Aluminum lends itself to a wide variety of industrial

applications, but because its chemical andphysical properties set it apart from other metals,

welding of aluminum requires special processes, techniques,and expertise. At this conference, a distinguished panel of aluminum-

industry experts will survey the state of the art in aluminum weldingtechnology and practice

Gathered in one place at one time:The best and the brightest minds

in aluminum welding

Welding Aluminum 2006The 10th AWS/AA Aluminum Welding

ConferenceOctober 30-31, 2006

at the FABTECH & AWS Welding Show,Atlanta, Georgia

Sponsored by

MONDAY, OCTOBER 30, 2006

8:30 AM - 12:30 PM SESSION I:

INTRODUCTION

1. WELCOME AND OVERVIEW OF ALUMINUM WELDING

Tony Anderson, ESAB Welding & Cutting Products,Florence, SC

Mr. Anderson will present an overview of alu-minum welding applications, the many alloysinvolved, appropriate welding processes, andfundamental differences between the weldingof aluminum and other materials.

2. THE ALUMINUM DESIGNATION SYSTEM& CHARACTERISTICS OF ALUMINUM ALLOYS

Peter Pollak, The Aluminum Association, Inc.,Washington, DC

Mr. Pollak will explain The AluminumAssociation’s aluminum alloy and temper designation system, and the physical andmechanical properties of aluminum alloys.

3. ALUMINUM WELDING METALLURGY

Frank G.Armao,The Lincoln Electric Company, Cleveland, OH

Mr. Armao will focus on the basics of aluminumalloy metallurgy, the effects of welding on alloyproperties, filler alloy selection, and judicioususe of preheat.

10:45 AM - 11 AM Refreshment Break

4. FILLER ALLOY SELECTION

Tony Anderson, ESAB Welding & Cutting Products,Florence, SC

The design of successful welding procedurespecifications requires an understanding of filleralloy selection variables, including welded component service requirements and the char-acteristics of the base alloy being welded. Mr.Anderson’s presentation will provide such anunderstanding.

5. METAL PREPARATION FOR ALUMINUM WELDING

William Christy, Novelis Inc., Kingston, Ontario, Canada

Mr. Christy will discuss metal preparation, oneof the key steps in producing good qualitywelded joints.

12:30 PM - 1:30 PM Lunch

1:30 PM - 4:45 PM SESSION II:

FUSION WELDINGPROCESSES

6. GAS METAL ARC WELDING OF ALUMINUM ALLOYS

Frank G.Armao,The Lincoln Electric Company, Cleveland, OH

Mr. Armao will explain metal transfer modes,shielding gas types, wire feed systems, andpower source selection: constant voltage, con-stant current, pulse, or variable polarity.

The American Welding Society and The Aluminum Association invite you to explore the manyindustrial applications and processes for welding of aluminum. This wide-ranging conferencewill include a metallurgical overview of aluminum and its many alloys, filler alloy selectionand metal preparation, fusion and solid-state welding processes, and techniques for design-ing welds to ensure maximum performance.

Conference attendees also will have ample opportunity to network informally with the presenters and other participants, and to enjoy the many activities and exhibits of the annualFABTECH & AWS Welding Show in Atlanta’s Georgia World Congress Center.

Conference Program

Welding Aluminum 2006The 10th AWS/AA Aluminum Welding Conference & Exhibition

October 30-31, 2006

7. GAS TUNGSTEN ARC WELDING AND VARIABLE POLARITY PLASMA ARC WELDING OF ALUMINUM

William Christy, Novelis Inc., Kingston, Ontario, Canada

Mr. Christy will discuss the application of gastungsten arc welding and variable polarityplasma arc welding to the welding of aluminum.

3 PM - 3:15 PM Refreshment Break

8. HIGH ENERGY DENSITY BEAM WELDING OF ALUMINUM

William Christy, Novelis Inc., Kingston, Ontario, Canada

Mr. Christy will discuss laser and non-vacuumelectron beam welding of aluminum alloys.

9. APPLICATION OF THE AWS STRUCTURAL WELDING CODE—ALUMINUM

Tony Anderson, ESAB Welding & Cutting Products,Florence, SC

Mr.Anderson serves on the D1.2 Committee. Hewill reveal the extent of the Code's latest revi-sion: when, where, and how to apply AWSD1.2/D1.2M:2003, Structural Welding Code—Aluminum, for qualification provisions to ensurequality workmanship and structural integrity.

TUESDAY, OCTOBER 31, 2006

8:30 AM - 11 AM SESSION III:

DESIGN

10. DESIGN AND PERFORMANCE OF ALUMINUM WELDS

Tony Anderson, ESAB Welding & Cutting Products,Florence, SC

Mr. Anderson will explain how to extract maxi-mum performance from aluminum welds byfactoring strength, toughness, fatigue, corro-sion, and other variables into their design.

11. ALUMINUM WELD DISCONTINUITIES:CAUSES AND CURES

Kyle Williams, Alcoa Technical Center, Alcoa Center, PA

Mr.Williams will review discontinuities normallyencountered in aluminum arc welds, methodsto detect them, possible causes of the faults,and the means to avoid them.

12. ROBOTIC APPLICATIONS

Frank G.Armao,The Lincoln Electric Company, Cleveland, OH

Mr. Armao will review the latest developmentsin arc welding power source design and wirefeeding concepts for robotic arc welding of alu-minum. New programmable power source out-put wave forms for popular aluminum wirechemistries offer additional flexibility for thoseseeking to optimize production applications.

10:45 AM - 11 AM Refreshment Break

11 AM - 4:30 PM SESSION IV:

SOLID STATE PROCESSES

13. OVERVIEW OF SOLID STATE JOINING PROCESSES FOR ALUMINUM

Donald J. Spinella, Alcoa Technical Center,Alcoa Center, PA

Mr. Spinella will provide an overview of solid-state joining processes used on aluminum,including ultrasonic, upset butt, flash, friction,high frequency, and explosive welding.

14. FRICTION STIR WELDING OF ALUMINUM ALLOYS

Jeff Defalco, ESAB Welding & Cutting Products,Florence, SC

Mr. Defalco will present friction stir welding asa viable solid-state aluminum welding processduring which parent material melting, fillermetal, and shield gases are absent. He willdescribe the benefits of eliminating the illeffects caused by solidification.

12:30 PM - 1:30 PM Lunch

15. MECHANICAL FASTENING

Jim Hutchison, Alcoa Fastening Systems, Waco, TX

Mr. Hutchison will discuss aspects of mechanicalfastening for aluminum and for multi-materialcombinations. He will compare various typesof mechanical fastening systems, adhesives,and welding, and describe each system’sadvantages and drawbacks.

16. RESISTANCE SPOT WELDING OF ALUMINUM

Donald J. Spinella, Alcoa Technical Center, Alcoa Center, PA

Mr. Spinella will review resistance weldingprocesses commonly used to join light-gaugestructures, highlighting design, performance,quality assurance, and production issues asso-ciated with aluminum.

3:15 PM - 4:00 PM Panel Discussion

SPEAKERS’ BIOGRAPHIES

Tony Anderson is the corporate technical trainingmanager for ESAB North America. Prior to his cur-rent position he was the technical director ofAlcoTec Wire Corporation. He holds a B.S. degreein welding engineering and an M.S. degree inindustrial engineering management and qualityassurance. He is a Senior Member of the TheWelding Institute and a Registered CharteredEngineer with the British Engineering Council UK.He chairs the Aluminum Association TechnicalAdvisory Committee for Welding and Joining. He ischairman of the AWS Subcommittee on AluminumPiping, vice chairman of the AWS Subcommittee 7on Aluminum Structures, and a member of severalother AWS committees and subcommittees. Hewrites a question and answer column for theWelding Journal. Mr. Anderson is a CertifiedQuality Engineer with the American Society forQuality, a Fellow of the International Association ofQuality Practitioners, and an AWS Certified WeldingInspector and Certified Welding Educator.

Frank G. Armao is a member of the LincolnElectric Company’s Welding Technology Center.Asgroup leader for non-ferrous materials, he isresponsible for evaluating customer welding pro-cedures, equipment, and consumables for alu-minum applications to improve quality andfunctionality and to reduce fabrication costs. Healso carries out domestic and international train-ing programs for customers and distributors.Before joining Lincoln Electric in 1999, Mr. Armaowas a technical specialist for Alcoa, Inc., at theAlcoa Technical Center, where he led the arc-weld-ing group, managed large automotive prototypingprograms, and helped to set up production lines.Mr. Armao earned his B.S. and M.S. degrees inmetallurgical engineering from the PolytechnicInstitute of Brooklyn. He is a member of AWS andASM International, and is a former CertifiedWelding Inspector. He has presented papers andconducted seminars on aluminum welding tech-nology. He serves on the AWS Welding HandbookCommittee, chairs the AWS D1(H) AluminumSubcommittee and the AWS D10.7 Subcommittee,and is a member of the D1 Main Committee andthe Aluminum Association Technical AdvisoryPanel on Welding and Joining.

William Christy is a Welding Specialist atNovelis, Inc. (formerly Alcan) in Kingston, Ontario,Canada. After graduating from St. LawrenceCollege in Kingston with a diploma in mechanicalengineering technology, he joined the Researchand Development Centre of Alcan where he heldpositions in structural testing and smelter reduc-tion technology. In 1980, he joined the weldingdivision. Since then, he has worked on new alloydevelopment, welding wire testing, explosivewelding of pipelines, joining of composites, met-allizing for corrosion and wear protection, anddeveloping weld procedures for automotive appli-

cations using most welding processes, includingelectron beam and laser welding. Mr. Christy is amember of the Aluminum Association's AdvisoryPanel on Welding and Joining, a member of AWS,and a member of the AWS D3 and D8Subcommittees.

Jeff Defalco is the welding automation businessmanager for engineering systems at ESABWelding and Cutting. He holds a Master’s degreein international management and engineering sci-ences. He has been instrumental in promotingESAB’s 12 years of experience in producing robustfriction stir welding systems. He has given pre-sentations throughout North America on topicssuch as Friction Stir Welding Basics; Applications;Joint Configurations; and How To Weld Faster,Thicker, and Easier.

Jim Hutchison is the global marketing managerfor Alcoa Fastening Systems (AFS) CommercialProducts Group in Waco, TX. He studied advertis-ing management and general studies at OhioUniversity and Indiana University. Mr. Hutchisonhas 28 years of experience in the fastener indus-try (including 16 years with AFS) in sales, salesmanagement, and marketing, with a focus onproduct and application training.

Peter Pollak is manager of product standardsand electrical services for The AluminumAssociation in Washington, DC. He has worked forWestinghouse Electric, RCA Institutes, and GeneralCable Corp. Mr. Pollak is a member of AWS, TheMetallurgical Society, the American Society forTesting and Materials, and the Institute ofElectrical and Electronic Engineers. A registeredProfessional Engineer, licensed in Washington, DC,Virginia, New York, and New Jersey, he receivedhis B.S. and M.S degrees in electrical engineeringfrom New York University.

Donald J. Spinella is responsible for resistanceand forge welding activities at the Alcoa TechnicalCenter. Previously, he designed and tested arcwelding power supplies for The Lincoln ElectricCompany. He received his B.S. and M.S. degreesin electrical engineering from Case WesternUniversity. He has authored papers, conductedpresentations, and holds three patents. His inter-ests include power systems, manufacturing, andprocess control.

Kyle L. Williams is a welding technologist withinthe Product Manufacturing Division of the AlcoaTechnical Center, providing domestic and interna-tional joining support to Alcoa’s customers andbusiness units. He joined Alcoa, Inc., in 1987. Hereceived an Associate of Science degree in weld-ing engineering technology from WestmorelandCounty Community College in Youngwood, PA. Mr.Williams is an AWS Certified Welding Inspectorand serves on the Aluminum Association’sTechnical Committee on Welding & Joining andthe AWS D1.2, Structural Welding Code—Aluminum Committee.

CONFERENCE REGISTRATION FEES

Code: COAC-10AWS/AA Member: $550Nonmember: $680

Your conference registration fee includes twolunches and all refreshment breaks. You willreceive a CD containing copies of all presenta-tions, an attendee roster, an exhibit roster, aspeaker roster for post-event interaction andfollow-up, and the following complimentarybooks:

• AWS D1.2/D1.2M:2003, Structural Welding Code—Aluminum (a $132 value)

• Welding Aluminum: Theory and Practice,Fourth Edition, 2002 (a $100 value)

• Aluminum Standard and Data - 2003(a $115 value)

• Pink Sheet - Designation and Chemical Composition Limit for Aluminum Alloys in the Form of Casting and Ingot, April 2002 (a $22 value)

• Teal Sheet - International Alloy Designations and Chemical Composition Limits for Wrought Aluminum Alloys, April 2004 (a $30 value)

Call now to register: 800-443-9353, ext. 224.

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