U1_WC4__ 15.07.

14 16:09 Seite 1

The
Welding
Issue

04
Institute

2014

www.welding-and-cutting.info Technical journal for welding and allied processes

/ Perfect Welding / Solar Energy / Perfect Charging

/ Newly designed from first principles, TPS/i is a MIG/MAG welding system that pushes out the
boundaries of the possible. Improving communication between man and machine was a big part
of what we built into this new system, but we didn’t stop there: we also created the option of
investing in an intelligent system that’s open to new applications and is constantly being evolved.
For users, this means being able to weld faster and more accurately, with less spattering and a
more stable arc. The intelligent revolution in welding technology is beginning right now.
www.fronius.com

»ME AND MY WELDING

SYSTEM – WE TALK
PLAIN TEXT TO EACH
OTHER. EXACT
INFORMATION FOR
THE EXACT WELDING
TASK I WANT TO
ACCOMPLISH.«
Werner Karner, Magna Steyr Engineering
Fahrzeugtechnik AG & Co KG

1 0 15:31

TWI celebrates its first 15 Brazing tungsten carbide - One-sided Nd:YAG laser beam
NSIRC students Part 1: Setting the scene welding for the manufacture of
T-joints made of aluminium
alloys for aircraft construction

Welding Cutting final indd 2 24 01 2012 15:47:24

 Bundled DVS Technical Codes in the area of
Electron Beam Welding | Adhesive Bonding Technology | Rail Vehicle Construction
English Edition Volume 8
DVS Technical Codes
on Electron Beam Welding
1st Edition, September 2013
52 Pages
Order No.: 180009
Price: 18.90 EUR
Selected Translations Elaborated by Working
Group V 9.1 “Electron Beam Welding” of the
Technical Committee of the German Welding
Society – DVS
The documents cover the topics of “welda-
bility of metallic materials”, “case hardening”,
“x-ray protection”, “recommendations for the
cleaning of the joining zone”, “test procedures
for the quality assurance” and “wedge speci-
men for the joining zone”, “test procedures for
the quality assurance” and “”wedge specimen
for the verification of electron beam welds” as
well as fundamental principle for the “designing
of components” and “utilization of non-vacuum
electron beam welding”.
The publication should help to work more effec-
tively by using EB technology and improving the
quality of your products and to strengthen the
competitiveness of your company.
Including DVS 3201, DVS 3204, DVS 3205,
DVS 3210, DVS 3212, DVS 3213, DVS 3220,
DVS 3221
DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf
T +49. (0)2 11. 15 91-161 • F +49. (0)2 11. 15 91-250 • media@dvs-hg.de • www.dvs-media.info
AZ_Englisch_Edition_Volume.indd 1
English Edition Volume 5
DVS Technical Codes
on Adhesive Bonding Technology
1st Edition, September 2013
32 Pages
Order No.: 180006
Price: 12.90 EUR
Selected Translations Elaborated by Working
Group V 8 “Adhesive Bonding Technology”
of the Technical Committee of the German
Welding Society – DVS
Three of the most important sets of rules relating
to adhesive bonding technology are presented
in this brochure and, for the urgent needs of in-
dustry, have been created in the working bodies
dealing with adhesive bonding technology on
the Technical Committee of DVS.
Including DVS 3310, DVS 3311, DVS 3320-1
English Edition Volume 6
DVS Technical Codes
on Rail Vehicle Construction
1st Edition, September 2013
80 Pages
Order No.: 180007
Price: 25.90 EUR
Selected Translations Elaborated by Working
Group A 7 “Welding in Rail Vehicle Construc-
tion” of the Technical Committee of the German
Welding Society – DVS
The technical codes included in this publication
were elaborated with the objectives of contri-
buting to harmonization in relation to the dimen-
sioning of rail vehicles and of proposing a rele-
vant, integrated set of rules.
DVS 1608 “Design and strength assessment
of welded structures from aluminium alloys in
railway applications” and DVS 1612 “Design
and endurance strength assessment of weld-
ed joints with steels in rail vehicle construction”
include notes for the configuration and stipula-
tions for the designing of welded structures as
well as a compilation of welded structure details
which are essential for rail vehicle construction.
The technical codes specify in more concrete
terms the requirements included in the DIN EN
15085 series of European standards “Railway
applications – Welding of railway vehicles and
components” in order to define weld perfor-
mance classes taking account of strength and
safety requirements.
Including DVS 1608, DVS 1612
14.10.2013 09:59:25
187_WC4_Edi__ 15.07.14 16:10 Seite 187

EDITORIAL

Focus on Technicians
A year on from the UK Prime Minister‘s announcement of a re-
newed focus on Engineering Technicians, The Welding Institute
is doing more than ever before to support professional recognition
of Technicians in our industries.

Read more in The Welding Institute News Editorial on page 229.

Eur Ing Chris Eady BSc(Hons) MSc CEng MRAeS FWeldI

Associate Director Professional Affairs
The Welding Institute

Welding and Cutting 13 (2014) No. 4 187

188_189_WC4_Contents__ 15.07.14 17:06 Seite 188

CONTENTS WELDING AND CUTTING 04/2014

News 190 “Nextcut“:Diodelaserforleading-edge

cuttingapplications
190 SueDunkertonawardedOBEforServices
toHealthandEngineering
191 TWIwelcomesadelegationfromthe
MinistryofWorks,Malaysia
192 Engineeringdoctoratestudentwins
RichardDolbyRollsRoycePrize
192 “e-Weld“tomakeweldingeducation
pervasivethroughdistancelearning
193 TWIcelebratesitsfirst15NSIRCstudents
194 Upwardtrendinregisteredengineersand
techniciansintheUKforthefirsttimein

190 “Nextcut“: Diode laser for leading-edge

cutting applications

From Companies 196

12years

AbicorBinzelawardedthe2013“Product
InnovationLeadership”prizebyFrost&
TWI South East Asia will move to new purpose- SullivanforweldingtorchesinEurope
built headquarters in Kuala Lumpur the late summer
198 eperfectdrive
of 2014.
200 Hightemperaturecarburisationtrialsen-
ableoptimisationofmanufacturingpro-
ceduresinanaggressiveenvironment
202 efutureofsurfacetechnology–
theemergenceofsmartcoatings
203 Newlive-streamingmicroscopyprovides
moreaccessformembers
204 ShortMessages
205 Products

Welding Practice 208 Informationaboutpracticalwelding

Events 211 “ALUMINIUM“worldtradefaircontinues

ongrowthcoursein2014
212 Fromthe3rdconference“Join-Trans“
212 January2015:Startofthefirst“Metal
MiddleEast“inDubai
213 Eventonhotisostaticpressing
ofmaterialsforoffshore/energy
applicationsheldinAberdeen
215 6th“INDIAESSENWELDING&
CUTTING“inMumbai

Reports 216 Brazingtungstencarbide–

Part1:Settingthescene
222 Specialprocessofultrasonic-assistedsol-
Relaxed welding with the “ABIMIG A T
LW“ torch of Abicor Binzel.
196 deringorbrazing:Exploitingpotentials

188 Welding and Cutting 13 (2014) No. 4

188_189_WC4_Contents__ 15.07.14 17:06 Seite 189

The
Welding Issue

01
Institute

04
2014

www.welding-and-cutting.info Technical journal for welding and allied processes

Technical journal for welding and allied processes of

the DVS – German Welding Society, Düsseldorf,
the Professional Division of The Welding Institute, Cambridge,
and the Institut de Soudure, Paris

Produced in Collaboration between

198 One drive shaft drives four drive rollers.

The interlocking guarantees synchronous
wire feeding. Each drive roller shaft is
borne on two ball bearings.

Specialist Articles 226 Structuraladhesivebondingonpainted

surfaces
ClaudiaUnger,ManuelSchiel,
KlausDilger
236 Characterisationofmagneticallyde-
flectedarcsandapplicationpotentialfor
thebrazingofgalvanisedsteelsheets
MartinHäßler,SaschaRose,UweFüssel
245 One-sidedNd:YAGlaserbeam
weldingforthemanufactureofT-joints
madeofaluminiumalloysforaircraft
construction
15:47:24

202 Surface coating process of particular

large components: Screw for plastics
processing

VolkerVentzke,StefanRiekehr,
ManfredHorstmann,PeterHaack,
NikolaiKashaev

249 EditorialPreview
250 Books
250 Imprint/AdIndex

National Pages 220 InformationfromtheDVS–German

WeldingSociety
229 TWINews–TheNewsletterof
TheWeldingInstitute

211
At “ALUMINIUM 2014”, the world’s largest
trade event of the aluminium industry,
aluminium producers and converters meet
with suppliers of technologies and equip-
ment for production, further processing
and finishing.

Welding and Cutting 13 (2014) No. 4 189

190_194_WC4_News__ 15.07.14 16:13 Seite 190
NEWS
“Nextcut“: Diode laser for leading-edge
cutting applications
Although laser processes in manufac-
turing has seen a recent rise and their per-
formance is acknowledged, even though
actual usage has lingered in most cases,
with actual usage rates in manufacturing
remaning low overall. To ensure that lasers
become more pervasive in manufacturing
environments and that companies are able
to better leverage its usage according to
their manufacturing processes, a qualifica-
tion of laser-based manufacturing solutions
and of their production relevant properties
is in order.
Hence the European project „Lashare“
(Laser equipment assessment for high im-
pact innovation in the manufacturing Euro-
pean industry) has been established to ad-
dress the risk and facilitate the technology
Sue Dunkerton awarded OBE for
Services to Health and Engineering
TWI – The Welding Institute, Cam-
bridge/UK, has announced that former TWI
Associate Director and advanced materials
specialist Sue Dunkerton has been recog-
nised in the Queen‘s Birthday Honours List
with an OBE (Officer of the Order of the
British Empire) for her Services to Health
and Engineering.
Sue worked at TWI for over 34 years,
building TWI‘s engineering capabilities
across a wide range of materials and sectors,
not least aerospace and medical. Her work
in medical devices included establishing the
Medical Devices Faraday Partnership, help-
190
transfer by providing a robust framework for
the assessment of laser equipment and tech-
nologies, covering the entire value chain
from the technology components, such as
the laser source, to the customised equip-
ment for a given manufacturing application.
Fourteen later equipment assessment (LEA)
experiments have been formed to evaluate
the properties of laser manufacturing equip-
ment in accordance with the demands of
the manufacturing industry.
One of the assessments, named “Next-
cut“ (Multi wavelength diode laser source
for cutting applications) will evaluate the
use of diode laser for high quality cutting
applications at high speed. The use of diode
lasers directly, without the intermediate
step of the fibre or disc amplification, will
lead to optimised wall plug
efficiencies, significantly
decrease capital equip-
ment costs, decreased
maintenance intervals and
increased productivity due
to shorter diode laser
wavelengths which give
higher absorption than fi-
bre and disc laser.
The “Nextcut“ assess-
ment will validate the state-
of-the-art „Diocut“ laser
cutting system for use by
typical European job-
ing to evolve this to the HealthTech and
Medicines KTN, and ultimately into the
Technology Strategy Board‘s Knowledge
Transfer Network. In manufacturing, Sue‘s
role in the UK and European Platforms for
“Manufuture“ helped recognition for a
strong manufacturing capability in the UK,
in line with TWI‘s development of key
process technologies.
Sue said, ‚I was truly surprised and ho-
noured by the award, much of which is down
to my work and that of the people I worked
with at TWI. I am grateful for the contribu-
tions of colleagues and friends over the
shops. The validated end-user benefits will
include increased productivity, reduced op-
erating costs, resulting in significantly in-
creased margins for SME laser cutting job-
shops.
Specific objectives of “Nextcut“ are:
• Produce and integrate a diode laser
source with a CNC flat-bed system for
cutting;
• Carry out an experimental matrix of
cutting trials based upon the typical Eu-
ropean job-shop requirements;
• Perform production-like validation of
the equipment in a job-shop environ-
ment;
• Perform a techno-economic compari-
son of the results against existing laser
cutting solutions.
Project partners involved in “Nextcut“ are:
• TWI – research institute to carry out
cutting trials using different materials
and thicknesses;
• Lissotschenko Mikrooptik GmbH
(LIMO) – diode laser manufacturer;
• European Federation for Welding, Join-
ing and Cutting (EWF) – end user;
• Laser Expertise Ltd – laser job shop and
end user.
(According to press information from EWF)
Advanced
materials
specialist
Sue Dunker-
ton has been
recognised
in the
Queen‘s
Birthday Ho-
nours List.
years.’ Sue Dunkerton is currently a Director
at the Knowledge Transfer Network, and is
based in Great Shelford, Cambridge/UK.
(According to press information from TWI)
Welding and Cutting 13 (2014) No. 4
190_194_WC4_News__ 15.07.14 16:13 Seite 191
TWI welcomes a delegation from the
Ministry of Works, Malaysia
Chief Executive of TWI – The Welding
Institute, Christoph Wiesner, and staff from
TWI South East Asia have given the
Malaysian Government Minister of Works
Datuk Fadillah Yusof and the Chief Execu-
tive of the Malaysian Construction Industry
Development Board (CIDB) Dato‘ Sri Judin
Karim a warm reception at the company‘s
Cambridge headquarters. The Minister vis-
ited the UK for a series of tours to leading
research and technology organisations – af-
firming existing associations and conducting
discussions on a new phase of co-operation.
Building on a successful collaboration
formed in the early 2000s between TWI
South East Asia and the government-run
Malaysian Construction Academy (Akademi
Binaan Malaysia), this new series of discus-
sions focused on advanced skills to further
develop Malaysian human capital.
Following presentations by Christoph
Wiesner and Tat-Hean Gan, Technology Di-
rector of the new National Structural Integri-
ty Research Centre (NSIRC), the Malaysian
Minister of Works led a discussion on his
TWI South East
Asia will move
to new purpose-
built headquarters
in Kuala Lumpur
the late summer
of 2014.
Welding and Cutting 13 (2014) No. 4
Welding processes in the spotlight as
Malaysian Minister of Works, Datuk
Fadillah Yusof (centre), tours TWI‘s
Cambridge laboratories.
government‘s strategy for advanced
skills progression, focusing on in-
tegrity and assuring the quality of
testing and inspection.
The Minister spoke about the op-
portunity to develop an enhanced
programme of work for training and
certification and academic excel-
lence with equal co-operation be-
tween the Construction Industry
Development Board, the National Metals
Technology Centre (NAMTEQ), TWI and
NSIRC. He noted that such an initiative would
hold‚ definite potential‘ for his country.
During the day, the delegation visited
TWI‘s materials joining and engineering la-
boratories, and viewed the construction
progress of the new facilities at TWI, which
have at its core the new NSIRC laboratories
and amenities.
TWI has been offering training, exam-
inations and certification in Malaysia for over
30 years. Its South East Asia regional office,
which also offers engineering and technol-
ogy services, is based in Kuala Lumpur. TWI
South East Asia will move to new purpose-
built headquarters in Kuala Lumpur the late
summer of 2014. TWI South East Asia offers
a complete catalogue of training courses in
welding, inspection and related technolo-
gies, also operating four centres in conjunc-
tion with the Malaysian Construction Acad-
emy (Akademi Binaan Malaysia/ ABM in Jo-
hor, Sarawak, Sabah and Selangor. (Accord-
ing to press information from TWI)
190_194_WC4_News__ 15.07.14 16:13 Seite 192
NEWS
Engineering doctorate student wins
Richard Dolby Rolls Royce Prize
Nick Brown – a Surrey Engineering Doc-
torate (EngD) student spending four years
with TWI Ltd, Cambridge/UK – has won the
Richard Dolby Rolls Royce Prize for his re-
search into an alternative way of machining
composite materials. Open to all profession-
als belonging to TWI, the prize was awarded
to Nick following his presentation to a panel
that included the company‘s current and
former research directors.
Impressing the judges with his enthusi-
asm for his subject, Nick‘s presentation fo-
cused on research conducted during his En-
gineering Doctorate – a four-year pro-
gramme offered by the Centre for Doctoral
Training in Micro- and NanoMaterials and
Technologies at Surrey. For the majority of
the programme, EngD students are based at
their sponsoring company‘s premises, ap-
plying their academic knowledge to real
business challenges.
Composite materials, which offer advan-
tages in terms of strength and stiffness over
“e-Weld“ to make welding education pervasive
through distance learning
The need for new welding profession-
als, together with the retraining of current
professionals, is a pressing challenge that
the manufacturing industry in Europe
faces to ensure its long-term competitive-
ness. This area has seen a dwindling num-
Professional Extreme
The welding table with a hardness up to 850 Vickers.
» extreme hard-wearing,
plasma nitrided tool steel
» scratch and rust insensitive
surface
» more stability and load capacity for
highest loading
» modified ergonomics for saver
and easier working
Order our free catalogue (approx. 600 Seiten).
Bernd Siegmund GmbH · Aehrenstraße 29 · 86845 Grossaitingen
info@siegmund-group.com · www.siegmund-group.com
192
metals, are increasingly being used across
many industries to reduce the weight of
structures and components. However, cre-
ating the assembly holes used for fastening
these composites is problematic because
drilling – the most commonly used tech-
nique – breaks the continuous fibres that
run the length of the material, reducing its
overall strength. Other methods such as
laser are significantly more expensive.
Nick‘s challenge was to find a way of ma-
chining holes without breaking or removing
the fibres from the composite‘s structure,
which he successfully achieved by develop-
ing a technique for separating the fibres in-
stead of cutting them.
The research project contributes to a
central pool of resources made available by
TWI to its members. Run as a non-profit dis-
tributing organisation, TWI‘s membership
is made up of a wide range of organisations
from major players such as Rolls Royce to
small niche companies.
ber of youngsters embracing the profession
in the last decade while retraining of pro-
fessionals has followed the same trend.
This can be traced not only to the lack of
attractiveness of the welding activity but,
more importantly, to the poor appeal that
win
ne
r2
013
See Professional Extreme live:
AMB Stuttgart
16.09. - 20.09.2014
Hall 6, Stand D78
The Engineering
Doctorate stu-
dent Nick Brown
has won the
Richard Dolby
Rolls Royce Prize
for his research
into an alterna-
tive way of ma-
chining compos-
ite materials.
Speaking about his award, Nick said,
“Winning the prize was a good surprise, par-
ticularly because my research project was
composites-related and I work in a mainly
metals-based organisation. This demon-
strates that industry is becoming open to
these new materials.” Nick received the
Richard Dolby Rolls Royce Prize at TWI‘s an-
nual awards ceremony, held at King‘s College
in Cambridge/UK in July. (See also page 229
ff. in the TWI News section in this issue).
The next Richard Dolby Rolls Royce
Prize will be held and awarded in 2016. More
details are available by e-mail: profession-
al@twi.co.uk (According to press informa-
tion from TWI and the University of Surrey)
current training methodologies, based on
in-room courses, have for prospective stu-
dents. This trend was described in a Work-
ing Paper by DVS – German Welding Soci-
ety in February 2008 that clearly showed a
downturn in the availability of trained
welding specialists in Germany, a trend
seen in Europe overall, and one that needs
to be swiftly addressed.
To illustrate the relevance and opportu-
nities that exist in welding, and to counter
the perception conveyed by the trend just
mentioned before, a study about the eco-
nomic importance of welding technology in
Europe (“The Economic Importance of
Welding and Joining in Europe“, 2009) has
shown its relevance, by concluding that
welding represents an annual added value
of roughly 86 billion euros.
Focusing on a very successful tool, an in-
teractive CD, developed by SLV Duisburg
(one of the largest training and educational
institutes for welding engineering in Ger-
Welding and Cutting 13 (2014) No. 4
190_194_WC4_News__ 15.07.14 16:13 Seite 193
many) the work will be oriented to translate
and implement this particular material for
use in other countries, namely Croatia and
Hungary. This project, “e-Weld“, aims to over-
come the more traditional approaches to
welding education and greatly improve the
overall welding education environment in
the aforementioned countries, since it will be
a more appealing activity to a wider audience,
ensuring a steady increase in the number of
welding students in those countries and im-
proving the conditions for distance welding
training. The project will also focus on im-
proving the number of qualified welders from
these countries, by decreasing the predomi-
nance of in-room training classes.
Objectives of the project
The “e-Weld“ project objectives are:
• Development of two versions of a CD
for specific use in training classes in tar-
get partnership countries;
• Improvement of distance learning prac-
tices according to the different needs
TWI celebrates its first 15 NSIRC students
The National Structural Integrity Re-
search Centre (NSIRC), managed by TWI,
has welcomed two new PhD students, taking
the total number of students to 15. This
number considerably exceeds the initial stu-
dent intake target of 11, agreed with the Re-
gional Growth Fund of the UK Department
for Business, Innovation and Skills, one of
the funding bodies behind NSIRC. The two
engineering graduates, whose degrees will
be accredited through Brunel University, will
focus their research on the use of data min-
ing techniques and data analysis for the life
extension of engineering structures and
components.
Antonio Camacho will research into the
development of vibration-based condition
monitoring for the assessment of rotating
parts and static structures. The cost-saving
benefit of monitoring machinery and static
structures has been increasingly attractive
to the industry in previous decades. It allows
operators to carry out maintenance and
evaluate the lifetime of their assets. Anto-
nio‘s research will consider data-mining
techniques to extract structural integrity in-
formation from long-term trending data to
increase confidence in damage detection.
Francisco Arteche will research data
analysis and its interpretation for use in re-
Welding and Cutting 13 (2014) No. 4
of the partner countries, mainly Hun-
gary and Croatia;
• Increase in the number of welding
trainees in the partnership countries;
• Overall improvement of welding activ-
ities’ appeal to prospective students.
The stated objectives are clearly related to Eu-
ropean priorities, since they aim to improve
the quality of vocational education and train-
ing practices and also will take into account
the actual reality and market needs of the part-
nership countries. This project will be an ef-
fective means to improve the existing distance
training methodologies as well as implement-
ing new ones, based in the extensive expertise
of GSI-SLV and EWF – European Welding Fed-
eration, therefore increasing the number of
trained welding specialists.
The CD developed at the end of the “e-
Weld“ project will be an essential tool for
the improvement of these countries’ rate of
qualified welding personnel, through the
use of more effective and user-friendly train-
ing methodologies and practices.
maining life assessments. Industries often
struggle to use data in a meaningful way in
order to determine the remaining life of their
plant and equipment. At times, the data has
substantial uncertainty that needs to be
quantified for its use in remaining life as-
sessments. Sometimes the data provide
measurement of underlying factors that in-
fluence remaining life assessments and
therefore give only an indirect estimate of
condition of the asset. Francisco‘s research
will develop an innovative approach for data
analyses and its interpretation to improve
Project‘s background and qualifi-
cation guidelines
Currently, the training and qualification
of welding engineers is harmonised through-
out Europe according to the Qualification
Guideline from EWF. However, distance learn-
ing courses and methodologies as envisaged
by the project consortium are still underde-
veloped and require urgent improvement.
Since 1992 EWF has been upgrading skills and
competencies in welding related courses, con-
tributing to the qualification, certification and
training of over 250,000 trainees.
EWF, as a European umbrella organisa-
tion for the welding community in 31 coun-
tries, makes the added value of this project
substantially larger and more disseminated.
This project also supports EU policies of free
movement of personnel providing equal
training backgrounds, improves training
quality and lifelong learning as well as qual-
ification transparency and, more important,
enhances employability. (According to press
information from EWF)
and support decision-making in asset in-
tegrity management.
Last year, TWI welcomed government
support from the UK Regional Growth Fund
to kick-start the NSIRC expansion initiative.
This, together with funding put forward by
TWI and a grant awarded to Brunel Univer-
sity from the Higher Education Funding
Council for England (HEFCE), will supply
new laboratories and facilities for research
and development as part of the National
Structural Integrity Research Centre. (Ac-
cording to press information from TWI)
193
190_194_WC4_News__ 15.07.14 16:13 Seite 194

NEWS

Upward trend in registered engineers and technicians in

the UK for the first time in 12 years
The Engineering Council, London/UK,
has announced that for the first time since
2001, the total number of individuals on the
national register of Engineering Technicians
(EngTech), Incorporated Engineers (IEng),
Chartered Engineers (CEng) and ICT Tech-
nicians (ICTTech) has increased. The An-
nual Registration Statistics 2013 report, is-
sued in spring 2014, shows that the down-
ward trend in the total number of profes-
sionally registered engineers and techni-
cians has reversed and begun to climb in an
upward facing direction.
“This is a welcome outcome for UK en-
gineering,” says Jon Prichard CEng FICE FIn-
stRE, CEO of the Engineering Council.
“Maintaining high professional standards is
key to the delivery of value to the economy.
With almost 40% of professionally registered
engineers and technicians currently listed
on the register now over 60 years of age, and
another 13% falling into the 55-59 year age
bracket, it is vital that we ensure a strong
pipeline of highly skilled men and women
to replace these registrants as they reach re-
tirement.”
This breakthrough comes as a result of
the year on year increase in the number of
new registrants experienced over the past
six years, coupled with the number of those
no longer holding professionally registered
status having decreased over the past two
years. Comparing the 2013 figures to those
of 2007, the number of individuals achieving
professional registration has risen by 93%.
Jon Prichard adds: “Now we have
reached this important milestone in terms
of stemming the net outflow of skilled pro-
fessionals, it is vital that we continue to focus
attention on raising awareness of the value
of professional registration for engineers and
technicians. We are, therefore, working
closely with the professional engineering in-
stitutions to address this, in particular for
technicians where we have highlighted the
greatest skills gap to be filled, and I hope to
be able to report further good news this time
next year.”
Other relevant statistics in the report
show that registrants based outside the UK
still represent 18% of the total. Meanwhile,
the number of females becoming profes-
sionally registered continues to rise gradu-
ally, with a healthy increase of 28% in new
female registrations compared to 2012 num-
bers. However, females still only represent
4.36% of the total and it is clear that there is
still a lot to be done to attract more women
into the profession. (According to press in-
formation from the Engineering Council)

DVS-TV goes international

www.dvs-tv.de/international

English-language news programme and more from the world of

welding, cutting and coating technology.

Web TV for welding, cutting and coating technology

DVS-TV GmbH | Aachener Str. 172 | 40223 Düsseldorf | Telefon: 0211 1591-220 | Fax: 0211 1591-150 | E-Mail: info@dvs-tv.de

194 Welding and Cutting 13 (2014) No. 4

196_207_WC4_Comp__ 15.07.14 16:30 Seite 196

FROM COMPANIES

Abicor Binzel awarded the 2013 “Product

Innovation Leadership” prize by Frost & Sullivan for
welding torches in Europe
Prof. Schu-
www.dvstv.de/international
bert grate-
fully accepts
The 2013 “European Product Innovation the award.
Leadership Award” for welding torches ho-
nours Abicor Binzel’s ongoing work to in-
crease benefits for users in the area of man-
ual welding.
Frost & Sullivan is a 50-year-old re-
nowned market research and consulting
company with more than 1,800 analysts and
consultants and 40 branches worldwide. It
monitors more than 300 industries and
250,000 companies and each year honours
outstanding product solutions with the Best
Practice Product Leadership Award.
Frost & Sullivan cites the useful, positive
product features of the “ABIMIG A T LW” stant contact with major companies in the features/functionalities of the torches, their
torch series and the “RAB GRIP” fume ex- welding industry. That allows them to regu- innovative elements, the acceptance of the
tractor torch series, in conjunction with the larly track trends and positive developments product on the market, the value added by
“FES 200” high-vacuum extractor and the in the welding-torch market before the real using the product, and the product quality.
fast market acceptance of these products, as market research begins. Market participants One aspect that Frost & Sullivan rated
key success factors on the welding-torch are compared, and their performance and as very positive for the “ABIMIG A T LW”
market. best practices are measured through inter- torch series and the “RAB GRIP” fume ex-
Each year, Frost & Sullivan awards this views, analyses and extensive secondary re- tractor torch series, together with the “FES
prize to a company that has demonstrated search. Next, the team actively contacts the 200” high-vacuum extractor, were Abicor
innovation in terms of product features and companies being considered for the award. Binzel’s improvements to working condi-
functionality, thereby offering users im- After evaluating the information about the tions for welders in terms of health and safe-
proved quality and higher utility value. The manufacturer, the team focuses on its cus- ty, through innovative, groundbreaking de-
award also honors the fast acceptance these tomers, users and direct competitors. The sign-related approaches. Abicor Binzel de-
innovations in the market. first evaluation criterion is whether the termined, by analysing its customers’ needs
Frost & Sullivan’s “tracking teams” con- torches had a demonstrably positive effect in advance, that there was a clear market
sisting of industry analysts, explore the wide on the welders’ day-to-day practical work. need for welding torches that offer welders
variety of industrial sectors and are in con- Then detailed analyses focus on the product safety and handling comfort, and thus pos-

Axel Schumann, Executive Product Manager at Abicor Binzel, Prof. Dr.-Ing.

Emil Schubert, Managing Director of Abicor Binzel, and Muthukumar
Viswanathan, Frost & Sullivan (from left to right). Relaxed welding with the “ABIMIG A T LW“ torch of Abicor Binzel.

196 Welding and Cutting 13 (2014) No. 4

196_207_WC4_Comp__ 16.07.14 15:57 Seite 197

analysis, Frost & Sullivan applied its propri- The ITW Orbital Cutting & Welding group with
its brands ORBITALUM TOOLS and E.H. WACHS
etary 360° analysis method, checking and
provides global customers one source for the
analysing all of the criteria through feedback finest in pipe & tube cutting, beveling and orbital
interviews with customers, users and direct welding products.
competitors.
Thanks to customer-oriented focus on
improving the safety and health of welders,
Abicor Binzel successfully increased the an-
nual production volume for its advanced
fume extraction torches by about 30% in
2013.
“These groundbreaking products are ful-
ly compatible with the world’s leading weld-
ing-torch sources. In addition, Abicor Binzel
ensures that all of its technology is patent-
protected in terms of design, utility and the
full scope of service, wherever possible,” says Open Orbital Weld Heads
Archana Chauhan, Research Manager at ORBIWELD

“RAB GRIP“ torch with “FES-200“ fume extrac-

Frost & Sullivan.
“The high-quality and long-lasting orig- ORBITAL | CUTTING & BEVELING
tion
inal Abicor Binzel replacement parts for
itively effecting their health. In addition, welding torches give users a significant in-
Abicor Binzel spent nearly two years per- crease in welding efficiency. Abicor Binzel’s
forming research in collaboration with Jus- international manufacturing, distribution
tus-Liebig University in Gießen/Germany and service network secures the delivery of
(JLU). The goal of this research was to sci- welding torches and wear parts worldwide,”
entifically evaluate what causes a welder to continues Archana Chauhan. ORBITALUM E.H. WACHS ORBITALUM
become physically fatigued, and what were “With the ′ABIMIG A T LW′ welding se- Pipe Cutting and Portable Milling Tube Squaring Machines
the best ways to counteract this. Based on ries and the ′RAB GRIP′ series, Abicor Binzel Beveling Machines Machines Trav-LCutter: RPG: The required,
GF & RA: Safe cold cutting and high-quality tube
the conclusions of the university’s Depart- is playing an important role in improving The optimum prepara- beveling. Compact end preparation for
ment of Sports Medicine, Abicor Binzel de- safety and health conditions for manual tion for automated design, easy set-up. orbital welding! Space
welding! Square, Horizontal and vertical saving, light weight
veloped the advanced “ABIMIG A T LW” welding,” Archana Chauhan states. “Overall, burr-free and cold preparation. and portable machine;
torch series – a more lightweight, modular the use of these products leads to a signifi- machining process. burr-free and square
tube end.
and flexible torch series with advanced fea- cant jump in productivity for users’ operat-
tures for manual welding that offers high ing processes because they optimise time
performance. and operating costs.”
Frost & Sullivan’s market analysis then The ceremonial granting and presenta- ORBITAL | WELDING
compared Abicor Binzel products with the tion of the award took place during the
welding torches available on the market American Welding Society Show in Chicago,
from other manufacturers. IL, November 2013, at the Abicor Binzel USA
Based on its latest welding-torch market booth. After a short speech by a leading an-
analysis, Frost & Sullivan honored Abicor alyst from Frost & Sullivan, the award was
Binzel with the 2013 European Frost & Sul- handed over to Prof. Dr. Emil Schubert,
livan Award for product leadership in the Managing Director of Abicor Binzel. Prof.
ORBITALUM ORBITALUM ORBITALUM
area of welding torches. Dr. Schubert was justifiably proud of the ho- Open orbital weld P16 AVC: Tube-to-tube- HX 16 series: Open weld
According to Frost & Sullivan’s research, nour, and recognised the good work by the heads ORBIWELD with sheet orbital weld heads especially made
extremely compact heads with electronic for heat exchanger
the weight reduction in the “ABIMIG A T product management team for manual torch design: Arc length is arc voltage control applications – the
LW” and “RAB GRIP” torches, and efficient lines as well as the development department kept at a constant gap (AVC). Welding with optimum solution for
mechanically. Water- the highest of accuracy welding of pre-mounted
fume extraction, were the main factors that at Abicor Binzel. He emphasised that be- cooled TIG Torch head and consistent quality. elbows.
led to the product lines’ very fast acceptance cause of declining numbers of qualified can be swiveled in any
direction.
on the market – as confirmed by positive welders worldwide, Abicor Binzel is con-
sales figures. In particular, weight reduction sciously making active contributions to re- www.orbitalum.com
due to the use of low-weight “BIKOX” from duce the burdens placed on welders, and to
Abicor Binzel demonstrably reduces the improve health conditions. (According to
strain on welders. In the next stage of the press information from Abicor Binzel)

ORBITALUM TOOLS GMBH | An ITW Company

Josef-Schuettler-Str. 17 | 78224 Singen, Germany
Tel. +49 (0) 77 31 792-0 | Fax +49 (0) 77 31 792-524
tools@orbitalum.com | www.orbitalum.com

Welding and Cutting 13 (2014) No. 4

CUT. PREP. WELD. ONE SOURCE.

196_207_WC4_Comp__ 15.07.14 16:30 Seite 198
FROM COMPANIES
The perfect drive
The “drive 4X” wire feeder is a complete-
ly new development by the Mündersbach/
Germany-based welding machine manu-
facturer EWM. With this innovation, the user
gets all components of the MIG/MAG weld-
ing process chain from one source: from the
power source to the wire feeder with com-
pletely newly developed wire feed mecha-
nism to the welding torch. And, of course,
also the filler materials. If the quality of all
components is aligned, this means highest
quality for the weld seam. The “drive 4X”
uses the innovative “Multimatrix” technol-
ogy designed to save money, secure jobs and
protect the environment.
Wire feeding – safe and precise
The core is the new wire feed mecha-
nism. Each wire feed roller is driven by its
own cogwheel. As these four cogwheels are
interlocked with the drive shaft, the wire
feed rollers are guaranteed to run synchro-
nously. The result is a safe and reliable wire
feeding.
The new wire feed
mechanism — the core
of the “drive 4X”
(Photos: EWM AG)
198
The driving shafts of the four wire feed
rollers are each mounted on two ball bear-
ings and hence especially long-life and fa-
tigue endurable, compared to the usually
used wear-prone sliding bearings. Two set-
screws can be used to adjust the contact
pressure of the roller pair simply and indi-
vidually – to match the material used.
With a diameter of 37 mm, each wire
feed roller is comparably large. So, the wire
supporting areas are also large and the pres-
sure on the wire is very even. This stabilises
the transport.
Drive rollers – unmistakable
Different filler metals and different wire
diameters require appropriate wire feed
roller sets which each consist of four wire
feed rollers of the same kind. The wire feed
rollers are colour-coded and available for
wire diameters from 0.8 to 1.6 mm. V-
grooves are suitable for steel, stainless steel,
flux cored and solder wires, U-grooves are
suitable for feeding aluminium materials.
One drive shaft
drives four drive
rollers. The inter-
locking guarantees
synchronous wire
feeding. Each drive
roller shaft is borne
on two ball bear-
ings.
News 4/2014
www.dvstv.de/international
The colour codes allow a clear distinction
between the ten different roller packages to
rule out any confusion. The wire is always
fed correctly and precisely.
Roller change – fast, safe and
without tools
The exchange of the rollers is a special
highlight. They are replaced safely and with-
out tools. As nothing is dismounted, there
are no parts that can be lost. The roller hold-
er is unlocked and folded open without re-
moving it from the wire feeder. The rollers
are then exchanged and the roller holder is
closed and locked. Done. Thanks to the in-
terior lighting, this can also be done where
lighting conditions are poor.
Automatic threading – for
minimal set-up times
Threading the filler metal in is as un-
problematic as the roller change. The wire
is simply inserted into the wire feed nipple,
the rest is done by the wire feed mechanism
that transports the wire until it comes out of
the torch’s contact tip. The wire spool is ex-
changed in no time, including threading in.
Use at the construction site –
robust and mobile
Not just the inside of the “drive 4X” is
wholly new but the exterior of the robust de-
vice also meets modern requirements. The
layout is ergonomic: the carrying handle is
arranged to perfectly balance the wire feed
mechanism and the low weight makes trans-
port easy. The dimensions are suitable for
manholes to enable work at spots difficult
to access. As standard, the “drive 4X” is
equipped with sliding rails. Certainly advan-
tageous is the optional wheel mounting kit
that enables the device to run on wheels. A
lifting eye is provided for transport with a
crane – with an additional protective plate
for especially rough use.
Intermediate hose package –
connecting without intervention
into the device
All connections of the wire feed mecha-
nism are easily accessible from the outside,
only shielded by a protective flap. Interme-
diate hose packages are connected without
Welding and Cutting 13 (2014) No. 4
196_207_WC4_Comp__ 15.07.14 16:30 Seite 199

Function torch – lightweight and

The wire diameter determines the colour of the wire feed rollers. An additional yellow mark at the
edge distinguishes the U-groove for aluminium wires from the V-groove.
tools and without the need of expert per-
sonnel. This is of particular advantage at
construction sites, for frequent retooling and
when transporting the device. The central
and water connection at the front is recessed
and additionally equipped with a plastic im-
pact protection.
“Multimatrix” wire feeder control
unit – one for all
With the “drive 4X”, there is just one ma-
chine-independent, universal control unit
for all “Multimatrix” MIG/MAG welding ma-
chines of EWM’s “alpha Q”, “Phoenix” and
“Taurus Synergic S” series. To use the full
range of applications of the “drive 4X“, the
devices are as standard equipped for all in-
novative and standard welding methods.
The “Multimatrix” control unit has a
stand-by mode that saves energy during
welding breaks. Essential information such
as the “Job” number that indicates the cur-
rent welding job, the kilowatt indication for
calculation of the energy input per unit
length and the motor current of the wire
feed mechanism for improved operational
safety can is visible at a glance.
Rollers can be exchanged in just three steps without tools and without parts that can be lost:
1. Unlock the roller holder, 2. fold the undetachable roller holders open, 3. replace the roller.
ergonomic
The “MT” function torch also meets the
requirements of “Multimatrix”: The signals
for operational control and indication are
transmitted via the standard central con-
nection. A separate control cable and addi-
tional connectors are no longer required.
This reduces the weight, improves the han-
dling and makes the torch user-friendly.
“drive 4X“ – scoring with many
options
Other options supplement the “drive
4X” wire feed mechanism to configure it
individually: This includes the connection
for supply from a drum, the torch neck, the
additional load bushing for the gouging
torch or the electrode holder, as well as the
integrated flow meter for the central gas
supply. (According to press information
from EWM)

Chinese Steel Grades

Comparison of Chinese steel grades with steel designations according to EN and DIN
This bilingual (German/English) reference work explains the Chinese standards system as well as the classification and designation
systems for Chinese steels. The correspondence between the most common Chinese steel grades and their European equivalents
are presented in several tables according to application or product form. The overview of Chinese steels with the corresponding
European material numbers allows quick and easy conversion.

From the Content:

System and Codes of Chinese standards (CN standards)
Classification and designation system for Chinese steels
Overview of CN standards according to steel products
CN, EN, DIN and EN DIN steel names
CN steel grades

1st edition 2010

Peter Marks, Heinz Günter Trost
280 pp.; Paperback
Publisher: DIN, Berlin
Price: 26.80 Euro
Oder by email to: britta.wingartz@dvs-hg.de

DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf

Tel: +49 (0) 211/1591 161 • Fax: +49 (0) 211/1591 250 • media@dvs-hg.de • www.dvs-media.info

Welding and Cutting 13 (2014) No. 4 199

196_207_WC4_Comp__ 15.07.14 16:30 Seite 200

FROM COMPANIES

High temperature carburisation trials enable

optimisation of manufacturing procedures in an
aggressive environment
A series of materials selection trials car-
ried out by TWI from Cambridge/UK on be-
half of an industrial member company has
allowed the company to optimise its com-
ponent fabrication procedures prior to, and
during, the manufacturing process. The high
temperature study, which has relevance to
all industries where high temperature gases
are present, identified materials with in-
creased durability and resistance in a specific
aggressive environment. As a further result
of the work, the member company made sev-
eral modifications to the design of its reactor
interior to boost component lifetime.
TWI was contacted by an industrial
member company regarding an issue with
high temperature (above 1,000°C) process-
ing of oxide powders in a specialised flowing
gas mixture. While the furnace design was
robust, several components within the fur- Fig. 1 • Small-scale high temperature corrosion cell during sample extraction operations.
nace were experiencing accelerated degra-
dation and failure within a few days of ex- team decided to use simulated gas mixtures This cell is capable of safely testing speci-
posure. Preliminary investigations deter- mimicking the most severe conditions ob- mens under flowing gas mixtures containing
mined that the material used to construct served within the furnace. Several different HCl, CO, CO2, H2, CH4, moisture and oxygen,
these components was not compatible with high temperature alloys were exposed to with test durations of up to eight weeks and
the extremely aggressive environment pres- these environments for at least two weeks temperatures up to 1,120°C. Up to five sam-
ent. The company commissioned TWI to each. To more closely copy the micro-envi- ples may be tested simultaneously with no
carry out materials performance trials, to ronment present at the component surface, cross-contamination, Fig. 1.
select a material with a longer lifetime and some samples were also covered with the In consultation with the member com-
better resistance to the environment. oxide powder, which partially reduced as pany, the project team selected a test tem-
Given that the composition of the gas the test progressed. perature of 1,100°C and two specific reduc-
changed depending on temperature, loca- TWI constructed a new small-scale high ing/carburising gas mixtures (10%CO-
tion, amount of powder and time, the project temperature corrosion cell for the project. 1%CO2-Argon or 90%CO-2.5%H2-Argon) to

Fig. 2 • Adherence of oxide to coupon surface and sub-surface carburisa- Fig. 3 • Extensive and heavy carburisation of alloy “601” due to a small
tion of alloy “Haynes 214”. flaw in the diffusion coating.

200 Welding and Cutting 13 (2014) No. 4

196_207_WC4_Comp__ 15.07.14 16:30 Seite 201
provide a range of test environments from
mildly carburising to heavily carburising.
Based on TWI’s extensive industrial experi-
ence and a review of the available literature,
it then chose nine candidate nickel-based,
iron-based and cobalt-based high tempera-
ture alloys with the required strength. Beta-
aluminide diffusion coatings were applied to
the exterior of a subset of these coupons to
assess its efficacy as a protective coating. Dif-
ferent surface finishes (as-received, ground,
pre-oxidised or polished) were also applied
to assess the effect of surface pre-treatment.
Each coupon was submerged in oxide
powder (or tested without the presence of
oxide powder) and exposed to the flowing
gas mixtures over several weeks at 1,100°C.
After extraction, the oxide powder was
brushed away, leaving alloy coupons that
showed vastly different performance. Some
were visibly corroded, others apparently un-
touched by the environment. Yet, when sec-
tioned and examined in detail by light mi-
croscopy and scanning electron microscopy,
every single alloy coupon displayed some
sign of change. When no oxide powder was
present, the project team observed mass gain
from carbon uptake (up to 5 mg/cm2). When
oxide powder was present, mass change
measurements were not meaningful, as ox-
ide powder adhered strongly to the surface
in some areas of the sample surface but ma-
terial loss was clearly visible in other areas.
The corrosion was a mixture of carburi-
sation and oxidation, with several chromi-
um-rich and aluminium-rich oxides forming
at the surface. A discolouration and change
in the surface texture of each coupon was
visible to the naked eye, with the texture
change indicating removal of some material
from the surface. In some cases, the team
observed general attack and voids which had
formed below the surface. In others, the at-
tack was primarily intergranular with asso-
ciated carbide precipitation along the grain
boundaries. There was no direct correlation
between elemental composition and resist-
ance to the environment, though generally
chromium depletion along grain boundaries
would be mitigated by the presence of more
stable carbide formers such as niobium, as
well as higher overall chromium contents.
Additional molybdenum and lower iron con-
tents may also be beneficial, Fig. 2.
Alloy “Haynes 230” and “625” both
showed good performance in these trials, with
no change observed to the substrate beyond
a depth of 65 µm, and minimal material losses.
Alloy “600” also performed reasonably well,
Welding and Cutting 13 (2014) No. 4
though the attack was more general in this coated specimen of alloy “601”, carburisation
case. At the opposite end of the scale, Kanthal was observed up to 110 µm below the sub-
APM experienced massive attack in this en- strate surface. In a region of coated alloy
vironment, with pits up to 0.8 mm deep, ma- “601” with a small imperfection in the coat-
terial loss and multiple sub-surface voids. Oth- ing, attack at the surface was extensive and
er alloys tested (“601”, “602CA”, “693”, “Haynes carburisation reached depths of 2,600 µm,
214”, “Hastelloy X”) showed intermediate per- radiating outwards from the coating flaw.
formance. In addition, the oxide powder This is shown in Fig. 3.
bonded to the surface of the coupons during Based on its materials assessment, TWI
testing, leading to formation of mixed oxide recommended that alloy “Haynes 230” and
phases and detachment of metallic particles alloy “625” be studied further for fabrication
when the oxide was removed. of components in this challenging environ-
The surface finish did not make a sig- ment. It also recommended polishing or ma-
nificant difference to the depth or mecha- chining components to reduce adherence
nism of corrosion, even when the coupon of the oxide powder to the surface. This
was pre-oxidised. However, there was a sig- would lead to an increased lifetime as less
nificant difference in adherence of the oxide material could be removed by adhesion-re-
powder to the coupon depending on the fin- moval or by erosion/wear.
ish, with the polished surface retaining the The applied beta-aluminide coating was
least oxide powder after testing. also generally protective against the envi-
The aluminide diffusion coating showed ronment but the coating quality required
good protective characteristics in this envi- further refinement, as any local flaws could
ronment, with less extensive sub-surface lead to catastrophic and rapid failure. TWI
carburisation, and reduced oxidation. How- did not recommend its use at the current
ever, any flaws, cracks or imperfections in time, but recommended further refinement
the coating led to catastrophic carburisation of the coating application process. (Accord-
and a focus on a single region. On an un- ing to press information from TWI)
www.linn.de
Brazing, pre-heating, welding.
High frequency generators up
to 200 kW, 100 kHz - 27,12 MHz.
Medium frequency inverter up to
1000 kW, 2 - 100 kHz.
Brazing, annealing, heat treatment. Chamber furnaces up to
2300 °C,1000 l . Many options.
Heat treatment. Shuttle kilns up to 1400 °C, 3000 l.
201
196_207_WC4_Comp__ 15.07.14 16:30 Seite 202

FROM COMPANIES

The future of surface technology – the emergence of

smart coatings
Thanks to new processes, an unprece- Surface coating process
dented variety of coatings that perform bet- of particular large com-
ter than ever before can now be produced. ponents: Screw for plas-
In future, coatings will also have sensory and tics processing-
responsive capabilities, or self-healing prop-
erties.
The fundamental idea of surface engi-
neering – i.e. the separate optimisation of
the volume and surface properties of an ob-
ject – is almost as old as the mankind itself.
However, the greatest progress has been
made since the middle of the last century,
when it became possible to apply coating
technology such as chemical vapour depo-
sition (CVD) and physical vapour deposition
(PVD) in industrial production: “Thanks to Tools during the PVD
the industrial use of hard coatings for tools, coating process.
it was suddenly possible to process new ma-
terials such as ultra-hard titanium alloys ef-
ficiently and economically. Then, just before
the new millennium, we finally saw the
breakthrough in thin-film technology for
coating components, which gave rise to
technological advances such as low-emis-
sion diesel engines,” says Kirsten Bobzin,
Head of the Surface Engineering Institute
(IOT) at RWTH Aachen University/Ger-
many, summarising the major develop-
ments of recent decades.

Coating structures with almost

any properties
Today, the research community is again
excited by the prospect of major new pos-
sibilities: “New PVD coating technologies
are increasingly making it possible to over-
ride the thermodynamic laws of chemistry
to a large extent and to combine almost any
elements to make coatings,” explains
Bobzin. Put simply, this means that many
more coating systems offering even more
advanced performance will be feasible in
the future. This wide variety of coatings will
be made possible by a number of develop-
ments, including pulsed plasma-based
coating processes such as HIPIMS (High
Power Impulse Magnetron Sputtering).
There is virtually no other PVD technology
that can deposit individual atomic nano -
structures on the surface of a tool or com-
ponent with the same level of accuracy and
reproducibility. Kirsten Bobzin has no
doubts that, “in the future, we will be able
to simulate crystalline coating structures
with almost any properties on a computer
and then synthesize them.” The new coat-
ing processes are therefore now giving rise
to the next innovation phase in surface en-
gineering: for example, researchers are
working on the computer-assisted design
of boride-based coatings. The challenge
here is to increase the strength of the coat-
ing, thereby optimising its anti-wear prop-
erties, but at the same time ensuring that
the precise degree of elasticity is achieved
that is needed to prevent the coating from
chipping or cracking: “Over the years to
come, it will be possible to design materials
almost at will and treat components very
specifically. As a result, we are going to see
tremendous growth in surface technology,”
predicts Bobzin.
Sensory coatings that react to
changes
Alex Dommann from Empa, a research
institute for material sciences and technol-
ogy within the ETH (Swiss Federal Insti-
tutes of Technology) domain, also believes
that a key focus of the next few years will
be on the range of elements that can be
used as coating materials and the large
number of possible applications which has
again seen a significant increase: “In the
short term, for example, I think there is po-
tential for combustion processes in engines
to be optimised further through the use of
innovative coatings,” explains the physicist
and crystallography expert. In the medium
to long term, he believes that the trend will
be toward multifunctional coatings or coat-

202 Welding and Cutting 13 (2014) No. 4

196_207_WC4_Comp__ 15.07.14 16:30 Seite 203
ings with sensory properties. These will be
capable of detecting the smallest of changes
in ambient conditions, such as tempera-
ture, pressure, humidity, pH value or light,
and either transmitting this information or
reacting automatically to these changes.
A possible scenario, for example, would
be a smart dressing for a wound. Body tem-
peratures rise in the event of an inflamma-
tion and the pH value of the skin also
changes. A sensory coating on a dressing
would detect these changes and release an
antibiotic already contained in the dress-
ing. It would also be possible for the dress-
ing to change colour to alert the patient
and physician to this complication. Anoth-
er feasible application would be coatings
that change their photonic properties ac-
cording to the time of the year – such as ar-
chitectural glass that darkens automatically
in response to solar radiation. Researchers
New live-streaming microscopy provides
more access for members
TWI from Cambridge/UK has advanced
the way in which it can correspond with In-
dustrial Members during the microscopy
process, becoming the first company to in-
troduce the ability to live-stream the proce-
dure and results directly to the customer.
Microscopy is a powerful tool in the
study of materials, allowing the identifica-
tion of the microstructural features which
control the properties. TWI’s light mi-
croscopy facilities allow it to image samples
at up to 1000x magnification. By analysis of
these images, accurate measurements may
be made of features including pits, cracks,
coatings, grain sizes and volume/area frac-
tions of the different microstructural fea-
tures.
TWI is the only company to use spe-
cialised webcams connecting the trinocular
and stereo microscopes to the “Webex” sys-
tem to provide a live video feed of this analy-
sis directly to the client. Providing access of
a clear, high definition image of exactly what
the engineering team are viewing, from the
macrograph of the whole structure to a mi-
crograph of a magnified section.
This technology not only allows the
client to view the analysis process but to
have an active role within it. For the first
time, a client can ask questions and draw
Welding and Cutting 13 (2014) No. 4
are even thinking about self-healing coat-
ings: if a component received a hard knock
that caused the coating to crack, the coating
would automatically reinforce itself at the
site affected.
Applying coatings where they are
needed
Whereas nowadays standard processes
generally require the entire component to
be coated, coatings of the future will only be
applied to the specific areas where the rele-
vant property such as heat resistance, wear
resistance or impact strength is actually re-
quired: “In the future, a complete turbine
blade will emerge as a single unit from a 3D
printer – complete with the various coatings
required in the different areas,” explains
Dommann, as he outlines future possibili-
ties. The Empa scientist is in no doubt that
flexibility on this scale for the manufacture
attention to specific areas of the images of
screen in order to have queries resolved im-
mediately by the team of experts at TWI.
There is also the capability to create still im-
ages during the process for the company’s
records. Making the analytical process more
efficient and reducing the downtime of the
equipment or structure that is affected.
If a sample is on site and cannot be
transferred to the laboratory, replicas of each
etched surface can be taken using specially
prepared acetate which replicates the ma-
terial’s microstructure in a form that can be
subjected to high light microscopy.
DLC coated automotive components are state of
the art.
of parts and components, combined with
the option of producing even the very small-
est of batch sizes, will fundamentally trans-
form the industry. (According to press in-
formation from Oerlikon Metco)
Live-streaming mi-
croscopy allows instant
materials analysis.
This technology does not only have use
in the analysis of faults and failures in solely
business cases but is also advancing TWI’s
capability in areas of litigation and is en-
hancing its potential to be used as a char-
acter witness. Because the technology is
live it ensures that the images shown are
accurate and are not being manipulated in
any form.
The technology’s versatility is not re-
stricted to metals and can be used across of
a spectrum of materials including ceramic,
composite, polymer and organic. (According
to press information from TWI)
203
196_207_WC4_Comp__ 15.07.14 16:30 Seite 204
FROM COMPANIES
Short Messages
New Fronius facility in
East Kilbride/UK
The Fronius UK Welding Division has
opened a new facility in East Kilbride, Scot-
land/UK. This is its second site, expanding
its presence throughout the UK and provid-
ing a more localised service to Fronius’ Scot-
tish customers. The new facility, part of the
company’s growth strategy, houses offices,
a service/repair centre, warehouse and
demonstration area and sees the Scottish
team increase to 8 with the potential of cre-
ating more jobs in the area by the end of
2014. This brings the total number of current
Fronius employees in the UK to 56. Fronius
U.K. Ltd, a subsidiary of Fronius Interna-
tional GmbH, has appointed Sales Manager
for the North, James Anderson, to head up
the new site. James holds over 13 years’ ex-
perience in the welding industry of which 5
he has spent with Fronius. An important
goal for the Fronius team is to increase its
share of the market. A strong local presence,
know-how and premium products mean
that Fronius UK is well on its way to becom-
ing a more powerful force in the market-
place. The new site in central Scotland en-
ables the team of experts and sales repre-
sentatives to provide prompt, efficient as-
sistance and advice.
Fronius U.K. Ltd: James Anderson, Regional Sales
Manager, Northern UK. (Photo: Fronius Interna-
tional GmbH)
204
Results of Student Cutting and
Welding Contest
Victor Technologies, St. Louis, MO/USA
has announced the six winners of its 2013
“A Cut Above” contest for students in weld-
ing and cutting programs at secondary and
post-secondary schools in the USA. The in-
dividual winners from 2013 are Terrance
Biggers from Tennessee College of Applied
Technologies, Union City, TN (instructor
James Daniels); Michael Bramblett from
George Stone Technical Center, Pensacola,
This “Victor Man” sculpture won Highland High
School a Victor cutting and Tweco welding
package valued at more than $4,000. Shown
frol left to right are Garrett Shafer, Ryland Bar-
ney, Cody Gifford and instructor Curtis Willems.
FL (instructor James Mathews) and
Jonathan Lawler from Bellingham Technical
College, Bellingham, WA (instructor Sarah
Patterson). The themes of the winning es-
says were, respectively, Terrance’s discovery
of the limitless options for fabricating works
of art using cutting and welding, the life-
changing influence of welding on Michael’s
future and Jonathan’s evolving passion to
combine welding with a strong sense of
community. Two of the team winners hail
from Highland High School in Gilbert, AZ,
Team students Matthew Focht, Jack Daniel
and Brett Eschliman, guided by instructor
Curtis Willems, recreated a Victor torch on
a 6:1 scale, while students Ryland Barney,
Cody Gifford and Garrett Shafer, also in-
structed by Willems, built a “Victor Man”
sculpture. From Assabet Valley Technical
High School in Marlborough, MA, students
John Dantonio and Lauren Quinn, with di-
rection from instructor Chris Wittmier, built
the “Star Wars Venator Cruiser.” Both teams
incorporated an oxy-fuel, air-fuel or plasma
cutting process in their team metal fabrica-
tion project. Individual winners won a $ 250
cash prize for their winning essay on the
theme of “A Cut Above,” describing how cut-
ting has influenced their lives. Members of
the winning team each won a $ 500 cash
prize for submitting a cutting project. All
schools associated with the winners also
won a cutting, welding and gas control pack-
age.
Relocation of the Indian office
Fine Tubes, Plymouth/UK, a leading
manufacturer and global supplier of preci-
sion tubes for critical applications, is delight-
ed to announce that it is strategically relo-
cating its office in India to keep up with the
growing demand for its high quality tubing
products. As a result of the company’s in-
creased global capabilities, following its
partnership agreement with US-based Su-
perior Tube Company, Fine Tubes had al-
ready identified the need for additional re-
sources and a larger facility in India. In order
to maintain the highest levels of service
across a wider customer base in the region
Noida being known as the industrial hub
near Delhi/India, was the first choice for the
new office location. Gagan Sood, Fine Tubes’
Business Development Executive India,
commented “With an ever increasing de-
mand for Fine Tubes high specification
tubes in India and Superior Tubes coming
on board as a strategic partner, it was nec-
essary to relocate to a new office with greater
resources. The new facility situated in the
industrial hub of Noida will ensure we will
continue to provide high levels of service to
our growing customer base including Larsen
& Toubro, Bharat Heavy Electricals Limited,
Reliance Industries Limited, Lakshmi Pre-
cision Tools and Hindustan Aeronautics
Limited.”
The new Fine Tubes address in Noida/India.
Grand opening AWL China
The grand opening of AWL Automation
Welding and Cutting Equipment (Wuxi) Co.,
Ltd., is a fact., Over 100 guests attended the
event on 8 April 2014 and were able to see
the facility and the high standards of AWL
in Wuxi/China with their own eyes. Among
the many guests were also high officials from
the Chinese and Dutch governments, in-
cluding Mr. Jianping Yang, Standing Com-
Welding and Cutting 13 (2014) No. 4
196_207_WC4_Comp__ 15.07.14 16:30 Seite 205
The new AWL facility in Wuxi/China.
mittee of Wuxi Huishan District, Mrs. Yan
Wu, Deputy District Mayor of Wuxi Huishan
People’s Government, Mrs. Conny Bieze,
Vice Governor of the Province of Gelderland
and Mr. David Naves, Deputy Consul Gen-
eral of The Kingdom of The Netherlands
Shanghai. The Grand Opening began with
an official meeting between the Chinese and
Dutch Governments and AWL’s Board of Di-
rectors. At the AWL facility, several guest
speakers took to the stage to express their
enthusiasm for and commitment to the es-
tablishment of AWL in Wuxi. Attendees had
the opportunity to look around the shop
floor, where ABB, Fanuc and Trumpf had
arranged demonstrations. The facility in
China covers over 2,500 m2 and is equipped
to handle projects with high levels of au-
tomation and complexity. The team in Wuxi
is able to support these projects from build-
ing to commissioning and service. For now
engineering is being done by the Dutch col-
leagues. The last couple of months have seen
the first projects being successfully commis-
sioned at customer sites. The order portfolio
shows a steady growth, exceeding the com-
pany’s initial expectations. AWL is therefore
very optimistic about the future.
Technology and equipment for
welding school in Oman
Made in Germany for the Arabian
Peninsula: In Oman, Kemper GmbH from
Vreden/Germany will equip one of the
biggest welding schools in the region. In the
capital city of Muscat the equipment man-
ufacturer will be furnishing 100 welding
work stations with its extraction and filter
technology and with welding booths. In-
stallation of the equipment began in April.
With that, Kemper strengthens its market
position in the Middle East. The successes
abroad testify to the market position of the
German technology leader for extraction
and filter technology. One of the biggest
welding schools in the region is currently
being built from scratch in Muscat, the cap-
ital of Oman. The planning office in charge
Welding and Cutting 13 (2014) No. 4
China. Due to the increase of this facility,
Valk Welding will also be able to become
more efficient for the distribution and direct
sales of welding wire and consumables from
its Danish subsidiary. Within Denmark de-
liveries can be realised within 24 hours using
the warehouse in Nørre Aaby, which is lo-
cated extremely centrally in Denmark (bor-
der between mainland and the isle of Fyn).
Equipment will protect trainees against ultra- Since the service of the property is only be-
fine dust particles. ing used for 25% with buildings, new sched-
uled expansions, such as technical center,
of execution contacted Kemper itself and as well as welding wire storage, will be pos-
ordered the comprehensive equipment. sible. The actual purchase of the building
Soon the welding trainees will be working has been realised in the last months. As of 1
simultaneously at 100 welding work sta- September 2014, the complete building will
tions. Kemper will be furnishing all of the be available for Valk Welding in order to sup-
work stations with welding booths, com- port its growth on the Scandinavian market.
plete with special noise protection walls.
The booths are each two by two metres in
size. Each booth has its own exhaust arm.
25 exhaust arms each are connected via a
pipe system to a central suction system of
the type “System 9000”. With an extraction
capacity of 25,000 m3/h each, each Kemper
system provides a high degree of assurance
for the welders at their work stations, by
protecting them against welding fumes that
are harmful to health. Harmful, ultra-fine
dust particles are captured along with the Valk Welding handles the growth on the Danish
welding fumes. These are separated from market with the purchase of premises and
the air by the membrane of the integrated buildings in Nørre Aaby.
filter. Kemper is supplying the full equip-
ment and will be responsible for installation
on location.
Products
Purchase of premises and build-
ings in Nørre Aaby/Denmark
Valk Welding, Alblasserdam/The Nether- High performance in a portable
lands purchased the premises and buildings package
in Nørre Aaby/Denmark from the former The manufacturer of plasma, laser and
owner. The buildings, which were already waterjet cutting systems provides the
rented for over 5 years, now became prop- “Powermax30 XP” (Fig. 1), a new plasma
erty of Valk Welding, which means that the cutting system that delivers high perform-
available service for Valk Welding in the ance in a small portable package. The new
buildings, will increase by 300%. This in-
crease of available office and technical serv-
ice was necessary partially to handle the
growth on the Danish market, but also to be
ready for the expected growth on the total
Scandinavian market. The Valk Welding
team in Denmark has grown to six employ-
ees and is being supported by local sales
and service in Sweden. Because of the in-
ternationalisation of Valk Welding, as well
as the Scandinavian customers, Valk Weld-
ing Denmark AS can offer a ‘full support
service’ to production facilities from Danish
companies elsewhere in Europe or even in Fig. 1
205
196_207_WC4_Comp__ 15.07.14 16:30 Seite 206
FROM COMPANIES
system is 50% more powerful than its pred-
ecessor, yet maintains the “Powermax 30”’s
light weight and small size. It features a
two-in-one design for high power cutting
on thick metal and detailed cutting on thin
metal using “FineCut” consumables. The
recommended cut capacity is 10 mm with
a severance capacity of 16 mm. In addition,
the “Powermax 30 XP” contains a re-
designed “Duramax” torch and consum-
ables that last twice as long as those found
on the “Powermax 30” for a lower overall
operating cost. The system, like all “Pow-
ermax” systems, is easy to use with simple
controls. In addition, it is rugged and reli-
able with “Hypertherm Certified” reliabil-
ity to perform in the most demanding en-
vironments. It is available from authorised
Hypertherm partners around the world.
(Hypertherm Europe B.V., Vaartveld 9, 4704
SE Roosendaal/The Netherlands; www.hy-
pertherm.com)
Addition for „Weld Purge
Monitor“ family
Fig. 2
“Weld Purge Monitors” are an essential
tool for the Process Industry with various
models serving different levels of weld
purge requirement. There are applications
that can be satisfied with monitors meas-
uring down to 100 ppm and for the higher
specification industries such as Aerospace,
Food and Drinks, Semi-conductor, Biofuels
etc that need to achieve oxgyen levels down
to 10 ppm there are other models. One such
model has just been developed for the
Process Industries and that is the “PurgEye
200” (Fig. 2) which is now rolling off the
production lines partially to meet an order
for 30 units from the Far East. This is a hand
held, battery driven monitor that will read
very accurately down to 10 ppm. It is prob-
ably the lowest cost “Weld Purge Monitor”
of its kind even though it contains an in-
ternal electro-mechanical pump for draw-
206
ing samples of gas automatically over the
sensor before discharging it to atmosphere.
The lifetime sensor eliminates the need for
changing cells once every year or so, sub-
ject to the type of usage the “wet” cells re-
ceive. Alarm signals can be given by the
“PurgEye 200” to show when the purge gas
level is within or outside the preset range.
(Huntingdon Fusion Techniques, Stukeley
Meadow, Burry Port, Carms SA16 0BU/UK;
www.huntingdonfusion.com)
Downhole casing and pipe cutting
system
Centura Oil Inc., a Minnesota/USA-
based waterjet service contractor to the oil,
gas and mining industries, has developed a
unique downhole casing and pipe cutting
system that can fit inside pipes as small as
2” ID (51 mm) and cut multiple layers of
grouted casing in a single pass with a 55K
PSI (3,800 bar) abrasive waterjet. Operable
in hazardous environments, Centura Oil’s
“CenJet 90” casing and pipe cutting system
is designed especially for oil, gas and mining
applications, including plug and abandon
operations. Its cutting process does not ex-
ceed 140°F (60°C), minimising the chance
of ignition. The “CenJet 90” is powered by a
55K PSI, 200hp Jet Edge waterjet intensifier
pump and features a modified Jet Edge
Permalign abrasive jet cutting head that is
coupled to coiled steel tubing or conven-
tional threaded rods. The system, which is
capable of cutting 16” (406 mm) thick steel,
is deployed into the pipe or casing and cuts
from the inside. It can perform cuts up to
300 feet (91 m) from the surface and can cut
at any angle, horizontal, vertical and even
overhead. The “CenJet 90” uses only four
gallons (15 l) of water and one pound (.45
kg) of garnet abrasive per minute. Garnet is
a natural stone that can normally be dis-
posed of in a landfill. The effluent created
by the waterjet cutting process is circulated
to the surface using formation water, treated
Fig. 3
water in strata prone to swelling, or nitrogen
for an explosion-proof environment. The re-
turns and cuttings are handled in accor-
dance with industry standards (Fig. 3 Photo:
Centura Oil Inc.). (Jet Edge, Inc., 12070 43rd
Street N.E., St. Michael, MN/USA; www.jet-
edge.com)
MIG-MAG inverter power
Fig. 4
The company is expanding its range of
durable, inverter-based MIG-MAG units
with the new “MicorMIG” series (Fig. 4).
The patented “Micor” inverter technology
is bearing fruit for the first time in the wide-
ranging MIG-MAG application. The “Mi-
corMIG” series combines the special weld-
ing features of the fully resonant “Micor”
technology with an innovative operating
concept and simple upgrading of welding
processes, welding programs and additional
functions. Enclosed in a compact, robust
housing, the infinitely variable unit is ex-
tremely versatile in use – suitable for use in
small businesses all the way to industrial
companies. The “Micor” technology en-
ables an extremely stable, powerful arc with
outstanding welding properties for steel,
stainless steel and aluminium. In the
process, in comparison with traditional
transformer units the “MicorMIG” is ex-
tremely energy-efficient, which means low-
er power consumption, and the units are
less susceptible to fluctuations in the power
grid, thanks to the innovative inverter tech-
nology. The standard function of the end
crater filling purposefully reduces the weld-
ing current so that the melt bath can cool
down and the end crater can be filled with
material with a low application of power.
The multi-stage dynamic regulation also
provides for an optimal welding seam. It
regulates the characteristics of the arc from
soft to hard and thereby adjusts to the re-
quirements of the welding task and the in-
Welding and Cutting 13 (2014) No. 4
196_207_WC4_Comp__ 15.07.14 16:30 Seite 207
dividual preferences of the welder. The core
of the new “MicorMIG” series is the newly
developed user interface. The user can se-
lect from three different levels – Basic, Ba-
sicPlus and ControlPro – depending on re-
quirements. In the process, the provider has
equipped the EN-1090-certified unit (Ba-
sicPlus or higher) with an upgrade concept
to provide a secure investment for the fu-
ture. (Lorch Schweisstechnik GmbH, Im
Anwänder 24-26, 71549 Auenwald/Ger-
many; www.lorch.eu)
The redifinition of the automatic
welding helmet
The adaptive shade autopilot of the
“e684” (Fig. 5) is based on a newly developed
sensor concept, which measures the bright-
ness of the welding arc and automatically
F
BERKENHOF
adjusts the shade level. Welders can con-
centrate fully on their work without inter-
rupting the welding process, even when the
welding parameters change. The “e684” is
an automated welding helmet with protec-
tion level 5 to 13. The patented “twilight”
function opens the darkening filter very gen-
tly so that the welder’s eyes are not adversely
affected by sudden light state. Combined
with a true colour filter, the latest 4x1 display
represents a darkening filter technology
milestone comparable with “TV HD” tech-
nology. The silver helmet design is timeless
and at the same time ensures that welders
Fig. 5
always keep cool thanks to the heat-reflec-
tive lacquer. Full expandability of the weld-
ing helmet with a respiratory system, indus- pensable companion and thus protecting
trial hard hat, breast and neck protector and the investment in the long term. (optrel AG,
dioptre lenses comes as the company’s stan- Industriestrasse 2, CH-9630 Wattwil/
dard, making the “e684” a welder’s indis- Switzerland; www.optrel.com)
For permanent
joining
®
bercoweld
High-tech wire solutions made of
copper for brazing and welding.
firmly bonded joints
good gap bridging
high corrosion resistance
www.bercoweld.com
208_209_WC4_Practice__ 15.07.14 16:21 Seite 208

WELDING PRACTICE

Utilise hearing protection correctly!

Fig. 1 • Before ear plugs made of foam are in-
serted into the auditory canal, they must be
formed into a thin roll by kneading and twisting
them. Subsequently, they must be inserted into
the auditory canal immediately in order to posi-
tion them correctly.
Even relatively “quiet“ noises may cause
stress reactions which lower the powers of
concentration and decrease the working
performance. The longer effects of higher
noise levels are detrimental to health - above
all, damage to the hearing capacity. On the
other hand, the employer must protect his
employees by marking noise areas and pro-
viding hearing protection.
However, the effects of the hearing pro-
tection used as protection against noise are
frequently not as good in practice as pre-
sumed on the basis of the data from the man-
ufacturer. In many cases, this is due to the fact
that they are not positioned or inserted cor-
rectly. This was the result of an investigation
conducted by the Institute of Safety at Work
of the German Statutory Accident Insurance
Association and the North and South Employ-
ers’ Liability Insurance Association in the Met-
al Industry. According to this, measurements
on ear muffs and ear plugs highlighted the
necessity for the employees in the plants to
regularly practise the correct use of the hear-
ing protection. In practice, hearing protection
frequently gives rise to low sound insulation.
Indeed, the insulation effect specified
by the manufacturer relates to measure-
ments in optimum (laboratory) conditions.
In contrast, the hearing protection is often
used in a non-ideal way in practice. For quite
a long time already, there have thus been
correction values by which the data from
the manufacturer is decreased. Even today,
these so-called practical deductions are still
applicable to the greatest possible extent.
From the outset, easy-to-use products
such as finish-shaped ear plugs and otoplas-
tics (these are parts individually adapted to Fig. 2 • The introduction into the auditory canal
the auditory canal of the wearer in question) is facilitated if this is straightened by pulling
offer more protection with a regular func- the ear.
tional check by the manufacturer. They also
have the lowest correction value of 3 dB (unit may therefore improve its protective effect
of measurement for the sound level). In con- considerably.
trast, it is highest (9 dB) for plugs which the Because recent findings show that a
wearer must form before use. change of approx. 6 to 10 dB in the level cor-
Regular practice in the correct utilisation responds to the doubling of the perceived
of the hearing protection (see Figs. 1 and 2) loudness. (According to VMBG Mitt. 5/09)
Plasma cutting – Effect of nozzle wear
In the case of plas-
ma cutting, the wear of
the nozzle and the
cathode exerts effects
not only on the rectan-
gularity and inclina-
tion tolerances of the
cut but also on the
burr attachment (see
the picture). In this re-
spect, the condition of
the nozzle has an up to
four times greater in-
fluence on the cutting
quality than the wear
of the cathode. Effect of nozzle wear on the cutting quality in plasma cutting.

Welding speed and welding torch position in

gas-shielded metal arc welding
Even with properly set welding param-
eters, the MAG welder must pay attention
to the correct welding speed and the right
welding torch position in order to produce
a defect-free weld. If the torch is manipu-
lated too slowly, the weld pool runs ahead
so that the arc burns on the liquid weld met-
al. The base material is then not melted
completely and this results in a lack of fu-
sion. The welding torch position influences
the behaviour of the weld pool during weld-
ing. It may produce or avoid welding defects
and also exert effects on the appearance of
the weld.
If the welding torch is held in a forehand
position in the welding direction, the weld
pool runs ahead once again but this can be
counteracted by increasing the welding
speed. This welding torch manipulation
causes the welding bead to become wide
and flat. With backhand welding torch ma-
nipulation, the welding bead becomes nar-
row and convex. In any case, the weld metal
is then pushed backwards and the arc burns

208 Welding and Cutting 13 (2014) No. 4

208_209_WC4_Practice__ 15.07.14 16:21 Seite 209

on the base material. The consequence is Influence of the

deep penetration. With this knowledge, the welding torch posi-
welder can adapt the welding torch position tion on the weld
to the welding task in question. The first lay- shape.
er of a fillet weld must fuse the root point
and is therefore manufactured with back-
hand welding torch manipulation. Forehand
torch manipulation is favourable for the
welding of a flat cover layer.

Tungsten inert gas welding in two-cycle

or four-cycle operation
In the case of tungsten inert gas welding,
there is the possibility of operating the in-
stallation in two-cycle or four-cycle opera-
tion. In two-cycle operation, the welding
current and the shielding gas flow as soon
as the torch push-button is pressed. When
the push-button is released, both are
switched off together.
In four-cycle operation, the welding cur- Welding
rent is switched on when the torch push-but- amperage
ton is actuated and released for the first time
and the welding operation only ends when Time
the torch push-button is actuated and re-
Pressing Releasing Pressing Releasing
leased once again. With some machines, spe-
Welding torch
cial functions for the start and end of the weld
push-button
are tied to four-cycle operation, Table 1. These
include a prepurge gas flow time, a post-
Time
purge gas flow time and the controlled in- High-voltage With sinusoidal alternating current
crease and decrease in the welding current. pulses
The prepurge gas flow time ensures adequate
protection of the tungsten electrode during
Time
the ignition operation. The decreased current
after the third cycle is needed in order to fill
up end craters. In the post-purge gas flow Shielding gas
time, the shielding gas protects not only the volume
welding point until the complete solidifica- Time
tion but also the hot tungsten electrode. The Prepurge flow Post-purge flow
corresponding time is set using a regulator.
A customary time is five seconds, Fig. 1. Fig. 1 • Four-cycle operation in tungsten inert gas welding.
Two-cycle operation mainly serves to tack
and weld short seams. Four-cycle operation
is used for the actual longer welding work.

Table 1 • Functions during TIG welding in four-cycle operation

First cycle Second cycle Third cycle Fourth cycle

Press and hold down the push-but- Release the push-button and the set Press and hold down the push-but- Release the push button and the
ton, the prepurge shielding gas flows welding amperage takes effect ton once again and the amperage is power is turned off, shielding gas
for an adjustable time, the igniting aid decreased in a continuously adjusta- flows in the post-purge gas flow time.
starts and the arc ignites at an adju- ble time
stable low amperage.*
* If the arc does not ignite, the shielding gas and the igniting aid are switched off once again.

Welding and Cutting 13 (2014) No. 4 209

 Recommended for global players in the steel industry

International Comparison of Steels

In a time of growing international interdependence in the
steel industry, the comparison of materials is crucial for
identifying the closest possible correspondence between
different national types of steel. This book is a vital source of
information for all those involved in the global steel industry.
This English and German tabular comparison of steels
covers materials from the most globally active regions in
the sector. The chemical values for each material are in-
cluded as a further tool for identifying comparable steel ty-
pes. The European material numbers provide the basis for
this comprehensive tabular comparison of steel types from
major industrial regions of the world (EU, USA, Russia,
China, India and Japan).

Contents

1. Country codes
2. Steel grades compared with chemical analysis
3. Steel names, listed alphanumerically by
index number (EU/DE material no.)
4. List of cited standards
4.1 German and European material standards
4.2 Chinese material standards
4.3 Indian material standards
4.4 Japanese material standards
4.5 Russian material standards
4.6 US material standards
4.7 ISO material standards

Internationaler Stahlvergleich /
International Comparison of Steels
German/English, Peter Marks, Walter Tirler,
1st edition 2010, 784 pages
Order no 500091

Preis: 128.00 EUR

DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf

T +49. (0)2 11. 15 91-161 • F +49. (0)2 11. 15 91-250 • media@dvs-hg.de • www.dvs-media.info

AZ_Stahlvergleich_NCD.indd 2 29.01.2014 11:28:07

211_215_WC4_Events__ 15.07.14 16:22 Seite 211

EVENTS

“ALUMINIUM“ world trade fair continues on growth

course in 2014
The “ALUMINIUM” world fair is prepar-
ing for its 10th edition, to be held in Düssel-
dorf from 7 to 9 October 2014. A few months
before the world’s largest industry meeting
place is due to open, almost 700 interna-
tional exhibitors have registered for partici-
pation, and more than 80% of the exhibition
space has already been booked. Trade fair
organiser Reed Exhibitions is optimistic and
expects to continue the success of previous
years with “ALUMINIUM 2014”.
It just keeps growing and growing. When
it moved from the Ruhr to the Rhine two
years ago, the trade fair experienced quite a
boost. And the signs point to further growth
yet again for “ALUMINIUM 2014”, even if this
will be slightly more moderate than at its
Düsseldorf debut. Reed Exhibitions current-
ly expects a 5% increase in exhibition space,
as well as higher exhibitor and visitor num-
bers. More than 950 exhibitors are expected
for the 10th edition of “ALUMINIUM” – two
years ago, that number was 907 companies
from 51 countries.
Already, Halls 9 to 12 of the Düsseldorf
Exhibition Centre are almost fully booked. As
a result, the reserve space originally set aside
in the four halls, which are organised along
theme lines, has already been occupied.
Therefore, a better gross-to-net ratio is the
aim in allocating space in Hall 13, which will
have a higher stand density and house both
the “Surface” and the “Metalworking and Pro-
cessing” segments under a single roof.
“ALUMINIUM 2014 conference“
As the institutional patron of the trade
fair, the GDA – the German Confederation
of the Aluminium Industry will once again
organise the “ALUMINIUM 2014 Confer-
ence” which accompanies the trade fair. In-
dustry experts will give an overview of the
future prospects of aluminium in a wide
range of application markets from 7 to 9 Oc-
At “ALUMINIUM 2014”,
the world’s largest trade
event of the aluminium
industry, aluminium pro-
ducers and converters
meet with suppliers of
technologies and equip-
ment for production,
further processing and
finishing.
tober 2014 in the CCD Ost. The programme
features a total of five sessions, on a range
of subjects including, among others, Auto-
motive and Markets. The call for papers
started at the end of February. The confer-
ence language is English.
“COMPOSITES EUROPE 2014”
“COMPOSITES EUROPE” will again be
held in Düsseldorf at the same dates as
“ALUMINIUM”. At the European Trade Fair
for Composite Materials, more than 400 ex-
hibitors will present trends in the field of re-
inforced plastics. With a total of 1,300 ex-
hibitors, the two events transform the Düs-
seldorf Exhibition Centre into one of the
world’s largest lightweight construction fo-
rums. For trade fair visitors, passing from
one fair to the other will be simplified: The
“ALUMINIUM” admission ticket is valid for
both fairs. (According to press information
from Reed Exhibitions Deutschland)

Practice of thermal spraying

Guidance for technical personnel
Practice of thermal spraying 1st Edition 2014
176 Pages, 114 Pictures, 20 Tables
This reference book reveals and explains interesting and important areas of thermal spraying. Numerous
tables, diagrams and pictures supplement and enhance the written information. This practice-related refe- English Edition Volume 10
rence book is intended for the thermal sprayer, the student, the expert, the engineer and everybody, who Order No.: 180 011
is interested in and would like more information about the thermal spraying. The book compiles the current
technical knowledge of thermal spraying and offers it in an understandable and comprehensive manner. Price: 39.50 Euro

DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf • T +49. (0)2 11. 15 91-162 • F +49. (0)2 11. 15 91-150 • vertrieb@dvs-hg.de • www.dvs-media.eu

Welding and Cutting 13 (2014) No. 4 211

211_215_WC4_Events__ 15.07.14 16:22 Seite 212
EVENTS
From the 3rd conference “Join-Trans“
The Schweißtechnische Lehr- und Ver-
suchsanstalt Halle GmbH and the ECWRV
(European Committee for Welding on Rail-
way Vehicles) staged the 3rd conference
“Join-Trans”, “Joining and Construction of
Railway Vehicles”, on 6 and 7 th May 2014 in
Halle (Saale)/Germany. It was already ap-
parent beforehand that the event would be
a special one this year. Around 80 specialists
in the field of railway vehicle construction
from China, Denmark, Germany, France,
United Kingdom, Austria, Poland, Sweden,
Slovenia, Spain, Switzerland, the Czech Re-
public and Turkey took up the invitation.
The attendee numbers from the two preced-
ing events in 2010 and 2012 were exceeded.
Professor Dr.-Ing. Steffen Keitel, Man-
aging Director of SLV Halle GmbH and
Chairman of the ECWRV, opened the Eng-
lish-language conference on the afternoon
of 6 May 2014 in the large conference hall at
SLV Halle GmbH. During the course of the
two-day event the guests of SLV Halle GmbH
could take advantage of an excellent plat-
form on which to expand the transfer of
knowledge in the field of welding technology
for railway vehicle construction and ex-
January 2015: Start of the first
“Metal Middle East“ in Dubai
There has been an addition to the prod-
uct family of the “bright world of metals”:
From 10 to 13 January 2015, the first “Metal
Middle East” will take place in Dubai. The
successful trade fair duo, consisting of “Tube
Arabia” – organised by Messe Düsseldorf –
212
change experiences regarding the design
and manufacture of railway vehicles from a
welding technology viewpoint.
The first day of the conference culmi-
nated in a well-attended evening event at
the Saline-Museum Halle. The hosts at the
museum gave the attentive conference par-
ticipants a brief presentation of the history
of the Halloren salt workers. Many of those
present were gaining a first insight into the
long tradition of salt production in Halle and
the hard-working lifestyle of the Halloren in
the past centuries.
The second day of the conference once
again offered excellent speakers, with pre-
sentations illustrating the state of the art in
welding technology for railway vehicle con-
struction and the application of internation-
al standards.
In keeping with tradition, the interna-
tional conference had a supporting exhibi-
tion of well-known suppliers and developers
of welding equipment, such as Carl Cloos
Schweißtechnik GmbH, Haiger; EWM AG,
Mündersbach; Kemppi GmbH, Langgöns;
Lorch Schweißtechnik GmbH, Auenwald;
Photon Laser Manufacturing GmbH, Schön-
and “Arabia Essen Welding & Cutting”, a joint
project from Messe Essen, Messe Düsseldorf
and Al Fajer Information & Services, are be-
ing complemented by the new event. “Metal
Middle East” is positioning itself as the in-
dustry’s foremost international trade and
walde-Glien; Sonotec Ultraschallsensorik
Halle GmbH, Halle (Saale) and TÜV Rhein-
land Industrie Service GmbH, Cologne.
The third staging of the English-lan-
guage “Join-Trans - Joining and Construc-
tion of Railway Vehicles” conference has
seen it conclusively established as interna-
tional parallel to the longstanding national
conference “Joining and Design in Railway
Vehicle Construction”, staged at SLV Halle.
All participants agreed that this confer-
ence was an extremely successful one and
that a repeat in 2016 is the logical progres-
sion. Many of those present already declared
their intention to participate in the 4th “Join-
Trans” 2016 before leaving the conference.
(According to press information from SLV
Halle)
contact platform for the Middle East and the
United Arab Emirates. Moreover, the con-
current staging of the events will generate
important synergies for visitors. The latest
innovations in the broad fields of foundry
engineering, metallurgy and thermal pro-
Welding and Cutting 13 (2014) No. 4
211_215_WC4_Events__ 16.07.14 14:22 Seite 213
cessing technology will be presented to the
trade visitors.
Organised in collaboration with Messe
Düsseldorf and local organiser, Al Fajer In-
formation & Services, “Metal Middle Eas“t
will bring together not only renowned com-
panies from the United Arab Emirates and
the Middle East, but also international cor-
porations from the metal and steel industry.
Erhard Wienkamp, member of the board
at Messe Düsseldorf, looks optimistically to-
ward the upcoming premiere. “We are con-
vinced that we are offering our customers
the right industry and contact platform for
the Middle Eastern market at the right time
with Metal Middle East.”
“Metal Middle East” is being supported
by the Foundry Machinery, Metallurgical
Plants and Rolling Mills and Thermo
Process Technology associations of VDMA
(German Engineering Federation), CECOF
(European Committee of Industrial Fur-
nace and Heating Equipment Associa-
tions), CEMAFON (European Foundry
Equipment Suppliers Association), and EU-
nited Metallurgy (European Metallurgical
Equipment Association). “Tube Arabia” is
supported by the International Tube Asso-
ciation (ITA), while DVS (German Welding
Society) stands behind “Arabia Essen Weld-
ing & Cutting”.
The United Arab Emirates (UAE) is con-
sidered the most important hub for trade
between Europe, Asia and Africa. In addi-
tion, the federation of the seven emirates on
the Persian Gulf, along with the Middle East,
is an extremely attractive market for com-
panies and investors alike. The Middle East-
Event on hot isostatic pressing of materials for
offshore/energy applications held in Aberdeen
The Particulate Engineering Committee
of the IOM3 – Institute of Materials, Minerals
and Mining in the UK held its long antici-
pated event on Hot Isostatic Pressing (HIP)
of materials for offshore/energy on 16 April
2014 in Aberdeen/UK at the facilities of TWI
– The Welding Institute. The event was a one
day meeting attended by about 30 delegates
that filled comfortably the premises to its
capacity. It was an opportunity for the end
users from the oil and gas industry sector,
powders, consumables, engineering services
and other end user communities to come
together and capture the latest develop-
Welding and Cutting 13 (2014) No. 4
The fair trio in Dubai: Metal Middle East, Tube
Arabia and Arabia Welding and Cutting will take
place from 10 to 13 January 2015. (Photos:
Messe Düsseldorf)
ern states and the UAE possess one of the
largest oil reserves in the world, as well as
extensive natural gas deposits, and are
among the wealthiest nations on the planet.
Oil business, tourism and goods and serv-
ments in the field of HIP in particulate en-
gineering for offshore/energy applications.
The first two presentations in the morn-
ing session were dedicated to HIP applica-
tions and latest developments on equipment
for extended product performance as well
as application areas, where improved mi-
crostructures (fine grained and isotropic)
achieved through the process cycle and ef-
fective heat treatment regimes can increase
performance and life of components in use,
and offer net shape versatility in form of
complex geometries with most effective ma-
terial utilisation from powders.
ices are the most prof-
itable economic seg-
ments. The expansion
of industrial sectors,
high technology and
tourism benefit the de-
velopment of infra-
structure measures.
The continuing con-
struction boom, major
real estate investments
and the rising per
capita income have
led to a rapid increase
in the demand for steel and tube products.
Experts estimate that the consumption of
finished steel products will reach approxi-
mately 8 million tons by the end of 2014.
Messe Düsseldorf and Al Fajer Informa-
tion & Services will be organising “Tube Ara-
bia” – the trade fair for tube manufacturing
machinery – for the fifth time already in
2015, and will be collaborating with Messe
Essen on “Arabia Essen Welding & Cutting”
for the second time.
As organiser of the leading international
trade fairs Gifa, Metec, Thermprocess and
Newcast, Messe Düsseldorf is bringing its
expertise in this area to the gulf region for
the first time with a proprietary trade fair.
Further information on “Metal Middle
East” is available from Messe Düsseldorf,
Mr Daniel Ryfisch, RyfischD@messe-dues-
seldorf.de, +49-(0)211-4560-7793, or Ms
Katja Burbulla, BurbullaK@messe-duessel-
dorf.de, +49-(0)211-4560-7707. (According
to press information from Messe Düssel-
dorf )
After a warm welcome and introduction
by the PEC-Chair Cem Selcuk, Tomas
Berglund of Sandvik took the stage to talk on
the HIP applications portfolio for offshore ap-
plications with examples of end user projects,
globally. This was followed by Johan Harne
of Avure Technologies also based in Sweden
from an HIP equipment supplier’s perspec-
tive, with a particular focus on improved heat
treatment regimes integrated in the equip-
ment as part of the HIP process for creating
structures with superior mechanical proper-
ties which would not only offer enhanced
performance but also which would have not
213
211_215_WC4_Events__ 15.07.14 16:22 Seite 214
EVENTS
Delegates at the HIP for offshore event held at TWI – The Welding Institute in Aberdeen/UK on
16 April 2014.
been readily obtainable conventionally. Then
Karin Jakobsson of Erasteel reported from a
study on the influence of stainless steel pow-
der characteristics on mechanical and cor-
rosion properties of HIP near net shape parts
for oil and gas applications.
After a refreshment break during which
the delegates had ample time to network
and engage in further discussions, the final
part of the morning session resumed. Sean
Fewell of TWI from Cambridge/UK present-
ed, as the oil and gas programme manager,
on training considerations and competen-
cies in people for organisations, in the con-
text of oil and gas operations. It stimulated
the audience and raised awareness of the
criticality of developing a work culture based
on well trained and competent individuals
from top to bottom in a company environ-
ment for the benefit of high quality products,
processes and services. The final presenta-
tion before lunch was by Cem Selcuk on
non-destructive testing for net-shape appli-
cations and approaches that can be imple-
mented for online quality control in manu-
facturing environment such as the use of
digital radiography for avoiding potential re-
ject of parts and failure in actual use, and
possibly guided wave ultrasonics (UT), de-
pending on the size of the components,
since HIP parts have been considered to be
well receptive to UT in light of their fine
grained homogeneous microstructures. This
was followed by an introduction to the Na-
tional Structural Integrity Research Centre
(NSIRC) – UK’s first industrially-led post-
graduate development centre at the TWI site
in Granta Park, Cambridge, which is con-
sidered to be a strategic project driven by
214
Brunel University and TWI for generating
qualified personnel that industry can benefit
from and thereby addressing skills shortage.
The audience was informed to contact Dr.
Cem Selcuk for any enquiries on the topic.
After an interactive morning session,
delegates were gathered for a photo and over
lunch several dialogues were held, giving
the opportunity to explore potential collab-
oration and new applications. This lead to
especially different industry representatives,
notably small and medium-sized enterpris-
es, to make contacts with each other and
discuss potential business to develop with
input from research and development or-
ganisations and large entreprises as suppli-
ers or end users.
The afternoon session kicked off with a
presentation from Barry Burdett on the HIP
Facility Programme at the Nuclear Advanced
Manufacturing Research Centre (Nuclear
AMRC) in Rotherham/UK, with examples
of microstructural features and some his-
toric work that can be referred to in devel-
oping HIP. Paul Goodwin of Laser Cladding
Technologies then took a different direction
moving away from HIP process to additive
manufacturing for the oil and gas offshore
industry, which was a real eye opener in that
respect. He gave a comprehensive technol-
ogy update, from the developments and key
considerations in the offshore market. The
increasing number of applications has led
to a growing market for repair of compo-
nents, for instance, and new areas of devel-
opment (such as 3D forming) and potential
solutions where particulate materials can
play a key role as observed in extending life
of engineering structures were highlighted.
After a few comments and questions that
were answered, the final stage in the session
led to the next presentation by Daniel Brooks
of the Manufacturing Technology Centre
(MTC) in Coventry/UK on an overview of
Powder HIP: The drive towards net shape
components. It was a an informative speech
with emphasis on adaptive machining for
the HIP process that has been investigated
and developed, plus latest equipment ac-
quisition at the MTC and mention of a new
additive manufacturing centre in the Mid-
lands in support of the technology area.
Jonathan Wroe of EPMA – European Powder
Metallurgy Association then informed the
audience about the latest incentives, plans
for future events and the dedicated sector
groups that have been established for HIP
and most recently additive manufacturing
under the EPMA umbrella. Cem Selcuk fi-
nally rounded off the last discussions reflect-
ing upon the day. He closed the forum after
acknowledging the supporting organisations
and the audience for their interest in the
event, which is regarded as the first of its
kind in Aberdeen (at the heart of the oil and
gas industry in Europe), and notifications
for future initiatives that are ahead.
For updates and information on the Par-
ticulate Engineering Committee, please visit
www.iom3.org/content/particulate-engi-
neering.
Dr. Cem Selcuk, PEC Chair, Cambridge/UK
The event was hosted
by TWI and supported
by EPMA – European
Powder Metallurgy As-
sociation.
Welding and Cutting 13 (2014) No. 4
211_215_WC4_Events__ 15.07.14 16:22 Seite 215

6th “INDIA ESSEN WELDING & CUTTING“ in Mumbai

The international joining technology in-
dustry is meeting again at the “INDIA ESSEN
WELDING & CUTTING” in the autumn. This
industry event for the South Asian region is
being held from 28 to 30 October 2014 in
Mumbai, India’s most important industrial
metropolis. A large number of trade visitors
is expected: the theme-related trade fairs,
“Tube India”, “Metallurgy India” and “Wire
& Cable India”, are being held at the same
time. In 2012, the strong fair quartet attract-
ed some 10,500 decision-makers from in-
ternational companies.
With the 6th “INDIA ESSEN WELDING
& CUTTING”, Messe Essen, together with its
partner, Messe Düsseldorf India as well as
the patron, the German Welding Society (DVS
– Deutscher Verband für Schweißen und ver-
wandte Verfahren e.V.), is offering the opti-
mum setting for entering one of the world’s
most dynamic growth markets. India’s econ-
omy is continuing to expand in spite of a
slight slowdown: probably by 5% in 2014.
The Foreign Office therefore considers
India to be the most important market of
the future at present after
China and expects the
country to generate the
world’s third-largest gross
domestic product by the
middle of this century.
However, the densely pop-
ulated country is facing
tremendous challenges –
including that of the infra-
structure. Transport routes,
industrial equipment and
housing are to be improved through projects
involving billions, such as the establishment
and expansion of industrial corridors. Proj-
ects which also have great potential for join-
ing technology.
In addition to the presentation of new
technologies and services, the “INDIA ES-
SEN WELDING & CUTTING” is also devoted
to the exchange of knowledge between man-
ufacturers, users and researchers. The DVS
will therefore again enhance the show with
a top-calibre specialised
conference. It is entitled
“High-Performance Weld-
ing Technologies” in 2014.
This international trade
event from the “SCHWEIS-
SEN & SCHNEIDEN” trade
fair family is also being sup-
ported by the IWS (Indian
Welding Society) and the
CMES (Chinese Mechani-
cal Engineering Society). At
the request of the DVS, the German Federal
Ministry for Economic Affairs and Energy is
also sponsoring the fair participation of Ger-
man companies. A total of 36 exhibitors will
be presenting themselves on the pavilion
“Made in Germany“ covering all the shows.
More information: www.india-essen-weld-
ing-cutting.com (According to press infor-
mation from Messe Essen)

Specialized information for joining, cutting and coating technology

Magazines
Specialist Books on Welding Technology
Welding Technology in Practise
Publications for the practical and theoretical training
DVS Reports
Software
Standards
Dictionaries/Lexicons

DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf

T +49. (0)2 11. 15 91-162 • F +49. (0)2 11. 15 91-250 • vertrieb@dvs-hg.de • www.dvs-media.eu

Welding and Cutting 13 (2014) No. 4 215

216_219_WC4_reports_w30000048__ 15.07.14 16:24 Seite 216
REPORTS
Brazing tungsten carbide – Part 1: Setting the scene
Introduction
Despite its high intrinsic cost, the use of
tungsten carbide as a replacement for tool
steels in such industrial applications as the
cutting edges of lathe tools, wire-drawing
dies and press tools is growing each year. In
addition to it being a preferred substitute
for high-speed steel, tungsten carbide is also
widely used internationally as a tipping ma-
terial for such diverse applications as den-
tal-, oil-, masonry- and rock-drilling tools.
It is also used as a hard and wear-resistant
tip for the cutting areas of routers, milling
cutters and high-speed circular-saw blades.
This increasing use is driven by the en-
gineering and mining industries. Long ago
they recognised that despite the compara-
tively high cost of the material, by using
tungsten carbide as the tipping material they
invariably enjoyed a substantial increase in
both tool life and the working speeds that
could be employed with the finished tools.
It is also abundantly clear that its economic
use depends, to a very large extent, on the
strength and longevity of the permanent
joints that have to be made between the
tungsten carbide and the backing material
to which it has been joined. The preferred
method of producing such joints is by braz-
ing, and this series of three articles also
touch on three of the available heating tech-
nologies (flame, induction, Reducing atmos-
phere furnaces) that have a specific part to
play in the manufacture of certain types of
the tungsten carbide tipped tools that are
available.
The three articles in this series are:
• Part 1: Setting the scene
• Part 2. Brazing filler materials and fluxes
for brazing tungsten carbide
• Part 3: Brazing carbide-tipped rock-
drills
Clearly, before we can begin the study of the
various brazing procedures that are used for
the joining of tungsten carbide, it is neces-
sary to take a moment or two to consider its
basic formulation.
What is tungsten carbide?
An appreciation of what tungsten car-
bide is and what it contains will help to ex-
plain some of the potential technical diffi-
culties that have to be taken into considera-
tion when this material is to be brazed.
These factors also play an important part
where, in some specific circumstances, a
216
particular combination of process parame-
ters has to be employed to resolve the diffi-
culties that users will have previously en-
countered when attempting to braze tung-
sten carbide.
Tungsten carbide is usually a sintered
product, with cobalt being used as the ‚ce-
ment‘ that binds the particles of tungsten car-
bide together (hence the generic name, ce-
mented tungsten carbide). By varying the rel-
ative amounts of cobalt and tungsten carbide
in the mixture, materials that possess signifi-
cantly different properties can be produced.
For example, with increasing cobalt content
the ductility of the tungsten carbide increases,
while with decreasing cobalt content the ma-
terial becomes harder (see Table 1).
In general, the materials are relatively
easy to wet with molten brazing alloy and it
is significant to the overall degree of wetting
that can be achieved, that the higher the
cobalt content, the easier it is to wet the car-
bide. The reverse is also true, and it therefore
follows that with increasing hardness of the
carbide wetting becomes progressively more
difficult to achieve. This is because the
molten brazing alloy dissolves a some of the
cobalt in the tungsten carbide, and it is this
‚new filler alloy‘ (brazing material +cobalt)
that makes the joint. The reality is that the
greater the initial cobalt content the greater
the wetting ability of the ‚new‘ filler material,
and vice versa!
For certain very specialised applications,
for example where the carbide is to be used
to tip a tool that is intended for the machin-
ing of ferritic and martensitic stainless steels,
the basic formulation of the material might
incorporate small additions, typically 1 to
2%, of titanium-carbide, tantalum-carbide
or both. From the point of view of brazing,
even though these are very small additions,
they have a profound effect on the ease with
which the material can be brazed.
Table 1 • Cemented carbide grades for wood, plastic and paper processing (Data drawn from the lit-
erature of Cerametal S.A. Luxembourg).
Grade ISO Code Cobalt Density
weight % (g/cm3)
SMG 02 None 5.5 15.25
H10C K10 5.5 15.00
H20C K20 6 14.95
Ca2 K20 7 14.90
H30C K30 8.5 14.65
H40C K40 12 14.30
As already mentioned, conventional
tungsten carbide is relatively easy to wet with
molten brazing alloy when brazing in air.
The ease of wetting is very significantly re-
duced when titanium- or tantalum-carbide
are present in the product; this is due to the
refractory nature of the surface oxides on
these materials. This inevitably leads to an
increase in the level of joint unsoundness
that can be anticipated. The message is clear
– design engineers must think long and hard
before specifying a material that includes
these refractory metal carbides in their ma-
trix if it is subsequently proposed to join the
tip to its support by brazing. In this situation
vacuum brazing with an ‚active‘ brazing al-
loy, might be the best route to follow.
It is clear from Fig. 1 that the use of the
filler material conforming to ISO 17672: 2010
Type Ag 449 is attractive if the tool is likely
to experience moderately elevated temper-
atures in service. Experience shows that
when tips are lost in service, it is probable
that the reason is more associated with the
fact that the tip of the tool had been over-
heated while being used rather than because
the initial braze was of suspect strength. This
will be particularly true in those cases where
no coolant has been used during the ma-
chining process. Here one can attain a work-
ing temperature at the cutting face of the
tool of 400°C or above
Softer grades of tungsten carbide
During the past 20 years or so certain
softer grades of carbide have been intro-
duced. This softness is due to the presence
of a relatively high level of free carbon in the
matrix that is present by design. In other
special cases, free carbon can occur in the
matrix at brazing temperature as a result of
thermal decomposition at the surface of
small chips of man-made diamonds that
have been incorporated into the carbide ma-
Hardness Transverse rupture stress
HV10 (N/mm2)
2350 1800
1765 2150
1640 2200
1550 2600
1420 2800
1330 3000
Welding and Cutting 13 (2014) No. 4
216_219_WC4_reports_w30000048__ 15.07.14 16:24 Seite 217
trix during its manufacture to improve its
wear-resistance. Free carbon derived in this
manner is most certainly not there by de-
sign. In either of these situations the car-
bides are difficult to wet unless the brazing
alloy contains moderate amounts of man-
ganese which tends to react with the free
carbon to produce manganese carbide so
tending to reduce the difficulty with wetting.
While success cannot be guaranteed it
would certainly be worth trying the brazing
filler material that conforms to ISO 17672:
2010 Type Ag 449. This material contains an
appreciable quantity of manganese and as
we shall see in Part 2 of this series, this
makes it the obvious choice in such cases.
What properties do we need in the
brazed joint?
The joint between a piece of tungsten
carbide and its backing material needs to
satisfy four basic requirements:
• It must withstand the contractional
stresses that arise in the brazed assem-
bly as the joint cools from brazing tem-
perature.
• It must be able to accommodate the
changes in stress levels that will arise
when the brazed assembly is subse-
quently machined to its final shape.
• It must be able to cushion and help ab-
sorb the stress shocks that the assembly
will experience in service.
• It must not be the first part of the as-
sembly to fail if the component is ex-
posed to a load of such a magnitude
that it fails.
The next section of this article considers the
brazing of tungsten carbide from first prin-
ciples and establishes the basic criteria that
need to be satisfied to achieve a best practice
solution to the brazing of the material.
The brazing parameters that must
be achieved
The brazing of tungsten carbide is con-
sidered by some people to be special. While
it is true that it is not the easiest material to
braze, the rules that govern its successful
outcome are precisely the same as those that
underpin all brazing procedures.
There are six fundamental factors that
need to be examined. These are:
• Joint and component cleanliness
• Joint design
• Brazing alloy pre-placement in the joint
• Brazing alloy selection
• Flux selection
• Heating process
Welding and Cutting 13 (2014) No. 4
Joint and component cleanliness
It is self-evident that for a brazing ma-
terial to wet and flow on the surface of a
parent material, the surface of that material
must be clean. The question that immedi-
ately springs to mind is, “What do you
mean by clean?” Unfortunately there is no
universally satisfactory answer to this
question, however it is generally accepted
that surfaces that are free from oxide layers,
extraneous dirt and oil can be brazed sat-
isfactorily. To ensure freedom of the sur-
face by contaminants such as dirt and oil
is relatively easy to ensure. However, with
the exception of silver, gold and the plat-
inum-group metals, at room temperature
an oxide film covers all metals. It is also
the case that even if the layer of oxide ir
removed, it immediately begins to reform!
If wetting and flow of a molten filler mate-
rial is to occur, the surface has to be free
from oxides while the flow and wetting is
taking place.
When heating is carried out in air, as
the temperature of the parent metal in-
creases the thickness of the oxide layer
grows progressively thicker. As a result, it
is clear that the outside agency that has to
be used to remove the oxides in order for
brazing to occur has to be very efficient and
begin its task at a temperature that is at
least 50°C below the solidus temperature
of the filler material that is to be used to
make the joint. This agency may be a
fusible flux, a reducing or inert atmosphere,
a vacuum, or a combination of these alter-
natives. The use of a flux and also a reduc-
ing atmosphere are matters that this series
of articles will discuss at the appropriate
point in the text. The use of inert gases and
vacuum are not addressed in this series
since they tend to be methods that are em-
ployed for the brazing of poly crystalline
diamond (PCD). This is a very specialised
technology that will form the subject of
some specific papers later.
Fig. 1 • The high-
temperature strength
of two filler materials
used for brazing
PCD-tipped tungsten
carbide to their back-
ing pieces (Taken
from: Industrial Braz-
ing Practice, 2nd Edi-
tion, by P. M. Roberts.
CRC Press, Boca Ra-
ton, FL/USA, April
2013)
Fig. 2 • The effect on
wetting efficiency
when a refractory ox-
ide is used as an
abrasive medium for
grit-blasting cleaning
of a surface.
217
216_219_WC4_reports_w30000048__ 15.07.14 16:24 Seite 218
REPORTS
Fig. 3 • The represen -
tation of thermal stress
arising from the
cooling of a tungsten to
steel brazed joint.
Fig. 4 • The application of a bending stress due to differential contraction of the components of a
brazed joint made between tungsten carbide and a steel backing backing-piece can result in cracking
of the carbide.
To ensure the complete removal of ex-
traneous dirt or adherent oxide scale from
the steel backing pieces, some form of me-
chanical removal, such as grit blasting, is
recommended. However, it should be noted
that grit blasting can lead to an extra prob-
lem arising rather than being the solution
to the one that exists! This is because during
the blasting operation there is the ever-pre-
sent risk that the abrading material, which
is very hard, will become embedded in the
surface of the material being cleaned. If this
occurs, the subsequent wetting of that sur-
face by molten brazing alloy will be seriously
impaired, perhaps to the point of impossi-
bility (see Fig. 2). In such circumstances
while the grit-blasted surface will appear to
be cleaner that the oxidised surface, the re-
ality will be that the grit-blasting operation
has simply replaced one unsatisfactory sur-
face with another.
Clearly, the means of achieving surface
cleanliness of the parts to be joined by braz-
ing must always be at the forefront of the
mind of the operator when engaged in any
brazing procedure. It cannot be over-empha-
sised how important it is to avoid the use of
refractory oxides (e.g. alumina, silica) as the
abrading material. This is because neither
alumina nor silica is capable of being wetted
by conventional brazing alloys operating in
conjunction with a flux. As a result, severe
joint unsoundness is a high probability. If
grit blasting is considered to be essential, ei-
ther steel shot or tungsten carbide grit are
the options best suited to the process.
218
Irrespective of the blasting medium that
is to be used, it is essential to arrange matters
so that the abrasive medium is directed
along the surface of the material to be
cleaned, rather than from directly above the
area to which the carbide insert will subse-
quently be brazed. By this means the risk of
embedding the particles in the surface of
the steel will be minimized. The particle-
size of the grit that is used is also important:
it should lie in the range 40 to 260 μm. This
is a matter to which we will return in Part 3
of this series of articles.
A word of caution: it is quite common to
find that ‚as-sintered‘ tungsten carbide is cov-
ered by a layer of eta-phase material. Surpris-
ingly, this layer is very easy to wet with molten
brazing alloy, but nevertheless it must be re-
moved from the surface of the tungsten car-
bide as part of the cleaning procedures. The
problem is that the degree of adhesion be-
tween this phase and the tungsten carbide is
Table 2 • The coefficient expansion of some ma-
terials that might be brazed to tungsten carbide.
Material % increase in length
when heated from room
temperature to 700°C
Tungsten carbide 0.400
Low carbon steel 1.219
Carbon steel 1.218
Low alloy steel 1.190
304 stainless steel 1.630
310 stainless steel 1.450
316 stainless steel 1.630
Ferritic stainless steel 1.090
Cast iron 1.100
relatively poor. If brazing is conducted while
it is still in place, the strength of the resultant
joint would be a measure of the strength of
adhesion between the eta-phase and the car-
bide, rather than the value of a direct joint
between the substrate and pure carbide.
The removal of that phase can be
achieved by lapping the carbide inserts with
a mixture of tungsten carbide and silicon ni-
tride grit. If this mixture is found to be too
expensive, a less expensive treatment, but
one which is somewhat less effective, would
be by using only silicon carbide grit.
Lapping is very often carried out by tum-
bling the carbide pieces with the abrading
medium in a stainless steel container, paraf-
fin being used as the lubricant. This proce-
dure is very effective in removing all traces
of eta-phase from the surface of the carbide.
During the tumbling process, however, there
is also some abrasion of the interior of the
stainless steel container. It has been demon-
strated that some of the steel that is abraded
from the surface of the container during the
tumbling process can be deposited as a thin
layer on the surface of the carbide. It is clearly
undesirable to remove one surface layer and
then replace it with another. Consequently,
at the conclusion of the lapping operation it
is common practice to remove this thin steel
layer from the carbide inserts by tumbling
them in a plastic container in a 20% solution
of warm (40°C), nitric acid for 2 to 3 minutes,
followed by a warm-water wash.
Following these procedures and prior to
assembly, the components should be de-
greased in a suitable organic solvent. The
effectiveness of the degreasing process will
be greatly enhanced if the bath containing
the solvent is subjected to ultrasonic vibra-
tion. Following this final stage of the clean-
ing operation it is recommended that the
operators should wear lint gloves when han-
dling the parts. This will avoid contamina-
tion of the surfaces of the carbide inserts
with any perspiration or grease that the op-
erators may have on their hands.
Joint design: The problems and
solutions of stress
The two basic components comprising
the brazed joint, the steel backing piece and
the insert of tungsten carbide, have widely
differing coefficients of linear expansion. In
general terms, the backing material is three
time that of the carbide, and in extreme cas-
es four times (see Table 2).
This factor is important in terms of the
joint‘s integrity and life of the finished tools.
Welding and Cutting 13 (2014) No. 4
216_219_WC4_reports_w30000048__ 15.07.14 16:24 Seite 219
The larger the tool and size of the tungsten
carbide to be brazed, the greater is the in-
fluence on joint integrity due to the in-
evitable differential expansion that will oc-
cur and the effect of the subsequent post-
braze contraction that will also occur on the
service life of the tool in question.
The shape and mode of their operation
determines the geometrical configuration of
practically all carbide-tipped tools. The reality
is that the only design parameters that are
under the direct control of the tool manufac-
turer are the dimension of the joint gap that
exists between the carbide insert and the
backing piece and the point of location of the
tungsten carbide insert within the joint. There
is absolutely no doubt that the dimensions
of these two factors are critical in relation to
the long-term integrity of the brazing alloy
layer in finished tools. If the joint gaps are too
small, stresses will arise due to the differential
contraction of the parts as they cool from
brazing temperature. The level of stress with-
in the joint is also materially affected by the
location point of the carbide insert within the
joint. These stresses may result in either the
cracking of the carbide or generation of mi-
cro-cracks in the brazing alloy layer, and these
potential problems are clearly matters that
will be of concern to the manufacturer and
must be taken into consideration at the de-
sign-stage of a new tool.
With increases in the physical size of the
tool and the differential expansion between
the tungsten carbide insert and its backing
piece, the problem of ensuring the produc-
tion of a properly filled joint also becomes a
critical parameter.
If the physical size of the joint gap makes
it difficult to ensure a high degree of filling,
the resultant joint will inevitably contain a
relatively high incidence of voids. This can
Welding and Cutting 13 (2014) No. 4
be a particular problem in the case of rock-
drilling tools because of their size; the pres-
ence of voids in the brazing alloy layer will
act as initiation sites for stress-induced
cracking. As a consequence of these consid-
erations a balance has to be struck between
a gap that is too large or too small.
Fig. 3 is an example of a typical joint
where a piece of tungsten carbide has been
joined to a steel backing piece. At the moment
the heating stage of the brazing operation is
discontinued and the brazing alloy solidifies,
the section of the shown in the Figure can be
represented by the rectangle ABCD. From the
data given in Table 2 it is clear that the steel
backing-piece will experience a greater
amount of contraction-movement than the
piece of tungsten carbide. Thus, at room tem-
perature this section of the joint is represent-
ed by the parallelogram ABC1D1.
Consequently, during the cooling
process the relatively short distance AD (i.e.
the thickness of the layer of brazing filler
material in the joint) has been subjected to
the quite large amount of applied strain rep-
resented by DD1. Unfortunately, it would
not be too surprising to find that the filler
material within the joint had failed due to
the shear-loading it had experienced during
the cooling stage of the brazing process.
However, if it had not failed it is clear that
the finished joint would certainly contain a
high level of residual stress that could lead
to premature joint failure during the sub-
sequent service life of the tool of which it
forms a part.
Let us now consider a typical case where
it is required to braze a piece of tungsten car-
bide strip that is 3.8 × 3.0 × 1.5 mm to a piece
of carbon steel that has a thickness of 2 mm.
The situations that will arise during the braz-
ing operation are described in detail below.
During Heating to 700°C
Here the components will experience
unrestrained expansion. Because the di-
mensions are relatively small, the effect of
thermal expansion on the width and thick-
ness of the piece of carbide can be safely ig-
nored. Its change in length is quite another
matter; this will increase from 38 to 38.152
mm. At the same time, the 38-mm long piece
of carbon steel that is situated beneath the
carbide insert will expand to 38.464 mm.
This means that the steel will expand 0.312
mm more than the carbide.
During cooling from brazing
temperature
Once heating is discontinued, the two
components will attempt to contract back
to their starting sizes. Contraction is resisted
by the presence of the brazing alloy in the
joint. One of three things may occur:
1. The brazing alloy is unable to absorb
the contractional stresses and micro-
cracks appear in the joint. These factors
can clearly weaken the joint.
2. The alloy has sufficient thickness to ab-
sorb the contractional stress, but is left
in a highly stressed state.
3. The alloy is tough enough to absorb the
stresses that are applied, but because
of the dimensions of the components
the whole assembly is subjected to a
bending moment (Fig. 4). This might
result in fracture of the carbide. If the
carbide insert does not fracture, the as-
sembly will be in such a stressed state
that there will be a high risk of stress
failure occurring in the carbide when
the tool is subsequently ground to fin-
ished size.
P. M. Roberts, Delphi Brazing Consultants,
Congleton, Cheshire/UK
219
220_221_WC4_DVS_Info__ 15.07.14 16:25 Seite 220
International welding competition in China:
DVS team secured Golden Trophy
Group photo of all the participants, team leaders and supervisors in the “ARC Cup“.
Two second places and one third place
– that was the very good outcome for the
German team in the international “ARC
Cup“ in Peking/China. Furthermore, the
Germans were able to gain the victory in the
team classification and thus to take the
Golden Trophy home with them.
The “ARC Cup“ which was held in Peking
on 4 to 8 June 2014 in Peking began in 2008
as an international competition between
welders from Lower Saxony/Germany and
the Peking region. The idea arose two years
earlier during an entrepreneurs’ trip to Chi-
na organised by the Lower Saxony / Bremen
Federal State Metal Association. Since 2010,
this contest has now been staged in the form
of an international competition for the third
time already.
For Germany, DVS sent a 15-strong dele-
gation to China. Not only the six young
welders (including the four victors of the na-
220
tional “Young Welders 2013“ competition in
Essen) but also supervisors, welding instruc-
tors and members of the national “Young
Welders“ working group went on the trip. As
representatives of DVS, Yvonne Reichsthaler
(welding instructor at the Vocational Educa-
tion and Technology Centre of the South
Thuringia Chamber of Handicrafts) was in-
volved as the team leader as well as Heinz
M. Klein from GSI and Dietmar Berndt, Low-
er Saxony / Bremen Federal State Metal As-
sociation, as the head of the delegation. Oth-
er participating nations were Austria, Be-
larus, Bulgaria, Czech Republic, United King-
dom, Indonesia, Korea, Mongolia, Rumania,
Singapore, Ukraine and the host country Chi-
na. As the winner of the “Weld Cup 2013“ in
Essen, Austria competed in all four welding
processes with the complete victorious team.
On 4 June 2014 the event started with an
opening ceremony which, just like the
Olympics, began with
the march-in and in-
troduction of the indi-
vidual nations and ul-
timately ended with
the oath for an open
and fair contest being
administered to the
participants. 250 Chi-
nese welders and 42
participants from the
other twelve countries
competed against each
“Team Germany“ with
the Golden Trophy for
the team victory.
other: six welding processes, 45 welding
booths, six robot welding stations and 779
test pieces to be assessed. After four exciting
days, the competition was over for the par-
ticipants but the work for the jury was still
far from finished. While the participants and
the supervisors were able to celebrate exu-
berantly in the final evening with an inter-
national cultural programme, the jury had
to put in a night shift.
After the meticulous assessment of the
test pieces, the victors had been decided.
The presentation ceremony began with the
announcement of the individual victors. For
the German team, these were Constanze
Gebhardt (second place in manual metal
arc welding), Hans-Peter Lutz (second place
in metal active gas welding) and Robert
Schumann (third place in gas welding). In
addition, Hans-Peter Lutz achieved second
place in the special prize for “Young Welders
Under 22 Years of Age“. The winners in the
first three places in each process received
not only the coveted medals but also an ad-
ditional cash prize. However, the greatest
success for the German participants could
be registered in the team classification. Here,
the German team was able to pick up points
with the above-average results of all six par-
ticipants. At the end, it was Gold for Ger-
many. The entire team had tears of joy in
their eyes. “A deserved victory. You made
good use of the chance to exact revenge.
Congratulations,“ was the comment made
by the Austrians.
Personal thanks from the head of the
German delegation who also performed the
function of the “Chief Referee“ during the
Welding and Cutting 13 (2014) No. 4
220_221_WC4_DVS_Info__ 15.07.14 16:25 Seite 221
contests went to the Chinese organisation
committee and, quite particularly, to the pa-
tron of the event, Dr. Liu Zhenying, President
of Beijing ARC Xinxing Science & Technol-
ogy Co. and Secretary-General of the Asso-
ciation for International Welding Technol-
DVS Media’s homepage and online shop in a new design
DVS Media GmbH has revamped its
homepage and online shop and adjusted
them to the corporate design. The home-
page can be called up in English or German
at www.dvs-media.eu. The top titles from
the programme of the publishing house
form the heart of the start page. A themati-
cally structured menu on the left side pro-
vides guidance through the rest of the pro-
gramme and makes it easier to find sought-
after products. Anybody who would like to
set up a customer account can do so but or-
ders are possible as a visitor too.
18th international welding competition
“Linde Golden Trophy“
On 14 and 15 April 2014, the 18th interna-
tional welding competition “Linde Golden
Trophy“ took place at the Metal Technology
College in Frydek Mistek in the North-East
of the Czech Republic. The competition was
staged in the manual metal arc, metal active
gas, tungsten inert gas and gas welding
processes for college students under 19 years
of age. 125 participants from the Czech Re-
public, Slovakia, Ukraine and Germany
qualified for this competition. The partici-
pants had to execute three different speci-
mens in various positions (transverse butt
weld, vertical-up butt weld and semi-over-
head fillet weld) in the welding process of
their choice.
Sean Martin Knoll, Sergey Rotmann,
Robin Bauknecht, Andreas Rabe and
Hannes Vollbarth went to the starting line
for the Chemnitz Educational Workshop.
With a fantastic performance, Hannes was
able to reach third place in tungsten inert
gas welding. The victors received a large
Welding and Cutting 13 (2014) No. 4
ogy Cooperation in China, for the great com- Hong Zhang, EWM Germany, who travelled
mmitment during the preparation and stag- from Shanghai and, even during the arrival
ing of this competition. An event of this mag- at the airport, was already available as an
nitude does not function without sponsors interpreter and supervisor and that right into
or supervision in situ. The German team the late hours of the evening.
was supported in an outstanding way by Dr. Dietmar Berndt, Magdeburg
In addition to the diverse range on offer
in the shop and the accustomed menu items
such as “Contact“ or “Member Login“, there
is the “Experts“ item on the bottom left of
the Internet page for everybody interested
in joining technology. This includes the Ger-
man/English dictionary “The ABC of Join-
ing“, sources of supply and job offers. Various
downloads, links to the Internet broadcast-
ing station DVS-TV and the information net-
work schweissen.net as well as the access to
the shop for promotional items can also be
found on the new homepage.
number of presents, sponsored by renowned visited an old steelworks and the Fire Service
companies in the joining, cutting and coat- Museum in Ostrava. Information about the
ing sectors. vocational education in the Czech Republic
In the subsequent supporting pro- and Ukraine was exchanged as well.
gramme, the participants in the competition Thomas Schubert, Chemnitz
The German team
in the welding
competition
“Linde Golden
Trophy“, from left
to right: Ingo Al-
brecht (supervi-
sor), Robin
Bauknecht,
Hannes Vollbarth,
Andreas Rabe,
Sergey Rotmann,
Sean Martin Knoll
and Thomas
Schubert (super-
visor).
221
222_224_WC4_reports_w30000049__ 15.07.14 16:46 Seite 222
REPORTS
Special process of ultrasonic-assisted soldering or
brazing: Exploiting potentials
Fig. 1 • Ultrasonic soldering bath according to C. A. Denslow. [4]
As far as the joining of aluminium-based
materials is concerned, ultrasonic-assisted
soldering or brazing has advantages,
amongst other reasons, due to their short
process times and to the expendability of
flux. Ongoing investigations are dealing with
optimised process variants to achieve im-
proved mechanical properties of the sol-
dered or brazed joints. Applications can be
found wherever lightweight constructions
are in demand.
In addition to the suitable soldering or
brazing metal and the required heating tech-
nology, the wetting of the base material by
the molten solder or braze metal is a basic
prerequisite for the creation of a soldered or
brazed joint. For this purpose, it is necessary
to eliminate the contaminations and oxides
located on the workpiece’s surface. To this
end, plant ashes were already used as flux in
ancient times. Mineral salts such as borax
were utilised for brazed joints. Today, it is
possible to differentiate the methods of elim-
inating oxides, for example, into soldering
or brazing using fluxes, in a reducing or inert
shielding gas, in a vacuum or with the aid of
mechanical-activated processes.
The last group also includes ultrasonic-
assisted soldering or brazing which this ar-
ticle addresses. This is a young and little-
known process whose development is di-
222
rectly coupled to the discovery of the elec-
tricity and to the industrialisation. In this re-
spect, the foundation is formed by the piezo-
electric effect discovered by the Curies in
1883. Even in modern ultrasonic-assisted sol-
dering or brazing processes, this effect is used
for the joining of aluminium and magnesium
in order to remove the particularly firmly ad-
hering and dense oxides from the work-
piece’s surface. The conventional elimination
of oxides by fluxes entails disadvantages
since it requires the thorough cleaning of the
components in order to avoid corrosion.
Soldering baths have prevailed in
practice
Flux-free processes to which ultrasonic-
assisted soldering may be assigned are
based on the abrasive removal or destruc-
tion of the oxides. This is caused by cavita-
tion effects which the ultrasonic waves in-
duce within the solder. The occurring local
shearing of the liquid leads to blistering in
the molten solder. The subsequent, sponta-
neous disintegration of these blisters pro-
ceeds at a very high speed. Therefore, pres-
sure peaks over 1,000  bar may occur and
destroy the oxides.
Different variants are possible on the ap-
plication side [3]. Not only ultrasonic sol-
dering irons but also ultrasonic soldering
baths should be mentioned. It is primarily
soldering baths (Fig. 1) which have prevailed
in practice, e.g. for the manufacture of alu-
minium heat exchangers [4,  5]. In elec-
trotechnology and electronics too, ultrasonic
soldering is utilised for the manufacture of
thermal and electric contacts on materials
which are difficult to wet. This results in ap-
plications, for example, for power compo-
nents, sensors and actuators as well as for
the assembly of housings and heat sinks.
The process is particularly attractive because
of the expendability of flux.
Ongoing investigations are concerned
with the brazing of particle-reinforced alu-
minium matrix composites and also with
the manufacture of brazing alloys with finely
distributed ceramic reinforcing particles
with the aid of ultrasound (Fig. 2) [6, 7]. In
this respect, the erosion (dissolution) of the
base material matrix by the molten braze
metal is used in a targeted way in order to
expose the reinforcing particles from the
base material and to incorporate them into
the brazed joint. The resulting composite
braze metal exhibits improved mechanical
properties compared with the conventional
brazing alloy.
Such concepts are applied wherever
lightweight constructions are required. The
wetting and the gap filling can be improved
substantially by the use of ultrasound [8].
Striving for low joining
temperatures
The problems during the joining of these
composite materials mainly result from their
thermal sensitivity. In this respect, an exces-
sive heat input may lead to negative changes
in the properties of the base materials. This
constitutes a problem especially in the case
of particle-reinforced composites. Accord-
ingly, short process times which are char-
acteristic for resistance and induction
Fig. 2 • Formation of a
particle-reinforced braze
metal with improved me-
chanical properties due to
the targeted utilisation of
the erosion of the base
material matrix (alumini-
um alloy). [7]
Welding and Cutting 13 (2014) No. 4
222_224_WC4_reports_w30000049__ 16.07.14 09:02 Seite 223

History of soldering and brazing

Soldering and brazing are amongst the
oldest joining processes. As early as
4000 B.C., pieces of jewellery were cre-
ated in Mesopotamia using the crafts-
manship of soldering with a blowpipe.
Egyptian goldsmiths were also familiar
with brazed joints on pieces of jew-
ellery and on chain links. The archae-
ological find of a Celtic bronze sword
manufactured around 1100 B.C. ex-
hibits a pale metal at the joint between
the blade and the hilt. This suggests
the joining technology of brazing. Ex-
cavations in Pompeii revealed brazed
lead pipes. Amongst experts, it is well-
known that the Romans were also ac-
quainted with various tin solder met-
als. For example, there was a solder
metal, called “argentarium“, which was
composed of equal contents of lead Fig. 3 • Schematic drawing (left) and photograph (right) of the test setup for ultrasonic-assisted brazing.
and tin. A similar soldering alloy which
is still well-known even today is com- processes and low joining temperatures Chemnitz/Germany is ultrasonic-assisted
posed of 60% tin and 40% lead (com- should be striven for. brazing using the resistance heating of alu-
position by mass) [1, 2]. The subject of ongoing research work at minium and aluminium-matrix composites
Chemnitz University of Technology in with particle contents up to 10% by volume

Wissen kompakt / compact knowledge – Electron beam technologies

The book deals with the general connections in the use of electron beam technology for materials processing.

It explains, in the most comprehensible way possible, the natural-scientific and technical foundations of
electron beam technology, the functioning methods of various machine systems and the possibilities of the
diverse technologies.

It helps to eliminate deficiency in information about electron beam techniques and technologies in the field
of materials processing.

The book gives engineers in the industry as well as students of mechanical engineering, manufacturing and
the like an important basis for the widespread use of the potential of these advanced technologies.

SCHWEISSEN UND SCHNEIDEN – Wissen kompakt / compact knowledge

Vol 1e: Electron beam technologies

Order No.: 600702, Dr. Klaus-Rainer Schulze, 1st Edition 2012

Price: 22,00 Euro | Price: 17,60 Euro (for subscribers of SCHWEISSEN UND SCHNEIDEN)

DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf

T +49. (0)2 11. 15 91-161 • F +49. (0)2 11. 15 91-250 • media@dvs-hg.de • www.dvs-media.info

Welding and Cutting 13 (2014) No. 4 223

222_224_WC4_reports_w30000049__ 15.07.14 16:46 Seite 224
REPORTS
Fig. 4 • Geometry of the contact face.
[9]. Zinc/aluminium alloys (e.g. ZnAl4) are
utilised as brazing metals. The test setup de-
veloped specifically for this purpose is
shown in Fig. 3. A sonotrode is used to in-
troduce the ultrasound at a frequency of
20 kHz into the workpieces to be joined. For
the direct resistance heating, the compo-
nents are contacted using copper electrodes.
The effective influencing variables result
from the Joule effect. Accordingly, the heat
quantity arising at the joint is affected by the
amperage, the electrical resistance at the
contact point between both workpieces and
the time: Q = I² · R · t (Q = heat quantity [J]; I
= amperage [A]; R = electrical resistance [Ω];
t = time [s]).
The amperage is a setup-specific char-
acteristic variable. The chosen process time
should be short. The utilised specimen ma-
terial, the surface finish at the contact face
and the geometry of the joint affect the elec-
trical resistance crucially. To get a brazed
joint with as few defects as possible, heating
in the center of the specimen is striven for.
This can be explained by the flow direction
of the braze metal opposite to the tempera-
ture gradient. Plane joining faces turned out
to be unsuitable for this purpose due to the
undefined size of the actual contact face and
the surface roughness. For that reason con-
tact geometries with a cylindrical pin in the
center of the contact face were developed
with reference to stud welding (Fig. 4).
In order to determine the development
and propagation of the heat, the tempera-
ture gradient during the brazing process was
recorded with a thermographic camera (Fig.
5). The targeted heat input into the joining
zone with only very small thermal influences
on the rest of the base material could be ver-
ified.
Another process variable which influ-
ences not only the resistance at the contact
faces but also the coupling of the sonotrode
224
Fig. 5 • Thermographs showing the temperature distribution in the workpieces.
and the workpieces is the pressing force. Ac-
cordingly, a higher ultrasonic power also re-
quires a higher pressing force in order to en-
sure constant contact between the joining
faces. Moreover, because the strength of the
base material decreases as the temperature
rises, the surface pressure causes a defor-
mation of the contact pin during the brazing
operation. However, the pressing force does
not exert a direct effect on the joining
strength. In contrast with this, an increase
in the input ultrasonic power leads to an in-
creased joining strength. This can be ex-
plained by the cavitation processes. Maxi-
mum values of 160 MPa are achieved.
Industrial implementation and estab-
lishing are possible on the basis of the results
of the research work. Moreover, comprehen-
sive understanding of the process permits
optimum quality assurance and thus a con-
stantly high product quality.
Exploiting new applications
Ultrasonic-assisted brazing is suitable
for the flux-free joining of aluminium-based
materials. The advantages of the process
predominantly relate to the short process
times and the small thermal influences on
the workpieces to be joined. However, there
are restrictions with regard to the geometries
of the workpieces and the joining faces. For
instance, the components to be joined
should exhibit the same dimensions. The
size of the attainable joining face is affected
by the brazing temperature and the efficien-
cy of the power source. The electrical prop-
erties of the base materials are also decisive
in this respect. The attainable joining
strength always depends on the utilised
brazing process as well as on the base ma-
terial and brazing metal. In the case of the
shown example, a joining strength up to
160 MPa was achieved on aluminium-ma-
trix composites using ZnAl braze metals.
The process of ultrasonic-assisted braz-
ing will be the subject of future research
work. With the development of new materi-
als, it is also necessary to provide suitable
joining processes. Until now, there have
been only few mass applications of the
process. This article should also help to raise
the level of awareness in order to exploit new
applications.
Dr.-Ing. Sebastian Weis and Univ.-Prof.
Dr.-Ing. habil. Bernhard Wielage,
Chemnitz University of Technology,
Chemnitz/Germany
Literature
[1] Petrunin, I. E.: Handbuch Löttechnik. Verlag
Technik, Berlin 1991.
[2] Linde, v. R.: Löten. Werkstattbücher (Hrsg.
Haake, H.) Issue 28, Springer-Verlag, Berlin
1950.
[3] Wielage, B.; et al.: Einfluss des Ultraschalls
auf die Ausbildung der Sprödphasen
während des Hochtemperaturlötprozesses.
VS-Berichte Band 92, pp. 23/30. DVS-Ver-
lag, Düsseldorf 1984.
[4] Denslow, C. A.: Ultrasonic Soldering Equip-
ment for Aluminium Heat Exchangers.
Welding Journal 55 (1976), No. 2, pp. 101/07.
[5] Wielage, B.; et al.: Löten von Aluminium
mit Ultraschall. 2. Werkstofftechnisches
Kolloquium, TU Chemnitz (1999), pp.
116/23.
[6] Xu, Z., et al.: Interface structure of ultrasonic
vibration aided interaction between Zn–Al
alloy and Al2O3p/6061Al composite. Com-
posites Science and Technology 65 (2005),
No. 13, pp. 1959/63.
[7] Zhang, Y., et al.: Ultrasonic dissolution of
brazing of 55% SiCp/A356 composites.
Transactions of Nonferrous Metals Society
of China 20 (2010), No. 5, pp. 746/50.
[8] Yan, J., et al. : Ultrasonic assisted fabrication
of particle reinforced bonds joining alu-
minum metal matrix composites. Materials
& Design 32 (2011), No. 1, pp. 343/47.
[9] Wielage, B., et al.: Low-melting composite
filler metals. Engineering and Computa-
tional Mechanics 164 (2011), EM3, pp.
127/32.
Welding and Cutting 13 (2014) No. 4
 Try the leading journal for
Welding and Cutting in Europe – Now!

Technical and Scientific Journal of the The

Issue

03
Welding
Institute

DVS – German Welding Society 2011

WELDING AND CUTTING is an international trade journal which

is editorially oriented to welding, cutting and brazing/soldering
technology, including the numerous peripheral areas. www.welding-and-cutting.info Technical journal for welding and allied processes

It includes regular and comprehensive reports from industry,

science and the practice of the welding technology sector, takes
Precision in Detail
up not only new developments but also economic questions and Small holes, fine inside and outside contours:
the precision of Contour Cut revolutionises

thus serves as an important source of information which is used

plasma cutting of mild steel.

A new technology without additional

costs and components!

by an international expert public throughout the world. Because Contour Cut is integrated as
standard in all HiFocus systems.

mple !
Order your free sa
Kjellberg Finsterwalde Plasma und Maschinen GmbH Phone: +49 3531 – 500 0 · E-mail: plasma@kjellberg.de
Germany · Leipziger Straße 82 · 03238 Finsterwalde www.kjellberg.de/plasma

Editorial Features: Third “Schweisstec“ welding trade Welding ferrous metals: Stress corrosion cracking of
fair in the new Landesmesse How can you be sure of carbon steel in ethanol
Stuttgart in June 2011 accurate preheat?

Research, Development and Application

Training
Welding_Cutting_final.indd 1 24.01.2012 15:47:24

Welding, Cutting, Soldering, Brazing, Bonding etc.

Materials (Ferrous and Non-ferrous Metals, Plastics,
Base and Filler Materials and Ancillaries)
Design
Cost Calculations and Production in the Manufacture of Steel
Frequency: 6 x per annum
Structures, Vessels, Plants Vehicles and Machinery
Subscription rate: 122.00 €
Welding Machines including Robots and Control Systems
plus postage costs: 29.00 €
Materials Testing (Destructive and Non-Destructive)
Health and Safety at Work www.welding-and-cutting.info

DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf

P +49. (0)2 11. 15 91-159 • F +49. (0)2 11. 15 91-150 • media@dvs-hg.de • www.dvs-media.eu

AZ_welding_and_cutting_210x297mm_NCD.indd 1 30.01.2014 11:41:11

226_228_WC4_SpA_w20000036__ 15.07.14 16:48 Seite 226

SPECIALIST ARTICLES

Structural adhesive bonding on painted surfaces

In recent times, so-called “multi-material structures“ have been utilised THE AUTHORS
in vehicle construction to an increasing extent. This inevitably leads to ad-
Dipl.-Ing. Claudia Unger is a Scientific Employee
justments in the existing fabrication processes using joining technology. at the Laser Zentrum Hannover e. V. in
Until now, it has been the state of the art to apply the adhesive for structural Hanover/Germany.
adhesive-bonded joints already in the body shell, i.e. very early in the
process chain, and to cure the mostly one-component structural adhesives
while the body shell is passing through the cataphoretic paint drier. If
structurally relevant components are to be replaced by fibre-reinforced
plastics, these must be joined to the already painted bodywork in the final Dipl.-Ing. Manuel Schiel is a Scientific Employee
assembly. If a painted joining member and an unpainted joining member at the Institute of Joining and Welding of the
or two painted joining members are to be joined with each other by means Brunswick University of Technology in
Brunswick/Germany.
of the adhesive bonding technology in this way, there are several different
procedures. On the one hand, the regions relevant to the adhesive bonding
operation can be masked before the painting. On the other hand, auto-
mated paint removal before the adhesive bonding is conceivable. Direct Univ.-Prof. Dr.-Ing. Prof. h. c. Klaus Dilger is the
adhesive bonding on the finish-painted surface is imaginable as well. In Head of the Institute of Joining and Welding of the
the case of the first point, it is merely necessary to take account of process Brunswick University of Technology in
sequences with regard to masking and demasking. Therefore, it is not in- Brunswick/Germany.
tended to deal with this separately. Within the framework of the project
portrayed here, investigations were conducted instead into methods of es-
tablishing mechanical properties of the overall joint as well as into process-
es for removing the paint using different laser beam sources.
mentioned that the bondline thickness should be as thin
as possible to achieve the highest stiffness possible and
1 Characterised paints and modified testing to minimise strain within this layer. In a further step the
methods second adherend is bonded onto the painted side of the
During the work two representative paints (white and
silver metallic) were analysed regarding their behaviour
within an adhesively bonded joint. Both paints consist of
four different layers which are, from bottom to top: elec-
tro-coating (ec), filler, colour and transparent topcoat (c.f.
Fig. 1). In a first step lap-shear specimens according to
DIN EN 1465 were prepared from the painted metal
sheets. These tests can be very well applied for a direct
comparison of different paints and/or different pre-treat-
ment methods.
For a more precise characterisation of the mechanical
behaviour of the material, especially regarding different
load cases, the mentioned test is not applicable. Therefore
the butt-joint test as well as the test according to Arcan
[1] are well established in the characterisation of structural
bonds. Although the presented testing methods were de-
signed for steel-steel bonds, the butt joint test and the Ar-
can sample can be easily adopted for the testing of differ-
ent coatings or paints. The adherends must therefore be
painted separately which may result in a different quality
than in series production. Since there are painted metal
sheets available from quality control in series production
it is favourable to use these sheets for a direct comparison
of the paint properties. Since these sheets are painted in
series production the paint has the same quality. With the
modifications presented in the following it is possible to
use these sheets in the mentioned testing geometries. Fig.
2 shows a schematic illustration.
In a first step the painted metal sheet is bonded with
the unpainted side onto the first adherend. It should be Fig. 1 • Characterised paints (top: white, bottom: silver).

226 Welding and Cutting 13 (2014) No. 4

226_228_WC4_SpA_w20000036__ 15.07.14 16:48 Seite 227

tion strategy. If the laser removes the filler, then the EC

Fig. 2 • Schematic of round butt joint testing and arcan speci-
men.
sheet. The adhesive used in this case is the one which is
characterised together with the paint. Is has therefore to
be assured that the strength of this adhesive is inferior to
the one used in the first joint to assure failure in the second
bondline.
2 Mechanical characterisation
At this point the results of the mechanical characteri-
sation using the Arcan specimen will be presented. The
Arcan specimen was developed to determine adhesive
properties in multi-axial loading cases. The two stress
components (tension and shear) were plotted separately
for the three testing groups in Fig. 3. One can easily de-
termine the directionality of the results as well as the de-
pendency on the used paint. These experiments show in
an exemplary manner the inferior strength of the paint in
comparison to the adhesive.
layer is at least partly ablated, too.
Fig. 4 shows absorption measurements of the colour
lacquer layers and the EC layer in the wavelength range
from 2,500 nm to 20,000 nm. Only in the wavelength range
from 4,000 nm to 6,000 nm the absorption of the EC layer
is around 10% lower than the upper coloured layers. In
this wavelength range, commercially available lasers with
high output power are not available. At the CO2-laser
wavelength of 10.6 µm the absorption differs by less than
5%. Therefore, ablation experiments by CO2-laser with a
pulse duration in the µs-range were conducted. However,
neither a self-limiting ablation process was possible since
the ablation thresholds of the lacquer layers are too close
together.
A second possible strategy for lacquer removal is a
parameter-controlled ablation of the upper layers. For this
purpose, the laser parameters are adjusted in a way that
the ablation process results repeatably in a constant lac-
quer layer thickness. Nevertheless, the challenge is to cre-
ate a remaining lacquer layer thickness with minimum

3 Process adaption / paint removal

The mechanical tests have shown that the paint has
to be considered when executing adhesively bonded joints
since it represents the weakest part. To increase the bond-
ing strength one or several lacquer layers can be removed
prior to the adhesive bonding. In this study, the removal
via selective laser ablation was investigated. The laser-
based lacquer removal was conducted at the “Laser Zen-
trum Hannover“(LZH) and at the “CleanLaser GmbH”, a Fig. 3 • Polar plot of the arcan results with fitted FE parameters.
member of the SME user’s committee. Laser parameters,
such as laser wavelength and laser power, should be cho-
sen in a way that the ablation process stops by itself on
the EC layer. This strategy implies that the upper layers
show a lower ablation threshold than the underlying EC
layer.
In a first step the wavelength-dependent absorptivity
of the colour lacquer layers as well as the EC layer was
measured since the ablation thresholds of the different
lacquer layers are strongly dependent on the absorption.
The measurement revealed that the absorption of the EC
layer is never lower than the absorption of the upper layers
in the wavelength range from 250 to 2,000 nm. Further-
more, laser ablation experiments with ns-pulsed laser sys-
tems operating at 355 nm, 532 nm and 1064 nm were con-
ducted. The ablation experiments confirmed the spectral
absorption measurements. A self-limited ablation process
was not possible by varying laser output power and abla- Fig. 4 • Absorption spectrum of different paint layers.

Welding and Cutting 13 (2014) No. 4 227

226_228_WC4_SpA_w20000036__ 15.07.14 16:48 Seite 228

SPECIALIST ARTICLES

Fig. 5 • UV based Fig. 7 • Comparison of lap shear strength after different pre-
ablation of the treatments.
white (left) and
silver (right) paint the metal sheets. These results are presented in Fig. 7. It
up to the filler. is obvious that, due to an adequate pre-treatment, the re-
Ablation rates of
sulting strength increases significantly and even doubles
2,88 cm²/s (white
in the case of silver paint. The results derived from these
paint) and 2,75
cm²/s (silver paint)
quasi-static tests can be transferred qualitatively to high
were reached. strain-rates. Also in this case the failure occurs within the
paint and especially within the silver layer.

Fig. 6 • IR based 4 Conclusion

ablation of the
white (top) and
silver (buttom)
paint up to the
filler: Ablation
rates of 2,6 cm²/s
(white paint) and
3,9 cm²/s (silver
paint) were
reached.
thickness tolerance while the initial layer thickness varies.
The ablation into the filler was detected as being the best
strategy to enable constant adhesive bonding results with
varying initial layer thickness.
At the LZH, ablation studies with a UV-laser (Coherent
AVIA 23, 355 nm) emitting nanosecond laser pulses were
conducted. Fig. 5 shows reflected light microscopic images
and metallographic cross-sections. The cross-sections
show homogeneous ablation with low ripple. In cooper-
ation with “Clean Laser GmbH” ablation by means of an
IR-nanosecond-laser (CL 150, 1064 nm) was accom-
plished (Fig. 6). Further investigations showed that even
higher ablation speeds than the ones given in Fig. 6 could
be reached for both lacquer colours.
Following the laser treatment lap-shear specimens
according to DIN EN 1465 were prepared and tested from
The presented mechanical tests have shown that the
failure properties of painted joints are strongly depend-
ent on the paint composition and the loading conditions.
These tests showed similar failure modes for the silver
paint and partly different failure for the white case. The
properties of the joint are significantly influenced by the
paint and have to be investigated during the develop-
ment of a product. It was also shown that adequate pre-
treatment methods can be used to increase the joint
strength.
Literature
[1] Cognard, J.Y.: Numerical analysis of edge effects in adhe-
sively-bonded assemblies – Application to the determina-
tion of the adhesive behaviour. Computers & Structures 86
(2008), pp.1704/17.
ACKNOWLEDGEMENTS
The presented results were acquired in the context of the interna-
tional research project “CrabLacs - Crash resistant adhesive
bonding of lacquered surfaces”. This work was financed by the
German Federal Ministry of Economics and Technology and the
Cypriot Research Promotion Foundation between 2010 and 2012.
The authors would like to thank every partner for their contribu-
tion to this project.

228 Welding and Cutting 13 (2014) No. 4

229_235_WC4_TWI_News__ 15.07.14 16:52 Seite 229
NEWS
Editorial
Focus on Technicians
In June 2013, the UK Prime Minister announced a scheme to de-
velop 100,000 new Engineering Technicians by 2018. David
Cameron said: “Apprenticeships are at the heart of our mission to
rebuild the economy, giving young people the chance to learn a
trade and to build their careers, creating a truly world-class, high-
skilled workforce that can compete and thrive in the global race.”
The aim of the scheme is to ensure that, on successful completion,
each apprentice will have the appropriate competences to attain
the globally recognised professional registration designation of
Engineering Technician (EngTech).
This aim to have Engineering Council registration as the destina-
tion of an engineering apprenticeship is directly in line with the
recommendations made by Doug Richard in The Richard Review
of Apprenticeships, published in November 2012, which state that,
‘The focus of apprenticeships should be on the outcome. There
should be recognised industry standards at the heart of every
apprenticeship. They should clearly set out what apprentices
should know, and be able to do, at the end of their apprenticeship,
at a high level which is meaningful and relevant for employers.
These standards should form the basis of new apprenticeship qual-
ifications, which replace apprenticeship frameworks, the current
qualifications which comprise them and the current national occu-
pational standards which underpin them. There should be just one
apprenticeship qualification for each occupation associated with
an apprenticeship. They should link to standards for professional
registration in sectors where these exist and are well-recognised.’
Not for the first time, the scheme announced by David Cameron
is designed to engage the Licensed Professional Engineering In-
stitutions in development and registration of Engineering Techni-
cians and to elevate the profile of apprentices and Engineering
Technicians to a level similar to that already present in many of
the UK’s fellow European Member States. The separate and refo-
cused EngTech standard was published in UK-SPEC (UK Stan-
dard for Professional Engineering Competence) in 2002. A
campaign sought to persuade the UK Department for Trade and
Industry to recognise the deficit in recognition of technicians com-
pared to competing nations and, by 2009, all but two PEIs were li-
censed for EngTech and the Engineering Council had published a
White Paper calling for ‘recognition of a technician class’.
Although one of the smaller Institutions, and possibly because of
it, The Welding Institute has always strongly valued and supported
Technicians. Whilst in the middle of the table of 36 Professional En-
gineering Institutions for registration of Incorporated Engineers and
Chartered Engineers, The Welding Institute is fifth out of 36 for reg-
istration of EngTechs, and has over 1,000 Technician (TechWeldI)
members, exceeding 40% of the total Professional Membership.
Even before the Downing Street announcement, The Welding Insti-
tute had revised the composition of its Professional Board to engage
more Engineering Technicians in the governance of the Institute;
vacancies still exist, and interested EngTechs are encouraged to put
themselves forward for this high-profile and influential task.
The Welding Institute is working with employers to make a Trail-
blazer proposal to the UK Department for Business, Innovation and
Skills for the definition of a Welding Apprenticeship that will sup-
port government aims for a more highly-skilled and flexible work-
Welding and Cutting 13 (2014) No. 4
July
August
2014
The Newsletter of The Welding Institute
force. It is expected that this new welding apprenticeship will build
on the work done by The Welding Institute in developing the Eu-
ropean and International Welder Diplomas through its contribu-
tions to the European Federation for Welding, Joining and Cutting
(EWF) and the International Institute of Welding (IIW), draw on
TWI Certification Ltd’s credibility as a Recognised Third Party Or-
ganisation for approval of welding procedures and certification of
welders in accordance with European and International standards
in support of industry requirements, and its abilities in assessing
the capabilities of welder training organisations using CSWTO and
the competence of their instructors and examiners using CSWIP.
However, The Welding Institute not only recognises the value of
end-to-end formal education and training in an apprenticeship, it
also embraces the professional development that occurs through ex-
periential, work-based learning. As recognised in UK-SPEC, ‘many
potential Engineering Technicians have not had the advantage of
formal training but are able to demonstrate that they have acquired
the necessary competence through substantial working experience.’
Individuals who have not undergone an approved apprenticeship
or with an approved qualification at Level 3 or above may apply for
an Individual Route assessment; The Welding Institute’s assessors
are skilled and experienced in conducting such verification of Tech-
nician competence, often through a workplace assessment.
For those who do not possess the exemplifying formal qualifica-
tions but have developed their careers by following vocational
training routes, using non-formal role-specific training, The Weld-
ing Institute utilises the accredited competence assessment inher-
ent in the CSWIP personnel certification scheme to also assess
individuals against UK-SPEC requirements. The Welding Institute
has undertaken a number of mapping exercises of CSWIP certifi-
cation criteria against the UK-SPEC competence requirements,
and has gained approval from the Engineering Council for the fol-
lowing role-specific personnel certification standards to be used
as direct routes to registration as EngTech; CSWIP 3.3U ROV In-
spector, CSWIP 3.4U Underwater Inspection Controller, CSWIP
Welding Instructor, CSWIP 3.2 Senior Welding Inspector, and
CSWIP Welding Quality Control Coordinator. These approved di-
rect routes to registration permit industry-specific professional de-
velopment to be recognised by professional registration. The
recent inclusion of CSWIP Welding Instructor was specifically to
support experienced welding tutors and instructors who never
had the opportunity to follow formal education but are coming
under increasing pressure to support their competence with a
Level 3 engineering qualification; EngTech registration exemplifies
that level of knowledge and understanding. Work is now under-
way to enhance the CSWIP Welding Supervisor competence re-
quirements to more clearly support the welding coordination
tasks and responsibilities specified in ISO 3834 and ISO 14731, and
they will then be mapped against UK-SPEC with the aim of creat-
ing another direct route to EngTech registration.
As discussed in the previous issue of the Welding and Cutting
Journal, some employers and some individuals question the need
for registration as they are already delivering the required tasks
effectively. However, UK-SPEC is a full competence standard that
not only demands verification of technical knowledge and under-
standing, skills, and experience but also requires a commitment
to a professional code of conduct. The Welding Institute Rules of
229
229_235_WC4_TWI_News__ 15.07.14 16:52 Seite 230

TWI NEWS ··· TWI NEWS ··· TWI NEWS ··· T

Professional Conduct enable an EngTech registrant to recognise
their obligations to society, their profession, and the environment,
and supports them to exercise their responsibilities in an ethical
manner and to undertake continuing professional development.
With increasing autonomy in manufacturing, production and op-
eration, greater emphasis on self-certification of tasks, and more
reliance placed on the integrity of individuals to achieve the nec-
essary quality of output, this focus on behaviours within the sup-
portive environment of The Welding Institute’s knowledge net-
work is a significant benefit to the individual and the employer.
Eur Ing Chris Eady BSc(Hons) MSc CEng MRAeS FWeldI
Associate Director for Professional Affairs
The Welding Institute

The Welding Institute Annual Awards and Dinner 2014 fessional Affairs, Chris Eady, with invited presenters including
The Welding Institute’s President, Bertil Pekkari, with Professor
The Welding Institute’s Annual Awards and Dinner took place on Sir Colin Humphries, Steve Beech, Richard Dolby OBE and Peter
1 July 2014 at King’s College, Cambridge, with over 200 invited Bateman.
guests from industry and academia. The event
began with an Awards Presentation Ceremony
presided over by TWI Associate Director of Pro-

The awards were presented by Bertil Pekkari,

President of The Welding Institute

The Brooker Award

Larke-Lillicrap Award

sponsored by Johnson Matthey, plc. is awarded annually

in recognition of the recipient’s personal contribution to the
science, technology and industrial exploitation of metal
joining. It recognises high industrial, research or educa-
tional responsibility of a character which has beneficially
influenced the advancement of metal joining technology.
Wayne Thomas

Bevan Braithwaite Award for Enterprise

is made in recognition of the recipient’s enterprise to the awarded annually to the individual or team who has had most influence or impact upon the practical application of
benefit of welding and joining. It recognises enthusiastic novel welding or joining knowledge or technology. The subject may be presented in a published academic or research
and passionate promotion of a vision, and strategic drive paper but the nomination will be assessed on its practical application value and impact on welding and joining in real-
to cause that vision to become a successful reality. world engineering.

Tom Palmer TAIWAN Friction Stir Welding Programme (Jonathan Martin, Mike Russell, John Matwiejew and Alex
Robelou)

230 Welding and Cutting 13 (2014) No. 4

229_235_WC4_TWI_News__ 16.07.14 14:21 Seite 231

··· TWI NEWS ··· TWI NEWS ··· TWI NEWS

Distinguished Service Awards TWI Commendation Award

are offered in recognition of outstanding contributions to The Welding Institute on a national basis, as a result of which provides recognition for special achievements by a member
the position of the Institute has been significantly advanced. of TWI staff.
David Fell (left) and Julian French (right) Matthew Doré

Richard Weck Award

Richard Dolby
Rolls-Royce Prize

is presented biennially by the Younger

Members Committee to the young person
(or group of people, if involved in a joint
project), who has no more than five years’
experience after completing full time edu-
cation.
Presented by Steve Beech, Rolls-Royce,
and Dr Richard Dolby OBE
Nicholas Brown

awarded annually to the TWI author(s) of the Industrial

Members’ Report from the Core Research Programme con-
sidered most worthy in the year of issue.
Chris Punshon
SkillWeld Trophy 2013 The Armourers & Brasiers’ Company
Awards series

The Welding Institute Branch Loyal

Service Awards

Kurt Rogers
supporting education and innovation in metals and mate-
rials presented by Professor Sir Colin Humphries
Anthony Smith and Scott Pearson (not present)
EWF Best European Welding
Co-ordinator 2012
Best PhD Student

in recognition of outstanding service to the Branches.

Presented by David Howarth, Chair of Professional Board
(top) Stan Rowden, Manchester, (bottom) Neville
Williams, South Wales, and Frank Fitzgerald, Presented by Chris Eady Juan Luis Ferrando Chacon
Teesside (not present)
Alan Robinson

Welding and Cutting 13 (2014) No. 4 231

229_235_WC4_TWI_News__ 15.07.14 16:52 Seite 232

TWI NEWS ··· TWI NEWS ··· TWI NEWS ··· T

Best STEM Ambassador: Best TWI/OU Foundation
Degree Student:
Craig Coppen

Recognising that the achievements of the award winners would not have been possible
without teamwork, and in a year of business growth for the TWI group enabled through
successful partnerships – particularly with the development of new facilities for the Na-
tional Structural Integrity Research Centre in Cambridge, new laboratories in Port Talbot
and Kuala Lumpur, and a strengthened professional association with The Armourers &
Brasiers’ Company – guest speaker Robert Sorrell, BP Vice President for Public Partner-
ships, focused on collaboration as the key to the advancement of materials sciences.
Matthew Haslett

Teacher of the Year Award 2013 Jo Bradshaw

on the right
Second place awarded to Jo Bradshaw, Tutor at Pembrokeshire
of the picture
College and Chairman of The Welding Institute South Wales at the awards
Branch ceremony.

Before embarking on a career teaching welding, Jo attended Pem-

brokeshire College where she studied the Level 3 Fashion and Tex-
tiles course – for which she was named Student of the Year! To
broaden her creative skill set, alongside this course, Jo also under-
took the Welding for Sculpture workshop where she first uncovered
her talent for welding.
Following the course, Jo gained a place at Swansea University to
study Surface Pattern Design. It was here that she was tested for
dyslexia after struggling to understand the reading lists and find
her way around the library. The tests indicated that Jo was dyslexic
and this played a big part in her decision to withdraw from the
course after just three months.
Unable to fulfil her university plans, Jo returned to Pembrokeshire
and after twelve months of doing odd jobs she undertook the NVQ
Level 2 in Welding at Prestige Training before going to Doosan Bab-
cocks for the Level 3 Improvership for Welding. Whilst working
with Babcocks, Jo travelled the length and breadth of the UK work-
ing on shutdowns on oil refineries and power stations as an appren-
tice welder.
Returning to Pembrokeshire to finish her apprenticeship with local
company Ledwoods, Jo took on the post of welding technician at
MITEC in 2009. She quickly progressed to the position of lecturer,
first working with the 14-16 school groups before taking course
tutor responsibility for the Level 1 and 2 courses. For the last three
years Jo has been course tutor for the intensive 40-week Level 3 pro-
gramme linked to local employers.
Still relatively new to teaching (she completed her PGCE in 2013 for
which she was awarded Student of the Year) Jo was then nominated
for the ‘Teacher of the Year’ award, as she is without doubt one of
the most hard-working, enthusiastic and passionate tutors to be
working at Pembrokeshire College. Jo is able to effortlessly blend
her natural flair for welding with an ability to impart her knowledge
to learners in a way that has seen the College secure numerous
WorldSkills finalists and one WorldSkills UK gold medal champion
since she joined MITEC just five years ago. In the BOC welding
competitions Jo’s learners have secured first place every year from
2009-2012 and Jo has had learners selected to train for the World-
Skills GB team for the last two years.
With a genuine interest in her learners, Jo attains a level of respect
from students that many far more experienced lecturers would envy.
Having worked on sites all over the UK, Jo has gained a wealth of
knowledge, experience and valuable industry insights beyond her
years. Through hands-on teaching methods Jo is able to pass this
first-hand knowledge of the sector directly onto her students and
thoroughly deserves the second place award for ‘Teacher of the
Year.’
Congratulations Jo!
Manchester branch report
April 2014
Bellows and expansion joints – fabricating for project programmes
Stan Rowden and John Cardwell
At the Manchester TWI Branch meeting in April 2014, the members
and guests were entertained by two branch committee members
who have over 100 years of manufacturing experience between
them. These were Stan Rowden FWeldI, who had worked in the ICI
Wilton Engineering Research Department, the Davy Power Gas
Corporation, Mather & Platt Research Laboratories, and Bird Preci-
sion Bellows (later Senior Bird Aerospace); and John Cardwell
FChInst AWeldI, who had worked at Simon Carves, J Pickup &
Sons, and Flexion.
Stan Rowden began the presentation by noting the various stan-
dards that could apply to the fabrication of bellows assemblies, the
most commonly used being the EJMA standard (Expansion Joints
Manufacturing Association, started in the USA in 1955).
Bellow and expansion joints could be used in environments varying
from high temperatures over 650C down to cryogenic temperatures
below -200C, be capable of withstanding high pressures up to 40bar,
or to be used in ultra high vacuum facilities, as well as being able
to cope with fatigue and vibration stresses. Additionally there could
be highly corrosive atmospheres to be contained, such as in flue gas
desulphurisation plant.

232 Welding and Cutting 13 (2014) No. 4

 229_235_WC4_TWI_News__ 15.07.14 16:52 Seite 233

S ··· TWI NEWS ··· TWI NEWS ··· TWI NEWS

New members
Name Member Grade Branch

Philippa Moore Fellow Eastern Counties

Jay C Shahani Fellow Overseas
George B Murray Fellow Overseas
Rajil Saraswat SenMember Overseas
Krzysztof B Miazga SenMember London
Robert Lloyd SenMember Overseas
Lemuel D Navajas SenMember Overseas
Thomas Etoubleau SenMember London
Nuno V Da Costa Pepe SenMember North Scottish
William Kelly Member North Scottish
Keith Philip Stephens Member Manchester
Bertrand Flipo Member Eastern Counties
Mohd Khalid Bin Mohd Nor Member Eastern Counties
Hany M H Elmantawy Member DUBAI
Benjamin Unthank IncMember Teesside
Paul Craigmyle IncMember North Scottish
Paul D Welsh IncMember North Scottish
Ajay Kumar G Kurup Technician Overseas
Paolo Bruno Serzio Technician Overseas
Nicholas Alex Mills Technician Southern Counties
Stan Rowden, John Cardwell, Stephen Billing (Branch Chairman), Alan Gray (Branch Cornelis Theodorus Maria Veeken Technician Overseas
Treasurer) and some smaller examples of expansion joints. Bryan Munro Technician North Scottish
Michael Christopher Hennessey Technician Liverpool
Simon John Wallace Technician Southern Counties
Gordon Lilley Technician Teesside
The materials involved could be fabric, rubber or plastic but per- Somasundara N Shanmuga Venkatesan Technician Overseas
haps of more interest to welders were the metal alloys including 316 George Edward Griffiths Technician Liverpool
George Stuart McKay Technician Overseas
and 321 stainless steels, Inconel 625, Incoloy 800 and 825, titanium Jason Harrison Technician North Scottish
alloys and also Monel 400. In the heating and ventilation industry, Atanu Kumar Nayak Technician Overseas
brass bellows were widely used. Myles Kelly Technician Scottish
Thomas Fox Technician Scottish
For many applications the units were fabricated by welding flat Demko Tol Technician Overseas
rings together to form the bellows, the sizes of which could range Alan James Paton Technician Overseas
from an outside diameter of 15-4000mm. The welding technique Christopher Otto Lindstaedt Technician Northumbria
Michael Scott Technician Northumbria
had to be selected taking into consideration the material and the
Anbalangan s/o Subramaniam Technician Overseas
section thickness, which could range typically from 0.5-50mm, and Lucky Leonard Zondo Technician Overseas
included autogenous TIG, plasma, manual metal arc, and resistance Christopher Kennedy Technician Southern Counties
spot and seam welding. Stephen Mackay Technician Teesside
Radha Krishnan Ramachandran Technician Overseas
The use of bellows assemblies was critical in many types of indus- Danny Beukelman Technician Overseas
trial plant, including aerospace, gas/oil installations, petrochemical Selvan Panchavarnam Guruswamy Technician Overseas
plant, iron and steel-making plants, industrial engines, heavy elec- Stephen Wheatley Technician Teesside
Ronald Thomas Cowell Technician Liverpool
trical plant and the power generation industry. Cassiano Dias De Aguiar Maciel Tehcnician London
John Cardwell began his part of the presentation by discussing many Paul Harry Douglas Dabbs Technician Overseas
of the critical design features of several types of bellows, including Alan Thain Technician North Scottish
Yap Hooi Heng Tehcnician Overseas
unrestrained units, as well as the hinged and gimballed ones, and Palani A/L Elumalai Technician Overseas
he explained some of the criteria for successful manufacture. Proper Gary Ramshaw Technician Northumbria
sequencing of the assembly was important, in order that full access Ryan Bellward Technician Eastern Counties
Vince Dawkins Technician Teesside
to the various joints required to be made in the later phases of the
Andrew D Pollitt Technician Manchester
fabrication was not impaired by sections already welded. Vitalijs Jefimovs Technician Eastern Counties
He commented on the Flixborough disaster, which occurred almost Martin Gilder Technician Eastern Counties
exactly 40 years ago and when 28 people were killed following the Stephen D Rice Technician West Midlands

failure of a bellows assembly. Later examination pointed to stress

corrosion cracking in the 316 stainless steel units due to the unex-
pected presence of nitrates in the service environment.
Several prestige applications were also highlighted, and these in-
cluded the gimbal joints in the Blue Streak space rocket built by the
UK and tested at Woomera in Australia in the 1950s. In blast fur-
naces there were frequently 12-16 expansion joints designed into
the tuyères, made of 316L and up to about 400mm in diameter. Bel-
lows units had also been fabricated for use in liquid metal nuclear
reactors. Of recent interest, because of the discovery of the Higgs-
Boson particle there last year, the bellows units fabricated some
years earlier (1200mm diameter) were manufactured for the cryo-
genic pipework in the FermiLab facility at CERN in Geneva.
This highly entertaining and educational presentation was thor-
oughly enjoyed by the audience.
Highland and Islands Branch
AGM
June 2014
It is hard to believe that the youngest UK branch is three years old
and to celebrate the occasion the renowned TWI stalwart, Rachel
Wall, was in attendance. This was a very busy evening with the
AGM, a talk and a very special presentation. All this took place
against the competition of the opening of football’s World Cup and
a rainy night. Despite all those issues 25% of the membership found
their way to the Chieftain Hotel in Inverness to welcome a local pre-
senter - Kenny Rodgers. His amusing talk titled ‘Compliance, Qual-
ity and Common-sense’ had been postponed from this time last year

Welding and Cutting 13 (2014) No. 4 233

229_235_WC4_TWI_News__ 15.07.14 16:52 Seite 234
TWI NEWS ··· TWI NEWS ··· TWI NEWS ··· T
but was still fresh and up to
date. It provoked much dis-
cussion and debate that
lasted long past the end of
the meeting. In fact it is still
causing amusement, compar-
isons and discussion such
was its sublime content.
The AGM returned the same
team, led by Crawford
Lochhead, for the next year
but most have expressed a de-
sire for the younger members
to take over. The excellent at-
tendance at the meetings
throughout the year and a rea-
sonable bank balance all point
to a healthy branch. This jus-
tifies Chris Eady’s statement,
Nikita MacDonald, Rachel Wall and Crawford at the inaugural meeting on 8
Lochhead September 2011, “It is long
overdue that a branch was
formed in the Highlands with all the industry around here.” So keen
to attend are some, that they came straight from work and, in some
cases, went back to complete their shift in the workshop.
A very special presentation took place because the branch had in-
stigated a welding competition between the local colleges within
the University of the Highlands and Islands (UHI). The two colleges
that took part were Inverness and North Highland (Thurso) which
are the two closest colleges within the UHI region that are training
welders. They are located more than 100 miles apart and the journey
distance would be the equivalent of travelling from TWI in Abing-
ton to Birmingham or Mablethorpe or Brighton or Abington, Ox-
fordshire but on some of the worst roads in the UK.
This competition was not in the same league as Worldskills, Ap-
prentice Welder or Weldcup but was set up to generate interest in
welding and competing in a friendly, open and helpful manner. The
prime reason for the competition was to give the students the feel
for what a ‘coded’ welder has to experience when testing out for a
job in the industry. The students are all in their first year of a fabri-
cation and welding course and were welding to the standard laid
down in the Scottish National Certificate units for MMA and
MIG/MAG processes. The first leg took place in Inverness, where
the MMA process was used, and the following week Thurso was
the location with their excellent Energy and Technology Centre fa-
cilities. This involved a six hour round trip but for three of the stu-
dents they had a further hour and a half to travel to get home from
the college. The North Highland College engineering premises are
so impressive that they have to be seen to be believed.
The competition was judged by Crawford Lochhead and Alex Mac-
Farlane on behalf of the Branch and two committee members do-
nated the prizes on behalf of their employers. Nikita MacDonald
from Inverness won the overall competition and a welding machine
for her personal use whilst Adam Bremner, Thurso, was the runner-
up. The winning shield was presented at the conclusion of the meet-
ing to Nikita with Rachel Wall and Crawford Lochhead in
attendance. Nikita said “This competition was a great opportunity
to get noticed by senior members of the industry. I’ve really enjoyed
meeting students from North Highland College UHI too. Tonight
was nerveracking getting to meet the local guys involved in the in-
dustry. I was very glad that Rachel (Wall) was there and grateful for
her support and guidance in a room full of men.”
234
We would like to reinforce Chris Eady’s editorial about the Skills
Show competition, in the 2013 issue 6, and his comments towards
the end of the article about the personal endeavours of the partici-
pants. The runner-up, Adam Bremner has taken up employment
with a local engineering company. But on reflection it is sad to re-
port, that even after winning this competition, Nikita has not been
offered a job. Is this the best our welding industry can offer females
making (and winning) their way into the sector?
Eastern Counties Branch
Lecture:
Earthquake engineering – an overview
Tim Courtney, Principal Consultant, Nuclear Risk,
Lloyds Register
14 May 2014
Tim Courtney works for Lloyd's Register Group Services Ltd as a
Principal Consultant dealing with nuclear risk. As the UK appears
to be committed to building more nuclear power stations the risk
associated with their operation becomes vital to us all. The accept-
ability of the risk posed by such high hazard industries has come
under increased scrutiny in the wake of the highly publicised
Fukushima incident that was triggered by an earthquake. Tim noted
that it is possible to design to withstand such large earthquakes, as
illustrated by the less well-known success story at Japan’s Onagawa
Nuclear Power Station.
He began his presentation with a definition of an earthquake as: ‘A
sudden release of strain energy that has been built up over many
years of gradual relative motion across a tectonic plate boundary or
across a geological fault.’ Pictures and maps showed how the heat-
ing and cooling of the earth’s crust caused the tectonic plate move-
ment and where on the globe the plate intersections were to be
found. In the 24 hours preceding the talk there had been 31 events
(magnitude 2.5+), mostly around the Pacific rim (earthquakes are
not at all uncommon).
He described the different plate movements (divergent, convergent
transformational) and the wave types which were generated (eg the
relatively fast moving compressive P-wave - can give a few seconds
warning of an imminent quake).
There are many perceptions and misconceptions, for example:
• Is the frequency of earthquakes increasing? (no)
• Can earthquakes be predicted? (yes, on known faults but not with
accuracy on timing)
• Can earthquakes be withstood? (yes, given selection of a suitable
site)
In view of the responses to these questions the need to assess the
risks associated with earthquakes is crucial. Risk being the Proba-
bility times the Consequence of an event. This discussion of risk led
Tsunami approach-
ing the shore
Welding and Cutting 13 (2014) No. 4
 229_235_WC4_TWI_News__ 15.07.14 16:52 Seite 235

S ··· TWI NEWS ··· TWI NEWS ··· TWI NEWS

to definitions of magnitude (The Richter logarithmic scale indicating Tim had been fortunate to visit this plant post earthquake and his
the amount of energy released) and the intensity (categorising the closing remarks on this success story were:
effects on structures and effects felt by people). The latter varies ac- • The plant staff are very knowledgeable, professional and with ob-
cording to distance from epicentre and local soil conditions. Useful vious commitment to safe operation
engineering measures are those which allow prediction of forces • The structural elements were remarkably unaffected given the
and displacements; acceleration time histories response spectra are magnitude and duration of the ground motion
often utilised. • The plant’s safety systems functioned successfully during and
Tim then went through the steps taken in determining the risks to after the earthquake
a nuclear plant, as a result of an earthquake at a planned building • The seismic performance of the plant’s non-safety systems and
site. He described how data was collected on the history of events, lower class seismic systems indicates significant seismic margins
which enabled estimates to be made on the strength and position in design of safety-related systems
of future events, and data on the local ground conditions. Then • Tsunami impact was more significant than earthquake damage
there was the assessment of the safety critical items of the plant, • Seismic upgrades contributed to limiting the earthquake damage
which led to the determination of how those buildings and systems to a few instances, despite the very large earthquake of 11 March
could be protected. There is considerable conservatism in the ap- 2011
proach taken giving confidence that the risks can be managed to ac- An excellent set of pictures, graphs and tables made following this
ceptable levels and the structure will withstand the earthquake. quite complex subject very easy and Tim was bombarded with
Tim then discussed the seismic behaviour of the Onagawa nuclear many questions. If the approaches he outlined are followed then I
power station which, located 120km north of Fukushima Daiichi, believe we can have confidence in the safety of future nuclear
was the closest nuclear facility to the epicentre (80km) of the great plants.
eastern earthquake and tsunami of 11 March 2011. It probably ex-
perienced the most severe ground movement of any of the nuclear J Weston
power plants and a 13 metre tsunami. The operators of this plant
had heeded historical tsunami indications and built the installation
relatively high above sea level (adding to costs). They had revised
the risk assessment calculations during the life of the plant and Deceased
made the appropriate modifications. As a result the plant was shut
down safely and suffered relatively little damage. The monitoring Name Grade Joined Branch
instrumentation indicated that the acceleration recorded at various
Peter Nursall Senior Member 1951 East Midlands
levels within the structures during the event closely matched those Leslie Allan Spooner Senior Member 1955 South Wales
predicted by the assessing engineers.

Welding and Cutting 13 (2014) No. 4 235

236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 236
SPECIALIST ARTICLES
Characterisation of magnetically deflected arcs
and application potential for the brazing of galvanised
steel sheets
As part of an AiF project, investigations are being conducted into the sta-
bilisation of the arc attachment by means of magnetic oscillation. An in-
novative and specially cooled TIG demonstrator torch with adjusted shield-
ing gas coverage and a powerful magnetic field module for the quick mag-
netic oscillation of the arc was developed and tried out for this purpose.
Various diagnostic methods for the characterisation of the arc deflection
and of the energy input into the workpiece are presented as well. Only
with the aid of the “split anode procedure“ it is possible to quantify the
exact deflection of the arc and of the energy input. Optical evaluation of
the arc deflection is not suitable for the prediction of the energy input into
the workpiece. In brazed flange seams on galvanised steel sheets, it was
possible to highlight the improvement potential of a magnetically oscillated
arc compared with the conventional tungsten inert gas (TIG) process.
1 Introduction
In comparison, the arc is only rarely used for the braz-
ing of thin sheets with fillet seams in lap and flange joints
in spite of its costs being substantially lower than those of
the laser [1]. Although different arc process variants have
been developed and utilised in recent years, they have
been pushed back once again in the meantime particularly
due to the refinement of the diode lasers. This is caused
by the fact that the process reliability, especially at high
advance speeds, is limited by the irregular attachment
and burning-through of the arc, Fig. 1. The consequences
of these process instabilities are defective joints which re-
quire complicated and cost-intensive remachining. A suf-
ficient and uniform energy input into both sheets is nec-
essary in order to increase the process reliability.
The deflection of the arc offers the possibilities of forc-
ing a stable arc attachment and influencing the energy in-
put into the workpiece. Although the mechanical move-
ment of the electrode makes it possible to deflect the arc
and to prevent the one-sided attachment of the arc, this
only gives rise to low oscillation frequencies which lead to
oscillation tracks on the sheet at high advance speeds. In
contrast, the magnetic oscillation [2-5] offers the possibility
of forcing a stable arc attachment even at high oscillation
frequencies. Any disturbing influences are compensated
by the superimposed permanent magnetic oscillation of
236
THE AUTHORS
Dipl.-Ing. Martin Häßler studied Mechanical En-
gineering at the Dresden University of Technology
with the advanced subject of Production Technolo-
gy from 2005 to 2011. He has worked as a scienti-
fic employee in the Arc Processes working group
at the Professorship of Joining Technology and As-
sembly at the Dresden University of Technology
since 2011. He deals with the investigation and
application of modern arc processes. Not only
diagnostic methods but also numerical simulation
are utilised in this respect.
Dr.-Ing. Sascha Rose studied Mechanical Engi-
neering at the Dresden University of Technology.
He has worked as a scientific employee at the Pro-
fessorship of Joining Technology and Assembly at
the Dresden University of Technology since 2008
and is currently the head of the Arc Processes wor-
king group there.
Prof. Dr.-Ing. habil. Uwe Füssel is the director of
the Professorship of Joining Technology and As-
sembly at the Institute of Surface and Fabrication
Technology (IOF) at the Dresden University of
Technology in Dresden/Germany.
the arc, Fig. 1. A few commercial systems with magnetic
arc deflection are known [6; 7] and partially available [8;
9]. However, these systems have only reached compara-
tively low arc oscillation frequencies until now. Moreover,
for deflected arcs, there is no knowledge about the influ-
ences exerted on the shielding gas flow and on the energy
input into the workpiece. In particular, the characterisation
and understanding of the arc deflection are necessary for
the selection of favourable oscillation parameters. These
aspects were processed as part of the AiF project 16.779 B.
2 Objective and solution path
The aim was to increase the process reliability in the
case of TIG brazing using the periodic magnetic deflection
of the arc. This was intended to open
up new areas of application for the TIG
process, to reduce the remachining and
to increase the advance speed.
An innovative and well-cooled TIG
demonstrator torch with a powerful and
Fig. 1 • Production of a defined arc
attachment on the workpiece using the
periodic oscillation of the arc.
Welding and Cutting 13 (2014) No. 4
236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 237

highly dynamic magnetic field module for the quick oscil-

lation of the arc as well as adjusted shielding gas coverage
was developed during the work. The process gas flow and
the influences exerted on it by the deflected arc were
analysed with an arc model in ANSYS CFX and were vali-
dated with modern arc diagnostics, such as the schlieren
technique and the particle image velocimetry (PIV)
method. The findings were implemented and tried out in
an improved shielding gas nozzle. Moreover, the genera-
tion and control of the magnetic field as well as new mag-
netic core materials were analysed and were improved
with regard to the large and quick deflection of the arc. Fig. 2 • Magnetic field measurement using a Hall sensor; left: influence of the
Investigations were subsequently conducted on the designing parameters, right: determination of the magnetic flux density on the
demonstrator.
demonstrator in order to quantify the arc deflection. In
addition to the arc deflection which has primarily been
determined optically on high-speed photographs until
now, the deflection of the arc was also established by tak-
ing current and energy input measurements on the work-
piece. The split anode method used for this purpose per-
mits the exact measurement of the current and energy in-
put distributions into the workpiece and thus the quan-
tification of the arc deflection. The sensitive parameters
for influencing the arc deflection were established by vary-
ing the process parameters.
Parameters suitable for the brazing of reference com-
ponents using an oscillating arc were derived and tried
out on the basis of the results. The improvement in the
tolerance capability of the joining process due to the mag-
netic oscillation of the arc in comparison with the con-
ventional process for the brazing of galvanised steel sheets
in flange joints was investigated in tests. Not only the lat- as the frequency rises is caused by the increase in the in- Fig. 3 • Compari-
eral torch misalignment in relation to the groove, the ductive resistance in the coils. Therefore, the supply volt- son of the maxi-
height misalignment and the brazing gap between the age provided by the power section is no longer sufficient mum measured
sheets, but also the brazing speed were varied. in order to maintain the stipulated amperage. magnetic flux
densities for coils
It was recognised that, in the future, the magnetic field
which have ferri-
3 TIG demonstrator will have to be produced by coils with a low number of
tic (iron core) and
3.1 Magnetic field module and controller windings but with a considerably stronger power module soft-ferritic core
In order to design a magnetic field module for high os- which will have high voltage reserves. An AC (alternating materials and are
cillation frequencies of the arc, the designing parameters of current) welding power source is used for this purpose. operated with si-
the coil (including the coil shapes, the magnetic core mate- The advantage of this setup is that the modified welding nusoidal current
rials as well as the magnetic core shape) are investigated on power source satisfies all the safety requirements and can courses.
a special measuring stand, Fig. 2 left. The magnetic flux den- be operated in a welding technology environment without
sity is established using a Hall sensor (type: Honeywell any special restrictions. The quick change in the orienta-
SS496A1) enclosed in a plastic housing. Recesses are located tion of the magnetic field (demagnetisation) is supported
in the housing in order to accommodate two opposite coils by a load resistance in a series connection in the power
with magnetic cores. The magnetic field on the demonstrator circuit of the coil, Fig. 4.
was also measured in another test rig, Fig. 2 right.
The utilisation of soft-ferritic core materials which are
typically used as the core material for high-frequency ap-
plications (f > 1 kHz) does not offer any advantages in
comparison to normal iron cores for the intended target
frequencies in the three-digit hertz range. At a frequency
as from 100 Hz, a steep drop in the maximum attainable
magnetic flux density can be observed with both core ma-
terials, Fig. 3. The decrease in the magnetic flux density

Fig. 4 • Setup of the magnetic arc oscillation device

consisting of a modified AC welding power source
(left), a load resistance and the demonstrator.

Welding and Cutting 13 (2014) No. 4 237

236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 238
SPECIALIST ARTICLES
Fig. 5 • Numerical 180° model of the TIG torch.
3.2 Shielding gas flow with a deflected arc
The ANSYS CFX 13 software was used for the numer-
ical investigations into the shielding gas flow with a de-
flected TIG arc. In the model, a simplified TIG welding
torch (consisting of the cathode, the workpiece as well as
the shielding gas nozzle and the surrounding flow space)
is set up in a mirror-symmetrical model (180°), Fig. 5. The
calculation of the flow is based on the equations for the
energy, mass and momentum conservation. The equation
system for the flow mechanics must be extended for the
investigation into arc processes so that the effects of the
arc column and the plasma flow (electrodynamics) are
also taken into account. A magnetohydrodynamic model
is used for this purpose. The underlying equations were
published in detail in [10; 11]. Not only the diffusion but
also the turbulent mixing must be taken into consideration
for the modelling of the mixing of shielding gas with at-
mospheric gases. In this respect, it is necessary to take
account of the diffusion depending on the gas tempera-
ture. The temperature-dependent diffusion coefficients
of argon/air mixtures according to Murphy [12] are used.
The magnetic field which the coils produced on the
demonstrator was measured with the aid of the Hall sensor
and an equivalent, external homogeneous magnetic field
of 5 mT was implemented in the model.
The numerical investigations show a substantial de-
terioration in the shielding gas coverage towards the arc
Fig. 6 • Numerical flow model (top) showing the deterioration in the shielding gas coverage as a consequence of the arc deflection and validation of the
gas flow by means of PIV measurement (bottom).
238
deflection due to the external magnetic field, Fig. 6 top.
High oxygen concentrations are calculated due to the in-
creased diffusion of oxygen caused by the high arc tem-
peratures and air swirling phenomena as a consequence
of turbulences in the region of the arc deflection. There is
no lateral suction effect from the non-deflected region of
the shielding gas flow into the arc. The shielding gas cov-
erage on the side not affected by the arc remains very
good. In PIV investigations, it was possible to experimen-
tally confirm this numerically calculated flow field, Fig. 6
bottom. Moreover, strong turbulence of the lateral flow
as a consequence of the arc deflection was established in
schlieren investigations.
A comparison of the variants with different shielding
gas nozzle shapes in combination with different flow rates
has shown that the use of a shielding gas nozzle geometry
widened in the deflection direction of the arc in combi-
nation with a laminarisation insert for the uniform distri- Fig. 7 • Standard
bution of the gas flow leads to a distinct improvement in automatic weld-
ing torch (left)
the shielding gas coverage. Moreover, the larger shielding
and adapted TIG
gas nozzle geometry serves to avoid any thermal over-
welding torch
loading of the nozzle as a result of the arc deflection. Due with a newly de-
to the good cooling of the nozzle, a shielding gas nozzle veloped shielding
made of ceramic does not have to be used in the tests. gas nozzle and an
The work was performed with contact ignition. However, improved magne-
it is necessary to utilise a ceramic nozzle for the non-con- tic field module
tact ignition of the arc (HF ignition). for magnetic arc
oscillation (right).
Welding and Cutting 13 (2014) No. 4
236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 239

Fig. 8 • High-
speed camera
photographs of
the magnetic arc
deflection at a
welding current
of 100 A and an
oscillation fre-
quency of 100 Hz
on structural
steel.

3.3 Setting-up and testing of the demonstrator

The findings from the optimisation of the flow and
from the designing of the magnetic field module were im-
plemented in a demonstrator torch, Fig. 7. A modified au-
tomatic welding torch with an altered shielding gas nozzle
and an adapted magnetic field module is used. The shield-
ing gas nozzle consists of two copper components, a
screw-on heat sink with water cooling and a push-on noz-
zle. The cross-sectional area of the shielding gas outflow
is widened towards the arc deflection. The better shielding
gas coverage is achieved in this way. An additional lattice
insert in the shielding gas nozzle ensures a laminar shield-
ing gas flow which is uniform around the circumference.
The magnetic field module (consisting of two coils with
magnetic cores and one magnetic yoke) is axially fixed to
the torch.
For the setting-up of the magnetic field module, a
temperature-resistant winding wire (temperature load- operation are used. The base material is mild steel (1.0037). Fig. 9 • Compari-
bearing capacity: up to 180°C, thermal class: H) was In spite of the utilised ferritic base material, large arc de- son of camera
wound on to a structure consisting of a solid iron core flections on both sides of the welding torch can be ob- photographs and
and an electrical sheet. 35 windings made of the enamel- numerically cal-
served on the photographs. In loading tests, it was possible
culated arc radia-
insulated copper wire with a diameter of 1.25 mm are to operate the demonstrator reliably at a maximum welding
tion without
used in each case. This results in a low inductance of the amperage of 200 A with an oscillating arc.
and with arc de-
coil. The structures have recesses in the magnetic yoke so flection.
that they can be axially fastened to the torch without dis- 4 Diagnosis of the arc deflection
turbing the magnetic flux. So-called pole shoes lead to The previously practised assessment of arc deflections
the local compression of the magnetic field in the region consists of the optical evaluation of the arc shape. Fig. 9
of the arc. In order to prevent any damage to the magnetic shows the determination of the optical deflection in the
cores or the coils due to the energy input of the arc or to experiment and in the numerical model on the basis of
the ohmic heating of the coil, direct cooling with water the arc radiation. By defining an external magnetic field
was integrated into the magnetic cores. and an arc at the same amperage as in the experiment,
Fig. 8 shows high-speed photographs of the oscillating an arc with an almost identical shape is predicted in the
arc for eight points in time uniformly distributed across a numerical model. However, the arc shape on the photo-
sinusoidal oscillation cycle. A welding current of 100 A, graph changes depending on the exposure time of the
an electrode clearance of 5 mm and an oscillation frequen- camera. Therefore, it is no longer possible to make a clear
cy of 100 Hz at a maximum coil current of 10 A in sinusoidal description of the optical arc deflection. The optical eval-

Welding and Cutting 13 (2014) No. 4 239

236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 240

SPECIALIST ARTICLES

a new graph. The current and energy input distributions

can thus be portrayed in steps, Fig. 11.
The representation of the current distribution in the
bar view permits the visualisation of the arc deflection as
well as the comparison of the intensity with the reference
arc and portrays the principle of the courses of the current
and energy distributions on the workpiece. Fig. 11 shows
that the current distribution on the workpiece is shifted
and, all in all, widened by the magnetic deflection of the
arc. Compared with the non-deflected arc, this results in
a flatter current distribution with a lower maximum cur-
rent density.
Fig. 12 shows those distributions of the current and
the heat flux inputs into the workpiece with a deflected
arc which were determined experimentally using the split
anode procedure. In each case, the experimentally deter-
mined current and heat flux distributions are represented
uation of the arc deflection must be called Fig. 10 • Test setup for measuring using two range bars in which 50% (green) or 90% (red) of
into question, above all in the case of arcs the electric current density and the the total value is reached. One point on the workpiece sur-
with extreme deflections or kinked arc heat flux density [10]. face illustrates the locations (root) of the maximum current
columns.
The energy input into the component
and thus the distribution of the heat flux
density on the workpiece surface are de-
cisive for the welding results. The test set-
up of Nestor [13] with the refinements of
the Dresden University of Technology ac-
cording to [11; 14] is used for measuring
the electric current density and the heat
flux density. Two copper plates which are
galvanically and thermally decoupled
from each other are set up for this pur-
pose. The arc is manipulated perpendi-
cular to the separation plane across the
plates, Fig. 10.
For rotationally symmetrical arcs, the
electric currents and the heat fluxes can
be converted into a radial current density
distribution depending on the distance
away from the separation plane of the
copper plates. However, unsymmetrical
distributions of the current and heat flux
densities on the workpiece must be ex-
pected with deflected arcs. Thus, it is not
possible to convert the measured curve
into a distribution curve using the
Abelian integral. A new evaluation ap-
proach with which the current and ener-
gy distributions on the workpiece can be
visualised even for arcs which are not ro-
tationally symmetrical was developed
thereafter. In this respect, it is assumed
that the deflected arc alters only slightly
perpendicular to the deflection direction.
Individual sections are formed around
the common intersection point of the dis-
tribution curves. The ranges correspond Fig. 11 • Evaluation of the current and heat flux distributions for arcs which are not rotationally symme-
to different proportions of the total value trical, established using the split anode procedure; top: reference measurement of a non-deflected arc,
and are portrayed as a range bar chart on bottom: magnetically deflected arc with a shifted and widened current distribution.

240 Welding and Cutting 13 (2014) No. 4

236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 241

Fig. 12 • Experimentally (top) and numeri-

cally (bottom) determined arc deflections for
a magnetically deflected 100 A TIG arc; left:
optical arc deflection, centre: deflection of
the current input into the workpiece, right:
deflection of the heat flux input into the
workpiece.

input (purple) and heat flux input (or-

ange). In contrast with the optical arc de-
flection (cyan), a substantially smaller de-
flection of the arc is determined for the
current and heat flux distributions on the
workpiece. Therefore, the optical arc de-
flection is not suitable for predicting the
energy input location on the workpiece. In contrast with
the root of the electric current distribution, the location of
the maximum heat flux input (orange) is shifted more ex-
tremely due to the one-sided outflow of the hot plasma
gas in the deflection direction over the workpiece.

5 Parameter setting
For the practical application of the arc oscillation tech-
nique, it is necessary to know the essential factors for in-
fluencing the arc deflection. For this purpose, the sensi-
tivity of the arc deflection as well as the current and energy
inputs with altered welding process parameters are in-
vestigated without and with arc deflection. An external
magnetic field of 2.5 mT (coil current: 2 A) is applied with
a defected arc. The base material, the welding amperage,
the electrode clearance, the pole shoe position, the cath-
ode angle, the shielding gas volume flow as well as the
shielding gas type are altered.
With an equally large external magnetic field, tests on
a ferritic (1.0037) base material show a smaller arc de-
flection than on an austenitic steel (1.4301), Fig. 13. The Fig. 13 • Determination of the optical arc deflection and the penetration
cause of the small arc deflection on ferrites results from profile on various steel materials, in each case without and with arc deflec-
tion; top: ferritic steel (1.0037), bottom: austenitic steel (1.4301).

Fig. 14 • Ex-
perimentally
determined
distributions
of current and
heat flux in-
puts as well as
arc deflections
for different
amperages.

Welding and Cutting 13 (2014) No. 4 241

236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 242
SPECIALIST ARTICLES
an increased magnetic stray flux through the base material
as a consequence of the better magnetic conductivity
(magnetic permeability μr) of the ferrite. This decreases
the magnetic field available for the arc deflection in the
region of the arc. Therefore, it is necessary to adjust the
arc oscillation parameters with an altered base material.
Moreover, the deflection of the arc leads to the surface
deformation of the seam. In the transverse section, it is
also possible to observe a wider and simultaneously flatter
penetration profile with a deflected arc, Fig. 11. Below,
Fig. 15 • Influence of the torch misalignment on the brazability; right: tolerance field of the brazing process
without and with a magnetically oscillated arc, left: sheet specimens with a torch misalignment of 0.5 mm.
Fig. 16 • Influence of the sheet gap size on the brazability; right: tolerance field of the brazing process
without and with a magnetically oscillated arc, left: brazed sheet specimens with a gap of 1.0 mm bet-
ween the joining members.
242
the split anode procedure is used for the analysis of the
energy input profile on the workpiece and of the arc de-
flection.
Fig. 14 shows the influences exerted by the current
and heat flux densities as well as by the arc deflection for
different amperages without and with arc deflection. There
is no linear connection between the utilised welding am-
perage and the arc deflection. If the welding amperage is
increased from 100 A to 125 A, the shifting of the root on
the workpiece remains nearly constant. Thus, it is not pos-
sible to deflect the arc by just any distance
and this constitutes a process limit. At
the same time, the deflection limit can
be used in order to form a stable root on
the workpiece which cannot be influ-
enced from outside even by process fluc-
tuations or disturbances.
The arc deflection is modified not only
by the arc amperage but also by an alter-
ation in the electrode clearance or in the
position of the pole shoes as well as by
the change to another shielding gas. With
a deflected 100 A TIG arc, the increase in
the electrode clearance from 5 mm to 8
mm leads to twice the arc deflection
while it is halved when the shielding gas
composition is changed from argon to an
argon/helium mixture (50% / 50%). In
contrast, alterations in the cathode angle
or in the shielding gas volume flow are
negligible in relation to the attainable arc
deflection.
6 Component testing
First of all, the suitability of various
brazing materials was checked in tests
relating to the brazing of galvanised steel
sheets in flange joints. CuAl8 and CuSn6P
brazing materials were used in addition
to the standard CuSi3Mn1 brazing mate-
rial. Tests with CuSi3Mn1 and CuAl8
brazing materials showed a low repro-
ducibility. Therefore, the CuSn6P brazing
material was utilised for further tests in
order to improve the tolerance capability
of the joining process using the magnetic
oscillation of the arc. Hot-dip-galvanised
(DX54+Z100) and electrogalvanised
(DC06+ZE75/75 B PO) steel sheets with
and without phosphated surfaces were
brazed. The 0.8 mm thick sheets were
provided with a flange radius of 2 mm.
Not only the lateral torch misalignment
in relation to the groove, the height mis-
alignment and the brazing gap between
the sheets but also the brazing speed
were varied. Wires with a diameter of 1.6
mm were used as the brazing material.
The distance between the electrode and
Welding and Cutting 13 (2014) No. 4
236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 243

the top side of the sheet was 1 mm. A

sinusoidal coil current at a mean am-
perage of 2 A (2.5 mT) was used with
the magnetically oscillated arc. An os-
cillation frequency of 100 Hz was stip-
ulated in order to prevent any unde-
sirable arc oscillation tracks on the
top side of the sheet even at high ad-
vance speeds.
It was possible to establish that
the magnetic oscillation of the arc
permits slightly wider tolerances than Fig. 17 • Overview of the alteration in the process tolerance field during the brazing of galvanised sheets in
in the conventional TIG process with- flange joints using a magnetically oscillated arc.
out any oscillation, above all during
the positioning of the torch over the single V flange groove, a slight deterioration in the brazing results is also observed
Fig. 15. While hardly any deviation from the central posi- because of a wider energy input into the sheet. Thus, the
tion is tolerated in the conventional process without any wire is melted only insufficiently. It is therefore necessary
periodic arc deflection, electrode position deviations of to adjust the filler material and the welding amperage to
up to 0.5 mm from the central position can be managed the altered energy distribution.
using a magnetically oscillated arc. Moreover, the periodic Moreover, investigations with various brazing mate-
deflection of the arc leads to a better gap-bridging capacity rials show that the influences which can be exerted on
so that any gaps between both sheets can be compensated the process are extremely dependent on the flow behav-
for in a better way, Fig. 16. iour of the brazing material. Hardly any improvements
On the other hand, no influence was established in can be achieved particularly with the „standard“
relation to the compensation for a height misalignment CuSi3Mn1 brazing material. A low viscosity of the brazing
between both joining members. At high brazing speeds, material (e.g. CuSn6P) is necessary in order to make use

Now including DIN EN

ISO 9001:2008-12

Thermal spraying – Standards and Technical

Bulletins for Quality Assurance
Thermal spraying protects materials from wear, corrosion, extreme temperatures, Thermal spraying – Standards and
Technical Bulletins for Quality Assurance
chemical loading, and other effects. The DIN EN and DIN EN ISO Standards included
in this CD-ROM, and their corresponding DVS technical rules cover all significant as-
Order number: 509770
pects of this topic, such as material characteristics, test methods, surface treatment,
ISBN: 978-3-87155-977-6
classification, delivery conditions, etc., with a special emphasis on quality and safety.
Most of the documents are available in both English and German. The CD-ROM Price: 199.00 Euro
comes with yearly updates.
System requirements:
State of : September 2013. Windows-PC; Windows XP, Windows Vista or Windows 7;
On subscription only. Purchase implies subscription for at least one year. 128 MB RAM; no hard drive memory requirement.

DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf

T +49. (0)2 11. 15 91-162 • F +49. (0)2 11. 15 91-150 • vertrieb@dvs-hg.de • www.dvs-media.eu

Welding and Cutting 13 (2014) No. 4 243

236_244_WC4_SpA_w20000035__ 15.07.14 16:56 Seite 244
SPECIALIST ARTICLES
of the advantages of a magnetically oscillated arc while
extending the process tolerance field. It is thus necessary
to adjust the brazing material to the process in order to
exploit the advantages of a magnetically oscillated TIG
arc to the full.
7 Concluding remarks
Various possibilities of characterising the arc deflec-
tion were investigated within as part of the project. It was
recognised that the optical evaluation of the arc deflection
is not suitable for predicting the energy input into the
workpiece. The arc deflection and the location of the en-
ergy input can only be detected correctly with the aid of
the split anode method. In brazing experiments on flange
seams, the efficiency of the demonstrator was proven and
the improvement potential compared with a conventional
TIG process was highlighted. It was possible to show that
the periodic deflection of the arc serves to widen the tol-
erance field in which a high-quality brazed seam can be
produced. Above all with regard to the still manageable
gap-bridging capacity between the joining members and
to the positioning of the torch above the flange, it was
possible to achieve improvements in comparison with
the conventional process without any arc deflection. How-
ever, the improvements are extremely dependent on the
flow behaviour of the brazing material. Therefore, it is
necessary to adjust the brazing material to the oscillated
process.
Literature
[1] Hamann, W.: Plasmalöten in der Fertigung der Automo-
bilindustrie. Firmenschrift EWM HIGHTEC WELDING,
Mündersbach 2003.
[2] Hughes, R. V., and R. P. Walduck: Electromagnetic arc path
control in robot plasma welding. The Int. J. of Advanced
Manufacturing Technology 1 (1985), No. 1, pp. 9/25.
[3] Kang, Y. H., and S. J. Na: A study of the modeling of mag-
netic arc deflection and dynamic analysis of arc sensor.
Wdg. J. 81 (2002), No. 1, pp. 8 s/13 s.
[4] Tseng, C. H., and W. F. Savage: The effect of arc oscillation.
Wdg. J. 50 (1971), No. 11, pp. 777 s/86 s.
[5] Dilthey, U.: Beitrag zur Lichtbogensteuerung durch trans-
versale Zusatzmagnetfelder bei mechanisierten Lichtbo-
genschweissverfahren. Diss., TH Aachen 1972.
[6] Mckelvie, Y. D.: Lichtbogen-Schutzgas-Schweißgerät mit
magnetischer Ablenkung des Lichtbogens. Patent DE
935688, 1952.
[7] N. N.: Einrichtung zur magnetischen Ablenkung eines
Schweißlichtbogens. Patent DE 1615485, 1967.
Correction
In the last issue of Welding and Cutting 3/2014, p. 171, we mistook two author
photos with each other (Univ.-Prof. Dr. med. Thomas Kraus and Dipl.-Ing. Klaus
Lenz). We apologise to the authors and our readers. Please find the correction to
the following article:
“Characterisation of the biological effect of ultrafine particles in welding fumes
after controlled exposure – Effect of the MIG welding of aluminum and the MIG
brazing of zinc-coated materials“
244
[8] N. N.: Cyclomatic Product Line. Company information, In-
ternet: http://www.jetline.com/product.aspx?i=14523&c=
31&pp=8&sb=0&p=0. Jetline Engineering, Irvine/USA, ac-
cess: September 25, 2013.
[9] N. N.: Cergy-Pontoise Cedex/France 2008, http://www.saf-
airliquide.com/FR/prod_mater/fiches/notvent/produc-
tivite/9231_1.pdf.
[10] Füssel, U., u. a.: Numerische und experimentelle Unter-
suchungen zur gezielten Beeinflussung des Lichtbogens
und des Schweißbads beim Schutzgasschweißen durch die
Schutzgaseigenschaften und die Schutzgaszusammenset-
zung. Abschlussbericht, IGF-Nr. 15.774 B/DVS-Nr. 03.082.
IOF, Dresden 2010.
[11] Schnick, M.: Numerische und experimentelle Verfahrens-
und Brennerentwicklung beim Plasmalichtbogen-
schweißen. Diss., TU Dresden 2011.
[12] Murphy, A. B.: Transport coefficients of air, argon-air, nitro-
gen-air, and oxygen-air plasmas. Plasma Chemistry and
Plasma Processing 15 (1995), No. 2, pp. 279/307.
[13] Nestor, O. H.: Heat intensity and current density distribu-
tions at the anode of high current, inert gas arcs. Linde
Company, Division of Union Carbide Corporation, Indi-
anapolis, Indiana/USA 1961.
[14] Zähr, J., et al.: Numerical investigations of process gases and
their influence on TIG-welding. In: Mathematical modeling
of weld phenomena 9 (ed. Cerjak, H. and N. Enzinger), pp.
111/25. Proceedings, 9th Int. Seminar on Numerical Analy-
sis of Weldability (Graz 2009), ISBN 978 3 85125 127 2, pp.
111/125, Verlag d. Techn. Univ. Graz, Graz/Austria 2011.
[15] Dreher, M., et al.: Methods and results referring the shield-
ing gas flow in GMAW - Part I: Methods. IIW Doc. XII 2053
12.
ACKNOWLEDGEMENTS
The IGF Project IGF 16.779 B / DVS
Number 03.097 of the research asso-
ciation „Forschungsvereinigung
Schweißen und verwandte Verfahren
des DVS, Aachener Straße 172,
40223 Düsseldorf“ was, on the basis
of a resolution of the Lower House
of the German Parliament, promoted by the German Ministry of
Economic Affairs and Technology via the Industrial Research Al-
liance (AiF) within the framework of the programme for the pro-
motion of joint industrial research and development (IGF).
We would like to express our gratitude for the promotion and sup-
port during the execution of the research work. Furthermore, our
thanks go to the firms collaborating within the framework of the
project-accompanying committee for the interesting discussions
and suggestions relating to the execution of the project as well as
for the support in the form of contributions in kind and services.
Dipl.-Ing. Univ.-Prof.
Klaus Lenz Dr. med.
Thomas Kraus
Welding and Cutting 13 (2014) No. 4
245_249_WC4_SpA_w20000034__ 15.07.14 16:59 Seite 245
One-sided Nd:YAG laser beam welding for the
manufacture of T-joints made of aluminium alloys for
aircraft construction
In aircraft construction, T-joints between aluminium alloys are manufac-
tured either by riveting or by two-sided laser beam welding. This article
describes one-sided Nd:YAG laser beam welding as a method of manufac-
turing skin/clip joints between the AA6156-T4/AA6013-T6 and AA2139-T3/
AA6013-T6 aluminium material combinations in T-joint designs. One fun-
damental problem associated with this procedure is the high porosity level
in T-joints executed by means of one-sided laser beam welding. It is shown
that the formation of pores is determined not only by the types of the alu-
minium alloys, the variations in the welding directions and the preparation
of the joining faces but also by an excessive angle of incidence between
the laser beam and the skin field. The laser beam must be transmitted in
the bonding region between the clip and the skin field in order to reduce
the porosity level by decreasing the angle of incidence.
1 Introduction
Two-sided laser beam welding for the manufacture of
skin/stringer joints between aluminium alloys in fuselage
structures has proven its worth in aircraft construction
[1...3]. Defect-free and symmetrical laser beam welds can
be achieved with this process [1...4]. The question of the
extent to which skin/clip joints made of AA6156-T4/
AA6013-T6 and AA2139-T3/AA6013-T6 in T-joints can be
executed by means of one-sided Nd:YAG laser beam weld-
ing in cw operation was examined within the framework
of this feasibility study. The intended use of clips (sheet
metal parts attached to the skin field perpendicular to the
stringers) is to have pressure frames assembled on them.
Aluminium alloys from the AA6XXX family, e.g. the
AA6156-T4 and 2 AA6013-T6 aluminium alloys used in this
paper, are classed as weldable [1...5]. The restricted weld-
ability of AA2024 led to the development of the AA2139
aluminium alloy [2] which was also utilised during the in-
vestigations described here. The objectives were to adjust
Table 1 • Type of preparation of the joining faces and parame-
ters for laser beam welding.
Type of preparation of the joining faces
Variant 1 No machining, only cleaning with
acetone
Variant 2 Skin and clip ground manually,
cleaning with acetone
Variant 3 Skin and clip ground mechanically,
cleaning with acetone
Variant 4 Skin blasted with SiO2 beads and clip
ground manually, acetone cleaning
Variant 5 Skin and clip blasted with SiO2 beads,
cleaning with acetone
Laser beam welding parameters
cw power 3.0 kW
Focal length 200 mm
Focus position 0.0 mm
Advance speed 1.2 - 3.0 m/min
Wire feed 4.0 - 5.0 m/min
Helium flow rate 10 - 25 l/min on the radiation exposure side,
10 - 15 l/min on the rear side
Angle and height 25° at 0.7 mm in relation to the skin
of incidence
Welding and Cutting 13 (2014) No. 4
THE AUTHORS
Dipl.-Phys. Volker Ventzke acquired his final qualifi-
cation as a graduate physicist at the University of Ham-
burg/Germany. Since 1996, he has been working as a
scientist at the Helmholtz Centre in Geesthacht (for-
merly the Research Centre of the Society for Nuclear
Energy Utilisation in Shipbuilding and Shipping – GKSS),
“Joining and Assessment“ Department, and has been
responsible for the materials analytics laboratory (SEM,
EDX, EBSD, gas analytics and metallography) there.
Dipl.-Ing. Stefan Riekehr concluded his studies in
Materials Sciences at the Clausthal University of Tech-
nology in Clausthal/Germany as a graduate engineer
in 1995. Since 1996, he has worked at the Helmholtz
Centre in Geesthacht, “Joining and Assessment“ De-
partment, and has been responsible for materials
testing and for the fracture-mechanical assessment
of laser-welded joints. Moreover, he has been re-
sponsible for the laser welding activities since 2001.
Dipl.-Phys. Manfred Horstmann is a scientific em-
ployee at the Institute for Materials Research, Mate-
rials Mechanics Division, at the Helmholtz Centre in
Geesthacht/Germany. Here, he is responsible for the
fatigue laboratory in the “Joining and Assessment
(WMF)“ Department.
Peter Haack is a technical employee at the Institute
for Materials Research, Materials Mechanics Division,
at the Helmholtz Centre in Geesthacht/Germany. He
is responsible for the radiographic testing laboratory
in the “Joining and Assessment (WMF)“ Department.
Dr.-Ing. Nikolai Kashaev concluded his studies in
Energy-Related Mechanical Engineering with the ad-
vanced subject of electrical aerospace engines and
power plants at the Baumann University of Techno-
logy in Moscow/Russia in 2001. Subsequently, he
worked as a scientific employee at the Foundation
Institute for Materials Technology in Bremen/Germany
for four years. In 2005, he then obtained his doctoral
degree on the subject of “New approaches to plasma
boronising and plasma nitriding“. After various acti-
vities in industry, he has been the Head of the “Join-
ing and Assessment“ Department at the Institute for
Materials Research and Materials Mechanics at the
Helmholtz Centre in Geesthacht since 2010.
the one-sided laser beam welding process to the materials
to be joined taking account of the T-joint geometry and to
assess the quality of the joints. Reference points for process
optimisation were to be derived from the investigations.
The approach of one-sided laser beam welding for the
245
245_249_WC4_SpA_w20000034__ 15.07.14 16:59 Seite 246

SPECIALIST ARTICLES

manufacture of T-joints is primarily ap-

propriate whenever the components to
be joined exhibit difficult accessibility
due to geometrical boundary condi-
tions. This may be the case when
stringers run in the longitudinal direc-
tion of the fuselage and the clips must
be positioned between them. The pe-
culiarity of skin/clip joints relates to the
fact that these are short welds whose
respective welding-in points are located
within a fuselage structure subjected to
mechanical stresses. In this respect,
these points mark the geometrical in-
terface between the skin and the clip
and act like notches. Another peculiar-
ity may be seen in the fact that the heat
input during one-sided laser beam
welding and the temperature distribu-
tion resulting from this are not symmet- Fig. 1 • Test arrangement for the Nd:YAG laser beam welding of T-joints (a) and welding direction variations (b).
rical, as is the case in two-sided laser
beam welding [6].

2 Materials and procedure

For the execution of the laser beam
welding tests, the AA6156-T4 (thick-
ness: d = 4.5 mm) and AA2139-T3 (d =
3.2 mm) aluminium alloys were select-
ed as the skin material and the
AA6013-T6 (d = 2.0 mm) aluminium al-
loy as the clip material. The specimen
preparations and the parameters for the
laser beam welding tests are specified
in Table 1. Amongst other information,
this indicates that the preparation of
the joining faces has been systemati-
cally modified in order to eliminate any
oxide coatings or contaminations. The
welding test arrangement is portrayed
schematically on Fig. 1a. The welding
directions have also been varied. In this
respect, T-joint configurations were
manufactured with one starting point
(A) and one finishing point (E), with
two starting points (A1 and A2) and one
finishing point (E) as well as with two
finishing points (E1 and E2) and one
starting point (A). These direction vari- Fig. 2 • Investigation results of T-joints manufactured by means of Nd:YAG laser beam welding; a) stress-
ations are shown on Fig. 1b. number curve, b) crack initiation at the finishing point, c) parallel section (shows macropores and a crack at
The welding directions and the the finishing point).
preparations of the joining faces were
varied in order to evaluate their influences on the quality DIN EN ISO 17636-1 and metallographically using longi-
of the laser beam weld. The welding direction variation tudinal and parallel polished specimens. The characteri-
was based on the deliberation that, in production condi- sation of the T-joints was rounded off by a microhardness
tions, a skin/clip setup may exhibit difficult accessibility test, an endurance strength test and a tensile test. Further-
as a consequence of geometrical limitations caused by more, temperature measurements were taken on the
stringers already welded with the skin field and by laser- T-joints executed by means of one-sided laser beam weld-
optical components. The T-joints have been assessed non- ing in order to obtain information about the local distri-
destructively by means of a radiographic test according to bution of the maximum temperatures.

246 Welding and Cutting 13 (2014) No. 4

245_249_WC4_SpA_w20000034__ 15.07.14 16:59 Seite 247

tioned exactly. In contrast, the direc-

tion variation with two starting points
A1 and A2 and one finishing point E
supplied complete weld penetration in
the longitudinal direction, Fig. 4b.
The welding-in points at the respective
clip ends of a T-joint constitute a geo-
metrical interface between the skin and
the clip and thus act like notches from
which cracks can originate. Figs. 2a and
2b show that this was the case and that
stress concentrations have led to the for-
mation of a fatigue crack in the heat-af-
fected zone between the skin subjected
to mechanical stresses and the un-
loaded clip. During the propagation, the
Fig. 3 • Positive prints of radiographic films; a) macropores in the weld at an angle of incidence of 25°; b)
crack initially remained in the heat-af-
effect of decreasing the angle of incidence to 11° on the weld quality. fected zone and then spread into the
base material of the skin nearly perpen-
dicular to the weld. Here, it may be stated that no cracks
originated from the pores. A stress-number diagram is por-
trayed on Fig. 2a. It can be established that the differences
between the respective T-joint variants are slight. The frac-
ture failure was not determined by the materials or the
welding direction variations according to Fig. 1b themselves
but instead by the notch effect in the interfacial region be-
tween the clip and the skin.
Tensile tests have been performed on AA6156-T4 as
the base material, on a laser-beam-welded butt joint made
of this alloy and on a T-joint manufactured by means of
one-sided laser beam welding between AA6156-T4 as the
skin material and AA6013-T6 as the clip material with one
starting point and one finishing point. In the T-joints, the
skin material was subjected to stresses transverse to the
laser beam weld until the fracture failure. The established
characteristic data is summarised in Table 2. The
Rp0.2(FZ)/Rp0.2(GW) and Rm(FZ)/Rm(GW) bonding efficiencies of
the butt joints are approx. 91% and approx. 89% respec-
Fig. 4 • Longitu- tively and may be seen in connection with the loss in hard-
dinal sections 3 Results and discussion ness as a consequence of the local elimination of the pre-
through T-joints The T-joints manufactured with the laser beam weld- cipitation hardening [7; 8]. The fact that the butt joint ex-
manufactured by
ing parameters specified in Table 1 are characterised by hibits a substantially lower elongation at fracture (i.e. 5%)
means of Nd:YAG
an asymmetrical weld shape. In part, the welds exhibit than the base material may be attributed to strain concen-
laser beam wel-
ding (macropores
sinking on the root side. One-sided laser beam welding
arranged on the led not only to complete weld penetration in the T-joint
but also to a welding-in process in the skin region with Table 2 • Yield strength Rp0.2, tensile strength Rm, elongation at
root side in the
maximum weld penetration depths of 1.0 to 2.5 mm, Fig. fracture A50mm, bonding efficiencies Rp0.2(FZ)/Rp0.2(GW) and
skin region); di-
2c. The radiographic test indicated that all the laser-beam- Rm(FZ)/Rm(GW): comparison between the AA6156-T4 base material
rection variations:
(GW), the butt joint made of AA6156-T4 and the T-joint bet-
a) E2-A–E1, b) welded T-joints are characterised by high porosity levels,
ween AA6156-T4 (skin) and AA6013-T6 (clip).
A2–E–A1. Fig. 3a. The macropores are distributed over the entire
Specimens Rp0.2 Rm A50mm Rp0.2(FZ)/Rp0.2(GW) Rm(FZ)/Rm(GW)
weld length. The panoramic photographs on Fig. 4 were [MPa] [MPa] [%] [%] [%]
taken with a light microscope and, using the example of AA6156-T4
232 326 21.5
T-joints with three welding-in points, show that these Base material
AA6156-T4
macropores can be encountered principally on the root 211 289 5.0 90.9 88.7
Butt joint
side. The direction variation with two finishing points E1 1246L_0 232 308 7.4 100.0 94.5
and E2 and one starting point A in the centre of the laser 1246L_1 232 321 10.6 100.0 98.5
1246L_2 230 320 10.4 99.1 98.2
beam weld must be regarded as unfavourable because no
1246L_3 230 318 9.7 99.1 97.5
overlapping occurred there, Fig. 4a. One essential reason 1246L_4 236 325 8.4 101.7 99.7
related to the fact that the laser beam could not be posi- 1246L_5 228 311 8.6 98.3 95.4

Welding and Cutting 13 (2014) No. 4 247

245_249_WC4_SpA_w20000034__ 15.07.14 16:59 Seite 248

SPECIALIST ARTICLES

trations in the laser beam weld or at the

laser beam weld [9]. This means that the
entire deformation was restricted to a short
specimen length corresponding to the
width from the heat-affected zone and the
laser beam weld. In relation to the whole
testing length of 50 mm, that led to the low
elongation at fracture although the laser
beam weld itself is characterised by duc-
tility [9]. In comparison with the butt joint,
the T-joints exhibited higher values for the
yield strength and the tensile strength. This
may be attributed to a stiffening effect
caused by the clip. The fracture failure
mainly occurred along the fusion line.
The metallographic investigations
could not clarify the cause of the formation
of pores. However, the temperature meas-
urements supplied an indication of the
cause of their origination. The graphical
plotting of the maximum temperatures
over the positions of the thermocouples
clearly shows that these maximum tem-
peratures were lower on the rear side of
the T-joint than on the radiation exposure
side and in the clip, Fig. 5a. This was asso-
ciated with a local drop in hardness which
was higher on the radiation exposure side
than on the rear side. Thus, there is a local
correlation between the microhardness
and the maximum temperature. During
one-sided laser beam welding, the clip act-
ed like a cold trap with the consequence
that the weld pool could probably solidify
more quickly on the root side than on the
radiation exposure side in the clip and skin
regions. Not all the gases entrapped on the
root side could emerge from the melt be-
cause the solidification rate there was high-
er than the degassing rate and residual gas-
es were consequently entrapped as macropores. Moreover, with the parameters specified in Table 1 led to the for- Fig. 5 • Local dis-
tribution of the
the porosity development is caused by the good heat con- mation of a large number of macropores in the weld ir-
maximum tempe-
duction of the aluminium alloys. Comparative investiga- respective of the material type, the welding direction vari-
ratures on the ra-
tions into the manufacture of T-joints made of the AZ31 ations and the procedure for the preparation of the join-
diation exposure
magnesium alloy in the same process conditions have ing faces. The welding-in points at the respective clip and rear sides as
shown that these were nearly pore-free [10]. It could be ends act like notches. This favours the crack initiation in well as in the clip
concluded from this that the angle of incidence of 25° was the skin region subjected to mechanical stresses. The loss (skin: AA6156-T4,
too high in the case of the aluminium alloys investigated in hardness and the structural heterogeneity in the re- thickness: 6 mm;
here and may therefore be considered as a cause of the gions of the weld and the heat-affected zone led to frac- clip: AA6013-T6,
high porosity level. The radiographs, Fig. 3, seem to confirm ture failure there when the skin material was subjected thickness: 2 mm).
this. They show that the porosity level could be lowered to quasi-static tensile stresses transverse to the weld. It
substantially by decreasing the angle of incidence from was possible to achieve a significant reduction in the
25° to 11°. The preparation of the joining faces according porosity level by decreasing the angle of incidence from
to Variant 2 proved to be sufficient, Table 1. 25° to 11°.

4 Concluding remarks Literature

[1] Tao, W., et al.: Double-sided fiber laser beam welding process
One-sided Nd:YAG laser beam welding for the manu-
of T-joints for aluminum aircraft fuselage panels: Filler wire
facture of T-joints between AA6156-T4 and AA2139-T3 as melting behavior, process stability, and their effects on po-
the skin materials and AA6013-T6 as the clip material rosity defects. Optics & Laser Technology 52 (2013), pp. 1/9.

248 Welding and Cutting 13 (2014) No. 4

245_249_WC4_SpA_w20000034__ 15.07.14 16:59 Seite 249

[2] Dittrich, D., et al.: Laser beam welding of hard to weld Al al-
loys for a regional aircraft fuselage design - First results.
Physics Proceedia 12 (2011), pp. 6/10.
[3] Pacchione, M., and J. Telgkamp: Challenges of the metallic
fuselage. 25th Int. Congress of the Aeronautical Sciences.
ICAS 2006, pp. 1/12.
[4] Enz, J., et al.: Prozessoptimierung für das Laserstrahl-
schweißen von hochfesten Aluminium-Lithium-Legierun-
gen. Schw. Schn. 64 (2012), Issue 8, pp. 482/85.
[5] Lenczowski, B.: New lightweight alloys for welded aircraft
structure. ICAS 2002, pp. 401.1/401.4.
[6] Siva Shanmugam, N., et al.: A transient finite element simu-
lation of the temperature and bead profiles of T-joint laser
welds. Materials and Design 31 (2010), pp. 4528/4542.
[7] Çam, G., et al.: Characterization of laser and electron beam
welded Al alloys. Practical Metallography 37 (2000) 2, pp.
59/89.
[8] Ma, T., and G. den Ouden: Softening behaviour of Al-Zn-Mg
alloys due to welding. Materials Science and Engineering,
A266 (1999), pp. 198/204.
[9] Vaidya, W. V., et al.: Mechanical behavior of laser beam and
friction stir welded aluminium alloys for airframes. Welding
in the World, 48 (2004), pp. 261/73.
[10] Kashaev, N., et al.: Fatigue, Fatigue Crack Propagation,
Fracture Behaviour of Laser Beam-Welded AZ31 Magnesium
Sheets (submitted at the Materials Science Forum 2014).

Welding and Cutting – editorial preview

Issue 5 (September/October) Issue 6 (November/December)
• Examples of applications in welding and cutting technology • Automation using robots and sensors for welding and cutting
• EuroBLECH – International exhibition for sheet metal working • Welding in plant, tank and pipeline construction
• Fabtech/AWS Show in Atlanta/USA • Examples of applications in welding and cutting technology

Closing date for advertisements and editiorial contributions: Closing date for advertisements and editorial contributions:
20 August 2014 27 October 2014

The editorial preview is subject to modifications.

For information about advertising, please contact:

Iris Jansen, DVS Media GmbH, Düsseldorf/Germany, e-mail iris.jansen@dvs-hg.de

For information about submitting editorial contributions, please contact:

Anja Labussek, DVS Media GmbH, Düsseldorf/Germany, e-mail anja.labussek@dvs-hg.de
Penny Edmundson, TWI, Cambridge/UK, e-mail penny.edmundson@twi.co.uk

Welding and Cutting 13 (2014) No. 4 249

250_WC4_BOOKS_Impr__ 16.07.14 15:50 Seite 250

PUBLICATIONS

Technical journal for welding and allied processes

Books
Proceedings “8th International
Congress Aluminium Brazing“
Edited by DVS – German Welding Soci-
ety. 114 pages. DVS Media, Düsseldorf 2014.
Price Euro 120.–.
The proceedings contain the manuscripts
of all lectures held in English language at the
8th International Congress on Aluminium
Brazing that took place on 3 to 5 June 2014 in
Düsseldorf/Germany and attracted 250 par-
ticipants. The 22 lectures shed light from dif-
ferent sides on the world of brazing of alu-
minum materials. A wide range of topics from
research and practice is covered, starting
from the materials topic through applications,
devices, process and quality control, up to
research and development.
Practice of thermal spraying –
Guidance for technical personnel
By H. A. Mathesius and W. Krömmer.
184 pages. DVS Media, Düsseldorf 2014.
Price Euro 39.50.
This practice-related reference book
turns to the thermal injection moulder, the
student, the expert, the engineer and every-
body who is interested in and would like to
know more about thermal injection mould-
ing. The book compiles the current technical
knowledge of thermal injection and offers
it in an understandable and comprehensive
manner. Numerous tables, diagrams and
pictures supplement and enhance the writ-
ten information.
Elementary materials science
By William F. Hosford. 200 pages. ASM
International, Materials Park/OH, USA.
Price approx. Euro 74.–.
The book covers the subject of materials
science without any equations. It is intended
primarily for students with limited science
backgrounds who are interested in materi-
als. The book also will be useful for non-
technical professionals in the materials in-
dustry. The introductory chapter presents
the basics underlying the study of materials:
bonding, crystal structures and amorphous
materials. Other important aspects of ma-
terials science are covered in chapters de-
voted to phase relations, mechanical, elec-
trical and magnetic behaviour as well as cor-
rosion. Non-ferrous metals, iron and steel,
ceramics, polymers, composites and wood
are each covered in separate chapters. Chap-
ters on forming and shaping, and recycling
round out this important basic volume on a
growing interdisciplinary scientific field.
Publisher:
DVS – German Welding Society, Düsseldorf/Germany, in
collaboration with The Welding Institute, Cambridge/UK
and the Institut de Soudure, Paris/France
Publishing House:
DVS Media GmbH,
PO Box 10 19 65, D-40010 Düsseldorf,
Aachener Straße 172, D-40233 Düsseldorf,
Telephone +49 (0) 211 1591-0,
Telefax +49 (0) 211 1591-150,
E-Mail media@dvs-hg.de,
Internet www.dvs-media.info,
Management: Dirk Sieben
Editorial Board: Dipl.-Ing. Dietmar Rippegather
(managing editor/responsible),
E-mail dietmar.rippegather@dvs-hg.de,
Anja Labussek, Rosemarie Karner,
Telefax +49 (0) 211 1591-350
Penny Edmundson (WJS News),
E-mail penny.edmundson@twi.co.uk
Frédérique Champigny (IS News),
E-mail f.champigny@institutdesoudure.com
UK Editorial Advisory Panel: Norman Cooper, Alan
Denney, Chris Eady (Chairman), David Millar, Dietmar
Rippegather, Dr. Paul Woollin
Advisory Board: Dipl.-Ing. K. P. Behrendt, Dr.-Ing. R.
Boecking, Dr.-Ing. C. Bruns, Prof. Dr.-Ing. H. Cramer, Prof.
Dr.-Ing. K. Dilger, Prof. Dr.-Ing. L. Dorn, Prof. Dr.-Ing. habil. U.
Füssel, Dr.-Ing. P. Gröger, Prof. Dr.-Ing. E. Haberstroh, Prof.
Dr.-Ing. A. Hobbacher, Dr.-Ing. T. Kannengießer, Dipl.-Ing. W.
Kleinkröger, Dr.-Ing. H. Krappitz, Prof. Dr.-Ing. B. Leuschen,
Dr. C. Mayer, Dipl.-Ing. K. Möhwald, Dr.-Ing. K. Nassenstein,
Prof. Dr.-Ing. D. Paulinus, Dipl.-Ing. C. Prinz, Prof. Dr.-Ing. C.
Radscheit, Prof. Dr.-Ing. U. Reisgen, Dipl.-Ing. E. Schofer, Dr.-
Ing. F. Schreiber, Dr. sc. techn. K.-R. Schulze, D. Sieben (CEO
of the DVS Publishing House), Dipl.-Ing. V. E. Spiegel-Cio-
banu, Dr.-Ing. S. Trube, Dr.-Ing. G. Wilhelm, Prof. Dr.-Ing. H.
Wohlfahrt
Advertising: Iris Jansen (responsible),
Telephone + 49 (0) 211 1591-151
E-mail iris.jansen@dvs-hg.de,
Boris Hanisch, Telephone +49 (0) 211 1591-152,
E-mail boris.hanisch@dvs-hg.de.

For currently valid prices please see Price List

No. 13, effective 1st January 2014

Circulation: Michael Lembcke,

Telephone +49 (0) 211 1591-160,
E-mail michael.lembcke@dvs-hg.de

Printing: D+L Printpartner GmbH, Bocholt/Germany

Terms of Delivery: WELDING and CUTTING is published six

times a year. Members of the DVS (German Welding Society)
List of companies in the advertisement section receive a discount on the regular subscription price. Subscrip-
tion is possible either directly through the DVS Media GmbH
or through your local bookstore. Single issues are available at
Berkenhoff GmbH Herborn/Germany 207 a price of 20.50€ (plus shipment costs), the price for a one-
DVS Media GmbH Düsseldorf/Germany IFC, IBC, BC, 199 year subscription for print is 122.-€, online + print 160.-€
plus shipment costs (22.-€ within Germany, 29.-€ abroad);
DVS-TV GmbH Düsseldorf/Germany 194 online 85.-€. Delivery by airmail is possible upon request.
Fronius International GmbH Wels-Thalheim/Austria Title Membership of The Welding Institute includes the subscrip-
Istituto Italiano della Saldatura Genova/Italy 195 tion to WELDING and CUTTING.

Linn High Therm GmbH
Lorch Schweißtechnik GmbH
Orbitalum Tools GmbH
Bernd Siegmund GmbH
Weldas Europe B.V.
Eschenfelden/Germany 201 The subscribers and/or the advertisers cannot assert any
compensation claims for a reduction in services due to
Auenwald/Germany 191 force majeure or to other circumstances for which the pu-
blishing house is not a fault (e.g. strike).
Singen/Germany 197
Grossaitingen/Germany 192 WELDING and CUTTING as well as all the contributions, fi-
gures and tables included in this journal are protected by
Bergen op Zoom/The Netherlands 193 copyright. With the exception of the statutorily authorised
cases, any utilisation without the consent of the DVS
Media GmbH is punishable.

When the work is accepted for publication, the author

transfers to the publishing house the exclusive publishing
rights for the period until the copyright expires. This trans-
fer of rights relates, in particular, to the rights of the publi-
shing house to reproduce the work for commercial
purposes as a copy (microfilm, photocopy, CD-ROM or
other processes) and/or to include it in electronic or other
databases.

We do not accept any liability for manuscripts submitted

without solicitation.

250 ISSN 1612-3433 Schweißen und Schneiden 1/2012

 Order form

Order
DVS Media GmbH
c/o Boris Hanisch
Fon:+49 211/1591-152
Fax: +49 211/1591-150

Entry:

____________________________________________________________________________________
Company

____________________________________________________________________________________
Street Address

____________________________________________________________________________________
Postal Code, City

____________________________________________________________________________________
Phone: Fax:

____________________________________________________________________________________
e-mail: Internet:

Alphabetical classification under letter: (please mark with a cross)

A|B|C|D|E|F|G|H|I|J|K|L|M|N|O|P|Q|R|S|T|U|V|W|X|Y|Z

under the following key-words:

Code-No.: (you can find the list of products at the previous page)

1. ___________ 6. ___________ 11.___________ 16. __________ 21. __________ 26. __________

2. ___________ 7. ___________ 12.___________ 17. __________ 22. __________ 27. __________
3. ___________ 8. ___________ 13.___________ 18. __________ 23. __________ 28. __________
4. ___________ 9. ___________ 14.___________ 19. __________ 24. __________ 29. __________
5. ___________ 10. ___________ 15.___________ 20. __________ 25. __________ 30. __________

Contact person: ___________________________________________________________________

Sign: ___________________________________________________________________

Date: __________________ Signature: ____________________________________________

ABC (2014) No. 4

 Software

Preparation of welding procedure specifications, management of welding

procedure testing and welder performance qualifications.

The software was specially designed as a welding pl-
anning tool based on DIN Standards and as an instru-
ment for welder qualification management.
Also integrated are parent material, filler metal and
shielding gas databases to which users can add their
own data. The software supports the simple develop-
ment and management of welding procedure speci-
fications according to DIN EN ISO 15609 Part 1 and
DIN EN ISO 15614.
The computer programme is easy to use, and because
it incorporates the full texts of the two standards as pdf
files in German and English it is an efficient aid that will
prove invaluable in everyday working practice.

Welding Planner
Bilingual: German and English
Single User Version, 3rd edition 2012
Order No. 101085, Price: 298,00 EUR
Up-Date, 3rd edition 2012
Order No. 101197, Price: 98,00 EUR
System Requirements: Processor 1 GHz
Random Access Memory 512 MB
Disc space 33 MB
System Software: running under Windows-Systems

DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf

T +49. (0)2 11. 15 91-162 • F +49. (0)2 11. 15 91-250 • vertrieb@dvs-hg.de • www.dvs-media.eu

AZ_Schweissaufgabenplaner_englisch_NCD.indd 1 28.02.2014 12:22:48