April 2010 *m ifferent Crome-Moly Steels ^V/oUliii« •How to Select an Engine-Drive Power Source •Competency Models Help Prepare Job Skills •Welding Education Opportunities 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 For more information on choosing When your critical welding require- flat and horizontal or all position low the Select-Arc low alloy electrode ments demand a high quality, low alloy electrode that is ideally suited that is just right for your specific alloy, gas-shielded, flux cored elec- to handle your individual need. welding requirement, call us today trode, insist on specifying Select-Arc. Select-Arc's comprehensive selection at 1-800-341-5215 or visit our of low alloy electrode grades includes; Select-Arc offers an expanding lineup website at www.select-arc.com. of over 50 premium wires specially • Nickel Bearing designed for welding low alloy and • Nickel-Molybdenum Bearing high strength steels. Whatever your • Nickel-Molybdenum- application - from bridge construction Chromium Bearing SELECT to oil exploration equipment, pressure • Manganese-Molybdenum Bearing vessels to petroleum plants, mining • Carbon-Molybdenum Bearing machinery to submarines, and so • Chromium-Molybdenum Bearing ARC me. ®' • Weathering Steel many others - we can provide the For Info go to www.aws.org/ad-index "NO SHORTCUTS" It's part discipline, part pride and all passion that fuels Shane 'Cajun' Guidry, a native of New Orleans, Louisiana. "If you take pride in your work, then welding is for you," he says. "Because every weld you make is your signature." Shane's passion for welding runs deeper than your average metalworker. His work has brought him from Russia to the 40-below tempertures of Alaska. Today he works as an AWS Certified Welding Inspector, where his 'no shortcuts' attitude has made him a reliable team member. "For every weld I inspect, I pretend a member of my family will depend on it," he says. SHANE NEEDS EQUIPMENT HE CAN RELY ON. THAT'S WHY HE CHOOSES TWECO. ABOARD THE U.S.S. NIMITZ HE USED TWECOTONG ELECTRODE HOLDERS TO REPAIR A WEAPONS ELEVATOR. "THEY'RE INTERCHANGEABLE, DEPENDABLE, AND SAFE," HE SAYS. While in Alaska, Shane used Tweco arctic cables on an exploratory drilling site. He said, "Even after dropping them seven stories down, they came up clean and ready to go again." SHANE GUIDRY AWS Certified Welding Inspector PM Testing Inc. Shane carries the torch - will you? THERMADYNE, A GLOBAL CUTTING AND WELDING LEADER, joins the American Welding Society in encouraging individuals to practice the art, craftsmanship and professions of welding, metalworking and fabrication. Victor, Thermal Dynamics, Thermal Arc, Arcair, Tweco, Stoody, Cigweld and TurboTorch are among the Thermadyne family of brands that you can count on for safety, reliability and quality. For more information visit www.thermadyne.com/tweco or call Thermadyne Customer Care at 1-800-426-1888 www.thermadyne.com 'THERMADYNE American Welding Society i/ad-inde)* * Sustaining Company Member Kimberly-Clark * *J ROFESSIONA Want peace of mind for generations? Let^s get it done. Generations of professional welders have trusted the JACKSON SAFETY* Brand for superior performance and peace of mind. Today, the JACKSON SAFETY* Brand heritage and product line is stronger than ever - and winning over a new generation - as part of KIMBERLY-CLARK PROFESSIONAL*. LET US PROVE IT. Together, we can achieve a higher level of protection, cost-savings and productivity. For your fff££Site Survey, enter promo code WJ410at www.kcproveit.com ,' 'MT;T 'i \] JACKSON SAFETY Brand l WELDING SAFETY • PERSONAL PROTECTIVE EQUIPMENT • WORK ZONE SAFETY www.jacksonsafety.com/welding For Info go to www.aws.org/ad-index CONTENTS April 2010 • Volume 89 • Number 4 Features 33 Welding and Postweld Heat Treatment of P91 Steels Proper design, filler metals, heat treatment, and welding AWS Web site www.aws.org procedures, along with skilled personnel, all factor into Departments joining these creep-resistant steels W. F. Newell Jr. Editorial 4 38 Selecting an Engine-Driven Welding Machine Washington Watchword 6 Before selecting your engine-drive power source know what Press Time News 8 questions to ask and the specific applications for its use E. Snyder News of the Industry 10 Brazing Q&A 14 42 Best Practices for GTAW 4130 Chrome-Moly Tubing Aluminum QM 20 Here is a step-by-step approach for the successful joining of 4130 Letters to the Editor 24 T. Bevis and A. Weyenberg Book Review 26 New Products 28 46 Techniques for Joining 1 'ACr-'AMo Steels Understanding modern welding techniques will lead to Welding Workbook 60 successful repeatability in joining these steels Coming Events 62 J. Brennan and B. Fletcher Society News 69 50 Weld Integrity Critical to Tower Cranes Tech Topics 70 Welds must be strong and defect-free for the construction of Interpretation D1.1 tower cranes G. Trammer Errata C5.4-93 Amendments B2.1-1-019 and 53 Using Competency Models to Build a Career Ladder in B2.1-1-020 Welding Competency models help determine the knowledge, skills, Guide to A WS Services 89 and abilities to perform successfully in everyday life, in school, New Literature 90 and at work D. W. Dickinson Personnel 94 Welding School Profiles 100 Classifieds 116 Welding Research Supplement Advertiser index 118 65-s Microstructural Changes in Grade 22 Ferritic Steel Clad Successively with Ni-Based and 9Cr Filler Metals A nickel-based interlayer is demonstrated to prevent hard and soft zone formation during postweld heat treatment R. Anand et al. Welding Journal (ISSN 0043-2296) is published 75-s Development of a Time-Resolved Energy Absorption monthly hy the American Welding Society for Measurement Technique for Laser Beam Spot Welds $120.00 per year in the United States and posses- The mapping of energy transfer and melting efficiency helps in the sions, $160 per year in foreign countries: $7.50 per single issue for domestic AWS members and selection of welding parameters and pulse shape design $10.00 per single issue for nonmembers and J. T. Norris et al. $14.00 single issue for international. American Welding Society is located at 550 NW LeJeune Rd., Miami, FL 33126-5671; telephone (305) 443-9353. 82-s Characterization of Welding Fume from SMAW Periodicals postage paid in Miami, Fla., and addi- Electrodes — Part II tional mailing offices. POSTMASTER: Send address This study classifies fume particles into three distinct morphologies changes to Welding Journal, 550 NW LeJeune Rd., and characterizes each according to composition and structure Miami, FL 33126-5671. Canada Post: Publications Mail Agreement #40612608 Canada Returns to be J. W. Sowards et al. sent to Bleuchip International, P.O. Box 25542, London, ON N6C 6B2 On the cover: Cagnazzi Racing chassis fabricator Todd Bevis uses the Readers of Welding Journal may make copies of articles for personal, archival, educational or re- gas tungsten arc welding process to modify the 4130 chrome-moly roll search purposes, and which are not for sale or re- cage of a National Hot Rod Association Pro Stock dragster. (Photo sale. Permission is granted to quote from articles, courtesy of Miller Electric Mfg. Co.) provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright. WELDING JOURNAL American Welding Society EDITORIAL Founded in 1919 to Advance the Science, Technoiogy and Appiication of Weiding Thinking beyond the Officers Ordinary President John C. Bruskotter Bruskotter Consulting Services, LLC Vice President John L. Mendoza As publisher of the Welding Journal, all kinds of information come across my Lone Star Welding desk/computer every month. The categories are usually pretty simple to split between Vice President William A. Rice Jr. usable and unusable. On occasion, though, one bit of information comes in that fits snug- OKI Bering ly into that special category of bizarre. I got one the other day from a company that claims to have harnessed the brain's electrical impulses generated by your thoughts. Vice President Nancy C. Cole Here is a simplified explanation of how it works. Through relaxation or concentration NCC Engineering you control alpha or beta brainwaves; the electrical patterns generated by these brain- Treasurer Robert G. Pali waves are picked up by a headset and transferred to a computer; the company's software transforms the brainwaves into a control signal. The computer can then send a message J. P. Nissen Co. over the Internet that will control electrical devices. In fact, a demonstration of the com- Executive Director Ray W. Shook pany's capabilities may have already occurred by the time you read this editorial. The American Welding Society company claims that during the Winter Olympics in Vancouver (Feb. 12-28), visitors will be given the opportunity to control light displays in Toronto, Ottawa, and Niagara Falls just by focusing their thoughts on the sight they are seeing. Sound a little farfetched? Directors Definitely, but who knows. Mind control has been on the fringes of science for a long B. P. Albrecht (At Large), Miller Electric Mfg. Co. time. J. R. Bray (Dist. IS), Affiliated Machiner}', Inc. I've also come across ongoing research in the field of welding that also sounds unbe- lievable. It is nanowelding. To get an idea of what we are talking about, consider that a D. B. DeCorte (At Large), RoMan Mfg., Inc. nanometer is one billionth of a meter. Take a meter stick and divide it into a billion parts G. Fairbanks (Dist. 9), Fairbanb Inspection & Testing Services and you are looking at some very small slivers. In fact, it is material on the atomic and T. A. Ferri (Dist. 1), Thermadyne Industries molecular level. What are being joined are single-wall and multiwall carbon tubes. These D. A. Flood (Dist. 22), Tri Tool, Inc. tubes, especially the single-wall variety, have great potential in efficient electrical and heat conductivity. They also have very high strength making them candidates for a vari- M. V. Harris (Dist. 15), Vallej' National Gases ety of other products, including bulletproof vests. So far, experiments have shown that a R. A. Harris (Dist. 10), Consultant soldering process utilizing a filler material less than 250 atoms across has been success- D. C. Howard (Dist. 7), Concurrent Technologies Corp. ful. Laser-stimulated discharges and electron beam irradiation have been used in join- ing. Experiments have also been conducted with ultrasonic welding. The welding is tak- J. Jones (Dist. 17), Thermadyne Industries ing place on a minuscule scale, observed and manipulated through electron scanning and W. A. Komlos (Dist. 2d),ArcTech LLC transmission electron microscopes. D. Landon (Dist. 16), VermeerMfg. Co. You might ask why carbon tubes need to be joined in the first place. To be used in a R.C.Lanier(Dist.4),HttC.C. viable product there has to be stability in the juncture where the tubes cross. Welding gives them that. All of this is highly experimental now, and it will be years before anything close G. E. Lawson (Past President), ESAB Welding & Cutting Prod. to commercial production is accomplished, but it does give a new perspective to welding. T. J. Lienert (At Large), Los Alamos National Laboratory It is a great example of the necessity of the welding process to the success of material fab- J. Livesay (Dist. 8), Tennessee Technolog}' Center rication for products that are on the edges of scientific advancement. So the next time D. L. McQuaid (At Large), DL McQuaid & Associates someone belittles welding as an occupation, let them know that without it, some of the most advanced prod- V. Y. Matthews (Past President), Lincoln Electric Co. (ret.) ucts of the future might never come to be. S. Mattson (Dist. 5), Mattson Repair Service S. P. Moian (Dist. 12), PDM Bridge, LLC T. C. Parker (Dist. U), Milkr Electric Mfg. Co. K. A. Phy (Dist. 6), KA Phy Services, Inc. W. R. Polanin (Dist. 13), Illinois Central College N. Saminich (Dist. 21), Ninyo & Moore N. S. Shannon (Dist. 19), Carlson Testing of Portland T.A.Siewert(AtLarge),iW5r Andrew Cullison E. Siradakis (Dist. ll),Aiigas Great Lakes Publisher, Welding Journal K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv D. R. Wilson (At Large), Wilson Industries M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute APRIL 2010 Capacity I Precision I Strength Greiner's new Plate Processing System. Eliminates welds, which takes labor out of the equation. Result? Higher strength and lower cost! • Plasma & oxy-fuel torches that can cut up to a 10-inch thick carbon steel plate • Quick-Drill (concurrent drill, tap, countersink & surface mill) capability • 160-foot long by 17-foot wide water table INDUSTRIESINC • Contour beveling capability • Structural Steel Fabrication At Gfeinet", we've always been about absolute precision and constant • Steel Plate & Sheet Metal Fabricate • Miscellaneous Metals quality. Over the years, we've added equipment to handle jobs that few • Machining could match. We continue to "super-size" our capabilities while doing more • Rolling & Forming Services on the fabrication end that reduces labor time on the installation end - • Cutting Services resulting in a better product at a lower cost. How's that for value-added? • Industrial Coatings • Industrial & Electrical Contracting Call us at 800-782-2110 for a free quote on your • Crane Rental & Trucking Services • Heat-Bending Services next Metal Drilling & Cutting job. (AISC Certified for Major Steel www.greinerindustries.com Bridge Fabrication) For Info go to www.aws.org/ad-index WASHINGTON BY HUGH K. WEBSTER WATCHWORD AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE White House Presents Plan to Increased Effort on Exports Planned Revitalize Manufacturing The Obama Administration has established the National Ex- port Initiative in an attempt to boost U.S. exports. This will take The White House has prepared "A Framework for Revitaliz- the form largely of increased funding for key federal agencies. ing American Manufacturing," which identifies seven ways in Specifically, a 20% budget increase is being sought for the Com- which the federal government can assist the U.S. manufacturing merce Department's International Trade Administration, most industry: of which would be used to hire additional trade experts to advise 1. Provide workers with the opportunity to obtain the skills and serve as advocates for U.S. companies. In addition, to im- necessary to be highly productive; prove access to credit, the Export-Import Bank, which generally 2. Invest in the creation of new technologies and business provides financing when private banks will not, will be increas- practices; ing its financing available for small- and medium-size businesses 3. Develop stable and efficient capital markets for business from $4 billion to $6 billion in 2010, and there is a budget in- investment; crease planned for this agency as well. 4. Help communities and workers transition to a better The National Export Initiative is being led by a newly created future; Export Promotion Cabinet consisting of federal agencies such as 5. Invest in an advanced transportation infrastructure; the Departments of Commerce, State, and Treasury, as well as 6. Ensure market access and a level playing field; and the U.S. Trade Representative, the Small Business Administra- 7. Improve the business climate, especially for manufacturing. tion, and the Export Import Bank. By this fall, each agency is The full report is available at the following Web site: supposed to submit a detailed plan about how it will enhance www.whitehouse.gov/sites/default/files/microsites/20091216- U.S. exports. maunfacturing-framework.pdf. Decline in Defense Industrial Base Noted Manufacturing Strategy Legislation Introduced The U.S. Department of Defense (DoD), in its 2010 Quad- rennial Defense Review (QDR), for the first time acknowledges Describing federal government support for manufacturing as an erosion of the defense industrial base. According to the QDR, "disjointed, ad hoc, and reactive," more than two dozen mem- which is the most important strategic document issued by DoD, bers of Congress are sponsoring the National Manufacturing "America's defense industry has consolidated and contracted Strategy Act (H.R. 4692). This legislation would create a federal around 20th-century platforms rather than developing the broad Manufacturing Strategy Board that would undertake a quadren- and flexible portfolio of systems that today's security environ- nial in-depth analysis of the manufacturing sector and develop a ment demands." The QDR recommends that Congress abandon comprehensive strategy for enhancing its competitiveness and its "outdated hands-off" approach to the defense industry and promoting its success in the global economy. The U.S. Govern- instead "be prepared to intervene when absolutely necessary to ment Accountability Office would be tasked with reviewing the create and or sustain competition, innovation, and essential in- strategy development process and analyzing the implementation dustrial capabilities." of recommendations. The National Academy of Sciences would also play a role by conducting periodic in-depth studies on man- International Labor Comparisons Program ufacturing and related issues to assist the Manufacturing Strat- May Be Eliminated egy Board. The Obama Administration is proposing to eliminate the In- Comprehensive Tax Reform Bill ternational Labor Comparisons (ILC) program as part of the 2011 federal budget reductions. The ILC provides international The Bipartisan Tax Fairness and Simplification Act of 2010 comparisons of hourly compensation costs; productivity and unit would significantly alter the current tax structure in the U.S. by labor costs; labor force, employment, and unemployment rates; eliminating or at least consolidating the approximately 10,000 and consumer prices. The comparisons relate primarily to the exemptions, deductions, credits, and similar items that currently major industrial countries, but other countries are included in exist. certain measures. For companies, the legislation has three major components. If this occurs, the Bureau of Labor Standards annual study The first is to replace the existing six corporate tax rates and eight International Comparisons of Hourly Compensation Costs in Man- brackets with a single flat rate of 24%. This is designed in large ufacturing will cease publication. There are other sources of for- part to make U.S. companies more competitive internationally, eign compensation and related data, such as the Organization as the current U.S. corporate income tax rate is the second- for Economic Cooperation and Development and the Interna- highest in the industrialized world. tional Labor Organization, but the ILC is considered the most In addition, this bill is intended to make capital investments authoritative because of how it vets and adjusts the data to en- more cost effective for small businesses with gross receipts of up sure consistent comparisons, particularly with respect to wages to $1 million to expense all equipment and inventory costs in a sin- and productivity. • gle tax year. Finally, a new 35% exclusion and a progressive rate structure for dividend and long-term capital gains income would be created, and the holding period for the first $500,000 of a tax- Contact the AWS Washington Government Affairs Office at payer's capital gains income would be reduced to six months. 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail [email protected],- FAX (202) 835-0243. APRIL 2010 The machines that need service ieast are hacked hy service that's hest. Koike Aronson builds its cutting and welding machines to give you years of trouble-free production. Should one ever need service, however, we'll send out one of the very experts who builds our machines. They'll get you back up faster. But they're not often needed thanks to our high quality production standards: • Every machine is fully assembled, integrated and tested before shipment. • Each component is researched and chosen for the application required and provided with the latest technology. • Machines are completely fabricated from start to finish at our Arcade, New York facility. • Machines are heavy-duty designs made of structural steel fully welded by certified welders. • Koike Aronson has come out of the recent downturn as financially strong as we went in, so you can count on us to be I around for years. i Give us a call and put Koike reliabilit i work in your operation. Versagraph Headstock &Tailstock ISO 9001 Positioners BUREAU VERITAS Certification Koike Aronson, Inc./Ransome Arcade, NY USA 800-252-5232 www.koike.com For Info go to www.aws.org/ad-index PI7E55 TIME WELJMMBi NEWS Publisher Andrew Cullison Southern Co. Obtains DOE Support for Nation's First Nuclear Units in 30 Years Editorial Editorial Director Andrew Cullison Editor Mary Ruth Johnsen Southern Co., Atlanta, Ga., recently announced the U.S. Department of Energy Associate Editor Howard M. Woodward (DOE) has offered its subsidiary, Georgia Power, a conditional commitment for loan Associate Editor Kristin Campbell guarantees to construct the nation's first nuclear power units in more than 30 years. Peer Review Coordinator Erin Adams "We are honored by the administration's confidence in our ability to build the na- tion's first new nuclear power plant in more than three decades," said Southern Co. Publisher Emeritus Jeff Weber CEO David Ratcliffe following an event where President Obama and Secretary of En- ergy Steven Chu announced this award. "It's an important endorsement in the role nu- Graphics and Production clear power must play in diversifying our nation's energy mix and helping to curb green- Production Manager Zaida Chavez house gas emissions." Senior Production Coordinator Brenda Flores The new units will be located at Plant Vogtle near Waynesboro, Ga. The conditional commitment is for loan guarantees that would apply to future borrowings related to the Advertising construction of Vogtle Units 3 and 4, which are expected to begin commercial operation National Sales Director Rob Saltzstein in 2016 and 2017, respectively. Total guaranteed borrowings would not exceed 70% of Advertising Sales Representative Lea Garrigan Badwy the company's eligible projected costs and are expected to be funded by Federal Financ- Senior Advertising Production Manager Frank Wilson ing Bank. Adding these units is expected to create approximately 3500 jobs during con- Subscriptions struction and an additional 800 permanent jobs once operations begin. Subscriptions Representative Edalia Suarez Georgia Power has 90 days to accept the conditional commitment, including obtain- [email protected] ing any necessary regulatory approvals. The company will work with the DOE to final- ize loan guarantees; also, final approval and issuance of these are subject to receipt of American Welding Society the Combined Operating License from the U.S. Nuclear Regulatory Commission, com- 550 NW LeJeune Rd., Miami, PL 33126 pletion of final agreements, receipt of any other required regulatory approvals, and sat- (305) 443-9353 or (800) 443-9353 isfaction of other conditions. Along with Georgia Power's portion of the two 1100-MW reactors, remaining own- Publications, Expositions, Marketing Committee ership is divided among Oglethorpe Power Corp., Municipal Electric Authority of Geor- D. L. Doench, Chair gia, and Dalton Utilities. Currently, total cost of the new units is projected to be approx- Hobart Brothers Co. imately $14 billion. Southern Nuclear, a subsidiary of Southern Co., will oversee con- S. Bartholomew, Vice Chair struction and operate the two new units for Georgia Power and the other owners. ESAB Welding & Cutting Prod. J. D. Weber, Secretary Airgas Rejects Acquisition Offers from Air Products American Welding Society D. Brown, Weiler Brush J. Deckrow, Hypertherm Airgas, Inc., Radnor, Pa., announced Feb. 22 its board of directors had voted unani- D.DeCorte, RoManMfg. mously to reject the unsolicited tender offer from Air Products & Chemicals, Inc., Lehigh J. R. Franklin, Sellstrom Mfg. Co. Valley, Pa., to acquire all outstanding common shares of the company at a price of D. Levin, Airgas $60/share in cash. The board noted this value is unchanged from the unsolicited pro- E. C. Lipphardt, Consultant posal made Feb. 4, which it rejected Feb. 9. J. Mueller, Thermadyne Industries The basis for this recommendation is provided in Airgas's Schedule 14D-9 filed with R.G.?ali,J.P.NissenCo. the Securities and Exchange Commission. "The Airgas Board of Directors is unanimous J. F. Saenger Jr., Consultant in its belief that the Air Products offer significantly undervalues Airgas and fails to re- S. Smith, Weld-Aid Products D. Wilson, Wilson Industries flect the value of our industry-leading position and future growth prospects," said Air- P. Wittke, Lincoln Electric Co. gas Chairman and CEO Peter McCausland. J. C. Bruskotter, Ex Off., Bruskotter Consulting Services Additional reasons for the board's decision, detailed in its 14D-9 filing, include the H. Castner, Ex Off., Edbon Welding Institute following: The offer is highly uncertain and any payments made to Airgas stockholders L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems would be considerably deferred; the offer's extraordinarily broad conditions render it il- S. Liu, Ex Off., Colorado School of Mines lusory; and Air Products's acquisition of Airgas will likely reduce value. For more infor- E. Norman, Ex Off., Southwest Area Career Center mation on these unsolicited proposals, go to the Investor Information section of the R. W. Shook, Ex Off, American Welding Society company's Web site at www.airgas.com. National Standard Partners with Flux Cored Welding Wire Manufacturer National Standard, Niles, Mich., a Heico Wire Group company and supplier of solid Copyright © 2010 by American Welding Society in both printed and eiec- tronic formats. The Society is not responsible for any statement made or carbon steel and stainless steel wires to the North American welding industry, has formed opinion expressed herein. Data and information developed by the authors a strategic alliance with RevWires LLC, a new cored wire manufacturing company lo- of specific articles are for informational purposes only and are not in- tended for use without independent, substantiating investigation on the cated in Troy, Ohio. This partnership provides National Standard with flux cored wires. part of potential users. "The addition of these unique new products will help us better serve our customers, and we look forward to making these industry-leading products available to them," said Jim Hillebrandt, president and CEO of Heico Wire Group. BPA In addition, this cored wire product line will provide new sales and market opportu- nities to National Standard's existing distributors. APRIL 2010
Description: