January 2009

120 Pages·2010·13.02 MB·English

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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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CONTENTS
AWS Web site www.aws.org
January 2009 • Volume 88 • Number 1
Departments
Features
Press Time News 4
32 Examining the Mechanical Properties of High-Strength Steel
Weld Metals
Editorial 6
Proper understanding of the relationship between chemistry
News of the Industry 8
and weld metal properties will aid the development of
consumables and processes
International Update 14
J. E. Ramirez
Stainless Q&A 20
40 Making Better Gas Metal Arc Welds
RWMAQ&A 22
Proper equipment, good technique, and correct machine
settings all go hand in hand in making good welds
Letters to the Editor 24
A. Monk and G. Bauer
New Products 26
44 The 2008 AWS Expo in Review
Conferences 56
The 2008 AWS Welding Show proved to be a technology
Coming Events 58
bonanza
A. Cullison, K. Campbell, and M. R. Johnsen
Society News 61
Tech Topics 64
52 Pulsed Technology Increases Cladding Travel Speed
A pulsed gas metal arc welding system that contained
01.1 Interpretations 64
factory-set pulsing programs improved Inconel® cladding
of boiler tubes
Guide to A WS Services 80
J. Rappl
Welding Workbook 82
New Literature 88
Personnel 92
Welding Research Supplement
Classifieds 98
Advertiser Index 101
1 -s A CCT Diagram for an Offshore Pipeline Steel of X70 Type
A CCT diagram valid for the heat-affected zone of welded X70
pipeline steel was established
M. I. Onsoien et al.
7-s Metallurgical Investigation into Ductility Dip Cracking in
Ni-Based Alloys: Part I
In this study both macroscopic mechanical and microscopic
measures were quantified and compared for different
combinations of filler metal and Ni-Cr-Fe alloys
F. F. Noecker II and J. N. DuPont
Welding Journal {\SSfi 0043-2296) is published
monthly by the American Welding Society for
$120.00 per year in the United States and posses-
sions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and
$10.00 per single issue for nonmembers and
$14.00 single issue for international. American
Welding Society is located at 550 NW LeJeune Rd.,
Miami, FL 33126-5671; telephone [phone].
Periodicals postage paid in Miami, Fla., and addi-
tional mailing offices. POSTMASTER: Send address
changes to Welding Journal, 550 NW LeJeune Rd.,
Miami, FL 33126-5671. Canada Post: Publications
Mail Agreement #40612608 Canada Returns to be
sent to Bleuchip International, P.O. Box 25542,
London, ON N6C 6B2
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,
On the cover: During gas metal arc welding, the gun and consumables are ex-
provided customary acknowledgment of authors
posed to continual mechanical and heat stress; therefore, proper gun mainte-
and sources is made. Starred (*) items excluded
nance and troubleshooting are essential to maintaining productivity and avoid-
from copyright.
ing unnecessary downtime. (Photo courtesy of Bernard, Beecher, III.)
WELDING JOURNAL
WELflM?
PI7E55 TIME
NEWS
NTSB Reaches Decision on I-35W Bridge Coiiapse
Publisher Andrew Cullison
Editorial
The National Transportation Safety Board (NTSB), Washington, D.C., recently
Editorial Director Andrew Cullison
determined the probable cause of the I-35W bridge's collapse in Minneapolis, Minn.,
Editor Mary Ruth Johnsen
was the inadequate load capacity, due to a design error by Sverdrup & Parcel and Asso-
Associate Editor Howard M. Woodward
ciates, Inc., of the gusset plates at the U10 nodes. These failed under a combination of
Associate Editor Kristin Campbell
substantial increases in the weight of the bridge, which resulted from previous modifica-
Peer Review Coordinator Erin Adams
tions, and the traffic and concentrated construction loads on the bridge on the day of
the accident.
Publisher Emeritus Jeff Weber
"We believe this thorough investigation should put to rest any speculation as to the
root cause of this terrible accident and provide a roadmap for improvements to prevent
Graphics and Production
future tragedies," said NTSB Acting Chairman Mark V. Rosenker. "We came to this
Production Manager Zaida Chavez
conclusion only through exhaustive efforts to eliminate each potential area that might
Senior Production Coordinator Brenda Flores
have caused or contributed to this accident."
On August 1, 2007, the eight-lane, 1907-ft-long I-35W highway bridge over the Mis-
Advertising
sissippi River experienced a catastrophic failure in the main span of the deck truss. One
National Sales Director Rob Saltzstein
thousand feet of the deck truss collapsed, with about 456 ft of the main span falling 108
Advertising Sales Representative Lea Garrigan Badwy
ft into the 15-ft-deep river.
Advertising Production Manager Frank Wilson
The failure of Sverdrup & Parcel's quality control procedures to ensure the appro-
Subscriptions
priate main truss gusset plate calculations were performed for the I-35W bridge and in-
Subscriptions Representative Edalia Suarez
adequate design review by federal and state transportation officials contributed to this;
[email protected]
so did the generally accepted practice among federal and state transportation officials
of giving inadequate attention to gusset plates during inspections for conditions of dis-
American Welding Society
tortion and excluding gusset plates in load rating analysis.
550 NW LeJeune Rd., Miami, PL 33126
The NTSB, as a result of its investigation, made nine recommendations to the Fed-
[phone] or [phone]
eral Highway Administration and the American Association of State Highway and Trans-
portation Officials dealing with improving bridge design review procedures, bridge
Pubiications, Expositions, Marketing Committee
inspection procedures, bridge inspection, training, and load rating evaluations.
D. L. Doench, Chair
Hobart Brothers Co.
Outiook Given for Metai Forming and Fabricating Industry
T A. Barry, Vice Chair
Miller Electric Mfg. Co.
J. D. Weber, Secretary
In a survey by management consulting firm Homburg & Partner, Cambridge, Mass.,
American Welding Society
201 U.S. companies in the metal forming and fabricating industry were asked to give a
P. Baka, The Lincoln Electric Co.
2009/2010 outlook on market development and specify key success factors.
S. Bartholomew, ESAB Welding & Cutting Prod.
Innovation came in as the top key success factor for the next three years by more
D. Brown, Weiler Brush
than 25% of the surveyed companies. Efficient automation is the imperative goal when
J. Deckrow, Hypertherm
dealing with production costs and process management, which considered together form
D.DeCorte, RoManMfg.
the most important key factors for 30% of the participants. Also, nearly 15% of the sur-
J. Dillhoff, OKI Bering
veyed companies see expanding into global markets as the key success factor.
J. R. Franklin, Sellstrom Mfg. Co.
In the United States, industry's growth is estimated as 7% in 2009 and 10% in 2010
D. Levin, Airgas
and worldwide as 12% in 2009 and 15% in 2010. About one-third concur the U.S. finan-
J. Mueller, Thermadyne Industries
R.G.Pali,/.PMraen Co.
cial crisis will not render into a cash flow problem, yet it is commonly agreed this has a
J. F. Saenger Jr., Consultant
negative effect on growth rates for the metal forming and fabricating market. The auto-
S. Smith, Weld-Aid Products
motive producers crisis is seen as a threat, too, but management perceives it less
D. Wilson, Wilson Industries
critically.
J. C. Bruskotter, Ex Off., Bruskotter Consulting Services
The firm's in-depth discussions have shown top management of market leaders pre-
H. Castner, Ex Off., Edison Welding Institute
dominantly disagree with the highly positive growth rates of U.S. markets, however, and
L. G. Kvidahl, Ex Off, Northrup Grumman Ship Systems
instead expect they will stay flat or perhaps increase slightly positive with up to 2% in
G. E. Lawson, Ex Off, ESAB Welding & Cutting Prod.
2009, depending on the regarded segment.
E. C. Lipphardt, Ex Off., Consultant
S. Liu, Ex Off, Colorado School of Mines
ESAB Receives Major Wind Energy Industry Order
E. Norman, Ex Off., Southwest Area Career Center
R. W. Shook, Ex Off, American Welding Society
ESAB Welding & Cutting Products has made its largest ever, single-customer order
for welding and cutting equipment and consumables. Wind tower manufacturer Vestas
Towers A/S, a part of Vestas Wind Systems A/S, placed the multimillion dollar purchase.
Copyright © 2009 by American Weiding Society in both printed and
This complete equipment and consumables package will be supplied. In addition,
eiectronic formats. The Society is not responsible for any statement made
or opinion expressed herein. Data and information developed by the au-
the full order comprises automated cutting equipment manufactured by the company in
thors of specific articles are for informational purposes only and are not
Florence, S.C.; heavy automation welding equipment manufactured by it in Sweden;
intended for use without independent, substantiating investigation on the
part of potential users.
and positioning and handling equipment supplied by its newly acquired facility in Singa-
pore. The column and boom equipment will include ESAB's latest telescopic
technology. Also, the company is well positioned to supply the welding consumables
BPA
once the wind tower factory comes into production.
During 2009, the full equipment package will be delivered and installed.
JANUARY 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
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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.
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• 250 lb minimums for custom metal cored, flux cored
or open arc wire.
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
Setting Goals and Making
Officers
President Victor Y. Matthews
Them Happen
The Lincoln Electric Co.
Vice President John C. Bruskotter
Bruskotter Consulting Services, LLC
I'd like to extend my best wishes to ail of you in this new year, the 90th year for AWS.
I hope everyone had a wonderful holiday season and that 2009 will bring with it new
Vice President John L. Mendoza
opportunities for each of us.
CPS Energy
At this time of year it is natural to set goals. We all have them, both personal and pro-
Vice President William A. Rice Jr.
fessional. For many of us, our personal goals begin with a set of New Year's resolutions.
OKI Bering
We all need to have our sights set on achieving a result for the year whether it be losing
some weight, getting more exercise, buying a new car, or accomplishing some repairs
Treasurer Earl C. Lipphardt
around the house. The list can be quite long.
Consultant
In addition, most of us also have professional goals, either those we set for ourselves
or, most likely, goals that are requirements from our employer. Companies have goals
Executive Director Ray W. Shook
set by their boards of directors, committees, and other management entitites. The
American Welding Society
American Welding Society is similar to the rest of corporate America in that it too sets
goals. Some are set by the Finance Committee, some by our Compensation Committee,
Directors
and some are set by the Board of Directors. Goal setting is the thing that actually puts
us on a course or direction to being successful.
B. P. Albrecht (At Large), Miller Electric Mfg. Co.
During my address at the AWS Annual Meeting in Las Vegas this past October, I list-
J. R. Bray (Dist. IS), Affiliated Machinery, Inc.
ed four major areas of growth for AWS: Welding Education, Career Expansion,
H. R. Castner (At Large), Edison Welding Institute
Technology Support, and Membership Attraction.
D. B. DeCorte (At Large), RoMan Mfg. Inc.
Welding Education includes both individuals getting into the profession at some level
through education and training, and improving the awareness and pride of our profes-
G. Fairbanks (Dist. 9), Fairbanb Inspection & Testing Services
sion by those outside of it, such as government and educational entities.
D. A. Flood (Dist. 22), Tri Tool, Inc.
Career Expansion means growing in experience and knowledge or specializing one's
M. V. Harris (Dist. 15), Vallej' National Gases
training.
Technology Support occurs when the profession's infrastructure responds to the
R. A. Harris (Dist. 10), Consultant
changes in the demand from the field applications. A lot of new designs and other devel-
D. C. Howard (Dist. 7), Concurrent Technologies Corp.
opments occur when the old way of doing things or the processes and materials used will
J. Jones (Dist. 17), Thermadyne
no longer do the job. Necessity has always been the catalyst for change.
W. A. Komlos (Dist. 20),ArcTech LLC
Membership Attraction will occur when AWS is successful in the first three areas.
These four areas are generalized versions of goals that are part of the overall strate-
D. Landon (Dist. 16), VemeerMfg. Co.
gic plan for AWS.
R.C.Lanier(Dist.4),HttC.C.
During my talk at the Annual Meeting, I closed with a challenge to every person in
G. E. Lawson (Past President), ESAB Welding & Cutting Prod.
attendance there and I now offer you all the same challenge: Bring one new person into
J. Livesay (Dist. 8), Tennessee Technology Center
the welding profession. I ask you to mentor, train, or counsel a neighbor, son or daugh-
ter, nephew or niece, a friend of a friend, or a kid who lives on your street. Help them to
D. L McQuaid (At Large), DL McQuaid & Associates
make a career goal that includes options within the welding profession. We need new
S. Mattson (Dist. 5), Mattson Repair Service
people in every discipline related to welding: electrical engineers, mechanical engineers,
S. P. Moran (Dist. 12), Miller Electric Mfg. Co.
metallurgists, welding engineers, computer programmers, welders, ironworkers, sheet-
metal workers, boilermakers, pipeline welders. The list goes on and on. We need people
R. L. Norris (Dist. 1), Consultant
to design and manufacture welding equipment and consumables as well as those who will
T. C. Parker (Dist. U), Miller Electric Mfg. Co.
use them. We also need people to set the standards and regulations used for the profes-
K. A. Phy (Dist. 6), Entergy Nuclear Operations, Inc.
sion. From the earliest times, mankind has been building things. Welding lets us build
W. R. Polanin (Dist. 13), Illinob Central College
bigger and better.
Goals are only an indication of what we want to accomplish; it takes a plan and hard
N. Saminich (Dist. 21), Ninyo & Moore
work to make them happen. I am happy to report that our membership will hit the 55,000
N. S. Shannon (Dist. 19), Carbon Testing of Portland
mark very soon if it has not already by the time you
T.A.Siewert(AtLarge),iV/5r
receive this editorial. That is an indicator that we are
E. Siradakis (Dist. \\),Airgas Great Lakes
succeeding in some of our goals. Together we can grow
the infrastructure of AWS.
K. R. Stockton (Dist. 2), PSE&G Maplewood Testing Serv.
I plan to speak at many AWS Sections this year,
G. D. Uttrachi (Past President), WA Technology, LLC
and I know I'll get the opportunity to hear many suc-
D. R. Wilson (At Large), Wilson Industries
cess stories. Please share those stories with the entire
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
AWS membership by sending in your monthly meeting
reports to the Welding Journal.
In the meantime, I hope you all have a great year.
Victor Y. Matthews
AWS President
JANUARY 2009
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II
NEWS OF THE
INDUSTRY
DMI Industries Increases Production to Meet Wind Energy Demands
DMI Industries is increasing production capacity
by 25% at its manufacturing facility in Fort Erie, On-
tario, Canada. This will meet the need for wind towers
in the northern tier of the United States and south-
eastern and south-central regions of Canada.
Expansions include the addition of many new sub-
merged arc welding stations to increase weld capac-
ity, allowing for more than 20% greater flow of prod-
uct through the facility, along with more beveling abil-
ity in plate processing. An extra fit-up line has added
to the facility's capacity to build more tower sections
on a week-by-week basis, and new material-handling
equipment facilitates the move of more finished
product.
According to Tony Claroni, Fort Erie general man-
ager, the weld shop's increased capacity has prompted
a need for more skilled workers throughout facility
departments, resulting in the recent hiring of nearly
100 employees. The plant now employs more than 200
people.
To provide more towers, DMI Industries is uppingproduction
ability in Canada with several submerged arc stations for weld
capacity and an additional fit-up line. The company's welders
(one is shown at left) expertly manipulate tons of steel plate
into towers that can be as much as 16 ft wide and more than
250 ft tall when erected. (Courtesy of DMI Industries.)
Exhibition Supporting the Weiding
The first-ever "Where Are the Welders?" Instructional Forum
and Career Fair attracted more than 40 high school students and
Profession Goes Successfuiiy
parents at the Spencer High School Industrial Tech building in
Spencer, Iowa, on Nov. 10. Career possibilities in industrial tech-
nology were shown during the three-hour event to students in
Buena Vista, Clay, Dickinson, and Emmet counties.
"What a great way for area employers to connect with Corri-
dor students who have a passion for welding as well as metal fab-
rication and machining," said Shaun Arneson, vice president,
Iowa Lakes Corridor Development Corp. This agency hosted the
forum and fair, part of its workforce initiative, that let welding
instructors, employers, and local manufacturers share their in-
sights on the welding and fabrication industries.
Involvement consisted of more than 12 area employers.
Demonstrations included a wire weld demo by John Tatman,
Maurer Manufacturing, and Chris McKay, Airgas North Cen-
tral, as well as a robotic weld demo by Northwest Iowa Commu-
nity College. In addition, Jeff Merryman of Employment Con-
nections, Inc., spoke on the topic of "Job Seeking Skills"; Jamie
Slipke of Rosenboom Machine & Tool, Inc., presented "Welding
as a Career"; and Jeff Steiner of Polaris Industries, Inc., discussed
During the "Where Are the Welders?" event, many students (some
and demonstrated "Welding Technologies and Automation."
of whom are pictured) learned details about gas tungsten arc
The employers/instructors and students who attended pro-
welding, participated in demonstrations, and learned of career
vided an evaluation overall rating of 91% and 92%, respectively.
opportunities.
JANUARY 2009