W E’R E C O M M I T T E D T O T H E F U T U R E O F W E L D I N G

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

Some say welding

is a static industry –
that there’s nothing to
learn about joining metal
with metal. But at Lincoln
Electric, we think there will
always be new ways to improve
productivity. That’s why we spend
more on research and development
than any other company in welding.
Our view is long range: we plan to
stay No. 1 in arc welding and cutting.
And we’ll keep inventing the new tech-
nologies that drive your business forward.

www.lincolnelectric.com
HIGHLIGHTS
• Over 400 Exhibitors
• Sneak Preview of What's New and Hot at the 2004 Exposition
• 34th International Brazing and Soldering Symposium
• Automatic Welding Conference:
Getting the Most Out of Your Automatic Welding Investment
• Professional Program: Peer-Reviewed Papers
• $2,500 First Prize for Best Welder in the
First AWS Professional Welders Competition
• World-Class Bookstore with Thousands of Titles
• Robotic Arc Welding Course
• AWS D1.1/D1.1M:2004 Courses
• Essentials of Steel Weldment Design Short Course
• Advanced Commercial Development Session
• SEVEN SPECIAL-INTEREST PAVILIONS – Each a Show Within the Show
• Brazing and Soldering
• Gas Suppliers
• GAWDA Single-Day Pavilion
• Job Shop Interests
• Laser Welding and Cutting
• Nondestructive Examination
• Resistance Welding
• FREE SESSIONS:
• Computer Security
• Interview with Authority on Weld Design
• Trans-Alaska Pipeline
• Valdez Marine Terminal
• World Trade Center Tragedy
3
 A Quick Guide to the AWS Welding Show 2004
Age restriction on Exposition floor . . . . . . . . . . . . . . . . . Page 6
Aluminum welding – Professional Program . . . . . . . . . Page 18
Arc welding and power sources – Seminar . . . . . . . . . Page 27
Army exhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
Automatic Welding Conference . . . . . . . . . . . . . . . . . . Page 28
Awards ceremony and luncheon . . . . . . . . . . . . . . . . . Page 10
Brazing and soldering – 34th International Symposium . . Page 22
Competitive events
Poster Session . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
Professional Welders Competition . . . . . . . . . . . . Page 11
Continuing education – Conferences and Seminars . . . Page 26
D1.1/D1.1M:2004, Structural Welding Code—Steel
Seminars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 27
Days and hours (Convention and Exposition) . . . . . . . . . Page 6
Design
Steel weldment design (free) . . . . . . . . . . . . Pages 24, 26
Introduction to Design of Weldments seminar . . . . Page 31
Education Program
Education sessions . . . . . . . . . . . . . . . . . . . . . . . Page 25
Plant tours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26
Plummer Memorial Education Lecture (free) . . . Pages 10, 25
Student Day (College Careers in Welding) . . . . . . . Page 26
Electron beam welding – Professional Program . . . . . . Page 20
Exhibitors
Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
What’s New and Hot . . . . . . . . . . . . . . . . . . . . . . Page 15
Exposition
Days and hours . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Opening ceremony . . . . . . . . . . . . . . . . . . . . . . . Page 10
VIP Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 34
FCAW/SMAW – Professional Program . . . . . . . . . . . . . Page 18
Forensics and weld performance – Professional Program . . Page 18
Foundation
Recognition luncheon . . . . . . . . . . . . . . . . . . . . . Page 10
Silent auction . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
Free sessions
Advanced commercial development session . . . . . Page 31
College Careers in Welding . . . . . . . . . . . . . . . . . Page 26
Comfort A. Adams Lecture . . . . . . . . . . . . . . . . . . Page 10
Computer Procedures, Policies, and Security . . . . Page 25
Education Program . . . . . . . . . . . . . . . . . . . . . . . Page 25
Field construction/repair . . . . . . . . . . . . . . . . . . . Page 24
Hydrocarbon Vapor Collection at
Valdez Marine Terminal . . . . . . . . . . . . . . . . . . . Page 25
Interview with Dr. Omer Blodgett . . . . . . . . . Pages 24, 26
Maintenance Welding on the
Trans-Alaska Pipeline . . . . . . . . . . . . . . . . . . . . Page 24
Manufacturability of fuel cell products . . . . . . . . . Page 31
Plummer Memorial Education Lecture . . . . . . Pages 10, 25
World Trade Center tragedy . . . . . . . . . . . . . . . . . Page 24
4
Fuel cells – Advanced commercial development session . . Page 31
Gas metal arc welding – Professional Program . . . Pages 18, 19
Guests – Registration . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Hotels
Location map . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 35
Reservation form . . . . . . . . . . . . . . . . . . . . . . . . Page 32
Reservations information . . . . . . . . . . . . . . . . . . . . Page 7
Laser beam welding – Professional Program . . . . Pages 19, 20
Lectures
Comfort A. Adams (free) . . . . . . . . . . . . . . . . . . . Page 10
Plummer Memorial Education (free) . . . . . . . Pages 10, 25
Materials – Professional Program . . . . . . . . . . . . . . . . Page 18
Navy research – Professional Program . . . . . . . . . . . . Page 20
Planning for cost-effective welding – Seminar . . . . . . . Page 27
Professional Program – By day and session . . . . . . . . . Page 18
Quality management – Seminar . . . . . . . . . . . . . . . . . Page 28
Reception – AWS Officers’ . . . . . . . . . . . . . . . . . . . . . Page 10
Registration
By mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 33, 34
On-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 33, 34
On-site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Seminar registration form . . . . . . . . . . . . . . . . . . Page 33
Student . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
VIP Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 34
Robotic arc welding – Seminar . . . . . . . . . . . . . . . . . . Page 30
Solid-state joining – Professional Program . . . . . . . . . . Page 20
Stainless steel welding – Seminar . . . . . . . . . . . . . . . . Page 31
Travel
Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Car rental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
Local in Chicago . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
Week at a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
Weldability – Professional Program . . . . . . . . . . . . . . . Page 19
Welding procedure specifications – Seminar . . . . . . . . Page 30
AWS AT A GLANCE
About Membership
AWS serves nearly 50,000 individual members and
1,100 corporate members worldwide. Individual members
comprise engineers, scientists, educators, researchers,
welders, inspectors, welding supervisors, company execu-
tives and officers, and sales associates. Corporate members
include welding manufacturers, independent welding shops,
distributorships, end users, and educational institutions.
Member interests include automatic, semiautomatic,
and manual welding; brazing and soldering; cutting;
ceramics; lamination; robotics; lasers; and welding
inspection, safety, and health.
AWS Magazines
The Welding Journal – a major monthly magazine specifi-
cally serving the welding, brazing, soldering, allied joining
and cutting, and manufacturing industries – is mailed to all
AWS members. The publication includes authoritative arti-
cles that can help your business and professional develop-
ment, as well as news, "how-to" stories, research reports,
advertisements, and much more. Winner of more than 65
editorial and design awards.
In addition, Inspection Trends – the magazine for
materials inspection and testing personnel – is mailed to
individuals and facilities certified by AWS, including all
Certified Welding Inspectors.
Technical Publications
AWS offers over 300 books, charts, CDs, replicas, and
proceedings, as well as software. In addition, AWS has
developed more than 200 codes, recommended practices,
and guides, produced under strict American National
Standards Institute (ANSI) procedures. They include one of
the most consulted codes in the world, AWS D1.1/D1.1M,
Structural Welding Code—Steel. We publish a free
annual 40-page, full-color catalog. You can download
this catalog from the AWS Welding Store Online at
http://www.aws.org/cgi-bin/shop. Also visit the AWS
Book Store, managed by Global Engineering Documents,
at the 2004 AWS Welding Show. Members receive a
25 percent discount on publications produced by AWS.
Education Programs
AWS education programs include international,
national, and local conferences; seminars; individual cor-
porate programs; and study guides. Subjects range from
the basics to the most recent advances in technology. AWS
offers the award-winning S.E.N.S.E. (Schools Excelling
through National Skills Education) program to all qualified
U.S. welding educational groups.
AWS Foundation
Established in 1989 to support research and education
in welding and related technologies, the AWS Foundation
is committed to awarding more than $300,000 annually
in undergraduate scholarships and graduate research
fellowships. In addition, the Foundation hosts other
programs, such as the Engineering Your Future instruc-
tors’ guide, a student loan program, and career promo-
tional videos such as the award-winning Welding:
So Hot, It’s Cool (downloadable from www.aws.org).
AWS Certification
AWS maintains the National Registry of all certified or
accredited professionals and entities related to weld-
ing. The testing facilities used to conduct the qualifi-
cation procedures are AWS accredited, and AWS also
develops customized welder qualification programs
for other organizations, including private companies.
The AWS Certified Welding Inspector (CWI) program
has been in effect since 1979. To date, over 47,000
people have been certified. CWIs help ensure the
highest quality of welding.
In 1989, the AWS Certified Welder Program was launched
to certify the qualifications of welders nationwide.
Welding instructors can earn an important credential
through the AWS Certified Welding Educator program,
established in 1991.
AWS offers a nationally and internationally recognized
portable certification for nondestructive testing profes-
sionals. Other AWS programs include the Senior Certified
Welding Inspector and Certified Welding Engineer.
New certification programs in development are the Certifi-
cation for Radiographic Interpreters, Certification of Robotic
Process Operators and Technicians, Certified Welding
Supervisors, and Certified Steel Structure Inspector.
Compete Through Smarter Welding 5
 GENERAL ATTENDANCE INFORMATION
McCormick Place Air Travel
The 2004 AWS Welding Show, International Exposition Special Air-Fare Savings
and Annual Convention will be at McCormick Place The American Welding Society has appointed One-Stop
Lakeside Center, 2301 South Lake Shore Drive, Chicago, Chicago/ITS as the official air-travel coordinator for the
Illinois 60616. McCormick Place is 23 miles from O'Hare 2004 Welding Show. Save time and money when you book
International Airport and 10 miles from Midway Airport. your air travel on-line.
For further information, contact McCormick Place at
One-Stop Chicago provides attendees with airline reservations
312-791-7000, fax 312-791-6543,
at the lowest available published fare and best journey
Web www.mccormickplace.com
time. The service fee per ticket issued is $20, or $15 if you
Exposition Hours book on-line. Go to www.aws.org/expo and click on Travel.
Call One-Stop Chicago toll-free at 1-800-621-1083. Outside
Tuesday, April 6 9 AM–5 PM the USA and Canada, call 847-940-1176 Monday through
Wednesday, April 7 9 AM–5 PM Friday, 8 AM to 5 PM (Central Time).
Thursday, April 8 9 AM–3 PM Fly on the official airlines – American, Delta, and ATA –
and save!
Registration Hours American offers 10 percent off the lowest applicable
On-site registration at McCormick Place: published fare when you book and ticket 30 days or more
before travel. Save five percent when you book within 29
Monday, April 5 8 AM–5 PM
days of travel. Or take advantage of American’s zone fares
Tuesday, April 6 8 AM–5 PM for savings on midweek travel to the meeting. Two-day
Wednesday, April 7 8 AM–5 PM minimum stay; no Saturday-night stay required. Zone
fares are fully refundable, less service fee. Discounts are
Thursday, April 8 8 AM–2 PM based on round-trip applicable published fares. Applicable
restrictions must be met.
Spouse/Guest Registration
Delta offers 10 percent off the lowest applicable published
All spouses and guests accompanying Exposition or
fare when you book and ticket 60 days or more before
Convention attendees must register and receive a badge to
travel. Save five percent when you book within 59 days
visit the exhibit area.
of travel. Booking classes A, D, I, U, and T are not eligible
for the meeting discount. Or take advantage of Delta’s
Student Registration
zone fares for savings on midweek travel to the meeting.
AWS offers complimentary registration to the Welding Two-day minimum stay; no Saturday-night stay required.
Show for student groups accompanied by their instructor. Zone fares are fully refundable, less service fee. Discounts
Student Day at the 2004 AWS Welding Show is Thursday, are based on round-trip applicable published fares.
April 8. Instructors are encouraged to register their groups Applicable restrictions must be met.
before March 12, 2004. For Advance Student Registration
ATA flies into Midway Airport and offers a 10 percent discount
Forms, please call 800-443-9353, ext. 256.
off its published fares. Valid travel dates are April 5 through 9,
2004. Blackout dates are April 3, 4, 10, and 11, 2004.
Exposition Visitor
Age Requirements To call the official airlines directly:
Age requirements for Exposition visitors: Persons under 16 American Airlines: 800-433-1790,
years of age are not allowed on the show floor at any time; Reference file number: A9444AE
those 16 to 18 years of age must be accompanied by an Delta Air Lines: 800-241-6760,
adult at all times. Although extensive safety measures have Reference file number: 199821A
been taken to protect visitors, these precautions are aimed ATA: 877-726-0815. Tell the reservations agent you are
at individuals who have attained a certain age and height. with the AWSWES group and refer to convention code
Please help us safeguard your youngsters by observing 040608 and ticket designator code AWSWES.
this rule.

Advance registration—See pages 33 and 34.

6
Airport Transportation
Chicago O’Hare International Airport
Taxis – Available curbside on the lower level of each
terminal. A ride from O’Hare to downtown Chicago costs
about $38 and takes about 30 minutes, depending on traffic.
Passenger Vans – Continental’s Airport Express ticket
counters are across from baggage claim areas. A van ride
from O’Hare to downtown Chicago costs $21 per person
one way, $39 round trip. Telephone: 773-247-1200.
Chicago Transit Authority (CTA) – Trains take 40 minutes
between O’Hare and downtown, and cost $1.50. Trains
leave from inside the terminal on the lower level every 10
minutes during day and evening hours.
Telephone: 312-836-7000.
Midway Airport
Midway Airport has three terminals, A, B, and C.
All vehicle pick-up services are in the main lobby at the
center entrance of the airport.
Taxis – Available in front of the main terminal. A ride from
Midway Airport to downtown Chicago costs $20 to $25 and
takes 20 to 30 minutes, depending on traffic.
Passenger Vans – Continental’s Airport Express desk is
across from the Southwest Airlines ticket counter. A van
ride from Midway Airport to downtown Chicago costs $16
per person one way, $30 round trip.
Telephone: 773-247-1200.
Chicago Transit Authority (CTA) – Trains take 30 minutes
between Midway Airport and downtown Chicago, and cost
$1.50. Trains leave from a station connected to the east
side of the airport. Telephone: 312-836-7000.
Car Rental Discounts
Hertz is the official car rental agency for the 2004 AWS
Welding Show. Save $5 a day (up to $25 per week), PLUS
get your AWS Member discount, when you rent with Hertz
to attend the AWS Welding Show. To reserve on-line, go to
www.aws.org/expo and click Travel. To reserve by telephone,
call 800-654-2210. Mention CDP# 75641 and PC# 946746
to take advantage of this offer.
Parking
Eight thousand parking spaces are available in lots and
garages near McCormick Place. Rates are $14 per entry.
Hotel Information
Hotel rooms for the 2004 AWS Welding Show, International
Exposition and Annual Convention are available to attendees
at discounted rates. Make your reservation through the
AWS Welding Show Housing Bureau by March 5, 2004,
to ensure negotiated rates.
To reserve hotel rooms, please go to our Web site at
www.aws.org/expo or complete the hotel reservation form
and send it to AWS Welding Show/ONE-STOP CHICAGO/ITS.
Sending the housing form to AWS headquarters will
delay your hotel reservation.
The telephone numbers are:
800-424-5248 (toll free, U.S./Canada) or
847-940-2152 (outside U.S./Canada).
FAX 800-521-6017 (toll free, U.S./Canada) or
847-940-2386 (outside U.S./Canada).
Getting To McCormick Place
Complimentary shuttle bus service will be provided April 5
through April 8 from all official hotels to McCormick Place.
Hours of operation will be posted in each hotel lobby.
Alternate transportation is available on the METRA electric
commuter railroad’s direct service to and from downtown
Chicago. For further information, call 312-836-7000.
Taxis are plentiful, with more than 5,800 in service. Check
the directional signs to see which gates are designated for
drop-off and pick-up. Taxis to the downtown area usually
are available beginning two hours before the show closes.
Ask the taxi starter or any McCormick Place Security
Officer for assistance.
Compete Through Smarter Welding 7
WEEK AT A GLANCE
EVENT EXPOSITION SOCIETY PROFESSIONAL PROGRAM

SUNDAY,
APRIL 4

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

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

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

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

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

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

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

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

8
 BRAZING AND SOLDERING EDUCATION PROGRAM CONTINUING EDUCATION SPECIAL PROGRAMS
CONFERENCES/SEMINARS
Gases and Welding Distributors
Association: GAWDA University’s Spring
Management Conference
Manufacturer Hospitalities

8:30 AM–4:30 PM GAWDA

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

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

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

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

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

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

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

10
Tuesday, April 6, and
Wednesday, April 7, 2004
12:30 PM–4:30 PM
Professional Welders Competition
McCormick Place
Compete for cash and prizes in the AWS Professional
Welders Competition to be held on the Expo floor during
the 2004 AWS Welding Show.
Contestants will create a multipass horizontal fillet weld
using shielded metal arc welding on low-carbon steel.
A panel of certified welding inspectors will evaluate
weldments based on speed, weld length, and quality.
To be eligible, contestants must be professional welders
over the age of 19, and must pay a $10 entrance fee.
On-line preregistration at www.aws.org/expo begins
December 1, 2003. On-site registration (and check-in for
preregistrants) will begin Tuesday, April 6, and continue
through Wednesday morning, April 7. Competitive welding
will begin on Tuesday afternoon, April 6, and continue on
Wednesday afternoon, April 7.
The first-place winner will receive a $2,500 prize and a
custom-painted welding helmet. The second-place winner
will receive $1,000; the third-place winner will receive
$500. Each of the top 10 welders will receive an AWS
duffel bag. Each participant will receive an official AWS
Professional Welders Competition T-shirt.
Winners will be announced on Thursday, April 8, at 1 PM.
All contestants are encouraged to attend the award
presentation.
For more information on the Professional Welders
Competition, contact the AWS Education Department,
800-443-9353, ext. 229.
Wednesday, April 7, 2004
7:30 AM–8:30 AM
Prayer Breakfast
McCormick Place
Fellowship and inspiration to start your day. Tickets: $20
Daily—Show Hours
AWS Foundation – Silent Auction
McCormick Place
To help those entering the welding industry achieve their
career goals, place your bid on an array of products and
prizes. All proceeds go to welding scholarships.
Poster Session
McCormick Place on Exposition floor
Graphic displays of technical achievements for close,
first-hand examination. Posters present welding results
and related material that are best communicated visually,
and research results that call for close study of photo-
micrographs, tables, systems architecture, or other
illustrative materials.
This year’s posters appear in four categories:
• Two-year degree or certificate student level
• Four-year degree student level
• Graduate degree student level
• Professional/commercial level
Poster competition authors will be available on Tuesday,
April 6, 2004, from noon to 2 PM to answer questions.
Results will be available Wednesday, April 7.
Special U.S. Army Exhibit
McCormick Place on Exposition floor
Welding experts from the Army's Aberdeen Proving
Grounds will be on hand to demonstrate through lecture,
video, and actual equipment—including a mobile welding
lab—how battle damage to weapons is assessed and
repaired. The exhibit will essentially replicate an actual
field site used during combat. Aberdeen Proving Grounds
has one of the world's largest teaching labs, with 147
booths housed in an $18 million facility.
Compete Through Smarter Welding 11
 EXHIBITORS
Bold = AWS Sustaining Member

A Colorado School of Mines Hitco Carbon Composites, Inc.

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

R
R/D Tech
Rankin Industries, Inc.
Ready Welder Corporation
Redtail International
Resistance Welder Manufacturers Association
Revco Industries, Inc.
Rex-Cut Products, Inc. 13
Compete Through Smarter Welding
If you don’t have this, you don’t have the latest
welding requirements for quality fabrication.
The industry reference since 1928, the 2004 edition covers:
• Design of Welded Connections
• Pre-qualification of Welding Procedure Specifications
• Qualification for Procedures and Personnel
Available at
• Fabrication
the AWS Bookstore
• Inspection
at the Show
• Stud Welding
• Strengthening and Repair of Existing Structures

NEW for 2004

• Clarifies when an engineer’s approval is needed
• Details newest allowable stress range formulae
• Latest restrictions on pre-qualified FCAW and GMAW
power sources
• Most current tolerances for PJP and CJP groove welds
• Adjusts welder qualification essential variables
• Adjusts pre-qualification figure details
• Latest revision of the pre-qualified base metal list

Order today. Call us at 800.854.7179

or visit global.ihs.com to get your copy.
ANSI approved, Department of Defense adopted, NASA NON- AWS
preferred, U.S. customary and metric units of measurement. MEMBER MEMBER

D1.1/D1.1M:2004 (Web Order Code: D1.1/D1.M) $344 $258

D1.1/D1.1M:2004 CD (Web Order Code: D1.1/D1.1M CD) $375 $281

Full D1.1-2004 text, as well as graphics and tables now
on a CD-ROM. Find specific provisions fast with five
convenient search methods.
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© American Welding Society 2004 TEC1031AP
WHAT’S NEW
AND HOT AT THE 2004 EXPO
We asked some of the industry’s leading
companies what new products they plan to
introduce at the 2004 Exposition. Their answers
fall into two main categories: ergonomics and
computerization. New welding equipment is
being designed with operator comfort, efficiency,
and safety in mind, while digital technology
enhances precision and productivity on the job.
Here are some of the innovative new products
you will see at the 2004 Welding Show:
Motor in the Cable
To make push-pull welding more comfortable and
convenient for the operator, ABICOR Binzel Corp. in
Frederick, MD, will introduce its new ABICONDA™ series
of push-pull MIG welding guns. The innovative ABICONDA
350 ampere air-cooled and 500 ampere water-cooled
push-pull guns house the motor in the cable instead of
at the front end of the gun, making the ABICONDA much
lighter in weight and easier to use.
Instead of a pistol-grip handle, the ABICONDA guns have
the popular ALPHA-style handle, with the trigger readily
accessible on the bottom for added comfort. This natural
hand grip puts less strain on the fingers and wrist.
On both the air-cooled and water-cooled models, the
front end of the gun and torch cable can be removed and
replaced easily. The power cable, water hoses, and con-
duits have a sturdy outer sheathing for easier maneuver-
ability. They are available in 10-, 15-, and 25-foot lengths.
For better inventory control, the air-cooled ABICONDA
consumables are interchangeable with ALPHA Mig-Guns,
and the water-cooled ABICONDA consumables are inter-
changeable with ABIMIG Mig-Guns.
A potentiometer for wire speed control is optional on the
handle. The ABICONDA does not require an integrated
wire drive unit and will fit any commercially available
wire drive unit fitted with an ABICOR Binzel adaptor kit.
This reduces capital investment when the ABICONDA is
used with existing equipment.
ABICOR Binzel Corp. also will introduce, in conjunction with
Highyag Lasertechnologie GmbH, advanced tools for laser
welding and cutting. Highyag welding and cutting heads
are adaptable to most laser power source manufacturers.
The product range includes mirrors, lens covers, fiber-optic
cables, and a wide range of peripheral equipment.
In addition, ABICOR offers the new Highyag Hybrid welding
head, which combines the proven MIG process with
modern laser welding, producing a quality weld through
increased tolerances and processing speeds. Highyag
products are modular and easily adaptable to different
processing requirements.
Variable-Speed Foot Control
Variable-speed foot control on a welding positioner gives
the operator maximum control of the rotation of the posi-
tioner table top, saving time and increasing productivity. At
the 2004 Exposition, Genstar Technologies Co., Inc., of
Chino, CA, will introduce a variable-speed industrial-style
foot-control option for all of its GENTEC welding positioners
from 200 pounds to 45,000 pounds.
This variable-speed unit supports all of the standard
control features: on/off, contactor control, speed, and
time. Optional control features include variable speed,
weld travel control, and sequencer.
The foot control operates like a gas pedal over the full
speed range. A light touch moves the part at the slowest
imaginable speed, giving the operator the exact speed
required for a weld with a minimum of effort in manipulat-
ing the welding torch. At full speed, the operator can index
or jog the part rapidly into the next area to be welded.
With Genstar’s variable-speed foot-control kits, users
can employ variable speed for manual welding applica-
tions, or reconfigure the welding positioner into hundreds
Compete Through Smarter Welding 15
 of different applications within minutes. With do-it-your-
self accessory packages, various stages of automation up
to fully automatic welding systems can be achieved.
Consumer-Loyalty Program
You’ve heard of frequent-flyer, frequent-shopper, and
frequent-stay programs that build consumer loyalty. Now
comes the first such program in the welding industry,
JUMP™ (Jackson Upgrade Mastery Program), which
Jackson Products of Belmont, MI, will introduce at the
2004 Exposition.
JUMP’s goal is to increase welding safety. It provides end-
users with upgrade incentives, rebate offers, sneak-peeks
at Jackson’s latest welding technologies, and up-to-date
information about the firm’s top-of-the-line EQC welding
helmets. Each welding helmet package includes a product-
specific JUMP card that gives the consumer a personal
"Thank You" along with rebate offers and JUMP registra-
tion/warranty opportunities. Consumers simply fill out and
mail the postage-paid JUMP registration card in the package.
JUMP’s Welding Instructor Program also encourages
students to use Jackson helmets and register for JUMP.
Instructors can keep track of student-enrollment totals
and receive free Jackson EQC welding helmets. For every
40 students who enroll in JUMP, a registered instructor
will receive a Journeyman® auto-darkening helmet.
Instructors may continue building their enrollment to 80
students to receive a Master Variable auto-darkening
helmet, or to 120 students to receive a NexGen™ EQC®
auto-darkening helmet. JUMP instructors also will
receive follow-up correspondence with updated student
JUMP enrollment totals, welding-safety information,
promotions, and product literature.
JUMP instructor packets have been sent to more than
6,200 welding instructors in grade schools, high schools,
community colleges,vocational/technical schools, and
universities across the country.
Jackson plans to expand JUMP with additional elements,
such as personalized newsletters and JUMP Bags for
students containing basic accessories that every beginning
welder needs.
Jackson also will debut its new Huntsman® Solera™ solar-
powered auto-darkening filter. The Solera features two
solar panels, two sensors, and a two-year warranty, at a
distributor price 30 % lower than the previous Solex 2100.
The new Solera lens will be available in the Huntsman line
as a cartridge or in the 981P helmet, and as a running
change under the Jackson Apprentice name.
16
Digital Communication & Control
As welding technology shifts from analog to digital control,
The Lincoln Electric Company of Cleveland, OH, is position-
ing itself in the forefront of that shift. Lincoln has incorpo-
rated the latest developments in its Nextweld™ technolo-
gies and processes into its newest Power Wave™ power
sources and Power Feed™ wire feeders. These highly
engineered components are designed to work together
in a sophisticated software-driven welding system.
These products reflect the latest Nextweld thinking from
Lincoln in digital communication and Waveform Control
Technology™. For example, they are equipped to allow
fast, flexible component communications using Lincoln’s
ArcLink® communications protocol. They also feature new
process- and production-monitoring capabilities with real-
time feedback on arc current, voltage, wire-feed speed,
arc time, and other machine-status conditions. At the
2004 Exposition, Lincoln will demonstrate networked
remote monitoring and control of welding systems via
Ethernet Web connections.
Lincoln also will introduce a new level of welding flexibility
for industrial environments with its new “M” version modu-
lar power sources and wire feeders. Fabricators may
change interface modules as their needs change to gain
added networking capability, using DeviceNet or Ethernet
for remote system diagnostics, weld mode selection, data
logging, and other functions. They will save time download-
ing or transferring weld parameters using the infra-red port
with a Palm® OS-based hand-held computer.
In the welding consumables realm, Lincoln will introduce
Innershield® flux-cored self-shielded electrodes with
MicroFlux™ Technology. This proprietary fill technology
packs smaller particles of more uniform size into the
electrode core to deliver a more forgiving arc and higher
deposition rates while minimizing gas marking.
Also, Lincoln SuperArc® MIG wire electrode, with
MicroGuard™ Ultra surface-engineering technology,
benefits from a proprietary surface treatment. It guards
against poor feedability, and contains arc-enhancement
agents that contribute to a smooth, stable arc.
Flexible Multi-MIG System
New multi-MIG welding systems that employ flexible
welding software to provide the perfect arc for every
MIG welding process will be introduced at the 2004
Exposition by Miller Electric Mfg. Co. of Appleton, WI. The
processing power of Miller’s new Axcess 450 and Auto-
Axcess 450 (the latter for automated applications) solves
these complex physics problems with a simple interface
that prompts operators to enter the wire type, wire diame-
ter, gas combination, and process desired. Then Axcess
provides the best solution. After that, the operator selects
desired wire feed speed; the system maintains a constant
arc length throughout the appropriate welding range.
Software is available for steel, stainless steel, and alumin-
um wires; 100 percent CO2 and 98/2, 95/5, 90/10, and
75/25 argon/CO2 gas mixtures; and MIG, pulsed MIG,
metal cored, Accupulse™ (a hybrid, pulsed spray transfer
process that cools the weld puddle and adapts to the
joint condition), and RMD™ (Regulated Metal Deposition,
an ultra-low-heat input, low-spatter, hybrid short-circuit
transfer MIG welding process ideal for filling gaps and
welding thin materials or root passes on pipe). For other
welding applications and custom programs, operators
can fine-tune an existing program using Miller’s optional
WaveWriter™ graphical software on a standard M series
Palm® PDA.
The Axcess 450 and Auto-Axcess 450 will have an output
of 450 amperes/38 volts at 100 percent duty cycle and
maximum output of 600 amperes/38 volts at 60 percent
duty cycle. Voltage range in the constant voltage (CV)
mode is 10 to 44 volts with 85 volts DC maximum open-
circuit voltage. They accept any primary power from 208
volts through 575 volts, single-phase or three-phase, 50
hertz or 60 hertz. Their dimensions are 22 in. x 15.5 in. x
28.5 in. Each weighs 175 pounds.
New Lightweight Inverters
For maximum portability and arc quality in shielded metal
arc welding and gas tungsten arc welding of steel and
stainless steel, Miller also will introduce its new Maxstar“
150 Series of inverters offering the most output per pound
of any inverters available.
Miller’s revolutionary Fast Switch technology enables the
Maxstar 150 to weigh just 13.7 pounds (five to 10 pounds
lighter than competitive units), have a five-ampere to
150-ampere welding range on 115 to 230 volts AC primary
power, and provide outstanding arc performance.
All Maxstar 150 models have stick output of 150 amperes
at 30 percent duty cycle using 230 volts AC power. This
enables nearly unlimited welding with a 1/8-in. diameter
stick electrode, suitable for 80 percent of all stick applica-
tions. Operators in the maintenance/repair, construction,
mechanical contractor, food/beverage/dairy/restaurant,
shipboard welding, experimental aircraft, and farm/ranch
industries all will benefit.
Through its Auto-Line™ feature, the Maxstar 150 automati-
cally connects to 115 through 230 volts AC single-phase
power, ± 10 percent, so operators can plug it in and begin
welding without delay. Auto-Line also maintains a steady
arc even if primary power varies when welding. It over-
comes “dirty” power, a common problem in rural areas or
on construction sites.
The Maxstar 150 is available in three models:
• S, for stick-only welding with E6013 and E7018
electrodes.
• STL, for stick or TIG output and Miller’s Lift-Arc™ starting
method, which provides inclusion-free TIG arc starts
without the use of high frequency.
• STH, with all features of the other machines, plus built-
in high-frequency noncontact arc starting and pulsing
controls to eliminate tungsten or material contamination.
Precision Process Control Delivers
Advances in high-definition plasma technology are bring-
ing precision cutting to ever-thicker materials. The process
is increasingly controlled by computers, and refinements in
torch technology are achieving arc densities (amperage
per square inch) two to three times higher than standard
plasma.
At the 2004 Exposition, Thermal Dynamics, a Thermadyne
company located in West Lebanon, NH, will debut its
Ultra-Cut™ 150, the first fully computerized high-definition
plasma arc cutting system with consumables conveniently
contained in a cartridge instead of the torch head. To
change applications, an operator now can simply change
cartridges in a matter of seconds.
Gas selection, flow, and power-supply amperage are all
digitally controlled. The cutting process now is more
consistent, forgiving, and user-friendly, delivering an
exceptionally wide window of parameter adjustment to
provide precise cuts free of dross and slag.
Another innovative feature is a closed-loop feedback system
using mass flow meters for very precise gas flow. Unlike
orifices with pre-measured settings, or ball-type flow
meters that provide approximate measures, a mass flow
meter counts gas molecules to calculate continuously the
exact flow of both the plasma and shield gases. The
Thermal Dynamics Ultra-Cut automatic gas control provides
real-time readings to a computer, which responds by adjust-
ing the aperture as the work proceeds, yielding uniform cuts.
The Ultra-Cut 150 is the first in a new family of products –
some higher in amperage, others lower – to be introduced
during 2004. All will employ Thermal Dynamics’ new
XT™-300 torch, using technology that automatically
self-aligns the consumables. The firm says that Ultra-
Cut’s rigorous control of consumables alignment,
amperage, and gas flow will achieve economies by
making the consumables last longer, and will enhance
the system’s work performance.
Compete Through Smarter Welding 17
 PROFESSIONAL PROGRAM
Tuesday, April 6, 2004
MORNING SESSIONS:
9 AM–Noon
SESSION 1
Aluminum Welding
A. 10 AM Variable Polarity Arc
Welding Studies on 6061/A1203/10w,
by T. Lienert, Los Alamos National
Laboratory, Los Alamos, NM
B. 10:35 AM Aluminum Flux Cored
Wire Development, by G. J. Atkins
and D. L. Olson, Colorado School of
Mines, Golden, CO
C. 11:10 AM Electrical Resistance
Hot Upset Welding of Aluminum Alloy
5454, by F. Feng, Alcan International
Limited, Kingston, ON, Canada
SESSION 2
Forensics and Weld Performance
A. 10 AM Forensic Study of the
Steel in the World Trade Center,
by T. Siewert, F. Gayle, R. Fields,
D. McColskey, and C. McCowan,
National Institute of Standards and
Technology, Boulder, CO
B. 10:35 AM Fitness-for-Service
Evaluation of Bulkheads, by C. Tsai,
The Ohio State University, Columbus,
OH; G. Jung, Edison Welding Institute,
Columbus, OH; and P. W. Sauser, U.S.
Army Corps of Engineers, Saint Paul, MN
C. 11:10 AM A Thermal Method
to Reduce Buckling Distortion, by
R. Dull, Edison Welding Institute,
Columbus, OH
D. 11:45 AM Weld Repair of the
U. S. Capitol Dome, by T. Siewert and
C. McCowan, National Institute of
Standards and Technology, Boulder,
CO; K. Hildebrand, AoC, Washington,
DC; R. Bushey, ESAB Welding &
Cutting Products, Hanover, PA; and
D. Kotecki, The Lincoln Electric Co.,
Cleveland, OH
18
SESSION 3
GMAW Ferrous 1
A. 10 AM In Situ Weld Pool
Measurement Using Stereovision,
by C. Debrunner, T. Vincent,
J. P. Steele, and F. Al-Baiya,
Colorado School of Mines, Golden, CO
B. 10:35 AM Characterizing
Adaptive Arc Length Control Methods
for Pulsed Gas Metal Arc Welding,
by B. Baughman and D. Harwig,
Edison Welding Institute, Columbus,
OH; and R. Richardson, The Ohio
State University, Columbus, OH
C. 11:10 AM Influence of Procedure
Variables on C-Mn-Ni-Mo Metal
Cored Wire Ferritic All-Weld Metal,
by M. R. de Rissone, Facultad Regional
San Nicolas UTN; H. Svoboda,
Facultad de Ingenieria UBA; E. S. Surian,
FR San Nicolas UTN; and L. de Vedia,
UNSAM, CIC (Buenos Aires, Argentina)
AFTERNOON SESSIONS:
2 PM–5 PM
SESSION 4
FCAW/SMAW
A. 2 PM Hydrogen Reduction
in FCAW Steel Weld: Metal
Spectroscopic Monitoring of Arc
During Deposition, by J. Chandler,
C. Clasper, S. Liu, and G. Edwards,
Colorado School of Mines, Golden, CO
B. 2:35 PM Fluoride and Yttrium
Additions in Steel Welds: Effects on
Hydrogen and Weld Metal Properties,
by C. Clasper, J. Chandler, G. Edwards,
and S. Liu, Colorado School of Mines,
Golden, CO
C. 3:10 PM Characterization of
Microconstituents in Welds Using
FCAW-S Consumables, by J. Major
and S. Liu, Colorado School of Mines,
Golden, CO; and M. Quintana and C.
Dallam, The Lincoln Electric Co.,
Cleveland, OH
D. 3:45 PM Modeling of Fe-C-Al-Mn
Steel Weld Microstructure, by
S. S. Babu, S. A. David, and J. M.
Vitek, Oak Ridge National Laboratory,
Oak Ridge, TN; J. W. Elmer, Lawrence
Livermore National Laboratory,
Livermore, CA; and M. Quintana, The
Lincoln Electric Co., Cleveland, OH
E. 4:20 PM Optimization of SMA
Weld Metal Composition,
by M. Marimuthu, S. S. Babu, and
S. A. David, Oak Ridge National
Laboratory, Oak Ridge, TN
SESSION 5
GMAW Ferrous 2
A. 2 PM Heat Transfer Fluid Flow
and Solidified Surface Profile
During Gas Metal Arc Fillet Welding,
by W. Zhang, C. H. Kim, and T.
DebRoy, Pennsylvania State
University, University Park, PA
B. 2:35 PM Determination of
Unknown Welding Parameters for
GMA Fillet Welding Using a Smart
Model, by A. Kumar and T. DebRoy,
Pennsylvania State University,
University Park, PA
C. 3:10 PM The Humping
Phenomenon in High Speed GMA
Welds, by T. C. Nguyen, D. C.
Weckman, D. A. Johnson, and H. W.
Kerr, University of Waterloo, Waterloo,
ON, Canada
D. 3:45 PM Robotic Out-of-Position
GMAW Welding Downhill: A Study
of Performance and Parameters,
by J. P. Steele, T. Vincent, and
C. Debrunner, Colorado School of
Mines, Golden, CO
SESSION 6
Materials
A. 2 PM Stray Grain Formation
During Welding of Single Crystals,
by J. M. Vitek, S.S. Babu, S. A. David,
and J. W. Park, Oak Ridge National
Laboratory, Oak Ridge, TN
B. 2:35 PM Deformation Strains
in Single Crystal Alloy Welds, by
O. M. Barabash, J. A. Horton, Jr., S. S.
Babu, R. I. Barabash, and S. A. David,
Oak Ridge National Laboratory, Oak
Ridge, TN
C. 3:10 PM Topological Features
of Grains in the HAZ, by S. Mishra
and T. DebRoy, Pennsylvania State
University, University Park, PA
D. 3:45 PM Direct Metal Deposition
of Copper onto Steel Using a Nickel
Interlayer, by F. F. Noecker II and
J. N. DuPont, Lehigh University,
Bethlehem, PA
E. 4:20 PM Fluxless Plasma
Soldering of Lead-Free Solders, by
J. P. Jung and Y. N. Zhou, University of
Waterloo, Waterloo, ON, Canada; J. K.
Moon, LG Electronics Institute, Seoul,
Korea; and K. I. Kang and J. S. Lee,
University of Seoul, Seoul, Korea
F. 4:55 PM The Microstructure
Characterization of Synchronous
Vibratory Welding, by C. W. Kuo
and W. Wu, National Chung Hsing
University, Taichung, Taiwan, Republic
of China
Wednesday, April 7, 2004
MORNING SESSIONS:
9 AM–Noon
SESSION 5
GMAW Non-Ferrous
A. 9 AM Distortion Control in
Welding Aluminum GIS Vessel, by
C. Tsai, The Ohio State University,
Columbus, OH; D. S. Chou, IWTRL,
Taipei, Taiwan, Republic of China;
S. S. Lin, Chung-Hsing E&M Ltd.,
Taipei, Taiwan, Republic of China;
and G. Jung, Edison Welding Institute,
Columbus, OH
B. 9:35 AM Fundamental Studies
on the Relationship Between Plastic
Strains and Distortion in Fillet Welded
T-Joints, by G. Jung, Edison Welding
Institute, Columbus, OH; and C. Tsai,
The Ohio State University, Columbus, OH
C. 10:10 AM Liquation, Cracking,
and Backfilling in Partial-Penetration
Welds of Aluminum Alloys Comparing
Alloys 2024, 6061, and 7075, by
S. Kou, C. Huang, and G. Cao,
University of Wisconsin, Madison, WI
D. 10:45 AM Gas Metal Arc
Welding of Titanium: Producing Full
Penetration, Contaminant-Free Welds,
by G. M. Chirieleison and
S. Liu, Colorado School of Mines,
Golden, CO; M. Wells, Naval Surface
Warfare Center, West Bethesda, MD;
and S. Luckowski, US Army ARDEC,
Picatinny Arsenal, NJ
E. 11:20 AM Contact Models of
GMAW Wire Liner Friction: An Inverse
Photoelastic Solution, by T. Padilla,
J. R. Berger, and D. R. Munoz,
Colorado School of Mines, Golden,
CO; T. P. Quinn, National Institute of
Standards and Technology, Boulder,
CO; and R. A. L. Rorrer, University of
Colorado, Denver, CO
SESSION 8
Laser Beam Welding I
A. 9 AM A Novel Approach to
Laser Weld-Bonding Al Autos, by
R. W. Messler, Jr., E. A. Johnson, and
J. Y. Levene, Rensselaer Polytechnic
Institute, Troy, NY; L. Chen, University
of Rochester, Rochester, NY; and
S. Bohnenstiehl, Montana Technical
University, Butte, MT
B. 9:35 AM Effect of Temporal Pulse
Shaping on Cracking Susceptibility of
AA 6061-T6 Aluminum Alloy, by
J. Zhang, D. C. Weckman, and
Y. N. Zhou, University of Waterloo,
Waterloo, ON, Canada
Compete Through Smarter Welding
C. 10:10 AM Radial Alignment of
Photonic Packages with Sequential
Laser Spot Welds, by P. W.
Fuerschbach, J. T. Norris, and
J. E. Bernal, Sandia National
Laboratories, Albuquerque, NM
D. 10:45 AM Analysis of Welding
Induced Submicron Movements
in Laser Micro-Welding of
Optoelectronic Packages, by Z. Feng,
Oak Ridge National Laboratory, Oak
Ridge, TN; and J. Lu, Luxtera, Inc., Lake
Forrest, CA
E. 11:20 AM A Coupled Thermal
and Microstructure Model for Laser
Processing of Ti-6Al-4V, by S. M.
Kelly, S. S. Babu, S. A. David, and
T. Zacharia, Oak Ridge National
Laboratory, Oak Ridge, TN; and S. L.
Kampe, Virginia Polytechnic Institute
and State University, Blacksburg, VA
SESSION 9
Weldability
A. 9 AM Repair Weldability of Heat-
Resistant Alloys, by S. Shi and J. C.
Lippold, The Ohio State University,
Columbus, OH; and J. Ramirez,
Edison Welding Institute, Columbus, OH
B. 9:35 AM Development of a
Modified Cast-Pin Tear Test, by
D. Ryan and J. C. Lippold, The Ohio
State University, Columbus, OH
C. 10:10 AM The Effect of C, Nb,
and Ti Additions on Ductility-Dip
Cracking in Austenitic Stainless
Steels, by A. J. Ramirez, J. W. Sowards,
and J. C. Lippold, The Ohio State
University, Columbus, OH
D. 10:45 AM Ranking the
Resistance of Wrought Superalloys
to Strain Age Cracking, by M. Rowe,
Haynes International, Inc., Kokomo, IN
E. 11:20 AM The Effect of
Chromium on the Weldability and
Corrosion Behavior of Fe-Al Weld,
by J. R. Regina, J. N. DuPont, and
A. R. Marder, Lehigh University,
Bethlehem, PA
19
 F. 11:55 AM *Analysis of Crack
Formation in the Longitudinal
Varestraint Test, by C. V. Robino,
G. A. Knorovsky, and M. Reece,
Sandia National Laboratories,
Albuquerque, NM; J. N. DuPont,
Lehigh University, Bethlelem, PA;
and Z. Feng, Oak Ridge National
Laboratory, Oak Ridge, TN
AFTERNOON SESSIONS
2 PM–5PM
SESSION 10
Electron Beam Welding
A. 2 PM *Electron Beam
Diagnostics and Weld Transfer, by
T. Palmer, J. W. Elmer, and P. Terrill,
Lawrence Livermore National
Laboratory, Livermore, CA; and
K. Nicklas and T. M. Mustaleski,
BWXT Y-12 Plant, Oak Ridge, TN
B. 2:35 PM Effect of HED Welding
on the Microstructural Development
of Superaustenitic Stainless Steels,
by M. J. Perricone and J. N. DuPont,
Lehigh University, Bethlehem, PA
C. 3:10 PM *The Role of Pressure
in Welding (and Cutting) Processes:
Comparing Pressure Effects of Heat
Sources for Various Weld Processes,
by G. A. Knorovsky and D. O. MacCallum,
Sandia National Laboratories,
Albuquerque, NM
D. 3:45 PM *Controlled Scanning
Electron Beam Micro-to-Nano
Welding: Micro-to-Nano Electron
Beam Welding via Adapted
Scanning Electron Microscopy, by
B. M. Nowak-Neely, D. O. MacCallum,
and G. A. Knorovsky, Sandia National
Laboratories, Albuquerque, NM
SESSION 11
Laser Beam Welding 2
A. 2 PM *Beam Profiling of a
3.3kw CW Cd:YAG Laser, by
T. Lienert and R. W. Carpenter,
Los Alamos National Laboratory,
Los Alamos, NM
20
B. 2:35 PM Alloying Element
Vaporization during Laser Spot
Welding of 304 Stainless Steel, by
X. He and T. DebRoy, Pennsylvania
State University, University Park, PA;
and P. W. Fuerschbach, Sandia
National Laboratories, Albuquerque, NM
C. 3:10 PM Identifying Uncertain
Material Parameters in Weld Pool by
Integrated Modeling, by A. De,
IIT Bombay, Mumbai, India;
and T. DebRoy, Pennsylvania State
University, University Park, PA
D. 3:45 PM *Laser and E-Beam
Joining Unusual Fe-Base, Ni-Base,
and Refractory Alloys, by
D. O. MacCallum, B. M. Nowak-Neely,
G. A. Knorovsky, and F. M. Hooper,
Sandia National Laboratories,
Albuquerque, NM
E. 4:20 PM Optimization of a Laser+
GMAW Hybrid Welding Process,
by P. Kinney, Robert W. Hunt Co.,
Pittsburgh PA; and D. Farson, The
Ohio State University, Columbus OH
SESSION 12
Solid-State Joining
A. 2 PM Inertia Welding for High-
Pressure Hydrogen Storage,
by M. C. Balmforth, G. K. Hicken,
and J. D. Puskar, Sandia National
Laboratories, Livermore, CA
B. 2:35 PM *Microstructural
Characterization of Inertia Welded
2l-6-9 Stainless Steel, by J. D. Puskar,
B. P. Somerday, D. K. Balch, C. H.
Cadden, and M. C. Balmforth, Sandia
National Laboratories, Livermore, CA
C. 3:10 PM Prediction of Residual
Stresses and Property Distributions
in Friction Stir Welds of Aluminum
Alloy 6061-T6, by Z. Feng, X. Li Wang,
and S. A. David, Oak Ridge National
Laboratory, Oak Ridge, TN
D. 3:45 PM Effects of Ti-C Coating
on Electrode Degradation: Tip Life
Improvement for RSW With HDG
Steel, by K. R. Chan, S. J. Dong,
Y. N. Zhou, and Y. Ding, University of
Waterloo, Waterloo, ON, Canada
E. 4:20 PM Modeling Resistance
Spot Welding Electrode Life, by
S. S. Babu and M. L. Santella, Oak
Ridge National Laboratory, Oak Ridge,
TN; and W. Petterson and J. E. Gould,
Edison Welding Institute, Columbus, OH
Thursday, April 8, 2004
MORNING SESSIONS:
9 AM–Noon
SESSION SP1
Current Research Topics
in the U.S. Navy
Sponsored by the U.S. Navy
A. 9 AM Shielding Gas Dewpoint
Study for Titanium Welding, by
K. N. Tran, M. E. Wells, and
D. R. Forrest, Naval Surface Warfare
Center, West Bethesda, MD
B. 9:35 AM Friction Stir Processing
of Nickel Aluminum Bronze, by
J. P. Nguyen, M. Posada, J. J. DeLoach,
R. S. Fielder, and W. A. Palko,
Naval Surface Warfare Center, West
Bethesda, MD
C. 10:10 AM The Effects of Tandem
Submerged Arc Welding Process
Parameters on HAZ Toughness in
HSLA-65: Numerical and Experimental
Simulations, by D. R. Forrest,
J. J. DeLoach, and R. J. Wong,
Naval Surface Warfare Center, West
Bethesda, MD
D. 10:45 AM Weldability of
Dissimilar High Strength Steel
Weldments, by J. Kalp and
J. P. Nguyen, Naval Surface Warfare
Center, West Bethesda, MD
E. 11:20 AM A Neural Network
Analysis of HSLA Weld Wire: A New
Weld Metal Composition for 100 ksi
Weld Wire, by E. A. Metzbower,
US Naval Research Laboratory,
Washington, DC; and J. J. DeLoach,
Naval Surface Warfare Center, West
Bethesda, MD
*Paper sponsored by the U.S. Department
of Energy/Interagency Manufacturing
Operations Group/Subgroup on Joining
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TH5
 34TH INTERNATIONAL BRAZING
AND SOLDERING SYMPOSIUM
(included in Professional Program fee)

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

9 AM–NOON 2 PM–5 PM

SESSION BS1 SESSION BS2

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

22
 Wednesday, April 7, 2004

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

BREAK
10:30 AM–10:45 AM

D. 10:45 AM Flexure Testing of

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

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

where convenience and bargains will meet.

The 2004 AWS Book Store, operated by Global Engineering

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

Compete Through Smarter Welding 23

 FREE SESSIONS
Because the following sessions at
McCormick Place are free and likely to
attract a large audience, on-line
preregistration is advisable. To
preregister, go to www.aws.org/expo
after December 1, 2003.
Wednesday, April 7, 2004
8 AM–9:30 AM
Structural Engineer Response to the
World Trade Center Tragedy
Emmanuel E. Velivasakis, P.E., the
lead forensic investigator at the World
Trade Center, participated and directed
some 300 engineers in securing
Ground Zero for safe search-and-
rescue efforts in the hours and days
following the World Trade Center
tragedy. In this presentation, he will
discuss his team’s assessment,
demolition, and temporary stabilization
efforts at the disaster site. A question-
and-answer period will follow.
Mr. Velivasakis is president and
managing principal of LZA Technology,
a division of The Thornton-Tomasetti
Group in New York City.
10 AM–11:30 AM
An Interview with the World’s
Leading Welding Design Expert
Omer Blodgett, Sc.D., P.E., is recognized
throughout the world for his knowledge
of welded design and his outstanding
ability to communicate, dramatize,
and illustrate it. Dr. Blodgett was
among the notables inducted in the
first Class of AWS Fellows in 1991.
He continues to present his Essential
Elements of Steel Weldment Design
for Manufactured Products course
for The Lincoln Electric Company,
Cleveland, OH, where he is the senior
design consultant. (See program
schedule for Thursday, April 8).
Another well-known welding expert,
Duane Miller, Sc.D., P.E., will act as
the interviewer and will moderate
an audience question-and-answer
period. Dr. Miller serves as vice chair
24
of the AWS D1 Structural Welding
Committee and chair of the D1L
Seismic Issues Subcommittee. He is
manager of The Lincoln Electric
Company’s Welding Technology Center
and a welding-design consultant for
the firm.
Wednesday, April 7, 2004
9 AM–2 PM Field Construction
and/or Field Repair Sponsored by the
AWS Welding Industry Network (WIN)
9 AM–9:45 AM Field Welding
Repair – Common Problems and
Their Solutions, by Keynote Speaker
Dave McQuaid, D. L. McQuaid &
Associates, Inc., Bethel Park, PA
9:45 AM–10:30AM Automated
Ultrasonic Inspection Applications
on Field-Erected Tanks and Vessels,
by Ron Kruzic, Chicago Bridge &
Iron, Plainfield, IL
10:30 AM–11:15 AM Production
Welding of Alloy 59 Material for
Corrosion-Resistant Applications,
by Mark Butts, Chicago Bridge &
Iron, Plainfield, IL
11:15 AM–Noon Welding Symbols
for a Global Manufacturing
Environment, by Jerry Warren,
C & H Global, Burr Ridge, IL
Noon–1 PM
LUNCH ON YOUR OWN
1 PM–1:45 PM Welding of the
International Space Station
Thermal-Control Units – Keeping
Cool in Space, by Ernest Levert,
Lockheed Martin Missiles & Fire
Control, Dallas, TX
2:30 PM–3:30 PM
Challenges of Maintenance Welding
on the Trans-Alaska Crude Oil
Pipeline and Fuel Gas Line Repairs
Construction on the Trans-Alaska
Pipeline System (TAPS) spanned two
years, and involved more than 30,000
workers. Twenty-eight years later, it
remains the largest and most expen-
sive privately funded construction
project ever undertaken. Seventeen
percent of America’s oil moves through
the 48-inch-diameter pipeline as it
winds 800 miles under and above
the ground through the nation’s most
environmentally sensitive land.
The risk of damage to the pipeline
during welding maintenance and
repairs is increasing as a reduction
in the flow of crude oil causes the
pipeline’s operating temperature to
decrease.
Bill Bruce, principal materials section
engineer at Edison Welding Institute
in Columbus, Ohio, and Alan Beckett,
welding program steward at Alyeska
Pipeline Service Company in Anchorage,
Alaska, will share the alternative
procedures that researchers have
devised to avoid weld cracking.
In addition, they will discuss the safety
methods they use to make in-service
repairs to the gas transmission
pipeline supplying fuel to the north-
ern pump stations on TAPS.
An audience question-and-answer
period will follow their presentation.
Seating is limited. Please preregister
on-line at www.aws.org/expo for the
free session with Bill Bruce and Alan
Beckett.
The presentation will focus on find-
ings discussed in the white papers,
Review and Requalification of
Procedures for Maintenance Welding
on the Trans-Alaska Pipeline,
co-authored by Bruce; Mike Rosenfeld,
Kiefner & Associates, Columbus,
Ohio; and Beckett; and Trans-Alaska
Pipeline Fuel Gas Line In-Service
Repairs, by Beckett; Frank Caito,
Veco Engineering, Fairbanks, Alaska;
and Kurt Helms, Houston Nana JV,
Fairbanks, Alaska.
 3:30 PM–4:30 PM
Removing Dangerous Gases from
Ships Loading Crude Oil at Valdez
As tanker ships take on crude oil at
the Valdez Marine Terminal, the desti-
nation of the Trans-Alaska Pipeline
System, stainless-steel arms capture
flammable hydrocarbon vapors. FMC
Energy Systems in Sens, France, a
subsidiary of FMC Technologies, Inc.,
fabricated these devices, which are
the world’s first duplex stainless-steel
marine vapor-collection arms.
Tony Balowski, a welding engineer
from the Alyeska Pipeline Service
Company at Valdez Marine Terminal,
will share insider details of the
extensive research and testing that
created this revolutionary develop-
ment in welded fabrication.
The presentation will focus on
findings discussed in the white paper,
Fabrication of World’s First Duplex
Stainless Steel Loading Arms,
by Balowski and Chuck Strub,
Alyeska Pipeline Service Company,
Anchorage, Alaska.
Thursday, April 8, 2004
8 AM–10:30 AM
Computer Procedures, Policies, and
Security: Is Your Computer, Network,
Intranet, or Internet Safe from
Mischief, or Worse, Mayhem?
Did you know that a $20 software
program that automates the process
of computer forensics enables anyone
to retrieve and view e-mails, por-
nography, and other secrets from a
computer, even if the files were creat-
ed years ago? In today’s atmosphere
of spiraling litigation, no company or
consultancy, large or small, can afford
just to cross its fingers and hope it
won’t be the victim of a virus, hacker,
or disgruntled former employee.
If you don’t know that every click you
make on the Windows 98 Start Menu
is logged and permanently stored on
a hidden encrypted database; if you
think that deleting “Internet cache
and history” will protect you; or if
you’re planning to upgrade to a net-
worked or higher system, you must
attend this session.
Security experts from Information
Handling Services, Englewood, CO,
will provide hints, tips, and insider
information to help you secure your
computer operations.
This free session will cover:
• Data protection, including
encryption, data erasers, and
secure USB drives.
• Communications protection,
including anti-virus tools, firewalls,
wireless security, secure e-mail,
anti-spam, anti-spyware, and
secure browsing.
• Physical protection, including
laptops, surveillance, and
hardware authentication.

2004 EDUCATION PROGRAM

Tuesday, April 6, 2004
EDUCATION SESSION 1
9 AM–10 AM 2004 Plummer Memorial Educational
Lecture Welder Training: What Can We Learn From the
Cockpit? by Byron May, manager, repair process and
materials engineering, United Air Lines, San Francisco, CA
10:10 AM–10:40 AM Integrating Technology into the
Classroom: The Modernized Welding Program at New
Horizons Regional Education Center, by E. Dupree,
New Horizons Regional Education Center, Hampton, VA;
J. C. Barto III and A. D. Robertson, Training Modernization
Group, Inc., Chesapeake, VA; and G. A. Roy, Northrup
Grumman Newport News, Newport News, VA
10:45 AM–11:15 AM Education and Training Strategies
for Advanced Welding Technology, by Dr. W. R. Polanin,
Illinois Central College, East Peoria, IL
11:20 AM–11:50 AM A Model for Industry and Technical
School Cooperation: Helping Students Transition from the
Classroom to the Workplace, by G. A. Roy, Northrup
Grumman Newport News, Newport News, VA; J. C. Barto III
and L. T. Saylor, Training Modernization Group, Inc.,
Chesapeake, VA; and E. Dupree, New Horizons Regional
Education Center, Hampton, VA
Noon–1:30 PM LUNCH ON YOUR OWN
EDUCATION SESSION 2
1:30 PM–2 PM S.E.N.S.E. Questions and Answers:
A Guide to the Changes in AWS Welding Curriculum
Guidelines, by Ed Norman, Southwest Area Career Center,
Monett, MO
2:05 PM–2:35 PM The Education and Training of
Welding Technicians, by James R. Hannahs, P.E., Edison
Community College, Piqua, OH
2:45 PM–3:45 PM Panel Discussion Attracting Students
to the Welding Industry
25
Compete Through Smarter Welding
 Wednesday, April 7, 2004
10:00 AM–11:30 AM
The Education Committee encourages everyone to
attend An Interview with the World’s Leading Welding
Design Expert, featuring Dr. Omer Blodgett. (See page 24
for details.)
Noon–4 PM Plant Tour
Registration available on-site; see www.aws.org/expo for
more information.
CONTINUING EDUCATION
CONFERENCES AND SEMINARS
The nonmember conference fee includes a two-year
membership in the American Welding Society.
About the Instructors
Ed Bohnart (SCWI, CWE, CRAW-T, and former Certified
Welder) of Winneconne, WI, is president of Welding
Education & Consulting. He launched his consulting
practice, with offices in Florida and Wisconsin, after a
successful career directing Miller Electric Manufacturing
Company’s training operations. Prior to joining Miller
Electric, he was welding instructor at Father Flanagan’s
Boys Home, Boys Town, NB. He is an AWS Distinguished
Member and Past President. Bohnart remains active with
the SkillsUSA organization and chairs the AWS Skills
Competition Committee, which conducts the U.S. Open
Weld Trials to select the U.S. competitor for the World Skills
Competition. For six years, Bohnart chaired the AWS C5
Committee on Arc Welding and Cutting Processes, and he
remains active on the committee as an advisor.
Dr. Richard Campbell of Purity Systems, Inc., Louisville,
CO, is an expert on welding stainless steels and
nickel alloys. He serves on the AWS Gas Tungsten Arc
Welding and Sanitary Applications Committees and on
ASME’s BioProcessing Equipment Standards Materials
Joining Subcommittee. He holds a B.S. degree from
LeTourneau University and a Ph.D. from Rensselaer
Polytechnic Institute.
26
Thursday, April 8, 2004
EDUCATION SESSION 3
9 AM–11:15 AM Student Day: College Careers in Welding
This session is free to all registered attendees.
9 AM–9:30 AM Higher Education in Welding Engineering,
by Yoni Adonyi, LeTourneau University, Longview, TX
9:35 AM–10:05 AM Welding Engineering Education
under a Manufacturing Engineering Program, by Leijun Li,
Utah State University, Logan, UT
10:10 AM–10:40 AM Graduate Research and Engineer-
ing Career in Welding - Perspectives of a Metallurgical
Engineer, by Greg Chirieleison, The Colorado School of
Mines, Golden, CO
10:45 AM–11:15 AM You Want Me to Do What? –
Relating My Education to My Internship Experience,
Caleb Roepke, LeTourneau University, Longview, TX
Ken Coryell, a welding quality consultant based near
Cleveland in Burton, OH, has been an AWS faculty member
for over 17 years. His experience includes over 30 years of
welding quality assurance, quality control, nondestructive
examination, and welding engineering for the electric utility,
petrochemical, aerospace, shipbuilding, and structural indus-
tries. He is an AWS SCWI, an ASNT Level III certificate holder
in radiography and liquid penetrant testing, and a Registered
Professional Engineer. He earned bachelor’s and master’s
degrees in Welding Engineering from The Ohio State Univer-
sity. His professional affiliations include AWS, ASNT, ASME,
ASM, and the National Society of Professional Engineers.
Eugene G. Hornberger of Hampton, VA, is a welding
consultant for Richmond, VA-based Arcet Equipment
Company. Previously, he was in charge of welder training
for Newport News Shipbuilding. Within AWS, he has served
on the board of directors and has chaired the AWS
Education Committee. He has written and edited several
books, including Welding Processes and Practices, coau-
thored with AWS Fellow (Class of 1993) August Manz.
He was the editor for the new AWS publication, Design
and Planning Manual for Cost Effective Welding, and is
working on several other publication projects for the
Society. Hornberger teaches welding and troubleshoots for
Arcet’s customers, and as a senior instructor he leads AWS
seminars on preparing for the CWI examination.
 Professional Development Hours
Sessions offer one Professional Development
Hour (PDH) for each hour of instruction. PDHs can
be used toward an AWS recertification or other
educational requirement.
Monday, April 5, 2004
8:30 AM–4:30 PM
Road Map through the D1.1/D1.1M:2004,
Structural Welding Code—Steel
Instructor: Ken W. Coryell
Fees: Member: $345, Nonmember: $470
This one-day program provides a comprehensive overview of the
AWS D1.1/D1.1M:2004, Structural Welding Code—Steel. Each of
the code sections, including General Requirements, Design of
Welded Connections, Prequalification, Qualification, Fabrication,
Inspection, Stud Welding, and Strengthening and Repair of
Existing Structures, will be summarized with emphasis on their
interrelationships and usage. In addition, the role of mandatory
and nonmandatory annexes will be reviewed, along with tips on
using the code Commentary.
Who Should Attend:
This program will benefit managers, engineers, supervisors,
inspectors, and other decision-makers who need comprehensive
understanding of what is, and what is not, covered by AWS
D1.1/D1.1M:2004 to improve their job effectiveness.
Attendees must bring their own copy of AWS D1.1/D1.1M:
2004, Structural Welding Code—Steel. Order it on-line at
www.global@ihs.com, or call IHS/Global Engineering at
800-854-7179.
Professional Development Hours: See box on this page.
Monday, April 5, 2004
8:30 AM–4:30 PM
Planning for Cost-Effective Welding
Instructor: Eugene G. Hornberger
Fees: Member: $345, Nonmember: $470
Get a better understanding of what is required to fabricate a
product. This course provides the background needed by engi-
neers, supervisors, and senior technicians who have welding-
management responsibilities. It covers often-overlooked aspects
of accepting the job and examining the requirements for fabricat-
ing the product, and reviews the best methods for building the
product.
The course will cover basic welding processes, safety, nondestruc-
tive examination, welding metallurgy, weld discontinuities, and
calculating weld costs.
Anyone with these questions should attend:
• How does a pre-bid review group work? What is its
makeup? What does it do?
• What are capabilities of the welding processes?
What are their advantages or disadvantages?
• What are the safety aspects involved with the welding
operation?
• What changes occur to the metals structure when welded?
• What are some of the effects that fatigue has on life of
the weldment? What can we do to eliminate or minimize
detrimental effects?
• What types of defects and discontinuities may we encounter?
• Is nondestructive examination (NDE) required?
What does it tell us?
Attendees will receive a copy of the Design and Planning Manual
for Cost-Effective Welding, a $68 value.
Professional Development Hours: See box on this page.
Tuesday, April 6, 2004
8:30 AM–4:30 PM
Inspection to the AWS D1.1/D1.1M:2004,
Structural Welding Code—Steel
Instructor: Ken W. Coryell
Fees: Member: $345, Nonmember: $470
This one-day course is devoted to inspection of structural steel
welds. Inspector qualifications and the responsibilities of inspec-
tors and contractors will be covered. Procedures and techniques
for visual, liquid penetrant, magnetic particle, radiographic, and
ultrasonic inspection are highlighted as a prelude to a detailed
review of the inspection acceptance standards. Test method fun-
damentals will be covered, where necessary, to understand the
more in-depth tables and criteria, along with tips on what to look
for in inspection reports.
Who Should Attend:
Supervisors, engineers, inspectors, and auditors will gain a better
understanding of weld quality from this presentation.
Topics covered:
• General inspection requirements, including basis of
inspector qualifications, inspection of materials,
inspection of Welding Procedure Specifications (WPSs)
and equipment, inspection of qualifications, and
inspection of work and records
• Acceptance criteria, including visual, liquid penetrant,
magnetic particle, radiographic, and ultrasonic test
methods for all design loading conditions
• NDE procedures, including personnel qualification,
radiographic testing, ultrasonic testing, magnetic particle
testing, and liquid penetrant testing
Attendees must bring their own copy of AWS D1.1/D1.1M:
2004, Structural Welding Code—Steel. Order it on-line at
www.global@ihs.com, or call IHS/Global Engineering at
800-854-7179.
Professional Development Hours: See box on this page.
Tuesday, April 6, 2004
8:30 AM–4:30 PM
Arc Welding and Power Sources
Instructor: Edward R. Bohnart
Fees: Member: $345, Nonmember: $470
Veteran welder Ed Bohnart has poured 30 years of hands-on
experience into this much-needed and highly demanded program
from AWS. This isn't an advanced course inflated with theory. It's
a primer directed at engineering professionals with evolving
responsibilities in welding, or for the ambitious senior technician.
If extracting the most from power sources has been a constant
problem, if you need to know the ins and outs of set-up and smooth
operation, or if this facet of welding is a new job responsibility, then
take advantage of this opportunity. The program will benefit profes-
Compete Through Smarter Welding 27
 sionals who specify arc welding equipment and processes, such
as engineers, technicians, welders, supervisors, and set-up and
maintenance personnel. Purchasers will particularly benefit.
Topics include:
• Equipment operating precautions
• Equipment and process fundamentals for GTAW, SMAW,
GMAW, FCAW, and CAC; voltage, amperage, and metering
• Power sources
• Controls
• Problems and troubleshooting
• Common misunderstandings
• How to get more performance from your existing equipment
• Why your electric power bill is the most commonly
overlooked expense
• How to use product specifications to select the power
source with the right features
Attendees will receive the following American Welding Society
publications, valued at $176:
— The Professional's Advisor on Arc Welding Power Sources
— Recommended Practices for Gas Tungsten Arc Welding
— Recommended Practices for Gas Metal Arc Welding
Professional Development Hours: See box, page 27.
Tuesday and Wednesday, April 6 and 7, 2004
8:30 AM–4:30 PM
Welding Fabricator Quality Management System
Working Seminar
Instructors: Terry Logan and Anna Petroski
Fees: Member: $550, Nonmember: $675
This two-day event is focused on small to medium-sized organiza-
tions. Participants will review the elements of a quality-management
system and how it can be applied effectively to a welding fabrica-
tor’s business in an inspiring and entertaining way. The event will
teach you the value of the effective implementation of procedures
that manage the entire business. It is not just QA and QC that can
have a profound effect on business improvement.
Welding fabricators also will benefit from participating in group
discussions where they will learn about the direction and experi-
ences of other fabricators in the quest for improved quality.
Attendees will learn to apply the requirements of the AWS
Welding Fabricator qualification, as well as related codes and
standards.
Topics Covered:
• Quality personnel requirements
• Management support and organization
• Quality document and procedure control
• Quality records
• Material control
• Welding procedures
• Filler materials
• Welder performance qualification
• Inspection
• Nonconformance
• Measuring and testing equipment
• Quality audits
Attendees will receive a copy of the AWS B5.17:2000, Specifi-
cation for the Qualification of Welding Fabricators, valued at $24.
Professional Development Hours: See box, page 27.
28
THE AUTOMATIC WELDING CONFERE
Wednesday and Thursday, April 7 and 8, 2004
Wednesday 9 AM–4:10 PM, Thursday 9 AM–11:30 AM
Getting the Most Out of Your Automatic Welding Investment
Fees: Member: $550, Nonmember: $675
The time has come to reduce your welding costs. Automatic
welding is the way to do it. Engineers have been discussing
automatic welding for decades, but many of these discussions
have not really hit the bull’s-eye – cost-effectiveness. More than
ever, industry must pay more attention to automatic welding. If a
company is not using it, why not? And, if a company is using it,
then what can be done to improve the process? How can the
quality of the weldment be improved? As the quality is improved,
the cost will be driven down. This conference will examine the
improvements to conventional automatic-welding processes, and
present some of the newer methods such as laser welding, fric-
tion stir welding, magnetic forge welding, and hybrid welding.
You also will hear about monitors, vision systems, joint tracking
systems, robotics, and laser cameras.
Professional Development Hours: See box, page 27.
Wednesday, April 7
SESSION I
9 AM–12:10 PM
WELCOME
Robert Irving, consultant, Yardley, PA
Conference Chair
1. Systems Approach to Welding Automation,
by Donald L. Lynn, Welding and Joining Management Group,
Dayton, KY
Productivity in automated welding begins with a systems
approach to potential welding applications. A systems approach
will identify the best production candidates for automated weld-
ing, and ensure the highest productivity once the automated
welding begins.
2. The AWS A9.4 Network Specification for Weld Cell Integration,
by William G. Rippey, National Institute of Standards and
Technology, Gaithersburg, MD
This presentation describes functional and technical details of
the CAN-based protocol, A9.4, being developed by the AWS A9
committee. This network technology is replacing point-to-point
electronic links to connect power sources, wire feeders, gas
controllers, and other devices for hard automation and robotic arc
welding, and will make integration of weld cell devices more
efficient and effective.
Refreshment Break
3. Optimizing the GMAW Process Using Digital Technology,
by Randy Broadwater, Miller Electric Manufacturing/ITW,
Appleton, WI
The use of digital waveform control technology with modern power
conversion platforms opens opportunities for developing hybrid
welding process and arc transfer modes. Now a choice of arc
NCE
transfer modes is available from a single power source, opening
the possibility of applying a specific mode to the joint at hand to
optimize welding performance. Now travel speeds, deposition
rates, spatter reduction, and gap filling can be optimized. Digital
network technology also opens up the ability to communicate,
store, and retrieve data on robot controllers, palm handhelds, and
PCs, and to send weld programs via e-mail.
4. Development of a Portable Laser-Guided Welding Travel
Carriage, by Ed Celesti, Bug-O Systems, Pittsburgh, PA
A consortium that includes Bug-O Systems and MEL Mikroelectronik
GmbH has developed a portable, fully-integrated, laser-guided
three-axis travel carriage. The unit reads the weld joint and will
adapt its travel and oscillation speed according to the fit-up.
Preprogramming of root fill and cover passes is possible. The
machine can perform multi-layer, multi-pass welds on butt joints,
T-joints, and lap joints.
5. Robotic Metal Cored Robotic Arc Welding with
Small Diameter Wires, by Chris Anderson, Motoman, Inc.,
Carrollton, OH
At a given current level, metal cored wires provide higher deposi-
tion than solid wires. This can be used to increase weld travel
speeds or fill gaps in thinner sheet metal components. In addition,
powdered chemical agents added to the core can improve weld-
ability with coated materials or mechanical properties of the weld.
12:10 PM–1:10 PM LUNCH ON YOUR OWN
SESSION II
1:10 PM–4:10 PM
6. Automated Laser Processing and Impact on Manufacturing
Costs, by Paul Denney, Edison Welding Institute, Columbus, OH
Laser processing (welding, cutting, drilling, and cladding) has
made a major impact in manufacturing. Although they are capital-
intensive, lasers have been put into operation in industries as
diverse as medicine, electronics, and shipbuilding. The presenta-
tion will give an overview of how lasers are being used and justi-
fied.
7. Use of Models to Improve the Cost and Quality of Welds,
by Dr. Gordon Clark, The Ohio State University, Worthington, OH
The paper presents three models. The cost model includes a
general approach to estimating cycle time in automated systems.
Two quality models use data from a small number of welds to
estimate the probability of covering a joint and the yield from
welds subject to porosity.
8. How Robotics Can Reduce Overall Manufacturing Costs,
by Richard Monaco, Wrayco Industries, Inc., Stow, OH
American manufacturing is faced with fierce global competition.
Automated welding can be a successful process to reduce labor
cost and improve quality. The speaker will share his experience in
the transformation of a welding shop from primarily manual weld-
ing to robotics. Understand how automated welding can enhance
your company’s growth even in difficult economic times.
Refreshment Break
9. Trends in Transgun Resistance Spot Welding,
by Mark Siehling, RoMan Manufacturing Co., Grand Rapids, MI
The increasing application of transguns for resistance spot-
welding operations is having a positive effect on cost and quality.
Reducing robot payloads and increasing system reliability have
made dramatic improvements in flexible automation.
10. Friction Stir Welding of Aluminum for Automotive
Applications, by Arthur P. Scafe, Tower Automotive, Inc.,
Rochester Hills, MI
Friction stir welding (FSW) now is in use on automotive compo-
nents for vehicles produced in America. With this new joining
technology, the industry must learn how to apply the technology
in both current and future designs. This presentation will focus
on the parameters and the design considerations in FSW, and
will cover potential applications on suspensions, body structures,
cradles and frames, and the future of FSW in steel products.
Thursday, April 8
SESSION III
9 AM–11:30 AM
11. Networked Welding: Information for the Future,
by Chris Bailey, The Lincoln Electric Co., Cleveland, OH
A new generation of digital welding equipment is designed to
harness the economic power of the Net in an increasingly com-
petitive global market. Embedded networking capability inside
welding equipment allows inter-connectivity of power sources and
associated machinery in a production environment. The resulting
economy of scale of standard network components and software
can dramatically drive down the cost of the development, deploy-
ment, and user training for such networks.
12. Shielding Gas Selection and Its Impact on Automated
Welding Quality, Productivity, and Cost, by Kevin A. Lyttle,
Praxair, Inc., Tonawanda, NY
When the shielding gas blend is tailored to the application,
significant improvements in quality and productivity can result in
reduced welding cost. Examples of carbon and stainless steel
applications show savings of at least 10 percent when the best
gas blend is selected.
Refreshment Break
13. An Overview of Hybrid Welding, by Christian Walz, Center for
Coatings and Laser Applications, Plymouth, MI
Hybrid welding, a combination of laser beam welding and a
conventional arc welding process such as GMA welding or GTA
welding, is one of today’s hot topics in the laser industry. How does
it work? What are the advantages? What are potential applica-
tions? These are some of the questions asked in most discussions
about this “new” process. The presentation tries to answer these
questions and shows some current applications of the process.
Compete Through Smarter Welding 29
 THE AUTOMATIC WELDING D16.3/D16.3M:2001, Risk Assessment Guide for Robotic
CONFERENCE (CONTINUED) Arc Welding
D16.4:1999, Specification for Qualification of Robotic Arc
14. Reintegration or New Equipment, by Harlon Neumann, Welding Personnel
Genesis Systems Group, Davenport, IA QC19:2002, Standard for AWS Certification of Robotic Arc
A neutral look at what considerations can affect your decision Welding—Operators and Technicians
to purchase new robotic arc welding equipment or to use ARE-10, Monitoring and Control of Welding and Joining
existing assets: Processes
• Product characteristics ARE-11, Mechanized, Automated, and Robotic Welding
• Program volumes and life Professional Development Hours: See box, page 27.
• Workcell design
• Safety Wednesday, April 7, 2004
• Maintenance 8:30 AM–4:30 PM
• Floor space The Why and How of Welding Procedure Specifications
• Head-to-head comparisons and calculations Instructor: Ken W. Coryell
Professional Development Hours: See box, page 27. Fees: Member: $345, Nonmember: $470
If you are responsible for planning a welding operation, which
of the following items are the most critical: base metal, welding
Wednesday and Thursday, April 7 and 8, 2004 process, filler metal, current and range, voltage and travel speed,
8:30 AM–4:30 PM joint design tolerances, joint and surface preparation, tack weld-
Certified Robotic Arc Welding Technician and Operators Seminar ing, welding position, preheat and interpass temperature, or
Instructor: Edward R. Bohnart shielding gas? This course provides the answers.
Fees: Member: $550, Nonmember: $675
The instructor, Ken Coryell, uses his 25 years of international and
This new AWS credential signifies that the robotic arc welding oper- domestic experience in weld quality to shed light on the most
ator or technician has demonstrated the capability of working common problems, misunderstandings, and mistakes. Coryell
safely and effectively in the arc welding cell. Because proof of offers insider advice, hints, and tips on optimum use of the
active practice or re-examination is required every three years, Procedure Qualification Record (PQR) and the Welding Procedure
certification also signifies that the operator or technician is current Specification (WPS).
with the welding industry’s standards.
This program will benefit owners, managers, engineers, and
AWS is offering a two-day training seminar to cover the central supervisors who must qualify, write, or revise their own welding
requirements that will be tested if the participant wishes to procedure specifications to satisfy codes and contract documents.
proceed on to credentialing. Professionals needing a broad
Topics Covered:
overview of automation and robotics issues also should attend.
• Proper preparation and qualification of welding procedure
The topics covered in this seminar include: specifications
• Weld equipment setup • Selecting and documenting welding variables
• GMAW plus other gas-shielded processes • Documenting standard procedure qualification testing
• Weld examination for commonly used processes for joining ferrous plate
• Terms and definitions and pipe materials
• Symbols – welding and robotics
You Can Learn To:
• Safety
• Specify essential and non-essential variables commonly
• Destructive testing
used in sample AWS, ASME, and API code formats
• Conversion and calculations
• Use standards when preparing procedures
• Robot programming
• Document welding variables and qualification tests
• Welding procedures
• Avoid the pitfalls in revising previously qualified procedures
• Programming logic
• Kinematic concepts Attendees will receive a copy of the AWS B2.1:2000,
• Robot arc welding cell components Specification for Welding Procedure and Performance
• Review of AWS D16.4:1999, Specification for Qualification, valued at $120.
Qualification of Robotic Welding Personnel
• Review of AWS QC19:2002, Standard for AWS Certification of
Robotic Arc Welding—Operators and Technicians
• Requirements for the AWS performance portion of the
certification text
Attendees will receive a copy of the following American Welding
Society publications, valued at $236:
D16.2/D16.2M:2001, Guide for Components of Robotic
and Automatic Welding Systems

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

HOTEL REGISTRATION FORM source code: DIST01

Choose one of four convenient ways to reserve a room:

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

Check One: Attendee Exhibitor

First Name________________________________________________Middle Initial_______Last Name ______________________________________

Company __________________________________________________________________________________________________________________

Address_____________________________________________________________________City __________________________________________

State/Province_______________________________________Zip+4____________________________Country ________________________________

Phone_______________________________Fax_______________________________E-mail ______________________________________________

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

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

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

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

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

Bill my credit card: Amex MasterCard Visa Discover Diners Club

Card Number: ______________________________________________Exp. Date: ________________________________

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

32
 April 5-8, 2004 IMPORTANT: Please fill out sections B through K
McCormick Place, Chicago, IL on the reverse side of this form.

SEMINAR REGISTRATION FORM source code: DIST01

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

SOCIETY ACTIVITIES DATE HOURS CODE MEMBER NON-MBR

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

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

CONFERENCES (INCLUDES EXHIBIT FEE) DATE HOURS CODE MEMBER NON-MBR*

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

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

TOTAL FEES (PAYMENT MUST ACCOMPANY YOUR REGISTRATION) $

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

Card Number: ______________________________________________Exp. Date: ________________________________

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

Compete Through Smarter Welding 33

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

FREE VIP REGISTRATION (EXHIBITS ONLY)

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

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

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

AWS WELDING SHOW 2004 MAKE COPIES TO REGISTER YOUR TEAM!

Professional Programs, Conferences, Seminars
Presentations from leading experts on the latest technical FOUR EASY WAYS TO REGISTER:
and management developments.
ONLINE: www.aws.org/expo
❏ YES! Please send more information FAX: 708-344-4444
PHONE: 877-868-5290 (toll free)
❏ Please check here should you MAIL: AWS Welding Show c/o CompuSystems, Inc.
require special assistance. P.O. Box 581, Brookfield, IL 60513-0581

34
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