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wmu kj February 2009 ding Aerospace Industry •Guns and Torches Updat d Mea Accurate Fill Crash Resistance of Aluminum PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING AND ALLIED JOINING AND CUTTING PROCESSES, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING One Word Defines y^ Select-Arc's New El^ctrodeune and ReputatidAtkfpr Quality—. r. \ m rf Select-Arc, Inc. has earned teristics, consistent deposit electrodes' higher deposi- Discover for yourself the an outstanding reputation chemistry and excellent many benefits of specifying tion rates improve produc- in the industry as a manu- overall performance you tivity and reduce welding Select-Arc's new premium facturer of premium quality have come to expect from costs. stainless steel electrodes. Call tubular welding electrodes Select-Arc. us today at 1-800-341-5215 SelectAUoy's smooth bead for carbon and low alloy or you can visit our website contour, easy peeling slag, The chart below shows steel welding. at www.select-arc.com for that SelectAlloy flux cored minimal spatter, closely more information. Now Select-Arc has controlled weld deposit expanded its range of compositions and metal Typical Deposition Rates for exceptional products soundness deliver addi- Various Stainiess Steel Consumables SELECT with the introduction tional savings. of a complete line of xCor .0 45' Fli .045" vletaK :ored The Select 400-Series austenitic, martensitic Elect rode El ectrod // 7 metal cored electrodes A and ferritic stainless s ^ offer the same advan- y\ steel electrodes. Both ft 600 Enterprise Drive tages as SelectAlloy and the new SelectAlloy Xo 45" So idWir e EO. Box 259 /' 4 Elect ode are ideally suited for and Select stainless Fort Loramie,OH 43845-0239 difficult-to-weld appli- steel wires deliver the Phone: (937) 295-5215 . 5/32" Covered ^, cations, such as auto superior feedability su- Fax: (888) 511-5217 Electrode www. select-arc. com exhaust systems. perb welding charac- Current (amps) For Info go to www.aws.org/ad-index Weld greener. Weld smarter. Get the clean, green, smart weld wire you need. National Standard wire produces less smoke and fumes for a cleaner, safer workplace and less spatter for less rework and cleanup. Recyclable packaging and CopperFree® weld wire help you create a greener environment. Proprietary engineered matte, textured finish holds the right amount of lubricant for smoother feeds and higher productivity. It produces cleaner welds and more arc stability. And it reduces wear and tear to your welding equipment for a smarter operation. National Standard weld wire exceeds AWS specifications. Manufactured in the USA with precise alloy chemistries, it's drawn to exact diameter for maximum consistency and strength. Use the cleanest, greenest, smartest weld wire and make things better for the environment... and for your business. Contact your National Standard distributor or visit www.nationalstandard.com. o NATIONAL STANDARD A HEICO WIRE GROUP COMPANY Customer Service: 800-777-1618 www.nationalstandard.com A cleaner weld. A greener weld. For Info go to www.aws.org/ad-index AA f Cold Metal Transfer - CMT "The cool new way to weld" CMT incorporates wire motions into the digital process. Virtually spatter free MIG welding This makes it possible to weld with lower thermal input and high possible with 100 % C0 2 process stability. Welcome to the Fronius "Cold Revolution"! Perfect characteristics for cladding equals low dilution FRONIUS USA, LLC 10421 Citation Drive, Suite 1100, Brighton Michigan 48116, USA Thin sheet, low heat input, Tel: 1-810-220-4414, Fax: 1-810-220-4424 low distortion email: [email protected] www.fronius-usa.com PERFECT WELDING For Info go to www.aws.org/ad-index CONTENTS AWS Web site www.aws.org February 2009 • Volume 88 • Number 2 Departments Features Washington Watchword 4 28 In-Process Quality Assurance for Aerospace Welding In-process quality assurance can be used to preclude the Press Time News 6 occurrence of defects in aircraft and aerospace structures Editorial 8 V. R. Dave et al. News of the Industry 12 34 Current Technology in Welding Guns and Torches Aluminum Q&A 20 Highlights are presented of the latest guns and torches technology for gas metal arc, flux cored arc, and gas New Products 24 tungsten arc welding A. Cullison, K. Campbell, and M. R. Johnsen Welding Workbook 54 Coming Events 56 38 How to Accurately Measure Fillet Welds A manufacturer of tubular assemblies for the aerospace and Society News 61 other industries developed a novel method for taking fillet Tech Topics 73 weld readings J. Pavilanis Guide to A WS Services 87 New Literature 92 42 Optimizing Crash Resistance of Welded Aluminum Structures Numerical design tools were developed to aid in the Personnel 94 selection and optimization of alloy composition, temper, and process conditions for age-hardening aluminum alloys Classifieds 99 O. R. Myhr et al. Advertiser Index 102 46 Real-Time Crack Detection in Aerospace Structures A system has been developed for detecting the initiation of cracks during low-cycle fatigue tests in real time and prior to damage occurring to components and tooling Welding Research Supplement 21 -s Hyperbaric GMA Welding of Duplex Stainless Steel at 12 and 35 Bar Tests showed excellent mechanical properties were achieved in underwater duplex stainless steel welds made under dry hyperbaric conditions O. M. Akselsen et al. Welding Journal {\SSfi 0043-2296) is published monthly by the American Welding Society for 29-s Control of Longitudinal Bending Distortion of Built-Up $120.00 per year in the United States and posses- Beams by High-Frequency Induction Heating sions, $160 per year in foreign countries: $7.50 The location and intensity of induction heat input were per single issue for domestic AWS members and determined in order to mitigate longitudinal bending distortion $10.00 per single issue for nonmembers and $14.00 single issue for international. American of built-up beams during fabrication Welding Society is located at 550 NW LeJeune Rd., J. U. Park et al. Miami, FL 33126-5671; telephone (305) 443-9353. Periodicals postage paid in Miami, Fla., and addi- tional mailing offices. POSTMASTER: Send address 35-s Three-Dimensional Analysis of Molten Pool in GMA-Laser changes to Welding Journal, 550 NW LeJeune Rd., Hybrid Welding Miami, FL 33126-5671. Canada Post: Publications Analytical models of GMA and laser keyhole welding were Mail Agreement #40612608 Canada Returns to be merged to simulate hybrid welding and show the flow patterns of sent to Bleuchip International, P.O. Box 25542, London, ON N6C 6B2 the molten pool J.-H. Cho and S.-J. Na Readers of Welding Journal my make copies of articles for personal, archival, educational or re- search purposes, and which are not for sale or re- sale. Permission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright. WELDING JOURNAL WASHINGTON BY HUGH K. WEBSTER WATCHWORD AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE Small Business Administration Cabinet charging pollutants into the air and water, laundering money, and making criminally false statements. Status May Be Restored Most OSHA Whlstleblower Complaints Lack Support is growing in Washington to once again make the ad- Merit ministrator of the U.S. Small Business Administration (SBA) a Cabinet-level position. The SBA briefly held Cabinet status under It is a violation of federal law for an employer to retaliate in any the Clinton administration. The rationale is that the SBA adminis- manner against an employee who reports a workplace safety or trator will have greater stature as a Cabinet member and therefore health violation or otherwise exercises his or her rights under fed- can promote the mission of the SBA more effectively. This move eral occupational safety and health laws. In 2008, of the 1259 retal- would also emphasize the importance of small business to the U.S. iation charges investigated by the Occupational Safety and Health economy. Key members of Congress and President-Elect Barack Administration (OSHA), 80% were either dismissed or ultimately Obama's transition team have endorsed this action. withdrawn. Only 20% were found have to merit. Definition of 'Independent Contractor' May Economic Stimulus to Go beyond Public Be Narrowed Works A common method of attempting to predict what legislation Most of the attention given to the planned economic stimulus may be favored by the new administration is by examining bills that legislation that is expected to be enacted in early 2009 has been on President-Elect Barack Obama introduced while serving as a U.S. public works infrastructure projects, but there are several other as- Senator. One such bill would have made it more difficult for em- pects that are relevant to industry. Those identified include the ployers to classify workers as independent contractors as opposed following: to employees. Employers do not have to provide benefits to inde- • Provision of a $3000 refundable tax credit for each additional pendent contractors, and therefore many employers prefer that full-time employee hired by companies in 2009 and 2010; classification. • Extension of the small business investment expensing limit to The legislation advocated by then-Senator Obama would have $250,000 through the end of 2009; voided a provision in the law that currently allows employers to • Elimination of all capital gains taxes on investments made in designate workers as independent contractors based on long-stand- small and startup businesses; ing practice in that particular industry. The bill also would have • Making the Research and Development tax credit greatly expanded the authority of the Internal Revenue Service in permanent; this area, including with respect to issuing regulations on how work- • Creation of a nationwide emergency lending facility for small ers should be classified. businesses to be run through the Small Business Administration's Disaster Loan Program; OSHA Issues Final Personal Protective • Temporary elimination of the fees on the SBAs 7(a) and 504 Equipment Rule Correction loan guarantee programs for small businesses; • Creation of an Advanced Manufacturing Fund to identify and The final Occupational Safety and Health Administration invest in the most compelling advanced manufacturing strategies; (OSHA) rule on Clarification of Employers' Duty to Provide Per- • Doubling of federal funding for the manufacturing extension sonal Protective Equipment and Train Each Employee became ef- partnership program that works with manufacturers across the fective December 12. The rule revises OSHA standards to clarify country to improve efficiency, implement new technology, and that, for employers to be in compliance, they must provide personal strengthen company growth; protective equipment (PPE) and hazards training for each em- • Doubling of federal funding for basic research; and ployee covered by the standards. • Creation of a national network of public-private business The final rule does not impose any new substantive require- incubators. ments. The duty to provide PPE of all types, including respira- Federal Web Site Managers Urge President- tors, and training to employees already exists in the law, and this new final rule adds no new compliance burden. Rather, the final Elect to Increase Transparency rule achieves greater consistency in the applicable OSHA regu- lations, provides clearer notice of the nature of the employer's Government officials in charge of managing federal Web sites duty under existing PPE and training provisions, and clarifies are urging the incoming administration to establish Web commu- that separate per-employee citations and penalties may be im- nications as a core government business function and transform posed by OSHA. these Web sites into truly helpful sources of information for the U.S. public. There are approximately 24,000 U.S. government Web Environmental Protection Agency Creates sites currently in operation, but most tout organizational achieve- 'Most Wanted' Web Site ments instead of effectively delivering basic information and serv- ices. Legal, security, privacy, and internal policy concerns are partly responsible, according to the Federal Web Managers Council, but The U.S. Environmental Protection Agency has established the in addition many federal agencies tend to focus more on technol- first-ever federal database of fugitives accused of violating environ- ogy and Web site infrastructure than improving content and mental laws and evading arrest. The Web site, www.epa.gov/fugitives, service delivery. • includes photos of the accused, summaries of their alleged envi- ronmental violations, and information on each fugitive's last known Contact the AWS Washington Government Affairs Office at whereabouts. The alleged violations include smuggling of ozone- 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail depleting substances, illegally disposing of hazardous waste, dis- [email protected],- FAX (202) 835-0243. FEBRUARY 2009 ISO 9001:2000 Certified WELD MOLD COMPANY YOUR ONE-STOP SHOP FOR WELDING ALLOYS SINCE 1945 We offer: • Stock tool steel alloys from .035" to 156" in spool and www.weldmold.com cut lengths. Electrodes from 1/16" to 3/4" diameter. • Stock maintenance and repair alloys .035-.156 solid, phone 800.521.9755 metal cored, flux cored in spool and cut length. • All grades of hard facing products, electrodes, flux fax 810.229.9580 cored and open arc wires. • 100 lb minimums for custom electrode manufacturing. Brighton, Mi 48116 • 250 lb minimums for custom metal cored, flux cored or open arc wire. For Info go to www.aws.org/ad-index WELflM? PI7E55 TIME NEWS Publisher Andrew Cullison American Welding Society Adds $1.1 Miiiion to Schoiarship Endowments Editorial Editorial Director Andrew Cullison Editor Mary Ruth Johnsen The American Welding Society (AWS), Miami, Fla., has recently added $1.1 million Associate Editor Howard M. Woodward to the multimillion-dollar portfolio of scholarship endowments of the AWS Foundation. Associate Editor Kristin Campbell Funding from the American Welding Society's cash reserves will enable the AWS Foun- Peer Review Coordinator Erin Adams dation to increase its scholarship awards to future welding professionals. "This major new endowment is specifically targeted to those individuals who are Publisher Emeritus Jeff Weber seeking a career in welding," said Sam Gentry, executive director, AWS Foundation. "This will help meet the urgent need for welding personnel in the American workplace." Graphics and Production There is a projected shortage of 200,000 welders in the United States by 2010, and Production Manager Zaida Chavez retiring welders are exceeding new welders coming into the field. Also, according to Senior Production Coordinator Brenda Flores Gentry, the average age of a welder is currently about 54. Welders are now needed in manufacturing and construction, particularly in major Advertising energy and infrastructure projects across the country. Local AWS District volunteers National Sales Director Rob Saltzstein are going to be the primary means of distributing the new scholarship money in accor- Advertising Sales Representative Lea Garrigan Badwy dance with local industry needs. Senior Advertising Production Manager Frank Wilson "Volunteer leaders in AWS Districts know the needs and trends of local industry," Subscriptions said Gentry, "so they can efficiently distribute scholarships to the best candidates, whether Subscriptions Representative Edalia Suarez they are entering a technical school program or a college." [email protected] Aerospace Weiding Minneapolis Achieves EASA Approval American Welding Society 550 NW LeJeune Rd., Miami, PL 33126 Aerospace Welding Minneapolis, Inc., Eagan, Minn., has gained Part 145 EASA ap- (305) 443-9353 or (800) 443-9353 proval from the European Aviation Safety Agency. This certificate has been issued under the terms of the current Bilateral Aviation Safety Agreement and the associated Main- Pubiications, Expositions, Marketing Committee tenance Implementation Procedures. It allows the company to export all overhauled D. L. Doench, Chair and repaired parts to customers in any EASA member country. Hobart Brothers Co. T A. Barry, Vice Chair Furthermore, AWI's staff includes a FAA designee with Designated Manufacturing Miller Electric Mfg. Co. Inspection Representative status, allowing for the issuance of Export Certificates of Air- J. D. Weber, Secretary worthiness on all of the Aero-Power® brand parts. American Welding Society P. Baka, The Lincoln Electric Co. Employers Cautioned against Cutting Back on Workplace S. Bartholomew, ESAB Welding & Cutting Prod. Safety in Times of Economic Difficulty D. Brown, Weiler Brush J. Deckrow, Hypertherm D.DeCorte, RoManMfg. American Society of Safety Engineers' (ASSE) President Warren K. Brown of Fair- J. Dillhoff, OKI Bering born, Ohio, recently referred to reports of some companies cutting safety processes hop- J. R. Franklin, Sellstrom Mfg. Co. ing to reduce costs. "Workplace safety processes must be in place at all times," Brown D. Levin, Airgas said. "They are even more critical during business downturns." J. Mueller, Thermadyne Industries Laura Comstock, president-elect of the ASSE South Carolina Chapter, also offered R.G.Pali,/.PMraen Co. input. "Some safety-related purchases and testing can be deferred, but other purchases, J. F. Saenger Jr., Consultant such as those for employee personal protective equipment like hardhats, safety glasses, S. Smith, Weld-Aid Products and respirators, are critical to operations," Comstock said. D. Wilson, Wilson Industries Plus, the South Carolina ASSE chapter suggests employees can take measures to J. C. Bruskotter, Ex Off., Bruskotter Consulting Services help companies save money. This can be done by following safe working procedures and H. Castner, Ex Off., Edison Welding Institute practices to prevent injuries, related downtime, and expenses; properly using, cleaning, L. G. Kvidahl, Ex Off, Northrup Grumman Ship Systems G. E. Lawson, Ex Off, ESAB Welding & Cutting Prod. and caring for protective equipment; reusing gloves whenever possible for as long as E. C. Lipphardt, Ex Off., Consultant possible; and keeping track of safety glasses and reusable hearing protection. S. Liu, Ex Off, Colorado School of Mines "Money cut from safety processes now could have an enormous cost later; this can E. Norman, Ex Off., Southwest Area Career Center be from injury and health care costs, fines, lost production time, employee morale, or R. W. Shook, Ex Off, American Welding Society worst of all, employee injury or even death. There are better and smarter ways to pro- tect the bottom line," Brown added. KUKA Lands Key Aircraft Order Copyright © 2009 by American Welding Society in both printed and eiec- tronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information deveioped by the authors KUKA Robotics, Clinton Township, Mich., has received a blanket order from the of specific articles are for informational purposes only and are not in- tended for use without independent, substantiating investigation on the European aircraft manufacturer Airbus S.A.S. This is for the delivery of 41 omniMove part of potential users. mobile platforms, which feature a flexible horizontal range of motion in all directions and can rotate on the spot, for assembly of the Airbus A350 XWB. The assembly plat- BPA forms will be used in the French, British, German, and Spanish Airbus factories to sub- assemble the plane's wings and fuselage sections. The term of the blanket order is five years. FEBRUARY 2009 We Back Them Better Because We Build Them Better. " New 2-YEAR WARRANTY on all oike Aronson/Ransome positioning eqoipment. 7^ . fhen y positioning equipment that's this reliable, you can back it with a standard i/arranty that no one else en tries to offer: a full 2 years n materials and workmanship. And should your Koike positioner ever need service-under warranty or after-we'll send out from our U.S. factory one of the same master technicians who build our positioners. We're the only company in the industry who does that, too. Koike offers positioners that can handle standard parts or awkward objects in any shape and at any angle from 100 lbs. to 4 million lbs. So we probably have the positioning equipment that can make your welding more profitable. We definitely have the warranty that will keep you up and running. B Koike Aronson, Inc./Ransome Arcade, NY USA 800-252-5232 Houston, TX 800-868-0640 www.koike.com For Info go to www.aws.org/ad-index American Welding Society EDITORIAL Founded in 1919 to Advance the Science, Technology and Application of Welding AWS Gears New Membership Officers President Victor Y. Matthews Package to Welders The Lincoln Electric Co. Vice President John C. Bruskotter Bruskotter Consulting Services, LLC The Membership Committee and the staff of the AWS Membership Department are Vice President John L. Mendoza always looking for enhancements to our membership benefits. Following two years of CPS Energy concentrated effort to better service the needs of our members who identify themselves as welders, AWS is now ready to introduce the most significant additions to our benefits Vice President William A. Rice Jr. in many years. OKI Bering While the overall number of AWS members continues to grow, the number of mem- bers identifying themselves as welders remains steady — about 8% of the total. Through Treasurer Earl C. Lipphardt a national firm that specializes in large surveys, AWS contacted a large number of Consultant welders asking them directly about the present membership package and soliciting their Executive Director Ray W. Shook ideas on enhancements that may make a Society membership more attractive to a greater number of welders. American Welding Society In direct response to their suggestions, the Membership Committee has developed several new member benefits, which include the following: Directors 1. Discounts on tools/equipment of the trade. The welders contacted during the sur- vey emphasized that a valuable benefit would be discounts on their needed tools. AWS B. P. Albrecht (At Large), Miller Electric Mfg. Co. has worked with GAWDA (Gases and Welding Distributors Association) to provide this J. R. Bray (Dist. IS), Affiliated Machinery, Inc. benefit. Participating welding distributors will now offer a discount on materials for AWS H. R. Castner (At Large), Edison Welding Institute members. The names and locations on these distributors will be maintained on the AWS D. B. DeCorte (At Large), RoMan Mfg. Inc. Web site (www.aws.org). The magnitude of the discount and the materials included as a member benefit will be determined by each individual distributor. G. Fairbanks (Dist. 9), Fairbanb Inspection & Testing Services 2. Access to AWS health insurance program. Many welders identified the need for D. A. Flood (Dist. 22), Tri Tool, Inc. affordable health insurance as a valuable benefit. AWS has finalized an agreement with M. V. Harris (Dist. 15), Vallej' National Gases a major insurance underwriter to offer not only health insurance but also many other R. A. Harris (Dist. 10), Consultant types of insurance coverage for AWS members. 3. Publications exclusively for welders. The survey revealed that welders would like D. C. Howard (Dist. 7), Concurrent Technologies Corp. information that was specifically directed toward their interests. One item that was iden- J. Jones (Dist. 17), Thermadyne tified by a high percentage of the respondents was a package of welding projects that can W. A. Komlos (Dist. 20),ArcTech LLC be used to construct a variety of items. To address this request, AWS and the Lincoln D. Landon (Dist. 16), VermeerMfg. Co. Electric Foundation will make the well-known and respected Arc Welding Projects, Volume IV, available as a new publication selection for welders who have just become R.C.Lanier(Dist.4),HttC.C. members of the Society. G. E. Lawson (Past President), ESAB Welding & Cutting Prod. 4. Welders Exchange Bulletin Board on the AWS Web site. A method for the "welder" J. Livesay (Dist. 8), Tennessee Technology Center members to better communicate with other welders was also requested. Through the addition of a new bulletin board feature on the AWS Web site, a welder will be able to D. L McQuaid (At Large), DL McQuaid & Associates ask a question, share a successful project, or seek a solution to a problem. Other welders, S. Mattson (Dist. 5), Mattson Repair Service then, will be able to easily respond and share their experiences. This bulletin board will S. P. Moran (Dist. 12), Miller Electric Mfg. Co be dedicated to allowing welders to communicate with their peers. R. L. Norris (Dist. 1), Consultant 5. Discounts on dental plans, prescriptions, and more. AWS is providing a compre- hensive package of discounts on many things that should add value to a membership. It T. C. Parker (Dist. U), Miller Electric Mfg. Co. is anticipated that many of these programs will become a welcome incentive to welders K. A. Phy (Dist. 6), Entergy Nuclear Operations, Inc. wanting to join AWS. W. R. Polanin (Dist. 13), Illinob Central College As you can see, AWS went directly to welders, asked what they would like to have as N. Saminich (Dist. 21), Ninyo & Moore a member benefit, and as a result, has developed a new plan in response to the interests defined by this vital segment of our industry. The N. S. Shannon (Dist. 19), Carbon Testing of Portland Membership Committee is pleased to offer this new T.A.Siewert(AtLarge),iV/5r program and anticipates these benefits will be attrac- E. Siradakis (Dist. \\),Airgas Great Lakes tive to welders. On a closing note, I am asking for your help in K. R. Stockton (Dist. 2), PSE&G Maplewood Testing Serv. spreading the news. Share this information with the G. D. Uttrachi (Past President), WA Technology, LLC welders you know and encourage them to take advan- D. R. Wilson (At Large), Wilson Industries tage of the opportunity to not only join the premier M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute welding society in the world, but to reap the values provided by these newly added benefits. Lee G. Kvidahl Chair, AWS Membership Committee FEBRUARY 2009

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Feb 2, 2009 technology for gas metal arc, flux cored arc, and gas tungsten arc other industries developed a novel method for taking fillet weld readings.
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Most books are stored in the elastic cloud where traffic is expensive. For this reason, we have a limit on daily download.