iIValue-Time-Weighted Average (TLV ®- TWA) from 0.2 milligrams per cubic meter (mg]m 3) to 0.03...

O

November ,,.\ . ~ "...~

r. i i I •

1 t I

and Adva~nces Electroslag Claddii~g Wins Havy Approval ~~':

/ I, PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING

0 0

"THE GOLD MEDAUSTS" There are four good reasons why KOBELCO

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Kobelco's most advanced manufacturing facility enables us to produce high quality wires spool after spool.

Kobelco has highly reliable production management system and quality assurance system which is sometimes called "Kobelco Standard" by major heavy industries.

Kobelco Flux-cored wire know-how's were developed based on 100% C02 shielding gas market. Accordingly, you can get super results when used in Ar-C02 mix shielding gas in terms of less spatter and low fume levels.

Kobelco has the largest Research and Development Organization that enables us to create a product just right for specific demands.

Our Gold Meda l is ts DW Stainless Series (for all major stainless alloys1 .~,~

- - - A . " ~ :

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DW-50 (AWS E71T-1/1M)

DW-50 is an All Position Flux-cored wire with fast-freeze formulation. DW-50 has the Lowest Fume Level compared to other brands and has excellent weldability not only in flat and horizontal position but in vertical and overhead welding as well.

Fr0ntiprc-711 (AWS E71 T-1/1 M, 12/12M) Frontiarc-711 is an All Position Flux-cored wire with medium-freeze formulation. Because of its Stable Arc and Fluid Nature, Frontiarc-711 is excellent for long, continuous welds that demand consistency. Fluid Weld Puddle allows Frontiarc-711 to be more forgiving when welding through mill scale or rust.

MXA-70C6 (AWS E70C-6M) MXA-70C6 is a highly efficient Metal-cored wire for carbon steel. MXA-70C6 has an Excellent Wide Range Spray Transfer which eliminates much of the spatter generation.

KOBELCO WELDING OF AMERICA INC. CircleNo. 29 on Reader lnfo-Card

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AR02-6

THE WELDING EXPERTS

CONTENTS Features

41

November 2002 • Volume 81 • Number 11

Electroslag Process Clads Ship Shafts A West Coast forging company qualifies the electroslag process to Navy requirements L. S c o t t a n d R. A n d r e i n i

4 3 A New Metal Spray Option The concept of "cold spray" heats up as the application of this solid-state deposition process gains momentum J. Intrater

4 8

5 0

5 3

Mark This Event m A Great Show Is Coming Your Way Prepare for a Golden Anniversary celebration as the AWS Welding Show gears up for 2003

Thermal Spray Basics Different thermal spray processes are broken down into their fundamentals T. D e g i t z a n d K. D o b l e r

Recent Advances in Cored Wires for Hardfacing Ease of use and ability to automate contribute to the growing market for cored hardfacing welding wires R. Menon

Welding Research Supplement

233-s The Effect of Multiple Postweld Heat Treatment Cycles on the Weldability of Waspaloy® Postweld heat-treatment cycles were simulated to study the effect on liquation cracking susceptibility in the heat-affected zone M . O i a n a n d d . C . L i p p o l d

AWS Web site http://www.aws.org

Departments Press-Time News ................ 4

Editorial ............................ 6

News of the Industry . . . . . . . . . . . . 10

CyberNetes . . . . . . . . . . . . . . . . . . . . . . 14

Letter to the Editor . . . . . . . . . . . . . . 16

AWS Financial Report . . . . . . . . . . 24

New Products .................... 34

Navy Joining Center . . . . . . . . . . . . 60

Welding Workbook . . . . . . . . . . . . . . 61

Coming Events . . . . . . . . . . . . . . . . . . 62

Society News . . . . . . . . . . . . . . . . . . . . 67

Guide to AWS Services . . . . . . . . . . 82

Stainless Q&A . . . . . . . . . . . . . . . . . . . . 86

New Literature .................. 91

Personnel ........................ 94

Classifieds ........................ 95

Advertiser Index .................. 97

239-S Microstructual Variations in a High- Strength Structural Steel Weld under Isoheat Input Conditions Microstructural variations and their relationship to heat input and welding parameters were studied as they related to mechanical properties B. B a s u a n d R. R a m a n

249-S Keyhole Double-Sided Arc Welding Process Narrow-groove welding of thick sections was accomplished with two opposing torches Y. M. Zhang et al.

256-SAging of Braze Joints: Interface Reactions in Base Metal/Filler Metal Couples, Part Ih High-Temperature Au-Ni-Ti Braze Alloy The mechanical performance of a brazing alloy shows promise for applications where long-term aging and exposure to elevated temperatures are factors P. T. V i a n c o e t al.

Welding Journal (ISSN 0043-2296) is published monthly by the American Welding Society for $90.00 per year in the United States and p o s s e s -

s i o n s , $130 per year in foreign countries: $6.00 per single issue for AWS members and $8.00 per single i s s u e f o r nonmembers. American Welding So- ciety is located at 550 NW LeJeune Rd., Miami, FL 33126-5671; telephone (305) 443-9353. Periodi- cals postage paid in Miami, Fla., and additional mailing offices. I~$1ffilsIr~: Send address changes to Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126-5671.

Readers of Welding Journal may make copies of articles for personal, archival, educational or research purposes, and which are not for sale or resale. Per- mission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright.

t W E L D I N G J O U R N A ~

PRESS TIME NEWS J

NWSA Changes Name The board of directors of the National

Welding Supply Associat ion (NWSA) unanimously approved changing the organization's name to Gases and Welding Distributors Association (GAWDA) at its recent annual convention in Orlando, Fla.

Executive Director Rick Doyle said a search for a name that more accurately re- flects the business of the members and business NWSA represents began more than a year ago. The new name represents

a stronger focus on a broader segment of the industry, i.e., those in health and home care and helium and CO 2 beverage business, and recognizes the organizat ion 's members come from Canada as well as the United States. The new name and a new logo were revealed during the convention.

More information on the organization, which is headquar tered in Philadelphia, Pa., can be obtained on its Web site at www.gawda.org.

ACGIH Seeks Comments on Manganese Limits

The American Conference of Govern- mental Industrial Hygienists (ACGIH®) announced in January 2002 that manganese was one of the substances added to the Notice of Intended Change (NIC). Manganese was added to the NIC with a proposal to lower the Threshold Limit Value-Time-Weighted Average (TLV ®- TWA) from 0.2 milligrams per cubic meter (mg]m 3) to 0.03 mg/m 3 respirable. The TLV-TWA is the t ime-weighted average concentration for a conventional 8-hour work day and a 40-hour work week, to which it is believed that nearly all workers may be repeatedly exposed, day after day, without adverse effect.

Proposal to Lower

The proposed reduction of the TLV from 0.2 mg/m 3 (total particulate) to 0.03 mg/m 3 (respirable particulate) represents nearly an order of magnitude reduction. If implemented, it may have a significant impact on the welding industry, potentially resulting in increased requirements for welders to use air-supplied respirators to comply with the proposed TLV.

The A C G I H requests comments or suggestions concerning this action, accompanied by substantiating evidence in the form of peer-reviewed articles, be sent to The Science Group, ACGIH, 1330 Kem- per Meadow Dr., Cincinnati, OH 45240.

North American Market for Welding Equipment and Supplies to Cross $4.6 Billion by 2007

The North American market for metal welding equipment and supplies is estimated at $3.9 billion in 2002 and is expected to grow at a 3.5% average annual rate to more than $4.6 billion in 2007. The information is part of a soon-to-be-released study from Business Communica- tions Co., Inc., Norwalk, Conn., www. bcc research, com.

According to the study, titled RGB-264 Metal Welding Equipment and Supplies, the overall welding market is keeping up with the GDP and inflation.

The study says in part: "Welding is a mature market in North America, serving industries such as automotive, fabrication, shipbuilding, and infrastructure, all of which are either cyclical, static, or in de- cline. Many welding manufacturers grow by acquisition or by taking sales from competitors. To grow, they are diversifying in related industrial products, consultation, or inventory management. Despite this, growth opportunities exist in metal welding equipment and supplies. Some firms are adapting welding technology to serve other uses and thus expanding into new

markets. A few are introducing new welding technology or reintroducing improved versions of older technology that had been abandoned. Since infrastructure building requires large amounts of metal welding, some firms have expanded into the most rapidly developing Third World nations. As always, resourceful and creative manufacturers find ways to make a profit."

Welding areas the study states are growing faster than average include

• Orbital welding, which is growing rapidly in the Third World. The market is estimated at $18 to $20 million per year in 2002.

• Low cost gas metal arc welding kits being sold through mass merchandis- ers rather than through tradi t ional welding distributors. The process is re- placing oxyfuel welding in consumer markets.

• Industrializing Third World nations are building infrastructure, which requires welding equipment of all kinds. Export markets for welding are generally healthier than domestic markets.

I E 1 NOVEMBER 2002 I

Publisher Jeff Weber Assistant Publisher Christine Tarafa

Editorial Editor/Editorial Director Andrew CuUison

Senior Editor Mary Ruth Johnsen Associate Editor Susan Campbell

Assistant Editor Doreen Yamamoto Peer Review Coordinator Doreen Kubish

Contributing Editor Bob Irving

Graphics and Production Creative Director Jose Lopez

Production Editor Zaida Chavez

Advertising National Sales Director Rob Saltzstein

National Sales Representative Sheila Tait Advertising Sales Promotion Coordinator Lea Garrigan

Advertising Production Frank Wilson

Subscriptions Orlando Collado

American Welding Society 550 NW LeJeune Rd., Miami, FL 33126

(800) 443-9353, ext. 290

Publications, Expositions, Marketing Committee G. D. Uttrachi, Committee Chairman

WA Technology, LLC G. O. Wilcox, Vice Chairman

Thermadyne Industries J. D. Weber, Secretary

American Welding Society P. Albert, Krautkramer Bmuson

T. A. Barry, Miller Electric Mfg. Co. C. E. Boyer, ABB Robotics

T. C. Conard, ABICOR Binzel D. L. Doench, Hobart Brothers Co. J. R. Franklin, Sellstrom Mfg. Co.

N. R. Helton, Pandjiris, Inc. E. C. Lipphardt, Ex Off., Consultant

V. Y. Matthews, The Lincoln Electric Co. G. M. Nally, Consultant

R. G. Pali, J. P. Nissen Co. S. Roberts, Whitney Punch Press

J. E Saenger, Jr., Edison Welding Institute R. D. Smith, The Lincoln Electric Co.

D. Trees, John Deere & Co. B. Damkroger, Ex Off-, Sandia National Laboratories

D. C. Klingman, Ex Off., The Lincoln Electric Co. L. G. Kvidahl, Ex Off, Northrop Grumman Corp.

D. J. Landon, Ex Off, VermeerM/g. Co. E. D. Levert, Ex Off., Lockheed Martin Missiles and Fire Control

T. M. Mustaleski, Ex Off., BWX'I:Y12LLC J. G. Postle, Ex OK, Postle Industries

William A. Rice, Jr, Ex Off., American Welding Society

Copyright © 2002 by American Welding Society in both printed and electronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

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Weldk~lg wire to robotic standards. Circle No. 31 on Reader Info-Card

i ~ 'dX'. { i - ~ L s x'.,0 . . . . . i.o

EDITORIAl

Show Your Support

A year has quickly passed since I successfully fulfilled my quest to become treasurer of the American Welding Society. When I decided to seek this position, I had very little idea of everything that would happen this year.

I knew, of course, that the treasurer 's main duty is overseeing the financial health of the Society and serving as an advisor regarding the organizat ion 's financial future. The posit ion inheri ts o ther duties as well: chair of the F inance Commit tee , m e m b e r of the Board of Directors and Executive Commit tee , t reasurer of the AWS Foundat ion , and member of some awards committees, to name a few. Much of this I knew and p lanned for in accepting the title. I expected to be involved with all the entities that have a financial bearing on the Society. But what I did not foresee was just how involved I would become with the operations and personnel of the Miami office.

There have been some trying times this year, but we have weathered them and con- t inue to improve our operations daily. Executive Director William Rice has been an im- measurable asset to our progress and, with the cooperat ion of a t remendous staff, has begun to turn us once again toward the profitability needed to sustain us in the future.

I can tell you our f inancial posit ion is very solid. While we are not yet able to put a lot back into our reserve accounts, we are more than able to meet our routine expenditures as well as improve staff efficiency by providing them with the upgraded equipment they need to serve you better.

Yes, as treasurer of AWS, I can tell you we are financially sound and will be for a long time, bu t money is only part of what keeps the Amer ican Welding Society going. The key to keeping this organizat ion vital is the support it gets from you. AWS is your professional society. It is your involvement that defines our Sections, committees, and the AWS Welding Show. We need you to be active members. Your Sections need at tendance at the local meetings, the districts need your presence at the conferences, and nat ional needs you at the Show.

You can really make a difference in this organization merely by a t tending this year 's Show April 8-10 at Detroit 's Cobo Conference/Exhibition Center. Suppliers need a reason to exhibit; you are that reason. We need you, the members , and your companies to make the extra effort to assure your at tendance in Detroit. Many of you have asked how to show suppor t for AWS and this is one of the best ways I can think of. Not only will you be helping your own vendors and all the other manufacturers of welding equipment and accessories, you'll be helping yourself. The Show presents so many educational and networking opportuni t ies that you ' re sure to leave there with your welding knowledge increased.

The Amer ican Welding Society cont inues to move forward, but it needs your help. Now is the oppor tun i ty for you to suppor t AWS, your vendors , and your industry by being a part of this year's AWS Show in Detroit.

I realize the treasurer is supposed to talk about our financial needs, but our real need is your involvement in all aspects of the Society. With your active par t ic ipat ion, the money will take care of itself.

Earl C. Lipphardt /1 WS Treasurer

E , 1 B NOVEMBER 2002 I

Founded in 1919 to Advance the Science, Technology and Application of Welding

O f f i c e r s President E. D. Levert

Lockheed Martin Missiles and Fire Control

Vice President T. M. Mustaleski BWXT-Y12LLC

Vice President James E. Greer Moraine Valley Community College

Vice President Damian J. Kotecki The Lincoln Electric Co.

Treasurer Earl C. Lipphardt Consultant

Executive Director William A. Rice, Jr. American Welding Society

D i r e c t o r s

O. AI-Erhaycm (At Large),JOMlnstitute

R. L Am (Past President), Teletherm Technologies, Inc.

A. J. Badeaux, Sr. (Dist. 3), CrosslandHigh School

H. J. Bax (Dist. 14), Cee Kay Supply

M. D. Bell (Dist. 22), Preventive Metallu~

L. J. Bennett (Dist. 21 ), Allan Hancock College

J. C. Brusk0tter (Dist. 9), Project Specialists, Inc.

C. E Burg (Dist. 16),Ames Laboratory

N. A. Chapman (Dist. 6), Entergy Nuclear Northeast

S. C. Chapple (Dist. ll),Flex-N-Gate, LLC

N. C. Cole (At Large ), NCC Engineering

W. J. Enger0n (Dist. 5), EngineeredAlloy/Systems & Supply

A. E Fleury (Dist. 2),A. E Fleury&Associates

J. R. Franklin (At Large), Sellstrom Mfg,. Co.

J. A. Grantham (Dist. 20), WJMG West

J. D. Heikkinen (Dist. 15), Spartan Sauna Heaters, Inc.

W. E. Honey (Dist. 8),AnchorResearch Corp.

J. L. Hunter (Dist. 13 ), Mitsubishi Motor M fg. o[ America, Inc.

R. D. Kellum (At Large), Willamette Welding Supply

M. D. Kersey (Dist. 12), The Lincoln Electric Co.

R. C. Lanier (Dist. 4), Pitt Community College

G. E. Lawson (At Large), ESAB Welding & Cutting Products

V. Y. Matthews (Dist. 10), The Lincoln Electric Co.

J. L. Mend0za (Dist. 18), City Public Service

L. W. Myers (Past President), Consultant

G. H. Putnam (Dist. 1), ThermalDynamics

O. P. Reich (Dist. 17), Texas State Technical College at Waco

R. J. Tabernik (Dist. 7), The Lincoln Electric Co.

G. E. Uttrachi (At Large), WA Technology, LLC

P. E Zammit (Dist. 19), Brooklyn Iron Works, Inc.

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Practical Reference G.utde. to Welding T,tan,um

FMPK: 2 0 0 0 Filler Metal Comparison Charts and CD-ROM Get the working knowledge you need: There are thousands of filler metal products, each with a distinctive trade name - - most conforming within AWS' filler metal classifications. In the marketplace, right now. You need the ultimate guide - - the 2000 edition of Filler Metal Comparison Charts.

FMC: 2 0 0 0 This first edition since 1993 has: • 83 national and international suppliers along with

their mailing address, telephone, fax and website address-- over half were not in the 1993 FMC

• Handy indexes arranged by classification numbers (1,500) and brand names (ll,00O) for fmding information quickly

• AWS classifications used as "chapters" • 438 pages, 8-1/2"x 11", softbound

F M D M : 2 0 0 0 Now with a super software aid - - The Filler Metal Data Manager • Searchable by welding process, filler metal alloy,

filler metal specification, company name and product name

• Technical support by email • Search results preserved as "preferred lists" • Special annotation fields on pop-ups~, Book (FMC: 2000) .......................... - .,],i~0 8 0 . 0 0 AWS Members .................................. ~ 6 0 . 0 0 CD-ROM (FMDM: 2000) .................. 160.00 AWS Members .................................. 120.00 Book and CD (FMPI~ 2000) ............ 288.00 AWS Members .................................. 216.00

Are you hesitant about specifying titanium? If so, this new guide dispels the weldability myths. In ll-pages, it succinctly makes short work of negative perceptions about welding this versatile metal. Topics include backing gas shielding, chambers, joint design, equipment, consumables, filler metal transfer, and special welding conditions for GTAW, GMAW, PAW, electron and laser beam welding, and resistance welding. Five handy tables. Compiler/editor Eugene Hornberger used sources from hWS, TWI and NASA, and the review and advice of the International Titanium Association, to produce this Guide. 11 pages, softbound. Published in 1999. PRGT ............................ ~4¢0~ 22..00 AWS Members .......... ~ I7.00

Nothing beats the convenience of a chart PHSS WC & DC Structural Steel Preheat Chart Suggested Preheat Temperatures for Welding Structural Steel Materials has welding processes, material thickness and minimum preheat temperatures in the Row or X axis. In the Column or Y aJds-- 18 structural steel materials, from ASTM A36 to API 5L Gr. X42, to C1.2 to ASTM A517. When you need to know quickly, nothing beats the convenience of a chart. Laminated two-tone. Published in 1996. Desk size is 11" x 17"; wall size is 22"x 28". PHSS WC & DC ..................... 20.00 AWS Members ....................... ~ /5:.00

AWS FMS WC & DC Suggested Filler Materials for Welding Structural Steels Four welding processes are listed in the Row or X axis: SMAW, GMAW, FCAW, and SAW are listed. In the Column or Y axis are 17 structural steels, from ASTM A36 to ASTM A710 Gr. A~ C1.2 to ASTM A517. When you need to know quickly (example: What are appropriate filler materials for ASTM A53. {]r. B, if you're using SMAW?) - - nothing beats the convenience of a chart. Laminated two-tone chart comes as desk and wall set. AWS FMS WC & DC ....... ...~ 2 0 . 0 0 AWS Members ................. • ~ / £ 0 0

EWH: 1-1 1 Effects of Welding on Health Vol. 11 Eleventh in the series, this volume is divided into three sections summarizing recent studies of occupational exposures, information on the human health effects of welding, and the effects of welding on experimental animals and cell cultures. Includes 171 citations, 13 tables, and 7 figures. Order No ................................. Coverage EWH-1 ................................ 1940-1977 EWH-2 ................................ 1978-1979 EWH-3 ................................ 1979-1980 EWH-4 ................................ 1980-1982 EWH-5 ................................ 1982-1984 EWH-6 ................................ 1984-1985 EWH-7 ................................ 1986-1987 EWH-8 ................................ 1988-1989 EWIt-9 ................................ 1990-1991 EWH.10 ................................ 1992-1994 EWH-11 ................................ 1995-1996

EWH: 1-11 .............................. R e a c h 3 ~ O O AWS Members ...................... . ~ t ~ each 2 6 . 0 0

EWII: 1-10 Index* EWH-I (book index) ............ /6.00 AWS Members ....................... ~ " / 2 .00

EWH-ICD (CD index) ........... .JJf~_ 4 8 . 0 0 AWS Members ........................ .7~ 36.00 *Vol. 11 is not included.

This universal qualification document is an excellent tool to ensure economical quality. Covers all welding processes and an exhaustive array of materials used in metal fabrication. Indispensable for those who design and manufacture non-code products but who may also be performing to I80 9000. Experience shows Specification for Welding Procedure and Performance Qualification adapts to the requirements of ]80 9000.

Spells-out requirements for the qualification of welding procedures and the requirements for the performance qualification of welders and welding operators for manual, semiautomatic, machine and automatic welding.

WELDIN6 PROCESSES INCLUDE: • Oxyfuel Gas Welding

• Electroslag Welding • Electrogas Welding • Electron Beam Welding • Laser Beam Welding • Stud Arc Welding

B2.1 (}IVES COMPLETE COVERAGE OF: • Base Metals • Filler Metals • Qualification Variables • Testing Requirements

ANSI-Approved. Adopted by the Department of Defense. Published in 1998, 219 pages, 24 tables, 34 figures. B2.1:1998 ............................... . ,],~0 5"~OO AWS Members ..................... ~ 4 / . 00

CAWF Characterization of Arc Welding Fumes Analysis based on a variety of rods and wires. Published in 1983, 56 pages. CAWF ...................................... .__~.,~ 22.00 AW8 Members ..................... .~ /ZOO

LVOS Lab Validation of Ozone Sampling with Spill Proof Impingers Published in 1983, 50 pages. LVOS ...................................... ~00_ 2 g .o 0 AWS Members ..................... • ~ 21.00

FSW Fire Safety in Welding and Cutting Learn the outline of precautionary measures and safe practices and help avoid the hazards of fire and explosion. Published in 1992, 20 pages. FSW (25 copies) ..................... ~ /O OO AWS Members ...................... ~ oo.OO

AWS-S Seguridad en la Soldadura por Arco Spanish language version of Arc Welding Safely (AWS). Published in 1988, 9 pages. A AWS-S (25 copies) ................ -___~ / 5 . 0 0 AW8 Members ..................... ~ g.OO

A 9 . 1 - 9 2 Standard Guide for Describing Arc Welds in Computerized Material Property and Nondestructive Examination Databases Developed in cooperation with ASNT's Committee E49 on Computerization of Material Property Data. Guide is divided into two parts: weld identification and weld properties and NDE data. Data fields necessary to uniquely define an arc weld-- the same data needed to produce a Procedure Qualification Record - - are provided, An excellent tem- plate whether you're computerized or still using conventional methods. 9 pages, published . . . i n 1992. ANSI Approved. A9.1-92 ................................... . ~ . ~ / 6 . 0 0 AWS Members ..................... ~ /2.00

A 9 . 2 - 9 2 Standard Guide for Recording Arc Weld Material Property and Nondestructive Examination Data in Computerized Databases Companion to A9.1-92 providing the balance of information necessary to completely document your welding by format- ting the fields and types of mechanical property and NDE data that should be entered into a weld property database. Search, retrieve and duplicate successful combinations. Excellent document for computerized and noncomputerized operations. 7 pages, published ~ . , i n 1992. ANSI Approved. A9.2-92 ....................................... • ~ 16.00 AWS Members ......................... . : . ~ 12.00

E G 3 . 0 - 9 6 Guide for the Training and Qualification of Welding Personnel: Level I I - Advanced Welder A competency-based curriculum detailing the minimum acceptable skill requirements for the training and qualification of advanced welders. Published in

160 pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AWS Members ............................................ ~ 2 ~ O O ELW- Set B (EG3.0-96 and QCl1-96) ...... 72.00 AWS Members .............................................. 54.00

E G 4 . 0 - 9 6 Guide for the Training and Qualification of Welding Personnel: Level III, Expert Welder h competency-based curriculum detailing the minimum acceptable skill requirements for the training and qualification of expert welders. Published in 1996, 149 pages. EG4.0-96 ...................................................... . . ~ ' 3 2 . 0 0 AWS Members ............................................ ~f,n~ 2 4 . 0 0 ELW- Set C (EG4.0-96 and QC12-96) ....:.72.00 AW8 Members .............................................. 54,00

Q C 1 0 - 9 5 Specification for Qualification and Certification of Entry Level Welders P,~quirements and program for AWS to certify entry level welders. This certification requires performance qualification and practical knowledge tests. Published in 1995, 20 pages. QC10-95 .................................... j~d~* 3 2 . 0 0 AWS Members ...................... ~ /ZOO

Q C 1 1 - 9 6 Specification for Qualification and Certification for Level II - Advanced Welders Requirements and program for AWS to certify advanced level welders, This certification requires performance qualification and practical knowledge tests. Published in 1996, 31 pages. QCll-96 .................................. ~ 32.00 AWS Members ...................... ~ /ZOO

Q C 1 2 - 9 6 Specification for Qualification and Certification for Level III - Expert Welder Requirements and program for AWS to certify expert level welders. This certification requires performance qualification and practical knowledge tests, Published in 1996, 25 pages. QC12-96 .................................. j ~ 32 .00 AWS Members ...................... ~ /ZOO

To order or for more

information: 800 -854-7179 (USA/Canada)

fax: 303-397-2740 global.ihs.com

VEWS OF THE

I N D U S T R Y ]

Welders Give Away Flags to Demonstrate Patriotism

Students planted flags distributed as part of the American Welding Society patriotism project in the Memorial Gardens at Thaddeus Stevens College of Technology, Lancaster, Pa., following a ceremony to honor the victims and heroes of September 11, 2001.

Hundreds of American Welding Society members across the United States recently distributed American flags at intersec-

tions, festivals, malls, and other locations in a nationwide display of unity. Most chose to commemorate the tragedy of September 11, 2001, on Saturday, September 14, to demonstrate their belief patriotism should be observed every day of the year. Some participants, however, elected to distribute the flags on the 1 lth.

AWS organized the nationwide demonstration as an opportunity for welders, those people responsible for building much of America's infrastructure, to publicly show their patriotism and dedication to their communities.

Flags were distributed at Thaddeus Stevens College of Tech- nology, Lancaster, Pa., on September 11. "The flags gave the students a way to honor the victims and heroes of our national tragedy," commented Stephan E. Hower, senior instructor of the Metals Fabrication and Welding Technology program. Senior students from the program distributed the flags prior to a ceremony at the school. "They asked the students receiving the flags if they would please 'plant ' them in our Memorial Gardens after the event. All of the flags were installed in the gardens with a great deal of silent respect for the victims and heroes of the 9/11 tragedy," Hower said.

The following AWS Sections participated in the patriotism project: Lancaster, Pa.; York Central, Pa.; Charlotte, N.C.; Palm Beach, Fla.; South Carolina; Niagara Frontier, N.Y.; Wheeling, W.Va.; Asheville (Western North Carolina), N.C.; Mahoning Val- ley (Youngstown), Ohio; Stark Central (Canton), Ohio; Detroit, Mich.; Peoria, I11.; Des Moines, Iowa; Kansas City, Mo.; Sioux- land (Sioux Falls), S.D.; San Francisco, Calif.

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Caterpillar Developing Cyber Fab Shop

Caterpillar is developing an automated fabrication shop that will operate completely unmanned. Shown is the robotic welding equipment that makes up part of the system.

Caterpillar, Inc., is developing a cyber fab shop that will run completely unmanned production by integrating automated laser beam cutting, precision forming, and welding equipment. The shop is currently in the testing and research phase.

Laser CMS (Cyber Manufacturing System) equipment from Mazak Nissho Iwai, Schaum- burg, IlL, is key to development of the shop.The CMS equipment automatically retrieves,

loads, laser cuts, and unloads material as well as sorts and stacks the finished parts and discards the scrap. It also features integrated CAD/CAM software.

Once the material has been cut, it transfers downstream where unattended operation continues. To perform automated bending, Caterpillar installed an ABB RoboBender® cell with IRB 6400R robot to load and unload a Pullmax OptiFlex 230 press brake. The shop also includes an ABB FlexArc® cell with an IRB 4400 for robotic welding. Plans for the cyber fab shop include integrating operations into one line controller and automating the transfer of parts from operation to operation.

Northrop Grumman Receives Contract to Build Four U.S. Navy Destroyers

The U.S. Navy recently awarded Northrop Grumman Corp. a contract valued at $1.9 billion to build four additional DDG 51- class, Aegis guided missile destroyers. The contract was awarded to Northrop Grumman's Ship Systems sector in Pascagoula, Miss.

The contract brings the total ships awarded in the program to 60. Northrop Grumann Ships Systems has received contracts for 28 Aegis destroyers; it has already delivered 17 of them. Under this multiyear contract, Northrop Grumman and General Dy- namics' Bath Iron Works shipyard will build one more ship each in fiscal years 2002-2005. Bath Iron Works will also build an additional option ship in fiscal 2004 and 2005.

The Navy's Aegis fleet provides primary protection for the Navy's battle forces. Aegis destroyers are 505.5 ft long, with a beam of 66.5 ft. Four gas turbine engines power the 300-ton ships to speeds in excess of 30 knots.

Industry Notes

• USF Surface Preparation, which is headquartered in Lake- wood, Colo., recently opened a job shop location in Greenville, N.C., that specializes in shot peening and vibratory finishing for the defense, aerospace, medical, automotive, and power generation industries. The shop's finishing services range from deburring and vibratory finishing to peening of gas turbine blades and vanes. The shop also offers process consultation and certification, media sampling, blast cleaning system surveys, and sample processing.

American alloy flux cored welding wires If you think Stoody is just superior hardfacing, think again. Our nickel and stainless all-position and flat horizontal flux cored wires are the industry standard thanks to exceptional weldability.

NICKEL CORED WIRES: 55, 82, 182, 625, 276, 622 STAINLESS CORED WIRES: 308L, 309L, 316L

And if your needs are more specific, call Stoody for a special chemistry or special ferrite product.

For more information, contact your local Stoody distributor or call

(314) 746-2135 www.stoody.com

STIOOOY


WELDING JOURNAL i | m

• Dynabrade, Inc., an industrial abrasive power tool manufacturer, recently acquired Nu-Matic Grinders, Inc., Cleveland, Ohio, a manufacturer of air-inflated backup wheels and machine leveling jacks and related products. Terms were not discussed. Nu-Matic's product line includes pneumatic wheels and floor wedges and jacks to level heavy equipment.

• ATI Industrial Automation, Apex, N.C., a manufacturer of robotic peripheral and automation components, was recently named as one of the 50 fastest growing technology companies in North Carolina for the third consecutive year. Deloitte & Touche, in association with several other organizations, gives the award to technology companies that show exceptional growth over the previous five years.

• BDI Europa Ltd. (BDIE), Orrel, Wigan, U.K., recently purchased certain assets from the WTC Group Ltd. The purchase exclusively authorizes BDIE to manufacture and supply products previously offered by WTC. The products include WTC's entire line of gas tungsten arc and plasma arc welding equipment, including torches, heads, and spare parts.

• Piping Technology & Products, Inc., Houston, Tex., recently designed and manufactured 70 horizontal, C-type constants for a furnace application located in Venezuela. Sizes of the constants ranged from 32 to 64 with a total travel of 4.5-10.5 in. and loads varying from 1149 to 5149 lb. They were fabricated from carbon steel and painted to protect them from the heat of the furnace.

• Weldtech Training, Brampton, Ont., Canada, recently developed Welding Procedure Specifications and provided training to qualify more than 80 welders to the requirements of AWS D1.6, Structural Welding Code - - Stainless Steel. M.J. Mfg., a division of Martinrea International Inc., is using the standard in the manufacture of 40-ft-long, stainless steel bus frames. Fabrication of the frames is part of a multiyear contract for the

Orion VI bus developed and designed by Orion Bus Indus- tries. It is believed to be the largest single use of D1.6 for stainless steel fabrication in North America.

S e r m a t e c h C o m p l e t e s Large Tank Project

Sermatech Surface Engineering, Limerick, Pa., recently completed lining this 30, O00-gal tank with fabric-backed PTFE for a pharma- ceutical company. The tank was fabricated from 0.25-in.-thick Type 304 stainless steel. It measured approximately 12 ft in diameter and 34 ft long and featured 15 nozzles/manway openings. Shown is the inside of the tank being spark tested. Inset is an exterior view of the completed tank prior to shipping.

BUG-GY-VERT An a u t o m a t e d fi l let w e l d e r that can c l imb a vert ical plate. • Lightweight and portable. • Trackless, magnetic welding travel carriage. • Produces continuous non-stop welding. • Can perform vertical, horizontal and down

hand welds. • Cordless, rechargeable battery operated. • Four wheel drive provides constant precise

travel speed. • Available with or without torch oscillation. • Works with any handheld MIG torch. For more information on the BUG-GY-VERT call: 800-245-3186 extension 55 Welding and Cutting Automation Since 1948.

3001 West Carson Street Pittsburgh, PA USA 15204-1899 Phone: 1-412-331-1776 * Fax: 1-412-331-0383 http://www.bugo.com ¢ (

s p a NOVEMBER 2002


WELDING SHOPS! ]

'IHE ANSWER HIR i ilIEPE ilIEPll AWS AFFiLiATE COMPANY MEMBERSHIP MEMBER BENEFITS:

• Priceless exposure of your shop with free publicity on AWS's 40,000-visitors-a-month website.

• $50 OFF a job posting on AWS JobFind www.aws.org/jobfind, your connection to hundreds of welders, inspectors and other job seekers!

• An AWS Individual Membership ($75 value), which includes need-to-know technical information through a FREE monthly subscription to the Welding Journal. WJ covers the latest trends, events, news and products guaranteed to make your job easier.

• Quick access to welding information through a personal library of AWS Pocket Handbooks:

L Everyday Pocket Handbook for Arc Welding Steel Everyday Pocket Handbook for Vu~ual Inspection and Weld Discontinuities - Causes and Remedies

a Everyday Pocket Handbook for Gas Metal Arc and Flux-Cored Arc Welding

• A 62% discount on freight shipments with Yellow Transportation, Inc.

• Practical information through The American Welder, a special section of the Welding Journal geared toward front-line welders.

To join, or fer mere infermation call: [800] 443-9353, ext. 480 or [305] 443-9353, ext. 480 Visit us on-line at www.aws.org Real-wnrld business solutions for welding and fabricating shops

• Exclusive usage of the AWS Affiliate Company Member logo on your business card and promotional material for a competitive edge.

• Walt plaque to show your company's affiliation with the world's premier welding association.

• Window decal to display on your shop's storefront.

• Free passes to the AWS Welding Show for you and your shop's best employees.

• Unmatched networking opportunities at local Section Meetings, the annual AWS Welding Show, as well as at AWS-sponsored educational events.

• Professional development via discounts on world- renowned and industry-wide AWS Certification programs, conferences and workshops.

• Technical information through a 25% Members'- only discount on 300+ industry-specific AWS Publications and technical standards.

Join an elite group of over 400 AWS Sustaining Company Members and enjoy:

• Your choice of one of these money- saving benefits:

1. AWS Standards Library ($6,500 value) 2. Discount Promotional Package - save

on Welding Journal advertising and booth space at the AWS WELDING SHOW (save thousands)

3. 10 additional AWS Individual Memberships ($870 value)

Plus... • 10 AWS Individual Memberships

($870 value); each Individual Membership includes a FREE subscription to the Welding Journal, a FREE AWS publication (up to

a $188 value), Members'-only discounts and much more

• Free company publicity- give your company a global presence in the Welding Journal, on the AWS Website, and at the AWS WELDING SHOW

• Exclusive usage of the AWS Sustaining Company logo on your company's letterhead and on promotional materials for a competitive edge

• An attractive AWS Sustaining Company wall plaque

• Free hyperlink from AWS's 40,000-visitors-a- month websi*e to your company's website

• 200 complimentary VIP passes to the AWS WELDING SHOW

• An additional 5% discount off the already- reduced member price of any AWS conference or seminar registration

• Up to 62% off Yellow Freight shipping charges, outbound or inbound, short or long haul

AND MUCH MORE...

Also ava i lab le AWS Suppor t ing Company Membership a n d AWS E duca t i ona l I n s t i t u t i o n Membersh ip

For more information on AWS Corporate Membership, call

(800) 443-9353, ext. 253 or 260. E-mail:

[email protected] for an application.

Ameri_____can Weld______iing Society 550 N.W. LeJeune Rd. Miami, Florida 33126 Visit our website at www.aws.org

y o u r o r g a n i z a t i o n n e e d s s o l u t i o n s .

A W S m e a n s a n s w e r s .

~. Y B E R N O T E $

idl•T,• i A COLLECTION OF INDUSTRY NEWS FROM THE INTERNET

Materials Research News Available

Materials Research Society. The mission of this organization, which is composed of materials researchers from academia, industry, and government, is to promote communicat ion for the advancement of interdisciplinary materials research to improve the quality of life. The site is full of society-related information including how to join, a history of the organization, details on its awards program, its constitution and bylaws, and how to sign up for its e-mail newsletter.

In addition, the site provides plenty of materials research-related news, abstracts of articles pr inted in the Journal of Materials Research, on-line symposium proceedings, and a variety of other publications. Some publications are available to the general public, others are for members only. Visitors can also search volumes of proceedings by author, title, keyword, or volume title.

The site also includes a classified ad section consisting primarily of materials research and engineering posit ions in universities around the United States.

w w ~ m r s . o ~

Site Adds More Cryogenic Information

Taylor-Wharton. The company, an operating unit of Harsco Corp.'s Gas and Fluid Control Group, recently expanded the cryogenic-related areas of its Web site. Taylor-Wharton supplies cryogenic equipment, gas cylinders, and valves for a wide variety of gas and fluid applications.

The site offers specifications for the items in its product line, technical bulletins, literature that can be either downloaded in PDF format or ordered from the company's fulfillment center. Also available are

contact and geographical information on all of its U.S. sales personnel. Contact information and links to their respective Web sites are provided for each member of the company's network of repair/service centers.

A detai led set of FAQs provides information such as the following:

"Question: My cylinder vents through the relief valve when in use. What should I do?

'~mswer: The relief device is there to vent the expanding gases and prevent an explosion. Be more concerned about relief valves that do not vent at all. Tanks that have been overfilled may have springs that are compromised and relieve at too low a pressure. Review your fill procedures and replace the relief valve."

www.taylorwharton.com

Eye Safety Information A Highlight of Site

A key element of the site, however, is the "Safety Resources" pages, which are full of information. Links are provided to safety-related organizations and there's a glossary of safety terms and a list of common abbreviations and acronyms for industry and government agencies and industry terms. Details are provided regarding pertinent OSHA standards and te lephone numbers are provided for OSHA area offices.

The site offers injury statistics and safety facts, answers a lineup of eye protection- related FAQs, and provides information regarding first aid for eye injuries and ultraviolet radiation. Following are the site's "Seven Steps to Workplace Safety:" 1) Perform a facility eye safety analysis, 2) test for vision problems, 3) select protective eyewear, 4) require compliance, 5) plan for emergencies, 6) train and educate, and 7) make it official - - in writing.

The site also includes a constant industry and government news feed and a distributor resource center.

www.gatewaysafety.com

Upgraded Site Features Steel Rolling Capabilities

H~re~Dt~Stl, ~

m

Gateway Safety, Inc. The company, a maker of eye, face, and head protection equipment based in Cleveland, Ohio, recently revamped its Web site in order to make it "an easy-to-navigate, single source of product and safety facts and advice." The product information pages cover each of the company's more than 50 products. The site features a l i terature download center where users can also request that the actual pieces be mailed to them. Visitors can also request quotes.

Greer Steel. The company, a producer of cold-rolled strip steel, has upgraded its Web site to include more information on its capabilities, equipment, and quality processes. Overviews are provided about the capabilities of the company's Dover, Ohio, and Ferndale , Mich., plants, including the thicknesses, carbon steel grades, and surface finishes each plant can produce. It also includes pages outl ining the types of equipment available at the two facilities. The site also offers details about the company's quality policies and news.

www.greersteel.com

i l ~ ! NOVEMBER 2002

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LETTERS TO THE EDITOR ]

Reader Reacts to Shielding Gas Article

The following letter was sent by a reader who takes issue with Nathan Moyer's article on shielding gases that appeared in the September 2002 edition of the Welding Journal. Moyer's response follows.

Dear Editor:

I feel I must comment on an article in this month's AWS Journal titled "The Evolution of Shielding Gases," written by Nathan Moyer of Linde Gases.

I 'm employed by BOC Gases of Murray Hill, N.J., and feel justified and obligated to comment given my background. My whole professional career to date has been promoting welding and cutting technology. At the moment, I direct BOC's laser gases program; not too long ago I was product manager for welding shielding gases. I served on the A5S committee as an author and contributor to AWS 5.32, Specification for Welding Shielding Gases. Above and beyond this, my father, Stephen L. Sullivan, is credited with having made the first gas metal arc welding gun while employed by Air Reduction Co. (now BOC) in 1948.

In his article, Moyer suggests the evolution of shielding gases began with helium and CO 2. It's true the GTAW process as developed by Northrup Aircraft during WWlI used helium as a shielding gas, but to my knowledge, the first successful experiments using the GMAW process ( invented by Air Reduction Co. in 1948) were made using argon.

Argon worked well because the first experiments using GMAW were made on aluminum, not carbon steel, as many have suggested over the years. The U.S. Navy was anxious to come up with a way to weld aluminum superstructures. Despite the high perceived cost of argon at that time, the Navy knew they had finally found a process that not only worked well but also saved endless labor hours. The Air Reduction team dubbed the GMAW process the "Aircomatic" process and patented it in 1948. The invention was also presented that year at the AWS Convention in Philadelphia.

Over the years, new shielding gases were formulated for welding different types of metals using various metal transfer modes. Shielding gases do far more than prevent oxidation and contamina-

tion of the molten weld metal from the atmosphere. Choice of shielding gases affects the shape of the weld, penetration, deposition rates, and deposition efficiencies. The cost of weld labor can be reduced and the worker's environment improved simply by changing shielding gases. BOC conducted extensive research on fume and particulate generation using the gas metal arc welding process. We determined the best way to reduce ozone in the welder's breathing zone was to alter the wavelength of ultraviolet (UV) rays emitted during welding. The gases industry, as represented by the AWS A5S Committee, agrees this was best done by adding helium. While additions of nitric oxide to the shielding gas can reduce ozone in the welding zone, it has little effect on reducing ozone in the welder's breathing zone.

I take exception to Moyer's article because it does not accurately reflect the true evolution of shielding gases, does not give credit where it is due, and uses a technical journal to promote a proprietary commercial product promising dubious results.

Thank you for allowing me to express my opinion. Perhaps we can set the record straight.

Dennis M. Sullivan Murray Hill, N.J.

Dear Mr. Sullivan:

Thank you for offering additional information on the recent Welding Journal article I authored titled "The Evolution of ShieMing Gas." I did not include much detail about the history of GMA W guns and power sources. The focus of the article is shielding gases.

My source for most of the early history of the GMA W process was the A WS Welding Handbook, Vol. 2, "Welding Processes." Under the heading "History," on page 158, you will find a discussion of CO 2,s early use in the GMA W of carbon steels.

The article focuses on the fundamental purpose of shielding gas - - to keep atmos- pheric nitrogen and oxygen away from the molten weld pool as it cools. As you point out, shielding gases have many important effects on the weld. In addition to the effects you mention, sh&lding gas also affects spatter levels, bead wetting, travel speed, and, with some materials, the mechanical properties of the resulting weld metal. It is true that choosing the correct gas can reduce the overall cost of welding.

It is clear from past research, adding small quantities of nitric oxide to shielding gases has the effect of reducing ozone emis- sions from the welding zone. The Ohio State University and The Danish Institute of Welding performed two such research studies supporting these conclusions. The following statement is a commentary from a 1991 report done by the Department o f Welding Engineering of The Ohio State University titled "Evaluation of Mison® Gas for Welding Carbon and Stainless Steels."

"The results of this investigation into gas generation rates during GMA Wand GTA W welding indicate [the] gas does appreciably reduce the ozone emission rate while increasing the nitrogen dioxide rate.., com- mensurately.

"Extrapolation of these results to actual concentrations of the gases in the welder's breathing zone could well be, however, unreliable. Concentration in the breathing zone will be affected by local gas flow patterns and the position of the welder's head. Further, ozone could also be generated outside of the zone where nitric oxide is effective at reducing the gas but where it could still enter the breathing zone."

Experience has taught us the gas's impact on a welder's breathing zone is situ- ational However, one thing we've found is for sure: we have many welders who would not use anything else.

Nathan Moyer Cleveland, Ohio

Dear Reader

The Welding Journal e nc ou rages an

exchange o f ideas th rough le t te r s to

t he e d i t o r . P l e a s e s end o u r l e t t e r s

to t he W e l d i n g j o u r n a l D e p t . , 550

N W L e J e u n e Rd . , M i a m i , F L

33126. You can a lso r e a c h us by

F A X at (305) 443-7404 o r by

s e n d i n g an e - m a i l to D o r e e n

Y a m a m o t o at y a m a m o t o @ a w s . o r g .

i [ .1N NOVEMBER 2002 I

Help Ensure Our industr ........... and Receive a Free Ball

Found a t i o n , I n c .

~ ucation

t o nearlY/

ast ~jear, the `kWS F • arded more than SBO0,000

Lone hundred ann se~L,~ away many qualified applicants due industrY. IJi°wever' we still turned to lack of additional funds. We're proud of the fact that 94% of our funds go directl:~ into scholarships and fellowships ~ which is our mission. But, we want to do better, and

we need ~our help ~" can launch its "Gold Collar ScholarshiP" ~ith ~jour gift, the Foundation enter our of $~5 or more, we ll program and add new scholarships to students wanting to

our Thank you. Simpl~ industrY. It's so important to us that, for every gift fill send you a customized, low-profile, ball cap as out the card and enclose check or credit card information (or make a pledge ~ we'll bill you) and mail it to us in the envelope prodded.

.ks a team, we can make sure our future welders and other welding

industry professionals are properl~ educated!

~., / f -)

Ron pierce, Chairman `k~S Foundation

Dear Friend:

Never has the need been greater for more and better qualified personnel to enter the welding field.

Education is the answer to the challenge of establishing a strong, dynamic workforce to meet the

necessary advancements in technology and quality production for industry. Join us and become a

partner in achieving mutual goals.

Thank you,

Ronald C. Pierce Chairman Board of Trustees AWS Foundation

Major Sponsor $ 5,000- Up

Partner $1,000 - 4,999

Friend $ I00- 999

Supporter $1- 99

Gifts are generally tax deductible.

Please contact me about estate planning or deferred-gifting opportunities.

With your pledge of $35 or more, we will send you a specially designed "Welding Builds America" ball cap.

@ Foundation, Inc. Bu#ding Welding's Future through Education

AWS Foundation, Inc. 550 N. W. LeJeune Road Miami, FL 33126 Phone: 800-443-9353 ext 293 Fax: 305-443-7559 e-marl: [email protected] Web.: www.aws.org

HERE'S MY COMMITMENT: Total Pledge $

Amount Enclosed $

Balance Due $

l i e

Q One Time Q Quarterly • Monthly

Please make checks payable to: AWS Foundation, Inc. 550 N.W. LeJeune Rd. Miami, FL 33126 305-445-6628 * 800-443-9353 ext. 293

Enclosed is my gift of: $ Major Sponsor $ Friend

Name Title

Company.

Address

E-Mail

$ Partner $. Supporter

City_ Business Phone

State Zip

Home Phone (optional)

Card

D Discover

Card Number

Signature

D American Express D Visa vI MasterCard i:l Carte Blanche

_Expiration Date

Date

I ! ; '

.~ il ̧

i .

Detroit .,elcomes back the

American WeldfLng Society Apr i l 8 - 10, 2 0 0 3 • C o b o C e n t e r

Since 1999 the Motor City has been undergoing a massive renaissance. F rom the t ime you land in Detroit at the new Northwest Airlines/Edward H. McNamara World Terminal to the t ime you call it a day and relax in your newly renovated hotel r o o m you will experience a new Detroit.

After the show or meeting enjoy one of three new Las Vegas style casinos, one of many new restaurants or check out a baseball game at the new Comerica Park.

Congratulations on your 50th Anniversary Welding Show

it 's a / g r e a t t ime in

d e t r o i t e t r o i t . c o m I - ~ ~ ~ ;:

For a complete list of events and ~ ~ ~

other visitor information - " ~ ~ ~

visit www.visitdetroit.com ~ - v

or call 1-800-DETROIT for a free

Visit Detroit magazine. Circle No. 9 on Reader Info-Card

.... ~ ~.

AWS Foundation Year End Recognition

fJ

Highlights of 2OO1-2OO2

The Foundation, along with Section support, surpassed $400,000 in scholarship and fellowship funding, serving more than 250 students.

The student loan program, initiated two years ago, has helped many students with h)w-interest-rate loans, totaling more than $42,000.

The Foundation has established five additional National Scholarships this year: l) The William A. and Ann M. Brothers Scholarship, which awards $2,500 to a student pursuing a four-year degree in a welding-related program. 2) The Amos and Marilyn Winsand-Detroit Section Named Scholarship awards $2,500 to a student pursuing an Associate's or bachelor's degree in Welding Engineering, Welding Engineering Technology, or a related field and who is a resident of Michigan or attending a Michigan college. 3) The Hypertherm-lnternational HyTeeh Leadership Scholarship, which awards $2,500 to a graduate student pursuing

an advanced degree in Engineering Management, our first graduate scholarship. 4) The Arsham Amirildan Engineering Scholarship, which awards $2,500 a student pursuing a minimum four- year degree in civil engineering or a welding- related program at an accredited engineering university. 5) Airgas - Je r ry Baker Scholarship, which awards $2,500 to a student pursuing a four-year degree in Welding Engineering or Welding Engineering Technology.

Our Graduate Research Fellowship grants are $25,000 per year, and are matched in-kind by the institution of higher learning where the student is engaged in postgraduate work. Grants are renewable up to three years.

Gold Collar Scholarship Challenge Group The AWS Foundation recognizes the following corporations for their challenge gifts to establish our Gold Collar Scholarship Program: Major Challenger: ~ t ~ " Challengers: Norco Inc., Weldstar

Services and Programs Offered by the AWS Foundation

Miller Electric Mfg. Co. - Sponsor of the U.S. Open Weld Trails Scholarship

The AWS Foundation is grateful to tile Miller Electric Manufacturing Company, which is the proud sponsor of this $40,000 scholarship implemented in 1995. This award recognizes and provides financial assistance to contestants representing the United States in the World Skills Competition. To become eligible for this scholarship, the applicant must compete in the National VICA USA Skills Competition for welding, and advance to the AWS Weld Trials at the AWS International Welding and Fabrication Exposition and Convention, which is held on a bi-annual basis. Winners of the AWS Weld Trials then participate in the International Competition. Past recipients competing in the international competition are as follows:

2OO1 Dien Tran Bronze Medal Winner

1999 Ray Connolly Gold Medal Winner

1997 Glen Kay 111 International Finalist

1995 Branden Muehlbrandt Silver Medal Winner

1993 Nick Peterson* Bronze Medal Winner

1991 Robert Pope* Gold Medal Winner

"1991 and 1993 recipients received alternate scholarship funds, which were prior to the start of the Miller Scholarship.

N.'fional Scholarship Program H~ ward E. Adkins Memorial Scholarship An gas-Jerry Baker Memorial Scholarship All gas-Terry Jarvis Memorial Scholarship Ar ;ham Amirikian Engineering Scholarship Ed ward J. Brady Scholarship William A. and Ann M. Brothers Scholarship Dr nald E Hastings Scholarship William B. Howell Memorial Scholarship H$ pertherm-International HyTech Leadership

Scholarship Joim C. Lincoln Memorial Scholarship M'.LtSUO Bridge Company, Ltd., of Japan

Scholarship Miller Electric International Youth Skills

Competition Scholarship Pr txair International Scholarship JeJry Robinson-Inweld Corporation

Scholarship Jmnes A. Turner, Jr., Memorial Scholarship

Other Scholarships Int ernational Scholarship Anlos and Marilyn Winsand-Detroit Section Na reed Scholarship

Scholarship Programs in Development Tei B. Jefferson Scholarship Rc bert L. O'Brien Memorial Scholarship Rc nald C. Pierce Scholarship Th,,rmadyne Industries Scholarship G( t :1 Collar Scholarship

Graduate Research Fellowships Caterpillar Fellowship Glenn J. Gibson Fellowship Miller Electric Fellowship Navy Joining Fellowship (2) AWS Fellowship

Educational Tools Engineering Your Future 'Welding: So Hot It's Cool' Video 'Hot Careers in Welding' Video

Donor Recognition Diamond Donors Innovators for Tomorrow Leaders In Excellence Partners in Progress

Other Recognition Visionary Club (Estate Planners) Memorials and Honorariums

Student Loan Program This program is funded by Mr. Jim Gibson, to honor, his father, Mr. Glenn J. Gibson, in his desire to advance educational opportunities within the welding industry. Student Loan Program funds are presented to individuals nationwide who wish to enter the welding field but do not have the resources to start.

K,r full information on this year's scholarship re c ipients, please visit the official AWS Foundation Website at www.aws.org/foundation/index.html

Foundation, Inc. Building Welding's Future through Education 550 N.W. LeJeune Road

Miami, Florida 33126

800-443-9353, ext. 293

305-445-6628

305-443-7559 Fax e-mail: [email protected]

www.aws.org/foundation/index.html

Creative thinking for the productive application of modern welding technology continues to be the primary focus of AWS in serving its worldwide membership and the materials joining industry.

Creative thinking for the productive

application of modern welding technology

continues to be the primary focus ofhWS in

serving its worldwide membership and the

materials joining industry.

We are proud to report that through

careful planning and prudent financial

management the Society maintained a

relatively even course of operations during

the year, despite a weakened national

economy. While total revenues did not

meet expectations, our overall position was

strengthened with a surplus of $10,000 at

the end of the fiscal year. We are proposing

a budget of $16.7 million for next year with

an anticipated surplus of approximately

$626,000.

While most technical societies

suffered severe downturns in the past year,

several factors contributed to our year-end

results and our projected growth for

next year. Stringent cost control measures

were instituted. Certain operations were

reorganized, including an enhanced

marketing function. New membership and

certification programs, along with industry-

specific services, were introduced. The

Society is indebted to its volunteers and its

headquarters staff for their dedicated

leadership in serving our industry during

this period of uncertainty.

The AWS Welding Show, while well

below previous years, managed to outper-

form many major trade shows. Post-show

surveys of the MAX International Expo, in

which hWS was a partner with the

Precision Metalforming Association,

indicated that our exhibitors and attendees

prefer a show dedicated solely to serving

the vertical welding industry market. As a

result, the 2003 Show in Detroit will return

to being totally oriented to welding and

materials joining. It will mark the 50th

anniversary of the exhibition and every

effort is going into making it the welding

industry's premier event.

In the international arena, we

continue to maintain a close liaison with

IIW and several of our sister societies and

counterpart organizations with whom

we have Agreements of Professional

Cooperation. These Agreements strengthen

our leadership position on important

international welding issues. Currently, the

Society has 19 International Sections with

more than 5,000 AWS members. In addition,

we enjoy an ongoing demand for our

welding certifications around the world.

Our website, www.aws.org, was

redesigned to better serve our members

and customers due to the rapidly expanding

use the site is receiving. Visitors to the

website this past year totaled 671,607

and produced revenues for products and

services of $289,000.

h renovation of our Miami headquar-

ters also was completed during the past

year. The remodeling was undertaken to

streamline our operations through the

latest innovations in modern office design

and to reflect the world-class posture of the

American Welding Society.

In summary, the events of September

llth and the subsequent business down-

turn had an impact upon our industry and

our organization. We faced the challenge

they brought and made difficult financial

and operating decisions. As a result, we

believe the Society will be ahead of the

curve as the economy continues to

strengthen. Critical decisions will continue

to be made. The needs of our membership

will continue to be served, and we will

remain committed to the future of the

welding industry. These are the tenets that

have positioned hWS at the apex of welding

and materials joining. The Board of

Directors is confident they will serve the

Society well in the year ahead.

AWS Fellows Inducted at 2002 Annual Meeting

First Class of AWS Counselors Inducted at 2002 Annual Meeting

~ Dr. JohnBarsom Mr. Donald E. Powers

Dr. Mike L, Santella Mr. Herbert E. Cable

yak',,#

Dr. Sindo Kou Mr. RickTe D, Messer

| ,

Mr. John O. Milewski Mr. Werner H, Quasebard~

,¢ Mr. John E Shaughnessy

Mr. ~Ahrren E. Mayott (Phoh)graph not a~ailable)

American Welding Society, Inc. and AWS Foundation Combined Statement of Financial Position

May 31, 2002 with Comparative Totals for 2001

ASSETS

Cash and cash equivalents (Note 2C) Grants and contracts receivable Accounts receivable, less allowance for

possible losses of $127,799 and $131,576 in 2002 and 2001, respectively

Pledges receivable (Note 3) Inventory Prepaid and other assets (Note 21) Deposits and other receivables (Note 11) Investments (Note 4) Property and equipment, less

accumulated depreciation (Note 5)

Operating Reserve AWS Total Total Fund Fund Foundation 2002 2001

$ 372,349 32,900

1,214,213

438,618 1,001,308

181,097

41,927

TOTAL ASSETS

$ 392,948 $ 807,224 $ 1,962,377 50,000 82,900 103,047

LIABILITIES AND NET ASSETS

LIABILITIES

Accounts payable and accrued expenses

Deferred membership, subscription and

convention income

Capital leases

TOTAL LIABILITIES

3,728,313

48,143 1,262,356 1,848,409 215,426 215,426 373,258

438,618 999,978 120,796 1,122,104 593,542 24,341 205,438 125,959

2,951,789 6,680,102 5,449,412

COMMITMENTS AND CONTINGENCIES (Note 10)

NET ASSETS Unrestricted Temporarily restricted (Note 6) Permanently restricted (Note 7)

TOTAL NET ASSETS (Note 8)

2,647,822 2,647,822 2,425,547

$ 5,888,307 $ 3,770,240 $ 3,803,443 $ 13,461,990 $ 13,881,529

TOTAL LIABILITIES AND NET ASSETS

$ 1,938,844 $ $ 23,577 $ 1,962,421 $ 2,442,291

2,190,493 2,190,493 2,209,986 1591592 159~592 3781801

41288~929 23,577 4,312,506 5,031,078

1,599,378 3,770,240 5,369,618 5,307,371 1,711,535 1,711,535 1,530,815 2,068,331 2,068,331 2,012,265

1,599,378 3,770,240 3,779,866 9,149,484 8,850,451

$ 5,888,307 $ 3,770,240 $ 3,803,443 $ 13,461,990 $ 13,881,529

The accompanying notes are an integral part of these combined financial statements.

American Welding Society, Inc., and AWS Foundation Combined Statements of Activities and Changes in Net Assets

For the Year Ended May 31, 2002 with Comparative Totals for 2001

Unrestricted Net Assets Revenues Expenses Net

OPERATING ACTIVITIES:

Convention $ 2,803,951 $ 1,513,205 $ 1,290,746 Education 1,602,617 1,360,510 242,107 Conference 393,326 547,530 (154,204) International marketing and

governmental affairs 16,515 373,430 (356,915) Marketing and corporate communications 630,410 (630,410) AWS Foundation 230,423 (230,423) WEMCO 73,435 233,014 (159,579) Navy Joining Center Membership 3,132,434 1,581,508 1,550,926 Certification 4,006,503 1,265,485 2,741,018 Technical 2,133,775 1,454,076 679,699 Publications 2,201,224 2,626,772 (425,548) Administration 13,103 4,556,488 (4,543,385) Building operations 49,409 49,409 Interest income 6,452 6,452 Board approved programs (Note 9)

TOTAL OPERATING FUND 16,432,744 16,422,260 10,484

Temporarily Restricted Net Assets

Permanently Restricted Net Assets

Total Total 2002 2001

$ 112901746 $1,696,070 242,107 41,014 (154,204) (123,472)

(356,915) (471,850) (630,410) (631,632) (230,423) (208,170) (159,579) (183,492)

1,550,926 1,789,134 2,741,018 2,166,524

679,699 83,227 (425,548) (576,873)

(4,543,385) (4,524,870)

6,452 8,974 (51,737)

10,484 (987,153)

RESERVE Loss on investments reported at fair value (71,135) (71,135) TFPS, Inc. 25,352 21,324 4,028 Interest and dividends 118,870 118,870

TOTAL RESERVE FUND 73,087 21,324 51,763

(71,135) (80,153) 4,028 3,005

118,870 197,686 51,763 120,538

AWS FOUNDATION Donations Interest Gain on investments reported

at fair value Reclassifications- net assets

released from restrictions by satisfaction of purpose restrictions

Operating expenses Scholarships Fellowships Fundraising and other

TOTAL AWS FOUNDATION

304,043 304,043 $ 304,650 $ 56,066 664,759 890,643 80,310 80,310 57,579 137,889 160,053

50,327 50,327 50,327 97,823

181,509 181,509 (181,509) 181,292 (181,292) (181,292) (232,600) 139,823 (139,823) (139,823) (135,177) 132,001 (132,001) (132,001) (155,667) 163,073 (163,073) (163,073) (262,614)

616,189 616,189 180,720 56,066 236,786 362,461

CHANGE IN NET ASSETS BEGINNING NET ASSETS ENDING NET ASSETS

62,247 180,720 56,066 2 9 9 , 0 3 3 (504,154) 5,307,371 1,530,815 2,012,265 8,850,451 9,354,605

$ 5,369,618 $ 1,711,535 $ 2,068,331 $ 9~149,484 $ 8,850,451


American Welding Society, Inc. and AWS Foundation Combined Statement of Cash Flows

For the Year Ended May 31, 2002 with Comparative Totals for 2001

CASH FLOWS FROM OPERATING ACTIVITIES: Change in net assets h~ustments to reconcile change in net assets

to net cash provided by operating activities: (Gains) Losses on investments reported at fair value Depreciation Provision for losses on accounts receivable Decrease in accounts receivable Decrease in pledges receivable Decrease (increase) in grants and contract receivable Decrease in inventory (Increase) decrease in prepaids and other assets Increase in deposits and other receivables Decrease in accounts payable and accrued expenses Increase (decrease) in deferred membership, subscription and convention income

Net cash provided by operating activities

Operating Reserve AWS Total Total Fund F u n d Foundation 2002 2001

$ 10,484 $ 51,763 $ 236,786 $ 299,033 $ (504,154)

289,820 20,000

539,825

6,252 561,360

(491,068) (68,860)

(369,667)

71,135

(6,956)

(50,327) 20,808 (17,670) 289,820 494,949 20,000 30,000

26,228 566,053 1,037,381 157,832 157,832 42,992 13,895 20,147 (28,724)

561,360 507,650 (37,494) (528,562) 360,077 (10,619) (79,479) (57,971)

(103,247) (479,870) (1,075,684)

5,507 (25,000) (19,493) (502,848) 503,653 115,942 208,054 827,649 285,998

CASH FLOWS FROM INVESTING ACTIVITIES: Purchases of property and equipment, net Maturities of debt and other equity securities Purchase of debt and other equity securities

Net cash use in investing activities

(512,095) (512,095) (355,580) 1,645,022

(118,870) (1,132,628) (1,251,498) (1,926,652) (512,095) (118,870) (1,132,628) (1,763,593) (637,210)

(219,209) (219,209) (183,690) (219,209) (219,209) (183,690)

CASH FLOWS FROM FINANCING ACTMTIES: Payments on capital leases

Net cash used in financing activities

N~DECREASEINCASHAND CASHEQUIV~ENTS (227,651) (2,928) (924,574) ( i ,155,153) (534,902)

CASH AND CASH EQUIVALENTS AT THE BEGINNING OF YEAR 600,000 44,855 1,317,522 1,962,377 2,497,279

$ 372,349 $ 41,927 $ 392,948 $ 807,224 $ 1,962,377 CASH AND CASH EQUIVALENTS

AT THE END OF YEAR


American Welding Society, Inc. and AWS Foundation Notes to Combined Financial Statements May 31, 2002

NOTE I- NATURE OF ORGANIZATION D) INVENTORY

The accompanying combined financial statements include the accounts of American Welding Society, Inc., its wholly-owned subsidiary, TFPS, Inc., and its affiliate, AWS Foundation (collectively, the "Organizations").

All material inter-organization accounts and transactions have been eliminated in combination. American Welding Society, Inc. and AWS Foundation are not-for-profit entities, exempt from income tax under Section 501 (c)(3) of the Internal Revenue Code and are primarily engaged in welding technology, education and research activities. For income tax purposes, publication advertising revenue and rental income are considered unrelated business income and subject to income tax. TFPS, Inc., a taxable organization, engages in profit-oriented activities.

NOTE 2- SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES

A) FUND BALANCES

The accounts of the Organizations are categorized into separate funds. The purpose and net asset classification are as follows:

Operating - This fund is used to account for all unrestricted net assets of American Welding Society, Inc., except for those account- ed for in the reserve fund.

Reserve- This fund is used to account for Board designated reserve funds which are to be used to supplement the cash needs of the operating fund and to account for the activities of TFPS, Inc.

AWS Foundation - AWS Foundation's temporarily restricted net assets consist of donor restricted contributions to be used for awards and scholarships. Permanently restricted net assets consist solely of an endowment fund.

B) ESTIMATES

The preparation of the financial statements in conformity with U.S. generally accepted accounting principles requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities at the date of the financial statements and the reported amounts of revenues and expenses during the report- ing period. Actual results could differ from those estimates.

C) CASH AND CASH EQUIVALENTS

The Organizations place their cash with quality financial institutions. At times such balances may temporarily be in excess of the insurance limits of the Federal Deposit Insurance Corporation. The Organizations have not experienced any losses in such accounts.

The Organizations consider all unrestricted investments in highly liquid debt instruments purchased with a maturity of three months or less to be cash equivalents. At May 31, 2002, cash and cash equivalents include repurchase agreements of $476,257.

Inventory consists primarily of work-in-process relating to various publications and are valued at cost. Cost is determined by the actual expenditures incurred in the production process.

E) INVESTMENTS

The Organizations report their investments under SFAS No. 124, Accounting for Certain Investments Held by Not-for-Profit Organizations. Under SFAS No. 124, a not-for-profit organization is required to report investments in equity securities with readily determinable fair values and all investments in debt securities at fair value, with unrealized gains and losses included in the combined statements of activities. The fair value of marketable securities is determined by quoted market prices.

F) PROPERTY AND EQUIPMENT

Property and equipment are stated at cost. Expenditures for additions, renewals and betterments are capitalized; expenditures for maintenance and repairs are charged to expenses as incurred. Upon retirement or disposal of assets, the cost and accumulated depreciation are eliminated from the accounts and the resulting gain or loss is included in revenues or expenses. Depreciation is computed using the straight-line method over the following estimated useful lives:

Years

Building and improvements 14- 29 Furniture and equipment 5 - 7 Transportation equipment 3

G) REVENUE RECOGNITION

The Organizations conduct an annual convention near the Organizations' fiscal year-end. The Organizations recognize convention revenue in the fiscal year the convention is held, or normally held, thereby recognizing one event during any fiscal year.

Membership and subscription revenues are deferred when received and recognized as revenue when earned, substantially in the subsequent year.

Gifts of cash or other assets are reported as restricted revenue if they are received with donor stipulations that limit the use of the donated assets. When a donor restriction expires, that is, when a stipulated time restriction ends or purpose restriction is accomplished, temporarily restricted net assets are reclassified to unrestricted net assets and reported in the statement of activities as net assets released from restrictions. However, if the restriction is received and met in the same period, the amount is recorded as unrestricted revenue. Unrestricted gifts of property and equipment are recorded as revenues at the date of donation and are valued at fair value.


NOTE 2- SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES (CONTINUED) NOTE 3- PLEDGES RECEIVABLE

G) REVENUE RECOGNITION (CONTINUED) Unconditional promises are expected to be realized as follows:

Endowments received are subject to restrictions that the principal be invested and only the income be used for scholarships and fellowships. Such investment income is recognized as temporarily restricted revenues when earned. However, if the restriction is received and met in the same period, the amount is recorded as unrestricted revenue.

H) ALLOCATION OF EXPENSES

The costs of performing the Organizations' various activities have been summarized on a functional basis in the accompanying statement of activities. Certain occupancy costs have been allocated among the activities benefited.

The Publications Business Unit publishes the Welding Journal magazine on a monthly basis and the expenses are stated in the departmental operating statement. The Membership Department as part of a member benefits, distributes the Welding Journal to more than 48,000 members. For the years ended May 31, 2002 and 2001, the annual cost of the production of the Welding Journal related to the distribution to members amounted to $895,000 and $908,900, respectively.

I) PREPAIDS AND OTHER ASSETS

Prepaids and other assets consists primarily of work-in-precess costs relating to various publications that have not yet been released for distribution. Once the publication is complete and ready for its intended use, the costs are amortized over the life of the publications, usually between two to three years. Additionally, expenditures which relate to programs for the next fiscal year are reported as a prepaid asset and are expensed during the next year as the related program function takes place.

In one year or less $ 118,001 Between one and five years 90,925 More than five years 6,500

$ 215,426

Pledges receivable in the amount of $80,925 as of May 31, 2002 are restricted for awards and scholarships. Management believes that all pledges are fully collectible and, therefore has not recorded an allowance for collection losses.

NOTE 4- INVESTMENTS

Investments, which are comprised entirely of mutual funds, are presented in the combined financial statements at their fair market values and consist of the following at May 31, 2002:

SEI Investments:

Core Fixed Income Fund $ 534,446 Intermediate Duration Government Fund 511,559 GNMA Fund 406,958 Bond Index Fund 404,439 Large Cap Value Fund 395,926 Large Cap Growth Fund 188,702 Small Cap Value Fund 81,801 Small Cap Growth Fund 49,903 International Equity Fund 135,493 Prime Obligation Fund 11,085

Vanguard Investments:

Long-Term Treasury Fund Long-Term Bond Index Fund

505,709 502,292

Reserve Fund Investments 3,728,313

Vanguard Investments:

Prime Money Market Fund 1,414,416 High-Yield Corporate Fund 165,061 Intermediate-Term Corporate Fund 381,803 Long-Term Bond Index Fund 167,484 Short-Term Bond Index Fund 227,532 Short-Term Corporate Fund 247,528 Stock Market Index Fund 347,965

AWS Foundation Investments .2,951,789

Total Investments $ 6,680,102


NOTE 4- INVESTMENTS (CONTINUED) Investment income consisted of the following for the year ended May 31, 2002:

Reserve AWS Fund Foundation

Interest and dividends $ 118,870 $ 137,889 Net realized and unrealized gains (losses)

on investments (71~135) 50,327 $ 47,735 $ 188,216

NOTE 5 - PROPERTY AND EQUIPMENT

NOTE 8- TOTAL NET ASSETS

Changes in net assets during the year ended May 31, 2002 are as follows:

AWS Operating Reserve Foundation Total

NET ASSETS, June 1, 2001 $1,588,894 $ 3,718,477 $ 3,543,080 $ 8,850,451 Change in net assets 10,484 51,763 236,786 299,033 NET ASSETS, May31,2002 $1,599,378 $ 3,770,240 $ 3,779,866 $ 9,149,484

Major classes of property and equipment consist of the following as of May 31, 2002: NOTE 9- BOARD APPROVED PROGRAMS

Land $ 816,726 Building and improvements 4,289,022 Furniture and equipment 3,212,137 Transportation equipment 21,564 Equipment under capital leases 411,186

8,750,635

Less accumulated depreciation (including $308,625 on equipment under capital leases as of May 31, 2002) 6,102,813

$ 2,647,822

Depreciation expense for the year ended May 31, 2002 was $289,820. Effective June 1, 2001, the Organizations changed their accounting estimates relating to depreciation. The estimated service lives for building and improvements and for most furniture and equipment were extended to 29 years and 7 years, respectively. The change was made in order to match the financial depreciable lives of the assets to the actual economic lives based on future use. As a result of the change, the 2002 change in net assets was increased by approximately $177,000.

NOTE 6- TEMPORARILY RESTRICTED NET ASSETS

American Welding Society, Inc.'s Board of Directors periodically approves expenditures for special programs designed, among other things, to further the development and public awareness of welding technology, education and standards. For the year ended May 31, 2002 and 2001, such special program expenses amounted to $0 and $51,737, respectively.

NOTE 10- COMMITMENTS AND CONTINGENCIES

EMPLOYEES' HEALTH BENEFITS

The Organizations are self insured for employees' health benefits to the extent of $50,000 per employee per annum. Claims in excess of $50,000 are reinsured. The accrued expenses include approximately $85,000 in connection with un-reimbursed claims as of May 31, 2002. The Organizations incurred health insurance expenses totaling approximately $985,000 during the year ended May 31, 2002.

DEFERRED COMPENSATION PLAN

American Welding Society, Inc.'s Executive Director was employed under the terms of an employment contract. The contract provides for base compensation and bonuses at the discretion of the Board of Directors as well as severance compensation under certain circumstances. Additionally, the contract addresses post-separation benefits.

Net assets in the amount of $1,711,535 as of May 31, 2002, are restricted for awards and scholarships. Net assets of $181,509 were released from donor restrictions by granting awards and scholarships.

NOTE 7 - PERMANENTLY RESTRICTED NET ASSETS

Net assets in the amount of $2,068,331 as of May 31, 2002, are permanently restricted endowments which are to provide a source of funds predominantly for educational, research and other charitable purposes.

The contract, which was for a 3-year term, was self-renewing unless canceled timely by either party. The Society elected not to renew the contract, and therefore the Executive Director's employment with the Society ended. The Executive Director has claimed that he is owed various medical and retirement benefits pursuant to the contract. On a present value basis, his claims approximate $2,900,000.

The Society has engaged legal counsel to address this matter. It is the Society's belief that such claims are without merit supported by legal counsel's opinion that the Executive Director is not entitled to the amounts claimed due. The Society has accrued $540,000 as its best estimate of this contingent liability.

The accrued obligation of $540,000 includes $180,000 charged to current operations with the remaining balance of $360,000 having been accrued prior to the year ended May 31, 2002.

NOTE 10- COMMITMENTS AND CONTINGENCIES (CONTINUED) NOTE 11- RELATED PARTY TRANSACTIONS

ROYALTY AGREEMENT

During 2001, the American Welding Society, Inc. (the "Organization") entered into a Copyright License Agreement with Information Handling Services ("IHS"), whereby IHS has been given rights to duplicate, package, facsimile transmit, promote, distribute, sell or lease the Organization's standards and technical publications. The term of the agreement is for sixty months and commenced on January 1, 2001. IHS guarantees the Organization that the total royalty payments to the Organization will equal or exceed minimum amounts of $1,300,000 for each of the upcoming years. The guarantee is contingent upon the Organization not entering into any other agreements with third parties that will adversely affect the economics of the agreement. The Organization will continue to produce new and revised publications and will continue to release these publications periodically as indicated, and the list price will be no less than the prices as indicated in the Organization's catalog. Under the terms of this agreement the Organization earned approximately $1,869,000 during the year ended May 31, 2002.

AWS Foundation administers investments on behalf of certain affil- iated sections. The investments aggregated $1,069,560 at May 31, 2002 and are not included in the combined financial statements.

The American Welding Society has loaned monies to a number of employees at the Society. Generally, the loans bear interest at 8% per annum and are repaid via monthly payroll deductions. The repayment terms range from less than a year to five years. The loans are not collateralized. The balance outstanding at May 31, 2002 was $75,500 and is reported with the financial statement cap- tion "Deposits and Other Receivables".

NOTE 12- CAPITAL LEASES

The Organizations lease certain computer and other office equipment under capital leases expiring on various dates through the year 2005. Assets are depreciated over the lower of their related lease terms or their estimated productive lives. Depreciation of assets under capital leases totaled $85,394 for the year ended May 31, 2002.

LITIGATION

The Organizations are exposed to various asserted and unasserted potential claims encountered in the normal course of business. In the opinion of management, the resolution of these matters will not have a material effect on the Organizations' financial position or results of operations.

The following is a schedule of future minimum lease payments under the capital leases:

2003 $ 81,294 2004 76,640 2005 1,658

The Organizations have filed a lawsuit against parties who con- tracted to provide services including the installation of a computer system. Management has determined that the computer system was not capable of handling the business requirements of the organization. As a result, the Organizations have filed a lawsuit, which claims approximately $2,800,000 in damages. These financial statements do not include a provision for the collection of the amount claimed. Furthermore, the defendant to this lawsuit has fried a counterclaim of approximately $212,000, plus their attorney fees, as well as replevin of certain personal property valued in excess of $15,000. The Organizations deny the allegations of the counterclaim and have vigorously defended against them. The case has not been set for trial.

Total minimum lease payments $ 159,592

independent Auditor's Report

To the Board of Directors American Welding Society, Inc. and AWS Foundation

We have audited the accompanying combined statements of financial position of American Welding Society, Inc. and AWS Foundation ("AWS") as of May 31, 2002 and the related combined statements of activities and changes in net assets and cash flows for the year then ended. These financial statements are the responsibility of AWS's management. Our responsibility is to express an opinion on these financial statements based on our audit. Information for the year ended May 31, 2001 is presented for comparative purposes only and was extracted from the audited combined financial statements presented for that year on which we expressed an unqualified opinion in our report dated August 21, 2001.

We conducted our audit in accordance with U.S. generally accepted auditing standards. Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements. An audit also includes assessing the accounting principles used and significant estimates made by management, as well as evaluating the overall financial statement presentation. We believe that our audit provides a reasonable basis for our opinion.

In our opinion, the combined financial statements referred to above present fairly, in all material respects, the financial position of American Welding Society, Inc. and AWS Foundation as of May 31, 2002, and the changes in its net assets and its cash flows for the year then ended in conformity with U.S. generally accepted accounting principles.

Morrison, Brown, Argiz & Company Certified Public Accountants Miami, Florida July 25, 2002

AmericanWelding Society

550 N.W. LeJeune Road Miami, Florida 33126

800-443-9353 305-443-9353 305-443-7559 Fax e-mail: [email protected] www.aws.org

Foundation, Inc. Building Welding's Future through Education


800-443-9353, ext. 293 305-445-6628 305-443-7559 Fax e-mail: [email protected] www.aws.org/foundation/index.html

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ing wire offers superior weldability for a wide range of single- and double-layer applications. The wire is a specially formulated chromium carbide alloy designed to produce a high concentration of primary carbides that improve wear resistance and durability. It can be applied to carbon, low- alloy, and manganese steels and cast irons in applications such as coal pulverizer rebuilding. Additional applications include cladding inside pipes and elbows, hardface plate cladding, gyratory mantles, and multiple-layer hardface buildup. The wire has a hardness HRC of 58-64 and is suitable for hot-wear applications of up to 900°E It is available in a Y~-in.-diameter (2.8-mm) wire with an amperage range of 400-650 and voltage range of 28-32 and a ~-in.-diameter (3.2-mm) wire with an amperage range of 450-650 and voltage range of 29-32. Neither requires any shielding gas.

Stoody Co. 102 101 S. Hanley Rd., Ste. 600, St. Louis, MO 63105

Software Improves Welding Parts Storage and Retrieval

FastPicT"PL (parts Iocator) software offers improved system throughput and employee productivity in welding parts storage and retrieval operations. The soft-

ware gives operators of automated storage and retrieval systems the capability to enter a part number into the system and have the stored items automatically delivered to them. The software creates a basic parts inventory by tracking stocking keeping units and quantities. The software runs on Windows® 95, 98, NT, and 2000. It supports any TCP/IP network and is SQL/OBDC-enabled for easier, faster database connectivity. Features such as bar code scanning, bulk storage management, paper pick lists, pick banding, continuous batch picking, and a wide selec-

tion of supervisory reports and options are also available.

FastPic Systems 41 Eisenhower Dr., Ste. A, Westbrook, ME 04092

103

High-Purity Ceramic and Metal Powders Offered

The company offers high-purity ceramic and metal powders, including both common and highly specialized materials, such as oxides, carbides, silicides, chro- mates, and borates. Powders are available in a variety of particle sizes in small or large quantities. Purity is greater than 99.5% and commonly reaches values of 99.9% or higher. The powders comple-

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

WE MAKE Stainless Cast iron Cobalt AISI Nickel

410NiMo FC 3 3 % Ni 1 4130 ENiCrFe-2 502 FC 5 5 % Ni 6 4140 ENiCrFe-3 505 FC 9 9 % Ni 12 4340 ENiCrCoMo-1 E2553 FC 21 ERNiCrMo-3 E2209 FC 2101 ERNiCr-3

E630 FC 904L FC

THE ABOVE ARE JUST A FEW OF THE CORED WIRES THAT WE MAKE. FOR MORE INFORMATION CALL:


WELDING JOURNAL J<~."Jl

ment the company's line of ceramic adhe- schedule triggers. Guns are designed with sives, sealants, and coatings, an ergonomic handle and have 11 parts.

Aremco Products, Inc. 707-B Executive Blvd., Valley Cottage, NY 10989

104

Air-Cooled Welding Gun Works in High Heat

The Spray Master TM air-cooled GMAW guns for high heat applications are available in 250-, 350-, and 450-A models. The series' guns come equipped with heavy-duty contact tips and diffusers.

l _aAreos k

Short conductor tubes allow operators to get closer to the workpiece. The guns are rated at 80% duty cycle with argon/CO 2 gases. The 350- and 450-A models are available with optional locking or dual-

Tweco Arcair 101 S. Hanley Rd., Ste. 600, St. Louis, MO 63105

105

Narrow Orbital Weld Head Ideal for Limited Clearence

•

Manufacturer of Superior Quafity Welding Consumables Since 1919

We're the little guys who can turn on a dime to meet all your requirements/

Specialized in tested material - 1st welding manufacturer to have an N stamp, approved to supply the nuclear industry!

• ASME Nuclear Certificate #448 • Mil-l-45208A Inspection • Canadian Welding Bureau

• ISO 9002 Certificate #GQC230 • American Bureau of shipping • Navy Nuclear

We've added a Thermal Spray Division capable of providing products ranging from thermal spray wires to preferred arc wire feeder systems.

For product information, visit us at www.arco.us

Arcos Industries, LCC • One Arcos Drive, Mount Carmel, PA 17851

(570) 339-5200 • (800) 233-8460 • Fax (570) 339-5206

C ail: (welding inquiries) - [email protected] • (thermal spray inquiries) - [email protected]


The company's Model 8-6625 orbital weld head for fusion gas tungsten arc welding of fittings, tubing, and thin-wall pipe has a narrow width that makes the heads ideal for limited clearance applications such as welding fitting-to-fitting or fitting-to-valve body assemblies. The head welds materials such as stainless steel, titanium, Hastelloy TM, and other autoge- nously weldable alloys.

Arc Machines, Inc. 106 10500 Orbital Way, Pacoima, CA 91331

Gauge Tests Electrode Force Accuracy

The CSI-FGAT-1100 electrode force gauge accuracy tester allows the user to determine if a force gauge is reading accurately or should be sent out for calibra- tion. The device utilizes a dead-weight system. The standard unit model applies up to 1100 lb of test force in l l0-1b incre- ments. Other size ranges are available.

Cellar Services, Inc. 107 5580 Gatewood, Ste. 108, Sterling Hts., MI 48310

Job-Site Radio Withstands Harsh Environments

The Model 49-24-0200 job-si te radio is designed to withstand the harsh punish- ment of professional job sites. The radio is powered by a two-way Rockford Fos- gate® sound system with a three-stage Punch EQ TM bass boost. Equipped with a high-end digital tuner and flexible 360- deg direct ional antenna, the radio provides clear reception even in remote areas.

IB { , ' IB N O V E M B E R 2 0 0 2 1

The impact-resistant shell, steel handle, and blow-molded base protect the radio from up to an 8-ft drop to concrete. It op- erates on 120-V AC power or 12-, 14.4-, and 18-V batteries and has an auxiliary stereo input jack for CD, MP3, or most other audio devices.

Milwaukee Electric Tool Corp. 13135 W. Lisbon Rd., Brookfield, WI 53005

108

Rack-Mountable Cooling System Saves Floor Space

The company's five 19-in. rack-mountable cooling systems provide up to 2100 W of cooling capacity and reduce floor space requirements. The systems are available with copper, stainless steel, and aluminum heat exchangers and are com- patible with a variety of cooling fluids such as water, deionized, water, EGW, and oil. The systems are used for cooling lasers, semiconductor capital equipment, analytical instruments, and medical equipment. Three different cooling capacities - - 500, 1300, and 2100 W - - are available with a variety of electrical and pump options.

Lytron Inc. 109 55 Dragon Ct., Woburn, MA 01801

Filtration System Offers Efficient Fluid Mist Collection

DTi

! __. Ill'i: ;

The MistBuster Quad utilizes a four- stage filtration process to eliminate mist and smoke from the air stream. In the first stage, mechanical mist impingers capture most of the larger mist droplets, which are coalesced and returned to the coolant sump. The second stage electrostatic precipitator provides an electrical charge on the remaining contaminates, which are then collected on a collection plate. The third stage, which is also an electrostatic precipitator, collects the remaining particulate. A fourth stage aluminum postfil- ter entraps any particles that may have agglomerated on the cell plates. The filtration system has no consumable filters to

replace, uses an economical fractional horsepower motor, and is quiet, rated 70 dBA at 6 ft on high speed.

Air Quality Engineering, Inc. 110 7140 Northland Dr. No., Minneapolis, MN 55428-1520

Six-Inch Slide Switch Grinder Made for Demanding Applications

The company's 1706AE 6-in. slide switch grinder has a 12-A, 9300 rpm motor for demanding applications. Epoxy-

coated field windings provide added protection and endurance while the Service Minder TM brushes aid preventive maintenance. Other features include protected and sealed switches; heavy-duty metal gear housings; and ball- and needle-bearing construction for smooth power trans- mission and extended life. The tool-free adjustable guard, spindle lock, slide switch, Constant Response TM circuitry, and slim motor design that reduces bar- rel diameter are additional features.

Bosch Tools 111 4600 W. Peterson Ave., Chicago, IL 60646

The Most Advanced PAPR Available!

We've reinvented the powered air-purifying respirator for welders. The result is a lightweight, compact, all-in-one system: Speedglas" with Adflo".

• Brushless Motor: 3 times the design life of traditional motors.

• Automatic Airflow Control: constant airflow, regardless of battery charge and filter loading.

• New Ventilated Leather Belt: shaped for maximum freedom of movement and back support.

:iiiii: Adflo" Turbo HE filter Optional Adf lo ' Filter Cover cartridge

NiMII Bailer? charges in 3 hours

• Two-Systems-ln-One: the High Efficiency (HE) particle filter can be "stacked" onto an optional Adflo cartridge, which provides additional protection against specific fume vapors.

• 1 year warranty.

HORNELL H O R N E L L , I N C .

2 3 7 4 E D I S O N B L V D . • T ~ V I N S B U R G , O H 4 4 0 8 7 U S A TEL= 8 0 0 - 6 2 8 - 9 2 1 8 • 3 3 0 - 4 2 5 - 8 8 8 0 • F A X : 3 3 0 - 4 2 5 - 4 8 7 6

i n f o . u s @ h o r n e l l . c o m o w w w . h o r n e l h c o m

~2002 Hornell. Exclusive desi~,ns protected by patents worldwide. Adflo', Speedglas', Fresh-air' and S'~deWindows '~ are trademarks of Hornell.


I WELDING JOURNAL DqrB

Downdraft Table Collects Industrial Contaminants

The DT-3000 version 2, heavy-duty downdraft table collects dust, smoke, and fumes from industrial operations including metalworking, wood/plastics, composites, or other dust-producing applications. The table has a work surface area of 3'/2 x 5 ft. The unit is completely self contained with motor blower, high-efficiency cartridge filters, and a self-cleaning system for the collected dust. The table can be placed flat against a wall or in a corner. Options include back and side shields with integrated work light, fiberglass or PVC- coated grates, and HEPA after filters.

Airflow® Systems Inc. 11221 Pagemill Rd., Dallas, TX 75243-8314

112

Spatter Mat Reduces Fatigue

The company's Spat ter-Mat reduces fatigue and withstands spatter from welding operations. Its specially formulated rubber surface repels sparks and hot metal shards. The buoyant sponge base allevi- ates leg and back stress while minimizing overall body fatigue. With '/_,-in. overall thickness, edges are beveled for safety. The pebbled surface provides traction.

Wilson Industries, Inc. 123 Explorer St., Pomona, CA 91768

113

Large Angle Grinder Provides On-the-Job Safety

The company's W23-180 and W23-230 large-angle grinders designed for cutting and grinding applications feature a 7- or 9-in. wheel. The grinders incorporate a two-step power switch at the rear of the tool, allowing users to tackle large jobs safely. Users must have the first but ton depressed to engage the power switch, preventing accidental turn on during operation. The grinders feature a flexible rear handle that rotate 90 deg for comfort during cutting operations. A three-position handle for left- or r ight-handed operation allows users to turn the tool 90 deg to cut vertically and still have a firm grasp on the grinder.

Metabo Corp. 114 1231 Wilson Dr., West Chester, PA 19380

Cover the Wor ld Praxa i r Sur face Technologies has the wor ld covered. From next generation thermal spray materials to innovative spray equipment, our experts can provide coating solutions for today's demanding environment. Our extensive line of powders and wires, combined with our high performance spray equipment, can give you an edge, no matter where you are in the world.

When you specify Praxair brand products, you'll discover a world of difference. To find out more, call us today or visit our web site at: w w w , praxa i r thermalspray .com

j/ PRAXAIRo SURFACE TECHNOLOGIES

'rAl r

Praxair Surface Technologies, Inc. 1555 Main Street Indianapolis, IN 46224 317-240-2650 Tel 317-240-2225 Fax

TAFA Incorporated 146 Pembroke Road Concord, NH 03301 603-224-9585 Tel 603-225-4342 Fax

Praxair, the Flowing Airstream design, the TAFA logo, and the FLAME design are trademarks of Praxair S.T. Technologies, Inc. in the United States and other countries. TAFA Incorporated is a wholly owned subsidiary of Praxair Surface Technologies, Inc. Copyright © 2002 Praxair S.T. Technology, Inc. All rights reserved.


ngllrllflg Wltll carrion ann low-alloy construction steels. The American Welding Society has released the latest version of the D1.5 Bridge Welding Code, outlining requirements of the American Association of State Highway and Transportation Officials (AASHTO) for building highway bridges made from carbon and low-alloy construction steels. Chapters cover inspection, qualification, structural details, stud welding, welded joint details, workmanship and more. This new edition features the latest AASHTO revisions and

zou-page ~i-approveu uocumenL conLams 35 tables, 77 figures, and several annexes. Welding and construction professionals and designers will find this book essential for all forms of bridge work.

NEW EDITION HIGHLIGHTS: • Implementation of U.S. Customary Units • Provisions for undermatching electrode

usage • Added commentary section • New requirements for the modified

WP$ qualification tests

A ~ O J.VJL~I[I[U~****oH,,,,,,,,,,,,*~ J.OO.UU

To order your copy of the 01.5:2002 Bridge Welding Code, phone Global Engineering Documents at (800) 854-7179, or visit their webpage at: www.global.ihs.com.

~ r DOCUMENTS o

<•AmericanWelding Society Founded in 1919 to Advance the Science, Technology and Application of Welding

NEW,/SEMINAR DAYS AND TIME

American Welding Society . • .~., . i ' ~ ~ . .

~ / / / Founded in 19"19 to Advance the Science, ~;:~.~;-::J.,,. . ~ i L . . : . . . . ~ ~ .

Technology and Application of Welding . ~ . , " ~ ~ ' ~.a ' :

AWS Certification is the welding industry's most respected sign of .pp..,nnnpnu ii!i! il

DECEMBER 2002 SEMINAR DATES EXAM DATES MIAMI, FL ................................ 12/1-6 ...................................... 12/7/2002

JANUARY 2003 SEMINAR DATES EXAM DATES BATON ROUGE, LA .................. 1/19-24 .................................... 1/25/2003

DALLAS, TX ............................ 1/19-24 .................................. 1/25/2003

FRESNO, CA ............................ 1/26-31 .................................... 2/1/2003

PHILADELPHIA, PA .................. 1/26-31 .................................... 2/1/2003

FEBRUARY 2003 SEMINAR DATES EXAM DATES COLUMBUS, OH ...................... 2/3-7 AT NBBPVI ...................... 2/812003

CORPUS CHRISTI, "IX .............. 2./9-14 ...................................... 2/15/2003

NORFOLK, VA .......................... 2/2-7 ........................................ 2/8/2003

SEATTLE, WA .......................... 2/9-14 ...................................... 2/15/2003

TAMPA, FL .............................. 2/2-7 ........................................ 2/8/2003

MARCH 2003 SEMINAR DATES EXAM DATES CHARLOTTE, NC ...................... 3/2-7 .......................................... 3/8/2003

SAN FRANCISCO, CA .............. 3/2-7 .......................................... 3/8/2003

SPRINGFIELD, IL ...................... 3/9-14 ........................................ 3/15/2003

LAS VEGAS, NV ........................ 3/9-14 ........................................ 3/15/2003

NEWARK, NJ ............................ 3/16-21 ...................................... 3/22/2003

PHOENIX, AZ .......................... 3/23-28 ...................................... 3/29/2003

Seminar and Exam Schedule

Course Sehedu]e

DI,I Code Clime ............................................ Sunday; i p,m.- 5 p.m,

Monday; 8 a.m.- Noon

AP11104 Code Clinic .................................. Monday; 1 p.m.- 5 p.m.

Welding h s p a i o n Tedmology .................. Tuesday-Thursday; 8 a.m.- 5 p.m,

Visual h s p a i o n Workshop ........................ Friday; 8 a.m.- 5 p.m.

Exam .......................................................... Saturday; report for exam at 7:30 a,m,

To register or for more information on an exam prep course, call (800) 443-9353. ext. 229; to request an application for CWI exam qualification, call ext 273.

To find out about AWS Customized In-House Training and Quality Assurance Programs for your company, call AWS, toll-free at 1-800-443-9353, ext. 482, or check Hie box on the registration form.

Visit our website www.aws.org for additional dates.

A~S reser',es the right to cancel or change the published date of an exam preparation seminar listed if a.n insufficient number of re~slrations are received. Prices are subject to change ~ithout notice.

i;

\ ,

|eeping Weldws Sate is the Ton Priority! The potential for injury from Radiation, Burns, Vapors, and Explosions is substantial when welders perform their jobs improperly or when their work area is not maintained in an orderly, safe, clean and prudent manner. In addition, a myriad of agencies exert control over worker safety.

WeldAcademy can help prevent work site accidents! This 10 module web-based course covers several topics essential to everyone in the welding industry.

," ¢ " :~ ' ,a

v

Module 2: Safe Practices for Welding. Personnel

Equipment, Procedures, Situations, and Documentation needed to comply with mandated safety requirements, and prevent accidents on the job!

Call today to learn more about this exciting new training course for the welding industry.

1-888-488-KNOW (1-888-488-5669) 8am-5pm (CST)

¢1 Visit us online at www.weldacademy.com

Circ le No. 10 on Reader Info-Card

F U = Atter~d t!se AWS WELDING SHOW. You ':.~iil see the i ~eSL!its ~n yo,,~r p!ofi l margin.

The AWS Welding Show: If you have JOINING NEEDS, we have your SOLUTIONS.

e~

o o = .

,, J

:r 2'. r "~'~

•WEI.DING S H O W 2 0 0 3 Celebrat ing 50 years of Service

April 8-10, 2003 Cobo Hall, Detroit, Michigan USA

By a t tend ing the A W S W e l d i n g S h o w , y o u c a n e x p e c t a n s w e r s .

In today's tough economy, you need to stay competitive, which means you have to stay at the head of your industry. At the AWS Welding Show, you can get close-up and hands-on with the newest equipment and latest products in your industry. See exactly what a product looks like, learn how it works and evaluate competitive products. Attend valuable seminars, conferences and free lectures. Mingle with the top minds of your trade. Advance your career or your business by attending the AWS Welding Show. You will see the results in your profit margin!

American Welding Sociely

Technology and Application of Welding


(800) 443-9353. Fax (305) 443-7559

/ Forging company meets

Navy requirements for Inconel ®

cladding of submarine propeller shafts

BY LES SCOTT AND ROCKY ANDREINI

LES SCOTT (206-762-1100) and ROCKYANDREINI are with

Jorgensen Forge Corp., Seattle, Wash.

For more than 60 years, the Jorgensen Forge facility has been manufactur ing ship shafts for both naval and commercial applications. The facility is located on 22 acres south of Seattle, Wash., and it encompasses 350,000 sq ft of manufacturing space with integrated melting, forging, heat treating, and machining capability operating within the framework of ISO 9002 quality standards.

The Navy built the facility in the late 1930s and it opened in 1940. It was designed to support West Coast shipyards with forged and machined ship shafting and, until 1963, was operated by Isaacson Iron Works as a Navy facility. The plant was purchased by Earle M. Jorgensen in 1965.

Today, Jorgensen Forge is a fully integrated, open die forging facility pr imari ly serving the marine, aircraft , aerospace, oil field, and power generation industries.

The facility produces propulsion shafting and other types of marine hardware from small aluminum bronze shafts for coastal mine hunters to CVN-class aircraft carrier propeller shafts.

WELDING JOURNAL E . t H

Table 1 - - Optimized Variables for Inconel 625 Electroslag Cladding

Current Voltage Machine type Travel speed Strip feed speed Bead-to-bead tie-in overlap Strip feed angle Contact tip-to-work distance Preheating/Interpass temperature Postweld stress relieving temperature

570-670 A 24-30 V DCEP constant voltage 7-10 in./min 60-90 in./min 0.090-0.180 in. 7 deg. B.T.D.C. __. 1 deg 1.1-1.9 in. 400-500°F 100°F or 50°F below the actual temperature of the shaft

Note: Strip size is 30 mm.

Fig. 2 - - Dye penetrant test of electroslag cladding.

Development and Application of Electroslag Strip Cladding

Inconel® 625 cladding is applied to the shafts of Navy vessels in selected locations for increased corrosion protection and long-term reduction in overall maintenance costs.

Jorgensen Forge started to research and develop an electroslag process for strip cladding of Virginia-class submarine propulsion shafting in 1999. The electrode utilized is a 625 strip (EQIC-Mo-3), 30 mm wide x 0.5 mm thick. A 45-mm strip was also tried, but the 30-mm strip proved more effective. A DCEP constant voltage power supply is used. The technical reference guide developed by the Department of Materials Science and Engineering at the Ore- gon Graduate Institute of Science and Tech- nology was the critical starting point for the process development and application.

The weld procedure qualification required by NAVSEA standards was performed in 1999, using nickel-molybdenum Class 1 base material per MIL-S-23284 The desired clad- dding thickness was 0.380 in. Improved quality and deposition speed were desired in an

effort to significantly reduce overall costs. The technology was utilized on the shaft

body only. No effort was made to qualify on the flange end of the shaft, where gas metal arc pulsed welding (GMAW-P) technology is still used, due to strip feeding and other setup issues. The strip width chosen for qualification and subsequent production was 30 mm due to previous operating experience by the Oregon Graduate Center and NAVSEA. The turning lathe utilized for production cladding required a new drive system to slow the head stock speed to a level satisfactory for electroslag cladding. Qualification test clad appearance is shown in Fig. 1.

Process Results

The technique was successfully qualified and utilized for the first time in NAVSEA history on the initial Virginia-class submarine shaft. Jorgensen Forge, working closely with a few critical suppliers, made substantial improvement on previous industry-standard strip cladding efforts. The major variables, with pertinent parameters, are shown in Table 1.

Table 2 - - Clad Thickness Dilution Results

Cladding % Fe % Mo % Cr Thickness (in.)

¼6 8.33 8.31 20.32 2.39 8.76 21.03

~6 2.25 8.84 21.08 ¼ 2.28 8.71 21.05

Required for ¼ in. 9% max 8% rain Information only

Dilution of iron into the 625 cladding layer, which lowers the molybdenum content in the cladding, is of particular concern in any high- alloy cladding of low-alloy steel. Dilution re- suits using electroslag strip cladding were excellent, as shown in Table 2.

One of the critical challenges overcome in process development was bead-to-bead tie-in. With the maximum interpass temperature being 500°F, it was found that single-pass stringer beads, coupled with stopping and in- dexing for tie-in, was the best approach to temperature control and prevention of continuous slag inclusions.

Improvement in deposition speed was realized. Rates of approximately four times those of the GMAW-P process previously used for the shaft were achieved, with resultant time and cost savings.

Surface quality, as exhibited by liquid penetrant inspection, is an absolute requirement of any successful cladding technique. The requirement was acceptance per liquid penetrant inspection techniques to MIL-STD-2035A (SH) Class I. No problems were encountered meeting this, as seen in Fig. 2.

Summary

Jorgensen Forge successfully qualified and utilized an electroslag strip cladding (ESS) process to clad the Virginia-class submarine propeller shaft. NAVSEA requirements were readily met, and improvements in quality and process speed were realized. In addition to these improvements, the ESS process is an environmental improvement due to the arc elim- ination and significant fume reduction.

Work is presently progressing to qualify the same procedure to MIL-S-23284 Class 5 material, and to utilize the ESS technology on other defense and commercial applications. •

Acknowledgments

Jorgensen Forge received excellent help along the process development path from numerous suppliers and consultants. We especially extend our sincere thanks to Devasco In- ternational, Preston-Eastin Inc., Weld Engi- neering Company, and Bob Turpin of Portland State University.

EP, i NOVEMBER 2002

l i d

I1 1[I

pure AI coating

i

: ........... I ¸

Fig. 2 - - While the process can be used to de-

posit coatings on a wide variety o f substrates, a metallic surface with some degree o f ductility is preferred. Here, the solid-state deposition technique is being used to deposit a pure AI coating onto a 6061 AI plate. The nozzle is cemented carbide with a brass housing and it has an X-Y raster control.

I e r m a l spray is a method of depositing coatings that range from metals, which are melted and "splat" sprayed, to ceramics, which have been successfully sprayed by heating the ceramic powders to above their melting points. In recent years, a new concept called "cold spray" has emerged out of work performed in Russia, principally by Papyrin (Ref. 1). This work actually revived a concept originally credited to Samuel Thurston (Refs. 2, 3), whose two patents from 1902 formally introduced the spraying of solid powder particles into protective coatings on common metal surfaces. Much of the recent explo- ration regarding this technique in the United States has been conducted at Sandia National Laboratory in Albuquerque, N.Mex.

In the cold spray process, the powders are sprayed through a nozzle at supersonic velocity at temperatures below their thermal softening point. It is now common to perform such spraying in an inert gas stream. The powders will then deposit into

WELDING JOURNAL E . ~ !

continuous coatings when impinged upon a suitable surface. The general theory behind why the coating builds is the high impact of the particles leads to mechanical alloying and bonding between the powders and the substrate or the depositing powders and the coating as it builds up.

Depending upon the powder's particle size distribution and its ductility, extensive cold working within the coating is observed, particularly at temperatures below which thermal softening of the powders occurs. In addition, with many materials, articles can be spray-formed into bulk, monolithic structures.

Inovati, Santa Barbara, Calif., has developed and patented a new solid-state deposition technique it calls "kinetic metallization (KM)" (Refs. 4-6) - - Fig. 1. This technique is capable of depositing fully dense, adherent coatings of a variety of metals on standard metal surfaces without costly surface preparation. Since the thermally conditioned powders are deposited at well below their respective melting points, the coatings exhibit very fine grain size and it is possible to avoid heat distortion of the workpiece being coated and interdiffusion of multilayer coatings. The process utilizes a set of specific deposition parameters that include • Accelerant gas composition • Optimized particle velocity • Nozzle design • Specific and efficient powder

treatments that can include particle heating.

The advantage of depositing unmelted, solid particles is preservation of fine grain size in the final coating. Using this technique, Inovati has successfully spray- formed two particularly temperature- sensitive materials: amorphous aluminum and nano-crystalline aluminum. The respective attractiveness of depositing these materials is that by avoiding high heat, the amorphous phase can build up without crystallizing, and nano-crystalline aluminum, which features micron-sized particles with sub-micron grain structure, can be deposited while avoiding grain growth. Accordingly, solid-state spray forming (SSF) becomes a means for building up material without sacrificing microstructure quality. In these examples, the two materials' microstructures directly impact their strength-to-weight ratio and specific stiffness. High stiffness is particularly

attractive in aerospace design and construction.

The following are among the coatings and spray-formed structures that have been successfully prepared using the process: • Aluminum and aluminum alloys • AI-25% SiC • Titanium and titanium alloys • WC-17% Co • Stainless steel • Nickel • Chromium • Copper and copper alloys • Pure niobium • Composite mixtures of metallic powders.

In general, with this process, coatings can be deposited on substrates of various chemistries and hardness values. How- ever, it is usually advantageous to have a metallic surface with some degree of ductility because it promotes successful bonding upon particle impact - - Fig. 2. Even with a suitable combination of substrate and deposition source, the depositing powder will not stick one hundred percent. Therefore, deposition efficiency - - the factor that quantifies the amount of sprayed material that will stick as opposed to the amount that will effectively reflect off the workpiece - - must be considered.

The starting spray powder will always be critical to deposition. The trend in thermal spray is to deposit coarser sizes (e.g., +325 mesh, which is +44/~m) principally to avoid powders whose higher surface- to-volume ratios would promote oxidation or other undesired surface reactions during thermal deposition, which would severely compromise final coating integrity. In SSF, a wide particle size distribution with sufficient ultrafine particles is generally preferred so as to minimize the grain size of the final sprayed microstructure and maximize its density. This can be a challenge with some materials because some powders are limited in fine particle size availability. Finer particles also tend to cost more. Fortunately, many desirable coating metals are available in sufficiently fine particle size and that also possess the following characteristics: • Sufficiently ductile to deform into a

fully dense coating • Available at an adequately low cost • Exhibit adequate flow characteristics,

in a properly designed powder feeder, so as to spray-deposit effectively.

With respect to powder availability, some limitations exist as to availability of certain powders at ultrafine particle size, e.g., < 5 ~m. These are powders that either cannot be readily processed to such particle sizes (generally due to high ductility, which prevents powder milling, coupled with a lack of economical precipitation techniques to alterna- tively process these powders), or materials that are particularly pyrophoric at very fine particle sizes. In the latter case, Ti, Zr, and Hf are of particular concern. These metals can be purchased at coarser particle sizes (e.g., > 15/xm) and can substantially benefit in their deposition quality if aided by some heat. Though heating may substantially improve a particle's cohesiveness and de- formability, it is not required to heat the particle to sufficiently high temperatures and/or in sufficiently reactive gases so as to induce grain growth or heavy surface reactions (e.g., oxidation and/or carburization, which can occur in high- velocity oxyfuel spraying), let alone fully melt the starting powder. The use of inert accelerant gases further allows for reactive metals to deposit while not si- multaneously forming particle surface reaction phases.

As ment ioned previously, powder feeding is a critical part of this thermal spray process. In particular, the powder must be fluidized in a closed cylinder and injected into a static pressure in excess of several atmospheres. This requires specific engineering so as to provide both airtight containment of the powder and efficient entrainment of the powder into the gas stream (Ref. 7).

Also critical is spray nozzle design. The spray nozzle must be able to do the following: • Aerodynamical ly support the spray

dynamics, in particular high particle velocity, which can approach 1000 m/s

• Resist internal abrasive wear • Allow for a narrow spray dispersion

(generally <2 deg). In order to achieve proper flow, nozzles are made from very hard carbide ceramics and are internally configured with high specificity. Proper nozzle design and establishment of general deposition parameters, which can vary a bit from powder to powder, will optimize a coating's microstructure and its growth rate.

Uses for the New Technique

Corrosion Resistance

The most common type of corrosion is the rusting of carbon steel. Rusting is the oxidation of iron in steel when the iron reacts with water and oxygen. Rust is a hy- drated ferric oxide (Fe203.nH20, where n is usually 112). Rusting entails oxidation of metallic iron to ferrous ion (Fe +2) followed by the reaction of the ferrous ion with oxygen and water. The reaction can be catalyzed through the presence of acids, as well as metals (e.g., copper and tin) below iron in the electromotive series. Because iron is so widely used, protecting it against rust is important.

Stainless steels are alloys of steel that contain such metals as chromium and nickel. They do not corrode as readily because the added metals help form a hard, adherent oxide coating that resists further attack. Stainless steels are substantially more expensive than plain carbon steels; therefore, it is often desirable to use carbon steel for applications in corrosive environments and enhance their performance through surface coating.

Although metals such as aluminum, chromium, zinc, and titanium that are above iron in the electromotive series can, under select circumstances, corrode more readily than iron, their oxides form a ten- uous coating that protects the metal from further attack. Rust, however, is brittle and flakes off the surface of the iron, con- tinually exposing a fresh surface.

Other types of corrosion include oxidation and/or chemical erosion (often by salt or acid attack) of such metals as copper, brass, bronze, and aluminum and aluminum alloys. These materials can be attractive for use in various applications due to such factors as machinability, formability, and cost. Barrier or sacrificial coatings can be attractive for protecting these metals as well.

As a Replacement for Other l~pes of Coatings

Providing various metals with enhanced surface corrosion resistance can considerably extend their usefulness in many applications. Rusting of steel, for

example, can be inhibited by excluding air and water from the iron surface (e.g., by painting or hot dip galvanizing) or by plating the steel with a protective coating of another metal. Metals used for plating include chromium, nickel, tin, and zinc. Metals have been applied as barrier coatings for decades. The most commonly used application method for pure metals on metallic surfaces is electroplating. In electroplating, ionic salts of the metal being deposited are placed in aqueous solution and an applied voltage induces decomposition of the salt into ionically pure metal, which is then deposited out onto a work surface.

Thermal spray processes, such as high velocity oxyfuel (HVOF), produce coatings through the melting of powders and the splatter of these melted powders onto a substrate surface. The result is an inho- mogeneous microstructure forms and there is a risk of thermal damage to the substrate as well as excessive reactivity of the coating (e.g., brittle phase formation with the substrate and/or oxidation of the coating).

A primary concern with plating is that highly poisonous and carcinogenic chem- icals must generally be used in order to provide active ionic availability of the metal being deposited. In chrome plating, the chromium ion exists in a hexavalent state, which is highly poisonous to human beings and poses an ongoing waste containment problem.

The U.S. Environmental Protection Agency has taken steps to curtail use of chromium plating. Some limited work has been performed using trivalent chromium but with substantial compromise in such properties as film integrity and adhesion.

Work is under way to develop such coatings as Cr and Ni (as well as AI- matrix composites) sprayed with this solid-state process that can act as a sub- stitute for electrodeposition of these metals, without sacrificing purity or microstructural quality. The primary limita- tion of any spray coating compared to electrodeposition is it is a line-of-sight deposition method.

Figures 3-8 offer examples of some of the materials applied and applications the new technique has been used for. Figure 3 is a micrograph of a WC-17% Co fine powder sprayed onto 1018 carbon steel. Here, because of the inert carrier gas and com-

I WELDING JOURNAL ~,~ ' !

paratively low temperature of deposition, a particularly fine grain powder could be deposited without concern over surface reactions, including excessive oxide formation, and thus entrapment in the final coating. WC-Co compositions are useful for both corrosion and wear resistance. In another application, a steel telecommunications rack was prepared with an aluminum-chromium composite coating acting as an electrical grounding path with good corrosion resistance. Here, the metal layer served as a sub- stitute for a zinc-chromate conversion coating that, due to the use of poisonous chemi- cals, was no longer available locally to the

customer. Figure 4 is an SEM cross-section image of that coating on 2024 A1.

Diffusion Barriers

Some metal coatings can be required to serve as a diffusion barrier between two metals that may pose a high likelihood of forming low melting phases or brittle inter- metallics if they begin to react. Figure 5 is a pure niobium layer that has been spray- deposited using the new technique onto copper to act as a barrier to a subsequent layer of aluminum.

Brazing

Preliminary explorations have been made of using the technique as a means for depositing braze powders onto surfaces so as to avoid binder burnout issues with pastes and wetting issues with foils.

Figure 6 shows an aluminum braze joint prepared by using solid-state thermal spray to deposit 4047 AI braze powder onto 3000 aluminum at 0.004-in. thickness followed by mating to a fresh piece and then vacuum furnace reflowing of the mated parts.

Spray Forming

Figure 7 shows the surface of an AI-25 wt-% SiC composite plate that has been spray-formed using the new process. Again, the advantage of this type of spray forming is the ability to preserve a finer microstructure than possible through conventional melt-spray methods (Ref. 8). The process has been used to spray-form AI-SiC to more than ¼ in. in thickness. It has also been used to spray-form spacecraft components and

brake rotors. Figure 8 is an aluminum part shown as-sprayed. The spraying was performed over a hexagonal plastic mandrel

that was then removed.

Some limited work performed on spray- forming of titanium at > 90% density greatly benefited from post hot isostatic pressing of the block to full density (Ref. 9).

Summary "Kinetic metallization" is a novel means

of depositing metal and metal-based composite coatings with fine and uniform microstructure. This is made possible through

the spraying of fine powders at temperatures below their melting points. If sufficient

particle velocity is achieved, the deposition will adhere to the substrate and to itself as it builds up. Spray-forming in the solid state is also afforded with this technique.

Applications include wear-resistant AI composites, structural materials with high specific strength, thermal management substrates, and braze powder deposition.O

References

1. Alkhimov, A. P., Papyrin, A. N., et al. 1997.

Gas-Dynamic Spraying Method for Applying a Coating. U.S. Patent #B1-5,302,414.

2. Thurston, S. 1902. Method of Impacting One Metal upon Another. U.S. Patent #706,701.

3. Thurston, S. 1902. Process of Coating One Metal with Another Metal. U.S. Patent #706,702.

4. Tapphom, R. M., and Gabel, H. 2000. A Coating or Ablation Applicator with a Debris Re-

covery Attachment. U.S. Patent #6,074,135. 5. Tapphorn, R. M., and Gabel, H. 2001. A

System and Process for Solid-State Deposition and Consolidation of High Velocity Particles Using Plastic Deformation. U.S. patent pending.

6. Tapphom, R. M., and Intrater, J. 2002. Ki- netic metallization - - a solid-state coating and spray-forming technology. Final report. Huntsville, Ala.: Missile Defense Agency, Science and Tech- nology: U.S. Army Space and Missile Defense Command. Contract No. DASG60-00-C-0004.

7. Gabel, H., and Tapphom, R. M. 2001. Pow- der Fluidizing Devices and Portable Deposition Apparatus for Coating and Spray Forming. U.S. patent pending.

8. Tapphorn, R. M. 1998. Solid-state spray- forming of near-net-shape structural materials. Final report. Ballistic Missile Defense Organiza- tion, Science and Technology: U.S. Air Force, Air Force Material Command, Air Force Research Laboratory. Report No. AFRL/VS-PL-TR-98- 1002. Contract no. F29601-97-C-0109.

9. Tapphom, R. M., and Gabel, H. 1998. The

solid-state spray forming of low-oxide titanium components. Journal of Metals 50(9): 45-46, 76.

CALL FOR PAPERS

13th International Conference on Computer Technology in Welding June 18-19 , 2003 m Orlando, Florida

This is the thirteenth 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 June 18 and 19, 2003, in Orlando, Fla. Authors from around the world are strongly encouraged to submit an abstract, as attendance from an international audience will be encouraged.

Authors should submit the Author Form together with an abstract of no more than 500 words to American Welding Society, Conference Department, 550 NW LeJeune Road, Miami, FL 33126, by November 15, 2002. The abstract should be sufficiently descriptive to give a clear idea of the content of the proposed paper, typed, and between 250 and 400 words in length. Authors will be notified of acceptance by December 13, 2002. Completed manuscripts will be required from selected speakers by February 24, 2003.

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 SimulationNisualization • 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., WPS, PQR) • Databases, Database Applications, and Knowledge Bases • Standards

You may fax your application and abstract in at 1-305-648-1655, or via e-mail at [email protected]. If you would like to submit your abstract on-line, you may do so at www.aws.org.

Author Application Form

Please print and assure all information is legible.

Author's Name: Please check how you are addressed: Title or Positions:

Mr. Ms. Dr. Other

Organization: Mailing Address: City: State: Zip Code: Telephone: Fax: E-mail

Country

For joint authorships:

Name: Name: Organization: Organization: Address: Address: E-maih E-mail:

Please ensure your abstract is typed and between 250 and 400 words in length. Remember, the cutoff date to submit your abstract is NOVEMBER 15, 2002.

The 2003 AWS WELDING SHOW will be packed full of technology, knowledge, and special events

Get ready to celebrate 50 years of the AWS Welding

Show. Yes, April 8-10, 2003, will mark 50 years of continuous

exhibitions

AWS was

by the American Welding Society. The first year

the exclusive organizer and sponsor of an all-

welding exhibition was 1953, and the Show was in Houston, Tex.

Fifty years later, the Show comes to Cobo Center, in Detroit,

Mich. Get ready to celebrate this Golden Anniversary in 2003.

For more information on Detroit visit www.visitdetroit.com or call 1-800-DETROIT.

E!:I NOVEMBER 2002 ]

Host City Is Looking Good

Ambitious redevelopment and renovations in Detroit to the tune of $17 billion have created a new look since the American Welding Society Show was last in the Motor City in 1999. A new airport terminal, two new stadiums, three casinos, renovated hotel rooms, and muse- ums are sparking excitement about Detroit.

Many will experience their first look at a changed Detroit when they land at the new Northwest Airlines World Terminal at Metro Airport. Then, they might enjoy a Tigers baseball game at the new Comerica Park. This open-air, state-of- the-art stadium features views of the Detroit skyline, a Ferris wheel, comfort- able seats, and good food. Right next door is Ford Field - - home of the Detroit Lions and Super Bowl XL in 2006.

Detroi t now offers three new Las Vegas-style casinos - - M G M Grand, MotorCity, and Greektown. Each offer 75,000 sq ft of gaming space, restaurants, and nightly entertainment.

Detroit 's signature building - - the Renaissance Center - - has completed major renovations to the hotel, retail space, and public space. Renovated rooms, added restaurant selections, and the new Wintergarden are welcome additions. A 3000-ft riverfront promenade between Joe Louis Arena and the Renaissance Center makes the walk to Cobo Center scenic and enjoyable.

Area favorites like Henry Ford Museum, Greektown, and the museum district are great for sightseeing among locals and visitors. The Detroit Zoo has added new exhibits and a new Science Center awaits your visit.

Great Way to Learn m and Earn m Credit Hours

Your AWS certification may well be the single most valuable piece of paper you own. It represents the effort you made to upgrade your skills and capabilities and shows the world that you achieved a worthwhile goal in your professional career. Your responsibility now is to continue your professional development though participation in workshops and seminars that will count toward recertification requirements under several programs. Not only will you gain valuable knowledge and solutions to the challenges you face every day, but you will accrue credits toward recertification of your AWS credentials. The AWS Welding

Show is the single best opportunity to see the latest in welding technology, network with other professionals in your field, and gain credits toward ensuring your future as a welding professional.

Below is a list of learning opportunities at the 2003 Welding Show with assigned credit hours. • 9th AWS/AA Aluminum Welding

Conference - - Apri l 7-8, 2003; Credits: 14.

• Road Map Through the 2002 DI.1 Code - - April 7, 2003; Credits: 7.

• Design & Planning for Cost-Effective Welding - - April 7, 2003; Credits: 7.

• What Professionals Need to Know About Metallurgy - - April 8-9, 2003; Credits: 14.

• Inspection to the 2002:DI.1 Code - - April 8, 2003; Credits: 7.

• Arc Welding and Power Sources - - April 8, 2003; Credits: 7.

• Safety and Ventilation Strategies for Welding and Finishing Operat ions Conference - - April 9, 2003; Credits: 7.

• Welding of Stainless Steels - - April 9-10, 2003; Credits: 14.

• Why and How of Welding Procedure Specifications - - Apri l 9, 2003; Credits: 7.

• Conference on High Currents Used in Resistance Welding - - April 9, 2003; Credits: 7.

• Safety in Welding & Cutting Operations - - How to Improve Your Company's Profitability - - April 10, 2003; Credits: 7.

Foundation's Silent Auction Is Win-Win for Everyone

The AWS Foundation will hold its Silent Auction and annual raffle during the Welding Show. Your participation in this event means more scholarships for students of welding since 100% of pro- ceeds goes directly to scholarship funds. Help those who are entering our industry achieve their career goals.

If you would like to contribute a gift for the auction, please contact the AWS Foundation at 1-800-443-9353, ext. 461, or e-mail to [email protected]. Gifts must have a minimum retail value of $250.

Come and See, Come and Exhibit

For information about attending or exhibiting at the 50th Anniversary Welding Show contact the Convention and Expositions Dept. at (800) 443-9353, ext. 256 or, outside the U.S., at (305) 443- 9353, ext. 256; FAX: (305) 441-7451; or visit www.aws.org. •

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Knowing the advantages and limitations of the various thermal spray

techniques can help you select the best process for your surfacing application

BY TODD DEGITZ AND KLAUS DOBLER

TODD D E ( i l I Z (twdcgitz(-stlmctallizing.com) is Sah,s Manager and KLA US DOBLER i.s 771ermal Spray Engineep; St. Louis Metallizing Co.. St. Louis, Mo.

An Intro to Thermal Spray

Thermal spraying, like weld cladding or chrome plating, is a coating process. In thermal spray, wire or powder is melted by a flame or electricity and sprayed onto the workpiece. During the actual process, the spray torch makes successive passes across the workpiece to produce a coating. Like all industrial processes, thermal spraying has its advantages and limitations. These have to be kept in mind in order to take proper advantage of thermal-sprayed coatings. The following are some of the benefits of thermal spray coatings. • Reduced Cost. In lieu of making the en-

tire part out of an expensive material, a high-performance material is sprayed onto a low-cost base material.

• Low Heat Input. Thermal-sprayed coatings do not impact the substrates ' microstructure. The coating does not penetrate the base material , i.e., there is no heat-affected zone.

• Versatility. Almost any metal, ceramic, or plastic can be sprayed.

• Thickness Range. Coatings can be sprayed from 0.001 in. to more than 1 in. thick, depending on the material and spray system. Coating thickness generally range from 0.001 to 0.100 in.

• Processing Speed. Spray rates range from 3 to 60 lb/h depending on the material and the spray system.

Some of the limitations of thermal spray include the following: • The bond mechanism between the coat-

ing and workpiece is primarily mechanical, not metallurgical.

• Thermal spraying is a line-of-sight process.

• The coatings are considerably stronger in compression than in tension.

• The coatings have poor resistance to pinpoint loading.

The Thermal Spray Processes

Flame Spraying

In the f lame-spraying process, oxygen and a fuel gas, such as acetylene, p ropane , or propylene , are fed into a torch and ignited to create a flame. Ei- ther powder or wire is injected into the f lame where it is mel ted and sprayed onto the workpiece.

F lame spraying requires very litt le equipment and can be readily performed in the factory or on site. The process is fairly inexpensive and is general ly used for the application of metal alloys. With

WELDING JOURNAL B , ' l i i

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Fig. 1 - - A heat exchanger tube bundle being ~prayed with a tungsten carbide-cobalt coating.

Since its inception almost a century ago, thermal

spraying has evolved from a technology designed to

be a cost-effective repair of worn components and

mismachined parts to a process used to provide

improved part performance and longer life to OEM com-

ponents. As part of its growth process, thermal spray

has developed from the original flame spray process to

electric arc, plasma, and high-velocity oxyfuel systems.

In addition, the palette of materials available for

thermal spraying has expanded from metal alloys to

ceramics, polymers, and carbides. One of the many

industrial areas in which thermal spray has established

itself is as a low-cost hardfacing alternative to weld

cladding and chrome plating.

The aim of this article is to introduce the characteris-

tics of the four thermal spray processes m flame,

arc, plasma, and high-velocity oxyfuel (HVOF) - - and

to discuss the different types of wear-resistant

and/or corrosion-resistant coatings these processes can

produce.

Fig. 2 - - 1he lllll~SlCll caHmlc-ct)bah c~)al- ing applied to this drill cone provides It(q, lt wear resistance.

Fig. 3 - - l'h c 1 t I /OF l)ro4"css hci/tg , w d to apply a chromium carbide coating to this ball valve.

relat ively low par t ic le velocit ies , the f lame spray process will provide the largest bui ldups for a given mater ia l of any of the thermal spray processes. Low particle velocities also result in coatings that are more porous and oxidized as compared to o ther thermal spray coatings. Porosi ty can be advantageous in areas where oil is used as a lubricant. A certain amount of oil is always re ta ined within the coating and thus increases the life of the coating. The oxides increase hardness and enhance wear resistance. With regard to hardfacing, self-fluxing alloys are typically appl ied by f lame spraying and then fused onto the component. The fusing process ensures metallurgical bonding to the substrate, high interparticle adhesive strength, and very low porosity levels.

Arc Spraying In the arc spray process, two wires are

inserted into the torch and brought into contact with each o the r at the nozzle. The electr ical load placed on the wires causes the tips of the wires to melt when they touch. A carr ier gas such as air or nitrogen is used to strip the molten material off the wires and to transport it to

the workpiece. Arc spraying is relatively inexpensive, easy to learn, portable, and fairly s imple to maintain. Low par t ic le velocities enable high maximum coating thickness for a given mater ia l . Recent advancements in nozzle and torch configurations are providing greater control over coat ing quali ty and the spray pat- tern. With the right equipment, it 's possible to produce an elongated spray pat- tern or to spray componen t s with very small in ternal d iameters . As far as its shortcomings, arc spraying is l imited to e lectr ical ly conduct ive solid wires and cored wires.

Plasma Spraying

The plasma spray process is considered to be the most versatile of all the thermal spray processes. During operation, gases such as argon, nitrogen, helium, or hydrogen are passed through a torch. An electric arc disassociates and ionizes the gases. Beyond the nozzle, the atomic components recombine, giving off a t remendous amount of heat. In fact, the plasma core temperatures are typically greater than 10,000°C, well above the melting temperature of any material. Powder is injected into this flame, melted, and accelerated to the workpiece.

Plasma spraying was initially developed to spray ceramics and is still the premier process for applying them. Metals and plastics can also be sprayed with this technique. The part icle velocit ies for plasma are higher than for those of flame and arc spraying and result in coatings that are typically denser and have a finer as-sprayed surface roughness. The trade- off of increased density, however, is that the maximum coating thickness for a given material is usually reduced. As both metals and ceramics can be effectively sprayed with this technique, plasma spraying lends itself to au tomat ion and to reducing process steps. For instance, ceramic coatings typically require a metall ic bond coat to improve bond strength. With the plasma system, it's possible to initially apply the bond coat and then immediately follow with the ceramic material.

High-Velocity Oxyfuel

The high-veloci ty oxyfuel ( H V O F ) process was invented only 20 years ago, yet it has expanded the applicat ion possibilities for thermal spraying into areas that were once unat ta inable . In H V O F spraying, a combination of process gases such as hydrogen, oxygen, propylene , air, or ke rosene are in jected into the combustion chamber of the torch at high

pressure and ignited. The resul tant gas veloci t ies achieve supersonic speeds. The powder is in jected into the f lame and also acce le ra ted to supersonic speeds. The results are the densest thermal spray coatings available.

The H V O F process is the p re fe r r ed technique for spraying wear - res i s tan t carbides and is also sui table for applying wear- and/or corrosion-resis tant alloys like Haste l loy, Triballoy, and In- conel ®. Due to the high kinetic energy and low thermal energy the H V O F process imparts on the spray materials , H V O F coatings are very dense with less than 1% porosi ty, have very high bond strengths, fine as-sprayed surface finishes, and low oxide levels.

These p roper t i e s have enabled H V O F sprayed coat ings to become an a t t ract ive a l te rna t ive to c ladding and chrome plating.

Fol lowing are examples of appl ications using the HVOF process.

Figure 1 shows a heat exchanger tube bundle sprayed with a tungsten carbide- cobalt coating. The coating is being appl ied with the H V O F process in lieu of cladding because the dense, erosion-resistant coating provides a low-cost alternative.

In the second appl icat ion, the same type of coat ing was appl ied to a drill cone - - Fig. 2. The tungsten carb ide- cobal t coating was specified to provide high wear resistance.

In Fig. 3, the HVOF process was used to apply a chromium carbide coating to a ball valve. Chromium carbide was selected in order to provide wear and corrosion resistance. After spraying, the coating may be ground and polished to dimension or left in the as-sprayed condition.

Out look Thermal spraying, like all processes,

has inherent advantages and limitations. By understanding the variety of successful appl ica t ions , a choice can be made that will save the manufac tu re r or processor substantial downtime and increase profits, thereby resulting in an excellent return on investment.

Case his tor ies from industr ies such as power, chemical, petrochemical, con- s truct ion, mining, and pulp and pape r show componen t service life increased by 50 to 75%. By reducing p r e m a t u r e componen t fai lure, thermal sprayed par ts will save thousands of dol lars in forced outages.

With a variety of choices as to application methods and coat ing selections, thermal sprayed surfaces offer a solution for parts renewal, wear prevention, and corrosion resistance.O

~"P.,I NOVEMBER 2002

, : ~ = .%, ~c : , . . . . . , .

c : ' : : , ; .

Fig. I - - Relative wear resistance o f some typical iron-based alloys.

The share of cored wires as consumables for hardfacing has risen

steadily over the past decade. Hardfacing with cored wires has

replaced the relatively s lower shie lded metal arc welding (SMAW)

process due to advances made in weldability, e a s e of use , and the

ability to automate wire application processes . In the United States,

the market share of cored wires utilized for hardfacing exceeds 75%.

It is substantially lower in the developing countries where labor costs

are significantly lower, which makes SMAW more competitive.

RA VI M E N O N ([email protected]) is Vice President, Technology, Stoody Co., a Thermadyne company, Bowling Green, Ky.

Why Cored Wires? Cored wires offer a unique method for

producing and applying special alloy compositions that can combat wear and/or corrosion. In fact, many of the hardfacing compositions in use today cannot be produced as solid continuous wires due to the inherent brittleness of the alloys. Further, the cored wire approach is cost effective in that small lots of special composition can be produced.

Cored Wire Design Cored wire design is relatively simple.

The outer sheath or tube forms the base matrix of the alloy and the core constituent is typically a mechanical mixture of powders. These powders can be comprised of purely metallic constituents or a combination of metallic and nonmetallic constituents. Metal cored wires are defined as those wires where metallic constituents comprise 95% or more of the core. Flux cored wires have more than 5% nonmetallic constituents in the core. The wires are produced at high production speeds in today's modern mills where the core materials are fed in continuously into formed strip. Control systems in place allow the precise metering of the powder, thus maintaining a fill ratio that results in the desired alloy composition and welding characteristics. The tube configuration typically is either "butt" for relatively low fill ratios or "lap" for higher fill ratios. The welding processes with which these wires can be used are shown in Table 1. Wire diameters can range from ¼ in. to as small

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Fig. 2 - -Di lu t ion comparison o f submerged arc surfacing vs. electroslag surfacing. A - - Twin-wire submerged arc; B - - twin-wire electroslag.

Table 1 - - Types of Cored Wires for Hardfacing

Typical Core Constituents

Metal Cored Metal Powder + Nonmetallics <5%

Flux Cored Metal Powder + Nonmetallics >5%

Applicable Welding Process

GMAW, GTAW, PAW, SAW, OAW, FCAW-S (Open Arc) FCAW-G, FCAW-S( Open Arc )

Table 2 - - Typical Iron-Based Hardfacing Alloys

Nominal Typical Hardness Microstructure Composition Rockwell (HRC) Carbides

0.2C-1.5Mn-0.7Cr 28 Ferrite-Bainite 0.3Cr-5Cr-lW 50 Martensite-Retained

Austenite 1.0C- 14Mn-4Cr-3.5Ni As-welded: 20 Austenite

Work hardened: 35 3C-25Cr 47 Austenite/Chromium Carbide 5C-25Cr 47 Austenite/Chromium Carbide 2C-7Cr-6Ti 53 Martensite/Titanium Carbide 6C-28Cr 59 Austenite/Chromium Carbide 6C-19Cr-5Mo- 60 Austenite/Chromium 5Cb-2W-2V Carbide/Complex Cb, W, V

Carbides

as 0.035 in. The most popular diameters are 'A and 7~ in. for the submerged arc and Alloy open arc processes and '/,6 and 0.045 in. for Type the gas-shielded processes. These wires are available in packaging forms ranging from 5-1b spools to 500-1b packs suitable 423 for use in robotic applications. 423N

423 Mod.

Alloy l~pes Hardfacing cored wires are most com-

monly available as iron-based, nickel- based, and cobalt-based alloys. A description of the most popular types has been presented earlier (Ref. 1). This article focuses on some of the more recent developments that have taken place through the technology of making cored wires.

The largest family of wires available today is in iron-based alloys. Iron-based materials are the most economical alloys available for a wide range of applications. The wire sheath material is typically a low- carbon steel, and the core materials can range from simple metal powders to constituents that can result in various matrix- carbide combinations. Typical iron-based composit ions are listed in Table 2 (from Ref. 1). The relative abrasion resistance of the alloys as measured by the ASTM G65 Practice A wear test is reproduced in Fig. 1 (from Ref. 1).

Nickel-based alloys also comprise a significant volume of hardfacing alloys, especially in applications where abrasion is accompanied with corrosion. The Ni-Cr- B-Si system is popular because it has a relatively low melting point (approximately 1800°F) and, therefore, can be applied

Table 3 - - Martensitic Stainless Steels Used for Cladding Continuous Caster Rolls

Typical As-Welded Composition Hardness, HRC

0.12C- 12Cr- 1Mo-Nb-V 45 0.05C- 12Cr- 1Mo-Nb-V-N 48 0.05C-12Cr-3Mo-V-W 42

Average Tons of Steels Processed in High Wear Caster

800,000 1,250,000 1,100,000

with a lower thermal shock to the base material. These alloys have commonly been applied using cast rod or powder consumables. Cored wires are now available that can significantly improve the deposit ion rate and manufacturing efficiency. These nickel-based systems are also available with tungsten carbide incorporated into the wire that provides a surface with an outstanding combination of wear and corrosion resistance. Another area of growth in cored wires as far as nickel-based alloys are concerned has been in the development of all-position wires for welding and cladding. Several corrosion- and heat- resistant wires are now available.

Cobalt-based alloys are primarily used in environments that combine high temperature and wear. Although significant quantities of these alloys are applied using continuous cast rod with the oxyacetylene and gas tungsten arc welding (GTAW) processes, large quantities of cored wires are also being utilized with the gas metal arc welding (GMAW) and GTAW processes.

Cored wires have also been developed in other alloy systems such as aluminum and copper. These have been primarily for ther-

mal spraying with twin-wire arc systems. Vir- tually any combination of sheath (matrix) and alloy core systems can be developed. Key requirements are that the sheath has the ductility to be reduced to the desired diameter with the required fill ratio.

Current Trends in Cored Wire Product ion

As has been pointed out, hardfacing with cored wires has been a trend that has been steadily on the rise. In the past, weldability and operability of the wires was not a major issue. However, the situation is significantly different now, with users of the wires essentially demanding the following characteristics: • Higher deposit ion rates at lower heat

inputs • Required deposit chemistries with ap-

plication of a minimum number of layers (preferably one)

• Wires that have excellent weldabili ty and good operability with minimal spatter loss

• Smooth tie-ins with multipass beads so minimal machining is required to fin-

m,-s1--, NOVEMBER 2002

Table 4 - - Chemistry of a One-Layer Alloy 423 Deposit on 4140 Plate with Cored Wire Electroslag Process

Position C Mn Si Cr Ni Mo P

Surface 0.17 0.8 0.5 11.3 1.8 0.9 0.11 3 mm from BM 0.17 0.8 0.5 11.2 1.8 0.9 0.007 2 mm from BM 0.18 0.8 0.5 11.2 1.8 0.9 0.003 1 mm from BM 0.17 0.8 0.5 10.7 1.8 0.9 0.018

S Nb V

0.008 0.18 0.21 0.010 0.18 0.20 0.009 0.18 0.21 0.010 0.16 0.19

Table 5 - - Iron-Based Chromium Carbide Wire Composit ions Used to Clad Coal Pulverizer Rolls

Alloy Type

5C-25Cr 5C-25Cr (microalloyed) 5C-25Cr-Nb-V

ASTM G65 Roll Wear (in.) Practice A per 500,000 Weight Loss Tons of Coal

( g m s ) Pulverized

0.14 2 0.11 1

0.08 In test

Table 6 - - Normalized Wear Rate of Some Iron-Based Hardfacing Alloys as Determined by the Pin Abrasion Test

Alloy Normalized Type Wear Rate

2C-7Cr-6Ti 0.278 6C-19Cr-5Mo-5Nb-2W-2V 0.227 5C-25Cr 0.060 (microalloyed) 5C-25Cr-Nb-V 0.033

Table 7 - - Iron-Based, Smal l -Diameter 0.035- in. (0.9-mm) Wires

Alloy Nominal Hardness Type Composition HRC

Ferrite-Bainite 0.2C-1Cr-0.3Mo 29 Martensitic 0.5C-6Cr 55 Austenite-Cr 4C-15Cr 62 Carbide

ish the cladding. Even if a finishing operation is not required, smooth tie-ins will avoid a preferential path for wear

• Small-diameter wires so hardfacing applications can be made on thin components at low heat inputs

• Wires that can be applied out of position for situations where a component cannot be positioned for welding to be performed in the flat position. In the next several sections, examples

are given of wires that have been developed for iron- and nickel-based alloys that have found wide applications in important industry segments.

Fig. 3 - - Bead surface appearance with cored wire electroslag surfacing.

Iron Based Wires

Steel Mill Applications

Significant portions of steel mill components are hardfaced. The largest application is for rebuilding of rolls, specifically continuous caster rolls, which experience significant wear and corrosion in service. This typically leads to thermal fatigue cracking and roll wear. Today these rolls are routinely hardfaced with martensitic stainless steels of the 420 type and modified versions (423 type). The claddings are primarily applied using the submerged arc process with cored wires. From the early use of martensitic stainless of the 420 type, a host of new alloys has been developed (Ref. 2) to improve characteristics such as resistance to thermal fatigue cracking as well as corrosion resistance. Some of the more recent alloys are shown in Table 3. Because corrosion has been identified as a critical issue, the alloys have been modified by reducing carbon content and enhancing nitrogen and molybdenum content to improve strength and corrosion resistance. Signifi- cant roll life improvements have been reported in a continuous caster with the improved alloys. Table 3 shows the results

obtained in production runs at a caster where a high degree of wear is associated with the process.

Cored wires have also been developed for rebuilding rolls in other areas of the steel mill. Examples are tool steels of the Fe-Cr-Nb type for edger rolls and Fe-Cr- V type for pinch rolls in the hot strip mill.

Electroslag Surfacing with Cored Wires

Although electroslag surfacing with strip has been a relatively well-established process, it suffers from the fact special composition strips are not readily available. This is primarily because many hardfacing compositions are difficult to work down to the strip dimensions required for surfacing. Further, small lot quantities are difficult to melt economically. Electroslag surfacing with cored wires (Ref. 3) combines the low dilution advantages of electroslag surfacing with strip and the versatility of submerged arc surfacing with cored wires. With this process, the target weld metal composition can be achieved in a single layer as opposed to the multiple layers required in submerged arc welding (SAW). Figure 2 compares the dilution obtained with this process to that of SAW. Dilution levels of less than 10% can

WELDING JOURNAL B~,"~'!

Fig. 4 - - Examples o f the use o f check- crack-free 2C- 7Cr-6Ti hardfacing wire. A - - High-pressure cement roll; B - - cultivator flight.

Fig. 5 - - Microstructures o f i ron-based chromium carbide deposits (IOOX). A - - Typical 5C-25Cr deposit; B - - 5C-25Cr (microalloyed).

l.,~,'l NOVEMBER 2002 I

Fig. 6 - - Pulverizer roll wear after processing 500,000 tons o f coal. A - - 5C-25Cr deposit, 2-in. wear; B - - 5C-25Cr (microalloyed), 1-in. wear.

be achieved, thus enabling the desired composit ion of the surface in a single layer. Low dilution also results in a desirable uniformity in composition from the surface to the weld metal/base metal interface. Table 4 shows the composition of an electroslag deposit made from a 423 grade of martensitic stainless steel. This composition, as was pointed out earlier, is widely used for cladding rolls used in steel mill continuous casters. The table shows the composition of the cladding as a function of distance from the interface. Even at 1 mm from the interface, which represents a wear level of about 85%, the chromium content is only 0.5% lower than at the top surface. At 2 mm from the interface, which corresponds to a wear level of about 67%, the composition is virtually identical to that of the surface. This uniformity of composition maintains the corrosion resistance of the cladding as it wears in service.

Other a t tendant advantages of electroslag surfacing are the smooth bead tie- ins achieved and a "cleaner" weld deposit with lower oxygen contents. Smooth bead tie-ins require minimal machining to finish the cladding prior to service - - Fig. 3. Single-layer electroslag deposits with cored wires have oxygen contents of typically 0.025% vs. about 0.05% in multiple- layer submerged arc surfacing deposits.

Check-Crack-Free Hardfacing Wires

Many of the hardfacing deposits that exhibit a high degree of abrasion resistance also exhibit the phenomenon of "relief check-cracking." These cracks, commonly known in hardfacing parlance as "check-cracks," occur in brittle claddings and help relieve contraction stresses resulting from weld solidification and subsequent cooling to room temperature . However, these cracks can make the cladding susceptible to breakage or spalling, especially under high-impact and high-stress conditions. This situation is

particularly exacerbated when cladding is performed on materials with poor weldability (such as high-carbon steels). Al- though martensit ic alloys of Type 0.3C- 5Cr- lW can be deposited check-crack free in multiple layers and their deposits can achieve hardnesses exceeding HRC 50, their abrasion resistance is relatively poor, well below that of the chromium carbide- containing, iron-based alloys - - Fig. 1. In this regard, the martensitic-TiC alloy (2C- 7Cr-6Ti) performs remarkably well in applications that require high abrasion resistance under high-stress and high- impact conditions. Its relative abrasion resistance is shown in Fig. 1. An example of its use on a cement high-pressure roll is shown in Fig. 4A. In another application on the edge of a cultivator flight (Fig. 4B), the martensitic-TiC cladding provides a high degree of wear and impact resistance when compared to an iron-based chromium carbide cladding. The nature of the base material (1080 steel) also makes this application more difficult due to the tendency to form a hard heat- affected zone (HAZ).

Power Plant Applications

Coal-fired plants still generate a significant fraction of the power utilized in the United States and throughout the world. The process stream in these plants involves significant mater ial handling. Coal pulverizing is an integral part of the operation. This is conducted in mills capable of pulverizing large amounts of coal into talc-like consistency before being transported to the burners. The mills ba- sically involve a set of rolls (usually three) rotating over a grinding ring into which the lump coal is introduced. Roll materials are typically wear-resistant steels such as NI-Hard®. Rebuilding is usually performed using open-arc wires that deposit chromium carbide in an austenitic matrix (5C-25Cr type). The development of a proper rel ief check-crack pat tern in the cladding is critical to avoid disbonding.

0.7

0.6

0.5 A E

0.4

0.3

0.2

0.1

0 1 Layer WP-SL 2 Layer WP 1 Layer WP AR 500 Plate

Fig. 7 - - A S T M G65 Practice A wear data comparing abrasion resistance o f conventional wear plate wire (WP) and single-layer wear plate wire (WP-SL ) to quenched and tempered A R 500plate.

When done properly, clad rolls can out- last the base casting materials. However, even under the best conditions, spalling of the cladding can still be a problem due to the inherent lack of toughness of the cladding alloys.

Modified chromium-carbide claddings have been developed with a microstructure that optimizes wear resistance and toughness. This is accomplished by microalloy- ing through which a finer chromium carbide microstructure is generated. The microstructure of a conventional iron-based chromium carbide wire deposit is compared to that of a modified version in Fig. 5. The finer carbide structure imparts enhanced wear resistance along with toughness. ASTM G65 Practice A results for these deposits are compared in Table 5. The table also shows the improvement in pulverizer roll life with the modified alloy. Fig- ure 6 shows the appearance of the rolls after they have been in service for about 500,000 tons of coal. The rolls clad with microalloyed chromium-carbide exhibited about half the wear when compared to rolls clad with conventional carbide.

Modified chromium carbide-type wires have found application in many areas of material handling such as cladding the inside of pipe for slurry transportation, mining chutes, cement mill grinding rolls, and liners and wear plates. Further enhance- ment of wear resistance is accomplished by addition of secondary carbide formers such as Mo, Nb, V, W, etc. Although complex carbide wires of the Fe-6C-19Cr- 5Mo-5Nb-2W-2V type have been available for the past twenty years, they suffer from an inherent disadvantage in that they are relatively brittle and more than two

layers cannot be applied for fear of spal- lation. Further, the compositional make- up of these alloys makes them relatively expensive. Composit ional optimization has now allowed manufacture of complex carbide wires that can be multipassed. A comparison of the ASTM G65 Practice A wear resistance of these wires to a conventional Cr carbide is shown in Table 5. There are other wear tests that can simulate wear that occurs during crushing and grinding, i.e., high stress abrasion. A pin- on-drum test (Ref. 4) can be used to simulate such conditions. In such tests, the modified complex carbide deposit was ranked the highest. The results of these tests are shown in Table 6. Field tests with this alloy on cement grinding rolls and segments indicate improved performance over conventional chromium carbides.

W e a r P la te W i r e s

Significant quantities of cored wires are used in the fabrication of wear plates. These are primarily deposited using the open arc process. Multiple-head machines perform cladding with ~-in. (3.2-mm) wires at deposition rates that exceed 30 lb/h per head. Weldability of these wires has been improved significantly. They generate relatively low slag volumes and spatter levels and deposition efficiencies exceed 95%. The composition of these wires is enriched over that of conventional chromium carbide wires to result in the desired microstructure in one or two layers. Typical wire compositions have 6-7% carbon and 25-30% chromium. Additional enhance- ments in composition can result in an improvement in abrasion resistance of the sin-

Fig. 8 - - Small-diameter 0.035-in. 4C-15Cr hardfacing wire applied on H-in. edge with GMA W.. A - - Top view; B - - cross section.

gle-layer deposit to be equal to that of the standard wire deposit in two layers. How- ever, such wires are limited to single-layer applications only. The abrasion resistance of the deposits from these wires is compared in Fig. 7.

S m a l l - D i a m e t e r H a r d f a c i n g W i r e s

Most iron-based hardfacing wires are made with carbon steel strip into which alloy powders are incorporated to achieve the desired compositions. As alloy compositions increase, thus increasing the fill ratio in the wire, they get increasingly difficult to manufacture. Until a decade ago, high-fill wires were being produced to diameters only down to ¼6 in. (1.6 mm). However, with newer wire forming and drawing technology, high-fill wires are now available down to 0.035-in. (0.9-ram) diameter . Typical composit ions of wires currently available are shown in Table 7. With these wires, it is possible to clad thin materials or edges where a larger-diameter wire may result in loss of pool control. These 0.035-in. wires can also be used to clad the inside of small-diameter tubing. An example of a deposit on a '/,-in. edge is shown in Fig. 8. Very good pool control is achieved with a CV power source operating DCEE No pulsing is required.

WELDING JOURNAL l . . l r i

"ft,: ~ : _ ~ , ~ ' ~ ~,~ ~ - . _ ' e , . ~ ,:r . . .~-~ g . . ~ ° ~ ~ .¢_~ . . ~

. . . , .

, . . . . . . , . , . . . . , , , , . ,

Fig. 9 - - Nickel-WC cored wire deposit ( I OOX).

Out-of-Position Hardfacing Wires

Recent flux cored technology has been used to develop wires that can be applied out of position in a manner similar to flux cored joining wires. These wires enable the application of hardfacing in areas that had to be hitherto positioned for welding. These wires are appl ied at high deposition rates (6-8 lb/h) in the spray mode using mixed gas (75%Ar-25%CO2) shielding. Significant cost savings in labor can be achieved if this technology is adopted in the right application.

Nickel-Based Wires

Wires for Hardfacing

As has been pointed out in a previous article (Ref. 1), the most common abrasion-resistant nickel alloys are of the Ni- Cr-B-Si (Alloys 40, 50, 60) type. Cored wires are readily available for these alloy types. Cored wires are also now available that have tungsten carbide incorporated into them. The relatively low melting point of the Ni-based matrix when compared to iron-based alloys enables a larger volume fraction of the carbides to survive the transfer across the arc, thus resulting in deposits with extremely high abrasion resistance. A microstructure of a deposi t from a wire containing 65% tungsten carbide is shown in Fig. 9. These wires are appl ied where extremely high abrasion conditions are encountered, e.g., dredg- ing teeth. The life of such teeth was improved more than 75% when compared to cladding with iron-based chromium carbide wires.

Wires for Corrosion and Heat Resistance

Nickel-based alloys of the 82, 182, 625, and 622 types are now available as flux cored wires that can be applied in the flat posit ion or out of position. These wires can be operated using either mixed gas of the 75%Ar-25CO 2 type or 100% CO 2. The wires have a wide operat ing range and deposition rates as high as 15 lb/h can be achieved, depending on the choice of welding parameters . The wires can be used for joining or cladding. Significant advantages in labor cost can be gained with the use of these wires, especially for on-site in-situ welding where components cannot be reposi t ioned to be welded or clad in the flat position. These wires are currently being manufactured to the equivalent covered electrode specifications. A new specification covering nickel- based flux cored wires is being written by the AWS A5E Subcommittee on Nickel and Nickel Alloy Filler Metals.

Cored Wires for Twin-Arc Spraying

Cored wires offer a convenient method for developing specialized consumables for arc spraying. Virtually all metal-cored wires can be thermally sprayed. More common ones for these are iron-based wires containing chromium carbide and nickel- based wires containing tungsten carbide. Typical applications are on boiler tubes and water walls where significant wear can occur from particulate and fly-ash erosion. The Ni-WC spray deposits possess a significantly higher wear resistance and should be considered for such areas.

Specifications for Hardfacing Wires

The American Welding Society's A5G Subcommittee on Hardfacing Filler Met- als recently revised specifications that clas- sify the covered electrodes and bare rods and wires used for hardfacing. Specifica- tion A5.13:2000 has been revised to include all shielded metal arc electrodes whereas specification A5.21:2001 covers all noncoated products. This includes bare rod as well as solid and cored wires. Thus, cored cobalt-based wires now have a classification that differentiates them from solid rod and wire. Refer to the specifications for further details.

Summary Cored wires offer a unique route to

achieving hardfacing compositions. Spe- cial compositions for specific needs can be economically produced in small lots. In most cases these wires can be used with existing equipment for GMAW and GTAW processes. High deposit ion rates can be achieved with deposit ion efficiencies exceeding 90%. Flux cored technology has now enabled the introduction of all-position wires that can significantly enhance the economics of field applications. •

Acknowledgments

The author would like to thank Dr. Daya Singh, senior product developement engineer, and Jim Henry, supervisor, Ap- plications Laboratory at the Stoody Com- pany, for their assistance in prepara t ion of this article. Thanks also go to Jim Rode and Richard Cook, Stoody national account managers, for their assistance in obtaining field application data.

References

1. Menon, R. 1996. New developments in hardfacing alloys. Welding Journal (2): 43--49.

2. U.S. Patent 6,232,0000. Abrasion, Corrosion, and Gall Resistant Overlay Al- loys.

3. U.S. Patent 6,127,644. Electroslag Surfacing Using Wire Electrodes.

4. Hawk, J. A., Wilson, R. D., Tylczak, J. H., and Dogan, O. N. 1999. Laboratory abrasive wear tests: investigation of test methods and alloy correlation. Wear, P. 225-229, 1031-1042.

II.~:II NOVEMBER 2002 I

AWS FELLOWSHIPS

To: Professors Engaged in Joining Research

_~U~l.'ect: Request for Proposals for AWS Fellowships for the 2003-04 Academic Year

The American Welding Society (AWS) seeks to foster university research in joining and to recognize outstanding faculty and student talent. We are again requesting your proposals for consideration by AWS.

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 January 6, 2003. New AWS Fellowships will be announced at the AWS Annual Meeting, April 8-10, 2003.

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 will be contingent on demonstration of reasonable progress in the research or in graduate studies.

The AWS Fellowship is awarded to the student for graduate research toward a Masters or Ph.D Degree under a sponsoring professor at a North American University. The qualifications of the Graduate Student are 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.

DETAILS

The Proposal should include:

1. Executive Summary 2. Annualized Breakdown of Funding Required and Purpose of Funds (Student Salary, Tuition, etc.) 3. Matching Funding or Other Support for Intended Research 4. Duration of Project 5. Statement of Problem and Objectives 6. Current Status of Relevant Research 7. Technical Plan of Action 8. Qualifications of Researchers 9. Pertinent Literature References and Related Publications 10. Special Equipment Required and Availability 11. Statement of Critical Issues Which Will Influence Success or Failure of Research

In addition,

1. 2. 3.

4.

the proposal must include:

Student's Academic History, Resume and Transcript Recommendation(s) Indicating Qualifications for Research 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. Proposal should be sent electronically by January 6, 2003, to:

Richard D. French ([email protected]) Deputy Executive Director American Welding Society 550 N.W. LeJeune Rd., Miami, FL 33126

Yours sincerely,

William A. Rice, Jr. Executive Director American Welding Society

IAVY JOINING C E N T E R J A MANTECH CENTER OF EXCELLENCE OPERATED BY EWI

Applying Transitional Friction Welding to Engine Components

O

The Navy Joining Center (NJC) is con- ducting a Navy MANTECH project to develop and demonstrate the use of translational friction welding (TFW) to produce titanium turbine engine bladed-disk ("blisk") components. This project is a cooperative effort with NAVAIR, the Edison Welding Institute (EWI), and an industry partner. The blisks will be used to enhance the performance of existing Navy aircraft such as the F18 and will also be applicable to the Joint Strike Fighter.

Conventional aircraft turbine engine powerplants are made up of disk components that have mechanically attached airfoil/blades. These blades are attached individually to the disk by using a precision-machined dovetail slot arrange- ment. Advanced military engine designs for U.S. Navy aircraft are implementing one-piece bladed disc (blisk) components in their powerplants. Conventional blisks are produced by machining the disk and blades from large one-piece forgings. Making a one-piece blisk with blades integrated in the disk offers substantial performance advantages by significantly reducing the rotating mass of a conventional turbine rotor assembly. Performance advantages include increased thrust-to- weight ratio, reduced specific fuel consumption, and reduced throttle response time. While these blisks offer the performance advantages listed above, performance could be enhanced further and manufacturing costs reduced if the large one-piece forging could be replaced by a TFW fabricated assembly.

A TFW blisk is a hybrid structure that uses frictional heating and local forging to attach the blades directly and permanently to a rotor disk. TFW will permit the use of smaller disks and individual blade forgings, which could be made of the same or dissimilar materials and processed to produce optimum mechanical properties for enhanced design. TFW will also eliminate the need for extensive and detailed machining of the complex airfoil geometry.

Use of the TFW process also allows individual blades to be replaced if they become damaged in service by foreign objects

or erosion wear. This repair method would significantly reduce engine repair costs when compared to current methods involving either limited blending or total replacement of the damaged blisk assembly.

The TFW development project consists of three phases including

• Joint Design and Weld Characteriza- tion

• Preliminary Manufacturing Demon- stration

• Full-scale Manufacturing Demonstra- tion.

This NJC project will produce full-size prototype components for subsequent performance testing. It will also provide the necessary design data and fabrication experience needed to implement TFW in production for new manufacture and repair.

For more information on applying translational friction welding to engine components, contact Tim Trapp of the Navy Joining Center at (614) 688-5231 (e-mail: t [email protected]). ,

Navy Joining Center will be Presenting at DMC 2 0 0 2

Visit the Navy Joining Center at the Defense Manufacturing Conference (DMC 2002) "MANTECH: Strategic Edge for Transformation." The conference will be held December 2-5 at the Wyndham Anatole Hotel in Dallas, Tex. NJC will be located at booth #205.

Information on NJC projects will be given in poster and presentation sessions.

For additional information on the conference, visit the Defense Manufacturing Conference Web site at www. dmc. utcdayton, com.

I 'I .JC Operated by

EIMi

The Navy Joining Center 1250 Arthur E. Adams Dr. Columbus, OH 43221 Phone: (614) 688-5010 FAX: (614) 688-5001 e-mail: NJC@ewiorg www: http://ww~.ew~org Contact: Larry Brown

E ~ o l NOVEMBER 2002

WORKBOOK I Datasheet 255a

Thermal Spray Processes Thermal spraying processes deposit metallic or nonmetallic

materials in a molten or semimolten state onto a prepared substrate to form a coating. The coating is excellent for repairing worn parts and improving new or used equipment performance.

There are five commonly used processes for thermal spraying. The arc wire process (Fig. 1) utilizes an electric arc to melt continuously fed metallic wires. Compressed air or an inert gas atomizes the molten metal and propels it to the substrate.

In the flame wire process (Fig. 2), a continuously fed wire is brought to a molten state by an oxygen/fuel flame. The molten particles are atomized and propelled onto the substrate by the force of burning gases and compressed air.

The plasma powder process (Fig. 3) uses a tungsten electrode to generate an arc. A gas or gas mixture passes through a copper nozzle at the tip of the electrode. The arc excites the gas in this channel into a plasma state, creating extremely high temperatures. The arc is forced outside the nozzle where a mechanism feeds a metallic or nonmetallic material in powder form into it. The molten powder is then propelled onto the substrate at sonic or greater velocities.

With the f lame powder process (Fig. 4), an oxygen/fuel flame melts powder material. This molten material is propelled to the substrate by the force of burning gases and compressed air.

The high velocity oxygen fuel (HVOF) process (Fig. 5) corn- busts a mixture of oxygen and fuel gas at high pressure. This burning mixture is accelerated to supersonic speeds by specially shaped constricting nozzles. Metallic or nonmetallic powders are fed into this high-velocity flame where they are propelled onto the substrate, impacting to form a dense coating with high bond strength.

C O N S ~

WIRE

C O N S ~

WIRE

Fig. 1 - - Arc wire process.

~ A I R CAP

=-"' 7=i II

FUEL GAS t " ~ B ~ N I N G GASES

Fig. 3 - - P lasma p o w d e r process.

Fig. 4 - - F l a m e p o w d e r process.

FLAME f SUgSTRATE i

- - POWOER / PLUS CARR ( E~ GAS

. OXY- FUEL COMPRESSED A t R

-- -]<

~ C O M P R E S S E D A I R

SPRAYED MATERIAL

Fig. 2 - - F l a m e wire process. Fig. 5 - - High velocity oxygen f u e l process.

Excerpted from the Thermal Spray M a n u a l - - Practice, Theory, a n d Appl ica t ion .

WELDING JOURNAL I , 1 i .

~.OMIN6 EVENTS[ NOTE:ADIAMOND(•)DENOTESANAWS-SPONSOREDEVENT

Conferences and Exhibitions 34th International SAMPE Technical Conference: 2002 Materials & Processing - - Ideas to Reality. November 4-7, Renaissance Harborplace Hotel, Baltimore, Md. Sponsored by the Society for the Advancement of Material and Process Engineering (SAMPE). Contact: Priscella Heredia, Conference/Symposia Assistant Manager, SAMPE, (626) 331- 0616 ext. 610, FAX: (626) 332-8929, e-mail [email protected]; www.sampe.org.

• Charting the Course of Welding at U.S. Shipyards Conference. November 13-14, Portsmouth, Va. Sponsored by AWS. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 449 or, outside the U.S., (305) 443-9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

23rd Army Science Conference: Transformational Science and Technology for the Army...A Race for Speed and Precision. December 2-5, Renaissance Orlando Resort, Orlando, Fla. For conference details and registration, visit www.asc2OO2.com.

• Conference on Welding Aluminum for Cars and Trucks. December 3-4, Detroit, Mich. Sponsored by the American Welding Society. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 449 or, outside the U.S., (305) 443-9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

• Seventh Robotic Arc Welding Conference and Exhibition. February 10-11, 2003, Orlando, Fla. Sponsored by the American Welding Society. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 449 or, outside the U.S., (305) 443-9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

• 2nd International Brazing & Soldering Conference. February 17-19, 2003, San Diego, Calif. Sponsored by the American Welding Society and ASM International. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443- 9353 ext. 449 or, outside the U.S., (305) 443-9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

WESTEC Advanced Productivity Exposition. March 24-27, 2003, Los Angeles Convention Center, Los Angeles, Calif. Sponsored by the Society of Manufacturing Engineers (SME), American Machine Tool Distributors' Association, and the Association for Manufacturing Technology. Contact: SME Customer Service, (800) 733-4763 or, outside the United States, (313) 271-1500; www.sme.org/westec.

• AWS Welding Show. April 8-10, Cobo Conference/Exhibition Center, Detroit, Mich. Exhibition of the latest and best technology in the welding industry. Contact AWS Convention and Exhibition Dept., 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 256 or, outside the U.S., (305) 443-9353 ext. 256, FAX: (305) 441-7451; www.aws.org.

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• Conference on Welding of Earthmoving and Construction Equipment. May 20-21, 2003, Chicago, Ill. Sponsored by the American Welding Society. Contact AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 449 or, outside the U.S., (305) 443-9353 ext. 449, FAX: (305) 443-1552; www. a ws. org.

Welding Korea 2003. August 27-30, 2003, Indian Hall, COEX, Seoul, Korea. Organized by the Korea Welding Industry Cooperative and COEX. Contact: Welding Korea 2003 Secretariat, COEX World Trade Center, Samsung-dong, Gangnam-gu, Seoul, 135-731, Korea, (02) 6000-1055, 1056, FAX: (02) 6000-1309, e-mail: [email protected] or [email protected];

www. weldingshow, co. kr.

Educational Opportunities Structural Welding: Design and Specification and Steel Connections: Seismic Applications. November 6-7, Portland, Oreg.; November 19-20, Chicago, Ill.; December 2-3, Phoenix, Ariz.; December 5-6, Las Vegas, Nev. Contact: Steel Structures Technology Center, 24110 Meadowbrook Rd., Ste. 104, Novi, MI 48375-3406; (248) 893-0132, FAX: (248) 893-0134; www.steel

structures, com.

ASME Continuing Education Institute Short Courses on Welding. ASME Section IX, Welding and Brazing Qualifications. November 4-6 and March 10-12, 2003, Las Vegas, Nev.; May 5-7, 2003, Houston, Tex. Practical Welding Technology. March 10-12, 2003, Las Vegas, Nev.; June 2--4, Pittsburgh, Pa. Contact: (800) THE-ASME.

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1" x 1.75" Bottom feed • Designed for trailing shield and other applications. 1.25" x 1.75" Top feed 1" x 3" Bottom feed 1" x 3" Top feed ._,. 1" x 4" Bottom side feed ,,y" 2.75" x 3" Bottom feed

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WELDING JOURNAL m,-!c~

A W S I n t e r n a t i o n a l C e r t i f i c a t i o n E v e n t s E d u c a t i o n a l O p p o r t u n i t i e s

MEXICO Location: DALUS S.A., Monterrey, N.L. CWI Training: November 4-8; Examination: November 9 Contact: Martha Laura Garcla Telephone: (5281) 83861717, FAX: (5281) 83864780 e-mail: martha.garcia@ dalus.com

CHENNAI, INDIA Location: Industrial Quality Concepts C W I Training: N o v e m b e r 11-17; Examina t i on : N o v e m b e r 19 C W I Training: D e c e m b e r 6-10; Examina t ion : D e c e m b e r 12 C W I Training: D e c e m b e r 11-17; Examina t ion : D e c e m b e r 19 Con tac t : V. R a g h a v e n d r a n Te l ephone : 44-499-3826, FAX: 44-499-3826 e-mai l : iqc.in.org@vsnLcom

SINGAPORE Location: Setsco Services Pte Ltd. CWI Training: December 2-6; Examination: December 9 Telephone: 65-566-7777, FAX: 65-566-7718

AL-KHOBAR, SAUDI ARABIA Location: Nondestructive Technology Testing Center (ND'Iq'C), Damman facility CWI Training: December 21-25 Examination: December 26 Contact: Sudhir Phansalkar Telephone: 966-3-882-7522, FAX: 966-3-882-8417 e-mail: [email protected]

Stellite Coatings Introduces

t Kote III

The Jet Kote ® II1 is the latest addition to our Jet Kote ® family of high po,~ . . . . . . nvt~r systems.

The Jet Kote • HI was de., convenience and effieien combines the high quail is known for with consisq performance.

Broad range of material Capable of spraying 20 Deposit effieciencies uF CE approved Online storage of spray Complete process moni Multiple fuel selections

For more information, contact us at 800-235-9353.

Stellite Coatings 1201 Eisenhower Dr N Goshen, IN 46526

www.stellite.com je t Kote, JK, and 5lelllle are irademartks of Deloro Steele, Inc.

Circle No. 36 on Reader In fo-Card

B,'5_,m NOVEMBER 2002

AWS Schedule m CWI /CWE Prep Courses and Exams

Exam application must be submitted six weeks before exam date. For exam information and an application, contact the AWS Certification Dept., (800) 443-9353 ext. 273. For exam pr~p course information, contact the AWS Education Dept., (80)0 443-9353 ext. 229.

Cities Exam Prep CWl/CWE Courses Exams

Atlanta, Ga.

Baton Rouge, La.

Chicago, Ill.

Columbus, Ohio

Columbus, Ohio

Corpus Christi, Tex.

Dallas, Tex.

Dallas, Tex.

November 3-8 November 9 (API 1104 Clinic also offered) January 19-24, 2003 January 25, 2003 (API 1104 Clinic also offered) November 10-15 November 16 (API 1104 Clinic also offered) November 18-22 November 23 (API 1104 Clinic also offered) February 3-7, 2003 February 8, 2003 (API 1104 Clinic also offered) Febuary 9-14, 2003 February 15, 2003 (API 1104 Clinic also offered) January 19-24, 2003 January 25, 2003 (API 1104 Clinic also offered) January 20-25, 2003 9-YEAR RECERTIFICATION COURSE

Fresno, Calif.

Hartford, Conn.

Kansas City, Mo.

Knoxville, Tenn.

January 26-31, 2003 February 1, 2003 (API 1104 Clinic also offered) November 3-8 November 9 (API 1104 Clinic also offered) November 10-15 November 16 (API 1104 Clinic also offered) EXAM ONLY January 18, 2001

Louisville, Ky.

Miami, Fla.

Miami, Fla.

November 10-15 November 16 (API 1104 Clinic also offered) December 1-6 December 7 (API 1104 Clinic also offered) December 9-14 9-YEAR RECERTIFICATION COURSE

Miami, Fla. February 17-22 9-YEAR RECERTIFICATION COURSE

Miami, Fla. February 23-28, 2003 March 1, 2003 (API 1104 Clinic also offered) Feburary 2-7, 2003 Feburary 8, 2003 (API 1104 Clinic also offered) January 26-31, 2003 February 1, 2003 (API 1104 Clinic also offered) November 3-8 November 9 (API 1104 Clinic also offered) November 17-22 November 23 (API 1104 Clinic also offered) November 18-22 9-YEAR RECERTIFICATION COURSE

Norfolk, Va.

Philadelphia, Pa.

Portland, Oreg.

Sacramento, Calif.

Sacramento, Calif.

St. Louis EXAM ONLY December 7 San Antonio, Tex.

Seattle, Wash.

Tampa, Fla.

November 17-22 November 23 (API 1104 Clinic also offered) February 9-14, 2003 Febuary 15, 2003 (API 1104 Clinic also offered) Feburary 2-7, 2003 Feburary 8, 2003 (API 1104 Clinic also offered)

Thermal Spray Powders & Wires

• Flame Spraying: FLSP

• Plasma Spraying:

APS, VPS

• Arc Spraying: ASP

• High Velocity Flame

Spraying:

HVOF I HVAF / HVCW

Tungsten Carbide

• Flux- and Metal Cored Wires

• Electrodes

• PTA - Welding

• Oxyacetylene Welding

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Circle No. 24 on Reader Info-Card Circle No. 20 on Reader Info-Card

lll~ l[ldll~.b dig ~glllldllCllL; tllCy WUII t LLll[J, pU~l~ ItlU~; UL LBU ULL,

They will withstand heat and weathering under adverse conditions.

The Feltip Paint Markers are available in Standard and Fine-Line versions, and in nine high-gloss, lead-free colors: white, yellow, red, black, blue, green, orange, silver and goId.


ECONOMICALLY PRICED TUNGSTEN GRINDER SAFETY: Enclosed diamond wheel grinding area

WELD QIIAI,II~': 20 Ra finish improves tungsten life, starting & arc stability

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V i s i t o u r w e b s i t e : w w w . d i a r n o n d g r o u n d . c o m Circle No. 22 on Reader Info-Card

WELDING JOURNAL 1l,-3,t

FOCUS: The AWS WELDING SHOW is your answer to gaining the most exposure for your industry.

Exhibit at the AWS WELDING SHOW: The right audience. The perfect forum for opportunity.

,,Q

~.." The AWS Welding Show offers every- .. thing from basic arc welding systems

. ~ ~ 1 ~ . ~ 1 ~ - to robotic, laser, resistance, and electron beam technologies. The AWS Welding Show covers it all. This is

~t~,~ the definitive, core event for welding , technology and applications. ~lhb.

?

, , ,~ , , ,| Did you know that most AWS Welding Show attendees make significant

..... : n purchases within six months of visiting ~ i the show?

a The AWS Welding Show attracts ' ~ " m l I I more professionals in engineering,

manufacturing, corporate and production management, purchasing, design, welding, and production.

i ~ ~ ~ ' more exhibit space, and influences It attracts more exhibitors, allocates

~:-~--' ~ more purchasing decisions.

, • C e l e b r a t i n g 5 0 y e a r s o f S e r v i c e

April 8-10, 2003 -~ Detroit, Michigan USA

ICC and NECA/IBEW Apprentices Aid Habitat for Humanity in Peoria

Each semester, Eric Ockerhausen, an instructor at Illinois Central College (ICC), in East Peoria, I11., and member of the American Welding Society's Peoria Section, teaches welder training classes for apprentices of the National Electrical Contractors Association/International Brotherhood of Electrical Workers (NECA/IBEW). The course runs a full 16 weeks, or until a student successfully com- pletes all coursework. Ockerhausen structured the joint electrical apprentice training program to fulfill the welder training portion of their apprenticeship. "I have designed the course to cover the type of welding they will have to do on the job as well as getting them some practical experience in fabrication," he said. "Because they will have to weld unistrut and conduit and need to be able to use a 115-V mini- mig on the job, we cover this in the class. The students in this class have also built small projects and repaired furniture for the college to gain real hands-on experience. All this is done within the guidelines of the course and keeping in mind the time, abilities of the students, and the tools and materials available." Each semester, for practical experience, Ockerhausen has students take on two to three welding projects that, while teaching the student welding skills, benefit either the college or the community.

In the past, members of Ockerhausen's apprentice training program have completed various community service projects. The work of several classes has benefited the Peoria Chapter of Habitat for Humanity International. Apprentices from the spring 2000 semester built the organization a work bench/table, the spring 2001 semester fabricated trash carts, and another group constructed drywall carts - - Fig. 1.

While deciding on hands-on projects for members of the spring 2002 apprentice program, Ockerhausen again turned to Habitat for Humanity. He found the organi-

Fig. 2 - Volunteers of the Peoria Chapter of Habitat for Humanity's first WomenBuild construction project are shown utilizing the scaffolding built by the members of the spring 2002 NECA/IBEW apprentice training program at Illinois Central College.

Fig. 1 - - Members of a previous NECA/1BEW apprentice training program with one of the drywall carts they built for the Peoria Chapter of Habitat for Humanity.

zation's "WomenBuild" Committee was in need of scaffolding for its first project. WomenBuild is the first all-female construction project for Habitat for Humanity. The project requires the all- volunteer construction crew be totally female. The Peoria Habitat for Humanity chapter plans for one house to be built each year under the WomenBuild program.

Ockerhausen agreed to have his apprentice class build the required scaffolding, which students fabricated from unistrut - - Fig. 2. The scaffolding project was so successful, Ockerhausen is considering having his class build more for the WomenBuild project next spring. In addition, Ockerhausen plans for his 2003 NECA/IBEW apprentice training class to build a picnic table for that year's WomenBuild house.

In addition to a community service project, Ockerhausen also has his apprentices complete a project for the school each year. Past projects include golf bag holders for the physical education department, a mobile storage lock- er for the school's fitness center, and roof ramps to assist the maintenance department when it is necessary to move filters, compressors, or fan motors in order to make repairs.

Additional information on ICC's NECA/IBEW apprentice training program, a photo gallery of completed projects, and plans for the aforemen- tioned scaffolding can be obtained from Ockerhausen's faculty page on the ICC Web site at http://faculty.icc.cc.il.us/ eockerhausen/. *

m

WELDING JOURNAL E,-' lr l

AWS Skil l C o m p e t i t i o n C o m m i t t e e R e l e a s e s N a m e s of Weld Pre t r ia l C a n d i d a t e s

Twenty-five candidates have qualified to participate in the American Weld- ing Society's Welding Pretrials. These student welders are all state gold medal champions and have competed at the 2001 and 2002 SkillsUSA/VICA Na- C H A M P I O N S H I P S tional Championships and, because of their outstanding performances, have been recognized to compete at the next level. The candidates names, along with the names of their schools and instructors, are listed below

The purpose of the welding pretrials is to select the six most qualified participants to compete at the AWS U.S. Open Weld Trials, which will be held April 8-10, 2003, in conjunction with the AWS Welding Show in Detroit, Mich. The winner of the Weld Trials will represent the United States at the World Skills Competition, sponsored by the International Your Skills Organization, in St. Gallen, Switzerland, in June 2003. The World Skills Competition takes place every other year.

The winner of the AWS U.S. Open Weld Trials receives a $40,000, four-year scholarship through the AWS Foundation (sponsored by Miller Electric Mfg. Co.), up to $1000 in AWS publications, a four-year AWS membership, and AWS Certification, for which he or she qualifies at the Trials. The American Welding Society also provides a grant to SkillsUSANICA to cover travel and lodging expenses for the U.S. competitor and his instructor for the trip to St. Gallen, Switzerland, to compete in the World Skills Competition. Travel expenses will also be provided in this grant for the SkilIsUSA competitors to compete at the AWS U.S. Open Weld Trials in Detroit.

Candidates qualified to compete in the AWS Welding Pretrials are Jarad Williams (Instructor Jim Higdon), Dekalb County Technology Center, Rainsville, Ala.; Johnathan Jackson (Instructor Brenda Butler), South Georgia Technical Insti- tute, Americus, Ga.; Mathew McKinley (Instructor Gary Miller), Beck Area Voca- tional Center, Red Bud, Ill.; Tom Foster (Instructor Kevin Carter), Pike Central High School, Petersburg, Ind.; Lester Brandon (Instructor Karl Watson), Wayne County Area Technical Center, Monticello, Ky.; Joel Stanley (Instructor David Hartley), Northern Penobscot Region 3 Vocational School, Lincoln, Maine; Jason Van Aken (Instructor Cathy Lundquist), Lansing Community College, Lansing, Mich.; Miles Tilley (Instructor Walt Sisler), Flatrock High School, Flatrock, Mich.; Cody Sarsland (Instructor Loren Hjelle), Ridgewater College, Hutchinson, Minn.; Mark Johnson (Instructor Porter Soley), Pearl River Community College, Poplarville, Miss.; Matt Smith (Instructor Tim Gill), Lex La-Ray Technical Center, Lexington, Mo.; Joe}, Lorenz (Instructor Jeff Pelster), SE Community College-Milford, Milford, Nebr.; Matt Smith (Instructor Dick Borino), Great Basin College, Elko, Nev.; Matt Krebs (Instructor Al Trujillo), Santa Fe High School, Santa Fe, N.Mex.; Derek Polaikis (In- structor Richard Depue), Alfred State College-Vo Tech, Wellsville, N.Y.; Lance Strabe (Instructor Harlan Arneson), North Dakota State College of Science, Wah- peton, N.D.; J. T. Sayre (Instructor Jamey Valega), Meridian Technical Center, Still- water, Okla.; Josh Meuli (Instructor Red Ayers) Linn-Benton Community College, Albany, Ore.; Blake Fulton (Instructor Jeff Ball), Andrews High School, Andrews, S.C.; Barry Weis (Instructor Luke Steinmetz), Western Dakota Technical Institute, Rapid City, S.D.; Josh Burgess (Instructor Art Sanderson), Cumberland County High School, Crossville, Tenn.; James Feistel, Instructor Randy Howell), Lamar University Institute of Technology, Beaumont, Tex.; Christopher Long (Instructor Jess Ander- son), MacArthur High School, San Antonio, Tex.; Joe Lester (Instructor Carl Fitzer), Putnam County Vo-Tech Center, Eleanor, W.Va.; and Douglas Tennant (Instructor Scott Tennant), Bay Port High School, Green Bay, Wis.

For further information on the AWS Welding Pretrials, contact Ed Bohnart, chairman of the AWS Skills Competition Committee, at Welding Education & Con- sulting, 130 Harbor Pointe Ct., Winneconne, WI 54986, telephone: (920) 582-0477, e-mail: [email protected], or Chris Pollock, secretary to the Skills Competition Committee, at American Welding Society, 550 NW LeJeune Rd., Miami, FL 33126, telephone (800) 443-9353 ext. 219, e-mail [email protected]. •

2 0 0 1 - 2 0 0 2 District Membership Awards

District Section

1 Green & White Mountains

2 Long Island

3 Lehigh Valley

4 Tidewater

5 North Central Florida

6 Syracuse

7 Dayton

8 Greater Huntsville

9 Baton Rouge

10 Northwestern Pennsylvania

11 *

12 Upper Peninsula

13 Illinois Valley

14 Mississippi Valley

15 Northern Plains

16 Southeast Nebraska

17 Central Texas

18 Lake Charles

19 British Columbia

20 Wyoming

21 San Diego

22 Fresno

* No Section within the District had an increase in its membership. •

AWS Announces the Henry C. Neitzel National M e m b e r s h i p Award Winners

The winner of the Henry C. Neitzel National Membership Award for the greatest net numerical increase for 2001-2002 is the Lehigh Valley Section District 3.

The winner of the Henry C. Neitzel National Membership Award for the greatest net percentage increase for 2001-2002 is the British Columbia Section, District 19. •

IK~:]I NOVEMBER 2002

AWS Welcomes New Supporting Companies New Educational Institutions

American Institute of Occupational Trades

1235 W. Fullerton Ave. Chicago, IL 60614

Columbiana County Career Technical Center

9364 State Rte. 45 Lisbon, OH 44432

Coney American Institute 1235 W Fullerton Ave. Chicago IL 60614

KT-Tech Lake Cumberland A.T.C. P.O. Box 599 Russell Springs, KY 42642

Polaris Career Center 7285 Old Oak Blvd. Middleburg, OH 44130

Swiss Hills Vocational School 46601 SR 78 Woodsfield, OH 43793

Weldtech Training, Inc. 26 Pantages Court Brampton, Ontario L6S 5B7 Canada

AWS Membership Member As of Grades October 1, 2 0 0 2

Sustaining Companies ...................... 422

Supporting Companies ...................... 257

Educational Institutions .................... 294

Affiliate Companies .............................. 6

Total Corporate Members .... 979

Individual Members .................... 43,484

Student Members .......................... 4,232

Tota l M e m b e r s ... 4 7 , 7 1 6

Sustaining Member Companies

TURCK, Inc. 3 0 0 0 Campus Dr. Plymouth, MN 55441 Tel.: (800) 5 4 4 - 7 7 6 9 or (763) 5 5 3 - 7 3 0 0 Fax: (888) 3 6 4 - 3 5 7 7 or (763) 5 5 3 - 0 7 0 8 www.turck-usa.com/

TURCK, Inc., manufactures and sells a broad line of sensing and connectivity products including inductive, capacitive, ultrasonic, pressure, flow, cylinder, LDT, molded cordsets, junction boxes, and IS components. The company offers advanced sensing solutions to help manufacturers improve their automated processes, products, and profits. Its goal is to help companies reach and exceed

their manufacturing objectives through the effective use of automation, with a constant focus on the needs and service requirements of its customers.

TURCK's clients are from a variety of industrial and commercial markets, both domestically and internationally, including the automotive, food and beverage, material handling, and semiconductor industries. •

AWS Welcomes New Affiliate Companies American Welding Supplies &

Fire Equipment, Inc. 1800 E. Main Ave., P.O. Box 613 West Fargo, ND 58078

Bonfitto, Inc. 1029 Brooke Blvd. Reading, PA 19607

Edwards Steel 1777 McKinley Ave. Columbus, OH 43222

Shanghai Shinei Ind. Co., Ltd. 798 Ying Lun Rd. Waigaoqiao FTZ Pudong Shanghai 200131 China

Supermetal Structures Inc. 1955, 5 St. St. Romuald G6W 5M6 Quebec Canada

Estructuras y Montajes Ferrum S.A. de C.A.

Aldama 130-2 Col. Atemajac Del Valle Zapopan Jalisco 45190 Mexico

Weld Inspection & Consulting EO. Box 841 1021 Ben Rd. St. Albans, WV 25177

AWS Honors Distinguished Member

The following American Welding Society member has attained the status of Distinguished Member for his participation in the Society's leadership, professional development activities, and membership recruitment.

James C. Papritan Florida Space Coast

To qualify for distinguished membership status, applicants must accrue 35 points or more from at least four categories: national AWS leadership, local AWS leadership, professional development, and AWS membership recruitment. If you believe you qualify, contact the AWS Membership Department at (800) 443-9353 ext. 480 or, outside the United States, (305) 443-9353 ext. 480 or FAX (305) 443- 7559. •

WELDING JOURNAL I , ' # l

DISTRICT 3 Director: Alan J. Badeaux, Sr. Phone: (301) 449-4800, ext. 286

LANCASTER AUGUST 29 Activity: The Section's Executive Board held a planning meeting to discuss the upcoming year at the Thaddeaus Stevens College welding lab.

YORK-CENTRAL PENNSYLVANIA SEPTEMBER ] 1 Activity: Section members handed out flags at the West Manchester Mall in remembrance of the victims of September 11, 2001. There was an enthusiastic response to the giveaway and all flags were handed out within 50 minutes.

SEPTEMBER 12 Activity: The Executive Board held its final planning meeting for the year.

Handing out flags in remembrance of September 11 for the York-Central Pennsylvania Section are, from left, Chairman George Bottenfield, Secretary Claudia Bottenfield, past Chairman Mike Bunnell, Student Advisor Carter Shoenfelt, and Student Representative Director Travis Ort.

Lancaster Section Executive Board members pose for a photograph during their August planning meeting

DI,II NOVEMBER 2002

Travis Ort was named Student Representative and was appointed Student Director on the Executive Board.

Attending the York-Central Pennsylva- nia Section's final Executive Board meeting are, front row from left, Mar- garet Malehorn, Travis Ort, Claudia Bottenfield, George Bottenfield, back row from left, Carter Shoenfelt, Ed Calaman, and Mike Brunnell.

DISTRICT 5 Director: Wayne J. Engeron Phone: (404) 501-9185

i " ~ ~ , ~

Florida West Coast Chairman Lee Clemens, right, presenting a speaker's gift to John Minton.

FLORIDA WEST COAST SEPTEMBER 11 Speaker: John Minton, president. Affiliation: Tampa Bay Laser Center, Tampa, Fla. Topic: Laser cutting technology. Activity: Minton presented unique samples from a variety of materials cut by a laser cutting machine. Each meeting at- tendee received a special gift.

SPECIAL OFFER (See reverse) - IT'S EASIER THAN EVER TO RECRUIT NEW AWS INDIVIDUAL MEMBERS

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 have a voice in a global community that promotes and takes pride in the materials joining industry.

8. For Members'-only discounts on car rentals, insurance, and more!

7. To obtain valuable technical knowledge with 300+ publications available.

6, To experience the wave of the future through the world's largest materials joining show by attending the AWS Welding Show.

5. For on-going training through AWS seminars and conferences,

4. To save hundreds of dollars with Members'-only discounts on all AWS publications, conferences, seminars and certification programs,

3. Because your FREE annual subscription to the Welding Joumal will provide you with valuable information to keep you at the forefront of the materials joining industry.

2. For career advancement through networking opportunities at local Section Meetings and by utilizing the AWS Website which includes AWS JobFind.

And the #1 reason to become an AWS Member,.. . , .Because of the savings, knowledge and prestige

you'll receive from the premier Society for materials joining professionals.

PRIZE CATEGORIES President's Honor Roll: Recruit 14 new Individual Members and receive an ~eric~3 Welder r'' T-shirt.

President's Club: Recruit 6-10 nev, Individual Members and receive an :Mnerican Welder ~,a polo shirt.

President's Roundtable: Recruit 11-19 new Individual Members and receive an American Welder ~M watch.

President's Guild: Recruit 20 or more new lndNdual Menlbel~ and receive an ,.~lerican Welder TM watch, a one-year free AWS Membership, the "Shelton Ritter Member Proposer e\ward" Certificate and membership in the Winner's Circle.

Winner's Circle: All Members who recruit 20 or more new Individual Members will receive annual recognition in the Welding Journal and will be honored at the/\\VS Welding Show.

SPECIAL PRIZES Participants will also be eligible to win prizes in specialized categories, Prizes will be awarded at the close of the campaign (June 2003).

Sponsor of the Year: The individual who sponsors the greatest number of new Individual Members during the campaign will receive a plaque, a trip to the 200q AWS Welding Show, and recognition at the A~S Awards Luncheon at the A\% Welding Shov<

Student Sponsor Prize: AWS Membe~ who sponsor two or more Student Members will receive an American Welder TM T-shin.

The AWS Member who sponsors the most Student Members will receive a free, one-year AWS Membership and an American Welder/'a polo shin.

International Sponsor Prize: Any member residing outside the [ nited States, Canada and Me;oco who sponsors the most new lndividn',d Members, will receive a compliment~ ,~V,S Membership renewal.

LUCK OF THE DRAW For every new rnember you sponsor, yo/lr name is entered into a quarterly drawing. The more new members you sponsor, the greater your chances of winning, t'rizes will be awarded in .November 2002, a.s well as in February and June 2003. Prizes Include: • American Welder TM T-shirt • Comphmentax? :~,WS Membership renewal • ,'uneric:m Welder TM polo shirt • American Welder rM ba,,,ebMl cap

SUPER SECTION CHALLENGE The t~S Section in each District that achieves the highest net percentage increase in new Individual Members before the June 2003 deadline will receive special recognition in the Weldi,z~Journal and a District Membership Award.

Tile AWS Sections with the highest numerical increase and greatest net percentage increase in new Individual Members will each receive the Neitzel Membership :~,ward.

Visit our website http://,a~'.aws.org

DISTRICT 7 Director: Robert J. Tabernik Phone: (614) 4 8 8 - 7 9 1 3

PITTSBURGH MAY 2002 Speaker: Ken Kasuniek, owner, and AWS Pittsburgh Section chairman. Affiliation: Kasunick Welding CO. Activities: The Section's Student Day activities included presentations on employment and opportunities in the welding industry, as well as the role of welding instructors in helping to shape the future careers of their students. A door prize of a Victor cutting machine was presented. Certificates were presented to the winners of the Section's Annual Weld-Off Competition. Jeremy Winters received first place in the postsecondary class, James Tart took first place in the high school class, second place in the high school class was won by Jakob Siler, and Ben I_ape placed third in the high school class.

NORTHEAST MISSISSIPPI SEPTEMBER 5 Activity: Section members toured the Weyer Haevser pulp and paper complex in Columbus, Miss.

CHATTANOOGA SEPTEMBER 19 Speaker:. Blaine W. Roberts. Affiliation: Tennessee Valley Authority. Topic: Repairs of high-temperature stages of HP and IP turbine rotors with welding. Activity: Section awards were presented.

DISTRICT 9 Director: John Bruskotter Phone: (504) 3 6 3 - 5 9 0 0

PASCAGOULA SEPTEMBER 19 Speaker: Lee Kvidahl, section manager of welding and manufacturing and AWS

DISTRICT 10 Director=. W1¢40¢ Y. Matthems Phone=. ~tSl mm-zs,~

High school audents at the Stark Central Section's SkiUsUSA/VICA Semi-Final Welding Competition take a break/'or a

Pictured above are Stark Central Section members and area business representative who took the time to act as judges at the Skills USA~PICA Semi-F'mal Weld- ing Compefition hosted by the Secao~

Attending the Pittsburgh Section's Student Day are winners of the Section Annual Weld- Off Competition, from left, Jeremy Winters, first place postsecondary class; James Tart, first place high school level; Jakob Siler, second place high school; and Ben Lape, third place high school level. At right is Section Chairman Ken Kasunick.

COLUMBUS SEPTEMBER 12 Activity: Arran MeCready guided Sec- tion members on a tour of the Griffin Wheel Co. in Columbus, Ohio. The company is a foundry that produces rail wheels for freight cars.

DISTRICT 8 Director:. Wallace E. Honey Phone: (256) 3 3 2 - 3 3 6 6

NASHVILLE AUGUST 24 Activity: The Section held it's 8th An- nual Golf Tournament at the Farm Lakes Golf Course.

past president. Affiliation: Northrop Grumman Ship Systems, Pascagoula, Miss. Topic: An innovative approach to visual inspection of welds. Activity:This was a joint meeting with the AWS Mobile Section.

MOBILE SEPTEMBER 19 Speaker: Lee Kvidahl, section manager of welding and manufacturing. Affiliation: Northrop Grumman Ship Systems, Pascagoula, Miss. Topic: An innovative approach to visual inspection of welds. Activity: This was a joint meeting with the AWS Pascagoula Section.

STARK CENTRAL SEPTEMBER 19 Activity: Section members hosted the area SkilIsUSA/VICA Semi-Final Welding Competition at the R. G. Drage Vocational School Section members and area business representatives acted as judges for the competition.

DISTRICT 1 1 Director:. Scott C. Chapple Phone: (586) 7 7 2 - 1 5 1 4

DETROIT SEPTEMBER Speakers: Tom Musta l~k i , AWS vice president, and Julian E. Pate II, director of education. Affiliations: BWXT-Y12LLC and Focus: HOPE, respectively. Topic:. Futures in welding.

WFI DING JOURNAL D ' ~ !

Scholarship winners and welding instructors pose for a photograph during the Detroit Section's 2002-2003 Students" Night. Pictured are, back row, from left, Professor Jeff Carney, Shaun McGrath, George Meeker II, Michael Schmidt, Morgan Neilson, Josh Kessler, second row, from left, Instructor Walt Sisl~ Ted Luszcynski, Zachary Klumpp, Chris Burch, Nathan Hoffman, Justin McNeil& Kevin Roossinck; and front row, from left, Mark Barker, Shawn Power~ Nickolas Chittendetg Charles Siegert, Chris Aultman, and Professor Ken Kuk.

DISTRICT 12 Director. Michael D. Kersey Phone: (262) 6 5 0 - 9 3 6 4

Many Keasel, center, presents speakers' gifts to Julian E. Pate III, left, and A WS Vice President Tom Mustaleski during the Detroit Section's Students" Night.

FOX VALLEY SEPTEMBER 9 Activity: The Fox Valley Section kicked off its year with the 2002 Fall Golf Scramble at Irish Springs, in Freedom, Wis. After golfing, members and guest attended a dinner meeting that included the election of officers and presentation of awards. Treasurer Tom Treiber planned the event.

Activity: The evening was devoted to Students' Night. The Section awarded a total of $31,000 in 2002-2003 academic scholarships to 23 welding engineering technology students at Ferris State University. The Robert L. Wilcox scholarship was awarded to Zachary Klumpp, and the Amos and Marilyn Winsand scholarship was presented to Chris Aultman. In addition to the monies awarded to Ferris State students, $5300 in scholarships were awarded to the top eight finishers in the Section's 29th Annual High School Welding Contest, which was held at Schoolcraft College. Scholarship recipients were invited to the September meeting as guests of the Section.

SEPTEMBER 10 Speaker. Amly Weyenberg, motor sports representative. Affiliation: Miller Electric Mfg. Co., Appleton, Wis. Topic: Welding with racing applications.

DISTRICT 18 Director. John Mendoam Phone: (210) 8 6 0 - 2 5 9 2

CORPUS CHRISTI AUGUST 22 Activities: The Section held Spouses" Night at the Corpus Christi Greyhound Racetrack. District 18 Director John Memioza updated members on AWS activities and presented awards. Stanford Jones received the Section Educator Award, the District Educator Award was presented to Raul Robles, Tommy Campbell was selected to receive the District 18 Director Award, and John Rails was honored with the Private Educator Award, The Dalton E. Hamilton Memorial CWI of the Year Award, and a special District 18 Director Award.

SErrEMBER 19 Speaker: Avery Harrell, sales consultant. Affiliation: Swagelok. Topic:. Orbital welding

HOUSTON SEPTEMBER 18 Speaker. Ernest Levert, AWS president.

Posing with awards they received at the Corpus Christi Section's August meeting are, from left, Stanford Jones, Paul Robles, Tommy Campbel~ and John Palls.

torte= NOVEMBER 2002 I

Sabine Section guest speaker James Amy, center in white hat, demonstrating magnetic particle testing to Section members.

AWS President Ernest Levert, third from left, with members of the Texas A&M Univer- sity A WS Student Chapter during the Houston Section's September meeting.

San Antonio Section officers with District 18 Director John Mendoza, center, at the Sec- tion's Annual A WS Picnic and Dance.

Affiliation: Lockheed Martin Missiles and Fire Control. Topic: Innovation and applications of electron beam welding. Activity: The meeting was attended by members of the AWS Student Chapter at Texas A&M University, College Station, Tex. Students from the College of the Mainland in Texas City, Tex., also attended the meeting. They are in the process of forming a new AWS Student Chapter.

SAN ANTONIO AUGUST 24 Activity: The Section held its Annual AWS Picnic and Dance at Braun Hall in San Antonio, Tex. Lawrence Schenk

served as picnic chairman.The picnic was dedicated in loving memory of long- time AWS member Ernest Jefferson. Awards presented during the picnic in- eluded the District Educator Award to Kenneth Lynn, the District Meritorious Award to Charlie Lemmons, the Dis- trict 18 Director Award to Frances Guerrero, and the Dalton E. Hamilton Memorial CWI of the Year Award to District 18 Director John Mendoza.

SABINE SEPTEMBER 17 Speakers: James Amy and Mark Clark. Affiliation: METCO NDT Services, Beaumont, Tex. Topic: Magnetic particle testing.

Activities: The Section's 2002-2003 of- fleers were introduced, and AWS shirts were presented to new board members David Morgan and Darwin De Jean.

DISTRICT 19 Director:. Phil Zammit Phone: (509) 468 -2310 ext. 120

ALASKA SEPTEMBER 20 Speakers: John Griffith, district manager, and Dan Rogers, sales representative. Affiliation: Thermadyne Industries and Air Liquide, respectively. Topic: Victor's training CD-ROMs.

DISTRICT 21 Director. Les Bennett Phone: (805) 9 2 9 - 2 3 5 6

Long Beach~Orange County Section out- going Chairman Robert S. Waldron, left, receiving an Appreciation Plaque from incoming Chairman IVmford Sartin.

I WELDING JOURNAL D'L.'I

Long Beach~Orange County Section officers, from left, Publicity Chairman Larry Gustafvson, Ladies Representative Kathy Hutchison, Treasurer Richard Hutchison, In- coming Chairman Winford Sartin, and Secretary Mike Greeley pose for a photo during the Section's May installation of officers.

Long Beach~Orange County Section members preparing to raffle off the door prize of a Lincoln Electric welding machine during Student Night.

Long Beach/ Orange County APRIL Activity: The Section held Student Night. Scholarships were presented to Amanda Kinsman, David Sean John- son, and Mikayla Martin. The event was a great success with approximately 200 people attending.

]V~Y Activity: The Section's officers for the 2002-2003 year were installed. The of- ricers are Chairman Winford Sartin, Vice Chairman Robert S. Waldron, Sec- retary Mike Greeley, and Treasurer Richard Hutchison.

DISTRICT 22 Director. Mark Bell Phone: (209) 3 6 7 - 1 3 9 8

SACRAMENTO VALLEY SEPTEMBER 18 Speaker: Kevin Karamanos, regional

lirA[,'! NOVEMBER 2002 I

Kevin Karamanos, right, accepting a speaker's gift from Sacramento Valley Vice Chairman Dale Flood.

sales manager. Affiliation: MK Products, Los Angeles, Calif. Topic: Closed-chamber pipe and tube welding.

INTERNATIONAL SECTION

ISRAEL JUNE 25 Activity: The National Welding Confer- ence was held in Tel Aviv with 260 welding professionals attending. The meeting included three parallel sessions and a trade show by leading Israeli welding companies. The keynote speaker was Itzhak Peled.

AUGUST 6 Speaker: Victor Levine. Topic: Focused light welding system using Xenon light.•

S e c t i o n E v e n t s C a l e n d a r ALASKA JANUARY 17, 2003 Activity:. Technical meeting. Topic: To be announced.

FEBRUARY 14, 2003 Activity:. Welding equipment show. I_ocation: UAA Welding Lab, Anchor- age, Alaska.

FOX VALLEY NOVEMBER 12 Speaker:. AWS President Ernest Levert. Affiliation: Lockheed Martin Missiles and Fire Control. Topic: Welding on the Space Station.

LANCASTER NOVEMBER 7 Activity:. Tour of the Heil Tank Interna- tional plant with the AWS York-Central Pennsylvania Section. Contact Margaret Malehorn for reser- vations at (717) 854-7085.

TIDEWATER NOVEMBER 13-14 Activity: Charting the Course in Weld- ing at U.S. Shipyards Conference. Location: Portsmouth Renaissance Hotel.

JANUARY 16, 2003 Activity: Joint meeting with ASNT Topic: Marine sonic side scan sonar.

FEBRUARY 3--7, 2003 Activity:. CWI seminar.

FEBRUARY 8, 2003 Activity: CWI exam.

MARCH 13, 2003 Activity. To be announced.

YORK-CENTRAL PENNSYLVANIA NOVEMBER 7 Activity:. Tour of the Hell Tank Interna- tional plant with the AWS Lancaster Section. Contact Margaret Malehorn for reser- vations at (717) 854-7085.

JANUARY 9, 2003 Speaker: Michael Sebergandio, the AWS Matsuo Bridge Scholarship winner and The Pennsylvania State Univer- sity student.

Know Your Distr ict Directors • DISTRICT 1 Geoffrey H. Putnam Principal Engineer Associate Thermal Dynamics Industrial Park #2 West Lebanon, NH 03784 Phone: (603) 298-5711, ext. 3315 FAX: (603) 298-6461 e-mail: [email protected]

• D ISTR ICT2 Alfred E Fleury A. E Fleury & Associates 10 Glen Rd. Bound Brook, NJ 08805 Phone: (732) 868-0768 e-maih [email protected]

• D ISTR ICT3 Alan J. Badeaux, Sr. 4 Queen Victoria St. Lapalta, MD 20646 Cell Phone: (301) 535-4709, (301) 753-4324, or (301)449-4800, ext. 286 e-mail: [email protected]

• DISTRICT 4 Roy C. Lanier, Welding Dept. Chairman Pitt Community College P.O. Drawer 7007, Hwy. 11 South Greenville, NC 27835-7007 Phone: (252) 321-4285 FAX: (252) 321-4611 e-mail: [email protected], cc. nc. us

• D ISTR ICT5 Wayne J. Engeron, Sr. Engineered Alloys/Systems

& Supply Co. 1454 Kelton Dr. Stone Mountain, GA 30083 Phone: (404) 501-9185 FAX: (404) 501-0956 e-maih eas l [email protected]

• DISTRICT 6 Neal Chapman Entergy Nuclear Northeast EO. Box 110 Lycoming, NY 13093 Phone: (315) 349-6960 e-maih [email protected] or nchapma @entergy. corn

• DISTRICT 7 Robert J. Tabernik, District Manager The Lincoln Electric Co. 2101 Riverside Dr. Columbus, OH 43221 Phone: (614) 488-7913 FAX: (614) 488-8003 e-maih robert_j_tabernik@

lincolnelectric, com

• D ISTR ICT8 Wallace E. Honey 8775 Old Water Plant Rd.

Russellville, AL 35654 Phone: (256) 332-3366 e-maih [email protected]

• DISTRICT 9 John C. Bruskotter c/o Production Management

Industries, L.L.C. 2804 Peters Rd. (70058) EO. Box 44 Harvey, LA 70059 Phone: (504) 363-5900 FAX: (504) 363-5209

• DISTRICT 10 Victor Y. Matthews Customer Svc. Rep. The Lincoln Electric Co. 7955 Dines Rd. Novelty, OH 44072 Phone: (216) 383-2638 FAX: (216) 383-2400 e-mail: vic_matthews@

lincolnelectric.com

• DISTRICT 11 Scott Chapple FLEX-N-GATE LLC 27027 Groesbeck Hwy. Warren, MI 48089-1512 Phone: (586) 772-1514 e-mail: [email protected]

• DISTRICT 12 Michael D. Kersey Technical Sales Representative The Lincoln Electric Co. W223 N798 Saratoga Dr. # H Waukesha, WI 53186 Phone: (262) 650-9364 FAX: (262) 650-9370 e-mail: michael_d_kersey@

lincolnelectric.com

• DISTRICT 13 Jesse L. Hunter Senior Staff Engineer-Quality Control Mitsubishi Motor Mfg. of America, Inc. 202 W. Cleveland, P. O. Box 79 Heyworth, IL 61745 Phone: (309) 888-8956 FAX: (309) 888-8991 e-mail: [email protected]

• DISTRICT 14 Hil Bax Cee Kay Supply Inc. 5835 Manchester Ave. St. Louis, MO 63110 Phone: (314) 644-3500, ext. 105 FAX: (314) 644-4336 e-mail: [email protected]

• DISTRICT 15 Jack D. Heikkinen, President Spartan Sauna Heaters, Inc. 7484 Malta Rd.

Eveleth, MN 55734 Phone: (800) 249-2774 e-mail: [email protected]

• DISTRICT 16 Charles Burg,

Sr. Research Technician Ames Laboratory/IPRT 213 8th St. Ames, IA 50010 Phone: (515) 294-5429 FAX: (515) 294-0568 e-mail: [email protected]

• DISTRICT 17 Oren P. Reich, Instructor Texas State Technical College

at Waco 3801 Campus Dr. Waco, TX 76705 Phone: (254) 867-2203 FAX: (254) 867-3550 e-mail: [email protected]

• DISTRICT 18 John L. Mendoza Technical Trainer City Public Service 3319 Kashmuir San Antonio, TX 78223-1612 Phone: (210) 860-2592 e-mail: mendoza [email protected]

• DISTRICT 19 Philip E Zammit Quality Assurance Manager Brooklyn Iron Works Inc. 2401 E. Brooklyn Spokane, WA 99217 Phone: (509) 468-2310, ext. 120 FAX: (509) 468-0284 e-mail: pzammit@

brooklynindustriaL corn

• DISTRICT 20 Jesse A. Grantham WJMG West 7100 N. Broadway, Ste. 1C Denver, CO 80221 Phone: (303) 451-6759 FAX: (303) 280-4747 e -mail: jesse @wjmg. corn

• DISTRICT 21 Les Bennett 495 Colonial Place Nipomo, CA 93444-5404 Phone: (805) 929-2356 e-mall: lesweld@aoLcom

• DISTRICT 22 Mark D. Bell, Principal Consultant Preventive Metallurgy 14114 Sargent Ave. Gait, CA 95632 Phone: (209) 367-1398 e-mail: [email protected] t

WELDING JOURNAL rural

Errata for AWS D 1. l ID 1.1M:2002, Structural Welding Code - - Steel, and AWS A3.0:2001, Standard Welding Terms and Definitions The following errata items apply to AWS DI.1/DI.IM." 2002 and A WSA3. O. The subsection~figure~table~annex number is followed in parentheses by the Code page number and any other information needevL

Errata for AWS D. I . /D.1M: 2002, Structura l Welding Code E S tee l

Section 2.23.2.3 (page 17) - Reference to "2.23.6.6" is incorrect, change to "2.20.6.6."

Figure 2.14 (page 49) - For upper right-hand corner box section detail, change "lower branch member" to "main member."

Table 3.1, Group II (page 63) - For ASTM A 588 and A 606, change superscript "5" to "2."

Table 3.2 (page 65) - For ASTM A 36 in Group A and Group B (left column), delete ,3/, in. thickness limitations."

Table 3.2 (page 66) - Under "Group C (Welding Process)," change "GTAW" to "FCAW."

Table 4.5, Item 30 (page 135) - Change "Table 4.7" to "Table 4.8."

Table 4.8 (page 139) - Delete note 1 superscript after PQR Base Metal in first column header.

Table 4.10, Note 5 (page 142) - Change "See Table 4.8" to "See Table 4.9."

Section 5.27 (page 192) - Change incorrect reference to "2.36.6.6(3)" to "2.20.6.6(3)."

Figure III-1 (page 272) - On lower-right hand of page, change " C = H A Z 2mm" to " C = H A Z lmm."

Page 314 - In CJP groove weld (tubular definition), change "Figures 2.4" to Figures 2.21."

Index (page 493) - The references for "End returns" are incorrect, change references to "2.3.2.1, 2.8.3.3."

Index (page 502) - Reference for "Yield line analysis" is incorrect, change reference "C2.40.2.1" to "C2.24.2.1

Table 3.3 (page 67) - Delete superscript "3" next to SAW and GMAW.

Figures 3.3 and 3.4, Note 3 (page 72) - Change "(see 2.27.5)" to "(see 2.17.2)."

Figures 3.3 and 3.4, Note 9 (page 72) - Change "limitations of Note E" to "limitations of Note 6."

Errata for AWS A3.0:2001, Standard Welding Terms a n d Def in i t ions

Figure 56 (page 116) - At bottom of page, change "thermit welding" to "thermite welding." •

AWS Detroit Section Hosts Sheet Metal Welding Conference X

The American Welding Society's Detroit Section hosted Sheet Metal Welding Conference X on May 14 through 17 in Sterling Heights, Mich. The Conference was attended by 300 people from 11 countries and 105 companies and institutions.

Throughout the two and one-half day conference, 35 technical papers were presented. Topics ranged from automotive welding and joining to automotive aluminum welding. On May 16, Ken Kreafle of Toyota spoke on "Future Trends in Industrial Management Systems - - How to Embrace the Change."

The conference proceedings are available on CD-ROM. For more information, visit the conference Web site at http://sheetmetalwelding.org. ¢

~ NOVEMBER 2002 ]

Ken Kreafle of Toyota during his presentation at the Detroit Section's Sheet Metal Conference X..

Technical Committee Meetings

All A WS techaicai committee meet- iags are open to the public. Persous wish- ing to ~ a mecting skoold contaet tbe staff secretary of the committee as listed below at AWS, 550 NW LeJeune Rd., Miami, FL 33126; telepboue: (800) 443- 9353 or, outside the United States, (305) 443-9353.

November 5, SSPC/NACE/AWS Tri-So- ciety Thermal Spray Committee on the Corrosion Protection of Steel. Tampa, Fla. Standards preparation meeting. Staff contact: Edward E Mitchell, ext. 254.

November 5, Subcommittee on Ther- mal Spray Operator Qualification. Tampa, Fla. Standards preparation meeting. Staff contact: Edward E Mitchell, ext. 254.

November 7, Subcommittee on Hot Gas Welding and Extrusion Welding. Las Vegas, Nev. Standards preparation meeting. Staff contact: Edward E Mitchell, ext. 254.

November 13, Subcommittee on Reac- five Alloys. Columbus, Ohio. Standards preparation meeting. Staff contact: Ed- ward E Mitchell, ext. 254.

November 13, Subcommittee on Tita- nium and Zirconium Filler Metals. Columbus, Ohio. Standards preparation meeting. Staff contact: Edward E Mitchell, ext. 254.

December 4-5, Safety and Health Com- mittee. Miami, Fla. Standards preparation and general meeting. Staff contact: Stephen E Hedrick, ext. 305. •

Submit Your Technical Committee Reports

Committee Chairmen - - We want to recognize the efforts of your committee and inform our readers of its accomplishments. Send a brief profile of its activities and recent accomplishments, along with a member roster and contact numbers, and we will publish it in the Welding Journal's Society News section.

Send your submissions to Susan Campbell, Associate Editor, American Welding Society, 550 NW LeJeune Rd., Miami, FL 33126, Telephone, (305) 443- 9353 ext. 244, e-mail: campbell@ aws.org. •

Standards Notices Standards for Public Review

A FIrS was approved as an accredited stondueds-preparing organizatiou by the American Nntiacml Standards Institute (ANSI) in 1979. AWS rules, as approved by ANSI, require all sto~lavds be open to public review for comment during the approval process. This column also advis- es of ANSI approval of documents. The following standards are submitted for public review. A draft copy may be obtained by contacting Rosolinda O'Neill at A WS, Technical Services Business Unit, 550 NW LeJeu~e Rd. Miami, FL 33126; tdepboue: (800) 443-9353, ext. 451 or, outside the United States, (305) 443-9353, ext. 451; e-mail: [email protected].

C2.20/C2.20M:2002, Specification for Thermal Spraying Zinc Anodes on Steel Reinforced Concrete. New standard. $8.00. [ANSI Public Review expires December 3, 2002.]

iSO Draft Standards for Public Review

Copies of the following Draft lnterna6om~ Stamtards are available for review and comment through your national standards body, which in the United States is ANSI, 25 W. 43rd St., Fourth Fi., New York, NY 10036; tele- plmne (212) 642-49~. Any ~ m m ~ regarding ISO documents Mumld be sent to your natiaml stondards body.

In the United States, if you wish to participate in the development of International Standards for welding, contact Andr~ Davis at AWS, 550 NW L~eune Rd., Miami, FL 33126; telephone (800) 443-9353; e-mail: [email protected]. Otherwise, contact your mtioud standueds body.

ISO/DIS 68 48, Arc welding and cutting - - Nonconsumable Tungsten Electrodes- Classification.

ISO/DIS 9606-2, Qualification test of welders - - fus ion w e l d i n g - Part 2: Aluminum and aluminum alloys.

ISO/DIS 15296, Gas welding equipment - - Terminology - - Terms used for gas welding equipment.

New Standard Approved by ANSI

B5.14:2002, Specification for the Qualification of Welding Sales

Retmesentatives. Approval date: July 12, 2002.

New Standards Approved by ANSI

B2.1-1/8-227:2002, Standard Welding Procedure SpecOication (WPS) for Gas Tungsten Arc Welding of Carbon Steel (M-1/P-US-1, Groups 1 or 2) to Aastenitic Stainless Steel ( M-8/P-8/S-~ Group 1), ~6 through 1-~ inch thick, ER3Og(L), As-Welded Condition, Primarily Pipe Applications. Approval date: August 28, 2002.

B2.1-1/8-228:2002, Standard Welding Procedure Specification (WPS) for Shielded Metal Arc Welding of Carbon Steel (M-I/P-US-I, Groups 1 or 2) to Aastenitic Stainless Steel ( M-8/P-8/S-~ Group 1), ~ through 1-½ inch thick, E309(L)-lS, -16" or -17, As-Welded Condition, Primarily Pipe Applications. Approval date: August 28, 2002.

B2.1-1/8-229:2002, Standard Welding Procedure Specification (WPS) for Gas TungstenArc Welding followed by Shielded Metal Arc Welding of Carbon Steel (M-UP-US-l, Groups 1 or 2) to Austenitic Stainless Steel ( M-8/P-8/S-8, Group 1), ~ through 1-½ inch thick, ER3Og(L) and E309(L)-lS, -16" or -17, As-Welded Condition, Primarily Pipe Applications. Approval date: August 28,2002.

B2.1-1/8-230:2002, Standard Welding Procedure Spec'~cation (WPS) for Gas Tungsten Arc Welding, with Consumable Insert Root of Carbon Steel (M-1/P-1/S- 1, Groups I or 2) to Austenitic Stainless Steel ( M-8/P-8/S-& Group 1), ¼6 through 1-½ inch thick, IN309 and ER3Og(L ), As-Welded Condition, Primarily Pipe Applications. Approval date: August 28, 2002.

B2.1-1/8-231:2002, Standard WeMing Procedure Specification (WPS) for Gas Tungsten Arc Welding with Containable Insert Root followed by Shielded Metal Arc Welding of Carbon Steel (M-UP-US- 1, Groups 1 or 2) to Aastenitic Stainless Steel (M-8/P-8/S-8, Group 1), ~ through 1-½ inch thick, IN309, ER309, and E309-15,- 16' or 17, or 1N309, ER3OgL, and ER309(L)-15, -16, or -17, As- Welded Condition, Primarily Pipe Applications. Approval date: August 28, 2~Y2. •

I WELDING JOURNAL B '~ !

AWS Pub l i ca t ions AWS Releases Thirteen Revised SWPSs for Welding Steel

The American Welding Society (AWS) has released 13 revised Standard Weld- ing Procedure Specifications (SWISs) for welding 10- through 18-gauge galvanized and carbon steel and austenitic stainless steel sheet metal in the as-welded condition, with or without backin~ The new specifications are as follows:

AWS B2.1-1-003:2002, Standard Welding Procedure Specification for Gas Metal Arc Welding (Short Circtdang Transfer Mode) of Galvanized Steel (M-l), 18-10 Gauge~ in the As-Welded Condition, With or W'tthout Backing.

AWS B2.1-1--004:2~2, Standard Welding Procedure Specifu=ation for Gas Metal Arc Welding (Short Orcmiting Transfer Mode) of Carbon Steel (M-L Group 1).

AWS B2.1-8-005:2002, Standard Welding Procedure Specifw.ation for Gas Metal Arc Welding (Short Circuiting Transfer Mode) of Aastenitic Stainless Steel (1t4-8, P-8, or S- 8).

AWS B2.1-1/8-006:2002, Standard Welding ~ Specification for Gas Metal Arc Welding (Short Ciwadang Transfer Mode) of Carbon Steel to Austenitic Stainless Steel (M-l, TOM-& e-S Or S-8).

AWS B2.1-1-007:2002, Standard Welding Procedure Specifw.ation for Gas Tungsten Arc Wetang of ~ Sted (M-l).

AWS B2.1-1-008:2002, Standard Welding Procedure Specification for Gas Tungsten Arc We~,~, of ca,bon Steel (M-L 1"-1, Or S-I).

AWS B2.1-8-009:2002, Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Austenitic Stainless Steel (M-& P-& or S-8).

AWS B2.1-1/8-010:2002, Standard Welding Pror2Mum Specification for Gas Tungsten Arc Welding of Carbon Steel to Austenitic Stainless Steel (M-l, P-l, Or S-1 To M-& P-8, ORS-8).

AWS B2.1-1-011:2002, Standard Welding Procedure Specifw.ation for Shielded Metal Arc Welding of ~ Steel (g-1).

AWS B2.1-1-012:2002, Standard Welding ~ u r e Specification for Shielded Metal Arc Welding of C.arbtm Steel (M-L P-L orS-1 ToM-l, P-l, orS-l).

AWS B2.1-8-013:2002, Standard Welding Procedure Specifw.ation for Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-& Group 1).

AWS B2.1-1/8-014:2002, Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel to Austenitic Stainless Steel (M-1 To M-8/P-8/S-& Group 1).

AWS B2.1-22-015:2002, Standard Welding Procedu~ Specification for Gas Tungsten Arc Welding of A l ~ (M/P/S-22 to M/P/S-22).

These SWPSs outline the essential variables for welding steel in the thickness range of 18 through 10 gauge using semiautomatic gas metal arc welding (short-circuiting transfer mode), shielded metal are welding, or manual gas tungsten welding. Readers will also learn the operating conditions necessary to fabricate the weldment. The SWPSs address base metal, filler metal specifications, joint designs for groove welds and fillet welds, and other requirements to implement the SWPS. These revised SWPSs super- sede previously published standards with the same designations.

Each specification is 12 pages long and sells for $180 for AWS members; $240 for nonmembers.

Ordering Information To order AWS publications, call (800) 854-7179 or, outside the United States,

(303) 397-7956 or visit the AWS Web site at www.aws.org. •

District 21 Director and Family Express Thanks for Support

District 21 Director Robert Schneider, Jr., along with his wife, Evelyn, and family, would like to thanks their many friends and associates throughout the American Welding Society for their expressions of sympa- thy and support on the loss of their son, Bob Schneider III. •

Member Dues Adjustment

The AWS Board of Directors, act- Lag on the recommendations made by the Membership Committee, approved a dues adjustment to $80 for the "Individual Member" classification effective January 1, 2003.

AWS Individual Members enjoy the following updated benefits: • A free publication, upon joining, and

upon the publication of the latest Welding Handbook (upon request);

l Jefferson's Welding Encyclopedia (CD-ROM)

I Design and Planning Manual for Cost-Effective Welding Handbook

I Welding Metallurgy I Welding Handbook (latest edi-

tion) • Monthly subscription to the award-

winning Welding Journal • Practical info via The American

14~/der, a special Welding Journal section geared toward the front-line welder

• 25% Members'-only discount on hundreds of AWS publications and 140+ industry codes

• Access to AWS JobFind at www.aws.org/jobfind - - welding's ultimate on-line career center

• AWS member certificate and card to show your affiliation with the world's premier welding association

• Free admission to the annual AWS Welding Show in Detroit, Mich., on April 8--10, 2003

• Simultaneous membership in a local AWS Section and networking opportunities at Section meetings

• Member discounts on world- renowned AWS Certification Programs, conferences and seminars

• Discounts on American Welder" Gear at www.aws.org/gear

• Discounts on car rentals, express shipping, auto and health insurance

• Coming soon, access to an elite "Members-Only" area of the AWS Web site www.aws.org. •

11:911 NOVEMBER 2002 I

AWS Indiana Section To Host Student Night

On November 18, the AWS Indiana Section will hold its Annual Student Night at the McKenzie Career Center. The event will begin at 6:00 p.m. in the Center 's welding lab.

AWS President Ernest Levert of Lockheed Martin Missiles and Fire Control in Dallas, Tex., will be the featured speaker at the event. Also on hand will be master blacksmiths and students to perform demonstrations.

For more information on the AWS Indiana Section's Annual Student Night, visit the McKenzie Career Cen- ter 's Web site at www.msdlt.kl2.in.us/ mckenzie/welding/awsnighrhtm or contact Ed Wyatt at (317) 576-6420, e-mail: wiUiam wyatt @msdlt.k l 2.in- us. •

Dist r ic t 9 D i r e c t o r P resen ts A w a r d s

The District Director Award provides a means for District Directors to recognize individuals who have contributed their time and effort to the affairs of their local Section and/or District.

District 9 Director John C. Bruskotter presented the following in his District with this award for 2001-2002.

Robe r t Wel ls Mobile

J i m Cooley Birmingham

C h a r l e s Lewis A c a d / a n a

George F a i r b a n k s Rickye M e s s e r Baton Rouge

S a m Bai ley John Pajak

Tony D e M a r c o N e w Orleans

2 0 0 2 - 2 0 0 3 M e m b e r - G e t - A - M e m b e r Campa ign

~,,~is,,. r.o~ ~ ~ ,~ a ~.. ~ ~ ~ t"~ 71 of a~. Wel .~ J ~ If ~ u ~ , ~ any ~ ~ ~vur m e m ~ ~ o ~ r ~eu s , ~ e ca .

Membership De4mmnem at (800) 443-9353 exL ,t~¢.

W k m w ~ l~v=le (,4 WS Members sponsoring 20 or more new Individual Members, per year,, since June l, 1999.)

J. Compton, San Fernando Va//ey * ~ E. H. Ezell, Mob~e ~ J. Merzthal, Peru** B. A. Mikeska, Houston* R. L Peaslee, Demg/t* W L. Shreve, Fox Valley* G. Taylor, Paseagou/a** T Weaver, Johnaown/Altoona* G. Woomer, JohnstownJA/toona* R. Wray, Nebraska*

*Denotes the number o f times an Indi- vidual Member has achieved W'mner's Circle status. Status will be awarded at the close o f each membership campaign year.

~ CmdM (,4 WS Members sponsoffang 20 or more new Individual Members between June 1, 2002, and May 31, 2003.)

~ R o m t d t a b l e (AWS Members sponsoring 11-19 new Individual Members between June 1, 2002, and May 31, 2003.)

G. Fairbank~ Jr., Baton Rouge i 13 J. Grantham, Colorado - - 11

(A WS members sponsoring 6-1O new lndividual Members between June 1, 2002, and May 31, 2003.)

M. Kincheioe, Ho/ston Va/ley ~ 7 J. Scott, Houston, 7

I ~ e s k l e a t ~ 14mmr Ik41 (A WS members sponsoring 1-5 new In- dividual Members between June L 2002, and May 31, 2003. Only those sponsoring 2 or more A WS lndividual Members areliu~)

E Luenin~ Houston ~ 5 G. W Taylor, ~ - - 5 G. Baum, D a n ~ - - 3 IL Corsaro, N / a ~ m Fron t / e r - - 3 G. Melee, R t r h e s ~ - - 3 G. O'Connor, New Jersey - - 3 P. Zammit, Spokane - - 3 A. M. Mechancial, Ho/atm Va//ey-- 2 J. Biegas, Rochester m 2 E Bonifatti, l n t e m a ~ n a / - - 2 A. Duschere, Long Island - - 2 R_ Howard, Lou/sville ~ 2 S. Hunt, S / u z v e / x ~ - - 2 D. Moulton, Sag/haw V a / / e y - 2 J. Norrish, in t emat /ona / - - 2 R. Robles, A/aska - - 2

(A WS membe~ sponsoK~ 3 or m o ~ new A WS Student Members between June 1, .~00~ and May 31, 2OO3.)

D. Scott, Peor/a - - 4 4 C. Wesley, Northmmem Pa. m 24 G. Woomer, l ~ A / t o o n a - - 18 R. Fulmer, Tw/n T t e r s - 14 S. C a l d e r ~ / b r d a n d - - 10 T Strickland, At/tuna - - 5 P. Baldwin, Peoda - - 4 D. Combs, Santa C/ara Va//ey - - 4 E. Norman, O m d c - - 4 t

American Welder Gear Available on the AWS Web Site

The American Welding Society proudly introduces a new line of Amer- ican Welder® Gear . The line carries more than 60 products ranging from pens to apparel to watches. AWS mem- bets receive a 10% discount on purchases. To check out the full line o f American Welder Gear , visit the AWS Web site www.awgow,/gear/or call (800) 443-9353 or, outside the United States, (305) 443-9353, to request a catalog.O

Deadline Nears for AWS Foundation Scholarships

Don't forget to submit your application for an AWS Foundation National Scholarship by January 15, 2003, the deadline for the 2003-2004 school term.

For further information on the AWS Foundat ion scholarship and s tudent loan pmgrmns, visit the AWS Founda- tion on the Web at w ~ w . a w & o c g / ~ - lion~ or contact Vicki Pinsky at AWS Foundat ion, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 212, e-mail tp/[email protected].,

I :IDING JOURNAL l l : i l l

GUIDE TO AWS SERVICES 550 NW LeJeune Rd., Miami, FL 331 26

Phone (800) 443-9353; (888) WELDING FAX (305) 443-7559; Internet: www.aws.org Phone extensions appear in parentheses.

E-Mail addresses available on the AWS Web site. A ~ ~ Ernest D. Levert, Senior Staff Engineer Lockheed Martin Missiles and Fife Control P.O. Box 650003, Mail Stop WT-48 Dallas, TX 75265-OOO3

ADMINISTRATION Executive Director William A. Rice, Jr . . . . . . . . . . . . . . . . . . . (210)

Deputy Executive Directors Richard D. French ................................ t218) Jeffre~ R. Hufse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . [264~ John J. MeLaughlin ............................. ~235)

Assistant Executive Director Debbie A. Cadavid . . . . . . . . . . . . . . . . (222)

Corporate Director of Quality Management Systems and Human Resources Administration Linda K. Henderson ............................. (298)

Chief Financial Officer Frank R. Tarafa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (252)

Im=OI~BATION S B t ~ ¢ I ~ Corporate Director Joe Cilli ........................................... (258)

i R E S e M M ~ Director Luisa Hernandez ... . . . . . . . . . . . . . . . . . . . . . . . . . . . (266)

D A T ~ ADMINIWI11ATION Corporate Director of Database Administration Jim Lankford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (214)

INTERNATIONAL I N S T I T U T E OF WELDING Information ..................................... (294)

Provides liaison activities involving other .professional societies and standards organizatums, nationally and internationally.

aOMIlPd4MEIffT ~ ~ : R V I O I B Hugh K. Webster Webster, Chamberlain & Bean Washington, D.C. (2O2) 466-2976 FAX (202) 835-0243

Identifies sources of funding for welding education and research & development. Moni- tors legislative and regulatory issues important to the industry.

W E L D I N G EQUIPMENT M A N U F A G 1 1 J R E R S C O M M I T ' T E E Associate Executive Director Richard L. Alley ................................. (217)

w m u m t m m m m r ~ w ~ m m t tmNj A s s ~ a t e Executive Director Richard L Alley .............................. (217)

r~BI~tF.IWI1ON & ~ Exhibiting Information .................. (242, 295)

Associate Executive Director of Convention Sales Richard L Alley .................................. (217)

Director of Convention & Exlx~tions John Ospina ..................................... (462)

Organizes the week-long annual AWS Interna- tional Welding and Fabricating Exposition and Convention. Regulates space assignments, registration materials, and other Expo activities.

PUIm.I~&TION s r ~ n f l N ~ , l l Department Information .................... (275)

Director Andrew Cullison . . . . . . . . . . . . . . (249)

WWLImNQ Publisher Jeff Weber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (246)

Editor/F_Mitorial Director Andrew Cnllison . . . . . . . . . . . . . . . . . . . . . . . . (249)

National Sales Director Rob Saltzstein . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (243)

w r = L D I N G I I A N D B O O K Welding Handbook Editor Annette O'Brien . . . . . . . . . . . . . . . . . . . . . . . . . . (303)

Publishes AWS's monthly magazine, the Weld- ing Journal, which provides information on the state of the welding industry, its technology, and Society activities. Publishes Inspection Trends, the Welding Handbook and books on general welding subjects.

I W U m t ~ T m G A N D D E t N ~ N Corporate Director Jeff Weber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (246)

Plans and coordinates marketing of AWS products and services. Responsible for print adver- rising, as well as design and print production of the Welding Journal, Inspection Trends, the annual Welding Show Program, and other AWS promotional publications.

~ R I A I I O t B Manager Amy Townsend . . . . . . . . . . . . . . . . . . . . . . . . (308)

D E V E L O P I ~ = N T Corporate Director Dchrah C. Weir . . . . . . . . . . . . . . . . . . . . . . . . . . ...4482)

Investigates and/or proposes new products and services. Researches effectiveness of existing programs.

i ~ t M B E R Department Information . . . . . . . . . . . . . . . (480)

Associate Executive Director Cassie R. BurreH . . . . . . . . . . . . . . . . . . . . . . . . (253)

Director Rhenda A. Mayo ............................... (260)

Serves as a liaison between Section members and AWS headquarters. Informs members about AWS benefits and other activities of interest.

EDUCATIONAL P R O D U C T DEVELOPMENT Director Christopher B. Pollock . . . . . . . . . . . . . . . . . . . . . (219)

Information on education products, projects, and programs. Responsible for the S.E.N.S.E. program for welding education, and dissemination of training and education information on the Web.

~ & S E M t t U M I Director Giselle I. Hofsey ............................... (278)

Responsible for nat ional and local conferences/exhibi t ions and seminars on industry topics ranging from the basics to the leading edge o f technology. Organizes CW1, SCWI, and other seminars designed for preparation for certification.

¢ F . i W W l O A 1 1 O N ~ Managing Director Wendy S. Reeve . . . . (2]5)

Director Terry Perez . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (470)

Informat ion and application materials on certi fying welders, welding inspectors, and educators. .(273)

INTERNATIONAL DEVELOPMENT l ~ r ~ o r Walter Herrera . . . . . . . . . . . . . . . . . . (475)

FIELLOW$ A N D C O I J N ~ g L O l l Managing Director Wendy S. Reeve . . . . . . . . . . . . . . . . . . . . . . . . (215)

Coordinates AWS Fellow and Counselor nominees.

AW8 AWAIRD6 Senior Coordinator Vicki Pinsky . . . . . . . (212)

Coordinates awards nominees.

S E R V I G P J

D e p m n g m ~ a m n s t m (340) Managing Director Leonard r . Connor ................................ (302) Welding Qualification, Computerization, Technical Activities Committee

Andrew R. Davis .................................... (466) International Standards Program Manager , Welding in Marine Construction, Inspection, Mechanical Testing of Welds

St=.ph~ P. H ~ . . . . . . . . . . . . . . . . . . (305)

John L Gayler . . . . . . . . . . . . . . . . . . . . . . . (472) Structural Welding, Persomgl and Facilities Qual~cafion

Rakesb Gupta .................................... (30]) Filler Metals and Allied Products, Insmanentation for Wdding, Sheet Metal We~Img,

Ea E siitchcn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (254) Thermal Spray, Iron Castings, Joining Plasti~ &

Harold P. Ellison ............................. (299) Resistance Welding, High-Eocrgy Beam Welding and Cutting, Oxyfuel Gas Welding & Cutting, Automotive Welding, Aircraft and Aerospace

Peter Howe ...................................... (309) Arc Welding & Cutting, Piping & Tubing, Machinery and Equipment , Robotics and Automat ic Welding, Food Processing Equipment

Tamimigal gmlUm"

S m l k w ~ ¢ o e r d h l a l m r Rosalinda O'Neill ............................. (451)

AWS .publishes more than 160 volumes of material, including standards that are used throughout the industry.

With regard to tedm/cal inquiries, oral opinions on AWS standards may be rendered. However, such opinions represent only the personal opinions o f the lmr tkadar imiividuals giving them. These individeals do not speak on behalf o f AWS, nor do these oral ~ constitute official or u n o ~ opinions or interpretations of AWS. In addition, oral opinions me ~mformal and simuld not be esed as a ~ e for an o4ficial i n t ~

Wrdm 81TE ~ T I O N

(414)

m : P . i l N O V E M B E R 2 0 0 2 I

Nominees for National Off ice

Only Sustaining Members , Members , Honorary Members , Life Members , or Re- t ired Members who have been members for a per iod of at least three years shall be eligible for election as a Director or National Officer.

It is the duty of the National Nominating Committee to nominate candidates for national office. The committee shall hold an open meeting, preferably at the Annual Meet- ing, at which members may appear to present and discuss the eligibility of all candidates.

To be considered a candidate for positions of President, Vice President, Treasurer, or Director-at-Large, the following qualifications and conditions apply:

President: To be eligible to hold the office of President, an individual must have served as a Vice President for at least one year.

Vice President: To be eligible to hold the office of Vice President , an individual must have served at least one year as a Director , o ther than Executive Di rec tor and Secretary.

Treasurer: To be eligible to hold the office of Treasurer, an individual must be a member of the Society, o ther than a Student Member , must be frequent ly available to the National Office, and should be of executive status in business or industry with experience in financial affairs.

Director-a t -Large: To be eligible for elect ion as a Director-a t -Large, an individual shall previously have held office as Chairman of a Section; as Chairman or Vice Chairman of a standing, technical or special commit tee of the Society; or as District Director.

Interested parties are to send a letter stating which particular office they are seeking, including a s ta tement of qualif ications, their willingness and ability to serve if nominated and elected, and 20 copies of their biographical sketch.

This material should be sent to Richard L. A m , Chairman, National Nominat ing Commit tee , American Welding Society, 550 NW LeJeune Rd., Miami, FL 33126.

The next meet ing of the National Nominat ing Commit tee is currently scheduled for Apr i l 2003, in Det ro i t , Mich. The terms of office for candidates nomina ted at this meeting will commence June 1, 2004. •

Honorary-Meritorious Awards The Honorary-Meritorious Awards Committee has the duty to make recommendations

regarding nominees presented for Honorary Membership, National Meritorious Certificate, William lrrgang 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 follow, and the submission deadline for consideration is July 1 prior to the year of presentation. All candidate material should be sent to the attention of John J. McLanghlin, Secretary, Honorary-Meritorious Awards Committee, 550 NW LeJeune Rd., Miami, FL 33126.

National Mer i tor ious Cert i f icate Award: This award is given in recognition of the candidate's counsel, loyalty, and de- votion to the affairs of the Society, assistance in promoting cordial relations with industry and other organizations, and for the contribution of time and effort on be- haft of the Society.

Will iam Irrgang Memor ia l Award: This award is administered by the American Welding Society and sponsored by The Lin- coln Electric Co. to honor the late William Irrgang. It is awarded each year to the individual who has done the most to enhance the American Welding Society's goal of advanc- ing the science and technology of welding over the past five-year period.

G e o r g e E. Will is Award: This award is administered by the American Welding So- ciety and sponsored by The Lincoln Elec- tric Co. to honor George E. Willis. It is awarded each year to an individual for promoting the advancement of welding internationally by fostering cooperative participation in areas such as technology transfer, standards rationalization, and promotion of industrial goodwill.

In ternat ional Mer i tor ious Cert i f i - cate Award: This award is given in recognition of the candidate's significant contributions to the worldwide welding industry. This award should reflect "Service to the International Welding Community" in the broadest terms. The awardee is not required to be a member of the American Welding Society. Multiple awards can be given per year as the situation dictates. The award consists of a certificate to be presented at the award's luncheon or at another time as appropriate in conjunction with the AWS President's travel itinerary, and, if appropriate, a one-year membership to AWS.

Honorary Membersh ip Award: An Honorary Member shall be a person of ac- knowledged eminence in the welding profession, or who is accredited with exceptional accomplishments in the development of the welding art, upon whom the Ameri- can Welding Society sees fit to confer an honorary distinction. An Honorary Mem- ber shall have full rights of membership. •

TELl[WELD FAX: (305) 443-5951

PUBLIGATION SALES & ORDERS Call Global Engineering Documents (800) 854-7179 toll free or (303) 397-7956

REPRINTS To order custom reprints of articles in the Welding Journal , contact Denis Mulligan (800) 259-0470

It is the intent of the American Welding Society to build the Society to the highest quality standards possible. We welcome any suggestions you may have.

Please contact any of the staff listed on the previous page or A WS President Ernest D. Levert, Senior. Staff Engineo;, Lockheed Mar- tin Missiles and Fire Contro~ P.O. Box 650003, Mail Stop WT-48, Dallas, TX 75265-0003.

A W $ M I S S I O N S T A T E M E N T

The mission o f the American Welding Society is to provide quality products and services to our members and the industry which will advance the science, technolo-

gy and application o f materials-joining throughout the world.

AWS FOUNDATION, INC. 550 NW LeJeune Rd.

Miami, FL 33126 (305) 445-~28

(800) 443-9353, ext. 293 Or e-mail: [email protected]

General Information (800) 443-9353, ext. 689

Chairman, Board of Trustees Ronald C. Pierce

Executive Director William A. Rice, Jr.

Director of Development Robert B. Witherell

The AWS Foundation is a not-for-profit corporation established to provide support for

educational and scientific endeavors of the American Welding Society. Information on

gift-giving programs is available upon request.

IS09001 Registered Organization

I WELDING JOURNAL E*I

Participate in the

84th Annual AWS Convention Poster Competition

Detroit, Michigan April 8-10, 2003

Students, educators, researchers, engineers, technical committees, consultants, and anyone else in a welding- or joining-related field are invited to participate in the world's leading annual welding event by visually displaying their technical accomplishments in a brief graphic presentation, suitable for close, first-hand examination by interested individuals.

Posters provide an ideal format to present results that are best communicated visually, more suited for display than verbal presentation before a large audience; new techniques or procedures that are best discussed in detail individually with interested viewers; brief reports on work in progress; and results that call for the close study of photomicrographs or other illustrative materials.

Two Ca tegor ies

There are two categories: Student and Commercial.

Professional category is available to display recent advances in welding technology. Blatant advertisement or sales- oriented pasters will not be accepted. Prizes will be awarded for first, second, third, and honorable mention where warranted. No prize will be awarded solely because of number (or lack thereof) of entries in a category.

A w a r d s

Judging is based equally on presentation/clarity and technical merit. Awards are made, where warranted, in two categories; Student and Commercial. All first place winners will be recognized at the following year's AWS Authors' Breakfast and Awards Luncheon.

Student Professional (in each of 3 levels)

First Place Plaque $200 + Plaque Second Place Ribbon $100 + Ribbon Third Place Ribbon $50 + Ribbon Honorable Mention Ribbon Ribbon

ExpetRSeS ." Up to a maximum of $1,000 travel expenses will be reimbursed for the top student winner in each level to attend and be recognized at the following year's AWS Authors' Breakfast and Awards Luncheon. (NO travel expenses will be paid for the top winner in the Professional Division.)

Rules

I.

.

Complete the Poster Session Application on the back of this page and mail it with a 200-word description (Le., abstract) of your poster topic by December 1, 2002, to Technical Papers Coordinator, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126, or electronically to <[email protected]>. You may also obtain an application by visiting our website at www.aws.org.

You will be notified in February if your proposed Poster Session topic has been accepted. If so, you should do the following:

~I, Mount your material on either 22 x 28-in.-wide or 44 x 28-in.-wide (maximum) poster board, or prepare your material so that it can be mounted for you on one of those sizes of poster board. Laminated digital prints, or digital prints already mounted on backing, may be 40 X 30 in. wide (maximum).

41, plan to use a flat display format that is large enough to read from 6 to 8 ft away.

POSTER APPLICATION 84th Annual AWS Convention

Detroit, Michigan April 8-10, 2003

Complete form and mail with 200-word abstract by December 1, 2002, to Technical Papers Coordinator, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126, or e-mail to <dorcas @ aws.org> DEADLINE: December 1, 2002.

POSTER TITLE OR TOPIC:

CATEGORY: (Check One) O Professional B - Undergraduate (4-year) degree student

School Name

O A - Certificate or 2-year degree student ~3 C - Graduate degree student

Degree/Certificate you are seeking Professor's name School Mailing Address City State Zip. Country

POSTER AUTHORS Name Title or position Mailing address

Company or organization

City State .Zip/Postal Code Country Area/Country Code Telephone FAX e-mail address

For joint authors, give names and FULL MAILING address of other authors (list separately and attach if necessary):

1st Name -13tie or position Mailing address

Area/country Code Telephone Company or Organization

FAX

City. 2nd Name -13tie or position Mailing address

State Zip/Postal Code Country. Area/Country Code Telephone

Company or Organization FAX

City. State Zip/Postal Code Country

Abstract

The 200-word abstract should include the following; 4, Overall significance to welding (or, in Category A only,

materials science ) community. 4, Newness or originality of poster content 4, What your illustrations (if any) show 4, Important points stressed in poster 4, Where relevant, potential economic impact of the work

described by the poster

Poster Presentation

The presence of a personal representative is not mandatory,

STAINLESS [ ~ & A I BY OAMIAN J. KOTECKI

Q : i have a contract to fulf i l l that cal ls for we ld ing Ni tronic 30 s ta in le s s steel frames and structures. As this base metal is new to me, I am unsure what filler metal I shou ld use . Are there any cracking issues I should be aware of, and is the WRC- 1992 diagram suitable for predicting ferrite in a GTA root p a s s wi thout f i l ler metal?

Table 1 - - 304L and Nitronic 30 Compositions

Steel % C % Mn % P % S % Si % Cr % Ni % N

304L 0.030 2.00 0.045 0.030 0.75 18.0 to 8.0 to 0.10 (UNS $30403) max. max. max. max. max. 20.0 12.0 max. Nitronic 30 0.030 7.0 to 0.040 0.030 1.00 15.0 to 1.50 to 0.15 to (UNS $20400) max. 9.0 max. max. max. 17.0 3.00 0.30

A: N i t r o n i e 30 is o n e o f a fami ly of aus ten i t ic s tainless s teels tha t differ f rom a c o m m o n aus t en i t i c s ta in less such as 304L in tha t mos t of the nickel of the 304L has b e e n replaced by a combina t ion of hi- Steel t rogen and m a n g a n e s e . Nickel is r espon- sible, in 304L, for mak ing the alloy s table aus t en i t e . In the case of N i t ron ic 30, the h igh m a n g a n e s e ( a b o u t 8 % ) se rves to m a k e n i t r o g e n m o r e so luble , and the ni- t r o g e n does t he j o b of s tab i l iz ing the a u s t e n i t e m i c r o s t r u c t u r e . Table 1 compares the composi t ion ranges of 304L and N i t r o n i c 30, as spec i f ied in t he A S T M A240 s tandard .

A n n e a l e d Ni t ronic 30 has considerably h i g h e r s t r e n g t h t h a n a n n e a l e d 304L, which is one of the a t t rac t ions of the alloy. Table 2 c o m p a r e s the m e c h a n i c a l p r o p - Filler erty requ i rements , in the annea l ed condi- Metal t ion , o f t he two alloys, as spec i f ied in A S T M A240. 308L

T h e r e is no exact ma tch for Ni t ronic 30 209 in the A W S fi l ler me ta l spec i f ica t ions . However , it is no t necessary to provide an 219 exact m a t c h as long as the p r o p e r t i e s of the filler meta l equal or exceed the impor- 240 t a n t p r o p e r t i e s o f the base meta l . I f corrosion resis tance is the main concern, 308L 2209 ti l ler meta l should pe r fo rm as well or bet- t e r unless the e n v i r o n m e n t conta ins chlo- r ides . I f t he e n v i r o n m e n t c o n t a i n s chlo- r ides , m a k i n g p i t t ing or s t ress co r ro s ion cracking possibilities, then I suggest a low- nickel austeni t ic stainless steel filler meta l such as 209, 219, o r 240. You may, however, e n c o u n t e r difficulty ob ta in ing these fi l ler me ta l s because they are no t readi ly available. A n o t h e r choice would be a more readi ly available duplex ferr i t ic-austeni t ic 308L stainless filler meta l such as 2209. 209

219 The 209, 219, 240, and 2209 filler met- 240

als are also s t reng th ma tches for Ni t ronic 2209 30, while 308L is an u n d e r m a t c h i n g fil ler me ta l . Table 3 lists the c o m p o s i t i o n s of these fi l ler me ta l s as g iven in A WS A5.4, Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding. T h e 240 c o m p o s i t i o n is the c loses t m a t c h to Ni- t ron ic 30. Table 4 lists the c o r r e s p o n d i n g mechan ica l p roper ty r equ i r emen t s . A WS A5.9, Specification for Bare Stainless Steel Welding Electrodes and Rods, gives t he

Table 2 - - 304L and Nitronic 30 Mechanical Property Requirements

Tensile Strength, Yield Strength, % Elongation in Rockwell B minimum minimum 2 in., minimum Hardness,

maximum

304L 70 ksi (485 MPa) 25 ksi (170 MPa) 40.0 92 (UNS $30403) Nitronic 30 95 ksi (655 MPa) 48 ksi (330 MPa) 35.0 100 (UNS $20400)

Table 3 - - Filler Metal Compositions from AWS A5.4 Suitable for Nitronic 30

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

0.04 0.5 to 0.04 0.03 0.90 18.0 to 9.0 to 0.75 - - max. 2.5 max. max. max. 21.0 11.0 max. 0.06 4.0 to 0.04 0.03 0.90 20.5 to 9.5 to 1.5 to 0.10 to max. 7.0 max. max. max. 24.0 12.0 3.0 0.30 0.06 8.0 to 0.04 0.03 1.00 19.0 to 5.5 to 0.75 0.10 to max. 10.0 max. max. max. 21.5 7.0 max. 0.30 0.06 10.5 to 0.04 0.03 1.00 17.0 to 4.0 to 0.75 0.10 to max. 13.5 max. max. max. 19.0 6.0 max. 0.30 0.04 0.5 to 0.04 0.03 0.90 21.5 to 8.5 to 2.5 to 0.08 to max. 2.5 max. max. max. 23.5 10.5 3.5 0.20

Table 4 - - Filler Metal Mechanical Property Requirements from AWS A5.4

Filler Metal Tensile Strength, minimum

75 ksi (520 MPa) 100 ksi (690 MPa) 90 ksi (602 MPa) 100 ksi (690 MPa) 100 ksi (690 MPa)

% Elongation in 2 in., minimum

35 15 15 15 20

ba re wires in all fou r of these al loys for gas m e t a l arc weld ing , s u b m e r g e d arc welding, or gas tungs ten arc welding, bu t no mechanica l p roper ty r equ i r emen t s are specified. Flux cored wires with mechan i - cal p r o p e r t y r e q u i r e m e n t s for 2209 and

308L, bu t no t for 209, 219, or 240, a re specif ied in AWS A5.22, Specification for Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding. As with any aus ten i t i c s ta in less steel ,

II-[.'~ NOVEMBER 2002 [

Table 5 - - Reported F1N of Espy vs. Predictions of the WRC-1992 Diagram

Nitronic % C % Mn % Si % Cr % Ni % Mo % N % V % Nb Alloy

33 0.057 12.8 0.42 17.5 3.7 - - 0.33 - - - - 35W 0.070 11.2 0.36 18.3 4.8 - - 0.16 - - - - 35W 0.059 10.8 0.33 18.7 4.8 - - 0.17 - - - - 35W 0.060 13.5 0.10 18.2 5.2 - - 0.17 - - - - 35W 0.068 13.4 0.10 19.2 5.1 - - 0.18 - - - - 35W 0.042 11.7 0.46 18.3 4.2 - - 0.19 - - - - 35W 0.042 11.8 0.47 18.5 4.2 - - 0.20 - - - - 40 0.027 9.1 0.64 20.3 7.1 - - 0.28 - - - - 40 0.026 8.8 0.72 20.1 7.0 - - 0.29 - - - - 40 0.033 8.9 0.64 20.3 7.3 - - 0.30 - - - - 40 0.020 8.9 0.68 20.2 7.2 - - 0.31 - - - - 40 0.017 8.9 0.73 20.1 7.2 - - 0.32 - - - - 40 0.022 9.2 0.62 20.2 7.1 - - 0.33 - - - - 40W 0.030 8.3 0.42 20.3 6.8 - - 0.25 - - - - 50 0.038 4.7 0.55 21.0 12.5 2.2 0.23 0.16 0.18 50 0.036 4.8 0.46 21.5 12.6 2.2 0.25 0.15 0.17 50 0.041 5.0 0.47 21.7 12.7 2.2 0.26 0.18 0.16 50 0.050 5.4 0.42 21.5 12.4 2.1 0.27 0.19 0.20 50 0.043 4.8 0.52 20.9 12.7 2.2 0.28 0.17 0.17 50W 0.046 6.1 0.41 20.9 10.1 1.8 0.21 0.23 - - 50W 0.046 6.2 0.32 21.1 10.3 1.8 0.21 0.23 - - 50W 0.033 6.5 0.26 21.6 10.3 1.9 0.21 0.25 - - 50W 0.047 6.1 0.41 21.9 10.5 2.0 0.22 0.24 - - 50W 0.034 6.1 0.38 21.4 10.6 1.8 0.24 0.22 - - 50W 0.036 6.2 0.60 21.6 10.6 1.8 0.25 0.23 - - 60 0.076 8.5 4.2 17.4 8.4 - - 0.13 - - - - 60W 0.058 7.7 3.4 18.5 9.4 - - 0.14 - - - -

Espy WRC- Measured FN 1992 FN

1 0.7 6 7.6 4 10.2 4 6.3 5 9.1 6 11.5 7 11.5 3 4.5 4 3.7 2 2.7 2 3.2 3 2.7 2 2.4 5 7.0 3 1.9 2 2.4 5 2.0 1 1.3 0 0.2 5 6.0 7 6.1 8 7.0 9 8.0 8 5.7 7 5.6 7 0 4 0

c r ack ing i s sues c e n t e r a r o u n d t he p r e s e n c e o r a b s e n c e o f a l i t t le f e r r i t e in t h e w e l d m e t a l a n d in t h e h o t t e s t p a r t o f t h e h e a t - a f f e c t e d z o n e . T w e n t y y e a r s ago , H a r r y E s p y 1 r e p o r t e d o n w e l d i n g o f s e v e r a l o f t h e N i t r o n i c s t a i n l e s s e s . N i t r o n i c 30 w a s n o t o n e o f t he a l loys c o n s i d e r e d in t ha t re- po r t , b u t it d id i n c l u d e N i t r o n i c 33, w h i c h is s imi la r , a n d fo r w h i c h 240 fi l ler m e t a l is a m a t c h . E s p y s h o w e d fe r r i t e in t he h o t t e s t p a r t o f t h e h e a t - a f f e c t e d z o n e a n d in a u - t o g e n o u s we ld m e t a l wi th N i t r o n i c 33. H e t r i e d to p r e d i c t t h e f e r r i t e h e m e a s u r e d u s i n g t h e c o n s t i t u t i o n d i a g r a m s o f t h a t t i m e , t h e S c h a e f f l e r d i a g r a m a n d t h e D e - L o n g d i a g r a m , b u t g o t p o o r a g r e e m e n t . H e t h e n p r o d u c e d a m o d i f i e d S c h a e f f l e r d i a g r a m t h a t s e e m e d to r e a s o n a b l y p r e - dict t h e m e a s u r e d fe r r i t e h e o b s e r v e d . H i s d i a g r a m t r e a t e d t h e m a n g a n e s e e f f e c t as a c o n s t a n t in t h e n icke l e q u i v a l e n t a n d of- f e r ed a va r i ab le e f fec t for n i t r o g e n . Today , o f c o u r s e , t h e W R C - 1 9 9 2 d i a g r a m is t h e official c o n s t i t u t i o n d i a g r a m o f t he A S M E C o d e , b u t it w a s n o t a v a i l a b l e to E s p y . It is i n t e r e s t i n g to tes t E s p y ' s r e su l t s a s c o m - p a r e d to t h e p r e d i c t i o n s o f t h e W R C - 1 9 9 2 d i a g r a m to s e e h o w wel l t h e y a g r e e . T h a t is d o n e in Table 5.

W i t h t h e e x c e p t i o n o f N i t r o n i c 60 a n d N i t r o n i c 60W, t h e W R C - 1 9 9 2 F N p r e d i c - t i ons a g r e e wel l w i th t h e m e a s u r e d v a l u e s E s p y r e p o r t e d . T h e 60 a n d 6 0 W c o m p o - s i t i o n s i n c l u d e m o r e t h a n 3 % s i l i con , w h i c h is wel l o u t s i d e t h e 0 to 1% Si r a n g e c o n s i d e r e d in d e v e l o p i n g t h e W R C - 1 9 9 2 d i a g r a m , so t h e l a ck o f a g r e e m e n t is n o t

s u r p r i s i n g . I t h a s l o n g b e e n s u s p e c t e d sil- i c o n a b o v e 1% b e g i n s to ac t a s a f e r r i t e - p r o m o t i n g e l e m e n t .

A t any ra te , it s e e m s t h e W R C - 1 9 9 2 di- a g r a m c a n be u s e d to a n t i c i p a t e r o o t p a s s a u t o g e n o u s we ld Fe r r i t e N u m b e r . So y o n c a n u s e it, w i t h t h e b a s e m e t a l c o m p o s i - t i o n , t o e s t i m a t e t h e G T A W r o o t p a s s w e l d a b i l i t y o f N i t r o n i c 30 s t e e l o r o f t h e o t h e r a l loys in Tab l e 5, e x c e p t f o r 60 a n d 60W. •

all your local distributor or 888-494-B01

1. Espy, R. H. 1982. Weldability o f nitrogen- strengthened stainless steels. W e l d i n g J o u r - na l 61(5): 149-s to 156-s.

DAMIAN J. KOTECKI is Technical Director for

Stainless and High-Alloy Product Development

for The Lincoln Electric Co., Cleveland, Ohio.

He is a member o f the A WS ASD Subcommittee

on Stainless Steel Filler Metals; A W S D1

Structural Welding Committee, Subcommittee

on Stainless Steel Welding; and a member and

past chair of the Welding Research 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 or via e-mail at

[email protected].

Fraction of the Cost

Tack I

Tram

[] wJbrc ~,r

L All Link-it • Link Welder Auto & Manual Fusion Welders i [~ l ' ; l l l ~[',t ~ i ~1~-I I I q I I [~111 ~ 1 I l l | I'TIT] 1-'!

i ~ l ; l d,i l~I ~it',1 il~ I I I ' ~ I-Ei [~----1,' I~]11 IJ I [J] d i


W E L D I N G J O U R N A L I E : ~ ' i

American Welding Society

Friends and Colleagues:

We're into the tenth year of the programr and 92 individuals have now entered into the fraternity of Fellows. Again, I encourage you to submit nomination packages for those individuals whom you feel have a history of accomplishments and contributions to our profession consistent with the standards set by the existing Fellows. In particular, I would make a special request that you look to the most senior members of your Section or District in considering members for nomination. In many cases, the colleagues and peers of these individuals who are the most familiar with their contributions, and who would normally nominate the candidater are no longer with us. I want to be sure that we take the extra effort required to make sure that those truly worthy are not overlooked because no obvious individual was available to start the nomination process.

For specifics on the nomination requirements, please contact Wendy Sue Reeve, at AWS headquarters in Miami, or simply follow the instructions on the Fellows nomination form in this issue of the Welding Journal. Please remember, we all benefit in the honoring of those who have made major contributions to our chosen profession and livelihood. The deadline for submission is February l r 2003. The Committee looks forward to receiving numerous Fellow nominations for 2004 consideration.

Sincerely,

Dr. Alexander Lesnewich Chairman, AWS Fellows Selection Committee

DATE

AWS MEMBER NO.

HOME ADDRESS

CLASS OF 2004

FELLOW N O M I N A T I O N F O R M

(please type or print in black ink)

NAME OF CANDIDATE

YEARS OF AWS MEMBERSHIP

CITY

PRESENT COMPANY/INSTITUTION AFFILIATION

TITLE/POSITION

STATE ZIP CODE PHONE

BUSINESS ADDRESS

CITY

ACADEMIC BACKGROUND, AS APPLICABLE:

INSTITUTION


MAJOR & MINOR

DEGREES OR CERTIFICATES/YEAR

LICENSED PROFESSIONAL ENGINEER: YES

SIGNIFICANT WORK EXPERIENCE:

COMPANY/CITY/STATE

NO STATE

POSITION

COMPANY/CITY/STATE

YEARS

POSITION YEARS

SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:

SUGGESTED CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE SELECTED AS AN AWS FELLOW. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE INCORPORATED WITHIN THE CITATION CERTIFICATE.

**MOST IMPORTANT** The Fellows Committee selection criteria are strongly based on and extracted from the categories identified below. All infor-

mation and support material provided by the candidate's Fellow Proposer, Nominating Members and peers is considered. Provide as much detailed information as possible regarding:

The candidate's accomplishments under areas identified below (use separate sheet for each category): A. Research & Development B. Education C. Manufacturing D. Design and Inventions E. Other (e.g., Standards Development, National and International Liaison) Evidence of accomplishment should include sustained service and performance in the promotion of joining technology; pub-

lication of papers, articles and books; innovative development of joining technology; service to AWS and other technical societies; and list and description of patents, awards and honors.

SUBMITTED BY: PROPOSER AWS Member No. The Proposer wil l serve as the contact if the Selection Committee requires further information. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition to the Proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should be submitted.

NOMINATING MEMBER: AWS Member No.




SUBMISSION DEADLINE FEBRUARY 1, 2003


Nomination of AWS Fellows

I. DEFINITION AND HISTORY The American Welding Society, in 1990, established the honor of Fellow of the Society to

recognize members for distinguished contributions to the field of welding science and technology, and for promoting and sustaining the professional stature of the field. Election as a Fellow of the Society is based on the reputation and outstanding accomplishments of the individual. Such accomplishments will have advanced the science, technology and application of welding in specific areas such as research and development, education, manufacturing, design and other areas the Society may determine, as evidenced by:

* Sustained service and performance in the advancement of welding science and technology

* Publication of papers, articles and books which enhance knowledge of welding * Innovative development of welding technology

II. RULES A. B. C.

Candidates shall have 10 years of membership in AWS Candidates shall be nominated by any five members of the Society Nominations shall be submitted on the official form available from AWS Headquarters

D. Nominations must be submitted to AWS Headquarters no later than February I of the year prior to that in which the award is to be presented

E. Nominations shall remain valid for three years F. All information on nominees will be held in strict confidence G. No more than two posthumous Fellows may be elected each year

III. NUMBER OF FELLOWS TO BE ELECTED Maximum of 10 Fellows selected, as determined by the

selection committee

Return comoleted Fellow nomination Dackaee to: v

Wendy S. Reeve American Welding Society 550 N.W. LeJeune Road Miami, FL 33126

Telephone: 800-443-9353, extension 215

SUBMISSION DEADLINE: February 1, 2003

~IEH FOR MORE INFORMATION, CIRCLE NUMBER ON READER INFORMATION CARD.

r , ~ LITERATURE I

Guides Feature Product and Metal Application Information

i o , , , - c , , , , , i , , . , . . . .

Application Guide

for Metal

Available from ASME International, a Leader in Codes...

. . . . . . Essential Training in Welding

has made available an interactive CD- R a M for contractors and subcontractors titled Surety Bonds for Contractors. The CD contains narrated Microsoft® Pow- erPoint® presentations explaining the basics of bonding, how to obtain surety credit, and the value and benefits of contract surety bonds. For free copies of the CD, visit the Office's Web site, www.sio.org, or call SIO at (202) 686-7463.

Surety Information Office 5225 Wisconsin Ave. NW, Ste. 600 Washington, DC 20015-2014

Brochure Highlights Portable Plasma Cutting System

The company's full-color, six-page Ap- plication Guide for Metal is a comprehensive abrasive guide for a variety of metal applications including carbon and stainless steel, exotic and nonferrous metals, and cast iron.The guide features detailed, metal-specific charts that provide guid- ance on proper abrasive grit, wet/dry usage, and proper application pressures for metal applications. Also included are quick-reference application suggestions for the company's metal-oriented abrasive products. The company also offers a ceramic grain guide and its resin-bonded granulate abrasive, COMPACTGRAIN.

VSM Abrasives Corp. 1012 E. Wabash St., O'Fallon, MO 63366-2774

115

CD-ROM Explains Basics of Surety Bonds

The Surety Information Office (SIO)

The full-color Drag-Gun" brochure provides complete specifications and an application guide for sheet metal, HVAC installation/spiral duct, metal stud construction, and food service equipment and metal art fabrication. The application guide identifies performance ratings on

COR-MET m---- ®

S P E C I A L T Y C O R E D W I R E A N D C O A T E D E L E C T R O D E S

@

(810) 227-3251 www.cor-met.com

FAX" (810) 227-9266

J oin the lens of thousands of engineers who turn to The American Society of

Mechonkal Engineers for expert training in the application of the Section IX Welding & Brazing Qualification and other codes.

Visit www.asme.org/weldtraining for complete details of the following courses available throughout the year at sites across the country...

ASME Section IX Welding & Brazing Qualifications - also available in Spanish

I~ Practical Welding Technology

I~ Blueprint Reading and Graphic Symbols including ASME B16.25

While earning CEUs, you trade experiences with fellow engineers grappling with the same problems that you face.

For m o r e i n f o r m a t i o n inc lud ing the most

c o n v e n i e n t locat ions a n d d a t e s , visit:

www.asme.org/weldtraining



WELDING JOURNAL E 4 ] i .

mild steel, stainless steel, aluminum, and galvanized steel. Ordering information for the five available 120- and 220-V units, including CE models, is provided in the brochure.

Thermal Dynamics Corp. 116 101 S. Hanley Rd., St*. 600, SL Louis, M O 63105

Guide Details Explosion- Proof Safety Products

The company's Guide to Explosion- Proof Safety Light Curtains is a full-color

Vibratory Stress Re l ie f Reduces Res idual Stresses

Due to Welding " F o r m u l a 6 2 " m e t hod utilizes high ampli- tude vibrat ions to reduce peak residual stresses close to yield stress levels near the weld center line. Vibrations remove high tensile

residual stresses due to welding in ferrous and non-ferrous metals. S e n d for

free brochure . STRESS R E L I E F E n G I n E E R I n G c o m p A n Y

1725 MonroviaAve. , A-1 • Costa Mesa, CA 92627 (949) 642-7820 . FAX (949) 642-0430


Less handling, easier positioning, faster and cleaner welds.

. . . . . L ,=w

Atlas Pipemate and Idler Rolls • Unit with idler rolls supports balanced

loads up to 1000 lb. • Rotates pipe and tube up to 17" dia. • Portable, low profile for shop or field • Dual speed 0 to 30 in/rain or 0 to 60

in/rain • High frequency filter prevents

interference with GTA welding

Atlas Rotaw Table Positioners • Two models: 9" table, 100 lb. capacity,

10" tilt table, 200 lb. capacity • Heavy duty grounding circuit for stick

electrode, MIG or TIG welding • Low profile for bench mounting • Foot switch for feathering speed and

on/off control • Heavy duty steel construction • Front panel speed and rotation controls

Other handling and welding aids...Atlas Pipe Supports, ~ Atlas Roller Stands, Atlas Pipe Dolfies

ATLAS WELDING ACCESSORIES, INC. Troy, MI 48099

~.~ 8 0 0 - 9 6 2 - 9 3 5 3 email: [email protected]


I ~ Y i NOVEMBER 2002

guide detailing product information, specifications, and options for its new line of MiniSafe MS4600-EP safety light curtains, BeamSafe II-EP long-range single- beam safety controls, and BeamSafe III- C-EP compact single-beam safety controls.

Scientific Technologies Inc. 6550 Dumbarton Circle, Fremont, CA 94555

117

Catalog Features Lifters

= r , = ~ , i

¢¢ ~ t ,,m= ~ w

The Strong-Bac® catalog contains an extensive selection of lifters. The 68-page catalog includes lifting and spreader beams; mechanical sheet/bundle lifters; coil hooks and grabs; pallet lifters; paper roll handling equipment; crane blocks; specialty lifting tongs; vacuum lifters; Posi-Turner® load rotating beams; and the company's complete line of mill duty lifters.

The Caldwell Group, Inc. 5055 26th Ave., Rockford, IL 61109

118

Video and Kit Details Safe Operation of Oxyfuel Equipment and Gases

Improper handling of oxyfuel equipment and compressed gas cylinders can lead to injuries, property damage, and loss of life. Learning proper handling techniques for this equipment is critical to achieve a safe workplace. For that reason, the company offers a comprehensive safety video titled "Oxy-Fuel Equipment Safety and Op-

erations," a 40-min video aimed at students and professionals. The video discusses all aspects of oxyfuel cutting, welding, brazing, and heating safety. The video costs $29.99. A Spanish language version of this video will be available in 2003. The company also offers the safety video in a kit that includes 30 safety meeting guides, 30 rule violation quizzes, six animated safety posters, and a condensed company catalog. The kit costs $39.99.

Smith Equipment Co. 2601 Lockheed Ave., Watertown, SD 57201.5636

Guide Aids Weld Metal Selection

The company's Weld Metal Selector Guide helps consumers identify the appropriate product for a particular application. To use the guide, an operator specifies a metal type, grade, strength requirement, and the type of welding process to be used, and the guide will recommend an electrode. Users can choose from American Society of Testing and Materials (ASTM), American Petroleum Institute (API), or American Bureau of Shipping (ABS) specifications. The guide covers shielded metal arc, gas metal arc, and submerged arc welding, as well as self-shielded and gas- shielded flux-cored electrodes. Also included is general information on each clas-

WELD METAL 5ELEETDR GUIDE

Eff~t~,~ Merch, 2OO2

sification, such as tensile strength, yield strength, and steel chemistry. The guide is presented in chart format. The first two pages consist of a legend of the codes that appear throughout the remainder of the literature. These codes make it easy for the user to quickly find the electrode that works best with the application.

The Lincoln Electric Co. 22801 St. Clair Ave., Cleveland, OH 44117-1199

119

Brochure Describes Lifting and Positioning Equipment

The company's 16-page, full-color

brochure titled "Improve Productivity and Safety with Efficient Lifting and Position- ing" describes its full line of lifting and handling equipment. The brochure shows models in various product lines such as work positioning tables, special-use lift tables, container tilters, pallet handling equipment, and portable lifts. The brochure also contains information on custom lifts such as coil cars, vertical reciprocating conveyors, dock lifts, roll handling tables, and container unloaders.

Southworth Products Corp. P.O. Box 1380, Portland, ME 04104-1380

120

Together we c rea te the future

m

1

We are a leading manufacturer of custom engineered metal alloy powders for use in Thermal Sur- facing Processes. Specific processes include HVOF, Plasma, Spray-Fusing, PTA, Puddle Torch Welding, and Vacuum Brazing.

Please contact us at 800 745 3422 (toll free).

North Amer ican H6gani is IB North American HSgan~s Inc., 111 H~gan~s Way,

Hollsopple, PA 15935-6416, USA Fax 8144792211,www.northamericanhoganas.com


J Polym O www.polyrnetcorp.com ..... ~ ' 10073 Commerce Park Dr. Cincinnati, OH 45246


WELDING JOURNAL Bl~i<lB

PERSONNEL

Metabo Appoints Vice President

. . . . 1 Metabo Corp., West Chester, Pa., has appointed David Smith as executive vice president. Smith previously served as Metabo's vice president of marketing. His responsibilities

David Smith will extend from marketing, adver-

tising, and sales promotions to customer and technical services, distribution channel development, and MIS functions. Be- fore joining Metabo, Smith was vice president of marketing for AAMCO Transmis- sions and was employed at Hilti Fastening Systems. He holds a bachelor 's degree from American University and an MBA in international business from George Washington University.

ABICOR Binzel USA President Semiretires

ABICOR Binzel USA, Frederick, Md., announced that president and CEO for North American operations, Thomas C. Conard, has semi- retired. He has re- linquished his cur-

Thomas C. Conard rent full-t ime re- sponsibil i t ies en- compassing man-

agement of the facilities in Maryland, Canada, and Mexico. Conard will remain an active member of the board of directors for the company while serving as a long-term consultant. Conard will also continue to represent the company at industry-related events, as well as serve on the AWS PEMCO and W E M C O Com- mittees.

CONCOA Expands Management Team

CONCOA, Virginia Beach, Va., has named three new district managers. Keith McGrath was named district manager for the Mid-Atlantic, George Lindley [AWS] district manager for the South Central region, and Lee Hiner [AWS] district manager for the Pacific Northwest and west-

MEMBER MILESTONE

Porter Receives Texnikoi Outstanding Alumnus Award

Nancy C. Por ter [AWS] was awarded the Texnikoi Outstanding Alumna Award from The Ohio State University's College of Engineering. Texnikoi is an organization of undergraduate students in the College of Engineering whose purpose is to recognize qualities of leadership, integrity, and personality as exemplified by active participation and leadership in extracurricular activities. Each year, the active membership selects a young alumnus who demonstrates leadership through his or her achievements since graduation as a recipient of the Texnikoi Outstanding Alumnus Award.

Porter received a bachelor of science degree in welding engineering in 1985. In 1994, she returned to OSU to join the Edison Welding Institute. In this position, she worked with 16 national Manufacturing Extension Partnership Centers playing a key role in the development and success of the National Excellence in Materials Joining Initiative's JoinNet Program. Porter currently serves as the Ohio Programs Manager.

Porter serves on the external advisory committee for OSU's Department of Indus- trial, Welding, and Systems Engineering. She is an active board member of The Ohio State University Welding Engineering Alumni Society and is immediate past president of that organization.

ern Canada. In these positions, their responsibilities include spearheading sales through developing new markets for the company's product line and overseeing sales team training and support. They will work with distr ibutors to improve product and applications knowledge, understand market potential, and identify end- user needs.

Obituaries

Richard "Dick" Allard

Richard "Dick" Al lard [AWS] died suddenly Saturday, August 3, of a heart attack. Allard was a salesman for more than 25 years in Wisconsin's metal fabricating industry. He was most recently employed at Machinery & Welder Corp., West Allis, Wis. Allard was a Vietnam-era veteran of the U.S. Navy.

Allard is survived by his wife, Judith; his children and their spouses, Kenneth (Sandra), Barbara Hillman (Erich), Keith, and Stacey; grandchildren Krystal, Colin, Kyle, and Cody; and his brothers and their wives, Chester (Betty), Clayton, Donald (Iris), and Jack Harriet.

Charles E. Ridenour

Charles E. Ridenour [AWS] passed away in his home on August 21. He was a Life Member of the American Welding Society (AWS) and a past chairman of the AWS Chicago Section.

Ridenour served in Germany during World War II in the 99th Army Division, 394th Infantry regiment. He graduated from the University of Michigan with a

bachelor 's degree in metallurgical engineering in 1948. He began his career in the welding industry as a welding development metallurgist from 1948 to 1977 at Amsco Div.,

Charles E. Ridenour Abex Corp. in Chicago Heights,

Ill. He continued his career at Amsco as the division metallurgist until 1983, when he transferred to the Amsco Welding Products facility in Wauseon, Ohio. He retired from the company in 1985 when it was sold to the Stoody Co.

Ridenour emerged from retirement in 1986 to work on formulating flux cored welding wires for Tri-Mark, Inc. He once again ret ired in 2000 from ITW Hobar t Brothers Co.

During his career, Ridenour developed a wide range of welding electrodes for austenitic manganese steels, stainless steels, cobalt, and nickel-based alloys and holds several patents on hardfacing and manganese steel e lectrodes and electroslag welding processes.

Ridenour served on the AWS Hand- book Committee, subcommittees on surfacing filler metal, Rai l road Welding Committee, and Welding Research Coun- cil. He also served on the American Soci- ety for Metals Handbook Committee and was active in the American Foundrymen's Society.

Ridenour is survived by three nieces, Eileen Leasure, Jo-Anne Christman, and Barbara Shureen; and one great niece, Jenifer Bender.

mz~m NOVEMBER 2002

~LASSIFIED$

1 HAVE 30 YFA R,',; EXI'I,J{II,ZNt'I, AS A NATIONWIDE WELDING ENGINEERING SPECIALIST

Numerous client companies have engaged me to recruit welding pros at various levels of experience.

If your expertise is Welding Engineering:

Call 732-390-4600 • Fax 732-390-9769 e-mail [email protected] or Mail Resume to

Bill Elias, Dept WE PO Box 396, E.Brunswick, NJ 08816

ELIAS ASSOCIATES "Annually A National Award Winning Search F i r m "

AWS CWI & NDT MACTEC

Engineering and Consulting, Inc. The San Diego office of a leading national engineering firm has an immediate need for AWS Certified Welding In-

eCtors with NDT Level I1 to join us in lifornia performing owner QA on the

State Bridge Retrofit program. This is a prevailing wage project. The ideal candidate will- have current AWS CWl, UT shearwave/flaw detection experience and RT film interpretation experience m accordance with AWS D1.5. Travel required. Send resume to

MACTFC Attn: L. Tackett

9177 SkyPark Ct., Ste. A San Diego, CA 92123 Fax: (858) 268-1352

E-maih [email protected] (M/F/D/V, EOE)

POSITION AVAI LABLE Research Staff

Oak Ridge National Laboratory (ORNL) is seeking a scientist or engineer to work on welding processes, process modeling, and microstructure modeling of ferrous and nonferrous alloys. The candidate must have a Ph.D. in welding engineering or materials science with expertise in process modeling, microstructure modeling, stress analysis, and friction stir welding. A few years of R&D experience in industry including proposal project development is essential. Knowledge of neu- tron scattering application to welding is desirable. Please send your resume to Dr. Stan A. David before December 1, 2002, at the following address:

Oak Ridge National Laboratory Metals and Ceramics Division

Building 4508, MS-6095 P.O. Box 2008

Oak Ridge, TN 37831-6095

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4DVERTISIN( INDEX

A e l e c t r o n i c B o n d i n g , I n c . . . . . . . . . . . . . . . . . . . w w w . a b i u s a . n e t .............................. 87

Al l F a b C o r p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . a l l f a b c o r p . c o m ...................... 63

A m e r i c a n T o r c h T i p ............................ w w w . a m e r i c a n t o r c h t i p . c o m ............ 7

A r c o s I n d u s t r i e s , L L C ........................ w w w . a r c o s . u s ................................. .36

A S M E .................................................. w w w . a s m e . o r g / w e l d t r a i n i n g .......... 91

A t l a s W e l d i n g A c c e s s o r i e s , I n c . . . . . . . . . w w w . a t l a s w e l d . c o m ........................ 92

A W S C o n f e r e n c e D e p t . . . . . . . . . . . . . . . . . . . . . . . w w w . a w s . o r g .................................. 10

A W S C o n v e n t i o n S e r v i c e s .................. w w w . a w s . o r g ............................ 40, 66

A W S Foundation Dept . . . . . . . . . . . . . . . . . . . . . . . w w w . a w s . o r g ............................ 17, 18

A W S M e m b e r s h i p S e r v i c e s ................ w w w . a w s . o r g ...................... 13, 34 , 97

A W S T e c h n i c a l S e r v i c e s .................... w w w . a w s . o r g ................................ 8, 9

B e r e i c h R o b o t - S y s t e m e ...................... w w w . s m t - s y s t e m e . d e ...................... 62

B u g - O S y s t e m s I n c .. . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . b u g o . c o m ................................ 12 C o r - M e t .............................................. w w w . c o r - m e t . c o m ................... .35, 91

C - S p e c .................................................. w w w . w e l d o f f i c e . c o m ...................... 65

D e - S t a - C o I n d u s t r i e s .......................... w w w . d e s t a c o . c o m .......................... 62

D e t r o i t C o n v e n t i o n C e n t e r ................ w w w . v i s i t d e t r o i t . c o m .................... 21 Diamond Ground P r o d u c t s .............. w w w . d i a m o n d g r o u n d . c o m ............ 65

D i v e r s A c a d e m y I n t e r n a t i o n a l .......... w w w . d i v e r s a c a d e m y . c o m .............. 63

Durum I n c . , U S A ................................ w w w . d u r u m u s a . c o m ...................... 65

E S A B W e l d i n g a n d C u t t i n g P r o d . . . . . w w w . e s a b . c o m ............................ O B C

Hornell, I n c .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . h o r n e l l . c o m .......................... 37

H y p e r t h e m .......................................... w w w . h y p e r t h e r m . c o m .................... 15

J. P. Nissen, Jr. Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . n i s s e n m a r k e r s . c o m .............. 65

K o b e l c o W e l d i n g o f A m e r i c a , I n c . . . . . w w w . k o b e l c o w e l d i n g . c o m .......... I F C

Lincoln E l e c t r i c C o m p a n y ................ w w w . l i n c o l n e l e c t r i c . c o m ................ 2

National-Standard .............................. w w w . n a t i o n a l s t a n d a r d . c o m ............ 5

N o r t h A m e r i c a n H o g a n a s , I n c . . . . . . . . . w w w . n o r t h a m e r i c a n h o g a n a s . c o m 93

P o l y m e t C o r p ....................................... w w w . p o l y m e t c o r p . c o m .................. 93

P r a x a i r S u r f a c e T e c h n o l o g i e s ............ w w w . p r a x a i r t h e r m a i s p r a y . c o m . . . .38

S a i n t - G o b a i n A b r a s i v e s .................... w w w . n o r t o n a b r a s i v e s . c o m .............. 1

S e l e c t A r c , I n c .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . s e l e c t - a r c . c o m .................... I B C

Stellite C o a t i n g s .................................. w w w . s t e l l i t e . c o m ............................ 64

S t o o d y / T h e r m a d y n e ............................ w w w . s t o o d y . c o m ............................ 11

S t r e s s R e l i e f E n g i n e e r i n g C o ... . . . . . . . . . . e - m a i h f o r m u l a 6 2 @ a o l . c o m ........ 92

W e l d A c a d e m y .................................... w w w . w e i d a c a d e m y . c o m ................. .39

W e l d H u g g e r , L . L . C . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w e l d h u g g e r . c o m .................... 63

I F C = I n s i d e F r o n t C o v e r

I B C = I n s i d e B a c k C o v e r

O B C = O u t s i d e B a c k C o v e r

Statement of Ownership, Management and Circulation for U.S. Postal Service (Required by U.S.C. 3685)

1. TITLE OF PUBLICATION: Welding Journal 2. PUBLICATION NO.: ISSN 0043-2296 3 DATE OF FILING: September 30, 2002 4. FREQUENCY OF ISSUE: Monthly 5. NO. OF ISSUES PUBLISHED ANNUALLY: 12 6. ANNUAL SUBSCRIPTION: $90.00 7. MAILING ADDRESS OF KNOWN OFFICE OF PUBLICATION: 550 N.W. LeJeune Rd., Miami, Dade County, Florida 33126 8. MAILING ADDRESS OF THE HEADQUARTERS OR GENERAL BUSINESS OFFICES OF THE PUBLISHERS:

550 NW LeJeune Rd., Miami, Dade County, Florida 33126 9. NAMES AND COMPLETE ADDRESS OF PUBLISHER, EDITOR AND MANAGING EDITOR:

PUBLISHER: Jeffrey D. Weber, AWS, 550 NW LeJeune Rd., Miami, Florida 33126 EDITOR: Andrew Cullisen, AWS, 550 NW LeJeune Rd., Miami, Florida 33126 MANAGING EDITOR: None

OWNER: NAME: American Welding Society, Inc. ADDRESS: 550 NW LeJeune Rd., Miami, Florida 33126 KNOWN BONDHOLDERS, MORTGAGEES, AND OTHER SECURITY HOLDERS OWNING OR HOLDING 1 PERCENT OR MORE OF TOTAL AMOUNT OF BONDS, MORTGAGES OR OTHER SECURITIES: None The purpose, function, and nonprofit status of this organization and the exempt status for Federal income tax purposes:

10. 11.

12.

13. 15.

16.

Has not changed during preceding 12 months Publication Tittle: Welding Journal EXTENT AND NATURE OF CIRCULATION:

14. Issue date for Circulation Data Below: October 2002

Average No. Copies Each Issue During Preceding 12 Months

A. Total No. Copies Printed (Net Press Run) 51,625 B. Paid and/or Requested Circulation

1. Paid / Requested Outside-County Mail Subscriptions Stated on Form 3541 49,009 2. Paid In-County Subscriptions Stated on Form 3541 None 3. Sales Through Dealers and Carriers, None Street Vendor, Counter Sales, and other Non-USPS Paid Distribution 4. Other Classes Mailed Through the USPS None

C. Total Paid / Requested Circulation 49,009 D. Free Distribution by Mail (Samples, complimentary and other free)

1. Outside-County as State on Form 3541 408 2. In-County as Stated on Form 3541 None 3. Other Classes Mailed Through the USPS None

E. Free Distribution Outside the Mail (Carriers or other means) None F. Total Free Distribution 408 G. Total Distribution 49,417 H. Copies not Distributed 2,208 I. Total 51,625 J. Percent Paid and / or Requested Circulation 99.2% Statement of Ownership will be printed in the November 2002 issue of this publication. I certify that the statements made by above are correct and complete: J. D. Weber, Publisher

Actual No.Copies of Single Issue Published Nearest to Filing Date

51,500

48,471 None None

None 48,471

423 None None None 423 48,894 2,606 51,500 99.2%

W E L D I N G J O U R N A L ~ l


Friends and Colleagues:

The American Welding Society established the honor of Counselor to recognize individual members for a career of distinguished organizational leadership that has enhanced the image and impact of the welding industry. Election as a Counselor shall be based on an individual's career of outstanding accomplishment.

To be eligible for appointment, an individual shall have demonstrated his or her leadership in the welding industry by one or more of the following:

• Leadership of or within an organization that has made a substantial contribution to the welding industry. The individual's organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities.

• Leadership of or within an organization that has made a substantial contribution to training and vocational education in the welding industry. The individual's organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities.

For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS headquarters in Miami, or simply follow the instructions on the Counselor nomination form in this issue of the Welding Journal. The deadline for submission is February 1, 2003. The committee looks forward to receiving these nominations for 2004 consideration.

Sincerely,

L. W. Myers Chairman, Counselor Selection Committee

DATE

AWS MEMBER NO.

HOME ADDRESS

CLASS OF 2004

COUNSELOR NOMINATION FORM

(please type or print in black ink)

NAME OF CANDIDATE

YEARS OF AWS MEMBERSHIP

CITY

PRESENT COMPANY/INSTITUTION AFFILIATION

T TLE/POSITION.


BUSINESS ADDRESS

CITY

ACADEMIC BACKGROUND, AS APPLICABLE:

INSTITUTION


MAJOR & MINOR

DEGREES OR CERTIFICATES/YEAR

LICENSED PROFESSIONAL ENGINEER: YES

SIGNIFICANT WORK EXPERIENCE:

COMPANY/CITY/STATE

NO STATE

POSITION

COMPANY/CITY/STATE

YEARS

POSITION YEARS

SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:

SUGGESTED CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE SELECTED AS AN AWS COUNSELOR. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE INCORPORATED WITHIN THE CITATION CERTIFICATE.

**MOST IMPORTANT** The Counselor Selection Committee criteria are strongly based on and extracted from the categories identified below. All in-

formation and support material provided by the candidate's Counselor Proposer, Nominating Members and peers are considered.

SUBMITTED BY: PROPOSER AWS Member No The proposer wil l serve as the contact if the Selection Committee requires further information. The proposer is encouraged to include a detailed biography of the candidate and letters of recommendation from individuals describing the specific accomplishments of the candidate. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition to the proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should be submitted.

NOMINATING MEMBER: AWS Member No. NOMINATING MEMBER: AWS Member No. NOMINATING MEMBER: AWS Member No. NOMINATING MEMBER: AWS Member No.

SUBMISSION DEADLINE FEBRUARY 1, 2003


Nomination of AWS Counselor

I. HISTORYAND BACKGROUND In 1999, the American Welding Society established the honor of Counselor to recognize indi-

vidual members for a career of distinguished organizational leadership that has enhanced the image and impact of the welding industry. Election as a Counselor shall be based on an individual's career of outstanding accomplishment.

To be eligible for appointment, an individual shall have demonstrated his or her leadership in the welding industry by one or more of the following:

• Leadership of or within an organization that has made a substantial contribution to the welding industry. (The individual's organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities such as AWS, IIW, WRC, VICA, NEMA, NSRP SP7 or other similar groups.)

• Leadership of or within an organization that has made substantial contribution to training and vocational education in the welding industry. (The individual's organization shall have shown an ongoing commitment to the industry, as evidenced by support of partici pation of its employees in industry activities such as AWS, IIW, WRC, VlCA, NEMA, NSRP SP7 or other similar groups.)

II. RULES A. B.

III.

Candidates for Counselor shall have at least I0 years of membership in AWS. Each candidate for Counselor shall be nominated by at least five members of the Society.

C. Nominations shall be submitted on the official form available from AWS headquarters.

D. Nominations must be submitted to AWS headquarters no later than February I of the year prior to that in which the award is to be presented.

E. Nominations shall remain valid for three years. F. All information on nominees will be held in strict confidence. G. Candidates who have been elected as Fellows of AWS shall not be eligible for

election as Counselors. Candidates may not be nominated for both of these awards at the same time.

NUMBER OF COUNSELORS TO BE SELECTED 2001 Class of Counselors:

Year one, maximum of 20 Counselors selected, as determined by the committee 2002 Class of Counselors:

Year two, maximum of 20 Counselors selected, as determined by the committee 2003 Class of Counselors:

Year three, maximum of 15 Counselors selected, as determined by the committee 2004 Class of Counselors:

Year four, and thereafter: maximum of 10 Counselors selected, as determined by the committee

Return completed Counselor nomination Package to: v

Wendy S. Reeve American Welding Society 550 N.W. LeJeune Road Miami, FL 33126

Telephone: 800-443-9353, extension 215

SUBMISSION DEADLINE: February 1, 2003

. . . . . . . W E L D I N G R E S E A R C H

SUPPLEMENT TO THE WELDING JOURNAL, NOVEMBER 2002 Sponsored by the American Welding Society and the Welding Research Council

The Effect of Multiple Postweld Heat Treatment Cycles on the Weldability of

Waspaloy® Changes in grain boundary character distribution after multiple PWHT cycles were

found to affect HAZ liquation cracking during repair welding

BY M. QIAN AND J. C. LIPPOLD

ABSTRACT. The heat-affected-zone (HAZ) liquation cracking susceptibility of wrought Waspaloy® subjected to simulated, multiple postweld heat treatment (PWHT) cycles was evaluated using hot ductility testing. The behavior of both a wrought bar material and a forged turbine disk was evaluated. A long-term isothermal heat treatment was used to simulate multiple PWHT cycles that Waspaloy turbine engine components would experience during periodic weld repair. The we[dability degradation of Waspaloy after a 1079°C/40-h heat treatment is primarily due to increased grain size from long- term, e levated- temperature exposure. The finer grain size of the wrought bar ac- counted for its minimal degradation of weldability, while coarse grains resulted in a drastic deterioration of wektability in the forged disk. The degradation of weldability is associated with the short-time, high- temperature grain boundary (GB) weakening resulting from MC-type carbide constitutional liquation and segregation- induced GB liquation in the simulated H A Z of Waspaloy materials. A 1079°C/100-h treatment resulted in a restoration of the weldability of the forged disk even with comparable coarse grain size to that of simulated 1079°C/40-h treated material. The effect of grain size and the fraction of special grain boundaries on the HAZ liquation cracking behavior is discussed with regard to the simulated multiple PWHT cycles.

Introduction

Weld repair of aircraft gas turbine en-

M. QIAN A N D ,l. C. LIPI 'OLD are with The Ohio State Univet:s'i(v, Columbus, Ohio.

gine components, including blades, buck- ets, and static (nonrotating) components has become increasingly prevalent as a means of extending engine life and reducing the costs associated with component replacement. As part of the repair welding process, the precipi tat ion-hardened superalloys must undergo postweld heat treatment (PWHT) to restore their mechanical properties. Because components are subject to multiple repairs over their lifetimes, they are also exposed to multiple cycles of PWHT consisting of solution treatment fl)llowed by aging. It has been observed the weldability of some superal- Ioys degrades after an accumulation of repair/PWHT cycles (Refs. 1-5). The purpose of this study was to develop a better understanding of the relationship between multiple PWHT cycles and the weldability of Waspaloy.

It should be noted material for this investigation was taken from a turbine rotor disk. Repair of disk materials by welding is generally not allowed and this paper does not suggest repair of these components be conducted. Rather, the disk was a ready source of Waspaloy material that exhibited metallurgical characteristics of interest in this investigation.

KEY WORDS

Waspaloy® Postweld Heat Treatment (PWHT) Weldability Heat-Affected Zone (HAZ) Liquation Cracking Special Grain Boundary Grain Size Intergranular Fracture

Experimental Procedure

Two Waspaloy materials were used in this study. One was a wrought bar in the solution-annealed condition. The other was a forged aircraft turbine disk, 84(I mm (31.5 in.) in diameter, with a bimodal grain structure (Ref. 6), provided in the fully heat-treated condition, i.e., solution heat treated at 1079°C (1975°F) and aged at 760°C (1400°F). The chemical compositions of these two materials are listed in N~ble I.

Initially, the use of a hmg-term isothermal heat treatment to simulate multiple PWHT cycles was investigated to shorten the experimental period in sample preparation. The premise in the use of this approach was that the solution treatment employed in PWHT results in the metallurgical "degradat ion" of the material since the aging portion of the heat treatment is reversible, i.e., the aging precipi- tate, ~/"-Ni3(A1,Ti ), dissolves during the solutionizing portion of the PWHT cycle. Both Waspaloy bar and disk materials were used for the simulation with the following heat treatment conditions (Ref. 7): 1) 1079°C (1975°F)/4h for ten cycles with furnace cooling between cycles, and 2) an isothermal hold at 1079°C for 40 h. Both heat t reatments were conducted in an argon-protected tube furnace. In addition, the 1079°C/40-h treatment was also conducted in air in a box furnace (BF) with air cooling for comparison. For the final long- term, isothermal heat treatments, the box furnace with no protective atmosphere was used to treat bulk Waspaloy materials. Test specimens were then machined from these bulk samples, so they were not affected by the surface oxidation of the bulk sample.

The weldability of Waspaloy materials

WELDING JOURNAL

WELDING RESEARCH IO0

90

8o

7O

~oo

i 2O

10

ON COOLING i i I

Temperetu,re. "C

1300 1,1o0

Fig. 1 - - Gleeble'~ hot-ductility "signatures'" o f Waspaloy bar.

in both the as-received and simulated multiple PWHT conditions was evaluated using the Gleeble ~M hot-ductility test. Test specimens were 6.35_+0.05 mm (0.25_+0.002 in.) in diameter and 100 mm (4 in.) in length, with threads on both ends. Samples were removed longitudinally in the bar and radially from the forged disk. A Type K (chromel-alumel) thermocouple was spot welded to the midpoint of the sample for temperature measurement and control. Heating and cooling rates followed thermal simulation parameters from a series of nickel-based superalloys used by previous researchers (Refs. 3-5, 8). The hot ductility testing conditions used a heating rate of 11 l°C/s (200°F/s), hold time at test temperature 0.5 s, cooling rate of 43°C/s (77°F/s), and stroke rate of 25 mm/s (1 in./s) to fracture the samples. All samples were tested in argon. Temperature, stroke, and load were continuously monitored throughout the test. Ductility, in terms of reduction of area of the fracture surface, was subsequently measured using a binocular microscope.

Hot ductility samples were examined using both optical microscopy and scanning electron microscopy (SEM). Elec- trolytic etching with 10% aqueous chromic acid was used to reveal microstructures of interest. For the hard-to- etch, long-term solution-treated materials, an etchant consisting of 15 mL HC1, 10 mL acetic acid, 10 mL HNO 3, and 2-5 drops of glycerol was used. Grain size was measured in Feret diameter (dr) on digi- tally recorded optical images using Image- Tool 2.0 (Ref. 9). Sufficient grains in three to five areas of each sample were counted to yield the average grain size and standard deviation. Energy-dispersive spectroscopy (EDS) analysis was performed in the SEM for phase identification.

The measurement of grain boundary character distribution (GBCD) in terms of z was conducted by using orientation imaging microscopy (OIM T M ) . Electrolytic polishing with a 15% HCI and 85%

CH3OH electrolyte was used to prepare OIM specimens. OIM was conducted on a Phillips XL-30 Envi- ronmental SEM equipped with an Argus-20 real-time image processor coupled with Channel 4.2 software to control electron backscatter diffraction (EBSD) acquisition and ma- nipulate, analyze, and display EBSD data. Beam scanning coupled with SEM dynamic focusing was conducted to acquire electron backscatter patterns (EBSPs) of areas of interest to generate relevant image mapping. Results of GBCD, such as fraction of special GBs and high-angle GBs were obtained from the mapping by using Channel 4.2 analyzing software (Ref. 10).

Results and Discussion

Thermal simulation using long-term isothermal solution heat treatment for the multiple-cycle heat treatment produced comparable microstructure, grain size, and hardness levels in the Waspaloy material evaluated, as shown in Table 2. Similar experiments performed with Alloy 718 and IN939 r~" provided similar results and reinforced the use of isothermal heat treatments to simulate multiple thermal cycles (Ref. 6). Consequently, long-term (40 h) isothermal heat treatments at 1079°C (1975°F) were applied to bulk materials, from which the Gleeble hot-ductility specimens were produced.

Typical Gleeble hot-ductility "signatures" for the Waspaloy material are shown in Fig. 1. These curves demonstrate the change in ductility during both on- heating and on-cooling simulated weld

Fig. 2 - - Fractography ~/'tlte Wa.s7)ah~v har tested at t/t(" N D T showing IG features. A - -As-rece ived; B - - 1079°C/40h-treated.

thermal cycles. For the quantitative evaluation of liquation cracking susceptibility, a few critical values are determined. Table 3 lists these values in terms of nil ductility temperature (NDT), nil strength temperature (NST), ductility recovery temperature (DRT), and liquation temperature range (LTR), where LTR is the difference between NST and DRT. Within the LTR, the materials show no ductility during cooling. Therefore, the LTR value can be used to quantify susceptibility to liquation cracking, with larger values indicating higher susceptibility. For comparison, a temperature range of T - D R T is also

• . P

hsted, where T is the peak temperature for on-cooling ~est T is determined ap-

• " . p .

proximately at the midpoint of NST and NDT for each material.

For both Waspaloy bar and disk materials, the Gleeble hot ductility results indicate the susceptibility to liquation cracking increased after the 1079°C/40-h treatment (Table 3), which represents the case of multiple PWHT in the repair process. The bar material showed slightly deteriorated weldability while the disk showed a drastic degradation in weldability, as indicated by the increase in LTR from 126 to 270°C.

Fractography revealed the fracture

P,,I<"I~"I NOVEMBER 2002 I

: : :,,: WELDING RESEARCH

Fig. 3 - - Fractography o f DRT samples o f Waspaloy disk showing IG Jeatares. A - - As-received; B - - 1079°C/40-h treated.

morphology is intergranular (IG) in samples of both the bar and disk tested above DRT and NDT, as shown in Figs. 2 and 3, Element respectively. This clearly indicated high- temperature GB weakening is the major C contributor to failure. Besides, the coarse- Mn grained fracture surface also revealed the Si

S effect of the long-term isothermal treat- P ment on the microstructure. Microstruc- Fe tural analysis suggested such GB weaken- Cu ing is caused by two simultaneous Co liquation phenomena in the simulated Mo HAZ of Waspaloy materials, i.e., carbide Ti constitutional liquation and segregation- induced GB liquation - - Fig. 4. From Figs. 4A and B, it can be seen that constitutional liquation and GB penetration is associated with the interaction of Ti-rich MC carbides and the ~/-nickel matrix, from Waspaloy which a reaction zone formed, resulting in the formation of eutectic carbides. The typical segregation-induced GB liquation for both bar and disk materials is shown in Bar Figs. 4C and D. The coarse GB constituents are complex boron-rich (around Disk 50 at.-%) eutectics, detected by EDS of (bimodal the area. Based on the metallurgical grain analysis, it can be summarized this weld- structure) ability degradation is primarily related to coarse intergranular fracture due to increased grain size resulting from the long- term isothermal heat treatment.

Grain size is a well-known factor influencing material properties. With regard to Waspaloy the weldability degradation described above, larger grain size represents less grain boundary area and correspondingly Bar fewer triple junctions among grains (Refs. 11, 12). The propagation resistance for li- Disk quation cracking with IG features in coarse-grained material (1079°C/40h) was therefore reduced.

Since the Waspaloy disk showed drastic weldability degradation with increasing grain size as a response to 1079°C (1975°F)/40-h thermal effect, the 100-h treatment at 1079°C (1975°F) in the box furnace with air cooling was conducted on

Table 1 - - Chemical Composition of Waspaioy Materials

Bar, wt-% Disk, w t - % Element Bar, wt-% Disk, wt-%

0.049 0.033 AI 1.32 1.27 0.02 0.02 Zr 0.05 0.07 0.08 0.03 V 0.06

<0.003 <0.003 Nb 0.07 <0.01 <0.01 B 0.002 0.005

1.09 1.52 W 0.13 0.02 0.01 "Pa <0.01

12.95 12.23 Cr 19.09 18.34 4.09 3.69 Ni Rem. Rem. 2.85 3.12

Table 2 - - Comparison of Grain Size, Hardness, and Microstructural Features for the Thermal Simulation

Heat Treatment Grain Size Hardness Microstructural Condition (d,), lam HV1 Features

As-received 14.8 - 5.8 296.8 - 1.8 1079°/4h-10 cycles 146.8 - 59 326.4 _ 3.4 Grain growth; 1079°C/40h 144.5 +- 58 325.6 - 2.5 MC carbide 1079°C/40h (BF) 145.2 - .49 339.2 - 7.0 stringers As-received (aged) 189 - 114 46 - 24 398.4 _+ 5.4 1079°/4h-10 cycles 532 _ 107 273 -+ 88 277.2 -+ 26.13 Grain growth; 1079°C/40h 559 _ 182 255 +- 86 272.9 -+ 18.3 equiaxed grain

with annealing twins.

Table 3 1 Results of Gleeble Hot Ductility Testing of Waspaloy Materials

Condition NDT NST DRT Peak Temp LTR Tp-DRT (°C) (°C) (°C) (Tr) (°C) (°C) (°C)

As-received 1246 1302 1093 1280 209 187 1079°C/40 h 1253 1302 1065 1280 237 215 As-received 1243 1330 1204 1286 126 82 1079°C/40 h 1232 1308 1038 1270 270 232 1079°C/100 h 1232 1303 1218 1270 85 52

Note: LTR = NST-DRT.

the disk material to determine if further weldability degradation occurred. Com- paring the LTR values of the disk material in Table 3, it is obvious that, tested with the

same T_ level as that of 1079°C/40-h v

treated Waspaloy disk, 1079°C/100-h treated samples showed a reduced LTR and a corresponding lower (Tp-DRT)

WELDING JOURNAL P~"~.'I

WELDING RESEARCH

Fig. 4 - - Evidence o f liquation p h e n o m e n a in N S T samples. A - - Carbide consti tutional liquation; B - - liquation reaction zone around a M C carbide in A;

C - - G B liquation; D - - detail o f C showing boron-rich G B constituents.

Table 4 - - Grain Size and Distribution of Waspaloy Disk Material .

Large Grain Small Grain Area Ratio of Waspaloy Size Area Size (d,), Area Large to Small Grain Disk ~tm (%) p.m (%)

As-received 189.1 __. 114 43.8 46.4-- + 24 56.2 0.78 10798C/40h 559 __. 182 64.7 255 __. 86 35.3 1.83 10798C/100h 586 _ 171 71.5 250 __+ 87 28.5 2.51

Table 5 m Grain Boundary Character Distribution (GBCD) of the Waspaloy Disk Material

GBCD (%) As-Received I079°C/40h 1079°C/100h

$3 39.7 51.7 65.8 $3, < 111 >/60°-Twin 38.0 49.6 64.9 $9 and $27 2.3 1.43 0.75 Total 5" ~ 29 45.6 56.2 69.4 Random 54.4 43.8 30.6

value• This indicates an improvement in weldability after isothermal treatment of 1079°C/100-h relative to 40-h-treated material Note that T affects the ductility of

• . P

on-coohng samples, including the DRT value, which was observed in the experiments. Therefore, it can be reasonably expected the as-received disk should have an even smaller LTR at least equivalent to

P,,g[,'-l$.'t NOVEMBER 2002

that of 1079°C/100-h-treated Waspaloy disk if the same T_ was applied.

• . P . . .

The gram size and dmtnbut]on of 1079°C/100-h-treated Waspaloy disk were acquired as shown in Table 4, along with those of other two conditions of the disk materials. It is noted there is a slight grain size increase for the 1079°C/100-h-treated disk. Besides, there is also a notable in-

crease of fraction of large grains relative to the small ones for the 100-h-treated samples compared with the 40-h-treated ones and the as-received. It is, therefore, clear the improved resistance to liquation cracking of the 1079°C/100-h-treated Was- paloy disk cannot be explained by a grain- size effect. Fractographic and microstructural features were examined to explore potential causes for such an improved resistance. It was observed annealing twins were abundant in the 1079°C/100-h - treated Waspaloy disk samples. Figure 5 shows representative twin-related fracture morphology of samples tested above the DRT, as evidenced by wavy features on the intergranular fracture surface. Inspection of the microstructure revealed some grain boundary segments are resistant to IG fracture.

This is illustrated clearly in 1079°C/100-h-treated Waspaloy disk samples as shown in Fig. 6. It can be seen the crack propagation along GBs ceased at some twin-related segments (Figs. 6, A and B). Wavy dimple-shaped fracture pat- tern was also seen on the segment interfaces (Fig. 6A), which corresponds to the phenomena observed in Fig. 5. The grain boundary character distribution (GBCD) was therefore evaluated using OIM to

Fig. 5 - - Twin-related "wa~y" fracture sulfiwes of 1079°C/lO0-h-tlvated Wa,vmloy disk hot-ductifity samples. A - - NDT; B - - detail o/A; C - - on-coohng at

I024°C; D - - detail of C.

Fig. 6 - - Grain boundary (GB) segments resistant to lG./?ac'ture in 1079°C/lO0-h-treated Waspaloy disk. A - - Sample tested between NDT aml NSTI" B - -

N D T sample showing twin-related GB segments hindering the fracture propagation.

quantify the twinning effect. The acquired volume fraction of

GBCD differentiated as Y3 CSL (Coinci- dence-Site-Latt ice) boundaries, special GBs (Y<29), and random GBs are shown in Table 5. The values are percentages of the part icular boundary in the total boundary length. It can be seen that the fraction of Z3 CSL boundaries represents the majority of the total special grain

boundaries. The fraction of special GBs of the Waspaloy disk materials increased with an increase of the isothermal hold duration, where 1079°C/100-h t reatment yielded the highest fraction of special GBs. Since HAZ liquation cracking is intergranular due to the GB liquation that occurred at high temperatures, the behavior of special GBs was investigated. These special GBs have been previously re-

ported to be beneficial to IG degradations as well as weldability (Refs. 11-15).

Figure 7 presents a typical SEM micrograph and the matched OIM image showing boundary orientation. It can be seen some GB segments of an individual GB do not show signs of liquation while others do. GB segments 2, 4, 5, 7, and 8 are not liquated. Note segments 2, 4, and 5 are the intersected parts of two different pairs of

WELDING JOURNAL [,,~]r~..1

WELDING RESEARCH

Fig. 7 - - Boundary differentiation of Waspaloy bar. A - - SEM micrograph; B - - O1M image: H- high-angle GB; L- low-angle GB.

twin boundaries with two respective, original high-angle GBs, as shown in Fig. 7B. Segment 2 is composed of sections of special GBs (Z13a and Z25a) and high-angle GBs, while segment 4 comprises several sections of Z CSL boundaries (i.e., Yl3a, Z25a, and E37a). Segment 5 is simply a high-angle GB, however, intersected by a twin. The other two segments, 7 and 8, are not liquated and are identified as Z39a and a low-angle GB, respectively. It can be summarized, based on the microstructurai and OIM analysis, that the increase of resistance to liquation and therefore resistance to IG fracture is closely related to the beneficial effect of special grain boundaries. The E CSL GBs, low-angle GBs, and even twin-related, high-angle GBs also showed resistance to liquation.

It is evident, therefore, that a high volume fraction of special GBs, especially Y3 boundaries, generated in the Waspaloy disk through 1079°C/100-h treatment ac- counted for the improved weldability. With regard to effects on HAZ liquation cracking, this study has shown both grain size and special GBs have an important influence, but the GBCD can have a domi- nant effect. Even with relatively large grain size, the cracking susceptibility of the disk material was significantly reduced by increasing the fraction of special GBs. This suggests grain boundary engineering (GBE) techniques can be used to improve the weldability of wrought Waspaloy materials exposed to multiple PWHT cycles following weld repair.

Conclusions

1) The weldability degradation of Was- paloy materials in 1079°C/40-h condition is primarily due to increased grain size from long-term reheats. Finer grain size accounts for the minimal degradation of weldability in the wrought bar, while coarse grains resulted in a drastic deterio-

ration ofweldability in the forged disk. 2) Local Ti-rich, MC-type carbide con-

sti tutional liquation and segregation- induced grain boundary liquation are responsible for HAZ liquation cracking behavior.

3) The 1079°C/100-h t reatment re- stored the weldability of the Waspaloy disk, even with comparable coarse grain size to that of 1079°C/40-h-treated material. This improvement resulted from the high fraction of special grain boundaries resulting from this heat treatment.

4) Grain size and special grain boundary are the two primary factors influencing H A Z liquation cracking after multiple PWHTs. The presence of abundant special grain boundaries dominated the effect of grain size in the heat-affected zone of the Waspaloy bar stock and the forged disk.

Acknowledgments

Sincere appreciation is expressed to Edison Welding Institute for research funding and Pratt and Whitney for providing some experimental materials.

References

1. Chou, C. P., and Chao, C. H. 1988. Repair weldability studies of Alloy 718 using versatile Varestraint test. Superalloys 1988, pp. 785-794. The Metallurgical Society/AIME.

2. Lippold, J. C., Mehl, M., Lu, Q., Lin, W., and Kelly, T. J. 1996. Effect of composition, microstructure, and thermal treatment on the repair weldability of Alloy 718. 77thAnnualAWS Convention Abstracts, pp. 124-125. Miami, Fla.: American Welding Society.

3. Hooijmans, J. W., Lippold. J. C., and Lin, W. 1997. Effect of multiple postweld heat treatment on the weldability of Alloy 718. Superal- loys 718, 625, 706 and Various Derivatives, pp. 721-730. Minerals, Metals and Materials Soci- ety/AIME.

4. Mehl, M. E., and Lippold, J. C. 1997. El-

fect of 6-phase precipitation on the repair weldability of Alloy 718. Superalloys 718, 625, 706 and Various Derivatives, pp. 731-741. Minerals, Metals and Materials Society/AIME.

5. Bowers, R. J., and Lippold, J. C. 1997. Ef- fect of composition and heat treatment cycles on the repair weldability of Alloy 718. Joining and Repair of Gas Turbine Components, pp. 41-50. Materials Park, Ohio: ASM Interna- tional.

6. Qian, M. 2001. An investigation of the repair weldability of Waspaloy and Alloy 718. Ph.D. dissertation. The Ohio State University, Columbus, Ohio.

7. Waspaloy, Alloy Digest. 1967. Filing Code: Ni-129.

8. Lin, W., Lippold, J. C., and Baeslack, W. A. III. 1993. An evaluation of heat-affected zone liquation cracking susceptibility, part 1: development of a method for quantification. Welding Journal 72(4): 135-s to 153-s.

9. Image Tool 1997. Program developed at the University of Texas Health Science Center at San Antonio, Texas. Available at http://www.ddsdx.uthscsa.edu

10. Channel 4.2 software electronic files. 2000. Developed by HKL Technology, Inc.

11. Palumbo, G., King, P. J., Aust, K. T., Erb, U., and Lichtenberger, P. C. 1991. Grain boundary design and control for intergranular stress-corrosion resistance. Scripta Metallurgica et Materialia 25: 1775-1780.

12. Cheung, C., Erb, U., and Palumbo, G. 1994. Application of grain boundary engineering concepts to alleviate intergranular cracking in Alloy 600 and 690. Materials Science and En- gineering A 185: 39--43.

13. Palumbo, G. 1997. Thermomechanical Processing of Metallic Materials. U.S. patent No. 5,702,543.

14. Manufacturing Process for Enhancing Weldability and High Temperature Performance of Superalloys. 1998. Integran Technologies.

15. Lehockey, E. M., and Palumbo, G. 1997. On the creep behavior of grain boundary engineered nickel. Materials Science and Engineer- ing A 237: 168-172.

I~.,~]:E,.'t NOVEMBER 2002

WELDING RESEARCH

Microstructural Variations in a High-Strength Structural Steel Weld

under Isoheat Input Conditions

Weld bead morphologies influence weld cooling rate and hence the acicular ferrite content in steel

ABSTRACT. Bead-in-groove submerged arc welding of quenched and tempered (Q & T) HSLA steel using a suitable welding wire and an agglomerated basic flux (basicity index = 3.1) was carried out under heat input conditions varying from 1.9 to 3.7 kJ/mm. The heat input was adjusted by varying the welding current and welding speed with the machine operated in the constant voltage mode (32-33 VDC). From several welds prepared using a range of currents (4(10-8(1(t A) and speeds (3-13 mm/s), nine welds were selected. These welds represented those prepared under isoheat input conditions with different current and speed combinations. It was found all the parameters (namely, prior austenitic grain size, inclusion characteristics, cooling rate) influencing the w)lume fraction of intragranularly precipitated acicular ferrite in the weld showed significantly different dependence at a particular heat input depending upon the welding current and speed combination used. A new cooling rate parameter (NA/CI) based on the weld nugget cross- sectional area (NA) and the fusion zone/heat-affected zone interface length (CI) were defined. Using multiple regression analysis, a correlation between acicular ferrite content and the different influencing parameters as mentioned above was defined having ~90% correlation co- efficient. This correlation can be utilized in setting up the trial welding parameters fl)r similar grades of steel substrates and consumables with an aim to maximizing the acicular ferrite content.

Introduction

In the use of high-strength steels tk)r structural applications, the greatest concern is achievement of the desired mechanical properties in the weld, particularly low-temperature toughness. To

B. BASU is Scientis't, Naval Materials Research Laboratopy, Naval Dockyalzl, Mmnbai, hldia. R. RAMAN is Prq/'essol; Metallm,~,ical En,q, incering and Materials Science Department, Indian Insti- tute o[ Technolo~' - Bomba3: MumbaL India.

BY B. BASU AND R. RAMAN

economically achieve the required combination of high strength and excellent low temperature toughness in welds for con- structional applications, appropriate selection of welding parameters must be addressed. It is a common practice to correlate the various weld metal properties with heat input. Thus, the effects of individual welding parameters such as current and speed are not properly assessed when combined in the form of heat input. The effects of wlriation of welding current and speed are expected to result in subtle variations in microstructure leading to mechanical properties anywhere between highly desirable to highly deleterious, even though welding might have been carried out using tile same heat input. Pub- lished information (Refs. 1-4) is available in a very general manner on the effect of welding parameters, particularly heat input, on the structure and properties of high-strength steel welds. However, the effects of individual welding parameters, like current and speed, on the wtrious microstructural and mechanical properties have hardly been systematically addressed, particularly under isoheat input conditions.

It is well established that weld microstructure containing intragranularly formed acicular ferrite, due to its fine basket-weave-like structure, helps to achieve good low-temperature toughness (Refs. 5-8). Extent of formation of such a structure is a result of competition with unde- sirable higher temperature ferrite morphologies and involves the complex

KEY WORDS

Submerged Arc Welding HSLA Steel lsoheat Input Conditions Acicular Ferrite Grain Boundary Ferrite Polygonal Ferrite Ferrite Side Plate CCT Diagram

interaction between welding parameters, plate and welding wire chemistry, flux composition, and, significantly, the actual cooling rate the weld experiences. Using the classical approach (Ref. 9) of heat flow in fusion welding, it is possible to estimate the cooling rate experienced by the weld. However, these estimates are rarely accurate, especially with respect to the fusion zone. This is because these empirical equations do not take into account the weld nugget macromorphology that is expected to play a decisive role in the weld cooling rate. Further, the macromor- phologies of the weld nugget are expected to depend on the individual welding parameters and cannot be accurately correlated with heat input. In this work, an at- tempt has been made to study microstructural variations in a submerged arc weld of a high-strength steel under different isoheat input conditions.

Experimental

Tile objective of the present work is to study the effects of heat input, as a whole, and individual welding parameters such as welding current and speed, under isoheat input conditions, on the microstructural variations of as-deposi ted weld metal obtained by single-pass, bead-in- groove welding. The single-pass, bead-in- groove welds were character ized for chemistry including oxygen, volume fraction of various microstructural phases, sizes of prior austenitic grains, and inclusion characteristics.

Materials

Base plate - - A 22-mm-thick HSLA steel was used for the experiment.

Welding Wire A 3.15-ram-diameter, copper-coated alloyed wire was used as welding wire. Chemical analysis of the base plate and the welding wire used in the experiments is shown in Table 1. F l u x - - A highly basic, commercially available agglomerated flux with basicity 3.1 was used to carry out the welding. To drive away the moisture absorbed during stor-

WELDING JOURNAL l,,'.I,~[41~1

W E L D I N G R E S E A R C H

A Top view

Run-on tab

IbA

Test weld Run-offtab

100 mm 300 mm I~A 100 mm

B

\ 6 0 ° / T M " I ~ / ...... • r.o mm 2zo mm I

d is0mm . /

Fig. 1 1 Schematic o f the.iomt geometry. A 1 Top view, B - - s M e view (sectmn AA ).

Table I - - C h e m i c a l C o m p o s i t i o n (wt-%) of Base Meta l and Welding Wire

Elements C Si Mn Ni ('r Mo S P ('u

Base Metal (1.08 0.23 0.4 1.8 0.44 0.29 <0.01 <(},01 0.3g Welding Wire 0.04 (I.I 0.81 2.6 0,07 0.24 <0.01 <0.01 0.1 I

Table 2 - - C h e m i c a l C o m p o s i t i o n of Flux

Constituents MgO CaF2 SiO2 AI20~ TiO~ MnO CaO

Wt-% 36 26 13 12 (1.5 0.5 12

Table 3 - - Welding P a r a m e t e r s

Code Current Speed Ileal Input (Amp) (ram/s) (k.I/mm)

E 425 7.00 1.07 F 425 4.75 2.9 I G 425 3.70 3.73 1 625 1(I.83 1.87 D 625 7.00 2.90 C 625 5.45 3.72 H 8(10 13.90 1.87 J g00 g.90 2.92 K 800 7.00 3.71

age, the flux was heated in a drying oven at 35(l°C for 2 h just before use. The approximate composi t ion of the flux constituents is shown in Table 2.

Weld Preparation

J o i n t G e o m e t r y - - The plates were ground to a bright metal finish befl~re depositing the beads. Single-pass, bead-in- groove welds were made on 22-mm-thick, 360- x 150-mm steel plates using submerged arc welding (SAW). A SAW machine in constant voltage mode carried out the welding. The joint geometry used for carrying out the test welds is shown in Fig. 1. The run-on tabs allowed enough time to adjust welding current and voltage, while the run-off tabs pre- vented crater formation within the actual weld of interest. Thus, for each deposit, 300- mm-long deposits of acceptable quality could be achieved.

W e l d i n g P a r a m e t e r s - - A series of s u b -

merged arc welds was produced using a range of heat inputs from 2 to 4 k J/ram at varying current levels from 425 to g()0 A. Since a large amount of mechanical, metallurgical, and chemical characterization work w a s to be done, nine welds were selected from a number of exper imenta l welds. The basis for selection was to include as wide a range of welding speeds as possible. The nine welds selected for analysis represented three heat input levels at three current levels, as illustrated in Table 3. This selection made it possible to study the proper t ies of var ious welds under isoheat input condit ions but with different combinations of individual welding parameters , specifically current and speed. Submerged arc welding was performed using direct current , e lec t rode positive with an initial electrode extension of 22 ram, under constant voltage. Weld- ing voltage was kept constant at 32 33 V fl~r all welding trials.

Characterization of the Welds

The prepared welds were separa ted from the run-on and run-off tabs. The separated welds were used for chemical elemental analysis including oxygen content, quant i ta t ive meta l lography, inclusion characteris t ics , and weld bead morphology.

Chemical Analysis - - Chemical composition of the as-received base plate and core wire were obtained using an emission spec t romete r for the e lements man- ganesc, silicon, nickel, chromium, copper, wmadium, and phosphorus and using an interstitial combustion analyzer for carbon and sulfur. Oxygen and ni t rogen analysis of the samples was carried out using an infrared oxygen analyzer. The samples for oxygen and nitrogen analysis were taken from the center of the welds and carefully machined using a cooling solution into small cylindrical specimens 2 mm in diameter and 5 mm in length. The chemical analysis, including oxygen, was the average of three results.

Q u a n t i t a t i v e M e t a l l o g r a p h y - - O u a n -

t i t a t i v e metal lography was carried out using an inverted microscope at tached with an image analyzer. The experimental welds were sectioned transverse as well as

inclined to the wcMing direction for metallographic examination, as shown in Fig. 2. Sectioning of the samples for quantitative metallography was done near the middle of the length of the weldment, at two different locations. Due to distortion during sectioning, the measu remen t on a transverse section may not give the true prior austenitic grain size. Therefore, inclined sections, perpendicu lar to the columnar grains, were prepared and approximately equiaxed austeni tc grains were observed and measured. The size of the prior austenile grains w a s measured by tracing ahmg individual grains and measuring the enclosed area using a computerized image analyzer. More than 100 prior austenite grains were measured from 5 to I(I different fields for all the individual welds. The specimens were mechanically polished to a 0.25-p diamond finish in an

P.Egl~'] NOVEMBER 2002

Inclined _ ~ 7 ~ ............................. ,......i~)/.... STT: ti;ir s e Z~/'"" ~ ~ ' \ _ \ i""";] ........... section ~ .................

~ Cl (Fusion Zone Boundary Length)

(Nugget Area)

k~g. 2 - - Sctwmatic showing the sample prelmratiun Jor microstructurul characterization. (Inclined section - - prior austenitic grain size determination; t r a n s v e r s e s e c l i o l l I m i c r o x l r b t c l l o ' a l o b s e r v a t i o n .

k~g. 3 - - Schematic o f weM bead s/towing dij]k'rent bend morphologies.

Table 4 - - Chemical Composition of Experimental Welds

Code C Mn Si S P Ni

E 0.077 (I.77 0.22 0.009 11.1/20 2.47 F I).055 1/.77 0.21 0.006 0.020 2.611 G 0.054 0.78 0.19 0.007 11.023 2.41 I 0.1170 0.76 0.22 0.(1115 0.(121 2.50 D 0.0(:,4 0.73 0.23 0.006 0.019 2.47 C 1/.1163 0.75 I).24 0.006 0.020 2.46 H 11.1175 0.77 0.25 0.t)05 0.016 2.31 J 0.1165 0.77 11.23 0.005 0.018 2.61 K 0.064 0.77 0.22 0.0115 0.018 2.63

Cr Mo Cu O N P~m (ppm) (ppm)

11.24 0.25 0.47 394 146 0.216 0.23 0.25 0.47 335 l 17 0.195 0.22 0.25 0.45 378 130 0.189 (I.25 0.26 0.51 454 127 (/.212 0.26 0.25 1/.49 404 124 0.203 0.24 0.25 0.49 340 136 0.203 0.24 I).25 11.50 457 161 0.214 0.27 0.26 0.45 403 126 0.208 0.24 0.25 0.47 383 140 0.206

automatic polisher. The weld metal nfi- crostructure was revealed by etching with a freshly prepared 2% nital solution. The volume fraction of different microstructural constituents, namely, grain boundary ferrite (GBF), polygonal ferrite (PF), ferrite side plate (FSP), and acicular ferrite (AF), were obtained from more than 500 point counts carried out at a magnification of 500X on a transverse section.

Inclusion A n a l y s i s - - Measurement of volume fraction of nonmetallic weld metal inclusions was carried out on transverse sections of the welds. The polished samples were observed without etching at 1500X magnification under an optical nil- cmscope attached with an image analyzer. More than 500 inclusions from various fields were taken for quantitative analysis. Due to limitations in the accuracy of detection levels of the optical microscope, inclusions having a diameter of less than 0.20/a were not considered for analysis.

Weld N u g g e t M o r p h o l o g y - - T h e morphology of the weld nuggets was measured from samples in the direction transverse to the welding direction. Sectioning of the samples was done at the center of the length of the weld nuggets. Nugget morphologies were measured by tracing an en- larged (10X) image of the polished and maeroetched section of the weld profile using a profile projector. The various nugget morphologies measured, as per the schematic of weld bead dimensions shown in Fig. 3, were nugget area (NA) mm 2 and fusion zone boundary length (C l) nun.

Resul ts

Weld Chemical Analysis

The chemical compositions of the experimental welds are given in Table 4.

Weld Bead Morphology

The weld nugget morphologies have been tabulated in Table 5. It is assumed the weld nugget cross section is the same throughout the weld length. Hence, the nugget area (NA) (considering unit length of weld) can be assumed to represent the amount of metal fused and the amount of heat to be extracted by the surrounding base metal. In SAW, the cooling of the weld essentially takes place due to the surrounding base metal and, therefore, the fusion zone/HAZ boundary length (C1) (again considering unit length of weld) can be assumed to represent the area through which the heat is transferred. It has been observed that with an increase in current, at each of the three heat input levels, the nugget area increases I Fig. 4. The fusion zone boundary length (C1) was observed to increase with current at all heat input levels (Fig. 5) except at the highest current and highest heat input combination.

Prior Austenite Grain Size (g)

The variations in austenitic grain sizes (g) with current under isoheat input con-

ditions are listed in Table 5 and shown in Fig. 6. It should be noted the values given are the average of about 100 measurements from different fields done on each weld. Typical micrographs with clearly de- lineated prior austenite grains are shown in Fig. 7A-C.

Volume Fraction of Various Phases

Classification of various phases present in the weld was done by IIW method, based on the recommendations of Abson and Par- geter (Ref. 10). The different phases identified and quantified were acicular ferrite, grain boundary ferrite, polygonal ferrite, and ferrite side plates. From the results (Table 6), it can be seen the volume fraction of AF, in general, is quite high and varied between 67 and 84%. It is interesting to note (Fig. 8) that acicular ferrite content shows significant differences in dependence on the welding current although heat input remains the same. This is particularly so at higher levels of welding current at which the weld bead morphology is likely to change significantly due to increased penetration. This is likely to affect cooling rate significantly, as will be explained later, and, hence, AF content. The microstructures showing various phases of the welds are shown in Fig. 9A-C.

Inclusion Analysis

Inclusion analysis was done using an optical microscope coupled to an image

WELDING J O U R N A L P~! ! i~ l

WELDING RESEARCH

2 0 0 4 0

tSO

160

~ 140

~ 120

't~ tO0

Z 811 [3-----'-----

60 J I I ................ •

4 0 0 5 0 0 6 0 0 7 0 0 8 0 0 9 0 0

Cun*e nt ( A r a p . )

..e- 1 . 9 k J / m m "~" 2 . 9 k J / m m ~ 3 . 7 k J / m m

Fig. 4 - Hlriation of mtg.get area with current under isoheat inlmt conditions.

3 5

A E g 30

2 5

2 0

/ /

4 0 0 5 0 0 6 0 0 7 0 0 8 0 0 9 0 0

Current (Amp.)

Fig. 5 - - Variation q f li~sion zone boundary let gth (C I ) with cun'ent under isoheat input conditions.

Table 5 - - Bead Morphology and Prior Austenite Grain Size of Experimental Welds

Code Nugget Area Fusion Zone Grain Size NA (mm:) Boundary Length (p.)

CI (mm)

E 72.4 22.1 99.3 F 102.11 26.7 131).(} G 120.2 28.2 155.5 1 80.6 25.2 95./I D 124.11 27.6 135.7 C 177.5 34.8 146.9 H 100.8 26.5 89.11 J 127.11 30.5 110.11 K 181.4 32.3 132.0

Table 6 - - V o l u m e Fraction of Various Microstructural Phases and Inclusion Analysis in Experimental welds

Volume fraction of various phases (%) Code AF GBF PF FSP Inclusion S i z e Volume Pcrcent

(3-D), dv(p) (3-D), f(%)

E 77.6 17.2 1.6 3.6 11.495 11.011146 F 70.6 22.6 2.11 4.8 11.5114 0.11t1148 G 67.0 27.2 1.0 4.8 1/.547 0.00229 I 73.8 19.1 3.1 4.0 1).43g 0.110264 D 71.6 21.2 2.4 4.8 11.485 11.0017 I C 68.0 25.1 2.6 4.3 11.495 11.011158 H 79.7 16.4 2. I 2.8 11.458 /I.I)11235 J 84.0 14.0 1.0 1.0 0.476 0.110137 K 76.7 18.0 3.1 2.2 0.505 0.1)0124

analyzer. However, the photographs shown in Fig. 10A-C are SEM images of the polished and tmetched surface of the weld cross section showing the presence of inclusions. The measured size (average diameter) and volume fraction of inclusions are as listed in Table 6 and graphically shown in Fig. 1 IA-C. There is a distribution of inclusion sizes. Further details on inclusion distribution will be discussed in a subsequent paper primarily focusing on the aspects of weld metal inclusions. The term 3-D means inclusion analysis done in three dimensions, i.e., volumetric. It is well known formation of intragranular acicular

P~fiP~'! N O V E M B E R 2002

ferrite crucially depends on the presence of an optimum amount of inclusions. It is seen from the figures the inclusion content significantly differs in welds made under isoheat input conditions but with different combinations of current and speed.

D i s c u s s i o n

It is well established (Refs. 5-8) that the toughness of ferrous welds is dependent on the presence of a microstructure predominantly consisting of intragranularly formed acicular ferrite (AF). This is because of a basket-weave-type morphology, 1-3 #.t in

size, with high angle boundaries and random orientation. This morphology makes the AF inherently resistant to crack propagation (Ref. 8) and to have low transition temperature values. On the other hand, presence of large proportions of upper bainite, ferrite side plates, or grain boundary ferrite are considered to be detrimental to toughness. These structures provide easy crack propagation paths, especially when continuous films of carbides are present between ferrite laths or plates.

The final microstructure developed as a result of welding is principally governed by the relative position of the continuous cooling transformation (CCT) diagram for the particular weld metal and the actual weld cooling curve. The position of the CCT curve will depend on the carbon content, percentage of hardenability elements, prior ygrain size, and the presence of inclusions. It should be noted, in general, the role of hardenability elements is to delay the transformation (shift the CCT curve to the right). On the other hand, an increase in inclusions favors the transformation (shift the CCT curve to the left). The higher the prior austenite grain size, the more the CCT curve will be shifted toward the right and vice versa. For a given weld composition and cooling rate, the type of microstructure will essentially depend on the level of inclusions and prior y grain size. Thus, development of a weld microstructure is a result of complex interaction between the material being welded, its thickness, and different welding parameters, as schematically depicted in Fig. 12. It should be stressed the overall conditions required to obtain predominantly AF structure lie in between those that promote martensite and bainite type of transformation (faster rate of cooling and shifting of cooling CCT curve to longer periods) and those that promote formation of a (slower cooling rate and shorter periods). It is apparent conditions

160 150

140

130

1 2 0

N 0 110 (o lOO

90 ~9 80

70 400

L i B i

500 600 700 800 C u r r e n t ( A m p . )

"~ 1.gkJ/mm -~'2.9kJ/mm "~3.7kJ/mm [

900

Fig. 6 - - Variation o f prior austenitic grain size with current under isoheat input conditions.

8 5

8O

E .~ 75

8 ~ 7o

6 5

400 500 600 700 800 900

Current (Amp.)

[ ~ 1 .gkJ/mm "~" 2 .gkJ /mm * 3 . 7 k J / m m / i

k J

Fig. 8 - - Variation o f acicular ferrite content with current under &oheat input conditions.

Table 7 - - Interdependency of Factors

NA/C1 Ratio Prior y Grain Size, Inclusion vol. ft., Inclusion Size, g (mm) f (%) dv (la)

NA/C1 ratio 1" - - 1" ,[. 1"

Prior y Grain Size 1 ̀g(mm)

Inclusion vol. fr.,l" f(%)

Inclusion Size, 1" dv (~t)

J, "r

Fig. 7 - - Micrographs showing prior austcnite grains. A - - Weld H (IOOX); B - - Weld C (IOOX); C - - Weld G (63X).

for maximizing A F require optimization of various interrelated parameters.

In the present case, variation in the weld compositions obtained during various welding trials was not significant (di-

lution varied between 50 and 60%) except in the case of carbon content. The minimum carbon content was 0.054% (Weld G) and maximum 0.077% (Weld E). How- ever, for most of the welds, carbon content was between 0.063 and 0.075%. An increase in carbon content is known to shift the CCT curve to longer times. However, this effect has not been considered significant as compared to other parameters because the differences in the carbon contents of the welds are not very large, especially in view of the presence of other alloying elements that contribute to hardenability. Thus, the CCT curve, as far as the role of hardenability elements are concerned, can reasonably be assumed to be fixed. Hence, one needs to essentially consider the prior austenite grain size and the volume fraction of inclusions found in different welds, both of which showed substantial variations in different welds (Ta- bles 5, 6).

Last, but not least, the actual cooling rate experienced by the weld should be considered. It is important to know in studying the effect of welding parameters, for convenience' sake, the parameters are usually combined and expressed as heat input. This approach, although practical, may not reflect the individual effects of the various welding parameters, which could be signifi-

cant and might vary under identical heat input conditions. This important aspect is clearly seen in Figs. 4-6, 8, and 11, wherein there is significant difference in the results (nugget parameters, ~/grain size, etc.) obtained under identical heat inputs but with different welding current and speed combinations. This implies the cooling rate the weld experiences may not have a monoto- nic dependence on heat input, especially when the welding current is high.

From Fig. 4 and Table 5, it is clear with an increase in current there is an increase in NA. The NA will depend on penetration and the factors that tend to increase width and reinforcement. At the highest heat input, a sharp increase is also noted in NA when going from 425 to 625 A. However, from 625 to 800 A, the change is not significant. Thus, it is seen under constant heat input conditions a wide variation in nugget area is obtained and the variation increases as heat input is increased. Under these conditions, it is unrealistic to expect similar weld metal properties when the same heat input but different welding current and speed combinations are used.

Dependence of Heat Extraction from FZ on the Weld Nugget Morphology

Empirical expressions for weld cooling

WELDING JOURNAL P.,SKE..1

WELDING RESEARCH

Fig. 9 - - A - - Micrograph showing GBF in Weld E (250X); B - - micrograph showing FSP in Weld G (500X); C - - micrograph showingAF in Weld J (]O00X).

Fig. 1 0 - - Micrographs showing weld metal inclusions. A - - Weld I (3000X); B - - Weld G (3000X); C - - Weld K (3000X).

rate available as thick and thin plate solutions (Refs. 9, 11) do not take into account the effect of the wide variety of nugget morphologies obtainable under the same heat input but with different welding speed and current combinations. These solutions do not agree with the actual weld cooling rates measured (Ref. 12). A simple approach is presented here introducing the concept of NA/C1 ratio (Ref. 13). In the conventional approach, the cooling rate is qualitatively thought to be directly proportional to the effective plate thickness and inversely proportional to the heat input. In the present approach, the cooling rate the weld actually experiences is thought to be related to NA/C1. With increasing current at constant heat input, welding speed is required to be increased proportionately. This leads to an increase in the dimensionless operating parameter, n, given by n = H l x v2/k; where k is a material-related constant involving thermophysical constant properties (Ref. 14). It is

established that, with increasing n, weld NA increases. Obviously, melting efficiency will increase for the same heat input. Note the operating parameter is proportional to the square of the welding speed at any given heat input.

As defined earlier, nugget area (NA) quantitatively represents the amount of heat required to be dissipated by the surrounding substrate metal and will depend on heat input in the conventional sense. C1, on the other hand, represents the FZ/HAZ interface available for conduct- ing away the heat that accumulates in the fusion zone. For cooling rate estimation, it is common practice to evaluate effective plate thickness, heat input, thermal diffu- sivity of the material, and joint geometry. Based on the value of this effective plate thickness, it is assumed the heat transfer in 2-D or 3-D and approximate solutions are used to estimate the cooling rate experienced by the weld. In the present approach, the ratio NA/C1 is proposed to

represent the cooling rate. Exclusions of thermophysical properties in this relationship are justified because the same material is being considered in all the welds.

The relationship is not expected to be linear but, with the assumptions made in defining NA and C1, it can be stated the greater the ratio, the lesser the cooling rate and vice versa. The positive feature of this approach is inclusion of the morphological feature of the weld nugget resulting from the particular combinations of welding parameters, which is not possible in the conventional approach (Refs. 13, 15). A plot of NA/C1 vs. current at various heat inputs is shown in Fig. 13. It is clearly unreasonable to expect identical cooling rates for welds prepared with the same heat input but different current and speed combinations.

Maximization of Aeieular Ferrite in Microstructure

Development of a weld microstructure consisting predominantly of intragranularly formed acicular ferrite (75% or more) (Ref. 16) has always been the aim when welding carbon and low-alloy steels. It is generally accepted (Ref. 17) achievement of the above depends on favorable disposition of interdependent factors such as the following: prior austenite grain size, presence of optimum volume fraction of potent nucleation sites such as inclusions 0.2-0.5/1 in size, fusion zone chemistry with respect to hardenability elements, and cooling rate actually experienced by the weld. On cooling, the austenite trans- forms to a variety of micromorphologies as follows (approximate transformation starting temperatures are in parentheses): grain boundary ferrite (-800°C), ferrite side plates (-750°C), polygonal ferrite (-750-650°C), and acicular ferrite (-650°C) (Ref. 7). In addition, a variety of residual phases (Ref. 18), referred to as microphases, consisting of small amounts of martensite, retained austenite, and de- generate pearlite, also form. Usually the transformation to ferrite morphologies is quite efficient and the total amount of residual phases not significant. Since cooling is continuous, the final microstructure will contain many of the previously mentioned phases with the volume percent distribution of each phase decided by the particular combination of interrelated factors mentioned earlier that exist during welding. As suggested in a recent work (Ref. 19), it is useful to visualize a small region in the weld CCT diagram called the acicular ferrite window. If the actual weld cooling curve passes through the fair portion of this window, then acicular ferrite will be maximized. The position of this window will be decided by the first three factors mentioned earlier - - Fig. 14. It should be remembered Fig. 14 is just a schematic

P,,~515."! NOVEMBER 2002


A 0 .56

0 .54

~ 0 .52

.~ 0.5

0 . 4 8

~ 0.46 t -

0 . 4 4

0 .42

400 9 0 0

.......................................... L t •

500 600 700 800

C u r r e n t ( A m p . )

/ ~ 1 . 9 k J / m m o 2 . 9 k J / m m ~ - 3 . 7 k J / m m ]

B

2 . 5

I,i.

_E ~- 1.5 "6

1

4OO

I I . . . . . . . . . . 1~ 1

500 600 700 800 900

Current (Amp. )

Fig. 11 A ¼o'iation o f inelusion size with current under isoheat input conditions; B - - variation o f inehtsion volume fi'action with current under isoheat input conditions.

t ................

• Plait t rrent

6

5.5

o 5

4.5

~ 4 z

3 . 5

3

/ /

400 500 600 700 800 900

Current (Amp.)

lV~, ,. 12 - - The various factors" that t)lay a role in deciding weld microstrueture. F(~{. 13 - - Plot o/" NA/C1 ratio with current under isoheat input eomlitions.

representation of an ideal situation. The key to maximizing acicular ferrite is for the actual weld cooling rate to aw)id the FSP formation zone as far as possible. This is because once FSP is nucleated, it grows at a rapid rate with the growth terminating on soft impingement with other FSP by acicular ferrite. Since all these factors are related to the welding parameters, in principle it should be possible to determine, for a given set of conditkms, optimum parameter settings for maximizing acicular ferrite. However, it is essential to first obtain correlation between factors that are responsible for the metallurgical phenomena leading to acicular ferrite formation.

Prior Austenite Grain Size (g)

It is well established (Refs. 20-22) that a minimum prior austenite grain size is required below which formation of acicular ferrite is not favored. The primary reason is the greater availability of grain boundary nucleation and growth sites for the high- temperature diffusional transformation products, i.e., GBE By the time the kinetics of these reactions slow down parabolically, limited nontransformed austenite is avail-

able for the low-temperature displacive process of forming acicular ferrite leading to an inadequate volume fraction of the desirable phase (Ref. 6). As the grain size increases, R)rmation of acicular ferrite is encouraged, provided other factors are favorable. However, above a particular grain size, formation of AF is discouraged due to shitting of the CCT curve to longer times leading to lower temperature transformation products such as bainite and martensite (Ref. 16). The available infor- marion suggests an optimum size; however, that would depend on other factors, it has been reported for a certain weld chemistry (low Ti-B welds of low C steels), optimum values lie in the range of 20-60 it (ReE 17). From Fig. 6, it is clear prior austenite grain sizes can be significantly different under the same heat input but with different current and speed combinations. This is more pro- nounced at higher heat inputs. It should also be remembered the size would also depend on the cooling rate represented by NA/CI and inclusion volume fraction. Lower values of the former and higher values of the latter should lead to smaller grain size. Under isoheat input conditions (Fig. 6), the prior 7grain size decreased with

an increase in current level. This indicated fl)r welds made with identical heat inputs but different combinations of welding current and speed, the resultant microstructures may not be the same because the prior y grain size influences the microstructural transfl)rmation to a great extent. This will definitely have its effect, in turn, on the final mechanical properties of the weld metal.

Volume Fraction of Inclusions

It is well established (Ref. 17) that prcs- ence of an adequate amount of inclusions of sizes greater than (/.25 p is necessary to allow the intragranular formation of acicular ferrite. Controversy exists (Relk 22, 23) as to whether the potency of these inch> sions depends on their chemical nature or whether they merely provide inert surfaces to enable the nucleation of the acicular ferrite. However, the following are clear as far as the role of these inclusions:

a) There is no possibility of obtaining any acicular ferrite in the absence of inclusions.

b) The inclusion size should be in the range of 0.25 to (I.50 microns.

c) Inclusions at the grain boundaries have a dual role to play, i.e., smaller ones

I WELDING JOURNAL


I CULAR A C I

I formers K ~ FERRITE w'"°°w

, . . . . . . . . . . . . . . . . . . . .

i ACjCuLAR i i FERRITE i [coolinll rat~

CR2 CRI

l o g t ,......-~

Fig. 14 - - Schematic showing the position of the acicular ferrite window and CCT diagram with respect to alloying element~, austenite grain size, and cooling rate.

8 5

A 8 0 ~e

75

70

6 5 I I I I

3 3 . 5 4 4 . 5 5

( N A / C 1 ) r a t i o

[ _ _

5 . 5 6

• L O W & M e d i u m C u r r e n t ( ~ H l g h C u r ~ e n t ( 8 O O A ) 4 2 5 & 6 2 5 A )

Fig. 15 - - Variation o f acicular ferrite content with NA/C I ratio.

9 0

8 5 A

.~ 8 0

7 5

ca ~ 7o

6 5

0 . 1 5

r z : 0 .67

N A / .... •

I _ I I L L

0 . 1 6 0 . 1 7 0 . 1 8 0 . 1 9 0 . 2 0 . 2 1

Fig. 16 - - Correlation o[ acicular ferrite content with NA/C1 ratio and prior austenitic grain size.

restrict grain growth and larger ones encourage nonacicular ferrite transforma- tions (both these events are detrimental to the final microstructure formed).

d) The above leads to an upper limit to the desired volume fraction of inclusions.

e) The greater the volume fraction (less than the upper limit), the smaller the interinclusion distances will be and the finer the acicular ferrite plates.

f) Several plates of acicular ferrite can form per inclusion.

As in the case of other metallurgical factors, inclusion characteristics, namely, inclusion size and volume fraction, significantly depend on the welding current and speed combinations used even though carried out at same heat input (see, respectively, Figs. l l A , B). It is seen from these figures and Table 4 there exists some correlation between oxygen content in the weld and inclusion volume fraction, especially at medium and higher heat inputs.

Cooling Rate

Weld cooling rate plays the decisive

role in determining weld microstructure. The general effect of increasing the cooling rate is to lower transformation temperatures. When cooled at sufficiently low rates, the microstructure predominantly tends to become polygonal ferrite- pearlite. As the cooling rate is progres- sively increased, there is a tendency for the polygonal ferrite to be refined and become limited to the prior austenite grain boundaries (Ref. 24). This morphology is often referred to as grain boundary al- lotriomorphs. Increased cooling rates also reduce, and eventually eliminate, the pearlite phase. The weld microstructure can also show Widmanstatten side plate morphologies that grow out of the large polygonal ferrite grains at low cooling rates or out of the grain boundary allotri- omorphs at higher cooling rates. An increased cooling rate tends to increase the ratio of side plates to polygonal ferrite in the final microstructure. It is useful to remember kinetics of side plate growth, which is a displacive phenomena and relies on the instability of the austenite/ferrite interface, is extremely fast as corn-

pared to the diffusion-limited parabolic growth rate of grain boundary ferrites. At intermediate cooling rates, provided inclusions are present, intragranular formation of acicular ferrite is encouraged. At still higher cooling rates, the lath ferrite structure, consisting of colonies of parallel laths of ferrite separated by retained austenite or carbides, dominates. Finally, at the highest cooling rates, depending upon the hardenabil i ty elements, lath martensite is formed.

Recall, in the present work, cooling rate is represented by NA/C1 and, from Fig. 15, it is clear, at the same heat input, obtaining significantly different microstructure is possible depending upon t h e w e l d i n g c u r r e n t a n d s p e e d combination.

Interdependency of the Factors

It is useful to discuss the interdependency between the three factors discussed previously. It should be noted fusion zone chemistry has not been discussed because it is assumed, since there has not been sig-

NOVEMBER 2002 I

WELDING RESEARCH 9 0

8 5

8O "E ,,=

75

~ "/0 >

65 0,29

r 2 = 0 . 8 2

( NA I ....

%AF = 2 1 I x ~ - J

l 0.3

I J

o.31 o.a2 o.aa o.a4 o.a5 o.ao oat o.as o.a9

°141 gO.4l x fO.l I J

Fig. 17- - Correlation o/'acictdar /~,n'ite content as a fimction of NA/C1 ratio, prior auslenilic ,gram size, aml inclusion volume j)'action.

i 75

1 70

65

..--...I

, / ' ' " " "'"t

! I

",.

I I _

0.42 OA4 0.46 0.48 0,5 0`52 0`54 0.58

Fig. 18 - - Variation o/'acicular ferrite co#uent with mean inclusion size.

nificant variation in them, with the limited experimental data generated, the discussion will be of a qualitative nature based on basic principles of the welding process. Table 7 shows the matrix of the factors discussed and indicates how each can influence the other.

For higher NA/CI, cooling is slower so the weld will spend a longer time at higher temperatures, leading to larger austenite grain size. At the same time, there will be greater chance for the inclusions to be absorbed by the slag leading to a drop in the volume fraction of inclusions. Fur ther- more, the average size of the inclusion is likely to be larger. It is unlikely prior austenite grain size is likely to influence the other factors. With respect to inclusion parameters, greater w)lume fraction will lead to a greater presence of inclusions at the grain boundaries, some of which can act as grain pinning agents and lead to reduction in grain size. As the inclusion size increases, prior austenite grain size will tend to increase because of lesser pinning potent ia l . It is clear from the previous quali tative s tatements , the cooling rate represented by NA/C1 will have a domi- nant role to play in deciding the nature of weld microstructure as it appears to affect all the other factors affecting the ultimate weld microstructures.

Dependence of Correlation between Different Factors Responsible for the Formation of Acicular Ferrite

Since NA/CI appears to play a domi- nant role in deciding the microstructure, the percentage of acicular ferrite as a function of NA/CI was plotted as in Fig. 15. It was found necessary to fit the data points cor responding to higher current separately from the data points corresponding to low and medium currents. The figure also shows, for similar cooling conditions, a higher volume fraction of AF

is obtained at high currents . This could be related to the fact at higher currents the weld pool is subjected to significantly greater convective flow since the con- t r ibut ion by elec- t romagnet ic stir- ring effects is larger. This can have an effect on the inclusion characteristics leading to different microstructures.

To remove the above separation, other factors, namely, prior austenite grain size (g) and volume fraction of inclusions, were incorporated one by one. The first correlation (Fig. 16) was obtained by performing regression analysis between the percentage of acicular ferrite and the combination of NA/C 1 and g. The following correlation was then obtained:

NA / °> ( ' ~ a v = 4o5.s x t c i )

(g)o4~

s s r ~ = 0 . 9 0 • !

. . . .

%AF = 3 2 9 x ~ = • / . - i

~'°l I ' 1

65 i ~ t l l t J

0.19 0.2 0.21 0.22 0.23 0.24 0.25 0.26

g0.44 x f,0.043 ]

/~ig. 1 9 - Con'elation of acicular ferrite content with NA/CI ratio, au,stenite grain size (g), and modified volume.fizwtion qf inclusions (f').

(1)

The correlat ion was not a good one since r 2 was only 0.67. An improvement to r 2 = 1.).82 was observed by including the volume fraction of inclusions (f) - - Fig. 17. The improved relationship was

~. VA )o.14

% A F = 2 1 1 × v ~1 (2) × (r)""

To further improve the correlat ion, help was taken from the fact there is a critical range of inclusion size that is likely to be most potent (Ref. 25). From Fig. 18, it can be seen volurne fraction of AF is maximized when the sizes of the inclusions are within a range of 0.44 to 0.5 p_. O11 performing regression analysis between % A F and the combination of N A / C I , g, and.f/ represent the modified volume fraction of inclusions (only inclusions between 0.44 and 0.5 ~u were considered), a higher r 2 value of 1.).90 was obtained - - Fig. 19. The ultimate relationship obtained was

I NA ) Ill7

% A F = 329 × C1 (3) o<,4

The correlation shown in Equation 3 appears to be reasonably acceptable considering the complexity of the processes involved. The practical utility of the corre-

I W E L D I N G J O U R N A L i

WELDING RESEARCH lation can only be realized when the same can be represented in terms of welding parameters. Each of the terms appearing in Equat ion 3 has been correlated with welding current and speed (Ref. 13). It was then possible to correlate the A F content with welding parameters. That will form the subject of a subsequent paper. The utility of this correlation for setting up the practical welding parameters appears to be restricted as it involves sectioning of the weld. However, this correlation can serve the purpose of giving starting welding parameters for similar grades of steel substrates and consumables. The magnitude of exponents of the various terms in Equa- tion 3 are possibly indicative of the allow- able tolerance of the three main factors responsible for obtaining a given level of A F content in the weld microstrueture. Prior austenite grain size appears to be most critical as indicated by a relatively high value of exponent 0.44 as compared to other exponents. A very small value for the exponent on inclusion volume fraction (0.043) does not mean that without the inclusion it is possible to obtain any intragranular ly fo rmed AF. All it possibly means is a wide range of inclusion content is acceptable to get the desired A F content in the weld microstructure.

Conclusions

From the present investigation, it is seen significant variations in bead morphology and weld microstructure can occur under identical heat input but with different current and travel speed combinations. From the present investigation, the following major conclusions can be made.

1) Depending upon the welding current and travel speed combinations used, significantly different dependence of all the influencing parameters were observed even though heat input was the same. This can be attributed to differences in the weld bead morphologies. Different weld bead morphologies are likely to lead to different weld cooling rates that will affect the microstructure by itself and also different microstructural features, e.g., austenite grain size, inclusion parameters , that, in turn, will further contribute to the final AF content.

2) A new cool ing pa ramete r NA/C1 was found to be a useful representation of the actual weld cooling rate. Rosenthal 's work on moving heat source allows express ion of the cool ing rate based on quant i t ies that can be measured /de te r - mined prior to welding (plate thickness, heat input, preheat, etc.). But it need not necessarily represent the true cooling rate because of the empirical nature of defining the heat transfer situation and also in not taking cognizance of the actual bead morphology that forms.

3) Using multiple regression analysis along with other interdependent factors, a correlat ion between acicular ferrite and the influencing parameters was obtained with a high degree of correlation coeffi- cient. From the magnitude of the exponents of the various terms in the correlation derived, it appears prior austeni te grain size is the most critical factor. On the other hand, the low value of the exponent on inclusion volume fraction suggests that, although necessary, some variations in the inclusion volume fraction can be tolerated to obtain a desirable A F content . The magni tude of the exponent on factor NA/C1, which represents the true cooling rate, is i n t e rmed ia t e and indicative of grea ter to lerance than that al lowed for prior austenite grain size.

4) The correlation has been derived on the basis of sectioning of the welds. How- ever, the correlation can serve the purpose of obtaining starting welding parameters for similar grades of steel substrates and consumables. For this it is necessary to establish the corre la t ion be tween various factors and welding parameters (Ref. 13).

5) The full utility of this correlation derived for the present combination of steel substrates and consumables can be realized if realistic mathematical modeling of weld bead morphology, i.e., NA/C1 ratio and micros t ruc tura l fea tures like prior austenite grain size and inclusion volume fraction can be performed.

Relerences

1. Dixon, B., and Hakansson, K. 1995. Effect of welding parameters on weld zone toughness and hardness in 690 MPa steel. WeMing Journal 64(4): 122-s.

2. Oldland, P. T., Ramsay, C. W., Matlock, D. K., and Olson, D. L. 1989. Significant features of high-strength steel weld metal microstructures. Welding Journal 58(4): 158-s.

3. Smith, N. J., McGrath, J. "E, Giaqetto, J. A., and Orr, R. E 1989. Microstructures/ mechanical property relationships of submerged arc welds in HSLA 80 steels. Welding Journal 58(3): 112-s.

4. Gianetto, J. A., Smith, N. J., McGrath, J. T., and Bowker, J. '12. 1992. Effect of composition and energy input on structure and properties of high-strength weld metals. Welding Jour- nal 61(11): 407-s.

5. Farrar, R. A., and Zhang, Z. 1995. Aspect ratios and morphology of acicular ferrite in C- Mn-Ni weld metals. Materials" Science ~'chnology 11: 759.

6. Ricks, R. A., Howell, P. R., and Barritte, G. S. 1982. Nature of acicular ferrite in HSLA steel weld metal. Journal of Materials Science 17: 732.

7. Abson, D. J., and Dolby, R. E. 1978. Weld Inst. Res. Bull. 19: 202-207,

8. Bhadeshia, H. K. D. H. 1991). Proc. Conf

on the Metallurgy, Welding and Qualification of Microalloyed (HSLA) Steel Weldments. Hous- ton, Tcx., pp. 34-69.

9. Rosenthal, D. 1941. Mathematical theory of heat distribution during welding and cutting. Welding Journal 20(5): 220-s to 234-s.

10. Abson, D. J., and Pargeter, R. J. 1986. Factors influencing as-deposited strength, microstructure and toughness of manual metal arc welds suitable for C-Mn steel fabricators. Inter- national Metals' Review 31(4): 141-194.

11. Easterling, K. 1992. httroduction to Phys- ical Metallurg~ of Welding. Butterworth-Heine- man Ltd., p. 20.

12. Chakraborty, A. P, Thibau, R., and Bala, S. R. 1985. Cooling characteristics of bead-on- plate welds. Metal Construction (3): 178 R.

13. Basu, B. 21)00. Effect of welding parameters on the structure and properties of a submerged arc weld of a high-strength structural steel. Ph.D. dissertation, liT - Bombay.

14. Messier, R. W. 1999. Principles of Weld- ing Processes - - Physics, CTzemistry and Metal- lurgy. John Wiley & Sons Inc., A Wiley Inter- science Publication., p. 167.

15. Basu, B., and Raman, R. 2000. Influence of weld bead morphologies on the structure and properties of submerged arc weld metal. Paper No. WM-21, Symposium on Joining of Materials, Tiruchirapalli, India.

16. Farrar, R. A., and Harrison, P. L. 1987. Acicular ferrite in carbon-manganese weld metals: An overview. Journal of Mater Sci. 22(11): 3812.

17. Thewlis, G. 1994. Transformation kinetics of ferrous weld metal. Mater Science Tech. 2: 110-125.

18. Honeycombe, Sir. R., and Bhadeshia H. K. D. H. 1995. Steels - - Microstructure and Prop- erties, p. 280. London, U.K.: Edward Arnold.

19. Yelpale, P. S. 2000. Influence of the presence of active gas in shielding gas mixture on weld quality. M. Tech. dissertation. IIT - Bombay.

20. Grong, O., and Matlock, D. K. 1986. Mi- crostruture development in mild and low-alloy steel weld metals. Int. Mater Rev. 3111): 27.

21. Ferrante, M., and Farrar, R. A. 1982. The role of oxygen rich inclusions in determining the microstructure of weld metal deposits. Journal of Mat. Sci. 17: 3293.

22. Liu, S., and Olson, D. L. 1986. The role of inclusions in controlling HSLA steel weld metal microstructues. Welding Journal 55(6): 139-s.

23. Brooksbank, D., and Andrews, K. W. 1972. Stress fields around inclusions and their relation to mechanical properties. Journal of the Iron and Steel Institute, pp. 210-246.

24. Harrison, P., and Farrar, R. 1987. Mi- crostructure and toughness of C-Mn and C- Mn-Ni weld metal - - Part I. Metals' Construction 7: 392R-399R.

25. Mills, A. R., Thewlis, G., and Whiteman, J. A. 1987. The nature of inclusions in steel weld metals and their influence on the formation of acicular ferrite. Mater. Sci. Tech. 3: 1051-1061.

P,,~:lS='! NOVEMBER 2002

WELDING RESEARCH

Keyhole Double-Sided Arc Welding Process

A process is developed for deep joint penetration welding in a narrow groove on plate up to -in. thick

BY Y. M. ZHANG, S. B. ZHANG, AND M. JIANG

ABSTRACT. Double-sided arcing uses two torches on the opposite sides of the workpiece to force the welding current to flow through the thickness. If a keyhole is established through the thickness, part of the welding current will flow through the keyhole and maintain the electric arc inside the keyhole. It was found the through- thickness direction of the welding current and the establishment of a keyhole both helped enhance the concentration of the arc and the density of the arc energy. In addition, the presence of the arc in the keyhole provided a mechanism to directly heat the workpiece through the thickness, as well as a mechanism to compensate the energy consumed during heating. In this study, a double-sided arcing technique was developed into a welding process for deep, narrow joint penetration. Experi- ments confirmed the characteristics of this process.

Introduction

Productivity improvement is a major focus for the welding industry and its associated research community, especially in welding of thick materials. Improved methods and processes are required to weld thick materials in a single pass to optimize productivity. Currently the primary processes used for this are electron beam welding and laser beam welding. Both processes require close-tolerance joint fitup and are expensive to operate. Electron beam welding generally requires the use of a vacuum chamber and is, therefore, somewhat limited in application. Laser systems require high capital investment and have high operating and maintenance costs.

High capital investment, maintenance costs, and the positioning and fitup accu-

Y M. ZHANG (ymzhangQrengr.uky.edu), S. B. ZHANG, AND M. JIANG are with WeMing Re- search Laboratory, Center Jot Robotics and Manujacturing Systems and Department of Elec- trical Engineering, University of Kentucky, Lex- ington, Ky.

racy requirements (Ref. 1) are among the factors that weaken the laser's competi- tiveness compared to traditional arc welding processes in certain heavy industry applications. However, if the material is not so thick that the reduction in the number of passes is dramatic, the time needed for additional positioning and fitup adjustment due to the high requirement may not justify the high cost. Hence, for such applications, methods or processes that achieve penetration up to ~ in. and that leverage the advantages of conventional arc welding in terms of reduced fitup tolerance, standard operating procedure, personnel, and costs may provide competitive solutions.

One method that improves penetration is to spray a fluxing agent on the workpiece surface during gas tungsten arc welding to modify the flow in the weld pool (Ref. 2). Investigations have focused on experiments for suitable fluxing agents, which are typically mixtures of inorganic powders suspended in a volatile medium, for different materials. This method, referred to as flux-assisted gas tungten arc welding (GTAW), has found successful applications in pipe welding.

Another method to improve penetration in arc welding is to improve the energy density of the arc because energy density is the primary factor responsible for the penetration difference between laser/electron beam welding and arc welding. Research has been done to improve arc concentration by using magnetic means (Refs. 3, 4). However, in addition

KEY WORDS

Double-Sided Welding Keyhole Narrow Joint Narrow Groove Deep Penetration Thick Weldments

to the configuration complexity, the effect on arc concentration was found to be lira- fled. Hence, this study explores another method to improve arc concentration and arc energy density to improve penetration with arc welding.

Double-Sided Arcing

Tile proposed arc concentration method relies on a different arcing technique. As can be seen in Fig. IA, a regular arc welding system uses an electrical connection (workpiece lead) between the workpiece and the power supply to allow the welding current to complete a loop. The electric arc is established between the workpicce and the torch. However, if the workpiece is disconnected from the power supply and a second torch is placed on the opposite side of the workpiece to complete the current loop, as can be seen in Fig. 1 B, the electric arc can be simultane- ously established between the workpiece and each of the torches, as shown in Fig. 2, where torch one and torch two are for plasma arc welding (PAW) and gas tungsten arc welding (GTAW), respectively. Because the arc is established on both sides of the workpiece, this phenomenon is referred to as double-sided arcing (DSA), and the resultant welding process is referred to as double-sided arc welding (DSAW). Of course, the double-sided arcing phenomenon can be explained by established arc physics. However, it generates certain unique characteristics that are not associated with regular arcing processes.

An obvious characteristic is the direction of the current. Because of the connection between the workpiece and the power supply, the workpiece is an essential element of the current loop in regular arc welding. The current travels in the workpiece at directions approximately parallel to the surface of the workpiece. For example, in keyhole PAW, the majority of the welding current flows from the arc into the surface of the workpiece (Ref. 5). The keyhole is filled with an electrically

W E L D I N G J O U R N A L P.,~[.t,H..']

A

Electrode ~ ~

Plasma Jet /~ and Keyhole

B

Work

ZT

- /

Fig. 1 - - Schematic diagrams of wehling systems. A - - Regular welding system; B - - double-sided arc welding system.

Fig. 2 - - Double-sided arcing phenomenon. 7he workpiece is between the two arcs.

neutral mix of ions and electrons, and the welding current is absent in the keyhole. However, in the double-sided arcing process, the current has to flow through the thickness of the workpiece.

Although the through-thickness direction of the current is associated with different torch combinations (Ref. 6), the specific approach in this study is to use a combination of a PAW torch and a GTAW torch, as shown in Fig. 3, to establish a keyhole through the workpiece. A GTAW/ GTAW torch combination has been used to AC weld aluminum in a nonkeyhole mode. (Refs. 7, 8). It is known that the PAW torch has a constricting orifice such that electrons emitted from the tungsten electrode flow through the ionized plasma gas and form a highly constricted plasma jet. This plasma jet melts the workpiece and can displace the molten metal to form a keyhole or deep narrow cavity. There- fore, the PAW/GTAW torch combination may generate the keyhole double-sided arcing phenomenon.

When the keyhole is present, the ionized plasma gas flows from the PAW torch side to the GTAW torch side through the keyhole. Because the ionized plasma gas is an electric conductor, it provides a possible path for the current to flow through the thickness, as shown in Fig. 3. Another possible path of the current is through the metal around the keyhole. For the current to flow through the keyhole, the minimum voltage principle (Ref. 9), i.e., the current takes the path that minimizes the voltage drop, must be satisfied as the necessary condition.

Figure 4 shows the decomposition of the voltage drops for the two paths. If the current takes the metal path, the electrons emitted from the PAW torch's electrode must enter the metal and then re-emit from the bottom surface (the surface of the workpiece on the GTAW torch side). Therefore, the voltage drop will be

v= VEc +VcI+VwA+ VWC+Vc2 +VEA (1)

where VEC = voltage of electrode cathode; Vcl = voltage of arc column one; VwA = voltage of work anode; Vwc = voltage of work cathode; Vc2 = voltage of arc column two; and VEA = voltage of electrode anode. However, if the keyhole is the current path, the voltage drop will be

V = VEc +Vcl + V K + Vc2+VEA (2)

where V K is the voltage of the keyhole arc column. The minimum voltage principle can only be satisfied if the following condition is met:

V K < V w . 4 +Vwe, (3)

When the thickness of the workpiece, which is approximately the length of the keyhole, is given, the voltage across the keyhole column can be determined as

F K = E L K (4)

where E (V/mm) is the electric field and L K (mm) is the length of the keyhole column. Although E depends on a number of parameters , it is typically considered a constant when the current and the composition of the shielding gas are given (Ref. 9). For example, if the shielding gas is argon and the current is 200 A, E = 0.65 V/mm. Further, if the thickness is ½ in. (12.5 mm), V K = 8V. On the other hand, when the current and the shielding gas are 200 A and argon, respectively, the sum of the cathode and anode voltage drop is approximately 9 V. Hence, for materials ~ in. thick or thinner, the minimum voltage principle can be satisfied. As a result, it becomes possible for the keyhole to become an element of the current loop and for the electric arc to be present in the keyhole if the thickness is not greater than ~. in.

Arc Concentration and Energy Compensation

+1 Power Supply

Shielding gas nozzle Shielding gas nozzle ~ ]

we,dpo l l ye,ho,e . . . . . . . . .

\ ® . . . . . c _ ~ _ _ . / _ i ~ _ ~ i ~ i a ® ~ . . . . . . .

~ f i c e gas Shielding gas GTAWarcl . I ~,__' . . . . . "~-'~"~'~, • ~,. rlasma ~ l ' e ~;lllelOll'lg gas

GTAW Torch Workpiece PAW Torch

Fig. 3 - - Proposed welding system for keyhoh, DSA W..

Figures 5 and 6 show the arc behaviors for regular PAW and DSAW before and after the keyhole is established. Two phenomena can be observed from these figures. First, in comparison with regular plasma arc, the plasma arc in DSAW becomes much more concentrated despite the use of similar welding parameters. Second, after the keyhole is established, the plasma arc in DSAW is further concentrated while the regular plasma arc remains unchanged.

During DSAW, current has to flow from one torch to another through the workpiece, or the keyhole, as illustrated in Fig. 4. If the current flows through the workpiece instead of the keyhole, the elec-

NOVEMBER 2002

WELDING RESEARCH

A V (volt.) , ,

; ~ it p, a

2

~" "" ) L (ram)

Work fiece

B volt.) V I

d

r

i i i

' ' II ) L (nun)

:1 I t

GTA~V arc L ~ Plasma arc

Workpieee

Fig. 4 - - Voltage decomposition in DSA W A - - Nonkeyhole mode," B - - keyhole mode.

trons must exit from the workpiece through the cathode on the GTAW side surface of the workpiece to the GTAW electrode. Because of the large current needed for welding, the electrons tend to emit from the workpiece from an area rather than a small spot. Hence, the workpiece cathode is typically much less focused than the anode (Ref. 9). As a result, the GTAW arc in DSAW is much broader than the plasma arc.

Assume the radius of the workpiece cathode is 3 mm and the thickness of the workpiece is 10 mm. The radius of the plasma jet is approximately 1 mm. That is, the radius of the current flow increases by 2 mm through a 10-mm distance. The average diffusion angle of the current in the workpiece is thus a = Tan -l 0.2 = 10 deg. Because this diffusion angle is so small, the electrons can easily realize their transition in direction when they enter the workpiece from the plasma arc column. The trajectory of the electrons (current) in the plasma arc column is not affected by the workpiece. However, for regular PAW, the electrons have a nearly 90-deg transition in direction when they enter the workpiece. To realize such a large transition in travel direction, the electrons must change their direction prior to "landing" on the workpiece. The arc column in regular plasma arc welding, thus, must be subject to a divergence. Hence, the plasma arc in DSAW is much more concentrated than the regular plasma arc, as seen in Figs. 5A and 6A.

The establishment of the keyhole further enhances the concentration of the plasma arc in DSAW. After the keyhole is established, the current may take the keyhole as the path. In this case, the current

A P l a s m a a r c

I

Fig. 5 - - A r c behaviors before and after the keyhole is established during regular P A W The efflux plasma indicates the establishment o f the keyhole. Welding current: 120 A, diameter o f the orifice: 2.4 mm, flow rate o f the orifice gas (argon): 1.8 L/min. A - - Before; B - - after

flows through the keyhole without being affected by the workpiece cathode, the diameter of which is much larger than that of the keyhole. The plasma arc can thus be further concentrated. As can be seen, the diameter of the plasma arc in Fig. 6B is less than 70% of that in Fig. 6A. Hence, the density of the plasma arc is at least doubled after the keyhole is established.

As can be seen in Fig. 6B, the GTAW arc is still broad after the keyhole is established. This indicates that, although the electrons can flow through the keyhole to minimize the voltage, part of them actually flow through the workpiece, causing a cathode on the workpiece. Therefore, during keyhole DSAW, only part of the current goes through the keyhole. The rest of the current flows through the workpiece.

An interesting question is why part of the current goes through the workpiece in-

stead of the keyhole, which minimizes the voltage. Although detailed studies, which are beyond the scope of this paper and which first introduced keyhole DSAW, are needed to answer this fundamental question, the authors suspect the high-speed impact of the electrons on the workpiece may be the factor responsible. In fact, part of the electrons may hit the workpiece when they are traveling along the keyhole, which is not perfectly straight. Because of the high speed of the electrons in the highly constricted plasma jet, the electrons have sufficient energy to enter the workpiece.

Another interesting question is what percent of current flows through the workpiece, rather than through the keyhole, after the keyhole is established. It is un- derstandable that an accurate estimate of this percentage is difficult because it may depend on many parameters, such as the

I WELDING JOURNAL I,',,~115,1

WELDING RESEARCH

Fig. 6 - - Arc behaviors before and after the keyhole is established during DSA IV.. WeMhtg cunent: 120 A, diameter o f the orifice: 2.4 mm, flow rate o f the orifice gas (argon): 1.8 L/m#t. A - - Before; B - - after.

shape of the keyhole, the diameter of the orifice, the flow rate of the orifice gas, and the speed of the electrons, etc. However, experimental results in Fig. 6 give us an approximate estimate. In Fig. 6, the density of the arc, or current, is doubled after the keyhole is established. If we assume this concentration in the current flow is caused by the establishment of the keyhole, one may estimate at least 50% of the current flows through the keyhole.

To verify the accuracy of the above estimate, the voltage signal when the process changes from keyhole to nonkeyhole mode is recorded for keyhole DSAW, as seen in Fig. 7. In the experiment, the thickness of the workpiece is 6.4 mm. The ratio of the current p flowing through the keyhole can be estimated by using the following equation:

a v = ( V w c + vwA) -

{ V K P + ( V w c + V w A ) ( 1 - p ) } = ( V w c + VWA - VK) p (5)

where AV is the voltage decrease from

nonkeyhole to keyhole mode, which is approximately 3.5 V; V r is the voltage drop of the keyhole column, which is approximately 4 V when the thickness is 6.4 mm; V w c + VWA is the voltage drop if the current fully flows through the workpiece; and the weighted sum VKp + ( V w c + VwA)(1 - p ) is used as an estimate of the average voltage of the keyhole and the workpiece. Equation 5 gives

A V 3.5 p = - = 0.58

VWC + VWA - V K 10 - 4 (6)

Hence, analysis of the voltage decrease suggests that more than 50% of the current flows through the keyhole. This is similar to the estimation made based on the arc concentration.

It should be pointed out that, with regard to the estimate for arc concentration after the establishment of the keyhole, the voltage decrease associated with the establishment of the keyhole is only observed during DSAW, not during regular PAW. Figure 8 plots the voltage signal dur-

Table 1 - - lnvar iant Welding P a r a m e t e r s

Orifice diameter Electrode diameter: PAW torch Electrode diameter: GTAW torch Flow rate of orifice gas Flow rate of shielding gas (plasma torch) Flow rate of shielding gas (GTAW torch) Standoff (PAW electrode) Standoff (GTAW electrode)

1.57 mm (0.062 in.) 4.8 mm (~q6 in.) 4.8 mm (~/,6 in.) 1.15 L/rain (2.5 ft,/h) 13.8 L/min (30 ft-,/h) 23 L/min (50 fP/h) 6 mm (0.24 in.) 10 mm (0.38 in.)

ing nonkeyhole and keyhole mode for regular PAW. No difference in the voltage signal can be found. Of course, it is under- s tandable because the majority of the current during regular plasma arc welding is "earthed" through the surface of the workpiece (Ref. 5). The establishment of the keyhole plays no noticeable role in changing the arc behavior (current flow distribution) and the voltage.

In addition to the arc concentration as analyzed above, another unique characteristic associated with DSAW - - energy compensation along the thickness - - is caused by the presence of the arc in the keyhole. That is, in regular keyhole PAW, the current does not flow through the keyhole (Ref. 5). The ionized gas jet thus loses its initial energy, gained before it enters into the keyhole from the arc, to heat the wall of the keyhole without energy compensation. However, in the keyhole DSAW process, the current flowing in the ionized gas jet generates the arc in the keyhole. As a result, the energy consumed to heat the wall of the keyhole can be at least partially compensated. For k-in.- (9.5-mm-) thick material, V K = 6 V, which is approximately ~ of the welding voltage, and the compensated arc energy is approximately ~4 of the total arc energy. More importantly, this part of energy directly heats the workpiece through the thickness direction radially. Its contribution to the penetration is thus much more effective than the arc energy in other parts of the arc. Hence, although an accurate estimate of its contribution to penetrat ion improvement requires detailed studies beyond the scope of this in- troductory work, it is certain this contribution is quite significant.

Experiments and Results

The keyhole double-sided arcing technique may be used to develop an effective keyhole DSAW process to achieve narrow, deep penetration. To this end, an experimental setup, shown in Fig. 3, was developed. It uses a DC constant-current power source. This DC power supply is capable of providing a constant current from 50 to 200 A with voltage up to 50 V. A regular PAW torch and a GTAW torch are connected to the negative terminal and positive terminal of the power supply, respectively.

Table 2 - - Variable Welding P a r a m e t e r s

Sample Process Thickness No. (mm)

1 PAW 6.4 2 DSAW 9.5 3 DSAW 12.7

Type of Root Filler Welding Welding Travel Welding Joint Opening Metal Voltage Current Speed Position

Use (V) (A) (mm/min)

Sq. Butt Zero None 30 70 40 Flat Sq. Butt Zero None 45 70 80 Flat Sq. Butt Zero None 45 70 50 Uphill

PT~"P.,I$.'] NOVEMBER 2002

5 , , l /vc voltage :: i

, : i !

'~ 10~ 2 : --: ',-~ ..... !

0 2.5 5 7.5 9 11.5 13 15.5 18 ~ m e (s)

Fig. 7 - - Vohage signal in keyhole and nonkeyhole mode during DSA W.

~ t~cvat,~e

eff l t~ plasma signal

~ 1 . . . . . . . . . . . . . . ] . . . . . . . . . . . . . I :: . . . . . . . . . . . . . . . i " - ' m l ; ' Z ~ V ~ i ~ . . . . . . . . . . .

o " 2.5 ' 5 " 7.5 ' 9 " 11.5 ' 13

Fig. 8 - - Voltage signal in keyhole and nonkeyhole mode during regular PAW. The efflux plasma signal indicates the establishment of the keyhole.

The austenitic stainless steel used in the experiments is commercial plate Type 304 (wt-% 0.08 C, 2.00 Mn, 1.0 Si, 18.0-20.0 Cr, 8.0-10.5 Ni, 0.045 P, 0.03 S and Bal. Fe). Since keyhole PAW achieves deeper penetration than all existing arc welding processes, comparison will be made between PAW and DASW. Because of the improved arc concentration, DSAW is capable of penetrating 12.7 mm (~ in.) in a single pass. On the other hand, it is not easy to keyhole plasma arc weld stainless or other steel plates as thick as 9.7 mm (g in.) in a single pass without producing a gap (Ref. 10). Hence, 6.4-ram- (¼-in.-) thick plate was welded using keyhole PAW, and 9.5-mm- (~ -in.-) and 12.7-mm- (~ -in.-) thick plates were welded using keyhole DSAW, respectively, for comparison.

Because no previous data is available, experiments have been done to determine the welding parameters for keyhole DSAW. The criterion is that the selected welding parameters produce the desired full penetration without melt-through. Because of the impact of the plasma, underfill typically results in the plasma arc side. However, desired reinforcement can be easily achieved by a standard follow-up cover pass. To ease the comparison, filler metal is not used in this study for both PAW and DSAW. Tables 1 and 2 list the experimentally determined welding parameters.

N a r r o w , D e e p J o i n t P e n e t r a t i o n

Figure 9 shows a keyhole double-sided arc weld, Sample 2 in Table 2, on 9.7-mm- (X-in.-) thick stainless steel plate. The welding speed was 80 mm/min. The width of the weld zone in the middle portion along the thickness direction remains below 2.5 mm. For the same thickness, a 10-kW laser beam achieves full penetra-

Fig. 9 - - Keyhole doubh'-sided arc butt joint weM on 9.5-mm (g-in.) plate (Sample 2). Position: flat, welding current: 70 A, travel speed: 80 mm/min, filler metah none.

Fig. 10-- Keyhole double-sided alz" butt weld ol7 12. 7-mm (½-in.) plate (Sample 3). Position: uphill welding current: 70 A, travel speed: 50 mm/min, filler metal." none.

tion with a narrower weld of 2 mm (Ref. 1). Of course, the speeds achieved with lasers are much faster.

Figure 10 gives a keyhole double-sided arc weld (Sample 3 in Table 2) on 12.7- mm- (X-in.-) thick stainless steel plate. The welding speed was 50 mm/min. The width of the weld zone in the middle portion along the thickness direction remains below 3.5 mm. For the same thickness, a 9.1-kW laser beam achieves full penetration at the width of 3 mm (Ref. 11).

It can be seen that deep, narrow penetration has been achieved by the keyhole DSAW process. Such deep penetrat ion significantly reduces the weld pool and makes it possible to weld thicker materials in a single pass without melt-through. For example, in typical applications, E-in.- thick steel plates require machined bevels and five to six passes (Ref. 12). As can be seen, keyhole DSAW achieved full penetration without bevel in a single pass. The resultant productivity improvement and filler metal reduction are substantial.

H e a t I n p u t

The power of an arc can be calculated as

e.,~ = tv (7)

Where I and Vare the welding current and welding voltage, respectively. However, the actual heat input into the workpiece is not exactly given by the power of the arc.

For regular PAW, the voltage can be de- composed into

v = VEc + v c + VwA (8)

where VEC = voltage of the electrode cathode, V c = voltage of the plasma arc column, and VwA = the voltage of the workpiece anode. Among the three voltage components, VEC, V c, and VwA, the heat input into the workpiece is primarily determined by the latter two. Therefore, the effective power of the arc, which will be converted as the workpiece heat input during keyhole PAW, can be expressed as

WELDING J O U R N A L P2-,,'f<l~,."]


Fig. 11 - - Solidification stmetznz, s o f the weld metal zones. A - - Sample 1: PA W, 6. 4 ram, butt joint, no filler metak B - - Sample 2: DSAW, 9.5 ram, butt joint, no filler metal.

I / . . . , I

-. .~. ~ . ~ ~ ~..q ~ .,:: ~,tt~-I, •

• ~ ' : : ' ~7 " ,~ " : .

Fig. 12 - - Micrographs around the weld boundaries. A - - Sample 1:P,4 W 6.4 ram, butt joint, no filler

metal; B - - Sample 3: DSA W,, 12. 7 ram, butt joint, no filler metal.

. . . .

t A ~ ~ ~ . . . ~ [ L ~ ~ ~ I Fig. 13 - - Micrographs in the center o f the weld boundaries. A - - Sample 1: PAW,, 6.4 mm, butt joint, no filler metal; B - - Sample 3: DSA W, 12. 7 mm, butt joint, no filler metal

ee, r = IT](VC'I-VWA) = 7 ] ( V - V E C ) (9)

where r/<1 is a constant, which accounts for the heat loss of the arc due to radiation, and is referred to as the arc efficiency.

For keyhole DSAW, the parts of the welding current flowing through the keyhole and the metal surrounding the keyhole are p l and (1 - p ) I , respectively. For the convenience of discussion, assume the arc consists of two parallel arcs corresponding to the two parts of the current. For both arcs, the anode and cathode voltage on both tungsten electrodes should be removed from the total voltage during computing the effective power. This implies the effective power during keyhole DSAW can be estimated as

Pe, d = 71P I (Vcl+VK+Vc2) + 72(1 -p)I(Vcl +VwA + VWC + VC2) = nlpI(V~- VEC- V~)+ n2(1 -p ) I (V 2 - VEC- VF~ ) (10)

where V 1 is the voltage of the arc corresponding to the part of the current flowing through the keyhole, and V 2 is the voltage of the arc corresponding to the part of the current flowing through the metal surrounding the keyhole, and constants 71 < 1 and 72 <1 are their efficiency. Because the heat generated by the cathode and anode spots is almost totally put into the workpiece, the arc efficiency for three arc columns is not higher than that for two arc columns and a anode and

cathode pair, i.e., 71 < 72. Whenp = 0.5,

Pe.. <- O'57J(Vt - V E c - Ven + Ve- VEc- V ~ ) = 72t{O.5(Zl + V 2) - VEC - PEA)} = rl f f ( V - VEC - VEA) (11)

where V is the average voltage measured. Further, because VWA > > VwC, the arc efficiency for two arc columns and an anode and cathode pair is not higher than that for one arc column and an anode. That is, 72 < 7. As a result,

• Oe, d<- 0 I ( V - V E C - V ~ ) (12)

Equations 9 and 12 provide a way to estimate the heat input into the workpiece for the welded samples in the experiments. In the first comparison, the ratio of heat input of the keyhole DSAW to the regular keyhole PAW is computed. As seen below, the computed ratio of heat input between these two processes is independent of the arc efficiency in Equations 9 and 12. Hence, in the following discussion, a typical value 0.7 is assumed for the arc efficiency. Hence, for Samples 2 and 3 where current and voltage are 70 A and 40 V

P e r < 770(45 - VEC - VEA) = X 7 0 ( 4 5 - 9) = 1764 W (13)

For Sample 1 (¼ in. thick),

Pe, r = h I ( V - V E C ) = 7 7 0 ( 3 0 - V E c ) =

O. 7 x 70 (30-2 ) = 1372 W (14)

To penetrate ¼-in:thick plate, regular keyhole PAW uses a 1372-W effective heat source at the travel speed of 40 mm/min. For keyhole DSAW, ~-in.-thick plate can be penetrated using a 1764-W effective heat source at the travel speed of 80 mm/min. The heat input of keyhole DSAW for-~-in.-thick plate is thus only approximately 60% the heat input of regular keyhole PAW for ¼-in:thick plate. If keyhole PAW is used to penetrate -~-in.-thick plate, the heat input would be at least double the heat input used for ¼-in. plate. Hence, the heat input required to weld ~- in.-thick plate by keyhole DSAW is at most 30% of that needed by keyhole PAW.

The heat input comparison can also be made between DSAW and laser beam welding. For 9.5-mm- (X-in.-) thick plate, a 10-kW laser beam can achieve full penetration at the travel speed of 80 in./min, or 2032 mm/min (Ref. 1). The heat input is thus approximately 20% as the heat input of keyhole DSAW. For 12.7-mm- (~- in.-) thick plate, a 9.1-kW laser beam achieves the full penetration at the travel speed 900 mm/min. The heat input into the workpiece is again approximately 20% of the heat input associated with keyhole DSAW for the same thickness.

P,,1.."fil$." 1 N O V E M B E R 2002

WELDING RESEARCH Weld Shape

As can be seen in Figs. 9 and 10, the cross sections of double-sided arc welds are approximately symmetrical and hour- glass shaped. Although detailed studies are needed to determine the effectiveness of this shape in thermal distortion and residual stress reduction, it is certain the thermal distort ion and residual stress must be reduced.

Grain Structure

Specimens cut from the weld samples are mechanically polished and chemically etched with a solution of 340 g FeCI 3 6H20 + 125mL HCI + 40 mL HNO 3 + 250 mL H20 to reveal the macrostructure and electrolytically etched with a solution of 10 g oxalic acid + 100 mL water to determine the microstructure. The macrostructures are examined using a Nikon SMZS00 stereoscopic zoom microscope. The microstructures are observed by using a Nikon Epiphot 300 optical metallurgical microscope and a Hitachi S- 32011 scanning electron microscope (SEM), operated at 20 kV.

Figure 11 shows the morphologies of solidification macrostructures in the welded joint in comparison with keyhole PAW joints. Figure 12 shows the microstructures around the weld boundary, and Fig. 13 shows the microstructures in the center of the weld metal zone. Compared to regular plasma arc welded joint (Figs. 11A, 12A, and 13A), fine equiaxed solidification grains were formed in the bulk of the weld metal zone of DSAW, with only a very narrow columnar region ahmg the weld boundary, as shown in Figs. l lB, 12B, and 13B.

Generally, the solidification structure is controlled by the solidification parame- t e r s - the solidification growth rate R and the thermal gradient in the liquid G L. The ratio of the two parameters GL/R normally changes from a maximum value at the fusion boundary to a minimum along the center of the weld. These changing solidification conditions result in a weld solidification structure changing from pla- nar at the weld boundary to columnar dendrite and then to equiaxed dendrite grain along the weld center (Ref. 13). For DSAW process, it was found the fraction and width of the fine equiaxed grain region gradually increases in the weld metal zone along with an increase in the depth of penetration. It is known that when the penetra t ion increases, the amount of molten metal increases. Such an increase in the amount of molten material helps heat the workpiece before cooling; hence, the thermal gradient during cooling is reduced. This tends to allow an increase in

the amount of fine equiaxed grains produced.

C o n c l u s i o n s

Double-sided arcing phenomenon and technique have been used to develop the keyhole DSAW process. Observation and analysis show the through-thickness direction of the current and the establishment of the keyhole both play significant roles in enhancing arc concentration.

Experimental data and analysis suggest at least part of the current flows through the keyhole if the keyhole provides a minimum voltage path. The presence of the current in the keyhole generates an energy compensation not found in other arc welding processes.

The keyhole DSAW process has proven capable of achieving deep, narrow joint penetration on square-groove, thick stainless steel plates up to ~-in. in a single pass.

Keyhole DSAW reduces heat input into the workpiece by at least 70% in comparison with regular keyhole PAW, which achieves the deepest and narrowest penetration at the least heat input of all existing arc welding processes. In other words, keyhole DSAW requires only 311% of the heat input needed by keyhole PAW.

Welds produced by keyhole DSAW are less than 1 mm wider than those produced by the laser process. To penetrate the same thickness of stainless steel plates up to 7_, in. thick, the heat input into the workpiece by the keyhole DSAW process is approximately five times as much as that input by a high-power (approximately 10-kW) laser.

Welds produced by keyhole DSAW are approximately symmetrical and hour- glass shaped.

Keyhole DSAW tends to increase the amount of the desirable equiaxed grains in the solidified welds.

Detailed studies are needed to fully disclose the metallurgical implications and mechanical propert ies for keyhole DSAW of different materials, including the impact of heat input reduction and symmetrical shape on thermal distortion and residual stress, and to quantitatively analyze the phenomena during double- sided arcing and the keyhole double-sided arc welding process.

Acknowledgments

This work was funded by the National Science Foundation under Grant DMI-98 12981 and the Center for Robotics and Manufacturing Systems at the University of Kentucky. The authors would also like to thank The Lincoln Electric Company, Thermal Arc, Inc., and NASA Marshall

Space Flight Center for financial, equipment, and material support. Finally, the authors wish to thank the late Warren Mayott at The Electric Boat and Dr. Arthur Nunes at Marshall Space Flight Center for fruitful technical discussions.

Rel'erences

I. Wehlin+ Ihmdhook. 8th edition, Vol. 2, Welding

Processes. Miami, Fla.: American Welding Society.

2. McGaughy, ]1 20110. Two new technologies may

increase pipe production and reduce cos|. Welding

Journal 70(8): (~5 66. 3. Wclz, W. 1990. Magnclically impelled arc pres-

sure wclding of non-magnclic steels. Schweissen trod

Sclmeidem 42(2): 24-26.

4. Saloh, '1], Katayama, J., loka, S., alld Otani, M.

1990. Expcrinlcntal sitidy on IOt;lthlg bch;lvior o[ [ll-C

during magnclically impelled arc butt welding. Quar

terh' .hmrmd 01" the ,lapam'se Wehting Society 81 I ):

71-77. 5. Dowdcn, J., aild Kapadia, P. 1994. Phisina al-C

welding: a nlathcmatical model of the arc..IoluJlal o1'

Ph?,Mcs (D): Applied Physics 27:9112 910.

(~. Zllang, Y. M., and Zhal/g, S. I~. 19c)9. Method

of arc welding using dual scrial opposed torches. U.S.

Patent, No. 5,9911,446.

7. Zhang, Y. M., and Zhang, S. B. 1999. Welding

aluminum Alloy 6061 wilh opposing dual torch (SLAW

process. Wehli#lg.hmrnal 78(6): 202-s to 2(i6-s.

8, Zhang, Y. M., Pan, (7. X., and Male, A. | - 2000.

hnprovcrllenl of microstrucltii-cs alld properties of

60111 aluminum alloy wcldments using double-sided

arc welding process. Melallu~ivical "lhmsaction~ A

31( 10): 2537-2543. 9. Lancaster, J. E 1986.7he l'~hysics q[" [+?lding. Ox-

ford, Pergamon Press.

I(L ltalmoy, E., IR)stclwoll, it., and RalllSlalld, A.

19i,14. New applications of plasma keyhole welding.

• Z>hling in the WoHd 34:285-29 I.

II. Dawes, (7. 1992. Laser Wehling: a Practical

GuMe, Cambridge, England: Abington Publishing.

12. Welding Workbook. 2000. Downhill welding of

pipe. WehlmgJountal 79(8): 67 68.

13. Puchaicchi, ,I. 1998. Control of distortion of

welded steel structures. ~'hling.hmrmU 77(8): 4c~-52.

WELDING J O U R N A L P,,g'~"l.-I

WELDING RESEARCH

Aging of Braze Joints: Interface Reactions in Base Metal/Filler Metal Couples,

Part I1: High-Temperature Au-Ni-Ti Braze Alloy

An examination of the effects of aging in brazed joints made with 81Au-17.5Ni- 1.5Ti filler metal and Thermo-Span TM or AISI Type 347 stainless steel base metals

revealed excellent wetting and spreading

BY P. T. VIANCO, F. M. HOSKING, J. J. STEPHENS, C. A. WALKER, M. K. NEILSEN, S. J. GLASS, AND S. L. MONROE

ABSTRACT. The effects of aging were examined in brazed joints made with 81Au- 17.5Ni-l.5Ti filler metal and Thermo- Span'M or AISI Type 347 stainless steel base metals. Excellent wetting and spreading were observed with both base metals. The Thermo-Span/Au-Ni-Ti and A|SI Type 347 stainless steel/Au-Ni-Ti joints exhibited an interdiffusion zone at the base metal/filler metal interfaces. Aging caused the interfacial diffusion zone to grow. Four-point bend strength tests and microstructural analysis identified a phase precipitation mechanism that maximized the joint strength when aged at 460°C.

Introduction

Engineered ceramics, such as silicon nitride (Si3N4) and partially stabilized zir- conia (PSZ), have the physical and mechanical properties that allow their potential use in reciprocating and turbine engine systems (Refs. l-3). Because metal alloy parts will still comprise a majority of heat engine components, there is a need for joining techniques of three categories: 1) metal-to-metal, 2) ceramic-to-ceramic, and 3) metal-to-ceramic.

The mechanical performance of any braze joint depends upon its microstructure. There are three critical regions in the brazed joint structure: 1) the filler metal, 2) the interface(s) between the filler metal and the base material, and 3) the base material(s). The initial microstructure of the brazed joint depends upon the base material and filler metal compositions as well as the brazing process parameters (Refs. 4-6). Exposure of the joint to prolonged

P 77. VIANCO ([email protected]), E M. HOSKING, J. J. STEPHENS, C. A. WALKER, M. K. NEILSEN, S. J. GLASS, and S. L. MONROE are with Sandia Na- tional Laboratories, Albuquerque, N. Mex.

time periods at elevated temperature can cause solid-state reactions to occur in the filler metal, base materials, and at the interfaces. In particular, the development of interface reaction products can significantly alter the performance of the brazed joint.

The aging of brazed joints under long- term, elevated temperature exposure has not been extensively studied. Shimoo et al. studied the kinetics of solid-state reactions between Si3N 4 and Ni (Ref. 7). Most aging studies have examined the interface microstructure that develops initially between the molten filler metal and the base material during the brazing process (Refs. 8-10).

An investigation was conducted to study the metal/metal interactions that occur within the joints made between two filler metals and two base metals. This report (Part 1I) examines the aging between a Au-Ni-Ti filler metal and the two base metals Thermo-Span'M and an AISI Type 347 stainless steel. (A prior study examined the aging of brazed joints made with a Ag-Cu:Fi filler metal and Thermo-Span or l nconel® 718 base metals, those results were reported as Part I.) Analytical tools were used to characterize the joint nil- crostructures; four-point bend tests were used to determine the effect of microstructural changes on the mechanical performance of the joint.

KEY WORDS

Brazing Brazement Ceramic Inconel® Thermo-Span '" Aging Precipitation Strengthening

Experimental Procedures

Materials - Base Metals

The two base metals and nominal compositions (wt-%) used in this study were 1) Thermo-Span, 24.5Ni-29.0Co-5.5Cr- 4.8Nb-(Si, Ti, Al)-bal. Fe (Ref. 1l) and 2) AISI "lype 347 stainless steel, 18Cr- l 1Ni- 2Mn- 1Si-(3h, Nb)-0.(18C-bal. Fe. Thermo- Span is a precipitation-hardened alloy received in the solution-annealed condition (1093°C, I h, air cool), rib ensure consistent material properties, the Thermo- Span was exposed to a precipitation- annealing heat treatment. The precipitation-hardened condition was confirmed through RockwelI-C (HRc) hardness measurements. Six measurements were performed on three bare metal blanks. The heat treatment schedules and hard- uess data are presented below.

Thermo-Span (as-received HR c = 23 _+ 2, solution a,mealed):

Solution annealing (at the mill): 1093°C (2000°F) for 1 h; air cool.

Precipitation annealing: 718°C (1324°F) for 8 h; furnace cool at ll.015°C/s (0.027°F/s) to 62 I°C(1150°F); hold at 621°C for 8 h; air cooling.

Post-heat treatment HR c = 39_ + l

All brazing experiments were performed on base metal specimens, the surfaces of which were ground to a nominal x/32 finish. Profilometer traces determined the exact roughness as an arithmetic average roughness (RA) number. Four measurements were made, two in one direction and the other two in a per- pendicular direction, over a distance of 6 mm. The mean and _+ one standard deviation RA data are shown in "ihble 1. The solution and aging heat treatment given to the Thermo-Span resulted in a significant

P4.;I,15,.'1 NOVEMBER 2002

0.076 mm

...... !0 25.4 mm

IE]lIl 6.4 mm Base meta U b~Base metal

Filler metal W spacer (0.051 mm)

Fig. 1 - - Assembly configurations,for tile metal~metal test samples.

/

Fig. 2 - - Schematic diagram o f the sessile drop conOguration used to assess the wettability o f the braze alloys. The quantitative metric is the contact angle, O. The symbol "r" is the effective spread radius assuming a circular footprint, and "h" is the height o f the filler metal mound.

Table l - - Arithmetic Average Roughness (RA) of the Metall ic Test Samples with a ~]32 Finish Surface Prnf i l omet~ Data (Med. Scan Speed)

Test Material Condition RA (/zm)

Thermo-SpanrM Solution treated 0.19 _+ 0.02 Thermo-Span Solution treated 0.09 _+ 0.02

and aged 347 stainless steel As-received 0.03 + t).t)l

reduction in surface roughness after grinding as compared to that of the as-received material. The roughness of the AISI Type 347 stainless steel surface was similar to that of the aged Thermo-Span alloy.

Materials - Brazing Filler Metals

The filler metal was Wilbraze r,, 81172R (Ref. 12). This material had a nominal composition of 81Au-17.5Ni-1.5Ti (wt-%). The baseline composition was 82Au-18Ni (Tmelt = 955°C). Titanium was added (largely at the expense of the nickel component) to form an active braze alloy (ABA). Two batches of material were used in the study, one having a foil thickness of 0.051 mm ([).002 in.) and the other having a 0.025- mm (0.001-in.) foil thickness. Atomic emission spectroscopy (AES) was used to con- firm the compositions of both material batches. The composition of the 0.05 l-ram- thick (0.001-in.) stock was 81.0 -+ 1.2Au, 17.6 -+ 0.1Ni, and 1.9Ti. The composition of the 0.l)25-mm-thick (0.002-in.) foil was 80.9 -+ 5.6Au, 16.8 -+ 0.7Ni, and 1.9Ti. The Au- Ni-Ti material had a cited melting range of 990 to 1020°C (1814 to 1868°F). The solidus temperatures, recorded by an in-house differential thermal analysis (DTA) study, were identical for both foils at 957°C (1755°F).

Parent Block, Brazed Joint Assembly

The test specimen configuration used

to evaluate the brazed joint microstructures, and from which the mechanical strength test pieces were fabricated, is shown in Fig. 1. The "parent" block of each base metal measured 25.4 x 25.4 x 6.4 mm (1.0 x 1.0 x 0.25 in.). Two blocks were joined along the 25.4 x 6.4 mm (1.0 x 0.25 in.) face, which had been ground to a nominal ~132 finish. A piece of filler metal measuring 25.4 x 6.4 mm (1.0 x 0.25 in.) was placed between the two block surfaces. The ,joint clearance was controlled by the placement of two 0.051-mm-diameter (0.002-in.) tungsten wires in the joint clearance. The parent blocks, tungsten wires, and filler metal foil were stacked within a graphite fixture that maintained their alignment during the brazing process. A nominal mass was placed on top of the stack to ensure formation of the desired joint clearance.

Brazing Process

An extensive development effort was conducted to determine suitable brazing process parameters. First, an assessment was made of the variations in brazing temperature and time on wetting and joint microstructure. The nominal peak temperature was 1040°C (1904°F). The nominal peak time was 3 min. The brazing cycle was performed under a vacuum of 6.7 to 11 x 10 -5 Pa (5 to 8 x 10 7 Torr) measured at the brazing temperature. The resulting mean and -+ one standard deviation for the process temperature and time period

temp.

1000°C 5 ~ 5 " C / m i n 900~C ~

/min ~ Furnace

time

Fig. 3 - - Time and temperature parameters for the At¢-Ni- Ti brazing process.

following five furnace cycles were 1047_+5°C (1917+9°F) and 2.0-+0.3 min, respectively. The remainder of each temperature-time profile showed similarly good run-to-run consistency.

Sessile drop (area-of-spread) experiments assessed the filler metal wetting- and-spreading behavior as a function of brazing temperature and time. A filler metal preform was placed on the surface of each base material. The specimens were then exposed to one of the brazing cycles. The quantitative metric was the contact angle, 0, that formed at the droplet front - - Fig. 2. The value of 0 was calculated from the volume, V, of filler metal used to make the drop; an effective radius, r, of the footprint area; and the assumption the sessile drops were in the form of a spheri- cal cap having a height, h. The value of h was calculated by Equation 1:

h = { [ ( 3 V / r t ) 2 + r6]1 /2 + 3 V / ~ } 1 / 3 - { [(3V/rc)2 + r 6 l l / 2 - 3 V / ~ } 1 / 3 (1)

The contact angle was then calculated by equation 2:

0 = tan- I [2rh/(r2-h2)] (2)

WELDING JOURNAL P4.1r~l

WELDING RESEARCH

11m

~ 3.0 mm

f 6.4 mm A Filler metal

__ .S0mm ~ 5 1 mm

~ 4 . 0 mm 4.0 mm

B

Fig. 4 - - A - - Schematic diagram showhlg fabricadon o f test pieces from the brazed parent blocks; B - - dimensions o f the four-point bend bars used in the mechanhral tests corresponding to MIL-STD- 1942A, Type B geometry.

i i b=4.0 mm ~ ~ j~,

"1 ~1" d - 3 0 m m

I '10 m~'20 mm vl 1 , = . 0 m m

F Fmax

Displacement

s 3 Pmax L . . . .

Fig. 5 - - Schematic diagram o f the fimr-point bend test per MIL-STD- 1942A. The flexure strength, S, was computed from the mtrrimurn force, F,,,,~c

Table 2 - - S e s s i l e Drop Contact Angle Per the Peak Brazing Temperature (_+ l standard deviation)

Contact Angle Values (o) Au-Ni-Ti

Substrate Material 1000°C 1033°C 1053°C Material Condition (1832°F) ( 189 I°F) (1927°F)

Thermo-SpanTM Solution treated - - - - - - Thermo-Span Solution treated 5.7 0.5 0.3

and aged (0.2) (1.5) 347 stainless steel As-received 5.6 3.5 3.0

(4.0) (1.4)

The values of the contact angles for each base metal and brazing process are listed in Table 2. In some cases, replicate samples were evaluated to determine the scatter in these measurements. The data in Table 2 shows the contact angles were very low, indicating excellent wetting and spreading by the braze alloys on the substrate materials. The scatter numbers indicated Au-Ni-Ti filler metal performance was relatively insensitive to the brazing temperature range of 1000 to 1053°C (1832 to 1927°F) for a nominal brazing time of 3 rain.

The selected brazing process for the Au- Ni-Ti filler metal is illustrated in Fig. 3. Each cycle began with a temperature rise of

10°C/min (18°F/min), to a subsolidus temperature of 900°C (1652°F). A hold time of 5 min allowed the specimen and fixturing to reach an equilibrium temperature. The temperature was then raised at 5°C/min (9°F/min) to the brazing temperature of 1000°C (1832°F) for 7 min. A reduced brazing temperature and longer brazing time (vis-b.-vis the wetting experiments) were used to ensure a more repeatable brazing cycle. The specimen temperature was ramped down at 5°C/min (9°F/min) through the solidus point, to the previous holding temperature of 900°C (1652°F). This controlled cooling step duplicated a brazing process for metal-ceramic joints that minimizes the buildup of residual

stresses caused by thermal expansion mis- match across the joint. The cooling rate was then increased to 10°C/min (18°F/min) until a temperature of approximately 400°C (752°F) was reached, after which the assembly was allowed to furnace cool to room temperature.

The brazing cycle potentially placed the Thermo-Span alloy back into a solu- tionized condition. The base metal would require a precipitation aging treatment after the brazing process to obtain the desired properties. This circumstance illus- trates the need to understand aging processes in brazed joints and their potential impact on joint performance.

Microstructural Analysis of Sessile Drop Samples

Sessile drop samples were used in some assessments of the interface reactions in the aged couples. The aged samples were evaluated using optical microscopy, scanning electron microscopy (SEM), and electron microprobe analysis (EMPA) techniques.

Mechanical Test Specimen Fabrication

Mechanical strength measurements were performed on individual specimens cut from brazed parent blocks. Shown in Fig. 4A is a schematic diagram illustrating the manner in which tests specimens were cut from brazed blocks. The cuts produced seven test pieces having a width ground to a dimension of 3.0 mm (0.12 in.). Only those five pieces originating from the center portion of the block assembly were used to avoid the tungsten spacer wire. The final dimensions of the test specimens (Fig. 4B) were reached by a grinding operation that reduced the original "thickness dimension" from 6.4 mm (0.25 in.) to 4.0 mm (0.16 in.). Sample geometry com- plied with MIL-STD-1942A, "Flexure Strength of High Performance Ceramics at Ambient Temperature." Four of the five test samples were used for mechanical tests. The remaining sample was cross sectioned and its microstructure analyzed to supplement data obtained from the sessile drop samples.

Four-Point Bend Mechanical Strength Test Procedure

The four-point bend test setup (per MIL-STD-1942A) is shown in Fig. 5. The test specimen was placed on top of two outer support rollers separated by a distance of 40 mm; the ground surface was in contact with the rollers. The two inner or "loading" rollers separated by a distance of 20 mm (0.79 in.) were positioned on top of the specimen. No significant preload was applied prior to the start of testing.

P,,~;E~,',] NOVEMBER 2002

1 W E L D I N G R E S E A R C H

Substrate

Fig. 6 - - A - - SEM micrograph of the Au-Ni-Ti sessile drop on the Thermo- Span alloy showing the precursor film structure; B - - schematic diagram o f the precursor film formed by the spreading Au- Ni- Ti filler metal.

The specimen was subjected to a constant cross head displacement rate of 8.3 x 10 3 mm/s (3.3 x 10 "4 in./s). The flexure strength, S, was computed according to the following equation:

S = 3 Fmax L ( 3 )

4 b d 2

where Fmo ~ is the maximum force (load); L is a support roller span of 40 mm (1.6 in.); b is the specimen width of 4.0 mm (0.16 in.); and d is the specimen thickness of 3.0 mm (0.12 in.). Strength data were represented by the mean and standard deviation of the multiple tests.

Aging Environments

The aging treatments were performed at temperatures of 225°C (437°F), 460°C (860°F), and 700°C (1292°F), and time periods of 100, 200, and 300 days. Each specimen was placed in a quartz ampoule along with a piece of Ta foil. The ampoule was then backfilled with Ar at a 10-mtorr (1.3-Pa) pressure and sealed. The Ta foil served as a getter for residual oxygen.

Fig. 7 - - A --Low-magnification SEM micrograph o f zone 1 o['the precursor film ]~'om a Au-Ni-Ti sessile drop on the Thermo-Span base meta# B - - high-magnification SEM micrograph of zone 1; C - - nickel X-ray dot map o f the precursor film surface shown in Fig. B; D - -go ld X-ray dot map of the film area in Fig. B.

I Thermo.Span T M A [ Type 347 B " stainless steel

<::~u-N-r - - - " + - . . . . . : ~

Type 347 ' . m i ~ ! l l stainless steel '=='1

Fig. 8 - - Optical micrographs showing cross sections o f A - - The Thermo-Span ; B - - the 347 stainless steel, four-point bend joints made with the Au-Ni-Ti filler metal. The Thermo-Span sample was etched in a H20/HCI/HNO3/CrO 3 solution. The Type 347 stainless steel sample was etched in Villela 's solution followed by a FeCl 3 solution.

Sessile drop specimens were fabricated to evaluate microstructural changes due to these aging treatments. A more limited range of aging parameters was used for the four-point bend samples due to material availability; those parameters were 460°C (860°F) and 700°C(1292°F) and the time periods were 87 and 200 days.

Results and Discussion

Sessile Drop Morphology from the Wetting and Spreading Experiments

An SEM micrograph of the leading edge of the Au-Ni-Ti sessile drop on Thermo-Span resulting from the brazing

WELDING JOURNAL P,,~"~I~4

WELDING RESEARCH . . . . .

io g, Au-Ni-Ti

Thermo-Span TM

20 30 40 50 DIMnncI (tJm)

loo

8o . . . . . . . . . . . . . . . . I . . . . I . . . . I . . . . [ . . . .

- ~ - - ~ Fe

NI

s 10 i s 2o 25 a o 35 4o

DIM~nce (pm)

Fig. 9 - - Representative EMPA trace o f the interface region between Au-Ni- Ti filler metal and Thermo-Span base metal in the as-fabricated condition.

Fig. 10 - - Representative EMPA trace o f the interface region between Au-Ni- Ti filler metal and Type 347 stainless steel base metal in the as-fabricated condition.

1000

800

6 0 0 Flexure

Strength, S (MPa)

40C

- - - E - -

200 -

A u - N I - T i , A u - N i - T i , T.-Span Type 347

F i l l e r m e t a l - base alloy couples

Fig. 11 - - Four-point bend strengths o f the as- fabricated joints made with Thermo-Span and Type 347 stainless steel base metals. The length o f the bars equal the data mean; the individual test values are included within each bar.

conditions of 1053°C (1927°F) and 7 min appears in Fig. 6A. A schematic diagram of the Au-Ni-Ti sessile drop surface morphology appears in Fig. 6B. Three distinct regions were observed: the bulk filler metal as well as "zone 1" and "zone 2" of a precursor film. Low- and high-magnification SEM micrographs of zone 1 appear in Figs. 7A and 7B, respectively. Energy- dispersive X-ray analysis (EDXA) maps of nickel and gold are shown in Figs. 7C and 7D, respectively, for the area in Fig. 7B. The EDXA determined zone 1 to be comprised of nickel-rich islands in a matrix of gold-rich phase. There was no significant- titanium signal. The EDXA also detected the presence of iron, silicon, and chromium, which suggested some dissolu-

_~.,,~. ~..7,,nle~ ~.

~ ' ~ Lk~.." ~

i

Fig. 12 - - A - - Low-magnification SEM photograph o f the fracture surface o f a Thermo-Span base metal/Au-Ni-Ti filler metal joint tested in the as-fabricated condition; B - - a high-magnification SEM photograph o f the same.

tion of the underlying Thermo-Span substrate material had taken place.

The morphology of zone 2 was similar to that of zone 1 with the exception that the segregation of the nickel and gold constituents into nickel-rich islands in a gold- rich matrix was less distinct. Analysis did not reveal the presence of titanium.

The same evaluation was made of the wetting and spreading behavior by the Au- Ni-Ti filler metal over the Type 347 stainless steel. The same brazing conditions

were used. A two-zone precursor film morphology was observed, having the same gold and nickel elemental distribu- tions as were identified with the Thermo- Span base metal.

B r a z e d Joint M icrost ruc ture - - A s - F a b r i c a t e d Condi t ion

The brazed joint microstructures that formed between the Au-Ni-Ti filler metal and the Thermo-Span and Type 347 stainless steel base metals were examined through observations of cross sections. Representative micrographs of the as-fabricated Thermo-Span/Au-Ni-Ti and Type 347 stainless steel/Au-Ni-Ti joints are shown in Figs. 8A and 8B, respectively. The Thermo-Span joints (Fig. 8A) exhibited reaction zones at the filler metal/base metal interfaces. Such reaction zones were not apparent in the Type 347 stainless steel/Au-Ni-Ti couples. Grain boundary infiltration and dissolution were observed in the base metals along the interface, going to a depth of approximately ~ to 1 grain for the Thermo-Span material and 1 to 2 grains deep in the Type 347 stainless steel.

Figure 9 shows a representative electron microprobe analysis (EMPA) trace that was taken across the Thermo-Span base metal/Au-Ni-Ti filler metal interface. No intermetallic compound layers were identified. Rather, a compositional transition zone was observed that ranged from 15/zm to approximately 35/zm wide. A concentrat ion maximum of Ni was observed. There was no preferential concentration of titanium within the zone. Con- centration gradients of iron and cobalt, and to a lesser degree niobium and chromium, indicated base metal dissolution and some liquid-state diffusion were active during the brazing process. There

P-[,'Itl~."! NOVEMBER 2002

were significant concentrations of iron (10 at .-%) and cobalt (7 at .-%) and trace amounts of chromium and niobium in the filler metal away from the interface; the titanium, gold, and nickel concentrations there were commensurate with the nominal composition of the filler metal.

Electron microprobe analysis was performed across the interface between the Au-Ni-Ti filler metal and the Type 347 stainless steel base metal. A representative EMPA trace is shown in Fig. 10. A transition zone was observed between the filler metal and the base metal. In Fig. 10, that zone was approximately 8/zm wide, but was as wide as 15 to 30/zm at some locations. As in the case of the Thermo- Span alloy, a similar Ni concentrat ion peak was observed in that zone. Titanium was not present at significant levels in the transition zone.

Elevated concentrations of iron (17 at. -%) and chromium (4 at .-%) were observed in the filler metal. A comparison w a s made of the EMPA trace in Fig. 10 with that of the Thermo-Span/Au-Ni-Ti couple in Fig. 9. A higher iron concentration was observed in the remaining filler metal of the Type 347/Au-Ni-Ti couples. The greater iron levels in the latter couples was likely due to the higher Fe concentration in that base metal.

A few isolated voids were observed in the filler metal. Those voids did not have a morphology that indicated poor wetting of the base alloy surfaces. Rather, possible causes included, individually or in combination: 1) outgassing by the base metals and/or filler metal at the elevated temperatures; 2) insufficient filler metal quantity to keep the joint clearance filled under the extensive interface reactions; and 3) solidification shrinkage.

Four-Point Bending Strength As-Fabr icated Condi t ion

Four-point bend strengths are shown in

Fig. 11 for the as-fabricated joints made with Thermo-Span and the AISI Type 347 stainless steel base metals using the Au- Ni-Ti filler metal. The Thermo-Span joints exhibited the highest strengths at a mean value of 880 MPa (128 ksi). In fact, some deformation of Thermo-Span base metal w a s observed that may have resulted from partial solution annealing during the brazing cycle. On the other hand, the Type 347 stainless steel joints had relatively low strength of 340 + - 139 MPa (49+-20 ksi).

Cross sections of post-tested Thermo- Span and Type 347 stainless steel braze joints indicated the fracture paths of both specimen types were in the filler metal. A low-magnification SEM image of the Thermo-Span specimen fracture surface is shown in Fig. 12A. A 3000X magnification image of the fracture surface in Fig. 12B shows extensive deformation in the material at this scale. Within that deformation, individual particles were also observed. Similar low- and high-magnification SEM images of the fracture surface of a Au-Ni-Ti filler metal/Type 347 stainless steel base metal joint are shown in Fig. 13. The 3000X magnification view in Fig. 13B distinguished a faceted appearance to the fracture surface indicative of an intergranular failure mode. The facet size w a s

approximately 1 to 2/zm (3.9 x 10 -5 in. to 7.8 x 10 -5 in.). Therefore, an intergranular failure mode may have been responsible for the reduced strength of the brazed joints made to the Type 347 stainless steel base metal. A possible source of this failure mode was the elevated concentrations of iron and chromium found in the filler metal in these joints.

Brazed Joint Microstructure - - Post -Aging Condi t ion

Small changes in the braze joint microstructure were observed for couples formed between the Thermo-Span base metal and Au-Ni-Ti filler metal after aging

Fig. 13 - - A - - Low-magni/ication SEM photograph o f the fracture surface o f a Type 347stain- less steel base metal/..4u-Ni-Ti filler metal joint tested in the as-fabricated condition; B - - a high- magnification photograph o f the same.

at 225°C (437°F) or 460°C (860°F). The interface reaction zone retained a high concentration of nickel. There was no development of intermetallic compounds. The filler metal microstructure likewise remained unchanged from that observed in the as-fabricated specimens.

Joint microstructure did change in specimens exposed to a 700°C (1292°F) aging temperature. Shown in Fig. 14A is a low-magnification micrograph of the Thermo-Span/Au-Ni-Ti joint after aging for 437 days. Two distinct morphologies were observed: a lighter area was located

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Fig. 14 - - A - - Low-magnification, optical micrograph o f a Thermo-Span/Au-Ni-Ti joint after aging at 700°C (1292°F) for 437 days. The base metal, reaction zones, and filler metal have been identified; B - - a high-magnification, optical micrograph o f the reaction zone formed between the base alloy and filler metal.

WELDING JOURNAL P.,I."]iE,,.1

WELDING RESEARCH

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Fig. 15 - - Electron microprobe analysis trace across the reaction zone formed between Thermo-Span base metal and the Au-Ni-Ti filler metal after aging at 700°C (1292°F) for 437 days.

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Fig. 16 - - A n optical micrograph (differential interJ~,n'nce contrast) taken o f a Type 347stainless steel/Au-Ni-Ti sample aged at 225°C (437~F) for 300 days. The demarcation line in the filler metal has been noted.

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Fig. 1 7 - - A n optical micrograph (differential interference contrast) taken o f the Type 347stainless steel/Au-Ni-Ti sample aged at 700°C (1292°1:) for 437 days. The Au-Ni-Ti filler metal, reaction zones, and Type 347 stainless steel base metal regions have been noted.

Fig. 18 - - Electron microprobe analysis trace across a Type 347 stainless steel/Au-Ni-Ti braze joint aged at 700°C (1292°F) for 437 days.

at the center of the joint with a width of approximately 55 Izm (0.0021 in.), and two reaction layers of darker contrast were located to either side of the center region and had thicknesses of 60 to 80/xm (0.0023 to 0.0031 in.). A comparison of this aged microstructure with that of the as-fabricated specimen (Fig. 8A) indicated the aging treatment caused 1) changes to the filler metal and interface reaction zone microstructures and 2) enlargement of the interracial reaction zones by a factor of two to three. The high magnification micrograph in Fig. 14B suggests significant phase formation had taken place along Thermo-Span grain boundaries as well as within the grains themselves.

The chemical composition of the Thermo-Span/Au-Ni-Ti reaction zone and neighboring Thermo-Span base metal were identified by EMPA - - Fig. 15. A grain boundary phase, which formed in the nearby Thermo-Span base material, was examined first. Unaged Thermo-Span alloy exhibited an enrichment of niobium

and cobalt as well as reduced levels of nickel, iron, and chromium at the grain boundaries. In the case of aged Thermo- Span/Au-Ni-Ti couples, the Thermo-Span grain boundaries exhibited a further increase in the niobium concentration; however, the cobalt concentration decreased there. In addition, the grain boundaries showed significant concentrations of gold and nickel, as well as the appearance of a small titanium concentration. Concur- rently, the iron and chromium concentrations dropped below their nominal values for the bulk Thermo-Span base metal. When nickel content was adjusted for its nominal concentration in the base metal, the grain boundary showed a composition of 78Au-21Ni-lTi (wt-%) plus Nb. The Au-Ni-Ti combination was very similar to the nominal composition of the filler metal (81Au-17.5Ni-l.5Ti, wt-%). This analysis suggests the 700°C (1292°F), 437 day aging condition allowed solid-state diffusion of the filler metal elements gold, nickel, and titanium along the Thermo-

Span grain boundaries such that the filler metal composition was essentially reproduced at the expense of iron, cobalt, and chromium.

Recall the as-fabricated Thermo- Span/Au-Ni-Ti joints exhibited a reaction zone having a relatively smooth concentration gradient of gold, nickel, iron, and other elements between the base and filler metal (see Fig. 9). Aging appears to have caused a noticeable segregation of elements. First, at the boundary between the reaction zone and the (nominal) Au- Ni-Ti filler metal, a gold concentration increase was observed. Second, the filler metal contained a matrix phase and a particle phase. The matrix phase had the following composition: gold (67 at.-%), titanium (15 at.-%), nickel (12 at.-%), iron (3 at.-%), cobalt (2 at.-%), and chromium (1 at.-%). The particle phase had the repro- ducible (_ 1 at.-%) composition of iron (36 at.-%), nickel (33 at.-%), cobalt (24 at.-%), chromium (5 at.-%), and gold (1-2 at.-%). Binary phase diagrams of the Cr-

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Fig. 19 - - Bar chart showing the Jour-point bend strength o f the Thermo- Fig. 21 - - Bar chart showing the four-point bend strength o f the T)pe 347 Span/Au-Ni-Ti joints after aging, stainless steel/Au-Ni-Ti joints after aging.

Fe, Cr-Ni, and Fe-Ni alloy systems exhibit extensive regions of mutual solubility, of course when fully liquid, but also when solid at high temperatures. However, those high- temperature solid solutions generally decompose by phase separation at lower temperatures. A similar scenario was hypothesized to have occurred in the braze joint. That is, aging caused phase separation of the filler metal, which now included dissolved base metal components, into the matrix and particle phases discussed above. That scenario appeared to be more likely than the formation of two phases by long-range, solid-state diffusion of the Thermo-Span base metal constituents during the aging treatment.

The aged braze joints made between the Type 347 stainless steel base metal and Au-Ni-Ti filler metal were similarly examined. The braze joint area, including the filler metal and the reaction zones, did not grow significantly after aging for up to 300 days at ei ther 225°C (437°F) or 460°C (860°F). However, an artifact that was associated with these aging conditions was a demarcation line down the center of the joint. This artifact is shown by the optical micrograph in Fig. 16 of a specimen aged at 225°C (437°F) for 300 days. Electron microprobe analysis determined the line to be rich in nickel and titanium. Gold and iron were also present as was a trace of chromium. A specific composition of the line could not be determined due to its thin stature.

An appreciable increase in size of the braze joint was observed for Type 347 stainless steel/Au-Ni-Ti couples aged at 700°C (1292°F). This point is illustrated by the optical micrograph in Fig. 17 of the specimen aged for 437 days. A reaction

zone approximately 35 p.m (0.0014 in.) developed at the base metal/filler metal interface. Because the Au-Ni-Ti filler metal region exhibited a thickness similar to that in the as-fabricated case, the reaction zones formed along the stainless steel grain boundaries and then developed further into the base metal by subsequent "consumption" of the base metal grain.

A representat ive EMPA trace made across the braze joint is shown in Fig. 18. At the interface between the stainless steel and reaction zone, gold and ti tanium peaks were accompanied by a minimum in the Fe concentration. Progressing through the reaction zone, from the stainless steel to the filler metal, the following trends were noted: iron, chromium, manganese, and ti tanium concentrat ions remained relatively constant at 54 at.-%, 13 at.-%, < 1 at.-%, and 0 at.-%, respectively. An increase in nickel concentration from 22 to 30 at.-%, and a decrease in the gold concentration from 6 to I at.-% was observed.

The Au-Ni-Ti filler metal was comprised of two phases, a matrix phase and a particle phase (which, again, was not present in the as-fabricated joint). The matrix phase contained from 8 to 10 at.-% of each of the following elements: iron, nickel, manganese, and chromium as well as 2 at.-% of titanium; the remaining content was gold. The gold/nickel ratio was much higher after aging than was its value in the as-fabricated joint. The particle phase had a composition of iron (55 at.-%), nickel (30 at.-%), chromium (13 at.-%), and gold (2 at.-%). Aside from the presence and/or absence of particular elements per the respective base metal compositions, differences in the matrix and particle phase compositions between these Au-Ni-Ti/Type 347

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Fig,. 20 - - SI':M l~lumW'al~h.s q f the l)aclmz' surfaces o l" Thermo-Span/Au-Ni-Ti, Jbur-point bend joints .wecimens. A - - ht the as-fabricated condition; B - - J o l l o w i n g aging at 700°C (1292°F) Jor 200 days.

stainless steel couples and similarly aged Au-Ni-Ti/Thermo-Span couples reflected primarily the different compositions of the respective base metals• As was hypothesized in the analysis of the latter couples, the particle phase formed during the aging treatment by precipitation of compounds comprised of elements dissolved in the filler metal at the time the joint was formed.

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Post Aging

Shown in Fig. 19 is a bar chart depict- ing the four-point bend strength of Thermo-Span/Au-Ni-Ti joints after aging. The bend strength increased from a mean value of 880 MPa (128 ksi) for the as- brazed joints to mean values of 1020 MPa (148 ksi) and 1000 MPa (145 ksi) after aging at 460°C (860°F) for 87 and 2(10 days, respectively. The joint strengths then decreased to values of 601) MPa (87.1 ksi) and 410 MPa (59.5 ksi) when aged at 700°C (1292°F) for the same respective time periods. Scanning electron microscopy of the fracture surfaces together with optical microscopy and EMPA evalu- ations of fracture surface cross sections showed failure within the filler metal for the high-strength specimens aged at 460°C (860°F).

The strength decrease for Thermo- Span/Au-Ni-Ti couples after aging at 700°C (1292°F) was accompanied by the two previously described microstructural changes: 1) the development of a reaction zone at the Thermo-Span/Au-Ni-Ti interface and 2) the precipitation of a particle phase in the remaining filler metal. Shown in Fig. 20A is a SEM photograph of the fracture surface representing the as-fabricated condition. (Note the magnification is significantly lower than that of Fig. 12B.) Shown in Fig. 20B is the fracture surface of the specimen tested after aging at 700°C (1292°F) for 200 days. The larger scale of deformation associated with the as-fabricated sample was replaced by mixture of smaller scale deformation surrounding particles for the aged sample. The latter fracture surface morphology is consistent with particle precipitation in the filler metal.

In summary, the effect of aging on the four-point strengths of Thermo-Span/Au- Ni-Ti couples reflected a precipitation strengthening mechanism based upon particles comprised of base metal elements dissolved in the filler metal at the time of brazing. The strengthening was maximized when aging at 460°C (860°F) as the formation of nanometer space particles took place. However, aging at 700°C (1292°F) resulted in an over-aging condition. The particles grew significantly larger, now being visible in cross section and on the SEM fracture surface - - Fig. 20. Concurrent with particle enlargement was a drop in joint strength.

The strength behavior of Type 347 stainless steel/Au-Ni-Ti joints as a function of aging is shown in Fig. 21. The strength of the as-fabricated specimens was 340

causecl an increase~n s~irength to 680 MPa (98.7 ksi) and 605 MPa (87.8 ksi) for time periods of 87 and 200 days, respectively. However, aging at 700°C (1292°F) resulted in a strength decrease to 461 MPa (66.9 ksi) after 87 days and 426 MPa (61.8 ksi) after 200 days. This dependence of ,joint strength on aging was very similar to the Thermo-Span/Au-Ni-Ti couples. That similarity also extended to the fracture surface morphologies (Fig. 20), as determined by SEM analysis.

Summary

1 ) The effects of aging on microstructure and bend strength were examined fl)r brazed joints made with 81Au- 17.5Ni- 1.5Ti filler metal and either Thermo-Span or AIS! Type 347 stainless steel base metals.

2) Excellent wetting and spreading were exhibited by the Au-Ni-Ti filler metal on both base metal surfaces.

3) Sessile drop morphology showed a two-zone precursor structure at the edge of the spreading Au-Ni-Ti filler metal.

4) A 15- to 35-p,m-wide reaction zone formed at the interface between the Thermo-Span alloy and Au-Ni-Ti filler metal in the as-fabricated joints. Aging at 700°C (1292°F) caused the reaction zone to grow; however, the mechanical strength behavior of the joints was not affected by the zone.

5) Significant quantities of iron (10 at.-%) and cobalt (7 at.-%), and trace amounts of chromium and niobium, were identified in the filler metal area of the as- fabricated Thermo-Span joints. Aging at 700°C (1292°F) caused the precipitation of particles in the filler metal area, which had the following composition: Fe (36 at.-%), Ni (33 at.-%), Co (24 at.-%), Cr (5 at.-%), and Au (1-2 at.-%). The precipi- tates originated from base metal elements that dissolved into the filler metal at the time the braze joint was made.

6) Type 347 stainless steel/Au-Ni-Ti joints exhibited similar microstructural features in the as-fabricated condition, as well as changes to those features after aging, as were observed with the Thermo- Span base metal. The compositions of the interface reaction zone and particles that precipitated in the filler metal area after aging reflected the particular composition of the stainless steel base metal.

7) The effect of aging on the four-point bend strengths of the Thermo-Span/Au- Ni-Ti and AISI Type 347 stainless steel couples indicated a precipitation strengthening mechanism. Specifically, strength-

(860gF). An over-aging con~lition resulted from heat treating at 700°C (1292°F) as indicated by a drop in bend strength.

Acknowledgments

The authors wish to thank A. Kilgo, who performed the metallographic sample preparation; P. Hlava, who performed the EMPA; and B. Ritchey for the SEM micrographs. The authors would also like to thank C. Robino for his very thorough review of the manuscript.

Sandia is a multiprogram laboratory operated by Sandia Corp., a Lockheed Martin company, for the U.S. Department of Energy under contract DE-AC04- 94AL85000.

References

1. Mangin, C., Neely, J., and Clark, J. 1993. The potential for advanced ceramics in automotive engine applications. Journal qf Metals June: 23-27.

2. DeLuca, M., and Swain, J. 1987. An advanced ceramic-to-metal joining process. Ceram. Eng. Sci. Proc. 8[7-8]: 602-610.

3. Santella, M. 1993. Joining of ceramics for beat engine applications. Ceramic Tech. Project- Semiannual Prog. Rep. For Oct. 1992-March 1993, ORNL/TM-12428: 167-180.

4. Bex, W. 1989. Metallurgical study of su- peralloy brazing alloys. Proc. Propulsion and Ene~,,etics panel at the 72nd Specialists' Meeting, Bath, UK.3-5 Oct.: pp. 27-1 to 27-12.

5. Sasabe, K. 1991. Effect of joint clearance on fatigue strength of brazed joint. Trans. Nat. Res. Inst. For Metals 33(1), pp. 3641.

6. Dicus, D., and Buckley, J. 1972 The effects of high-temperature brazing and thermal cycling on the mechanical properties of Hastel- Ioy X. NASA Langley Research Center Report: L-8376, pp. 1-21.

7. Shimoo, T, Kobayashi, Y., and Okamura, K. 1992. Kinetics of reaction of Si3N 4 with Ni. Jour. of the Cer. Soc. of Japan, Inter. Edition 100, pp. 8111-806.

8. Naka, M. 1992. Controlling of ceramic- metal interracial structure using molten metals. Trans. Weld. Res. Inst. 21: 1-7.

9. Boadi, J., Yano, T and lseki, T. 1987. Brazing of pressureless-sintered SiC using Ag- Cu-Ti alloy. Jour. of Mater Sci. 22: 2431-2434.

10. Bang, K., and Liu, S. 1994. Interracial reaction between alumina and Cu-Ti filler metal during reactive metal brazing. Welding Journal 73:54-s to 60-s.

11. Thermo-Span is a registered trademark of Carpenter Technologies Corp.

12. Wilbraze TM is a registered trademark of the former Wilkinson Corp.

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