weld - American Welding Society

200 Pages·2006·20.85 MB·English

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PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING
AND ALLIED PROCESSES, INCLUDING JOINING, BRAZING, SOLDERING, CUTTING, AND THERMAL SPRAYING
One Word Defines ^x
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INTRODUCING
TT
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Circle No. 98 on Reader Info-Card
CONTENTS
November 2005 • Volume 84 • Number 11 AWS Web site http://www.aws.org
Departments
Features
40 A Simple Approach to Hot Tap and Repair Sleeve
Press Time News 4
Welding
Safety and maintaining wold integrity are the two major Editorial 6
concerns that must he understoodwhen welding onto in-
service pipelines News of the Industry 10
W. A. Bruce
CyberNotes 16
47 What Can We Do about Our Ailing Bridges? Point of View 18
Federal studies see automating bridge construction as one Stephen Liu
of the best ways to keep up with refurbishing our aging
infrastructure Stainless Q&A 20
T. Siewert et al. New Products 22
50 Optimizing Power Distribution for Lean Welding A WS Financial Report 30
Processes
AWS Professional Program ....60
A method is offered to locate the origin and magnitude of
high simultaneous resistance spot welding so a distribution AWS Exhibitors List 78
network can be devised for lean manufacturing
AWS Exhibit Highlights 85
C. A. Wallis
Na vy Joining Center 118
54 Maintenance and Repair Welding in the Open
Coming Events 120
Sea
Advances in underwater wet welding, especially in the area Welding Workbook 126
of consumables, are making it a more viable means of main
tenance and repair Society News 127
F. Perez-Guerrero and S. Liu
Tech Topics 128
Guide to A WS Services 139
Conferences 142
Welding Research Supplement
Personnel 144
New Literature 146
165-s Effects of Process Parameters on Angular
Distortion of Gas Metal Arc Welded Structural RedHot 159
Steel Plates
Classifieds 167
Mathematical models were developed to correlate out-
of-plane distortion with process variables Advertiser Index 170
V. Vel Murugan and V. Gunaraj
172-s Development of Requirements for Resistance
Spot Welding Dual-Phase (DP600) Steels
Part 1 — The Causes of Interfacial Fracture
Its high strength and light weight make DP-600 very
attractive for auto bodies, but wide acceptance will depend
on the proof of spot weld integrity
M. Marya and X. Q. Gayden
Welding Journal (ISSN 0043-2296) is published
monthly by the American Welding Society for
$90.00 per year in the United States and posses
sions. $130 per year in foreign countries: $6.00 per
single issue for AWS members and $8.00 per sin
gle issue for nonmembers. American Welding So
ciety is located at 550 NW LeJeune Rd., Miami. FL
33126-5671: telephone [phone]. Periodi
cals postage paid in Miami, Fla., and additional mail
Cover photo — Michigan Avenue. Perhaps the most recognizable ing offices. POSTMASTER: Send address changes
to Welding Journal, 550 NW LeJeune Rd„ Miami.
street name in Chicago, Michigan Avenue offers a variety of depart FL 33126-5671.
ment stores, specialty shops, and restaurants. The "Magnificent
Mile" runs along North Michigan Avenue from Oak Street to the Readers of Welding Journal may make copies of ar
ticles for personal, archival, educational or research
Chicago River. This upscale shopping district provides the latest in
purposes, and which are not for sale or resale. Per
fashion at stores like Bloomingdale's, Saks Fifth Avenue, Marshall mission is granted to guote from articles, provided
Field's, and Lord & Taylor. Photo by - Ron Schramm. customary acknowledgment of authors and
sources is made. Starred (*) items excluded from
copyright.
WELDING JOURNAL
WELjMMS
PRESS TIME
NEWS
Dofasco Completes Acquisition of Copperweld Mechanical Publisher Andrew Cullison
Tubing and Automotive Components Businesses Editorial
Editor/Editorial Director Andrew Cullison
Dofasco, Inc., Hamilton, Ont.. Canada, has recently completed the acquisition of Senior Editor Man Ruth Johnsen
certain assets of Copperweld Holding Co.. Pittsburgh, Pa., through a transaction with Associate Editor Howard M. Woodward
Atlas Tube, Inc., Harrow, Ont., Canada. Assistant Editor Kristin Campbell
The transaction, announced on August 17, was completed effective October 3 at a Peer Review Coordinator Doreen Kubish
purchase price of $177.8 million. It is expected that this price will be reduced by post-
closing adjustments. Publisher Emeritus Jeff Weber
Dofasco purchased the assets related to Copperweld's mechanical tubing and auto
Graphics and Production
motive components businesses from Atlas immediately following the acquisition of Cop
Managing Editor Zaida Chavez
perweld Holding Co. by Atlas.
Production Assistant Brenda Flores
InterSense Delivers Tracking Systems to Support Welding Advertising
Simulator Program National Sales Director Rob Saltzstein
Advertising Sales Representative Lea Garrigan Badwy
Advertising Production Frank Wilson
InterSense, Inc., Bedford, Mass.. has delivered the first production order to support
Immersion's CS WAVE welding simulator program. Subscriptions
CS WAVE was developed for and is distributed by the French company Communica Leidy Brigman
tions & Systems (CS) in partnership with Association Nationale pour la Formation Pro- [email protected]
fessionnelle des Adultes (AFPA). Immersion's recent order is being installed at several
technical training schools under the direction of the AFPA. The AFPA agency is part of American Welding Society
the French Ministry of Social Affairs, Labor, and Solidarity: its goal is to train adults 550 NW LeJeune Rd.. Miami, FL 33126
with new technical skills. [phone] or [phone]
"The primary goal of CS WAVE is to train students in mastering welding gestures,"
said Christophe Chartier, president of Immersion SAS. "CS WAVE is designed to intro Publications, Expositions, Marketing Committee
duce and familiarize students with basic welding techniques. It does not replace the real R. D. Smith. Chair
training, but will make up about a third of the overall training process." The Lincoln Electric Co.
D. L. Doench, Vice Chair
During training, the speed, distance, trajectory, and angle of the welding tool are
Hobart Brothers Co.
measured by the InterSense tracking system; then, these data are reported to a net
J.D.Weber. Secretary
worked, supervisor workstation. These measurements are then compared to ideal ges
American Welding Society
tures and reported back to the supervisor for analysis.
R. L. Arn. WELDtech International
M. C. Balmforth. Sandia National Laboratories
U.S. Army Extends General Dynamics Robotics Alliance T. A. Barry, Miller Electric Mfg. Co.
R. Durda. The Nordam Group
The U.S. Army Research Laboratory, Westminster, Md., has extended its Robotics J. R. Franklin. Sellstrom Mfg. Co.
Collaborative Technology Alliance (CTA) with General Dynamics Robotic Systems for R. G. Pali. J. P. Nissen Co.
L. Pierce, Cee Kay Supply
an additional three years. The contract continues General Dynamics' role as the lead
J. F. Saenger. Jr.. Consultant
for a robotics-focused consortium, has a value of approximately $28 million, and will
S. Smith, Weld-Aid Products
run through fiscal year 2009.
H. Castner. Ex Off.. Edison Welding Institute
Initiated in 2001, the Robotics CTA is a consortium of academic, industrial, and gov
D. C. Klingman. Ex Off, The Lincoln Electric Co.
ernment partners focusing cutting-edge robotics research on the core autonomous sys D. J. Kotecki. Ex Off. The Lincoln Electric Co.
tems capabilities that will provide soldiers and other DoD personnel with new tactical L. G. Kvidahl. Ex Off.. Northrup Grumman Ship Systems
capabilities. General Dynamics' initial funding for the Robotics CTA was $42 million G. E. Lawson. Ex Off.. ESAB Welding & Cutting Products
for robotics research, with an additional time and materials agreement capped at $60 E. D. Levert, Sr., Ex Off., Lockheed Martin
million for transitioning research products. E. C. Lipphardt. Ex Off.. Consultant
S. Liu, Ex Off.. Colorado School of Mines
R. W. Shook. Ex Off, American Welding Societ}'
E&E Engineering Receives Training Grant
D. R. Wilson. Ex Off. Wilson Industries
E&E Engineering, Inc., Warren, Mich., a manufacturer and supplier of tooling com
ponents, material handling products, and ergonomic systems for the automotive and
manufacturing tooling community, recently learned it will receive a $26,618 grant for
worker training in the areas of lean manufacturing and quality systems. Henry Ford
Community College will assist in the administering of grants and facilitate all training Copyright 6 2005 by American Welding Society in both printed and elec
tronic formats. Tltc Society is not responsible for any statement made or
sessions for the 57 employees at the company.
opinion expressed herein. Data and information developed by the authors
E&E Engineering is a 2005 applicant of the Manufacturing Competitiveness Pro of specific articles are for informational purposes only and are not in
tended for use without independent, substantiating investigation on the
gram Job Training Grant facilitated by the Michigan Economic Development Corp. and part of potential users.
the Michigan Manufacturing Technology Center, which formed a partnership in 2003 to
train tool and die industry workers in new manufacturing methods.
The company has established a schedule for the planned education courses and will BPA
complete its training by the end of 2005. INTERNATIONAL
NOVEMBER 2005
Hodgson Custom Rolling Inc.
s^penrv/iincPeQs aa wwiirdlpe uvaarriipettvy nof f ininrtdiiuQstrtirpiecs; inin f hthpe F EMNFERRRGYY {"---— / Jlflij^^»-ri ~^
SECTORS of hydro, petro chemical, atomic, gas, oil,
wind, etc. in addition to those in heavy manufacturing, -y
steel, pulp & paper, mining, marine, forestry, etc.
Hodgson's commitment to providing customers
superior products and personalized professional
service has earned itself a reputation for excellence,
making the name HODGSON synonymous with
"paramount quality and workmanship".
Hodgson Custom Rolling Inc. is one of North
America's largest plate rolling, forming, section
rolling and fabricating companies.
PLATE ROLLING & FLATTENING ,
Hodgson Custom Rolling specializes in the rolling and flattening of heavy
plate up to 7" thick and up to 12 feet wide. Cylinders and segments can be
rolled to diameters ranging from 10" to over 20 feet. Products made include
ASME pressure vessel sections. Crane Hoist Drums, thick walled pipe, etc.
PRESS BRAKE FORMING & HOT FORMING
Hodgson Custom Rolling's brake department processes all types of steel sections
and plate up to 14" thick. Developed shapes such as cones, trapezoids, parabolas,
reducers (round to round, square to round) etc.
STRUCTURAL SECTION ROLLING
Hodgson Custom Rolling has the expertise to roll curved structural sections into
a wide range of shapes and sizes (angle, wide flange beam, I-beam, channel, bar,
tee section, pipe, tubing, rail, etc.). We specialize in Spiral Staircase Stringers,
flanges, support beams, gear blanks, etc.
FABRICATING
Hodgson Custom Rolling combines expertise in rolling, forming, assembly and .,
welding to produce various fabrications including kiln sections, rope drums, heavy
weldments, ladles, pressure vessel parts, multiple Components for Heavy Equipment
applications etc.
/Ho
Hodgson
ASME Certified
ISO 9001:2000
Custom Rolling Inc.
5580 Kalar Road Telephone: [phone] U.S. Address:
Niagara Falls Toll-free: [phone] M.P.O. Box 1526
Ontario, Canada Fax: [phone] Niagara Falls, N.Y.
L2H 3L1 E-mail: [email protected] 14302 -1526
Website: www.hodgsoncustomrolling.com
HOD
N CAN HELP SOLVE YOUR PROBLEMS
Circle No. 59 on Reader Info-Card
EDITORIAL American Welding Society
^ iaa^K^tJ Founded in 1919 to Advance the Science,
Technology and Application of Welding
See It for Yourself
Officers
President Damian J. Kotecki
The Lincoln Electric Co.
I clearly remember the first AWS Show I attended. It was in St. Louis in 1976, and I
Vice President Gerald D. Uttrachi
had been working in the industry for only three years. When I walked through the Show
WA Technology, LLC
hall entrance, I was amazed. The welding industry on display was an awesome sight to a
26-year-old. I was extremely impressed by the number of exhibitors and the size of the Vice President Gene E. Lawson
show.
ESAB Welding & Cutting Products
I've now worked in the industry for 32 years, an industry that has undergone many
changes since I attended my first AWS Show. Technology has changed in equipment, Vice President Victor Y. Matthews
consumables, and related products. There have been a significant number of end-user, The Lincoln Electric Co.
distributor, and manufacturer consolidations. We have evolved to a "global" economy
Treasurer Earl C. Lipphardt
and the world has become smaller.
Consultant
These consolidations and the advent of the Internet have caused trade shows to
change as well. To fully understand these changes, AWS retained the services of a mar Executive Director Ray W Shook
ket research company to determine the buying thought process of individuals who at American Welding Society
tend trade shows. Following that study, a special AWS Presidential Committee was
formed to examine the future of the AWS Welding Show. The committee was made up
of representatives from a variety of exhibitors with Rusty Franklin as chair. The com Directors
mittee reviewed a number of different options and concluded the most logical one was
T. R. Alberts (Dist. 4), New River Community College
to form an alliance with FABTECH International. Ultimately an agreement with
B. P. Albrecht (At Large), Miller Electric Mfg. Co.
FABTECH was reached.
AWS thanks its members and customers for their support of its 52 stand-alone shows, 0. Al-Erhayem (At Large),70M
especially the support given to the Dallas Show held earlier this year. AWS realizes it A. J. Badeaux. Sr. (Dist. 3), Charles Cty. Career & Tech. Center
was making no small request when it asked you to support two shows in one calendar
K. S. Baucher (Dist. 22). Technicon Engineering Services, Inc.
year.
J. C. Bruskotter (Dist. 9). Bruskotter Consulting Semces
The American Welding Society is pleased to have this inaugural Show with our
FABTECH partners in Chicago this month (November 13-16). FABTECH is comprised C. F. Burg (Dist. 16), Ames Laboratory 1PRT
of the Society of Manufacturing Engineers (SME) and the Fabricators and Manufactur N. M. Carlson (Dist. 20), Idaho National Laboratory
ers Association (FMA). Together we feel we have put together an alliance that will add
H. R. Castner (At Large), Edison Welding Institute
value to everyone in the welding industry — end users, distributors, and exhibitors.
N. A. Chapman (Dist. 6). Entergy Nuclear Northeast
Following are just some of the highlights of the FABTECH International and AWS
Welding Show: S. C. Chappie (At Large). Consultant
• Total size of the Show will be close to 350.000 square feet. N. C. Cole (At Large). NCC Engineering
• Welding and related products will encompass close to 100,000 square feet, making
J. D. Compton (Dist. 21). College of the Canyons
this Show comparable in size to Dallas '05 (86,000) and Chicago '04 (90,000).
L. P. Connor (Dist. 5), Consultant
• Professional Welder Contest. This is the second time AWS is conducting this contest,
which is being held every other year and showcases the talents of professional welders. J. E. Greer (Past President). Moraine Valley C. C.
• An outstanding Professional Program compiled by the AWS Technical Papers Com M. V. Harris (Dist. 15). Reynolds Welding Supply
mittee, chaired by Stephen Liu.
R. A. Harris (Dist. 10). Penton Publishing Co.
• A lineup of outstanding AWS conferences, including Welding of Stainless Steel, Fric
tion Stir Welding, and Welding and Fabrication of Food Industry Equipment. W. E. Honey (Dist. 8). Anchor Research Corp.
• The RWMA Welding School D. C. Howard (Dist. 7). Concurrent Technologies Corp.
• Brazing and Soldering Commercial Sessions and an "Interview with a Legend," Bob J. L. Hunter (Dist. 13). Mitsubishi Motor Mfg. of America. Inc.
Peaslee
J. L. Mendoza (Dist. 18), Qty Public Setvice
• A one-day contact booth program bv the Gases and Welding Distributors Association
(GAWDA) S. P. Moran (Dist. 12), Miller Electric Mfg. Co.
• FABTECH Technical Conferences T. M. Mustaleski (Past President), BWXT Y-12. LLC
This new alliance is yet another change within our industry, a change AWS believes
R. L. Norris (Dist. 1), Merriam Graves Corp.
is positive. One thing hasn't changed though. The sight of the welding industry on dis
T. C. Parker (Dist. 14), Miller Electric Mfg. Co.
play is just as impressive today as it was back in 1976
when I walked into my first Show. See it for yourself. 0. P. Reich (Dist. 17). Texas State Technical College at Waco
Come and visit us in Chicago. We look forward to meet W. A. Rice (At Large). OKI Bering. Inc.
ing you there.
E. Siradakis (Dist. 11),Airgas Great Lakes
K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv.
P. E Zammit (Dist. 19). Brooklyn Iron Works. Inc.
Ray W. Shook
A WS Executive Director
NOVEMBER 2005
F^K
^
&h:
Valued Harris Calorific & J.W. Harris Distributors
David Nangle, President
You are Cordially Invited to Attend
Harris Calorific's 100 Year Birthday Celebration
.-..."' sis
Welcome the Newest Addition to
the Lincoln Electric Family of Companies.,
TT^
Come Celebrate with Us at the Fabtech/AWS Show
November 13th - 16th
McCormick Place, Chicago, IL. Booth # 5065!!i
Circle No. 70 on Reader Info-Card
www.harrissccaalloorriiffiicc..ccoomm ,. ':.:;;; Bring this ad to our celebration and receive a free gift. . www.jwharris.com
ADVANCED TECHNOLOGY MEETS
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the Harley-Davidson Welding Helmets
provide premium style with unrivaled
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design. Extended coverage ofthe helmet
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For more information call 800-682-0839 or check
us out at www.bacou-dalloz.com
i-iM'Jil'tl'M'l ©2005 H-D. All rights reserved. Manufactured by Bacou-Dalloz
under license from Harley-Davidson Motor Company.
www.bacou-dalloz.com
Circle No. 21 on Reader Info-Card