Professional Documents
Culture Documents
Aws WJ 201807
Aws WJ 201807
Summer
Welding
Projects
Fabrication
Update
Cordless Tools
American Welder:
Celebrating Welding’s
Diverse Population
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
July 2018 • Volume 97 • Number 7 CONTENTS
FEATURES
34 Evaluating FCAW-G Electrodes
A fabricator discusses what he has learned about 44
gas-shielded flux cored arc welding electrodes
B. Gulas
84 88
Six Nations Polytechnic to Start This historical landmark designation recognizes sites and
events that have played a prominent role in the discovery,
Welders Program for Low-Income development, and growth of metals, metalworking, and all
Women; Tuition-Free Training Provided engineered metals.
Training Center in Republic of Congo Launches France. The passenger-freight capsule is currently near com-
Plan to Modernize Vocational Training pletion at Carbures in Spain and scheduled for delivery to
the facility this summer for assembly and integration.
The two-phase process will begin with a closed 320-m
system that will be operational this year. A second, full-scale
system of 1 km elevated by pylons at a height of 5.8 m will
be completed in 2019.
“Five years ago, we set out to solve transportation’s most
pressing problems: efficiency, comfort, and speed. Today we
take an important step forward to begin to achieve that
goal,” said HyperloopTT CEO Dirk Ahlborn. “Hyperloop is
more than just displays of rapid acceleration and more than
just breaking speed records. The real opportunity is to create
an efficient and safe system with an unparalleled passenger
experience.”
The Don Bosco Vocational Training Center has implemented
a project to support the modernization of vocational training Kemppi Unveils Robotic Welding
by increasing teacher training, purchasing new equipment,
and creating new courses.
Application Center in China
Kemppi, headquar-
The Don Bosco Vocational Training Center in Brazzaville, tered in Lahti, Fin-
the capital of the Republic of Congo, has recently launched a land, has opened up a
project to develop the skills of teachers, purchase new equip- robotic welding appli-
ment, and create new vocational training workshops. The cation center in Kemp-
project, which officially launched in May and will run pi China’s subsidiary
through October, aims to improve teachers’ training and in- facilities in Beijing,
crease student enrollment by 3000 over the next three China, to strengthen
years. its robotic welding
To support teachers, Salesian missionaries will expand business and speed up
the library, address current problems related to the trans- its growth in Asia.
port of teachers to and from school, and increase educator The new Beijing-based Kemppi ro- The center is
salaries. The plan will also offer teachers scholarships to botic welding application center is equipped with the
continue their education and improve their skills. equipped with the company’s ro- company’s range of ro-
Additionally, funding will be used to purchase new equip- botic welding equipment. botic welding equip-
ment for courses in electrotechnical, air conditioning and ment and robots from
heating systems, lathing and welding, and carpentry. The well-known manufac-
project will also purchase new tools for the creation of a turers. In the center, visitors can see the welding automa-
driving school within the auto mechanics course to ensure tion systems in action.
graduating students pass the driver’s test and earn their dri- Robotic welding and Asia are both strategic focus areas for
ver’s license. Kemppi. Kemppi had its first deliveries to China already at the
Lastly, the training center intends to start new courses end of the 1980s and has invested significantly in robotic
in construction, renewable energies, as well as maintenance welding solution development during the past years. The ro-
of computers and networks, electronic, and audiovisual botic welding application center is a natural next step in serv-
equipment. ing the important and fast-growing robotic welding markets in
China and Southeast Asia even better,” said Hannu Jokela, vice
Hyperloop Begins Construction of Passenger president Asia Pacific and export sales, Kemppi Oy.
and Freight System in France
Xiris Opens European Office in Germany to
Hyperloop Trans- Better Support Local Customers
portation Technolo-
gies (HyperloopTT), Xiris Automation Inc., Burlington, Ontario, Canada, a
a California-based provider of quality control solutions for welding and tube
transportation and and pipe industries, has opened a European sales and serv-
technology company, ice office in Ratingen, Germany, near Düsseldorf, to better
has begun construc- support its growing customer base in Europe.
tion of a full-scale, As part of this initiative, the company will now be able to
passenger-ready cap- offer annual recertification services of their weld inspection
The full-scale Hyperloop tubes ar-
rive at the company’s Toulouse re- sule near its research systems used in the tube industry from the Ratingen office,
search and development center. and development helping customers achieve optimal equipment performance
center in Toulouse, and drive quality assurance. WJ
Industry Notes
• Fischer Technology has opened a Chicago, Ill., sales and
service facility. Craig Kuchta, the new representative and
technical advisor for this office, has more than 20 years of
technical instrumentation sales and support of products
by many manufacturers. The company’s regional offices
support its line of test and measurement instrumentation.
Huntington Ingalls Industries’ Employees are welder certification, management systems registration, and
Honored by the Manufacturing Institute training services, has recently celebrated 70 years in the
Canadian welding industry. Following on the heels of its an-
Three female em- niversary, the company is transitioning all of its business
ployees at Virginia- units to unite them under one brand: CWB. The organiza-
based Huntington tion announced the initiative will help industry more easily
Ingalls Industries’ identify their complete offerings and better allow clients to
Newport News learn about all of the services they have to offer.
Shipbuilding divi- “We’re excited about our new unified brand identity for
sion were recog- our various service offerings,” said Craig Martin, vice presi-
nized by the Manu- dent of public safety. “It’s a visual reflection of CWB Group’s
facturing Institute commitment to see the Canadian welding sector be sustain-
for their achieve- able and successful in the years ahead both through the de-
ments in science, livery of value-added services and as a strong voice to pro-
technology, engi- mote and advocate for our industry.”
Newport News Shipbuilding employ-
ees (from left) Kelli Gilliam, Marissa neering, and pro-
Webb, and Danyelle Saunders were duction at the 2018
honored at the 2018 STEP Ahead Women in Manu- Metal Fatigue Solutions Opens Headquarters
Awards in Washington, D.C. (Photo facturing STEP in New York City’s Empire State Building
courtesy of the National Association Ahead Awards.
of Manufacturers.) Kelli Gilliam, fore- Metal Fatigue Solutions, Las Vegas, Nev., a producer of non-
man/craft instruc- destructive examination and structural health monitoring
tor; Danyelle Saun- technology systems for civil and industrial infrastructure, has
ders, engineering manager; and Marissa Webb, industrial opened an office in New York City’s Empire State Building.
engineer, were among 130 women honored during an Its newly established east coast regional headquarters will
awards reception in Washington, D.C. Saunders was also rec- serve as a user base for companies or projects in New York,
ognized as a STEP Ahead Award honoree, and Gilliam and New Jersey, Connecticut, and Maryland. It will also provide
Webb were recognized as emerging leaders. access to Washington, D.C., where the company consults
The STEP Ahead Awards honor women who have demon- with officials at the Department of Transportation and oth-
strated excellence and leadership in their careers and repre- er federal agencies overseeing the nation’s civil infrastruc-
sent all levels of the manufacturing industry, as well as en- ture, which encompasses bridges, aviation, wind turbines,
couraged women to mentor and support the next generation oil rigs, and pipelines.
of female talent to pursue manufacturing careers.
A: This is a very good question. in.-wide weld, continuous wave (CW) metals and the desired power density
During an economy where companies power must be used. value of 1.5 E 06 W/in.2, the compu-
are seeing increased demand for their Continuous wave laser power is tation using the formulas provided in
products, and the ramp-up time for able to produce good quality keyhole a recent column (Ref. 2) and incorpo-
increased capacity is very short, se- welds up to 0.600 in. (15.2 mm) deep rated in mathematical algorithms
lecting new manufacturing equipment in class II and 0.120 in. (3.0 mm) in (Ref. 3) yields the following laser weld
as well as qualifying the equipment class I metals. In the previous exam- parameters:
and the process, will understandably ple, the 0.020-in.- (0.5-mm-) wide For w 0.020 in., p 0.020 in. (AR
create anxiety. weld may be produced with a weld 1.0), 80% overlap, use E 4.67
The following is the suggested way penetration of 0.050 in. (1.3 mm) joules, t 0.0155 s, PR 50 Hz; travel
to approach the selection of the laser deep and an AR value of 2.5. speed 12 in./min. Average power
and the laser beam delivery optics for 3. Volume of metal to be weld- 233 W; peak power 301 W. The vol.
laser welding: ed. The volume of the material to be of metal melted 0.006 in.3/min.
1. Material. Identify the charac- processed defines the average power Continuous wave laser power.
teristics of the materials to be laser of the laser. Comparison of the vol- At the optimal welding speed, the re-
welded. This information is available ume of metal welded with the same lationship between the bead width
and has been covered in this column laser in the pulsed versus power mode and the diameter of the laser beam is
previously. Check the Classification of is provided in Table 1. the same as in pulsed laser welding.
Materials (Refs. 1, 2) for the power 4. Selection of the beam deliv- So are the comments about the optics.
density values required to couple the ery optics. The equipment designer The difference is in the power density
laser beam with the surface of differ- will determine what optics to use to values. For keyhole welding, the de-
ent materials. More on this later. collimate the laser beam, what fiber sired power density is approximately
2. Weld penetration and AR1 re- optic cable to use to deliver the beam 2.5 E 07 W/in.2. This requirement
quirement. These help to define the to the target, and so forth. What you defines the minimum CW power
temporal characteristics of the laser should be concerned about is the di- (threshold) needed to achieve the
power and laser weld process. ameter of the focused beam and the power density for keyhole weld.
Pulsed laser power is able to pro- spatial profile of the laser beam as it is Therefore, Pmin for the 0.050-in. weld
duce good quality conduction welds focused on the target. penetration, keyhole weld 5000 W;
with penetration from 0.001 in. Pulsed laser power. To compute and Pmin for the 0.020-in. weld pene-
(0.025 mm) to approximately 0.060 the energy per pulse and the pulse tration, conduction weld 300 W.
in. (1.5 mm) in class II metals (carbon width for delivering the correct power Higher power is recommended be-
steel, stainless steel, titanium, and so density to the target, we need to re- cause the operating range of lasers is
forth) and from 0.001 in. to approx- member that the diameter beam as fo- 10100% of full power.
imately 0.030 in. (0.76 mm) in class I cused on the target will be approxi- Based on published data (Ref. 3),
metals (copper, aluminum, tungsten, mately 80% of the bead width. the following laser weld parameters
and so forth). The recommended val- Referring to the above example, to may be used:
ue of AR is between 0.6 and 1.0. For produce a bead width of 0.020 in. (0.5 For w 0.020 in., p 0.020 in., use
example, if the weld bead is 0.020 in. mm), the beam diameter should be 750 W at 197 in./min (5 m/min); vol.
(0.5 mm) wide, the weld penetration 0.016 in. (400 m). The 400-m spot melted 0.039 in.3/min (three times
should be between 0.012 in. (0.3 mm) may be produced with a 400-m fiber- the average power used in pulsed weld-
and 0.020 in. (0.5 mm). So, if greater optic cable and the correctly chosen ing, but 6.5 times the volume melted).
penetration is required for the 0.020- optics. Optical fibers of this diameter This is understandable because in
typically deliver a spatial profile that pulsed welding, the weld nuggets over-
1
Aspect ratio of the weld. is uniform (top hat). Assuming class II lap the previous weld nuggets.
Summary
1. There is a significant difference
between the productivity of pulsed
power welding and CW power welding.
2. When the required weld penetra-
tion is achievable with conduction
welding and the number of units to be
welded is low, a laser of a few hundred
W of average power and good pulsing
capabilities would work well. Good
pulsing capability implies easy pro-
gramming of the pulse parameters.
3. If you need to produce laser
welds with AR larger than 1.5 (key-
hole welding), then a laser in the pow-
er range of 5000–6000 W is the right
choice. The good news is that the
higher power CW solid-state lasers
(fiber lasers, disk lasers, and direct
diode lasers) may be pulsed and make
pulsed welds, too. Also, the cost of the
laser does not change linearly with its
power rating. So going from 500 to
5000 W does not mean price increase
times ten.
4. The most important characteris-
tics of the beam delivery optical sys-
tem are its ability to produce the re-
quired diameter of the focused laser
beam and a spatial profile, which
should be uniform across the laser
beam, called top hat. WJ
References
Alloy Tensile Strength ksi (MPa) Yield Strength ksi (MPa) % Elongation
Fig. 1 — Typical bottom-ejecting guided bend test fixture. (Source: Fig. 6.1, AWS
B4.0:2016.)
Fig. 2 — Typical bottom-guided bend test fixture. (Source: Fig. 6.2, AWS B4.0:2016.)
material, and the kink can lead to tear- wrap-around fixture forces all parts of
ing at the interface due to the strain the bend test specimen to stretch es-
concentration. sentially the same amount regardless
One way to combat this tendency to of variations in yield strength within
develop a kink at the interface be- the specimen.
tween weaker and stronger metals is In addition to the concern about
to change from the normal three-point kinking of the test specimen when
bending configuration that occurs in a there is a strength mismatch within
bottom-ejecting guided bend test fix- the test specimen, each of the three
ture (Fig. 1) or bottom-guided bend bend test fixtures offers a concern in
test fixture (Fig. 2) to a wrap-around conducting the test. The test specimen
guided bend test fixture (Fig. 3). The in the bottom-ejecting fixture tends to
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hat can you learn about fabri- gas-shielded FCAW [flux cored arc such as grinding and preheating, elim-
cating heavy weldments with welding] electrodes, and many compa- inating piping porosity, all-position
large-diameter cored elec- nies make them. Within any given performance, weld pool control, pa-
trodes from someone who holds a product line, there are a lot of differ- rameter flexibility, and weld bead ap-
master of fine arts in sculpture? Quite ent choices and nuances to each elec- pearance. He eventually selected an
a bit if that person also holds qualifica- trode. Finding the right electrodes for AWS E71T-1 electrode featuring a
tions to requirements of AWS D1.1, my operation took several years of tri- thinner sheath and higher fill ratio be-
Structural Welding Code — Steel, and al and error,” said Dave Rubin, owner cause “this technology creates a very
AWS 14.1, Specification for Welding of of Farm Fabrication in Lebanon, Ohio. forgiving all-position electrode.”
Industrial and Mill Cranes and Other Rubin evaluated FCAW-G elec- Comparatively new, thin-sheath
Material Handling Equipment. trodes for their ability to reduce the FCAW electrodes offer a different set
“There are hundreds of different need for nonvalue-added activities of benefits compared to thick-sheath
Some of Rubin’s gas-shielded flux cored arc weld beads. The ’39 Ford pickup he restored sits in the background.
Renaissance Welder
Rubin chose the name Farm Fabri-
cation as an homage to the hard- Fig. 2 — Farm Fabrication specializes in heavy weldments for cranes, infrastructure,
working, fix-anything work ethic of heavy repair, and steel industries.
the American farmer. However, rather
than farm equipment, the company State University in New York (2001) AK Steel’s Middletown Works. While
specializes in heavy weldments for and then a master of fine arts in sculp- much of the mill welding used E7018
cranes, infrastructure, heavy repair, ture from the University of Washing- electrodes, because the expansive en-
and steel industries — Fig. 2. ton in Seattle, Wash. (2004). vironment was more like a construc-
Rubin works out of a 2400-sq-ft However, after relocating to his tion site than a shop, Rubin said he
shop he designed himself, moving wife’s home town of Lebanon, located quickly learned the nuances of large-
heavy weldments with a 20,000-lb between Dayton and Cincinnati, Rubin scale, high-capacity overhead cranes
gantry crane and a fork truck with a needed to earn a living and found em- — Fig. 3.
6500-lb capacity. Most of his work in- ployment at a local welding shop. For “Being hands-on with repairing
volves A36 plates from 1⁄4 to 8 in. thick, the next four years, he predominantly cranes for four years taught me where
but his nonindustrial projects include used FCAW and gas metal arc welding to look for stress points, cracks, and
metal sculptures, a restaurant build (GMAW) processes. With the opportu- what would fail and what would not,”
with a 90-ft metal bar, bottle and wine nity for a pay raise, Rubin became lead he recalled. As an example, he pointed
racks, and a restored 1939 Ford pick- welder for a crane service company at out that cranes in the mill’s hot strip
up. In short, Rubin is a bit of a Renais-
sance welder, applying multiprocess
welding, fabricating, and design skills
and equipment to anything he sets his
mind to.
Growing up in New York’s Hudson
Valley region, Rubin was introduced to
shielded metal arc welding (SMAW)
from his father. He started out “just
gluing junk together” before moving
on to 55-gal drum barbecues and fix-
ing trailers (as a side note, his two
sons have started down the same path,
with Rubin introducing them to
SMAW at ages eight and six). Rubin’s
craftsmanship includes woodworking
skills developed alongside his father,
who renovated historic homes, and an
appreciation of art from his mother,
an accomplished musician and wool
spinner. Literally putting his hands to
work, Rubin pursued his bachelor of Fig. 3 — Dave Rubin, owner of Farm Fabrication, understands the nuances of welding
large-scale, high-capacity overhead crane components using the FCAW-G process.
fine arts in sculpture from Plattsburgh
Table 1 — Comparison of 1⁄16-in. E71T-1 Electrodes Using 75% Argon/25% CO2 Shielding Gas
Low end 178 A (122 in./min) 178 A (114 in./min) 175 A (118 in./min)
High end 262 A (220 in./min) 245 A (197 in./min) 276 A (228 in./min)
Voltage range 22.7–26.2 22.0–25.5 22.0–26.5
Current range 84 A 67 A 101 A
WFS range 98 in./min 63 in./min 110 in./min
Table 2 — Comparison of 1⁄16-in. E71T-1 Electrodes Using 100% CO2 Shielding Gas
Low end 165 A (126 in./min) 162 A (114 in./min) 160 A (114 in./min)
High end 195 A (153 in./min) 245 A (197 in./min) 270 A (240 in./min)
Voltage range 25.2–56.5 21.2–26.2 19.7–26.5
Current range 30 A 83 A 101 A
WFS range 27 in./min 83 in./min 126 in./min
Notes: Electrodes with a T-1 classification must have a minimum low temperature toughness of 20 ft/lb min at 0°F, where those with a T-9 classification have a
toughness of 20 ft/lb min at –20°F. The “D” designated a seismic classification and the H8 indicates the maximum milliliters of diffusible hydrogen per 100 g of weld
metal. Thin-sheath technology is also used on other electrode classifications as well, including T-12.
T
his summer, tap into your creative side by welding of skills and materials.
various home-made projects. You can keep them for Before you start, please remember safety comes first. Be
yourself, save them for future gifts, or even donate sure to follow practices outlined in the American National
them for fundraisers. And if you know of any teenagers Standards Institute (ANSI) Standard, Z49.1:2012, Safety in
looking to do something productive while they’re out of Welding, Cutting, and Allied Processes.
school, why not get them involved? Fun summer creations Now, just like mixing a fresh batch of lemonade to keep
from a hot-water tank BBQ grill to a brazed fighter plane you hydrated on a sunny day, here are recipes to build
(as described in this article) can be crafted using a variety unique projects you can be proud of.
of the grill. Weld (angle up) to all four the tank, and using bolt in center, bolt
legs, and weld in cross member (angle it to the tank — Fig. 5. Tack weld the
iron down) for mesh support. Cut and nut as well.
weld ½- or ¾-in. flat expanded metal Cut two pieces of 1-in. angle iron
inside of the bottom tray. the length of the tank, excluding the
Use two, 6- to 8-in. bearing-type, curve. Clamp the first piece of angle
hard-rubber wheels on one set of legs, iron to the door opening, approxi-
marking and welding the bolts to put mately 11⁄4 in. below its lip (angle
on the wheels (cut off excess with a down), and spot weld using GMAW or
band saw). For stability, weld caps to shielded metal arc welding. Use a small
the bottom of the other legs — Fig. 2. level to mark the tank’s backside rest-
Mark and cut out a grill door, just ing on the front angle. Hold up the
above half of the tank, using a plasma other previously cut angle iron, upside
cutting device. down, and spot weld in place.
Measure the length and width of Cut two pieces of 1-in. angle iron
the tank, approximately 3 to 4 in. across the tank’s width, weld (angle
above the bottom. Using 1-in. angle down) the bottom of the angle at the
iron, cut and build two square/rectan- top level of the front and back pieces.
gle shelves (for charcoal). Cut and weld Also, cut a ½-in.-flat expanded metal
(angle up) ¾-in. raised expanded met- to fit in the tank’s end pieces, from
al. With the expanded metal, cut two the curve to the cross, and tack weld in
half (moon) pieces to cover the curve position.
in the tank, and weld one to each char- Measure the distance on the cook-
coal tray — Figs. 3, 4. ing surface, length and width, then
Fig. 8 — The finished, painted hot-
Fabricate a 3-in. circle with vent cut and build two square/rectangle
water tank BBQ grill.
holes, then line it up on the bottom of shelves, loose enough to be easily lift-
Birdhouse
Heather Grys-Luecht (heather.
grysluecht@mstc.edu), the manager of
continuing education at Mid-State
Technical College’s Wisconsin Rapids
Campus, gave birdhouse building
guidelines. This project enables prac-
ticing basic skills.
Last year, as a collaborative effort
between Mid-State Technical College’s
School of Advanced Manufacturing &
Engineering, and the Continuing Edu-
cation Department, a two-night metal
garden sculpture community educa-
tion class took place — Fig. 9. The
premise was to give community mem-
bers, many of whom had never experi-
enced a manufacturing-like environ-
ment, a chance to learn skills and use a Fig. 9 — Attendees in Mid-State’s metal garden sculpture class last year look on as
their instructor demonstrates how to assemble and tack weld birdhouses.
medium for artistic expression.
“The first few times we ran the
class, the majority of the participants
were female and over the age of 50,
but ages ranged from 12 years old
(with a parent) to over 70,” Grys-
Luecht said. This success led the col-
lege to create a 32-h, eight-week class
on welding for the home and garden.
“It has been exciting to see so much
interest in our welding classes and to
see students, men and women alike,
progress in skill level and creativity
over such a short period of time,”
added Michael Schultz, Mid-State in-
dustrial mechanical technician pro-
gram instructor.
Materials
• 14-gauge mild steel sheet cut into Fig. 10 — The birdhouse blueprint specifying its various parts and dimensions.
these dimensions: 6 8.8 in., bent up
to 90 deg, for the bottom; 7.5 11 in., sheet, with an outer radius of 1.0000 house components, including the
also bent up to 90 deg, for the top/ and an inner radius of 0.6250, for the top/roof, bottom, back wall, front wall,
roof; 4.5 4.5 in., with a circle cut in hanger perch, and hanger — Figs. 10, 11.
it, for the front wall; and 4.5 4.5 in. Note: Components for this project
for the back wall Building Process were precut on a computer numerical
• ¼-in. mild steel rod, 2 in. long, for control plasma table, but materials
the perch Following what’s specified in the may be precut using manual methods
• A semicircle in 14-gauge mild steel blueprint, gather all the precut bird- — Fig. 12. Remove any sharp edges or
Fig. 14 — The roof is attached, along Fig. 15 — The top hanger’s in place. Fig. 16 — A birdhouse that’s been dec-
with the perch next to the center cut- oratively welded.
out. — Fig. 13. Make the tack welds on the
inside of the birdhouse for a cleaner top/roof and tack weld it to the walls.
slag from plasma-cut edges; a chipping look. Place a short stitch weld, about 1½
hammer for slag and a file to remove Place the perch approximately ¼ in. in. long, at the center of each roof/wall
burrs are all that’s needed. into the hole, in the front wall, and seam in the front and back — Fig. 14.
Using gas metal arc welding weld from the inside. Center the hanger on the peak of
(GMAW), with 75%/25% argon/CO2 Finish welding the walls to the bot- the roof and tack weld both sides of
shielding gas and 0.035-in. E70S-6 tom from the inside with two stitch each connection point — Fig. 15.
filler wire, tack the front and back welds, ¾ to 1 in. long, evenly spaced To finish your birdhouse, paint it or
walls on to the bottom section, with along the inside seams. decoratively weld it to your personal
three evenly spaced tacks on each side Evenly space the overhang of the taste — Fig. 16.
Building Process
C
ordless power tools have been batteries, drop in voltage through the contenders in the cordless market.
progressively taking over the discharge cycle, weight, self-discharge LiHD cells are slightly larger and
market (see lead photo). Today, rates, and other issues. longer than traditional cells, offering
manufacturers as well as construction The market has changed a lot in the higher power output and storage capa-
and industrial end users are entwined past 10 to 15 years since lithium-ion bility. Together with optimized battery
with cordless power tools, but around batteries were developed and started pack architectures, they open doors
60 years ago, a cordless power tool taking over the cordless tool market. for cordless applications never imag-
wasn’t even an option. Lithium-ion batteries offer more pow- ined before.
Cordless tools were introduced in er and performance in a lighter, small- Learn about the pros of going cord-
the early 1960s with drills, using er package with the ability to handle less in this article.
heavy nickel-cadmium (Ni-Cd) batter- tough industrial applications, and they
ies at low voltages (4 V). These tools are longer lasting and quicker to Air and Electric Tool
did not offer much power nor runtime, charge. The memory effect is now a Background Details
but where needed, they offered a solu- thing of the past; batteries can be
tion. Progressively, technology im- charged and discharged at any time There are numerous benefits to go-
proved and the range of tools broad- without performance loss. Some man- ing cordless. Pneumatic air hoses and
ened as well as the adoption of cord- ufacturers even started offering an un- electrical extension cords can pose
less tool use. Nonetheless, cordless limited warranty, regardless of the hazards at job locations. One of the
tools never really conquered the number of charging cycles. most common job-site injuries is due
heavy-duty construction and industri- Since 2015, the use of new lithium to tripping hazards; it’s the third most
al space because of Ni-Cd technology high-density cells (LiHD) has allowed common cause of worker downtime.
limitations, such as memory effect re- larger tools, like 6-in. and even 9-in. By eliminating the need for air hoses
ducing the runtime and the life of the cordless grinders, to become major and extension cords, this is one safety
Charger Characteristics
Charging technologies are also
adapting to the industrial world. If one
charger is not enough for the number
of workers on a job site, some manu-
facturers offer multibay chargers,
which can charge up to eight batteries
at the same time. Multibay chargers
are ideal for metal cutting and grind-
ing because there’s always a battery
charged and waiting to be used.
For high-use applications, fast
chargers are now available from some
Fig. 1 — Cordless rivet guns are now as fast as pneumatic models. manufacturers, reducing the charging
time of larger batteries from more
consideration that can be eradicated tronic protection. Heavy-duty exten- than two hours to less than one hour.
instantly. sion cords are also expensive, and the Air-cooled systems allow the user to
Also, if users find themselves in a setup time involved is longer, especial- place a hot battery in the charger and
situation where the cord or hose is not ly if the user needs to move to a new for it to start charging in virtually no
long enough, and they try to make it workstation or location. time after it is removed from the tool.
reach farther, they could cause materi- Additionally, when an operator is The charger’s built-in-fan system
als or other tools in the workspace to required to use a tool on scaffolding, a quickly cools the inside of the battery
be knocked over, creating a more dan- ladder, or tethered to a structure in pack as it begins the charging cycle.
gerous environment for their cowork- the air, cordless tools give them the This kind of charger allows the battery
ers. option to work anywhere and at any to survive more charge and discharge
Air lines can also pose a challenge if time. A good rule to follow is this: If cycles.
the pressure and airflow requirements the operator is working in an area and
of the tool being used is not met. This needs to move more than 3 ft in any Heavy-Duty Considerations
can lead to the tool performing im- direction, go cordless.
properly or even failing. Futhermore, There are fewer and fewer times
maintaining a compressor for air tool when the benefits of using a corded
use can be costly and noisy. For in- The Cordless Movement tool outweigh going cordless, especial-
stance, even if the proper airflow and ly when it comes to heavy-duty pro-
pressure are delivered by the compres- Fifteen years ago, who would have duction jobs, or if an end user is in a
sor, both values significantly drop af- imagined that cordless drills would be static heavy-duty environment.
ter the hundreds of feet (and some- mainstream? Yet today, no mainte- Sometimes it may not make sense
times even miles) of pneumatic lines nance, repair, and overhaul operator, to replace a corded tool with a cordless
that can run throughout a factory or plumber, or electrician would not even one. Examples include a chop saw sta-
shipyard. In addition, compressors and think of “plugging in” to a wall socket tioned in a shop, a large angle grinder
air lines need a lot of maintenance, es- when there’s a cordless option avail- or production grinder with high-power
pecially in humid environments and able. Only a very small amount of pro- needs, or a metal drill used for drilling
climates, increasing the operating duction applications still justifies the large holes at a high frequency. How-
cost. The cost associated with air lines need for corded tools. There are even ever, with the advent of more power-
is often overlooked when making a powerful cordless job-site vacuums ful cordless tools, these examples are
tool-buying decision. Cordless is that can be carried anywhere, avoiding becoming less and less prevalent.
cheaper to operate in the long term, constant plugging and unplugging.
even though the upfront cost may Cordless and Metal
seem higher. Portable Performance Fabrication
When working with electric-corded
tools, using the incorrect length and Cordless power tools are easier to When it comes to metal fabrication,
gauge extension cord, or simply a low- maneuver with and, by definition, to- welding is the heart of the process. A
quality cord, can starve a tool of volt- tally portable. This is their main handful of manufacturers offer spe-
age, making it inefficient. The voltage strength. Modern batteries offer up to cialized, fully integrated cordless solu-
can drop significantly and reduce the 4.0 Ah in a compact 18-V, five-cell flat tions for before and after welding. Be-
RPM of the motor, which limits the ca- battery pack or 8.0 Ah in a standard cause lithium high-density batteries
pacity of the motor to cool itself down. ten-cell pack, which is plenty of run- allow for larger tool operation and
This leads to premature wear on the time for most common applications. longer runtime, there are now numer-
tool, even for tools equipped with elec- This includes drilling, riveting, bevel- ous cordless specialty tools available.
Evolving Technology
Premium tool manufacturers have
helped the cordless market grow with
better batteries and cordless tools that
last longer and are able to handle the
most demanding applications.
Battery Benefits
A focus is no longer just on the
mainstream, light-duty tools for elec-
tricians and plumbers, but on solu- Fig. 3 — The development of new batteries offering more output power makes way
tions for metal fabrication and the in- for the introduction of more powerful motors.
dustrial workplace. Manufacturers
concentrate on developing advanced all sorts of industrial applications with makes industrial applications that
battery technology, where energy very little limitation. were simply not an option a few years
management at the cell level during Metabo Corp., West Chester, Pa., ago possible.
the charge and discharge cycles en- offers a battery with a microchip that
hances the life of the battery packs. allows it to communicate with the tool Conclusion
These manufacturers also focus on and battery charger. The ongoing com-
systems that air-cool batteries to pro- munication ensures each battery cell is Simply put, the future of power
tect the charging cells against thermal evenly charged and discharged every tools is cordless. It is only a matter of
deterioration even after heavy use. time, extending the life of the battery time before technology catches up to
They further concentrate on de- and protecting the tool being used. the need for even more powerful,
signing components inside the battery The development of new batteries longer lasting, and compact batteries
that allow for higher current delivery offering more output power makes for a more diverse future in cordless
without resistance, maximizing the way for the introduction of more pow- industrial applications. WJ
power output and life of the tool. The erful motors — Fig. 3. The 1600-W
18-V standard battery packs now can machines are now available on 18-V
ANTOINE DERCHÉ
deliver up to 1600 or 3200 W when platforms; that’s the equivalent of up (aderche@metabousa.com) is the director
combined in a 36-V configuration. to a 13-A corded tool, or up to 3200 W of marketing and product management,
This kind of power opens the door to for a 36-V machine. This breakthrough Metabo Corp., West Chester, Pa.
WELDING
S UMMI T
American Welding Society®
aws.org
–2 0 18–
October 16 – 17, 2018
South Shore Harbour Resort & Conference Center
League City, TX
BRINGING
G VA
ALUE TO YOUR WELDING OPERAT
O TION
• Meet Indusstr y Experts • Network with
w Peers • Discuss Coommon Issues
• Gain PDH Credits • Attend Career Fair
Proogram Toopics:
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• Welder Training & Welder
e Performance
• Field Hea t Trea tmentt: An Essential Variable in Welding “Weldingg Yoour Teeam Life”
• Non-Destructive Examina tion: Cost vs Value
• Importance of Accuraa te Welding Procurement DAV
VID RUTTHERFORD
• Outsourcing Work Sccope and Recognizing Scope Split Foormer Navy S SEAL Motivational Speaker,
• Fundamental Projectt Success Author,, Peerform
mance Coach, and Host
$ OFF
$50 O ADMISSION BEFORE SEPTEMBER
R1
Co-sponsored by
REG
G ISTER
S NO
O W! American Welding Society®
HOUSTON SECTION
aws.org/summitreg
wss org/s
org/summitreg
g/ mmitreg
iit g Endorsed by the AWS D10 Committee on Piping and Tuubing
THE AWARDS
A
The Fellowships or Grants are to be in amounts of up to $25,000 per year. Proposals may be funded for a period of up to three years, however,
progress reports and requests for renewal must be submitted for the second and third years. Renewal by AWS will be contingent on demonstration
of reasonable progress in the research or in graduate studies.
The AWS Fellowship is awarded to the student for graduate research toward a Masters or Ph.D. Degree under a sponsoring prrofessor at a North
American University. The qualifications of the Graduate Student are key elements to be considered in the award. The academicc credentials, plans
and research history (if any) of the student should be provided. The student must prepare the proposal for the AWS Fellowsship. However, the
proposal must be under the auspices of a professor and accompanied by one or more letters of recommendation from the sponssoring professor or
others acquainted with the student's technical capabilities. Should the student selected by AWS be unable to accept the Fellowshhip or continue with
the research at any time during the period of the award, the award will be forfeited and no (further) funding provided by AWS. The bulk of AWS
funding should be for student support. AWS reserves the right not to make awards in the event that its Committee finnds all candidates
unsatisfactory.
RESEARCH TOPICS
Topics for the AWS Fello wship may span the full range of the joining industr y. Proposals for both a pplied and fundamental research topics
are welcome. The Committee may recommend topics to be considered and these will be posted at aws.org/graduatefelloowships.
DETTAIL
A LS
The Propposal should include: 6.Current Sta
S tus of Relevant Research
1. Exxecutive Summary 7.Technicaal Plan of Action
2. Annnualized Breakdown of Funding Required and 8.Qualifications of Researchers
Puurpose of Funds (Student Salary, Tuittion, etc.) 9.Pertinentt Literature References and Related
3. Maatching Funding or Other Support foor Intended Publicatioons
Reesearch 10. Special Equipment
E Required and Availability
4. Duuration of Project 11. Statemennt of Critical Issues Which Will Influeence
5. Staatement of Problem and Objectives Success or Failure of Research
In additioon,
o , tthee pproposal
oposa must
ust incclude:
1. Stuudent's Academic History, Resume and Transcript (Both undergraduatee and graduate)
2. Reecommendation(s) Indicating Qualifications for Research must include one o or more letters of recommendation
froom the sponsoring professor or otheers acquainted with the student's teechnical capabilities
3. Brief Section or Commentary on Impoortance of Research to the Welding Community
C and to AWS, including
Technical Merit, National Need, Long Term Benefits, etc.
4. Staatement Regarding Probability of Suuccess
aws.org
COMING EVENTS
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W offers the most accurrate, relevaant, and well-researchedd seminars in the weldingg industry.
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WS educational semiinar near you today!
AWS
W CERTIFIEDD WELDING INSPECTOR SEMINARS
Location Seeminar Date Exam Date Deadline Location Seminar Date Exam
am Date Deadline
San Francisco, CA Auug. 26-31 Sep. 1 Jul. 23 Kankakee, IL Oct. 14-19 Octt. 20 Sep. 10
Beaumont, TX
Beaumont Auug.
ug 26-31
26 31 Sep 1
Sep. Jul.
Jul 23 Denver, CO Oct.
Oct 21
21-26
26 Octtt. 27 Sep. 17
Sep
Nashville, TN Seep. 9-14 Sep. 15 Aug. 6 Des Moines, IAA Oct. 21-26 Octt. 27 Sep. 17
Portland, OR Seep. 9-14 Sep. 15 Aug. 6 Cleveland, OH
H Oct. 28-Nov. 2 Novv. 3 Sep. 24
Pittsburgh, PA Seep. 16-21 Sep. 22 Aug. 13 Sacramento, CA
C Nov. 4-9 Novv. 10 Oct. 1
Houston, TX Seep. 16-21 Sep. 22 Aug. 13 Dallas, TX Nov. 4-9 Novv. 10 Oct. 1
Kansas City, MO Seep. 23-28 Sep. 29 Aug. 20 Charlotte, NC Nov. 11-16 Novv. 17 Oct. 8
New Orleans,
Orleans LA Seep
ep. 23
23-28
28 Sep.
Sep 29 Aug. 20
Aug Reno,
Reno NV Nov. 25-30
25 30 Decc. 1 Oct
Oct. 22
Long Beach, CA Seep. 30-Oct. 5 Oct. 6 Aug. 27 Orlando, FL Nov. 25-30 Dec. 1 Oct. 22
Tuulsa, OK Seep. 30-Oct. 5 Oct. 6 Aug. 27 Houston, TX Dec. 2-7 Dec. 8 Oct. 29
Ann Arbor, MI Seep. 30-Oct. 5 Oct. 6 Aug. 27 Los Angeles, CA
C Dec. 2-7 Dec. 8 Oct. 29
Newark, NJ Occt. 7-12 Oct. 13 Sep. 3 Richmond, VA Dec. 9-14 Dec. 15 Nov. 5
Chattanooga, TN Occt. 7-12 Oct. 13 Sep. 3 Miami, FL Dec. 9-14 Dec. 15 Nov. 5
Note: The 2018 schedule for all certifications is posted online at Location Seminar Dates
aws.org/w/a/registrations/prices_schedules.html. Phoenix, AZ July 15–20
San Diego, CA July 29–Aug. 3
Orlando, FL Aug. 12–17
Certified Welding Inspector (CWI) Boston, MA Aug. 26–31
Denver, CO Sept. 9–14
Location Seminar Dates Exam Date Dallas, TX Sept. 23–28
Waco, TX July 8–13 July 14 Appleton, WI Oct. 7–12
Louisville, KY July 8–13 July 14 Omaha, NE Oct. 21–26
Houston, TX July 15–20 July 21 New Orleans, LA Oct. 28–Nov. 2
Phoenix, AZ July 15–20 July 21 Seattle, WA Nov. 11–16
Cleveland, OH July 15–20 July 21
Philadelphia, PA July 15–20 July 21
Baton Rouge, LA July 22–27 July 28 Certified Welding Educator (CWE)
Helena, MT July 22–27 July 28 Seminar and exam are given at all sites listed under Certified
Omaha, NE July 22–27 July 28 Welding Inspector. Seminar attendees will not attend the Code
Seattle, WA July 29–Aug. 3 Aug. 4 Clinic portion of the seminar (usually the first two days).
Chicago, IL July 29–Aug. 3 Aug. 4
Charlotte, NC Aug. 5–10 Aug. 11
Dallas, TX Aug. 12–17 Aug. 18 Certified Welding Sales Representative
San Diego, CA Aug. 12–17 Aug. 18 (CWSR)
Salt Lake City, UT Aug. 12–17 Aug. 18 CWSR exams are given at Prometric testing centers. More
Minneapolis, MN Aug. 19–24 Aug. 25 information at aws.org/certification/detail/certified-welding-
Miami, FL Aug. 19–24 Aug. 25 sales-representative.
San Francisco, CA Aug. 26–31 Sept. 1
Beaumont, TX Aug. 26–31 Sept. 1
Nashville, TN Sept. 9–14 Sept. 15 Certified Welding Supervisor (CWS)
Portland, OR Sept. 9–14 Sept. 15 CWS exams are given at Prometric testing centers. More infor-
Pittsburgh, PA Sept. 16–21 Sept. 22 mation at aws.org/certification/detail/certified-welding-supervisor.
Houston, TX Sept. 16–21 Sept. 22
Kansas City, MO Sept. 23–28 Sept. 29
New Orleans, LA Sept. 23–28 Sept. 29 Certified Radiographic Interpreter (CRI)
Long Beach, CA Sept. 30–Oct. 5 Oct. 6 The CRI certification can be a stand-alone credential or can
Tulsa, OK Sept. 30–Oct. 5 Oct. 6 exempt you from your next 9-Year Recertification. More in-
Detroit, MI Sept. 30–Oct. 5 Oct. 6 formation at aws.org/certification/detail/certified-radiographic-
S. Plainfield, NJ Oct. 7–12 Oct. 13 interpreter.
Chattanooga, TN Oct. 7–12 Oct. 13
Chicago, IL Oct. 14–19 Oct. 20 Location Seminar Dates Exam Date
Denver, CO Oct. 21–26 Oct. 27 Dallas, TX July 16–20 July 21
Des Moines, IA Oct. 21–26 Oct. 27 Kansas City, MO Aug. 20–24 Aug. 25
Cleveland, OH Oct. 28–Nov. 2 Nov. 3 Philadelphia, PA Sept. 17–21 Sept. 22
Atlanta, GA Oct. 28–Nov. 2 Nov. 3 Pittsburgh, PA Oct. 15–19 Oct. 20
Sacramento, CA Nov. 4–9 Nov. 10
Dallas, TX Nov. 4–9 Nov. 10
Charlotte, NC Nov. 11–16 Nov. 17
Reno, NV Nov. 25–30 Dec. 1 Certified Robotic Arc Welding (CRAW)
Orlando, FL Nov. 25–30 Dec. 1 OTC Daihen Inc., Tipp City, OH; (937) 667-0800, ext. 218
Houston, TX Dec. 2–7 Dec. 8 Lincoln Electric Co., Cleveland, OH; (216) 383-4723
Los Angeles, CA Dec. 2–7 Dec. 8 Wolf Robotics, Fort Collins, CO; (970) 225-7667
Norfolk, VA Dec. 9–14 Dec. 15 Milwaukee Area Technical College, Milwaukee, WI;
Miami, FL Dec. 9–14 Dec. 15 (414) 456-5454
College of the Canyons, Santa Clarita, CA; (651) 259-7800,
ext. 3062
9-Year Recertification Seminar for CWI/SCWI Ogden-Weber Applied Technology College, Ogden, UT;
For current CWIs and SCWIs needing to meet education re- (800) 627-8448
quirements without taking the exam. The exam can be taken
at any site listed under Certified Welding Inspector.
IMPORTANT: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. to confirm your course status before
making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications received after that time will be assessed a
$250 Fast Track fee. Please verify application deadline dates by visiting our website at aws.org/certification/docs/schedules.html. For information on AWS seminars
and certification programs, or to register online, visit aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.
Thomas Lienert Robert Roth Richard Polanin Dennis Eck Carey Chen
president vice president vice president vice president treasurer
Walter Sperko Sayee Raghunathan Douglas Desrochers Lynn Showalter Mike Sherman
directoratlarge directoratlarge Dist. 1 director Dist. 4 director Dist. 10 director
ing specialist at Saudi Aramco in Saudi years as deputy director. He has also chairman twice, second vice chairman
Arabia. He was the chair of the AWS been an AWS CWI test supervisor for once, treasurer five times, Awards
Saudi Arabian Section and credited 26 years. Committee member three times, sec-
with reinvigorating that Section, Larry Heckendorn has been nomi- retary twice, and deputy district direc-
which is 200-members strong. He is nated to serve as Dist. 7 director. Bio tor four times during his 34-year
also the Fellow of seven institutes. He and photo not available. tenure with AWS. He has also served
has worked for TWI Ltd. in Cambridge, Mike Sherman, nominated to serve on several AWS D1.1 committees.
UK; J. Ray McDermott Middle East as Dist. 10 director, is the owner of a Shawn McDaniel, nominated to
Inc. in Dubai; and Advani-Oerlikon full-service welding/fabrication facili- serve as Dist. 19 director, is a welding
Ltd. in India. ty. He has served two terms as the instructor at Big Bend Community
Douglas Desrochers, nominated to Cleveland Section chair and one term College, as well as an AWS CWI and
serve as Dist. 1 director, has worked as as the first vice chair, as well as one CWE. He has served as chairman of
a welding instructor at Old Colony Re- term as the second vice chair of the the Puget Sound Section, and is in-
gional Vocational Technical High Northeast Pennsylvania Section. He volved with the Inland Empire and
School for 23 years. He is also an AWS also served as the contract welding su- Spokane Sections. For his dedication,
Certified Welding Inspector (CWI) and pervisor on the ARES project for he has been awarded various District
an AWS Certified Educator (CWE). An NASA Glenn. and Section awards.
AWS member since 2000, he has Ronald Ashelford, nominated to Robert Purvis, nominated to serve
served as the chair, secretary, treasur- serve as Dist. 13 director, is a retired as Dist. 22 director, is employed as an
er, and technical representative of the 40-year member of Ironworkers LU- AWS CWI and CWE for the California
AWS Central Massachusetts/Rhode Is- 498, Rockford, Ill. He is currently a Dept. of Corrections and Rehabilita-
land Section. welding instructor at Rock Valley Col- tion at Folsom State Prison. Previous-
Lynn Showalter, nominated to lege as well as a member of the Weld- ly, he worked as an ironworker/welder
serve as Dist. 4 director, is a welding ing Advisory Committee. He has with the Local 433 in Los Angeles. He
engineer 4 with Newport News Ship- served as chair of the Blackhawk Sec- has also served as chairman of the
building, a division of Huntington In- tion for four years, as well as secretary Sacramento Valley Section, where he
galls Industries. He has served on the for 24 years. is still a member of the Executive
AWS Tidewater Section since 1992, Karl Fogelman, nominated to serve Board. WJ
with two terms as chairman and six as Dist. 16 director, has been Section
TECH TOPICS
Opportunities to Contribute to
AWS Technical Committees
AWS District 20 Director Pierrette Gorman presented the Grant Plaque to Salt Lake Community College (SLCC) during a Section meeting on
May 17. In September, the college is planning to dedicate its new building and computer lab to Sam Gentry, former executive director of
the AWS Foundation, who passed away on Aug. 5, 2017. Pictured (from left) are Bob Udy, AWS Utah Section treasurer and SLCC instructor;
Eric Heiser, SLCC’s dean of the School of Applied Technology and Technical Specialties; and Pierrette Gorman.
ETI – Ewer Testing & Inspection Inc. Prestressed Concrete North Central Kansas Technical
1131 S. 22 St. Construction LLC College
Bismarck, ND 58504 P.O. Box 311 2205 Wheatland Ave.
etitesting.com Newton, KS 67114 Hays, KS 67601
ETI Ewer Testing & Inspection Inc.
offers more than 40 years of experience Stahl Premier Welding Academy
in the nondestructive examination and 3201 W. Old Lincoln Wy. 15255 Gulf Freeway 141-D
inspection field, including welding pro- Wooster, OH 44691 Houston, TX 77034
cedure and performance qualifications
per AWS, ASME, and API codes. United Rentals Inc. Prospect Education – Charter
6929 E. Greenway Pky. College LLC
Fermi National Accelerator #200 750 Sandhill Rd., Ste. 100
Laboratory Scottsdale, AZ 85254 Reno, NV 89521
Kirk Rd. and Wilson St.
Batavia, IL 60510 Raymondville Agriculture Science
fnal.gov Educational Institution Department
Members 419 FM 3168
LSI Inc. Raymondville, TX 78580
6111 Technology Ct. Alvin C. York Institute
Jacksonville, FL 32221 701 N. Main St.
lsijax.com P.O. Box 70 Supporting Company
LSI Inc. provides training and tech- Jamestown, TN 38556 Members
nical support services to the U.S. gov-
ernment, foreign militaries, and the Associated Builders & Contractors Active Aircraft Welding Inc.
defense industry with trained, experi- New Mexico 23905 Clinton Keith 114-519
enced, and skilled personnel, who are 2821 Broadway Blvd. NE Wildomar, CA 92562
supported by modern technologies Albuquerque, NM 87107
and methods. Camtek Software
Creek Wood High School 492 Eastland Dr.
Maersk Olie og Gas A/S 3499 TN 4N C Decatur, GA 30030
Amerika Plads 29 Charlotte, TN 37036
Copenhagen, Hovedstaden SEC Soluciones Estructurales S.A.
Denmark, 2100 ECK – Welding Training Center de C.V.
maersk.com P.O. Box 52224, Riqqa Carretera Federal Mexico Puebla KM
Mangaf, Al Ahmadi 96.5, Puebla, Juan C. Bonilla
Novelis Inc. Kuwait City, 53462 Mexico, 72640
1950 Vaughn Rd.
Kennesaw, GA 30144 Fayette County Area Vo-Tech Sky Climber LLC
novelis.com 175 Georges Fairchance Rd. 1800 Pittsburgh Dr.
Uniontown, PA 15401 Delaware, OH 43015
RDI Oilfield Fabrication
1560 River Rd. Glen High School
Fruita, CO 81521 1320 Collaborative Wy. Welding Distributor
rdironworks.com Leander, TX 78641 Company Members
Jefferson State Community College MagneGas Welding Supply
Affiliate Companies 2601 Carson Rd. 11885 44 St. N.
Birmingham, AL 35215 Clearwater, FL 33762
Apella S.A.
101, Dim. Christou Mpeka St. Kelliher School District ULT LLC
Spata, Attiki 19004 345 4 St. NW 6000 W. Executive Dr., Ste. K
Greece Kelliher, MN 56650 Mequon, WI 53092
On May 4 and 5, AWS Sections gathered for the District 18 Conference held in the Wyndham Hotel at the El Paso Airport. Held for the first
time in El Paso, Tex., the event also changed the rotation of Sections that host the conference for the first time in 35 years. The El Paso Sec
tion was praised for doing a wonderful job hosting the Conference.
District 2
Ken Temme, director
(856) 264-8377
kenneth.temme@gmail.com
LONG ISLAND
May 10
Location: Wantaugh, N.Y. LONG ISLAND — May Section meeting attendees included (from left) Tom Gartland,
Presenters: Ray O’Leary and Ken Paul Rochon, District 2 Director Ken Temme, Harland Thompson, Section Chair Brian
Temme Cassidy, Ray O’Leary, Alex Duschere, Israel Rosado, and Levi Gejada.
CENTRAL MASSACHUSETTS/RHODE ISLAND — Pictured (from left) are Jennifer Lee, Notch Mechanical; Old Colony Welding Instruc-
tor Lance Davenport; Old Colony Students Dylan DeMedeiros; Ben Lavoie; Jospeh LaPointe; Joshua Smolinsky; Zachary Papadakis;
Jenna Desrochers; Kaitlyn Kroninger; Diman Regional Vo-Tech Student Colbey Pouliot; Welding Instructor Kevin DeSousa; and Dis-
trict Director Douglas A. Desrochers.
PHILADELPHIA/Dorchester Career
PHILADELPHIA/Dorchester Career and Technology Center Student Chapter — and Technology Center Student
Contest organizers and Welding Instructors (first and second from left) Christopher Chapter — CWIs Shaun Smith and
Baker and Harry Graham are seen with Rick Keen of Keen Compressed Gas (far Alex Gagnon, along with Penn Techni-
right) and contest winners (center from left) Dylan Ickes, 3rd place, Wicomico cal College graduate Daniel Fillipelli
County; Tyler Hickey, 2nd place, Cecil County; and Tyler Arnold, 1st place, Cecil County. judged the welding contest.
PHILADELPHIA — Salem County Vo-Tech Welding Instructor Stephanie Hoffman and her students posed in front of the AWS Ca-
reers in Welding Trailer when it visted their school in April.
q Mr. q Ms. q Mrs. q Dr. Please print • Duplicate this page as needed Type of Business (Check ONE only)
A q Contract construction
Last Name:_______________________________________________________________________________
B q Chemicals & allied products
C q Petroleum & coal industries
First Name:___________________________________________________________________ M.I:_______
D q Primary metal industries
E q Fabricated metal products
Birthdate: _____________________________ E-Mail:____________________________________________
F q Machinery except elect. (incl. gas welding)
G q Electrical equip., supplies, electrodes
Cell Phone ( )__________________________ Secondary Phone ( )______________________
H q Transportation equip. — air, aerospace
Were you ever an AWS Member? q YES q NO If “YES,” give year________ and Member #:____________________ I q Transportation equip. — automotive
J q Transportation equip. — boats, ships
Company (if applicable):___________________________________________________________________ K q Transportation equip. — railroad
L q Utilities
Address:________________________________________________________________________________ M q Welding distributors & retail trade
N q Misc. repair services (incl. welding shops)
_______________________________________________________________________________________ O q Educational Services (univ., libraries, schools)
P q Engineering & architectural services (incl. assns.)
City:_____________________________________State/Province:__________________________________ Q q Misc. business services (incl. commercial labs)
R q Government (federal, state, local)
Zip/PostalCode:_____________________Country:______________________________________________ S q Other
Who pays your dues?: q Company q Self-paid Sex: q Male q Female Job Classification (Check ONE only)
01 q President, owner, partner, officer
Education level: q High school diploma q Associate’s q Bachelor’s q Master’s q Doctoral
02 q Manager, director, superintendent (or assistant)
q Check here if you learned of the Society through an AWS Member? Member’s name:_______________________Member’s # (if known):________ 03 q Sales
04 q Purchasing
q Check here if you would prefer not to receive email updates on AWS programs, new Member benefits, savings opportunities and events.
05 q Engineer — welding
20 q Engineer — design
INDIVIDUAL MEMBERSHIP 21 q Engineer — manufacturing
06 q Engineer — other
è Please check each box that applies to the Membership or service you’d like, and then add the cost together to get your Total Payment. 10 q Architect designer
q AWS INDIVIDUAL MEMBERSHIP (One Year)......................................................................................................$88 12 q Metallurgist
13 q Research & development
AWS INDIVIDUAL MEMBERSHIP (Two Years) SAVE $25 New Members Only....................................$151 22 q Quality control
07 q Inspector, tester
q New Member Initiation Fee ...........................................................................................................................................$12
08 q Supervisor, foreman
OPTIONS AVAILABLE TO AWS INDIVIDUAL MEMBERS ONLY: 14 q Technician
09 q Welder, welding or cutting operator
A.) OPTIONAL Book Selection (Choose from 25 titles; up to a $192 value; includes shipping & handling) 11 q Consultant
q Individual Members in the U.S..................................................................................................................................$35 15 q Educator
17 q Librarian
q Individual Members outside the U.S (includes International shipping)...........................................................................$85 16 q Student
ONLY ONE SELECTION PLEASE. For more book choices visit https://app.aws.org/membership/books 18 q Customer Service
q Jefferson’s Welding Encyc.(CD-ROM only) q Design & Planning Manual for Cost-Effective Welding q Welding Metallurgy q Welding Inspection Handbook 19 q Other
Welding Handbook Selections: q WHB (9th Ed., Vol. 5) q WHB (9th Ed., Vol. 4) q WHB (9th Ed., Vol. 3) q WHB (9th Ed., Vol. 2) q WH (9th Ed., Vol. 1) Technical Interests (Check all that apply)
A q Ferrous metals
B.) OPTIONAL Welding Journal Hard Copy (for Members outside North America) B q Aluminum
C q Nonferrous metals except aluminum
q Individual Members outside North America (note: digital delivery of WJ is standard)..............................................$50
D q Advanced materials/Intermetallics
E q Ceramics
INDIVIDUAL MEMBERSHIP TOTAL PAYMENT..................................................................................$_____________ F q High energy beam processes
NOTE: Dues include $17.30 for Welding Journal subscription and $4.00 for the AWS Foundation.
G q Arc welding
H q Brazing and soldering
I q Resistance welding
STUDENT MEMBERSHIP J q Thermal spray
K q Cutting
q AWS STUDENT MEMBERSHIP (with digital Welding Journal magazine)................................................$15 L q NDT
M q Safety and health
q AWS STUDENT MEMBERSHIP (with hard copy Welding Journal magazine)..............................................$35
N q Bending and shearing
Option available only to students in U.S., Canada & Mexico.
O q Roll forming
P q Stamping and punching
PAYMENT INFORMATION Q q Aerospace
R q Automotive
Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card. S q Machinery
q Check q Money Order q AMEX q Diners Club q MasterCard q Visa q Discover q Other T q Marine
U q Piping and tubing
CC#:____________ / ____________ / ____________ / ____________ Expiration Date (mm/yy) ________ / ________ V q Pressure vessels and tanks
W q Sheet metal
X q Structures
Signature of Applicant:_________________________________________ Application Date:_______________________
Y q Other
Z q Automation
OFFICE USE ONLY Check #:_______________________________ Account #____________________________________ 1 q Robotics
Source Code: WJ Date:_________________________________ Amount:_____________________________________ 2 q Computerization of Welding
REV. 11/16
SECTION NEWS
District 3 ganized the contest and awards pre-
sentations with Davis acting as master
Sean Moran, director of ceremonies for the festivity. District
(717) 885-5039 3 Director Sean Moran was in atten-
sean.moran@ahydro.com dance for the event.
LANCASTER
April 19
Location: Lancaster County Career &
Technology Center, Mt. Joy, Pa.
Summary: Lancaster County Career &
Technology Center hosted the Penn-
sylvania state SkillsUSA welding com-
petition. The competition allowed stu-
dent welders from across the state to
compete in various welding/cutting
projects to determine who would rep-
resent Pennsylvania in the national
competition. AWS Lancaster and York
members from various industries vol- LANCASTER — A student prepares to READING — District Director Sean
unteered their time to judge the com- gas tungsten arc weld during the Moran (left) presented Vice Chair Craig
petitors, including District 3 Director SkillsUSA Pennsylvania state welding Davis with the AWS Meritorious Sec-
competition. tion CWI Award.
Sean Moran, Paul Muffuletto, Brent
Zimmerman, John Shellenberger,
Jesse Parker, and Contest Chairman
and Lancaster Section Secretary Dave
Watson. The Section thanks the com-
panies that donated the material to
make the competition possible includ-
ing Butler Mfg., High Steel Structures,
and Lincoln Electric.
READING
April 24
Location: Osgood’s Grill & Bar,
Robesonia, Pa.
Summary: Section members gathered
to present certificates and prizes to READING — Craig Davis (right) honored
the participants of the Reading Sec- Pennoni Associates with a plaque of
tion Welding Contest held in March. READING — Section Foundation Rep-
recognition expressing appreciation
The recipient of the Reading Section resentative David Hibshman (left) pre-
for the valued support the company
sented the Reading Section
Millennium Scholarship Karl has given to the Section. Len Nardone
Millennium Scholarship in the amount
Machamer, was in attendance and ac- (left), inspection and testing division
of $1250 to Karl W. Machamer (right).
cepted his award. Section Chair Hugo chief, accepted the award.
Garcia and Vice Chair Craig Davis or-
READING — Reading Section Welding Contest winners included (from left) Rylee Shafer, Level 2, 4th place; Andrew Lake, Level 1, 4th
place; Gabriel Burris, Level 3, 3rd place; Bailey Kerns, Level 3, 1st place; Andrew Kreis, Level 2, 1st place; Jack Yengo, Level 2, 2nd place;
Sethen Batz, Level 1, 1st place; Caleb Rapp, Level 1, 2nd place; and Kenneth Anderson, Level 3, 4th place.
FLORIDA WEST COAST — Golfers posed before starting the 25th Florida West Coast Section Scholarship Fundraiser Tournament.
CHARLOTTE — Nine-year Certified Welding Inspector students toured SteelFab. Seen are (front row from left) Dale Chance (assis-
tant manager, SteelFab), Derreld Yost, Allen West, Jaob Aldrich, Thomas Greene, Malick Simon, Joe Hoban, David Leapley, Chris J.
Fernandez, Marshall Gaddis, Freddie Shivdat, and Instructor Ron Theiss. Second row (from left) are Robert Lockamy, James Goans,
Mark Mikula, Andre Cummings, Ryan Tauer, Brennon Pope, Tim Edson, Jeff Clark, Jason Freeman, John LaPoint, Dave Johnson, and
Bruce Lanier (quality control manager, SteelFab). Back row (from left) are Chuck Recker, James Marsh, Carl Jenkins, Harvy Galloway,
Robin Purvis, Derek Kendrick, Charles Preston, Patrick Houston, Steve Renner, Dean L. Coulson, Brent Walsh, and Craig Wicks.
NORTH CENTRAL FLORIDA — District Director JT Mahoney (second from right) visited NORTH CENTRAL FLORIDA — Josh Es-
Southern Technical School of Welding Instructors (from left) Julio Gomez, Sandy posito, Marion Technical College, re-
Bishop Jr., and Lewis Phillips as well as Career Services Advisor Jessica Sierra. ceived a District Director Award.
NASHVILLE — Tennesee College of Applied Technology – Hartsville students (from AUBURN-OPELIKA — Frank Smith (left)
left) Raymond Sullivan, Jimmy Richmond, and Baxter Smith won the Tennesee Weld- was presented with a 25-Year Silver
ing Fabrication SkillsUSA Competition. Member Award.
AUBURN-OPELIKA — Section members are seen during their tour of American Buildings Co.
MOBILE — Boy Scout Troop 85 watches a demonstration during the Section’s Boy
Scout Welding Merit Badge training.
NEW ORLEANS — Seen with the greater New Orleans staff of Gas & Supply Inc. during the sponsor recognition awards were (front,
center from left to right) Section Chair Aldo Duron, AWS President Dale Flood, and Gas & Supply Co. President Ricky “Mousey”
Chiasson.
DETROIT — Members and guests are seen at the Section’s Educational PDH Night in April.
DETROIT — District Director Phil Temple (far right) gathered with Section award recipients.
RACINE-KENOSHA — Section members and students toured Lynch Display Vans. The company manufactures emergency re-
sponse and commercial specialty vehicles.
CHICAGO — Seen at the May meeting are (from left) Mike Vanovermeir, guest speaker; James Greer, AWS past president; Joe
Grelewicz, Orbital Engineering; and Section Chair John Hesseltine.
ST. LOUIS — The Section’s outstanding students met with AWS President Dale Flood. Students (pictured and not pictured) included
Clint Penny Jr., Ironworkers Local 392; Donald Koleson; Devin Hill, Jefferson College ATS; .Joe Candela, Jackson Bjornstad Jefferson
College; Josh R. Ruch, Southern Illinois Carpenters Joint Apprenticeship; Cathy Cook; Kyle Trunko, Ranken Technical College; Cory
Blair; Joseph Sapienza, Collinsville Area Vocational Center; Mark Anderson; Sierra Fox, Ironworkers Local 396; Jim Hunt; Jason Berry,
St. Charles Community College; Mike Kamp; Nathan Moist, Vatterott College Fairview Heights; Rick Beavers; Chris T. Elizondo, Lewis
& Clark Community College; Travis Jumper; Bruce Edward Yarbrough, IBEW Local 309; and Mike Stuart.
ST. LOUIS — AWS President Dale Flood acknowledged Section Scholarship recipients including (pictured and not pictured) Ian
Schwander ($1500 St. Louis Section Scholarship); Tyler Richard McIver ($1500 Hil Bax Memorial Scholarship); Colby Eilers ($1500
Garner Kimbrell Honorary Scholarship); Darvis Bell ($750 AWS Scholarship); Nathan Moist ($750 AWS Scholarship); Chris T. Elizondo
($750 AWS Scholarship); Brandon Smith ($750 AWS Scholarship); James Langley ($750 AWS Scholarship); Jake Weber ($750 AWS
Scholarship); Courtney Schaefer ($750 AWS Scholarship); Tony J. Zedolek ($750 AWS Scholarship); Bradley Hamilton ($750 AWS
Scholarship); Rocky A. Tucker ($750 AWS Scholarship); Stephan Weekly ($750 AWS Scholarship); Chris Musket ($750 AWS Scholar-
ship); and David Neunaber ($500 Pat Cody Memorial Scholarship).
ARROWHEAD — Winners of the Section’s 2018 Behind the Mask Welding Competition included (from left) Kyle Powers, Central
Lakes College, SMAW 3rd place; Alan Pietila, Central Lakes College, SMAW 1st place; Sonny Bonner, Mesabi Range College, GMAW 3rd
place; Jessie Nissila, Mesabi Range College, GMAW 2nd place and GTAW 2nd place; Greg Rider, Central Lakes College, SMAW 2nd
place, GMAW 1st place, and GTAW 3rd place; and Tristan Hulke, Central Lakes College, GTAW 1st place.
EASTERN IOWA — Section members and students are seen during the CNH Industrial tour.
NEBRASKA — Tour host Mark Caine (far left) is pictured with Section members and students.
EAST TEXAS
NORTH TEXAS
April 17
District 19
Location: UA Pipefitters and Plumbers Shawn McDaniel, director
April 26
Local 100, Garland, Tex. (509) 793-5182
Location: Tyler Junior College,
Summary: The Section held its first shawnm@bigbend.edu
Tyler, Tex.
Presenter: Richard Johnston, commer- annual North Texas Welding Rodeo.
cial diver, The Ocean Corp. Students from Hill College, Tarrant BRITISH COLUMBIA
Summary: The Section received a fan- County College, and Texas State Tech- March 28
tastic first-hand description of the nical College competed in both indi- Location: UAPIC, Delta, British Co-
commercial diving industry today. vidual and team events that had them lumbia, Canada
Johnston discussed water treatment welding in wacky and strange posi- Presenter: Dave Ruston, Acuren Group
Summary: The evening consisted of a
catered dinner at UAPIC, followed by
EAST TEXAS — Guest speaker Richard Johnston (far left) is seen with (from left)
BRITISH COLUMBIA — Section Chair
Section Chair Bryan Baker, District 17 Director J Jones, and Section Vice Chair Andy
Bernard Booth (left) presented a
Stormer.
speaker gift to Dave Ruston.
April 12
Location: Denver, Colo.
Presenter: James R. Hannahs, PE, CM-
fgE, CWI, Verity Technical Consultants
Summary: Hannahs presented a dis-
cussion on the history of NASCAR fab-
rication, a review of how the cars are
built today, the materials used, weld-
SPOKANE — Guest presenter John SPOKANE — Chris Walker, Section 1st ing processes applied, and showed a
Lopez spoke to Section members vice chair, presented a thank you gift video of a race at the Talladega Super-
about hardfacing. to guest speaker Justin Hoffman. speedway demonstrating the impor-
tance of these items.
COLORADO — Section board members (from left) Jeremy Mowry, Norma Escobedo, and Steve Unrein posed with presenters Jesse
Grantham, Richard Campbell, Tom Kienbaum, Bob Teuscher, Greg Garcia, and Anish Poudel.
COLORADO — Presenter James Hannahs spoke to Section members and guests about welding and driving NASCAR racing cars.
NEW MEXICO — Section members enjoyed a presentation on laser welding by Jeff Rodelas from Sandia National Laboratories.
Santa Fe Community College Student Chapter — Students from three area high schools competed in a welding competition at
Santa Fe Community College.
LONG BEACH/ORANGE COUNTY — The Section’s Student Scholarship Night was made possible by (from left) Neal Lembke, Hector
Carbajal, Justin Fox, David Stark, A. C. Goins, Warren Lozano, Ben Anderson, Mike Lannom, Paul Anderson, and Eric A. Budwig.
District 22 Conference — Representing District 22 at the annual conference were (from left) Ray Atnip, Ken Morris, Sacramento
Section Chair Jerry Wentland, Rob Purvis, District Director Kerry Shatell, Central Valley Section Chair Randy Emery, and Chris Huff.
Community College of ers committee with Omaha STEM mately 800 students. Since 2007, Mc-
Denver Hires Former Ecosystem, which works with families, Cane has held several leadership posi-
government, science centers and muse- tions at Bishop State Community Col-
Alum as Instructor ums, education partners, businesses, lege, Mobile, Ala. She most recently
and nonprofits to develop and imple- served as dean of instructional servic-
A former alum ment solutions to citywide workforce es and was responsible for all academic
of the Community challenges. programs across the four campuses.
College of Denver, She was also associate dean of instruc-
Colo., Jessica tion at Jefferson Davis Community
Schechter, has College in Brewton, Ala.
been hired as an NAM Elects GE Appliances
instructor there. Chief Operating Officer to
Schechter started Board of Directors
off as a stay-at- Damen Appoints President of
home mom and The National the Netherlands Chapter of
self-employed jew- Association of WISTA
elry maker, after Manufacturers
J. Schechter (NAM), Washing- Sylvia Boer,
she earned a jew-
elry-making cer- ton, D.C., has head of communi-
tificate from the American Jewelers elected Melanie cations for Damen
Institute in Portland, Ore. In 1998, Cook to its board Shipyards Group,
she earned an associate of arts degree of directors to ad- has been appoint-
in industrial design from the Art Insti- vance a manufac- ed president of the
tute of Colorado. In 2014, she enrolled turing policy agen- Netherlands chap-
in the Community College of Denver, da that promotes ter of the Women’s
majoring in fabrication welding. She growth and pros- International
was one of four female students in the M. Cook perity for all Amer- Shipping and
program with 60 men. While at school, icans. Cook is chief Trading Associa-
she worked as a fabricator for Demi operating officer of GE Appliances, tion (WISTA).
Urge from 2015 to 2017. Soon after, Louisville, Ky., a Haier company, and is S. Boer Boer has been a
Schechter completed an associate of part of the GE Appliances executive member since
applied science in fabrication welding council. She is responsible for end-to- 2008 and joined the organization’s
and has now started working as an in- end operating mechanisms, operational board in 2013. WISTA has 3000 mem-
structor for the program. She is cur- excellence, competitiveness, and infor- bers in 40 countries from diverse mar-
rently pursuing her bachelor of arts mation technology to align with overall itime-related organizations. Its chap-
degree in anthropology with a minor business objectives. For 22 years, she ters around the world aim to support
in women’s studies. has held various roles in the company. women in the industry via regular
meetings, workshops, presentation
speeches, and company visits. The
Metropolitan Community Huntington Ingalls Hires Netherlands chapter was founded in
College Names Director of Director of Education 2000 and currently has 140 members
from across the maritime industry.
Workforce and IT Innovation
Huntington In-
Metropolitan galls Industries,
Community Col- Newport News,
lege (MCC), Oma- Va., has appointed
ha, Neb., has Latitia D. McCane
named Victoria as director of edu- Reprints
Novak as director cation for The Ap-
of workforce and prentice School at Custom reprints of Welding Journal
IT innovation, Newport News articles, in quantities of 100 or
where she will aim Shipbuilding. Mc- more, may be purchased from
to drive public-pri- Cane is responsi- Jill Kaletha, national account
vate partnerships ble for the overall executive, Mossberg & Co. at
to enhance the L. D. McCane leadership, vision,
V. Novak Omaha area’s labor and strategic di- (800) 428-3340, ext. 149 or
pool by developing rection of craft training, academic de- (574) 289-9253, ext. 149.
relationships with businesses and en- livery, student services, accreditation,
trepreneurs who can collaborate with and recruitment for the school, which You can also send an email to
MCC students. In addition, Novak provides comprehensive four- to eight- jkaletha@mossbergco.com
serves as chairperson of the stakehold- year apprentice programs for approxi-
O
nce described as the poorest ma- ranks number five in a study of impov- dustry, the Motor City still enjoys a
jor city in the United States, De- erished communities (Ref. 3). Con- burgeoning manufacturing industry,
troit, Mich., is home to more tributing to the poverty crisis is the with more than 6200 skilled trade jobs
than 200,000 people living below the city’s high unemployment rate. expected to be available each year
poverty line (Refs. 1, 2). According to Despite its gaunt financial health, through 2022 (Ref. 4). However, in
the Detroit Free Press, it currently and the decline of its automotive in- spite of growing job opportunities,
René practices gas metal arc welding during a Women Who Weld® week-long class. She is now a full-time welding operator in
Ann Arbor, Mich.
many Detroiters don’t have the skill Six-Week Intensive Training Course To help graduates lead successful
set required to secure those jobs. professional and financial lives, stu-
One organization is stepping up to The six-week option offers a subsi- dents are offered résumé and inter-
the plate by tackling both the poverty dized training program for unemployed view preparation, financial literacy
crisis and the skills shortage: Women or underemployed women from 18 to and home-buying workshops, tours of
Who Weld®. Women Who Weld is a 40 years of age to help them establish a off-site production facilities, and op-
501(c)(3) nonprofit organization that career in welding and advanced manu- portunities to meet hiring employers.
teaches women sought-after welding facturing, free of charge — Fig. 1. In some cases, food, transportation,
skills and helps them attain gainful “The majority of the participants in and child care have been provided to
employment in the industry (see lead the subsidized training program are eliminate barriers to success.
photo). single mothers in their twenties who
“The automotive, aerospace, de- reside in Detroit — some in temporary Week-Long Intensive Training Class
fense, energy, construction, and trans- shelters — and have difficulty finding
portation industries still have a major or maintaining part-time employment The week-long option is a low-cost
presence in and around Detroit, and and rely on public assistance,” said training class for any-aged woman in-
they have a dire need for welders,” ex- Farr. “Some were formally incarcerated terested in learning how to perform
plained Samantha Farr, Women Who and have few family or friends to turn gas metal, gas tungsten, and shielded
Weld founder and lead instructor. “It is to for guidance.” metal arc welding — Fig. 2. According
therefore extremely important to train Offered once a year, this course is to Farr, this class mostly serves under-
women to weld and become a part of funded entirely through donations employed women who possess the
the industrial workforce, otherwise and grants, and requires participants means to pay for training. Held
women will miss out on well-paying to undergo a two-part interview throughout the year, it has a maxi-
opportunities.” process to determine their dedication mum capacity of six participants. Like
The following details how this to pursing a career in welding. the six-week course, the week-long
Detroit-based organization is using With a maximum capacity of ten class also provides résumé and inter-
welding to lead women out of poverty participants, the program provides view preparation to facilitate students’
and bolster the welding industry. hands-on training in gas metal arc transition into full-time jobs.
welding, which is a high-demand
Providing Training Options process in Detroit. So they’re ready for Single-Day Introductory Workshop
for Diverse Needs entry- or intermediate-level jobs, the
women are further instructed on how The single-day workshops provide
Women Who Weld knows that not to weld different metals in various po- basic training in gas metal arc welding
all women have the same needs. To sitions; operate multiple metalworking for 15 participants while informing
meet the varied financial demands and tools and machines; read blueprints; them about opportunities in the in-
professional goals of its diverse popu- and use angle finders and measuring dustry — Fig. 3. Primarily held in
lation, Women Who Weld offers three tapes. The women are also taught safe- Michigan, the single-day workshops
training modes: the six-week course, ty and welding terminology, as well as have also been offered in other states,
the week-long class, and the single-day the makeup and properties of differ- and recently in southern California,
workshop. ent metals, materials, and gases. with great success.
“The workshops are always really to turn our lives around and change all their fears of the machinery and the
fun and filled with a mix of women aspects of our lives; it wasn’t just a space, and just give it a try.”
who hold different occupations, such new career.” Fortson is currently pursuing a
as architects, waitresses, teachers, stu- Today, Manska is a welder for W In- bachelor’s in welding engineering at
dents, doctors, artists, engineers, re- ternational, Madison Heights, Mich., a The Ohio State University. She is also
tirees, etc.,” said Farr. full-service manufacturer of large an intern for General Electric’s avia-
Funds from both the week-long complex metal fabrications to serve tion division in Cincinnati, Ohio. She
classes and the single-day workshops the aerospace, automotive, commer- credits her time with the organization
are used to subsidize the cost of the cial, defense, and energy markets. for giving her an academic advantage.
six-week training course. She’s excited about new endeavors, “My experience with Women Who
and recently became certified to weld Weld helped me land the internship,
Unveiling New Possibilities government projects. and it’s helping me while I’m there as
“Before I was living paycheck to well,” Fortson said.
Those involved with Women Who paycheck, and now things are better,” Spurring life-changing opportuni-
Weld report that the organization she said. “I love what I do, and it ties is what motivates Farr to reach
helps unfold a new life. makes me happy.” more women and continue to grow the
Ashley Manska was “unhappy” be- Former Women Who Weld coin- organization.
fore learning to weld. As a bartender, structor Tylah Fortson also describes “Every time I receive a text, email,
she wasn’t making ends meet and felt seizing new opportunities after work- or phone call from a graduate telling
dissatisfied, but she didn’t know how ing with the organization for three me they’ve been promoted or have be-
to change her situation. Although months in 2017. As a coinstructor, she come certified in a new position, or
there are welders in her family, she expanded her knowledge base and ex- that they credit Women Who Weld
hadn’t considered it as a career path perience by performing a range of with saving their lives, it makes me
until a customer showed her a Women tasks she had never done before, such smile,” said Farr. “Knowing that all
Who Weld news clipping. as helping to secure donations; scout- these women have this skill, a job they
“A lot of people from my generation ing different manufacturing business- enjoy going to every day, and confi-
were told to go straight to college and es and welding jobs in the area; work- dence in their ability to positively im-
not get their hands dirty,” explained ing with Farr to create a class syllabus, pact their career path makes it all
Manska. daily schedules, blueprints, and practi- worth it.”
Manska completed the course in cal and written tests; training partici-
July 2017, and describes having a pants how to prep their workpieces Building a Strong Workforce
proud sense of accomplishment as well using various tools; conducting lec-
as a positive outlook for the future. tures; and fostering a team-oriented Graduates of the six-week course
“I never graduated from anything workspace. and the week-long class receive a certi-
before. I felt like I was starting a “It gave me the opportunity to fication of completion to share with
brand-new life, and I had a lot more learn, not just how to teach, but how hiring companies. According to Farr,
confidence,” she said. “I was in the pro- to combat the participant’s negative these graduates possess the skills re-
gram with a lot of women from the perception of welding,” she said. “I quired by industry to fulfill full-time
shelter, and we were in a bad place in have a better understanding of how to or apprenticeship positions right away
life. Samantha gave us the opportunity talk to women to help them overcome — Fig. 4. To date, the organization has
Television Personality and Lincoln Electric Spokesperson Jessi Combs works to break down barriers for the next generation of
female welders.
F
or Lili Kammeyer, a welding tech- cool, and then I realized, ‘Oh, there are “Being female, certainly 25 years
nology student at Davis Technical no other girls here.’” ago, in this industry was a rarity,” Byall
College (Davis Tech) in Kaysville, Although it may be easier for a remembered.
Utah, the message that women are woman to start welding than it used to When she was hired, Byall took her
welcome in welding matters. be, shadows of the male-only welding training seriously. But some of her cus-
“I’m very girly,” Kammeyer said. club remain, making it difficult for tomers and coworkers weren’t so sure.
“Going into the welding classroom, women to get jobs or promotions in “I got asked if I got my job because I
people would say, ‘You know cosmetol- the industry. That’s why the work of was female or because of who I knew,”
ogy is that way, right? Are you sure pioneers like Lisa Byall is so vital. As Byall recalled. “These questions were
you’re in the right place?’ and I’d say, role models for younger women in not asked of my male counterparts.”
‘Uh-huh, I’m in welding.’” welding, industry veterans offer sup- Jenny Farney, a sales engineer from
Her classmate, Oriahna Stockham, port and advice to younger welders. Lincoln Electric, also encountered sex-
agreed. “When I started the program, I When Byall, a portfolio manager of ism in the industry, especially at the
didn’t even think about being ‘a girl in welding consumables at Lincoln Elec- start. Farney was 23 when she re-
the welding department,’” Stockham tric, began her career in welding, she placed a man who had just retired.
said. “I just thought welding looked dealt with her share of doubters. “There was a lot of pushback from
Fig. 1 — Combs works to create change for women Fig. 2 — The first female graduating class from Lincoln Electric Welding
in the welding industry. School, ca. 1940s. (Photo courtesy of Lincoln Electric.)
A
t 8:00 a.m., hundreds of stu-
dents from Urban Assembly
New York Harbor School (NYHS)
ride the waves on a ferry to take them
to an island for first period class. The
high school, which was originally es-
tablished in 2003 in Bushwick, Brook-
lyn, and named afer the New York
Harbor, has a maritime-themed aca-
demic program where students can
earn technical credentials in one of
seven marine fields offered.
New York Harbor School stands out
with its unique location and its water-
focused curriculum. In 2010, the
school relocated to Governor’s Island
to give students direct harbor access,
as well as cut down on the hundreds of
hours they were spending on subways
and buses to make their way to the
shore, especially for freshmen, who
visit 17 different waterside spots
throughout the year. More than 524 of
its students commute on a daily basis,
taking the nearly 8-min ferry ride to
the island.
The public high school infuses the
standard New York State Education
Department curriculum with water-
related topics, exposing students to
the New York Harbor, as well as the
Hudson and East River. Students at
the school go out into the harbor,
dubbed their “outdoor laboratory,”
every Tuesday and Thursday.
Students enroll in one out of seven
career and technical education (CTE)
programs (vessel operations, ocean en-
gineering, marine systems technology,
professional/scientific diving, ad-
vanced marine biology research, aqua-
culture, and the most recent addition,
marine policy) to focus on for the rest
of their high school career. This can
lead to industry certification in marine
Welding Instructor Clarke Dennis demonstrates how to make a shielded metal arc science or technology and includes
weld for his marine systems technology welding students. work-based learning experiences,
has already proven to be a valuable as- plumbing, and metalwork in the internal combustion engine theory.
set there and with his students. Most spring semester. In the summer, inter- Juniors learn flux-cored arc, gas tung-
recently, he received the Outstanding ested juniors in good academic stand- sten arc, gas metal arc welding, marine
CTE Teacher Award. ing can have a junior summer intern- electronics, and fiberglass work. Sen-
ship. This internship is at least 54 h iors spend the first half of the year re-
The Curriculum and can offer students one credit. fining skills and applying them to
“Students intern at local marine their senior projects. The second half
The first two semesters of all seven services companies, The South Street is spent in internships,” affirmed Den-
programs is a foundation class for the Seaport Museum, Billion Oyster Proj- nis.
CTE programs. This allows freshmen ect, and GMD Shipyard,” said Dennis. In 2003, industry input led to the
to get a taste of the programs in addi- Upon senior year, MST students formation of the MST program. Now
tion to their regular academics. They prepare for graduation and the real with the increasing needs of local in-
are introduced to elements of all the world. They take marine systems tech- dustry and its unique curriculum, the
programs to think about which pro- nology V — composites, project plan- program is never short on students
gram best suits their interests and ning, customer service, college/post- vying for a seat.
goals. In the spring of their freshman secondary pathways, and marine sys- “MST has 68 students enrolled at
year, they rank their program choices tem technology VI/senior project, ma- this time. We generally have fewer
in order of preference. In their sopho- rine service technology SkillsUSA as- spots available than number of appli-
more year,the students choose the sessment. This includes final prepara- cants,” said Dennis.
CTE program they will focus on for tion and completion of the ABYC Ma- As tides are turning and women are
the rest of their high school career. rine Systems exam, SkillsUSA/senior forging into welding as a future career,
This leads to industry certification project, and an internship, among oth- Dennis proudly emphasizes half of his
in marine science or technology er modules. class is female — Fig. 2.
and includes work-based learning Students participate in real-world
experiences. learning as they progress, beginning The Facility
Marine systems technology students with visits to shipyards, marinas, boat-
begin their sophomore year with the yards, and manufacturing facilities, In addition to using the harbor as
marine systems technology I course advancing to applied maritime studies their “laboratory,” MST students also
during the fall semester and the marine where they work in the field under the use the welding shop to receive quality
systems technology II/marine propul- direction of their teachers and in con- learning and training. The 1000-sq-ft
sion systems course in the spring se- junction with industry partners. The lab facility, located on their water-
mester. They also begin to sign up for a culmination of these experiences is an front, features advanced technology
MST-related afterschool program (boat- internship, with specific technical allowing students to learn welding as
building, vessel maintenance, welding, learning goals formulated by the stu- well as blueprint reading, measuring,
and waterfront club) — Fig. 1. dent, teacher, and workplace mentor. and fabrication skills related to local
During their junior year, students Throughout those years, students will and maritime industry.
take the third course of marine sys- have been introduced to a variety of The facility includes a variety of
tems technology/marine electrical sys- welding processes. welding machines, personal protective
tems during the fall and marine sys- “Sophomores learn shielded metal equipment, metalworking equipment
tems technology IV/workplace safety, arc welding, basic woodworking, and and tools, supplies, and equipment for
Excerpted from the Welding Handbook, Ninth edition, Volume 3, Welding Processes, Part 2.
I want to encourage you to submit nomination packages for those individuals whom you feel have a
history of accomplishments and contributions to our proffession consistent with the standards set by
the existing AW WS Fellows. In particular, I would make a special request that, in considering members
for nomination, you look to the most senior members of your S Section or District. In many cases, the
colleagues and peers of these individuals who are the most faam miliar with their contributions, and who
would normally nominate the candidate, are no longer with us. I waant to be sure that we make the
extra efffort required to ensure that those truly worthy are not overlooked because no obvious
individual was available to start the nominating process.
For specifics on nomination requirements, please contact Chelsea Steel at csteel@aw ws.org at AWS
headquarters in Miami, or simply foollow the instructions on thhe Fellow nomination foorm located at
www.aws.org/fellow. Please remember, we all benefit in the honor
h ing of those who have made major
contributions to our chosen profeession and livelihood. The deaadline for submission is August 1,
2018. The Fellows Committee looks forward to receiving numerous Fellow nominations for 2019
consideration.
Sincerely,
Dr. Charles V. Robino
Chair, AWS Fellows Committee
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https://doi.org/10.29391/2018.97.018
A B
A B
C
C
Fig. 1 — Microstructure of the following: A and B — As-received Fig. 2 — A — Schematic of the welding passes; B — com-
P92 steel; and C — schematic of a prior austenite grain. plete weld joint; and C — cross section of the weld joint.
Element C Mn P S Si Cr Mo V Al Nb W Cu Ni N Fe
Base 0.10 0.58 0.007 0.003 0.48 9.09 0.42 0.24 0.02 0.07 1.86 0.03 0.30 0.02 Rest
Filler 0.11 0.60 0.008 0.005 0.19 8.90 0.45 0.22 — 0.06 1.82 0.04 0.35 0.06 Rest
lution of precipitates that provide the microstructure stabil- Results and Discussion
ity. The chemical compositions of as-received plates and
filler rod are depicted in Table 1. As-Received Material
The plates sized 150 60 12 mm were prepared from
as-received plates. A V-groove was produced for making The micrographs of P92 steel in low and high magnifica-
weld joints. The root height and groove angle were taken tions are shown in Fig. 1A and B, respectively. The low magni-
as 1.5 mm and 37.5 deg, respectively. Shielded metal arc fication micrograph consists of PAGBs with packets, laths,
welding (SMAW) was utilized to produce P92 steel weld packet boundaries, and blocks of laths, as shown in Fig. 1A.
joints. The P92 steel filler rod (flux coated, 4 mm diame- The distribution and morphology of coarse M23C6-type precipi-
ter) was used with a welding current of 140 A and arc volt- tates and fine MX precipitates at lath boundaries and PAGBs
age in the range of 23–26 V. Before welding, preheating were clearly seen at higher magnification, as shown in Fig. 1B.
was performed at a temperature of 300°C using flame Evolution of precipitates along PAGB, lath blocks, packet
heating. Before PWHT, the postweld heating was also per- boundaries, and inside intra lath region is shown in schematic
formed at 250°C for 40 min to remove the diffusible hy- diagram of Fig. 1C. It defines the lath boundaries, packet
drogen content (Ref. 19). boundaries, packet, columnar laths, PAGBs, coarse M23C6 pre-
After the postweld heating, postweld heat treatment cipitates, and fine MX precipitates. The ultimate tensile
(PWHT) was performed at 760°C for 2 h. To characterize strength (UTS), % elongation, microhardness, and impact
the sample, shaping, grinding, paper polishing, and cloth toughness of as-received P92 steel were measured as 678 ± 10
polishing were performed. After polishing, samples were MPa, 23 ± 2%, 227 ± 4 HV, and 198 ± 8 J, respectively.
etched in Vilella’s reagent. Samples were characterized us-
ing a field-emission scanning electron microscope (FES- Characterization of Weldments
EM), microhardness tester (Omnitech S. Auto), and verti-
cal tensile testing machine (Instron:5982) techniques. Ac- Figure 2A shows the weld joint after welding completion.
cording to ASTM E8/E8M, the transverse flat subsize ten- The optimized base material microstructure was changed
sile specimens were prepared with a gauge width of 6 mm completely by an applied welding cycle. Based on tempera-
and gauge length of 25 mm (Ref. 20). Room-temperature ture experience, the P92 weldments are divided into the
tensile tests were performed at a constant cross-head weld fusion zone and narrow heat-affected zones (HAZs).
speed of 1 mm/min. In addition, a Vicker’s microhardness Narrow HAZs show the continuous microstructure change
tester was used for the hardness measurement at a 500-g due to the varying temperature range, and it is divided into
load and dwell time of 10 s. coarse grain (CG), fine grain (FG), intercritical (IC), and
A B
C D
Fig. 3 — Secondary electron micrographs in the as-welded condition: A — Weld fusion zone; B — CGHAZ; C — FGHAZ; and D — ICHAZ.
overtempered base material. The P92 steel weld showing the The size of coarse M23C6 was observed to be varied from 574
weld fusion zone, various zones formed in the HAZ, and fea- to 723 nm with an average precipitate size of 638 ± 62 nm.
tures of the weld are shown in Fig. 2B. The fine MX precipitates are difficult to resolve using the
A typical untempered columnar lath microstructure of SEM micrographs. The growth of austenite grain impeded
the weld fusion zone is shown in Fig. 3A. The microstruc- by these undissolved precipitates resulted in the fine prior
ture also shows the -ferrite. In P92 steel, a high weight per- austenite grains (PAGs) structure. Some -ferrite patches
centage of ferrite stabilizer elements like W and Mo pro- were also observed in the FGHAZ. In P92 steel weldments,
mote -ferrite formation. In P92 steel weldments, the pres- the mild intercritical heat-affected zone (ICHAZ) was found
ence of -ferrite was undesired with respect to poor weld to be an interesting region, which had a mixed combination
toughness. The zone adjacent to the weld fusion zone expe- of new prior austenite grains and remaining coarse tem-
rienced temperatures much above the transformation tem- pered grains, with some undissolved precipitates and coarse
perature (Ac3) and denoted as coarse grain heat-affected tempered precipitates, as shown in Fig. 3D.
zone (CGHAZ). The dissolution of precipitates occurred at In the PWHT condition, evolution of dissolved precipi-
such a high temperature, which resulted in a higher amount tates occurs. After PWHT, the microstructural evolution and
of carbon (C) and nitrogen (N) in the solid-solution matrix. distribution of carbide precipitates in the weldments are
The pinning force by the precipitates was also reduced due shown in Fig. 4A–D. The PWHT of P92 weldments lead to
to dissolution of precipitates, which resulted in formation of the evolution of precipitates and coarsening of existing pre-
coarse grains of austenite. Hence, in the as-welded condi- cipitates. Evolution of precipitates and coarsening of exist-
tion, coarse grain lath martensitic structure was observed in ing precipitates in every zone of P92 steel weldments is
the CGHAZ, as shown in Fig. 3B. The fine grain heat-affect- shown in Fig. 4A–D. The PWHT results in overtempering of
ed zone (FGHAZ) experienced a temperature just above Ac3. the base metal. The overtempering does not contribute so
Fewer coarse M23C6 and fine MX precipitates remain much in microstructural change. Overtempering does not
undissolved because the temperature was not capable of allow the phase change, but it leads to negligible coarsening
dissolving the precipitates completely, as shown in Fig. 3C. of M23C6-type carbide precipitates.
A B
C D
Fig. 4 — Secondary electron micrographs after PWHT: A — Weld fusion zone; B — CGHAZ; C — FGHAZ; and D — ICHAZ.
Fig. 6 — A — FGHAZ after PWHT; B — line mapping results showing variation of elements; and C — EDS of coarse precipitate pres-
ent on the PAGB.
the weldments during the weld thermal cycle and PWHT. ured to be 453 ± 24 HV in the as-welded state. The weld fu-
The engineering stress-strain curve for the welded speci- sion zone undergoes the multipass welding effect, which re-
mens is shown Fig. 7. In the as-welded condition, the frac- sulted in a great variation in hardness due to autotempering
ture of the tensile specimen was noticed in the soft FGHAZ of the previous pass by subsequent pass. In the as-welded
region. In the as-welded condition, the ultimate tensile condition, a higher hardness in the weld fusion zone is at-
strength (UTS) and % elongation were measured to be 674 tributed to a presence of higher weight percentage of C and
± 18 MPa and 12.5 ± 3.5%, respectively. The ductility of N in the solution matrix. As it moves away from the weld fu-
weldments was measured to be lowest in the as-welded sion zone, a gradual decrease in hardness was observed. The
condition due to the high volume fraction of untempered CGHAZ and FGHAZ hardness were measured to be 417 HV
lath martensite. After PWHT, the fracture location was and 403 ± 12 HV, respectively. In the CGHAZ, a higher peak
shifted from FGHAZ to the overtempered base zone. After temperature results in the dissolution of precipitates that
PWHT, the UTS and % elongation were observed to be in- leads to C and N percentage in the solid-solution matrix.
creased as compared to the as-welded condition. In the That results in a higher hardness in the CGHAZ among all
PWHT condition, the UTS and % elongation were meas- HAZs. In the FGHAZ, partial dissolution of precipitates re-
ured to be 785 ± 25 MPa and 21 ±4%, respectively. The sults in less C and N in solid-solution matrix that leads to
UTS was observed for the FGHAZ and overtempered base poor hardness of the FGHAZ as compared to the CGHAZ.
metal. Fracture from the FGHAZ and overtempered zone After the FGHAZ, a sudden drop was observed in the hard-
shows the higher strength of the weld fusion zone. ness at the HAZ base boundary.
In the as-welded condition, the ICHAZ was identified as a
Hardness soft zone, and hardness was measured to be 214 HV. The
lowest hardness of the ICHAZ is attributed to the presence
The variation of microhardness in the weldments is of coarse undissolved M23C6 precipitates and overtempering
governed by the precipitation hardening and solid-solution of martensite. The PWHT results in a considerable reduction
strengthening. Variations of microhardness across the weld- in hardness throughout the weldments. After PWHT, the
ments for different conditions are shown in Fig. 8. weld fusion zone hardness was measured to be 224 ± 6 HV.
In the weld fusion zone, the microhardness was meas- The PWHT resulted in a decrease in solid-solution harden-
ing, but at the same time, the evolution of precipitates leads 4. Dudko, V., Belyakov, A., and Kaibyshev, R. 2016. Origin of
to precipitation hardening. In the PWHT condition, a reduc- threshold stresses in a P92-type steel. Trans. Indian Inst. Met. 69:
tion in solid-solution hardening was observed to be domi- 223–227. DOI: doi.org/10.1007/s12666-015-0757-8.
nated over the increase in precipitation hardening that re- 5. Maruyama, K., Sawada, K., and Koike, J. 2001. Strengthening
mechanisms of creep resistant tempered martensitic steel. ISIJ Int.
sulted in a decrease in the hardness of the weldments. The
41: 641–653.
average hardness of CGHAZ and FGHAZ was measured to be 6. Barbadikar, D. R., Deshmukh, G. S., Maddi, L., Laha, K., Para-
219 and 205 ± 10 HV, respectively. However, the soft ICHAZ meswaran, P., Ballal, A. R., Peshwe, D. R., Paretkar, R. K.,
zone still observed in the welded joints leads to poor creep Nandagopal, M., and Mathew, M. D. 2015. Effect of normalizing
strength of the P92 steel weldments. and tempering temperatures on microstructure and mechanical
properties of P92 steel. Int. J. Press. Vessel. Pip. 132–133: 97–105.
Conclusions DOI: doi.org/10.1016/j.ijpvp.2015.07.001.
7. Sklenicka, V., Kucharova, K., Svobodová, M., Kvapilová, M.,
Král, P., and Horváth, L. 2016. Creep properties in similar weld
The following conclusions can be made:
joint of a thick-walled P92 steel pipe. Mater. Charact. 119: 1–12.
• The microstructures of P92 steel weldments were char- DOI: doi.org/10.1016/j.matchar.2016.06.033.
acterized by the untempered lath martensite, lath packets, 8. Saini, N., Pandey, C., Mahapatra, M. M., Narang, H. K., Mulik, R.
lath boundaries, and -ferrite. S., and Kumar, P. 2017. A comparative study of ductile-brittle transi-
• After PWHT, the strength and ductility were increased. tion behavior and fractography of P91 and P92 steel. Eng. Fail. Anal.:
In the PWHT condition, it was observed that the fracture lo- 245–253. DOI: doi.org/10.1016/j.engfailanal.2017.06.044.
cation was shifted to overtempered base metal from the 9. Saini, N., Pandey, C., and Mahapatra, M. M. 2017. Characteri-
FGHAZ after the room-temperature tensile test. zation and evaluation of mechanical properties of CSEF P92 steel
• The microhardness of subzones of the P92 weldments for varying normalizing temperature. Mater. Sci. Eng. A 688: 250–
showed the great heterogeneity in the microstructure. Maxi- 261. DOI: doi.org/10.1016/j.msea.2017.02.022.
10. Shrestha, T., Alsagabi, S. F., Charit, I., Potirniche, G. P., and
mum and minimum hardness were measured to be 453 ± 24,
Glazoff, M. V. 2015. Effect of heat treatment on microstructure
and 214 HV for weld fusion zone and ICHAZ, respectively. and hardness of Grade 91 Steel. Metals 5: 131–149. DOI:
After PWHT, a considerable softening was noticed in each 10.3390/met5010131.
zone of the P92 steel weldments. 11. Sambamurthy, E., Dutta, S., Panda, A. K., Mitra, A., and
Roy, R. K. 2014. Evaluation of post-weld heat treatment behavior
References in modified 9Cr-1Mo steel weldment by magnetic Barkhausen
emission. Int. J. Press. Vessel. Pip. 123–124: 86–91. DOI:
doi.org/10.1016/j.ijpvp.2014.08.004.
1. Coussement, C., Dhooge, A., de Witte, M., Dobbelaere, R., 12. Pandey, C., Giri, A., Mahapatra, M. M., and Kumar, P. 2017.
and van der Donckt, E. 1991. High temperature properties of im- Characterization of microstructure of HAZs in as-welded and serv-
proved 9% Cr steel weldments. Int. J. Press. Vessel. Pip. 45: 163– ice condition of P91 pipe weldments. Met. Mater. Int. 23: 148–162.
178. DOI: doi.org/10.1016/0308-0161(91)90090-O. DOI: doi.org/10.1007/s12540-017-6394-5.
2. Wang, S. S., Peng, D. L., Chang, L., and Hui, X. D. 2013. En- 13. Onoro, J. 2006. Weld metal microstructure analysis of 9-
hanced mechanical properties induced by refined heat treatment 12% Cr steels. Int. J. Press. Vessel. Pip. 83: 540–545. DOI:
for 9Cr–0.5Mo–1.8W martensitic heat resistant steel. Mater. Des. doi.org/10.1016/j.ijpvp.2006.03.005.
50: 174–180. DOI: doi.org/10.1016/j.matdes.2013.01.072. 14. Cai, G., Svensson, L., and Andren, H. 1997. Effect of cooling
3. Sakthivel, T., Laha, K., Parameswaran, P., Panneer Selvi, S., after welding on microstructure and mechanical properties of 12
and Chandravathi, K. S. 2015. Effect of thermal aging on mi- Pct Cr steel weld metals. Metall. Mater. Trans. A 28A: 1417–1428.
crostructure and mechanical properties of P92 steel. Trans. Indian DOI: doi.org/10.1007/s11661-997-0204-5.
Inst. Met. 68: 411–421. DOI: doi.org/10.1007/s12666-014-0480-x. 15. Abson, D. J., and Rothwell, J. S. 2013. Review of type IV crack-
ing of weldments in 9 – 12 % Cr creep strength enhanced ferritic zones of P91 welded pipes. J. Mater. Eng. Perform. 25: 2195–2210.
steels. Int. Mater. Rev. 58: 437–473. DOI: doi.org/10.1179/ DOI: doi.org/10.1007/s11665-016-2064-x.
1743280412Y.0000000016. 20. ASTM-E8/E8M. 2017. Standard Test Methods and Definitions
16. Mandziej, S. T., Výrostková, A., and Chovet, C. 2011. Mi- for Mechanical Testing of Steel Products, pp. 1–49. DOI: 10.1520/
crostructure and creep rupture of P92-grade weld metal. Weld. A0370-17.2.
World 55: 37–51. DOI: doi.org/10.1007/BF03321294.
17. Xue, W., Qian-gang, P., Yao-yao, R., Wei, S., Hui-qiang, Z.,
and Hong, L. 2012. Microstructure and type IV cracking behavior
of HAZ in P92 steel weldment. Mater. Sci. Eng. A 552: 493–501.
DOI: doi.org/10.1016/j.msea.2012.05.076. NITIN SAINI (nit030078@gmail.com), CHANDAN PANDEY, and
18. Dodo, M. R., Ause, T., Adamu, M. A., and Ibrahim, Y. M. 2016. RAHUL S. MULIK are with the Department of Mechanical and
Effect of post-weld heat treatment on the microstructure and me- Industrial Engineering, Indian Institute of Technology Roorkee,
chanical properties of arc welded medium carbon steel. Niger. J. Tech- Uttrakhand, India. MANAS MOHAN MAHAPATRA is with the
nol. 35: 337–343. DOI: http://dx.doi.org/10.4314/njt.v35i2.14. School of Mechanical Sciences, Indian Institute of Technol-
19. Pandey, C., and Mahapatra, M. M. 2016. Effect of heat ogy, Bhubaneswar, Odisha, India.
treatment on microstructure and hot impact toughness of various
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https://doi.org/10.29391/2018.97.019
Composition C Mn Cr Mo Ni Si Nb Fe
Percent (wt-%) 0.3 0.3 0.8 0.3 0.8 0.3 0.05 other
Tensile Strength Yield Strength Elongation Impact Toughness (–40°C) Maximum Bending Angle
1723 MPa 1305 MPa 9.05% 14.3 J 180 deg
A B
Fig. 2 — Sample distribution and size for mechanical properties testing. A — Schematic; B — detailed dimensions.
Experimental Results
Joint Quality
Fig. 3 — Forming defects distribution under different parame-
Laser welding of thick section materials without filler ters. The five-pointed stars signify the occurrence of root
humping.
metal is often accompanied by defects such as spatter, root
humping, and pool sagging as well as root concavity, which
would all result in undercut or even underfill (Refs. 29, 30). shown in Fig. 3 and the five-pointed stars in it mean that
Previously, many studies have investigated the defects in root humping occurred. The welding appearance under dif-
laser welding (Refs. 31–34), but only isolated defects were ferent parameters are shown in Fig. 4. It can be seen that
generally focused on, and the distribution of defects under complete joint penetration welds were obtained, but the
different parameters weren’t discussed. This section shows typical forming defects mentioned above emerged under dif-
the distribution of defects within the process window. ferent parameters. As illustrated in Fig. 3, large quantities of
The defect distribution under different parameters is spatter are generated when the welding speed is more than
A B
C D
Fig. 4 — Welding appearance under different parameters. A — Spatters under 8 kW and 4 m/min; B — root humping under 6 kW
and 4 m/min; C — pool sagging under 6 kW and 1 m/min; D — root concavity under 10 kW and 1 m/min.
Step Procedure
No. Laser Power (kW) Welding Speed (m/min) Heat Input (kJ/mm)
1 8 3 0.16
2 6 2 0.18
3 10 2 0.30
B C
D E
F G
Fig. 7 — These OM and SEM micrographs show the microstructures in different subzones of the welded joints with 0.18 kJ/mm heat
input. A — Joint microstructures; B — WM; C — CGHAZ; D — FGHAZ; E — ICHAZ; F — SCHAZ near ICHAZ; G — SCHAZ.
A B
Fig. 9 — Microstructure of the base metal and weld metal. A — Base metal; B — weld metal.
A B C
Fig. 10 — SEM micrographs showing the microstructures in different positions of the ICHAZ. A — ICHAZ; B — A region; C — B region.
Microhardness
A A B
C D
1.0 to 2.0 mm, much less than the width of the arc-welded
joint (Ref. 16). The limited size could reduce the influence of
softening on the strength of the joint, but might lead to in-
homogeneous deformation during a bend test.
As is expected, various heat cycles would lead to a differ-
ent softening. As shown in Fig. 12, the width and minimum
hardness of the softening zone are influenced by heat input.
The width of the different joints were 1.31, 1.45, and 1.70
mm, respectively. Additionally, the minimum hardness was
348, 345, and 327 HV, respectively. The high-heat-input weld
exhibited a wider dimension and a more serious hardness
drop in the softening zone compared to low heat input. The
changes indicated that high heat input intensified the HAZ
softening.
C Tensile Properties
No. Laser Power Speed Heat Input Tensile Strength Elongation Fraction Initiation
(kW) (m/min) (kJ/mm) σUTS (MPa) A (%) Location Location
A B C
Fig. 14 — The fracture sections after tensile testing of the joints under different heat inputs. A — 0.16 kJ/mm; B — 0.18 kJ/mm; C —
0.30 kJ/mm.
Fig. 15 — The SEM micrographs of the fracture surface after the tensile test of the joints welded at a heat input of 0.16 kJ/mm.
Fig. 16 — The SEM micrographs of the fracture surface after the tensile test of the joints welded at a heat input of 0.30 kJ/mm.
No. Laser Power Speed Heat Input Maximum Bending Angle Bending Fraction
(kW) (m/min) (kJ/mm) (deg) Location
ratio due to porosity is just about 0.65%. As illustrated in parallel to the ICHAZ can be seen. The microstructure in the
Fig. 15, numerous short tearing ridges are observed on the platforms is severely tempered martensite with large
fracture surface of the joints. Tiny cleavage planes connect amounts of precipitates carbides, and the hardness is the
with each other through the tearing ridge, accompanied by a lowest. Therefore, the welded joints would break off at the
secondary crack. All of the above is a typical feature of qua- softened area and then expand to other zones of the joints
si-cleavage mode, which belongs to a brittle transgranular (Refs. 4, 39). The overall fracture direction is along 45 deg to
fracture. Moreover, some small dimples can be observed. the parallel direction. Various magnification SEM fracture
The existence of dimples and tearing ridges means some graphs for the welded specimen are shown in Fig. 16. The
plastic deformation occurred before the fracture. Thus, the fracture morphology in the platform is similar. It can be
fracture mechanism is a dominant brittle fracture, mixed seen that the platform is predominately composed of differ-
with a measure of ductile fracture. ent-sized equiaxed dimples, which are caused by simple ten-
For the joints with more than 0.18 kJ/mm heat input sile loading, and the morphology is usually in accordance
(parameters 2 and 3), the fracture was located in the HAZ with the characteristic of the fracture center (Refs. 40, 41).
and the weld metal (Fig. 14B and C). Platforms close and The graphs on the two 45-deg shear planes beside the plat-
A B C
Fig. 17 — The fracture sections of the bending joints under different heat input. A — 0.16 kJ/mm; B — 0.18 kJ/mm; C — 0.30 kJ/mm.
A B C
Fig. 18 — The macrographs of bending joints under different heat inputs, A — 0.13 kJ/mm; B — 0.18 kJ/mm; C — 0.30 kJ/mm.
form show small shearing dimples. The dimples have an 21.4-deg bending angle was obtained.
elongated parabolic shape, indicating the occurrence of For parameters with a heat input of more than 0.18
shearing motion and the final rapid failure of the sample kJ/mm (parameters 2 and 3), the bending samples fractured
(Refs. 42, 43). Combined with the minimum hardness on around the softening zone instead of the weld metal. The
the platform, it is speculated that the fracture might initiate larger bending angle (35.8 to 43.8 deg) is achieved because
at the platform and then extend along the 45-deg bevel. It of better plasticity in the zone. A similar bending angle was
could be concluded that the specimen failed in a typical duc- reported in laser welded ARMOX 500T steel (Ref. 9). During
tile fracture mode. That is why the elongation is larger com- a bend test, the specimen surface had the maximum tensile
pared with parameter 1. stress. Therefore, the fracture might initiate at the top of
around the ICHAZ (Fig.17) where the hardness is the lowest.
Bending and Charpy Impact Properties The fracture locates in the SCHAZ. The microstructure
around the fracture zone is tempered martensite with differ-
A three-point bend test was carried out at the top of the ent temper temperatures. The degree of the temper reduces
joints to evaluate the bending property of joints. The results progressively away from the weld center. Just like the ten-
are shown in Table 6. Compared with the base metal, the sion process, it extended along a 45-deg shear plane in the
laser welded joints have inadequate bending deformability initial stage. As the testing proceeded, the fracture turned
with only about a 40-deg bending angle before a complete around about 90 deg and extended along the 45-deg direc-
fracture was obtained. The base metal can easily realize a tion again (extending stage) since the hardness of the SC-
180-deg bending angle without a crack. HAZ increased gradually away from the weld center. Finally,
The fracture sections and macrograph of bending joints the samples ruptured along the ICHAZ. The SEM micro-
under different heat input are given in Figs. 17 and 18, re- graphs of the fracture surface on the tension stress zone of
spectively. As shown in Fig. 17, two different fracture loca- bending samples are given in Fig. 19. On both the 45-deg
tions are observed. bevels, cleavage surface can be seen clearly, which indicates
For parameters with a 0.16 kJ/mm heat input (parameter that the fracture mechanism of the two bevels is a brittle
1), the bending fracture occurred in the weld metal (Figs. fracture.
17A and 18A), where the metal is weakened by porosity, just As shown in Figs. 17 and 18, no joints were subjected to
like the tensile fracture. Since the plasticity of the weld met- significant plastic deformation and all the joints failed. This
al is very poor with a hardness of more than 500 HV, only a can be explained by the fact that, as illustrated in Fig. 18B
A B
Fig. 19 — SEM micrographs of the fracture surface on the tension stress zone of the bending samples at the heat input of 0.18
kJ/mm. A — 45-deg shear plane in the initial stage; B — 45-deg shear plane in the extending stage.
No. Laser Power Speed Heat Input Impact Energy Impact Fraction
(kW) (m/min) (kJ/mm) (–40°C, J) Location
A B C D
Fig. 20 — Impact fractures of the base metal and joints. A — The base metal; B — 0.16 kJ/mm; C — 0.18 kJ/mm; D — 0.30 kJ/mm.
time of solidification and the droplets are retained in the of the ICHAZ. Second, the UHSS is also softened in the
form of root humping instead of retuning into the weld. As a SCHAZ as the martensite in the original microstructure pre-
result, root humping occurs and leads to underfill on the cipitates carbides and then forms tempered martensite (Fig.
corresponding cross section. 11). Because the highest temper temperature is slightly low-
Weld pool sagging is one of the characteristics of a thick er than Ac1, the most heavily tempered martensite appears
section weld (Ref. 10). Once the melt pool is fully penetrat- in the SCHAZ close to the ICHAZ. Therefore, the most sig-
ed, pool sagging occurs. It might be associated with an nificant softening occurs in the zone. With the decrease of
amount of molten metal produced by the excessive heat in- peak temper temperature from the SCHAZ to the base met-
put and the downward melt flow with root humping. Gravi- al, the hardness rose gradually, but the SCHAZ still belonged
ty in the thick-section molten pool is as important as sur- to the softening zone. The results are consistent with previ-
face tension and recoil pressure. Once the plate is fully pene- ous research (Ref. 9).
trated, the molten metal flows toward the root of the weld
under the action of hydrostatic pressure from gravity and Fracture Mechanisms of Tensile and Bend Tests
the laser beam (Ref. 33). The dimensionless Bond number
represents the ratio of gravitational forces to surface tension Since the tension stress zone of the bending process is
forces (Ref. 46). With the increase of the Bond number, the similar to the tensile process, there exists homogeneity for
relative importance of gravity is becoming obvious. When the failure of the tensile and bending test. As shown in Figs.
the Bond number exceeds threshold levels, namely the grav- 14 and 17, the fractures might both initiate at the softening
ity is large enough and the surface tension cannot compen- zone close to the ICHAZ, where the hardness is the lowest
sate the hydrostatic pressure, pool sagging occurs (Refs. 10, and the microstructure is tempered martensite under high
30, 33). Too low a welding speed with excessive heat input temperature. Then the fractures extend along the 45-deg
would aggravate the defect. Maybe that is why serious pool direction as the tangential stress is the maximal. As the ten-
sagging happened at 1 m/min. With a further increase in sile and bend tests have their respective characters, there are
heat input, surface tension is totally unable to balance the some differences for the initiation location and propagation
hydrostatic pressure, molten metal is partly out of the weld, path of the fracture. For the bend test, the top and root of
and then a significant root concavity appears (Fig. 4D). the joints withstand tensile and compressive loadings, re-
spectively. The stress on the specimen surface is the maxi-
Softening Mechanisms of the HAZ mum, so it’s very sensitive to softening. Therefore, the frac-
ture initiates at the joint surface instead of inside. More-
The results described in the microstructure and micro- over, the crack propagation paths of tensile and bending
hardness sections indicate that the lath martensite in the fractures are different. For the tensile test, since the soften-
weld metal, CGHAZ, and FGHAZ resulted in hardening of ing zone is close to the ICHAZ and the ICHAZ is inclined be-
the joints. But the ICHAZ and SCHAZ showed microstruc- cause of the hourglass weld shape (Ref. 35), the fracture
ture degradation and hardness decreased, which would have might have the inertia of extending along the incline into
a significant impact on the mechanical behavior of the laser the weld metal quickly. It could be the reason why the crack
welded joints. The analysis indicated that there might exist propagated to the weld metal instead of trapping in the soft-
two softening mechanisms in laser welded UHSS joints. ening zone after initiation. For the bend test, the expanding
First, the joints are softened in the ICHAZ since the dual- process carried on slowly and gradually. The cracking path in
phase microstructure of the ferrite and martensite ap- the tension stress zone of the bend samples is all 45 deg in
peared. As shown in Fig. 10A, the ferrite appeared at Ac3 and the SCHAZ, but there is a 90-deg turn, which may result
reached the maximum quantity at Ac1. The corresponding from increasing hardness away from the weld center. A simi-
volume of martensite deceased gradually as it approached lar propagating path was reported and some simulations
the SCHAZ, which resulted in a sharp drop in the hardness about the crack growth trajectory were done (Refs. 47, 48).
Based on the maximum tangential stress (MTS) criterion the joints with low-heat input (0.16 kJ/mm).
(Ref. 47), the fracture path would deviate from the original 2. The microstructures and hardness of joints keep a
crack line. The maximum tangential stress criterion or the good corresponding relationship. In the weld metal and the
minimum strain energy density criterion has been frequent- CGHAZ, the microstructures are predominately lath
ly used for predicting the angle of deflection (Ref. 47). For martensite with high hardness. The maximum hardness lo-
the 45-deg original crack, the deflecting angle is about 90 cates in the FGHAZ, which is consistent with fine equiaxed
deg. In this research, the crack of the bending specimens ex- martensite. Two softening mechanisms occur in the HAZ. A
tends along the 45-deg shear plane in the initial stage and sharp hardness decrease occurs in the ICHAZ as it exhibits a
then deviates from the crack tip. The deflecting direction is dual-phase microstructure of ferrite and martensite. The
toward the loading point, namely tends to the weld. minimum hardness of joints locates in the SCHAZ since the
original microstructure precipitates carbides and forms tem-
Influence of Porosity on Mechanical Properties pered martensite.
3. More than 94% of the strength and 50% of the elonga-
The existence of porosity in joints has significant affects tion of the base material are achieved in a tensile test. For
on the mechanical property of joints. For the tensile test, as the joints with more than 0.18 kJ/mm heat input, the frac-
mentioned above, there are some pores in the weld metal of ture initiates at the softening zone close to the ICHAZ
joints with 0.16 kJ/mm heat input (Fig. 6). However, the and propagates to the weld metal and the SCHAZ along the
tensile strength of the joints can reach 1618 MPa, very close 45-deg direction. The fracture is ductile with equiaxed and
to average strength (1620 MPa) under different parameters, shearing dimples. For the bend test, as the deformation
which might mean that the appearance of porosity exhibits mainly localizes in the softening zone due to nonuniform
little effect on the strength of joints. For the tensile and hardness distribution, no joints are subjected to significant
bending fracture, the porosity weakened the weld metal and plastic deformation and all bend specimens fail. When heat
led to complete failing in the zone instead of initiating at input is more than 0.18 kJ/mm, the bending fracture initi-
the softening zone. ates at the top of around the ICHAZ and extends along the
The smaller elongation (3.15%) and bending angle (21.4 45-deg shear plane with about a 40-deg bending angle. For
deg) are obtained for the joints with porosity. Namely, the the Charpy impact test, all the joints fractured in the form
fracture mechanism and ductility are significantly affected. of brittle mechanism. The maximum impact energy reaches
The existence of pores might also damage the impact prop- 60% of the base metal.
erty of the joints with porosity. That is why the impact ener- 4. The existence of porosity in joints with 0.16 kJ/mm
gy under parameter 1 is just about 4.3 J and significantly heat input has significant effects on the ductility, tough-
lower than other parameters. Related studies have shown ness, and fracture mechanism but little on the strength of
mechanical properties are obviously affected by porosity joints. For tensile and bend tests, porosity weakens the weld
(Ref. 49), but the sensitivity of the properties to porosity is metal and leads to fracturing in the WM instead of initiating
different. Ductility and toughness are highly sensitive and at the softening zone. The optimal parameter in this experi-
the value would drop immediately as the porosity appears ment is parameter 2 (6 kW and 2 m/min) with the best
(Refs. 50, 51). This may be attributed to stress concentra- strength (1623.5 MPa), ductility (4.75%), bending angle
tion and initial cracks at porosity (Ref. 52), but strength is (43.8 deg), and impact toughness (8.7 J).
tolerant of some porosity (Refs. 50, 51, 53, 54). For 5086-
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CHONG LUO, YUE ZHAO (zhao-yue@tsinghua.edu.cn, and JIGUO SHAN (shanjg@tsinghua.edu.cn) are with the Department of Mechan-
ical Engineering, Tsinghua University, Beijing, China. ZHAO and SHAN are also with the Key Laboratory for Advanced Materials Pro-
cessing Technology, Ministry of Education, Tsinghua University, Beijing, China. YANG CAO is with the School of Materials, Tsinghua Uni-
versity, Beijing, China. LIN ZHAO and CAO are with the Central Iron & Steel Research Institute, Beijing, China.