them are discussed below.
Issue 1: Entrapment of Oxide Films
Fig. 7 Mechanism and elimination of oxidefilm entrapment. A Mechanism; B

elimination by milling edges after shearing; C elimination by leaving an opening.
cleaned before welding.

Tensile testing results of the specimens prepared from the butt joint
welds show that good weld quality can
be achieved by CSC-GMAW. Except in
the presence of defects such as entrapped oxide films and air in the fu-
sion zone, which will be discussed subsequently, failure occurred outside the
fusion zone along the fusion boundary.
Sound welds can be made without
entrapments of oxide films and without a high crown. The average joint
It was observed that oxide films can

be very easily trapped in the fusion
zone. However, entrapment of oxide
films and air is mainly caused by the
combination of unusual physical properties of Mg rather than the welding
process used, as will be explained subsequently.
Figure 5 shows weld 002, which was
made with the as-sheared faying surfaces (Fig. 5A) in contact with each
other to form a butt joint. The top sur-
WELDING RESEARCH
Fig. 8 Folded oxide film as a potential site of crack initiation. A Schematic illustra
tion of transverse crosssection of fusion zone; B, D schematic fracture surfaces; C, E
fracture surfaces of tensile tested specimen (butt joint weld 051) confirming exis
tence of bifilm.
face (Fig. 5B) shows the weld is free of

spatter or open holes caused by hydrogen porosity. The transverse crosssection of the weld (Fig. 5C) shows a
toe angle of about 135 deg, which is
the angle between the crown and
workpiece top surface. The tensile test
curves (Fig. 5D) show that the ductility (elongation before failure) scatters
significantly from specimen to specimen of the same weld, from about 9%
in specimen 4 to 7% in specimen 5 and
6% in specimen 2. The tensile test
curve of specimen 1 is similar to that
of specimen 4 but not included because of accidental slippage at the beginning of tensile testing. It should be
pointed out that elongation in a transverse tension specimen does not give
an accurate assessment of ductility
due to the geometry of the weld itself
and the differences in strength of the
base metal, weld metal, and heat-affected zone. The elongation at failure
shown in Fig. 5D and subsequent figures is not meant to represent the actual weld ductility but just for comparing the levels of ductility of different
welds.
The side views of the tensile-tested
specimens (Fig. 5E) show the locations
of failure. Specimens 2 and 5 failed inside the fusion zone while the rest of
the specimens failed outside the fusion zone along the weld, that is, in
the partially melted zone (Ref. 20).
The fracture surface of specimen 5
(Fig. 5F) shows entrapped oxide films
in the fusion zone along the welding
direction. The left side of the fracture
surface corresponds to the photo of
specimen 5 shown in Fig. 5E. As
shown, air can be entrapped inside the
oxide films. The gas holes are air holes
because there was no hydrogen on the
faying surfaces during welding to
cause hydrogen porosity. The faying
surfaces were welded shortly after
preparation and cleaned with acetone
before welding. Oxide films were also
observed on the fracture surface of
specimen 2 (not shown). Thus, it is
clear from Fig. 5 that oxide films in the
Table 5 Current Settings for Butt Joint Welding with a Root Opening of 1.0 or 1.2 mm
Weld
#
Arc Time
Start
Current
Time
(A)
(ms)
Mid
Current Time
(A)
(ms)
Short Circuit Time

End
Current Time
(A)
(ms)
G001
45
4.0
55
6.0
45
G002
60
4.0
50
6.0
60
G003
42
4.0
52
6.0
42
G004
42
4.0
52
6.0
42
G005
41
4.0
51
6.0
41
G006
41
4.0
51
6.0
41
G007
40
4.0
50
6.0
40
G008
40
4.0
50
6.0
40
G009
38
4.0
48
6.0
38
G010
38
4.0
48
6.0
38
G011
37
4.0
47
6.0
37
Rise Rate of Current (A/ms): 250; Fall Rate of Current (A/ms): 250
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Start
Current Time
(A)
(ms)
70
70
70
70
70
70
70
70
70
70
70
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
Mid
Current Time
(A)
(ms)
70
70
70
70
70
70
70
70
70
70
70
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
2.5
2.5
End
Current
(A)
64
64
64
64
64
64
64
64
64
64
64
Time
(ms)
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
ms: milliseconds.
WELDING RESEARCH
fusion zone along the welding direction
can significantly decrease the ductility.
A
Mechanism of OxideFilm Entrapment

In order to understand how oxide
films are entrapped in butt joint welds
of Mg alloys, the faying surfaces before
welding were examined.
Figure 6 shows the as-sheared edges
of an AZ31Mg sheet and a 6061 Al
(~Al-1Mg-0.6Si) sheet, both prepared
with the same shear. Chipping is evident near the bottom of the AZ31 Mg
edge (Fig. 6A), which makes the lower
portion of the edge rough. Chipping
was observed on all sheared edges, parallel or normal to the rolling direction,
and welds were made parallel to the
rolling direction. The hexagonal closepacked (hcp) structure of Mg and its
alloys does not provide many slip
planes for plastic deformation (Ref.
22). Unable to deform much plastically, Mg sheets tend to chip off during
shearing. No chipping is visible on the
as-sheared 6061 Al edge (Fig. 6B). Unlike Mg, the face-centered cubic (fcc)
structure of Al and its alloys provides
more slip planes for plastic deformation to occur more easily.
The mechanism of oxide-film entrapment in butt joint welding of assheared Mg sheets is proposed in Fig.
7. When two as-sheared rough edges
are put together to form a butt joint,
an air channel exists between the lower portions of the faying surfaces (Fig.
C
D
F
Fig. 9 Elimination of oxide films from weld 007. A Milling of edge after shearing; B
top view; C transverse cross section; D tensile test curves; E top view of specimen 5
showing fracture along fusion boundary; F side views of tensile tested specimens. Unlike
weld 002 (Fig. 5), no specimens here show significant ductility reduction caused by oxide
films.
Table 6 WireSpeed Settings for Butt Joint Welding with a Root Opening of 1.0 or 1.2 mm
Wire Speed
Down
Up 1
Weld
#
Wire
Down
Speed
(MPM)
Delay
before
Wire Down
(ms)
Wire Up 1
Speed
(MPM)
Delay
before
Wire Up
(ms)
G001
G002
G003
G004
G005
G006
G007
G008
G009
G010
G011
15
15
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
0
0
4
4
4
4
4
4
4
4
4
15
15
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
0
0
6
6
6
6
6
6
6
6
6
MPM: meters per minute, ms: milliseconds.
Up 2
Wire Up 2
Speed
(MPM)
Arc
Length
(mm)
15
15
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
Penetration
Delay
(ms)
0
0
0
0
0
0
0
0
0
0
0
WELDING RESEARCH
7A). The channel is inaccessible by

the Ar shielding gas from the torch
above the workpiece. During welding
the faying surfaces ahead of the weld
pool are heated up. The tendency for
metals to oxidize is shown by the
Ellingham diagram for oxides (Ref.
23), which is a plot of the free energy
of oxide formation vs. temperature.
The Ellingham diagram shows that
Mg is one of the metals with the
strongest tendency to oxidize,
stronger than Al (Ref. 23). The combination of air, heating, and the very
high oxidation tendency of Mg causes
oxide films to form on the faying surfaces ahead of the weld pool. Because
of the very low density of Mg, the oxide films and air bubbles entrapped in
the weld pool may not be able to rise
quickly and escape from the weld
pool. The air channel can be avoided
as shown in Fig. 7B and C, which are
discussed subsequently.
Figure 8 explains how an entrapped oxide film can cause premature failure of a weld. A folded oxide
film present along the central plane
of the fusion zone can provide a very
sharp notch to initiate crack under
tension Fig. 8A. The resultant two
fracture surfaces should each show
the presence of an oxide film Fig.
8B, D. This is confirmed by the actual
fracture surfaces of the tensile-tested
E
D
Fig. 10 Elimination of oxide films from weld 008. A Rough edge caused by shearing;
B top view of weld; C transverse cross section; D tensiletesting curves; E side
views of tensile tested specimens. Unlike weld 002 (Fig. 5), no specimens here show sig
nificant ductility reduction caused by oxide films.
Table 7 Summary of Butt Joint Welds Made with a Root Opening < 1 mm
Weld
#
002
Butt Joint
Power
(W)
1.18mm groove;
922
no root opening
007
1.18mm groove
885
milled at; no root opening
008
1.18mm groove;
903
0.75mm root opening
047
0.77mm groove;
932
0.5mm root opening
049
0.77mm groove;
902
0.5mm root opening
051
0.77mm groove;
895
0.5mm root opening
052
0.77mm groove
841
053
0.77mm groove
874
054
square groove
877
056
1.18mm groove;
no root opening
971
AZ31B base metal
Travel Speed
(in./min)
Weld Penetration
UTS
(MPa)
Elongation
(%)
% Base
Metal UTS
18
full
275.7
7.3
94.8
18
full
283.2
8.8
97.6
18
full
285.8
8.2
98.4
34
full
273.5
6.5
94.2
26
full
269.7
5.2
92.9
18
full
261.9
4.6
90.2
18
full
263.5
4.1
90.8
26
full
260.1
4.1
89.6
34
full
246.5
3.1
84.9
18
full
290.3
29.4
100.0
WELDING RESEARCH
specimen of a butt joint weld (Fig. 8C,
E), that is, specimen 3 of weld 051 (to
be shown discussed subsequently).
Note that the oxide films on the two
fracture surfaces are nearly exact mirror images of each other.
Campbell (Ref. 24) reported that
oxide films can significantly degrade
metal castings. He showed how oxides
films can be introduced into the bulk
liquid metal just by pouring the liquid
metal into a crucible. For instance, the
oxide films covering the surface of the
liquid metal already in the crucible can
be pushed into the bulk liquid metal
by the stream of liquid metal still being poured into the crucible. When an
oxide film is folded, it can provide a
very sharp notch to significantly degrade the resultant casting. Campbell
(Ref. 24) called this double film defect
a bifilm as a convenient short-hand
to emphasize its double nature. The
faying surfaces in butt joint welding
might be a potential source for bifilms
to form along the weld central plane
and degrade the resultant weld. The
fact that the oxide films on the two
fracture surfaces of the tensile tested
specimen (Fig. 8C, E) are nearly exact
mirror images of each other suggests
the presence of bifilms. It is interesting to note that Coniglio and Cross
(Ref. 25) discussed the possible role of
bifilms in the initiation of cracks during weld-metal solidification.
Reducing Entrapment by Milling
Faying Surfaces
One way to reduce entrapment of oxide films in the fusion zone is to mill the
rough as-sheared faying surfaces
smooth before welding. This can eliminate the air channel that causes the entrapment. Figure 9 shows a butt joint
D
C
Fig. 11 Entrapment of oxide films in weld 051 caused by too small an opening be
tween assheared faying surfaces. A Top view; B transverse cross section; C ten
sile test curves showing lower ductility of specimens 2 and 3; D failure through fusion
zones of specimens 2 and 3; E fracture surfaces of specimens 2 and 3 (not 1, 4, and 5)
showing entrapped oxides and air.
weld, weld 007, made with the faying

surfaces milled flat after shearing
Fig. 9A. As compared to weld 002 made
with as-sheared faying surfaces (Fig. 5),
the tensile test curves (Fig. 9D) show

significantly less scatter in ductility. The
tensile-tested specimens (Fig. 9E, F)
show failure along the outside of the fu-
Table 8 Summary of Butt Joint Welds Made with a Root Opening of 1.0 or 1.2 mm
Weld #
G001
G002
G003
G004
G005
G006
G007
G008
G009
G010
G011
Butt Joint
Power (W)
Travel Speed (in./min)
Weld Penetration
1.18mm square groove; 1.0mm root opening

639
857
742
727
735
764
738
768
636
650
628
18
18
18
18
18
18
18
18
18
18
18
Partial
Meltthrough
Meltthrough
Full
Full
Meltthrough
Full
Meltthrough
Full
Full
Full
WELDING RESEARCH
Fig. 12 High crowns on butt joint welds made at travel speeds of the following: A
7.6 mm/s (18 in./min, weld 052); B 11.0 mm/s (26 in./min, weld 053); C 14.4 mm/s
(34 in./min, weld 054). Crown height is reduced by increasing travel speed but the toe
angle remains relatively small at 123 deg.
sion zone, consistent with the absence

of oxide-film entrapment. No air holes
are visible in the fusion zone Fig. 9F.
Reducing Entrapment by Separating
Faying Surfaces
Another way to help avoid entrapment of oxide films in the fusion zone
is to leave an opening between assheared faying surfaces. Since Ar is
heavier than air (Ref. 20), the Ar
shielding gas from the torch may enter
the opening near the weld pool and
keep air away. If oxide films still form
on the surfaces, the liquid filler metal
may be able to carry them away while

going through the opening.
Figure 10 shows a weld, weld 008,
made with a 0.75-mm opening between two as-sheared faying surfaces
Fig. 10A. The tensile test curves
(Fig. 10D) show significantly less scatter in ductility. Failure occurs along
the outside of the fusion boundary
(Fig. 10E), consistent with the absence
of entrapped oxide films in the fusion
zone. The effectiveness of a root opening in eliminating entrapment of oxide
films can be affected by the width of
the opening. A smaller opening allows
less room for Ar to purge the air be-
tween the surfaces and for the liquid

filler metal to flow through and carry
oxide films away from the surfaces (if
oxide films are present).
Figure 11 shows a butt joint weld
(weld 051) made with a 0.5-mm opening between two as-sheared faying
surfaces in the as-sheared condition.
The tensile test curves (Fig. 11C) show
much scatter in the ductility, with
specimens 2 and 3 being the lowest.
Tensile tested specimens 2 and 3 (Fig.
11D) show failure through the fusion
zone and oxide films and air bubble on
the fracture surfaces Fig. 11E. Besides less room for both Ar purging
and filler-metal flow, weld 051 is considerably narrower than weld 008
Fig. 10. The larger weld pool in the
case of weld 008 can be expected to
provide more room for strong fluid
flow to exist (Ref. 26) and carry the
entrapped oxide films away from the
faying surfaces.
Still another way to help reduce entrapment of oxide films is to provide
additional Ar shielding gas from below.
For instance, a backing plate can be
designed to allow Ar purging from under the butt joint.
It is worth noting that, referring to
Fig. 7C, flipping over the as-sheared
sheets without providing an opening in
between may not always work. It is true
that flipping over the as-sheared sheets
resembles a butt joint design with a single-V groove to allow the Ar shielding
gas to reach the heated faying surfaces
immediately ahead of the weld pool and
thus protect it from oxidation. However, close examinations of as-sheared
edges have revealed that chipping some-
Table 9 Current Settings for Lap Welding

Current
Weld
No.
Start
Current Time
(A)
(ms)
Arc Time
Mid
Current
Time
(A)
(ms)
End
Current Time
(A)
(ms)
012
67
4.0
88
10.0
78
016
59
4.0
80
10.0
70
018
55
4.0
76
10.0
66
019
55
4.0
76
10.0
66
020
55
4.0
76
10.0
66
022
74
4.0
95
10.0
85
025
53
4.0
74
10.0
64
031
70
5.0
90
15.0
80
Rise rate of current (A/ms): 250; fall rate of current (A/ms): 250
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Start
Current
Time
(A)
(ms)
96
96
96
96
96
96
96
110
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
Short Circuit Time

Mid
Current
Time
(A)
(ms)
106
106
106
106
106
106
106
130
3.0
3.0
3.0
3.0
3.0
3.0
3.0
4.0
End
Current
(A)
Time
(ms)
85
85
85
85
85
85
85
105
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
ms: milliseconds.
WELDING RESEARCH
times occurs at the mid height of a
sheared edge. That is, the rough portion
of an as-sheared edge can be at its mid
height instead of at its bottom. Thus,
air pockets can still exist between the
two faying surfaces to cause oxidation
and air bubbles if the as-sheared sheets
are just flipped over to form a butt joint
without an opening.
Issue 2: High Weld Crowns

It was found that a high weld crown
tends to form on a butt joint weld very
easily and that a higher crown tends to
be associated with lower ductility in
tensile testing. As is discussed subsequently, the low fluidity of liquid Mg is
responsible for the high crowns of butt
joint welds, but made worse by the
lower heat input in short-circuiting
type GMAW. As mentioned previously,
Lockwood (Ref. 10) and Rethmeier et
al. (Ref. 12) both showed high crowns
on butt joint welds made with shortcircuiting type GMAW though no explanations were given.
Figure 12 shows the crown height
can be significantly greater than the
workpiece thickness (1.6 mm). These
welds were made with faying surfaces
milled flat after shearing and without
an opening, welds 052 (Fig. 12A) at
7.6 mm/s, weld 053 (Fig. 12B) at 11.0
mm/s, and weld 054 (Fig. 12C) at 14.4
mm/s. As shown, increasing the travel
speed tends to decrease the crown
height. However, the toe angle remains unchanged at about 123 deg.
This, perhaps, is not surprising because the time available for the liquid
pool to spread out also decreases as
the travel speed increases.
For the purpose of discussion, a toe
angle significantly less than 135 deg
(weld 002 in Fig. 5C), for instance
130110 deg, will be called a relatively
small toe angle. A relatively small toe
angle means a more abrupt thickness
change and hence a significantly higher stress concentration at the toe. A
high stress concentration tends to act
as a crack initiation site under tension
or cyclic tensile loading and leads to
premature failure. A relatively small
toe angle can significantly reduce the
fatigue resistance of the weld (Ref.
20). As is shown subsequently, a relatively small toe angle tends to be associated with a lower ductility in tensile
testing.
D
C
Fig. 13 Weld 052 with a high crown. A Top view of weld; B transverse cross sec
tion; C tensile test curves; D side views of tensiletested specimens. Crown is high
er, toe angle smaller, and ductility lower than weld 007 Fig. 9.
Table 10 WireSpeed Settings for Lap Welding

Wire Speed
Down
Weld
No.
012
016
018
019
020
022
025
031
Up 1
Wire
Down
Speed
(MPM)
Delay
before
Wire Down
(ms)
13.0
25.0
19.0
19.0
19.0
14.8
13.0
25.0
2
4
4
4
4
4
2
0
Wire Up 1
Speed
(MPM)
13.0
25.0
19.0
19.0
19.0
14.8
13.0
25.0
Up 2
Delay
before
Wire Up
(ms)
Wire Up 2
Speed
(MPM)
Arc
Length
(mm)
Penetration
Delay
(ms)
3
6
6
6
6
6
3
0
13.0
25.0
19.0
19.0
19.0
14.8
13.0
25.0
0.3
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.8
0.8
0.0
0.0
0.0
0.8
0.4
0
MPM: meters per min, ms: milliseconds.
Weld 052 made at the lowest travel

speed of 7.6 mm/s is shown further in
Fig. 13. The transverse cross-section
macrograph Fig. 13B shows a high
crown of 2.1 mm. Tensile testing (Fig.
13C) indicates a low ductility of about
4%, about one half of the 89% of
welds 007 (Fig. 9) and 008 Fig. 10.
The tensile tested specimens show
failure outside the fusion zone Fig.
13D. In view of the absence of entrapped oxide films on their fracture
surfaces, the low ductility is likely to

be caused by the relatively small toe
angle. Since welds 052, 007, and 008
were made under similar welding parameters, the extent of recrystallization and grain growth in the heataffected zone (HAZ) can be expected
to be similar in these welds. Thus, the
lower ductility of weld 052 cannot be
caused by the differences in the HAZ.
Weld 053 made at the intermediate
travel speed of 11.0 mm/s showed
WELDING RESEARCH
oxide films away from the faying surfaces.
A
Mechanism of HighCrown Formation
D
C
Fig. 14 Weld 054 with a high crown. A Top view; B transverse cross section; C
tensile test curves; D side views of tensiletested specimens; E fracture surfaces of
specimens 1, 2, and 5 (not 3 and 4) showing entrapment of oxide films and air in spite of
milling faying surfaces after shearing.
similar results as weld 052.

Weld 054 made at the highest travel
speed of 14.4 mm/s is shown further
in Fig. 14. The transverse cross section
(Fig. 14B) shows that the crown height
is now reduced to 1.7 mm but the toe
angle is still relatively small at 123
deg. The tensile test curves (Fig. 14C)
show a highest ductility value of only
about 4% in specimen 4, and even lower values of about 23% in specimens
1, 2, and 5. Tensile-tested specimens
(Fig. 14D) show failure through the fusion zone and fracture surfaces (Fig.
14E) show entrapped oxide films and

air in specimens 1, 2, and 5. The entrapment is surprising because the
faying surfaces were milled flat after
shearing and put together without an
opening. It is likely that a very small
space and hence some residual air still
existed between the faying surfaces,
enough to cause oxidation in view of
the very high affinity of Mg for oxygen. Perhaps with a significantly larger
weld pool such as that associated with
the bigger weld (weld 007 in Fig. 9),
fluid flow may be stronger to carry the
The cause of high crowns is discussed as follows. Since no high

crowns were encountered during similar butt joint welding of Al sheets by
CSC-GMAW, the physical properties of
Mg are compared against those of Al
when considering the following three
factors.
The first factor is the / ratio,
where and are the surface tension
and density of the liquid metal, respectively. It is well known in floatingzone crystal growth that the maximum height of the molten zone in a
vertical solid rod that can be supported by its own surface tension is proportional to the square root of the /
ratio (Ref. 27). Thus, the crown height
may also increase with increasing /.
In fact, Campbell (Ref. 24) derived an
equation to show that the height of a
sessile drop on a substrate is proportional to the square root of the / ratio. The physical properties of the weld
pool depend on the weld pool composition, which in turn depends on the
workpiece composition, filler-metal
composition, and dilution level (Ref.
20). Since the physical properties of
the weld pool are not available, those
of pure Mg and Al are used in the discussion as an approximation. For Mg,
= 5590 dyne/m, = 1700 kg/m3 and
thus / = 3.29 dyne m2/kg. As for Al,
= 9140 dyne/m, = 2700 kg/m3 and
thus / = 3.39 dyne m2/kg (Ref. 28).
Since the / ratio is nearly identical
for both Mg and Al, the tendency for
Mg to have high crowns is unlikely to
be caused by a much higher / ratio.
The second factor to be considered
is the conduction of heat away from
the liquid metal to cause solidification.
The thermal conductivity k is 153
W/(m K) for Mg and 237 W/(m K) for
Al (Ref. 29). Thus, the lower thermal
conductivity of Mg suggests that the
high Mg weld crown is not caused by
the faster heat extraction from and
hence solidification of liquid Mg. The
thermal diffusivity equals to
k/(/Cp), where Cp is the heat of fusion. Cp is 1.05 J/(g K) for Mg and 0.91
J/(g K) for Al (Ref. 30). Thus, is 86
mm2/s for Mg and 97 mm2/s for Al.
Thus, the lower thermal diffusivity of
WELDING RESEARCH
Mg also suggests that the high crown
is not caused by the faster heat extraction from and hence solidification of
liquid Mg.
The third factor to be considered is
the low volumetric heat content of liquid Mg. The very low density of Mg reduces the amount of heat needed to be
removed per unit volume of liquid Mg
to be solidified. For comparison, the
heat of fusion and specific heat of Al
are, respectively, 398 J/g and 0.91 J/(g
K). Multiplying them by the density of
Al (2700 kg/m3) yields a 1.075 109
J/m3 volumetric heat of fusion and a
2.46 106 J/(m3 K) volumetric specific
heat of Al. As for Mg, the heat of fusion and specific heat are, respectively,
368 J/g and 1.05 J/(g K), which are
close to those of Al. However, the density of Mg, 1700 kg/m3, is about onethird lower than that of Al, 2700
kg/m3 (Ref. 30). Upon multiplication
by the density of Mg, the volumetric
heat of fusion of Mg becomes 6.26
108 J/m3 and the volumetric specific
heat 1.79 106 J/(m3 K), which are
significantly lower than those of Al.
Thus, because of the significantly lower density of Mg, the sensible heat
needed to be removed to cool down
the same liquid volume is 27% less for
Mg than for Al, and the latent heat
needed to be removed to solidify the
same liquid volume is 42% less for Mg
than for Al. In fact, this is exactly why
Mg die castings can be made significantly faster than Al ones (Ref. 31). In
Mg casting, the steel mold extracts
heat from the liquid metal. In Mg
welding, the steel backing plate and
the base metal extract heat from the
liquid metal.
Fig. 15 Mechanism and reduction of highcrown formation. A Mechanism; B

high weld crown; C crownheight reduction by providing an opening to help both ac
commodate filler metal deposit and let liquid metal quickly penetrate the workpiece; D
crown height reduction by deepening the groove in the backing plate to help accom
modate filler metal deposit.
It should be mentioned that in metal casting, the distance the liquid metal can flow before stopping is called
the fluidity. The fluidity is proportional to the volumetric heat content (both
the latent heat and the superheat) of
the liquid and the diameter of the
channel in the mold through which
the liquid metal flows (Ref. 31). It is

inversely proportional to the heat
transfer coefficient between the liquid
metal and mold, and the difference between the melting point and mold
temperature. The melting point of Mg
(650C) is close to that of Al (660C).
The heat transfer coefficient between
Table 11 Summary of Lap Welds
Weld
No.
Penetration
into Lower
Sheet
Average
Power
(W)
Travel Speed
(in./min)
Wire Position
from Edge
(mm)*
Maximum
Tensile Load (N)
Elongation
(%)
Maximum Tensile Load

(% of Base Metal)
012
016
018
019
020
022
025
031
full
full
partial
partial/full
partial
partial/full
partial
partial
1335
1104
1033
1036
1031
1472
999
1523
18
18
18
18
18
18
18
24
0
0.8
0.8
+0.8
0.8
5.0
+3.1
0.8
6470
5922
6807
7059
7428
8124
6775
8134
1.6
1.4
1.9
2.0
2.7
2.7
2.2
3.2
53.2
48.7
55.9
58.0
61.0
66.7
55.7
66.8
* Above upper sheet: < 0; above lower sheet: > 0.
WELDING RESEARCH
Fig. 16 High crown in Mg butt joint welding and its reduction. A High crown
caused by low fluidity of liquid Mg; B crown height reduced with a joint opening;
C crown height further reduced with a deeper groove. The best result may be be
tween B and C.
liquid Mg and solid Mg is likely similar

to that between liquid Al and solid Al.
Thus, the fluidity of the weld pool in
butt joint welding is likely to be proportional to volumetric heat content
of liquid.
Therefore, the mechanism of highcrown formation in Mg butt joint
welding is as follows: The fluidity of
the Mg weld pool is low because of the
low density and hence low volumetric
heat content. The edge of the weld
pool can solidify quickly and act as an
anchor to stop its further spreading
and hence lowering of the pool height,
as illustrated in Fig. 15A and B. In
GMAW, the power input is significantly reduced by short circuiting, including CSC-GMAW, in view of the absence
of the arc during the short circuit period. Thus, in short-circuiting GMAW
superheating of the liquid metal is limited, and this can further reduce the
fluidity and promote high crowns.
Figure 15C and D shows the crown

height can be reduced by providing a
root opening or deepening the groove
in the backing plate, respectively. Reducing the wire feed rate may also reduce the crown height. However, since
the welding current and hence heat input are also reduced, the volumetric
heat content and hence the fluidity
can also decrease.
Reducing Crown
Figure 16 is an example showing how
the high crown in a Mg butt joint weld
(Fig. 16A) can be reduced by widening a
joint opening and/or deepening the
groove in the backing plate. Widening
the opening between the faying surfaces
in butt joint welding (Fig. 16B) may help
reduce the crown height by accommodating the filler-metal deposit. It may
also allow the liquid metal to quickly
pass through the opening before solidi-
fying into a high crown. In general, less

welding current (slower overall wire
feeding) is needed when an opening is
provided because there is no need to
penetrate the workpiece. Deepening the
groove in the steel backing plate provides extra room under the joint to accommodate the filler-metal deposit and
reduce the crown height. A deep groove
plus a joint opening can make the crown
very short (Fig. 16C). Naturally, an excessively large root enforcement caused
by too deep a groove is also undesirable.
It was noticed that with a uniform
opening of 1.2 mm set up before welding, the opening at the weld-pool front
gradually closed as the pool approached
the finishing end of the weld. Metals
tend to shrink upon solidification because the density of solid metal S is
greater than the density of liquid metal
L. The solidification shrinkage, defined
as the ratio of (S L)/S, is 4.2% for
Mg (Ref. 31). The problem is that when
the root opening gradually shrank because of solidification shrinkage, the
pool penetration also gradually decreased. To overcome this problem, the
opening was widened linearly from 1.2
mm at the starting end of the weld to
2.0 mm at the finishing end. This was
done by putting a short vertical steel
wire of 1.2 mm diameter right before
the starting end and a similar wire of
2.0 mm diameter right after the finishing end. Driven by shrinkage, the Mg
sheets gradually deformed around the
wire during welding and reduced the
opening to 1.2 mm by the time the weld
pool reached the finishing end. In other
words, by providing a nonuniform
opening that increased from 1.2 to 2.0
mm before welding, a constant weld
opening 1.2 mm was obtained after
welding. Precautions, however, need to
be taken to avoid melt-through during
welding when butt joint welding with a
wide opening, especially when the
groove in the backing plate is deep.
Lap Joint Welding

Tables 9 and 10 show the current
settings and the wire-speed settings
for lap joint welding, respectively.
Table 11 summarizes the welding
conditions and tensile testing results
of the resultant lap joint welds.
Issue 3: Formation of Fingers
It was observed that lap joint welds
WELDING RESEARCH
almost always tended to stick out to
the lower sheets as protrusions, which
are called fingers here. Fingers are
caused mainly by the low density of
Mg instead of the welding process
used as is explained subsequently.
Figure 17 shows lap weld 018. The
torch was vertical and moving along
the joint line. This direction, in the
case of Fig. 17A, is the direction out
of the paper. The top view of the weld
(Fig. 17B) shows fingers extending
from the weld onto the lower sheet.
Most fingers do not fuse to the lower
sheet well enough to contribute to
bonding because their large surfacearea-to-volume ratio promotes quick
freezing and oxidation. Thus, they
tend to decrease the joint strength
and cause it to vary along the weld.
The transverse cross section of the
weld (Fig. 17C) shows a very small toe
angle of 55 deg on the lower sheet
side of the lap weld. Tensile testing
results (Fig. 17D) show ductility
(around 2%) significantly lower in lap
welds than in butt joint welds (up to
about 8%). A lower ductility in lap
welds than butt joint welds is expected because lap welds have an intrinsic
sharp notch at the fusion boundary
between the upper and lower sheets.
The tensile tested specimens (Fig.
17E) show failure from the sharp
notch through the fusion zone. Specimens 3 and 4 show no bonding between fingers and the lower sheet.
The fracture surface shows essentially
no oxide films or air bubbles.
It is worth mentioning that fingers
were also encountered in the study by
Song et al. (Ref. 21). The photograph
of the lap joint weld showed clear fingers though they were not mentioned
or discussed.
Mechanism of Finger Formation
The mechanism is illustrated in Fig.
18A. The very low density of Mg
makes the filler metal globule light.
Thus, it is difficult for gravity to detach the globule but easy for the arc jet
to push it away from the inclined pool
surface, as observed by high-speed
video (4000 frames/s) (Ref. 18).
Consequently, the globule keeps
growing and getting closer to the lower sheet and eventually touches it and
quickly solidifies on it as a finger.
When the globule touches the lower
Fig. 17 Finger formation in lap joint weld 018. A Schematic sketch of lap joint weld
ing (in the direction out of the paper); B top view of weld showing fingers extending
onto lower sheet; C transverse cross section showing very sharp angle between weld
and lower sheet; D tensile test curves; E side views of tensiletested specimens
showing failure through fusion zone (from sharp notch between two sheets) and no
bonding between fingers and lower sheet (specimens 3 and 4).
sheet, it is detached from the welding

wire tip and connected to the weld
pool. This is why the finger extends
from the weld onto the lower sheet.
Unlike in conventional GMAW, the
welding current is under tight control
in CSC-GMAW. Thus, there is no sudden current surge upon short circuiting to cause a sudden arc expansion to
expel the globule as spatter.
Eliminating Fingers by Blocking
Globule
Figure 18B and C show how to reduce fingers by blocking the filler-metal globule. The blocker can be an inert
material such as a steel bar coated
with boron nitride (BN) and placed on
the lower sheet at a proper distance
from the joint line Fig. 18B. It is intended to keep the growing globule
from stretching too far out over the
lower sheet to solidify as a finger. The
inert blocker can also be mounted on
the welding gun to travel with it during welding Fig. 18C. Fingers can
also be eliminated by tilting the welding gun toward the upper sheet (Fig.
18D) as is described subsequently.
Figure 19 shows a lap joint weld
(weld 020) made with a stationary
blocker Fig. 19A. The top view (Fig.
19B) shows that the weld edge on the
lower sheet is smooth and without any
fingers. The transverse cross section
(Fig. 19C) shows a 115 deg toe angle,
much larger than the 55 deg angle of
weld 018 Fig. 17C. Tensile test results (Fig. 19D) show slightly better
WELDING RESEARCH
ductility than weld 018 (Fig. 17D)
though still low as expected for a lap
weld. The tensile tested specimens
(Fig. 19E) show failure outside instead
of through the fusion zone as in the
case of weld 018 Fig. 17E.
Eliminating Fingers by Tilting Welding

Gun
Figure 20 shows a lap joint weld,
weld 031, made with the welding gun
tilted to shift the globule toward the
upper sheet Fig. 20A. The top view
(Fig. 20B) shows that the weld edge on
the lower sheet is smooth and without
any fingers. The transverse cross section (Fig. 20C) shows a toe angle of
111 deg on the lower sheet. Tensile
test results (Fig. 20D) show even better ductility than weld 020 (Fig. 19D),
though still low as expected for a lap
joint weld. The tensile tested specimens (Fig. 20E) again show failure
outside the fusion zone. Since failure
is through the lower sheet, the tensile
strength can be calculated based on
the thickness (1.6 mm) of the lower
sheet. The joint strength is 67% of the
base metal strength. Again, the joint
strength is expected to be lower for lap
joint welds than butt joint welds. It
can be seen from welds 018, 020, and
031 that lap joint welds without fingers tend to have higher ductility.
Conclusions
The following conclusions can be
drawn based on the results from the
butt and lap joint welding of AZ31
Mg sheets by CSC-GMAW:
1) Sound butt joint welds of Mg alloy sheets can be made by CSCGMAW without spatter and hydrogen
porosity, and they can approach 100%
of the base metal strength.
2) However, precautions need be
taken to avoid the formation of: 1)
entrapped oxide films inside butt
joint welds, 2) high crowns on butt
joint welds, and 3) fingers from lap
joint welds. These defects are caused
mainly by the unusual physical and
chemical properties of Mg rather than
the welding process itself. Weld tensile specimens containing one or
more of these defects are consistently
found to fail at a significantly lower
elongation.
3) The mechanism for oxide-film
Fig. 18 Mechanism and elimination of finger formation. A Mechanism; B elimi

nating fingers with stationary blocker; C eliminating fingers with moving blocker; D
eliminating fingers by torch tilting.
entrapment is as follows: The assheared edges of Mg sheets are rough

(due to the poor deformability of Mg
associated with its hcp structure),
and they can form an air channel to
cause the faying surfaces ahead of the
weld pool to oxidize (due to the very
high oxygen affinity of Mg), and the
oxide films and air bubbles entrapped
in the weld pool cannot rise quickly
to escape (due to the low density of
Mg).
4) A folded oxide film, called a bifilm, can form essentially along the
central plane of the fusion zone and
provide a very sharp notch to initiate
crack under tension, leading to premature failure.
5) Milling the rough as-sheared

edges of Mg sheets to make them
smooth or providing an opening between the as-sheared faying surfaces
can help eliminate the entrapment of
oxide films and air bubbles.
6) The mechanism for the formation of high crowns is as follows: The
low fluidity of Mg makes the weld
pool solidify quickly before spreading
out significantly to reduce the pool
height. The low fluidity is caused
mainly by the low density and hence
low volumetric heat content of Mg,
but it can be further reduced by the
short-circuiting mode of metal transfer, including that in CSC-GMAW.
7) Widening the root opening can
Chai et al Supp 201435 Jan 2015 WJ_Layout 1 12/12/14 8:15 AM Page 32
WELDING RESEARCH
The author Sindo Kou would like

to express his sincere thanks to Drs.
Jim Yen-lung Chen and Xiaohong Q.
Gayden of General Motors for getting
GMs approval to support the project
on GMAW welding of Mg alloys.
The authors would also like to
thank Bruce Albrecht, Todd Holverson, Rick Hutchison, and Joe Fink of
Miller Electric Manufacturing Co. and
ITW Global Welding Technology Center, both located in Appleton, Wis.,
for donating the CSC process controller and drive assembly, Invision
456 power source, XR-M wire feeder,
and welding gun used in the study.
Fig. 19 Elimination of fingers from lap weld 020 by blocking the globule. A station
ary blocker in the form of a BNcoated steel bar resting on lower sheet parallel to weld
ing direction; B top view of weld showing no fingers; C transverse crosssection; D
tensile test curves; E side views of tensiletested specimens showing failure out
side, instead of through, fusion zone (unlike weld 018 in Fig. 17).
help reduce the crown height by letting the liquid filler metal pass
through quickly before solidification
and providing extra space to accommodate the filler metal deposit. Deepening the groove in the backing plate
can also help reduce the crown height
by providing extra space to accommodate the filler metal deposit.
8) The mechanism for the formation of fingers is as follows: The low
Mg density makes the filler metal
globule light and hence difficult for
gravity to detach it but easy for the
arc jet to push it away from the inclined pool surface toward the lower
sheet. The globule keeps growing and
eventually touches the lower sheet to
solidify on it quickly as a finger.
9) Using a piece of inert material
(such as BN-coated steel) to block the
globule can help eliminate fingers.
The piece can either rest on the lower

sheet or travel with the welding gun.
Tilting the welding gun to shift the
globule toward the upper sheet can
also help eliminate fingers.
Acknowledgments
This work was supported by initially by General Motors and subsequently by the National Science Foundation under Grant No. IIP-1034695,
the American Welding Society Foundation Fellowship Program, and the
University of Wisconsin Foundation
through the Industry/University Collaborative Research Center (I/UCRC)
for Integrated Materials Joining Science for Energy Applications.
References
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Fig. 20 Elimination of fingers from lap weld 031 by welding gun tilting. A Tilting
the welding gun and hence the welding wire slightly toward the upper piece; B top
view of weld; C transverse cross section; D tensile test curves; E side views of
tensiletested specimens showing specimens failed outside, instead of through, fusion
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11. Lockwood, L. F. 1970. Pulse-arc
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12. Rethmeier, M., Wiesner, S., and
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14. Zhao, H., and DebRoy, T. 2001.
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Mechanism and remedy. Welding Journal

80: 204-s to 210-s.
15. Chi, C.-T., Chao, C.-G., Liu, T.-F.,
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16. Park, S. H. C., Sato, Y. S., and
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22. Prasad, K. E., Li, B., Dixit, N., Shaffer, M., Mathaudhu, S. N., and Ramesh, K.
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Peer Review 2015[1]_Layout 1 12/10/14 3:07 PM Page 34
AWS Peer Review Panel

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working in the same area; and 5) justification of the conclusions, based on the work performed. The following individuals serve on the AWS
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Cover January 2015_4/06 Cover 12/11/14 9:18 AM Page C1

WELDING JOURNAL VOLUME 94 NUMBER 1 JANUARY 2015

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January 2015_Layout 1 12/11/14 11:19 AM Page 3

January 2015 Volume 94 Number 1

The Case for Using LowHydrogen Covered Electrodes

FABTECH 2014 Heats up Atlanta

Creating a LeakTight Aircraft Relay Switch

WELDING RESEARCH SUPPLEMENT

Primary Chromium Carbide Fraction Control with

A unique induction heating-assisted underwater wet

16s Gas Metal Arc Welding of Magnesium Alloys:

JANUARY 2015 / WELDING JOURNAL 3

Welding Filler Metals for

voestalpine Bhler Welding

Welding Filler Metals for

voestalpine Bhler Welding

January 2015_Layout 1 12/12/14 10:17 AM Page 4

R. W. Roth (At Large), RoMan Manufacturing, Inc.

Design and Production

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Editorial January 2015_Layout 1 12/11/14 1:57 PM Page 6

A Triple Pass of the Torch

While the technol

Dr. Ken Ham of the Institute of Creation

6 WELDING JOURNAL / JANUARY 2015

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PRESS TIME NEWS

A view of SelectArcs building in Troy, Ohio.

Select-Arc, Inc., a manufacturer of welding electrode

Investment of $140 Million to Expand

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Structural Steel Fabrication

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NEWS OF THE INDUSTRY

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Changing Landscape in Troy, Ohio,

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