ding Aerospace Industry - American Welding Society

124 Pages·2010·13.87 MB·English

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: [phone]
. 5/32" Covered
^,
cations, such as auto
superior feedability su-
Fax: [phone]
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: [phone], Fax: [phone]
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 [phone].
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 [phone].
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 [phone]
metal cored, flux cored in spool and cut length.
• All grades of hard facing products, electrodes, flux
fax [phone]
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-
[phone] or [phone]
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