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 THE N E ~ DRIVING FORCE
AT THE CORE OF THE
MANUFACTURING INDUSTRY

The American Welding Society and
The Precision Metalforming Association.
We've fitted our two very successful shows
together because it's so logical. After all,
manufacturing starts with metalforming
followed by welding or one of its allied
joining processes. And with everything in
between, we've created MAX International to
be the only event you'll ever need to attend.
Information: 1-866-MAXEXPO(629-3976).

AmericanWeldingSociety and
International Welding and Fabricating
Exposition and Annual Convention

presents
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May 6-10, 2001 Visit us at

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 AWS Website: http'd/www.aws.org

Feature Articles M o n t h l y Columns

Ultrasonic Plastics Welding Basics
J. Devine Press-Time News .............. 7
An understanding of the basic steps in ultrasonic joining of plastic components ensures reliable
performance of the product/29 Washington Watchword ......... 9

Using Microwaves to Weld PVDF Pipes and Fittings Editorial . . . . . . . . . . . . . . . . . . . . 10

M. Dommer
Improvements in microwave joining technology may make it a process of choice on applications where Commentary ................. 12
infrared welding is now used/35
CyberNotes . . . . . . . . . . . . . . . . . . 16
Shot Peening and Heat Treatment Reduce Stress
M. S. Molzen and D. Hornbach Conferences ................. 17
Design engineers must understand residual stresses and how they affect the fatigue life of weldments/38
News of the Industry . . . . . . . . . . . 20
Resistance Seam Welding Benefits Stainless Application
The production of catalytic converter shells was greatly improved and scrap rates reduced with a specially Letters to the Editor . . . . . . . . . . . 23
designed seam welding system/43
New P r o d u c t s . . . . . . . . . . . . . . . . 24

Welding Workbook ........... 45

Welding Research Supplement Navy J o i n i n g C e n t e r ........... 49

The Statistical Models for Estimating the Amount of Spatter in the Short C o m i n g Events . . . . . . . . . . . . . . . 50
Circuit Transfer Mode of GMAW
M.J. Kang, et al. New Literature ............... 53
A study to predict spatter correlated waveform activity to different welding conditions to develop four different models/1-s
B r a z i n g Q&A . . . . . . . . . . . . . . . . . 54
Partially Melted Zone in Aluminum Welds: Solute Segregation and Mechanical Behavior
Huang, et al. Society N e w s . . . . . . . . . . . . . . . . . 55
The partially melted zone in gas metal arc welds of Alloy 2219 showed a weakness for hot cracking/9-s
Guide to AWS Services ......... 75
The Stress-Relief Cracking Susceptibility of a New Ferritic Steel m Part 2: Multiple-Pass
Heat-Affected Zone Simulations Stainless Steel Q&A . . . . . . . . . . . . 78
J. G. Nawrocki, et al.
A multipass technique was investigated as a means of reducing stress rehef cracking of steels that normally require postweld Personnel ................... 80
heat treatment/18-s
Classifieds .................. 86
Mechanical Properties of Plasma-Hardened 5% Chromium Tool Steel Deposited by Arc Weld-
ing Advertiser I n d e x . . . . . . . . . . . . . . 89
L. K. Leshchinskiy and S. S. Samotugin
Treatment using a highly concentrated plasma jet created a very hard surface resistant to breakage with impact/25-s

WeldingJournal (ISSN0043-2296) is publishedmonthly by the AmericanWeldingSocietyfor $90.00

per year in the United States and possessions,$130 per year in foreign countries: $6.00 per single
issue for AWS membersand $8.00 per single issuefor nonmemebers.AmericanWelding Societyis
located at 550 N.W. LeJeune Rd., Miami, FL 33126-5671; telephone (305) 443-9353. Periodicals
postage paid in Miami, FL, and additional mailing offices. POSTMASTER:Sendaddresschangesto
Welding Journal, 550 N.W. LeJeuneRd., Miami, FL 33126-5671.
Printed by R. R. Donnelley& Sons Co., Senatobia, Miss. Readersof Welding Journal may make
copies of articles for personal,archival,educationalor researchpurpose,and which are not for sales
or resale.Permission is grantedto quote from articles, providedcustomary acknowledgmentof au-
thors and sources is made. Starred (*) items excludedfrom copyright.
WELDING JOURNAL I 5
• if your work is based on a reputation for reliability and safety
• if you want the latest industry consensus on welding requirements
• if you want to improve your competitive position by referencing
the latest workmanship standards, inspection procedures and
acceptance criteria
Evolving since 1928, DI.I Structural Welding Code - - Steel is an industry consensus on the minimum
welding requirements that can ensure quality fabrication for the vast majority of industrial and commercial
applications. Developed under strict ANSI procedural rules; Dept. of Defense adopted.
For those involved in fabricating statically, or dynamically-loaded, steel structures including tubular shapes,
Dl.1 Structural Welding Code - - Steel is indispensable.
Important areas with comprehensive coverage
• Design of welded connections including: tubular and nontubular, statically or cyclically loaded
• Prequalification of Welding Procedure Specifications including: amperage, voltage, travel
speed, shielding gas flow rate, joint designs and specifications
• Qualification including: procedures and personnel
• Fabrication including: base metal, consumables, tolerances, assembly, repair, cleaning
• Inspection including: qualification, acceptance criteria, NDE, RT, UT
. Stud Weldingincluding: design, production control, inspection
• Strengtheningand RepairingExisting Structures including: design, stress analysis,
restoration or replacement, repairs
New for 2000:
Structural Welding Code- - ReinforcingSteel
This fifth edition of the ANSI-approved/noD-adopted standard covers
welding reinforcing steel in most reinforced concrete applications.
Includes allowable stresses, inspection, qualification, structural details,
joint details and workmanship requirements. Figures dearly illustrate
important welding considerations: unacceptable weld profiles, effective
weld sizes, details of joints of anchorages, base plates and inserts, etc.
9 tables, 5 annexes support 7 chapters. 45 pages, softbound, 3-hole
punched. Published in 1998.
D1.4-98 .................................. 76.00
AWSMembers ........................ 57.00
Structural Welding Code - - Sheet Steel
"One of the primary objectives of this code is to define the allowable
capacities used in sheet steel applications In which the transfer of
calculated load occurs." If you're responsible for the welding In steel
decks, panels, storage racks, and stud and joist framing members, to
name a few applications, this code helps you to effect consistently sound
welding of joints. Includes allowable load capacities, details of welded
connections, prequalillcation of WPSs, qualification, inspection, stud
welding. 7 tables, 44 figures, 5 annexes, and Commentary..76 pages,
softbound, 3-hole punched. ANSI-approvedand published in 1998.
D1.3-98 .................................. 96.00
AWSMembers ........................ 69.00
Bridge Welding Code
All metric edition was developed with cooperation from A,~HTOand
reflects its requirements Including those for NOT. Details requirements
for Inspection, qualification, structural details, stud welding, welded
joInt details, and workmanship. Indudes "Fraction Control Plan for
Nonredundant Bridge Members." 250 pages, with 35 tables, 77
llgures and several annexes. 8-1/2" x 11", softbound, 3-hole punched.
ANSI-approvedand published In 1996.
D1.5-96 ................................ 156.00
AW8 Members ...................... 117.00

Structural Welding Code - Aluminum

• new steels and electrodes including ASTM A992 and metal cored
GMAW electrodes
• UT-thickness regulations
• undersized fillet weld limits
• allowance for standard WPSs
This code set the rules and regulations necessary for welding structural
aluminum using the gas metal arc, gas tungsten arc, and plasma arc
welding processes, as well as stud welding and plasma arc gouging, in
dynamicallyloaded or cyclically-loaded nontubnlar structures as well
D1.1:2000 .............. 344.00 as tubular structures. Developed under strict ANSIrules, Structural
WeldingCode-Aluminum includes sections on Fabrication, Qualifination
AWS Members ........ 258.00 of WPSsand Personnel and Inspection. ANSI-approved,Dept. of Defense
adopted, 224 pages. Published In 1997, 25 tables, 53 figures, 10 annexes
as well as commentary organized by subject.
Order Now! 31.2-97 ................................ 124.00
AWSMembers ........................ 93.00
AWS has secured Global
StructuralWeldingCode- StainlessSteel
Engineering Documents for This new code establishesthe requirementsfor welding stainlesssteel
using the gas metal,shielded metal,fluxcored, and submergedarc welding
sales and order fullfillment processes, includingstud welding. The code coversdesign,fabrication,
to ensure Member and qualillcationand prequalificationof procedures, weldingpersonnel
qualification,and inspection.Includes79 figures,26 tables, and 12 annexes
customer satisfaction. in 224 softboundpages.
D1.6:1998 .............................. 124.00
Call (800)854-7179. AWSMembers ............................ 93.00
As always, credit cards are
~ AmericanWeldingSociety
secure on www.aws.org
550 NW LeJeune Rd., Miami, FL 33126
http://www.aws.org

A W S Enters into Partnership for
Publication Sales
All documents, standards and publications produced by the
American Welding Society are now available for purchase from
Colorado-based Global Engineering Documents.
AWS and Global entered into the agreement in December
to provide speedier service and lower shipping and handling
charges to Society members and customers.
For more information, visit the AWS Web site at
www.aws.org or call Global Engineering Documents at (800)
854-7179. Additional information will be available in the com-
ing months.
Praxair Quits Funding Internet-Based Business MetFabCity
Praxair, Inc., Danbury, Conn., has stopped funding Met-
FabCity, Inc., its independent business-to-business Internet site
as of the end of the fourth quarter of 2000. The move is part of
the industrial gases company's recently announced repositioning
program, which includes cost reducing measures such as the clos-
ing of high-cost manufacturing plants and a reduction of about
750 workers or 3% of the company's global work force.
MetFabCity was launched in April 2000 and was based in
Chicago. The company's aim was to bring together metal fabri-
cators, suppliers and customers via the Internet. It was to be a
one-stop portal that would enable fabricators to integrate elec-
tronic commerce into their sales, procurement and manufactur-
ing operations.
Praxair had invested $20 million in MetFabCity, including be-
Global Combines Technologies to
Install Pipeline in the Gulf of Mexico
Global Industries Offshore LLC, New Iberia, La., recently
used automatic gas metal arc welding in conjunction with its
patented "Mudbug" pipe burying technology to simultaneously
lay and bury 33 miles of 12-in.-diameter pipe for Williams Field
Services Gulf Coast Co. LP. This project marked the first time
Global combined automatic welding with its Mudbug technology.
The sour gas pipeline will collect products from offshore Al-
abama and transport it to a gather system in Mobile Bay. It was
installed to water depths of up to 120 ft using Global's
pipelay/bury barge Sea Constructor.
Forty-ft-long segments of pipe were welded into a continuous
line with the automatic equipment. The pipe was then laid and
buried with 3 ft of cover.
Press ews
Welding Portrayed as 'Ultra High
Tech' in TIME
Welding and other joining technologies were hailed as being
"ultra high tech" by TIME magazine in a special section on in-
ventors and inventions in its December 4, 2000, issue.
In a piece on what's coming up next in the world of manu-
facturing, the magazine said, "Welding is advanced materials
science these days and getting even more so." The story went on
to mention technologies such as electron beam, laser beam, ul-
trasonic and underwater welding.
The article included these comments from Prof. Koichi Ma-
subuchi of the Massachusetts Institute of Technology: "In the
future, we will further refine the tools of intelligent robotic
welding as well as employ 'virtual welding,' which will enable en-
gineers to test new techniques - - much as pilots now use flight
simulators."
tween $3 and $5 million in fourth quarter 2000, Dennis Reilley,
Praxair's chairman and CEO, said during a teleconference on
December 12. Praxair is investigating recovering some of its costs
through selling some portions of MetFabCity.
"The business concept has merit in theory," Reilley said, "but
I recognize the difficulty and uncertainty in turning these con-
cepts into viable business models." Therefore, the decision was
made to terminate funding by year end.
"I'm not confident enough that our concept was going to be
enough different from anybody else's to continue to spend money
on it," Reilley said.
Praxair's repositioning program will lead to a nonrecurring
charge to earnings in the fourth quarter of 2000 of approximately
$150 million before tax.
Deere Plans Improvements to
Tractor Manufacturing Plants
Deere & Co. recently announced it will invest more than $125 mil-
lion to update and improve manufacturing facilities for agricultural
equipment at the John Deere Waterloo Works in Waterloo, Iowa.
The investment will take place over the next four years at the
company's Westfield Avenue and Donald Street sites in Waterloo,
which partner to manufacture farm tractors. While most of the
upgrades will take place at the Westfield facility, plans call for au-
tomating the fabrication and welding of the operator station
frames, which takes place at the Donald Street facility.
As part of the plan, flow manufacturing and new technology
will be used at the Westfield site, which will relocate from multi-
story to single-story buildings. Four buildings will be used instead
of the current ten.
WELDING JOURNAL I 7
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The World Leader!
 BY HUGH K. WEBSTER
AWS Washington Government Affairs Office
107th Congress Brings New Chairmen
Even though the Republicans maintained control of the
House and Senate in the 2000 elections, chairs of key Congres-
sional committees will change hands, with potentially significant
consequences, as the 107th Congress begins its first session.
When the Republicans gained control in 1994, they instituted
mandatory term limits on committee chairmanships. This
means powerful committees such as Judiciary, Commerce, and
Financial Services will have a change in leadership. One notable
change is the likely move of Rep. James Sensenbrenner (R-Wis.)
to chairman of the House Judiciary Committee. Sensenbrenner
has been an active head of the Science Committee, and his in-
terest in technology and research issues is expected to shape the
agenda for Judiciary as well.
Rep. Marge Roukema (R-N.J.) is expected to become the
first female Republican to chair a major committee, most likely
the House Financial Services Committee.
Suits Filed Over Ergonomics Standard
The ink was hardly dry on the massive new ergonomics stan-
dard issued by the Occupational Safety and Health Administra-
tion (OSHA) late last year, when the two leading opponents of
the rule filed suit. Just one week after the final rule was pub-
lished in the Federal Register, both the U.S. Chamber of Com-
merce and the National Association of Manufacturers sued to
have the rule overturned. These leading business advocacy
groups maintain in their complaints that the ergonomics regu-
lation is flawed procedurally, scientifically and legally.
O S H A dedicated an unprecedented amount of resources to
this rule - - often seemingly to the exclusion of all else - - in
order to meet its goal of publishing by the end of 1999. The rule
itself comprises 608 pages in the Federal Register and is expected
to have a direct impact on more than 6 million work sites across
the country.
Federal Contractor Regulations Finalized
The business community was hit with a second major regu-
latory initiative at the end of 1999. Following issuance of the er-
gonomics standard by OSHA, the federal government then
promulgated its new rules for federal contractors. These rules,
under development for at least two years, create new criteria
for companies wishing to bid on federal contracts. These crite-
ria include the history of bidders in areas such as environment,
anti-trust, labor, employment, consumer protection and even
taxation. Companies that have a blemish in these areas may be
barred from bidding or being awarded a contract.
Federal contracting is estimated to be a $200 billion business,
and companies fear the new rules may result in their being unfairly
barred, or even blacklisted, from participating in that market.
PTO Web Site Upgraded to
State of the Art
The U.S. Patent Office Web site database has been signifi-
cantly upgraded and now includes every U.S. patent ever issued.
This amounts to a total of more than 6.5 million patents, dating
back to 1790. The site, www.uspto.gov, is updated weekly.
New Law Helps Fund Certification of
Military Personnel
The Veteran's and Dependent's Millennium Education Act,
passed by Congress and signed by the president late last year,
authorizes funds available under the Montgomery G.I. Bill to
pay for professional certification and licensing tests. This new
law takes effect March 1, 2001, and applies to all certification
and licensing programs approved in advance by the Secretary of
the Department of Veterans Affairs.
NIOSH Issues Injury, Illness Data Book
Worker Health Chartbook, 2000, published by the National
Institute for Occupational Safety and Health (NIOSH) in No-
vember 2000, is designed to combine, in one place, all relevant
current statistics on numbers and types of occupational injuries,
illnesses and deaths. Information is organized by year, as well as
incidence rates and trends over time. The data are drawn from
different systems administered by the Bureau of Labor Statis-
tics, OSHA and other agencies, including NIOSH itself.
This book is available free of charge on the NIOSH Web site,
www.cdc.gov/niosh/OO-127pd.html, or by calling NIOSH at (800)
356-4674.
President Sets Policy through Regulation
The president of the United States can exercise great influ-
ence on the laws and policies of the federal government largely
by persuasion, negotiation and wise use of the so-called bully
pulpit. But one area in which a president can have a more direct
influence is the federal agencies that promulgate the regulations
that implement laws passed by Congress. There are approxi-
mately 6000 political appointment positions in the Executive
Branch that can exert control over crucial policy decisions that
are filled by the president.
Contact the A WS Washington Government Affairs Office at 1747
Pennsylvania Ave. N. W., Washington, DC 20006; telephone (202)
466-2976; FAX (202) 835-0243.
WELDING JOURNAL I 9
 AMERICAN
WELDING SOCIETY
E + I + I + I = Success Officers
Now that we've entered the 21st century, I would like to share with you the President - - L. W. Myers
values I think will propel the welding industry forward. I believe our welding Consultant
careers and future depend on the above equation, in which E equals education
and I equals image of welding, international affairs and industry. Vice President - - R. L. Arn
Education. Many of you have asked, "How can I convince new people to Teletherm Technologies, Inc.
enter the field of welding when the pay scale is so low?" I say education is the
key to success. Veteran welding personnel and newcomers alike can increase Vice President - - E. D. Levert
their market value by upgrading their welding certifications, increasing their Lockheed Martin Missiles and Fire Control
level of education, learning special skills, etc., and AWS can help. It is com-
mitted to providing its members with the educational materials that can help Vice President - - T. M. Mustaleski
them obtain the level of welding education they need for a successful welding BWXT-Y 12 LLC
career. It offers certifications such as the Certified Welding Inspector,
Certified Welding E d u c a t o r and Certified Welding Engineer, and the Treasurer - - N. A. Hamers
Conference D e p a r t m e n t provides a variety of educational seminars each year. DaimlerChrysler
Once welding personnel increase their market value, they can locate new
welding career opportunities that can translate into higher salaries. Executive Director - - E G. DeLaurier, CAE
Image of Welding. We can help prepare the youth of today for welding
careers of tomorrow by participating in local AWS section events and school Directors
career day programs. I cannot overemphasize this: You will never know if you
have impacted someone's career decision unless you have tried. The AWS O. A1-Erhayem (At Large), JOM Institute
membership includes a vast and diversified group of welding professionals. All J. M. Appledorn (Dist. 18), The Lincoln Electric Co.
of us must help prepare the next generation of welding professionals by dis-
cussing welding opportunities and challenges within our own companies and B. J. Bastian (At Large), Benmar Associates
industries. If we do not address these issues, then there will remain a shortage H. J. Bax (Dist. 14), Cee Kaysupply
of qualified welding personnel. The next generation really does depend upon M. D. Bell (Dist. 22), PreventiveMetallurgy
each of us. We must change the image of welding by talking to individuals, H. E. Bennett (Dist. 8), BennettSalesCo.
groups and organizations. Several AWS committees are dedicated to improv- B. A. Bernstein (Dist. 5), TechniWadLab
ing the image of welding. Educating the public and school officials will help;
S. W. Bollinger (Past President), Consultam.
the only cost is your time and effort.
I n t e r n a t i o n a l Affairs. Global competition will create new challenges for C. B. Bottenfield (Dist. 3), DresselWeldingSupply
employers and welding professionals in the 21st century. The globalization of J. C. Bruskotter (Dist. 9), ProjectSpecialists,Inc.
the welding industry and increased opportunities for partnerships with com- C. E Burg (Dist. 16), AmesLaboratory
panies outside the United States make it very important to understand what is S. C. Chapple (Dist. 11), MidwayProductsGroup
happening in the worldwide welding community. The International Institute G. R. Crawmer (Dist. 6), GEPowerGenerationEngineering
of Welding (IIW) is a federation of welding societies from 41 countries dedi-
A. E Fleury (Dist. 2), A. E Fleury&Associates
cated to the exchange of scientific and technical information. You must get
involved if you plan on competing in the international fabricating markets. J. R. Franklin (At Large), SellstromMfg.Co.
Each year the American Council selects U.S. delegates to the various com- J. D. Heikkinen (Dist. 15), SpartanSaunaHeaters,Inc.
missions and other units of the IIW to represent U.S. positions. You can get J. L . H u n t e r ( D i s t . 13), Mitsubishi Motor Mfg. of America, Inc.
involved by serving as an expert on a commission. M. D. Kersey (Dist. 12), The LincolnElectricCo.
Industry. The Welding Industry Network Committee (WIN) was established N. R. Kirsch (Dist. 20), NortheasternJuniorCollege
to address the needs of welding end-users and to be the preferred forum for
D. J. Kotecki (At Large), The LincolnElectricCo.
these welding and fabricating technology professionals to interact. W I N will
represent industry and provide advice to AWS concerning current and future R. C. Lanier (Dist. 4), PittCommunityCollege
materials joining needs. I call on you to consider joining the WIN members at G. E. Lawson (At Large), ESABWelding&Cutting Products
their first annual conference, which will be V. Y. Matthews (Dist. 10), The LincolnElectricCo.
held in Cleveland, Ohio, during the MAX G. H. Putnam (Dist. 1), Thermal Dynamics
International show in May 2001. It's your O . E R e i c h ( D i s t . 17), Texas State Technical College at Waco
chance to be one of our industry's innovators.
E R. Schneider (Dist. 21), BobSchneiderConsultingServices
E + I + I + I = Success. Education is the
first step, but each of the others are impor- T. A. Siewert (At Large), NIST
tant if welding and materials joining are to R. J. Tabernik (Dist. 7), The Lincoln Electric Co.
thrive. I challenge you to get involved. As a R. J. Teuscher (Past President), CustomFabricationCo.
team player, you can make a difference. P. E Zammit (Dist. 19), Broo~aynIronWorks,Inc.

Ernest D. Levert
A WS Vice President and
Chairman, Welding Industry Network Committee

10 I JANUARY 2001
 Ask The Experts at
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tent designed for users just
like you. Whatever your
.... ,,,.. 1%, , ~ =,,,...'.= . . . . . . . .
field-construction, fabrica-
tion, automotive, home, or
farm-check here for the
~.~, latest every week.
=='~'=='~'-':~=:;~.=::~" • . . . . . . . . . . . . . . .
//I1:,%~-~ ! . . . . . . . . . . . . . . . . . . . . . . . . . . . .
//I:~F~ . . . . . . . . . . . . . . . . . . . . . . . . Curious about
oln ~ 2 ~ :~ ~ N ; ~ . ~ .... "~-~'-" where the world
:..... ' r J = = " - ==~ ' ~ of welding is
.................................
meeting?
r----~ ~...- .......... Don't miss another welding
;..';---~--.-,--~_. ,~. . . . . . . . . . . . . . . . . ~. event! Get a complete list of
~ l upcoming industry trade
..... .... ~'~~ ~ ' ~ ~ shows and Lincoln seminars
EL and schools. Who, what,
................ when, and where-they're
all here.
Need to refine your skills
and knowledge?
Browse Lincoln's on-line Tech Topics Library,
review Lincoln seminars or Welding School classes,
find your instruction manual, or order technical
and product literature on-line.
LINCOLNB
B! ELECTRIC
THE WELDING EXPERTS
The Lincoln Electric Company, Cleveland, Ohio 44117
216/481-8100
www. l incolnelectric, com/askus
Circle No. 19 on R e a d e r Info-Card
Com WELDING
Editorial Staff
Publisher
Jeff Weber
Editor
Andrew Cullison
Features Editor
JOURNAL

Mary Ruth Johnsen

Be a Step Ahead Managing Editor
Christine Tarafa
As the saying goes, change is the only constant. With the effects of the Associate Editor
Internet and the cyber-distribution arena, this is a very exciting time in our Susan Campbell
industry. Here today, obsolete tomorrow. We are becoming accustomed to the
Assistant Editor
rapidity of change because of e-commerce. There seems to be never-ending
Doreen Yamamoto
amounts of opportunities and options for doing business in the future.
The members of the Welding Equipment Manufacturers Committee Production Coordinator
(WEMCO) are addressing these ever-constant changes within our industry. Zaida Chavez
The "best in industry" will share ideas at the 5th Annual W E M C O Meeting Peer Review Coordinator
being held February 2 and 3 at the Rancho Bernardo Inn in San Diego, Calif. Doreen Kubish
The exchange of information at this meeting is definitely on the leading edge Contributing Editor
regarding the marketplace and distribution, and will provide direction for our Bob Irving
business efforts in the foreseeable future. Publications, Expositions,
W E M C O leadership has invited back, by popular demand, Brian Beaulieu
from the Institute for Trend Research. He will provide accurate and insightful
Marketing Committee
G. D. Uttrachi G . M . Nally
economic information regarding next year's business environment and oppor- Committee Chairman Consultant
tunities for the welding industry. Our needs are not only to survive but also to ESAB Welding & Cutting
prosper in today's constantly evolving, competitive business world, and R. G. Pali
Beaulieu will give WEMCO members the edge they need. G. O. Wilcox J. E Nissen Co.
Vice C h a i r m a n
Steve Epner, a leading director of traffic on the "Information Thermadyne Industries S. Roberts
Superhighway," will guide us away from dead-end business streets, make diffi- Whitney Punch Press
J. W e b e r
cult concepts understandable and usable, will share a broad range of survival Secretary J. E Saenger, Jr.
skills, give us the best approach to a successful road map and will teach us how American Welding Society Edison Welding Institute
to drive victoriously on the superhighway of prosperity. Epner will provide P. Albert R . D . Smith
information everyone can and will understand, from the seasoned "techie" to Krautkramer Branson The Lincoln Electric Co.
the CEO concerned about the company's bottom line. R. L. A r n E D. Winslow, Ex Off.
W E M C O leadership will also bring together leading Dot.com providers Teletherm Technologies, Inc. Hypertherm
and major manufacturers who are utilizing the latest technology for procure-
T. A. Barry E . D . Levert, Ex Off.
ment of products. These foremost business leaders will educate members Miller Electric Mfg. Co. Lockheed Martin
regarding B2B and other current e-commerce issues during the Saturday C. E. Boyer
Missiles and Fire Control
Morning Business Forum. Join your fellow welding equipment manufacturers ABB Robotics L . G . Kvidahl, Ex Off.
and be provided with tomorrow's industry information, which will help you Ingalls Shipbuilding
T C. C o n a r d
make better managerial decisions and steer your company to better business ABICOR Binzel N. H a m e r s , Ex Off.
conditions and profits. DaimlerChrysler
D. L. D o e n c h
WEMCO is on the move in a big way, constantly providing added value to Hobart Brothers Co. S.W. Bollinger, Ex Off.
its members. The six working committees within WEMCO have been very pro- Consultant
ductive over the past year, going above and beyond what was expected. It is the J. R. Franklin
Sellstrom Mfg. Co. J . C . Lippold, Ex Off.
Dynamic volunteer leadership from our dedicated W E M C O members provide The Ohio State University
our industry and our membership with benefits that some of us only dreamed N. R. Helton
of a few short years ago. Pandjiris, Inc. W. Gaskin, Ex Off.
Congratulations are in order to W E M C O Chairman Phil Winslow of Precision Metalforming Association
V. Y. Matthews
Hypertherm, his subcommittee chairmen and all of their hardworking com- The Lincoln Electric Co. L . W . Myers, Ex Off.
mittee volunteers. Keep up the good Consultant
work and excellent results. The T C. Myers
DovaTech Ltd. E G. D e L a u r i e r , CAE, Ex Off.
industry awaits the new milestone American Welding Society
you will set in the year 2001.
Advertising
Director of Sales Advertising Sales Representatives
Rob Saltzstein Blake and Michelle Holton
1-800-644-5563
Advertising Production Manager
Colleen Beem
Subscriptions
Nancy Batista
American Welding Society
550 N . W L e J e u n e Rd., Miami, F L 33126
Richard L. Alley (800) 443-9353
A WS Associate Executive Director Copyright © 2001 by American Welding Society in both printed and electronic
formats. The Society is not responsible for any statement made or opinion ex-
pressed herein. Data and information developed by the authors of specific ar-
ticles are for informational purposes only and are not intended for use with-
out independent, substantiating investigation on the part of potential users.
i z I JANUARY2001
Relief for robotic indigestion.

i::i

i!i

Y
[
Robotic indigestion doesn't
come from jalapefio peppers.
It comes from welding wire with
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Fortunately, there's a cure. National-Standard welding wire
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Its uniform cast and minimal helix ensure exact wire positioning.
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Get relief from robotic indigestion and unnecessary downtime.
Feed your automatic welding equipment N-S wire. For your FREE test
spool and the name of your local N-S distributor, contact National-Standard.
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Circle No. 21 on Reader Info-Card
 Jason just put down two c h e e s e b u r g e r s ,
a Coke ~ and 80 Ibs. of wire.
Not bad for his first day.

Adjustable, built-in pulsiHg

parameters deliver the
optimum settingsfor wire
thickness, joint ~ypeand
welding position.
 Miller,
The PoweroJBhle~'

Business is b o o m i n g . That's the g o o d news.

T h e b a d news is there's a growing shortage

of welders. W h i c h m e a n s y o u ' r e t u r n i n g

f ~ .......................................
to guys like Jason - - long on drive, short on
/

( ISSUE How a major metalforming e x p e r i e n c e - - to get t h e j o b done. T h a t ' s why

shop could make out-of-
position pulsed welding Miller's advanced welding t e c h n o l o g y is a
easier for its inexperienced
lot m o r e practical a n d reliable. Take o u r
operators.
p r e - p r o g r a m m a b l e Invision system. It makes
f"

(SOLUTION Invision 456P and 60M

Series dual wire feeder ....
difficult welds a piece of cake. A n d turns even

simplifies set-up and your g r e e n e s t o p e r a t o r into a p r o - - day one!

provides great arc
characteristics for easy,
T u r n i n g real world challenges into real world
consistent pulsed welding,
solutions. That's The P o w e r o f Blue'$

"The Invision allows us to

weld out-of-position very
easily compared with
Download
the high degree of skill
required by conventional

www.MillerWelds.com/invision
I-4-A-MILLER.

/
 A collection ~f btdustry news frorn the lnternet
!
BY MARY RUTH JOHNSEN, Features Editor
Airgas and supplyFORCE.com
Join Forces
Airgas, Inc., recently announced it
has joined supplyFORCE.com's North
American distributor network. Airgas,
Inc., distributes industrial, medical and
specialty gases and related equipment,
and it will augment supplyFORCE.com's
position in the safety product market.
In its first year, supplyFORCE.com
has built a distributor network of ap-
proximately 300 independent distribu-
tion companies with more than 3400
shipping locations across North Amer-
ica. The company is dedicated to pro-
viding its customers with national ac-
count and integrated supply solutions
and Web procurement options. Airgas
will add to that its network of 700 loca-
W e b Site Offers Racing/Welding I n f o r m a t i o n
Miller Electric Mfg. Co. Visitors to
the motor sports section of Miller's Web
site can now get answers to their racing-
related welding and fabricating ques-
tions. Andy Weyenberg
has raced cars for 14
years and trained weld-
ing equipment distribu-
tor technicians for 11.
Weyenberg has an-
swered racing and weld-
ing questions for hobby-
ists at trade shows for
years and wanted to be
available year-round on
the Web site.
"I personally respond
to every question within
about a week, and I post
the more interesting or
common questions on the
Web site," he said.
Recent questions and answers posted
include the following:
"When welding aluminum items such
as heads or intakes, which is the pre-
ferred method, M I G or TIG?" Answer:
"The T I G method is used to weld these
items because of its complete fusion and
accuracy of the repaired area. MIG,
being more of a production process,
would deposit too much material in the
161JANUARY2001
tions in 44 states, Canada and Mexico.
"We are thrilled about our partner-
ship with supplyFORCE.com," said
Peter McCausland, chairman and chief
executive officer of Airgas. "Supply-
F O R C E . c o m and its distribution net-
work will benefit from access to Airgas's
large customer base. We will benefit as a
premier supplier of gases and welding
supplies to their distribution network.
Together we will deliver the most effec-
tive supply chain management services
and the broadest product offering to na-
tional and local accounts."
Airgas may be visited on the Internet
at www.airgas.com; supplyFORCE.com
can be found at www.supplyforce.com.
affected area, causing excess post repair
machining and cleanup."
The motor sports section also includes
information about the racing teams
Miller sponsors, a gallery of photos
Weyenberg has taken at various races and
Miller racing gear. It also offers links to
the rest of the company's Web site.
The "Ask Andy!" page can be ac-
cessed through the company's main site
www.millerwelds.com or directly at the
following address:
http://www.millermotorsports.com
Carpenter Launches
On-Line Database
To serve its new e-business initiatives,
Carpenter Technology Corp., Wyomiss-
ing, Pa., recently introduced an on-line
database that will provide extensive,
searchable technical information to cus-
tomers looking for metals to fit their ap-
plications.
The database can be accessed at
www.carpenterdirect.com, an on-line
metals shopping site the company
launched in October 2000. The informa-
tion in the database is free to all regis-
tered users of the Web site.
Initially, the database includes data
sheets for materials sold through the
site, related technical papers and the
company's stainless steel Selectaloy® di-
agrams, which help customers choose
metals. Other information will be added
later.
The data will also be available at
www.carpentercare.com, the company's
proprietary customer support site and
selected portions will be available at
www.cartech.com, Carpenter's corporate
Web site.
Site Dedicated to Welding
Safety Products
Sentinel, LLC. The Sentinel Store is
an e-commerce site that offers the com-
pany's line of welding safety products di-
rect to consumers. Sentinel is based in
Menlo Park, Calif.
The site features information about
the Sentinel welding helmet, which is
made with Dupont Kevlar® brand fiber,
and the autodarkening filters available
for use with the helmet.
Visitors click on the "buy it here" but-
ton to reach an on-line order form. In-
formation is also included about ship-
ping and the company's privacy and
security policies.
Plans call for the site to include in-
formation on safety trends in the welding
industry, with links to a variety of indus-
try resources, but those pages are still
under development.
http :/ /www.sentinelsafety.com
Aws
AWS D I. I CODE WEEK
The #1 selling welding code now comes alive in a five-day seminar that begins with a roadmap of Dl.l:2000, Structural Welding
Code - - Steel. This is your opportunity to learn from an expert AWS instructor and ask your toughest questions about DI.1.
Code week continues with corresponding subjects geared toward engineers, supervisors, planners, welding inspectors and welding
technicians. Since your work is based on a reputation for reliability and safety, you want the latest industry consensus on prequalification. If
you want to improve your competitive position by referencing the latest workmanship standards, inspection procedures and acceptance
criteria, you won't want to miss this seminar! Each day will be in-depth and intense.

(Day 1, Monday) D I. I Road Map (Day 4,Thursday) Fabrication

Houston, Tern- - January 29, 2001 San Francisco,Calif.- - March 5, 2001 Houston, Ten-- February 1, 2001 San Francisco,Calif.- - March 8, 2001
St. Louis, Mo. - - April 9, 2001 Chicago, IlL - - July 16, 2001 St. Louis, Mo. -- April 12, 2001 Chicago,I11.- - July 19, 2001
Las Vegas,Nev. -- September 17, 2001 Atlanta, Ga.-- November5, 2001 Las Vegas,Nev. - - September 20, 2001 Atlanta, Ga. - - November8, 2001

(Day 2, Tuesday) Design of Welded (Day 5, Friday) Inspection

Connections Houston, Te~ - - February2, 2001 San Francisco,Calif.- - March 9, 2001
Houston, Tex.- - January 30, 2001 San Francisco,Calif.- - March 6, 2001 St. Louis, Mo. - - April 13, 2001 Chicago,I11.- - July 20, 2001
St. Louis, Mo. - - April 10, 2001 Chicago,I11.- - July 17, 2001 Las Vegas,Nev. - - September 21, 2001 Atlanta, Ga. - - November9, 2001
Las Vegas,Nev.-- September 18, 2001 Atlanta, Ga. - - November6, 2001
Pdces
(Day 3, Wednesday) Qualifications Member Nonmember
Houston, Te~:- - January 31, 2001 San Francisco,Calif.-- March 7, 2001 (One-day seminar) $345 $420
St. Louis, M o . - April 11, 2001 Chicago,I l l . - July 18, 2001 (Entire week) $795 $870
Las Vegas,Nev. - - September 19, 2001 Atlanta, Ga. - - November7, 2001

UPCOMING
A W S Sth R O B O T I C A R C W E L D I N G
CONFERENCE AND EXHIBITION
February 5-6, 2001 i Orlando, Fla.
This conference is aimed at welding engineers and technicians,
manufacturing specialists, managers and all others concerned
with the latest developments in the fast-changing field of arc
welding robotics and associated topics. Particular emphasis is
given to case studies of actual applications in motorcycle, ship
and heavy equipment manufacturing, and on criteria used in
robot selection. Other areas covered include the impact of the
Internet, fixturing, off-line programming, remote monitoring,
computer interfaces with welding cells and metal arc welding. A
special activity is a luncheon featuring a keynote speech on the
present status of robotic welding.
WELD CRACKING:
C A U S E S A N D CURES C O N F E R E N C E
June 7-8, 2001 m Houston, Tx.
Hydrogen-induced cracking isn't the only culprit that engineers
and QC professionals need to be on the alert against. AWS
experts will identify other, often unknown or overlooked
cracking scenarios, along with the best use of counteroffensives,
CONFERENCES
including preheat and peening. Other areas covered include the
best use of ultrasonics and Charpy tests, plus the lowdown on
new test options. This intense day-and-a-half program covers
cracking in steels, aluminum, stainless steels and titanium.
T H E C U T T I N G OF PLATES C O N F E R E N C E
July 17-18, 2001 1 Chicago, II.
For decades, the only plate cutting method was oxyfuel cutting.
It is still used, but recently, methods like plasma cutting, high-
definition plasma cutting, water jet cutting and both CO2 and
YAG laser cutting are more frequently used. Many companies
are in turmoil deciding which method is best. This conference
will provide engineers with greater understanding of the issue,
knowledge about the cost of equipment, payback, cutting
performance and valuable information that can be implemented
profitably into their company's production lines. This
conference will cover mostly steel, with some mention of
stainless and aluminum. Topics include laser cutting, plasma
cutting, high-definition plasma cutting, water jet cutting and
innovations in oxygen cutting.

F or further information contact: Conferences, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126, Telephone: I

I(800) 443-9353 ext. 223 or (305) 443-9353 ext. 223, FAX: (305) 443-1552. Visit the Conference Department homepage
http://www.aws.org for upcoming conferences and registration information.

WELDINGJOURNAL117
I
A Guaranteed Weld Process
Unbelievable!!!
How does your company design against weld failure?
We qualify an NDT with transverse tensiles and bends. Sometimes a low temperature charpy.

Will your weld transverse bend a 1 1/2" diameter pin with

LOF in the specimen?
Not possible, lack of fusion (LOF) destroys ductility, reduces strength and the weld fails.

Its true! But this weld is designed to resist failure even with LOF.

Unbelievable!!
How would your weld stand up against an explosion bulge test that requires 17%
reduction in area before failure?

~Brittle F r a c t u r e A n a l y s i s By D e f e n c e R e s e a r c h A t l a n t i c ~
Resistant To Fracture?

Wait a minute. How is that possible?

A failure resistant weld will qualify with defects of slag, porosity and LOF
throughout the weld. I

It's a fact almost all weld failures in ships, on and off highway transporters
(cars, trucks, dozers), structural buildings and bridges occur below a transition
where the weld has lost its toughness against cracking.
fracture transition
plastic | Plastic
Dynamic j~
Tear
Energy Upper Shelf DynamicTear ,'" ._____~K
Specimen ,, / " |Structure
(J) ,/
or ,/
[:harpy f fracture ,' / '
Average Specimen/
transition , ;
Shear Lip elastic I / / ~
Width
(ram) --~
Elastic Kic ,;//..X Elastic- Plastic JIC

Temperature

Youmustmovetransitionto a saferzonefor a morecrackresistantweld,

Can you do that?

Let our Weld Fracture Consultants advise you on how to develop your own
guaranteed weld process.You can guarantee longer life for your weldment
with built in crack resistance.
All communications will be in confidence. Call Toll Free 1-866-451-5795

Circle No. 22 on Reader Info-Card

**Weld Process International Ltd.**
Automobile Heads List of Century's
Greatest Engineering Achievements
The automobile is the greatest mechanical engineer-
ing achievement of the 20th century, according to a sur-
vey from the American Society of Mechanical Engineers
(ASME). The automobile topped the list of technologies
that made major contributions to engineering progress
and social and economic development during the past
100 years.
The organization's Mechanical Engineering magazine
cited numerous technical attributes of the automobile as
well as the auto industry's role in the development and
growth of specialized machine tools, modem manufac-
turing processes and efficient steel mills. These periph-
eral businesses "created thousands of jobs for construc-
tion workers, electricians and plant workers," according to the
magazine. "The auto has brought unprecedented freedom of
movement to individual members of society."
Following the automobile and rounding out the rest of the top
ten greatest mechanical engineering achievements are the
Apollo space flights, power generation, agricultural mechaniza-
Conference Details State of the A r t of Sheet Metal W e l d i n g
In its quest for greater fuel efficiency, the auto industry is
striving to make lighter weight vehicles. However, "lightweight
cars are a challenge from a welding standpoint" because of the
use of newer, more-difficult-to-weld materials, explained
Michael J. Karagoulis, chair of the AWS Detroit Section's Sheet
Metal Welding Conference IX. Approximately 150 persons
attended the conference, held October 17-20 in Sterling
Heights, Mich. It included the following sessions: resistance spot
welding of steel; aluminum joining technologies; related sheet
metal joining technologies such as laser beam welding and
pulsed gas metal arc welding; and resistance welding modeling
and control.
• Kurt Hofman of RoMan Mfg., Inc., presented work on
optimizing the thermal characteristics of resistance welding
transformers. He and coauthors Dietrich Roth, Stanley
Rutkowski, Mark Siehling and Kendall Ymker investigated
development of transformers with higher thermal or kVA ratings
in order to reach higher weld currents and increased duty cycles
while keeping the same physical dimensions of commonly used
transgnn transformers. While it was shown such a transformer
can be designed and manufactured, Hofman said, "This opti-
mization of thermal characteristics comes with the cost of higher
flux density than what was previously used and requirements that
the associated equipment be robust enough to withstand the
demand of higher continuous currents."
• William Faitel of Lamb Technicon Body and Assembly
Systems gave an overview of the Intelligent Resistance Welding
Program, a recently completed five-year project sponsored by
the automotive industry and the National Institute of Standards
and Technology. The goal of the program, Faitel said, "was to
7.0 I JANLJARY2001
tion, integrated circuit mass production, computer-aided design
and computer-aided manufacturing technology, bioengineering,
codes and standards, air conditioning and refrigeration, and the
airplane.
The survey conducted last year included 1400 responses deliv-
ered on-line and by mail.
make every weld a good weld." Typically, there are 2000 to 5000
spot welds in every car, Faitel reported, but because of a lack of
confidence in the quality and consistency in the welds, a typical
automobile has up to 30% more welds than required to maintain
its design requirements. Program participants were divided into
seven project teams that focused on topics such as developing
sensors for process monitoring, analysis of nugget growth, opti-
mizing welding equipment design and maintenance, and devel-
opment of monitor and feedback control systems for steel and
aluminum. Faitel hailed the program as a success and said it con-
tributed to the collective knowledge base regarding resistance
welding. More information about the program is available at
www.autobody.org.
• Jian Xie of the Edison Welding Institute reported on his
work on dual-beam laser beam welding. A 6-kW CO 2 laser beam
was split in two and the beams located in tandem during pro-
cessing. Experimental results showed the dual beam produced a
more stable keyhole, which resulted in improved weld quality in
both steel and aluminum. In steel, undercut, spatter, hardness
and the susceptibility to centerline cracking were reduced; in alu-
minum, it produced smooth weld surfaces and fewer defects such
as porosity and undercut.
The next Sheet Metal Welding Conference is tentatively
scheduled for February 2002. Anyone interested in presenting a
paper or in need of other information can contact Michael
Karagoulis via e-mail at michael.j.karagoulis@gm.com. Periodic
updates will also be posted on the AWS Detroit Section's Web
site at www.awsdetroit.org,or you can call the Section at (810)
231-2502 - - Mary Ruth Johnsen, FeaturesEditor.
Lincoln Welding Machines Featured
in Film CastAway
Equipment from the Lincoln Electric Co., Cleveland, Ohio, is
featured in the movie Cast Away, which opened in December.
The contemporary drama stars Tom Hanks as a man who is iso-
lated on a deserted island and then must transform himself both
physically and emotionally in order to survive.
At the beginning of the film, Hanks' character meets a woman
whose occupation is a welder. She displays her welding talent
using the Lincoln Electric equipment. "Specifically for the movie
shoots, we liked the look of the machine and the red cabinets,"
explained Tristan Borne, the fdm's gang boss. "The character
who is supposed to be welding is a passionate artist, and red por-
trays passion."
Following filming, the production company and Lincoln
donated the Power MIG ® 255, Square Wave" TIG 275, Pro-
Cut ® 55 and AC-225 machines to Herbert Hoover High School
in Glendale, Calif., for use in its automotive program.
World's Largest Autonomous
Submarine Christened
Cutthroat, the world's largest unmanned, autonomous subma-
fine, was recently christened at the Bayview, Idaho, facility of the
Acoustic Research Detachment (ARD) of the Carderock Div.,
Naval Surface Warfare Center, Naval Sea Systems Command
(NAVSEA).
The 110-ft-long, lO-ft-diameter unmanned sub is a large-scale
model of the future USS V/rg/n/a attack submarine. It will oper-
ate in Lake Pend Oreille in Idaho for testing advanced technolo-
Twelve hundred balloons were released following the christening of
the Cutthroat, the world's largest unmanned, autonomous
submarine.
gies for submarines while Newport News Shipbuilding and
General Dynamics Electric Boat build the Virginia.
The two shipbuilding firms designed and fabricated Cutthroat
[Large Scale Vehicle (LSV) 2]. Following testing and certifica-
tion ashore and on Lake Pend Oreille, the new vehicle will be
operated for NAVSEA by ARD. Plans for testing include
advanced sail designs and propulsar assemblies. The unmanned
sub boasts an advanced guidance navigation control system and
an on-board data acquisition system.
Children and instructors from nearby Athol Elementary
attended the christening ceremonies. Students selected the name
Cutthroat in 1997 after the Navy invited them to choose from a
list of indigenous Idaho fish. The Navy and its industry partners
have continued to keep the students informed of the submarine's
progress, and many attended the christening and signed their
names on the hull.

dANUFACTURERS OF CORED WELDING WIRE AND STICK ELECTRODES

We have been told that we are the best-kept secret in the welding industry. In an
effort to correct this situation w e advise that:

Stainless
WE M A KCast Iron Cobalt AISI Nickel
4 1 0 N i M o FC 33% Ni 1 4130 ENiCrFe-2
5 0 2 FC 55% Ni 6 4140 ENiCrFe-3
5 0 5 FC 99% Ni 12 4340 EniCrCoMo-1
E 2 5 5 3 FC 21 ERNiCrMo-3
E 2 2 0 9 FC 2101 ERNiCr-3
E 6 3 0 FC
9 0 4 L FC
THE ABOVE ARE JUST A FEW OF THE C O R E D WIRES T H A T WE MAKE. FOR M O R E
INFORMATION CALL:

Circle No. 4 on Reader Info-Card

WELDING JOURNAL J 21
Space Station C r e w Relies on
Gas Detection Instruments
Specially designed gas detection instru-
ments are being used aboard the
International Space Station to detect poten-
tially lethal carbon monoxide, hydrogen
cyanide and hydrogen chloride. The instru-
ments, which were made by Industrial
Scientific Corp., Oakdale, Pa., are also used
to back up the station's primary oxygen mon-
itoring system.
When the Expedition 1 crew arrived in
early November for their four-month-long
mission, the instruments were already in
place. The portable, hand-held instruments
are called, in NASA parlance, the CSA-CP,
for Compound Specific Analyzer-
Combustion Product. The CSA-CP instru-
ments have been in place on all space shuttle
missions since December 1999.
Orbiting at approximately 146 nautical Expedition 1 crew members, from left, Flight Engineer and Russian Cosmonaut Sergei
miles above the earth, the three-module Kr/kalev, International Space Station Commander Bill Shepherd and Soyuz Commander
space station weighs 67 tons, is 143 ft long and Russian Cosmonaut Yuri Gidzenko pose before a model of the International Space
and includes about 8800 ft 3 of habitable vol- Statiott The crew launched October 31 in a Soyuz capsule from the Baikonur Cosmod-
ume. By the time the U.S. Laboratory rome in Kazakhstan; awaiting them upon arrival were specially designed gas detection in-
Destiny is installed early this year, the struments. (Photo courtesy of NASA.)
International Space Station will have sur-
passed both Skylab and Mir in total livable
space. •

@ i~ ¸¸
J
•

LDedicatedto the pipe fabrication industry I

Setting

all AROUND world

T

AUTOMATIONLT|E
321 Hocquart Street, St, Bruno, QC CanadaJ3V 6B5
Tel.: (450) 461.1221 Fax: (450) 461-0808
.... www.tecnar-automation.com

22 1JANU~RY~O I Circle No. 24 on Reader Info-Card

Reliability of Tube-to-
Tubesheet Joints Debated
Dear Editor:
I regret to say I don't agree with some of
the statements put forth by Harry W. Ebert
in his article, Improving the Reliability of
Tube-to-Tubesheet Joints, published in the
September 2000 issue of the Welding Journal.
The roll or expand joints without grooves
shown in Fig. 1A, page 47, deserve much
more respect than they are given in the
article. Although Mr. Ebert says the joints
have only a "few applications," in reality
there are probably millions of these types of
tubes a t t a c h e d by e x p a n s i o n in surface
condensers everywhere.
F u r t h e r m o r e , the " i n e x p e r i e n c e d
organizations" Mr. Ebert refers to as having
sometimes selected the faulty joints are
actually among the best and largest turbine
g e n e r a t o r and t u r b i n e c o m p r e s s o r
manufacturers in the world. Besides turbine
equipment, some of these manufacturers a r e
also large producers of surface condensers
who sell the equipment independently from
the turbine. Surface condensers, incidentally,
are not c o v e r e d by A S M E or T E M A
standards but instead are covered by the
Standards for Steam Surface Condensers,
published by the Heat Exchange Institute.
Finally, Mr. Ebert says "unsatisfactory
results" were the outcome when using the
roll or expand-only joints. In my opinion, the
trillions of kilowatts produced every year by
thermal power plants all over the globe, not
to mention the billions of cubic meters of
countless gases compressed in chemical and
p e t r o c h e m i c a l plants, hardly i n d i c a t e
unsatisfactory results due to the use of these
joints.
As a final comment, I take issue with Mr.
Ebert's assertion that expanded joints with
grooves (Fig. 1B) are easy to replace. When
removing the tube already expanded from
the tubesheet, utmost care must be taken so
as not to damage the tube seat (i.e., the hole
walls).
Giovanni S. Crisi
AWS A5 Committee Advisory Member
While I appreciate the interest and
comments of Mr. Crisi, my experience indicates
rolled tube-to-tubesheet joints, which are
neither welded nor provided with grooves or a
similar concept (e.g., flaring), exhibit very low
reliability when subjected to changes in
pressure and~or temperature. While the initial
rolling may be adequate to pass a hydrostatic
test, the pressure and temperature cycles
associated with typical service conditions will
gradually relax the stresses that were set up
during rolling and provided a seal. This
relaxation will initiate leaks that are not
normally acceptable for ASME- and TEMA-
type heat exchangers and similar equipment.
Harry W. Ebert
Madison, N.J.

A R O N S O N POSITIONERS
POSITIONING
• Advanced cover gas-nozzle system acts like a miniature "Air Made Easy
Hockey" table to surround the weld in argon / inert gas.
Designed for a variety of welding cover gas applications. Now you can get Aronson positioning quality at a popu-
lar price. Koike Aronson engineered in the accuracy,
safety and reliability
you've come to
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] ~ ~ AllStainlessSteel316L and 135° tilt from
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visitourwebsiteat: wwwwe/dhugger.com Circle No. 18 on Reader Info-Card

Circle No. 27 on Reader Info-Oard

WELDING JOURNAL I 23

ro cts
For more information, circle number on
Reader Information Card.
Shape-Cutting Controls
Process Faster
The Plus family of shape-cutting con-
trols can produce processing speeds that
can do kerf calculations 80% faster and
have downloading speeds four times
faster than earlier versions of the prod-
uct. The Plus CNC Control family in-
cludes the 2.5 Plus, 2.8 Plus integrated
drive system, 1400 Plus and 1250 Plus
control systems. This line also has more
standard memory, new gantry and can-
tilever shape-cutting machines that
retrofit older machines and field up-
grade kits that will improve processing
speeds in older CNC units.Upgrade kits
have comprehensive step-by-step in-
structions with new software, a new pro-
cessor card and revised front panel.
Cleveland Motion Controls,
Burny Division
7550 Hub Pkwy., Cleveland, OH 44125
Electric-Powered Vise Reduces
Cost and Risk
The T-Vise T" electrically operated
vise provides the same ease of opera-
tion, fast actuation and holding power
common to hydraulically powered vises.
These features help reduce costs by
24 I JANUARY 2001
speeding part loading times by 300%,
reducing scrap through consistent
clamping pressures and minimizing the
risk of operator repetitive motion in-
juries. The T-Vise's footswitch cord
plugs into a normal ll0-V outlet and is
ready to clamp in less than 5 min. To
protect against electrical problems, the
T-Vise workholding vise with the
footswitch/GFI option includes a fast-
acting ground fault interrupter to auto-
matically cut electrical power should a
problem occur. The vise can be inte-
grated with machine controls for auto-
matic operation.
TCAM Technologies
6944 Spinach Dr., Mentor, OH 44060
Axial Flow Laser
Cuts More, Faster
The STS 4000-W CO e fast axial flow
laser provides increased capacity to
clean-cut stainless steel up to ¾-in. thick.
The laser increases the speeds at which
thinner stainless and galvanized steel can
I III I
~ 4o00 :
be processed for higher productivity
when cutting stainless and galvanized
steel as thin as 0.080 in. Nitrogen clean
cutting speeds of well over 225 in./min
can be achieved in this thickness range.
100 The STS 4000 has superpulse mode for
faster stainless piercing and gated pulse
mode for more consistent stainless cut-
ting. The power range is wide to enable
the cutting of intricate parts and deep-
penetration welding, as well as cladding
and heat-treating applications.
PRC Corporation
North Frontage Rd., Landing, NJ 07850
Rack Stores Drums Containing
Hazardous Materials
Haz-Rak eliminates contamination
TM
of factory floors, soil and groundwater
caused by chemical leaks and spills and
costly clean-ups that result from such ac-
cidents. The system is designed for
indoor/outdoor storage of solvents,
paints, motor oils, corrosives and other
regulated materials. Haz-Rak accommo-
dates 2-8 palletized 55-gal drums per
storage level with a maximum capacity
of 64 drums. Spill sump capacity ranges
from 150 to 1200 gal, exceeding the most
stringent environmental regulations.
The drums are constructed of heavy-
gauge steel inside and out and have a
chemical-resistant coating.
Haz-Stor 103
2454 Dempster St., DesPlaines, IL 60016
Helmet Keeps Welders Cooler
The Speedglas ® helmet features
101 aerodynamically-designed exhaust vents
that expel carbon dioxide and lower heat
and humidity. The welder's natural
breathing action directs exhaled air out
of the helmet through four vents that
lead to two thin, recessed openings found
on both sides of the helmet. The design
reduces carbon dioxide levels within the
welder's breathing zone because fresh,
incoming air is drawn from the area
around the welder's neck, which is usu-
ally away from the smoke plume. The
helmet is most beneficial to welders who
leave their helmets in the down position
for prolonged periods of time.
Hornell Speedglas 104
2374 Edison Blvd., Twinsburg, OH 44087
102 Welding Gripper is
Self-Centering
Model WPG-250 features a universal
three-jaw, self-centering welding gripper
that allows for increased versatility from
a single gripper. It has a clamping range
from 0.38 in. (10 mm) to 15 in. (381 mm)
and can be mounted on any make of po-
sitioner. Fast close/open action using a
lever firmly locks and releases the work-
piece. The WPG-250 is designed for
heavy use, but weighs about half as much
as a standard chuck providing minimal
reduction in positioner capacity. The door; wear bars at the sides of the
units enhance efficiency to operations workspace; and a floor reinforced for a
involving welding of fittings, flanges, etc. 2000 lb load on a removable subway
grate. There is a digital-indicating tem-
Gullco International Inc. 105 perature controller, manual reset excess
21568 Alexander Rd., Cleveland, OH 44146 t e m p e r a t u r e controller with separate
contactors and a recirculating blower air-
flow safety switch.
Lifting Device Adapts
to Variety of Jobs Grieve Corporation 108
500 Hart Road, Round Lake, IL 60073-2890
The MechLift is constructed on the
telescoping principle: one precision ex-
truded aluminum section runs on guides
inside another larger section. It can load
up to 325 lb and can be adapted to a va-
riety of overhead material handling ap-
plications.The Mech Lift offers high
torque resistance,' precise load place-
ment, smooth movement and low oper-
ator effort. The lift can be suspended
from a MovoMech aluminum overhead
traveling system with manual or motor -
actuated transport, or it can be incorpo-
rated into portal robots, knuckle-boom
cranes and similar systems.

EMH MovoMech Systems 106

550Crane Dr., Liverpool Industrial Park
Valley City, OH 44200

Power Supply Reduces

Contaminants

Model 207-HP is a 100-A micropro-
cessor-controlled tube welding power
supply and controller specifically de-
signed for use in clean rooms and other
areas where particulate shedding is of
concern. The unit utilizes an all-
stainless-steel gas system, as well as an
internal cooling system, eliminating the
need for external air flow. Model 207-
HP has high-purity, semiconductor-
grade gas connections and a polished
stainless steel housing. It is compatible
with all Arc Machines Model 9 series
weld heads.
Arc Machines, Inc.
10500 Orbital Way, Pacoima, CA 91331
Take the road to technology with Jetline's 9500
Contro||er
We p u t the h i g h e s t t e c h n o l o g y i n t o o u r p r o d u c t s so t h a t
you d o n ' t have to w o r r y a b o u t y o u r w e l d i n g process. Our
t e c h n o l o g y p r o v i d e s you w i t h the very best p e r f o r m a n c e
you shou]d e x p e c t f r o m y o u r w e l d i n g system.
J e t l i n e ' s u n i q u e 9500 System C o n t r o l l e r b r i n g s t e c h n o | o g y
to y o u r a p p l i c a t i o n . Just look at its f e a t u r e s :
Controls f o u r w e l d i n g p a r a m e t e r s - s i m u ] t a n e o u s ] y .
S u i t a b l e for a]] arc w e l d i n g processes.
107 Uses closed l o o p c o n t r o l for the u l t i m a t e i n a c c u r a c y .
Single or m u ] t i - p a s s w e l d c o n t r o l

Top-loading Oven Preheats Contact J e t l i n e - let the c o m p a n y w i t h the h i g h e s t

Large Molds t e c h n o l o g y i n hard a u t o m a t i o n b r i n g t h e i r k n o w l e d g e
a n d t e c h n i c a l e x p e r t i s e to b e a r to solve y o u r w e l d i n g
No. 848 is a 1000°F, electrically needs.
heated, top-loading oven used for pre-
heating large steel molds at a customer's
facility. Workspace dimensions are 6 x 3
x 3 ft. Heat is provided by an 80- kW jetline
engineering,
1 5 GOE]DYEAR STREET, IRVINE, CA g 2 6 I B
inc.
tubular heating element sheathed in In-
coloy. A 5000-ft3/min, 5-hp, recirculat- TEL: (949) 951-I 51 5 • FAX: (949) 951"9237
ing blower furnishes horizontal airflow ~'*'~IL: SALES@JETLINE.COM
across the load. This oven features 8-ft WWW.dETLINE,CnM
insulated walls; an aluminized steel in- AUTOMATICALLY T H E ~ BEm~'?~
terior and exterior; reinforced ¼-in steel
plate top; air-operated, rear-hinged
Circle No. 17 on Reader Info-Card

WELDING JOURNAL I 25
 Flux-Cored W i r e Offers High
Disposition Rates
The Outershield ® 71 Elite gas-
shielded, flux-cored wire produces a
bead in any position and has out-of-po-
sition pool control. Its fast freeze slag
characteristics are suitable for applica-
tions requiring high deposition rates in
the fiat, uphill and overhead positions.
Easy slag removal, lows patter/fume lev-
els and a smooth arc are other features.
The wire is available in 0.045-, 0.052- and
¼6-in. diameters in 10- and 33-1b spools,
a 600-1b coil and a 600-1b drum (not all
diameters available in each package
type). It can be used for fillet, lap and
butt joint welds on single- and multiple-
pass applications. The electrode was de-
veloped for all-position, semiautomatic
welding of mild steel and low-alloy steels.
Lincoln Electric Company
22801 St. Clair Ave., Cleveland, OH 44117-1199
Calibrator Features Weld-
Through Capability
The WP9000 is a hand-held force cal-
ibrator designed to withstand current fir-
astic
WEGENER is the world leader in the design and manufacture of
a vast array of PLASTIC WELDING EQUIPMENT and accessories.
"Self-contained hand welders for
repair work and small jobs
*Hot air hand welding systems for
fabrication of tanks, boxes, tank
liners, etc.
"Extrusion welding systems for
welding thicker gauged materials
"Machinery for bending and butt
fusing sheet material
"Pipe band saws & fusion machines
"Spark testers to check for voids in
welds, coatings and linings
"Customized training programs
available
Next time you need a PLASTICWELDERor have questions on PLASTICWELDING
applications, contact the SPECIALISTSat:
I,~L 16W231 S Frontage Road, Unit #12 I
rA ~]U ~ ~ ~ M ~ D
w w m '~B m, -, w m lib Ph (630) 789-0990 Fax(a30) 789-1380 |
,~ WHENTHEREQUIREMENT tSQUALITY
Circle No. 26 on Reader Info-Card
7.6 I JANUARY 2001
ing while calibrating the force for micro-
joining weld heads. It is portable, fits all
electrode sizes, measures instantaneous
weld-tip force and captures peak force
achieved during the weld cycle that help
establish quality process parameters and
109 eliminate poor-quality welds. The cali-
brator has 0.5% accuracy, is traceable to
NIST and can be recalibrated at the fac-
tory for a nominal charge. The sensor
head is small and comes in a one- or two-
handed version to meet various applica-
tion needs.
Sensotec
2080 Arlingate La., Columbus, OH 43228
i Fasteners Designed for
Hand welding using a hot air
welding gun
WEGENERNorth America, Inc.
Burr Ri,tge, ,, ~os2: I threaded configurations. Metric sizes
emaih in/o@wegener-no.com
Weld Head Designed for
Battery-Pack Manufacturing
The 508A/EZ high speed precision
weld head is designed for joining thin tab
material to battery cells to work in high-
volume production environments. Com-
bined with the new DC25 linear DC
power supply, it is suitable for battery
pack manufacturers. The 508 weld head
is driven by E Z - A I R ® technology that
repeatedly triggers the weld with no over-
force, regardless of speed or electrode
stroke. An integrated EZ-Clean function
assures easy electrode maintenance and
the force indicator light confirms repeat-
able firing. The weld head is fully assem-
110
bled and includes a base plate and stand
for "out-of-the-box" operation.
Unitek Equipment 111
1820 S. Myrtle Ave., Monrovia, CA 91017-7133
Arc Stud Welding
The company offers an array of low
carbon, stainless and aluminum fasten-
ers for use in the arc stud welding pro-
cess. Available in flux cored and gas-
shielded versions, the fasteners come in
a variety of sizes and shapes that can be
used in various stud welding applica-
tions. Specialty, round, square, rectan-
gular and irregular-shaped fasteners are
available. Sizes range from 14-gauge pins
to 1-in. diameter in threaded or un-
range up to M24. Materials include low
carbon steel, stainless steel and alu-
minum. Fasteners may be plated with
zinc, nickel, dichromate and other fin-
ishing materials. The standard thread is
U N C - 2 A for U.S. threads and 6 g for
metric threads. Custom thread sizes can
be provided upon request.
Image Industries
382 Balm Ct., Wood Dale, IL 60191
Plasma Station Adjusts
Height Automatically
The company's high-speed plasma
slide with automatic height control can
be used with conventional and precision
plasma torches. The slide increases the
speed of z-axis torch movement from 120
to 500 in./min. The system's rapid z-axis
torch movement and precise height con-
trol reduce the time required for initial
height sensing, piercing, cutting and col-
lision avoidance. Positive crash protec-
tion also reduces downtime and extends
consumable life. High speed without risk
of torch damage is harnessed by an
encoder-based, noncontact height con-
trol system.
ESAB Cutting Systems
411 S. Ebenezer Rd., Florence, SC 29501-0545
Cutting System
Boosts Productivity
The MPC2000 machine provides pre-
cision thermal cutting productivity. The
standard A C brushless servo drives and
precision planetary gearboxes provide
speeds up to 1000 in./min. The gantry-
style machine is designed to produce
high-quality parts in a multishift environ-
ment. A dual box-beam design supports
auxiliary equipment on the rear beam
while the front beam is dedicated to the
cutting process. Cutting widths of up to
24 ft are possible. A platform for high
acceleration and positioning speeds is
provided by linear ways in the cross axis
and precision-machined, l15-1b crane
rail in the longitudinal axis. Conven-
tional plasma up through 400 A and the
new 200- A precision plasma is sup-
ported, along with oxyfuel, markers and
112 a drill.
Messer-MG Systems & Welding
WI41 N9427 Fountain Blvd., Menomonee Falls, WI 53051
Triple-Scale Flow Meter for
G M A W and G T A W
The H2051 triple-scale flow meter
regulator for G M A W and G T A W has an
output of 0 to 50 ft3/h. Designed to be
attached to welding gas cylinders or man-
ifold systems, the unit measures inlet
pressure and shielding gas flow. The flow
tube has measuring scales for
argon/CO2, pure helium or argon, and
uses a highly visible red flow ball. The
unit's rubber O-ring valve, used around
the threads of the flow meter, is designed
to eleminate gas leaks.
Smith Equipment
2601 Lockheed Ave., Watertown, SD 57201
113
Autodarkening Helmet
Offers Large Viewing Area
Cutting edge welding helmet design
and state-of-the-art autodarkening tech-
nology have been combined in the
XVA'M (X-Tended Viewing A r e a ) line
of welding helmets. XVA models give TM
the welder the same wide viewing area
as a filter plate while retaining all the ef-
ficiency of an autodarkening filter. The
helmets are lightweight, waterproof,
solar-powered and 3.5 mm thick. Several
lines of manually variable filters are also
available.
Sellstrom Manufacturing
One Sellstrom Dr., Palatine, IL 60067
G M A W Arm Reaches
Long Distances
The 9000 series G M A W arms are for
industrial applications where the arm
must clear large, tall fixtures, reach long
distances and move up and down so the
operator can access the feeder and other
114
items built into the console. The arm uses
interlocking gears and crossover flexible
hoses in the articulating knuckle for un-
restricted movement, wire feed and fluid
flow. The use of HSS steel allows the
arms to reach more than 70 ft from one
end of the work area to the other. It can
support 200 lb of feeders and welding
wire at the arm's end in any position, and
it can accommodiate welding and con-
trol cables of up to 600 A in power.
Henning Hansen Inc. 117
P. O. Box 220, Pickering, Ont., Canada L1V 2R4
Oven Line Offers
Versatility
The company has introduced the
115 KEEN line of electrode and flux storage
ovens. The K-4RS is a fully insulated,
thermostatically controlled oven that can
store small amounts of spooled welding
wire. The unit is intended for smaller
shops or remote facilities in large plants
with limited storage needs. The oven
holds four 30-1b reels of welding wire cra-
dled in a perforated steel shelf. Units are
available in either a 120-or and 240-
model. The K-10 is a portable electrode
oven that may be operated in either a
horizontal or vertical position. These
units are designed to transfer electrodes
to the job site and maintain the integrity
of the electrodes throughout the welders'
shift. The K-10 is available in 120-V, 100-
W and 240-V, 100-W models.
Henkel 118
116 P.O. Box 1322, Hammond, LA 70404
WELDING JOURNAL J 27
February 5-6, 2001 • Orlando, Florida
• Complete conference on welding robotics
technology including the latest assembly For additional
automation, off-line programming, information
Internet support, and computer
interfacing
please call AWS
• Top equipment technical assistance at 1-800-443-9353
• 16 presenters from United States,
Germany, and United Kingdom
ext. 449 or visit
our website
at www.aws.org
and click on
Visit our website http:/Avww.aws.org
"CONFERENCES':
 Ultrasonic
Plastics
Welding
Basics
This ultrasonic welding primer will help ~ ~i~,ff

you understand how joint design

requirements and selection of welding
machine frequency affect
!: i ¸¸lid
the finished product

BY J A N E T D E V I N E

tnufacturers constantly search for equip-

"nent that will increase production, reduce
"ejects and otherwise improve their effi-
:iency. Ultrasonic welding - - used in the
medical, electrical, automotive, packaging, toy, housewares,
cosmetics and other industries - - achieves those objectives.
Ultrasonics can be used to insert metal fasteners in ther-
moplastic materials, to form a plastic rivet, to degate plastic
parts and to cut and seal films and fabrics, as well as to join
plastic parts together.
How does it work? Ultrasonic vibrational energy at the
interface of the plastic parts being joined causes the plastic
material to soften and flow in a fraction of a second. When
the material is pressed together and resolidifies, the bond is
made.
No glues or solvents are needed. Tooling can be designed
to secure and align the parts. Heating is confined to the in-
terface area so the assembled part is not too hot to handle.
Equipment can be integrated into automated lines.
There are two basic techniques: plunge welding and con-
tinuous welding. In plunge welding, the parts are placed
under a tool or horn; the horn descends to the part under
moderate pressure and the weld cycle is initiated. In the con-
tinuous welding process, the horn may "scan" the part, or
i~I~~!~ii~iiiii!i~ilililiiiii~ii~
~iii
the material is passed over or under the horn on a continu-
ous basis.

Principles of Operation
Every ultrasonic unit contains the following five ele-
ments:

JANET DEVINE is President of Sonobond Ultrasonics, West

Chester, Pa. (610-696-4710). She served as President of the Ul-
trasonic Industry Association from 1997 to 1999.

Fig. 1 - - Ultrasonic welding equipment such as this SureWeld line from Sonobond
comes in a variety o f sizes and styles, including microprocessor-controlled units, mod-
ular units and hand-held versions.
• A power supply that takes line
power at 50/60 cycles and changes it to a
high ultrasonic frequency of 20,000 cy-
cles per second or higher.
• A converter or transducer that
contains piezoelectric crystals that
change the incoming high-frequency
electrical signal to mechanical vibration
of the same frequency.
• A booster that transmits the vibra-
tion energy and increases its amplitude.
• A horn to deliver the vibration en-
ergy by contact with the parts to be
welded.
• A n anvil or nest to support the
workpiece. For bonding of textiles, the
pattern wheel replaces the anvil.
Equipment
Systems have evolved into a range of
sizes and styles to suit a wide range of ap-
plications - - Fig. 1.
The most common type is a press.
The welding press is equipped with a
pneumatic system to supply the neces-
sary contact force and the head is
mounted on a slide so it can be raised
and lowered to contact the part to be
welded. It is important the press be rigid
so bending deflections do not affect the
weld consistency.
The head is usually activated by a
palm button set. The ultrasonic energy
can be started just before the horn con-
tacts the part, after contact but before
full pressure is reached or when full pre-
set pressure is reached. After the ultra-
sonic energy is stopped, there is usually
30 [JANUARY2001
a short delay before pressure is released
to permit solidification of the plastic to
occur.
Many units are available with micro-
processor controls. These permit control
of the weld by time, energy or distance,
whereas the conventional welding ma-
chine is controlled by time only. Micro-
processor-equipped systems may also
have a port to transfer data to a printer
or computer for storage or for further
analysis. Some systems can receive data
from an external computer permitting
remote control.
Modular units are available, suitable
for incorporation into automated equip-
ment for special-purpose machines.
Some small units are available in hand-
held versions.
Power levels for 20-kHz equipment
are available at as high as 3000 W. Most
equipment sold falls into the 800-2000
W range. Design requirements dictate
that the higher the frequency the smaller
the unit. This also means higher fre-
quency units have less power handling
capacity and are suitable for the smaller,
more delicate or precision parts. Equip-
ment is available with frequencies of 20,
35, 40 and 70 kHz.
For continuous welding of film and
fabric, the ultrasonic system may be
built into a table that resembles a sewing
machine. The system is equipped with a
rotating wheel that can emboss or cut
the fabric with a wide range of patterns.
Other arrangements include multiple
head systems used for wide roll goods;
these may be used to quilt, slit or emboss
fabrics.
Horns
The horn is the part of the ultrasonic
system that contacts the parts to be
joined. The horn is designed to resonate
at the frequency of the ultrasonic system.
When the horn vibrates it stretches and
shrinks in length by a small amount. This
motion is referred to as the amplitude of
the horn.
Amplitude is measured as the peak-
to-peak motion at the face of the horn.
Increasing the voltage to the transducer
or changing the booster or the geome-
try of the horn can change this value.
Some plastics respond better at higher
amplitude.
The material of which the horn is
made must have good acoustical and
mechanical properties. These properties
are usually found in low-density materi-
als such as aluminum or titanium. How-
ever, steel or nickel alloys are sometimes
used when wear is a factor. Aluminum
can be chrome plated and titanium may
be carbide coated or carbide tipped to
reduce wear.
Horn Geometry
The shape and size of the parts to be
welded usually dictate the horn face.
The requirement the horn be a resonant
m e m b e r of the system dictates some
constraints.
The most commonly used horns are
stepped cylinder or stepped bar horns
- - Fig. 2. These are simple to machine
and capable of high gain (gain is ratio of
input amplitude to output amplitude).
Horn geometries include circular
fiat-faced horns, circular hollow horns,
rectangular horns and compound horns
- - Fig. 3. A compound horn is made up
of a rectangular or circular block horn
with extender horns attached by a stud to
the block horn face. This allows access to
recessed weld sites or clearance for pro-
trusions on the part to be welded.
Sharp transitions and tool marks
should be avoided because they can
cause stress risers that lead to cracking
of the horn. To prevent unwanted vibra-
tion in the width direction, horns wider
than 3-in. (7.62 cm) may need to be slot-
ted. Slots are located symmetrically
across the horn with the slot ending at
least ~in. (15.875 mm) from the face and
from the threaded stud hole. Slots are
radiused at the ends and edges to avoid
stress risers.
After a horn is made, its resonant fre-
quency is checked. Horn analyzers are
available for this measurement. The fre-
quency can be adjusted by removing ma-
terial from the horn. The horn at idle
should pull very low current from the
horn analyzer. If it does not, it may be
cracked or out of frequency range. Most
welding machines will indicate a fault if
the horn is defective.
Weldable Materials
The term plastic may be used for
thermoplastic or thermoset materials.
The latter burn when heated and cannot
be ultrasonically joined. Only thermo-
plastic materials are candidates for ul-
trasonic welding.
Thermoplastics can be further cate-
gorized as amorphous or crystalline.
Amorphous resins exhibit random,
spaghetti-like structure. They do not
greatly dampen energy introduced into
the material. As heat is applied, they
soften and do not have a sharply defined
melting temperature. Amorphous resins
include ABS, acrylic, polycarbonate,
polystyrene and polysulflme. Crystalline
resins have an orderly pattern, like
coiled springs. Just as metal springs
dampen vibration, so do crystalline ma-
terials. They also have a well-defined
melting temperature. Crystalline mate-
rials include acetal, nylon, polyester,
polyethylene, polypropylene and poly-
phenylene sulfide.
Alloys/blends are combinations of
amorphous and/or crystalline polymers
and the combinations seem endless.
Many trade names, e.g., Lexan (a
polycarbonate), are available in differ-
ing formulations usually indicated by a
number or alphanumeric designation.
Most plastics manufacturers offer exten-
sive technical advice.
Differing materials can be ultrasoni-
cally welded if their melting tempera-
tures are within 30°F and their composi-
tion is compatible. Figure 4 indicates
weldability and compatibility of wlrious
plastics.
The use of fillers and additives selec-
tively extends the performance and
properties of thermoplastics. These in-
clude colorants, flame retardants, lubri-
cants, minerals, mold release agents,
plasticizers and UV stabilizers that can
act to lubricate the surface and absorb
moisture, either of which can make ul-
trasonic welding more difficult. On the
other hand, if at low levels, the addition
of glass fibers, impact modifiers and re-
grind material may increase weldability.
Joint Design
To ensure that plastic assemblies are
adequately joined, they should be de-
signed at inception with a suitable joint
design. Many factors are taken into con-
matcly perpendicular to the vertical axis
of the ultrasonic system and parallel to
the face of the horn. The joint surface
should be in one plane. The distance be-
tween the horn face and the joint should
be within ¼ in. (6.35 ram) of the horn
face. This is referred to as a near field
weld. Far field welding is the term used
when the joint is farther away and is only
done when the plastic material can effi-
ciently transmit the ultrasonic energy to
the joint location. In general, this limits
far field welding to rigid amorphous ma-
terials, although some semicrystalline
materials can be welded far field given a
favorable geometry.
The joint geometry should be tai-
lored to the end product use. The parts
must not fit so tightly before joining that
they inhibit the vibration needed to in-
duce welding. Thin cross sections may
crack under the action of vibration, and
delicate parts, such as fine wires, may be-
come damaged when their enclosures
are welded. Obviously, the ideal condi-
tions are not always attainable and com-
promises can be made.
The simplest type of joint design uses
a triangular or, less frequently, a
rounded projection called an energy di-
rector. The ftmction of the energy direc-
tor is to provide a site to initiate the
rapid plasticization of the joining surface
by concentration of the energy.
Triangular energy directors have an
angle of 60 or 90 deg and a height from
0.008 to 0.040 in. (0.2 to 1.02 ram), de-
pending on the material, the wall thick-
ness, the requirements for the joint and
_
Cyll I Face
Compound H o r n
Fig,. 3 - - Horns come ill a variety o f geome-
tries, including hollow cylinder horns,
cylinder horns with rectangular faces and
compound horns.
the likelihood that excess melted plastic,
called "flash" will occur. The energy di-
rector is usually centered on one of the
parts to be joined and may be discontin-
uous around the edge of the part. In
some cases, usually when the wall thick-
ness is wide, two energy directors are
used, side by side, or staggered.
The choice of which molded part car-
ries the energy director is usually not im-
portant. When welding materials of dif-
ferent rigidity, the energy director is
usually placed on the softer part.
The molded parts should be designed
such that they retain their relative posi-
tion during welding. This can be done by
a centering provision designed into the
parts. Clearance between the two parts
should be small but at least 0.002 in.
(0.05 mm). If provision for centering the
parts is not present, then the nest or
holding fixture must provide this fea-
ture, although this is not the preferred
method.
If the parts have thin walls that may
bulge under pressure, it is advisable to
support the part up to the joining zone.
When welding with an energy direc-
tor, the idea is to melt and collapse the
energy director. It is important the
molded parts, the anvil or the stroke lim-
itation of the press does not impede this
motion.
WELDING JOURNAL 13
 Compatibility.of Thermoplastics for Ultrasonic Welding
This table should Cellutosics
only be used as
a guide.Variations
in resinsmay
directlyaffect
welding results.

,~s • • • 0 0 0
ABS/polycarbonate • •
(Cycoloy800) O0 • 0
Acetal
Acrylic • 0 :m-=-- - = - - - , - - - .,
Acryl
icPVC
(Kydex) 0 0 m mnmmmnmmmmmml
Acetate
)
i
Butyrate 0!
Propionate
Fluoropolymers
Nylon
Polycarbonate • 0 •
Polyethylene
Polypropylene
Polystyrene 0
Polysulfone • • 0
PPO (noryl)
PPS • • 0
PVC O
SAN - NAS 0 0 O 0 © •
Thermoplastic
Polyester
Urethane

• Denotes compatibiliW
O Denotes some compatibility, although not all grades and compositions

Fig. 4 - - Compatibility of thermoplastics for ultrasonic welding.

A number of joint designs using a 90-
deg energy director are shown in Fig. 5.
These include butt joints, step joints and
tongue and groove joints. The 90-deg
energy director is suitable for most
amorphous resins but 60 deg is preferred
for polycarbonate, acrylics and semicrys-
talline materials.
Crystalline materials may receive in-
complete fusion when an energy director
is used because material displaced from
the energy director may solidify before it
flows across the joint to form a seal. For
this reason, shear joints are often pre-
ferred. A carefully designed shear joint
can also achieve leaktight joints.
A shear joint uses an interference fit
between the walls of the parts to be
joined - - Fig 6. This necessitates the
melting and moving of molten plastic at
the joint as the parts are simultaneously
subjected to ultrasonic energy and
downward force. Because a shear joint
melts larger amounts of material, it may
require higher power and longer time
than a joint made using an energy direc-
tor. The shear joint also tends to impart
sideways motion into the part, so the
side walls should be well supported by
the nest or holding fixture. If necessary,
the fixture can be split to permit easier
loading and unloading of the parts.
The shear joint should also have a
lead-in to provide self-alignment of the
parts. The initial contact area at the base
of the lead-in should be small. The de-
sign shown in Fig. 6 is for a medium-size
part of up to 2 in. (5.08 cm) in diameter.
Smaller parts should have reduced in-
terference fit [0.008-0.012 in. (0.2-0.3
ram) per side] and larger parts an in-
creased interference fit of up to 0.020 in.
(0.5 ram) per side.
In general, semicrystalline parts up to
about 3~ in. (8.89 cm) in diameter can be
welded with a shear joint, but amor-
phous materials may be larger.
A combination shear joint and en-

32 I JANUARY2001
 THE 3 BASIC ENERGY DIRECTOR DESIGNS ARE:
BuI"rJOINT
TO BE AVOID£D
X
Height - is determined by material being joined
Base width - since included angle Is 90", base width is
Fig. 5 - - Basic energy director designs.
ergy director is sometimes used to pro-
duce a high-strength, leaktight weld.
Other Considerations
Part Size
Part size has an influence on the
power level required and the frequency
of the welding machine selected. For
large parts greater than 1~ in. (3.81 cm)
in diameter, or with any welding dimen-
sion longer than 2 in., select a 20-kHz
welding machine. The power level - -
typically available at about 1000, 1500,
2000 or 3000 W - - depends on the size
of the weld area, type of joint and the
material to be welded.
Smaller parts may use a 35- or 40-kHz
welding machine. These are available in
power ranges of 400-1000 W.
For very small welds, a 70-kHz, 100-
W system is available in press form or a
hand-held version. This system has been
used for high-speed ultrasonic staking of
plastic projections for 35-mm film car-
tridges and for single-use cameras.
Part Features
Sharp corners may fracture or melt
when exposed to ultrasonic vibration. To
reduce such stress fractures, corners and
edges should be radiused.
STEPJOINT TONGUEAND GROOVE
p-q
Energy Director Dimensional Design
although it is usually between .010" - .025"
always (2 x height)
~ B A S WIDTH
E ~'-- HEIGHT
Projections or tabs may fracture and
even fall off. This tendency is reduced if
the junction between the tab and the
body of the part is radiused. Sometimes
it is necessary to thicken the part, lightly
clamp it or, if possible, use a higher fre-
quency welding machine (35 or 40 kHz)
to reduce breakage.
Sizable holes, sharp angles or bends
within the part may also create problems
because the ultrasonic energy may be
deflected, leaving a section with little or
no fusion.
Thin, unsupported sections on a part
may vibrate or diaphragm. If the flexing
is severe, it may cause a hot spot in the
material, even causing a hole in the part.
COR MET
SPECIALTY
AND COATED
(810) 227-3251 FAX: (810) 227-9266
www.cor-met.com
®
Circle No. 5 on Reader Info-Card
Optional Recess 1
S1
.o,Wl.o
1, / ,
or W+
I-- ---I W = Wall
/ ~ J ~ . . hickness
Fig. 6 - - A s h e a r j o i n t d e s i g n .
Increasing the section thickness or
switching to a higher-frequency welding
machine may reduce this problem.
Sometimes reducing the amplitude of vi-
bration will help.
Applications
Ultrasonic welding is widely used for
various component assembly applica-
tions in the medical, chemical and elec-
trical industries as well as others. These
include liquid bearing vessels, IV com-
ponents, hearing aids, filter assemblies,
monitors and diagnostic components.
Ultrasonic textile joining, primarily
in nonwovens is used in medical gowns,
booties, caps, face masks, hygiene prod-
ucts, incontinence products, bed protec-
tors, surgical drapes, pillow covers and
filter media. •
CORED WIRE
ELECTRODES
WELDING JOURNAL J33
 ,qk

m m m m m m m

YES! I WANTTO SUPPORTWELDINGEDUCATION

BECAUSEIT'S THE FUTUREOF OUR INDUSTRY.
O $50 D $100 ~ $500 O $1,000 [~ Other$.
Name Title
Company
Street Address
City. State ZIP
Telephone FAX E-mail
Section Name (if applicable). Section No,
, Make checks payable to: 305-445-6628
Foundation, Inc. AWFoundation,
S Inc, Fax: 305-443-7559
-A Foundationof the America~nWel---dingSocie'-----'~ 550 NWLeJeune Road E-mail:found@aws,org
Miami, FL 33126 Website:www,aws,org/foundation
Scholarships are provided byfunding from the endowment. Scholarship applications available by mail or website.
 Using Microwaves to
Weld PVDF Pipes
and Fittings
Short heating times, low power consumption and precise heat application are
some of the benefits of a new technique that uses
microwaves to weld plastic pipe

BY M A R T I N D O M M E R

p ipes and fittings made of PVDF can be welded not only

by standard technologies such as heating element weld-
ing and infrared welding, but also by microwaves. This mi-
crowave welding technology includes several benefits: the \
energy needed to melt the plastic can be applied with preci- ( ( D "''~' G " ..........c :
sion and accuracy, focusing the field intensity allows a reduc- ~. j/// .,_ /
tion in energy input and the energy source need not be acti-
vated any longer than required for heating because the power
is available immediately and in the necessary volume.

Why Use Microwaves? \

Along with the well-known and well-tried heating ele-
ment welding process, infrared welding has been used in re-
cent years. This technology is mainly for special applications
that require absolute cleanliness, quick processing and small
beads. However, the infrared technology is limited when ex-
tremely high worker safety and short process cycles are re-
quired.
To solve those problems, welding with electromagnetic Fig. 1 - - The forms of polarization are shown clockwise from upper left:
waves - - microwaves - - has been developed. This technology electron polarization, atomic polarization, orientation polarization and
offers the following advantages: volume charge polarization.
• Very short heating times, due to volumetric heating of
the material, independent from thermal conduction.
• High worker safety because it uses cold heating elements. W h a t A r e Microwaves?
• Direct measurement of the melt temperature without the Microwaves are electromagnetic waves in the frequency
disturbing influence of heating elements. range between 300 MHz and 300 GHz. They lie between radio
• Extremely low power consumption because of high effi- waves and infrared radiation, are spreading in space and can be
ciency and no power loss. transmitted in special conductions. Microwaves consist of an
• Bead performance can be controlled. electric and a magnetic component directly combined with each
These advantages make welding with microwaves ideal for other. Their main applications at present are in communications
those applications that are, at the moment, the domain of in- and radar technology, as well as food heating.
frared welding or that simply could not be performed.

H o w Microwaves A r e Generated and Transmitted

MARTIN DOMMER, DipL-Ing., is with WIDOS GmbH, Ditzin-
gen, Germany.
Based on a paper presented at the A WS/DVS Conference on
Plastics Welding, Orlando, Fla., October 24-25, 2000.
For the generation of microwaves, high-frequency electro-
magnetic fields are built up and brought defined out of the
source. Industrial standards have been established but, because
of cost questions, frequencies of 2.45 GHz are normally used.
This radiation can be brought into the material to be heated only

WELDING JOURNAL I 35

Designofthesystem
Radiator
Tuner
Ckculator --~
Absorber
Magne~on
I During welding of unfilled plastics with microwaves, the ef-
Fig. 2 - - The microwave system design.
by means of wave guides with their respective tuners, or by ab-
sorbers via special wave-guide radiators.
Concerning construction and dimensions of the guides, the
arrangement discussed here follows fixed physical regularities
and is protected so that reflecting radiation cannot damage the
source. In addition, tuning pins change radiation in a way that
optimum efficiency is reached. The wave-guide radiator's geom-
etry is specially adjusted to the form of the material, thus en-
abling precise heating of the surfaces to be welded.
Heating with Microwaves
All atoms and molecules consist of positively charged pro-
tons and negative electrons. In steady position, these molecules
are placed either balanced (nonpolarized) or asymmetrically
(polar). The charge carriers (electrons) are displaced out of
their steady position through the influence of a high-frequency
electromagnetic field. Depending on the material and the mol-
ecular construction, different processes of polarization result,
which means the effect is not one separate process, but the sum
of different polarizations.
Following are the four polarization effects (Fig. 1):
• Electron polarization. This appears at very high frequen-
cies in the range of UV radiation by displacing the charges in di-
rection to the relative center within the atoms or molecules.
# Atomic polarization. This effect displaces or twists the com-
plete polar atoms or molecules within the material structure.
• Orientation polarization. In the steady position, polar mol-
ecules show a random-oriented position, which is aligned in one
direction under the influence of the microwaves.
• Volume charge polarization. If free charge carriers (atomic,
not caught, electrons) are present in a material, they will be
36 1JANUARY 2ooi
moved to the interfaces of the substance under the influence of
the microwaves.
Generally, at the displacement of these charge carriers cer-
tain movements, frictions and losses of power appear that are
converted to heat. These power losses are thus responsible for
the heating and the melting of the plastics.
The Plastics that Respond to
Microwaves and Why
The atoms caught in the relatively rigid chain react to mi-
crowaves rather inertly, which means they do not participate in
the heating caused by loss of energy. By contrast, molecules in
branches are comparatively flexible. For that reason, they react
more strongly to the influences of electromagnetic radiation,
thus causing the losses of power necessary for heat generation.
As a result, widespread branching causes a larger chain polarity
with a positive effect on heating with microwaves.
In the frequency ranges used for heating with microwaves,
polar plastics with comparatively strong branching are much
more suitable than plastics with almost linear chains.
Unfilled Plastics
fect of orientation polarization is of main importance.
Under the influence of electromagnetic radiation, molecular
chains with random-oriented polarity try to reach an order ac-
cording to the applied field. This process inevitably leads to mol-
ecular movement and to friction, resulting in heating and, ide-
ally, in melting.
Filled Plastics
During welding with microwaves of plastics that are filled
with conductive material, the effect of volume charge polariza-
tion is also important.
Under the influence of electromagnetic radiation, the free
charge carriers are moved by force into a spatial arrangement at
the interfaces according to the applied field. This effect is the
cause of heating through electric losses.
Welding Technology
Machine Design
An infrared welding machine specially modified for the re-
ception of the microwave emitter is used. Figure 2 shows the mi-
crowave emission system design.
Fully automatic motion and the precise pressure control of
the machine lead to consistent welding results. Contactless ther-
mometry controls the power supply and the intensity of the mi-
crowaves.
Clamping tools hold the plastic parts to be welded in place.
A program-controlled planer moves in position and planes the
pipe ends to the necessary dimensions. The microwave emitter,
which is also program controlled, moves on precise guides. The
joining force is controlled by means of an electric drive with
power sensor and is damped by a spring assembly.
Due to a special arrangement, welding can be carried out ei-
ther through pressure control or through limitation of the join-
ing path.
To ensure a sufficient melting depth, a melt temperature sen-
sor is mounted at the emitter. This assembly guarantees suffi-
ciently deep and high heating is reached, and avoids thermic
overstrain.
Preparation for Welding
H e a t i n p u t : 12.5 s a t a m a x i m u m t e m p e r a t u r e o f 2 5 7 ° C

The pipe ends are fixed in the clamping tools

and cut to the defined length by means of the ~Ts

planer. ~o --- -

Thus, the necessary position between the mi-

crowave guide radiator and the part surfaces is
reached, and the material is clean. The parts are
then checked for mismatch. A device makes verti-
cal or horizontal adjustments to eliminate any mis-
match.

Heating
As soon as the automatic starting device is trig-
gered, the microwave emitter is moved between
the pipe ends and kept in position. The wave-guide 0 1 2 3 4 5 6 7 IB 9 10 11 12 13 14 15 'P6 17 18 19 20 21 22 23 24 25 215 27 2~1 2g 30

radiators transfer the electromagnetic field onto

the pipe ends. When the pipe ends reach the de- Time

sired melting temperature, the radiator is removed

and the parts are joined.
Because of the system, all machine parts re-
main totally cool during heating, no rays at all
emerge, and only the plastic surfaces melt.
Power consumption reaches no higher than 250
W at a pipe dimension of 32-mm (1.25 in.) OD - -
Fig. 3. The radiator consumes power only during
the heating time. The reason is the high efficiency of the instal-
lation, as well as the direct power input. Preheating and holding
the heat during the total duty cycle is unnecessary. Because of
the convergence of energy, only a small area must be heated in-
stead of a large area such as with infrared welding, so power loss
is kept to a minimum.
Welding and Cool Down
The welding and cool down processes follow the known pres-
sure control system according to DVS standards and the limita-
tion of the joining path, and will not be described in more detail.
Fig. 3 - - Temperature progression.
In general, these tests produced good results because of the
volumetric heating and show very good residual melt.
Prospects for the Technology
The current boundaries of microwave welding technology
are determined by the geometry of the waveguide radiator.
Presently, they are being tested to a diameter of up to 63-mm
(2.5-in.) OD. The waveguide radiator's geometry results from
the wavelength and swing of the microwave radiation.
At present, unfilled plastics can only be welded if they have
a polar structure. An extension to nonpolarized, but modified
plastics and to filled modifications are being tested.

Results Fields of Application

Visual Inspection
Visual inspection allows a direct comparison with conven-
tional welding procedures, e.g., the infrared
technology or heating by contact, and gives
a first indication of the joint quality. Fur-
thermore, beads as small as possible become
more and more important in fulfilling the re-
quirements with respect to purity and flow A big advantage of the
resistance. For the visual assessment, thin
cuts of the weld tests were used to give indi- new technology is it
cations of residual melt and stress.
So far, the results have been good and are provides precise bead
currently being proved in an extensive test
series. A big advantage of the new technol- control.
ogy is it provides precise control of the bead.
By means of special arrangements, bead for-
mation can be modified so that the inside beads are minimized
without degradation.
Tensile and Bend Tests
The ratio of base material strength to joint strength for all
weld samples tested was at least 0.8. Currently, large-scale test
series are being carried out to substantiate these results.
Right now, the most important application fields for mi-
crowave technology are food drying and heating and communi-
cations and radar technology. Due to the new system, this tech-
nology can now be used for joining plastics in high-purity
applications.
Because machine parts remain cool and the
heating element is lightweight, this new mi-
crowave technology can also be used for ap-
plications that require especially high safety
requirements or take place in an explosive at-
mosphere. Since the energy can be trans-
ported easily, the energy source does not have
to be at the workplace at all times, making it
useful for jobs in inaccessible areas.
Work continues to further develop mi-
crowave welding technology. Topics being
studied include extending the wave-guide ra-
diator's geometry to all available pipe dimen-
sions, optimizing the required machine dimensions, extending
use of the technology to different plastics and finding new in-
dustrial applications. •

WELDING JOURNAL I 3"I

 ot Peening d
at Treatm e n
Reduce Stress
Designers of weldments must consider ways to relieve
residual stresses created by welding and grinding

B Y M A R K S. M O L Z E N A N D D O U G H O R N B A C H

160
140 ~ ~ _

R esidual stress directly affects a compo-

nent's fatigue life. Detrimental resid-
ual tensile stress decreases fatigue life
while beneficial residual compressive stress in-
creases fatigue life. The welding process induces
|
A
|
120
100
80
0
60
residual tensile stress that is detrimental to fa- 40 --
tigue life. Tensile stresses act to stretch or pull 0
20
apart the surface of the material. With enough
load cycles at a high enough tensile stress, a 0 -~----+--~-~
metal surface will initiate a crack. Significant im- 10000 100000 1000000 10000000
provements in fatigue life can be obtained by Number of O/des
modifying the residual stress levels in the mate-
rial. Two methods of performing this are Fig. 1 - - Typical stress vs. load cycle.
through heat treating and shot peening.

Defining Welding's Role in

Stress Formation
A n investigation was conducted to determine how detri-
ili/ mental residual stresses are created through the welding
process, and how welding stresses can be modified by shot peen-
ii~i
ing and heat treatment. Multiple carbon steel coupons were
welded and exposed to various shot peening parameters, vari-
ous temperature treatments, grinding treatment and combina-
tions of the above processes.
M A R K S. M O L Z E N is with Metal Improvement Co., Inc., Maple
Grove, Minn. DOUG H O R N B A C H is with Lambda Research,
Inc., Cincinnati, Ohio.
Based on a paper presented at the A WS Conference Weld Crack-
ing: Basic Solutions--Advanced Solutions, Milwaukee, Wis., July
20-21, 2000.
Explaining Metal Fatigue and Fracture
Metal fatigue is the phenomenon leading to fracture under
repeated or fluctuating stresses having a maximum value less
than the tensile strength of the material. The type of stress of
most concern is tensile stress. Tensile stress acts to stretch or pull
apart the surface of the material.
Fatigue may start at a single point or several points, depend-
ing on the shape of the critical section and the type of loading.
When a component is subjected to torsion and/or bending loads,
tensile stress is highest at the surface of the material, which is
where the overwhelming majority of cracks initiate. In addition,
the component's geometry can concentrate tensile stresses at
notches, holes and cross-sectional changes.
Fatigue fractures are progressive, beginning as minute cracks
that grow under the action of fluctuating tensile stress. A fatigue
crack usually starts at the surface parallel to the maximum shear
stress, but soon turns and advances perpendicular to the maxi-
mum tensile stress. Under the repeated action of the tensile

381 JANUARY2001
stresses, the crack grows, weakening the section. Variations in
cyclic loads cause small ridges or "beach marks" to develop on
the fracture surface. These marks indicate the position of the
advancing crack root at a given time. As the section gradually
weakens, the crack grows faster, and the beach marks get far-
ther apart, larger and more distinct. Thus, the presence of beach
marks often helps to pinpoint the origin of the fracture.
In general, residual stresses are beneficial when they are op-
posite to the applied loading stress. The amount of residual com-
pressive stress from shot peening is directly related to the re-
duction of the applied tensile stress, which can cause fatigue
failure. Hence, more compressive stress results in greater im-
provements in fatigue properties. This is especially important
since fatigue life is plotted as tensile stress on the vertical axis (on
a linear scale) and life cycles on the horizontal axis (on an expo-
nential scale). This means a linear decrease in tensile stress trans-
lates to an exponential increase in fatigue life. This is shown in
Fig. 1 with a graph commonly known as an S/N curve.
Some materials do not fail below a given stress level, no mat-
ter how many cycles they are subjected to. This stress, when
plotted on an S/N curve, is called the endurance limit. This is
noted by the dotted line in the graph (Fig. 1), which shows at
lower tensile stress levels, particularly the 50-ksi range, the life
of the component approaches infinity as 10 million or more cy-
cles can be expected. The purpose of shot peening is to induce
compressive stresses to lower or offset the tensile stresses that
cause fatigue failure.
Similarly, the stress to cause failure at any given number of
cycles is called the "fatigue strength," and the number of cycles
to failure at any given value of stress is called the "fatigue life."
This is represented on the above S/N curve; 50,000 cycles at 100
ksi and 200,000 cycles at 65 ksi.
Residual Stresses from the
Welding Process
Residual stresses are those that exist in a part independent
of external force or restraint. Neglect of these residual tensile
stresses created during welding processes can lead to stress cor-
rosion cracking, distortion, fatigue cracking, premature failures
in components and instances of overdesign. When applied and
residual stresses are accumulated, the net tensile stress seen by
the components is much greater than the actual load applied.
This is why welded components fail at the weld.
The American Welding Society (AWS) Welding H a n d b o o k
cautions readers to be mindful of residual tensile stresses from
welding if the fabrication is subject to fatigue loading as de-
scribed in the following statement: "Localized stresses within a
structure may result entirely from external loading, or there may
be a combination of applied and residual stresses. Residual
stresses are not cyclic, but they may augment or detract from ap-
plied stresses depending on their respective sign. For this rea-
son, it may be advantageous to induce compressive residual
stress in critical areas of the weldment where cyclic applied
stresses are expected."
The residual tensile stress from welding is created because
the welding consumable is applied in its molten state. The weld
is applied in its hottest, most expanded state. It then joins to the
base material, which is much cooler. The weld cools rapidly and
attempts to shrink from the cooling. Since it has already joined
to the cooler, stronger base material, it is unable to shrink. The
net result is a weld that is essentially being "stretched" by the
base material. The heat-affected zone is usually most affected
by the residual stress, and hence, where failure will usually
occur. Inconsistency in the welding consumable, chemistry, weld
geometry, porosity, etc., act as a stress riser for residual and ap-
plied tensile stress to initiate fatigue failure.
WeldedConditions
I ........
. , o . o I - - ~ ~ ....... ; . . . . -~
| ~ 0 0 ~ - J......... J
0.000 0.005 0.010 0.015 0.020 0.025 0.030 0.035
Depth (inches)
i---~---Welded Condition - ,,, - Welded & StressRelieved[
1~ Welded & Shot Peened --,--- Welded, SR & SP I
Fig. 2 - - Residual stress profile.
Residual Stresses from Grinding
Residual tensile stresses and surface brittleness can be
caused by the generation of high surface temperatures by fric-
tion during severe or conventional grinding operations. It has
been found that residual tensile stresses created by grinding can
approach the ultimate tensile strength of the material itself.
Residual tensile stresses will dramatically affect fatigue resis-
tance of ground parts.
In abusive and conventional grinding, tensile stress is created
from generation of excessive, localized heat. The localized area
attempts to expand. It cannot because it is surrounded by cooler,
stronger metal. This metal yields in compression due to the re-
sistance to its expansion. Upon cooling, the yielded material at-
tempts to contract. The surrounding material resists this con-
traction, thus creating a residual tensile stress.
Because heat is the major cause of residual stresses in grind-
ing, the importance of a coolant for controlling these stresses is
evident. Coolant is easily applied using automatic grinders, but
it is rarely used with manual or hand grinders. If an automatic
grinder with coolant is used with a gentle grind, this would, in
effect, cold work the material and induce a slight amount of ben-
eficial compressive stress at the surface.
Modifying Residual Stress
with Shot Peening
Shot peening is a cold working process used to increase the
fatigue properties of metal components. During the peening
process, the surface of the component is bombarded with small
spherical media called shot. Each piece of shot striking the ma-
terial acts as a tiny peening hammer, imparting to the surface a
small indentation or dimple. In order for the dimple to be cre-
ated, the surface fibers of the material must be yielded in ten-
sion. Below the surface, the f b e r s try to restore the surface to
its original shape, thereby producing, below the dimple, a hemi-
sphere of cold-worked material highly stressed in compression.
Overlapping dimples develop a uniform layer of residual
compressive stress in the metal. It is well known that cracks will
not develop in a compressively stressed zone. Since nearly all fa-
tigue failures originate at the surface of a part, compressive
stresses induced by shot peening provide considerable increase
in part life. When controlled properly, all surface area, which is
susceptible to fatigue crack initiation, is encapsulated in a uni-
form layer of high magnitude, compressive stress.
The three important variables when shot peening is applied
are the surface compressive stress, maximum compressive stress
and depth of compression. This surface compressive stress is the
stress at a depth of 0.000 in. or the very outermost surface layer.
The next important variable is the maximum compressive stress,
WELDING JOURNAL I 39
which usually occurs at 0.001-0.002 in. below the surface. The
maximum compressive residual stress produced at or under the
surface of a part by shot peening is at least as great as half the
tensile strength of the material being peened. The final variable
is the depth of the compressive layer, which is where the com-
pressive residual stresses convert to tensile residual stresses.
The subsurface tensile stress is a result of the previous welding
operation and restatic balancing of the near-surface compres-
sive layer.
Modification of Residual Stress through
Elevated Temperature
Complex parts that have been welded, cast or machined
often develop internal stresses that could cause distortion of
their shape or affect their fatigue strength. To relieve these
stresses, parts made from carbon steel are heated to between
1000 and 1200°F (538 and 649°C) and held at that temperature
for a period of time determined by their cross-sectional thick-
ness. Parts are then cooled slowly to minimize the development
of new residual stresses.
Metal is weaker when it is at higher temperatures. This is why
residual stress (compressive or tensile) is relieved at higher tem-
peratures. The strength of the metal is reduced and stresses are
able to relieve themselves. Higher temperatures and longer ex-
posure times are able to relieve more residual stress. The stress
relieving process is benefical for welding stress as it reduces it,
but detrimental for shot peening because beneficial compres-
sive stress is removed.
Using X-Ray Diffraction to Measure
Residual Stress
X-ray diffraction (XRD) is the most accurate and best de-
veloped method for quantifying residual stress due to various
mechanical/thermal treatments such as bending, coiling, shot
peening, welding, machining, various finishing operations, etc.,
and offers several advantages over other methods, such as me-
chanical, ultrasonic or magnetic techniques. XRD is a linear
elastic method in which the residual stress in a material is cal-
culated from the strain in the crystal lattice. The theoretical
basis and explanations are discussed elsewhere. XRD can be
employed to quantify the residual stress as a function of depth
to thousandths of an inch below the surface, with high resolu-
tion due to the shallow penetration of the X-ray beam. XRD
techniques are well established, having been standardized and
developed by both the SAE and the ASTM.
XRD methods have been used for many years in the aero-
space, automotive and nuclear industries to quantify residual
stresses and are employed in quality control applications to ver-
ify and confirm specific levels of compressive stress on shot-
p e e n e d components. As engineers rely more on residual
stresses to increase the performance of components, it is nec-
essary to understand and control residual stress levels.
To determine the residual stresses as a function of depth for
this test study, XRD residual stress measurements were ob-
tained in the longitudinal direction, parallel to the weld depo-
sition for the welded samples. Measurements were made from
the surface to a nominal depth of 15 x 10-3 in., in nominal in-
crements of 1 x 10-3 in., for the ground samples. Measurements
were made from the surface to a nominal depth of 30 x 10-3 in.,
in nominal depth increments of 2 x 1 0 -3 in., for the shot-peened
and welded samples. These depths were chosen to best define
the residual stress distribution due to grinding, shot peening and
welding. The residual stress measurements were made at mid-
length on the processed side of each sample.
40 [JANUARY 2001
Test Conditions
This study used 1018 carbon steel coupons 1 x 1 x 3 in. long.
The Brinell hardness was BHN 150-180 (R b 80-90). A certified
welding technician from Metal Improvement Co. used an AWS
E7018, ~2-in. electrode at 90 A.
The graph in Fig. 2 demonstrates the residual tensile stress
generated from this welding procedure. The stress is - 7.0 ksi
in tension at the surface. This tensile stress is detrimental and
will accelerate fatigue failure. For example, a component that
would normally experience a 40 ksi tensile stress will actually ex-
perience a net 47 ksi stress.
Stress-Relieved Welds
The graph in Fig. 2 demonstrates that the 7.0 ksi tensile stress
is reduced to - 3 ksi through stress relieving. The stress relief
temperature was l150°F for one hour. One can see that 100%
of the tensile stress is not removed by stress relieving. However,
any reduction of tensile stresses is beneficial from a fatigue
standpoint. If the tensile stress had a greater magnitude, it
would have experienced a greater decrease through stress re-
lieving than the 4 ksi above. Stress relieving will never reduce
the residual stress below zero.
Shot-Peened Welds
Figure 2 also shows the large stress reversal induced by shot
peening. The 7.0 ksi tensile stress has been converted to - 60
ksi of compressive stress at the surface. This represents a stress
reversal of - 67 ksi. Since less tensile/more compressive stress
is better, one can see noticeable benefits from shot peening
welds. A component that would normally experience a 40 ksi
tensile load (at the surface) will experience a net - 20 ksi com-
pressive stress. This will dramatically improve fatigue perfor-
mance in a repetitively loaded environment.
The shot peening parameters were hardened cast steel shot
(0.046-in. diameter) and the intensity or the kinetic energy used
was at a 6-7C. The depth of the compressive layer is - 0.023 in.
deep as shown in Fig. 2. This means that should a fatigue crack
ever develop, its growth will be resisted by the compressive layer
until it achieves a depth of - 0.023 in.. Compressive surface
stress provides this twofold benefit. Crack initiation is signifi-
cantly delayed and crack growth is significantly retarded.
Figure 3 is a 30X magnification of the shot-peened surface.
One can see the uniform overlapping dimples from the peening
process. In the welding process, it is important to minimize any
overlaps, folds or undercuts that would be geometrically too
small for the peening media to cover with dimples.
Stress-Relieved and Shot-Peened Welds
Stress relieving and shot peening are both used to lower ten-
sile stress conditions. Figure 2 shows the maximum compressive
stress is - 60 ksi, which is similar to the welded and shot-peened
condition. The depth of compression is - 0.032 in.
The reason for the additional compressive depth is the
coupon was shot peened after stress relieving. The thermal ex-
posure softened the material causing a decrease in the yield
strength of the metal. Shot peening, therefore, deformed a
deeper layer of material as a result of the decrease in material
strength.
One can see this is an optimal condition from a fatigue
standpoint. It should be noted that this process is the most ex-
 Fig. 3 - - Magnification of shot-peened weld sur-
face (30X).
pensive from a manufacturing perspective, since more opera-
tions are required.
S i n g l e P e e n e d Vs. D u a l P e e n e d
A dual shot-peen operation is used to improve fatigue prop-
erties beyond that of a single peened surface. This is accom-
plished by shot peening the same surface a second time at a re-
duced energy level (intensity). Figure 4 is a 30X magnification
of the dual peened surface. One can see the surface finish is less
aggressive than the single-peened surface finish. This is because
the smaller media is able to obliterate the high points from the
first peening operation.
Fatigue testing has shown dual intensity peening will produce
an even greater improvement in fatigue resistance than single
peening. The purpose of dual peening is to increase the com-
pressive stress at the surface fibers (depth = 0.000 in.) with a
secondary peening operation. By further compressing the top
surface fibers, initiation of a fatigue crack becomes more diffi-
cult. The dual peen was performed with a 0.023-in.-diameter
shot at a 10-12 A kinetic energy/intensity. Since this is a lower
intensity, there will be no change to the depth of the compres-
sive layer. It would take a greater intensity that has more kinetic
energy to drive in a deeper depth of compression.
The reason dual peening increases the surface compressive
stress is that the magnitude is a function of disruption or dim-
piing of the surface. A properly shot-peened surface has a uni-
form dimpled appearance. The surface consists of high points
and lower plateaus. These are the result of the surface material
being displaced as the peening media impacts it. A more ag-
Shot Peen vs Dual Peen
~ 40.0 ---T-------r-----.---~;---~----~
200 " " "
J .-t~.0
0.000 0.005 0.010 0.015 0,020 0.625 0.030 0.035
I~pth (inches)
Fig. 5 - - Residual stress profile o f single shot peen vs. dual peen.
Fig. 4 - - Magnification of dual-peened weld sur-
face (30X).
gressive peening operation (higher intensity) will result in larger
dimples. The high points are less compressed than the lower
plateaus.
The smaller media is able to further compact the high points
left from the first peening operation. The dual peening leaves
another uniformly dimpled surface, but the high points are
smaller than the first peening operation. This results in a finer
surface finish and more compressed top surface layer.
The graph in Fig. 5 demonstrates the surface improvement.
The (single-) peen operation from before resulted in an - 45 ksi
surface stress. The dual-peen operation further compressed the
surface to - 55 ksi. An improvement of 10 ksi at the outer sur-
face should significantly improve fatigue performance from a
single-peen operation. This is because on the S/N curve the ten-
sile stress is 10 ksi closer tO the endurance limit.
Residual Stresses from Grinding
The abusive and conventional grinding were done using a
hand-held grinder with a Norton aggressive bond, Type 27 grind-
ing wheel. In this process, material is removed by hard, sharp
particles plowing material out in furrows. Tensile stresses were
created from generation of excessive, localized heat. Abusive
grinding is generally indicated by a "red hot spot" on the metal
during grinding.
The graph in Fig. 6 shows the residual stress distribution cre-
ated by abusive and conventional grinding. This study evaluated
ground coupons that were both previously welded and not
welded. It is quite evident abusive and conventional grinding
generated high magnitudes of residual tensile stress at or near
Residual Stresses From Grinding
0.~ 0.003 0.006 O.~g 0.012 0.015 0.015
Depth (Inchee)
Abusive Grind (No Welding) J
Fig. 6 - - Residual stresses from grinding.
WELDING JOURNAL
 Shot Peened With Various times will relieve more stress. The study took similar shot-peened
30 Minute Bake T e m p e r a t u r u coupons (0.046-in. diameter at 6-7C). LCL Services, St. Paul,
Minn., baked three of them at 500, 700 and 900°F for 30 min.
30.0 oO Figure 7 demonstrates what various temperature treatments
]1 lo.o
v ~"4"
_,,m~D"~- - v will do to relieve residual compressive stresses. The outer sur-
-10.0 ~" face stress is primarily affected at the 500 and 700°F bakes. The
900°F bake relieved significantly more compressive stress than
the 500 and 700°F bakes. Note that - 50% of the compressive
stress remains after the 900°F bake. This is 150°F lower than the
-711.0
0.000 0.005 0.010 0.015 0.020 0.025 0.030
temperature the coupons were stress relieved at.

~ ~ . 4. ~ ( ~ i )
Conclusion

When weldments are used in a fatigue environment, the de-

Fig. 7 - - Shot peened with various 30-rain bake temperatures.
the surface of the material. The detrimental tensile stress is as
great (and opposite) as the shot peening compressive stress,
55 ksi. This tensile stress will, of course, dramatically decrease
fatigue resistance.
Shot Peening with Various Bake
Temperatures
This is an interesting study on how heat relieves residual
stresses (tensile or compressive) at various bake temperatures.
As stated previously, higher temperatures and/or longer bake
signer needs to consider stresses both from applied loads and
manufacturing processes. This study demonstrated that welding
and grinding processes create residual tensile stresses. These
stresses can be reduced and fatigue properties improved
through heat treating and shot peening. •
Acknowledgments
The authors would like to make special mention of all par-
ties who were involved in this technical study. All shot peening
and welding were done by Metal Improvement Company, Inc.,
Maple Grove, Minn. All X-ray diffraction was done by Lambda
Research, Inc., Cincinnati, Ohio. All scanning electron mi-
croscopy photographs were done by Seagate Technology, Min-
neapolis, Minn. All heat treatments were done by LCL Services,
Roseville, Minn.

Works Consulted

P. S. Prev6y. 1986. Metals Handbook., Vol. 10, pp. 380-392.

M. E. Hilley, ed. 1971. Residual Stress Measurement by X-Ray Dif-
fraction, SAE J784a, Society of Automotive Engineers, Warrendale, Pa.
ASTM, 1984. Standard Method for Verifyingthe Alignment of X-Ray
Diffraction Instrumentation for Residual Stress Measurement, E915, Vol.
3.01, Philadelphia, Pa.
ASTM, 1994. Standard Test Method for Determining the Effective
Elastic Parameterfor X-Ray Diffraction Measurements of Residual Stress
E1426-94, Vol. 3.01, Philadelphia, Pa.
Metal Improvement Co., Inc., Shot Peening Applications, Seventh
Edition, p. 4.
Cary, H. B. 1989. Modem Welding Technology, Second Edition, Pren-
tice Hall, Englewood Cliffs, N.J., pp. 46-54.
Kreith, E 1998. The CRC Handbook of Mechanical Engineering, CRC
Press, Washington D.C., pp. 12-16.

Circle No. 12 on Reader Info-Card

42 I WELDING JOURNAL
FIESISTAHCESEAPd
WELDIHGBEHEFITS
STAIHLESSAPPUCATiOH
A redesigned production system increased productivity by 50% and reduced
scrap rate to 1% on catalytic converter shells

ull of expensive metal and formed

F to a precision shape, the stainless
steel shell can't leak. A n d even though
it is a "no-show" part, it must be scratch
free. These are some of the challenges
that Walker Manufacturing had to solve
to produce a quality catalytic converter
shell.
Walker Manufacturing, Litchfield,
Mich., is a tier one supplier to the auto-
motive industry with expertise in manu-
facturing exhaust systems. An on-going
program to reduce waste and costs led
to a reengineering of the process for
manufacturing catalytic converter shells.
Throughput was increased by 50%, the
scrap rate was reduced by two thirds,
productivity increased and a coolant pre-
viously used was eliminated.

Doing It the Old Way

Originally, catalytic converter shells
were produced on a gas tungsten arc
(GTA) mill. The shells were formed
from coil-fed 409 stainless steel into a
tubular shape, notched for the cut-off
process and welded with the G T A W pro-
cess. They were then cut to a specified
length, sized to a final shape and the shell
edges deburred. It was a labor-intensive
process, according to Steve Sherwood,
senior process engineer.
Two people were needed for the
welding mill, two people to wash each
part of the coolant used in the cutting
process and four people to check length,
shape and deburr the shell. Deburring
both ends of the component was crucial
Based on information from Newcor Bay
City Division, Bay City, Mich. (517) 893-
9505.
Fig. 1 - - Resistance welding unit showing wheel electrode used to join the overlapping
edge of the shell.
and often required 100% inspection. The
shells were also checked for proper tol-
erances. Tooling changeover and re-
placement of deburring brushes required
extensive time.
There was also a recurring problem
with the welding operation. A t times a
pinhole leak developed when the arc was
initiated with the G T A W process. This
was an important quality issue because
hot exhaust gases could not leak from
the shell. With leak problems and burrs,
scrap rates approached 3%.
New Design Streamlines
Operation
To solve these problems and improve
the operation, a mash seam resistance
welding system (Fig. 1) was developed
by Newcor Bay City Division, Bay City,
Mich. The system automatically takes a
fiat stock stainless steel blank, forms it
into a shell, seam welds it and then sizes
it to the final dimensions.

WELDING JOURNAL I 43
 through the shell forming area. The
blank is then formed into a shell shape
overlapping the edges so it can next be
resistance seam welded. It is then plan-
ished, a process that rolls the weld flat
and reduces its height to within 15% of
the metal's original thickness. It is placed
into a station for forming its final size
and shape to a tolerance of ---0.020 in.
(0.5 mm) - - Fig. 2. The whole operation
gives a stronger weld, the right shape
and, cosmetically, a more attractive part.

Big I m p r o v e m e n t s

Scrap rates were reduced to 1% and

the 2300-2500 parts produced in an
eight-hour shift represent a 50% increase
in productivity. Mash seam welding elim-
inated the deburring process and the
coolant that was previously needed.
Tooling changeover now takes only 30
minutes.
Overall, quality is up, costs are down,
and inventory and shipping schedules are
Fig. 2 - - A f t e r the shell is welded, it is placed into a station where the component is fin- more controllable. •
ished to its final size and shape.

How It Works (0.05 to 0.12 in.) are loaded on a stacker

at one end of the welding machine. The
Fiat Type 409 stainless steel blanks blank is picked up by suction cups and
ranging in thickness from 1.4 to 3 mm placed on a conveyor that moves it

Supplied Air Protection

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Circle No. 14 on Reader Info-Card

44 JANUARY 2001
Datasheet 248a

we, Workbook
Practical information for welders and others involved in welding
and its allied processes.

Hydrogen Cracking
Hydrogen cracking can be a concern when welding carbon or
low-alloy steel. Also known as cold, underbead and delayed
cracking, the potential for this defect depends on the chemical
composition of the consumable and base metal, the weld zone
microstructure, hydrogen content in the weldment and the level
of stress the weldment is subjected to.
The crack, which can propagate in the weld metal or heat-
affected zone (HAZ), or both, appears upon cooling or after a
delay of several hours. It generally does not occur at a tempera-
ture above 300°F (150°C). The combination of hydrogen content
and tensile stress in a crack-susceptible microstructure makes the
probability of hydrogen cracking very high.
Atomic hydrogen diffuses very easily into molten steel. The
hydrogen may dissociate from water or hydrocarbons present in
the arc, and the molten metal absorbs the hot gas. The hydrogen
atoms diffuse throughout the weld metal and into the HAZ. The
hydrogen atoms find voids in the microstructural matrix, and the
proclivity for these atoms to come together and form diatomic or
molecular hydrogen is very great. If the concentration of mole-
cules is extensive within a localized area and the steel does not
yield sufficiently, high pressure can occur. With sufficient pres-
sure, a crack will occur.
Hydrogen in the arc can come from moisture in the electrode
covering or internal core ingredients, welding granular flux or
shielding gas. Lubricants on the base metal or the welding wire
can also break down into hydrogen atoms. If given sufficient time
during the cooling phase, the hydrogen dissipates harmlessly into
the atmosphere before it can be locked into the microstructure.
Therefore, control of cooling rates is very important with steels
susceptible to hydrogen cracking.
Limiting hydrogen to its minimum is also beneficial.
Electrodes specially formulated to be very low in hydrogen con-
tent have been developed for this purpose. A test for measuring
diffusible hydrogen from weld metal deposited with the shielded
metal arc, gas metal arc, flux cored arc and submerged arc weld-
ing processes has been developed by the American Welding
Society.
High local transformation stresses in martensite are thought to
make it more susceptible to hydrogen cracking. A mixture of fer-
rite and high-carbon martensite or bainite is very susceptible to
hydrogen cracking. This microstructure is produced during cool-
ing from austenite at a rate slightly faster than the critical cool-
ing rate of the steel. The formation of martensite in the weld
metal and H A Z can be minimized by controlling the cooling rate.
Weldability and resistance to hydrogen cracking generally
decreases as carbon content and martensite microstructure
increase in the weld or HAZ. These factors contribute to hard-
ening, which limits a weldment's ability to yield to internal stress-
es. There is a direct relationship with carbon content, martensite
and hardness - - Fig. 1.
Preheating and postheating reduce the chance of hydrogen
cracking. Preheating raises the temperature of the weldment to a
certain level prior to welding and maintains a specific interpass
temperature during the welding operation.
Postheating should be performed immediately after welding.
The temperature may be the same as the preheat and the hold-
ing time at temperature depends on joint thickness. The thicker
the weld area, the greater the path the hydrogen must take to
reach the surface.
Preheating and postheating reduce cooling rates, which
reduce H A Z hardness. They also reduce stress and increase the
rate at which hydrogen diffuses from the weld zone.
Consult knowledgeable sources for determining preheating
and postheating temperatures for specific steels and thicknesses.
60~
70

oI- / .......
~~.

Depending on the diffused hydrogen, a designator is attached / / /I- 5o9,0MA.TENS,TE

to the AWS classification of the electrode. The designator indi-
cates the maximum mL of hydrogen that would diffuse from 100 g
of weld metal when subjected to the standardized test. For exam-
o
"TI /"
ple, the designators H4, H8 and H16 indicate the hydrogen to dif-
fuse from 100 g of weld metal would not exceed 4, 8 or 16 mL, 20
respectively. These are all very low levels of hydrogen. In addition,
electrodes that have been specially formulated to resist moisture
pickup over extended periods of high humidity conditions are des-
ignated with an R if they satisfy a certain standard when subjected
i,o
o, ' I , I I I , I ,
to a moisture test. An example of a low-hydrogen electrode with 0 0.20 0.40 0.60 0.80 1.00
all of the designators is E7018-H4R. CARBON, wt. %
Steels with a martensitic microstructure are susceptible to
hydrogen cracking. Generally, these are high-strength steels.

Fig. 1 - - Relationship o f carbon content and hardness with a

Excerpted from Welding Handbook, Vol. 4, Eighth Edition.
martensitic microstructure.

WELDING JOURNAL I 45
 D a t a s h e e t 248b

Plastic Welding
Hot-Gas Welding
Polymeric materials (plastics) are used for
a multitude of products that require their
parts to be joined during fabrication. Fusion
I processes are used to join plastics and hot-gas
welding is one of the more common ones.
Hot-gas welding creates a weld by fusing
the joint using a filler rod. This process, which
is sometimes called hot-air welding, blows a
(B) Poor Penetration stream of heated gas or air onto a filler rod
and the surfaces to be joined. The hot stream
(A) Stress Cracking melts the filler rod and joint surfaces.
Pressure forces the filler rod into the joint to
create the weld. It is not necessary nor desir-
able to melt the entire filler rod. If excessive
heat is used, the polymer will decompose.
Where high-quality welds are required, an
inert gas such as dry nitrogen might be used,
although other inert gases can be used. In
applications where oxygen contamination is
not a concern, heated air is commonly used.
There must be a balance between gas flow
(C) Porous Weld (D) Distortion rate and temperature. Sufficient energy is
needed to create a weld but not deteriorate
the polymer. Also, since pressure is applied
to the rod, it cannot become soft and rubbery.
To start welding, the heated gas is directed to the end of the
filler rod and the joint until the area becomes shiny, indicating
melting. The torch is moved along the joint with a weaving
motion and pressure applied.
Weld quality (Fig. 2) is dependent on a variety of factors.
• The thermal stability of polymers vary; therefore, care must
be taken to prevent overheating of the material.
• The filler rod must be identical to the base material or
Fig. 2 - - Quality prob- stress cracking may occur.
(E) Decomposition lems that may be en- • Poor penetration can be avoided by using a tA2-in.(0.8-mm)
countered when weld- root opening. This allows the molten polymer to be pushed into
ing. the joint
• There must be a balance of temperature, travel speed and
ELECTRIC pressure. Underheating results in poor penetration, porosity and
TORCH ~i ~¢~,WELDING ROD distortion. With overheating, the polymer will become scorched
and decompose. Travel speed must be adjusted to allow suffi-
cient heating for welding but not permit melting through the
~ ~ / j S P E E D TIP base material. Pressure must force the polymers to intermingle,
but it should not be so great as to create stresses in the weld area
or notches on the weld surface.
• A joint cleaned of contaminants will provide the greatest
[ "~" \ / R O D IS strength.
\ \ J PREHEATED • Gouges or notches in the weld area will weaken the joint.
INTUBE • The welder must have the skill level to produce consistent
quality welds.
~""""..,.,~ /SHOE A variant of manual hot-gas welding uses a special tip fitted
N-'~ % ~./ PROVIDES to the welding gun - - Fig. 3. This tip facilitates feeding of the
~-- ~
~IIIIIIIIIIIIIIII/IIIIIII////I////III/II/IIIIIII/IIIII/IIII//JH~II~
PRESSURE filler rod into the heating chamber, and as the rod is melted, a
shoe on the tip forces it into the joint. The hot-gas process can
also be automated using a unit with feedback controls.
" HEAT
Fig. 3 - Hot-gas welding gun with special tip. Correction - - The November Welding Workbook Datasheet 246a ]
stated incorrect loads applied when microhardness testing. The I
correct loads are typically 100-500g, but as low as I g and as high J
Excerpted from Welding Handbook, Vol. 3, Eighth Edition. as 1000 g. I

46 I JANUARY 2001
 CALL FOR PAPERS

Eleventh International Conference on

Computer Technology in Welding

September 19 and 20, 2001 - - Columbus, Ohio

This is the eleventh in a series of computer conferences designed to provide the welding
industry with the latest information regarding the use of computers for welding. This conference,
jointly sponsored by the American Welding Society, The Welding Institute and the National
Institute of Standards and Technology, will be held September 19 and 20, 2001, in Columbus,
Ohio. Authors from around the world are strongly encouraged to submit an abstract, as atten-
dance from an international audience will be encouraged.

Authors should submit the Author Form (on reverse side), together with an abstract of no
more than 500, words to American Welding Society, Conference Department, 550 NW LeJeune
Road, Miami, FL 33126, by January 31, 2001. The abstract should be sufficiently descriptive to
give a clear idea of the content of the proposed paper. Authors will be notified of acceptance by
March 5, 2001. Complete manuscripts will be required from selected speakers by May 1, 2001.

Authors are not limited to any specific topics, except that papers should be appropriate for
the conference subject. Contributions are encouraged in the following areas:

• Modeling of Welds and Welding Processes"

• Off-Line Planning/Weld Simulation~Visualization
• Computerized Data Acquisition and Sensing Systems
• Real-Time Welding Information and Control Systems
• Weld Process' Automation
• Network and Web-Based Implementations
• Case Histories~Experiences with Commercial Software (by users)
• Welding Documentation (e.g., PQR)
• Databases, Database Applications and Knowledge Bases
• Standards

To ensure your paper's consideration for the conference, your abstract must be postmarked no
later than January 31, 2001.
 Author Application Form

Eleventh International Conference on C o m p u t e r Technology in Welding

S e p t e m b e r 19-20, 2001 m C o l u m b u s , Ohio

Date Mailed
Author's Name:
Please check how you are addressed: Mr. Ms. Dr. Other
Title or Position:
Organization:
Mailing Address:
City: State: Zip Code: Country:
Telephone: Fax:
For joint authorship, give names. (If more than two coauthors, please use separate sheet.)
Name: Name:
Organization: Organization:
Address: Address:

P R O P O S E D T I T L E (10 words or less):

ABSTRACT:
• Typed, double-spaced, 250-500 words, attached to this form.
• Be sure to give information to provide a clear idea of content of the proposed paper.
• If completed manuscript is available now, in addition to abstract, attach copy to this
form.
• Application form and abstract must be postmarked no later than January 31, 2001.

MANUSCRIPT DEADLINE:
• All manuscripts must be submitted no later than May 1, 2001.
• Guidelines for submission of manuscripts will be provided to authors
selected for the program.

PRESENTATION AND PUBLICATION OF PAPERS:

Has material in this paper been previously published or presented at any meeting?
Yes No When? Where?

Return to AWS postmarked no later than January 31, 2001, to the following address:
Conferences
American Welding Society
550 N.W. LeJeune Road
Miami, Florida 33126
Phone: (800) 443-9353, Ext. 223, or (305) 443-9353, Ext. 223
Fax: (305) 443-1552
 A MANTECH Center Of Excellence
I Center Operatedby ~ , ~ j

Improved Control of Welding Fume

for Shipbuilding
dison Welding Institute (EWI) is and increasing ship-

E leading a team of shipbuilders,

welding equipment manufactur-
ers and U.S. Navy personnel in a Na-
building cost. The es-
timated cost for U.S.
shipyards to comply
tional Shipbuilding Research Program with new Cr +6 stan-
(NSRP) project titled Reduction of dards using existing
Worker Exposure and Environmental approaches could
Release of Welding Emissions. This pro- total $604 million/
ject builds on past work by the NSRP, year. It is important
the Navy Joining Center and the U.S. for American ship-
Navy. builders to reduce
The project is funded by the National the release of air-
Shipbuilding Research Program Ad- borne emissions
vanced Shipbuilding Enterprise (NSRP from welding and
ASE).The following forms the project cutting in such a way
team: the productivity of
the work force is not
• Litton Avondale Industries compromised.
• Bath Iron Works The approach is to The EWl-led p ro j ect R e d u c t i o n o f Worker Exposure a n d
• Edison Welding Institute develop and apply ef- E n v i r o n m e n t a l Release o f Welding Emissions will access
• Electric Boat Corp. fective engineering c u r r e n t p ra ct i ces o f controlling w e l d i n g f u m e s , such as
• ESAB Welding Products controls to minimize seen above, a n d will develop a n d apply i m p r o v e d proce-
• Kura Environmental Consultant worker exposure and dures to m i n i m i z e emissions.
• T h e Lincoln Electric Co. the release of air-
• National Steel and Shipbuilding Co. borne emissions from
• Naval Surface Warfare Center- welding and cutting
processes. The project will assess the • Best practices guidelines and training
Carderock Division
state of current practice in shipyards, materials.
• Newport News Shipbuilding.
identify industry-specific requirements, This project will result in improved
The objective of this project is to im- develop and apply improved welding engineering controls that minimize
procedures to minimize emissions, re- worker exposure and the release of air-
prove worker safety and environmental
performance while sustaining shipyard fine engineering controls to remove borne emissions from welding and cut-
emissions at the source, identify prac- ting operations. Additional benefits to
productivity and minimizing added costs.
tices to reduce emissions and transfer the shipbuilding industry will be the
The welding fume produced when fabri-
the technology to industry. ability to reduce emissions in the most
cating structures for military and com-
The shipbuilders will take the lead economical manner with minimum im-
mercial ships may contain hexavalent
roles to identify and characterize present pact on productivity and production
chromium, manganese and nickel. The
practices, define requirements for new schedules.
Occupational Safety and Health Admin-
emission controls, set cost targets and Contact Ian Harris, (614) 688-5131,
istration is developing new standards re-
evaluate and apply the selected tech- ian_harris@ewi.org; or Harvey Castner,
ducing the permissible exposure limit for
nologies in shipyard production opera- (614) 688-5063, harvey_castner@
hexavalent chromium by as much as 200
tions. Project deliverables include the ewi.org for more information on this
times compared to present levels. The
following: project. •
American Conference of Governmental
and Industrial Hygienists recently re-
duced their published threshold limit • Baseline survey of current shipyard The Navy Joining Center
values for manganese and insoluble practices 1250Arthur E. Adams Dr.
nickel compounds by a factor of five. • Prioritized list of applications ~ d C Columbus, OH 43221
Phone: (614) 688-5010
While safety practices for welding • Data on worker exposure Operated by FAX:(614) 688-5001
and cutting are well established, they • Advanced engineering controls E ~ i e-mail:NJC@ewi.org
are often difficult to apply without sig- • Enhanced processes to reduce fume www:http://www.ewiorg
nificantly reducing worker productivity • Data from field trials Contact: Harvey Castner

WELDING JOURNAL I 49

Conferences and Exhibitions
Orlando 2001 Advanced Productivity Exposition. January
16-18, Orange County Convention Center, Orlando, Fla. Con-
tact Laura Heidrich, (313) 271-1500 ext. 1853 or e-mail:
heidlau@sme.org.
• 5th Robotic Arc Welding Conference and Exposition. Febru-
ary 2-6, Grosvenor Resort, Orlando, Fla. Sponsored by the
American Welding Society. Contact: AWS Conference Dept.,
550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext.
223, FAX: (305) 443-1552.
NACE Northern Area Western Conference. February 26-28,
Hilton Hotel, Anchorage, Alaska. Sponsored by NACE Inter-
national, the Corrosion Society. Contact: Dan Powell, Co-chair-
man, (403) 235-6400, e-mail: dan.powell@corrpro.ca.
International Laser Safety Conference. March 5-8, Catamaran
Resort Hotel, San Diego, Calif. Sponsored by the Laser Insti-
tute of America. Contact: LIA, 13501 Ingenuity Dr., Ste. 128,
Orlando, FL 32826.
Com ( Events
WESTEC 2001: Advanced Productivity Exposition. March
26-29, Los Angeles Convention Center, Los Angeles, Calif.
Sponsored by the Society of Manufacturing Engineers. Contact:
SME Customer Service, One SME Dr., Dearborn, MI 48121,
(800) 733-4763, (313) 271-1500, FAX: (313) 271-2861.
t Max International. May 6-10, 2001, IX Center, Cleveland,
Ohio. Cohosted by the American Welding Society and The Pre-
cision Metalforming Association, this collocated event is com-
prised of The AWS International Welding and Fabricating Ex-
position and Annual Conference and METALFORM
ExpoSium. Contact: AWS Convention and Expositions Dept.,
550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 256
or (305) 443-9353 ext. 256, FAX: (305) 442-7451.
Tenth International JOM Jubilee Conference on the Joining of
Materials, JOM-10. May 11-14, Helsing0r, Denmark. Cospon-
sored by the Institute for the Joining of Materials and AWS.
Contact: Institute for the Joining of Materials, Klintoh0j Va~nge
21, DK-3460 Birker0d, Denmark, 45 45 82 80 85, FAX 45 45 94
08 55 or e-mail: jom_aws@postl0.tele.dk.

NACE International - - Corrosion 2001, Conference and Exhi-
bition. March 11-16, George R. Brown Convention Center,
Houston, Tex. Sponsored by NACE International, the Corro-
sion Society. Contact: NACE Membership Services, (281) 228-
6223, FAX: (281) 228-6329, www.nace.org.
Twin Cities 2001 Advanced Productivity Exposition. May 15-17,
Minneapolis Convention Center, Minneapolis, Minn. Spon-
Note: A diamond (0) denotes an A WS-sponsored event.

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50 [ J A N U A R Y 2001
sored by the Society of Manufacturing Engineers (SME), Amer-
ican Machine Tool Distributors' Association (AMTDA) and
The Association for Manufacturing Technology (AMT). Con-
tact: SME Customer Service, (800) 733-4763 or (313) 271-1500
ext. 1600 or visit the SME Web site at www.sme.org.
International Robots and Vision Show. June 5-7, Rosemont
Convention Center, Chicago. Sponsored by the Robotic Indus-
tries Association (RIA) and Automated Imaging Association
(AIA). Contact: RIA/AIA, 900 Victors Way, RO. Box 3724, Ann
Arbor, MI 48106, (734) 994-6088, www. robotics.org or www.au-
tomated-imaging.org.
First Middle East Nondestructive Testing Conference and Ex-
hibition. September 24-26, Gulf International Convention Cen-
tre, Bahrain. Cosponsored by the Saudi Arabian Section of
American Society for Nondestructive Testing and The Bahrain
Society of Engineers. Contact: The Conference Secretariet,
Bahrain Society of Engineers, EO. Box 835, Maama, Bahrain,
973-727 100, FAX: 973-729 819, e-mail: Mohandis@batelco.
com. bh.
International Conference on Advances in Materials and Pro-
cessing Technologies. September 18-21, Legan6s, Madrid,
Spain. Contact: AMPT '01 Congress Secretariat, Fundaci6n
Universidad Carlos III, Congrega, Avda. de la Universidad, 30,
28911 Legan6s, Madrid, Spain, 34 91 624 91 42, FAX: 34 91 624
91 47, e-mail: congrega@fund.uc3m.es.
Machine Tool Exposition. September 24-26, 2001, Las Vegas
Convention Center, Las Vegas, Nev. Contact: William Yeates,
Show Manager, (702) 566-7300, FAX: (702) 566-7300.
Fourth Pacific Rim International Conference on Advanced Ma-
terials and Processing. December 11-15, Hilton Hawaiian Vil-
lage, Honolulu, Hawaii. Organized by the Chinese Society for
Metals, the Korean Institute of Metals and Materials, the Min-
erals, Metals and Materials Society and the Japan Institute of
Metals. Contact: The Japan Institute of Metals, AT1-N: PRICM
4 Secretariat, Aoba, Aramaki, Aoba-Ku, Sendai, 980-0845.
Educational Opportunities
Steel Buildings: Seismic Design, Construction and Inspection.
January 16-17, Portland, Ore.; January 18-19, Seattle, Wash.;
January 23-24, San Francisco, Calif.; January 25-26, Sacra-
mento, Calif.; January 30-31, Los Angeles (Buena Park), Calif.;
February 1-2, San Diego, Calif. Cosponsored by the American
Institute of Steel Construction and the Steel Structures Tech-
nology Center (SSTC). Contact: SSTC, (248) 344-2911; or
www.steelstructures.com.
Innovative Engineering and Inventive Problem Solving Course.
February 26-27, Orlando, Fla. Conducted by the American So-
ciety of Mechanical Engineers. Contact: Shari Romar, Senior
Education Specialist, ASME International, Three Park Ave.,
New York, NY 10016, (212) 591-7902, FAX: (212) 591-7143,
romar@asme.org.
ASME Section IX: Welding and Brazing Qualifications Course.
January 31-February 2, New Orleans, La. Conducted by the
American Society of Mechanical Engineers. Contact: Shari
Romar, Senior Education Specialist, ASME International,
Three Park Ave., New York, NY 10016, (212) 591-7902, FAX:
(212) 591-7143, e-mail: romars@asme.org.

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WELDING JOURNAL [ 51
 Educational Opportunities

AWS Schedule m CWI/CWE Prep Courses and E x a m s

E x a m a p p l i c a t i o n m u s t b e s u b m i t t e d six w e e k s b e f o r e e x a m d a t e . F o r e x a m i n f o r m a t i o n a n d a p p l i c a t i o n , c o n t a c t t h e A W S
C e r t i f i c a t i o n D e p t . , (800) 443-9353 ext. 273. F o r e x a m p r e p c o u r s e i n f o r m a t i o n , c o n t a c t t h e A W S E d u c a t i o n D e p t . , (800) 443-9353
ext. 229. D a t e s are s u b j e c t to c h a n g e .

Cities Exam Prep CWI/C%VE Cities Exam Prep CWI/CWE

Courses Exams Courses Exams

Anchorage, Alaska EXAM ONLY March 24, 2001 Los Angles, Calif. Jan. 22-26, 2001 Jan. 27, 2001
Feb. 26-March 2, 2001 March 3, 2001 (API 1104 clinic also offered)
Atlanta, Ga.
Miami, Fla. EXAM ONLY Jan. 18, 2001
(API 1104 clinic also offered)
Miami, Fla. EXAM ONLY March 15, 2001
Beaumont, Tex. June 11-15, 2001 June 16, 2001
Miami, Fla. EXAM ONLY May 17, 2001
(API 1104 Clinic & SCWl also offered)
Birmin[~ham, Ala. EXAM ONLY May 26, 2001 Miami, Fla. June 18-22, 2001 June 23, 2001
Buffalo, N.Y. EXAM ONLY Feb. 17, 2001 Minneapolis, Minn. March 5-9, 2001 March 10, 2001
Charlotte, N.C. Feb. 12-16, 2001 Feb. 17, 2001 Mobile, Ala. EXAM ONLY Feb. 17, 2001
Nashville, Tenn. May 21-25, 2001 May 26, 2001
Cincinnati Ohio May 14-18, 2001 May 19, 2001
(API 1104 clinic also offered)
Chica[~o, I11. April 30-May 4, 2001 May 5, 2001
Newark, N.J. EXAM ONLY Jan. 27, 2001
Columbus, Ohio EXAM ONLY March 3, 2001
Jan. 29-Feb. 2, 2001 Feb. 3, 2001 Newark, N.J. March 12-16, 2001 March 17, 2001
Dallas, Tex.
(API 1104 clinic also offered) Oklahoma City, Okla. Feb. 5-9, 2001 Feb. 10, 2001
Denver, Colo. Feb. 26-March 2, 2001 March 3, 2 0 0 1 Perrysbur~, Ohio EXAM ONLY March 24, 2001
Fresno, Calif. EXAM ONLY Jan. 13, 2001 Portland, Maine April 2 ~ , 2001 April 7, 2001
Gulfport, Miss. Feb. 19-23, 2001 Feb. 24, 2001 Phoenix, Ariz. March 19-23, 2001 March 24, 2001
Houston, Tex. March 5-9, 2001 March 10, 2001 Salt Lake City, Utah Jan. 29-Feb. 2, 2001 Feb. 3, 2001
(API 1104 clinic/ San Francisco Ca. May 14-18, 2001 May 19, 2001
Shreveport, La. Jan. 22-26, 2001 Jan. 27, 2001
SCWI also offered)
Knoxville, Tenn. March 12-16, 2001 March 17, 2001 Springfield, Mo. March 19-23, 2001 March 24, 2001
Tampa, Fla. Jan. 29-Feb. 2, 2001 Feb. 3, 2001
(API 1104 clinic also offered)
Las Vegas, Nev. EXAM ONLY Jan. 13, 2001 (API 1104 clinic also offered)
Las Vegas, Nev. April 23-27, 2001 April 28, 2001 Tulsa, Okla. EXAM ONLY March 10, 2001

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Circle No. 6 on Reader Info-Card

WELDING JOURNAL I 53

A brazing temperature does not allow for
B Y R. L. PEASLEE
Q: I keep hearing about boron in nickel
filler metals, but have no information as
to why it is there. What is boron, and why
is it in brazing filler metals? We are cur-
rently repairing cracked jet engine parts
using BNi-2 filler metal on nickel alloy
parts. The brazing is for 10 min at heat.
When we go back for a second brazing
operation, we find the shorter time of 5
min improves the surface appearance.
A: Boron is an element similar to nickel,
chromium and iron. When added to a
nickel-chromium alloy, it lowers the
melting temperature of the alloy, which
allows us to use the low-melting nickel-
chromium-boron alloy as a brazing filler
metal. Boron is a unique element be-
cause of its small molecular size. It read-
ily diffuses into the adjoining base met-
als, changing the chemistry and physical
properties of the brazing filler metal in
the joint. This process is defined as dif-
fusion brazing.
D e p e n d i n g on the requirements of
the parts during service application, dif-
fusion brazing allows the alteration of
the properties of the braze joint. The
original brazing filler metal, BNi-2, is
hard and has low ductility, as well as a
low melting temperature. During diffu-
sion brazing, the remelt temperature is
increased and can reach remelt temper-
atures exceeding 2500°F (1370°C). When
completely diffusion brazed with a
nickel-based metal, the remelt tempera-
ture will be the melting point of that base
metal. A t the same time, the hardness
will be equivalent to the base-metal
hardness and tensile strength of the butt
joint, and the stress rupture will be equiv-
alent to the base metal. After full diffu-
sion in the nickel-based metal, the braz-
ing filler metal will have disappeared,
and the grain structure goes right across
the joint. In this case, the elements of the
base metal have diffused into the braze
area, and the filler metal has been ho-
mogenized with the base metal.
You said you are brazing at 2050°F
(1121°C) for 10 min at heat for the first
brazing operation and, if you must go
back and apply more filler metal, you
braze for only 5 min at the brazing tem-
541 JANUARY2001
perature. Because this short time at the
much diffusion with the base metal, there
will be a centerline phase that is still low
melting and has low ductility.
When repairing parts for a jet engine,
it is necessary to know and understand
the service requirements for the partic-
ular part being repaired, as well as the
designer's reason for designing the part
that is to operate in the jet engine. If the
part is in the hot section of the jet en-
gine, it may see temperatures in the
range of the melting temperature of the
original BNi-2 filler metal. In this case,
longer diffusion times and/or higher tem-
peratures may be required to assure no
remelting of the braze will occur in the
engine, and it has a suitably high remelt
temperature and ductility for its service
requirements. If your particular part is
not in the high-temperature section, the
short time at t e m p e r a t u r e may be suit-
able, as long as high stress is not applied
to the part. The high stress may cause
cracking in the center-phase structure,
with low ductility.
An important part of the repair pro-
cedure is to have suitable inspection ca-
pabilities. If a crack goes all the way
through a part and is visible from the
back side, the filler metal can be applied
to one side and the part visually in-
spected, after brazing, on the opposite
side. When the crack does not go all the
way through, or cannot be inspected
from the back side, the filler metal
should not be applied over the full length
of the crack. When applying filler metal
over the entire length of the crack, it is
not possible to visually inspect the part
to assure adequate flow in the crack area
after brazing. A questionable atmo-
sphere, or other furnace problems, can
result in the filler metal setting on top of
the crack and not entering it. To assure
there is good visual inspection, it is im-
portant to apply the filler metal at one
end of a small crack, or at both ends of
larger cracks, and sometimes in the cen-
ter. If the filler metal flows adequately
along the joint between the two points
of application, you will have a good vi-
sual method of assuring the filler metal
flowed into the crack. If there was a fur-
nace problem and the filler metal did not
flow between the points of application,
additional filler metal could be a d d e d
next to the original point of application.
A f t e r the furnace is functioning ade-
quately, the part could be rebrazed and
have sufficient open space between the
points of application so that visual in-
spection can again be used to assure the
filler metal has adequately flowed into
the gap.
Another important part of the repair
brazing procedure is the cleaning of the
crack area. For base metals not contain-
ing aluminum, titanium or other similar
highly oxidized materials, hydrogen at-
mosphere cleaning is preferred, since the
hydrogen molecule is small enough to
get into any of the cracks and reduce the
metal oxides. The hydrogen molecule is
also small enough to go through the en-
tire thickness of the metal and remove
some of the unwanted elements picked
up during jet engine operation. A typi-
cal example of this is the combustion
chambers in high-flying aircraft that pick
up sulfur from the atmosphere. It was
noted sulfur was removed from the
nickel alloys of the combustion chamber
during hydrogen cleaning, thus regener-
ating the properties of the original base
metal. While cleaning of the parts in vac-
uum has been used, contamination from
the engine-operated parts, and from pre-
cleaning operations before brazing, put
a lot of contamination into the vacuum
furnace. Therefore, if the same furnace
is used for cleaning and brazing, atmo-
sphere quality will be reduced during the
brazing operation, and parts may not be
as good as those obtained from a vacuum
furnace dedicated only to brazing.
Base metal containing aluminum, ti-
tanium and similar highly oxidizable ma-
terials cannot be dissociated of their ox-
ides in hydrogen, or in the vacuum fur-
nace. They require special attention. A
special cleaning method known as fluo-
ride ion cleaning is accomplished in a
sealed retort with fluorine being added
to the atmosphere by one of a number
of methods. The fluorine reacts with the
oxides of aluminum and titanium and will
remove them. It also removes some of
the titanium and aluminum from the
base metal's surface, so parts can be re-
pair brazed in standard vacuum atmo-
sphere during the brazing operation.
When brazing is satisfactory, additional
time at the brazing t e m p e r a t u r e will
allow the titanium and aluminum to dif-
fuse back out to the surface, resulting in
the desired physical properties of the
base metal. If insufficient aluminum and
titanium have been removed from the
surface, aluminum and titanium oxides
-- c o n t i n u e d on p a g e 7 7
 /
N E W S
By Susan Campbell

¢ USS Albacore N a m e d A W S
Historical Welded Structure
n O c t o b e r , t h e A m e r i c a n W e l d i n g S o c i e t y (AWS)

i a n n o u n c e d t h e d e d i c a t i o n o f t h e USS A l b a c o r e
R e s e a r c h S u b m a r i n e as a n AWS H i s t o r i c a l W e l d e d
S t r u c t u r e . A p a r t o f t h e E x t r a o r d i n a r y W e l d e d Struc-
t u r e A w a r d P r o g r a m , t h e h i s t o r i c a l d e s i g n a t i o n is be-
s t o w e d o n t h e A l b a c o r e in r e c o g n i t i o n o f t h e ad-
v a n c e s it m a d e p o s s i b l e in w e l d i n g p r o c e s s e s , s o n a r
systems and submarine design.
T h e h u l l for t h e USS Albacore w a s laid o n M a r c h
15, 1952. It l a u n c h e d o n A u g u s t 1, 1953, a n d c o m m i s -
s i o n e d o n D e c e m b e r 5, 1953. It w a s d e s i g n e d solely as
an experimental vessel and carried no weapons. Her
i n n o v a t i v e hull design, t h e t e a r - d r o p hull, p r o v i d e d a n
e n g i n e e r i n g m o d e l for all f u t u r e U.S. Navy a n d foreign
s u b m a r i n e s . T h e d e s i g n o f t h e s u b m a r i n e w a s so suc- The USS A l b a c o r e tit its f i red resting place at Albacore I~lrk,
cessful, in 1966, s h e set a n e w u n d e r w a t e r s p e e d r e c o r d Portsmouth, N.H. (Photograph by Peter E. Randall, courtesy o f
a n d w a s n a m e d t h e w o r l d ' s fastest s u b m a r i n e . Albacore Park.)
T h e Albacore w a s r e t i r e d f r o m a c t i v e s e r v i c e o n
S e p t e m b e r 1, 1 9 7 2 , a n d w a s p l a c e d in a p e r m a n e n t A m e r i c a n W e l d i n g S o c i e t y P r e s i d e n t L.William M y e r s
d r y b e r t h . T h e s u b m a r i n e n o w s e r v e s as a m u s e u m a n d p r e s e n t e d t h e H i s t o r i c a l W e l d e d S t r u c t u r e A w a r d to Pro-
m e m o r i a l at t h e P o r t o f P o r t s m o u t h M u s e u m a n d A l b a - f e s s o r G e n e A l l m e n d i n g e r , o n e o f t h e s u b m a r i n e ' s origi-
c o r e Park in P o r t s m o u t h , N.H. nal designers, and to the staff of the museum.Albacore
P a r k D i r e c t o r R u s s e l l Van B i l l i a r d p r e s e n t e d P r e s i d e n t
M y e r s w i t h a b o o k o n t h e h i s t o r y o f t h e USS Al b a cor e .
T h e USS Albacore w a s n o m i n a t e d for t h i s a w a r d b y Russ
Morris, c h a i r m a n o f t h e AWS M a i n e S e c t i o n . T h e n o m i n a -
t i o n w a s a p p r o v e d b y t h e AWS Past P r e s i d e n t s C o m m i t -
tee, w h i c h v o t e s o n t h e a w a r d n o m i n a t i o n s .
T h e H i s t o r i c a l W e l d e d S t r u c t u r e A w a r d is p a r t o f t h e
Society's Extraordinary Welded Structure Award Program.
Presented to structures and vehicles that have pioneered
the science and application of welding, the Extraordinary
W e l d e d S t r u c t u r e A w a r d s are p r e s e n t e d b y t h e AWS Past
P r e s i d e n t ' s C o m m i t t e e . Past r e c i p i e n t s i n c l u d e t h e St. Louis
A r c h , t h e n u c l e a r a i r c r a f t c a r r i e r USS H a rry T r u m a n a n d
t h e E x t e r n a l Fuel Tank o f t h e NASA S p a c e Shuttle.
If y o u k n o w a s t r u c t u r e , s h i p , b r i d g e o r o t h e r feat o f
Albacore M u s e u m Director Russell Van Billiard, leJL pre- engineering that has led to advances in welding design
senting A WS President L. William Myers, center, with a and processes, contact Nannette Zapata,AWS Corporate
book on the history o f the USS Albacore. Professor Gene C o m m u n i c a t i o n s , 5 5 0 N.W. L e J e u n e Rd., Miami, FL 3 3 1 2 6 ,
Allmendinger, one o f the submarine's original designers, ( 8 0 0 ) 4 4 3 - 9 3 5 3 ext. 308, to n o m i n a t e it as a H i s t o r i c a l o r
looks on, homing the plaque awarded the Albacore as an Extraordinary Welded Structure. O
A WS Historical Structure. The USS A l b a c o r e can be seen
in the background.

WELDING JOURNAL I 55
• Skills USA Elects N a t i o n a l S e c o n d a r y S e c r e t a r y • Volunteers Sought for the
D9 Committee on Welding,
ast summer, Jacob Carter Brazing and Soldering of

L was elected National Skills-

USA Secondary Secretary
for the 2000-2001 school year.
Sheet Metal

he A m e r i c a n Welding Soci-
Carter is from Lexington, S.C.,
and a t t e n d s Lexington Applied
Technology Center.
T ety's (AWS) D9 C o m m i t t e e
on Welding, Brazing and Sol-
dering of Sheet Metal is looking to
Carter was e n c o u r a g e d by add m e m b e r s to the Committee.
his welding instructor, Herman The Committee r e c e n t l y pub-
Madden, to take a d v a n t a g e of lished AWS D 9 . 1 : 2 0 0 0 , S h e e t
the o p p o r t u n i t i e s SkilIsUSA M e t a l Welding Code.The Commit-
p r o v i d e s s t u d e n t s and r u n for tee is set to b e g i n the n e x t revi-
office. With that e n c o u r a g e - s i o n of the code. I n d i v i d u a l s
ment, he became state treasurer k n o w l e d g e a b l e in the w e l d i n g
of the South Carolina chapter. and braze w e l d i n g of sheet metal
He will take his leadership op- in n o n s t r u c t u r a l a p p l i c a t i o n s are
p o r t u n i t i e s even f u r t h e r as na- e n c o u r a g e d to apply. Contractors,
tional secretary. • welding instructors and welders
N a t i o n a l Skills USA Secondary Secretary
Jacob Carter, left, a n d his welding instruc- i n v o l v e d in h e a t i n g , v e n t i l a t i n g
tor Herman Madden. a n d air c o n d i t i o n i n g , food pro-
cessing equipment, cabinetry,
e l e c t r i c a l p a n e l s or o t h e r n o n -
structural applications are partic-
ularly sought.
• C A N WE T A I l ? If you are i n t e r e s t e d i n par-
ticipating in this work, please sub-
The Welding J o u r n a l staff encourages an exchange of ideas with you, our mit y o u r a p p l i c a t i o n o n the AWS
readers. If you'd like to ask a question, share an idea or voice an opinion, you can Web site at w w w . a w s . o r g or con-
call, write, e-mail or fax. Staff e-mail addresses are listed below, along with a guide tact the D9 Committee Secretary,
to help you interact with the right person. J o h n Gayler, at (800) 443-9353
ext. 472 or via e-mail at
P u b l i s h e r Jeff Weber A d v e r t i s i n g Sales D i r e c t o r gayler@aws.org. •
jweber@aws.org Rob Saltzstein
General Management, salty@aws.org
Reprint Permission, Advertising Sales
Copyright Issues
Advertising Production Manager • Errata for
Editor A n d r e w C u l l t s o n C o l l e e n Beem ANSI/AWS A 5 . 2 8 - 9 6
cullison@aws.org cday@aws.org
Article Submissions Advertising Production
• ANSI/AWS A5.28-96, Specifica-
Features Editor Advertising Coordinator tion for Low-Alloy Steel
Mary Ruth J o h n s e n Lea G a r r i g a n E l e c t r o d e s a n d R o d s f o r Gas
mjohnsen@aws.org garrigan@aws.org S h i e l d e d A r c Welding.
Feature Articles Production and Promotion
Page 4, Table 3 - Change the shielding
Associate Editor S u s a n C a m p b e l l Peer Review C o o r d i n a t o r
gas for the ER9OS-B9 from
campbell@aws.org Doreen Kubish
Society News doreen@aws.org "Argon/5%O2" to"Argon/5%CO2:' *
Peer Review of Research Papers
Assistant Editor D o r e e n Yamamoto
Yamamoto@aws.org D e p a r t m e n t Secretary • AWS F o u n d a t i o n
New Products Paola C h a c 6 n on the Web
pchacon@aws.org
M a n a g i n g Editor C h r i s t i n e Tarafa General Information For further information on the
ctarafa@aws.org AWS F o u n d a t i o n scholarship a n d
Design and Production Welding J o u r n a l Dept. s t u d e n t loan programs, visit the
550 N.W. LeJeune Rd. AWS F o u n d a t i o n o n the Web at
P r o d u c t i o n Assistant Zaida Chavez Miami, FL 33126 www.aws, org/foundation/.
zaida@aws.org (800) 443-9353 ext. 348
Design and Production FAX (305) 443-7404

561 JANUARY2001
 ¢ AWS H o n o r s F o u n d a t i o n B e n e f a c t o r
h e A m e r i c a n W e l d i n g S o c i e t y (AWS) h o n o r e d t h e l a t e G l e n n J.

T G i b s o n , c o - i n v e n t o r o f t h e gas m e t a l arc w e l d i n g ( G M A W ) p r o c e s s
a n d g e n e r o u s b e n e f a c t o r o f t h e AWS F o u n d a t i o n , at a c e r e m o n y
o f f i c i a l l y n a m i n g t h e AWS w e l d i n g l a b o r a t o r y i n h i s h o n o r . G i b s o n ,
w h o p a s s e d a w a y o n M a r c h 25, w a s t h e i n i t i a l b e n e f a c t o r o f t h e AWS
F o u n d a t i o n . G i b s o n ' s s o n J i m , t h e g u e s t o f h o n o r at t h e c e r e m o n y , of-
ficially opened the lab by cutting the ribbon and unveiling the com-
m e m o r a t i v e p l a q u e in h o n o r o f h i s f a t h e r .
A t t e n d i n g t h e c e r e m o n y w e r e AWS E x e c u t i v e D i r e c t o r F r a n k De-
Laurier, AWS F o u n d a t i o n C h a i r m a n R o n a l d C. P i e r c e , A W S P r e s i d e n t L.
W i l l i a m M y e r s a n d AWS Vice P r e s i d e n t R i c h a r d A r n , as w e l l as AWS s t a f f
members and guests. J i m Gibson c u t t i n g the r i b b o n to J}~r-
D e L a u r i e r b e g a n t h e t r i b u t e to G i b s o n b y r e c a l l i n g t h e f i r s t t i m e
m a l l y o p e n the w e l d i n g l a b o r a t o r y
h e m e t G i b s o n a l o n g w i t h AWS's t h e n - p r e s i d e n t R i c h a r d A l l e y a n d G u s
n a m e d in his f a t h e r ' s h o n o r a t A W S
M a n z . He s p o k e o f h o w g e n u i n e G i b s o n ' s p a s s i o n w a s f o r t h e w e l d i n g h e a d q u a r t e r s in M i a m i w i t h A WS Pres-
i n d u s t r y a n d o f h i s d e s i r e t o h e l p y o u n g p e o p l e r e a c h t h e i r g o a l o f ob- i d en t L. Wi l l i a m Myers l o o k i n g on.
taining an education in welding. He told of his surprise when, with-
out hesitation, Gibson generously contributed the initial endowment
t o c r e a t e t h e AWS F o u n d a t i o n .
F o u n d a t i o n C h a i r m a n R o n a l d C. P i e r c e , a p a s t p r e s i d e n t o f AWS,
t h e n i n t r o d u c e d G i b s o n ' s s o n , Jim.
Jim Gibson reminisced about growing up with a researcher whose
first unofficial welding lab was in the basement of the family's home.
As J i m said, "My f a t h e r , like a n y o t h e r s u c c e s s f u l m a n w h o p u s h e s t h e
e n v e l o p e , h a d h i s s h a r e o f s u c c e s s e s a n d h i s s h a r e o f failures." H e s p o k e
o f h i s f a t h e r ' s d e s i r e t o h e l p p e o p l e , a n d h i s s t r o n g b e l i e f i n t h e im-
p o r t a n c e o f e d u c a t i o n . T h r o u g h o u t h i s life G l e n n G i b s o n d o n a t e d gen-
e r o u s l y t o t h e AWS F o u n d a t i o n a n d L e h i g h U n i v e r s i t y , t w o i n s t i t u t i o n s
in which he strongly believed.Jim Gibson carried on his father's legacy
b y m a k i n g a g e n e r o u s c o n t r i b u t i o n to t h e AWS F o u n d a t i o n in his m e m o r y .
Glenn Gibson earned a degree in civil engineering from Lehigh
U n i v e r s i t y , B e t h l e h e m , Pa., i n 1 9 3 5 . H e r e c e i v e d a f e l l o w s h i p s p o n - t i m Gibson presenting the A WS P'ounda-
s o r e d b y t h e AWS S t r u c t u r a l S t e e l W e l d i n g C o m m i t t e e at t h e u n i v e r - tion's Chairman o f the Board o f Trustees
sity's Fritz Laboratory.After two years of structural welding research R o n a l d C. Pierce w i t h a generous dona-
and some advanced physical metallurgy courses, Gibson received his tion in m e m o r y o f his father, Glenn.
m a s t e r ' s d e g r e e in c i v i l e n g i n e e r -
ing from Lehigh.AfterWorld War
II, G i b s o n j o i n e d A i r c o t o w o r k
in r e s e a r c h a n d d e v e l o p m e n t i n
M u r r a y Hill, N . J . W h i l e at A i r c o
in 1950, G i b s o n c o - i n v e n t e d t h e
gas metal arc welding process.
The Muller, Gibson and Ander-
s o n p a t e n t 2 , 5 0 4 , 6 8 8 is c o n s i d -
ered by most experts in the
w e l d i n g i n d u s t r y as t h e b a s i c
gas m e t a l arc w e l d i n g p a t e n t .
I n 1962, G i b s o n b e g a n Gib-
son Tube, Inc., in his family's
basement.The company, which
h a d t w o t u b e m i l l s at t h e t i m e ,
resided there for two years until
G i b s o n r e l o c a t e d it. G i b s o n
headed up the company until
his retirement in 1982, when
Jim Gibson became president. • Inside the newly dedicated Glenn Gibson Memorial Welding Laboratory are, Jrom
right, A WS Vice President Richard Arn; J i m Gibson; F o u n d a t i o n C h a i r m a n Ron
Pierce, who is a past president o f A WS; and A WS President L. William Myers.

WELDING JOURNAL I $7
• UVEX G e n e r o u s l y Supports the AWS S.E.N.S.E. P r o g r a m
e UVEX Safety company gener-

•l--•o usly donated $5000 to the AWS

undation to be dispersed to
schools participating in theAWS S.E.N.S.E.
program.UVEX representatives presented
the check to Alan Badeaux, a welding in-
structor at Crossland Senior High School,
and students from hisAWS Student Chap-
ter at the annual International Welding
and Fabricating Convention and Exhibi-
tion in Chicago, Ill., inApril.The students
(wearing safety glasses) were at the AWS
show manning a booth representing their
Student Chapter
UVEX Safety, division of Bacou USA
Safety, Inc., is a leading manufacturer of
safety glasses headquarterd in Smithfield,
R.I.•

A W S • Tenth International
JOM Jubilee Conference
P U B L I C A T I O N S he I n s t i t u t e for t h e J o i n i n g
• AWS Releases Sheet Metal Welding Code
The American Welding Society (AWS) completed the revised and updated
T o f Materials (JOM) has an-
n o u n c e d t h e Ten t h Interna-
tional JOM Ju b i l ee C o n f e r e n c e on
t h e J o i n i n g of Materials, JOM-10,
edition of Sheet Metal Welding Code (AWS D9.1M/D9.1:200).This ANSI-approved
May 11-14, 2001, in Helsingor,
standard covers the arc and braze welding requirements for sheet metal. Sheet
Denmark.
Metal Welding Code includes procedures and performance requirements, as well
T h e f o l l o w i n g are t h e main
as welding workmanship and valuable inspection standards. Developed under
t h e m e s of JOM-10:
the guidance of the AWS D9 Committee on the Welding, Brazing and Soldering
of Sheet Metal, the code was created and has been updated to meet the special-
• Information technology,
ized needs of sheet metal and construction industries.
cases in its exploitation, as well as
Available for $60, $45 for members, Sheet Metal Welding Code is 46 pages
p r e d i c t i o n of its value, for f u t u r e
and includes 11 annexes, ten tables and 27 detailed figures. •
and p r e s e n t w el d i n g fabrication.
• Welding Educator Qualification
• R o b o t i z a t i o n and automa-
t i o n in w e l d i n g and a s s o c i a t e d
To help welding educators teach the next generation of welding profession-
processes.
als all the skills they need to succeed, the American Welding Society (AWS) re-
leased the latest edition of Specification f o r the Qualification of Welding Edu-
• Brazing, soldering and asso-
cators (AWS B5.5:2OO).ANSI-approved, this specification defines the require-
ciated p r o c e s s e s in n o n m e l t join-
ments and programs used to qualify welding educators. Designed as a supple-
ing.
ment to employer- or government-mandated teaching regulations, this AWS spec-
ification bases the qualification of a welding educator on a combination of expe-
JOM w e l c o m e s the active sup-
rience and education.The specification also requires welding educators possess
p o r t of AWS to the JOM-10 t h r o ugh
a demonstrable understanding of the complexities of welding.
s p e a k e r s and p a r t i c i p a n t s . AWS
Specification f o r the Qualification of Welding Educators includes sections
c o s p o n s o r e d previous JOM confer-
on educator qualification levels, the skills and knowledge needed by a welding
en ces 7 through 9.
educator and the welding experience that is required.This updated specification
For further information on JOM-
lists for $20, $15 forAWS members, and is 20 pages long. *
10, contact the Institute for the Join-
ing of Materials, Klintehoj V~enge 21,
¢ Ordering I n f o r m a t i o n DK-3460 Birkerod, Denmark; e-mail
to jom_aws@postl0.tele.dk; tele-
Copies of AWS publications can be o r d e r e d by calling Global Engineer- p h o n e 45 45 82 80 95; or FAX 45 45
ing D o c u m e n t s at (800) 854-7179 or t h r o u g h t h e AWS Web site at 94 08 55.0
www.aws, org. Additional information on AWS's programs and publications
can also be found on the Web site. •

S8 1JANUARY 2001
 ¢ Vice President Levert Visits Local School

m e r i c a n W e l d i n g S o c i e t y Vice P r e s i d e n t E r n e s t Lev-

A ert stopped by the Guardian Shepherd Christian

S c h o o l i n C o r a l G a b l e s , Fla., t o s p e a k w i t h t h e
kindergarten through third-grade students while he was
at h e a d q u a r t e r s for b o a r d m e e t i n g s in O c t o b e r .
Levert, w h o is a s e n i o r s t a f f m a n u f a c t u r i n g e n g i n e e r
f o r L o c k h e e d M a r t i n M i s s i l e s a n d Fire C o n t r o l i n Dallas,
Tex., o f t e n visits s c h o o l s t o talk to c h i l d r e n a b o u t h o w to
be successful and the importance of a good education.
During his presentation, Levert drew on the inter-
est of the children in the space program to tell them
about welding on the International Space Station and
w h a t h i s p o s i t i o n as t h e w e l d i n g p r o j e c t m a n a g e r e n -
tails. H e t h e n d i s c u s s e d h o w t o go a b o u t c h o o s i n g a ca-
reer. His a d v i c e t o s t u d e n t s w a s , " W i t h y o u r c a r e e r , p i c k
your passion. Choose a career where you can have fun
and have career growth." C h i l d r e n f r o m the G u a r d i a n S h e p h e r d C h r i s t i a n S c h o o l
The main thrust of Levert's presentation when he s u r r o u n d t h e i r g u e s t s p e a k e r , A W S Vice P r e s i d e n t E r n e s t
t a l k s t o k i d s is t h e i m p o r t a n c e o f s e t t i n g g o a l s , w h i c h , Levert, a f t e r his visit in October
as h e says, is " o n e o f t h e b e s t - k e p t s e c r e t s t o s u c c e s s . "
D u r i n g his s p e e c h e s at s c h o o l s , L e v e r t u s e s t h e a c r o n y m
G.O.A.L.S. t o p r e s c r i b e s u c c e s s . G.O.A.L.S. s t a n d s f o r t h e f o l l o w i n g : G - - G o f o r t h e gold. D o n ' t s e t t l e f o r a n y t h i n g
less; O - - O p p o r t u n i t y . M a k e t h e m o s t o f e v e r y c h a n c e y o u h a v e . F i n d s c h o l a r s h i p s a n d s u c c e e d ; A - - A t t i t u d e . Be
f o c u s e d , s u r r o u n d y o u r s e l f w i t h p o s i t i v e t h i n k e r s l i k e y o u r s e l f . A n d l e a r n f r o m y o u r m i s t a k e s ; L - - L e a d e r . Be a
l e a d e r ; S - - Stay w i t h it. D o n ' t give u p t h e ship! Stick t o it.
L e v e r t also d i s c u s s e d t h e i m p o r t a n c e o f e d u c a t i o n w i t h t h e k i d s a n d w h y t h e y s h o u l d stay in s c h o o l . He t o l d
t h e m , " H a r d w o r k p a y s off.You c a n d o it. My p h i l o s o p h y is w i t h G o d in y o u r life a n d f a i t h in y o u r s e l f , y o u c a n still
a c h i e v e y o u r goals, n o m a t t e r w h a t y o u ' r e told." •

• Israeli I n t e r n a t i o n a l S e c t i o n R e c e i v e s Charter
he Israeli International Section of

T t h e A m e r i c a n W e l d i n g S o c i e t y (AWS)
w a s c h a r t e r e d o n J u l y 19, 2 0 0 0 , at
the Welding & Joining 2000 Conference
B a n q u e t i n Tel Aviv, I s r a e l . C u r r e n t AWS
P r e s i d e n t L . W i l l i a m M y e r s a n d Past Presi-
dent John Moeller (1974-1975) attended
t h e C h a r t e r m e e t i n g a n d a d d r e s s e d t h e au-
d i e n c e o f a b o u t 140 p e o p l e t h a t w e r e p a r t
of the Welding Conference.
Moeller welcomed the audience and
expressed his hope that the symbolic act
o f c h a r t e r i n g t h e I s r a e l i I n t e r n a t i o n a l Sec-
t i o n is j u s t t h e b e g i n n i n g o f a f r u i t f u l a n d
beneficial relationship between theAmer-
ican and Israeli professional societies.
M y e r s t a l k e d a b o u t t h e o b j e c t i v e s o f AWS
a n d t h e h i s t o r y o f t h e Society.
Peter Magnus, the chief labor inspec-
t o r f o r t h e I s r a e l i g o v e r n m e n t , a l s o ad- Israeli I n t e r n a t i o n a l Section officers s i g n i n g the A WS CharteJ:
dressed the assembly. He stressed his
h o p e t h a t t h e l a t e s t g r o u p o f h o p e f u l s tak-
i n g t h e AWS C e r t i f i e d W e l d i n g I n s p e c t o r e x a m b e f o r e t h e e n d o f t h e y e a r w i l l h e l p t o r a i s e t h e q u a l i t y o f w e l d -
ing in Israel to higher standards.
F o l l o w i n g t h e e l e c t i o n o f S e c t i o n o f f i c e r s , M y e r s p r e s e n t e d n e w l y e l e c t e d S e c t i o n C h a i r m a n Dr. G a b r i e l
Kohn with the American Welding Society Charter and an anniversary payment. •

WELDING JOURNAL I s9
 • Sustaining Company Member Dues Update AWS WELCOMES
NEW SUPPORTING COMPANIES
f f e c t i v e J u n e 1, 2 0 0 0 , t h e f o l l o w i n g a d j u s t m e n t s have been imple-

E m e n t e d for AWS S u s t a i n i n g C o m p a n y M e m b e r s :

Dues: T h e a n n u a l d u e s are $ 7 5 0 , d o m e s t i c ; $ 8 5 0 , i n t e r n a t i o n a l ; p l u s a
New Supporting Companies

Clovis & Roche'

$ 5 0 0 i n i t i a t i o n fee. 4401 N o r t h I-lO Service Rd.West
Benefits: T h e e n h a n c e d AWS S u s t a i n i n g C o m p a n y M e m b e r b e n e f i t s Metaire, LA 70006
p a c k a g e i n c l u d e s o n e o f t h e f o l l o w i n g p r i m a r y o f f e r i n g s : 1) t h e c o m p l e t e
library o f AWS p u b l i c a t i o n s ( $ 5 6 0 0 v a l u e ) , i n c l u d i n g 1 3 0 + s p e c i f i c a - Metal Fabricators Co., Inc.
t i o n s , w i t h c o m p l i m e n t a r y p u b l i c a t i o n u p d a t e s i n c l u d e d ; o r 2) a d i s c o u n t P.O. Box 190
p r o m o t i o n a l p a c k a g e , i n c l u d i n g a 5% d i s c o u n t o n a d s in t h e Welding 3005 Robbins Rd.
Journal a n d a $4-per-sq-ft d i s c o u n t o n b o o t h s p a c e at t h e AWS/PMA S h o w ; Hiawatha, IA 52233
o r 3) ten a d d i t i o n a l AWS I n d i v i d u a l M e m b e r s h i p s f o r c o m p a n y e m -
ployees or customers.
In a d d i t i o n , A W S S u s t a i n i n g C o m p a n y M e m b e r s e n j o y t h e f o l l o w i n g : N e w Educational Institutions

• T e n f r e e I n d i v i d u a l M e m b e r s h i p s for c o m p a n y e m p l o y e e s o r c u s t o m e r s . Columbia-Montour Area Vocational-

Technical School
• Publicity of the company's name and product/service o f f e r i n g s in t h e 5050 W e p p e n h e i s e r Dr.
Welding Journal a n d o n t h e AWS W e b site. Bloomsburg, PA 17815

• C o m p a n y r e c o g n i t i o n at t h e a n n u a l AWS/PMA Show. Lima Senior High School

1 Spartan Way
• U s a g e o f t h e AWS S u s t a i n i n g C o m p a n y M e m b e r l o g o o n c o m p a n y l e t t e r - Lima, OH 45804
head and promotional material.
Roy Municipal Schools
• AWS S u s t a i n i n g C o m p a n y e n g r a v e d w a l l p l a q u e . P.O. Box 430
Roy, NM 87743
• F r e e h y p e r l i n k f r o m t h e AWS W e b s i t e t o t h e m e m b e r c o m p a n y ' s site.
SandersviUe RegionalTechnical Inst.
F o r i n f o r m a t i o n o n b e c o m i n g a n AWS S u s t a i n i n g C o m p a n y M e m b e r , 1189 D e e p s t e d Rd.
c o n t a c t t h e AWS M e m b e r s h i p D e p t . at ( 8 0 0 ) 4 4 3 - 9 3 5 3 ext. 418, FAX ( 3 0 5 ) P.O. Box 6179
4 4 3 - 5 6 4 7 o r w r i t e AWS, 5 5 0 N.W. L e J e u n e Rd., Miami, FL 3 3 1 2 6 . • SandersviUe, GA 31082

Truckee M e a d o w s
C o m m u n i t y College
Regional Technical Institute
• Member Dues Adjustment 7000 Dandini Blvd.
Reno, NV 89512
h e AWS B o a r d o f D i r e c t o r s , a c t i n g o n t h e r e c o m m e n d a t i o n s m a d e b y

T t h e M e m b e r s h i p C o m m i t t e e , a p p r o v e d a d u e s a d j u s t m e n t to $75 f o r
the "Regular Member" classification effective June 1,2000.
U p o n j o i n i n g , a n d e v e r y t h i r d m e m b e r s h i p year, R e g u l a r M e m b e r s ' d u e s
w i l l i n c l u d e a n e x p a n d e d p u b l i c a t i o n c h o i c e o f e i t h e r t h e l a t e s t Welding
Handbook, Welding Metallurgy,Jefferson "s Welding Encyclopedia, Solder- • AWS MEMBERSHIP
ing Handbook o r t h e Design and Planning Manual for Cost-Effective Weld-
ing u p o n r e q u e s t . In a d d i t i o n , AWS m e m b e r s r e c e i v e a m o n t h l y s u b s c r i p t i o n Member As of
to t h e a w a r d - w i n n i n g WeldingJournal.AWS-certified p e r s o n n e l also r e c e i v e Grades D e c e m b e r 1, 2 0 0 0
q u a r t e r l y issues of Inspection Trends m a g a z i n e .
AWS m e m b e r s e n j o y a c c e s s t o w i d e l y r e s p e c t e d t e c h n i c a l i n f o r m a -
t i o n in t h e m a t e r i a l s - j o i n i n g i n d u s t r y at d i s c o u n t e d r a t e s . M e m b e r s - o n l y
d i s c o u n t s a p p l y t o AWS t e c h n i c a l p u b l i c a t i o n s , as w e l l as t o p - n o t c h c e r - Individual M e m b e r s .............. 42,994
tifications, conferences and other educational offerings. Members also
b e n e f i t f r o m n e t w o r k i n g o p p o r t u n i t i e s at l o c a l S e c t i o n m e e t i n g s a n d at Student M e m b e r s .................... 4,895
t h e AWS/PMS S h o w . A W S m e m b e r s c a n c h o o s e b e t w e e n t w o v a l u e - a d d e d
membership package offerings -- the Gold and the Platinum member-
ship packages -- for modest fees.And, in the near future,AWS members
will enjoy members-only access to special information and services on T o t a l ............... 4 7 , 8 9 9
t h e AWS W e b site, www.aws.org. •

Sustaining C o m p a n y M e m b e r s .... 307

60 I JANUARY 2001
 SAFETY AN D H EALTH
T O P I C S
¢ Pacemakers and Welding • K e e p w e l d i n g p o w e r s o u r c e a n d c a b l e s as far
F a c t S h e e t N o . 16 a w a y as p r a c t i c a l .
• Do n o t w e l d w i t h r a p i d l y r e p e a t e d s h o r t s p u r t s
Introduction -- wait about ten seconds between each weld.
¢ If y o u f e e l s i c k , s t o p w e l d i n g i m m e d i a t e l y a n d
P a c c m a k e r s arc d e v i c e s t h a t are i m p l a n t e d in car- seek medical attention.
diac patients to ensure proper heart rhythm. Since • Do n o t w o r k a l o n e .
t h e s e d e v i c e s are e l e c t r i c a l in o p e r a t i o n , t h e i r a b i l i t y
to f u n c t i o n c a n b e a f f e c t e d b y s t r o n g e l e c t r o m a g n e t i c
fields (EMF). Talk to the Doctor

Welding and Electromagnetic
Electric arc welding and cutting processes pro-
duce intense electric and magnetic (electromagnetic)
fields. Persons with a pacemaker should not go near
welding or cutting operations until they have consulted
their doctor and obtained information from the manu-
facturer of the device.
If y o u a r e g e t t i n g a p a c e m a k e r a n d will b e w o r k -
Fields i n g w i t h o r a r o u n d w e l d i n g , talk w i t h y o u r d o c t o r . In-
form him of your occupation. Discuss your work
c l e a r l y w i t h h i m . P a c e m a k e r s differ, a n d y o u r d o c t o r
c a n s e l e c t o n e t h a t is less l i k e l y to b e a f f e c t e d b y in-
terference.
Information Sources

G u i d a n t C o r p . , 4 1 0 0 H a m l i n e Ave. N o r t h , St. Paul,

Steps to Reduce Exposure MN 5 5 1 1 2 - 5 7 9 8 , t e l e p h o n e : ( 8 0 0 ) CARDIAC [ ( 8 0 0 ) 227-
3422)1.
W e a r e r s o f p a c e m a k e r s s h o u l d o b s e r v e t h e follow- M e d t r o n i c , I n c . , 7 0 0 0 C e n t r a l Ave., N. E., Min-
ing p r e c a u t i o n s : n e a p o l i s , MN 5 5 4 3 2 - 3 5 7 6 , t e l e p h o n e ( 8 0 0 ) 505-4363.

¢ Do n o t u s e c u r r e n t s e t t i n g s h i g h e r t h a n n e c e s -
sary.
¢ K e e p t h e w e l d c a b l e s as c l o s e t o g e t h e r as p o s -
sible by twisting or taping them.
• C o n n e c t w o r k c l a m p t o w o r k p i c c e as c l o s e t o
t h e w e l d as p o s s i b l e .
• A r r a n g e c a b l e s to o n e s i d e a n d a w a y f r o m t h e
operator.
The Safety and Health Fact Sheets, 2 n d ed., cover all aspects
o f safety a n d health applicable to welding a n d cutting. The Fact
Sheets include 2 0 p a g e s on subjects such as f u m e s a n d gases,
radiation, noise a n d electrical hazards. Compiled in 1998. Price
f o r AWS m e m b e r s is $27; n o n m e m b e r s , $36. Copies of Safety
and Health Fact Sheets can be ordered by calling Global Engi-
neering D o c u m e n t s at (800) 854-71789 or through the A WS
Web site at www.aws.org.

• Sustaining Member Company

u nited Steel
Pro~
P r o d u c tJs( t s
Company
(USP) w a s f o u n d e d
in 1968 in N e w a r k ,
N.J., a n d h a s s i n c e
engaged exclu-
sively in t h e d e s i g n a n d m a n u f a c t u r e o f i n d u s t r i a l s t e e l
s t o r a g e r a c k p r o d u c t s . T h e c o m p a n y r e l o c a t e d to East
S t r o u d s b u r g , Pa., in 1989, w h e r e it c u r r e n t l y o p e r a t e s o u t
of t w o facilities t o t a l l i n g 5 1 0 , 0 0 0 sq ft.
USP o f f e r s t u r n k e y s e r v i c e s i n c l u d i n g t h e d e s i g n ,
m a n u f a c t u r e , delivery, i n s t a l l a t i o n a n d i m p l e m e n t a t i o n o f
s t o r a g e r a c k p r o d u c t s . It o f f e r s a n e x t e n s i v e v a r i e t y o f
r a c k c o n f i g u r a t i o n s in b o t h r o l l - f o r m e d a n d s t r u c t u r a l
s t e e l . T h e t w o p l a n t s h a v e t h e c a p a b i l i t y to tail load, v a n
load a n d f l a t b e d load for s h i p p i n g .
USP e m p l o y s m o r e t h a n 4 5 0 p e o p l e , i n c l u d i n g civil,
i n d u s t r i a l a n d m e c h a n i c a l e n g i n e e r s ; CAD d e s i g n e r s ; sales
and customer service representatives; quality assurance
p e r s o n n e l ; a n d s p e c i a l i s t s in all p h a s e s o f m a n u f a c t u r i n g .
T h e c o m p a n y h a s e a r n e d R-Mark C e r t i f i c a t i o n f r o m
t h e Rack M a n u f a c t u r e r s I n s t i t u t e . T h i s m e a n s USP's p r o d -
u c t s h a v e b e e n t e s t e d a n d r e v i e w e d to a s s u r e c o m p l i a n c e
w i t h t h e latest d e s i g n , safety a n d i n t e r n a t i o n a l s t a n d a r d s
as e s t a b l i s h e d b y t h e RMI for i n d u s t r i a l s t e e l s t o r a g e racks.
USP also m a i n t a i n s its o w n p r o g r a m s o f o n g o i n g e n g i -
n e e r i n g d e s i g n r e s e a r c h , p r o m p t e d by c h a n g i n g m a r k e t s
a n d t e c h n o l o g i c a l a d v a n c e s in m a n u f a c t u r i n g t e c h n i q u e s .
USP h a s t w o m o d e r n , a u t o m a t e d p l a n t s in Pennsylva-
nia a n d o p e r a t e s t h e largest p o w d e r c o a t i n g facility in t h e
Northeast United States.The company's factories meet or
e x c e e d all t h e latest U.S. safety r e q u i r e m e n t s . ¢

WELDING JOURNAL 1 61
 E I
N E
York-Central Pennsylt,ania Section members at their November
plant tour
DISTRICT I Award. Ovellette and Plumb spoke
D i r e c t o r : G e o f f r e y H. P u t n a m
Phone: (802) 439-5916
• CENTRAL MASSACHUSETTS/
RHODE ISLAND
SEPTEMBER 12
Speakers:Jeff and M i c h a e l Cook.
Affiliation: N e w Bedford Welding
Supply.
Topic:Visual and h y d r o t e s t i n g o f
cylinders.
Activity: M e m b e r s tr i e d a c u t t i n g
torch assembly with high-purity
gas, an alternative to acetylene.
• GREEN & WHITE MOUNTAIN
OCTOBER 12
Speaker: G u y P a y n e , h u m a n re-
sources manager.
Affiliation: Fab-Tech, I n c . , Col-
chester, Vt.
Activity: Members t o u r e d the Fab-
Tech plant. F o l l o w i n g the tour, a
d i s c u s s i o n was h e l d on t h e b e n e -
fits of AWS m e m b e r s h i p .
NOVEMBER9
Speakers: J e r r y O v e l l e t t e , owner,
and E r n i e P l u m b , owner.
Affiliations: Ovellette Welding and
Plumb Welding, respectively.
Topic: Flame bending.
Activity: District 1 D i r e c t o r G e o f -
frey Putnam presented Ernie
62 1JANUARY 2001
W S
James Danahe~; left, and his fathet;.p~seph, at
the Long Island Section's hands-on meeting in
October
P l u m b with a District Director's JUNE 8
on the flame b e n d i n g p r o c e s s and
Speaker: S t e v e S t e r n b e r g .
Affiliation: Keyspan Energy, Brent-
gave demonstrations on angle iron, w o o d , N.J.
a p i e c e o f flat st o ck and a large Topic: Trenchless technology.
beam.
• NEW JERSEY
• BOSTON Activity: Th e S e c t i o n t o u r e d t he
SEPTEMBER 19 PSEEG S e r v c o Central Mainte-
Speaker: R o n S t a h u r a s , t ech n i cal nance facility in Seawaren, N.J.
specialist.
Affiliation: Avesta W el d i n g Prod-
ucts, Inc. DISTRICT 3
Topic:The i m p o r t a n c e o f passiva- Director: Claudia Bottenfield
tion on stainless steel, i n c l u d i n g Phone: (717) 397-1312
e v a l u a t i n g su r f ace c o n d i t i o n s to
d e t e r m i n e use o f m e c h a n i c a l
c l e a n i n g , c h e m i c a l p i c k l i n g or a • YORK-CENTRAL PENNSYLVANIA
c o m b i n a t i o n of the two. NOVEMBER2.
Activity: T h e S e c t i o n r e c e i v e d a
t o u r of D o n s c o I n c . , W r i g h t s v i l l e ,
Pa. T h e t o u r was c o n d u c t e d by
D o n M a n n , g r a n d s o n o f t he
DISTRICT 2 founder, and F r e d I h r i g , the com-
pany's p e r s o n n e l director.
Director: A l f r e d F. F l e u r y
Phone: (732) 868-0768
• LONG ISLAND
DISTRICT 4
SEPTEMBER 14 Director: R o y C. L a n i e r
Activity:A hands-on m e e t i n g was Phone: (919) 321-4285
h e l d w i t h local w e l d i n g s u p p l y
v e n d o r s and manufacturers includ-
ing T.W. S m i t h , A w i s c o , A m e r i c a n • TRIANGLE
Industrial Gas and Presto Peconie. SEPTEMBER 14
Speaker: T e r r y B a x t e r , applica-
tions engineer.

Raymond Doan, left, g u e s t
s p e a k e r Doug Walker, center, a n d
D o n Mincey, right, a t the S o u t h
Carolina Section's October tour.
Walker a n d D o a n g a v e a u t o -
m a t i c GTAW d e m o n s t r a t i o n s f o r
the Section's members.
Affiliation: Westwood Robotics.
Topic: N e w t e c h n o l o g i e s in robot-
ics, r o b o t i c j u s t i f i c a t i o n and c o s t
savings for your applications.
OCTOBER 24
Speaker: D a n f o r d E l l i o t , superin-
tendent.
A f f i l i a t i o n : A t h e y Products, Corp.,
Wake Forest, N.C.
Activity: M e m b e r s t o u r e d the
Athey P r o d u c t s p l a n t . A t h e y Prod-
ucts s p o n s o r e d r e f r e s h m e n t s and
d o o r prizes for the Section.
DISTRICT
D i r e c t o r : B o r i s A. B e r n s t e i n
Phone: (787) 883-8383
• N O R T H CENTRAL FLORIDA
OCTOBER 10
S p e a k e r : J i m K e r n , plant mainte-
nance s u p er i n t en d e n t .
Affiliation: Forica Rock Industries,
T h o m p s o n S. Baker C e m e n t Plant,
Newberry, Fla.
Topic: Section m e m b e r s and guests
t o u r e d Florida Rock I n d u s t r i e s '
n e w $80 m i l l i o n T h o m p s o n S.
Baker C e m e n t Plant.
• SOUTH CAROLINA
OCTOBER 20
Speaker: D o u g W a l k e r , e n g i n e e r -
ing technical specialist.
Affiliation: Parker Hannifin,
Monck's Corner, S.C.
Topic: J et l i n e au t o m a ti c cold wire
GTAW process and plant operations.
Past Chairman o f the Atlanta Sec-
tion Tom Flynn, left, receiving the
District Meritorious A w a r d f r o m
District Director Carl Matricardi.
Activity: Welders R a y m o n d D o a n
and D o n M i n c e y assisted w i t h a
d e m o n s t r a t i o n of t h e a u t o m a t i c
GTAW p r o c e s s on 321 stainless
steel.
• ATLANTA
SEPTEMBER28
Speakers: B r u c e M o r r e t t and J e f f
Dillard.
A f f i l i a t i o n : H o b a r t Bros., Troy,
Ohio, Lawrenceville, Ga.
Topic: Metal core wire including a
lecture and demonstrations.
Activity: T o m F l y n n r e c e i v e d the
District Meritorious Award.
$ O FLORIDA WEST COAST
OCTOBER 11
Speaker: R o b e r t Z i m m e r , sales
engineer.
Affiliation:Panametrics, Palm Bay,
Fla.
Topic: Ultrasonic testing.
Activity: Section members
a w a r d e d $100 p e r m o n t h (maxi-
m u m $500) to D i e n T r a n to com-
p e t e in w e l d trials in his a t t e m p t
to r e p r e s e n t t h e U n i t e d States in
the World Skills Competition.
DISTRICT 6
D i r e c t o r : G e r a l d R. C r a w m e r
Phone: (518) 385-0570
• NORTHERN NEW Y O R K
OCTOBER 3
Speaker: D o u g T a n n e r .
A f f i l i a t i o n : S n o w Dock, Albany,
N.Y.
Activity: Th e S e c t i o n t o u r e d t h e
Florida West Coast Section Chair-
m a n Darryl Jardine, right, with
Dien Tran, who hopes to pass the
necessary welding trials in order to
represent the United States in the
World Skills Competition.
In October, the N o r t h e r n
N e w York Section toured
the USS Slater, p i c t u r e d
above. The Slater, w h i c h is
docked in Albany, N. Y., was
recently g r a n t e d a n AWS
Historical Welded Struc-
ture Award.
USS Slater (DE-766), a destroyer es-
c o r t f r o m World War II. Th e t o u r
was led by Tanner, w h o is an AWS
m e m b e r as well as a v o l u n t e e r for
t h e S l a t e r . T h e ship was r e c e n t l y
n a m e d a r e c i p i e n t of the AWS His-
torical Welded Structure Award.
• NIAGARA FRONTIER
OCTOBER 19
Activity: Section m e m b e r s visited
t h e Ford Stamping Plant to w a t c h
large presses stamp out the entire
side o f a van t h r o u g h a series of
hits. M e m b e r s sp o k e w i t h mainte-
n a n c e w e l d e r s and l e a r n e d of the
challenging projects in w h i ch they
participate.
• TWIN TIERS
OCTOBER 19
Speakers: K e l S h i p m a n and D a r -
rel Johns.
WELDING JOURNAL I 63

Pittsburgh Section ,~[icers, from &ft, First
Vice Chairman Ken Kasunick, Chairman
Dale Dodds and Secretary~Treasurer Tom
Myers at the October meeting.
Affiliation: C&D Machine Co., Inc.
Activity: T h e S e c t i o n t o u r e d t h e
C&D Machine plant to see the pre-
c i s i o n f a b r i c a t i n g and m a c h i n i n g
of metal products.
DISTRICT
Di rect o r : R o b e r t J. T a b e r n i k
Phone: (614) 4 8 8 - 7 9 1 3
• WHEELING
JuLY 21
Speaker: R i c k H e n d e r s h o t .
Affiliation: Sisterville Tanks Works,
Inc.
Topic: W e l d t e s t i n g - - d e s t r u c -
tive and n o n d e s t r u c t i v e , laser,
ASME C o d e , U s t a m p , p p s t a m p
a nd r s t a m p .
• PITTSBURGH
OCTOBER 10
Speaker: M a r i e Q u i n t a n a , s e n i o r
research engineer.
Affiliation:The Lincoln Electric Co.
Topic: Hydrogen cracking in pipe-
line girth welds.
• COLUMBUS
NOVEMBER9
Speaker: K i r w a n E l m e r s .
Affiliation: C u s t o m C o a c h Corp.,
Columbus, Ohio.
Topic: Elmers, f o u n d e r of the Cus-
tom Coach Corp., led Section mem-
bers on a tour of the plant. Custom
Coach Corp. m a n u f a c t u r e s e x e c u -
tive travel v e h i c l e s for c e l e b r i t i e s
and political candidates - - George
64 1JANUARY 2001
Mahoning Valley Section Treasurer
Alex Benyo, left, and Chairman Ken-
Past District 9 Director James neth Jones, right, presenting Past
Ivy, left, with Pascagoula Section Chairman Chuck Moore with Sec-
guest speaker Bud Hughes, cen- tion Appreciation Awards.
ter, and Chairman Troy Gerken.
W. Bush, AI Gore, J o h n McCain,
DISTRICT 9
Steve F o r b e s and Bill Bradley all Director: John Bruskotter
campaigned during the recent Phone: (504) 367-0603
p r e s i d e n t i a l e l e c t i o n s in C u s t o m
Coach vehicles.
• BATON ROUGE
OCTOBER 19
DISTRICT 8 Speaker: L a r r y Henderson,
7 D i r e c t o r : H a r r e l l E. B e n n e t t
owner.
Affiliation: W el d i n g Test Labora-
Phone: (423) 478-3624 tory.
Topic: The AWS DI.1 Structural
• NORTHEAST TENNESSEE Welding Code - - Steel.
SEPTEMBER 19
Speaker: T o m Mustaleski, vice pres- NOVEMBER 13
ident and research staff member. Speaker: A z i z A s p h a h a n i , presi-
Affiliation: AWS and BWXT-Y 12 dent.
LLC, respectively. Affiliation: ASM I n t e r n a t i o n a l ,
Topic:The AWS Entry Level Welder Peru, Ill.
Program. Topic: Stress co r r o si o n cracking o f
base metals and weldments.
OCTOBER 24 Activity: The Section held Career
Speaker: C r a i g Blue. Night with 59 high school students
Affiliation: Oak Ridge National from five area sch o o l s attending.
Laboratory, Oak Ridge,Tenn. Vendors held d e m o n s t r a t i o n s and
Topic: Infrared p r o c e s s i n g of ma- distributed information on careers
terials. in welding to students and parents.
The e v e n t was s p o n s o r e d by the
Central High School, Baton Rouge
• NORTHEAST MISSISSIPPI Student Chapter.
OCTOBER 26
Activity: Th e S e c t i o n t o u r e d t h e
CECO plant. • MOBILE
OCTOBER 19
O c t o b e r 27 Speaker: G e r a l d T a y l o r , presi-
Activity:The Section held a CMTE dent.
seminar, with more than 70 p e o p l e Affiliation: TechWeld, Pascagoula,
attending. Miss.
Topic: CWI testing.
N o v e m b e r 16
Activity: Members toured the Mer- • PASCAGOULA
cedes-Benz plant inTuscaloosa,Ala. OCTOBER 19
Speaker: Bu d H u g h e s , motor sports
vehicle technology instructor.
Affiliation: Lanier Technical Institute.
 Top Ten Reasons to be an AWS Member:
10. To encourage the next generation with AWS Scholarships awarded through
the AWS Foundation and discounted student memberships.
9. To strengthen your leadership skills by servingas a Section Officer or
Committee Member.
8. For discounts on travel accommodations, insurance,and more!
7. To gainaccessto technical knowledge with 300+ publications available.
6. To experience the wave of the future through the world's largest fabricating
show by attending MAX International.
5. BecauseAWSseminars and conferences allow you to establish
important contacts and increase knowledge.
4. To receive substantial discounts on allAWS publications, conferences,
seminarsand certification programs.
3. Becausethe WeldingJournal provides invaluable information through
informative articles on trends, products and new industry technology.
2. To build your network of peers and professionals by attending local Section
Meetings and utilizing bulletin boards on the AWS Website, <www.aws.org>.
And the #1 reason to become an AWS Member...
...Because the prestige of being an AWS Member is knowing that
you belong to the premier Society for materials joining professionals.

PRIZE CATEGORIES SPECIAL PRIZES LUCK OF THE DRAW

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Each member residing outside of the UnitedStates,
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For everynew member you sponsor, your name is entered
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sponsor, the greater your chances of winning. Prizeswill
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Prizes Include:
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of any AWS-producedofferingsuch as a publication,
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SUPER SECTION CHALLENGE
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Visit our website http://wv6v.aws.org
 s p e a k e r s and e x h i b i t o r s .
Section m e m b e r M i c h a e l
J. K a r a g o u l i s chaired the
conference.

Attending the Central Michigan Section's Octo-
ber meeting are, from left, Nan Jackson and guest
speakers Vern Messier and Dennis Randolph.
Topic: Th e i m p o r t a n c e of w e l d i n g
in motor sports.
DISTRICT
D i r e c t o r : V i c t o r Y. M a t t h e w s
Phone: (216) 383-2638
• M A H O N I N G VALLEY
OCTOBER 19
Activity: Section Chairman K e n -
n e t h J o n e s discussed Section busi-
ness for the 2000/2001 year.A pre-
sentation of the S.E.N.S.E. program
was given. Past Chairman C h u c k
M o o r e was presented with Section
Appreciation Awards.
O CENTRAL MICHIGAN
OCTOBER 17
Speakers: V e r n Messier,
s p eci al i st , and D e n n i s
R a n d o l p h , m a n a g i n g di-
rector.
Affiliation: Calhoun
County Community Devel-
opment, Marshall, Mich.
Topic:Two steel truss ve-
hi cl e b r i d g e s f r o m t h e
early 1900s that w e r e re-
s t o r e d and r e - e r e c t e d in
C a l h o u n C o u n t y ' s River-
side Park. Plans call for a
total o f 15 b r i d g e s to be
restored.
• WESTERN MICHIGAN
OCTOBER 23
I0 Speaker: D e n n i s K l i n g m a n , di-
r e c t o r of technical training.
Affiliation: Th e Li n co l n E l e c t r i c
Co., Cleveland, Ohio.
Topic: Motor sports welding.
• NORTHERN MICHIGAN
OCTOBER 24
Speaker: D e n n i s K l i n g m a n , di-
r e c t o r of technical training.
Affiliation: Th e Lincoln E l e c t r i c
Co., Cleveland, Ohio.
Topic: Motor sports welding.
Lakeshore Section m e m b e r David
Ramseur, left, discussing the pre-
sentation with guest speaker
Scott Christiansen. The November
meeting was a j o i n t meeting with
the AWS Lakeshore a n d Fox Val-
ley Sections.
• FOX VALLEY
• LAKESHORE
NOVEMBER9
Speaker: Scott Christiansen, sales
representative.
Affiliation: MG Systems.
Topic: O x y f u e l , p l a s m a arc and
laser c u t t i n g systems.
Activity: Samples of the various cut-
ting systems w e r e displayed. Film-
strips c o m p a r i n g the t h r e e differ-
ent speeds of cutting w e r e shown.
This was a joint m e e t i n g o f the
Lakeshore and Fox Valley Sections.
DISTRICT 13
Director: J . L. H u n t e r

DISTRICT 12 (309) 888-8956

DISTRICT I I
Director: Scott C. C h a p p l e
Phone: (913) 241-7242
• DETROIT
OCTOBER 17-20
Speaker: E r i c h S. P h i l l i p s , prin-
cipal s c i e n t i s t and p r a c t i c e direc-
tor, visual c o m m u n i c a t i o n .
Affiliation: Exponent, Inc.
Activity: The Section h e l d Sheet
Metal C o n f e r e n c e IX, a three-day
c o n f e r e n c e in w h i c h 30 p a p e r s
w e r e p r e s e n t e d . A p r e s e n t a t i o n ti-
tled Titanic: bad luck, bad judge-
m e n t or bad steel? was the d i n n e r
presentation.This year's conference
i n c l u d e d a total o f 201 a t t e n d e e s ,
D i r e c t o r : M i c h a e l D. K e r s e y • CHICAGO
NOVEMBER8
Phone: (262) 650-9364
Speaker: R i c h a r d A r n , president.
Affiliation: T e l e t h e r m T e c h n o l o -
• MADISON/BELOIT gies Inc., East Liverpool, Ohio.
SEPTEMBER21 Topic: Weld c l a d d i n g of steel and
Speaker: T e r r y H e s s e , owner. aluminum mill rolls.
Affiliation: Tech W el d i n g S e r v i c e Activity:Arn, also an AWS vice pres-
LLC. ident, gave a slide presentation cov-
Topic: Performance welding. ering his many years of e x p e r i e n c e
in the rolling mill industry. District
OCTOBER 19 13 D i r e c t o r J e s s e H u n t e r pre-
Speaker: T e r r y H e s s e and P h i l sented J o h n D e v r i e s with the Dis-
Fish. trict Meritorious Award, C h u c k
Occupation: CWIs. H u b b a r d with the Section Merito-
Topic: Certification or qualification, rious Award and M i k e F e s t a w i t h
does it really matter? the Section CWI of the YearAward.
A c t i v i t y : T h e Board h e l d a m e e t -
ing to discuss the rest of the year's
activities.

WELDING JOURNAL I 67
AWS Vice President Richard Arn, left, ac-
Attendees at the Indiana Section's Stttdent Night in November
cepting a speaker's plaque f r o m A WS Vice
President Jim Greer, center, and Chicago
Section Chairman Paul Burys. Greer is a
member o f the Chicago Section.

Cox, B o b M r a c e k and

D I S T R I C T 14 Lee L a r s o n .
Affilia tio n: N o r t h w e s t
Director: Hil Bax Technical College-
Phone: ( 3 1 4 ) 6 4 4 - 3 5 0 0 , ext. 1 0 5 Moorhead.
Activity: Th e S e c t i o n
held demonstrations
• INDIANA and d is t r ib u t ed schol-
OCTOBER 16 arship i n f o r m a t i o n to
Speaker: D o n Keddell. s t u d e n t s on Students'
A f f i l i a t i o n : Miller E l e c t r i c Mfg. Night.
Co., Appleton, Wis.
Topic: Th e gas m e t a l arc w e l d i n g Northern Plains Section Chairman Dave Lynnes,
• NORTHWEST right, looking on as two students try their h a n d at
process using aluminum. OCTOBER 25 GTA welding stainless steel pipe during the Section's
Speakers: P a u l R i e - Students" Night in October.
NOVEMBER m a n n , d i s t r i c t man-
Activity:The Section held Student's ager, and J o e L a m -
Night at IvyTechnical State College b r e c h t , d i s t r i c t sales
in A n d e r s o n , Ind. Past C h a i r m a n Activity: C e r t i f i c a t i o n s e m i n a r s
manager.
D o n D a v i s arranged for $2000 in w e r e h e l d at K i r k w o o d C o m m u -
Affiliations: C&G Systems and Ther-
prizes for attendees. nity College and Scott C o m m u n i t y
mal Dynamics, respectively.
Topic: Plasma arc cutting technology College.
and automated plasma arc systems.
D I S T R I C T 15 • KANSAS CITY
OCTOBER 12
Speaker: B a r r y H a m i l t o n , sales
D i r e c t o r : J. D. H e i k k i n e n
Phone: (218) 741-9693 D I S T R I C T 16 and operations coordinator.
Affiliation: Conam Inspection,
• AR R OW HEAD D i r e c t o r : C. F. B u r g Parkville, Mo.
OCTOBER 19 Phone: (515) 294-5428 Topic: Terms and a p p l i c a t i o n s of
Speaker: K e n Rikkola, maintenance Nondestructive examination.
• EASTERN IOWA
superintendent. OCTOBER 3
Affiliation: Murphy Oil Corp., Su- • MID-PLAINS
Activity: Section Chairman M i k e
perior, Wis. M y e r s hosted the Section's golf out- OCTOBER 18
Topic: Weld r e p a i r p r o c e s s e s and ing at Glynn's Creek Golf Course.
Speaker: F l o y d Y o u n g .
p r o c e d u r e s at the Murphy Oil Re- Affiliation: Nebraska Public
finery. H o w oil is refined. Power, Gerald G e n t l e m a n Station,
OCTOBER 3 AND 18
Speaker Mike Myers, Section Sutherland, Neb.
• NORTHERN PLAINS chairman and an AWS CWI.
Topics: S e c t i o n m e m b e r s t o u r e d
OCTOBER 19 t h e n e w c o n s t r u c t i o n of t h e Ger-
Affiliation: S.J. Smith Welding.
Speakers:Dave Lynnes, John ald G e n t l e m a n Station, w h i c h is

68 I JANUARY 2001
Kansas City Section guest speaker
B a r r y Hamilton, foreground, dur-
ing his presentation to the members.

Guest Speaker Howard Main demonstrating orbital gas tungsten arc welding
to Houston Section members.

Topic: P o r t a b l e c l a d d i n g and or-

bital gas t u n g s t e n arc w e l d i n g for
field piping.
Activity: Howard Main demon-
strated d i f f e r e n t t y p es of e q u i p -
ment ranging from pipe bevelers
to the orbital GTA w e l d i n g ma-
c h i n e f r o m Pipe Tools, Inc.'s
portable trailer.

Sabine Section Chairman Cart:j, Wes-

ley, left, thanking guest speaker Jack
Duplantis f o r his presentation. DISTRICT 18
D i r e c t o r : J . M. A p p l e d o r n
b e i n g u p d a t e d to m e e t EPA stan- Phone: (281) 847-9444
dards. While t h e r e , m e m b e r s saw North Texas Section Vice Chairman
o n e of the t w o largest c r a n e s in • H O U STO N J. Jones, left, with g u e s t s p e a k e r
North America and toured parts of SEPTEMBER20 Howard Main, center, and Kirk Jor-
the shut d o w n m a i n t e n a n c e o f Speaker: H o w a r d Mai n . dan in f r o n t o f Main's demonstra-
Generator 1. Affiliation: Pipe Tools, Inc. tion trailer.
Topic:Automatic orbital gas tung-
sten arc welding.

DISTRICT 17 Activity: Howard Main demon-

D i r e c t o r : O r e n P. R e i c h
Phone: (254) 867-2203
• CENTRAL ARKANSAS
OCTOBER 17
Speaker: B o b Hlass.
Affiliation:The Lincoln Electric Co.
Topic: Pulsed gas metal arc welding.
A c t i v i t y : Hlass was t h e w i n n e r of
the drawing for $100 AWS dollars.
• NORTH TEXAS
OCTOBER 17
Speaker: H o w a r d M a i n .
A f f i l i a t i o n : Pipe Tools Inc., Web-
ster, Tex.
strated orbital GTA w e l d i n g f r o m
Pipe Tools, Inc.'s, portable trailer.
OCTOBER 18
Speaker: L a r r y S m i t h , t e c h n i c a l
welding sales.
A f f i l i a t i o n : Air Liquide A m e r i c a ,
Houston, Tex.
Topic: Welding c o s t m a n a g e m e n t
for fabricators of carbon steel.
A c t i v i t y : D a v i d E c k was n a m e d
Section Secretary. Dr. Angie Price
received the Section Educator
Award f r o m District 18 D i r e c t o r
Jim Appledorn.
• SABINE
OCTOBER 17
Speaker: J a c k D u p l a n t i s , lead in-
structor.
Affiliation: Divers Den.
Topic: Commercial and sport diving.
Note: Coastal Welding Supply,
A m e r i c a n Welding Supply, C r o w n
Pipe Shop and Pat Tank, Inc., w e r e
r e c o g n i z e d for h a v i n g s p o n s o r e d
the Section for more than 30 years.
NOVEMBER 14
Speaker: J i m A p p l e d o r n , regional
sales manager and AWS District 18
director.
A f f i l i a t i o n : Th e Lincoln E l e c t r i c
Co., Houston,Tex.

WELDING JOURNAL ] 69
District 18 Director J i m Appledorn,
center, f l a n k e d by Sabine Section
a w a r d w i n n e r s Doyen Cordell, left,
a n d Alton Wolf, right.
District 18 Director J i m Appledorn
p r e s e n t i n g g u e s t speaker Larry
Smith with a speaker's plaque at the
Houston Section's October meeting.
Topic: Wel d i n g p r o c e d u r e s and
AWS National activities.
Activity:The Section was presented
with a banner patch for its increase
in m e m b e r s h i p . A l t o n W o l f re-
c e i v e d the M e r i t o r i o u s Award and
D o y e n C o r d e l l was h o n o r e d with
the CWI of the Year Award.
• ALASKA
OCTOBER 27
Speaker: Ed B o h n a r t , p r e s i d e n t
and AWS past p r e s i d e n t ( 1 9 9 5 -
1996).
Affiliation:Welding Education and
Consulting.
Topic:Welding p r o c e d u r e develop-
ment.
Activities: Twenty-five year Silver
Awards w e r e p r e s e n t e d to A l a n S.
Beckett, D o n a l d A. E r i c k s o n ,
E r n e s t K l e c h k a and G e r a l d H.
Park. L. L. C r e a r y received the Life
Member Award.
70 l .IANUARY 2001
San Diego Section Chairman Mike Kitten, lej?, presenting a plaque , f appreci-
ation to Jose Aguirre, who led the members on a tour o f the Lockheed Martin
Tank Assembly Building in October
D I S T R I C T 19
Director: Phil Zammit
Phone: ( 5 0 9 ) 4 6 8 - 2 3 1 0 ext. 1 2 0
• PUGET SOUND
NOVEMBER2
Speaker: R i c k P f e i f e r .
Affiliation: Sales Inc. and Speedglas.
Topic: T h e f u n c t i o n and use of
S p e e d g l a s e l e c t r o n i c h e l m e t s , in-
c l u d i n g fresh air and f u m e or gas
relief helmets.
Activity:A $500 scholarship was set
up for I nt er l ak e High School to
h o n o r J i m P. A g n e w for outstand-
ing s u p p o r t for and d e d i c a t i o n to
his students.
A c t i v i t y : G o r d y R o b e r t s o n was
p r e s e n t e d w i t h the AWS Outstand-
ing Contributions Award for his un-
failing s u p p o r t for m o r e than 26
years.
• COLORADO
D I S T R I C T 20
D i r e c t o r : N e i l R. K i r s c h
Phone: (970) 842-5695
OCTOBER 12
Speaker: S c o t t M e l t o n , r e g i o n a l
manager.
Affiliation: FANUC Robotics North
America, Inc., Lake Forest, Calif.
Topic: Robotic w e l d i n g - - c u r r e n t
developments.
A c t i v i t y : T h e Lincoln Electric Co.
technical representative Steve
D u r e n and district sales m a n a g e r
W a d e P i c k e t t also talked about ro-
b o t i c d e v e l o p e m e n t s and, a l o n g
w i t h Mel t o n , gave a live d e m o n -
stration.
• EASTERN I D A H O / M O N T A N A
OCTOBER 27
Speaker: Earl Perry.
Affiliation: Eaton Metal Products.
A c t i v i t y : Th e S e c t i o n t o u r e d t he
Eaton Metal P r o d u c t s P o c a t e l l o
plant for h eav y vessel fabrication.
The t o u r was f o l l o w e d by a v i d e o
of t h e f a b r i c a t i o n o f a 76-ft-long,
1,000,000 lb a u t o c l a v e for Twin
Creek Mine in Golconda, Nev.
• SAN DIEGO
D I S T R I C T 21
Director: F. R. S c h n e i d e r
Phone: (619) 693-1657
OCTOBER 18
Speaker: A n t h o n y K y r a k i d i s , en-
gineer, and J o s e A g u i r r e , w e l d i n g
engineer.
Affiliation: Lockheed Martin.
Topic: T h e o r y of laser cu t t i n g and
a p p l i c a t i o n used in the a e r o s p a c e
industry.
A c t i v i t y : Kyrakidis's p r e s e n t a t i o n
was f o l l o w e d by a d e m o n s t r a t i o n
using a PRC 2200-W CO x laser.
A g u i r r e t h e n led m e m b e r s o n a t o u r
o f t h e San D i e g o O p e r a t i o n s ' T a n k
A s s e m b l y Building.

• LOS ANGELES/INLAND EMPIRE

NOVEMBER 16
Speaker: B o b S c h n e i d e r , c h i e f c o n -
s u l t a n t a n d D i s t r i c t 19 d i r e c t o r .
Affiliation: Bob Schneider Con-
s u l t i n g S e r v i c e s a n d AWS.
Topic: A l u m i n u m w e l d i n g f o r t h e
moon landers and space station.

Sacramento Valley Section tqrst Vice Chairman a n d Treasurer Bob Boyer, at

p o d i u m on right, speaking at the Section's November meeting.

D I S T R I C T 22 a n d ASTM d y e p e n e t r a n t t e s t i n g Activities:The m e t i n g w a s h e l d at
Director: Mark Bell and other forms of nondestructive Sierra C o l l e g e in Rocklin, Calif. Sec-
Phone: (209) 367-1398 examination. tion members and guests toured the
c o l l e g e ' s w e l d i n g s c h o o l . I n addi-
• S A C R A M E N T O VALLEY tion, members of the area Union
NOVEMBER 16 I r o n w o r k e r s s p o k e o n t h e n e e d for
OCTOBER 19
Speaker: M i c h a e l L. W h i t e . Speaker: B o b B o y e r t r a i n i n g a n d m e m b e r s h i p g r o w t h in
Affiliation: Met-L-Chek. Affiliation: L o c k h e e d Martin. l i g h t o f t h e e c o n o m i c e x p a n s i o n in
Topic: Met-L-Check,ASNT, SAE/AMS Topic:Weld i n s p e c t i o n a n d t h e n e e d t h e S a c r a m e n t o area. •
for c e r t i f i e d i n s p e c t o r s .

• Student Chapters,
Send Us Your News STUDENT
Student Chapters are encour- A C T I V I T I E S
aged to send reports of their meet-
ings, activities and events, along
with photographs, for publication
in t h e Welding J o u r n a l ' s S t u d e n t
Activities d e p a r t m e n t .
Send y o u r m e e t i n g / e v e n t re-
p o r t s to

Susan Campbell, Associate Editor

Welding Journal
550 N.W LeJeune Rd.
Miami, FL 33126.

Reports can also be faxed to

(305) 443-4704 or e-mailed to
campbeU@aws, org. •
Lake Washington Ik, chnical College student m e m b e r s at their f i r s t meet-
ing in N o v e m b e r . The Chapter's advisor, R i c h a r d Larson, is s t a n d i n g ,
third f r o m right.
• V i s i t AWS o n t h e W e b
T h e w o r l d o f AWS is as close as
a click of y o u r m o u s e . W h i l e visiting
D I S T R I C T 19 • LAKE W A S H I N G T O N
TECHNICAL COLLEGE
Director: Phil Zammit NOVEMBER 1
t h e A m e r i c a n Welding Society's W e b
Phone: ( 5 0 9 ) 4 6 8 - 2 3 1 0 ext. 1 2 0 Activity: T h e S t u d e n t C h a p t e r m e t
site, y o u c a n r e n e w y o u r m e m b e r -
to elect officers. They are Carl
ship, b u y b o o k s a n d s t a n d a r d s a n d
Gronvold, chairman; Douglas
e v e n look for a n e w job.To see w h a t ' s
L e w , first vice c h a i r m a n ; T o b y L. D i d d l e , s e c o n d v i c e c h a i r m a n ; D e v r a A.
o n t h e W e b site for you, just visit
J o h n s o n , S e c r e t a r y ; D a r r e n A. W a l t e r , t r e a s u r e r . R i c h a r d L a r s o n w i l l
http:// www.aws.org. •
s e r v e as t h e C h a p t e r ' s a d v i s o r . He is a n AWS C e r t i f i e d W e l d i n g I n s p e c t o r
and Certified Welding Educator. •

WELDING JOURNAL I 71
 SECTION EVENTS CALENDAR

• F O X VALLEY • YORK-CENTRAL PENNSYLVANIA Activity: H a n d s - o n d e m o n s t r a t i o n

JANUARY 4 AND 5, 2001 JANUARY 4 and training.
Activity: ASME S e c t i o n IX Seminar. Speaker:John D e F e l i c e .
Location: P a p e r V a l l e y H o t e l a n d Topic: P r e c i s i o n C o m p o n e n t s C o r p . FEBRUARY 8
Conference Center, (920) 733-8000. Activity: South Pacific at t h e Boul-
For further information or to regis- FEBRUARY 1 der Dinner Theatre. Deadline for
ter, call ( 9 2 0 ) 8 4 5 - 5 9 9 2 . Speaker.'Jerry M a t h i s o n . r e s e r v a t i o n s is J a n u a r y 15. F o r fur-
Affiliation: ESAB. t h e r d e t a i l s o r i n f o r m a t i o n , call T e r r y
Activity: Past C h a i r m e n ' s Night. M c C l e l l a n d at ( 3 0 3 ) 9 8 2 - 8 5 8 2 .
• NEW JERSEY
JANUARY 16 MARCH MARCH 8
Miller Electric. Activity: Ladies' Night and an Speaker: T e r r y M c C l e l l a n d .
Topic:To b e a n n o u n c e d . e v e n i n g o n t h e d i n n e r train. Topic: H o w to w r i t e a WPA.
Date:To b e a n n o u n c e d .
FEBRUARY20 APRIL 12
T h e r m a l Dynamics. APRIl. 5 Speaker: C h u c k H o w a r d .
Topic: Simple a u t o m a t i o n for plasma arc Activity:Joint m e e t i n g w i t h ASNT. Topic: H o w to w r i t e a PQR.
cutting machines. Speaker." W i l l i a m D e F e l i c e .
Topic: C r y o g e n i c s . MAY 10
Speaker: J a c k H a r k n e s s .
• MILWAUKEE MAY 3 Topic: H o w to w r i t e a WQTR.
JANUARY 18 Speaker: C h a r l e s C o l b u r n , sculptor. Activity: S t u d e n t R e c o g n i t i o n a n d
Activity: H a n d s - o n Night. Topic: W e l d e d Art. A w a r d s Night.
Location: MATC W e s t Allis. Activity: S t u d e n t s ' Night.
JUNE 14
FEBRUARY 15 Activity: E x e c u t i v e B o a r d m e e t i n g .
Topic: W e l d i n g a n d i o i n i n g f a i l u r e • ALASKA
analysis. For further information on meet- AUGUST 9
ings, e-mail awsalaska@altavista.com. Activity: E x e c u t i v e B o a r d m e e t i n g .
MARCH 15
Topic: L a t e s t a d v a n c e m e n t s in s t u d JANUARY 19
welding and Scholarship Night. Location: A n c h o r a g e .

APRIL 19 FEBRUARY 16
Activity: ABB F l e x i b l e A u t o m a t i o n Topic:To b e a n n o u n c e d .
p l a n t tour. Location: A n c h o r a g e .
¢Announce Your
Section's Activities
MAY 17 MARCH 16
Activity: Past Chairmen's and Topic:To b e a n n o u n c e d . S t i m u l a t e a t t e n d a n c e at y o u r
Spouse's Night. Location: F a i r b a n k s . S e c t i o n ' s m e e t i n g s a n d t r a i n i n g pro-
g r a m s w i t h f r e e l i s t i n g s in t h e Sec-
APRIL 20 tion Meeting Calendar column of
• LAKESHORE Topic:To b e a n n o u n c e d . Society N e w s .
JANUARY 11 Location." A n c h o r a g e . Useful i n f o r m a t i o n i n c l u d e s y o u r
Activity: M i c r o b r e w e r y t o u r a n d din- S e c t i o n n a m e ; a c t i v i t y date, t i m e a n d
ner. MAY 19 l o c a t i o n ; s p e a k e r ' s n a m e , title, affil-
Activity:AWS Alaska S e c t i o n P i c n i c . iation and subject; and notices of
FEBRUARY 8 Location: Palmer, Alaska. g o l f o u t i n g s , s e m i n a r s , c o n t e s t s and
Activity: M a r i t i m e M u s e u m t o u r a n d o t h e r special Section activities.
S p o u s e ' s Night. If s o m e of y o u r m e e t i n g p l a n s are
• COLORADO sketchy, send the name and phone
MARCH 14 For meeting updates, call the n u m b e r of a p e r s o n to c o n t a c t for
Activity: S t u d e n t Day Event. Colorado Section's update line at m o r e information.
(303) 313-9645. Visit the Section's S e n d y o u r n e w c a l e n d a r to
APRIL 12 Web site at w w w . a w s 0 3 9 . t r i p o d . c o m . Susan Campbell,Associate Editor,
Activity: MG I n d u s t r i e s p l a n t tour. W e l d i n g J o u r n a l D e p t . , AWS, 5 5 0
JANUARY 11 N.W. L e J e u n e Rd., Miami, FL 3 3 1 2 6 ;
MAY 18 Speaker: M i k e R u d d e n . FAX: ( 3 0 5 ) 4 4 3 - 7 4 0 4 . ¢
Activity: D i s t r i c t C o n f e r e n c e . Topic: HEAT S t a t e - o f - t h e - a r t w e l d i n g
equipment.

72 I JANUARY 2001
 ¢ 2000-2001 Member-Get-A-Member Campaign
Listed belou, are the people participating in the 2000-2001 Member-Get-A-Member Campaign. For campaign rules
a n d a p r i z e list, p l e a s e s e e pc~ge 6 5 ~ g t h i s Welding Journal.
If you have any questions regardDtg your ntember proposer poDtts, please call the Membership Department at
( 8 0 0 ) 4 4 3 - 9 3 53 ext. 4 8 0 .

Winner's Circle President's Honor Roll R. Zabel, S o u t h e a s t Nebraska -- 2

lAWS Members sponsorDtg 20 or more
new Individual Members,
s i n c e J u n e I, 1 9 9 9 )
J. Compton, S a n t : e r n a n d o
E. H. Ezell, M o b i l e *
B.A. Mikeska, H o u s t o n *
W. L. Shreve, Fox Vallel,*
J. Merzthal, P e r u *
R. Wray, N e b r a s k a *
G. Woomer, J o h n s t o w n / A
*Denotes the number
Individual Member has achieved
Winner's Circle status. Status u,ill
be awarded at the close
membership cantpaign
President's Guild
lAWS Members sponsoring 20 or more
new Individual Members between June
I, 2 0 0 0 , a n d M a F 31, 2 0 0 1 . )
J. Compton, S a n F e r n a n d o
J. Merzthal, P e r u - - 21
G. W o o m e r , J o h n s t o w n / A
President's Roundtable
lAWS Members sponsoring
Indit,idual Members between June
2 0 0 0 , a n d Mal, 31, 2 0 0 1 . )
P Baldwin, Peoria -- 15
A.A.M-Alxlullfitbhar, S a u d i A r a b i a -
A. O. Smith III, T u l s a - - 13
G.Taylor, P a s c a g o u h t - - 13
L.J. Smith, H o u s t o n - - 1 2
E. H. Ezell, M o b i l e - - I 1
President's Club
lAWS members sponsoring
Individual Members between June
2 0 0 0 , a n d M a l , 31, 2 0 0 1 . )
C.Alonzo,Jr., S a n A n t o n i o
~ R. Beck, R o c h e s t e r - - 8
R. Buse, 3 1 o b i l e - - 6
( A W S m e m b e r s s p o n s o r D l g l - 5 n e w In-
per year, dit,idltal Members between .]tttte
2 0 0 0 , arid M a y 31, 2001. Only those
sponsorHlg 2 or more AWS llldit,idttal
~tllel~* M e m b e r s a r e listed.)
J.T. Blank, N o r t h e r n M i c h i g a n - - 5
C. M. Murray, C l e t , e l a n d - - 5
G. P. Neal, F o r t S m i t h - - 5
R. L. Peaslee, D e t r o i t B & S - - 5
Itoona* C.-L.Tsai, T a i u , a n - - 5
If. E. Cable, Sr., P i t t s b u r g h - - 4
of times an J. C. Cooley, B i r m i n g h a m -- 4
W (;idver)klr.,/xmg I~'h./()t~mg~, OtO~. - - 5
I). L. tlatfield, T l t l s a - - 4
of each J. H. Smitla,Jr., M o b i l e - - 4
Feat: M. R T y r o n , U t a h - - 4
J. N. Carney, W e s t e r n M i c h i g a n - - 3
R. Grays, &~,rn - - 3
C. R. Hein, C e n t r a l A r k a n s a s - - 3
S. l). Keskar, l n d i a - - 3
J. Koster, W e s t e r n M i c h i g a n - - 3
B. I, Marini, D e t r o i t - - 3
J.A. Rosado, P u g e t S o u n d - - 3
V a l l e y - - 41 R. I). Rux, W y o m i n g - - 3
J. D. Sanders, H o u s t o n - - 3
ltoona -- 20 M.A. Sandvig, N o r t h w e s t - - 3
B. Saraswat, I n d i a - - 3
L. Schwcinegruber, P i t t s b u r g h - - 3
M.Tait, L A . / l n l a n d E m p i r e - - 3
11-19 neu, R.Wright, S o u t h e r n 6 ? ~ l o r a d o - - 3
1, J. E. Campbell, M i h v a u k e e - - 2
I). S. l)odds, P i t t s b u r g h - - 2
T.A. Flynn, A t l a n t a - - 2
M. Gartman, N o r t h e a s t M i s s i s s i p p i - - 2
J. W. J a e g e r , S o u t h e r n Colorado -- 2
13 R. S. Judy, P o r t l a n d - - 2
J. Knapp, T u l s a - - 2
M.A. Latif, H o u s t o n - - 2
J. R. l,eavitt, S o u t h u , e s t I d a h o - - 2
J.A. l,ivesay, N a s h v i l l e - - 2
I). G. l,una, L . A . / l n l a n d E m p i r e - - 2
S. M. Mc(~asland, S [ l q ' a c u s e - - 2
H.V. McRac, N e w Y o r k - - 2
M. P. Mott, F l o r i d a W e s t C o a s t - - 2
6- I0 new C. N. Porco, C l e v e l a n d - - 2
l, A. Rcyna, N o r t h T e x a s - - 2
K. L. Rigsby, Neu~ Y o r k - - 2
H.A. Rodriguez, P u e r t o R i c o - - 2
-- 7 W ShieMs, N o r t h e a s t M i s s i s s i p p i - - 2
E Soto, N e t t , J e r s ¢ : l , - - 2
.1. Stewart, S a n g a n l o n Vall{[l' - - 2
G. S.Tcaguc, E a s t e r n C a r o l D t a s - - 2
J.Thomsl)son, G r e a t e r H u n t s v i l l e - - 2
E (;.X~alker, O z a r k - - 2
M. G.Weeks, S a b i n e - - 2
D.A.Wright, K a n s a s C i t y - - 2
J. Craft, L o u i s v i l l e -- 2
I,
Student Sponsors
(AWS members s p o n s o r D t g .3 o r m o r e
new AWS Student Members betu'een
. J u n e 1, 2 0 0 0 a n d Jh(l' .3 I, 2 0 0 1 . )
"1~M. Buchanan, M i d - O h i o Valley -- 29
PJ. Betts, M o b i l e - - 24
T. C. M u r r o w , A r i z o n a - - 22
J.Jones, N o r t h T e x a s - - 21
I). Serrano, P u e r t o R i c o - - 21
J.J. Daugherty, L o l t i s v i l l e - - 20
G.WoomerJohnstou,n/Altoona -- 20
M. R.Anderson, I n d i a n a - - 18
R.J. DePue, O l e a n - B r a d f o r d - - 1 8
K. R. Moore, C o r p u s C h r i s t i - - 18
H.Jackson, L A . / h d a n d E m p i r e - - 16
K.A. Ellis, , l l a o , l a n d - - 15
K.A. Dietrich, W h e e l i n g - - 1 4
S. E Siviski, M a i n e - - 1 4
J. H. Smith, M o b i l e - - 1 3
T. Strickland, A r i z o n a - - 1 3
H. R. Madron, M a r y l a n d - - 1 2
P. G. Childers, O k l a h o m a Ci O, - - 10
D. L Hatfield, T u l s a - - 10
W. H. Kielhorn, E a s t T e x a s - - 9
A. K. Mattox, L e x i n g t o n - - 9
R. Zabel, S o u t h e a s t N e b r a s k a - - 9
C.Alonzo,Jr., S a n A n t o n i o - - 8
M. E.Tait, L . A . / l n l a n d E m p i r e - - 7
J.q2 Blank, N o r t h e r n M i c h i g a n - - 6
W. L. Galvary, Jr., L o n g B e a c h - - 6
R. Schneider, W y o m i n g - - 6
J.J. Swoyer, L e h i g h Val&ge - - 6
P. Baldwin, P e o r i a - - 5
J. N. Carney, W e s t e r n M i c h i g a n - - 5
A. E. Classens, C h a r l o t t e - - 5
D..1. Nelson, P u g e t S o u n d - - 5
J. Punmmr, L o n g B c h . / ( h z o t g e C>tgl:- - 5
P. G. Walker, O z a r k - - 5
M.J. Bannester, M o b i l e - - 4
J. R. Carter, Sr., C a r o I D u l - - 4
R. S. Judy, P o r t l a n d - - 4
K. L Rigsby, Neu, }brk - - 4
J. I). Sanders, H o u s t o n - - 4
R. Grays, K e r n - - 3
P.()'I~xtD; EastelTt I d a h o ~ M o n t a n a - - 3
C.J. Ray, I n d i a n a - - 3
R. l). Rux, W y o m i n g - - 3
E. J. Warren, C o l o t ~ u l o - - 3
C. B . W c s l e y , N o r t h u , e s t e r n l~t. - - 3 ¢

WELDING JOURNAL I 73
 TAN
N(jTI
Standards for PINS
Development work has
begun on the following new or
revised standards. Directly and
materially affected individuals
are invited to contribute to the
development of such standards.
Those wanting to participate
may contact the Staff Engineer
listed with the document.
Participation on AWS Tech-
nical Committees and Subcom-
mittees is open to all persons.
A I . I : 2 O O X , Metric Practice G u i d e
f o r the Welding I n d u s t r y . T h i s m e t -
ric p r a c t i c e g u i d e is b a s e d o n t h e In-
t e r n a t i o n a l S y s t e m o f U n i t s (SI) as
d e f i n e d in t h e U.S. Federal Register
n o t i c e o f J u l y 28, 1 9 9 8 , " M e t r i c Sys-
tem of Measurement: Interpretation
of the International System of Units
for t h e U n i t e d States." ( O t h e r s o u r c e
d o c u m e n t s a n d s t y l e g u i d e s a r e ref-
e r e n c e d in A n n e x D . ) T h i s g u i d e c o n -
t a i n s s p e c i f i c a t i o n s o f t h e SI b a s e
units, derived units, prefixes and
r u l e s for t h e i r u s e inAWS d o c u m e n t s
a n d b y t h e w e l d i n g i n d u s t r y . It also
contains factors and rules for con-
v e r t i n g f r o m U.S. i n c h - p o u n d u n i t s
( o f t e n r e f e r r e d t o as U.S. c u s t o m a r y
u n i t s ) t o SI u n i t s a n d r e c o m m e n d a -
tions to industry for managing the
transition. Engineer: John Gayler
( 3 0 5 ) 4 4 3 - 9 3 5 3 ext. 472.
C2.24:200X, M o d i f i e d Layer Re-
m o v a l M e t h o d Procedure f o r Eval-
u a t i n g R e s i d u a l Stresses in Ther-
m a l Spray Coatings. T h i s d o c u m e n t
describes a recommended practice
for experimentally evaluating resid-
ual s t r e s s e s in t h e r m a l s p r a y c o a t -
i n g s . E n g i n e e r : Ed M i t c h e l l ( 3 0 5 )
4 4 3 - 9 3 5 3 ext. 254.
C 2 . 2 5 : 2 0 0 X , Specification f o r Solid
a n d Composite Wires a n d Ceramic
Rods f o r T h e r m a l S p r a y i n g . T h i s
specification prescribes require-
m e n t s f o r t h e c l a s s i f i c a t i o n o f fer-
rous and nonferrous solid and com-
p o s i t e w i r e s a n d c e r a m i c r o d s , as
manufactured for thermal spraying.
74 ]JANUARY2001
A
E n g i n e e r : Ed M i t c h e l l ( 3 0 5 ) 443-
9 3 5 3 ext. 254.
D 1 7 . 3 : 2 0 0 X , Specification f o r Fric-
tion Stir Welding o f A l u m i n u m f o r
Aerospace A p p l i c a t i o n s . T h i s s p e c i -
fication contains requirements for
the friction stir welding of aero-
space hardware. Engineer: Ed
M i t c h e l l ( 3 0 5 ) 4 4 3 - 9 3 5 3 ext. 254.
E G 2 . 0 : 2 0 0 X , Guide f o r the Training
a n d Q u a l i f i c a t i o n o f Welding Per-
s o n n e l E n t r y Level Welders. T h i s
g u i d e c o n t a i n s i n f o r m a t i o n to a s s i s t
e d u c a t i o n a n d t r a i n i n g f a c i l i t i e s in
the development and administration
of competency-based training that
leads to the qualification and certi-
fication of trainees in accordance
w i t h t h e r e q u i r e m e n t s ofAWS Q C 1 0 ,
Specification f o r the Q u a l i f i c a t i o n
a n d C e r t i f i c a t i o n f o r E n t r y Level
Welders. I n c l u d e d a r e s e c t i o n s o n
curriculum and qualification guide-
l i n e s , as w e l l as r e c o m m e n d a t i o n s
for facility planning, materials,
e q u i p m e n t a n d t o o l s . D i r e c t o r , Edu-
cation: Jim Cunningham (305) 443-
9 3 5 3 ext. 219.
QC10:2OOX, Specification f o r Qual-
ification and Certification for
E n t r y Level Welders. T h i s s t a n d a r d
defines the requirements and pro-
g r a m f o r t h e A m e r i c a n W e l d i n g So-
ciety to certify entry level welders.
The certification of entry level
w e l d e r s r e q u i r e s p e r f o r m a n c e qual-
ification and practical knowledge
tests.These tests require a minimum
of reading, computational and man-
ual skills to c o m p l e t e . D i r e c t o r , Ed-
u c a t i o n : J i m C u n n i n g h a m ( 3 0 5 ) 443-
9 3 5 3 ext. 219.
Standards for Public Review
AWS w a s a p p r o v e d as a n accred-
ited standards-preparing organiza-
t i o n b y t h e A m e r i c a n N a t i o n a l Stan-
d a r d s I n s t i t u t e (ANSI) i n 1979. AWS
r u l e s , as a p p r o v e d b y ANSI, r e q u i r e
that all s t a n d a r d s b e o p e n to p u b l i c
review for comment during the ap-
p r o v a l p r o c e s s . This c o l u m n a l s o ad-
v i s e s o f ANSI a p p r o v a l o f d o c u m e n t s .
The f o l l o w i n g s t a n d a r d s are s u b m i t -
t e d for p u b l i c r e v i e w . A c o p y m a y b e
obtained by sending the amount
s h o w n to AWS T e c h n i c a l D e p t . , 550
N.W. L e J e u n e Rd., M i a m i , FL 3 3 1 2 6 ,
or b y c a l l i n g ( 8 0 0 ) 334-9353.
A5.18/A5.18M:200X, Specification for
Carbon Steel Electrodes and Rods for
Gas Shielded Arc Welding. Revised stan-
dard. $17.00. [ANSI Public Review ex-
pires January 16, 2001 .] •
TECHNICAL COMMITTEE
MEETINGS
All AWS t e c h n i c a l c o m m i t t e e
m e e t i n g s are open to the p u b l i c .
Persons w i s h i n g to a t t e n d a meet-
ing s h o u l d c o n t a c t the s t a f f secre-
t a r y o f the c o m m i t t e e as listed
below at AWS, 550 N. W LeJeune Rd.,
M i a m i , FL 33126; telephone ( 3 0 5 )
443-9353.
F e b r u a r y 6 - 7 , 2000, G1B S u b c o m m i t -
t e e o n V i b r a t i o n W e l d i n g . F o r t Laud-
e r d a l e , Fla. S t a n d a r d s p r e p a r a t i o n
m e e t i n g . Staff c o n t a c t : J. L. Gayler. •
¢ Submit Your Technical
Committee Reports
C o m m i t t e e C h a i r m e n - - We
w a n t to r e c o g n i z e t h e e f f o r t s of y o u r
c o m m i t t e e a n d i n f o r m o u r r e a d e r s of
its a c c o m p l i s h m e n t s . Send a b r i e f pro-
file o f its activities a n d r e c e n t a c c o m -
p l i s h m e n t s , a l o n g w i t h a m e m b e r ros-
t e r a n d c o n t a c t n u m b e r s , a n d w e will
p u b l i s h it in t h e Welding Journal's So-
ciety N e w s section.
Send y o u r s u b m i s s i o n s to
Susan C a m p b e l l , A s s i s t a n t Editor
A m e r i c a n Welding Society
550 N.W LeJeune Rd.
Miami, FL 33126
T e l e p h o n e , (305) 443-9353 ext. 244,
FAX: ( 3 0 5 ) 443-7404
e-mail: campbell@ aws.org ¢
 GUIDE TO AWS SERVICES EDUCATION
Director
James R. Cunningham (219)
550 N.W. LeJeune Rd., Miami, FL 3 3 1 2 6
Phone (800) 443-9353;Telex 51-9245; (888)WELDING Information on education products, projects
FAX (305) 443-7559; Internet: www. aws. org and programs. CWl, SCWl attd o t h e r semi-
nars designed for assistance in Certification.
Phone extensions appear in parentheses. Responsible for the S.E.N.S.E. b e g i n n i n g
w e l d e r program and d i s s e m i n a t i o n of edu-
AWS PRESIDENT Corporate Director of Administrative Services cation information on the Web.
Jim Lankford (214)
L. William Myers
482 Wolf Run Road Corporate Director of Marketing CONFERENCES
Cuba, NY 14727 Technical Services Division
Debrah C.Weir (279) Director
GiseUe I. Rodriguez (278)
P r o m o t e s Soc i e t y p r o g r a m s a n d a c t i v i t i e s
to AWS m e m b e r s , t h e w e l d i n g c o m m u - Responsible for national and local confer-
nity a n d t h e g e n e r a l p u b l i c . e nc e s / e xhi bi t i ons and seminars on industry
ADMINISTRATION
t opi c s ranging from the basics to the lead-
ing edge of technology.
Executive Director CONVENTION & E X P O S m O N S
Frank G. DeLaurier, CAE (210) Exhibiting Information (221, 256)
Deputy Executive Directors Managing Director CERTIFICATION OPERATIONS
Richard D. French (218) Tom L. Davis (231) Information and a p p l i c a t i o n materials on
Jeffrey R. Hufsey (264) certifying welders, w e l d i n g i n s p e c t o r s and
John J. McLaughlin (235) O r g a n i z e s t h e w e e k - l o n g a n n u a l AWS In- educators. (273 )
t e r n a t i o n a l W e l d i n g a n d F a b r i c a t i n g Ex-
Assistant Executive Director position and Convention. Regulates Managing Director
Debbie A. Cadavid (222) space assignments, registration materi- Wendy S. Reeve (215)
als a n d o t h e r E x p o a c t i v i t i e s .
Director of Quality Management Systems A w a rds & Fellows
Linda K. Williams (298)
PUBLICATION SERVICES Managing Director
l)ivision Information (348) Wendy S. Reeve (215)
Corporate Director of Finance/Comptroller
Frank RTarafa (252) Managing Director (k)ordinatcs av~at~sand AWS kqlow nominct~.
Jeff Weber (246)
INFORMATION SERVICES
Corporate Director WELDING JOURNAL TELEWELD
Joe Cilli (258)
Publisher FAX: (305) 443-5951
HUMAN RESOURCES Jeff Weber (246)

Director Editor For information about AWS technical publi-

Luisa Hernandez (266) Andrew Cullison (249) cations, c ont a c t the Technical Services per-
sonnel listed below.
National Sales Director
INTERNATIONAL INSTITUTE Rob Saltzstein (243) TECHNICAL SERVICES
OF WELDING
WELDING HANDBOOK Department Information (340)
Information (294)
Welding Handbook Editor Managing Director
P r o v i d e s liaison a c t i v i t i e s i n v o l v i n g o t h e r Annette O'Brien (303) Leonard P. Connor (299)
p r o f e s s i o n a l s o c i e t i e s a n d s t a n d a r d s orga- Qualification, Inspection, Food
nizations, nationally a n d internationaLly. P u b l i s h e s AWS's m o n t h l y m a g a z i n e , t h e Processing Equipment
Welding J o u r n a l , w h i c h p r o v i d e s infor-
GOVERNMENT LIAISON SERVICES m a t i o n o n t h e s t a t e of t h e w e l d i n g in- Andrew R. Davis (466) International Standards
dustry, its t e c h n o l o g y a n d S o c i e t y activi- Program Manager, Welding in Marine
Hugh K.Webster ties. P u b l i s h e s t h e W e l d i n g H a n d b o o k Construction
Webster, Chamberlain & Bean and books on general welding subjects.
Washington, D.C. Stephen P. Hedrick (305) Safety and Health
(202) 4(X)-2976 Manager, Symbols mad Definitions
FAX (202) 835-0243 MEMBER SERVICES

Identifies sources of funding for welding ed- Department Information (261) Engineers
ucation and research & development. Moni-
tors legislative and regulatory issues impor- Managing Director Hardy H. Campbell Ill (300) Structural
tant to the industry. Cassie R. Burrell (253)
Rakesh Gupta (301) Filler Metals
WELDING EQUIPMENT Director
Rhenda A. Mayo (260) (a~MstopherB.tMllock(304) Brazing,Soldering,
MANUFACTURERS COMMITTEE Teslin~,Railroads,(k)mputerization,
Serves as a liaison between Section members Insmm~entation
Associate Executive Director
and AWS headquarters. Informs members about
Richard L.Alley (217)
AWS benefits and other activities of interest. Tim Potter (309) Robotics,Joining of Metals
and Alloys, Piping atld Tubing,
INDUSTRY ACI~ON COMMITTEE Friction Welding
CERTIFICATION PROGRAMS/
Associate Executive Director BUSINESS DEVELOPMENT John k Gaoler(472) Metric Practices,Sheet Metal,
Charles R. Fassinger (297) P l ~ e s and Composites, Personnel Qualification
Director of Int'l Business Development
COMMUNICATIONS Walter Herrera (475) Ed E Mitchell (254) Thermal Spray, High-En-
ergy Beam Welding and Cutting, Resistance
Corporate Director, Communications For customized certification and educational Welding, Automotive, Aerospace
Nannette M. Zapata (308) programs tu industry and government.

WELDING JOURNAL I 75

P U B L I C A T I O N SALES
Call Global Engineering Documents
(800) 854-7179
Publication orders.
Senior Publications Coordinator
Rosalinda O'Neill
AWS publishes more than 160 volumes of
material, including standards that are used
throughout the industry.
With regard to technical inquiries, oral opin-
ions on AWS standards may be rendered.
However, such opinions represent only the
personal opinions of the particular individ-
uals giving them.These individuals do not
speak on behalf of AWS, nor do these oral
opinions constitute official or unofficial opin-
ions or interpretations of AWS.In addition, oral
opinions are informal and should not be used
as a substitute for an official interpretation.
It is the i n t e n t o f the A m e r i c a n Weld-
i n g Society to b u i l d the Society to the
h i g h e s t q u a l i t y s t a n d a r d s possible. We
w e l c o m e a n y suggestions y o u m a y have.
Please co n t a c t a n y o f the s t a f f listed
o n the p r e v i o u s p a g e o r A W S P r e s i d e n t
L. W i l l i a m Myers, 4 8 2 W o l f R u n Road,
Cuba, N Y 14727.
AWS FOUNDATION, INC.
5 5 0 N.W. L e J e u n e Rd.
Miami, FL 3 3 1 2 6
(305) 445-6628
( 8 0 0 ) 4 4 3 - 9 3 5 3 , ext. 2 9 3
O r e-mail: b o b w @ a w s . o r g
Chairman, Board of Trustees
R o n a l d C. P i e r c e
Executive Director
F r a n k G. DeLaurier, CAE
Director of Development
Robert B.Witherell
T h e A W S F o u n d a t i o n is a n o t -
for-profit corporation estab-
lished to provide support for
educational and scientific
endeavors of the American
Welding Society. Information
on gift-giving programs is
available upon request.
76 ]JANUARY2001
• Nominees for National Office
O n l y S u s t a i n i n g M e m b e r s , M e m b e r s , H o n o r a r y M e m b e r s , Life M e m b e r s o r Re-
tired M e m b e r s w h o h a v e b e e n m e m b e r s for a p e r i o d o f at least t h r e e y e a r s shall b e
eligible for e l e c t i o n as a D i r e c t o r or National Officer.
It is t h e duty of t h e National N o m i n a t i n g C o m m i t t e e to n o m i n a t e candidates for na-
tional office.The c o m m i t t e e shall hold an o p e n meeting, preferably at t h e Annual Meet-
ing, at w h i c h m e m b e r s m a y a p p e a r to p r e s e n t a n d d i s c u s s t h e eligibility o f all candi-
dates.
To be c o n s i d e r e d a candidate for positions of President,Vice President,Treasurer or
Director-at-Large, the following qualifications and conditions apply:
(451) P r e s i d e n t : T o b e eligible to h o l d t h e office o f P r e s i d e n t , an i n d i v i d u a l m u s t h a v e
s e r v e d as a Vice P r e s i d e n t for at least o n e year.
Vice P r e s i d e n t : T o b e eligible to h o l d t h e office o f Vice P r e s i d e n t , a n i n d i v i d u a l
m u s t h a v e s e r v e d at least o n e y e a r as a Director, o t h e r t h a n E x e c u t i v e D i r e c t o r a n d
Secretary.
T r e a s u r e r : T o b e eligible to h o l d t h e office o f T r e a s u r e r , a n i n d i v i d u a l m u s t b e a
m e m b e r o f t h e Society, o t h e r t h a n a S t u d e n t M e m b e r , m u s t b e f r e q u e n t l y available
to t h e N a t i o n a l O f f i c e a n d s h o u l d b e o f e x e c u t i v e s t a t u s in b u s i n e s s o r i n d u s t r y
w i t h e x p e r i e n c e in financial affairs.
Director-at-Large:To b e eligible for e l e c t i o n as a Director-at-Large, a n i n d i v i d u a l
s h a l l p r e v i o u s l y h a v e h e l d o f f i c e as C h a i r m a n o f a S e c t i o n ; as C h a i r m a n o r Vice
C h a i r m a n o f a s t a n d i n g , t e c h n i c a l or special c o m m i t t e e o f t h e Society; o r as District
Director.
I n t e r e s t e d p a r t i e s a r e to s e n d a l e t t e r s t a t i n g w h i c h p a r t i c u l a r o f f i c e t h e y a r e
s e e k i n g , i n c l u d i n g a s t a t e m e n t o f qualifications, t h e i r w i l l i n g n e s s a n d ability to s e r v e
if n o m i n a t e d a n d e l e c t e d a n d 20 c o p i e s o f t h e i r b i o g r a p h i c a l s k e t c h .
T h i s m a t e r i a l s h o u l d b e s e n t to R o b e r t J . T e u s c h e r , C h a i r m a n , National N o m i n a t -
i n g C o m m i t t e e , A m e r i c a n W e l d i n g Society, 550 N.W. LeJeune Rd., Miami, FL 33 126.
T h e n e x t m e e t i n g o f t h e N a t i o n a l N o m i n a t i n g C o m m i t t e e is c u r r e n t l y s c h e d -
u l e d for May 1 , 2 0 0 1 , in C l e v e l a n d , O h i o . T h e t e r m s o f office for c a n d i d a t e s n o m i -
n a t e d at this m e e t i n g will c o m m e n c e J u n e 1,2002. •
• Honorary-Meritorious Awards
The Honorary-Meritorious Awards Committee has the duty to make recommendations
regarding nominees presented for Honorary Membership, National Meritorious Certificate,
William Irrgang Memorial and the George E. Willis Awards. These awards are presented in
conjunction with the AWS Exposition and Convention held each spring.The descriptions
of these awards Ibllow, and the submission deadline for consideration is July l prior to the
year of presentation. All candidate material should be sent to the attention of John J.
McLaughlin, Secretary, Honorary-Meritorious Awards Committee, 550 N.X~ LeJeune Road,
Miami, FL 33126.
N a t i o n a l M e r i t o r i o u s Certificate Award: International Meritorious Certifi-
This a w a r d is g i v e n in r e c o g n i t i o n o f t h e c a t e A w a r d : T h i s a w a r d is g i v e n in
c a n d i d a t e ' s c o u n s e l , loyalty a n d d e v o t i o n r e c o g n i t i o n o f t h e c a n d i d a t e ' s signifi-
to t h e affairs o f t h e Society, a s s i s t a n c e in c a n t c o n t r i b u t i o n s to t h e w o r l d w i d e
p r o m o t i n g cordial relations w i t h i n d u s t r y w e l d i n g i n d u s t r y . T h i s a w a r d s h o u l d re-
a n d o t h e r o r g a n i z a t i o n s , a n d for t h e con- f l e c t " S e r v i c e to t h e I n t e r n a t i o n a l Weld-
t r i b u t i o n o f t i m e a n d effort o n b e h a l f o f i n g C o m m u n i t y " in t h e b r o a d e s t t e r m s .
the Society. T h e a w a r d e e is n o t r e q u i r e d to b e a
m e m b e r o f t h e A m e r i c a n W e l d i n g So-
W i l l i a m I r r g a n g M e m o r i a l A w a r d : This ciety. M u l t i p l e a w a r d s c a n b e g i v e n p e r
award is administered by the American Weld- y e a r as t h e s i t u a t i o n d i c t a t e s . T h e
ing Society and s p o n s o r e d by The Lincoln a w a r d c o n s i s t s o f a c e r t i f i c a t e to b e
Electric C o m p a n y to h o n o r the late William p r e s e n t e d at t h e a w a r d ' s l u n c h e o n o r
Irrgang. It is awarded each year to t h e indi- at a n o t h e r t i m e as a p p r o p r i a t e in c o n -
vidual w h o h a s d o n e t h e m o s t to e n h a n c e j u n c t i o n w i t h t h e AWS P r e s i d e n t ' s
t h e A m e r i c a n Welding Society's goal of ad- t r a v e l i t i n e r a r y , a n d , if a p p r o p r i a t e , a
vancing the science and technology of o n e - y e a r m e m b e r s h i p to AWS.
welding over the past five-year period.
H o n o r a r y M e m b e r s h i p A w a r d : An
G e o r g e E. W i l l i s A w a r d : T h i s a w a r d is H o n o r a r y M e m b e r shall b e a p e r s o n o f
a d m i n i s t e r e d by t h e A m e r i c a n Welding So- a c k n o w l e d g e d e m i n e n c e in t h e w e l d -
ciety a n d s p o n s o r e d by T h e Lincoln Elec- i n g p r o f e s s i o n , o r w h o is a c c r e d i t e d
tric C o m p a n y to h o n o r George E.WiUis. It w i t h e x c e p t i o n a l a c c o m p l i s h m e n t s in
is a w a r d e d e a c h year to an individual for t h e d e v e l o p m e n t o f t h e w e l d i n g art,
promoting the advancement of welding u p o n w h o m t h e A m e r i c a n W e l d i n g So-
i n t e r n a t i o n a l l y by f o s t e r i n g c o o p e r a t i v e c i e t y s e e s fit to c o n f e r an h o n o r a r y dis-
p a r t i c i p a t i o n in areas s u c h as t e c h n o l o g y tinction. An Honorary Member shall
transfer, s t a n d a r d s rationalization a n d pro- h a v e full r i g h t s o f m e m b e r s h i p . •
m o t i o n of industrial goodwill.
 Catalog Highlights Personal
Protection Products
This 688-page catalog offers customers
products for fall protection, protective
clothing, hearing protection, biosafety,
first aid, labels and more. Besides prod-
uct selection, the catalog is a handy re-
source that offers safety-related charts and
illustrations, reference guides, glossary,
safety sources and hotline numbers.
Lab Safety Supply
P.O. Box 1368, Janesville, W153547-1368
Tips on Storing and Re-Drying
Electrodes Offered
Storing and Re-drying Electrodes pro-
vides tips on how to care for both low hy-
drogen and nonlow hydrogen electrodes.
The brochure explains how changes in
storage habits or proper re-drying of elec-
trodes that have been exposed to too much
moisture can be corrected. The first part
describes how to properly store low hy-
drogen and stainless electrodes by keep-
ing them in a hermetically sealed con-
tainer at a temperature of 250° to 300°F.
Next, tips for re-drying damaged elec-
trodes that have been exposed to damp-
ness are offered that can help restore the
electrodes' ability to deposit quality welds.
Step-by-step procedures, easy-to-read
charts and graphs are included.
Lincoln Electric Co.
22801 St. Clair Ave., Cleveland, OH 44117-1199
Marine W e l d i n g H a n d b o o k
Updated
This second edition of the company's
marine welding handbook incorporates
new technologies with long-standing in-
dustry practices in a comprehensive guide
to welding and cutting for shipboard ap-
plications. The updated handbook con-
tains more than 300 pages of detailed
"how-to" instruction with illustrations in-
cluding guidelines for determining the
processes and operating parameters best
suited for specific applications. Designed
to assist vessel operators in keeping down-
time and costs at a minimum, the manual
provides tips to help maintenance person-
nel maximize equipment performance and
service life. It emphasizes precautions and
practices necessary to ensure safety dur-
ing equipment storage, handling and use.
Ashland Chemical, Drew Marine
Division 130
One Drew Plaza, Boonton, NJ 07005
128
Guide to Automated
Deburring Introduced
A 12-page educational brochure pro-
vides information about automated de-
burring with brushes. The guide helps
readers determine the best brush and sys-
tem design for specific applications, keep-
ing pace with today's common use of wire
brushes and abrasive nylon filament
brushes in automated deburring environ-
ments. The brochure includes information
about a burr classification system, differ-
129
ent brush types available, advantages of
each brush type and examples of various
applications where the brushes can be
used. Operating parameters are included
as a starting point from which further anal-
ysis can be performed.
Weiler Corporation 131
One Wildwood Dr., Cresco, PA 18326-0149
will form during the brazing operation
and prevent proper flow of the filler
metal into the crack. It is, therefore, nec-
essary to control the process so there is
a known amount of surface depletion
after the F cleaning. It is also necessary
that the time in the brazing furnace be
short so the parts can be inspected and
rebrazed, if needed, before the base
metal titanium and aluminum diffuse to
the surface and prevent further brazing.
If there has been sufficient depletion, a
part coming out of the brazing furnace
should still be bright and clean. If the
part comes out of the brazing operation
showing a brown, blue or black surface,
the aluminum and titanium have oxi-
dized and further fluoride-ion cleaning
will be required before additional braz-
ing can be effective.
Braze repair of hot-section jet-engine
parts started back in 1957 and has been
growing in popularity ever since. Ade-
quately brazed repair parts have very
good service life. When thermal fatigue
cracking results from the cracks to be re-
paired, it is important to repair all of the
small grain boundary cracks around the
major crack area. If this is accomplished,
the braze repair will be highly superior
to a weld repair of the major crack only,
which leaves all of the minor grain
boundary cracks around the major crack
in place, thereby shortening service life
after the weld repair..
R. L. P E A S L E E is Vice President, Wall
Colmonoy Corp., Madison Heights, Mich. This
article is based on a column prepared for the
A WS Detroit Brazing and Soldering Division's
newsletter. Reader questions may be sent to Mr.
Peaslee c/o WeMingJournal, 550 N. W LeJeune
Rd., Miami, FL 33126.
WELDING JOURNAL I 77

Q&A
B Y D A M I A N J. KOTECKI
Q: I have to make a n u m b e r of joints o f
304L pipe to 316L pipe. From the stand-
p o i n t o f c o r r o s i o n r e s i s t a n c e , d o e s it
m a k e any difference if 308L filler metal
or 316L filler metal is used?
A : To begin, let's look at some compo-
sitions. Since you indicate the base met-
als are pipes, and the service is corro-
sion, I'll look to A S T M A312 Standard
Specification f o r Seamless and Welded
Austenitic Stainless Steel Pipes. I should
note that different ASTM stainless steel
base metal specifications sometimes
have different composition limits for
nominally the same grade of steel. F o r
filler metal compositions, I'll look to
AWS A5.4 for covered electrodes; AWS
A5.9 for bare wires for gas metal arc,
gas tungsten arc and submerged arc
welding; and A W S A5.22 for gas
shielded flux cored wires. The compo-
sitions are listed in Tables 1 and 2 for
both base metals and filler metals.
The elements responsible for corro-
sion resistance are chromium, nickel and
molybdenum. Looking at either table, it
can be noticed that the minimum
chromium and the minimum nickel for
the filler metals tend to be higher than
the corresponding minimum of the base
metals. This provides some assurance
the weld metal will at least match the
corrosion resistance of the correspond-
ing base metal.
In general, since 316L contains more
alloy, it has slightly better corrosion re-
sistance than 304L in most applications.
But the corrosion resistance of a joint
between the two base metals can be no
better than the corrosion resistance of
the less resistant base metal. If the filler
metal corrosion resistance at least
matches the corrosion resistance of the
less resistant base metal, then the weld
metal corrosion resistance should be ad-
equate for the intended service, as long
as both base metals are adequate.
So, the conclusion is, in virtually all
joints between 304L and 316L stainless
steels for corrosion resistant service, it
does not matter if the filler metal cho-
sen is 308L or 316L, except 308L is gen-
erally less costly.
Q: I've heard mention of a new genera-
tion o f s t a i n l e s s steels called s u p e r
m a r t e n s i t i c s t a i n l e s s steels. P l e a s e de-
fine them.
A: The so-called "super martensitic"
stainless steels are currently receiving a
lot of attention in Europe, particularly for

Table I - - 304L Base Metal vs. 308L Filler Metals

C, % Mn, % P, % S, % Si, % Cr, % Ni, % Mo, %

A 312 TP304L 0.035 max. 2.00 max. 0.040 max. 0.030 max. 0.75 max. 18.0 to 20.0 8.00 to 13.0 not specified
A5.4 308L 0.04 max. 0.5 to 2.5 0.04 max. 0.03 max. 0.90 max. 18.0 to 21.0 9.0 to 11.0 0.75 max.
A5.9 308L 0.03 max. 1.0 to 2.5 0.03 max. 0.03 max. 0.30 to 0.65 19.5 to 22.0 9.0 to 11.0 0.75 max.
A5.22 308L 0.04 max. 0.5 to 2.5 0.04 max. 0.03 max. 1.0 max. 18.0 to 21.0 9.0 to 11.0 0.5 max.

Table 2 - - 316L Base Metal and Filler Metal

C, % Mn, % P, % S, % Si, % Cr, % Ni, % Mo, %

A 312 TP316L 0.035 max. 2.00 max. 0.040 max. 0.030 max. 0.75 max. 16.0 to 18.0 10.0 to 15.0 2.0 to 3.0
A5.4 316L 0.04 max. 0.5 to 2.5 0.04 max. 0.03 max. 0.90 max. 17.0 to 20.0 11.0 to 14.0 2.0 to 3.0
A5.9 316L 0.03 max. 1.0 to 2.5 0.03 max. 0.03 max. 0.30 to 0.65 18.0 to 20.0 11.0 to 14.0 2.0 to 3.0
A5.22 316L 0.04 max. 0.5 to 2.5 0.04 max. 0.03 max. 1.0 max. 17.0 to 20.0 11.0 to 14.0 2.0 to 3.0

Table 3 - - Compositions of CA-6NM and Some Supermartensitic Stainless Steels

Alloy C, % Mn, % Si, % Cr, % Ni, % Mo, % Cu, % N, % Ti, %

CA-6NM 0.04 0.5 0.3 13.0 4.0 0.4 -- -- --

"Lean" supermartensitic 0.01 1.2 0.2 11.0 1.5 -- 0.5 <0.012 --
" M e d i u m " supermartensitic 0.01 0.6 0.4 13.4 3.8 0.4 -- 0.015 --
" H i g h " supermartensitic 0.01 0.4 0.2 12.0 6.5 2.5 -- -- 0.1

DAMIAN J. KOTECK1 is Technical Director

for Stainless and High-Alloy Producl
Development for The Lincoln Electric Co., Table 4 - - Boiling Points of Alloy Elements in ER308L Si
Cleveland, Ohio. He is a member of the A WA
A5D Subcommittee on Stainless Steel Fillet Element Mn Si Cr Ni Fe
Metals; A WS D1 Structural Welding Committee,
Subcommittee on Stainless Steel Welding; and a Boiling Temperature, °C 1962 2355 2672 2732 275O
member and past chair of the Welding Research (°F) (3564) (4271) (4842) (4950) (4982)
Council Subcommittee on Welding Stainless[
Steels and Nickel Base Alloys. Questions may be
sent to Mr. Kotecki c/o Welding Journal, 550
N.W. LeJeune Rd., Miami, FL 33126.

78 I JANUARY 2001
flow lines for off-shore oil, because they may be a lower cost alterna-
tive to duplex stainless steels. Since they are resistant to oil contami-
nated with water, carbon dioxide and limited levels of hydrogen sul-
fide, supermartinsitic stainless steels are being treated as if they were DOES YOUR
something new. Actually, the concept is rather old.
The idea behind these stainless steels is to produce low carbon
martensite so the material is weldable with little or no preheat, yet
WELDING TRAININ
still provides high strength. The casting alloy known in the United
States as C A - 6 N M (sometimes as 410NiMo) is virtually a super
martensitic stainless, and it is several decades old. A very complete
MEASURE UP TO
review of super martensitic stainless steels is contained in a larger
review by A. W. Marshall and J. C. M. Farrar, "Welding of Ferritic INDUSTRYSTANDARDS?
and Martensitic 13% Cr Stainless Steels," (IIW Document IX-1975-
00), which is soon to be published in Welding in the World. The main
difference between CA-6NM and a super martensitic stainless is in
the carbon content. CA-6NM is limited to 0.06% C maximum, and
is typically about 0.04%, while a super martensitic stainless always
contains less than 0.02% C.
Table 3 lists nominal compositions of CA-6NM and a few sam-
ple compositions of super martensitic stainlesses from the review by
Marshall and Farrar.
Unfortunately, matching composition filler metals available
today do not match the properties of the base metals, especially in
toughness. So, to date, the manufacturers of the super martensitic
stainless steels generally r e c o m m e n d 22% Cr or 25% Cr duplex
stainless steel filler metals (types 2209 and 2553, for example).

Q: When making a gas metal arc weld in 304L stainless with

ER308LSi filler metal, using 98% argon-2% oxygen shielding gas, I
find a deposit that looks like soot on the base metal for a distance of
about ~ in. from the weld edges. This soot brushes off easily, but I
don't like having to do that. What is causing the soot to form, and
what can be done to prevent it?

A: The first part of your question is easy to answer. I've used a scan-
ning electron microscope to semiquantitatively analyze the "soot." G/~Jt;II~IIGG IIUIll tll~ JFIUU~tlt Jillbi.ll.LILt; U I ¥¥~1tlIII~
It turns out to be oxides of iron, chromium, silicon, nickel and man- Technology* to w o r k for you.
ganese. What happens is that the arc is hot enough to cause vapor-
ization of some portion of all of the metal species in the filler wire. • Complete curriculum materials on att major processes
Then the metal vapors oxidize and condense on the cooler sur- • Modular design, i
roundings. Some of the condensed vapors are carried away by the • C|ose-up shots of the welding arc highlighting
air - - these are the welding fumes. A n d some of the vapors con- proper technique.
dense on the base metal near the weld - - these are the "soot" you • Easy-to-foUow "how-to" student workbook design-
observe. The concentration of the elements in this condensed "soot,"
and in the airborne fumes, depends on more than the concentration • Comprehensive instructor guides.
of each element in the wire. It also depends upon the boiling point • Based on AWS S.E.N.S.E. objectives, with standard
or vapor pressure of each element. Manganese, in particular, is pre- AWS terms and definitions used throughout.
sent in these oxides in greater percentage than in the filler metal be- • Welding software (Weld_IT =) for compelling
cause of its lower boiling temperature or higher vapor pressure. The presentations, custom handouts, procedure
Handbook of Chemistry and Physics lists boiling points for the vari- specifications, and more.
ous elements found in ER308LSi, as seen in Table 4.
The much lower boiling point of manganese, as compared to the For more information call
boiling points of all other elements present, accounts for the con- 800-332-9448, Ext. 5433
centration of Mn in welding fume (and in the "soot"), which tends
or visit www.weldin og=o~
to be approximately double (or more) the concentration of Mn in
the filler metal. See Fumes and Gases in the Welding Environment,
published by AWS.
As for the second part of your question - - preventing the "soot"
from forming - - I don't think you can in G M A welding. You can
lessen it by doing the same things that you can do to lessen fume,
for example, use less oxidizing gas (99% argon - 1% oxygen, for ex-
ample) and keep the arc voltage as low as possible. Or, if possible,
change to submerged arc welding, which totally eliminates the HOBARTINSTITUT]~
"soot.", OFWELDINGTECHNOLOGYl.a
WorM-Class Trainingfrom a World-Classlnsatution
© 2000 Hobart Institut~ of Wc|ding Technology

Circle No. 13 on Reader Info-Card

W E L D I N G J O U R N A L I 79
 territory that includes Kansas, Missouri,
Iowa, Arkansas, Nebraska and Okla-
$tapla Ultrasonics Appoints homa. Previously, he served distributors
Business Manager and end users, specializing in the hard-
facing and maintenance and repair alloy
Stapla Ultrasonics Corp., Wilming- businesses.
ton, Mass., has appointed Juergen Gae-
bier as business manager of plastic weld- Jackson Products Adds to
Personal Safety Group

St. Louis-based Jackson Products,

Inc. (JPI), has announced several per-
sonnel changes in its Personal Safety
Group. Tim Esposito [AWS] has been
Simone promoted to vice president of sales and
of two district managers. Frank Simone, marketing for the Group. Esposito pre-
who will be headquartered in New Jer- viously served as vice president of sales
sey, will work with distributors and end and marketing for the company's Jack-
users in the Northeast. He joins the com- son Products business. In his new posi-
pany with 25 years of experience in the tion, he will be responsible for all sales
sale, servicing and training of applica- within the welding and commercial
tion development in the hardfacing and safety markets.
maintenance and repair businesses. Oscar Konrany has been added as the
Gaebler Michael Sisco [AWS] will represent central regional manager of welding
the company as district manager of the safety. Kourany previously served as dis-
ing products. Gaebler will be responsi- trict sales manager for Jackson Products.
ble for building and managing the com- Mike Neldason [AWS] was appointed
pany's plastic welding business. Prior to director of specialty markets. Neklason
joining the company, Gaebler was busi- was previously the director of sales for
ness manager for Herrmann Ultrason- Kedman Co., a JPI business. Working
ics. He holds degrees in mechanical en- with Neklason in the specialty markets
gineering and accounting from KIB- is Tom Visnack [AWS], national sales
Erfurt and the University of Hamburg. manager for specialty markets.
In addition, Gaebler is currently pursu-
ing a degree in international business.
Member Milestone
Rankin Announces
Appointments DuPont Receives 2000
Presidential Early Career Award
Rankin Industries, Inc., San Diego,
Calif., has announced the appointment John DuPont [AWS], assistant pro-
Sisco fessor of materials science and engineer-
ing at Lehigh University, Bethlehem, Pa.,

ling Positioners has added to an already impressive list

Productivity by over 125 %
~ration welding positioners from 200 to 1250
ty. Compare our price, quality and features.
Call or Fax for free
brochures and price sheet.
We also sell used w e l d i n g p o s i t i o n e r s o f all sizes.
1235 L i n c o l n R o a d • A l l e g a n , M i c h i g a n 4 9 0 1 0
Toll F r e e 8 0 0 - 7 1 0 - 9 9 9 0 • P H : 6 1 6 - 6 7 3 - 6 5 7 2 • F A X : 6 1 6 - 6 7 3 - 1 6 4 4
Circle No. 2 on Reader Info-Card
of awards the highest honor bestowed by
the U.S. government on young scientists
and engineers, the 2000 Presidential
Early Career Award for Scientists and
Engineers (PECASE).
DuPont received the award during a
ceremony held October 24 at the White
House Old Executive Office Building.
Established by the Clinton adminis-
tration in 1996, the PECASE award rec-
ognizes young scientists and engineers
and helps to maintain U.S. leadership
in scientific research. In all, 60 re-
searchers representing nine federal
agencies received PECASE awards for
2000. DuPont was recognized "for ini-
tiating a highly interdisciplinary and col-

80 I JANUARY 2001
laborative research and education ef-
fort in solid free-form fabrication using
Laser Engineered Net Shaping (LENS)
processing."
LENS allows complex metallic parts
to be made directly from a computer-
aided drawing without the need for mold-
ing or tooling. Parts are made layer by
layer using metal powders and substrates,
allowing for the insertion of various ma-
terials to achieve desired properties. The
process decreases manufacturing costs
and time.
DuPont is collaborating with Herman
Nied, professor of mechanical engineer-
ing and mechanics at Lehigh University,
and Scott Hummel, an assistant profes-
sor of mechanical engineering at
Lafayette College on the project. He is
also working with scientists at Sandia Na-
tional Laboratory in New Mexico.
In addition to the PECASE, DuPont
has also received a CAREER (Faculty
Early Career Development) grant and
the Young Investigator Award from the
Office of Naval Research (ONR) this
year. The ONR award will support
DuPont's investigations into the laser
welding of austenitic stainless steels for
advanced double-hulled combatant ships.
In 1999, DuPont received the Ameri-
can Welding Society's Prof. Koichi Ma-
subuchi Award for "outstanding re-
searcher under 40 who has made signifi-
cant advances to the science and tech-
nology of joining materials." He has
twice won or shared the AWS Sparagen
Award for overall best research article
published in the WeldingJournal and the
Jennings Award for best research article
published by faculty and students.
Obituaries
Raymond F. Duhamel, Sr.
Raymond F. Duhamel, Sr. [AWS], of
Vernon, Conn., died October 21.
Duhamel attended Worcester Poly-
technic Institute and received a B.A. in
physics from the University of Connecti-
cut in 1960, which was followed by grad-
uate studies in physics at Trinity College.
Duhamel was employed for 33 years with
different divisions of United Technolo-
gies. While working at Hamilton Stan-
dard, he was involved in electron beam
welding (EBW) and the development of
new EBW equipment. While with United
Technologies Research Center and,
later, United Technologies Industrial
Laser, Duhamel was recognized for his
expertise in laser applications, assisting
many industrial clients with laser instal-
lations and applications. Upon retire-
ment from United Technologies, he be-
came director of applications for Con-
vergent Energy, where he worked for five
years until his final retirement.
Duhamel was a member of the Amer-
ican Welding Society and served on the
C7C and D8E subcommittees on Laser
Welding. He was also a member of the
Laser Institute of America and the Soci-
ety of Manufacturing Engineers.
Duhamel is survived by his wife,
Carol, four sons and daughters-in-law
and grandchildren.
Paul A. Patton
Paul A. Patton [AWS] died on
November 6 at his home.
Patton, a longtime member of the For tree planting and care ~nlotmahon. check
American Welding Society, spent 40 our websute at www.arborday.org.
years in the welding industry. He was in
sales and marketing with Eutectic Indus-
tries, MG Industries and Uniweld Corp.
Patton retired in 1997.
Patton is survived by his wife of 50
years, Vivian (Porterfield) Patton, a
Clear The Air
daughter, Holly Patton DuPlessis, and
one granddaughter, Mimi DuPlessis.
W h e n you plant a tree you're
helping the world breathe a little
Tibor Konkoly easier. Trees produce oxygen and
remove carbon dioxide from the air,
Tibor Konkoly [AWS] passed away on
October 3 in Budapest. helping keep our planet's atmosphere
Konkoly served as Professor Emeri- in balance.
tus and received his education at the Bu-
dapest University of Technology and Trees can help you breathe easier
Economics. In addition, Konkoly was
president of the Hungarian Standard In- in even more ways. Well-tended trees
stitution and represented GTE in the can increase the value of your home
leading bodies of IIW, IFHT and ICND. up to 15c~ or more. Trees that shade
your home from the hot summer sun
and shield it from harsh winter winds
2001 Editorial bring energy costs down. They also
Calendar provide food, shelter, and nesting sites
for songbirds.
FEBRUARY
SPECIAL EMPHASIS The fact is we all benefit when we
Safety and Health plant trees. For more information,
write: Conservation Trees, The
MARCH National Arbor Day Foundation,
• Understanding Welder Nebraska City, NE 68410.
Certification
• Welding in the Shipbuilding Whether in the country or in town,
Industry
• Advances and Applications in trees can make a world of difference.
Welding of Pipe & Tubing
APRIL
2001 Exposition Preview
~ The National
Arbor Day Foundation ®
www.arborday.org
WELDING JOURNAL I 81
 AWS FELLOWSHIPS AND WRC GRANTS-IN-AID

To__c:Professors Engaged in Joining Research

Subject: Request for Proposals for AWS Fellowships and for WRC Grants-in-Aid
for the 2001-02 Academic Year

The American Welding Society (AWS) and the Welding Research Council (WRC) seek to foster university
research in joining and to recognize outstanding faculty and student talent. Each of these two organizations has
its own programs to channel funding into graduate research programs at universities. In recent years, AWS and
WRC have coordinated their award programs and have made their respective selections based on responses to a
joint Request for Proposals. We are again requesting your proposals for consideration by AWS and WRC.

Please note that AWS and WRC have separate selection committees, criteria and objectives as described
below. However, if you wish, you need only provide a single proposal for consideration by the two organizations
in their respective evaluation activities. Of course, only one award, a Fellowship to the Student (from AWS) or a
Grant (from WRC) will be made for any one program of research at a university.

With both organizations, it is expected that the winning researchers will take advantage of the opportunity to
work with industry committees interested in the research topics and report work in progress.

Please note, there are important changes in the schedule which you must follow in order to enable the
awards to be made in a timely fashion. Proposals must be received at American Welding Society by February 5,
2001. New AWS Fellowships will be announced at the AWS Annual Meeting, May 6-10, 2001. WRC will notify
applicants for its Grants by mail by June 1,2001.

THE AWARDS

The Fellowships or Grants are to be in amounts of up to $25,000 per year, renewable for up to three years of
research. However, progress reports and requests for renewal must be submitted for the second and third years.
Renewal by AWS or WRC will be contingent on demonstration of reasonable progress in the research or in graduate
studies. WRC expects awardees to interact with any of its committees working in related areas of research.

The AWS Fellowship is awarded to the student for graduate research toward a Masters or Ph.D Degree
under a sponsoring professor at a North American University. The qualifications of the Graduate Student are the
key elements to be considered in the award. The academic credentials, plans and research history (if any) of the
student should be provided. The student must prepare the proposal for the AWS Fellowship. However, the
proposal must be under the auspices of a professor and accompanied by one or more letters of recommendation
from the sponsoring professor or others acquainted with the student's technical capabilities. Topics for the AWS
Fellowship may span the full range of the joining industry. Should the student selected by AWS be unable to
accept the Fellowship or continue with the research at any time during the period of the award, the award will be
forfeited and no (further) funding provided by AWS. The bulk of AWS funding should be for student support. AWS
reserves the right not to make awards in the event that its Committee finds all candidates unsatisfactory.

The WRC Grant is to the university and professor for support of research in the defined area. The student
need not be identified for consideration by WRC. Thus, if WRC makes the award for a proposal in which the
student has been identified a change may be made at any time without loss of the Grant from WRC. It is hoped
that the WRC funds will seed broader programs and any such plans to obtain follow-on or supplementary support
should be mentioned in the Proposal. Proposals may be for innovative research in new areas or for research of
interest to current WRC Committees. Subjects of interest to WRC Committees include underwater welding,
linepipe welding, evaluating susceptibility to hydrogen cracking, corrosion resisting alloys such as duplex or other
high alloy steels, high-strength welding consumables, hardfacing, automation or other timely subjects.

All proposals received will be considered for an award by WRC. Only those proposals containing suitable
supporting information about the student and identified as having been prepared by the student will be considered
by AWS. Please clearly specify in your cover letter if you intend AWS consideration.
SELECTION

The AWS and WRC selection committees operate separately, AWS may award up to six Fellowships.
WRC will award as many Grants as funding permits. The number will depend on the size of the requests and
the number of renewals from last year's group. Topics selected by WRC's group in recent years have been:

(a) Underwater Welding Consumables Research

(b) Joining of Particulate Reinforced Metal Matrix Composites
(c) ResidualStresses in Weldments
(d) FundamentalStudies on Metallurgical Causes for Reheat Cracking
(e) Analysis of Transient Liquid Phase (TLP) Diffusion Bonding
(f) HydrogenEffects on Cracking of Duplex Steel Welds
(g) BrazingAlloys for Ceramic Substrates
(h) On-Line Underwater Welding Control and Inspection by Ultrasonics
(i) W e l dPool Geometry
(j) Microstructureand Property Development of HSLA 100 and 130 Steel
(k) Crack Growth in Weldments
(I) Causes of Hot Cracking
(m) CorrosionBehavior of Welds

DETAILS

The Proposal should include:

1. Annualized Breakdown of Funding Required and Purpose of Funds (Student Salary, Tuition, etc.)
2. MatchingFunding or Other Support for Intended Research
3. Durationof Project
4. Statement of Problem and Objectives
5. Current Status of Relevant Research
6. TechnicalPlan of Action
7. Qualifications of Researchers
8. Pertinent Literature References and Related Publications
9. SpecialEquipment Required and Availability
10. Statement of Critical Issues Which Will Influence Success or Failure of Research

In addition, for the AWS Fellowship:

° Student's Academic History, Resume and Transcript

2. Recommendation(s) Indicating Qualifications for Research
3. Brief Section or Commentary on Importance of Research to the Welding Community and to AWS,
Including Technical Merit, National Need, Long Term Benefits, etc.
. Statement Regarding Probability of Success

The technical portion of the Proposal should be about ten typewritten pages. Four copies should be sent by
February 5, 2001, to:

Richard D. French
Deputy Executive Director
American Welding Society
550 N. W. LeJeune Rd.
Miami, FL 33126

Yours sincerely,

Frank G. DeLaurier Martin Prager

Executive Director Executive Director
American Welding Society Welding Research Council
 2001-2002
AWS CONGRESSIONAL FELLOW PROGRAM
I. PREFACE
A. Technology is affecting society to an ever-increasing extent;

B. Public policy issues affecting a broad constituency are increasingly based on

technological factors;

C. Informed decisions regarding public policy issues require the input of the
engineering profession, among others;

D. The engineering professional constitutes one of the nation's most valuable resources, and

E. This resource should be applied in the public interest to matters having a

technological content.

II. POLICY
A. AWSdeclares that it is the continuing policy of the American Welding Society to
1. be sensitive to the public's interests;
2. provide government at all levels with advice on engineering matters and
policies affecting the public interest; and
3. maintain a climate of understanding and credibility that will foster
continuing dialogue with the government.

B. As one measure for furthering its policy, The Board of Directors establishes a Congressional Fellow
Program to assist legislators and officials of the Congress in public policy deliberations. Each year,
AWSwill select a member, in a manner herein described, to serve as Congressional Fellow to assist
legislators and other federal officials.

C. It is preferential that AWSand the Fellow's employer share the compensation and the expenses of the
Fellow so that all parties have a financial interest in the program. However, a Fellow may serve with
full employer support, provided that she or he is selected in accordance with this policy and she or he
adheres to all AWSpolicies and guidelines of the program. AWS'sshare shall not exceed the amount
annuallybudgeted. A Fellowmay also participate with no employer support but recognizingthe limited stipend.

D. Although the Congressional Fellow is sponsored by AWS,the Fellow's primary objective is to provide
assistance to Congress while representing the welding engineering profession in objective fashion
without bias or favor toward AWSor her or his employer.

In addition, AWSwill help in furnishing whatever technical assistance a Congressional Fellow will
request of the Society.

E. It is desirable that the Congressional Fellow be familiar with AWSoperations and organizational
structure in order to obtain assistance promptly and efficiently.

F. Congressional Fellows must comply with the AWSpolicy on Conflict of Interest and any appropriate
rules of ethics of the host federal office.
III. PROCEDURE

A. Solicitation of applicants and Selection of Congressional Fellows

. AWSwill solicit applicants through appropriate means, including letters to companies,

announcements in the WeMingJournal,and appeals to the AWSleadership to identify candidates.

. The Candidate Review Committee shall

a. Reviewapplications;
b. Interview highly marked applicants;
c. Identify the best qualified among these for possible selection as a Congressional Fellow;
d. Forward list of recommendations for the AWSCongressional Fellows and necessary support
documents to the Government Affairs Liaison Committee for final selection and approval.

. Individuals chosen to be Congressional Fellow(s) will be assisted by the AWSWashington

Government Affairs Office in his or her placement with the staff of a Representative, Senator
or a congressional committee.

4. The selection of the Fellow will be announced by the President of AWS.

B. Requirements

The requirements for the Congressional Fellow Program are as follows:

1. A Congressional Fellow's term shall be twelve months, beginning in September.

. Government Affairs Liaison Committee shall select the Fellow(s) using objective selection criteria,
including a candidate's application, to determine a candidate's ability to communicate both
orally and in written form, and such other attributes as the committee deems necessary for
a candidate who will represent the welding profession.

. Sex, creed, race, ethnic background and political affiliation are expressly excluded as selection
criteria for Congressional Fellows.

. Fellows shall hold at least the AWSgrade of Member prior to submitting an application for
Congressional Fellow.

5. Fellows shall be citizens of the United States of America.

Deadline for Receiving Applications is February 1, 2001.

For a complete application package, contact:

Richard French
Deputy Executive Director
1-800-443-WELD, ext. 218
American Welding Society
550 N.W. LeJeune Rd.
Miami, Florida 33126
Visit our website http://www.aws.org
 (las
EMPLOYMENT OPPORTUNITIES

Quality Auditing Company (QAC), the company responsible for administering Full-time permanent positions for ex-
the American Institute of Steel Construction's (AISC) Quality Certification Program, perienced fitters, welders, erectors
is looking for a president. The successful candidate will become the individual re- and fabricators in established shop lo-
sponsible for the company that audits over 500 firms throughout the United States cated in the Mountains of Colorado.
Excellent wages and benefits package
a n d many foreign countries. The position will involve the complete managerial re- including insurance and paid vaca-
sponsibilities of QAC including personnel and P&L as well as the growth of the com- tions. World class skiing, fishing and
pany. The ideal candidate has an engineering degree, CWI certification, managerial hunting as well as excellent schools.
experience in 1) structural steel fabrication and erection industries or 2) an inspec-
tion agency performing work in those industries or 3) quality control/quality assur- Please call (970) 524-9632
ance in those industries. Being computer literate and having good communication or fax resume to (970) 524-9633.
skills, both written and verbal are essential. The position will be located in Chicago.
Please send resume to
H.L. Gurthet HIGH-TECH MANUFACTURER
AISC Inc.
One E. Wacker Drive, #3100 $1.7 MM Projected 2000 Sales/ $322k
Chicago, IL 60601-2001 EBITDA machined and fabricated proto-
or email to gurthet@aiscmail.com. types, production components and assem-
blies for the defense and commercial in-
dustries. Fabrication of metal and non-
metal prototypes and production
hardware, testing and inspecting of prod-
ucts. Preferred vendor for the DOD. Ex-
cellent reputation. Well managed, excel-
lent financial controls.
S.Walker - The March Group -
301-604-9408.
email: swalker Ca)marchgroup.com
Staff Engineer
Fortune 500 company has a position open for a staff engineer in Materials
Engineering. The successful candidate will be responsible for assisting the
Technical Director on issues related to materials selection, joining, failure analysis,
and materials development. The position requires a thorough understanding of
material properties (metallic and non-metallic), material behavior characteristics,
and manufacturing processes related to the use of these materials.
10,.,,.0'
Oerlikon Welding has an established
Qualifications: reputation as a global supplier of
Candidate should have a Doctorate's degree in Materials Engineering or welding consumables to diverse in-
Metallurgical Engineering with a minimum of five (5) years experience in heavy dustrial sectors including offshore oil
fabrication. Consideration will be given to applicants with a Master's degree if this and gas production platforms, pipe
has been supplemented with materials or materials joining research and five (5) manufacture, petrochemical and
years experience in heavy fabrication. power generation. We are currently
seeking a qualified individual for the
We offer competitive salary and benefits including: following position.
• Medical/Dental/Life Insurance
• Savings and Stock Investment Plan Sales Executive
• Relocation Assistance • Paid Vacation • Paid Retirement North American Region
• Company Sponsored Technical Education Program
This position is suited to applicants
Applicants selected will be subjsct to a security investigation and must meet eligibility w h o have a metallurgical and weld-
requirements for access to classified information.
Please apply to: ing engineering background together
GBNEII~IXL IDYNAIVIIC5 with experience of sales to large end
Electric Boat users and distributors. The position
Attn: Denise Pierson - D641 will be located in the southern part of
75 Eastern Point Road the USA.
Groton, CT 06340-4989
US CitizenshipRequired - Equal OpportmaityEmployer MIF/D/V
Applicants are requested to email
their CV in strictest confidence to
mail@oerlikonweld.com

S6 I JANUARY 2001
 •~ HORIZON
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W E L D I N G J O U R N A L I 87
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88 l JANUARY 2001
ABICOR Binzel .................................................................... 8 National Standard ............................................................. 13
Airflow Systems ................................................................. 52
All Fab Corp ...................................................................... 80 Praxair ........................................................................ 18&19
American Welding Society ..................................... 2,6,28,34
T.J. Clark ........................................................................... 51
Bernard Welding Equipment ........................................... IFC Tecnar ............................................................................... 22
Thermco ............................................................................ 52
Cor-Met ........................................................................ 21,33
Wegener ............................................................................ 26
Diamond Ground Products ................................................ 53 Weld Hugger ..................................................................... 23
Electron Beam Technologies ............................................ 50
ESAB Welding & Cutting Products ............................. 4,OBC

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Hobart Institute .................................................................. 79
Hornell Inc ......................................................................... 44

Innerlogic ......................................................................... IBC

J.P. Nissen ........................................................................ 50

Jetline Engineering ............................................................ 25

Koike Aronson ................................................................... 23

Lincoln Electric .................................................................. 11

Miller Electric Mfg. Co ................................................. 14&15

Call for Papers

The Tenth International JOM Jubilee Conference on Joining of Materials, JOM-10, is accepting papers for presentation May
11-14, 2001, in Helsingor, Denmark. Organized by the JOM Institute and held biennally since 1981, the conference
encourages the presentation of the latest in welding research and development with an emphasis on relevance to industrial
applications. It attracts engineers, scientists and educators from all over the world.
Papers are invited on, but are not limited to, the following topics:
• Welding processes and systems
• Weldability of materials
• Welding robotization and automation in manufacturing
• Welding instruction
• Artificial intelligence and computer technology in welding
• Weld sensor systems
• Arc stability and metal transfer
• Brazing, soldering and associated nonarc joining processes
Individuals interested in making a presentation should prepare a short abstract and include the name and address of the
author(s), and title of paper. Send it by mail or FAX, no later than February 15, 2001, to JOM Institute Secretariat, Klintehoj
Vaenge 21, DK-3460 Birkerod, Denmark; FAX 45 45 94 08 55; e-mail jom aws@postl0.tele.dk

W E L D I N G I O U R N A L I 89
 A W S Peer Review Panel
All papers published in the WeldingJournarsWelding Research Supplement undergo Peer Review before publication
for: 1) originality of the contribution; 2) technical value to the welding community; 3) prior publication of the material
being reviewed; 4) proper credit to others working in the same area; and 5) justification of the conclusions, based on
the work performed. The following individuals serve on the AWS Peer Review Panel and are experts in specific techni-
cal areas. All are volunteers in the program.

D. Abson D.L. Hallum Principal Reviewers

D. K. Aidun I.D. Harris
Y. Adonyi W. E Gale K.W. Mitehiner
D. G. Atteridge D.A. Hartman
C. E. Albright J.M. Gerken P.E. Murray
R. E. Avery R.T. Hemzacek
J. A. Brooks D.D. Harwig T.M. Mustaleski
S. S. Babu M.J. Higgins
H. R. Castner D. Hauser D.L. Oison
D. J. Ball T. Hikido
M. J. Cieslak G.K. Hicken B.M. Patchett
W L. Ballis J . E . Hinkel
M. J. Cola J.E. Indacochea M.A. Quintana
E Banerjee J. E Hinrichs
C. E. Cross J.L. Jellison T.P. Quinn
T. S. Bannos T. R Hirthe
C. B. Dallam M.Q. Johnson A. Rabinkin
R. E. Beal P. Hochanadel
B. Damkroger R.R. Kapoor B. Radhakrishnan
E R. Beckman D . G . Howden
V. R. Dav~ T.J. Kelly W.G. Reuter
S. S. Bhargava E Howe
S. A. David G.A. Knorovsky R.W. Richardson
B. Bjorneklett C. Hsu
T. DebRoy D.J. Kotecki J. E Saenger
O. Blodgett J.P. Hurley
J. H. Devletian R. Kovacevic M.L. Santella
R. J. Bowers D.L. Isenhour
R. D. Dixon E V. Lawrence, Jr. S.D. Sheppard
J. E. M. Braid J . R . Jachna
P. Dong W. Lin H.B. Smartt
K. L. Brown J. Jaeger
J. N. DuPont J.C. Lippoid B.R. Somers
S. B. Brown B.A. Jones
T. W. Eagar S. Liu D.J. Tillack
J. Bundy J.E. Jones
G. R. Edwards H.W. Ludewig C.L. Tsai
S. N. Burchett W Kanne
J. W. Elmer R.P. Martukanitz G.D. Uttrachi
M. L. Callabresi B. Kapadia
D. E Farson R. Menon D.R. White
D. A. Canonico A. Kar
Z. Feng S.J. Merrick T. Zacharia
K. W Carlson D . D . Kautz
S. R. Fiore R.W. Messier, Jr. Y. Zhou
N. M. Carlson H. W Kerr
L. H. Flasche D.W. Meyer
C. L. Chan D.S. Kim
P. W. Fuerschbach J.O. Milewski
Y. J. Chao J. E King
C. C. Chen S. Kolli
J. C. Chennat P.J. Konkol V. E. Merchant D . D . Rager T. L. VanderWert
B. A. Chin S. Kou M. T. Merlo K. E Rao I. Varol
G. E. Cook J.J. Kozelski W C. Mohr W. Ridgway R T. Vianco
R. E. Cook H . G . Kraus A. J. Moorhead A. Ritter K. K. Wang
R. A. Daemen K.W. Kramer T. Morrissett M.N. Ruoff D. K. Watney
S. Daniewicz J.J. Kwiatkowski L. W Mott D.J. Rybicki M. M. Weir
J. C. Danko E Lake C. G. Mukira E. E Rybicki C. E. Wirsing
J. DeLoach J . D . Landes K. Mundra K. Sampath C. E. Witherell
G. den Ouden J.W. Lee O. Myhr J.M. Sawhill, Jr. W E. Wood
X. Deng A. Lesnewich K. Nagarathnam A.P. Seidler J. Xie
E J. Ditzel G.K. Lewis E Nagy L.R. Shockley Y. E Yang
R. J. Dybas M.V. Li S. Nasla L.E. Shoemaker H. Zhang
H. W Ebert T.J. Lienert T. W Nelson M. Sierdzinski J. Zhang
G. M. Evans M.J. Lucas J. L. Novak T.A. Siewert S. Zhang
R. G. Fairbanks R . O . Lund A. Ortega S.D. Smith Y. M. Zhang
D. A. Fink K.A. Lyttle M. Parekh T.M. Sparschu
D. W. Fitting B. Madigan R. A. Patterson W.J. Sperko
W. R. Frick M.C. Maguire R. L. Peaslee D . E . Spindler
E. Friedman A.K. Majumdar D. D. Peter J. E . Stallmeyer
Y. R Gao M. Manohar E. Pfender R.J. Steele
J. A. Gianetto A. E Manz M. Piltch P.L. Sturgill
E E. Gibbs K. Masubuchi L. E. Pope D. W Trees
R Hall J. Mazumder N. Potluri A.J. Turner
M. Prager J.J. Vagi

90 I JANUARY 2001
 WELDING RESEARCH
SUPPLEMENT TO THE WELDING JOURNAL, JANUARY2001
Sponsored by the American Welding Society and the Welding ResearchCouncil
The Statistical Models for Estimating the
Amount of Spatter in the Short Circuit Transfer
Mode of GMAW
A study shows the optimal model for estimating the amount of spatter when consid-
ering arc extinction in short circuit transfer mode, using multiple regression analysis
ABSTRACT. Arc stability in the short cir-
cuit transfer mode of gas metal arc weld-
ing (GMAW) has a close relationship
with the regularity of metal transfer, and
metal transfer depends on several physi-
cal quantities (voltage, current, materials,
etc.) related to the growth and transfer of
the metal droplet. When the metal
droplets uniformly transfer to the weld
pool, the welding current and arc voltage
waveforms become regular. When they
are not uniformly transferred, the shape
of the waveforms become very irregular,
and hence, much more spatter is gener-
ated. The purpose of this study was to de-
velop a statistical model able to estimate
the amount of spatter quantitatively using
the waveforms in short circuit transfer
mode of GMAW. In this study, the spatter
was gathered under several welding con-
ditions, and, at the same time, the wave-
forms were measured. The factors repre-
senting the characteristics of the
waveforms were calculated from the
measured waveforms. Four different lin-
ear and nonlinear regression models
were proposed to estimate the amount of
spatter, performing the multiple regres-
sion analysis between each model and
the amount of spatter. The estimated re-
sults were compared to the amount of
M. J. KANG is with the Welding & Structural
Integrity Research Team, Research Institute of
Industrial Science and Technology, Pohang,
Korea. S. RHEEis an Associate Professorin the
Department of Mechanical Engineering,
Hanyang University, Seoul, Korea.
BY M. J. KANG A N D S. RHEE
spatter under several welding conditions,
and the best model, which appropriately
estimates the amount of spatter, was de-
veloped.
Introduction
The GMAW process characteristically
changes metal transfer modes due to
complex actions of forces related to the
melting phenomena of the electrode. Re-
cently, much research has been per-
formed on the arc stability estimation and
the metal transfer phenomena as mea-
suring technologies have developed.
Adam and Siewert (Ref. 1) performed a
statistical analysis for parameters from
the measured signals of welding current
and arc voltage, then classified the metal
transfer modes. Ogunbiyi and Norrish
(Ref. 2) proposed a mathematical index
model, which consisted of some signifi-
cant variables, and classified the metal
KEY WORDS
Transfer Mode
Short Circuiting
GMAW
Spatter
Regression Analysis
Arc Stability
WELDING RESEARCH SUPPLEMENT I I-s
transfer mode using the proposed index.
Arai, et al. (Ref. 3), showed there was a
close relationship between the standard
deviation of arc time and arc stability
based on human experience in short cir-
cuit transfer mode of CO 2 arc welding.
Lucas (Ref. 4) revealed the distribution
for the standard deviation of the short cir-
cuit peak current and the short circuit pe-
riod under various welding voltage con-
ditions, using several types of welding
power sources, and proved there was a
relationship between these standard de-
viations and arc stability. Mita, et al. (Ref.
5), obtained the standard deviations of
the waveform factors (the arc time, the
short circuit time, the average arc current
and the average short ci rcu it cu rrent, etc.)
from the measured waveforms for weld-
ing current and arc voltage. He proposed
several regression models, which were
composed of the waveform elements and
their standard deviations. He also devel-
oped an optimal regression model
among the models by using multiple re-
gression analysis, based on the assess-
ment of some experienced workers, and
considered the model as the arc stability
estimation index. He showed if the index
was high, then the arc would become un-
stable, and if it was low, the arc could be
estimated as stable. Shinoda and
Nishikawa (Ref. 6) proposed an index
that could distinguish the arc stability by
using welding current and arc voltage
waveforms in short circuit transfer mode.
Rehfeldt, et al. (Ref. 7), distinguished the
arc stability using the signals of arc volt-
 700

5O0
400

2O0

~o50 T
0
8O ( ~ '
>
~ , ,,o T

4O

....: & 2O

0 ~ 0 , , ,
o.2 o.22 o.24 o.26 0.28 o.3 0.1 0.15 O.2 O.25

time (see) time (sec)

Fig. 2 - - Waveforms of the arc voltage and welding current at a wire feed rate of
Fig. I - - The experimental apparatus setup used in this 3.4 re~rain. A - - 2 2 V; B - - 19 V.
study consists of a welding robot, a welding power
source, sensors for measuring the signals of welding cur-
rent and arc voltage, an A/D converter and a computer tion of the spatter are the metal the four regression models composed of
to gather the signals and to analyze the waveform char- droplet size and the magnitude the remaining factors that were not elim-
acteristics from the signals. of forces acting on the droplet. inated. Also, the factors that have high
Droplet size and force magni- probability values were removed.
tude are dependent on welding Hence, each estimation model that can
Table I - - Welding Conditions and the current and arc voltage waveforms. predict the amount of spatter is pro-
Number of Experiments per Setting Therefore, when these elements are sta- posed. The estimated results predicted
Condition tistically analyzed and when the correla- by the models were compared to the
tion between the amount of spatter and amount of spatter. Finally, the best model
Wire C T W D Welding No. of Welding the many regression models composed of for estimating the amount of spatter was
Feed (mm) Voltage Experiments these elements are investigated, an index proposed.
Rate (V) per Setting to quantitatively estimate arc stability can
(m/min) Condition be developed. The model to predict the Experimental Procedure
3.4 15 19V - 25V 6 amount of spatter can become a quanti-
15 20V - 26V 6 tative criterion to estimate arc stability The shielding gas used in the welding
6.0 20 21V - 27V 3 since arc stability is closely related to the experiments was 100% C O 2 with a flow
25 21V-27V 3 amount of spatter. In addition, the model rate of 20 L/min, and the electrode used
15 21V-27V 3 can become an important means to pre- was AWS ER70S-6 with a diameter of 1.2
7.3 20 22V - 28V 4 dict weld quality. It can also be used as mm. The workpiece was ASTM A36M
25 21V-27V 3
8.6 20 23V - 27V 6 an index to determine what changes in with a thickness of 6 mm. The welding
welding parameters must be made for speed was set at 5 mm/s and the total
good weld quality. welding time was 60 s (300 mm in
Therefore, the aim of this study was to length). The bead-on-plate welding was
age in short circuit transfer mode. Most develop a statistical model consisting of performed under various welding condi-
results reported so far were based on arc several waveform factors that closely tions, as shown in Table 1. Four wire feed
stability or the metal transfer mode, using represent waveform characteristics of rates of 3.4, 6.0, 7.3 and 8.6 m/min
the regularity of waveform factors or re- arc voltage and welding current to pre- (Table 1) were used. With the 3.4 m/min
lationships between the welder's knowl- dict the amount of spatter in short circuit wire feed rate, welding experiments were
edge and some models in order to esti- transfer for GMAW. Spatter, under sev- performed in 1-V increments from 19 to
mate the arc state. But the models were eral welding conditions, was gathered 25 V with a contact tube-to-work dis-
not explained quantitatively and even and the amount was measured. At the tance (CTWD) of 15 mm. To reduce ex-
lacked statistical verifications. There is a same time, the signals for welding cur- perimental error, welding was performed
possibility a large error can occur in pre- rent and arc voltage were measured, and six times under the same conditions.
dicting the arc stability with these mod- the waveform factors (the waveform ele- With the wire feed rate of 6.0 m/min,
els. ments and the standard deviations of welding experiments were performed in
In short circuit transfer of GMAW, the those elements) were obtained from the 1-V increments from 20 to 26 V with a
spatter, as well known, is generated at the measured signals. Four different linear CTWD of 15 mm. Welding was per-
instant the short circuit begins, or when and nonlinear regression models com- formed six times under the same condi-
the short circuit finishes and the arc is ig- posed of the waveform factors are pro- tions. Welding experiments with a 20-
nited again. If the short circuit time or the posed. A correlation analysis between mm CTWD were performed three times
arc time is irregular, much more spatter the amount of spatter and the constitu- at 1-V increments from 21 to 22 V. The
will be generated than when it is regular. tion factors of each model was executed, number of experiments performed for
Hence, it can be said the amount of spat- and some factors that cause multi- this study was 226.
ter is closely related to arc stability. The collinearity were eliminated. Multiple The welding voltage and current were
main factors that influence the genera- regression analysis was performed on used as setting variables. Welding cur-

2.s I JANUARY 2001


• GTW'D15~
i, . !
l |
18 19 20 21 22
welding voltage ( V )
8
CTWD2~ rm~
o 2
2 t
0 t ....... !t,,i,,I
I l
~ , l l m i l t A
u l l t
Fig. 3 - - The amount of spatter as the welding voltage changes at different wire feed
rates. A - - Wire feed rate 3.4 m/rain; B - - 6 m/rain; C - - 7.3 m/min; D - - 8 . 6 m/min.
rent was measured with a Hall sensor at-
tached to an earth cable. Arc voltage be-
tween the output terminals of the weld-
ing power source was measured. The
measured signals were transferred into
the computer via an A/D converter,
which has a maximum sampling rate of
200 kHz. The noise on the signals was re-
moved by a digital low-pass filter with
200 Hz cut-off frequencies. The welding
process was performed using a welding
robot and a constant-voltage-controlled
welding power source of transistorized
inverter type. In addition, spatter gener-
ated during welding was captured using
a brass device. It was not splashed out
during welding since this device was de-
signed to envelop the torch and the work-
piece completely. The sampling rate for
measuring the waveforms was 5000 sam-
ples/s. The waveform signals were col-
lected 10 s after the beginning of the
welding at 20-s intervals.
Waveform Factors in Short Circuit
Transfer Mode
In short circuit transfer mode, the arc
voltage and welding current waveforms
become regular under optimal condi-
tions - - Fig. 2A. If welding voltage is too
low, arc extinction occurs (Fig. 2B), and
16
• CTWD 15sm~ ~,
14 • CTWD 20 mm
~ 12 " c1"wD25"=" t 14o
• s ! lln,,!l
23 24 25 28 19 20 21 22 23 24 25 26 27
welding voltage ( V )
I • CTWD20m
'.
.~ 4
[ N o
! 20 s were calculated. When arc voltage
t i,
"
0
the waveforms are very irregular. In this
study, waveform characteristics that ex-
pressed the short circuit transfer mode
obtained to develop the spatter predic-
tion model used the following signal pro-
cessing methods.
Threshold voltage and average arc
voltage were used to distinguish the arc
time and the short circuit time from the
filtered signals. The positions calculated
were the rising one or the falling one to
threshold voltage. If average arc voltage
between two positions was higher than
the threshold voltage, the period when
the voltage was maintained higher than
the threshold voltage was regarded as the
arc time (Ta ). If the voltage was lower
than that, the period was regarded as the
short circuit time (Ts ). Adding the arc
time to the short circuit time was re-
garded as a period of short circuit trans-
fer (T). The maximum and minimum cur-
rents for a period of short circuit transfer
were regarded as the short circuit peak
current (Ip) and the instantaneous short
circuit current (Is), respectively. The aver-
age current during a short circuit transfer
(I) was calculated. The time interval
where arc voltage was maintained higher
than 50 V was regarded as the arc ex-
tinction time [T(Voc)], and it was re-
moved in calculating the above wave-
200
~ 180
160
120
"~ 100
~ so
60
.~ 20 • • . . . .
~ o
= -20
18 19 20 21 22 23 24 25 26 27
welding voltage (V)
28
Fig. 4 - - Number of arc extinctions with respect to welding
voltage at a CTWD of 15 mm.
form elements (Ta, Ts,T, Ip, Is and T).
Then, the number [N(Voc)] and the sum
[T(Voc)sum] of these time intervals during
became higher than 50 V, it indicated the
voltage between the contact tube and the
workpiece became the open circuit volt-
age, and welding current during this pe-
riod became zero. In addition, the stan-
dard deviations of waveform elements,
such as s[T], S[Ta], S[Ts], Slip], s[I s] s[T]
and s[T(Voc)] were obtained as other
waveform factors to express the wave-
form characteristics of short circuit trans-
fer mode precisely.
Development of Models for
Estimating the Amount of Spatter
The Characteristics of the
Spatter Generation
Figure 3 shows the amount of spatter
under several welding conditions. Ac-
cording to Fig. 3, it can be seen that little
spatter is generated at optimal welding
voltage, and that much spatter is gener-
ated when welding voltage is higher or
lower than the optimal voltage.
Linear RegressionModel in Overall Region
A linear regression model was com-
posed as Equation 1, using the 16 factors
obtained during 20 s of welding. A cor-
relation analysis was performed to inves-
tigate how much influence these factors
had on the amount of spatter. Table 2
shows the correlation coefficients be-
tween each factor and the amount of
spatter, and between the factors with
each other overall.
Y -- a + bT + cT a + dT s + elp + fl s
+ gi + hs[T] + is[Ta] + js[T s] + ks[Ip]
+ 1s[I s] + ms[T] + nN(Voc) + oT(Voc)
+ ps[T(Voc)] + qT(Voc)sum (1)
According to Table 2, the factors hav-
ing a high correlation coefficient with the
W E L D I N G RESEARCH SUPPLEMENT I 3-s
 14 16 model to predict the amount of spatter
using the remaining 13 factors, as shown
12 Fq "" = ~" 14 Fq • in Equation 2.
10 =e 12

8
•

"•
• •

•
.
~

~ 10
8 •
o" .
•
•

•
•

Y
+
= a + bT a + cT s + dip + el s + f[
gs[Ta] + hs[T s] + iS[Ip] + js[I s]
+ ks [I] + 1 N (Voc) + mT(Voc)
[4 + ns[T(Voc)] (2)

2 ~ 2 If some constitution factors in Equation 2

0 0 produce an error in predicting the
0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14 16 amount of spatter, then those factors
predicted result predicted result must also be eliminated. So, a hypothe-
16 16
sis test with respect to the factors in
Equation 2 was performed. In order to
14 F~ • 14 decide the acceptance or the rejection of
12 • "~- 12 the null hypothesis, a significant proba-
,o .; "~ 10 bility on the t-distribution was exam-
8 ~ "" ined, as shown in Table 3. In this study,
it was assumed the significance level
i 6 "6 6 was 5%. According to Table 3, the ob-
4 ~ served probability values of Ip, T, s[Ts],
2 f'. - s[]'], N(Voc), T(Voc) and s[T(Voc)] were
0 62.03%, 74.83%, 13.54%, 17.55%,
0
0 2 4 6 8 10 12 14 16
0 2 4 6 8 10 12 14 16
37.41%, 80.71% and 19.51%, respec-
predicted result predicted result tively. As the observed probability values
of these factors are much higher than the
Fig. 5 - - Comparison between predicted results by several proposed estimation models and the 5% significant level, the null hypothesis
amount of spatter. A - - Linear regression model for the region overall; B - - combined linear re- must be accepted and the factors were
gression model; C - - nonlinear regression model for the overall region; D - - combined non- eliminated in a model equation, as
linear regression model. shown in Equation 3.

Y = a + bT a +cT s + dl s + es[Ta] +
fS[Ip] + gs[I s] (3)
amount of spatter were T, Ta, s[T], S[Ta] factors have the same influence on spat-
md S[Ip] . In addition, the correlation co- ter generation. That is, these factors can The multiple correlation coefficients
,~fficients between T and Ta, s[T] and bring about the multicollinearity. Thus, between the prediction by Equation 3
s[Ta] , and N(Voc) and T(Voc)sum were T, siT] and T(Voc)sum were eliminated in and the amount of spatter was 0.874.
nearly I. Hence, it can be regarded these this study. So, we can make a linear The significant probability on the factors

Table 2 - - Correlation Coefficients between Each Factor and the Amount of Spatter, and between the Factors with Each Other in the Linear
Regression Model

Factors T Ta Ts Ip Is T s[T] s[Ta] s[TJ s[l,l s[l,l s[i] N(Voc) T(Voc) s[T(Voc)] T(Voc)sum
T I
Ta 0.9921 I
Ts -0.0528 -0.177 I
Ip 0.4154 0.3573 0.4161 1
Is 0.37417 0.4283 -0.475 0.54561 1
I -0.0524 -0.058 0.0475 0.6639 0.6528 1
s[-r] 0.94708 0.9367 -0.026 0.32129 0.2815 -0.191 1
sITa] 0.95742 0.9542 -0.085 0.31803 0.3214 43.183 0.9961 1
s[Ts] 0.0752 -0.024 0.7847 0.33896 -0.311 43.034 0.2389 0.1634 1
Slip] 0.33501 0.286 0.3523 0.3620 0.1085 0.0822 0.5085 0.4574 0.7222 1
s[I s] -0.091 -0.159 0.5543 0.2569 43.155 43.095 0.1171 0.0634 0.7805 0.7104 1
s[~'] -0.1568 -0.249 0.7528 0.4116 -0.219 0.089 -6E-06 -0.059 0.8464 0.6985 0.9231 1
N(Voc) -0.1363 -0.202 0.5374 0.1448 -0.257 43.201 0.0666 0.015 0.7266 0.662 0.9517 0.8847 1
T(Voc) -0.0437 -0.122 0.6315 0.1552 -0.419 -0.234 0.1459 0.0909 0.7855 0.6051 0.7762 0.8015 0.7569 1
s[T(Voc)] -0.1628 -0.243 0.6564 0.1438 -0.432 -0.203 0.0271 -0.029 0.7865 0.5884 0.8186 0.8466 0.8121 0.9262 1
T(Voc)sum -0.1405 -0.199 0.4815 0.1168 -0.241 43.227 0.0649 0.0153 0.6896 0.655 0.9412 0.8598 0.9815 0.7535 0.804 1
Spatter 0.91983 0.723 -0.109 0.1746 0.2615 -0.163 0.7457 0.7361 0.1749 0.5019 0.1986 0.0423 0.1799 0.0893 0.0129 0.1797

Table 3 - - Observed Probability Values of Factors in Linear Regression Model (Ref. 2)

Factors Ta Ts Ip Is T s[Ta] s[T s] S[lp] S[ls] s[T] N(Voc) T(Voc) s[T(Voc)]

P-value 5.8E-20 0.0009 0.6203 0.00522 0.7483 7.2E-13 0.1354 0.0029 2E-05 0.1755 0.3741 0.80714 0.19516

4 - s I JANUARY 2001
 .•5 ~. 1.6

~
....*.... pn~lit~dmmlz - - e - - l i n e a r regr~sion model in overall region
..-*-.. pnxlz-~lrm.~ ....~...- combined linear regression model
--@--- mountofslmttet
~4 .-~4 1.4 - --g6---nonlinear regression model in overall region
- - n - - combined nonlinear regression model
_ 1.2
| 3
,~ 1.0
II
",~ f 2 ~ 0.8
1 tX I 3
• 1 e~ 0"6
0.4
i0 0
19 20 21 22 23 24 25 26 0.2
19 20 21 22 23 24 25 26 !8
welding voltage (Y)
~5
welding voltage (V)
~ 0.0
18 19 2) 21 22 23 24 25 26
C~ 15ram [ ~
......... 1 ~ ,x~ull welding voltage (V)
smo~nt~ i p s ~ 4
--4t-.- ram.hiof ~aJ~m"

3 Fig. 7 - - Average rms errors between the predicted results

and the amount of spatter at a wire feed rate of 3.4 m/min.
42

i
~0 18 19 20 21 22 23
welding voltage (V)
Fig. 6 - - Comparison of the prediction by the I/near/nonlinear regression models and the amount
of spatter at a wire feed rate of 3.4 m/min. A - - Linear regression model for the overall region;
B - - combined linear regression model; C - - nonlinear regression model for the overall region;
D - - combined nonlinear regression model.
Table 4 - - Observed Probability Values of Factors in Linear Regression
Factors Y-intercept
P-values 0.001478
of Equation 3 was reassessed, as shown
in Table 4. With these coefficients, the
linear regression model shown in Equa-
tion 4 was developed.
Y = 2.8768 + 0.8658T a- 1.42Ts-
0.041s- 0.89siTa] + 0.0281 slip] +
0.052s[Is]
Linear Regression Model in the
Separated Region
Figure 4 shows the number of arc ex-
tinctions with respect to the welding volt-
age when the CTWD was set at 15 mm
and the wire feed rates were set at 3.4
and 6.0 m/min. In Fig. 4, it is revealed arc
extinction takes place much more when
the voltage is lower than the optimal volt-
age, and it does not take place when the
voltage is higher than the optimal volt-
age. Considering the results of Figs. 2 and
4, it can be seen the mechanism for spat-
ter generation is different depending on
the welding voltage. Thus, it is necessary
24 25 26
ol
18 19 20 21 22 23 24
welding v•ltage ( V )
Ta Ts Is s[Ta]
5E-26 2.1E-19 3E-14 1E-15
to separate the region where arc extinc-
tion exists or does not exist in order to
develop the regression models for esti-
mating the amount of spatter. In this case,
the factors that establish each regression
model may become different.
(4) Linear Regression Model in the Region
with Arc Extinction
A correlation analysis with 16 factors
was performed in the region where arc
extinction occurs. Like the overall region,
the correlation coefficients between T
and Ta, s[T] and S[Ta], and N(Voc) and
T(Voc)sum were nearly 1, and then the
factors T, siT] and sT(Voc)sum were
eliminated in Equation 1. Table 5 shows
the correlation coefficients between each
factor and the amount of spatter in the re-
gion with arc extinction.
In Table 2, T, Ta, s[T] and s[Ta] had
high correlation coefficients with respect
to the amount of spatter. These factors in
Table 5 showed very low correlation coef-
ficients, whereas, slip], s[Is], s[]'] and
25 26
N(Voc) showed high correlation coeffi-
cients. The significant probability on the
remaining factors not eliminated was ex-
amined. The observed probability values
of Ta, [, s[Ta], siTs], Slip], s[Is], T(Voc) and
s[T(Voc)] were 38.25%, 2.3%, 21.7%,
59.9%, 99.76%, 7.97%, 7.42% and
40.015%, respectively. As these values
were higher than the significance level,
these factors were eliminated. Here, even
though the observed probability value of
the factor, i, was 2.3%, the null hypothe-
sis for the factor was accepted. This is be-
cause the observed probability value of
slip] s[Is] the factor became higher than 5% when
6.21E-07 3E-18 the factors were eliminated one by one
from the highest value.
Equation 5 was obtained by applying
the coefficients of the remaining factors
in Equation 1. The multiple correlation
coefficients between the estimated re-
sults of Equation 5 and the amount of
spatter were 0.931. It was higher than the
multiple regression coefficient of Equa-
tion 4, which was 0.874.
Y = - 2.683 + 0.50103T s -
0.0141p + 0.040311 s + 0.01568s[T]
+ 0.0077N(Voc) (5)
Linear Regression Model in the Region
without Arc Extinction
In the region without arc extinction,
N(Voc), T(Voc), s[T(Voc)] and T(Voc)sum
were among the 16 factors of Equation 2
not generated; therefore, they must be
eliminated from Equation 1. In addition,
as the correlation coefficients between T
and Ta, and between s[T] and s[Ta] were
near 1, T and s[T] were eliminated. Table
6 shows the correlation coefficients be-
tween each factor and the amount of spat-
ter in the region without arc extinction.

W E L D I N G RESEARCH SUPPLEMENT I 5-s

Table 5 - - Correlation Coefficients between Each Factor and the Amount of Spatter in the Region with Arc Extinction

Factors T Ta Ts Ip Is f s[T a] s[T a] s[T s] slip] s[I s] s[f] N(Voc) T(Voc) s[T(Vo~)]
Spatter 0.0593 0.0437 0.1235 0.230 0.351 -0.006 0.431 0.3666 0.6504 0.7650 0.8886 0.8816 0.8436 0.4949 0.483

Table 6 - - Correlation Coefficients between Each Factor and the Amount of Spatter in the Region without Arc Extinction

Factors T Ta Ts Ip Is T s[T] sIT a] siT s] s[lp] s[l s] s[~]

Spatter 0.8165 0.8267 -0.1644 0.1757 0.2592 -0.2729 0.7914 0.7876 0.2565 0.6562 0.1398 -0.3033

11.6 ~'80
'~ ' I---~-l~,~==io, mod©li. . . . u~gio, '~
_ '~"
.~= 4.5 --e-- bccar r©gressionmod©l inov¢~ll~ion

i
~Imz~ r¢lK~ion 11~1 lit ~,~raIIregion
:.- A-.. combined linear tegr~sionmodel
--~... nonlinearreste~eien model in ov~'aU ~¢gion
--I~--oombined nonlinear ~ i o n model
~.~. / " - " .... bined linear regression moriel ! ....A--.combio~llinearmg~ssion mo~l
~ 1.0 l---~.-.nonlmear rcFsaion model in ovc¢llllregion --~-.ne~Jinear regxessionmodel in overall region
I= ~ /--O--combinednonlineerreBrenionmodel ~ ~ 3.5 --0--combinednonlinc~regre~Bionmodel

fN =.:= i
06
I i :E.-" I,.5 i'

'~ .-6 ~

!i:.1! ['...
!~0.0 I0.0 , '
19 33 21 22 23 24 25 26 27 28 ~ ~ 19 33 21 22 m 24 25 26 2"/ 28 ~ ~ 19 20 21 22 23 24 25 26 27 28

welding voltage(V) welding voltage(V) welding voltage(V)

Fig. 8 - - Average rms errors between the predicted results a n d the a m o u n t o f spatter at a wire feed rate o f 6 m/min. A - - C T W D 15 m m ; B - - C T W D
2 0 m m ; C - - C T W D 2 5 ram.

•~ 5.0 linear vegre~imt model in overall region

. =5 --41---linearregre~iola model in overall region
I --O-- linear regressi~mmodcl in overall region

!"I ,.o
-.~,--.combioodlio~at~ i o n m o d c l I *'~()3.0 .-&--.combited lire~re1~'~sionmodcl A-- combined linear regre~,~lionmodel
....
--@-.nonlinaLrreBn~uionmodelinov~alI~gion , ~ --~-.nelgh-,~legn:uie~rnodelinov~gn:gion ~ ~ 4.0 --sk--nonlinearregression model in ov~all region
- - 0 . - combioed nonlinest rvgreuion model [ ~.~ --O--combined nonlinvar~ i o n model -_r.-- ~ b i ~ d nonl~ear rogre~ion model

3.0
1
e

ii=.°
i i t.o
' , ~ 1.5 ~ "~2.o

! It.o
,,:1

"go5
~o.0
20 21 22 23 24 25 26 27 28 21 22 23 24 25 26 27 28 29 20 21 22 23 24 25 26 27 38
welding voltage(V) welding voltage(V) welding voltage (V)

Fig. 9 - - Average rms errors between the predicted results a n d the a m o u n t o f spatter at a wire feed rate o f 7.3 m/min. A - - C T W D 15 m m ; B - -
C T W D 2 0 m m ; C - - C T W D 2 5 mm.

The results of the correlation analysis served probability values for them were Nonlinear Regression Model in the
for Table 6 were very different from those larger than 5%. Applying the coefficients Overall Region
in the region with arc extinction, as of the remaining factors to Equation 1, in
shown in Table 5. Especially, the correla- the region without arc extinction, a linear In the correlation analysis of Table 1,
tion coefficients of T, Ta, s[T] a n d s[T a] regression model for estimating the the correlation coefficients between each
with the amount of spatter (Table 5) are amount of spatter was obtained (see factor and the amount of spatter express
very low values, but they showed a Equation 6). The multiple correlation co- only the linear relationship. Sometimes,
higher value in the region without arc ex- efficient between the estimated results of it may have a high nonlinear correlation
tinction. Thus, it can be seen the mecha- Equation 6 and the amount of spatter was coefficient, although a factor has a low
nism of spatter generation in the region 0.9165. It is much higher compared to linear correlation coefficient. Hence, a
without arc extinction differs from that in that of Equation 4, which was 0.874. nonlinear regression model could be
the region with arc extinction. The sig- considered, as shown in Equation 7.
nificant probability analysis on the re- Y = 5.697 + 1.0534T a
maining factors in Equation 1 was per- + 0.02421p - 0.0651 Y = a.-I b. TaC. Tsd. Ipe. Isf. Tg
formed in the region w i t h o u t arc - 1.5609s[T a] + 2.5924s[T s] • s I T ] h • s I r a ] i . s[Ts]J -S[Ip]k

extinction. As a result of the analysis, T s,, + 0.0704s[lp] - 0.1496s[I] (6) • s[ls]l • s[I]m • N(Voc)n • T(Vcc)a~°
Is and s[I s] were eliminated since the ob- • s[T(Voc)avg]P. T(Voc)sumq (7)

6-s I J A N U A R Y 2001
By taking the logarithm on both sides,
Equation 8 is obtained. It becomes a lin-
earized model similar to Equation 2.
l n Y = a* + blnT + c l n T a
+ dl nT s + el nip + fl nl s
+ gln]'+ hlns[T] + ilns[T a]
+ jl ns[Ts] + kl nS[Ip] + I1 ns[I s]
+ ml ns[]'] + nl nN(Voc)
+ o1 nT(Voc)avg + pl ns[T(Voc)avg]
+ ql nT(Voc)sum (8)
Where a* is lna. Since the correlation
coefficient between lnT and l n T a , be-
tween lns[T] and lns[Ta], and among
InN(Voc) 1 nT(Voc)avg and 1 nT(Voc)sum
was almost 1, the factors, lnT, lns[T],
1 nT(Voc)avg and 1 nT(Voc)sum were elim-
inated. The significant probability of the
remaining factors was checked. As a re-
sult, the observed probability values of
1nTa, 1 nT s, 1 nip, 1 nl s, 1 ns[Ts], 1 ns[T] and
1 nN(Voc) were larger than the significant
level of 5%. So, these factors were elim-
inated. Therefore, Equation 9 was pro-
posed as a nonlinear regression model
for the overall region• The multiple cor-
relation coefficient between the esti-
mated result of the regression model,
Equation 9, and the amount of spatter
was 0.91 09. This was much higher than
the multiple correlation of Equation 4,
which was 0•874.
Y = 0.010451 • T-1.12761 S[Ta]1.214463
•
. S[Ip]1.201309.S[ls]0.644028
• S[T(Voc)avg]~)-02396 (9)
Nonlinear Regression Model in
Separated Region
Nonlinear Regression Model in the Region
with Arc Extinction
Equation 8 was also used as a nonlin-
ear regression model in the region with
arc extinction. As the correlation coeffi-
cients between T and Ta, between s[T]
and s[Ta], and between N(Voc) and
T(Voc)sum were near to 1, T, s[T] and
T(Voc)sum were eliminated in Equation
8. In the region with arc extinction, the
significant probability of the remaining
factors was checked• As a result, a non-
linear regression model was established,
as shown in Equation 10. The multiple
correlation coefficient between the esti-
mated result of Equation 10 and the
amount of spatter was 0.9581. It was a
better result than the linear regression
model of Equation 5, 0.931, and of the
nonlinear regression model of Equation
9, 0.9109.
Y = 0.33823• Ta1"1681.Ts1.5313
• Ip.-4.3293. Is1.7668.sIT
L•sJ1~3.5712
s[l]2.6431 . N(Voc)0.2315
• s[1-(Vcc)avg]~).0119 (1 0)
Nonlinear Regression Model in the Region
without Arc Extinction
In the region without arc extinction,
the correlation coefficients between T
and Ta, and siT] and s[Ta] were nearly
1 ; therefore, T and s[T] were eliminated
in Equation 8. The significant probability
was investigated with the remaining fac-
tors. From the results, the regression
model of Equation 1 1 was established as
a nonlinear regression model in the re-
gion without arc extinction. The multiple
correlation coefficient between the esti-
mated value of Equation 11 and the
amount of spatter was 0.927. It can be
considered that the estimated result of
Equation 1 1 shows a better performance
than that of the nonlinear regression
model, Equation 6, whose coefficient
was 0.91 65 in the same region.
Y = 0.01 1628 • l_1.12975
. S[Ta]1.1481 . S[Ip~'1.45698
.S[I]-2.4543 (11)
Results and Discussion
Estimating Performance of Linear and
Nonlinear Regression Models on the
Amount of Spatter
Figure 5 shows the amount of spatter
estimated by each proposed regression
model. Figure 5A is the linear regression
model for the overall region, Equation 4,
and Fig. 5B is the combination of two
separated linear regression models,
Equations 5 and 6. Figure 5C is the non-
linear regression model, Equation 9, and
Fig. 5D is the combination of two sepa-
rated nonlinear regression models, Equa-
tions 10 and 1 1. According to Fig. 5, the
estimating performance of these models
have a linear relationship with the
amount of spatter, as determined by ex-
periment. The spatter estimation from the
linear model of Equation 4 (Fig. 5A)
showed a larger error than the other
models where the amount of spatter was
small. In that region, the estimating per-
formance of the nonlinear regression
models (Fig. 5C and 5D) is better than the
linear models - - Fig. 5A and 5B. How-
ever, when a large amount of spatter was
generated, the estimating performance of
these models was poor, while the com-
bined linear regression model (Fig. 5B)
had a much better estimating perfor-
mance when compared to the others.
Fitness of Linear and Nonlinear
Regression Models
Figure 6 shows how accurately the
W E L D I N G RESEARCH SUPPLEMENT J 7-s
linear and nonlinear models estimated
the amount of spatter with respect to the
change in the welding voltage, when the
wire feed rate was 3.4 m/min. Figure 7
shows the average root-mean-square
(rms) errors between the amount of spat-
ter and predicted results by the proposed
models under those conditions. Accord-
ing to Figs. 6 and 7, it can be seen the
nonlinear regression models express the
amount of spatter more accurately than
the linear regression models. Especially
where the amount of spatter was small,
the estimation errors by the nonlinear re-
gression models were near zero. How-
ever, where the amount of spatter was
large, the estimation errors by the non-
linear regression model were greater
overall. Also, even in the nonlinear re-
gression model, the estimation errors by
the combined nonlinear regression
model were much smaller than those of
the nonlinear regression model for the
overall region. Figure 8 shows the aver-
age root-mean-square (rms) errors be-
tween the amounts of spatter and pre-
dicted results by the proposed models,
when the wire feed rate was set at
6 m/min.
As shown in Figs. 8 and 3, the esti-
mating performance by the nonlinear re-
gression models was better than the lin-
ear regression models when the amount
of spatter was under 3 g/min. In the re-
gions where the amount of spatter was
greater than 3 g/min, the estimating er-
rors by the nonlinear regression models
were greater than those of the linear re-
gression models. Also, in those regions,
the estimating error by the combined lin-
ear regression model was smaller than
the linear regression model overall. A
similar tendency was shown with the
higher wire feed rate. In Fig. 9, it was, on
the whole, shown the estimating perfor-
mance of the combined linear regression
model was better than the others where
the amount of spatter was greater than
3.0 g/rain, and the combined nonlinear
regression model was the best model
where the amount of spatter was smaller
than 3.0 g/min.
Selection of the Optimal Model
for Estimating the Amount of Spatter
In the short circuit transfer mode of
GMAW, the multiple correlation coeffi-
cient for each of the four proposed linear
and nonlinear regression models and the
amount of spatter was the greatest for the
combined nonlinear regression model.
The linear regression model showed the
worst estimating performance overall. The
best models for estimating the amount of
spatter were the combined linear regres-
sion model when the amount of spatter
was greater than 3 g/min and the com-
bined nonlinear regression model when
the spatter was less than 3 g/min. There-
fore, to estimate spatter more accurately, it
is desirable to use the combined linear re-
gression model and the combined nonlin-
ear regressionmodel alternatively accord-
ing to the amount of spatter.
Conclusions
When welding with voltages above
and below optimal levels, the arc be-
comes unstable and a large amount of
spatter is generated. Also, when voltages
were below the optimum, arc extinction
took place. The more arc extinction, the
more spatter. Therefore, the amount of
spatter is dependent on the number of arc
extinctions when the welding voltage is
below the optimal. The factors with arc
extinction, which have a high correlation
coefficient on the amount of spatter, are
different from those without arc extinc-
tion. Also, the regression models in each
region are composed of different factors.
In order to estimate the amount of
spatter, two linear and nonlinear regres-
sion models were made factoring in arc
extinction. These models were compared
to two linear and nonlinear models that
did not consider arc extinction. The re-
gression models that considered arc ex-
tinction estimated spatter much better
than those that did not. Where there was
a small amount of spatter, the combined
nonlinear regression model showed the
best performance in estimating the
amount of spatter. In the region where
there was a large amount of spatter, the
combined linear regression model
showed more accuracy.
Acknowledgments
This work was supported by the Brain
Korea 21 Project and Critical Technology
21 Project of the Ministry of Science and
Technology, Korea.
Reference
1. Adam, G., and Siewert, T. 1990. Sens-
ing of GMAW droplet transfer modes using
ER100S electrode. Welding Journal 69(3):
103-s to 109-s.
2. Ogunbiyi, B., and Norrish, J. 1996.
GMAW metal transfer and arc stability assess-
ment using monitoring indices. Computer
Technology in Welding, Sixth International
Conference. The Welding Institute, Cam-
bridge, U.K.
3. Arai, T., Kobayashi, M., Yamada, T.,
Rokujiyo, M., Hirakoso, K., and Kaneko, T.
1983. The investigation of arc phenomena by
means of computer. Quarterly Journal of the
Japan Welding Society 1(3): 15-20.
4. Lucas,W. 1987. Microcomputer system,
software and expert system for welding engi-
neering. Welding Journal 66(4): 19-30.
5. Mita, T., Sakabe,A., and Yokoo, T. 1988.
Quantitative estimates of arc stability for CO 2
gas shielded arc welding. Welding Interna-
tional 2(2): 152-159.
6. Shinoda, T., and Nishikawa, H. 1995.
Monitoring and signal processing of short-
circuiting metal transfer of metal active gas
welding process. Proceedings of the Int. Conf.
on the Joining of Materials. JOM-7, pp.
558-565. The European Institute for the Join-
ing of Materials, Helsinger, Denmark.
7. Rehfeldt, D., Bollmann, A., Korge, T.,
Kost, N., and Rosket, W. 1991. Computer-
aided quality control by process analyzing
monitoring and documentation. Proceedings
of the Int. Conf. on the Joining of Materials.
JOM-5, pp. 11-16. The European Institute for
the Joining of Materials, Helsingor, Denmark.

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8-s I JANUARY 2001

 Partially Melted Zone in Aluminum Welds:
Solute Segregation and Mechanical Behavior
The liquated material solidifies with severe segregation into a low-strength,
low-ductility structure consisting of a solute-depleted ductile phase and a
solute-rich brittle eutectic
ABSTRACT. Aluminum Alloy 2219 was
welded by the gas metal arc welding
process to study the partially melted zone
(PMZ), which is a narrow region imme-
diately outside the fusion zone. Electron
probe microanalysis showed severe Cu
segregation occurred within the PMZ
when the liquated material solidified. So-
lidification began as a Cu-depleted oc
phase of about 2 to 3 wt-% Cu and ended
as a Cu-rich eutectic, ranging from nor-
mal coupled eutectic (c~+l)) of 33 wt-%
Cu to divorced eutectic (l)) of 53 wt-%
Cu. Consequently, cc exists as a strip next
to the grain boundary (GB) eutectic, and
surrounds large eutectic particles
within grains. Microhardness testing re-
vealed the Cu-depleted (z was much
softer than the eutectic. Tensile testing
was conducted perpendicular to the
weld, and the PMZ cracked. The maxi-
mum load and displacement before fail-
ure were both far below those of the base
metal before welding. The GB eutectic
fractured while the adjacent Cu-depleted
0~deformed readily under tension. Simi-
larly, large eutectic particles fractured
while the surrounding Cu-depleted 0~de-
formed. Because large eutectic particles
were elongated in the rolling direction,
they fractured easily under tension ap-
plied in the rolling direction. The maxi-
mum load before failure was slightly
lower in a weld perpendicular to the
rolling direction than in one parallel to it.
Introduction
Aluminum alloys tend to be suscepti-
ble to liquation along the grain boundary
(GB) and within grains in a very narrow
region immediately outside the weld fu-
sion zone called the partially melted
C. HUANG and 5. KOU are, respectively,
Graduate Student and Professor in the De-
partment of Materials Science and Engineer-
ing, University of Wisconsin-Madison, Madi-
son, Wis.
BY C. H U A N G A N D S. KOU
zone (PMZ) (Ref. 1). Grain boundary li-
quation can result in hot cracking during
welding (Refs. 1-7) or loss of ductility
after welding (Refs. 8-10).
Huang, et al. (Ref. 11), recently stud-
ied the liquation mechanism in the gas
metal arc welds of 2219 aluminum alloy,
which is essentially AI-6.3 wt-% Cu. Ex-
tensive liquation occurred both along
GBs and at locations of large prior-I) par-
ticles within grains. Large prior-I) parti-
cles refer to large l) particles present in
the base metal before welding. Two new
findings were of particular significance:
the liquation mechanism and the direc-
tional solidification behavior of the li-
quated material.
Liquation is initiated at the eutectic
temperature TE by the eutectic reaction
between the l) phase and the c~ matrix to
form liquid eutectic, and is followed by
further melting of the cc matrix above TE.
Solidification of the liquated material in
the PMZ is directional - - upward and to-
ward the weld.
The present study focuses on Cu seg-
regation in the PMZ and the response of
the PMZ to microhardness testing and
tensile testing.
Experimental Procedure
Alloy 2219, a high-strength aluminum
alloy, was selected because it is essen-
KEY WORDS
Alloy 2219
Partially Melted Zone
Grain Boundary Eutectic
Fusion Zone
Liquation
Solute Segregation
WELDING RESEARCH SUPPLEMENT I 9-s
tially a binary alloy of AI-6.3 wt-% Cu
and its solidification is, therefore, easy to
understand. The actual composition of
the workpiece is AI-6.33% Cu-0.34%
Mn-0.13% Fe-0.12% Zr-0.07% V-0.06%
Si-0.04% Ti-0.02% Zn by weight. The di-
mensions of the workpiece were 10 cm x
20 cm x 6.35 mm. The workpiece was
welded in the as-received condition of
T851 in the 10-cm direction. T8 stands
for solution heat treating, cold working,
followed by artificially aging, and T51
stands for stress relieving by stretching
(Ref. 12).
Gas metal arc welds were made per-
pendicular and parallel to the rolling di-
rection. The welding parameters were
6.35 mm/s (15 in./min) welding speed,
25.5 V arc voltage, 190 A average current
and Ar shielding. The welding wire was
a 1.2-mm-diameter wire of Alloy 2319
and the actual composition was AI-6.3%
Cu-0.3% Mn-0.18% Zr-0.15% Ti-0.15
Fe-0.10% V-0.10% Si. The wire feed
speed was 13.5 cm/s (320 in./min).
The resultant welds were etched with
a solution of 0.5 vol-% HF in water to re-
veal the microstructure by both optical
and scanning electron microscopy
(SEM). The SEM micrographs were taken
with secondary electron images at 15 kV.
Electron probe microanalysis (EPMA-
WDS) measured the Cu concentration.
Back-scattered image photographs were
taken at 15 kV and 35 nA. Quantitative
analyses and beam scan X-ray (dot) maps
were taken at 7 kV to minimize the elec-
tron scattering depth penetration.
Microhardness testing was conducted
using a Knoop microhardness tester with
a 10-g load and a 5-s duration. Tensile
testing was conducted perpendicular to
the welds with a constant cross-head
speed of 0.51 mm/min. Three tensile
specimens were tested for each condition
and the dimensions are shown in Fig. 1.
The reinforcement was left on two speci-
mens, but removed from the third.

50 mm 7--
z TE. The edge of the partially melted zone
U c
Fig. 1 - - Tensile testing specimen.
80O -
700 c
Solidus Liquidus
o 642i
600
m
=.9.
500
E the peak temperature during welding
400
300
0 6.3 10 20
AI
Fig. 2 - - AI-Cu phase diagram (Ref. 13).
Results and Discussion
For convenience, the aluminum-rich
portion of the AI-Cu phase diagram is
shown in Fig. 2 (Ref. 13). Alloy 2219 is
considered here as a binary AI-6.3% Cu
alloy as an approximation. As shown, the
(~ (AI-rich) phase has a Cu content of up
to 5.65%, the eutectic has a Cu/AI weight
ratio of about 33/67, and the e (AI2Cu)
phase has a Cu/AI weight ratio of about
53/47.
Solute Segregation
The specimens for EPMA were not
etched in order not to introduce surface-
condition-related errors in composition
measurements. Consequently, the EPMA
micrographs do not have high contrast.
Base Metal
Figure 3 shows the EPMA results of the
base metal. The Cu/AI weight ratios of
particles 1, 2 and 3 in Fig. 3A are
52.5/45.6, 52.5/44.7 and 53.7/44.4, re-
I 0-s I J A N U A R Y 2001
il,3mm Smrn
6.35 mm
L
30 40 50 60
Weight Percent Copper
spectively. These ratios are close to the
53/47 ratio of the O phase, thus suggest-
ing the particles in the base metal are the
O phase.
Figure 3B shows the Cu concentration
distribution along path WX, which cuts
across a GB at a small Oparticle, and path
YZ, which cuts across the same GB with-
out encountering a small e particle. The
maximum Cu concentration along path
WX - - about 18% - - is well below that
of 53% for the e phase, mainly because
the electron beam penetrates beyond a
small e particle into the low Cu (x matrix.
The Cu concentration along path YZ
shows the matrix is roughly 6%, and
there is no detectable Cu segregation at
the GB. In addition to AI and Cu, the con-
centrations of Mn and Si were also mea-
sured. No significant GB segregation of
Mn and Si was found.
Edge of the Partially Melted Zone
Figure 4 shows the results of EPMA at
the edge of the PMZ facing the base
metal, where the peak temperature dur-
ing welding is the eutectic temperature,
was first located by optical microscopy.
As will be shown later in Fig. 7, this is the
location where the particles change from
e (Fig. 7A) to eutectic - - Fig. 7B. The par-
ticles in Fig. 4A are on the average larger
than those in the base metal - - Fig. 3A.
The Cu/AI weight ratios of particles 1 and
2 are 39.6/57.6 and 37.6/61.1, respec-
tively. These ratios are much lower than
the 53/47 ratio of the O phase. Both the
larger average particle size and the lower
Cu/AI ratios suggest these are eutectic
particles produced by the eutectic reac-
tion between 0 particles and the sur-
rounding (x matrix. However, it remains a
question why the Cu/AI ratios of these
particles are higher than the 33/67 ratio
of the eutectic.
From Fig. 4B, again the Cu concentra-
tion of the matrix is roughly 6%, and
again there is no detectable Cu segrega-
tion to the GB, even at a location where
is TE.
Partially Melted Zone
Figure 5 shows the EPMA results in the
PMZ. The microstructure is shown in Fig.
5A and enlarged in part in Fig. 5B to in-
dicate the locations of composition mea-
surements. Figure 5C shows the Cu con-
centration distribution measured along
path WX across the GB. Severe segrega-
tion of Cu to the GB is evident. The Cu
concentration rises from about 2 to 3% in
the particle-free strip to a maximum of
about 27% at the GB. According to the
phase diagram (Fig. 2), the eutectic com-
position is 33.2% Cu, not 27%. This dis-
crepancy is likely caused by the back-
ground effect of the (x phase. This part of
the GB is thin, about 1.7 pm. In fact, if
the overall plane of the GB makes a shal-
low angle with the top surface of the
specimen, this part of the GB can be
much thinner than 1.7 pm. The penetra-
tion depth of the electron beam in the
specimen is likely to be about 1.5 tim at
7 kV, as determined by Monte Carlo sim-
ulations with software distributed by Joy
(Ref. 15).
Figure 5D shows the Cu concentra-
tion distribution measured along path
YZ. Severe segregation of Cu to the GB is
again evident. The Cu concentration rises
from about 2 to 3% in the particle-free
strip to a maximum of about 30% at the
GB, which is close to the 33% of the eu-
tectic. The discrepancy is smaller here
than in the previous case. Since this part
of the GB is thicker than the previous
one, the effect of beam penetration is
likely to be less.
Figure 6 shows EPMA results at an-
 (A)
= 40

- 30
E
O
= 20
r-

o •D 10
r- ,W=..=. =~.~,Ll~..,..-..t..~.
• i •
;- _ - ~• . . X
8 (B) O
Y Z (B)
0 t i I r i i I I I e

0 2 4 6 8 10 12 0 2 4 6 8 10 12 14
D i s t a n c e , I~m Distance, gm

Fig. 3 - - EPMA o f the base metal: A - - Electron micrograph; B - - paths Fig. 4 - - EPMA o f the edge o f the partially melted zone: A - - Electron
WX and YZ across the grain boundary. micrograph; B - - paths W X a n d YZ across the grain boundary.

other location in the PMZ. An electron
micrograph is shown in Fig. 6A to show
the locations of composition measure-
ments. Figure 6B shows the Cu concen-
tration distribution measured along path
WX. The maximum Cu concentration is
at the GB and is about 33%, which is the
eutectic composition. Had point X been
extended further into the particle-free
strip (like in Fig. 5B), the minimum Cu
concentration would have been lower,
say 2 to 3%.
Figure 6C shows the Cu concentra-
tion distribution measured along path
YZ. This time the Cu concentration
varies from a minimum about 2 to 3% in
the particle-free strip to a maximum of
about 55% at the GB and another maxi-
mum of about 50% at the particle near
point Z. These maximum Cu contents
are close to the 53% of the 8 phase. The
question is why the GB and the particle
appear to be 8.
Microstructure
As will be shown, scanning electron
micrographs reveal the eutectic structure
clearly but not the composition varia-
tions in the 0c phase. Optical micro-
graphs, on the other hand, have limited
structural resolution but show the 0~
phase lighter in color where it is depleted
in Cu. Therefore, both optical micro-
graphs and scanning electron micro-
graphs are used in the discussion of the
microstructure and its relation with the
composition data.
The solute segregation shown by
EPMA will be discussed in light of the op-
tical micrographs in Fig. 7. Before the dis-
cussion, however, it helps to mention
that, as shown recently (Ref. 11 ), the eu-
tectic along the GBs in the PMZ is often
divorced. Normal eutectic is typified by
the simultaneous growth of 0~and 0 in the
normal coupled fashion. In divorced eu-
tectic, however, the o~ phase of the eu-
tectic grows upon and is, therefore, in-
distinguishable from the primary 0~of the
matrix, leaving e alone visible. Divorced
eutectic shows no coupling (Ref. 16-21 ).
Base Metal
As shown in Fig. 7A the large white
particles in the base metal are often elon-
gated in the rolling direction (from left to
right). According to the phase diagram,
2219 aluminum consists of the (z phase
and the e phase. Therefore, these parti-
cles should be the e phase and should
have a Cu concentration of about 53%.
This is consistent with Cu concentrations
of particles 1 through 3 in Fig. 3A.
Edge of the Partially Melted Zone
As already mentioned, near the edge
of the PMZ, the maximum peak temper-
ature during welding is the eutectic tem-
perature, TE. According to the phase dia-
gram, the e particles react with the
surrounding (x matrix to form a eutectic
liquid.
Figure 7B shows two large eutectic par-
ticles near the edge of the PMZ. The one
on the right is larger than average and is
selected because, in optical micrographs,
microstructural details are more clearly
seen in larger particles. Both particles con-
sist of divorced eutectic (8) as well as nor-
mal eutectic (c( + e). The divorced eutec-
tic does not appear to be surrounded by
the normal eutectic. In fact, it scatters
rather than concentrates at the core of the
particles, suggesting it is not likely to be
the residual of e particles (like those in Fig.
7A) that have not reacted completely with
the surrounding ~ matrix.

WELDING RESEARCH SUPPLEMENT I I I-s

 ~40 ,

\
1°I2 x
(B)
o ol
o 2 ~, 6
Distance, m
=60
L)
(B) 50
40 ~. 40
e-

30
30
~ 20
20
/ ~10
o L. ~ z (c)
/ ~ 0 I [ I I , I i

10 '/ 0 10 20 30 40
X
(c)
Distance, ~m
0 L i t

o 2 ~, 6 8 lo 1'2 14 Fig. 6 - - EPMA o f partially melted zone: A - - Electron micrograph; B

Distance, l~m - - path WX across the grain boundary; C - - path YZ across the grain
boundary.

/% The same two eu-
tectic particles are
shown in the SEM
micrographs in Fig.
8A, B. Again, they
appear to consist of
coupled eutectic (c~
Y (D) + 8) and divorced
eutectic (8). The Cu
0 2, 4 6, 8 10
, 12
, 14 contents of the eu-
Distance, ~m tectic particles con-
taining some di-
Fig. 5 - - EPMA o f partially melted zone: A - - Electron micrograph; B vorced eutectic (~)
- - electron micrograph at higher magnification; C - - path WX across are expected to be
the grain boundary; D - - path YZ across the grain boundary. higher than 33%
because e has 53% Cu. This makes it pos-
sible for the eutectic particles near the
edge of the PMZ, such as particles 1 and
2 in Fig. 4A, to have more than 33% Cu.
It is interesting to note in Fig. 8A that
some thin but nearly continuous e is pre-
sent along parts of the GBs (it appears as
dark lines along the GBs in Fig. 7B). This
is clear evidence the small e particles
scattered along the GBs before welding
(Ref. 11 ) have reacted with the surround-
ing ~ to become eutectic liquid films.
Upon cooling, the GB films solidify as di-
vorced eutectic (8). It is also interesting to
note in Figs. 7B, 8A and 8B, the eutectic

12-$ I JANUARY 2001

 R
J

A r°llingdirecti°n~BC~
D ~ =
0ase metal \ ~ \fusion @ I I
(2219 AI) partially-melted--~ \zone i i
zone ~
I I

14
I I
, °

i !
I I

i ¢
!!
| g

I I
I I
i I
I
I !
n a

I |
i •
! £
(A) ||

i |

I L
I!
, .

II
I£
! am

I L
Ic
! L
I!
i i,
I in

I k
I •
I •

I£

I£
t ~

Fig. 7 - - O p t i c a l micrographs. A - - Base metal; B - - edge o f p a r t i a l l y m e l t e d z o n e ; C - - p a r t i a l l y m e l t e d z o n e ; D - - fusion zone. Ic

IC

particles are sharp at their intersections
with the GBs. This indicates the eutectic
liquid penetrates the GBs to some extent•
Partially Melted Zone
i u
appears divorced (0) where it is thin and cate a low Cu concentration of about 2 to I G
coupled (0~+0) where it is thicker. 3% in the ~ phase. ~u
In the PMZ, the maximum peak tem- If solid-state diffusion is negligible,
perature during welding is above the eu- the minimum Cu concentration of 2 to
tectic temperature, TE. At TE, 0 particles 3% in Figs. 5 and 6 suggests a local peak
d

An optical micrograph of the PMZ is
shown in Fig. 7C. The two largest eutec-
tic particles are both coupled (cz+0) and
divorced (0). Most of the numerous tiny
particles at isolated points within grains
are divorced eutectic (8). Most of the GB
eutectic is divorced, though the thicker
GB eutectic appears to be coupled.
One of the two eutectic particles is
shown in the SEM micrograph in Fig. 8C.
Again, the eutectic appears to be coupled
in some areas and divorced in others. The
divorced eutectic does not appear to be
concentrating at the core and surrounded
by the coupled eutectic. The GB eutectic
U
react with the cz matrix to form the eu- temperature of about 610°C during weld- nl
d
tectic liquid. As temperature rises above ing, according to the solidus line of the ©
T E, the eutectic liquid lowers its Cu con- phase diagram• This peak temperature is
¢
centration along the liquidus line of the not far below the 642°C liquidus tem- U
phase diagram (Fig. 2) by dissolving the perature representing the peak tempera- !
U
surrounding ~ matrix of a much lower Cu ture at the fusion boundary during weld- £
content. Upon cooling, the hypoeutectic ing. In other words, the areas
liquid solidifies first as Cu-depleted cz corresponding to Figs. 5B and 6A are ex-
and, finally, as the eutectic. In Fig. 7C, the pected to be close to the weld. Back-scat- il
¢
light-etching phase along the lower side tered micrographs lower in magnifica-
U
of the GB eutectic and surrounding the tions such as Fig. 5A show the areas are ¢J
large eutectic particles is the Cu-depleted about 100 gm away from the fusion U
cz phase that solidifies first. It gets darker boundary. ~..~
near the eutectic, reflecting increasing It is interesting to point out that the
Cu concentration. The EPMA results Cu-depleted ~ strip in the PMZ looks dif-
shown previously in Figs. 5 and 6 indi- ferent in different types of micrographs.
J
WELDING RESEARCH SUPPLEMENT I 13-s

Fig. 8 - - Scanning electron micrographs. A and B - - Edge o f partially melted zone; C - - partially melted zone; D - - fusion zone.
In an unetched EPMA electron micro-
graph (Fig. 5A), it appears dark. In an op-
tical micrograph etched with a HF solu-
tion (Fig. 7C), it appears light. In a SEM
micrograph etched with the same solu-
tion (Fig. 8C), it does not really stand out
clearly.
Fusion Zone
In the fusion zone the peak tempera-
ture during welding is above the liquidus
temperature of AI-6.3% Cu, which is
about 642°C - - Fig. 2. Since this is well
above the melting point of () (592°C), no
B can survive in the weld pool.
The optical micrograph in Fig. 7D
shows the interdendritic eutectic in the
fusion zone contains both coupled eu-
tectic (~+B) and divorced eutectic (~). As
already mentioned, divorced eutectic (B)
cannot be from residual B that survives
the heat of the welding process. The in-
ternal structure of the interdendritic eu-
tectic is similar to that of the large eutec-
tic particles in the P M Z - - Fig. 7B, C. This
14-s IJANUARY 2001
(B)
further suggests divorced eutectic (e) in
the PMZ eutectic particles is not likely to
be from residual e. The cores of the den-
drite arms, which solidify as the Cu-
depleted co, appear light in color while
the areas between the dendrite arms,
which solidify later and have more Cu,
appear darker. It is interesting to note
some small and nearly round interden-
dritic particles appear to be divorced
eutectic along.
The SEM micrograph of the eutectic
in Fig. 7D is shown in Fig. 8D. Again, the
interdentritic eutectic contains both
coupled eutectic (co+0) and divorced eu-
tectic (e).
Microhardness Testing
Figure 9 shows three Knoop micro-
hardness indents in the PMZ: from the
top down, one in the cxstrip, one on both
the GB eutectic and the c~ strip, and one
in the grain interior. The indent in the c~
strip is significantly wider than the other
two, suggesting the (x strip is much softer.
The hardness levels are HK 60.9 in the
eutectic-free o~ strip, HK 85.4 at the eu-
tectic GB and HK 91.6 in the grain inte-
rior, which is full of small eutectic parti-
cles. Apparently, the Cu-depleted c~
phase is much softer than the eutectic.
When the c~ phase is depleted in Cu, its
strength decreases because of reduced
solution strengthening.
Tensile Testing
As mentioned previously, tensile
specimens were tested both with and
without the reinforcement removed.
With the reinforcement removed, crack-
ing initiated in and propagated through
the fusion zone. With the reinforcement
kept, on the other hand, cracking initi-
ated in the PMZ and propagated along
the PMZ for some distance before stop-
ping or continuing into the heat-affected
zone. Leaving the reinforcement on the
weld appears to cause a stress concen-
tration effect and helps the crack to start
at the toe. The results from the tensile
 4000
base-metal
specimen
3000
z
"~ 2000
o

1000
0 ~Leelmden"~dol~ngon
(A)
0 1 2 3 4
Displacement, mm

Fig. 9 - - Microhardness indents in the partially melted zone.

(B)

(A)

(B)
Fig. 11 - - Tensile testing o f weld perpendicular to the rolling direction:
Fig. 1O - - Tensile-tested specimens: A - - Weld perpendicular to rolling A - - Load vs. displacement; B - - micrograph near fracture surface; C
direction; B - - weld parallel to rolling direction. - - micrograph away from fracture surface.

specimens with the reinforcement kept
will be discussed below.
Figure 10 shows two weld tensile
specimens; one, perpendicular to the
rolling direction (Fig. 10A) and the other,
parallel (Fig. 10B). In both cases the
crack runs along the PMZ, at least a good
portion of it.
Weld Perpendicular
to the Rolling Direction
The results of tensile testing for the
weld perpendicular to the rolling direc-
tion are shown in Fig. 11. Figure 11A
shows two curves of load vs. displace-
ment, one for the weld specimen and the
other for a base-metal specimen of the
same rolling direction. The weld speci-
men is much lower in both strength and
ductility than the base-metal specimen.
In addition, the load fluctuates near the
end of tensile testing.
An optical micrograph at the fracture
surface of the weld specimen is shown in

WELDING RESEARCH SUPPLEMENT I 15-s

 4000
base-metal
specimen
3000 \ --'--'-"
z
"~2000
1000 F-~- specimen ...I
romng
0 / ~~~/direction (A)
0 1 2 3 4
Displacement, mm

Fig. 12 - - Scanning electron micrograph showing fracture o f GB eu-

tectic and a eutectic particle in the PMZ o f a weld perpendicular to
the rolling direction.

Fig. 11B. Cracking appears to be both Effect of Rollin

transgranular and intergranular. Fracture Direction
of the large eutectic particles is evident.
Figure 11C is another optical micrograph The @ phase ne~
in the PMZ at a higher magnification. to the GB eutecti
Fracture is evident in both the GB eutec- and surroundin
tic and large eutectic particles. The SEM large eutectic part
micrograph in Fig. 12 clearly shows the cles is solute-d(
fracture of the GB eutectic. The grain pleted (about 2 tu
boundary fractures in Fig. 11 B and C are 3% Cu) and is, there-
like those shown in Fig.12. It is likely the fore, weak and soft.
microcracks in the fractured eutectic par- The microhardness
ticles and GB eutectic act as crack initia- testing has already
tion sites, and that they propagate and confirmed the Cu-
eventually cause failure. depleted ~ phase is
much softer than the
Weld Parallel to the Rolling Direction eutectic. The
phase deforms easily
Similar tensile testing results are under tensile load-
shown in Fig. 13 for the weld parallel to ing because it is
the rolling direction. As shown in Fig. weak and ductile.
13A, the weld specimen is again much The eutectic, on the
lower in both strength and ductility than other hand, is brittle
the base-metal specimen of the same and unable to de-
rolling direction. However, as compared form. The fact that
to the weld perpendicular to the rolling large eutectic parti-
direction (Fig. 11A), the maximum load cles and the GB eu- Fig. 13 - - Tensile testing of weld parallel to the rolling direction: A - -
is slightly higher and the maximum dis- tectic stick to Cu- Load vs. displacement; B - - micrograph near the fracture surface; C
placement slightly lower. Also, the load depleted ~ makes - - micrograph away from the fracture surface.
does not appear to be fluctuating before them susceptible to
it drops suddenly when the specimen be- fracture under tensile loading. tectic particles are elongated in the load-
gins to fail. The effect of the rolling direction is il- ing direction. This is because the prior-0
Figure 13B shows an optical micro- lustrated in Fig. 14. A single grain in the particles, which react with the surround-
graph at the fracture surface of the weld PMZ of the weld perpendicular to the ing ~ matrix and form these large eutec-
specimen. As compared to the weld per- rolling direction is shown schematically tic particles, are often elongated in the
pendicular to the rolling direction (Fig. in Fig. 14A, and that in the weld parallel rolling direction - - Fig. 7A. Eutectic par-
11 B), intergranular cracking seems to play to the rolling direction in Fig. 14B. In ticles elongated in the tensile loading di-
a greater role. Figure 13C shows another both cases the brittle GB eutectic is rection fracture more easily. The load
optical micrograph in the PMZ at a higher bonded to the soft ~ strip. As the @ strip fluctuations during tensile testing (Fig.
magnification. It shows fracture of the GB elongates under tensile loading, the GB 11A) are likely to be associated with the
eutectic, just like the weld perpendicular eutectic fractures. fracture of large eutectic particles - - Fig.
to the rolling direction (Fig. 11C), but not In the weld perpendicular to the 11B, C.
fracture of large eutectic particles. rolling direction (Fig. 14A), the large eu- In the weld parallel to the rolling di-

16-s I JANUARY 2001


Fracture of eutectic in partially melted
zone under tensile loading
loading direction
~
rollinq
d ~ n icro brittle eutectic A
crack J,~ , / c r a c k ~ ,
ductile (~ brittle eutectic" m=cro
cracks
ductile (~ brittle eutectic v
'l'coupledwheregrainboundaryis thickerand divorcedwhereit
is thinner
VCoupledor divorced
Fig. 14 -- Fracture of the partially melted zone under tensile loading:
A -- Weld perpendicular to the rolling direction; B -- weld parallel to
the rolling direction.
rection (Fig. 14B), however, the large eu-
tectic particles are less elongated in the
loading direction and are, therefore, less
likely to fractu re. Th is is believed to be as-
sociated with the slightly less maximum
displacement, slightly higher maximum
load and the absence of significant fluc-
tuations before failure.
Conclusions
The present study on welds of 2219
aluminum shows severe solute segrega-
tion can occur in the PMZ of an alu-
minum weld, resulting in a weak mi-
crostructure and poor mechanical
performance. Liquation is evident both
along GBs and at locations of prior-0 par-
ticles within grains. Severe Cu segrega-
tion occurs during solidification of the li-
quated material. Solidification begins
with a Cu-depleted 0c phase (about 2 to 3
wt-% Cu) and finishes with a Cu-rich eu-
tectic, which can range from normal eu-
tectic (33 wt-% Cu) to divorced eutectic
(55 wt-% Cu). The Cu-depleted {z phase
appears much softer than the eutectic.
The PMZ is very much weakened by the
microstructure of a weak ductile (z phase
and a brittle eutectic stick-
ing to each other. The max-
imum tensile load and dis-
placement are both well
b e l o w those of the base
metal before welding, and
the GB eutectic fractures. A
weld made perpendicular
to the rolling direction be-
/ haves differently from a
weld made parallel to it.
The former shows a slightly
lower m a x i m u m load,
slightly higher maximum
displacement and clearer
load fluctuations. Its large
micr.o eutectic particles are more
elongated in the loading
direction and are, there-
fore, easier to fracture.
Acknowledgments
This work was supported
by the National Science
Foundation under Grant
No. DMR-9803589. The
authors are grateful to
Bruce Albrecht and Todd
Holverson of Miller Electric
Mfg. Co., Appleton, Wis.,
for donating the welding
equipment (including the
Invision 456P power
source and the XR-M wire
feeder and gun) and for
their technical assistance
during the study.
References
1. Kou, S. 1987. Welding Metallurgy. New
York, N.Y.: John Wiley and Sons, pp. 29-59,
239-262.
2. Robinson, I. B. 1978. The Metallurgy of
Aluminum Welding. Pleasanton, Calif.:Kaiser
Aluminum Corp.
3. Gittos, N. F., and Scott, M. H. 1981.
Heat-affected zone cracking of AI-Mg-Si al-
loys. Welding Journal 60(6): 95-s to 103-s.
4. Dudas, J. H., and Collins, F. R. 1966.
Preventing weld cracks in high-strength alu-
minum alloys. Welding Journal45(6): 241 -s to
249-s.
5. Lippold, J. C., Nippes, E. F., and Savage,
W. F. 1977. An investigation of hot cracking in
5083-0 aluminum alloy weldments. Welding
Journal 56(6): 171 -s to 178-s.
6. Metzger, G. E. 1967. Some mechanical
properties of welds in 6061 aluminum alloy
sheet. Welding Journal 46(10): 457-s to 469-s.
7. Steenbergen,J. E., and Thornton, H. R.
1970. Quantitative determination of the con-
ditions for hot cracking during welding for
aluminum alloys. Welding Journal 49(2): 61 -s
to 68-s.
8. Gibbs, F. E. 1966. Development of filler
metals for welding AI-Zn-Mg alloy 7039.
Welding Journal 45(10): 445-s to 453-s.
9. Young, J. G. 1968. BWRA experience in
W E L D I N G RESEARCH SUPPLEMENT I 17-s
the welding of aluminum-zinc-magnesium al-
loys. Welding Journal 47(10): 451 -s to 461 -s.
10. Arthur, J. B. 1955. Fusion welding of
24S-T3 aluminum alloy. Welding Journal 34:
558-s to 569-s.
11. Huang, C., and Kou, S. 2000. Partially
melted zone in aluminum welds - - liquation
mechanism and directional solidification.
Welding Journal 79(5): 113-s to 120-s.
12. The Aluminum Association. 1982. Alu-
minum Standards and Data. Washington,
D.C.: The Aluminum Association, p. 15.
13. American Society for Metals. 1986. Bi-
nary Alloy Phase Diagrams, Vol. 1. Metals
Park, Ohio: American Society for Metals, p.
106.
14. Flemings, M. C. 1974. Solidification
Processing. New York, N.Y.: McGraw-Hill, p.
95.
15. Joy, D. C. 1991. An introduction to
Monte Carlo simulations. Scanning Mi-
croscopy 5(2): 329-337.
16. Collins, W. T., and Mondolfo, L. F.
1965. Divorced eutectic. Transactions of
the Metallurgical Society of AIME 233:
1671-1676.
17. Kofler, A. 1965. Precipitation anom-
alies during isothermal crystallization from
undercooled, binary organic melts. The Jour-
nal of the Australian Institute of Metals 10(2):
132-139.
18. Mondolfo, L. F. 1965. Nucleation in
eutectic alloys. The Journal of the Australian
Institute of Metals 10(2): 169-177.
19. Michael, F. X., Gigliotti, J. R., Colligan,
A., and Grahan, L. F. P. 1970. Halo formation
in eutectic alloy system. Metallurgical Trans-
actions 1: 891-897.
20. Barclay, R. S., Niessen, P., and Kerr, H.
W. 1973. Halo formation during unidirec-
tional solidification of off-eutectic binary al-
loys. Journal of Crystal Growth 20:175-182.
21. Bluni, S. T., Notis, M. R., and Marder,
A. R. 1995. Nucleation characteristics and mi-
crostructure in off-eutectic AI-Zn alloys. Acta
Metallurgica et Materialia 43(5): 1775-1782.
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 The Stress-Relief Cracking Susceptibility of a
New Ferritic Steel Part 2: Multiple-Pass
Heat-Affected Zone Simulations
The effect of using a multiple-pass weld procedure on the stress-relief cracking
susceptibility of a new ferritic steel was investigated and
compared to single-pass samples
BY J. G. NAWROCKI, J. N. DUPONT, C. V. ROBINO A N D A. R. MARDER
ABSTRACT. The stress-relief cracking HCM2S was shown to be more suscepti- can be used to improve the toughness of
susceptibility of multiple-pass welds in ble to stress-relief cracking than 2.25Cr- the HAZ much like a PWHT. With this
HCM2S, a new ferritic steel, and stan- 1Mo steel. Both alloys failed along prior approach, the heat of subsequent passes
dard 2.25Cr-1Mo steel has been evalu- austenite grain boundaries, but 2.25Cr- acts to temper previous passes (Ref. 3).
ated and compared to single-pass weld 1Mo steel exhibited significant macro- The prior austenite grain size can also be
results using Gleeble techniques. Simu- ductility when tested at 325 MPa, refined if the material is heated into the
lated coarse-grained heat-affected zones whereas HCM2S exhibited little ductility. austenite region to a temperature lower
(CGHAZ) were produced using two- and Lowering the applied stress in the 2.25Cr- than that reached during the first pass and
three-pass thermal cycle simulations and 1Mo steel samples to normalize for the recrystallization occurs. The reduced
tested at various postweld heat treatment yield strength resulted in lower ductility prior austenite grain size reduces hard-
(PWHT) temperatures. Light optical and values from the stress-relief cracking enability and, for a given amount of seg-
scanning electron microscopy were used tests. regant elements, provides more grain
to characterize the CGHAZ microstruc- Stress-relief cracking typically occurs boundary area over which the segregants
tures. The multipass samples of each ma- due to a combination of precipitation can be distributed. The result is with the
terial failed along grain boundaries (prior strengthening of the grain interiors, a pre- formation of smaller prior austenite
austenite or packet) normal to the tensile cipitate-free denuded zone, and/or tem- grains during multipass welding, the
axis and exhibited extensive plastic de- per embrittlement of the prior austenite original CGHAZ may now have a mi-
formation, indicating that stress-relief grain boundaries (Ref. 2). In single-pass crostructure that is more resistant to
cracking was avoided with the use of welds, stress-relief cracking mainly oc- stress-relief cracking than the CGHAZ
multipass simulations. The times to fail- curs in the CGHAZ region. However, produced from a single-pass weld. The
ure, when considering CGHAZ simula- with the exception of thin sections, weld- use of multipass or temper bead proce-
tions, were longer than those of the sin- ing Cr-Mo steels will require a multiple- dures can reduce the need for expensive,
gle-pass samples at each PWHT pass procedure. Alloy steel weldments time-consuming PWHT operations.
temperature. The ductility increased with such as 2.25Cr-1Mo used for pressure However, the weldments will be sub-
increasing PWHT temperature for each vessels typically require a postweld heat jected to in-service temperatures ranging
alloy and increased relative to the single- treatment. This is done to relieve residual from approximately 500 to 700°C, and,
pass samples at each PWHT temperature. stresses, improve mechanical properties, therefore, the effect of elevated tempera-
The differences in stress-relief cracking and reduce hydrogen-cracking suscepti- tures needs to be assessed. Also, for the
response between the single- and multi- bility of the HAZ. It is very difficult to temper bead procedure to be effective
ple-pass samples are discussed in terms PWHT large components after in-service and reliable, there must be precise con-
of the microstructural changes that take repairs are performed. Multipass welding trol of the bead size, sequencing and in-
place during the multiple-pass procedure procedures or temper-bead techniques terpass temperature. Therefore, the ob-
and subsequent PWHT. jective of Part 2 of this research is to
determine the effect of using a multiple-
Introduction pass weld procedure on the stress-relief
KEY WORDS cracking susceptibility of 2.25Cr-1Mo
In Part 1 of this investigation (Ref. 1), and HCM2S alloys relative to single-pass
a range of single-pass weld thermal sim- welds.
Stress Relief
ulations and postweld heat treatment
Multipass Welds
schedules were imposed on a new ferritic Experimental Procedure
Cracking Susceptibility
steel HCM2S and 2.25Cr-1Mo steel.
PWHT
Multipass Stress-ReliefCrackingTests
J. G. NAWROCKI, J. N. DUPONT and A. R. CG HAZ
MARDER are with Department of Materials Heat-Affected Zone The compositions of 2.25Cr-1Mo and
Science and Engineering, Lehigh University, Temper Bead HCM2S alloys used in this research can
Bethlehem, Pa. C. V. ROBINO is with Materi- Ferritic Steel be found in Part 1 (Ref. 1). Stress-relief
als Joining Department, Sandia National Lab- cracking tests were performed using a
oratories, Albuquerque, N.Mex. Gleeble thermomechanical simulator.

18-s I JANUARY 2001

 ~Temperature Profile
mmmmmStressProfile
1400 500
Tmai=i3~5°C '

1200
' ' ] ...... 400
1ooo

.~ 800

600

400
i '°°
E"

200

i i . . . . . , -. . . . . 0
0 '
o 200 400 600 800 1000
Time (see.)

Fig. 1 - - Schematic illustration o f a three-pass weld simulation and stress-

relief cracking test.

Unnotched, cylindrical specimens (105 steel was only tested using a two-
mm long, 10 mm in diameter) with pass simulation. Tests were per-
threaded ends were used. A schematic il- formed under a vacuum of approx-
lustration of a three-pass, stress-relief imately 100 millitorr to prevent
cracking test cycle can be seen in Fig. 1. decarburization and oxidation of
Each thermal cycle was produced using the samples, as well as decoher-
an energy input of 2 kJ/mm and a preheat ence of the thermocouples. The
temperature of 93°C. The peak tempera- time to failure was recorded as the
tures used for the first, second and third time elapsed after the PWHT tem-
passes were 1315, 925, and 700°C, re- perature was reached until sample
spectively. The interpass temperature was rupture. The ductility was mea-
approximately 300°C. These thermal cy- sured as the reduction in area dur-
cles are based on experimentally mea- ing PWHT.
sured values from actual shielded metal One half of each fractured
arc welds (Refs. 4, 5). A temperature of sample was reserved for fracto-
1315°C is representative of the peak tem- graphic examination by scanning
perature of the material adjacent to the electron microscopy. The remain-
fusion zone during welding. A tempera- ing half was electroless Ni-coated
ture of 925°C is above the upper critical to provide edge retention of the
temperature, A3, and the prior austenite fracture surface. Longitudinal
grain size will be decreased relative to the cross-sectional samples were then
first pass. The peak temperature of the polished to a O.04-1am finish using
third pass, 700°C, is sub-critical (below colloidal silica. Microhardness
the A 1 temperature) and the material will traces were performed on samples
not retransform to austenite upon heating. in the as-welded condition using
The third pass then acts as a tempering a Knoop indenter and a 500-g
pass. A tensile stress was imposed on the load. Samples were etched using
sample during cooling of the last pass and Vilella's reagent. Selected samples
held for the duration of the test to simu- were also etched using a solution
late the residual stressespresent in an ac- of 15 g sodium meta-bisulfite and Fig. 2 - - Photomicrographs o f the CGHAZ. Heat-af-
tual weldment. After cooling to room 100 mL H20 to reveal the prior fected zone simulations o f HCM2S. A - - One pass; B
temperature, the samples were then sub- austenite grain boundaries in the - - two passes; C - - three passes.
jected to a programmed, postweld heat multipass samples.
treatment temperature and held at con-
stant stress and temperature until failure. Results pass samples was N43 pm compared to
Postweld heat treatment (PWHT) temper- ~50 pm in the single-pass samples. How-
atures ranged between 625 and 725°C. Typical as-welded CGHAZ mi- ever, the prior austenite grain boundaries
HCM2S was tested at a stress of 325 MPa crostructures of both single- and multi- were difficult to reveal in the multipass
and 2.25Cr-1Mo steel at 270 MPa. A ple-pass samples for HCM2S and 2.25Cr- samples and the measurements represent
lower stress was used for 2.25Cr-lMo 1Mo alloys are shown in Figs. 2 and 3. approximate values and more error may
steel to help normalize the difference in The prior austenite grain size and subse- be involved than in the single-pass sam-
yield strength between the two materials. quent packet size have been refined rel- ples. It can be seen from Figs. 2 and 3,
HCM2S was tested using both two- and ative to the single-pass CGHAZs (Ref. 1). however, that the average length of the
three-pass simulations, but 2.25Cr-1Mo The prior austenite grain size of the multi- laths in the single-pass samples is greater

WELDING RESEARCH SUPPLEMENT I 19-s

 • HCM2S (l-lwms)
• HCM2S (2-1~m)

O 2.2~C~1Mo (l-pmo)
[] 2.2SCr-lMo ( ~ )
Approximate width of the H A Z

. . . . . . . . . . . . . . . . . . . . . . <~.. • , • . .-. •

^~<>0 0
450 00v 0 0
,0 0 0
0 0
>•omll•••!'•
&e w•
,
•,• ,•::llmim
I o

~n
350
'°|mmIpmmmilmmmm • 22

01 lO00 r- ~000 ~ O"

250 ]
~,iej
200
2 4 6 8 10 12 14 16
Distance (ram)

Fig. 4 - - Hardness traverses across the HAZ of single- and multiple-pass

simulation samples of HCM2S and 2.25Cr- I Mo steel.

• HCM2S l-Pau (325MPs)

• HCM2S 2-Patm(325 MPa)
• HCM2S ~ P m (325 MPa)
O 2.25C~1Mo l-Pare* (270 MPa)
[] 2.25C~1Mo 2-Pro (270 MIPa)

750
O )mere

700

Fig. 3 - - Photomicrographs of the CGHAZ. Heat-af-
fected zone simulations of 2.25Cr-lMo steel. A - -
One pass; B - - two passes.
than the multipass samples, which also
indicates a larger apparent prior austen-
ite grain size in the single-pass samples.
The apparent limited amount of grain re-
finement in the multipass samples is due
to the fast heating and cooling rates, and,
therefore, the limited amount of time
available for the transformation to
austenite upon heating.
Figure 4 shows hardness traverses
from each alloy in the multipass condi-
tions relative to the single-pass hardness
(2 kJ/mm energy input also). In the case
of HCM2S alloy, the peak hardness
dropped from a maximum of -380 HKN
in the single-pass sample to less than 350
HKN in the multiple-pass welds even
though the prior austenite grain and
packet size are smaller. The peak hard-
ness of the 2.25Cr-lMo alloy experi-
enced a significant decrease in hardness
from the first (-475) to the second pass
sample (< 350).
Figure 5 is a plot of the PWHT tem-
perature vs. the time to failure for both al-
loys from stress-relief cracking tests of
.a 3 I
Did No Fail (HC'M2S)
650
• ~ om-.~
2.25Cr-1~ o - Did ant fail
600
single- and multi-
ple-pass samples.
.L.
Failure occurred in 550
10 100 1000 10 4 l0 s
the former CGHAZ
in every sample. Time to Failure (sec.)
The time to failure
decreased as the Fig. 5 - - Postweld heat treatment temperature vs. the time to failure for
PWHT temperature single- and multipass HAZ simulation samples of HCM25 and 2.25Cr-
increased for each I M o steel.
sample. This is
mainly due to the
decrease in yield strength with increasing multiple-pass procedure. For HCM2S,
temperature and does not mean the sus- there was no discernable differences be-
ceptibility to stress-relief cracking in- tween the two- and three-pass samples.
creases as the PWHT temperature in- In the case of the 2.25Cr-1Mo alloy, fail-
creases. At each of the PWHT ure did occur at 625°C, but the time to
temperatures, the time to failure in- failure greatly increased relative to the
creased in the multiple-pass specimens single-pass samples. It should be noted
relative to the single-pass samples for that the single-pass 2.25Cr-1 Mo samples
both alloys. In the case of HCM2S tested tested at 575°C did not fail after six hours,
at 625°C, the multiple-pass specimen did and, therefore, multipass samples were
not fail after over six hours and the test not tested at this temperature.
was stopped. This is approximately the Figure 6 shows the variation in reduc-
time to failure for the single-pass samples tion in area with PWHT for single- and
at 575°C, which further emphasizes the multiple-pass weld samples of each alloy.
increase in rupture life as a result of the In general for the 2.25Cr-1Mo steel, the

20-s I JANUARY 2001

 • HCM2S l-Pass (325 MPt)
• HCM2S 2-Pass
• HCM2S 3-Pass
O 2.25Cr-lMo 1-Pass (270MPa)
[] 2,2SCr-lMo 2-Pass
@

3~
!
3~
[]
el
2~

2~

!(]

5 ¥

0 '
550 600 650 700 750
P W H T Temperature (°C)

Fig. 6 - - Reduction in area as a function of PWHT temperature for sin-

gle- and multiple-pass H A Z simulation samples of HCM25 and 2.25Cr-
I M o steel.

ductility increased with increasing PWHT
temperature. The reduction in area in-
creased significantly in the two-pass sam-
ples relative to the single-pass samples at
each PWHT temperature. The ductility is
also shown to increase in the HCM2S
alloy from the single-pass to the multipass
weld samples. The PWHT temperature
had no effect on the ductility of the sin-
gle-pass samples of HCM2S. However, as
the PWHT increased, the ductility in-
creased for the multiple-pass specimens
of HCM2S. There is no discernable differ-
ence between the results of the two- and
three-pass samples.
Figure 7 shows SEM photomicro-
graphs of the fracture surfaces of multi-
ple-pass samples tested at a PWHT tem-
perature of 675°C. Both the two- and
three-pass HCM2S samples (Fig. 7A, B)
exhibit extensive microvoid coalescence
indicative of the high ductility values
shown in Fig. 6. The 2.25Cr-1Mo two-
pass sample (Fig. 7C) was shown to have
similar ductility to the multiple-pass
HCM2S samples in Fig. 6. Figures 8 and
9 show typical cross-sectional light opti-
cal photomicrographs acquired from
fractured samples corresponding to those
in Fig. 7. The white outer layer in Figs. 8A,
8C and 9A is an electroless Ni-coating.
For the HCM2S alloy (Fig. 8A-E), it is now
seen that failure occurred both intergran-
ularly and transgranularly, which was not
evident from observation of the fracture
surfaces. Many secondary cracks can be
seen behind the fracture surface with
each being approximately normal to the
direction of the applied tensile stress. The
cracks are wavy as opposed to the
sharp cracks found along prior
austenite grain boundaries in the
single-pass samples (Ref. 1). The
cracks appear to run both across
and along prior austenite grain
and/or packet boundaries. The for-
mation of voids is evident at both
prior austenite grain boundaries
(large arrow) and within prior
austenite grains (small arrow) in
Fig. 8E. Many small precipitates
can be seen with a higher density
located at prior austenite grain
boundaries. Some carbides can
also be seen within grain interiors.
Carbides are known to act as mi-
crovoid nucleation sites in metal-
lic materials during creep (Ref. 6)
and conventional ductile failure
(Refs. 7, 8).
In the case of the 2.25Cr-1Mo
steel, failure also occurred pre-
dominantly along grain bound- Fig. 7 - - 5EM photomicrographs of fracture surfaces of
aries - - Fig. 9. The cracks are failed samples at 675°C. A - - Two-pass HCM2S; B - -
wavy and irregular in contrast to three-pass HCM2S; C - two-pass 2.25Cr-1Mo steel.
the straight and sharp cracks
found in the single-pass samples
(Ref. 1). Figure 9C clearly shows
the coalescence of voids along Discussion
grain boundaries only in areas approxi-
mately normal to the applied tensile The stress-relief cracking susceptibility
stress. Many carbides can be seen in the of alloys can be determined by the com-
multiple-pass samples of 2.25Cr-1Mo bination of two criteria: ductility and
alloy and previous work (Ref. 9) has mode of failure. As mentioned in Part 1 of
shown that Fe-, Cr- and Mo-based car- this work (Ref. 1), ductility is often used to
bides precipitate in this alloy under the compare alloys when Gleeble simulation
processing conditions/heat treatments techniques are used (Refs. 10, 11 ). Alloys
used in this research. that can appreciably soften during PWHT

WELDING RESEARCH SUPPLEMENT I 2 I-s


Tensile
Axis
Fig. 8 - - Photomicrographs of cross sections of HCM2S
samples tested at 675°C A, B - - Two passes; C, D, E have coarsened or
- - three passes.
can relieve residual
stresses by macroscopic
yielding. Alloys that re-
tai n their strength th rough
precipitation hardening
and form a denuded zone
adjacent to prior austen-
ite grain boundaries are
susceptible to low-ductil-
ity intergranular fracture
typical of stress-relief
cracking. When exposed
to elevated temperatures
during PWHT or in ser-
vice, segregation of tramp
elements to prior austen-
ite grain boundaries can
exacerbate stress-relief
Tensile cracking. According to
Axis the criteria for stress-relief
cracking susceptibility
outlined by Vinckier and
Pense (Ref. 10) as dis-
22-s I JANUARY 2001
cussed in Part 1, the
multiple-pass sam-
ples from both alloys
evaluated in this study
can generally be con-
sidered not suscepti-
ble to stress-relief
cracking at each
PWHT temperature.
The HCM2S three-
pass sample tested at
675°C is the only
sample considered
even slightly suscepti-
ble. It is interesting to
note that the prior
austenite grain size
and resultant packet
size decreased in the
multipass weld sam-
ples relative to the
single-pass samples.
A decrease in prior
austenite grain size
alone should increase
the strength and hard-
ness (Refs. 12, 13).
However, the hard-
ness was shown to
decrease in the finer-
prior austenite-
grained multipass
samples relative to
the larger prior
austenite-grained sin-
gle-pass samples.
Any undissolved car-
bides present after
the first pass may
carbides may have
formed during cool-
ing after the transfor-
mation to martensite,
i.e., autotempering. This is especially true
in materials having low carbon contents
and, consequently, a high martensite start
temperature such as HCM2S. In either
case, the carbides will coarsen during
subsequent passes, effectively lowering
the hardness. If carbides formed during
cooling (autotempering), these carbides
will most likely be cementite. The sec-
ondary hardening phenomena occurs
when more stable alloy carbides effec-
tively replace the cementite particles.
Due to the limited grain refinement after
the second pass, the second and third
passes may have acted as tempering
passes during which time any carbides
present will coarsen. Coarse particles are
more difficult to dissolve and replace than
small particles. Therefore, the coarse car-
bides present after the multipass proce-
dure tend to retard any secondary hard-
ening reactions relative to those in
tempered martensite (Ref. 6).
 The fracture mode
in the multipass sam-
ples gives further evi-
dence that these sam-
ples did not fail due to
stress-relief cracking.
The fractu re surfaces of
the HCM2S alloy
showed extensive mi-
crovoid coalescence
that is not typical of
stress-relief cracking.
Failure occurred along
prior austenite grain
and/or packet bound-
aries that are approxi-
mately normal to the
tensile axis similar to a
creep failure, but ex-
hibited a large amount
of plastic deformation.
The 2.25Cr-1Mo mul-
tiple-pass samples are
very similar to
HCM2S. These sam-
ples also exhibited extensive plastic de-
formation and microvoid coalescence.
Failure again occurred predominantly
along grain boundaries that are approxi-
mately normal to the tensile axis.
Figure 10 is a schematic illustration of
the microstructural changes that occur
during the single-pass welding simula-
tions and subsequent postweld heat
treatment relative to the multiple-pass
samples as well as the resultant failure
mechanisms. In the single-pass samples,
the alloying elements dissolve and
austenite grains are allowed to grow un-
inhibited, leading to a large austenite
grain size (although some carbides may
remain undissolved as discussed above).
During cooling, the austenite transforms
to martensite and the alloying elements
are trapped in solution. During PWHT,
carbides precipitate both in the grain in-
teriors (fine distribution) and at prior
austenite grain boundaries (coarse). The
grain boundary carbides could also be
the result of incomplete dissolution dur-
ing the first-pass thermal cycle. The grain
boundary carbides deplete the adjacent
region of alloying elements and a de-
nuded zone forms. Elemental segrega-
tion may also occur. Any strain will be
concentrated in soft denuded zones
leading to low-ductility, intergranular
failure with evidence of localized mi-
crovoid coalescence confined to the
prior austenite grain boundary regions. It
should be noted a denuded zone is not
essential in order for stress-relief crack-
ing to occur. In the case of the multiple-
pass samples, the prior austenite grain
and packet size are reduced during the
second pass when a peak temperature of
925°C is utilized. This temperature is
above the A 3 temperature
into the single-phase austen-
ite region. However, due to
the fast heating and cooling
rates, limited austenite grain
growth occurred. Therefore,
Tensile
the second pass acted more Axis
as a tempering pass, allow-
ing the carbides to form
and/or coarsen. The car-
bides may have acted as nu- Fig. 9 - - Photomicrographs o f a cross section o f a two-
cleation sites for the mi- pass 2.25Cr-1Mo sample tested at 675°C.
crovoids. Carbide particles
are well known to nucleate
voids during both creep (Ref.
6) and conventional ductile and soft denuded zone (which is ex-
failure (Refs. 7, 8). Small particles were pected in the single-pass simulations).
frequently found within voids on the As a result, the multipass specimens fail
fracture surfaces of the alloys studied in along grain boundaries and exhibit uni-
this research. This was especially true of form plastic deformation, indicating that
the HCM2S alloy as shown in Fig. 11 failure by a stress-relief cracking mecha-
(particles indicated by arrows). The car- nism has been avoided.
bides formed during cooling after a sim-
ulated welding pass or during PWHT. Conclusions
Carbides that formed during cooling of
the second pass have coarsened during The stress-relief cracking susceptibil-
the third pass and subsequent PWHT. ity of conventional 2.25Cr-1Mo and
The carbides present after the first pass, HCM2S steels was investigated using
if any, were unresolvable at these mag- Gleeble techniques to simulate multiple-
nifications and coarsened during subse- pass weld heat-affected zones. The re-
quent passes and PWHT. The carbides, sults were compared to those from sin-
along with the lower peak temperature, gle-pass samples described in Part 1 of
may have contributed to producing a this paper (Ref.1). The multipass samples
finer prior austenite grain size by pinning of each material failed by microvoid co-
austenite grain boundaries. This would alescence and the times to failure in-
help to explain why there are many car- creased in the multipass samples relative
bides located at prior austenite grain to the single-pass samples. The ductility
boundaries. In any event, the fine HAZ increased with increasing PWHT tem-
microstructure produced after the multi- perature and both materials exhibited
pass simulations is much softer and is not uniform plastic deformation. These fea-
expected to exhibit the strength gradi- tures indicate the multipass simulations
ents associated with a hard grain interior eliminated stress-relief cracking. Each
WELDING RESEARCH SUPPLEMENT [ 23-s
 1. 1315 de~reosC:

-austenite
- alloyingelementsdissolve

Single-Pass Simulations Multi-Pass Simulations

2. A f t e r C o o l i n e to Room Temmeratore from First pass

- alloying elements t r a p p e d in solution

- m a y b e some undissolved carbides

3. After ,~eeond Pass Cooled to Room Temmerature

Fig. 11 - - SEAlphotomicrograph of the fracture surface
of a two-pass HCM2S sample tested at 675°C showing

0
- r e d u c e d a u s t e n i t e g r a i n and packet size the presence of small particles within microvoids.
- interlath and intralath carbides
- undissolved carbides at prior austenite grain
boundaries
- p o s s i b l e t e m p e r i n g o f I st pass structure

4. After Post-Weld Heat Treatment

Elemental segregation at prior ~ -Carbideshave crostructures from continuous cooling trans-

in boundaries coarsened formation data. Welding Journal 37(7): 289-s
Precipitate-freedenudedzone to 294-s.
6. Kihara, S., Newkirk, J. B., Ohtomo, A.,
rain boundarycarbides and Saiga,Y. 1980. Metallurgical Transactions
A, 11A(6): 1019-1031.
~ Alloy carbidesin grain interiors
7. Senior, B. A., Noble, F. W., and Eyre, B.
5. Tensile Stress Annlied L. 1986. Acta Metallurgica 34(7): 1321-1327.
Strain concentrated 8. Curry, D. A., and Pratt, P. L. 1979. Ma-
ed zone terials Science and Engineering, Vol. 37, pp.
Voidsperpendicularto " " ~ b ~ 223-235.
tensileaxis "~,~~ 9. Baker, R. G., and Nutting, J. 1959. Jour-
nal of the Iron and Steel Institute, July, pp.
257-268.
10. Vinckier, A. G., and Pense, A. W.,
1974. WRC Bulletin 197.
Fig. 10 - - Schematic illustration of the microstructural changes and failure mode of sin- 11. Lundin, C. D., Liu, P., Qiao, C. Y. P.,
gle- and multiple-pass samples. Zhou, G., Khan, K. K., and Prager, M. 1996.
WRC Bulletin 411.
12. Petch, N. J. 1953. JI51,Vol. 173, p. 25.
13. Hall, E. O. 1951. Proc. Phys. Soc. B,
multipass sample failed primarily along acknowledge the sponsors of this re- Vol. 64, p. 747.
grain boundaries that were located ap- search including Sumitomo Metal Corp., 14. Honeycombe, R. W. K., and
proximately normal to the tensile axis. Mitsubishi Heavy Industries Ltd., Foster Bhadeshia, H. K. D. H. 1996. Steels: Mi-
The second pass, having a peak temper- Wheeler Development Corp. and Penn- crostructure and Properties, 2nd ed., Halstead
ature of 925°C, resulted in a decreased sylvania Power and Light Co. Press, New York, N.Y.
packet and prior austenite grain size. References
Coarse carbides were present both along
grain boundaries and within the grain in- 1. Nawrocki, J. G., DuPont, J. N., Robino,
teriors. These carbides formed during C. V., and Marder, A. R. 2000. The stress-relief
cooling from the first or second pass and cracking susceptibility of a new ferritic steel - -
coarsened during subsequent passes part 1: single-pass heat-affected zone simula-
and/or PWHT. The carbides then acted as tions. Welding Journal 79(12): 355-s.
microvoid nucleation sites. The elimina- 2. Meitzner, C. F. 1975. WRC Bulletin 211,
tion of stress-relief cracking by the multi- pp. 1-17.
pass simulations is attributed to forma- 3. ASM Handbook Vol. 6, Handbook of
tion of a HAZ microstructure which has joining and brazing, ASM International, Mate-
uniformly softened and does not contain rials Park, Ohio.
strength gradients associated with a hard 4. Nippes, E. F., Merrill, L. L., and
grain interior and soft denuded zone. Savage, W. F. 1949. Cooling rates in arc
welds in '/2-in. plates. Welding Journal
Acknowledgments 28(11): 556-s to 564-s.
5. Nippes, E. F., and Nelson, E. C. 1958.
The authors would like to gratefully Predictions of weld heat-affected zone mi-

24-s I JANUARY 2001

 Mechanical Properties of Plasma-Hardened 5%
Chromium Tool Steel Deposited by Arc Welding
Plasma heat treatment promotes an increase in mechanical properties
of deposited metal
BY L. K. LESHCHINSKIY A N D S. S. S A M O T U G I N
ABSTRACT. A complex technology is
proposed to increase the mechanical
properties of tools, dies and machine
components for hot work of metals. The
combination of hardfacing with a 5%
chromium deposited metal and subse-
quent surface treatment using a highly
concentrated plasma jet creates a hard
surface along with resistance to breakage
upon impact. The extremely fine-grained
martensite structure and relevant prop-
erty gradients of the plasma-jet-hardened
layer are almost identical to those treated
by laser and electron beams.
Due to rapid phase recrystallization,
the dissolution of primary carbides and
the saturation of a solid solution with car-
bon and alloying elements develop. This
leads to an increase in the degree of
tetragonality, microdistortions of the
crystal structure and to an increase in
hardness without a decrease in dynamic
fracture toughness because of the high
dislocation density and mosaic block
size reduction.
In its mechanical properties, marten-
sitic 5% chromium (0.20% C) deposited
metal after plasma hardening is close to
chromium hot-work die steels, signifi-
cantly surpassing them in dynamic frac-
ture toughness.
Introduction
Hardfacing has traditionally been
used to increase the performance of ma-
chine components, tools and spare parts.
Through the proper selection of a hard-
facing alloy and process, there is the pos-
sibility of achieving high service proper-
ties and of reducing the consumption of
metal. For hardfacing of tools, dies and
machine components used for hot defor-
mation of metal, 5% chromium tool steel
[5 Cr-0.5 Mo-0.15 V (0.20 C)] is widely
used (Refs.1, 2), but when compared to
L. K. LESHCHINSKIY was formerly with Azov
State Technical University, Mariupol, Ukraine.
S. S. SAMOTUGIN is with Azov State Techni-
cal University, Mariupol, Ukraine.
hot-work die steels, it needs improve-
ment in mechanical properties and wear
resistance.
A promising method for improving
hardness and wear resistance, without
the additional alloying of deposited
metal, is a surface heat treatment using a
highly concentrated heat source. The sur-
face heat treatment of metals by a highly
concentrated plasma jet similar to the
heat sources used more extensively - -
laser and electron beams-- makes it pos-
sible to carry out the power density
104-105 W/cm 2. Although not many ex-
perimental data reports are available on
plasma hardening, experience with the
application of plasma hardening indi-
cates the cooling rates of the surface lay-
ers of steels, their structure and hardness
are almost identical to those of the same
materials hardened by laser and electron
beams (Refs.1, 3-5).
Recent studies of plasma surface treat-
ment have shown high compressive resid-
ual stresses are formed in the quenched
layer. These stresses rapidly decrease at
the boundary of the quenched layer,
change their sign and transfer to tensile
stresses. The nonuniform distribution of
the residual stresses in the depth of the
heat-affected zone (HAZ) has a positive
effect on the fracture toughness of hard-
ened steels: cracks, caused by the exter-
nal cooling, cease to grow at the bound-
ary of the quenched layer.
According to the high cooling rates
and quenched structure in the HAZ of
KEY WORDS
5% Chromium Tool Steel
Surfacing/Hardfacing
Concentrated Heat Source
Plasma Surface Hardening
Heat-Affected Zone
Mechanical Properties
Fracture
WELDING RESEARCH SUPPLEMENT I 25-s
5% chromium deposited metal, reduc-
tion in impact strength and dynamic frac-
ture toughness can be expected. This
paper describes a study conducted to in-
vestigate the mechanical properties of
plasma-hardened deposited metal. Ex-
periments are described and discussed
using a comparison of microstructures,
fractographic pictures, X-ray diffraction
studies and mechanical tests of deposited
metal in the initial state and after plasma
surface hardening. The theoretical analy-
sis is also presented.
Experimental Procedure
Following multipass surfacing of 5 Cr-
0.5 Mo-0.15 V (0.20 C) metal using the
submerged arc welding process (Ref. 6),
10 x 10 x 55 mm Charpy specimens were
sectioned, mounted and plasma hard-
ened across one of the lateral faces - -
Fig. 1A. The specimens were machine
finished, including notching of the very
sharp, narrow notch in the middle of
HAZ - - Fig. lB. The sharpness of the
notch tip promoted early crack initiation
in the Charpy test; therefore, it simulated
a natural crack well enough to provide a
valid dynamic fracture toughness Kla test
result (Refs. 7, 8). The tests were con-
ducted at 20°C and ten specimens were
tested for each structural constitution.
When the Charpy test of each specimen
was completed, its shape after fracture
was checked to be sure the specimen was
fractured in the plane-strain fracture
toughness test.
The determination of K1a based on
Charpy impact tests requires proof the
specimen size used is satisfactory. The
correlation criterion (Refs. 7, 8) pertains
to a Charpy precracked specimen thick-
ness of B > 2.5 (KJoy) 2. For 5 Cr-0.5 Mo-
0.15 V (0.20 C) deposited metal, K~a-- 30
MPa~]m, oy = 900 MPa is the yield
strength in tension. The calculation de-
termines that when the left-hand member
B is equal to 10 mm, it is about ten times
greater than the right-hand member of
this inequality.
 "00
B

-\
'00

$00 0
/ .2 3 ~' Z~=,,,

Fig. 3 - - Hardness profile of 5% chromium deposited

metal quenched with a plasma jet.

Results and Discussion

Fig. I - - Multipass deposited metal sectioned into specimens for notch bar impact test- A single pass of the plasma jet with ex-
ing (A) and forming of the notch in the specimens (B). tremely high heating and cooling rates
forms a heat-affected zone of a circular
segment with the maximum depth (up to
5 mm) in the center and gradual reduc-
A B tion of the depth to zero when ap-
proaching the edge (the width is up to 20
mm) (Refs. 1,3-5). Table 1 shows the cal-
culated values of the heating temperature
and cooling rates in the HAZ of deposited
metal 5 Cr-0.5 Mo-0.15 V (0.20 C) for
distinct values of arc current I, travel
speed of the torch V and plasma gas re-
striction orifice D of the plasma jet with
a power of 30 kW generated by a non-
transferred plasma torch with a sectional
HV interelectrode insert. Calculated data
m R
were determined for the model of heat-
l i l l ! ing of a semi-infinite body by the Gauss-
5oo ian power density distribution of the
moving heat source. Plasma surface
hardening is carried out without HAZ
overlapping (Fig. 2A) as well as with HAZ
0 fO 20 ;30 ~ C , ~ O fO 20 30 0~, ~,.
overlapping - - Fig. 2B. The advantage of
treatment without HAZ overlapping is
the formation of a hardened layer with
more uniform hardness and higher wear
Fig. 2 - - Cross section of the HAZ of plasma hardening and distribution of the hard- resistance on the surface when compared
ness at the surface (Z = 0) of the deposited metal 5 Cr-0.5 Mo-O. 15 V (0.20 O. A - - to the treatment with HAZ overlapping.
Without overlapping of the HAZ; B - - with 30% overlap. At the same time, however, in the latter
case, the depth of the hardened layer is
more stable.
Following impact tests, fractured sur- and after plasma hardening were deter- The structure of the HAZ of a plasma
faces were analyzed with a scanning mined using an X-ray diffractometer jet single-pass hardened surface is inho-
electron microscope. Polished and (Refs. 9, 10) (see Appendix). mogeneous. The quenched zone
etched sections were examined using an Standard metallurgical procedures (marked 1 in Fig. 2) is placed directly
optical metallograph at magnification up were used to prepare samples for hard- below the hardened surface, where the
to 550X. Thin foil electron micrographs ness studies. A Vickers indenter with a rapidly increasing temperature is higher
were obtained at different magnifications 100-g load was used to measure hard- than Ac3. By increasing the distance to
to further analyze the structure of differ- ness along the different regions of the the surface, the transition region of the in-
ent regions of the HAZ. The carbide con- HAZ and the unaffected deposited metal. complete quenched structure (marked 2
tent was determined from the ratio of the The wear testing configuration included in Fig. 2) develops according to the heat-
masses of deposit precipitated during unidirectional metal/metal sliding with ing temperature range Ac3-Ac,. Below
electrolytic distribution and the dissolved an oil-abrasive interlayer between the this zone, the metal of the initial structure
part of the specimen. Phase constitution surfaces. This is related to the wear test- remains unchanged (marked 3 in Fig. 2).
and crystal lattice parameters in speci- ing configuration listed by the American The hardness values obtained in the
mens of deposited metal in an initial state Society for Lubrication Engineers (Ref. 8). quenching zone are relatively constant

26-s I JANUARY 2001

but drop steeply in the transition region
to the values of the initial state of the de-
posited metal - - Fig. 3. It shows the size
of the transition zone is not more than 0.5
mm, so the boundary between the
quenched and initial structures (Fig. 4)
can be described as abrupt.
A narrow (about 2 mm) tempering
zone is present in the quenched zone of
the first pass of the plasma jet, where the
second pass overlaps the first (Fig. 2B),
and the temperature of reheating in this
region is higher than Ac3 (marked 4 in
Fig. 2). The microstructure of the different
regions of the HAZ of the 5 Cr-0.5 Mo-
0.15 V (0.20 C) deposited metal is shown
in Fig. 5.
The initial structure of the 5 Cr-0.5 Mo-
Fig. 4 - - Microstructure of the 5 Cr-0.5 Mo-
0.15 V (0.20 C) deposited metal consists
0.15 V (0.20 C) deposited metal at the
of highly tempered lath martensite. At
boundary of the quenched and initial struc-
larger magnification it is possible to see
ture (400X).
the remaining stretched crystals, contain-
ing polygonal-shaped subgrains - - Fig.
6A. Their dimensions do not exceed the
sheaves (packets) being up to 2 p~m.
thickness of the initial martensite crystals.
Within the limits of one sheaf (packet),
Such a structure is formed in the process
some adjoining subgrains are disoriented
of surfacing of subsequent layers during
at angles of 2 to 3 deg, separated at the
the rapid cooling in the temperature range
plane { 110}(zl I{ 111 }7 by small-angle dis-
of the phase transformation. This results
location subboundaries (mostly twisted).
from rapid heat removal in the base metal,
Such a group can be presented as a
following heating to the temperature of
significant tempering, when the next lay- monocrystal with a layered dislocation
structure, without full relaxation, be-
ers of metal are deposited (Ref. 6). Lower
cause of high dislocation density inside
carbon content in martensite (Table 2),
each subgrain (Ref. 11). In addition to
when compared to the steel composition,
lath martensite, about 15% of the plate
testifies significant tempering takes place.
martensite is also detected in the struc-
At the same time, alloying with
ture of the hardened zone.
chromium, molybdenum, vanadium and
The constitution of the carbide phase
silicon, accompanied by a lower rate of
after plasma hardening is changed fun-
separation and growth of secondary car-
damentally by the dissolution of cemen-
bides, protects some supersaturation of
the s-solid solution (Ref. 11 ) because of a tite and of a large part (more than a half)
of the special carbides. Additionally, the
decrease in the rate of carbon diffusion
martensite matrix is saturated with car-
and an increase in the strength of chemi-
bon and alloying elements, all of which
cal bonds in the crystal lattice of the ~-
lead to an increase in parameters p, (z c/c~
solid solution. The carbon content in the
and Ao~/o~.The martensite structure in the
initial martensite remains high.
The initial structure of the deposited plasma quenching zone is also signifi-
cantly changed by the splitting of mosaic
metal is characterized by the presence of
blocks and an increase in dislocation
a large quantity of carbides. The carbide
phase is represented by cementite Fe3C density to more than an order-- Fig. 6C.
and complex carbides Me23C6.The hard- Such martensite may not be character-
ness of the deposited metal is HV ized on the radiographs as a structure of Fig. 5 - - Optical micrographs of the 5 Cr- 0.5
390-410 (Table 2) and, according to tetragonal crystal lattice featured in di- Mo- 0.15 V (0.20 0 deposited metal at the
modern classification, it can be classified vided doublets. This is explained by the HAZ regions. A - - At the quenched zone
as a martensite-carbide steel. formation of an inhomogeneous tetrago- (marked 1 in Fig. 1); B - - at the tempered
Following surface heating with a nal structure resulting from the partial de- zone with HAZ overlapping (marked4 in Fig.
composition (self-tempering) of marten- I); C - - at the initial structure (marked 3 in
highly concentrated plasma jet, natural
site. Within the martensite laths, thin Fig. 1) (550X).
cooling at a speed of the order of 105°C/s
leads to the formation of a hardened zone plate-like carbide particles (tertiary car-
with a fine-grained martensite structure. bides) oriented in several directions, are
The morphology of martensite at plasma precipitated - - Fig. 6D. The submicro- pering of finely dispersed martensite in
quenching does not change. Mostly lath scopic dimensions of these carbides (sev- the plasma quenched zone is stopped at
martensite is formed; however, it is sig- eral orders less than those of martensite the initial stage. Martensite of this zone in
nificantly fine-grained - - Fig. 6B. The av- laths), the remaining high carbon content its parameters is practically the same as
erage lath thickness, as visible in a thin- in (x-solid solution and the remaining pa- the original martensite. Similar results had
foil plane, is about 0.1 ~tm; the size of rameters (~, c/~ and A~(~ testify self-tem- been received for laser surface hardening

WELDING RESEARCH SUPPLEMENT I 27-s


Fig. 6 - - Electron micrographs of the structure of the 5 Cr-0.5 Mo-O. 15 V (0.20 C) deposited
metal A - - In the initial state (22,000X); B - - martensite laths (marked L 1 to L4) (18,000X); C - -
carbide phase in martensite (marked P) (32,000X); D - - dislocations in martensite (marked S)
(52,000X); E - - retained austenite (marked R) and martensite (32,000X). B through E are after
plasma hardening.
for steels of the same type of composition
(Ref. 12, 13), as well as for plasma hard-
ening of tool steels (Ref. 14, 15).
The retardation of martensite self-tem-
pering during rapid hardening is caused
by inhomogeneity of carbon distribution
in co-solid solution, which is inherited
from austenite in the areas of increased
carbon content (related to the average
carbon content in the initial state of de-
posited metal). These areas are more sta-
ble against the decomposition. Another
confirmation of the retardation in self-
tempering and the concentrated inhomo-
geneity of martensite is the appearance of
a heavily degenerated singlet (002) in the
X-ray structure analysis.
Supersaturation of a solid solution
with carbon and alloying elements as a
result of primary carbide dissolution pro-
motes an increase in hardness of de-
posited metal and a steep increase in dis-
location density with a simultaneous
increase in strength and deformation
ability. The remaining small special car-
bides and submicroscopic tertiary car-
bides in martensite crystals of the
quenched zone cannot be regarded as a
separate hardening phase, but only as a
particular in the stimulation to self-
28-s I JANUARY 2001
harden the martensite phase. Therefore,
the 5 Cr-0.5 Mo-0.15 V (0.20 C) de-
posited metal after plasma hardening
should be classified as belonging not to
the martensite-carbide class but strictly
to the martensite class. Finely dispersed
martensite can play the role of a matrix,
as well as of a strengthening phase. Such
a structure of the hardened metal has a
higher level of mechanical properties as
compared to the initial state - - hardness,
impact strength, dynamic fracture tough-
ness (Table 2). In addition, heat resistance
is increased: hardness around HV 500 re-
mains while the heating temperature is
raised up to 550°C. If stress-relief bulk
tempering is used after hardfacing before
plasma hardening, heat resistance can
reach 570°C (Ref. 1).
The increased retained austenite con-
tent also promotes the improvement of
mechanical properties of the hardened
deposited metal, especially of dynamic
fracture toughness. The y-phase in the
conditions of high heating and cooling
rates, short exposure time during plasma
surface treatment and inhomogeneity of
the solid solution (diminishing of tem-
perature range Ms-Mr), acquires a very
fine-grained structure. Because retained
austenite is located mainly in the inter-
layers between martensite laths (Fig. 6E),
this makes it possible to regard such a
structure as a layered quasi-composite,
like the laser surface treatment of cast
steel of similar composition (Ref. 12).
The special features of the phase and
structural transformation of plasma sur-
face hardening also influence the in-
creasing impact strength and dynamic
fracture toughness of 5% chromium de-
posited metal. The Charpy impact testing
system allowed, in addition to the values
of impact strength, the recording and
identifying of various stages of the failure
process, while measuring the impact ve-
locity, etc. - - Fig. 7. This is especially im-
portant when a complicated failure
process develops for a specimen of hard-
ened steel with the cross section of an
abrupt boundary from the quenched
(harder) structure to the initial (softer)
structure. The failure process is initiated
and extends within the hardened layer.
However, at the boundary, it ceases to
propagate. To continue the failure process
of such a specimen, significantly more
Charpy energy is necessary (Fig. 7B) when
compared to the energy necessary for the
failure of the specimen with a homoge-
neous structure - - Fig. 7A. The data on
impact strength (CVN = 48.0 J) and dy-
namic fracture toughness (Kid = 32.5
MPaqm) of the deposited metal after
plasma surface hardening show the en-
hancement as compared to the results of
the testing with a similar procedure for the
same type of specimens of the bulk-hard-
ened chromium hot-work die steel 5 Cr-
1.7 Mo-0.32 V (0.33 C). In the latter case,
CVN = 36.0 J and Kid = 25.3 MPaqm.
To obtain a better understanding of
the failure micromechanism of plasma-
hardened 5 Cr-0.5 Mo-0.15 V (0.20 C)
deposited metal, a fractographic exami-
nation was carried out on the fracture
surfaces of impact test specimens. The
failure micromechanism of the deposited
metal in the initial state is quasi-brittle, a
combination of transcrystalline cleavage
(dominant) + ductile microvoid coales-
cence - - Fig. 8A. Plasma hardening
causes a qualitative change in the failure Table 1 - - The Calculated Values of the Plasma Jet Heating Temperature and the Cooling Rates
micromechanism, it converts to purely
ductile microvoid c o a l e s c e n c e - Fig. D, mm I, A V, mm/s Heating Cooling rate*,
8B. As the data on the mechanical prop- temperature*, °C 10~ °C/s
erties of the deposited metal show (Table
2), after plasma heat treatment, an in- 6.0 300 7.0 1012/796 5.40/0.36
9.0 844/673 4.21/0.24
crease in hardness of the metal with ex- 400 7.0 1282/1011 9.12/0.87
tremely fine-grained martensite structure 9.0 1078/824 8.03/0.64
develops at the same time as an increase 4.0 300 7.0 802/574 4.25/0.38
in impact strength and dynamic fracture 9.0 663/467 3.16/0.24
toughness. This is the main advantage of 400 7.0 984/673 6.48/0.57
the proposed complex technology, in- 9.0 812/605 4.86/0.42
cluding hardfacing and subsequent
The* in thenumeratorforthedepthZ = 1 mm,in thedenominatorforZ = 3 mm.
plasma surface heat treatment. With tra-
ditional methods of tool and die steel
hardening using a heat treatment, there is Table 2 - - The Effect of Plasma Hardening on the Characteristics of 5Cr-0.5Mo-0.15V (0.20 C)
an increase in hardness usually with a de- Deposited Metal
crease of impact strength and dynamic
fracture toughness. Characteristics In the initial state After plasma hardening
Two competing failure micromech-
Quantity of retained up to 2.0 7.2
anisms of 5% chromium (0.20% C) de- austenite q.,, %
posited metal in the initial state are per- Carbide phase -10% Fe,C Traces Fe,C
formed - - transcrystalline cleavage as -5% Me uC, -2% Me:,C,
well as ductile microvoid coalescence. True physical widening of 0.0027 0.0032
These are conditional on structure inho- diffraction line of o~-Fe[3;,., radian
mogeneity - - the presence of relatively Martensite crystal lattice 2.8731 2.8992
large grains (packets) of highly tempered parameter c~, A °
Carbon content in martensite 0.147 0.195
martensite, large primary carbides and p, % of mass
dispersed particles of the strengthening Degree of tetragonality of 1.0077 1.0109
phase - - primary and secondary car- martensite lattice c/c~
bides. Kottrell's dislocation model is Microdistortions of crystal 0.47 1.18
used to describe the micromechanism of lattice A~o~ x 10
failure by cleavage (Ref. 1 7). According Dislocation density p 3 10,6, m -' 1.7 24.7
to this model, simultaneous slippage of Mosaic block size (of coherent 1.57 0.43
scattering areas) S x 10 ,~,m
dislocations is carried out in two cross- Hardness HV 390-410 520-540
ing planes. By an agglomeration at the Impact strength CVN, J 42.0 48.0
point of joining, new dislocations ap- Dynamic fracture toughness 28.2 32.5
pear. An agglomeration of dislocations Kla MPa~]m
of crossing planes occurs more easily Relative wear resistance 1.0 1.65
than in a distinct plane due to the re-
duction of repulsion forces for disloca-
tions with the same sign and their larger
concentration at the top of an agglomer-
ation. There is a stress concentration in
the vicinity of this top that leads to the
initiation of a brittle microcrack in the
crystallographic plane (100).
Achieving a purely ductile micro-
mechanism of failure of deposited metal
in the plasma quenching zone causes the
presence of submicroscopic particles of
carbides in the finely dispersed marten-
site matrix and high dislocation density.
To describe a micromechanism of dimple
rupture of ductile metal, with precipita-
tion of a dispersed strengthening phase,
Yokobori's dislocation model can be
used (Ref. 1 7). According to this model,
carbide particles and inclusions are the
obstacles to the dislocation movement. Fig. 7 - - Load-time response for Charpy notched bar impact test of the 5 Cr-0.5 Mo-O. 15 V (0.20
They create the stress concentration C) deposited metal. A - - In the initial state; B - - plasma hardened.
areas, cause slippage of dislocations and
develop dislocation cracks such as mi-
crocavities prior to the onset of the grow- ities take place. From a finite moment, character of distribution of the secondary
ing macrocrack. The failure is accompa- the localized deformation of ligaments phase particles determine the size of the
nied by macroductile deformation while between cavities is increased until the microcavities. Microcavities can be seen
the growth and merging of adjoining cav- ligaments break. The fragmentation and on the fracture surface - - Fig. 8B.

WELDING R E S E A R C H S U P P L E M E N T J 29-s

Fig. 8 - - Fracture surface from room temperature impact test of specimens of the 5 Cr-0.5 Mo-
O.15 V (0.20 0 deposited metal by means of a scanning electron microscope (400)0. A - - In
the initial state; B - - after plasma hardening.
Conclusions
The results, based on the investiga-
tions, confirm the effect of surface hard-
ening by a highly concentrated plasma
jet on the structure and mechanical prop-
erties of 5 Cr-0.5 Mo-0.15 V (0.20 C) de-
posited metal validates the following
conclusions:
• The structure of the deposited metal
in the initial state is highly tempered lath
martensite. The carbide phase is repre-
sented by cementite Fe3C and special
carbides Me2~C6.
• Plasma heat treatment of the de-
posited metal leads to full phase recrys-
tallization and rapid quenching with for-
mation of a hardened layer of very finely
dispersed martensite structure. Marten-
site morphology does not change; lath
martensite is being formed. Self-temper-
ing of martensite in the plasma quenched
zone is stopped at the initial stage and its
parameters are practically the same as
the original martensite.
• During plasma hardening, the full
dissolution of the cementite phase and of
the major part of the special carbides
takes place, which leads to additional
saturation of the solid solution with car-
bon and alloying elements. As a result,
there is an increase in the martensite
crystal lattice parameter 0c, degree of
tetragonality c/~c and microdistortions of
the crystal lattice A0c/cc. Hardness in-
creases from HV 390-410 to HV
520-540. The sharp rise in dislocation
density p and mosaic block size reduc-
tion S govern the simultaneous rise in
hardness, impact strength CVN and dy-
namic fracture toughness Kid.
• The rise in the dynamic fracture tough-
ness of the plasma-hardened deposited
metal is caused by qualitative alteration of
the micromechanism of failure from trans-
crystalline cleavage (Kottrell's dislocation
model) to ductile microvoid coalescence
(Yokobori's dislocation model).
30-s I JANUARY 2001
12. Molian, P.A. 1985. Structure and hard-
ness of laser-processedFe-0.2% C-5% Cr and
Fe-0.2% O10% Cr alloys. Journal of Material
Science 20:2903-2912.
13. Molian, P. A. 1986. Engineering appli-
cations and analysis of hardening data for laser
heat treated ferrous alloys. Surface Engineer-
ing 2(1): 19-28.
14. Leshchinskiy, L. K., et al. 1985. Struc-
ture and properties of deposited metal on car-
bon steels hardened with a plasma jet. Weld-
ing Production 32(11 ): 34-36.
15. Samotugin, S. S. 1998. Plasma treat-
ment of tool steels. Welding International
12(3): 225-228.
16. Hellan, K. 1984. Introduction to Frac-
ture Mechanics. New York, N.Y., McGraw-
Hill, pp. 142-153.
17. Yokobori, T. 1968. An Interdisciplinary
Approach to Fracture and Strength of Solids.
Acknowledgments
Groningen, Wolters-Noordhoff Scientific Pub-
lications, pp. 123-157.
The authors are grateful to V. Goritsky,
D. Khromov and E. Zarkhova for EM met-
Appendix: The Determination of
allographs, and to N. Solyanik, E. Lok-
Phase Constitution and Crystal
shina, O. Novohatskaya, V. Velgovol-
Structure Parameters
skaya, S. Disenhof and T. Kiritseva for
their help in carrying out this work.
The crystal structure of 5 Cr-0.5 Mo-
0.15 V (0.20 C) deposited metal in the
References
initial state and after plasma hardening
described in this study was determined
1. Leshchinskiy, L. K., Samotugin, S. S.,
using X-ray diffraction analysis.
Pirch, I. I., and Komar, V. I. 1990. Plasma Sur-
The martensite crystal lattice parame-
face Hardening. Kiev, Tekhnika. pp. 5-9,
ter cc was calculated from the equation
45-53.
based on Bragg's law:
2. Materials and Processes. Third Edition.
1985. Part A: Materials. New York, N.Y., pp.
~. = 20c.sin0/qh2+k2+12
255-259.
3. Gurarie, V. N. 1984. Hardening in steels
where ~, is the X-ray wavelength (for Fe
subjected to high-velocity intensive plasma
Kccradiation ~, = 1.936A°); 0c is the lattice
treatment. Metals Forum 7(1 ): 12-21.
spacing of martensite planes (h, k, I
4. Arata, Y. 1986. Plasma, Electron and
planes); h, k, I are the Miller indexes of
Laser Beam Technology. ASM International,
the diffracted direction; 20 is the angle of
Materials Park, Ohio, pp. 568-579.
deflection of the crystallographic planes
5. Metals Handbook. Vol. 4. 1995. Heat
[110]~; and [220]~ (the angle was mea-
Treating. ASM International, Materials Park,
sured accurately). The structure factors
Ohio, pp. 291-307.
were obtained from the experimental dif-
6. Leshchinskiy, L. K., Samotugin, S. S.,
fraction pattern and the result was deter-
Goritsky, V. M., Khromov, D. P., and Zarkhova,
mined by the extrapolation of parameters
E. I. 1996. Structure and crack resistance of
18Cr6MoVMnSi deposited metal after plasma CCuoand (~220to O[g._~90deg.
The carbon content in the martensite
strengthening. Avtomat. Svarka 8: 31-35.
p was calculated based on the inter-
7. Standard Test Methods for Mechanical
doublet distance A0 using the calibration
Testing of Metals. The Determination of the
graphical chart of A0 = f(p).
Dynamic Fracture Toughness (Crack Resis-
The degree of tetragonality of the
tance) RD 50-344-82. 1982. Moscow, USSR,
martensite lattice was obtained as c/co =
Standards.
1+0.0467p.
8. Metals Handbook. Vol. 8. 1995. Me-
The microdistortions of the crystal lat-
chanical Testing. ASM International, Materials
tice were calculated from ga/~c = 132J4
Park, Ohio, pp. 259-268, 601-603.
tg e220, where 13is the interaxial angle.
9. Mirkin, L. I. 1976. X-ray Structural
The dislocation density p was deter-
Analysis. Moscow, Nauka, pp. 135-149.
mined from the following equation: p =
10. Vasilev, D.M. 1977. Diffraction Meth-
2.4 [32u0 x 1016, m-2.
ods in Structural Analysis. Moscow, Metal-
lurgiya, pp. 67-78.
11. Kurdjumov, G. V., Utevskiy, L. M., and
Entin, R. I. 1977. Transformations in Iron and
Steel Moscow, Nauka, pp. 58-69, 105-114.
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