•Thermal Spraying for an Array of Applications - American Welding

120 Pages·2009·19.78 MB·English

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August 2008
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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
August 2008 • Volume 87 • Number 8 AWS Web sitewww.aws.org
26 Features Departments
*26 Thermal Spray Cooling Using Cryogenic Nitrogen Washington Watchword..........4
A new approach to cooling thermal spray deposits
Press Time News ................6
maintains part temperature within a ±20°F range
Editorial............................8
30 Workforce Development Programs Combat Welder Shortage
Innovative training programs across the country are News of the Industry............10
gearing up to replenish a dwindling welder workforce
K. Campbell Point of View ....................14
Aluminum Q&A..................16
34 Thermal Spray Techniques for Deep Bore Applications
An off-angle method of applying thermal spray deposits New Products....................18
was effective in coating the inside diameter of tubes to
greater depths than previously achieved Thermal Spray Section..........54
M. Froning et al.
Coming Events....................62
36 Chicago Aims to Bring Manufacturing Jobs Back to the City Welding Workbook..............66
A public/private partnership is working toward making
manufacturing more innovative and productive and Society News....................67
raising the skill level of the workforce
Tech Topics ......................68
D. Swinney
30
Interpretations D14.3, D14.6,
40 Cold Spray: A Solution for Architectural Glass
A cold spray process is used to deposit thin-film buss bars and D1.3......................68
on flat glass
Errata D15.1, D14.6..........69
J. Villafuerte
Guide to AWS Services..........83
44 Off-Line Development of Robot Motion Programs
A standard Excel® program is used to define the velocity New Literature....................86
path for a thermal spraying robot along conical-shaped parts
D. Moody Personnel ........................88
Classifieds........................91
48 Engineer Motivates Texas Schools to Offer Career Courses
in Welding Advertiser Index..................94
A welding champion convinces a local high school to take
on the task of training qualified welders to fit the needs of
industry
M. Crawford and R. McClellan
50 Comparison of Deposits of Wires Applied by Welding,
Thermal Spraying, and Spray and Fuse
36
A comparison study shows welding and thermal spraying
can both meet the needs of wear- and corrosion-resistant
applications
R. H. Unger et al.
Welding Research Supplement Welding Journal (ISSN 0043-2296) is published
monthly by the American Welding Society for
$120.00 per year in the United States and posses-
195-s Development of High-Temperature Air Braze Filler Metals for sions, $160 per year in foreign countries: $7.50
Use in Two-Step Joining and Sealing Processes per single issue for domestic AWS members and
48 $10.00 per single issue for nonmembers and
Palladium as an addition to filler metals for air brazing high-
$14.00 single issue for international. American
temperature devices was investigated for its melt elevator
Welding Society is located at 550 NW LeJeune Rd.,
characteristics Miami, FL 33126-5671; telephone [phone].
J. S. Hardy and K. S. Weil Periodicals postage paid in Miami, Fla., and addi-
tional mailing offices. POSTMASTER:Send address
202-s Liquation Tendency and Liquid-Film Formation in Friction changes to Welding Journal, 550 NW LeJeune Rd.,
Miami, FL 33126-5671. Canada Post:Publications
Stir Spot Welding
Mail Agreement #40612608 Canada Returns to be
A simple binary alloy with an easy-to-understand microstructure sent to Bleuchip International, P.O. Box 25542,
was studied for its liquation properties when friction stir welded London, ON N6C 6B2
Y. K. Yang et al.
Readers of Welding Journal may make copies of
articles for personal, archival, educational or re-
212-s Modeling and Analysis of the Arc Light Spectrum in
search purposes, and which are not for sale or re-
GMAW sale. Permission is granted to quote from articles,
The spectrum of radiation from the welding arc was analyzed and provided customary acknowledgment of authors
mathematical models were devised for both single and multiple and sources is made. Starred (*) items excluded
from copyright.
wavelengths
M. S. Weglowski
WELDING JOURNAL 3
Washington Watchword August 2008:Layout 1 7/11/08 8:57 AM Page 4
WASHINGTON
BY HUGH K. WEBSTER
WATCHWORD
AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
Intellectual Property Piracy Bill Introduced voluntary group, of at least five states from across the country,
would help align state STEM education efforts; and
It is estimated that the U.S. economy loses between $200 and • Establish the National STEM Education Research Reposi-
$250 billion per year, and has lost 750,000 jobs, due to intellec- tory. This clearinghouse would be a portal to information about
tual property theft. Some estimates indicate that counterfeit and all federally funded STEM education programs, making the re-
pirated goods comprise 6 to 9% of all world trade, the bulk of sults of the more than $3 billion the federal government spends
which violates the intellectual property rights of United States annually on STEM education available to local educators.
businesses and entrepreneurs.
Designed to respond to this serious situation, H.R. 4279, the Mandatory E-Verify Use on Federal
Prioritizing Resources and Organization for Intellectual Prop- Contracts Proposed
erty Act of 2008 (PRO IP Act), would do the following:
a) Raise the profile of the intellectual property issue by des-
A proposed rule has been issued by the Civilian Agency Ac-
ignating a chief intellectual property enforcement officer within
quisition Council and the Defense Acquisition Regulations Coun-
the White House;
cil to change from voluntary to mandatory the use of E-Verify by
b) Raise anticounterfeiting and piracy responsibilities to sen-
contractors and subcontractors that perform work on the federal
ior levels at the Department of Justice and Department of Home-
government’s domestic construction projects. E-Verify is an
land Security;
Internet-based system for submitting employees’ names, dates of
c) Create and implement a unified strategic plan for all rele-
birth, and Social Security numbers to check against federal data-
vant agencies for consistent and targeted international outreach
bases for work authorization purposes. The average cost for a
and technical assistance, guided by the priorities identified by
contractor with 50 employees to participate in E-Verify for the
the U.S. Trade Representative and with input from industry;
first year is estimated at approximately $1200.
d) Provide treble damages against complicit activity relating
to counterfeiting and double the level of statutory damages avail-
Commerce Department Highlights Exports
able (unchanged since 1996); and
e) Authorize civil enforcement by federal prosecutors against
counterfeiters and commercial or high-volume pirates where According to the U.S. Department of Commerce’s Census
criminal prosecutions are not feasible. Bureau and the U.S. Bureau of Economic Analysis, exports have
increased 18.2% to $609.8 billion year to date. Imports have also
Occupational Injuries May Be Underreported been on the rise, gaining 11.9% to $845.6 billion with the trade
deficit narrowing 1.7% during the same period. At this pace, ex-
ports could surpass the record-breaking numbers set in 2007.
The House Education and Labor Committee has issued a re-
And even though the trade deficit overall remains large, more
port raising the possibility that workplace injuries reported to
than one-half is attributable to oil.
the Occupational Safety and Health Administration (OSHA)
may not be an accurate reflection of the actual number of injuries
Sarbanes Oxley Section 404 Requirements
that occur.
Delayed for Small Businesses
According to the committee report, academic studies, media
reports, and worker testimony suggest that work-related injuries
and illnesses are significantly underreported. Experts have iden- The Securities and Exchange Commission has adopted a one-
tified many reasons for possible underreporting, including the year extension of the compliance date for smaller public compa-
severe disadvantages to employers if reported injuries are con- nies to meet the auditor attestation requirement of Section 404(b)
sidered high, such as increased likelihood of being inspected by of the Sarbanes-Oxley Act, meaning that smaller companies will
OSHA; higher workers’ compensation insurance premiums; and be required to start providing an attestation report in their an-
decreased chance of winning government contracts. Work- nual reports in fiscal years ending on or after December 19, 2009.
related illnesses are difficult to identify, especially when there
are long periods between exposure and illness, or when work- Last Piece of New Lobbying Law Now Effective
related illnesses are similar to other nonwork-related illnesses.
The Honest Leadership and Open Government Act was en-
New STEM Legislation Projected
acted in late 2007 to bring greater transparency and openness to
federal lobbying. One of the key components of that legislation
The recently introduced Enhancing Science, Technology, En- is also the last to come into effect. As of July 2008, for the first
gineering, and Mathematics (STEM) Education Act of 2008, time ever, registered lobbyists must disclose their own personal
H.R. 6104, is intended to enhance the coordination of U.S. sci- politicial activity — not just that of their clients. Disclosures must
ence, technology, engineering, and mathematics education ini- be made not only of direct contributions to the campaigns of can-
tiatives. This bill has the following four major components: didates, but also contributions to quasi-political causes and
• Elevating the STEM Education Subcommittee at the Presi- events, such as dinners honoring candidates, charities controlled
dent’s Office of Science Technology Policy, OSTP, to the stand- by candidates, payments to relatives of candidates, presidential
ing committee level; libraries, etc. It is these kinds of transactions that can forge a
• Establishing an Assistant Secretary for STEM Education at quid pro quo relationship between lobbyists and office holder or
the U.S. Department of Education. This office would bring to- candidates but until now have existed under the radar. ♦
gether the Department’s STEM education efforts and manage
programs such as Math and Science Partnerships and the Minor- Contact the AWS Washington Government Affairs Office at
ity Science and Engineering Improvement Program; 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail
• Creating the State Consortium on STEM Education. This [email protected]; FAX [phone].
4 AUGUST 2008
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PRESS TIME
NEWS
University of Akron Receives $500,000 from Dept. of Publisher Andrew Cullison
Defense for Corrosion Engineering Program Editorial
Editorial Director Andrew Cullison
A proposed new corrosion engineering program from The University of Akron (UA), Editor Mary Ruth Johnsen
Ohio — believed by the college to be the first bachelor’s degree program of its kind in Associate Editor Howard M. Woodward
the United States — is moving closer to development due to $500,000 in funding from Associate Editor Kristin Campbell
the U.S. Department of Defense (DoD). Peer Review Coordinator Erin Adams
The certification courses and associate degree program will be delivered from UA’s
new Medina County University Center, and the bachelor of science degree will be housed Publisher Emeritus Jeff Weber
in the College of Engineering. To complement this project, funding for a new Corrosion
Graphics and Production
Sciences Lab is being explored.
Production Manager Zaida Chavez
There are many reasons for establishing an undergraduate corrosion engineering de-
Senior Production Coordinator Brenda Flores
gree at UA, especially the opportunities to deliver courses via distance learning tech-
nologies, according to Dr. George Haritos, dean of the College of Engineering. “First, Advertising
there is a national economic imperative for effectively reducing the costs of corrosion to
National SalesDirector Rob Saltzstein
our nation’s public and private entities and infrastructure,” Haritos said. “Second, there
Advertising Sales Representative Lea Garrigan Badwy
is a national security mandate to address the impact of corrosion on military assets. Fi-
Advertising Production Manager Frank Wilson
nally, there is a gap in the academic training of engineers who are qualified to address
Subscriptions
the complex nature of corrosion prevention and mitigation.”
Director Dan Dunmire of the DoD’s Office of Corrosion Policy and Oversight added, [email protected]
“Because The University of Akron is part of a multiuniversity research and develop-
ment collaboration addressing Department of Defense corrosion requirements, the American Welding Society
DoD is excited about the university’s new program, which will not only help the Execu- 550 NW LeJeune Rd., Miami, FL 33126
tive Branch but the nation as well.” [phone] or [phone]
The funding was given to the university recently in a check-presentation ceremony.
Among the attendees were delegates from the DoD’s Office of Corrosion Policy and
Publications, Expositions, Marketing Committee
Oversight along with school officials. While on campus, the DoD representatives took
D. L. Doench, Chair
tours of UA’s College of Engineering and College of Polymer Science and Polymer En-
Hobart Brothers Co.
gineering, and conducted curriculum discussions with UA faculty and deans.
T. A. Barry, Vice Chair
California Dept. of Corrections and Rehabilitation Uses Miller Electric Mfg. Co.
J. D. Weber, Secretary
Virtual-Reality Welding Systems for Vocational Training
American Welding Society
R. L. Arn, WELDtech International
The California Department of Corrections and Rehabilitation (CDCR) recently pur- S. Bartholomew, ESAB Welding & Cutting Products
J. Deckrow, Hypertherm
chased 20 SimWelder™ virtual-reality units from SGI and VRSim, an SGI® channel
J. Dillhoff, OKI Bering
partner. Inmates throughout the state will learn a variety of welding skills that will help
J. R. Franklin, Sellstrom Mfg. Co.
them to secure jobs upon release. SGI Professional Services delivered the units in Janu-
J. Horvath, Thermadyne Industries
ary. The virtual-reality welding programs, with 27 students per class, will begin soon at
D. Levin, Airgas
20 separate sites.
J. Mueller, Thermadyne Industries
Using SimWelder, students enter an interactive virtual environment that merges com- R. G. Pali, J. P. Nissen Co.
puter-generated data with physical props. By simulating welding, no gas is burned, no J. F. Saenger Jr., Consultant
metal is consumed, and no waste is created. It also augments traditional training meth- S. Smith, Weld-Aid Products
ods by providing more passes to students and giving instructors objective feedback. D. Wilson, Wilson Industries
VRSim personnel trained CDCR’s welding instructors, giving direction and detailed J. C. Bruskotter, Ex Off., Bruskotter Consulting Services
instructions on how to assemble the machines, load the software, and run the calibra- H. Castner, Ex Off., Edison Welding Institute
tions. James Bruce, vocational vice principal, CDCR, expects the units will ultimately L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems
result in more students qualified to the requirements of the various American Welding G. E. Lawson, Ex Off., ESAB Welding & Cutting Products
E. C. Lipphardt, Ex Off., Consultant
Society codes prior to their release.
S. Liu, Ex Off., Colorado School of Mines
C. Martin, Ex Off., Phoenix International
Hobart Institute of Welding Technology Expands
E. Norman, Ex Off., Southwest Area Career Center
Training Area R. W. Shook,Ex Off., American Welding Society
Hobart Institute of Welding Technology, Troy, Ohio, has responded to the need for
trained welders by adding 8000 sq ft of training area to include two additional, large
Copyright © 2008 by American Welding Society in both printed and elec-
classrooms and lab space equipped with the latest technology. tronic formats. The Society is not responsible for any statement made or
Enrollment has doubled at the Institute during the last three years, necessitating a opinion expressed herein. Data and information developed by the authors
of specific articles are for informational purposes only and are not in-
second shift to be added during the 2007–08 school year, and accelerated the need for tended for use without independent, substantiating investigation on the
additional space to accommodate 75 more students. Also, it is expected that these new part of potential users.
classrooms will defer the need for a second shift in the immediate future.
This new area is set to open with the start of training on August 4 and will house
courses for Welding Technology and Blueprint Reading along with Oxyacetylene Weld-
ing. Pipe layout for fitters and welders will be presented in this part of the facility as
well.
MEMBER
6 AUGUST 2008
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Editorial August 2008LAYOUT:Layout 1 7/9/08 3:27 PM Page 8
EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Keeping Good Company
Officers
President Gene E. Lawson
ESAB Welding & Cutting Products
If it’s true that you’re known by the company you keep, then I’m quite lucky because
Vice President Victor Y. Matthews
I’m in with some very fine company indeed. I was recently honored with a promotion to
The Lincoln Electric Co.
the position of editor of the Welding Journal. That places me among a surprisingly small
group of individuals who have led the editorial direction of this publication; I’m the eighth Vice President John C. Bruskotter
person to hold the title of Welding Journal editor. Such a small number is practically Bruskotter Consulting Services, LLC
unheard of in the publishing world for a magazine that’s been around as long as this one
has — the Welding Journalhas been published continuously since January 1922.
Vice President John L. Mendoza
Let me tell you a little bit about the gentlemen who have preceded me in this position.
CPS Energy
William Spraragen (Jan. 1922 to Dec. 1954) — A founding member of the American
Welding Society, Spraragen served as the Welding Journal editor for an astounding 33 Treasurer Earl C. Lipphardt
years. Under his leadership, the magazine grew both in size and stature. The Welding Consultant
Research Supplement section was added during those years. The Society honors him
Executive Director Ray W. Shook
today by awarding the William Spraragen Memorial Award, which is presented for the
best paper published each year in the Research Supplement section. American Welding Society
Bonney E. Rossi (Jan. 1955 to Sept. 1960)— One of Spraragen’s protegés, Rossi was
a licensed Professional Engineer, a lecturer on welding engineering, and the author of Directors
several welding-related books. He first became involved with the Welding Journal as a
part-time assistant editor in October 1951 while serving as executive secretary to the B. P. Albrecht (At Large), Miller Electric Mfg. Co.
Pressure Vessel Research Committee of the Welding Research Council. O. Al-Erhayem (At Large), JOM
Theodore P. Schoonmaker (Oct. 1960 to Aug. 1971 and Jan. 1977 to Dec. 1981)— Ted A. J. Badeaux Sr. (Dist. 3), North Point H.S. for
Schoonmaker came to the Journalfrom the Linde Co., where he was technical informa-
Science, Technology & Industry
tion administrator for the Development Laboratory. During World War II, he saw early
action with the Army Air Corps over the Middle East before being shot down over J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
Naples, Italy, in 1943. He spent the rest of the war in Italian and German prison camps. H. R. Castner (At Large), Edison Welding Institute
After the war, he earned a degree in chemistry from Harvard. Schoonmaker’s second
N. A. Chapman (Dist. 6), Entergy Nuclear Northeast
stint as Welding Journaleditor began with the introduction of a new full-color cover.
J. D. Compton (Dist. 21), College of the Canyons
Fred L. Siegrist (Sept. 1971 to June 1972)— Siegrist had more than 20 years of expe-
rience in the metalworking and fabricating industries before joining the Welding Journal. G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
He had also been an associate editor of two other magazines before coming to AWS. D. A. Flood (Dist. 22), Tri Tool, Inc.
Carl H. Willer (July 1972 to Dec. 1976)— Willer, as he explained in his farewell edi-
M. V. Harris (Dist. 15), Valley National Gases
torial, spent “23 years in welded plate fabrication and 17 trying to explain what it’s all
R. A. Harris (Dist. 10), Consultant
about.” His four years as editor saw the introduction of modernized typefaces and for-
mat and the addition of some new departments. D. C. Howard (Dist. 7), Concurrent Technologies Corp.
Jeff Weber (Jan. 1982 to May 1996) — Currently Publisher Emeritus of the Welding J. Jones (Dist. 17), Thermadyne
Journaland an Associate Executive Director of AWS, Weber joined the Journalin 1977 as
W. A. Komlos (Dist. 20), ArcTech LLC
an assistant editor after having spent time at another welding magazine. During his tenure
as editor, the Welding Journalmoved into desktop publishing and ever-greater use of color. D. J. Kotecki (Past President), The Lincoln Electric Co.
Andrew Cullison (June 1996 to May 2008)— Cullison remains the magazine’s publish- D. Landon (Dist. 16), Vermeer Mfg. Co.
er and will continue to oversee the Welding Journal, Inspection Trends, and the Welding R. C. Lanier (Dist. 4), Pitt C.C.
Handbook. He came to the magazine from Alloy Rods in 1985 as technical editor. Among
J. Livesay (Dist. 8), Tennessee Technology Center
his accomplishments are the introductions of two new question-and-answer columns to the
magazine, the American Welder Supplement, and twice-yearly issues dedicated to brazing D. L. McQuaid (At Large), DL McQuaid & Associates
and soldering, as well as digital archiving of every issue of the magazine since its inception. S. Mattson (Dist. 5), Mattson Repair Service
I have been privileged to have worked for two of these men and to have known a
S. P. Moran (Dist. 12), Miller Electric Mfg. Co.
third. In this new position, I will be even more involved than I have in the past in article
R. L. Norris (Dist. 1), Merriam Graves Corp.
selection and in directing the editorial content of the magazine. These seven individuals
left an imprint on this magazine, and while it is too soon to know what mark I may leave, T. C. Parker (Dist. 14), Miller Electric Mfg. Co.
I can tell you I never want to see the “dumbing down” of the Welding Journal. There are W. R. Polanin (Dist. 13), Illinois Central College
those who consider the magazine too technical, while
W. A. Rice (At Large), OKI Bering, Inc.
others consider it not technical enough. I believe
N. S. Shannon (Dist. 19), Carlson Testing of Portland
there’s value in research-oriented individuals reading
about what’s happening in the industry on a day-to-day E. Siradakis (Dist. 11), Airgas Great Lakes
basis and feel that those with a hands-on bent should K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv.
reach beyond their everyday experience. After all,
G. D. Uttrachi (Past President), WA Technology, LLC
what is experimental today may be commonplace
tomorrow. The AWS membership possesses a wide D. R. Wilson (At Large), Wilson Industries
variety of interests and needs, and I think the pages of
this magazine should reflect those interests and needs.
Mary Ruth Johnsen
Editor,Welding Journal
8 AUGUST 2008