ifferent Crome-Moly Steels

150 Pages·2011·16.84 MB·English

April 2010
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ifferent Crome-Moly Steels
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•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
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"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?
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individuals to practice the art, craftsmanship and
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For more information visit www.thermadyne.com/tweco
or call Thermadyne Customer Care at 1-800-426-1888
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American Welding Society
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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 [phone].
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
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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 [phone].
APRIL 2010
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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-
[phone] or [phone]
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