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 FEBRUARY 2016

PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
For Info, go to www.aws.org/ad­index
For Info, go to www.aws.org/ad­index
For Info, go to www.aws.org/ad­index
February 2016 • Volume 95 • Number 2 CONTENTS
FEATURES
32 Low­Energy Impact Spot Welding of High­Strength aluminum foil and high electrical current to
Aluminum Alloys launch one piece of metal toward a stationary
A novel impact welding process utilizes a thin sheet — A. Vivek et al.

BRAZING & SOLDERING TODAY

36 Understanding the Run­Out Behavior of a Ag­Cu­Zr
Braze Alloy 44
Modifying filler metal composition or using a
barrier coating on Kovar™ show promise in
mitigating run-out — P. T. Vianco et al.

*44 Techniques for Successful Aluminum Vacuum­Brazed

Assemblies
No need for flux, high joint strength, lack of salt
contamination, and capability for joining large
surfaces and complex geometries are some of the
advantages vacuum brazing has to offer
R. Caracciolo et al.

THE AMERICAN WELDER

88 Fabricating without Fear
Daredevil depends on his own welding skill to 88 92
support his tightrope suspended high in the air
V. Hilton

92 Do’s and Don’ts of Welding Information

Management Systems
Electronic gathering of welding data in a
systematic way can help ensure the correct
parameters are being used and production is
performed in the most efficient manner
R. Lindeman

WELDING RESEARCH SUPPLEMENT

47­s Effect of Torch Height on Arc Stability in
Divided­Arc Processes
An experimental study was conducted to determine
the effect of torch height on the operation of the
divided-arc welding process — S. J. Chen et al.
57­s Liquation and Liquation Cracking in Partially
Melted Zones of Magnesium Welds
A variety of magnesium alloys was investigated to help
understand and predict liquation cracking susceptibility
X. Chai et al.
68­s TLP Bonding of Dissimilar FSX­414/IN738 System
with MBF80 Interlayer: Optimization of the
Bonding Time and Temperature
The effect of different temperatures on transient
liquid phase bonding was researched
B. Abbasi­Khazaei et al.

FEBRUARY 2016 / WELDING JOURNAL 3

 DEPARTMENTS
6 Editorial 56 Certification Schedule
8 Press Time News 59 Society News
10 Washington Watchword 68 Tech Topics
12 International Update 73 Section News
14 News of the Industry 85 Guide to AWS Services
18 Business Briefs 86 Personnel
20 Aluminum Q&A The American Welder
24 Brazing Q&A 96 Fact Sheet
26 Product & Print Spotlight 98 Learning Track
Brazing & Soldering Today 103 Brazing and Soldering Profiles On the cover: A Dynamic Fabrication
48 Technology News 110 Classifieds journeyman gas tungsten arc welds
aluminum aircraft spacers. (Courtesy of
52 Coming Events 111 Advertiser Index Dynamic Fabrication, Inc., Santa Ana,
Calif.)

M. Skiles (Dist. 9), Consultant D. Marquard, IBEDA Superflash

W. J. Sperko (At Large), Sperko Engineering Services
J. Stoll (Dist. 18), The Bohler Welding Group U.S.
H. W. Thompson (Dist. 2), UL, Inc.
R. P. Wilcox (Dist. 11), Consultant
OFFICERS J. A. Willard (Dist. 13), Kankakee Community College
D. R. Wilson (Past President), Welldean Enterprises
President David L. McQuaid
D. L. McQuaid and Associates, Inc.
WELDING JOURNAL
Vice President John R. Bray
Affiliated Machinery, Inc. Publisher — Andrew Cullison
Editorial
Vice President Dale Flood Editorial Director Andrew Cullison
Tri Tool, Inc. Editor Mary Ruth Johnsen
Associate Editor Kristin Campbell
Vice President Thomas J. Lienert
Los Alamos National Laboratory Assistant Editor Melissa Gomez
Assistant Editor Annik Babinski
Treasurer Carey Chen Peer Review Coord. Sonia Aleman
Cincinnati, Inc. Publisher Emeritus Jeff Weber
J. F. Saenger Jr., Consultant
S. Smith, Weld­Aid Products
D. Wilson, Welldean Enterprises
J. N. DuPont, Ex Off., Lehigh University
L. G. Kvidahl, Ex Off., Northrop Grumman
Ship Systems
D. J. Landon, Ex Off., Vermeer Mfg.
S. P. Moran, Ex Off., Weir American Hydro
E. Norman, Ex Off., Southwest Area Career Center
R. G. Pali, Ex Off., J. P. Nissen Co.
N. Scotchmer, Ex Off., Huys Industries
R. W. Shook, Ex Off., American Welding Society
American Welding Society
8669 NW 36 St., # 130, Miami, FL 33166­6672
(305) 443­9353 or (800) 443­9353

Executive Director Ray W. Shook Design and Production

American Welding Society
DIRECTORS
T. Anderson (At Large), ITW Welding North America
U. Aschemeier (Dist. 7), Subsea Global Solutions
D. J. Burgess (Dist. 8), Alstom Power
D. A. Desrochers (Dist. 1), Old Colony RVTHS
D. L. Doench (At Large), Hobart Bros. Co.
D. K. Eck (At Large), Praxair Distribution, Inc.
K. Fogleman (Dist. 16), Consultant
P. H. Gorman (Dist. 20), Sandia National Laboratories
S. A. Harris (Dist. 4), Altec Industries
J. Knapp (Dist. 17), Consultant
M. Krupnicki (Dist. 6), Mahany Welding Supply
D. J. Landon (Past President), Vermeer Mfg. Co.
S. Lindsey (Dist. 21), City of San Diego
D. E. Lynnes (Dist. 15), Lynnes Welding Training
Production Manager Zaida Chavez
Sr. Production Coordinator Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
Sr. Advertising Sales Exec. Sandra Jorgensen
Sr. Advertising Sales Exec. Annette Delagrange
Manager of Sales Operations Lea Paneca
Sr. Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Evelyn Andino
eandino@aws.org
MARKETING ADVISORY COUNCIL
(MAC)
Welding Journal (ISSN 0043­2296) is published monthly by
the American Welding Society for $120.00 per year in the United
States and possessions, $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 8669 NW 36th St., # 130,
Miami, FL 33166­6672; telephone (305) 443­9353. Periodicals
postage paid in Miami, Fla., and additional mailing offices. POST­
MASTER: Send address changes to Welding Journal, 8669 NW
36th St., # 130, Miami, FL 33166­6672. Canada Post: Publications
Mail Agreement #40612608 Canada Returns to be sent to
Bleuchip International, P.O. Box 25542, London, ON N6C 6B2,
Canada.
Readers of Welding Journal may make copies of articles for
personal, archival, educational or research purposes, and which
are not for sale or resale. Permission is granted to quote from arti­
cles, provided customary acknowledgment of authors and sources
is made. Starred (*) items excluded from copyright.
Copyright © 2016 by American Welding Society in both
printed and electronic formats. The Society is not responsible for
any statement made or opinion expressed herein. Data and infor­
mation developed by the authors of specific articles are for infor­
mational purposes only and are not intended for use without inde­
pendent, substantiating investigation on the part of potential users.

C. Matricardi (Dist. 5), Welding Solutions, Inc. D. L. Doench, Chair, Hobart Brothers Co.
S. M. McDaniel (Dist. 19), Big Bend Community College S. Bartholomew, Vice Chair, ESAB Welding
W. R. Polanin (At Large), Illinois Central College & Cutting Prod.
R. L. Richwine (Dist. 14), Ivy Tech State College Lorena Cora, Secretary, American Welding Society
D. J. Roland (Dist. 12), Airgas USA, LLC, D. Brown, Weiler Brush
North­Central Region C. Coffey, Lincoln Electric
R. W. Roth (At Large), RoMan Manufacturing D. DeCorte, RoMan Manufacturing
M. Sebergandio (Dist. 3), CNH America S. Fyffe, Astaras, Inc.
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co. D. Levin, Airgas
M. Sherman (Dist. 10), SW&E, LLC R. Madden, Hypertherm

4 WELDING JOURNAL / FEBRUARY 2016

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EDITORIAL
John Bray
A W S V ic e P r e s id e n t
“How we plant
that seed of excite­
ment in someone
to attend the local
Section meeting is
very important.
With the younger
generation so in
tune with technol­
ogy and social
media connections,
this has to be our
best path to main­
tain their interest
and desire to join
AWS.”
6 WELDING JOURNAL / FEBRUARY 2016
Planting the Seeds of Our Future
During a past American Welding Society
(AWS) board meeting, there was a discus-
sion about our Sections being the “grass-
roots of our Society.” This was stated by in-
coming District 10 Director Mike Sherman.
At the time, I did not really think about
the truth in that statement. However, re-
membering back to when I served on the
board of my local Houston Section for
twelve years made me realize that was the
“grassroots” of my AWS career.
Many of the volunteers who serve on our
committees, subcommittees, and the na-
tional AWS board of directors came up
through the Sections. That made me won-
der how so many people were first intro-
duced to AWS.
Our members attend local Section meet-
ings and are able to meet and network with
other members of our Society to exchange
ideas and concepts. But how do members
find their local Section meeting time and
location?
All you have to do is go to the AWS web-
site at aws.org. Click on “About” in the
upper-right corner of the headings. This will
bring up a screen that shows “Sections” at
the box on the right-hand side. Then click
on that and you will be taken to a screen
that has “Find a Section” in the box on the
right. Click on that, and it will take you to
the listing of all the Sections’ names in al-
phabetical order along with what city they
are located in. Then click on the Section
name you want, and the next screen gives
you a picture of that Section’s District Direc-
tor along with all of his or her information
and a listing of contacts for each Section.
Most Sections have websites that you
can click on to get all of their meeting in-
formation and contacts. Some even give
you pictures of past and future meetings
along with speakers and events. It is all de-
signed by AWS to help you get the informa-
tion you need to contact with the local Sec-
tions and Districts around the United
States, and it only takes a few seconds.
Information is critical to keep our “grass-
roots” fed and nurtured so we can grow our
membership. It can make you stop and
think about the fact that someone you met
at a local Section meeting might be the next
AWS president, and they don’t even know it
yet. As members of the Society, we have
such a great opportunity to help grow new
members.
How we plant that seed of excitement in
someone to attend the local Section meet-
ing is very important. With the younger
generation so in tune with technology and
social media connections, this has to be our
best path to maintain their interest and de-
sire to join AWS.
The staff at AWS is doing just that right
now with maintaining the following web-
sites and accounts:
• AWS WeldLink, awsweldlink.org
• Jobs In Welding, jobsinwelding.com
• Careers In Welding, careersinwelding. com
• Facebook, facebook.com/American
WeldingSociety
• Twitter, @AWSHQ
• Instagram, americanweldingsociety.
We need to discuss that information
about our new features at every meeting.
So, still the question comes back to how
do we grow those seeds into the roots of our
Society? In particular, how can we reach out
and develop in the next generation of men
and women an interest in the welding pro-
fession as an honorable way of life?
Senator Marco Rubio said, “Welders
make more money than philosophers,” and
we have to do a better job of getting the
message to people that you can make a very
good living by being a welder. Then the next
step is to show all of the different avenues
you can take in your welding career.
So with all of our new “AWS tools,” it is
our job as members to get the word out of
how valuable being involved in your local
Section really is. It goes back to being an
“AWS mentor.” The most important asset
we have is “people.”
When speaking at different engagements
about AWS, I am always amazed at how 138
AWS staff members maintain, serve, and as-
sist more than 72,000 members worldwide.
With the help of our staff and volun-
teers, the sky is the limit for what we can ac-
complish with growing our seeds for the fu-
ture of welding and AWS. WJ
For Info, go to www.aws.org/ad­index
PRESS TIME NEWS
Air Liquide Announces Agreement to
Acquire Airgas
Air Liquide, Paris, France, a world provider of gases, tech-
nologies, and services for industry/health, is set to acquire Air-
gas, Radnor, Pa., a supplier of industrial gases as well as associ-
ated products and services in the United States, which will be-
come a wholly owned subsidiary of the company.
Airgas shareholders will receive $143 per share in cash for
all outstanding shares of the company, representing a total en-
terprise value of $13.4 billion on a fully diluted basis and in-
cluding the assumption of Airgas debt.
“This transaction is compelling for our shareholders, aris-
ing from the persistent execution of our business strategy for
more than three decades. Air Liquide’s long-term vision and
strong heritage in the U.S. make it the right fit for our valued
customers, and the combination creates significant opportuni-
ties for the talented employees of both companies,” said Peter
McCausland, executive chairman of Airgas.
He further mentioned, “We are excited about the prospects
of integrating these two businesses to create the largest indus-
trial gas company in the world.”
The entity will be able to better serve users with multidis-
tribution networks in the United States and more product of-
ferings. In addition, the combined company will continue to
implement an approach that blends scientific expertise, tech-
nology, and customer insight.
The venture is subject to Airgas shareholders’ approval, re-
ceipt of necessary antitrust and other regulatory approvals,
plus customary conditions and provisions.
FANUC Achieves Record­Breaking 400,000
Robots Sold Worldwide
FANUC
America Corp.,
Rochester Hills,
Mich., a suppli-
er of robotics,
CNCs, and fac-
tory automa-
tion, has recent-
ly announced
that its parent
company,
FANUC America Corp. demonstrates fix­ FANUC Corp.,
tureless welding with its ARC Mate set a new world
100iC/12 robot, LR Mate 200iD/7L mini­ record for pro-
robot, and iRVision® 3D area sensor. ducing more
than 400,000
robots.
Mike Cicco, vice president, FANUC America, stated that
over the last several years, there’s been an increasing global de-
mand to implement the latest technologies in factories, and
this has stimulated production of industrial robots in general,
playing a major role in the company’s achievement.
“From a product standpoint, the recent drivers behind
reaching this milestone have been the popularity of the
FANUC R-2000iC series, the LR Mate 200iD series, and the
new CR-35iA collaborative green robot,” added Cicco.
8 WELDING JOURNAL / FEBRUARY 2016
Maritime Administration Offers Funding for Small
U.S. Shipyards; Applications Due February 16
The U.S. Department of Transportation’s Maritime Admin-
istration, Washington, D.C., recently announced the availabili-
ty of $4.9 million in federal funding to support capital im-
provements and employee training at small U.S. shipyards.
Provided through the Small Shipyard Grant Program, these
will support efficiency improvements and modernizations
that allow U.S. shipyards to compete more effectively in the
global marketplace.
Applications are due by 5 p.m. EST on February 16. The ad-
ministration intends to award grants no later than April 18.
Additional details can be found in the Federal Register at
http//1.usa.gov/1mG9jVj or by contacting David M. Heller, di-
rector, Office of Shipyards and Marine Engineering, Maritime
Administration, Room W21-318, 1200 New Jersey Ave., S.E.,
Washington, D.C. 20590; David.Heller@dot.gov.
Grants are offered to support many projects, including cap-
ital and related improvements, plus equipment upgrades that
foster ship construction, repair, and reconfiguration in small
shipyards across the United States. Also, the grants can be
used to support maritime training programs that improve
technical skills to enhance shipyard worker efficiency.
The Small Shipyard Grants, which are limited to no more
than 75% of the estimated improvement costs, are available to
U.S. shipyards with less than 1200 production employees.
Flexovit USA Begins Reconstruction Journey
Flexovit USA, Inc., an industrial abrasives manufacturer, is
in the process of starting to rebuild its manufacturing and
warehouse facilities in Angola, N.Y. A majority of the compa-
ny’s 100,000-sq-ft building collapsed due to record snowfall
that hit the western New York state area in late November
2014, dumping from 5 to 7 ft of snow in 48 h.
Since that time, the company has resumed manufacturing
resin-reinforced grinding/cutting wheels and abrasive flap
discs in undamaged sections of the property. It has also main-
tained sales and distribution services at its four distribution
centers.
Rebuilding the 62,000-sq-ft plant and warehouse will re-
store Flexovit’s full production capabilities. This should be
completed by fall 2016. As work progresses, the company ex-
pects to rehire employees laid off due to the event.
Weiler Secures SWATYCOMET from Avtotehna
Weiler Corp., Cresco, Pa., a provider of power brushes, abra-
sives, and maintenance products for surface conditioning, re-
cently announced the acquisition of SWATYCOMET d.o.o.,
Maribor, Slovenia, a manufacturer of bonded abrasives that
dates back to 1879. Through the transaction, Weiler also adds
a range of cut-off/grinding wheels and technical fabrics.
“It has been a pleasure to get to know some of the mem-
bers of the SWATYCOMET team during the sale process,
and I am excited to have them join the Weiler team. The
complementary nature of our products, geographies, and
company cultures makes this a great fit. Additionally, Weiler
customers will see immediate benefit as we expand our
TigerTM brand into the bonded abrasive category,” said Chris
Weiler, CEO, Weiler Corp. WJ
For Info, go to www.aws.org/ad­index
WASHINGTON WATCHWORD
New Education Law Highlights CTE
The Every Student Succeeds Act (ESSA) was passed by
Congress and signed by the President at the end of 2015.
ESSA is a four-year education reform law that replaces the
No Child Left Behind Act, which was enacted in 2002.
The Every Student Succeeds Act shows unprecedented
support for career and technical education. It includes career
and technical education (CTE) in its definition of a well-
rounded education, requires coordination of ESSA and CTE
plans by state and local education agencies, supports the in-
tegration of academic and CTE coursework, and encourages
states to include the progress of students in attaining career
and technical education proficiencies on state report cards.
Project Streamlining Bill Introduced
The Federal Permitting Improvement Act of 2015 (S.280)
is designed to streamline and improve the federal permit-
ting process by expediting permit decision making and in-
jecting certainty into the process by facilitating coordination
and deadline setting among agencies. The bill would also im-
prove transparency and reduce unnecessary delays caused
by litigation. Key reforms include the following:
• Creation of an interagency council to identify best prac-
tices and deadlines for required reviews and approvals of
various types of infrastructure projects
• Establishment of a formal role for a single “facilitating”
or “lead” agency to set a permitting timetable for each major
capital project
• Encouragement of greater cooperation with state and
local permitting authorities
• Creation of a public, on-line “dashboard” to track agency
progress on required approvals and reviews of major capital
projects and to provide access to relevant documents
• Requiring agencies to reach out to accept comments
from stakeholders early in the approval and review process,
with the aim of identifying and addressing important public
concerns early
• Requiring courts to consider potential job loss in weigh-
ing equitable considerations for injunctive relief.
“Race to the Shop” Manufacturing Grant
Legislation Reintroduced
Legislation has been introduced in the House and Senate
to create an annual $100 million competitive grant to pro-
mote reforms in workforce education and skills training for
manufacturing jobs. The Manufacturing Skills Act of 2015 is
similar to legislation considered, but not adopted, by Con-
gress in recent years and is inspired by the successful “Race
to the Top” program created by the Department of Educa-
tion, which created competition among schools to improve
student metrics across the country. “Race to the Shop”
would give similar incentives to states and cities to train for
HUGH K. WEBSTER, AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE — Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania
Ave. NW, Washington, DC 20006; e­mail hwebster@wc­b.com; FAX (202) 835­0243.
10 WELDING JOURNAL / FEBRUARY 2016
BY HUGH K. WEBSTER
manufacturing positions by awarding grants to up to five
states and five metropolitan areas with the strongest and
most comprehensive proposals. Each winner would receive
up to $10 million over a three-year period. The state or met-
ropolitan area receiving the grant would also be required to
provide at least 50% of the grant’s value in matching funds.
Government Seeks to Bolster Nuclear
Energy Industry
The federal government is taking steps to support the
U.S. nuclear industry. In the legislative arena, the recently
introduced Nuclear Energy Innovation Capabilities Act
would, according to its preamble, “enable civilian research
and development of advanced nuclear energy technologies
by private and public institutions and...expand theoretical
and practical knowledge of nuclear physics, chemistry, and
materials science.” The bill would accomplish this by di-
recting the Department of Energy (DOE) to focus its civil-
ian nuclear research and development activities toward
programs that enable the private sector, national laborato-
ries, and universities to carry out such experiments as are
necessary to promote scientific progress and enhance prac-
tical knowledge of nuclear engineering.
Recent initiatives by the White House include an an-
nouncement that costs incurred by an eligible project as part
of the licensing process, such as design certification, con-
struction permits, combined construction, and operating li-
censes, may be eligible for Department of Energy loan guar-
antees. This is in addition to the Department of Energy’s ex-
isting solicitation of $12.5 billion in loan guarantees avail-
able to support innovative nuclear energy projects. Also, the
Department of Energy has launched its Gateway for Acceler-
ated Innovation in Nuclear (GAIN) program, which is de-
signed to provide the nuclear energy community with
single-point access to nuclear energy-related capabilities and
expertise across DOE. The GAIN program also will feature
the DOE-published Nuclear Energy Infrastructure Database
and a small business voucher scheme.
OSHA Set to Issue Silica, Other Rules
The U.S. Occupational Safety and Health Administration
(OSHA) has issued its regulatory agenda for 2016, and it in-
cludes plans to issue several final and proposed rules.
Among the most anticipated concerns is increased safety
standards for occupational exposure to crystalline silica. An-
other will address the tracking of workplace injuries and ill-
nesses, in which OSHA is expected to impose new electronic
reporting obligations to most employers that are required to
keep OSHA 300 logs. Employers with 20 or more employees
also may be required to submit annual reports to OSHA elec-
tronically with the information provided on OSHA Form
300A. Perhaps most significant, OSHA plans to post the 300
logs and 300A forms on its website for public review. WJ
For Info, go to www.aws.org/ad­index
INTERNATIONAL UPDATE
German Nonprofit Research Institute Works to
Solve Steel and Aluminum Joining Challenges
Lazer Zen-
trum Hannover
eV (LZH), Han-
nover, Germany,
a nonprofit re-
search institute,
will work with
industry part-
ners and scien-
tists to solve the
challenges of
joining steel and
aluminum in
Laser welding of steel to aluminum (photo maritime con-
courtesy of Laser Zentrum Hannover). struction. The
company’s Laser
Welding of Steel
to Aluminum for Applications in Shipbuilding project aims
to develop, test, apply, and verify a laser processing head
and welding process.
The project also aims to replace the adapter piece currently
used in shipbuilding when joining different metals, which is
a complicated and cost-intensive joining technology. Ger-
man-based system manufacturers Precitec GmbH & Co. KG,
Scansonic MI GmbH, and TRUMPF Laser and Systemtech-
nik GmbH are working with LZH to develop a laser process-
ing head with a weld-penetration depth control.
Using the processing head, LZH will develop a welding
process under lab conditions to be tested in cooperation
with LASER on demand GmbH, Langenhagen, Germany.
The process will then be transferred to actual applications
by semifinished product manufacturers Druckguss Service
Deutschland GmbH and Hilbig GmbH, as well as shipyards
Fr. Lürssen Werft GmbH & Co. KG and Meyer Werft GmbH
& Co., all of which are based in Germany.
The project is funded by the German Federal Ministry for
Economics and Energy and supervised by Forschungszen-
trum Jülich GmbH, an interdisciplinary research center.
IIW Colloquium Held in the Netherlands
Attendees of the 5th IIW Colloquium visited EWM’s technology
center.
The 5th International Institute of Welding (IIW) Welding
Research and Collaboration Colloquium was recently held in
Limburg, the Netherlands. Organized by EWM AG, a welding
12 WELDING JOURNAL / FEBRUARY 2016
machine manufacturer, GSI SLV Munich, a research institute,
and Helmholtz-Zentrum Geesthacht, an interdisciplinary re-
search center, the event offered young scientists from Ger-
many, Portugal, Belgium, Hungary, Australia, Brazil, China,
and India a platform for debate and discussion.
Representatives from the automotive, aviation, aero-
space, and wind energy industries presented their scientific
developments. Future welding applications in these sectors
and associated challenges were discussed.
EWM organized an excursion to its technology center,
where international guests were able to explore welding
processes and learn more about the company’s latest devel-
opments in arc welding technology.
AWS Launches AWS Asia Website
The American Welding Society (AWS), Miami, Fla., has
launched an AWS Asia website, awsasia.org, to allow mem-
bers in China to access information in their native language
as well as in English. It has been designed to provide infor-
mation on services offered by AWS in Asia, including mem-
bership benefits, certifications, exposition details, online
education, and AWS publications and technical standards.
Highlights include quick links to areas of special interest
and search features.
“AWS is committed to the future of the welding profes-
sion in China, and the new AWS Asia website will allow us to
better serve the welding community there and become more
accessible to our members by keeping them up-to-date on
the latest news and opportunities,” said Jeff Kamentz, AWS
corporate director of global sales.
WEC Group Celebrates Success of Apprentices
WEC Group,
Ltd., Lan-
cashire, United
Kingdom, cele-
brated the suc-
cess of its
training acade-
my apprentices
at its annual
WEC Group apprentices pose with their Apprentice of
awards at the company’s annual awards the Year
ceremony. Awards cere-
mony. The
awards
evening, which was held at Whitehall Hotel, Darwen, United
Kingdom, recognizes the success of the company’s welding/
fabrication, CNC machining, and new business administra-
tion apprentices.
Students were presented with awards based on their com-
mitment, academic achievements, as well as welding and ma-
chining excellence. “The Apprentice of the Year Awards is a
tribute to the amount of effort and commitment our appren-
tices put into their work,” said Kris Mercer, WEC Group’s
training and development manager. “They are an exceptionally
talented group of young people and it’s important to reward
them for their efforts.” WJ
For Info, go to www.aws.org/ad­index
NEWS OF THE INDUSTRY
Brazosport College to Use $1 Million Award
for New Welding Facility
Posing (from left) are Greg Brooks, SI Group; Heather Wescott,
Shintech; Wendy Mazurkiewicz, Freeport LNG Development, L.P.;
Rick Przeworski, K­Bin; Chris Witte, BASF Corp.; Lisa LaBean, The
Dow Chemical Co.; Paul Cartlidge, Ascend Performance Materi­
als; Loris Canahuati, Braskem America; Dr. Millicent Valek, Bra­
zosport College; Roger Claeys, Shin­Etsu Silicones of America;
Shane Steelman, Vencorex; and Wayne McDowell, Chevron
Phillips Chemical Co.
The Brazoria County Petrochemical Council (BCPC) re-
cently announced a gift of $1 million to the Brazosport Col-
lege Foundation. The Lake Jackson, Tex., school will use this
award toward a new welding facility to be named the BCPC
Welding Technologies Lab.
In February, the lab and Freeport LNG Crafts Academy
will be dedicated. Classes are also set to start in the lab in
the 2016 spring semester.
“The partnership of Brazosport College with BCPC is vi-
tal to providing a skilled workforce that will support the
continued expansion of the petrochemical industry in the
Gulf Coast region,” said Brazosport College President Dr.
Millicent Valek.
More than 10 BCPC companies contributed to this gift,
including Air Liquide America Corp., BASF Corp., Chevron
Phillips Chemical Co., Gulf Chemical & Metallurgical Corp.,
and The Dow Chemical Co.
Report on Aluminum in Passenger Vehicles
Offers Insights by OEM Brand, Vehicle Segment
Aluminum in Passenger Vehicles — Trends, Implications, and
Opportunities presents trends on aluminum usage in cars
and light trucks. Conducted by ReportLinker, this study an-
alyzes automotive manufacturer and supplier strategies,
plus provides an overview of aluminum usage patterns in
vehicle systems. Insight is offered on aluminum usage by
original equipment manufacturer (OEM) brand, vehicle seg-
ment, and key vehicle models. It concludes with an outlook,
recommendations, and predictions on what will affect the
industry. Key findings are listed below.
• Automotive OEMs are expected to reduce overall aver-
14 WELDING JOURNAL / FEBRUARY 2016
age fleet weight to meet fuel and CO2 emission goals.
• Audi and Tesla, among luxury OEMs, and Ford, among
mass-market OEMs, are expected to have aluminum prolif-
erate into models across many vehicle segments by 2025.
• Aluminum is being used more in body-in-white applica-
tions, and resistance spot along with ultrasonic welding are
expected to increase aluminum-to-aluminum/alternate ma-
terial amalgamation.
• Aluminum is expected to become the backbone of
OEMs’ multimaterial strategy by 2025 beside Gen3 steel
grades and composites.
• North America and Europe are early adopters of alu-
minum as a primary material choice in higher margin
vehicles.
For more details, visit reportlinker.com/p03421859-
summary/view-report.html.
Lockheed Martin­Led Team Lays Keel on
Nation’s 15th Littoral Combat Ship
A welder authenticates the keel by welding the initials of Littoral
Combat Ship 15 sponsor Sharla Tester onto its plate. (Photo
credit: Joseph Mancini, Lockheed Martin.)
The Lockheed Martin-led industry team has officially laid
the keel for the U.S. Navy’s 15th Littoral Combat Ship, the fu-
ture USS Billings, in a ceremony at Fincantieri Marinette Ma-
rine in Marinette, Wis.
Sponsor Sharla D. Tester authenticated the keel. She had
her initials welded into a sheet of the ship’s steel, which will
ultimately be mounted in the vessel through its service.
“This will be a magnificent warship, and I know the peo-
ple of Billings, and all Montanans, will proudly support her
when she enters the Navy fleet to protect our nation,” Tester
said.
Billings is a flexible Freedom-variant Littoral Combat
Ship that will be designed and outfitted with systems to
conduct many missions.
Hobart Institute of Welding Technology to
Break Ground on Next­Generation Facility
The Hobart Institute of Welding Technology (HIWT) will
break ground on a more than 14,000-sq-foot “Next Genera-
tion Welder Learning Facility” at its Troy, Ohio, campus ear-
ly this year.
The new space represents an addition to the institute’s
existing 13-acre campus. It will feature capabilities for
welder education, welding procedures, welder qualification
testing, certification services, and specialized training.
“This investment grows our campus and allows HIWT to
strengthen its mission. With the high demand for welders
and the incredible shortage, this investment will allow
HIWT to continue doing its part to fill the void,” said Presi-
dent and CEO Scott A. Mazzulla.

Morrisville State College Adds Spark to

Welding Lab with Dominion Foundation Grant
The welding lab at Morrisville State College, Morrisville,
N.Y., will receive support thanks to a $30,000 grant from
the Dominion Foundation. Five new welding machines, pipe
holding clamps, a pipe beveler, a tungsten grinder, and a
spot welding machine will be purchased.
According to Graham Jones, an assistant professor of au-
tomotive technology who teaches the college’s welding class-
es, these courses support many majors, including automo-
tive and diesel technology, plus renewable energy. He also
noted seeing a trend the past few years with more students
going to welding classes as electives.
“It’s always good to know a little bit about repair and fab-
ricating,” Jones said. “No matter what industry you are in, it
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FEBRUARY 2016 / WELDING JOURNAL 15
 Messer Cutting Systems Celebrates
60th Anniversary

Morgan Bush, a renewable energy student, chips slag in Mor­

risville State College’s welding lab. (Photo by Franci Valenzano,
public relations associate.)

is valuable to have the skills to be able to fix something

yourself.”
Morgan Bush (pictured), a renewable energy student
from Carthage, is preparing for her future career by taking
the beginners welding class.
“I want to be a wind technician after I graduate, and I
know this will require welding at heights,” Bush said. “The
fact that the college is keeping up with the times and pur-
chasing new equipment means when I graduate, I will have
the most recent training on the latest machines, and I will
be ready to walk right into my field.”
Messer Cutting Systems, formerly known as CRO Engineering, re­
cently marked 60 years of precision cutting technology. This his­
toric photo shows its first machine, the Profimill.
Messer Cutting Systems, Menomonee Falls, Wis., is
celebrating 60 years in business. The company began under
CRO Engineering (representing the first names of founding
partners Carl, Rudy, and Orville) and was incorporated
in 1955 as a oxygen cutting machinery manufacturer

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16 WELDING JOURNAL / FEBRUARY 2016
with three employees in 3000 sq ft of rented space in
Milwaukee, Wis.
In 1969, according to the company, it delivered the first
American-built numerically controlled laser cutting machine
for shape cutting titanium in the aerospace industry.
Other highlights include Messer Griesheim GmbH pur-
chasing CRO in 1973 and changing the name to MG Cutting
Systems, which eventually became Messer Cutting Systems,
a subsidiary of Messer Cutting Systems GmbH Germany.
Today, the company is housed in a 100,000-sq-ft facility
with 190 employees and manufactures oxyfuel, plasma, and
laser plate machinery.
“Staying at the forefront in advancements has allowed
Messer to meet customer’s continual needs for the past 60
years and has laid a strong foundation to meet these needs
going into the future,” said President and CEO Bill Heller.

TRUMPF to Expand in Chicago

Last October, fabricating equipment and industrial laser
provider TRUMPF purchased approximately five acres of
land adjacent to Interstate Highway 90 in Hoffman Estates,
a northwestern suburb of Chicago, Ill. Located within one of
the core zones of the sheet metal business in North Ameri-
ca, this site will serve as future home of the TRUMPF Tech-
nology Center and the center of excellence for Industry 4.0.
The technology center will focus on integrating automa-
tion, material, and information flow with machine tools. It

— continued on page 109

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FEBRUARY 2016 / WELDING JOURNAL 17
BUSINESS BRIEFS
Ford F­Series Super Duty Brings $1.3 Billion
Investment, 2000 New Jobs to Kentucky Plant
This venture supports a new body shop, facility upgrades, and re­
tooling to build the truck. Pictured is team member Jerylann Vaden.
(Photo by Sam VarnHagen.)
Ford Motor Co. will create 2000 new jobs and invest $1.3
billion in its Kentucky Truck Plant to support launching the
new 2017 F-Series Super Duty truck. A body shop along
with facility upgrades and retooling will help build this alu-
minum-bodied truck at the facility.
Add to that the $80 million invested in 2014 to meet
growing demand for Super Duty trucks, as well as the $129
million to support Lincoln MKC production at the Louisville
Assembly Plant, and Ford has invested more than $1.5 bil-
lion in the commonwealth of Kentucky and the city of
Louisville in the past two years.
“Adding new jobs and more investment at Kentucky
Truck Plant not only secures a solid foundation for our UAW
members, but also strengthens the communities in which
they live, work, and play,” said Jimmy Settles, UAW vice
president, National Ford Department.
The 2017 pickup and chassis cab lineup will have a high-
strength steel frame; military-grade, aluminum-alloy body;
16 class-exclusive new features and up to seven cameras;
adaptive steering; plus Ford engineered/built gasoline and
diesel engines and transmissions.
Bilton Welding Reveals Record Earnings
Bilton Welding and Manufacturing, Ltd., Calgary, Cana-
da, a designer, engineer, and manufacturer of custom energy
equipment for the oil and gas market, has achieved a 116%
five-year growth rate at its fiscal year end on September 30,
2015. The company also witnessed a 21% sales growth with
a sustainable bottom line.
“Based on our market outlook, we expect a continued
strong sales performance over the next year,” said Jason
Greene, vice president of sales and marketing. “We’ve suc-
cessfully improved our efficiencies and supply chain...more-
over, we’ve created new opportunities by employing new
products and technology.”
President and CEO Robert Bilton added: “Operational in-
novation, diversification, and continued investment in our
team will be at the forefront of our strategic plan.”
18 WELDING JOURNAL / FEBRUARY 2016
Michigan Manufacturing International
Expands Facility
Michigan Manufacturing International, a supplier of
manufactured to print assemblies and components to origi-
nal equipment manufacturers, recently completed a 20,000-
sq-ft addition to its headquarters in Stevensville, Md.
This expansion occurred for future growth as well as to
accommodate tenants seeking affordable, quality work-
spaces with a Chesapeake Bay view. The addition can be di-
vided into nine spaces with each suite having its own sepa-
rate 480-V electric service and many other features.
“The additional space will enable us to meet our cus-
tomers’ needs by allowing for the installation of new ma-
chinery, increasing our warehouse storage capacity, and
adding workspace for our personnel,” said CEO Jacob Prak.
Report Released on U.S. Welding and Soldering
Equipment Market
U.S. Welding and Soldering Equipment Market – Analysis
and Forecast to 2020 presents current data of the market size
and volume, domestic production, exports and imports,
price dynamics, and turnover.
In addition, the report has industry information, includ-
ing life cycle, business locations, productivity, and employ-
ment divisions. There’s company profiles, too.
Product coverage includes arc welding machines, compo-
nents, and accessories (excluding electrodes and stud weld-
ing equipment); arc welding metal electrodes; resistance
welding machines; gas welding and cutting equipment; and
welding and soldering equipment manufacturing.
For more information, visit researchandmarkets.com.
Recent Acquisitions
• Alaska Governor Bill Walker recently announced the
state’s acquisition of TransCanada’s share of the Alaska LNG
project. Department of Natural Resources Commissioner
Mark Myers finalized the termination of the formal agree-
ment that established and guided the participation of Tran-
sCanada Alaska Midstream LP in the project. “Today is a his-
toric day. As Alaska faces a $3.5 billion budget deficit, this
gasoline project is our number-one get-well card. By gaining
an equal seat at the negotiating table, we are taking control
of our destiny and making significant progress in our effort
to deliver Alaska gas to the global market,” Walker said.
• Reliance Steel & Aluminum Co., Los Angeles, Calif., has
reached an agreement to purchase all the outstanding capi-
tal stock of Tubular Steel, Inc., St. Louis, Mo., a distributor
and processor of carbon/alloy/stainless steel pipe, tubing,
and bar products. It is expected to close early this year.
• Schaefer Ventilation Equipment, Sauk Rapids, Minn., has
been acquired by Pinnacle Products International, Inc., Yard-
ley, Pa., a provider of portable heating and ventilation equip-
ment. The addition of distribution in Europe, Asia, and
South America will speed global market development strate-
gies. Schaefer will continue operating from its headquarters,
and the management/sales leadership structure will remain. WJ
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ALUMINUM Q&A
BY TONY ANDERSON

Q: I have been informed that there Table 1 — Aluminum Base Metal Strengths Before and After Arc Welding
is a reduction of strength in an alu­
minum weld heat­affected zone Nonheat­Treatable Base Metals – Strengths Before and After Arc Welding
(HAZ) after arc welding and that Base Metal *Typical **Minimum Reduction in
this can be particularly pro­ and Temper Ultimate Tensile Ultimate Tensile Strength %
nounced when arc welding the Strength Before Strength After
heat­treatable base metals. What I Welding ksi Welding ksi
would like to know is how signifi­ 3004­H32 31 ksi 22 ksi 29%
cant is this reduction in base metal 3004­H38 41 ksi 22 ksi 46%
strength, does it differ in its extent 5052­H32 33 ksi 25 ksi 24%
between the heat­treatable and 5052­H38 42 ksi 25 ksi 40%
5086­H32 42 ksi 35 ksi 16%
the nonheat­treatable base met­ 5086­H38 52 ksi 35 ksi 33%
als, and what, if anything, can be 5083­H116 46 ksi 40 ksi 13%
done after welding to recover this
Heat­Treatable Base Metals – Strengths Before and After Arc Welding
lost strength and return the base
metal to its original condition? Base Metal *Typical **Minimum Reduction in
and Temper Ultimate Tensile Ultimate Tensile Strength %
Strength Before Strength After
Reduction in Strength in the Welding ksi Welding ksi

Weld Heat­Affected Zone 2219­T87 69 ksi 35 ksi 49%

(HAZ) After Arc Welding 6063­T6 35 ksi 17 ksi 51%
6061­T6 45 ksi 24 ksi 47%
6082­T6 49 ksi 28 ksi 43%
The reduction in strength after arc 7005­T53 57 ksi 40 ksi 30%
welding can be significant in both the
heat-treatable and nonheat-treatable
There can be a substantial reduction in strength after arc welding.
base metals (see Table 1 for examples). *The typical ultimate tensile strength for each base metal and temper (before welding) is taken from the Aluminum
The reduction in strength in the Association, Aluminum Standards and Data, Table 2.1, Typical Mechanical Properties.
weld HAZ is dependent on the specific **The minimum ultimate tensile strengths after welding are the values provided in AWS D1.2, Structural Welding
Code – Aluminum, Table 3.2, Tensile Strength of Welded Aluminum Alloys – Minimum Tensile Strengths.
base metal welded and its original
temper condition prior to welding, and
also to some extent the amount of
heat input introduced to the HAZ dur-
ing the welding operation. The
amount of heat developed in a base
metal during arc welding is normally
sufficient to reduce the strength of
both the strain-hardened (-H temper)
nonheat-treatable base metals and the
thermally treated (-T temper) heat-
treatable base metals. The reduction in
strength within the HAZ from arc
welding is unavoidable and directly as-
sociated with the heat of the welding
operation and its effect on the base
metal temper.
Note: The one exception is that no re-
duction in strength will be experienced in
either a heat-treatable or nonheat-treat-
able aluminum base metal when it is
welded in the -O temper. The -O temper,
which can be applied to both the heat-
treatable and nonheat-treatable base
metals, is the annealed condition and is
sometimes referred to as the dead soft Fig. 1 — The heat input during the arc welding process can influence the amount of
condition. In this dead soft condition, the strength reduction in the HAZ of 6061­T6 base metal; the higher the heat input, the lower
heat from the welding operation is unable the as­welded HAZ strength. This is true for all the heat­treatable base metals. Heat input
to further reduce the base metal strength. during welding of the nonheat­treatable base metals, such as the 5xxx series, is far less
Unfortunately, this fact is of very little critical in terms of how it will reduce the degree of strength loss in the HAZ. A 5083­H321
welded with a high heat input is shown in this same chart, and the reduction of strength
significance because, owing to its low-
in the HAZ is minimal when compared to the other examples of the 6061­T6 heat­
strength, -O temper base metal is very treatable base metal.
seldom used for structural applications.

20 WELDING JOURNAL / FEBRUARY 2016

Further, it is not recommended to weld
the heat-treatable base metals when they
are in the -O temper (annealed condition)
because they may have undesirable coarse
constituents. In this condition, the alloy-
ing elements may congregate at the grain
boundaries of the material and conse-
quently produce alloy-rich zones that are
susceptible to eutectic melting. If the
heat-treatable base metals are welded in
this condition, there is a possibility that
the alloy-rich grain boundaries may not
be able to withstand the shrinkage stress-
es during solidification. This may result
in the formation of cracks within the base
metal fusion zone immediately adjacent
to the weld.
The Heat­Treatable and
Nonheat­Treatable Base Metals
The effect of arc welding on the
various tempers is different when con-
sidering the heat-treatable and non-
heat-treatable base metals; conse-
quently, both these types of materials
need to be evaluated separately.
Heat­Treatable Base Metals – 2xxx,
6xxx, and 7xxx Series
and given the -T4 temper designation.
Precipitation heat treatment, also
known as artificial aging, is often used
after solution heat treatment. This in-
volves heating the -T4 material for a
controlled time (8 to 15 h) at a lower
temperature (around 250° to 500°F)
depending upon the base metal type.
This process, used after solution heat
treatment, optimizes alloy precipita-
tion, which increases strength and sta-
bilizes the material. A material in this
finished condition is said to be “solu-
tion heat treated and artificially aged”
and given the -T6 temper designation.
An example of a base metal in this
temper is the commonly used 6061-T6
base metal.
When these heat-treatable base
metals are heated during arc welding,
they are typically not heated for a suf-
ficient period of time to fully anneal
their structure (fully precipitate the al-
loying elements). However, they are
usually subjected to sufficient heating
to reduce their strength considerably.
While the duration of the heating
from the arc welding process is nor-
mally insufficient to fully anneal the
base material in the HAZ, it is suffi-
cient to partially precipitate alloying
elements out of solution. This will typ-
ically result in the base metal HAZ be-
coming overaged and the correspon-
ding loss of strength.
For an example of this reduction in
ultimate tensile strength, consider the
6061-T6 base alloy in the prewelded
condition (45 ksi – minimum tensile
strength), postweld condition (24 to
27 ksi – typical tensile strength of the
HAZ), and in the annealed condition
(18 ksi). As illustrated in Fig. 1, the
heat input during the arc welding
process can influence the amount of
strength reduction in the HAZ of the
6061-T6 base metal; the higher the
heat input, the lower the HAZ
strength.
Options Available for Postweld Heat
Treatment (PWHT) of Heat­Treatable
Base Metals
In the case of the heat-treatable al-
loys, there are procedures that can be
used to return the prewelded strength
to the HAZ.

The initial strength of these base

metals is produced by the addition of
alloying elements to pure aluminum.
These alloying elements include cop-
per for the 2xxx series, magnesium
and silicon (which form the compound
magnesium silicide) for the 6xxx se-
ries, and zinc for the 7xxx series.
When present in a given base met-
al, singly or in various combinations,
these elements exhibit increasing solid
solubility in aluminum as the tempera-
ture increases. Because of this reac-
tion, it is possible to produce signifi-
cant additional strengthening of the
heat-treatable base metals by subject-
ing them to an elevated thermal treat-
ment, quenching, and, when applica-
ble, precipitation heat-treatment
known also as artificial aging.
In solution heat treatment, the ma-
terial is heated to temperatures
around 900° to 1000°F, depending
upon the base metal type. This causes
the alloying elements within the mate-
rial to go into solid solution. Immedi-
ately following this heating process,
the material is rapidly quenched, usu-
ally in water, to trap the alloying ele-
ments in solution. A material in this
finished condition is said to be “solu-
tion heat treated and naturally aged”
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FEBRUARY 2016 / WELDING JOURNAL 21

 -T6 Temper. To fully recover the
original prewelded strength of a mate-
rial that was in a -T6 temper prior to
welding, a PWHT similar to that previ-
ously described for solution heat treat-
ment and artificial aging is required.
In many situations, heating a welded
structure to around 1000°F followed
by quenching in water and reheating
to around 350°F for extended periods
may not be entirely practical. This type
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22 WELDING JOURNAL / FEBRUARY 2016
of PWHT is not suited to localized ap-
plication; the entire structure is typi-
cally required to be subjected to the
procedure. When we consider the cost
of conducting such PWHT, size limita-
tions, and the possibility of producing
residual stress and/or distortion into
the structure, it is not surprising that
this type of heat treatment is not con-
ducted extensively in the aluminum
welding fabrication industry.
However, this type of PWHT is con-
ducted for some specialized applica-
tions. If full solution heat treatment
and artificial aging is to be performed
on a welded structure, it is advisable to
consider the use of a heat-treatable
filler metal. In the case of 6061-T6, a
suitable heat-treatable filler metal
would be Alloy 4943. A small addition
of magnesium to this silicon-based
filler metal allows it to produce mag-
nesium silicide (Mg2 Si) and respond to
this form of heat treatment. Using the
correct filler metal and conducting the
appropriate PWHT can return an arc
welded component that was originally
in the -T6 condition prior to welding
to its original strength.
-T4 Temper. One other option
that is sometimes seen as a more prac-
tical method of postweld thermal
treatment for the heat-treatable alu-
minum base metals is to choose a base
metal that is in the -T4 temper.
In the -T4 temper, the base metal
has been solution heat treated and
naturally aged; no artificial aging has
been performed on this material. The
typical ultimate tensile strength of
6061-T4 is 35 ksi, compared with 45
ksi for 6061-T6. After arc welding on
the 6061-T4 material, a considerable
loss in strength is seen in the HAZ.
However, the postweld thermal treat-
ment (postweld age only) required for
the 6061-T4 material to regain sub-
stantial strength in the HAZ (as well
as the entire structure) can be far
less complex than that required for
6061-T6.
As shown in Fig. 2, the 6061-T4
postweld aged condition exhibits im-
proved recovery of strength within the
HAZ along with typical -T6 properties
throughout the structure. The benefits
associated with this processing are
related to the fact that no high-
temperature solution heat treatment
and quenching are required, only more
moderate lower temperature artificial
aging. This method of postweld pro-
cessing is carried out by some manu-
facturers as a successful method of re-
gaining strength after arc welding and
as an alternative to full solution heat-
treatment and artificial aging.
As with the welding procedures
used when PWHT these base metals in
the -T6 temper, consideration of a
heat-treatable filler metal such as
4943 for the 6xxx series base metals is
important for improving weld
strength when performing postweld
aging on the -T4 materials.
 nonheat-treatable aluminum alloys,
there is no practical way to rework the
annealed HAZ to its original strain-
hardened condition. It is customary
when using these alloys to design
around the as-welded strength.

Conclusion
So in answer to the questions: the
reduction of strength in an aluminum
weld heat-affected zone can be signifi-
cant, and it will typically occur in
both the heat-treatable and nonheat-
treatable base metals. In general, the
reduction tends to be more pro-
nounced in the heat-treatable base
metals than it is in the nonheat
treatable.
What can be done after arc welding
to regain this lost strength and return
aluminum base metals to their original
unwelded condition? For the nonheat-
treatable base metals, no practical
Fig. 2 — This chart shows four examples of strength levels: 6061­T4 and 6061­T6 in the method of postweld processing is
as­welded condition, and both materials in the postweld aged only condition. The 6061­
T4 postweld aged condition exhibits an improved recovery of strength within the HAZ
available. For the heat-treatable base
along with typical ­T6 properties throughout the structure. The benefits associated with metals, variations of postweld thermal
this processing are related to the fact that no high­temperature solution heat treatment treatments are available for considera-
and quenching are required, only more moderate lower temperature artificial aging. tion. However, after explaining these
methods, I feel it is reasonable to say
Nonheat­Treatable Base Metals – ened and deformed crystals are re- that in reality, the majority of the
3xxx and 5xxx Series placed by new strain-free crystals. In heat-treatable alloys used for structur-
the case of the nonheat-treatable base al welding applications are used in the
The strength of these base metals is metals, the HAZ is transformed into same way as the nonheat-treatable
initially produced by alloying the alu- the annealed (dead soft) condition. alloys and that is in the as-welded
minum with additions of other ele- This transformation effect is unavoid- condition. WJ
ments. These alloying elements in- able in all alloys; regardless of the orig-
clude manganese for the 3xxx series inal prewelded temper, the strength-
and magnesium for the 5xxx series. ening effect of the strain hardening
A further increase in strength of condition will always be removed in TONY ANDERSON is director of aluminum
these alloys is obtained through vari- the base metal HAZ. technology, ITW Welding North America. He
ous degrees of cold working or strain Figure 1 shows a 5083-H321 welded is a Fellow of the British Welding Institute
hardening. Strain hardening is a with a high heat input, and the (TWI), a Registered Chartered Engineer with
the British Engineering Council, and holds
process that is used to increase the reduction of strength in the HAZ is numerous positions on AWS technical com­
strength of aluminum alloys that are minimal when compared with the mittees. He is chairman of the Aluminum As­
both heat treatable and nonheat treat- other examples of the 6061-T6 heat- sociation Technical Advisory Committee for
able. Strain hardening is accomplished treatable base metal. However, as can Welding and author of the book Welding
through change of shape by the appli- be seen in Table 1, the degree of Aluminum Questions and Answers currently
available from the AWS. Questions may be
cation of mechanical energy. strength loss can be more pronounced sent to Mr. Anderson c/o Welding Journal,
Most commercial available strain when welding the nonheat-treatable 8669 NW 36th St., #130, Miami, FL 33166­
hardened alloys are available in the base metals that are in the higher 6672; tony.anderson@millerwelds.com.
nonheat-treatable alloys and tempers. strength tempers. In practice, it is of-
As this physical deformation progress- ten the case that the nonheat-treatable
es (typically through rolling or draw- base metals are used in tempers that
ing), it produces an elongation of the are less severely affected when com- Change of Address?
material’s grain structure in the direc- pared to the heat-treatable base metals Moving?
tion of working that provides a pre- and their commonly used tempers.
ferred grain orientation, high level Make sure delivery of your Welding
of internal stress, and resultant in- Options Available for Postweld Heat Journal is not interrupted. Contact
crease in strength. When these strain- Treatment of Nonheat­Treatable Base Maria Trujillo in the Membership
hardened base metals are heated dur- Metals Department with your new address in-
ing arc welding, recrystallization takes formation — (800) 443-9353, ext. 204;
place in the HAZ, and the work-hard- Unfortunately, in the case of the mtrujillo@aws.org.

FEBRUARY 2016 / WELDING JOURNAL 23

BRAZING Q&A
Q: We braze Titanium Grade 2
parts in a vacuum using a standard
BTi­5 filler metal. The brazing tem­
perature is 900°C, according to
AWS A5.8, Specification for Filler
Metals for Brazing and Braze
Welding. When we set up the
process, we tested different dwell
times and found the strength of
the joints was very sensitive to the
dwell time value — even when
changed in 5­min increments. Our
first intention was to minimize
dwell time in order to minimize
the growth of brittle intermetallic
layers at the interface. However,
even 1­min dwell time resulted in
low joint shear strength. While the
joint had low strength at 5 min,
10–12 min showed strength al­
most double that at the short
dwell time. Hoping to further im­
prove the strength, we switched to
a 20–22­min dwell time. However,
the strength of the brazed joints
dropped again. Can you explain
this brazing quality volatility? The
second question we have is how to
optimize timing to provide stable
strength values of brazed joints.
A: Titanium brazing filler metals of
the Ti-Cu-Ni and Ti-Zr-Cu-Ni families
are characterized by high reaction abil-
ity and intense diffusion exchange
during interaction with base metals,
because A) the base metal does not
Fig. 1 — A crack propagated along the interface between carbon
steel and BTi­5 joint metal due to the formation of a brittle (Ti,
Zr)Fe2 intermetallic layer.
24 WELDING JOURNAL / FEBRUARY 2016
contain Cu, Ni, and Zr, and B) titani-
um forms a number of intermetallic
phases in contact with liquid filler
metals. Brittle intermetallic phases
(such as TiCu2, TiAl3, TiNi2, Ti3Cu4, (Ti,
Zr)2Cu, etc.) are formed in practically
all titanium brazed joints. For exam-
ple, brittle intermetallic phases are
found in a titanium-to-steel joint
shown in Fig. 1. Mostly, the fracture of
brazed joints is caused by an inter-
metallic layer formed at the interface
of the base metal, or at least inter-
metallic phases initiate the nucleation
of microcracks in the joint metal. This
may result in a significant decrease in
the strength of brazed joints.
If the thickness of the joint metal is
<50 microns (0.002 in.), the amount
of reaction occurring in components
such as copper or nickel is insufficient
to form a thick intermetallic layer at
the interface of the base metal. But
the volume of liquid filler metal (as a
source of copper and nickel) is much
larger in fillet areas, where a thick,
brittle layer is always formed at the ti-
tanium base interface. This layer may
initiate the first crack that is further
propagated into the joint. If titanium
is brazed to steel, the (Ti, Zr)Fe2 inter-
metallic layer formed at the steel in-
terface can also cause fracture of the
brazed joint — Fig. 1.
Therefore, the first recommenda-
tion for keeping stable quality and reli-
ability of titanium brazed joints is to
avoid large fillets. If you minimize the
Fig. 2 — Microstructure of Ti Grade 2 joint <50 microns thick
brazed by BTi­5 filler metal at 890°C for 5 min.
BY ALEXANDER E. SHAPIRO
size of chamfers, you minimize the
volume of liquid filler metal in fillet
areas, and subsequently limit the
growth of brittle intermetallic layers.
Figure 2 presents the microstruc-
ture of a joint brazed at a 5-min dwell
time. There is no intermetallic layer at
the interface, but we observe many
structural constituents, including an
eutectic layer in the middle of the joint
metal, the solid solution areas around
the eutectic, recrystallized, needle-like
grains of the diffusion zones, and fine
crystals of intermetallic phases (as de-
termined by EDX analysis) distributed
everywhere. This unstable and irregu-
lar microstructure comprised of com-
ponents with different hardness and
crystal structures — in other words,
many phase boundaries — causes low
strength of the brazed joint. The mi-
crostructure of titanium brazed joints
can be improved by adjusting the braz-
ing thermal cycle.
Thermal cycle plays an important
role in optimizing the microstructure
and in decreasing the presence of in-
termetallic phases in the joint metal.
There are two approaches to changing
the thermal cycle for these purposes.
The first approach is an additional dif-
fusion and aging heat treatment of a
brazed structure. This method re-
quires separate consideration; we shall
not discuss it here.
The second approach lies in the lim-
itation of reaction time between the
base and filler metal in order to pre-
 metal diffusion metals. Welding Journal 69 (12): 462-s
zones become so to 467-s.
large it can affect 2. Lee, J. G., Kim, G. H., Lee, M. K.,
the strength of and Rhee, C. K. 2010. Intermetallic
the brazed struc- formation in a Ti-Cu joint brazed us-
ture. Perhaps this ing a Zr-based amorphous alloy filler.
is the explanation Intermetallics 18: 529–535.
of low shear
strength after
20–22-min dwell
time in your case.
The bottom
This column is written sequentially by
line: There is an TIM P. HIRTHE, ALEXANDER E. SHAPIRO,
optimal holding and DAN KAY. Hirthe and Shapiro are
time value for members of and Kay is an advisor to the C3
brazing titanium Committee on Brazing and Soldering. All
at each selected three have contributed to the 5th edition of
AWS Brazing Handbook.
temperature, and Hirthe (timhirthe@aol.com) currently
Fig. 3 — Microstructure of Ti Grade 2 joint <50 microns thick this process pa- serves as a BSMC vice chair and owns his
brazed by BTi­5 filler metal at 890°C for 10 min. rameter should own consulting business.
be learned experi- Shapiro (ashapiro@titanium­
brazing.com) is brazing products manager at
vent their mutual diffusion or dissolu- mentally when Titanium Brazing, Inc., Columbus, Ohio.
tion and consequently to limit the setting up the production process. Kay (Dan@kaybrazing.com), with 40
growth of intermetallic phases. This years of experience in the industry, operates
approach can be effective for brazing References his own brazing training and consulting
business.
titanium using any filler metals but is Readers are requested to post their
especially effective for copper- or alu- 1. Onzawa, T., Suzumura, A., and questions for use in this column on the
minum-based filler metals that react Ko, M. B. 1990. Brazing of titanium Brazing Forum section of the BSMC
intensively with the base metal imme- using low-melting point Ti-based filler website www.brazingandsoldering.com.
diately after a base-to-liquid contact.
The most effective way to limit reac-
tion time is to decrease brazing tem-
perature. Decreasing holding time is
not so unambiguous, because a too-
short holding time may result in the
formation of a nonequilibrium joint
Education That Workks
metal structure that offsets the posi-
tive impact of inhibiting the formation
of intermetallics.
A number of tests (Refs. 1, 2)
proved that a too-short holding time
COOMMERCIALL
at the brazing temperature decreases
the strength of brazed joints.
Longer holding times, e.g., 10 min,
DIVE
I TRAINING
result in a joint metal free of coarse
eutectic, and the joint is characterized
AIM
M HIGH. DIVE DEEP.. Call Toda
o ay!
by a wide, fine eutectoid area having
more uniform microstructure due to
longer diffusion processes — Fig. 3.
Ti2Cu, (Ti, Zr)2Cu, Ti2Ni, and other in-
termetallic phases decomposed — at
least partially — and almost disap-
peared from the titanium alloy matrix.
This type of brazed joint microstruc-
ture provides higher strength.
A further increase of holding time
to 20–60 min may again result in a
change of the microstructure. Copper
and nickel continue to diffuse into the
titanium base metal, where they first
1.88800.238.D
80 IVE (3483)
83)
accumulated on the titanium grain ww
ww.diversacademy
.di
.diversacademy.ed
d . du
d
boundaries. The total width of the N
Near Atlantic City,, New Jersey
e
joint metal and the weakened base
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FEBRUARY 2016 / WELDING JOURNAL 25
PRODUCT & PRINT SPOTLIGHT
Soldering Paste Holds Its Form
and Stays in Place
NITRO Flux, a soldering paste for
the plumbing industry, is formulated
for effectiveness on copper, tin and
lead, and lead-free brass. The paste
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postsoldering residues can be easily
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AIM Alloys
aimalloys.com
(401) 429­5212
Study Analyzes Global Brazing
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A study titled “2015 Deep Research
Report on Global Brazing Materials In-
dustry” forecasts the market analysis
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26 WELDING JOURNAL / FEBRUARY 2016
key regions development status. With
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Deep Research Reports
deepresearchreports.com
(888) 391­5441
Data Analysis System Improves
Production Output
WeldCube, a documentation and
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50 power sources. It is compatible
with the company’s digital series, re-
sistance spot welding system
DeltaSpot, and intelligent welding de-
vice platform TPS/i. The system en-
ables the user to document and evalu-
ate data such as current, voltage, wire
speed, welding speed and time, arc and
dynamic correction, and job numbers
during manual and robot-aided weld-
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order to achieve an accurate analysis,
then output via a web browser, which
enables the results to be accessed from
any computer or mobile device.
Fronius International GmbH
fronius.com
(877) 376­6487
Amplifier Ventilates
Soldering Smoke
The company’s airflow amplifiers
extract smoke and debris to enhance
safety, ergonomics, and productivity.
The high-flow, bladeless blowers take
ordinary compressed air and amplify it
up to 60-fold, with no moving parts
for safety, in unducted applications.
They are easily mounted, ducted, and
moved, plus with adjustable airflow
and output, they can be tailored to the
project at hand. In addition to venti-
lating and exhausting welding fumes,
soldering and machine smoke, tank
fumes, and other gases, they can be
used for dedusting grain; trimming
operations such as paper or cloth; re-
moval of metal chips, sawdust, and
scrap; or conveying of plastic pellets,
small parts, capsules, powders, and
more.
Vortec
vortec.com
(800) 441­7475
Machine Performs AC GTA
Welding on Aluminum
to its product line, including several
wire formulations as well as plasma
transferred arc and laser cladding
powder families, all designed for ex-
treme abrasion resistance. They are
useful for restoring damaged compo-
nents and hardfacing parts to extend
serviceable life. The 155FC (25% WC)
is a gas-shielded buildup and buffer
layer alloy for thick buildup deposits of
up to four layers. The 160FC (48%
WC) hardfacing wire is available in an
open arc formulation with a maximum
hardness of 40–50 HRC. The 160FS
(50% WC) wire consumable for GMAW
incorporates spherical tungsten car-
bides that deliver better performance
in friction applications.
Stoody
stoody.com
(800) 426­1888

The Square Wave® TIG 200 welding

machine offers multiprocess GTA and
SMA welding for craftsmen, small
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enthusiasts, and hobbyists. Users can
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stainless, and chrome-moly when pre-
cision and bead appearance are impor-
tant. They can also switch to SMA
welding when working with thicker
materials or welding outdoors. AC fre-
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the machine for a wider or more nar-
row arc profile when GTA welding on
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tration on thicker aluminum materi-
als. The portable machine plugs into
standard 120- or 230-V input circuits
and weighs 46 lb. The GTA output
range is 10–200 A when operating on
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put range is 10–170 A when operating
on 230-V input and 10–90 A when op-
erating on 120-V input.

Lincoln Electric
lincolnelectric.com
(888) 935­3860

Hardfacing Alloys Designed

for Extreme Wear

The company has added nickel-

based tungsten carbide consumables
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FEBRUARY 2016 / WELDING JOURNAL 27

Electric Belt Conveyor Oven
Solders Metal Parts
The company’s No. 851 is a 650°F
electrically heated belt conveyor oven
used for soldering metal parts at a cus-
tomer’s facility. Workspace dimensions
measure 18 × 96 × 15 in. Also, 60 kW
installed in Nichrome wire heating ele-
ments provide the heat, while two
1000 ft3/min, 2-hp recirculating blow-
ers furnish downhill airflow to the
workloads. The oven features 5-in. in-
sulated walls, an aluminized steel exte-
rior, Type 304 stainless steel interior,
two 16-in.-diameter tube axial fans,
and a high-carbon steel flat wire con-
veyor belt with 1⁄4-hp motor drive. Safe-
ty and control equipment includes a
digital indicating temperature con-
troller, manual reset excess tempera-
ture controller with separate contac-
For info, go to www.aws.org/ad­index
28 WELDING JOURNAL / FEBRUARY 2016
tors, recirculating blower airflow safe-
ty switch, and fused disconnect
switch.
Grieve Corp.
grievecorp.com
(847) 546­8225
Catalog Features Ultrasonic
Cleaners
The company’s new 8-page full-
color catalog details its lineup of ultra-
sonic cleaners and accessories for
solvent-free cleaning. Each model fea-
tures side-mounted transducers to
eliminate blind spots on parts being
cleaned, and a V-bottom for easy
cleaning between batches. In addition
to machinery, the catalog includes ac-
cessories such as Ultra soap, oil skim-
mers, absorbent tubes, filters, and
coatings for baskets and tanks. The
cleaners are useful for applications
such as rubber and plastic parts, bear-
ings, bolts, transmission components,
engine parts prior to the assembly,
plastic injection molds, and more. In
addition to industrial environments,
they are also useful for automotive,
medical, pharmaceutical, aerospace,
engineering, and other industries.
Ultrasonic, LLC
ultrasonicllc.com
(513) 502­9746
Revised Laser Standard Now
Available
A revision of ANSI Z136.6, Safe Use
of Lasers Outdoors, is now available. A
tool for anyone operating a laser sys-
tem in an open-air environment, the
document provides guidance for the
safe use of potentially hazardous
lasers and laser systems (180 nm to
1 mm), where the establishment of
open beam paths is necessitated.
The latest edition was created with
the goal to update, clarify, and
streamline the standard to better re-
flect today’s outdoor laser operator’s
needs.
Laser Institute of America
lia.org
(407) 380­1553
Glow­in­the­Dark Floor Signs
Show Way Out in Emergency
Durable premade and custom glow-
in-the-dark signs ensure critical infor-
mation can be seen by building and ve-
hicle personnel in the event of an
emergency such as a power failure or
building filled with smoke during a
fire. The signs glow brightest for the
first 60 min, then fade to remain light-
ly visible for several hours in total
 Soldering Robots Include
Solder Tip Cleaning Station
The company’s F7000SR series, its
new line of desktop soldering robots,
features high repeatability that mini-
mizes the amount of rejects and keeps
the cost of ownership low. The solder-
ing robots can replace current hand
soldering applications or bring out-
darkness. Applications include evacua- sourced applications in house. The
tion maps, safety signage, instruction-
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Peel and stick glow floor decals are
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with OSHA Standard 1910.22(b)(2).

Visual Workplace, Inc.

visualworkplaceinc.com
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Soldering Iron Useful for

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The new 80-W soldering iron fea-

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FEBRUARY 2016 / WELDING JOURNAL 29

 system includes a built-in solder tip
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For Info, go to www.aws.org/ad­index
 Low-Energy Impact Spot
Welding of High-Strength
Aluminum Alloys
The results of impact welding of aluminum Alloys A5052 and
A7075 performed with the recently developed vaporizing foil
actuator welding technique are reported

C
onventional welding by means of
high heat input, fusion, and so-
lidification greatly alters the mi-
crostructure in the welded region and
can be detrimental to the weld’s
mechanical properties, especially in
the case of highly engineered, high
strength-to-weight ratio materials.
The strength of the heat-affected zone
(HAZ) can be reduced to as little as
one third the original strength of the
base material. Additionally, suscepti-
bility to corrosion is greatly increased
after welding certain alloys such as
6xxx and 7xxx series aluminum alloys.
Fasteners and structural adhesives
offer nonwelding joining solutions.
Solid-state welding techniques, such as
impact welding, friction stir welding,
Fig. 1 — Schematics of the VFAW process. A — Before and after experiment condi-
ultrasonic welding, and roll bonding
tions of the foil actuator; B — stackup of a typical VFAW assembly; C — closeup of
are some alternatives to fusion-based the welding operation.
welding and have undergone a certain
degree of industrial adoption so far.
Impact welding is of particular interest scouring of the colliding surfaces and tive industries. Vaporizing foil actua-
due to the potentially short cycle time subsequent bonding under high pres- tor welding currently operates at the
of the process, the possibility to join a sure — Fig. 1. Explosive welding same size scale as MPW while having
wide variety of metal combinations, (EXW) and magnetic pulse welding certain advantages over it. Longevity
and the ability to perform the process (MPW) are previously known and of the solenoid actuator used for MPW
over varying length scales. practiced methods of impact welding. is a major concern, whereas VFAW is
Vaporizing foil actuator welding Implementation of EXW in a designed to have a low-cost
(VFAW) is a novel impact welding traditional factory environment is not consumable for each cycle. With
technique that utilizes the force gener- possible due to safety regulations in VFAW, generated pressures and
ated by a thin aluminum foil vaporized transportation, storage, and handling achievable flyer sheet velocities are
by high electric current to launch one of explosives, and because of the much higher as compared to MPW;
piece of metal toward one or more sta- inability to automate such a process. therefore, a wider variety of materials
tionary target sheets (Ref. 1). At high Explosion welding is mostly used for can be effectively welded with VFAW.
speed, oblique impact between the welding thick plates for the shipbuild- This article illustrates VFAW of alu-
flyer sheet and target plate(s) leads to ing, nuclear, oil and gas, and locomo- minum Alloys A5052 and A7075. This

BY ANUPAM VIVEK, SCOTT M. WRIGHT, TAESEON LEE, GEOFFREY A. TABER, AND GLENN S. DAEHN

32 WELDING JOURNAL / FEBRUARY 2016


Fig. 2 — A — A5052/A7075 VFAW spot welded samples before and
after lap shear testing; B — a plot showing variation in load with
stroke during lap shear testing of the welded samples.
material combination is germane to
the effort in the automotive industry
toward vehicle weight reduction.
While 5xxx-series aluminum alloys are
increasingly being applied for inner
components of automotive structural
assembly, 7xxx-series alloys have been
scarcely utilized. This is despite the
superior mechanical properties offered
by 7xxx-series alloys as compared to
6xxx and 5xxx-series alloys. Forming
and joining are considered two major
barriers to the widespread implemen-
tation of 7xxx-series alloy as a
lightweight alternative. Although
there are certain drawbacks with the
method, it is possible to use hot
stamping to form 7xxx series into
components such as B-pillar outers
(Ref. 2). In this work, VFAW will be
presented as a promising technique for
solving the joining problem.
Experimental Procedure,
Results, and Discussion
A 0.0762-mm-thick aluminum foil,
with a shape as shown in Fig. 1, was
connected across the terminals of a
Maxwell-Magneform capacitor bank,
which has a short circuit current rise
time of 12 ms. While the capacitor
bank can be charged up to 16 kJ, for
these experiments it was operated at a
4-kJ energy level. Once this energy
was discharged through the foil, the
latter vaporized rapidly and formed a
Fig. 3 — A — Cross-section image of the welded sam-
ple depicting the lines along which microhardness
testing was performed; B — test data showing
constant microhardness on either side of the weld
interface.
high temperature gas that can push on
the 2-mm-thick A5052-H32 flyer
sheet. Some degree of confinement is
essential; accordingly, the other side of
the foil was backed by a block of steel
approximately 2 cm thick. The flyer
sheet was separated from the 2.3-mm-
thick A7075-T6 target plate by a 2.5-
mm-thick neoprene washer with an in-
side diameter of 19 mm and outside
diameter of 37 mm. The target plate
was backed by another block of steel
about 2 cm thick. The in-plane dimen-
sions of the flyer as well as the target
plates were 40 mm ¥ 120 mm. The two
were overlapped by 40 mm along the
length and the welding experiment
was conducted to create lap-joint spec-
imens. Due to the low strength of the
neoprene washer, it breaks and gets
ejected from between the flyer sheet
and target plate. Six welded samples
were created this way and subjected to
lap shear testing, microhardness test-
ing, and imaging.
In a separate experiment, the veloc-
ity of the flyer sheet was measured
using a device called the photonic
Doppler velocimeter (Ref. 3). In this
experiment, the target plate had a
through hole, which provided a line of
sight to the laser focusing probe. With
this technique, the evolution of the
flyer sheet velocity can be measured
with a submicrosecond temporal reso-
lution. Voltage was measured using a
1000:1 probe connected across the ter-
minals of the capacitor bank, and cur-
rent was measured by a 50-kA:1-V
Rogowski coil.
Figure 2A shows an impact spot
welded specimen before and after
lap shear testing. The load vs. displace-
ment data for each sample is plotted in
Fig. 2B. The samples failed outside the
weld nugget at an average load of 14.5
kN. The average nugget diameter was
10 mm. As compared to friction spot
welds and resistance spot welds
between similar materials, the welds
created by VFAW are roughly twice as
strong. This can be attributed to three
factors: 1) negligible thinning around
the welded area, 2) no HAZ, and 3)
very effective metallurgical joining at
the bond line. The weld cross-section
image in Fig. 3A depicts the character-
istic wavy morphology of an impact
welded interface in some parts of the
weld. The figure also shows the flyer
sheet retained its original thickness in
and around the weld. The microhard-
ness data (Fig. 3B) also reveals that
the Vicker’s hardness on both sides of
the weld interface and around the
weld nugget was held constant at the
base material level, which is 90 HV for
A5052 and 205 HV for A7075. This is
due to the low external input energy
to the weld. It turns out that the input
energy for VFAW is not only an order
of magnitude smaller than that for re-
sistance spot welding, but is also
merely a fraction of the energy
required for friction spot welding or
self-pierced riveting processes (Ref. 4).
FEBRUARY 2016 / WELDING JOURNAL 33
 Diagnostics show the impact velocity
was 770 m/s and the peak current was
100 kA. Based on rough estimates on
the mass of the circular flyer sheet,
the conversion efficiency from electri-
cal to kinetic energy in launching the
flyer sheet can be estimated as 5%.
Other impact welding techniques such
as MPW and EXW tend to offer less
than 1% energy efficiency.
Various combinations of mate-
rials including steel, aluminum, mag-
nesium, titanium, copper, bulk metal-
lic glass, niobium, nickel, and tungsten
have been successfully welded using
VFAW, and many of these studies
and examples are provided on a
website dedicated to these impulse
technologies (iml.osu.edu). Therefore,
VFAW has wide potential application
not only in automotive, but also in
aviation, appliances, and power
generation industries. However, like
any early-stage lab-based technology,
much development work is required
before the technique is commer-
cialized. The research group at The
Ohio State University has recognized
the following three main areas for im-
provement and is actively working on
them:
1. Automation: The present weld-
ing apparatus is a manually assembled
bench prototype. The placement, ener-
gization, and removal of the foil actua-
tor need to be automated to minimize
system downtime and increase
reproducibility.
2. Fixturing: As seen in Fig. 2B,
there is variation in the failure loads,
which is primarily due to variation in
the nugget size. More robust and
reproducible fixturing can mitigate
this issue. Furthermore, the welding
fixture will need to be adapted to
accommodate industrial components
and not just flat coupons.
3. Noise reduction and handling
of fumes: With a polycarbonate box
around the work area, the noise level
from a vaporization event was
measured as 105 decibels. This is near
the upper safe operating limit in a typ-
ical factory setting. Beside, the
gaseous products of each shot need to
be collected and properly disposed of
for an industrial operation.
Conclusions
In this work, A5052 and A7075
sheets were welded with 4-kJ input
energy for each weld. The average fail-
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34 WELDING JOURNAL / FEBRUARY 2016
ure load was 14.5 kN and all the sam-
ples failed in the base A5052 material.
The energy requirement for VFAW is
significantly lower than that for resist-
ance spot welding of aluminum alloys.
With minimal process-induced
changes in geometric and mechanical
properties of the base materials,
VFAW enables almost 100% joint effi-
ciency, which sets it apart from other
available joining techniques. Although
significant effort is required for full-
scale industrial implementation of this
technology, early signs show that
VFAW can play an important role in
the world of joining. WJ
Acknowledgments
The authors are thankful for spon-
sorship from the U.S. Department of
Energy’s Vehicle Technologies Office
under grant no. DE-EE0006451 and by
the ALCOA Foundation’s Advancing
Sustainability Research Initiative
under grant no. GRT00025327.
References
1. Vivek, A., Hansen, S. R., Liu, B.
C., and Daehn, G. S. 2013. Vaporizing
foil actuator: A tool for collision weld-
ing. Journal of Materials Processing
Technology 213(12): 2304–2311.
2. Harrison, N. R., and Luckey, S. G.
2014. Hot stamping of a B-pillar outer
from high strength aluminum sheet
AA7075. SAE International Journal of
Materials and Manufacturing 7, No.
2014-01-0981: 567–573.
3. Strand, O. T., Goosman, D. R.,
Martinez, C., Whitworth, T. L., and
Kuhlow, W. W. 2006. Compact system
for high-speed velocimetry using het-
erodyne techniques. Review of
Scientific Instruments 77(8): 083108.
4. Briskham, P., Blundell, N., Han,
L., Hewitt, R., Young, K., and Boomer,
D. 2006. Comparison of self-pierce riv-
eting, resistance spot welding, and
spot friction joining for aluminium au-
tomotive sheet. No. 2006-01-0774.
SAE Technical Paper.
ANUPAM VIVEK (vivek.4@osu.edu),
SCOTT M. WRIGHT, TAESEON LEE,
GEOFFREY A. TABER, and GLENN S. DAEHN
are with the Department of Materials
Science and Engineering at The Ohio State
University, Columbus, Ohio.
For Info, go to www.aws.org/ad­index
BRAZING & SOLDERING TODAY

Understanding the Run-Out

Behavior of a Ag-Cu-Zr Braze Alloy
BY P. T. VIANCO, C. A. WALKER,
The run-out process is explored when D. DE SMET, A. KILGO,
used to join alumina to an Fe-Ni-Co alloy B. M. MCKENZIE, P. M. KOTULA,
AND R. L. GRANT

T
he run-out phenomenon occurs
when a significant portion of the A
molten filler metal exits the gap
region and accumulates on an exterior,
base material surface. It can cause ex-
cessive void formation, plus wastes
filler metal and generates residual
stresses that crack brittle base materi-
als. This behavior was observed in ac-
tive braze joints made with 97Ag-1Cu-
2Zr (wt-%) filler metal when joining B
alumina (Al2O3) ceramic to Kovar™ (a
trademark of Carpenter Technologies,
Reading, Pa.).
The proposed mechanism for run-
out is an instability in the wetting and
spreading of molten filler metal. The
driving force for run-out was the reac-
tion between the Fe, Ni, and Co con-
stituents of Kovar™ with elemental Al
released by the reduction-oxidation re-
action between Zr and Al2O3.
Based on this study, a modification
to the filler metal composition, or use
of a barrier coating on the Kovar™ sur-
face, provide the most promising miti-
gation strategies against run-out.

Run-Out Phenomenon
Braze joint optimization requires
that the amount of filler metal sup-
plied to the gap be closely controlled.
Too little filler metal results in voids
and nonfilled regions in the braze- Fig. 1 — A — This photo shows run-out by an Ag-Cu-Zr active braze alloy being used to join
ment that jeopardize both strength two Al2O3 base materials to a Kovar™ spacer; B — a SEM photo shows run-out by means of
a metallographic cross section.
and hermeticity. On the other hand,
an excessive quantity of molten braze
alloy can be rejected from the gap, fitup or mechanical functions. ing to surfaces, is the generation of
only to collect on an exterior surface The run-out filler metal may wet to residual stresses in the base material.
as run-out; this not only causes un- ancillary structures, as shown in Fig. This phenomenon is illustrated in Fig.
sightly cosmetic defects and impedes 1, or simply freeze to nonwettable sur- 2. The run-out of an Au-Cu-Ni-Ti filler
visual as well as x-ray inspection, it faces. A particularly problematic con- metal caused cracking in the ceramic
may also interfere with next-assembly sequence, whether by wetting or freez- member of the assembly.

36 WELDING JOURNAL / FEBRUARY 2016


Fig. 2 — Optical micrograph shows cracking in the ceramic member
caused by run-out of the Au-Cu-Ti-Ni filler metal.
A Run-Out for the Target
B metal. The process conditions were
Fig. 4 — A, B — Photographs show run-
out experienced by the Kovar™ spacer/Ag-
Cu-Zr/Al2O3 braze joint. The tensile button
assemblies were brazed at 965°C (1769°F)
for 20 min in 600-torr Ar prior to being
pulled apart. The ceramic faying surfaces
are between the dashed circles.
The detrimental effects of run-out
have long been recognized by the braz-
ing industry. Several mitigation ap-
proaches have been explored to con-
trol it, which include the following:
BRAZING & SOLDERING TODAY
Fig. 3 — This photo shows the tensile button assembly. There are two
Al2O3 ceramic buttons brazed to either side of the Kovar™ spacer.
Fig. 5 — Photograph shows run-out (ar-
rows) experienced by the Kovar™
spacer/Ag-Cu-Zr/Al2O3 joint that was
brazed with a reduced amount of filler
985°C (1805°F) for 5 min in a 600-torr Ar
atmosphere.
• Reduce the peak brazing tempera-
ture to increase the viscosity of the
molten filler metal. Unfortunately,
filler metal viscosity is relatively insen-
sitive to peak temperature (except in
the presence of a pasty range).
• In light of the previous point, a
second approach is to add one or more
alloying elements to the filler metal to
create a wider pasty range.
• Modify the geometry of the base
material surface by adding corners
that would be expected to slow or halt
the flow of molten filler metal.
All of these measures have been
met with little or no success. The lack
of effectiveness implies that run-out is
not simply a physical displacement or
“squishing-out” of molten filler metal.
Rather, there are other driving forces
responsible for this phenomenon.
FEBRUARY 2016 / WELDING JOURNAL 37
Characterization of
Application
The Ag-Cu-Zr active braze alloy was
considered for an application that
joined Kovar™ to Al2O3 ceramic. The
tensile button configuration was used
to assess braze joint performance (Ref.
1). A photo of the tensile button as-
sembly is shown in Fig. 3.
Two Al2O3 “buttons” were brazed to
a Kovar™ “spacer.” The spacer had
0.038-mm (0.0015-in.) dimples that
controlled the thicknesses of both
gaps. The Ag-Cu-Zr filler metal was
preplaced in the gap with the form of
an annular ring. Its footprint was the
same as that of the Al2O3 faying sur-
face with a 10.2-mm (0.400-in.) inner
diameter and 15.9-mm (0.625-in.)
outer diameter. The preform was
0.051 mm (0.002 in.) thick.
Two varieties of Al2O3 ceramic were
used in this study; however, the slight
compositional variations responsible
for their different colors had a negligi-
ble effect on wetting or mechanical
properties.
Shown in each of Fig. 4A and B
are two, post-pull tested tensile but-
tons taken from different assemblies.
Both samples were brazed at 965°C
(1769°F) for 20 min in a 600-torr Ar
atmosphere. The yellow dashed circles
indicate the boundaries of the ceramic
faying surface area. The specimens ex-
hibited significant filler metal run-out.
Although two run-out “lobes” formed
BRAZING & SOLDERING TODAY
Fig. 6 — SEM photo shows the general microstructure of the braze
joint formed between the Kovar™ and Al2O3 ceramic base materials
using the Ag-Cu-Zr active filler metal. The process conditions were
985°C (1805°F), 5 min, and 600-torr Ar atmosphere.
in Fig. 4A, most often, there is only a
single lobe per side of the Kovar™
spacer, as shown in Fig. 4B.
An experiment was performed to
confirm that run-out was not simply
the squishing-out of excess filler metal
from the joint. A smaller footprint of
filler metal was placed in the same ten-
sile button braze joint by reducing the
outer diameter of the Ag-Cu-Zr pre-
form from 15.9 mm (0.625 in.) to 12.7
mm (0.500 in.). The tensile button was
assembled with a single such preform,
thereby reducing the filler metal vol-
ume by a total of 60%. The buttons
were brazed at 985°C for 5 min (600-
torr Ar).
Figure 5 shows a photograph of the
post-pull tested sample. The run-out
still occurred as identified by the ar-
rows. The lobes confirmed that this
phenomenon is a result of an instabili-
ty in the wetting and spreading behav-
ior of molten Ag-Cu-Zr on the Kovar™
base material.
This report describes a study with
the objective being to further investi-
Fig. 8 — SEM image shows the reaction sublayers that form at the Kovar™/Ag-Cu-Zr
interface.
38 WELDING JOURNAL / FEBRUARY 2016
Fig. 7 — High-magnification SEM image shows the immediate
Ag-Cu-Zr/Al2O3 interface and formation of the ZrO2 particles.
gate this hypothesis and to develop
potential mitigation steps that will
prevent it in the future.
Review of the Material
Systems
The materials system is the same as
that previously exemplified.
The filler metal is the active braze
alloy, 97Ag-1Cu-2Zr (wt-%, abbreviat-
ed Ag-Cu-Zr). The Ts is 940°–950°C
(1724°–1742°F) and Tl is 960°–970°C
(1760°–1778°F). The filler metal pre-
forms had these dimensions: 10.2-mm
(0.400-in.) inner diameter, 15.9-mm
(0.625-in.) outer diameter, and 0.051
mm (0.002 in.) thickness.
The base materials were Kovar™
and 94% Al2O3 ceramic. The nominal
braze process had a peak temperature
of 985°C (1805°F), time duration of 5
min at peak temperature, and a 600-
torr Ar atmosphere.
The braze joint microstructure is
exemplified by the SEM image in
Fig. 6. Besides the filler metal and base
materials, the brazements were char-
acterized by distinct reaction struc-
tures at the two interfaces.
Interface Reactions
Cross-Section Microstructure
A reaction zone developed near the
Ag-Cu-Zr/Al2O3 interface — Fig. 6.
The high-magnification, SEM image in
Fig. 7 shows the ZrO2 particles that
developed at the immediate Ag-Cu-
Zr/Al2O3 interface and then migrated a
short distance into the filler metal.
The ZrO2 particles were a product
of this reduction-oxidation (redox) re-
action between Zr and Al2O3 ceramic:
3Zr + 2Al2O3 = 4Al + 3ZrO2 (1)
However, this reaction is not spon-
taneous as determined by a balance of
equilibrium free energies. There are
three other mechanisms that could
drive the Zr/Al2O3 redox reaction into
spontaneity, including the following:
1. Zr/SiO2 (grain boundary phase)
redox reaction
2. Free energy of solution as ele-
mental Al enters the molten Ag-Cu-Zr
filler metal
3. Aluminide reactions at the
Kovar™/Ag-Cu-Zr interface.
The first mechanism would not
pose a significant effect given the lim-
 BRAZING & SOLDERING TODAY

A B

Fig. 9 — A — Photo shows a tensile button

that was pull tested to reveal run-out on
the Kovar™ spacer; B — SEM image shows
the “precursor foot” that developed ahead
of the filler metal fillet. The EDX maps
show the Fe, Ni, and Al constituents.

ited quantity of SiO2 present in the ce-

ramic. The second scenario could po-
tentially occur since the Ag-Al binary al-
loy phase diagram exhibits a eutectic
composition of 71Ag-29Al (wt-%) that
has a low eutectic temperature, at
567°C (1053°F), and extensive composi-
tion range in the d phase (Ag terminal
phase) that favors Al dissolution into
the filler metal (Ref. 2).
The third scenario could also gener- B
ate a significant driving force by the re-
action between Al, which is released by
the redox reaction at the Ag-Cu-Zr/
Al2O3 interface, with the Fe, Ni, or Co
constituents of KovarTM. Such reactions
would readily form highly stable, cova-
lent (intermetallic) compounds (Ref. 3).
The reaction at the Kovar™/Ag-Cu-
Zr interface is illustrated by the SEM
image in Fig. 8. There is the high Al,
(Fe, Ni, Co)x(Al, Zr)y layer that borders
with the bulk filler metal. Below it is
the high Zr, (Zr, Al)y(Fe, Ni, Co)x layer.
Lastly, the high Al was repeated adja-

Fig. 10 — A — Photo shows a tensile but-

ton and the area (yellow box) where run-
out was absent; B — SEM/BSE image as
well as Zr, Al, Fe, Ni, and Ag EDX maps at
the fillet edge.

FEBRUARY 2016 / WELDING JOURNAL 39

BRAZING & SOLDERING TODAY
Fig. 11 — A high-magnification SEM
(BSE) image shows the fillet edge and
particle phase compositions.
Fig. 12 — Schematic shows the four vari-
ants of individual tensile button and
spacer material based on Kovar™ or
Al2O3.
Fig. 13 — Schematic shows the observa-
tions of run-out for the four variants of
spacer and button base materials.
cent to the Kovar‘ base material. The
presence and morphologies of the sub-
layers varied sample to sample as well
as location to location along the same
interface.
The Cu constituent of the Ag-Cu-Zr
braze alloy did not have a detectable
presence in any of the interface reac-
tions. The filler metal retained its 2
wt-% Cu and became, effectively, an
Ag-Cu alloy. Also, both Zr and Al were
absent from the filler metal.
40 WELDING JOURNAL / FEBRUARY 2016
Fig. 14 — SEM image shows the cross section of the expected fillet that formed at the red
dot of the inset photo for the all-Kovar™ test sample.
Wetting Front Microstructure
The interface reactions were inves-
tigated with respect to their roles in
the wetting and spreading of molten
Ag-Cu-Zr filler metal on the Kovar™
surface.
Shown in Fig. 9A is a tensile button
having run-out (yellow box). The SEM
image in Fig. 9B shows a precursor
“foot” that extended approximately 40
mm from the edge of the Ag-Cu-Zr fil-
let. The composition of the precursor
foot was analyzed, qualitatively, by the
energy dispersive x-ray (EDX) tech-
nique. The Fe, Ni, and Al elemental
maps are also shown in Fig. 9B. The re-
gion “A” exhibited a very strong pres-
ence of Al, Ni, and Fe that indicated
the (Fe, Ni)-Al reaction. There is an en-
richment of Ni vs. Fe when compared
to unreacted Kovar™ at the lower,
right-hand region. Region “B” shows
the same reaction, albeit, with a lesser
presence of Al. Zirconium and Ag were
absent from the precursor foot.
The edge of the Ag-Cu-Zr fillet was
similarly analyzed where run-out was
absent. The tensile button and loca-
tion (yellow box) are shown in Fig.
10A. The corresponding SEM (BSE)
image, together with the EDX maps of
Fe, Ni, Al, Ag, and Zr are provided in
Fig. 10B.
The Ag map confirmed that these
images pertained to the edge of the fil-
let, not a precursor foot phenomenon.
The EDX maps show that particles
composed of Fe, Ni, Al, and Zr formed
at the very edge of the fillet.
The fillet edge location indicated by
the yellow box in Fig. 10B is shown at
high magnification in Fig. 11. There
were two particle phases that corre-
sponded to the high Al (Fe, Ni, Co)x(Al,
Zr)y and high Zr (Zr, Al)y(Fe, Ni, Co)x
compositions noted in the previous
cross sections. It was conjectured that
the formation of these particles im-
peded the further wetting and spread-
ing action of the Ag-Cu-Zr filler metal
by acting as a sink for Al, thus prevent-
ing formation of the precursor foot.
Base Material Geometry
The previous analysis suggests that
the reaction between the released Al
and Fe plus Ni constituents of Kovar™
underlie the wetting and spreading in-
stability responsible for run-out. The
next analysis examined the role of
molten Ag-Cu-Zr surface tension.

C D
Fig. 15 — A — SEM image shows the cross section of the Ag-Cu-Zr braze joint made be-
tween the Al2O3 spacer and the Kovar™ buttons; B — the medium magnification image
shows the top of the filler metal fillet; C, D — SEM image and EDX map of Al illustrate the
extent of the aluminide diffusion/reaction beyond the fillet edge.
Test Specimens
Tensile button samples were fabri-
cated that represented one of four
variants of the matrix of spacer and
base materials shown schematically in
Fig. 12.
The upper left-hand cell represents
the “all-Kovar™” joint that has the in-
dividual buttons and spacer fabricated
from Kovar™. To its right is the base-
line variant — Al2O3 buttons and a Ko-
var™ spacer. The lower left-hand cell
has Kovar™ buttons and an Al2O3 spac-
er, which is reverse to the traditional
configuration. Lastly, there is the “all-
ceramic” sample that has all of the
components constructed of Al2O3 ce-
ramic base material.
The parts were brazed with a 50.8-
mm- (0.002 in.-) thick Ag-Cu-Zr filler
metal preform under these conditions:
985°C (1805°F), 5 min, and 600-torr
Ar. The braze joint gap was controlled
by dimples on the Kovar™ spacer or
ribbon across the Al2O3 spacer.
Run-Out Behaviors
Each sample was inspected for run-
out. Those results are summarized in
BRAZING & SOLDERING TODAY
Fig. 13. As expected, the baseline sam-
ple exhibited run-out. There was an
absence of run-out in the all-Kovar™
braze joints. This finding confirmed
that the elemental Al released by the
Zr/Al2O3 redox reaction is required for
the run-out phenomenon to take
place, further substantiating the point
that the latter is not simply a physical
displacement (“squishing out”) of ex-
cess molten filler metal.
The all-Kovar™ samples exhibited
reaction layers at both Ag-Cu-Zr/Ko-
var™ interfaces. Those reactions,
which consumed all of the Zr from the
filler metal, were heavier in Ni than in
Fe. This proportionality is opposite to
that of the two elements in the Ko-
var™ base material. Cobalt was also
present in the reaction layers. This
sample established that there is a sig-
nificant driving force for Zr to react
with the Kovar™ base material. How-
ever, these reactions did not cause
run-out. Rather, there was the expect-
ed fillet formation around the joint, as
shown in Fig. 14.
The analysis turned to the samples
having Kovar™ buttons but a ceramic
spacer. Cross sections confirmed for-
mation of the ZrO2 reaction zone. The
Fig. 16 — Schematic shows the extension
of the Ag-Cu-Zr braze alloy fillet, “A,” that
would be required for the molten filler
metal to follow the aluminide
diffusion/reaction up the sidewall of the
Kovar™ button as run-out.
aluminide layer developed at the Ag-
Cu-Zr/Kovar™ interface and extended
well up the wall of the button as
shown by the series of SEM images
and EDX map of Al in Fig. 15.
All of the “ingredients” were pres-
ent for run-out, yet the phenomenon
did not take place.
The absence of run-out was caused
by the geometry of the fillet region
coupled with the molten filler metal
surface tension. This point is de-
scribed with the assistance of Fig. 16.
The solid blue line marks the limit of
the filler metal fillet. The fillet shape
that would be required to support run-
out up the button is described by the
dashed trace. However, achieving the
latter fillet would require the filler
metal to wet an additional distance “A”
further out on the Al2O3 surface.
The Ag-Cu-Zr active braze alloy can-
not spontaneously spread on the ce-
ramic surface. Therefore, the surface
tension of the molten filler metal would
not permit the latter to follow the reac-
tion layer and create a run-out lobe.
The final variant of this experiment
was the all-Al2O3 specimen. As expect-
ed, the redox reaction took place at
both Ag-Cu-Zr/Al2O3 interfaces. Run-
out was not observed on the Al2O3 sur-
faces, thereby confirming that the Ko-
var™ base material and, specifically,
the aluminide reactions, were required
for this behavior.
In the absence of the Kovar™ base
material, the Al2O3/Ag-Cu-Zr/Al2O3
provided the opportunity to deter-
mine the quantity of elemental Al gen-
erated by the redox reaction. Electron
probe microanalysis determined the
FEBRUARY 2016 / WELDING JOURNAL 41
BRAZING & SOLDERING TODAY
concentration of elemental Al in the
filler metal was in the range of 0.7–0.9
wt-% Al.
Such a relatively small quantity of
elemental Al was responsible for the
aluminide reactions and run-out phe-
nomenon observed in this brazement.
Last, this sample also provided evi-
dence that identified the likely driving
force behind the Zr/Al2O3 redox reac-
tion. The absence of the Kovar™ base
material eliminated the aluminide re-
actions as the primary driving force.
Therefore, it was concluded that the
free energy of solution generated by
elemental Al entering the molten filler
metal drove the spontaneity of the
Zr/Al2O3 redox reaction.
Conclusions
1. The run-out behavior degraded
the performance of braze joints made
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42 WELDING JOURNAL / FEBRUARY 2016
between Kovar™ and Al2O3 ceramic us-
ing the active filler metal, 97Ag-2Zr-
1Cu (wt-%). The phenomenon did not
respond to mitigation strategies, the
cause being “squishing out” of exces-
sive filler metal.
2. At the Ag-Cu-Zr/Al2O3 interface,
the redox reaction between Zr and the
Al2O3 released elemental Al into the
molten filler metal. The Al reacted
with the Kovar™ constituents, creating
the aluminide reaction layer responsi-
ble for the wetting and spreading in-
stability that generated run-out.
3. It was also learned that the free
energy of solution generated by ele-
mental Al entering the molten filler
metal drove the spontaneity of the
Zr/Al2O3 redox reaction.
4. Most important, however, the
findings of this study indicate that the
strategies having the greatest promise
of successfully mitigating run-out are
as follows: braze joint geometry that
takes advantage of the molten filler
metal’s surface tension, filler metal
modifications that inhibit the alu-
minide reaction at the Kovar™ surface,
or coatings on the Kovar™ surface that
prevent the aluminide reactions. WJ
Acknowledgments
The authors wish to thank Lisa
Deibler for her careful review of the
original IBSC 2015 proceedings manu-
script. Sandia is a multiprogram labo-
ratory operated by Sandia Corp., a
Lockheed Martin Co., for the United
States Department of Energy’s Na-
tional Nuclear Security Administration
under contract DE-AC04-94AL85000.
References
1. ASTM F19-11, Standard Test
Method for Tension and Vacuum Testing
Metallized Ceramic Seals.
2. The Ag-Al (Silver-Aluminum)
System. 1987. Ed. by A. McAlister.
Bull. of Alloy Phase Diagrams 8(6): 526.
3. Yue, T., Yang, H., Li, T., and
Huang, K. 2009. The synthesis of
graded thermal barrier coatings on
nickel substrates by laser induced
thermite reactions. Mater. Trans. Jap.
Inst. of Metals 50(1): 219–221.
P. T. VIANCO (ptvianc@sandia.gov), C. A.
WALKER, D. DE SMET, A. KILGO, B. M.
MCKENZIE, P. M. KOTULA, and R. L. GRANT
are with Sandia National Laboratories,
Albuquerque, N.Mex.
This manuscript won the Best Brazing
Paper at the 2015 International Brazing
and Soldering Conference (IBSC) held
April 19–22, 2015, in Long Beach, Calif.
Dear Readers:
The Welding Journal encourages
an exchange of ideas through letters
to the editor. Please send your
letters to the Welding Journal
Dept., 8669 NW 36th St., #130,
Miami, FL 33166. You can also
reach us by FAX at (305) 443-7404
or by sending an e-mail to Kristin
Campbell at kcampbell@aws.org.
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BRAZING & SOLDERING TODAY

Techniques for Successful

Aluminum Vacuum-Brazed
Assemblies
BY ROBERT CARACCIOLO,
Integrating the vacuum brazing process TIMOTHY DELAHANTY,
from prebraze component design to JOSEPH GIGLIO, AND
GREGG BALDASSARRE
finished machining is critical

T
oday, the demand for higher
thermal and mechanical per-
formance in aluminum assem-
blies used in numerous applications —
from cold plates to heat exchangers to
chassis — requires a higher level of
precision, increased joint strength and
integrity, and tighter mechanical de-
sign tolerances. Consequently, the
joining methods used to fabricate alu-
minum assemblies need to promote
clean interior surfaces and avoid con-
tamination by flux, salts, or filling ma-
terials that can cause corrosion, poros-
ity, and weak metallurgical bonds.
Several methods may be used for
joining aluminum assemblies. Many of
these methods — dip brazing, weld-
ing, soldering, epoxying, and friction
stir welding — have cleanliness and
repeatability issues.
In contrast, vacuum brazing has nu- In vacuum brazing, a vacuum furnace allows the joint paths to be purged of gases while the
merous advantages, which include furnace chamber is being evacuated.
• No need for brazing flux1, which
reduces the risk of corrosion and cre-
ates cleaner parts • Ability to join large surfaces and the unique characteristics of the
• Avoids oxidization of sensitive highly complex internal geometries process. In general, brazing is a
materials • Ensures uniform material proper- process of joining materials by heating
• No potential for salt contamina- ties during and after brazing. metal surfaces to the liquidus temper-
tion compared to dip brazing ature of a filler metal, which forms a
• High repeatability and controlla- metallurgical bond with the mating
bility for batch processing Understanding the surfaces — Fig. 1. Typically, the filler
• Produces joints with strength ap- Process metal is a braze foil of thickness rang-
proaching the base metal, resulting in ing from 0.001 to 0.005 in. The
leak-free parts with high proof pres- The advantages that aluminum vac- molten filler metal is drawn through
sures uum brazing brings are the result of the joint by capillary action.

1. In atmospheric brazing as opposed to vacuum brazing, a chemical compound applied to the joint surfaces before brazing, called “flux,” is used
to shield the surfaces from oxygen in the air that causes oxide formation. Heating a metal surface accelerates the formation of oxides, the result
of chemical combination between the hot metal and oxygen in the air. These oxides must be prevented from forming or the oxides will inhibit
the brazing filler metal from wetting and bonding to the surfaces. The flux helps wetting of the joint surface in the presence of air and oxidation
and absorbs any oxides that form during heating or that were not completely removed in the cleaning process.

44 WELDING JOURNAL / FEBRUARY 2016


Fig. 1 — Temperature distribution across liquid cold plate surface.
In vacuum brazing, a vacuum fur-
nace allows the joint paths to be
purged of gases while the furnace
chamber is being evacuated. The dy-
namic vacuum prevents oxidation of
the surfaces and, consequently, braz-
ing flux is not needed.
During preparation of the compo-
nents to be brazed, a cleaning process
removes the oxide layer and any resid-
ual machining oils. A filler metal pre-
form (typically Al-Si alloys for base
metal compatibility) is then placed be-
tween the aluminum parts to be
joined. Foil preforms are most com-
mon in aluminum vacuum brazing;
however, aluminum filler directly ap-
plied to the mating surfaces, called
“cladding,” can be used. After assembly
of the components, closely spaced
clamps are applied to the components
to provide uniform pressure during
the brazing operation.
During the braze cycle, the vacuum
furnace is heated to a point above the
melting temperature of the braze foil
(>450°C). Thermocouples are attached
to the component to monitor temper-
ature to ensure the proper braze tem-
perature is achieved. Digital program-
mable logic controllers (PLC) deter-
BRAZING & SOLDERING TODAY
mine the precise levels and timing of
both heating and vacuum levels.
Although brazing in a vacuum re-
quires additional time compared with
other methods, the technique greatly
reduces the risk of metal oxidation or
contamination. The vacuum furnace
cycle also facilitates temperature uni-
formity. At the braze temperature, the
molten filler metal is distributed by
capillary action and pressure, making a
thin and strong joint.
After the brazing process is com-
pleted, the parts are typically heat
treated to restore temper (a degree of
metal hardness and elasticity), which
allows machining at feeds and speeds
similar to unbrazed aluminum. If
there is internal geometry in the com-
ponent, such as cooling passages, a
leak test is performed. Depending on
the test requirement, a leak test can be
a simple bubble test, a pressure decay
test, or a more stringent helium leak
test. A bubble test involves submerg-
ing the component in a fluid, typically
water, pressurizing the flow passage,
and looking for signs of bubbles. Soap
and water can be used too. The pres-
sure decay test involves pressurizing
the internal passage and checking for
decreasing pressure of time. Helium
leak checking requires sophisticated
helium mass spectrometer equipment
to sense for helium molecules that are
able to permeate through extremely
small holes that bubble testing will
never uncover.
Unlike some forms of controlled at-
mosphere brazing (CAB), vacuum
brazing is not typically a high-volume
process due to batch cycle time. A fur-
nace load typically consists from one
to 100 parts depending on size of the
furnace and the parts.
Equipment controls and brazing
conditions are typically dictated by ap-
plicable industry standards. What dif-
ferentiates vendors is their under-
standing of the process and their
philosophies regarding braze compo-
nent and fixture design. These factors
play a significant role in consistency,
repeatability, and overall performance.
Factors for Success
Typically, the part of the vacuum
brazing process that end users focus
on is the design of the finished part.
In reality, a successful vacuum-brazed
assembly is the result of integrating all
FEBRUARY 2016 / WELDING JOURNAL 45
BRAZING & SOLDERING TODAY
Fig. 2 — An experienced vacuum-brazed cold plate designer can quickly identify jobs that would benefit from using clad aluminum, rather
than the conventional braze foil. (Pictured here is a CAD design of a cold plate completed.)
the manufacturing steps: rough ma-
chined prebraze component design,
assembly and fixturing, vacuum braz-
ing, heat treatment, final machining,
and testing.
Prebraze Component
Design
To start with, it’s critical to consid-
er the design of the prebraze compo-
nents. That’s because the prebraze
component design determines how
the assembly is going to behave
through the heat treat and aging
process that takes place after brazing.
The heat treat process involves a rapid
quench that causes distortion. The ob-
jective is to minimize this distortion
via prebraze component design.
The first step in the prebraze com-
ponent design process is to consider
the nature of the features that need to
be brazed. Due to postbrazing distor-
tion, attempting to braze components
machined to their final assembly di-
mensions creates difficulties when try-
ing to meet final assembly tolerances.
A better practice is to braze a rough-
46 WELDING JOURNAL / FEBRUARY 2016
machined “blank” assembly made with
oversized prebrazed components that
include external features for adequate
clamping and fixturing during vacuum
brazing. In other words, allow excess
material in the rough-machined
brazed-blank design to allow machin-
ing of intricate external features of the
final assembly during the final ma-
chining stage.
Another important consideration
in the brazed blank design is to avoid
creating unnecessary joints. Stacking
up generic, off-the-shelf plates merely
to save the raw material costs of buy-
ing a properly sized piece of aluminum
is short-sighted. Additional and un-
necessary joints can lead to increased
risk of braze joint failures. For this
reason, it is typically more cost effec-
tive to invest in properly designed pre-
brazed components and assembly
rather than risk poor yield at the com-
pletion of the brazing stage.
Best Practices
Complex final assembly design fea-
tures can be accommodated in the vac-
uum brazing process, but braze trials
are often advisable to ensure success,
especially on challenging assemblies.
Not every project has the budget for
braze trials, and so as a result, careful-
ly designing the rough-machined
blank design with the final assembly
design is a must. Best design practices
include
• Minimize the number of braze
joints. It’s important to evaluate
strength requirements and machining
issues on a case-by-case basis.
• Avoid elements protruding out of
the external surfaces — they can often
interfere with appropriate clamping.
• Design with a strong preference
for joints or bond lines that are in the
horizontal plane, which enable imme-
diate success and high repeatability.
• Avoid vacuum brazing very broad,
featureless surfaces together. Better
integrity of the finished component is
achieved if thick, solid areas are not
comprised of a series of thin plates
stacked together. Large featureless ar-
eas tend to exhibit a higher occurrence
of voids — especially in heavy parts.
• Where possible, avoid brazing
tubes into sockets. This cylindrical
geometry violates the design of a bond

line in the horizontal plane. While
possible, trial and error is required to
achieve success and ensure consisten-
cy; however, it adds cost.
• Ensure distributed and even
clamping pressure is applied over the
entire joint being brazed, especially on
thin components that do not translate
pressure well when they become soft
at elevated temperatures.
Consult over blank design early in
the process. To ensure a successful alu-
minum vacuum-brazed cold plate, heat
exchanger, or chassis assembly, collab-
orate with a brazing partner that has
demonstrated thermal and mechanical
engineering design, fabrication, and
material process and testing expertise.
A partner with demonstrated prebraze
component design and prebraze as-
sembly experience on numerous de-
sign configurations is highly recom-
mended. Early consultation and col-
laboration with an expert will save on
braze cycle costs and postbraze yield.
Design for Manufacture
and Assembly
Applying “design for manufacturing
and assembly (DFMA)” methodologies
and experience is equally important. It
is the combination of two methodolo-
gies, namely, design for manufacture,
which means the design for ease of
manufacture of the parts that will
form a product, and design for assem-
bly, which means the design of the
product for ease of assembly.
The DFMA process captures poten-
tial manufacturability design flaws in
prebrazed and postbrazed compo-
nents, and makes it easy to discuss
and implement possible improve-
ments. For example, a design may re-
quire large amounts of material to be
removed after brazing in a final ma-
chining operation. Depending on
geometry, a slight compromise in the
design for braze performance may
positively impact postbraze machining
and potentially lead to a part that is
more efficient to produce.
Other Filler Metal
Considerations
Some aluminum vacuum braze de-
signs also lend themselves toward clad
aluminum braze sheets as an alterna-
BRAZING & SOLDERING TODAY
tive to the lower cost braze foil filler
metal approach. A common clad alu-
minum alloy used in vacuum brazing is
comprised of a 6000 series aluminum
core with a thin layer of 4000 series
braze filler metal bonded to it. Using
clad aluminum reduces part count and
assembly labor time, and it can be
more forgiving than braze foil. In high
volumes, clad aluminum can be ob-
tained in many sizes; however, low-
volume jobs require the use of stock-
sized material. An experienced vacu-
um-brazed assembly designer can
quickly identify jobs that would bene-
fit from using clad aluminum — Fig. 2.
Postbraze Machining
The aluminum vacuum brazing
process inherently thermally cycles the
blank assembly. Thermal cycling ma-
chined components that get joined to-
gether can result in distortion or
warpage of the postbraze blank. As a
result, the postbraze assembly typical-
ly requires some postbraze or final ma-
chining to eliminate minor distortions
that would cause an out-of-tolerance
condition on the final assembly.
Postbraze machining to allow for
correcting mechanical distortion and
other minor surface imperfections
should be considered in the early de-
sign stages of the prebraze compo-
nents, prebrazed assembly, and post-
brazed blank.
The Machining Process
Postbraze machining is done after
the brazed part is stable. Machining
can be accomplished down to five
thousandths of an inch. Additional
tooling is often incorporated into the
braze clamps and fixtures to protect
the parts from being damaged when at
braze temperature. Using plates or fix-
tures may cause some discoloring or
rough spots. Furthermore, some braze
may squeeze out of the joints, requir-
ing cleanup in order to meet surface
finish or cosmetic requirements.
Heat Treating
Heat treating: Heat treating is con-
ducted after machining to achieve the
design-specified metal hardness. Solu-
tion heat treating is typically done
through air quenching in air. Air
quenching will cause some oxidization;
therefore, a skin or coating treatment
may be required where a clean appear-
ance is desired. An alternative to air
quenching is liquid submersion
quenching. We do this before machin-
ing to final shape.
Integrating the Process
Integrating the process from pre-
braze component design to finished
machining is critical. To ensure a suc-
cessful aluminum vacuum-brazed as-
sembly outcome, the best practices
and design rules identified previously
must be applied at the beginning of
the project. When the process is fully
integrated from prebraze component
design to postbraze machining and
testing, a repeatable, high product
yield manufacturing process is estab-
lished. More importantly, a well-inte-
grated design and manufacturing
process assures the best thermally and
mechanically performing and most re-
liable aluminum vacuum-brazed as-
semblies. Typical contract aluminum
vacuum brazing houses do not have
the integration of design and manu-
facturing process capabilities. An expe-
rienced, integrated firm can determine
brazing and finishing parameters
based on application, desired thermal
and mechanical performance, geome-
tries, and features.
By combining vertically integrated
engineering and manufacturing capa-
bilities, coupled with the identified
best practices and stringent quality
control steps, Thermacore produces
aluminum vacuum-brazed cold plates,
heat exchangers, and chassis that en-
sure high levels of performance and
reliability for demanding customer ap-
plications — maintaining near-perfect
yields on assemblies that utilize estab-
lished design principles. WJ
DR. ROBERT CARACCIOLO is engineering group
leader, Vacuum Braze and High Temperature,
TIMOTHY DELAHANTY is light metals project
manager, Materials Technology Division,
JOSEPH GIGLIO is vice president, Customer De-
velopment, Materials Technology Division, and
GREGG BALDASSARRE is vice president, Sales
and Marketing, at Thermacore, Inc. (therma-
core.com), Lancaster, Pa.
FEBRUARY 2016 / WELDING JOURNAL 47
BRAZING & SOLDERING TODAY
Effect of SiC Nanoparticles on
Shear Strength, Microstructure
of Molybdenum Brazed Joints
A doping of the microsized eutectic
alloy Mo.40-Ni.653 powder by SiC
nanoparticles applied in order to de-
crease the liquid alloy spreading over
pure Mo was studied at the Harbin In-
stitute of Technology, China, and the
University of Kentucky.
The addition of SiC nanoparticles
to the eutectic Mo-Ni brazing filler
metal changes both the microstructure
of the solidified Mo/Mo-Ni joints and
mechanical properties of the material
(Ref. 1).
The Mo-Ni powder was doped with
1, 3, and 5 wt-% of nano-SiC powder.
The maximum joint fracture stress lev-
el was observed in the specimen con-
taining 3 wt-% SiC additive. For the
first time, nano-indentation experi-
ments were carried out using atomic
force microscopy to measure the hard-
ness of submicrometer joint phases
with a resolution of <50 nm. The
strength of brazements, which are
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48 WELDING JOURNAL / FEBRUARY 2016
doped with “nano” SiC powder, is
equal to or even exceeding 50% of that
of pure Mo. The microstructure of the
doped samples depends strongly on
the concentration of the SiC power.
Both metalloids, Si and C, are dis-
solved upon filler metal melting, and
found as solid solution components in
Mo- and Ni-based intermetallic eutec-
tic joint phase components.
The major beneficial changes of the
brazed joint’s morphology due to alloy-
ing with SiC takes place in the joint mi-
crostructure. These changes are ex-
pressed in transformation, replace-
ment of typical eutectic morphology
consisting of dendrites embedded
within a mixture of lamellae into a new
type of refined microstructure consist-
ing of a mixture with very small, evenly
distributed eutectic crystals having
cuboidal and trapezoidal forms.
Low­Temperature Bonding of
Copper Using Silver
Nanoparticles
Nanoparticles exhibit a decrease in
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TECHNOLOGY NEWS
melting temperature in comparison to
the corresponding bulk material. After
melting or sintering of the nanoparti-
cles, the material behaves like the bulk
material. Therefore, high-strength and
temperature-resistant joints can be
produced at low temperatures.
The investigations made at Chem-
nitz Technical University, Germany,
proved that silver nanopaste offers a
great potential for joining copper and
other metals at temperatures below
500°C (Ref. 2).
The study showed that the organic
shell of silver nanoparticles decompos-
es at ~410°C, followed by a sintering
process. The sintered structure pos-
sesses thermal properties of bulk sil-
ver. Joints can be produced even at
lower temperatures, ~300°C, with the
satisfied strength ~95 MPa and high
temperature stability. The variation of
the process parameters reveals that the
joining pressure varied from 5 to 80
MPa exerts an essential positive effect
on the achievable strengths increased
from 20 to 95 MPa, and also on de-
creasing porosity from ~45 to ~10%.
The change of joining temperature
 TECHNOLOGY NEWS
in the range of 300°–400°C did not af-
fect the strength of the joints, while
increasing the holding time from 5 to
30 min improved the strength of cop-
per joints from ~45 to ~80 MPa.
Evaluation of Brazing Filler
Metals with a Reduced Content
of Active Elements for Joining
Alumina Ceramic
Active braze filler metals are widely
used to join nonmetals to metals and
nonmetals without metallization coat-
ings. Because active filler metal com-
positions are limited and designed to
work with various materials systems,
the amount of active element is often
more than required resulting in thick,
brittle reaction layers or reactions with
base materials that lead to excessive
braze filler metal flow.
Reduced quantities of the active el-
ements titanium and zirconium added
to standard braze filler metals were
tested at Sandia Laboratories, Albu-
querque, N.Mex., to determine the
quantities required to form continu-
Measure Ferrite Content with
h
the FISCHER FERITS
• Measurement range g 0.1
0 1 to 80%
% Fe or 0.1 1 to 110 FN

BRAZING & SOLDERING TODAY
ous reaction layers without compro-
mising tensile strength or promoting
excess filler metal wetting/flow. Tita-
nium or zirconium thin film, 0.5 mi-
crons thick, as active components
were deposited on conventional silver
and gold brazing foils by PVD tech-
niques (Ref. 3).
SEM/EDS analysis confirmed the
reaction layers formed were not con-
tinuous on either of the surfaces, as
compared to samples fabricated with
commercially manufactured active
brazing filler metals containing 2 wt-%
of titanium or zirconium. The average
tensile strengths of the samples
brazed using the 2 wt-% active ele-
ment were superior to the strengths of
those fabricated using the modified
filler metals having reduced active ele-
ment percentages.
Future test samples should include
greater concentrations of active ele-
ment and also amended filler metal
preparation methods, because the
analysis of the metallographic cross
sections also showed the tendency of
the sputter-deposited active element
to preferentially form a thicker, more
®
F ast anddE asy
y F ix es.
This is H o
Perform
m.
continuous reaction layer on the fay-
ing surface it was positioned adjacent
to during the prebrazing fixturing
process.
Metal Leaching of Brazed
Stainless Steel Joints into
Drinking Water
Stainless steel is replacing copper
alloys in heat exchangers and plumb-
ing systems for drinking water instal-
lations due to hygienic considerations
and improved corrosion resistance.
The hygienic suitability of stainless
steel for drinking water applications is
well investigated, documented, and
approved. However, hygienic aspects
of brazed joints made on stainless
steel components, such as heat ex-
changers, was not studied enough.
Leaching metals from brazed joints
of 316L stainless steel made by using
copper-, nickel-, and iron-based braz-
ing alloys in the form of amorphous
foils was examined by Vacuum-
schmelze, Hanau, Germany (Ref. 4).
The obtained results confirmed it is
ow I

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FEBRUARY 2016 / WELDING JOURNAL 49
BRAZING & SOLDERING TODAY
not possible to characterize corrosive
or hygienic aspects of a braze joint by
studying individual materials. It is im-
perative to analyze the metallurgical
bond and activities of the involved ma-
terials with respect to their thermal
processing.
It was found that not all nickel
brazing alloys are comparably suitable
for drinking water applications. In par-
ticular, the nickel brazing alloys con-
taining a high boron content, about 3
wt-%, are not applicable because they
release high values of nickel into the
water. The Ni-Cr brazing alloys with
lower boron content of ≤1.5 wt-% ex-
hibit the lowest metal leaching rates
and show much more convenience for
drinking water applications.
The copper-brazed 316L joints re-
lease a significant amount of Ni in ad-
dition to copper and iron. Brazed spec-
imens using the Ni-Cr-Si-B brazing
foils showed a significantly lower nick-
el leaching rate than that of the copper
brazed specimen. The general leaching
of metal ions (Cu + Ni + Fe) for the Cu-
brazed steel is orders of magnitude
higher than that of the specimens
brazed with the previously mentioned
Ni-Cr and Fe/Ni-Cr brazing foils.
Capillary Enhanced Dissolution
in Brazing
During a brazing process, dissolu-
tion (erosion) of the solid base metal
into the liquid filler metal is an in-
evitable phenomenon, which can be
enhanced by surface-tension-driven
molten metal flow. Severe dissolution
associated with base metal thickness
reduction can be detrimental for
brazed products.
An analytical model was established
by Delphi Thermal Systems, Lockport,
N.Y., that combines the mechanism of
both dissolution and surface-tension
driven molten metal flow. The model
explains the underlying physics of dis-
solution for a brazing process and as-
sociated impacts caused by the capil-
lary action (Ref. 5).
The model suggests that with low-
ering the Si content in the Al-Si alloy
cladding towards a reduced surface
tension to viscosity ratio at elevated
temperatures, the capillary action can
be weakened, thus achieving a sup-
pressed dissolution. To validate that
concept, two groups of aluminum
50 WELDING JOURNAL / FEBRUARY 2016
heat exchanger (HE) samples were
brazed using an industrial controlled-
atmosphere brazing furnace, and the
dissolution was examined.
The metallographic study of the
dissolution shows the baseline group
of the HE experienced an average dis-
solution up to 64%, which is consis-
tent with the results monitored for
mass production development sam-
ples. In contrast, the group of HE with
altered Si content in the clad experi-
enced a very low level of dissolution.
Therefore, the results show the base
metal dissolution can be largely im-
pacted by controlling the potential of
capillary molten clad flow, which sup-
ports the concept in the proposed
model.
Effects of Alkali and
Alkali­Earth Elements on
Surface Tension of Lead, Tin,
and Indium
Development and testing of new,
effective solders is still a problem in the
industry. Therefore, knowledge of
fundamental physical properties of
low-temperature molten alloys is
important.
The effects of alkali and alkali-earth
elements on the surface tension of
lead, tin, and indium that constitute
the major portion of solders were
studied by the North-Caucasus
Mining and Metallurgy University,
Vladikavkaz, Russia, using the method
of large droplet on graphite substrates.
The polythermic diagrams of sur-
face tensions and density of such bina-
ry alloy melts as Sn-0.1Ba, Sn-0.59Sr,
Sn-1.93Sr, In-(0.1-0.5)Na, Pb-0.3Li,
and Pb-0.2Ca (all in atomic %) were
determined based on experimental
data in the wide range of temperatures
200°–700°C (Ref. 6).
Diagrams of surface tensions and
density in the systems Sn-Ba, Pb-Li,
and In-Na liquid alloys are well repre-
sented by linear equations with nega-
tive temperature coefficients. In other
words, small additions of alkali and
alkali-earth elements decrease surface
tension of the solder base metals.
Nonlinear diagrams were found in the
systems of liquid Sn-Sr and Pb-Ca al-
loys that were explained by a specific
temperature effect on surface tension.
A repeatable process of ordering
surface structure was observed in the
TECHNOLOGY NEWS
molten alloy In-Na at a small addition
of sodium that resulted in significant
deviations of the surface tension val-
ues for some compositions of this alloy.
New Brazing Concept for
Joining Stainless Steels
A new method of brazing stainless
steel parts that aims to reduce the
process steps and production costs
was disclosed by Alfa Laval Corp.,
Lund, Sweden.
The method proved that it is possi-
ble to create a melted alloy of the par-
ent material by using a Mn3P2 or NiP
and pure silicon powder mixture as a
melting point depressant on the plate
surface in vacuum or in a hydrogen at-
mosphere. No additional brazing filler
metal is used. The composition of the
formed joint alloy after cooling has a
composition similar to the base metal.
Wetting of the facing surface is provid-
ed with a contact angle of <90 deg,
and a smooth joint is formed (Ref. 7).
For example, the Mn3P2 and pure
silicon powders are mixed at the
weight ratio 2.46:1, and a water-based
polymer binder is added. The paste is
placed onto the flat surface of a 316
stainless steel part and covered by a
254SMO steel part. The assembly is
heat treated for 2 h in vacuum at
1120°–1140°C. The joint metal com-
position is C 2.86, Si 2.40, P 1.43, Cr
18, Ni 18, Mo 5.6, Mn 1.63, and Fe
50.54 wt-%.
A similar joining procedure is car-
ried out if the stainless steel is coated
by a NiP layer 50 microns thick and a
pure silicon powder is placed onto this
coating. After heat treatment for 2 h
at 1120°C, the steel parts are brazed,
and the joint metal has the composi-
tion O 1.20, P 14.41, Cr 18, Ni 40.95,
Mo 4.77, Mn 0.51, and Fe 10.17 wt-%.
Aluminum Brazing of Hollow
Titanium Fan Blades
A method of brazing titanium fan
blades at the temperature below the
annealing temperature of Ti-6Al-4V al-
loy of thin-wall parts was disclosed by
United Technology Corp., South
Windsor, Conn.
Brazing below the annealing tem-
perature allows for the maintenance of
certified mechanical properties of the
 TECHNOLOGY NEWS BRAZING & SOLDERING TODAY

base metal. An aluminum alloy of the 1175°F (solidus of the aluminum braz- 4. Hartmann, T. Metal leaching of
Al-Cu-Mn system containing <3 wt-% ing alloy) on heating and 1175°F on brazed stainless steel joints into drinking
of copper and <5 wt-% of manganese cooling would be controlled to produce water. Paper #26.
and having a solidus-liquidus range a braze microstructure that satisfies 5. Liu, W., and Barten, B. L. Capillary
enhanced dissolution in brazing. Paper
within 1175°–1225°F (635°–663°C) is the required testing characteristic of
#60.
deposited at least on one of the forged brazed joints. WJ 6. Kashezhev, A. Z., Kutuiev, P. A.,
and machined titanium parts to be Ponezhev, M. K., and Sozaev, V. A. 2013.
brazed (Ref. 8). References Effects of alkali- and alkali-earth elements
The assembled fan blade is inserted on surface tension of lead, tin, and indium.
into a metallic foil bag constructed Refs. 1–5 are Proceedings of the 6th Inter- Melts, Journal of Russian Academy of Sci-
from stainless steel or nickel alloy foils national Brazing and Soldering Conference, ences No. 5: 66–77.
that can be sealed. The sealed, bagged April 19–22, 2015, Long Beach, Calif. 7. Sjödin, P., Walter, K., and Falkenberg,
fan blade is loaded into a vacuum com- F. 2015. A novel brazing concept. World
1. Sekulic, D. P., Fu, H., Rabinkin, A., Patent WO 2014/099067. Publication date
pression brazing furnace. Oxygen and Busbaher, D., Leone, E., and Preuss, T. Me- April 2, 2015.
nitrogen within the bag are evacuated, chanical properties of Mo-Ni brazing filler 8. Bales, D. A., and Watson, T. J. 2014.
and the bag is backfilled with dry ar- metal caused by additions of SiC nanopar- Aluminum brazing of hollow titanium fan
gon, then a negative atmosphere pres- ticle powder. Paper #59. blades. World Patent WO 2015/043977.
sure is maintained with the sealed bag. 2. Hausner, S., Weis, S., Wielage, B., and Publication date June 26, 2014.
Brazing could occur in a vacuum Wagner, G. Joining of copper at low tem-
furnace capable of maintaining a par- perature using Ag nanoparticles: Influence
tial pressure of argon to provide a pos- of process parameters on mechanical
strength. Paper #103.
itive pressure that will compress 3. Walker, C. A., Bishop, G., DeSmet,
brazed parts during the brazing cycle. D. J., and Brumbach, M. Single and double Information provided by ALEXANDER E.
Heating is carried out in the range of SHAPIRO (ashapiro@titanium­brazing.com)
reaction layer formation using reduced ac-
1225°–1290°F (663°–699°C) followed and LEO A. SHAPIRO, Titanium Brazing, Inc.,
tive element containing brazing filler met- Columbus, Ohio.
by immediate cooling. Time between als. Paper #56.

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FEBRUARY 2016 / WELDING JOURNAL 51

COMING EVENTS
AWS-SPONSORED EVENTS
For more information on AWS events:
aws.org/w/a/conferences/index
(800/305) 443­9353, ext. 455
FABTECH Canada. March 22–24. Toronto Congress Centre,
Toronto, Canada. Cosponsored by SME, Fabricators & Man-
ufacturers Association, American Welding Society, Precision
Metal Association, and Chemical Coaters Association Inter-
national. Companies specializing in fabricating, metal form-
ing, welding, and finishing will have the opportunity to net-
work, improve productivity, increase profits, and discover
innovative ways to expand in today’s competitive environ-
ment. For more information, visit fabtechcanada.com.
9th International Seminar & Conference on Advances in
Resistance Welding. April 12–15. Miami, Fla. AWS, RWMA,
and Swantec join forces to bring together industry experts
from leading institutes and companies to report on the lat-
est in materials, welding equipment, innovation, and indus-
trial applications of resistance welding. For more informa-
tion, visit aws.org/events/detail/9th-international-seminar-
conference-on-advances-in-resistance-welding.
For info, go to www.aws.org/ad­index
For info, go to www.aws.org/ad­index
52 WELDING JOURNAL / FEBRUARY 2016
10th International Conference on Trends in Welding
Research & 9th International Welding Symposium of Japan
Welding Society. Oct. 11–14. Hitotsubashi Hall, Tokyo,
Japan. The conference will cover the fundamental science of
welding and joining as well as a wide variety of applications
of welding and joining different materials in different indus-
tries. Abstracts due March 31. Full papers due June 30. Visit
trends2016.org for more information, or e-mail twr2016@
issjp.com.
U.S., CANADA, MEXICO EVENTS
3rd Lightweight Vehicle Manufacturing: Joining, Forming &
Quality Assurance Conference. February 24, 25. Detroit,
Mich. The GALM US Manufacturing conference will bring
the latest OEM-led case studies on enabling maximum resis-
tivity and performance for lightweight multimaterial joints
with the ultimate goal of lowering the costs and shortening
production cycles. Visit global-lightweight-vehicle-manufac-
turing.com for more information.
ShipTech 2016. March 1, 2. Charleston Marriott, Charleston,
S.C. The two-day event is intended as a forum for the do-
mestic shipbuilding industry, its supplier base, the U.S. Navy
program offices, and the U.S. Navy-sponsored shipbuilding
research programs to exchange information on shipbuilding
technical developments. E-mail shiptech@ctc.com or visit
nmc.ctc.com for more information.

ASTM International Copper Committee Workshop on Elec­

trical Conductors. April 13. Grand Hyatt San Antonio, San
Antonio, Tex. This workshop will address general principles
of annealing, softening of copper and aluminum, and some
annealing problems. Registration opens mid-February. Visit
astm.org/B05Wrkshp42016, call (610) 832-9677, or e-mail
hsparks@astm.org.

Lasers for Manufacturing Event®. April 26, 27. Cobb Galleria

Centre, Atlanta, Ga. Hosted by the Laser Institute of Ameri-
ca, this event will showcase advanced manufacturing with
lasers including marking, cutting, welding, and quality con-
trol. Visit laserevent.org or call (407) 380-1553 for more
information.

18th International Symposium on Zirconium in the Nuclear

For info, go to www.aws.org/ad­index

Industry. May 15–19. Westin Hilton Head Island Resort and
Spa in Hilton Head, S.C. ASTM International will host this
forum for new information on the fabrication, testing, de-
velopment, and characterization of both traditional and new
zirconium-based materials used in the nuclear industry. For
more information, visit astm.org/B1018thZrReg.

Additive Manufacturing Americas 2016. December 7–9.

Pasadena Convention Center, Pasadena, Calif. This is the
business-to-business show for additive manufacturing/3D
printing. This year’s show will incorporate a 3D printshow.
For more information, visit amshow-americas.com.

INTERNATIONAL EVENTS

International Conference on Civil, Mechanical, and Environ­ Well-MM atched

Using
mental Engineering Technologies — 2016. Feb. 26, 27. SVS
College of Engineering, Coimbatore, India. Call for papers in
Componentss. This is H ow I
ASME format. For more details, visit iccmeet.com or call +91
98945 70073.
Perforrm.
International Laser Technology Congress AKL ’16. April
27–29. Aachen, Germany. Topics covered include laser addi-
tive manufacturing, and process control, as well as laser
technology ABCs and laser material processing (micro and
macro). For more information call +49 241 8906-122 or vis-
it lasercongress.org.

Additive Manufacturing Europe 2016. June 28–30. RAI,

Amsterdam. This is the business-to-business show for addi-
tive manufacturing/3D printing. This year’s show will incor-
For info, go to www.aws.org/ad­index

porate a 3D printshow. For more information, visit

amshow-europe.com.

EuroBLECH 2016. Oct. 25–29. Hanover Exhibition Grounds,

Hanover, Germany. The 24th International Sheet Metal
Working Technology Exhibition is an international trade ex- Independent welding in the oil & gas industry
hibition for the sheet metal working industry and will serve has b ecome reality with UTPperform.
as a platform for interlinked sheet metal working produc-
tion. Call +44 (0)1727 814400 or visit euroblech.com for voestalpine Böhler Welding
more information. www.voestalpine.com/welding

— continued on page 55
FEBRUARY 2016 / WELDING JOURNAL 53
COMING EVENTS
— continued from page 53
EDUCATIONAL OPPORTUNITIES
AWS Certified Welding Supervisor Exam. Troy, Ohio. Classes
begin April 25, Oct. 10. Exams given April 29, Oct. 14. Ho-
bart Institute of Welding Technology; welding.org.
Certified Welding Inspector/Educator Courses. Troy, Ohio.
Classes begin Feb. 15, March 14, April 11, May 9, June 20,
July 18, Aug. 15, Sept. 19, Oct. 17, Nov. 7, and Dec. 5. Ex-
ams given Feb. 26, March 25, April 22, May 20, July 1, July
29, Aug. 26, Sept. 30, Oct. 28, Nov. 18, and Dec. 16. Hobart
Institute of Welding Technology; (800) 332-9448;
welding.org.
E­Courses in Destructive and Nondestructive Testing of
Welds and Other Welding­Related Topics. Online video
courses taken at one’s own pace offer certificates of comple-
tion and continuing education units. For information, con-
tact Hobart Institute of Welding Technology; welding.org/
product-category/online-courses/.
GE Industrial Computed Tomography (CT) Operator Course.
Learn to operate the 3D technology that is becoming more
prominent in industrial quality control and metrology.
For info, go to www.aws.org/ad­index
Lewistown, Pa., (315) 554-2039; geinspectionacademy.com.
Hypertherm Cutting Institute Online. Includes video tutori-
als, interactive e-learning courses, discussion forums, webi-
nars, and blogs. Visit hypertherm.com; hyperthermcutting
institute.com.
INTEG Courses. Courses in NDE disciplines to meet certifica-
tions to Canadian General Standards Board or Canadian Nu-
clear Safety Commission. The Canadian Welding Bureau;
(800) 844-6790; cwbgroup.org.
Laser Safety Online Courses. Courses include Medical Laser
Safety Officer, Laser Safety Training for Physicians, Indus-
trial Laser Safety, and Laser Safety in Educational Institu-
tions. Laser Institute of America; (800) 345-2737; lia.org.
Laser Safety Training Courses. Courses based on ANSI
Z136.1, Safe Use of Lasers. Orlando, Fla., or customer’s site.
Laser Institute of America; (800) 345-2737; lia.org.
Laser U — Online Education Portal. Offers practical infor-
mation to use on the job. Topics range from 3D printing to
drilling, welding, wireless and optical product requirements,
and many others. Visit website for complete information
and to sign up for modules. Laser Institute of America;
lia.org/laseru.
Laser Vision Seminars. Two-day classes, offered monthly
— continued on page 112
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FEBRUARY 2016 / WELDING JOURNAL 55
CERTIFICATION SCHEDULE Certification Seminars, Code Clinics, and Examinations

Note: The 2016 schedule for all certifications are posted online at 9­Year Recertification Seminar for CWI/SCWI
aws.org/w/a/registrations/prices_schedules.html. For current CWIs and SCWIs needing to meet education re-
quirements without taking the exam. The exam can be tak-
en at any site listed under Certified Welding Inspector.
Certified Welding Inspector (CWI)
Location Seminar Dates
Location Seminar Dates Exam Date
Denver, CO Feb. 21–26
Miami, FL Exam only Feb. 18
Dallas, TX Mar. 6–11
New Orleans, LA Feb. 21–26 Feb. 27
Miami, FL Mar. 13–18
Milwaukee, WI Feb. 21–26 Feb. 27
Sacramento, CA Apr. 10–15
San Diego, CA Feb. 28–Mar. 4 Mar. 5
Boston, MA Apr. 17–22
Kansas City, MO Feb. 28–Mar. 4 Mar. 5
Charlotte, NC May 1–6
Houston, TX Feb. 28–Mar. 4 Mar. 5
Pittsburgh, PA May 15–20
Norfolk, VA Feb. 28–Mar. 4 Mar. 5
Scottsdale, AZ Mar. 6–11 Mar. 12
Indianapolis, IN Mar. 6–11 Mar. 12
Boston, MA Mar. 6–11 Mar. 12
Certified Welding Educator (CWE)
Perrysburg, OH Exam only Mar. 12 Seminar and exam are given at all sites listed under Certified
Miami, FL Mar. 13–18 Mar. 19 Welding Inspector. Seminar attendees will not attend the Code
Birmingham, AL Mar. 13–18 Mar. 19 Clinic portion of the seminar (usually the first two days).
Chicago, IL Mar. 13–18 Mar. 19
Springfield, MO Mar. 13–18 Mar. 19
Dallas, TX Mar. 13–18 Mar. 19 Certified Welding Sales Representative (CWSR)
Miami, FL Exam only Apr. 7 CWSR exams will be given at CWI exam sites.
Minneapolis, MN Apr. 3–8 Apr. 9
Las Vegas, NV Apr. 3–8 Apr. 9
Portland, OR Apr. 3–8 Apr. 9
St. Louis, MO Exam only Apr. 9 Certified Welding Supervisor (CWS)
San Francisco, CA Apr. 10–15 Apr. 16 CWS exams are also given at all CWI exam sites.
Annapolis, MD Apr. 10–15 Apr. 16
Nashville, TN Apr. 10–15 Apr. 16 Location Seminar Dates Exam Date
Detroit, MI Apr. 17–22 Apr. 23 New Orleans, LA Apr. 4–8 Apr. 9
Corpus Christi, TX Apr. 17–22 Apr. 23 Cleveland, OH Sept. 19–23 Sept. 24
Fresno, CA May 1–6 May 7 Norfolk, VA Oct. 17–21 Oct. 22
Miami, FL May 1–6 May 7
Albuquerque, NM May 1–6 May 7
Syracuse, NY May 1–6 May 7
Oklahoma City, OK May 1–6 May 7 Certified Radiographic Interpreter (CRI)
Rapid City, SD May 1–6 May 7 The CRI certification can be a stand-alone credential or can
Knoxville, TX Exam only May 21 exempt you from your next 9-Year Recertification.
Jacksonville, FL May 15–20 May 21
Hutchinson, KS May 15–20 May 21 Location Seminar Dates Exam Date
Houston, TX May 15–20 May 21 Seattle, WA Feb. 22–26 Feb. 27
Spokane, WA May 15–20 May 21 Houston, TX Mar. 14–18 Mar. 19
Bakersfield, CA June 5–10 June 11 San Francisco, CA Apr. 11–15 Apr. 16
New Orleans, LA June 5–10 June 11 Las Vegas, NV May 2–6 May 7
Duluth, MN June 5–10 June 11 Cleveland, OH June 6–10 June 11
Pittsburgh, PA June 5–10 June 11
Miami, FL Exam only June 16
Hartford, CT June 12–17 June 18 Certified Robotic Arc Welding (CRAW)
Orlando, FL June 12–17 June 18 ABB, Inc., Auburn Hills, MI; (248) 391–8421
Memphis, TX June 12–17 June 18 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800, ext. 218
Beaumont, TX June 12–17 June 18 Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Los Angeles, CA July 10–15 July 16 Genesis-Systems Group, Davenport, IA; (563) 445-5688
Louisville, KY July 10–15 July 16 Wolf Robotics, Fort Collins, CO; (970) 225-7736
Omaha, NE July 10–15 July 16 On request at MATC, Milwaukee, WI; (414) 456-5454
Cleveland, OH July 10–15 July 16

IMPORTANT: This schedule is subject to change. Please verify your event dates with the Certification Dept. to confirm your course status
before making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications received
after that time will be assessed a $350 Fast Track fee. Please verify application deadline dates by visiting our website
aws.org/certification/docs/schedules.html. For information on AWS seminars and certification programs, or to register online, visit
aws.org/certification or call (800/305) 443­9353, ext. 273, for Certification; or ext. 455 for Seminars.

56 WELDING JOURNAL / FEBRUARY 2016

BY MELISSA GOMEZ — mgomez@aws.org
SOCIETY NEWS
Industry Leaders Recognized at FABTECH

The AWS 2016 board of directors assembled at FABTECH in Chicago, Ill.

Class of 2015 Counselors and Fellows Announced

The 2015 classes of AWS Fellows and
Counselors were recognized during
FABTECH in Chicago, Ill.
The Fellows are Yoni B. Adonyi,
Boain T. Alexandrov, Pingsha Dong,
Duane K. Miller, and Norman Y. Zhou.
The Counselors are John C. Bruskotter,
William F. Newell Jr., André Odermatt,
William A. Rice Jr., Carolyn K. Russell,
and Phillip I. Temple.
AWS Fellows are cited for “serving
the welding community and industry with
great distinction as individuals whose ca-
reers have contributed significantly to the
knowledge, science, and application of
welding.”
Yoni B. Adonyi is recognized for his
contributions to plate, tubular, and
sheet welding projects, and for coau-
thoring a patent on joining of mandrel
bar for jointless pipe production.
Boain T. Alexandrov is recognized
for developing innovative methods for
evaluating weldability, phase transfor-
mation analysis, and metallurgical
characterization that enables quantifi-
cation of nonequilibrium phenomena
and response to processing in conven-
tional and advanced alloys, and for his
significant contributions toward the
resolution of major weldability prob-
lems in the power-generation and oil
and gas sectors.
Pingsha Dong is recognized for his
research in weld fracture mechanics,
modeling of welded structures, studies
in residual stresses and distortion miti-
gations, and designs for fitness for
service. He’s developed numerous
unique and effective methods for pre-
dicting fatigue design and life predic-
tion of welded structures.
Duane K. Miller is cited for the de-
velopment of numerous major flagship
code books within the structural indus-
try and for continuously devoting his
time to enhancing and standardizing
national seismic welding
standards.
Norman Y. Zhou is cited for his ex-
tensive research in advanced materials

From left are Counselors John C. Bruskotter, William F. Newell Jr., André Odermatt, William A. Rice Jr., Carolyn K. Russell, Phillip I. Temple;
and Fellows Norman Y. Zhou, Yoni B. Adonyi, Duane K. Miller, Pingsha Dong, and Boain T. Alexandrov.

FEBRUARY 2016 / WELDING JOURNAL 59

SOCIETY NEWS
joining, and most notably, laser and
resistance welding, diffusion brazing,
microwelding, nanowelding, and laser
processing of NiTi alloys. His research
has provided him the opportunity to
author the first-of-its-kind publication
in microjoining and nanojoining as
well as coauthor more than 230 jour-
nal papers, books, and technical con-
ference presentations and reports.
AWS Counselors are recognized for
“serving the welding community and in-
dustry with distinction and organizational
leadership that has enhanced the image
and impact of the welding industry.”
John C. Bruskotter is recognized
for devoting more than 40 years to the
welding industry and demonstrating
expertise in all phases of oilfield con-
struction, with extensive experience in
the packaging of gas compression
modules, oil and gas production mod-
ules, and oilfield-related equipment.
He continuously ensures proper imple-
mentation of all operational phases
within the offshore installation indus-
try, providing management services
for a number of major projects.
Achievement Awards Presented at FABTECH
Charles V. Robino Todd A. Palmer
Comfort A. Adams Lecture Award
This award is presented to an outstand-
ing scientist or engineer for a lecture de-
scribing a new or distinctive development
in the field of welding. The lecture is pre-
sented during FABTECH.
“Engineering Approximations in
Welding — Bridging the Gap Be-
tween Speculation and Simulation”
Charles V. Robino, an AWS Fellow,
holds a PhD in materials engineering
from Lehigh University. He joined
Sandia National Laboratories in 1988
and is a Distinguished Member of the
Technical Staff in the Metallurgy and
Materials Dept. He has authored more
than 100 technical publications and
made more than 100 technical presen-
60 WELDING JOURNAL / FEBRUARY 2016
William F. Newell Jr. is cited for his
expertise in the control of corrosion
and residual stresses, and for his devel-
opment of procedures to comply with
the regulatory requirements of the nu-
clear, fossil fuel, and hydroelectric
power-generation fields, as well as the
manufacturing, heavy construction,
highway building, and autoracing
industries.
André Odermatt is recognized for
serving the welding industry for more
than 50 years in the European and
Unites States markets, designing a
wide range of welding equipment and
participating in the design and con-
struction of a manufacturing facility.
Odermatt established a welding mu-
seum to chronicle the history of weld-
ing and bring students into the weld-
ing industry.
William A. Rice Jr. is recognized for
his outstanding leadership in the weld-
ing industry, serving various roles in
welding supply companies, including
his own family-owned business and as
interim executive director of the
American Welding Society. He contin-
Jeffrey L. Mitchell YuMing Zhang
tations. Robino has held adjunct facul-
ty appointments at Lehigh University
and the Colorado School of Mines, is
recent past chairman of the New Mexi-
co Tech Materials Dept. External Advi-
sory Board, and a member of ASM
International.
Adams Memorial Membership Award
This award recognizes educators for
outstanding teaching activities in under-
graduate and postgraduate engineering
institutions.
Todd A. Palmer holds a PhD in ma-
terials science and engineering from
Pennsylvania State University, where
he is a research senior associate and an
associate professor of materials sci-
uously serves the industry as a con-
sultant to a number of corporations
with ties to the welding profession,
and is a member of advisory boards for
several others.
Carolyn K. Russell is recognized for
devoting more than 30 years to the
welding industry and developing inno-
vative metals-processing techniques to
provide manufacturing engineering
support to Marshall Space Flight Cen-
ter projects. She is an author of more
than 30 technical papers, books, and
handbooks.
Phillip I. Temple is recognized for
his 40-year career devoted to the
power-generation industry, consulting
for clients and specializing in design of
weldments, welded repairs and fabri-
cation, codes and standards, material
selection, failure analysis, and quality
assurance audits. He has provided
technical skills for welding nonde-
structive examination, material selec-
tion, coatings, corrosion, and in sup-
port of mechanical and civil
engineering design for numerous pub-
lications and handbooks.
Yan Shao
ence and engineering. Before joining
the university, Palmer was a metallur-
gist at Lawrence Livermore National
Laboratory. His current research fo-
cuses on the laser and electron beam
joining and additive manufacturing of
metallic materials.
Howard E. Adkins Memorial
Instructor Membership Award
This award recognizes instructors for
their outstanding teaching accomplish-
ments at the high school, trade school,
technical institute and community college
levels.
Jeffrey L. Mitchell, an AWS CWI
and CWE, is dean of Industrial Tech-
nologies at Kirkwood Community Col-

Jose E. Ramirez David R. Sigler
lege, Cedar Rapids, Iowa. Prior to be-
coming dean, he served as program di-
rector of industrial education for 25
years. He has also owned and operated
a stainless steel and aluminum manu-
facturing company specializing in gov-
ernment contracts.
Robert J. Conkling Memorial Award
This award is presented to the schools
that trained the two first-place winners
in the SkillsUSA welding competition.
2015 SkillsUSA Championships
Gold Medalist First­Place Schools
High School: S&W Washtenaw Consor-
tium, Saline, Mich.
Postsecondary School: Penn College of
Technology, Williamsport, Penn.
A. F. Davis Silver Medal Award
This award recognizes authors of pa-
pers published in the Welding Journal
during the previous calendar year that
represent the best contributions to the
progress of welding in the categories of
Machine Design, Maintenance and Sur-
facing, and Structure Design.
Machine Design
“Gas Metal Arc Welding Enhanced by
Using a Pulsed Laser”
YuMing Zhang, an AWS Fellow,
holds the James R. Boyd Professorship
in Electrical Engineering at the Uni-
versity of Kentucky, and is the founder
and president of Adaptive Intelligent
Systems, LLC, Lexington, Ky.
Yan Shao received his PhD from the
University of Kentucky in electrical
engineering. He is currently a welding
engineer at Caterpillar, Inc., Mossville,
Ill.
Maintenance and Surfacing
“Characterization of CSC-GMAW Tita-
nium-Rich Weld Overlays”
Jose E. Ramirez received his PhD in
metallurgical and materials engineer-
ing from Colorado School of Mines. He
has more than 25 years of experience
Sampath K. Vanimisetti
in materials, welding, and corrosion
technologies.
Structure Design
“Improving Fatigue Performance of
Spot Welds in Advanced High-
Strength Steels”
David R. Sigler received his PhD in
metallurgical engineering from Wayne
State University, Detroit, Mich., and
has since worked at the General Mo-
tors Research Laboratory. As a Nation-
al Science Foundation Fellow at WSU,
his research focused on understanding
the fatigue behavior of aluminum
alloys.
Sampath K. Vanimisetti works as a
senior technical lead and optimization
engineer in the Vehicle Engineering
Dept. of General Motors. He has pub-
lished 11 scientific papers and general
articles and holds four patents.
Distinguished Welder Award
This award recognizes individuals
who have exceptional welding skills and
experiences related to all aspects of the
art of welding.
David Elsloo, an AWS CWI, CWE,
and CWS, is the senior training and
development specialist for welding in-
struction at Vermeer Corp., Pella,
Iowa. During his 29 years with the
company, he has served as a welding
technician, group leader, welder, engi-
neering technician, job shop foreman,
and sales representative.
Excellence in Robotic and Automated
Arc Welding Award
This award recognizes significant in-
dividual achievements in the area of ro-
botic arc welding.
Jeffrey S. Noruk, an AWS CWI and
Counselor, has a master of science in
engineering management from Mil-
waukee School of Engineering. He is
president of Servo Robot Corp., and
was previously the manager of R&D
for both Tower Automotive and its
SOCIETY NEWS
David Elsloo Jeffrey S. Noruk
predecessor, A.O. Smith Automotive.
Noruk holds two patents for improv-
ing overall performance of automotive
structures.
W. H. Hobart Memorial Award
This award is presented to the authors
of the paper published in the Welding
Journal during the previous calendar
year that describes the best contribution
to pipe welding, the structural use of
pipe, or similar applications, excluding
the manufacture of pipe.
“Weldability of Niobium-Containing
High-Strength Steel for Pipelines”
Alexander Bortsov graduated from
Moscow Engineering-Physical Insti-
tute with a focus in physics of metals
and metallurgical science. His research
focuses on dual-phase automotive
steels, materials mechanics, low-alloy
and carbon steels, cladding metal,
weld metal, hot rolling, pipe produc-
tion, and quality of metal products.
Igor I. Frantov received his PhD
from Moscow Metallurgical Institute
with a focus in physical and chemical
welding processes. He is the head of
laboratory at I.P. Bardin Central Re-
search Institute for Ferrous Metallur-
gy Laboratory of Pipe-rolling, Technol-
ogy, Weldability, and Heat Treatment
in Moscow, Russia.
A. A. Velichko is with Izorsky Pipe
Plant, Kolpino, Russia.
I. Y. Utkin is with I.P. Bardin Cen-
tral Research Center for Ferrous Met-
allurgy, Moscow, Russia.
Honorary Membership Award
This award is presented to a person of
acknowledged eminence in the welding
profession or to an individual who is cred-
ited with exceptional accomplishments in
the industry.
Zhili Feng, an AWS Fellow, is group
leader of materials processing and
joining at Oak Ridge National Labora-
tory. Additionally, Feng is joint faculty
FEBRUARY 2016 / WELDING JOURNAL 61
SOCIETY NEWS
Alexander Bortsov Igor I. Frantov
David J. Landon Xiao Huang
professor at The Univeristy of Ten-
nessee, Knoxville, and guest professor
at Tsinghua University, China.
Thomas J. White, an AWS CWI and
Silver Member, is a maintenance engi-
neer and welder at the Beaver Valley
Power Station Duquesne Light/
FirstEnergy, Hookstown, Pa.
International Meritorious Certificate
Award
This certificate recognizes an individ-
ual who has made significant contribu-
tions or services to benefit the worldwide
welding industry.
Ajit K. Mukherjee is the executive
director of technical at Techno Electric
and Engineering Co., Ltd., Kolkata, In-
dia. He is a founding member of the
Indian Institute of Welding, and
served as its president from
2005–2008.
William Irrgang Memorial Award
This award recognizes the individual
who has done the most to enhance the
American Welding Society’s goal of ad-
vancing the science and technology of
welding over the past five years.
David J. Landon, an AWS CW, CWS,
CWI, and Counselor, is the manager of
welding engineering for Vermeer
Corp., Pella, Iowa. He has been a mem-
ber of the AWS D14 technical commit-
tee for Machinery and Equipment
62 WELDING JOURNAL / FEBRUARY 2016
Zhili Feng Thomas J. White
Jeffrey A. Badger Daryush K. Aidun
since 1993 and served as chair for six
years. He chaired the Technical Activi-
ties Committee for three years, served
on the board of directors from 2007
to 2011, was vice president from 2012
to 2014, and was the 2015 AWS
president.
Charles H. Jennings Memorial Award
This award recognizes the authors of
the most valuable paper written by a col-
lege student or faculty representative
published in the Welding Journal during
the previous calendar year.
“Brazing of CMSX-4 with a Boron- and
Silicon-Free Ni-Co-Zr-Hf-Cr-Ti-Al
Brazing Alloy”
Xiao Huang is a professor at Car-
leton University, Ottawa, Canada,
where she teaches materials- and man-
ufacturing-related courses. She holds
two U.S. patents and has published
one book and more than 130 peer-re-
viewed journal and conference papers.
James F. Lincoln Gold Medal Award
This award is presented for the paper
with a single author that represents the
best original contribution to the advance-
ment and use of welding published in the
Welding Journal during the previous cal-
endar year.
“Evaluation of Triangular, Engineered-
Shape Ceramic Abrasive in
Cutting Discs”
Ajit K. Mukherjee
Alireza Bahrami
Jeffrey A. Badger received his PhD
in mechanical engineering from Trini-
ty College in Dublin, Ireland. He works
as an independent expert consultant,
visiting companies around the world
and helping them improve their grind-
ing operations, set up research pro-
grams, and perform research into
grinding and abrasives.
McKay­Helm Award
This award is presented for best con-
tribution to the advancement of knowl-
edge of low-alloy steel, stainless steel, or
surfacing welding metals, involving the
use, development, or testing of these ma-
terials, as represented by articles pub-
lished in the Welding Journal during the
previous calendar year.
“Interaction of Gravity Forces in Spot
GTA Weld Pool”
Daryush K. Aidun received his PhD
in material science and engineering
from Rensselaer Polytechnic Institute.
He is a professor and chair of the Me-
chanical and Aeronautical Engineering
Department at Clarkson University.
Alireza Bahrami is a research and
development engineer at The Fulton
Companies, Pulaski, N.Y. He obtained
his PhD from Clarkson University in
mechanical engineering with a focus
on heat and mass transfer in welding
process.
Daniel T. Valentine earned his PhD
 SOCIETY NEWS

Daniel T. Valentine Yoshiaki Morisada Dennis D. Crockett Thomas J. Lienert Dean C. Phillips

Ali Ekrami Amir H. Kokabi Majid Pouranvari Richard T. Stone Eric J. Cox

in fluid dynamics from The Catholic
University of America. He is the affili-
ate director of the Clarkson Space
Grant Program, which is part of the
New York NASA Space Grant
Consortium.
Professor Koichi Masubuchi Award
This award is presented to an individ-
ual who has made significant contribu-
tions to the advancement of science and
technology of materials joining through
research and development.
Yoshiaki Morisada received his PhD
in environmental engineering from
Osaka University in Japan, where he
serves as a specially appointed associ-
ate professor at its Joining and Weld-
ing Research Institute.
Samuel Wylie Miller Memorial Medal
Award
This medal is awarded for meritorious
achievements that have contributed con-
spicuously to the advancement of the art
and science of welding and cutting.
Dennis D. Crockett earned a bache-
lor of science degree in physics from
John Carroll University and a bachelor
of science degree in metallurgical engi-
neering from Cleveland State Universi-
ty. While working for The Lincoln
Electric Co., he was awarded nine
welded-related patents and was vice
president of consumable R&D from
1993 to 2003. Crockett also serves on
several AWS technical committees.
National Meritorious Award
This award is given in recognition of
good counsel, loyalty, and devotion to the
affairs of the Society, and for promoting
cordial relations with industry and other
organizations.
Thomas J. Lienert, an AWS Fellow
and CWI, earned his PhD in materials
science and engineering from The
Ohio State University. He is a technical
staff member for R&D at Los Alamos
National Laboratory. Lienert is cur-
rently an AWS vice president, holds
various positions throughout AWS
committees, and serves as lead princi-
pal reviewer for the Welding Journal.
Dean C. Phillips graduated from
LeTorneau University and has more
than 40 years of experience in the
welding industry. He is the manager of
welding engineering for ITW, Hobart
Bros. Co. in Troy, Ohio.
Robert L. Peaslee
Memorial Brazing Award
This award recognizes the paper con-
sidered to be the best contribution to the
science or technology of brazing pub-
lished in the Welding Journal during the
previous calendar year.
“Diffusion Brazing Metallurgy of
IN718/Ni-Cr-Si-B-Fe/IN718”
Ali Ekrami received his PhD in ma-
terials science at the University of
Leeds in the United Kingdom. He has
been an academic member of the Ma-
terials Science and Engineering De-
partment at the Sharif University of
Technology, Tehran, Iran, since 1979.
Amir H. Kokabi is a professor at
Sharif University of Technology,
Tehran, Iran, where he has taught for
more than 40 years. He currently
teaches in the Department of Mathe-
matics and Science.
Majid Pouranvari received his PhD
in materials science and engineering
from Sharif University of Technology
in Iran, where he is currently an assis-
tant professor in the Dept. of Materi-
als Science and Engineering.
Plummer Memorial Education
Lecture Award
The award honors outstanding contri-
butions to the national education lectures
presented at the AWS FABTECH conven-
tion.
“The Physiological and Cognitive
Effects of Virtual Reality Training in
Welding”
Richard T. Stone received his PhD
in industrial engineering from the
State University of New York. He is an
associate professor in the Dept. of In-
dustrial and Manufacturing Systems
Engineering at Iowa State University.

FEBRUARY 2016 / WELDING JOURNAL 63

SOCIETY NEWS
Joseph Bundy Adrian Gerlich
Adam T. Hope John C. Lippold
His research focuses on human per-
formance engineering, particularly ap-
plied biomedical, biomechanical, and
cognitive engineering.
Private Sector Instructor
Membership Award
This award honors educators in the
welding community who teach in private
facilities and have, in the opinion of the
AWS Education Committee, advanced the
knowledge of welding to their students
through apprenticeship programs, inter-
nal corporate training programs, and
similar nonpublic education activities.
Eric J. Cox, an AWS CWE, CWI, and
CWS, is a full-time welding instructor
at the Des Moines Area Community
College. Previously, he worked at
Johnson Machine Works as a group
leader and area manager, and at Ver-
meer Corp. as a welder and group
leader.
Warren F. Savage Memorial Award
This award recognizes the paper pub-
lished in the Welding Journal Research
Supplement during the previous calendar
year that best represents innovative re-
search resulting in a better understand-
ing of the metallurgical principles related
to welding.
“Characterization of High-Strength
Weld Metal Containing Mg-Bearing
Inclusions”
64 WELDING JOURNAL / FEBRUARY 2016
Hossein Izadi Patricio F. Mendez
Jerry E. Gould Donald B. Decorte
Joseph Bundy received his bachelor
of science degree in metallurgical engi-
neering from The Ohio State Universi-
ty. He has been employed by Hobart
Bros. Co. for almost 30 years, where he
is currently the director of advanced
engineering for tubular wires, oversee-
ing product and process R&D.
Adrian Gerlich obtained his PhD in
materials science and engineering at
the University of Toronto. He has been
an associate professor at the Universi-
ty of Waterloo since 2012, and has
been appointed the NSERC/Trans-
Canada Industrial Research Chair in
Welding for Energy Infrastructure
since 2014.
Hossein Izadi earned his master of
science in materials science and engi-
neering from Ferdowsi University of
Mashhad in Mashhad-Iran. He joined
the Canadian Center of Welding and
Joining at the Dept. of Chemical and
Materials Engineering at University of
Alberta as a graduate student, where
he mainly worked on welding metal-
lurgy of ferrous and nonferrous alloys.
Patricio F. Mendez, an AWS Fellow,
is the Weldco/Industry chair in Weld-
ing and Joining and director of the
Canadian Centre for Welding and
Joining, University of Alberta. He
holds a PhD in materials engineering
for the Massachusetts Institute of
Technology.
Eric W. Fusner
Robert E. Shaw Jr.
William Spraragen Memorial Award
This award recognizes the best paper
published in the Welding Journal Re-
search Supplement during the previous
calendar year.
“Development of High-Cr, Ni-
Based Filler Metals Using Combined
Computational and Experimental
Techniques”
Eric W. Fusner received his master
of science degree in welding engineer-
ing from The Ohio State University.
He is a metallurgist at Cummins Emis-
sion Solutions where he built the ma-
terials engineering function within
CES and developed an ISO-16949-
compliant materials laboratory at the
technical facility in Stoughton, Wis.
Adam T. Hope is currently finishing
his PhD in welding engineering at The
Ohio State University. His work in-
volves optimizing a new alloy compo-
sition for construction and repair of
nuclear reactor components.
John C. Lippold, an AWS Fellow,
has served on the faculty of the Weld-
ing Engineering Program at The Ohio
State University since 1995. He re-
ceived his PhD at Rensselaer Polytech-
nic Institute, and has coauthored three
textbooks and published more than
250 papers.
R. D. Thomas Memorial Award
This award recognizes a member of
the American Council of the Internation-

Join or Renew:
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First Name:___________________________________________________________________ M.I:_______
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E q Fabricated metal products
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A.) OPTIONAL Book Selection (Choose from 25 titles; up to a $192 value; includes shipping & handling) 11 q Consultant
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ONLY ONE SELECTION PLEASE. For more book choices visit https://app.aws.org/membership/books 18 q Customer Service
q Jefferson’s Welding Encyc.(CD-ROM only) q Design & Planning Manual for Cost-Effective Welding q Welding Metallurgy q Welding Inspection Handbook 19 q Other

Welding Handbook Selections: q WHB (9th Ed., Vol. 5) q WHB (9th Ed., Vol. 4) q WHB (9th Ed., Vol. 3) q WHB (9th Ed., Vol. 2) q WH (9th Ed., Vol. 1) Technical Interests (Check all that apply)
Pocket Handbook Selections: q PHB-1 (Arc Welding Steel) q PHB-2 (Visual Inspection) q PHB-4 (GMAW / FCAW) A q Ferrous metals
B q Aluminum
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q Individual Members outside North America (note: digital delivery of WJ is standard)..............................................$50 D q Advanced materials/Intermetallics
E q Ceramics
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NOTE: Dues include $17.30 for Welding Journal subscription and $4.00 for the AWS Foundation. G q Arc welding
H q Brazing and soldering
I q Resistance welding
STUDENT MEMBERSHIP J q Thermal spray
K q Cutting
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Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card. S q Machinery
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CC#:____________ / ____________ / ____________ / ____________ Expiration Date (mm/yy) ________ / ________ V q Pressure vessels and tanks
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OFFICE USE ONLY Check #:_______________________________ Account #____________________________________ 1 q Robotics
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REV. 11/15

al Institute of Welding (IIW) or an AWS
member who has made a substantial con-
tribution to IIW activities.
Jerry E. Gould, an AWS Fellow, re-
ceived his PhD degree in metallurgical
engineering and materials science
from Carnegie-Mellon University.
Since 1985, he has been on the senior
technical staff at EWI, concentrating
on forge welding activities.
Elihu Thomson
Resistance Welding Award
This award recognizes an outstanding
contribution to the technology and appli-
cation of resistance welding, including
SOCIETY NEWS
equipment innovations, unique applica-
tions in production, a published paper, or
other activity of merit.
Donald B. DeCorte, an AWS Coun-
selor, received his degree from RETS
Electronic School and passed the first,
second, and third class FCC license ex-
aminations. He is the vice president at
RoMan Mfg., and has served a number
of committees within the AWS Detroit
and West Michigan Sections.
George E. Willis Award
This award is presented to an individ-
ual for promoting the advancement of
welding internationally, by fostering co-
operative participation in areas such as
technology transfer, standards rationali-
zation, and promotion of industrial
goodwill.
Robert E. Shaw Jr. is a professional
engineer and president of Steel Struc-
tures Technology Center, Inc. He
chairs IIW’s Select Committee on
Quality Management, and serves on
IIW’s Working Group on Regional Ac-
tivities, Working Group on Standardi-
zation, and Commission XIII on Fa-
tigue of Welded Components and
Structures.

Member Service Anniversaries Recognized at FABTECH

AWS President Dave Landon (far left) is shown with Gold Members celebrating 50 years of service to the Society — David Belforte, Jimmie
Bolton, Paul Miller, and Damian Kotecki.

Life Members, with 35 years of service to the Society, included Mark Anderson, James Appledorn, Craig Case, Frank Cichocki, Randall Coun­
selman, Donald DeCorte, Carl Dichler, Jerry Dutton, Thomas Ferri, Dave Fischer, Karl Fogleman, William Herdman, Timothy Hirthe, Paul
Huffman, Douglass Juhl (accepting posthumously for their father were Tim Juhl and Colleen Johnson), William Komlos, Joseph Laughlin,
Vernon Lewis, Thomas McCormack, William Overshiner, Mark Peterson, Michael Rebenack, Ronald Ruch, Larry Schweinegruber, Harland
Thompson, Philip Torchio III, Robert Walker, Jerry Warren, and Dan Zabel. Everyone is not pictured.

FEBRUARY 2016 / WELDING JOURNAL 67

SOCIETY NEWS

Silver Members celebrating 25 years of membership are Akira Baba, Stephen Bruno, Chris Chwala, Robert Cohen, Dennis Eck, Alan Freder­
ick, Viji Kuruvilla, Scott Lord, Clyde Martin, Robert Richwine, Marvin Rozendaal, and Douglas Steyer. Everyone is not pictured.

Sections Recognized for Sponsoring Welding Scholarships

Representing the Sections sponsoring new scholarships are Monty Rodgers, Darin Owens, and Karl Fogleman (Nebraska); Bill Rice and
Alexyia Paige (New Mexico); Nancy Cole (North Central Florida); and Michael Sebergandio (Reading).

TECH TOPICS
Technical Committee Meetings
All AWS technical committee
meetings are open to the public. Con-
tact the staff member listed at
(800/305) 443-9353 for information.
February 8, 9. D20 Committee on Ad-
ditive Manufacturing. Park City, Utah.
Contact: P. Portela, ext. 311,
pportela@aws.org.
February 9. Committee on Personnel
& Facilities Qualification. Miami, Fla.
Contact: S. P. Hedrick, ext. 305,
steveh@aws.org.
February 9–11. D15 Committee and
Subcommittees on Railroad Welding.
Dallas, Tex. Contact: J. Rosario,
ext. 308, jrosario@aws.org.
February 17. B2F Subcommittee on
Plastic Welding Qualification. Miami,
Fla. Contact: S. P. Hedrick, ext. 305,
steveh@aws.org.
February 17. G1A Subcommittee
on Hot Gas Welding and Extrusion
Welding. Miami, Fla. Contact:
S. P. Hedrick, ext. 305, steveh@aws.org.
February 24–26. J1F-Task Group 6 of
the J1 Committee on Resistance Weld-
ing Equipment. St. Petersburg, Fla.
Contact: M. E. Rodriguez, ext. 310,
mrodriguez@aws.org.
February 24–26. J1G-Task Group 7 of
the J1 Committee on Resistance Weld-
ing Equipment. St. Petersburg, Fla.
Contact: M. E. Rodriguez, ext. 310,
mrodriguez@aws.org.

68 WELDING JOURNAL / FEBRUARY 2016


New Standards Projects
Development work has begun on
the following new or revised stan-
dards. Affected individuals are invited
to contribute to their development.
Participation in all AWS Technical
committees is open to all persons.
C2.25/C2.25M:2012 (R201X), Spec-
ification for Thermal Spray Feedstock-
Wire and Rods. This specification pro-
vides the as-manufactured chemical
composition classification require-
ments for solid and composite wires
and ceramic rods for thermal spraying.
Requirements for standard sizes,
marking, manufacturing, and packag-
ing are included. Stakeholders: Ther-
mal spray community. Reaffirmed
Standard. Contact: J. Rosario, ext.
308, jrosario@aws.org.
Revised Standard Approved by ANSI
C3.4M/C3.4-2016, Specification for
Torch Brazing. Approval Date:
12/15/2015.
C3.5M/C3.5-2016, Specification for
Induction Brazing. Approval Date:
12/15/2015.
C3.6M/C3.6-2016, Specification for
Furnace Brazing. Approval Date:
12/15/2015.
ISO Draft Standards for Public Review
Copies of Draft International Stan-
dards are available for review and com-
ments through your national stan-
dards body, which in the United States
is ANSI, 25 West 43rd Street, Fourth
Floor, New York, NY 10036; (212)
642-4900. Any comments regarding
ISO documents should be sent to your
national standards body.
In the United States, if you wish to
participate in the development of In-
ternational Standards for welding,
contact Andrew Davis at AWS, 8669
NW 36 St., #130, Miami, FL 33166-
6672; (305) 443-9353 ext. 466, e-mail:
adavis@aws.org. Otherwise, contact
your national standards body.
ISO/DIS 15296, Gas welding equipment
— Vocabulary — Terms used for gas
welding equipment.
ISO/DIS 5175-1, Gas welding equip-
SOCIETY NEWS
ment — Safety devices —Part 1: Incor-
porating a flame (flashback) arrestor.
ISO/DIS 5175-2, Gas welding equip-
ment — Safety devices —Part 2: Not in-
corporating a flame (flashback) arrestor.
Errata
D1.1/D1.1.M:2015
Structural Welding Code — Steel
The following errata have been
identified and will be incorporated
into the next reprinting of this
document.
Page 105, Figure 3.5: Note “a” re-
place “5.14” with “5.13.”
Page 105, Figure 3.5: Note “a” re-
place “Table 3.7” with Table “3.6.”
Page 105, Figure 3.5: Note “b” re-
place “5.22.1” with “5.21.1.”
Page 105, Figure 3.5: replace “ALL
DIMENSIONS IN mm” with “ALL DI-
MENSIONS IN inches.”
Page 105, Figure 3.5: replace weld-
ing process “FMAW” with “GMAW.”
Page 106, Figure 3.5: replace weld-
ing process “FMAW” with “GMAW.”
Page 135, Table 4.10: replace title
“Welder and Welding Operator Quali-
fication-Production Welding Positions
Qualified by Plate, Pipe, and Box Tube
Tests (see 4.15.1)” with “Welder and
Welding Operator Qualification-Pro-
duction Welding Positions Qualified
by Plate Tests (see 4.15.1).”
Page 139, Table 4.14: add a vertical
line between Welding Process and Test
Location.
Page 198, 6.17.7: add an additional
sentence to the clause “Steel backing
shall not be considered part of the
weld or weld reinforcement in IQI
selection.”
Page 245, 7.2.6: replace “ASTM A29,
Standard Specification for Steel Bars,
Carbon and Alloy, Hot-Wrought, General
Requirements for Grades 1010 through
1020” with “ASTM A29/A29M-12e1,
Standard Specification for General Re-
quirements for Steel Bars, Carbon and
Alloy, Hot-Wrought, Grades 1010
through 1020.”
Page 502, C-4.8: replace the sen-
tence “However, departure from vari-
ables which affect the mechanical or
chemical composition of material
properties, or soundness of the weld-
ment is allowed without requalifica-
tion.” with “However, departure from
variables which affect the mechanical
or chemical composition of material
properties, or soundness of the weld-
ment is not allowed without requalifi-
cation.”
Page 590, Index-Electrodes, welder
qualification groups: replace “Table
9.15” with “Table 4.13.”
Page 591, Index-Filler Metals,
welder group designation: replace
“4.3.2.1” with “4.2.3.1 and Table 4.13.”
Page 591, Index-Fillet Welds, maxi-
mum size: replace “2.4.2.8” with
“2.4.2.9.”
Page 596, Index-Skewed T-joints:
replace “Figure 3.44” with “Figure 3.4.”
Page 596, Index-Statically Loaded
Structures, backing: replace “2.6.4.1”
with “5.9.1.5.”
Opportunities to Contribute to
AWS Technical Committees
The following committees welcome
new members. Some committees are
recruiting members with specific in-
terests in regard to the committee’s
scope, as marked below: Producers (P),
General Interest (G), Educators (E),
Consultants (C), and Users (U). For
more information, contact the staff
member listed or visit aws.org/
w/a/technical/comm_stand.html.
M. E. Rodriguez, ext. 310, mrodriguez@
aws.org
Automotive, D8 Committee (C,
E, G, U). Resistance welding, C1
Committee (C, E, G, U). Resistance
welding equipment, J1 Committee
(E, G, U).
J. Douglass, ext. 306, jdouglass@aws.org
Methods of weld inspection, B1
Committee (E, C, U). Brazing and
soldering, C3 Committee (G, E, C, U).
Welding in marine construction,
D3 Committee (G, E, C, U). Welding
of machinery and equipment, D14
Committee (G, E, C, U).
FEBRUARY 2016 / WELDING JOURNAL 69
SOCIETY NEWS
A. Naumann, ext. 313, anaumann@aws.org
Oxyfuel gas welding and cutting, C4
Committee (C, E, G, U). Friction weld­
ing, C6 Committee. Welding practices
and procedures for austenitic steels,
D10C Subcommittee. Aluminum pip­
ing, D10H Subcommittee. Chromium
molybdenum steel piping, D10I Sub-
committee. Welding of titanium pip­
ing, D10K Subcommittee. Purging and
root pass welding, D10S Subcommit-
tee. Low­carbon steel pipe, D10T Sub-
committee. Orbital pipe welding,
D10U Subcommittee. Duplex pipe
welding, D10Y Subcommittee. Reac­
tive alloys, G2D Subcommittee (G). Ti­
tanium and zirconium filler metals,
A5K Subcommittee.
P. Portela, ext. 311, pportela@aws.org
High­energy beam welding and cut­
ting, C7 Committee. Robotic and auto­
matic welding, D16 Committee (C, E,
G). Hybrid welding, C7D Subcommit-
tee (G).
J. Rosario, ext. 308, jrosario@aws.org
Procedure and performance qualifi­
cation, B2 Committee (E). Thermal
spraying, C2 Committee (C, E, G, U).
Welding iron castings, D11 Committee
(C, E, G, P, U). Railroad welding, D15
Committee (E, G).
J. Molin, ext. 304, jmolin@aws.org
Welding sheet metal, D9 Commit-
tee (G, P).
S. Hedrick, ext. 305, steveh@aws.org
Joining of plastics and composites,
G1 Committee. Safety and Health
Committee (E, U, G, C). Mechanical
testing of welds, B4 Committee.
R. Gupta, ext. 301, gupta@aws.org
Magnesium alloy filler metals, A5L
Subcommittee.

MEMBERSHIP ACTIVITIES

New AWS Supporters Future of Basra Company for QHSE QA/QC Inspecciones Tecnicas
Training Ricardo Lyon 988
Sustaining Members P.O. Box 2131 Providencia
Basra, Iraq 42001 Santiago, Santiago Metropolitana
Arc Training and Consultation Services Region Chile
2756 Transit Rd. Goad Co.
West Seneca, NY 14224 144 S. Kentucky Ave. Sea Box, Inc.
arctraining4u.com Independence, MO 64053 1 Sea Box Dr.
Arc Training and Consultation Servies Cinnaminson, NJ 08077
is a full-service weld training, weld H & H Resistance Welders
consultation, and weld testing compa- 28701 S. Hwy. 125 Educational Institutions
ny, offering training in all welding Afton, OK 74331
processes on all materials, of all levels. Ben Franklin Career Center
IPG Photonics 500 28 St.
Affiliate Companies 46695 Magellan Dunbar, WV 25064
Novi, MI 48377
All Tech Machine & Tool, Inc. Harper Independent School District
2700 W. Center St. Iron Fab, LLC 23122 W. Hwy. 290
Greenwood, AR 72936 1771 Progress Ave. Harper, TX 78631
Columbus, OH 43207
Ally Equipment Solutions Hi­Tech Aerospace Aviation Academy
3035 S. Dye Rd. Maxweld HC03 BOX 13545
Flint, MI 48507 Cra 39 39 D 59 Yuaco, PR 00698
Medellin Antioquia 050016633
Andre's Welding Services Colombia Horry Georgetown Technical College
13221 Lakeland Rd. 2050 Hwy. 501 E.
Santa Fe Springs, CA 90670 Modern Piping, Inc. Conway, SC 29526
500 Walford Rd. SW
CP Industries Cedar Rapid, IA 52404 Institute of Technical Trades
2214 Walnut St. 749 Warden Ave.
Mckeesport, PA 15132 Parhoon Toos Toronto, ON Canada, M1L 4A8
No. 318, Parvin Etesami St., Between
Clamptek USA, Inc. 24th and 26th, Mashhad S. Khorasan Tyler ISD Career and Technical Ctr.
2913-I Saturn St. Brea 9164867148 Iran 3013 Earol Campbell Pky.
Los Angeles, CA 92821 Tyler, TX 75702
Pearl Harbor Naval Shipyard & IMF
Dakota Ironworks, LLC 667 Safeguard St., Ste. 100 Western Area Career & Tech Ctr.
715 4th St. Code 134-2 Material Science & Eng Br 688 Western Ave.
Edgeley, ND 58433 JBPHH, HI 96860 Canonsburg, PA 15317

70 WELDING JOURNAL / FEBRUARY 2016

 SOCIETY NEWS
Westover Job Corps Ctr. WEMCO Holds Meet and Greet at FABTECH
103 Johnson Rd.
Chicopee, MA 01022

White Oak ISD

200 S. White Oak Rd.
White Oak, TX 75693

Supporting Company Members

Alaska Logistics, LLC
P.O. BOX 3512
Seattle, WA 98124
Challenge Mfg.
3914 Maple Crest Ct.
Grand Rapids, MI 49546

Coastal Industrial Service

3615 Peace St. At the AWS Foundation Meeting, held recently at FABTECH, Chairman Bill Rice (left) pres­
Farmville, NC 27828 ents outgoing AWS Treasurer Bob Pali with a welder statue for his six years of service.

Rosler Metal Finishing

1551 Denso Rd.
Battle Creek, MI 49037
Welding Distributor Members
MDM Tool Supply, LLC
P.O. BOX 1710
Broussard, LA 70518
Member­Get­A­Member
Campaign
Listed here are the members partici-
pating in the Member-Get-A-Member
Campaign that ran from Jan. 1 to Dec.
31, 2015. Members receive 5 points for
each individual Member and 1 point
for every Student Member they recruit.
For campaign rules and a prize list,
see page 65 of this Welding Journal.
Standings as of December 19 are listed.
If you have any questions regarding
your member proposer points, please
call the AWS Membership Department
at (800) 443-9353, ext. 480.
J. W. Morris, Mobile — 223
G. Bieniecki, Cleveland — 164
J. N. Carney, W. Michigan — 147
M. A. Pelegrino, Chicago — 127
M. G. Poss, Detroit — 115
M. Krupnicki, Rochester — 88
H. H. Hughes, Mahoning Valley — 86
D. Sorensen, Northwest — 58
G. G. Schroeter, Nebraska — 50
R. D. Zabel, Southeast Nebraska — 40
G. L. Gammill, NE Mississippi — 38
C. L. Claycomb, Kansas City — 37
T. Geisler, Pittsburgh — 36
D. E. Newman, Ozark — 36
P. Stigall, Chicago — 35
A. D. Stute, Madison-Beloit — 35
D. A. Saunders, Lakeshore — 34
J. J. Russell, Fox Valley — 27
R. L. Gilmer, Houston — 26
M. Ball, Canada — 25
B. R. Hackbarth, Milwaukee — 25
J. King, South Carolina — 25
R. F. Purvis, Sacramento — 25
R. Riggs, Tulsa — 25
M. J. Spodar, Dayton — 25
R. L. Thompson, Kansas — 25
S. Thornhill, St. Louis — 25
S. P. Siviski, Maine — 23
J. P. Theberge, Boston — 21
N. Baughman, Stark Central — 20
D. L. Galiher, Detroit — 20
B. Reidler, Houston — 20
B. Scott, Dayton — 20
R. Sublette, Colorado — 20
D. P. Thompson, SW Virginia — 20
R. A. Washenesky, Arrowhead — 20
W. H. Wilson, New Orleans — 19
R. J. Ferguson, Indiana — 18
J. Foley, Pittsburgh — 17
R. H. Randall, Detroit — 16
R. L. Richwine, Detroit — 16
M. A. Stevenson, J.A.K. — 16
M. Cyphert, NW Pa. — 15
C. A. Donnell, NW Ohio — 15
S. D. Lord, Rochester — 15
G. S. Mulee, South Carolina — 15
J. N. Burke, Louisville — 14
A. I. Duron, New Orleans — 14
W. D. Elliott, Houston — 14
D. Gibbons, Philadelphia — 14
S. H. Slagle, Cleveland — 14
K. J. Pruitt, Kansas City — 13
E. Sotack, Puget Sound — 13
B. Giordano Jr., Philadelphia — 12
C. A. Renfro, Chattanooga — 11
AWS Member Counts
January 1, 2016
Sustaining.................................595
Supporting ...............................353
Educational...............................730
Affiliate.....................................651
Welding Distributor ...................55
Total Corporate .......................2384
Individual ...........................60,427
Student + Transitional ...........12,089
Total Members ..................72,516

FEBRUARY 2016 / WELDING JOURNAL 71

SOCIETY NEWS
AWS Participates at Weld India

AWS personnel are shown with international representatives at Weld India in Navi Mumbai, India, held December 10–12, 2015. From left
are Jeff Kamentz, AWS, Jagjeet Singh, BSB Edge, Jugal Desai, Eurotech, Amey Salvi, Intertek, Sajesh Bhoir, BSB, and Mike Walsh, AWS.

A2 Committee Holds Fall Meeting

The A2 Committee on Defintions and Symbols (subcommittees A2B Definitions AWS A3.0 and A2C Symbols A2.4) held their Fall 2015
meeting in Columbus, Ohio, at the Edison Welding Institute. In attendance were (from left) Bill Beckman, Bryan Worley, JP Christein, John
Gullotti, Dave Beneteau, Chris Lander, Chuck Ford, Richard Holdren, Pat Newhouse, Ben Finney, Steve Borrero, Mike Ludwig, Nancy Porter,
Ben Grimmett, Johnny Dingler, and Larry Barley.

72 WELDING JOURNAL / FEBRUARY 2016

BY ANNIK BABINSKI — ababinski@aws.org
SECTION NEWS
Justin Heistand received the Section
District 1 Appreciation Award for his service as District 4
Douglas Desrochers, director the Lancaster Section chairman, and Stewart A. Harris, director
(508) 763-8011 Merilyn McLaughlin received her 25- (919) 824-0520
dadaws@comcast.net year Silver Member Award. stewart.harris@altec.com

District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com

Parkside CTE Student Chapter

December 18
Location: Parkside Career and Techni-
cal Education, Salisbury, Md.
Event: The Student Chapter collected
more than 190 cans of food to support
District 3 Conference — Left — Justin Heistand (from left) receives the Section Apprecia­
the Red Men food basket program. tion Award for his service as the Lancaster Section chairman from Mike Sebergandio, Dist.
Members have participated for several 3 director, and David Watson, Lancaster Section secretary. Right — Merilyn McLaughlin
years. recieves her 25­year Silver Member Award from Mike Sebergandio (from left), Dist. 3 di­
rector, Lorena Cora, AWS National Representative, and Richard Heisey, Reading Section
chairman.
District 3
Michael Sebergandio, director
(717) 471-2065
drweld13@gmail.com

District Conference
June 5
Location: Heritage Hills Golf Resort,
York, Pa.
Event: The District held its annual
conference in the summer. It was a
great opportunity for all of the Sec-
tions to come together and discuss the
past year’s successes, areas for im-
provement, ideas, and more. Lorena District 3 Conference — District Conference attendees are seen together: (from left) Front
Cora visited as the AWS National rep- row: Justin Heistand, Richard Heisey, Merilyn McLaughlin, and AWS Representative
resentative and briefed attendees on Lorena Cora. Back row: Mike Sebergandio, Dean Whitmer, Jason Deiter, Bradley Brand­
the latest from AWS headquarters. meir, Tom Jacobs, David Watson, Marc Malone, and Sharon Bally.

Parkside CTE Student Chapter — Student members pose for a photo with the cans they collected for the Red Men food basket program.

FEBRUARY 2016 / WELDING JOURNAL 73

SECTION NEWS
District 5
Carl Matricardi, director
(770) 356-2107
cmatricardi@aol.com

ATLANTA
October 13, 15
Location: Cumming, Ga., and Ac-
worth, Ga.
Speaker: Greg Engeron, president, Gas
& Supply – Georgia/South Carolina ATLANTA — Gas & Supply employees cut the opening ribbon with the Mayor of Acworth.
Division
Company Affiliation: EAS, Gas &
Supply
Topic: Open house at both locations
Activities: The Section was invited to
participate in an educational meeting
at Gas & Supply, where vendors and
AWS committee members were pres-
ent to answer questions and perform
live demonstrations of welding prod-
ucts. The Cumming location had 3
Lanier Technical Colleges participate
and 52 students attend. The Acworth
location had 3 technical colleges (For- ATLANTA — Left — (From left) Rene Engeron, Section chairman, Wayne Engeron, Life
tis, Chatahochee, and Georgia Trade Member, and Greg Engeron, president, Gas and Supply – Georgia/South Carolina Divi­
School) attend with 50 students. The sion, at the AWS table. Right — (On right) Doug Rouner (Lucas Milhaupt) performs a
Section raffled off 18 student member- demonstration for students at the Gas & Supply opening.
ships and welding bags with necessary
class equipment. Committee members
discussed benefits of and opportuni-
ties in the welding industry.

District 6
Michael Krupnicki, director
(585) 705-1764
mkrup@mahanyweld.com

District 7 PITTSBURGH — Posing after the plant tour are (from left) Kent Beedon, manager of
Uwe Aschemeier, director
(786) 473-9540 welding fabrication, Elliott Co., George Kirk, AWS Pittsburgh chairman, Mike Storms, di­
rector of operations, Elliot Co., Doug Richards, senior welding engineer, Elliott Co., Tim
uwe@sgsdiving.com Hayden, pipe shop welder, Elliott Co, and unknown person.

PITTSBURGH — Section members explored the Elliott Co. on a plant tour.

74 WELDING JOURNAL / FEBRUARY 2016


PITTSBURGH
September 29
Location: Elliott Co., Jeannette, Pa.
Event: The Section had more than 50
members attend a plant tour at Elliott
Co. in Jeannette, Pa. The company is
part of the Ebara Corp. headquartered
in Tokyo, Japan, and has a global net-
work of full-service repair centers,
field service teams, and sales and sup-
port staff. For more than 100 years,
the company has been a supplier of ro-
tating equipment, including centrifu-
gal and axial compressors, steam tur-
bines, and power recovery expanders.
SECTION NEWS
equipment, characteristic products,
and the composing room.
MOBILE
November 19
Location: Spanish Fort, Ala.
Speaker: Jackie Morris, owner and
consultant, Morris Marine & Consult-
ing, LLC
Topic: AWS Certification programs
Activities: Fifty Section members at-
tended this buffet dinner and speaker
presentation. Jackie Morris, Morris
Marine & Consulting, discussed some MOBILE — Section members and guests
significant changes to two of the most enjoyed dinner together.
popular AWS certification programs,

District 8
D. Joshua Burgess, director
(931) 260-7039
djoshuaburgess@gmail.com

Holston Valley Student Chapter

December 3
Location: Kingsport, Tenn.
Company Affiliation: Northeast State
Community College
Event: Student Chapter end-of- Holston Valley Student Chapter — Northeast State Community College Student Chapter
semester luncheon at Northeast State members (from left) Corey Snodgrass, Chris Slone, Laurie Baker, Zach Farmer, Logan Jenk­
Community College. ins, Nicole Manz­Young, and Tim Crowe are seen after the end­of­semester lunch.

NORTHEAST TENNESSEE
October 27
Location: Maryville, Tenn.
Presenter: Greg Wagner, PhD
Company Affiliation: Advanced Cata-
lyst Systems, LLC (ACS)
Topic: Products and Fabrication at ACS
Activities: Dr. Greg Wagner, ACS, gave
an overview of catalysis and fabrication
at the company. Steve Frana then led a
tour of the fabrication facilities with NORTHEAST TENNESSEE — Section members and Advanced Catalyst Systems employees
demonstrations of some processes. are seen after Dr. Greg Wagner’s presentation on catalysis and fabrication.

District 9
Michael Skiles, director
(337) 501-0304
michaelskiles@cox.net

AUBURN­OPELIKA
December 7
Location: Samlip Alabama Co., Alexan-
der, Ala.
Event: Joint meeting with IEEE, Ala-
bama Section and plant tour
Activities: The Section met at Samlip MOBILE — Left — Clay Byron (left) presents Jackie Morris with his AWS Silver Certificate
Alabama Co., a producer of automotive in recognition of his 25­year AWS membership. Middle — Jack Sparkers is seen with his
lighting. The company speaker showed Silver Certificate in recognition of 25 years of AWS membership. Right — Robert (Bob)
members and guests some of the Bjorensen celebrates his Life Membership award.

FEBRUARY 2016 / WELDING JOURNAL 75

SECTION NEWS
the CWI and the CWS. Morris has
taught numerous CWI and CWS prepa-
ration courses. Clay Byron, Section
chairman, presented Morris with his
25-year Silver Member Certificate, and
the Section CWI of the Year Award for
2014–2015. Gary Williams won the
split-the-pot draw and donated his
winnings back to the Section. Door
prizes were given out.
District 10
Mike Sherman, director
(216) 570-9348
mike@shermanswelding.com
Company Affiliation: Lincoln Electric ables. Bryan Parker was awarded the
and AWS Section Treasurer CWI of the Year, Ben Tresler and De-
Topics: AWS District 10 gave Central layne Jacobs were awarded Instructor of
Tech High School, Erie, Pa., a check for the Year, and Robert Ward received his
their students to attend FABTECH. Silver Certificate for 25 years of AWS
membership.
November 18
Location: Fortis Institute, Erie, Pa.
Presenter: Steve Sherman
Company Affiliation: Airgas
District 11
Robert P. Wilcox, director
Event: Steve Sherman spoke about (734) 721-8272
Airgas’s Weld Analysis Program and ad-
rmwilcox@wowway.com
vised members on how to track and cut
costs on welding gases and consum-

MAHONING VALLEY
November 19
Location: Rachel’s Restaurant, Austin-
town, Ohio
Event: Executive Committee meeting
Topic: Planning session for 2015–2016
and recruitment session for new
2016–2017 volunteers

NORTHWEST PENNSYLVANIA
November 10
Location: FABTECH, Chicago, Ill. MAHONING VALLEY — The Section’s Executive Committee members are seen with guests
Presenter: Marty Sidall and District Director Mike Sherman.

NORTHWEST PENNSYLVANIA — Marty Sidall (left) presents Donna Bastien and Central Tech High School with $1000 for its students to at­
tend the FABTECH convention.

NORTHWEST PENNSYLVANIA — Left — Bryan Parker (right) receives the CWI of the Year
Award from Eric Speer. Middle Left — Delayne Jacobs receives the Instructor of the Year NORTHWEST PENNSYLVANIA — Steve
Award. Middle Right — Robert Ward receives the 25­year Member Award. Right — Ben Sherman (left) receives a speaker gift
Tresler receives the Instructor of the Year Award. from Jason Neff.

76 WELDING JOURNAL / FEBRUARY 2016


Ferris State U. Student Chapter — Over
four days, 40 Section members and
welding students from FSU took turns
ringing the bell for the Salvation Army.
SECTION NEWS
DETROIT
December 11
Location: Western Golf and Country
Club, Redford, Mich.
Presenter: Dan Wellman, Section
chairman, vice president — sales and
marketing for OBARA Corp. USA
Activities: The Section hosted its holi-
day party at the Western Golf and
Country Club in Redford, Mich. Dan
Wellman acted as host for the annual
get-together. One hundred and five
members and guests enjoyed Christ-
mas favorites played on the piano by
Phil Cole. More than 30 prizes, rang-
ing from gift baskets to laptops, were
given out at the raffle. The Section
would like to thank the organizing
committee (Andre Young, Susann
Morfino, and John and Liz Sutter) as
well as the sponsors.
Ferris State U. Student Chapter
November 16–19
Location: Big Rapids, Mich.
Topic: Ferris State University (FSU)
Student Chapter Salvation Army bell
ringing
Activities: Over the course of four
days, 40 students, both members of
the AWS student chapter and other
welding students, took turns bell ring-
ing for the Salvation Army.

University of Toledo Student

Chapter
October 2
Location: University of Toledo, Toledo,
DETROIT — Section members and their guests: (from left) Alexa Lewis, Tom Pecoraro, Ohio
Ryan Jones, Ashley Webel, Jeff Peterson, Jason Douglas, and Reggie Scales enjoyed the Event: Restart ceremony of Student
annual holiday party. Chapter. President Guo Bo and Vice
President Yiwei Bian organized the
meeting and invited professors and
graduate students to attend. They
spoke to attendees about the main
functions of the chapter and its future,
as well as demonstrated recent efforts
of the chapter. Dr. Efstratios Niko-
laidis, director of the MIME depart-
ment, congratulated the students on
their effort. Kathryn Rose, secretary
to the Dean, also attended and pledged
to help the chapter.

William D. Ford CTC Student

Chapter
Blackhawk Technical College Student Chapter — Student Chapter members are seen at November 18
the BTC winter carnival, where they contributed four games: (Front row from left) Student Location: William D. Ford Career and
Chapter Advisor Dan Crifase, Michael J. Summerbell, Blake Steiner, Tremont Galbreath, Technical College, Westland, Mich.
and Alex Breidenstein, (back row from left) Student Chapter Advisor Bobbi Bishofberger, Presenter: Coley McLean, department
Justin Bell, Josh Smith, Savannah White, Jocelyn Breidenstein, Johnathon P. Graham, Ryan head, Schoolcraft College
Peterson, and Levi Bobba Fett. Topic: Careers in welding
Activity: Coley McLean, department
head of Schoolcraft College’s welding
program, spoke to members about ca-
reers in welding.

District 12
Daniel J. Roland, director
(920) 241-1542
daniel.roland@airgas.com
University of Toledo Student Chapter — Student chapter members are seen after their
pizza dinner and first meeting of the 2015–2016 year.

FEBRUARY 2016 / WELDING JOURNAL 77

SECTION NEWS
Blackhawk Technical College
Student Chapter
December 5
Location: Blackhawk Technical College
(BTC), Janesville, Wis.
Activities: The Blackhawk Technical
College Student Chapter participated
in the annual BTC winter carnival by
designing and building four separate
games for the event: two mini golf
games, a plinko game, and a bean bag
toss game. The event was open to the
public and students. About two hun-
dred people attended.
District 13
John Willard, director
(815) 954-4838
kustom_bilt@msn.com
ST. LOUIS
December 4
Location: Royal Orleans Banquet Cen-
ter, St. Louis, Mo.
Topic: Awards Ceremony, Banquet
Dinner, Door Prizes, Raffles
Event: Section members and guests
enjoyed dinner, drinks, and dancing
before Section awards were distributed
and raffle prizes were drawn. Chair-
man Mike Kamp, Treasurer Vic
Shorkey, Richard Freezor, Travis
Jumper, Jim Cashdollar, Ray Connolly,
Richard Kemlage, and Titannova Laser
were all honored.
August 17
Location: Berkeley, Mo.
Presenter: Scott Thornhill, Student
Chapter advisor, and Katie Phelan,
Student Chapter chairman and St.
Louis Section publicity chairman
Topic: Activation of new AWS Student
Chapter
Event: The Vatterott Student Chapter
began in June 2015. It is the first Stu-
dent Chapter to form at the Vatterott
Colleges, and one of only five chapters
in the state of Missouri. The chapter
began with 15 students and has grown
to 40.

District 14
Robert L. Richwine, director
(765) 606-7970
rlrichwine2@aol.com

INDIANA
December 12
Location: Turkey Run State Park, Ind.
Activity: The Section held its annual
Christmas party at Turkey Run State
Park in west central Indiana. A high-
light of the event includes the presen-
tation of Section and District Director
Awards. Five ladies who support the
Section’s activities were presented
with District Director Awards from
District Director Bob Richwine. INDIANA — Recipients of the District Director’s Award (front row) Feather Brosio, (back
Samuel Chance was presented the Sec- row) La Donna Dugger, Vicki Tucker, Amy Flynn, and Patti Richwine pose with District
tion Meritorious Award from Section Director Bob Richwine.
Chair Dave Jackson.

William D. Ford CTC Student Chapter — Student Chapter members pose after a lecture on careers in welding: (back row from left) Daw­
son Bargenser, Treasurer Jake Longuski, Secretary Ryan Sherman, Nick Caderet, James Benzyk, Vice Chairman Umar Black, Anthony Virjan,
and Marshall Dotson (front row from left) Chase Larson, Nikki Owens, Advisor Richard Randall, Rick Lawrence, Chairman Danny Thacker,
Guest Speaker Coley McLean, Advisor Assistant Wesley Pringle, and Michael Fowler.

78 WELDING JOURNAL / FEBRUARY 2016

 SECTION NEWS

ST. LOUIS — Section members stand with Host Dan Kania and Victor Technologies Guest Speaker Kevin Showers.

EAST TEXAS — Section members show the toys they collected for Toys for Tots.

ST. LOUIS — Award recipients are seen after the Section holiday party: (from left) Chair­
INDIANA — Sam Chance receives the man Mike Kamp, Treasurer Vic Shorkey, Richard Freezor, Travis Jumper, Jim Cashdollar,
Section Meritorious Award. Ray Connolly, Richard Kemlage, and a representative for Titannova Laser.

OKLAHOMA CITY — Section members gathered after the tour of Trinity Industries.

LeTourneau University Student Chapter — Dr. Tom Siewert (center) poses for a photo with LeTourneau University engineering students
and Kilgore Jr. welding students after his speech on failures and how we can learn from them.

FEBRUARY 2016 / WELDING JOURNAL 79

SECTION NEWS
November 19
Location: Berkeley, Mo.
Presenter: Host Dan Kania and Victor
Technologies Guest Speaker Kevin
Showers
Topic: Oxyfuel safety/operation
Event: Victor Equipment’s Kevin Show-
ers hosted an oxyfuel safety seminar for
the Section and discussed storage, set-
up, and operation of oxyfuel equipment.
One storage tip Showers provided was
not to travel with an uncovered cylinder
valve. While presenting, Showers
passed around replicas of torch tips and
regulators to break down nomenclature
and the function of each piece.
Vatterott College Student
Chapter
July 9
Location: Berkeley, Mo.
Presenters: Chapter Advisor Scott
Thornhill, Chapter Chairman Katie
Phelan
Topics: Start-up funds for the new Stu-
dent Chapter, raising funds to assist
with membership fees
Event: The Chapter’s activation com-
mittee sought out students who were
unable to spare the yearly dues because
of financial hardship, and offered to
cover their fees. An individual donated
nine mixed martial arts tickets to the
group and the Chapter raffled them to
raise enough money to cover five
applications.
October 1–31
Location: Berkeley, Mo.
Presenters: Chapter Advisor Scott
Thornhill, Chapter Chairman Katie
Phelan
Topic: Clothing drive for the month of
October
Event: The Student Chapter ran a cloth-
ing drive called Coats for Kids through-
out the month of October. The students
aimed to help the Crisis Nursery of the
Metropolitan area, which assists infants
to children of 12 years who are neglect-
ed, abused, or homeless. The students
managed to collect infant clothing and
supplies, as well as women’s and men’s
coats and jeans.
November 6
Location: Berkeley, Mo.
Topic: 50/50 raffle to raise funds for the
Chapter’s future goals
Event: Students held a 50/50 raffle to
cover administrative costs and to be
80 WELDING JOURNAL / FEBRUARY 2016
able to purchase AWS patches for mem-
bers. Over two months, the Chapter
sold tickets, and future Vice President
Richard Presly and Program Chairman
Martin Burkart built a raffle box for the
big draw. Charles Woodard of St. Louis,
Mo., won $1000, and donated $500 of
his winnings back to the Chapter. The
Chapter was able to buy patches for
every member, donate to the Crisis
Nursery, and cover a year’s worth of
bank fees thanks to the raffle.
District 15
David Lynnes, director
(701) 893-2295
dave@learntoweld.com
District 16
Karl Fogleman, director
(402) 677-2490
fogleman3@cox.net
Des Moines High School Central
Campus Student Chapter
November 30
Location: Ankeny Fire Department,
Ankeny, Iowa
Activity: Central Campus students
Hunter Matthews, Devin Anderson, and
Daniel Velez, under the direction of
Welding Instructor Ralph Young and Ed
Ackerman, fabricated an aluminum dia-
mond plate storage cabinet. The stu-
dents donated the cabinet to the Anke-
ny Fire Department, where it will be
used to store hand tools on the engine.
Students built the project from specifi-
cations developed by firefighter Gary
Sanders.
Vatterott College Student Chapter —
Students collected clothing and coats for
infants, children, and adults in need
during the month of October.
District 17
Jerry Knapp, director
(918) 813-0541
jgknapp@cox.net
EAST TEXAS
December 3
Location: Papacitas Restaurant,
Longview, Tex.
Event: Toys for Tots and dinner social
LeTourneau University Student
Chapter
November 19
Location: LeTourneau University,
Longview, Tex.
Presenter: Dr. Tom Siewert, Siewert
Consulting
Topic: A look at failures and how those
results are a teaching event that can be
applied to the future design of struc-
tures.
Event: The presentation summarized
the data collected between 2002 and
2004 on the behavior of steel and the
welds that framed the World Trade
Center Towers. LeTourneau University
engineering students and Kilgore Jr.
College welding students attended.
OKLAHOMA CITY
November 5
Location: Trinity Industries, Oklaho-
ma City, Ok.
Presenter: Ryan Welch, safety coordi-
nator, Trinity Industries, Oklahoma
City, Ok.
Topic: The company’s diverse fabrica-
tion, which includes rail, inland barge,
construction, and clean energy
Vatterott College Student Chapter —
Chapter Chair Katie Phelan presents
Charles Woodard (right) with his 50/50
raffle prize.
—continued on page 82
 SECTION NEWS

HOUSTON — Section members (from left) Mike Young, Eric Carl­

son, Scott Witkowski, Troy Griffin, and Willie Bunker after the Sec­ HOUSTON — Section members (from left) Richard Holdren, Peter
tion tour of Maverick Testing Laboratories. Carlson, Witkowski, Kinney, Gene Bickford, and Tom Myers after their presentation on
and Griffin work for Maverick. changes to D1.1:2015.

ANNOUNCE YOUR SECTION’S ACTIVITIES IN

ThE SECTION EVENTS CalENdaR
If you would like to submit a calendar listing, send along the
following information: Section name; activity name, date,
time, and location; and speaker name, title, affiliation, and
subject. If some of your meeting plans are pending, include
the name and e-mail or phone number of a contact person
for the event.
Please keep in mind that the Journal publication cut-off is
usually the 20th of the month, for 2 months ahead. For ex-
ample, if you want to have your May meeting in the April
Journal calendar, the deadline is February 20.
Send your calendar event listing to Annik Babinski, assis-
tant editor, by e-mail, ababinski@aws.org, or fax, (305) 443-
7404.

SECTION EVENTS Holston Valley New Orleans

CalENdaR February 9, 6 pm
Regional Center for Advanced Manu-
Please note that events are subject to change. facturing, 305 West Main Street,
Reach out to the listed contact to confirm. Kingsport, Tenn.
Presentation of AWS scholarships and
Colorado information on the Chatanooga State
C.C. welding program
February 12
Ladies’ Night April 12, All Day
Regional Center for Advanced Manu-
March 11 facturing, 305 West Main Street,
7th Annual Welding the Rockies Kingsport, Tenn.
Symposium Trade show of welding and cutting ma-
chines, tools, and clothing
April 14
AWS joint meeting with ASNT at May 10, 6 pm
Intermountain Testing Regional Center for Advanced Manu-
facturing, 305 West Main Street,
May 12 Kingsport, Tenn.
Student Award Night Section Awards meeting
Contact Bob Teuscher for more informa- Contact Jon J. Cookson for more infor-
tion about Colorado events at (303) 893- mation about Holston Valley events at
3602 or by e-mail at (757) 897-3748, or by e-mail at
bobteuscher@hotmail.com. jjcookson@northeaststate.edu.
February 16
Best Western Landmark Hotel, 2601
Severn Ave., Metairie, La.
Shane Searels of ESAB Gulf Coast Au-
tomation Sales will talk about new ICE
SAW technology.
March 1
Cafe Hope, 1101 Barataria Blvd., Mar-
rero, La.
President David McQuaid will update
the Section on AWS.
April 19
Best Western Landmark Hotel, 2601
Severn Ave., Metairie, La.
May 17
Location TBA
Contact D. J. Berger for more informa-
tion about New Orleans events at (504)
415-9165, or by e-mail at
dj@nationalitc.com.

FEBRUARY 2016 / WELDING JOURNAL 81

SECTION NEWS
—continued from page 80
Activity: Members enjoyed a plant
tour of Trinity Industries, which began
with a safety brief and informational
video about the company. Members
then toured the tank car manufactur-
ing facility, and saw the step-by-step
process involved in building a rail tank
car. After the plant tour, members
used Miller Electric’s LiveArc™, a sys-
tem to recruit, screen, train, and man-
age trainees’ performance through
motion-tracking technology that pro-
vides feedback to trainees to help
them improve their welding skills and
technique.
District 18
John Stoll, director
(713) 724-2350
John.Stoll@voestalpine.com
HOUSTON
December 4
Location: Houston, Tex.
Event: The Section toured the Maver-
ick Testing Laboratories plant. One
hundred Section members attended.
December 5
Location: Houston, Tex.
Presenters: Richard Holdren, Peter
Kinney, Gene Bickford, and Tom
Myers
Event: Fifty people attended the fall
educational meeting to hear about
changes to D1.1 for 2015.
District 19
Shawn McDaniel, director
(509) 793-5182
shawnm@bigbend.edu
SPOKANE
November 18
Location: AccraFab, Liberty Lake, Wash.
Presenter: Barry Stewart, AccraFab
Event: Barry Stewart gave Section
members a tour of the company’s facil-
ity. A record windstorm had left most
of the region without power and inter-
net/phone communication. In spite
of this, six members and students
attended.
82 WELDING JOURNAL / FEBRUARY 2016
PORTLAND
September
Location: Oaks Park, Portland, Ore.
Event: The Section held a fun-raising
barbeque to get members pumped up
for a year of fun and exciting meet-
ings. The Section went to Oaks Park
amusement park for fun games, excit-
ing rides, and delicious barbeque. The
turnout was high and the Section
hopes to repeat the event with double
the attendance this year. In 2015–
2016, the Section plans to expand the
skills and knowledge of its members.
District 20
Pierrette H. Gorman, director SPOKANE — In spite of a record­
(505) 284-9644
phgorma@sandia.gov
breaking windstorm that left the region
without power, six Section members
came to the plant tour at AccraFab:
COLORADO (from left) Barry Stewart, Randy Polito,
December 8 Kevin Sandquist, Andrew Zidrashko, and
Location: Denver, Colo. Jeremy Dodge.
Presenter: David Landon, 2014–2015
AWS President, Vermeer Corp.
Topic: A Triple Pass of the Torch: Tech-
nology, Heroism, and Mentorship
Activity: President Landon presented
a discussion of the unique history of
the Vermeer Corp. and the develop-
ment of the welding, testing, and in-
spection programs there. He reviewed
the different technological advances in
the welding fields and how they can be
applied to greatly benefit welding of all
types. He challenged the local AWS
IDAHO/MONTANA — Ofilia Tremblay
members to mentor the next genera- (left), Section member, and Wendy Bur­
tions of welders, and to always look to rington, Selway Corp. quality assurance
the future advancements of welding manager, chat during a tour of the com­
technology. pany’s steel fabrication facility in
Stevensville, Mont.
COLORADO — AWS 2014–2015 President David Landon visited the Section and encour­
aged members to mentor the next generation: (from left) Chairman Steve Unrein, Presi­
dent Landon, Past President and Vice Chairman Bob Teuscher, and Treasurer Tom
Kienbaum present a speaker gift to President Landon.

IDAHO/MONTANA
September 25
Location: Selway Corp., Stevensville,
Mont.
Presenter: Wendy Burrington, Selway
Corp. quality assurance manager
Event Topics: Plant tour of Selway
Corp., part of its participation in the
annual SteelDay event hosted by the
American Institute of Steel
Construction
Activity: Wendy Burrington, Section
member and the company’s quality as-
surance manager, invited Section mem-
bers to tour the company’s steel fabrica-
tion facility. Following the tour, Selway
provided refreshments for participants.
District 21
Sam Lindsey, director
(858) 740-1917
slindsey@sandiego.gov
ARIZONA
September 9
Location: East Valley Institute of Tech-
nology (EVIT) Welding Lab, Mesa, Ariz.
Presenters: Chairman Jerry Siko, EVIT
lead teacher, CWI Leon Zamora, and
Section Vice Chair Nick Martinez
Topics: Open meeting to members and
nonmembers, discussion of future
events for the Section, and update on
the ATF and the new student AWS Sec-
tions at EVIT
Activity: Vice Chair Nick Martinez pre-
sented his final draft of the new Section
scholarship, Halls of Knowledge, and
Treasurer Paul Moreno explained how
the Section is funding the scholarship.
SECTION NEWS
Topic: Tour of working sculpture/metal
fabrication studio and presentation of
Kevin Caron’s work online
Activities: Many students from East Val-
ley Institute of Technology’s welding
program attended this event. CWI Cur-
tis Casey brought some of his sculpture
students from Mesa Community
College.
SAN DIEGO
December 1
Location: Yuma, Ariz.
Presenters: Arizona Western College
President Dr. Glenn Mayle and staff
Topic: Celebration of completion of
multimillion dollar renovation to auto-
motive and welding facilities and an-
nouncement of the naming of the weld-
ing building after Dr. Ernest Lopez Sr.
Activities: Section members celebrated
the conclusion of renovations to the au-
tomotive and welding department at
Arizona Western College (AWC). The
welding building was named in honor of
founding professor of the welding de-
partment, Ernest Lopez Sr. The project
was supported by the college and part-
ner Northern Arizona University-Yuma,
and by the Title III Hispanic Serving In-
stitute STEM Pipeline Grant.
December 8
Location: Yuma, Ariz.
Presenters: Alfred Acosta, NDE techni-
cian and Kyle Stelzer, Olympus Scientif-
ic Solutions Americas
Topics: NDE Phased Array – Introduc-
tion to nondestructive examination
Activities: Students, faculty, industry
members, and guests were treated to a
technical presentation by Alfred Acosta,
an NDE Level III technician who shared
his more than 30 years of military and
civilian inspection experience with the
audience. During the first part of the
evening, Acosta outlined the fundamen-
tal principles of NDE. The second por-
tion was supported by other NDE tech-
nicians, and Kyle Stelzer of Olympus
Scientific Solutions gave audience mem-
bers hands-on demonstrations of NDE
equipment. Special thanks to Dr.
Ryszard Jastrzębski, director of the In-
stitute of Welding in Cracow, for the
wonderful posters he developed as a vi-
sual aid for welding.
District 22
Kerry E. Shatell, director
(925) 866-5434
kesi@pge.com
SAN FRANCISCO
December 2
Location: Spenger’s Restaurant, Berkely,
Calif.
Speaker: Kevin Moore, producer and co-
host of “What Could Possibly Go
Wrong?” TV series
Topics: Fabrication and Welding on TV:
What Could Possibly Go Wrong?
Activity: Forty-three members and
guests attended the holiday banquet
presentation, during which Kevin
Moore detailed the background engi-
neering and production of three chap-
ters of his TV series. Section Chairman
Mike Zinser was presented with a Dis-
trict Meritorious Certificate Award by
District 22 Director Kerry Shatell.

October 14
Location: Kevin Caron Studios,
Phoenix, Ariz.
Presenter: Kevin Caron, sculptor/fabri-
cator

SAN FRANCISCO — District Director

Kerry Shatell (left) presents Chairman SAN FRANCISCO — Section Chair Mike Zinser (left) says hello to Speaker Kevin Moore’s
Mike Zinser with the District Meritorious son, Gage, after hearing about the welding and fabrication behind the scenes on Moore’s
Award. TV series, “What Could Possibly Go Wrong?”

FEBRUARY 2016 / WELDING JOURNAL 83

SECTION NEWS

ARIZONA — Fran Johnston snapped this photo of Section members and guests after their open meeting.

ARIZONA — Students from East Valley Institute of Technology and Mesa Community College pose with Section Members at Kevin Caron’s
sculpture and fabrication studio.

SAN DIEGO — Professor Samuel Colton took this photo of the nondestructive examination lecture attendees.

SAN DIEGO — Arizona Western College welding program supporters celebrate completion of the renovations to the automotive and weld­
ing departments.

84 WELDING JOURNAL / FEBRUARY 2016

 Guide to AWS Services
American Welding Society® INTERNATIONAL SALES Technical Committee Activities, Additive Manufacturing,
8669 NW 36th St., #130 Managing Director of North American Sales Welding Qualification
Miami, FL 33166-6672 Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . . . . . . . . .(297)
(800/305) 443-9353; Fax: (305) 443-7559 Director — International Activities
Phone extensions are in parentheses. Learning Sales Representative Andrew Davis.. adavis@aws.org . . . . . . . . . . . . . . . . . .(466)
Efram Abrams.. eabrams@aws.org . . . . . . . . . . . . . . .(307) International Standards Activities, American Coun-
AWS PRESIDENT cil of the International Institute of Welding
David McQuaid . . . . . . . .davidlmcquaid@comcast.net Corporate Director, Global Sales
D. L. McQuaid and Associates, Inc. Jeff Kamentz..jkamentz@aws.org . . . . . . . . . . . . . . . .(233) Manager, Safety and Health
519 Gala Drive, Canonsburg, PA 15317 Oversees international business activities; certifi- Stephen Hedrick.. steveh@aws.org . . . . . . . . . . . . . . .(305)
cation, publications, and membership. Metric Practice, Safety and Health, Joining of Plas-
ADMINISTRATION tics and Composites, Personnel and Facilities Qualifica-
Executive Director PUBLICATION SERVICES tion, Mechanical Testing of Welds
Ray Shook.. rshook@aws.org . . . . . . . . . . . . . . . . . . . .(210) Dept. information . . . . . . . . . . . . . . . . . . . . . . . . . . . .(275)
Program Managers II
Senior Associate Executive Directors Managing Director Stephen Borrero... sborrero@aws.org . . . . . . . . . . . . .(334)
Cassie Burrell.. cburrell@aws.org . . . . . . . . . . . . . . . . .(253) Andrew Cullison.. cullison@aws.org . . . . . . . . . . . . . .(249) Definitions and Symbols, Structural Subcommittees
on Reinforcing Steel, Bridge Welding, Stainless Steel,
John Gayler.. gayler@aws.org . . . . . . . . . . . . . . . . . . .(472) Welding Journal Brazing and Soldering Manufacturers Committee
Publisher
Chief Financial Officer Andrew Cullison.. cullison@aws.org . . . . . . . . . . . . . .(249) Rakesh Gupta.. gupta@aws.org . . . . . . . . . . . . . . . . . .(301)
Gesana Villegas.. gvillegas@aws.org . . . . . . . . . . . . . .(252) Filler Metals and Allied Materials, International
Editor Filler Metals, UNS Numbers Assignment, Arc Welding
Chief Information Officer Mary Ruth Johnsen.. mjohnsen@aws.org . . . . . . . . . .(238) and Cutting Processes, Computerization of Welding In-
Emilio Del Riego..edelriego@aws.org . . . . . . . . . . . . . .(247) formation
Society News Editor
Board and Executive Director Services Melissa Gomez..mgomez@aws.org . . . . . . . . . . . . . . .(275) Jennifer Molin.. jmolin@aws.org . . . . . . . . . . . . . . . . .(304)
Associate Director Structural Welding, Sheet Metal Welding
Alex Diaz.. adiaz@aws.org . . . . . . . . . . . . . . . . . . . . . .(294) Section News Editor
Annik Babinski..ababinski@aws.org . . . . . . . . . . . . . .(256) Program Managers
AWS Awards, Fellows, Counselors John Douglass..jdouglass@aws.org . . . . . . . . . . . . . . .(306)
Board and Executive Director Services Welding Handbook Editor Brazing and Soldering, Methods of Weld Inspection,
Program Manager Kathy Sinnes.. ksinnes@aws.org . . . . . . . . . . . . . . . . .(255) Welding in Marine Construction, Welding of Machinery
Chelsea Lewis.. clewis@aws.org . . . . . . . . . . . . . . . . . .(293) and Equipment
Coordinates AWS awards and Fellow and Coun- MARKETING COMMUNICATIONS
selor nominations. Director Andre Naumann.. anaumann@aws.org . . . . . . . . . . . .(313)
Lorena Cora.. lcora@aws.org . . . . . . . . . . . . . . . . . . . .(417) Welding and Brazing in Aerospace, Joining of Metals
Administrative Services and Alloys, Piping and Tubing, Ti and Zr Filler Metals,
Corporate Director Public Relations Manager Friction Welding, Oxyfuel Gas Welding and Cutting
Hidail Nuñez..hidail@aws.org . . . . . . . . . . . . . . . . . . .(287) Cindy Weihl..cweihl@aws.org . . . . . . . . . . . . . . . . . . . .(416)
Peter Portela.. pportela@aws.org . . . . . . . . . . . . . . . . .(311)
HUMAN RESOURCES Webmaster High-Energy Beam Welding, Robotics Welding,
Director Jose Salgado..jsalgado@aws.org . . . . . . . . . . . . . . . . . .(456) Welding in Sanitary Applications, Additive Manufactur-
Gricelda Manalich.. gricelda@aws.org . . . . . . . . . . . . .(208) ing, Structural Welding Subcommittee on Titanium
Section Web Editor
Associate Director Henry Chinea...hchinea@aws.org . . . . . . . . . . . . . . . .(452) Maria Elena Rodriguez..mrodriguez@aws.org . . . . .. . (310)
Patrick Henry..phenry@aws.org . . . . . . . . . . . . . . . . .( 211) Automotive, Resistance Welding, Resistance Weld-
MEMBER SERVICES ing Equipment
INTERNATIONAL INSTITUTE OF WELDING Dept. information . . . . . . . . . . . . . . . . . . . . . . . . . . . .(480)
Senior Coordinator Jennifer Rosario.. jrosario@aws.org . . . . . . . . . . . . . .(308)
Sissibeth Lopez . . sissi@aws.org . . . . . . . . . . . . . . . . .(319) Senior Associate Executive Director Railroad Welding, Thermal Spraying, Welding Iron
Liaison services with other national and international Cassie Burrell.. cburrell@aws.org . . . . . . . . . . . . . . . . .(253) Castings, Welding Qualification
societies and standards organizations.
Corporate Director CUSTOMER OPERATIONS
GOVERNMENT LIAISON SERVICES Rhenda Kenny... rhenda@aws.org . . . . . . . . . . . . . . . .(260) Program Specialists
Hugh Webster . . . . . . . . . . . . . . . . . . . .hwebster@wc-b.com Serves as a liaison between members and AWS head- Vivian Pupo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(362)
Webster, Chamberlain & Bean, Washington, D.C. (202) quarters. Danielle Garcia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(361)
785-9500; F: (202) 835-0243. Answer customer questions about AWS.
Monitors federal issues of importance to the CERTIFICATION SERVICES
industry. Dept. information . . . . . . . . . . . . . . . . . . . . . . . . . . . .(273) AWS FOUNDATION, INC.
aws.org/w/a/foundation
CONVENTION AND EXPOSITIONS Managing Director General Information
Director, Convention and Meeting Services Judy Manso..jmanso@aws.org . . . . . . . . . . . . . . . . . . .(281) (800/305) 443-9353, ext. 212, vpinsky@aws.org
Matthew Rubin.....mrubin@aws.org . . . . . . . . . . . . . .(239)
Director of Agency Representation Chairman, Board of Trustees
ITSA — INTERNATIONAL THERMAL Terry Perez..tperez@aws.org . . . . . . . . . . . . . . . . . . . .(470) William A. Rice.. brice@oki-bering.com
SPRAY ASSOCIATION
Senior Manager and Editor EDUCATION SERVICES Executive Director, Foundation
Kathy Dusa....kathydusa@thermalspray.org . . . . . . . .(232) Director, Operations Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . . . . . . . . (331)
Martica Ventura.. mventura@aws.org . . . . . . . . . . . . .(224)
RWMA — RESISTANCE WELDING Corporate Director, Workforce Development
MANUFACTURING ALLIANCE Director, Development and Systems Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . . . .. . .. . (461)
Committee Specialist David Hernandez.. dhernandez@aws.org . . . . . . . . . .(219)
Adrian Bustillo....abustillo@aws.org. . . . .. . . . .. . . . . .(295) Associate Director of Scholarships
TECHNICAL SERVICES Vicki Pinsky.. vpinsky@aws.org. . . . . . . . . . . . . . . . . . . .. . . . (212)
WEMCO — ASSOCIATION OF WELDING Dept. information . . . . . . . . . . . . . . . . . . . . . . . . . . . .(340)
MANUFACTURERS The AWS Foundation is a not-for-profit 501(c)(3) charita-
Management Specialist Managing Director — Technical Services ble organization established to provide support for the educa-
Keila DeMoraes....kdemoraes@aws.org . . . . . . . . . . . .(444) Annette Alonso.. aalonso@aws.org . . . . . . . . . . . . . . .(299) tional and scientific endeavors of the American Welding Socie-
ty. Promote the Foundation’s work with your financial support.

FEBRUARY 2016 / WELDING JOURNAL 85

PERSONNEL

Alcoa Names Executive been with the company for three

Team Members years, and was formerly president of
ALM and CFO of Hawk Technology.
Myron Pundt has been promoted to
VP of engineering/R&D for the com-
pany. Pundt has been with the compa-
ny for 20 years.

Intelligrated Appoints Senior

Director
Scott Jenkins Doug Burnside
Intelligrated,
leadership role at Cincinnati, Ohio,
Detroit Diesel a provider of auto-
Roy Harvey William Oplinger
Corp., and various mated material
positions at Cum- handling systems,
Alcoa, New mins, Inc. has announced
York, N.Y., a light- Doug Burnside, the appointment
weight metals previously senior of Jon Tutuncu to
provider, has an- director of cus- the position of
nounced executive tomer care, has senior director,
management ap- been promoted to commercial opera-
pointments for vice president of tions and strategy.
the future Up- Jon Tutuncu He will be respon-
customer satisfac-
stream and Value- tion for the com- Doug Schenher sible for establish-
Add companies, pany. Burnside ing the company’s commercial opera-
expected to be- brings ten years of customer care, af- tions organization and for driving
come effective in termarket sales, and preowned certi- sales performance. Tutuncu has more
Ken Giacobbe
the second half of fied robot programs experience to the than 20 years of commercial opera-
2016 with the executive team. tions experience. Prior to joining the
completion of Alcoa’s separation. Doug Schenher, previously vice company, Tutuncu served as regional
Roy Harvey, executive vice presi- president of customer satisfaction, director, commercial operations for
dent and Alcoa president of global pri- has assumed the role of corporate vice General Electric Healthcare and as vice
mary products, will serve as CEO of president of the company. He has president of marketing for General
Upstream. William Oplinger, executive been with Yaskawa for 11 years, con- Electric Transportation.
vice president and CFO of Alcoa, will tributing to the development of cus-
serve as CFO of Upstream. Ken Gia- tomer satisfaction programs. In his
cobbe, CFO of Alcoa’s Engineered new role, Schenher will provide leader- GAWDA Selects 2015–2016
Products and Solutions business, will
serve as CFO of Value-Add. Klaus
ship and guidance on organizational President
development and planning for the
Kleinfeld, Alcoa chairman and CEO, company. The Gases and
will lead the Value-Add company as
Welding Distribu-
chairman and CEO. He will also initial-
tors Association
ly serve as chairman of Upstream. Hawk Technology Develops (GAWDA), Holly-
Leadership Team wood, Fla., a rep-
resentative of dis-
Yaskawa Motoman Announces Hawk Technology, Ltd., Rock Is- tributors and sup-
Organizational Changes land, Ill., a designer and manufacturer pliers of industrial
of tooling, fixtures, and other cus- gases and related
Yaskawa Motoman, Dayton, Ohio, tomized automated parts, has an- welding equip-
has announced key organizational nounced a series of changes to its ment supplies,
changes. Scott Jenkins has joined the leadership team. has elected Bill
company as vice president of North Josh Clare, previous president and Bill Visintainer Visintainer its
American sales and marketing. Jenkins CEO, will take on a leading role in 2015–2016 presi-
has nearly three decades of experience business development, and Rob dent. Visintainer, president, Atlas
in industrial manufacturing and distri- Doneth, previous automation manag- Welding Supply, Tuscaloosa, Ala.,
bution. He was formerly senior vice er for the company, will become presi- a gas and welding equipment supplier,
president of sales and marketing for dent. Mark Ross has been named has been involved with GAWDA
ITW Welding Group. He also held a CEO/CFO of the company. Ross has since 1983. Most recently, Visintainer

86 WELDING JOURNAL / FEBRUARY 2016

served as first vice president on GAW-
DA’s executive committee.
Nuts, Bolts & Thingamajigs
Foundation Elects Director
The Nuts, Bolts & Thingamajigs
(NBT) Foundation, Rockford, Ill., the
charitable foundation of the Fabrica-
tors & Manufacturers Association, In-
ternational, elected Franklin Mac-
cotan to serve as director for a two-
year term. Maccotan is director and
industry leader of manufacturing for
CNA, a commercial insurance writer,
where he oversees management of the
fabricated metals and industrial ma-
chinery subsegments. Maccotan has
been a strong fundraising advocate for
the NBT summer manufacturing camp
program.
Robotic Industries Association
Announces New Director
The Robotic Industries Association
(RIA), Ann Arbor, Mich., has wel-
comed Carole Franklin as its new di-
rector of standards development.
Franklin was formerly a project man-
ager and facilitator with consulting
firm Booz Allen Hamilton, where she
became familiar with automation top-
ics. In addition, Franklin spent 10
years with the Ford Motor Co., and
served as director of program manage-
ment with a tech-startup firm.
Miller, SkillsUSA Award
Top Welder with $40,000
Scholarship
Andrew Cardin, 22, of Sutton,
Mass., was recently awarded a
$40,000 scholarship, sponsored
by Miller Electric Mfg. Co., for
earning the welding spot on the 2015
SkillsUSA World Team. The award ex-
ists to inspire young welders and to
support the need for training on an
industry-wide basis. Students com-
pete at the annual SkillsUSA event to
represent the United States at the
WorldSkills event. As the TeamUSA fi-
nalist in 2015, Cardin represented the
United States at the WorldSkills event
in Brazil in August, where he won a
Medal of Excellence and finished fifth
WOORK
RK
among 38 welders.
NAM CEO Wins Award
SSM
MART
M ART
RT
Jay Timmons, CEO and president,
National Association of Manufactur-
ers (NAM), Washington, D.C., was
named the TRENDS 2016 Association
Executive of the Year by Association
TRENDS, a news and information
source for association leaders. Tim-
mons was honored for his work and
leadership at NAM, where, prior to his
appointment as president, he was ex-
ecutive vice president and senior vice
president of policy and government
relations.
FEMCO Welder Celebrates
45 Years
Model 200 Positioner
3 models av
,
.
Joe Parente
FEMCO, Punxsutawney, Pa., a man-
ufacturer of OEM and aftermarket
parts, recently marked 50 years at its
corporate headquarters, and celebrat-
ed Joe Parente, who has been in the
company’s welding and fabrication Modeel 1200 Pipemate
department for 45 years. Rottates pipe and tube
from 1 ½” to 17” diameter,,
Business Development
Promotions at Keller
North America
Keller North America, Hanover,
Md., a division of Keller Group plc, a
geotechnical construction service
provider, has appointed James
Hussin, P.E., to the position of busi-
ness development and marketing di-
rector. Hussin has more than 35 years
of experience in geotechnical engi-
neering and construction. Prior to this
— continued on page 112
For info, go to www.aws.org/ad­index
FEBRUARY 2016 / WELDING JOURNAL 87
THE AMERICAN WELDER

Fabricating without Fear

BY VIRGINIA HILTON
Artist, rock-climber, and welder Jamie
Hamilton fabricates his own tightrope
supports

Jamie Hamilton walks on the aerial installation, Amor Fati (2015, steel, aluminum, nylon, neoprene, 70 x 260 x 150 ft), located outside of
Santa Fe, N.Mex. Photo courtesy of Hannah Hughes.

H
ow confident are you in your
work? Would you bet your life
on it? That’s what aerial artist
and welder Jamie Hamilton does every
single day. He builds the support
structures for tight ropes that are sev-
eral hundred feet above the ground,
which he then walks across. He also
makes the safety nets that catch him
in case he falls.
For most people, the height alone
would be blindingly intimidating, but
Hamilton has been rock climbing since
he was eight years old. Since then, he’s
climbed summits in the Himalayas,
Alps, Canadian Rockies, and Yosemite.
He started learning about welding
and fabrication in high school. Hamil-
ton said he enjoyed building with met-
al. “I was fascinated by this material
that could become liquid, but was also
strong and ductile. I fell in love with
the material and the forgery of it.”
He built many practical structures

88 WELDING JOURNAL / FEBRUARY 2016


Fig. 1 — Image from a solo show at The Center for Contemporary Arts, Santa Fe, N.Mex. Photo courtesy of Nick Merrick, Hedrich Blessing.
while working as an apprentice for an
architectural blacksmith and found
that most of them were like works of
art. “When structures become totally
pragmatic, like a bridge, they become
beautiful. They’re not designed to be
that way, but in their purpose they
have a sense of artistry and grace,” he
said.
That beauty motivated him to con-
tinue his fabrication work, but with an
eye toward the arts. He studied sculp-
ture at Bard College in New York and
recently graduated with a masters in
fine arts from Transart University in
Germany — Fig. 1.
Once in his 30s, he decided he
wanted to find a way to combine all
three of his passions: athletics, fabri-
cating, and art. Soon after, he started
working on his first tightrope. “An ex-
ploration of possibility and structure
has always been a staple in my work,
but it becomes much more serious
when building aerial structures upon
which my life depends. I take a stance
of total responsibility when I become
engineer, designer, fabricator, and per-
former,” he explained.
The first thing he does before each
project is think about the scale of the
build. “I try to figure out how tall it’s
going to be. How will it be supported
or installed? Will it be across a gorge,
natural setting, or supported by truss-
es?” — Fig. 2.
FEBRUARY 2016 / WELDING JOURNAL 89
THE AMERICAN WELDER
Once he determines which support
system he is using, Hamilton heads to
his shop in Santa Fe to begin fabrica-
tion. “I have to start engineering the
dimensions and determine what will
be needed to support the load,” he ex-
plained. In the example of a self-
supporting rig, he essentially makes
two columns, anchored to the ground,
that are supported by lattice trusses
that support each end of the
tightrope.
Hamilton uses a Hypertherm Pow-
ermax85 plasma cutting machine to
build many of the customized steel
components that are anywhere from
¼ to 1 in. thick. “When building a steel
structure like this, you can’t go to a
THE AMERICAN WELDER

Fig. 2 — High-wire crossing a canyon outside of Santa Fe, N.Mex. Photo courtesy of Charles Calef.

90 WELDING JOURNAL / FEBRUARY 2016


Fig. 3 — Gas tungsten arc welding a component for a sculpture. Photo courtesy of
James Autery.
hardware store to buy the parts. I de-
sign and build many of them myself
with a handheld torch and various cut-
ting jigs,” he said. His aerial structures
and sculptures are almost exclusively
gas tungsten arc welded. He uses a
Miller Dynasty 350 as his primary
welding machine. If Hamilton has to
make a field or in-situ weld, he will use
shielded metal arc welding, but this is
very rare as almost all of his field con-
nections are made with bolts and pins.
The vast majority of his welding and
fabrication takes place in the shop.
In the past, he used grinders with
cutting disks to do some of the work
but found switching from abrasive to
plasma saved him hours of cutting
THE AMERICAN WELDER
time and money. He also said he felt
plasma was a safer option because
there wasn’t as much metal or grit de-
bris produced during each cut.
Once he has everything cut and
shaped, he welds the components of
the truss sections, which will become
the high wire’s support columns —
Fig. 3. The columns are built to sleeve
together at the joints. ”When I’m
erecting them, I lay them out, bolt
them together, then the hinges at the
base allow them to pivot upright via a
winch and jin pole,” he explained.
Just above the ground he weaves
his own safety net made of thousands
of sliced nylon ropes. The process can
take several months to complete.
Each time he takes the first step,
Fig. 4 — Portrait of Jamie Hamilton, cour-
tesy of Ben Gilkison, The Needles, Calif.
Hamilton said he tries to remain calm.
“While it seems totally crazy, even
though I am trying hard to focus,
sometimes my mind wanders, and I ac-
tually think about mundane things
like the bills I need to pay.”
Knowing that he made the struc-
ture gives him the confidence and
composure he needs to make it across.
“It gives me a sense of security know-
ing that I built it myself. I have nobody
else to blame if something goes
wrong,” said Hamilton — Fig. 4. That
mentality has carried over into other
parts of his life as well. “Real self-
responsibility. I don’t wish to blame
anyone else for things that go wrong
in my life. That has been a great lesson
from this.”
For more information about Jamie
Hamilton’s work, contact him at
arecibo@c1h2.net. WJ
VIRGINIA HILTON is a freelance writer.
FEBRUARY 2016 / WELDING JOURNAL 91
THE AMERICAN WELDER

Do’s and Don’ts of Welding

Information Management Systems
Following these tips will help you BY RYAN LINDEMAN

gain the best results

A
s companies seek to improve
quality and productivity, and to
reduce costs in their welding
operations, many turn to new equip-
ment or technologies to gain efficien-
cies to meet these goals. Welding in-
formation management systems can
help. These systems electronically
gather real-time data that empower
companies to drive positive change
throughout the welding operation.
There are several levels of welding
information management systems
available in the marketplace today —
from basic to advanced. These systems
can eliminate time-consuming manual
weld data collection and can be used
for semiautomatic or robotic welding.
They help ensure the correct welding
parameters are followed and can aug-
ment training efforts. In addition, the
systems make it easier to benchmark
continuous improvement efforts.
Basic systems often deliver welding
information via Web-based browsers,
and gauge high-level factors contribut-
ing to quality and productivity by
monitoring:
• Arc-on time and total deposition
rates
• Out-of-parameter welds.
Advanced systems expand on these
benefits by offering varying levels of
As companies seek to improve quality and productivity, and to reduce costs in their welding
control over key facets of the welding
operations, many turn to new equipment or technologies to gain efficiencies to meet these
operation. They operate via an Ether- goals. Welding information management systems can help.
net connection between the power
source and a PC-based application.
Benefits include, but are not limited
to, the following: as over- and underwelding management to engineers and welding
• Weld sequence control • Operator identification and per- operators — along with a commitment
• Monitoring of weld cell downtime formance metrics. to use the data to improve the welding
or arc-off time Successful implementation of any operation — Fig. 1.
• Workflow management and part welding information management sys- To gain the best results, consider
tracking tems requires careful planning. It also some important “do’s” and “don’ts” of
• Identification and reduction of entails collaboration between all stake- adding this technology into the weld-
missed and/or defective welds, as well holders — from business owners and ing operation.

92 WELDING JOURNAL / FEBRUARY 2016

 THE AMERICAN WELDER

— after all, they need to operate a

profitable and competitive business.
Help top management understand the
payback of this technology through a
trial run. With the assistance of a
welding equipment manufacturer, con-
duct a brief trial or pilot test that en-
ables the business to identify opportu-
nities for improvement, as well as con-
duct an assessment of the internal
network and infrastructure to deter-
mine the proper IT support for the
technology (e.g., wireless coverage or
wired Ethernet connections needed on
the shop floor).
During the trial, focus on the most
relevant factors to monitor and share
with top management in order to se-
cure buy-in with successful proof-of-
concept results. Consider the history
of the welding operation and problem-
atic issues that have been encoun-
tered. For example, has the company
had liability claims due to missed
welds? Encountered workflow chal-
lenges or arc-on productivity con-
cerns? Whichever the case, monitoring
the appropriate information illustrates
the best way to maximize ROI and im-
prove the welding operation.
Provide progress reports through-
out the trial to further secure top
management commitment and rein-
force the benefit of the system.

Do identify an internal project

champion.

After a company decides to invest

in the technology, choose an internal
project champion. This person is the
backbone of the project, serving as a
liaison to work with both top manage-
Fig. 1 — Successful implementation of both types of welding information management ment and the welding operators. Weld-
systems requires careful planning. It also entails collaboration between all stakeholders — ing or plant supervisors are strong
from owners and management to engineers and welding operators — along with a com- candidates for the job. They should be
mitment to use the data to improve the welding operation. encouraged to create a cross-function-
al team dedicated to assessing the
weld data, discussing potential modifi-
The Do’s supervisor introduces the idea of gath- cations to the welding operation, and
ering electronic weld data to top man- executing those changes.
There are four key factors that can agement. These individuals, along The internal project champion can
guide companies in their decision to with the welding operators, are most also help generate interest and accept-
implement welding information tech- closely engaged in the welding process. ance of the new technology on the
nology and help them achieve long- Therefore, they can speak to the need plant floor by educating welding oper-
term benefits. for the technology; the key is to speak ators of the benefits. Since welding op-
in the right language. erators play such a vital role in the
Do secure commitment from top Among top management, the justi- day-to-day welding process, securing
management. fication for adding any new technolo- their participation when making any
gy comes down to the expense and the changes is imperative. In some cases,
Typically a welding or production potential return on investment (ROI) it may be necessary to engage the

FEBRUARY 2016 / WELDING JOURNAL 93

THE AMERICAN WELDER
welding operators in additional train-
ing to gain the best results.
Ultimately, the internal project
champion’s goal is to identify and ad-
dress the opportunities revealed by
the welding information solution. He
or she holds the responsibility and au-
thority to drive the process of continu-
ous improvement and deliver results.
Do have a clear plan of attack.
Generate a baseline for improve-
ment as a first step when implement-
ing a welding information manage-
ment system. Doing so helps establish
expectations for success. The baseline
can include an assessment of current
arc-on time and deposition rates, as
well as part cycle time and weld quality
defects. From this baseline, the
company can determine goals for
improvements.
Moving forward from the baseline,
stakeholders should use the available
information to monitor trends and
challenge status quo. For example:
• Where is the company compared
to the baseline after a given period of
time?
• How can the company use insight
from the weld data to make improve-
ments?
• What procedural changes will help
increase productivity or achieve better
quality?
• How can the company improve
operations upstream or downstream
from the welding cell?
Commit enough resources to the
process and take a disciplined ap-
proach to the plan. Make sure there
are enough people to help implement
and sustain the improvements made
visible by the welding information.
Additionally, focus on logistics to fur-
ther ensure success, such as establish-
ing the appropriate network capabili-
ties so there is minimal downtime for
troubleshooting IT issues. There
should also be a plan for the frequency
of data review and reporting, and im-
provement progress.
Do share the results with
all stakeholders.
The success of these systems is the
result of collaboration among all
stakeholders. Keep everyone involved
apprised of the information being
monitored, and the improvements be-
94 WELDING JOURNAL / FEBRUARY 2016
ing targeted and achieved. Encourage
ongoing involvement and partnership
to work toward and reach operation
goals.
The data shared with stakeholders
and the changes being made in the
welding operation will vary according
to the audience. Top management will
likely want to focus on the cost-saving
element of the systems; they want to
understand how changes generate a
positive ROI and drive better prof-
itability. Welding supervisors and
welding operators should be made
aware of the results of changes on the
plant floor, including the successes, as
well as ongoing challenges.
The Don’ts
As with any change in the welding
operation, the introduction of welding
information technology can disrupt
the daily and long-term functioning of
the process if employed without prop-
er precautions. Here are two key items
to minimize trouble.
Don’t try to do too much
too quickly.
These systems best serve compa-
nies by delivering incremental im-
provements. Trials should start out
small, with the technology in only a
few welding cells. Additionally, compa-
nies should look for the “low-hanging
fruit” — they can target the easiest is-
sues to resolve or those that are most
beneficial. The focus often depends on
where the company is experiencing the
most pain.
As a best practice, companies
should first address changes that do
not require large amounts of re-
sources. Doing so creates momentum
with quick wins, helps avoid changes
that are too complex to handle early in
the proces,s and minimizes the risk of
employees abandoning the project. In-
volve all stakeholders to make sure the
improvements being sought are rele-
vant. For example, if improving work-
flow is a goal, involve a manufacturing
engineer, as well as the welding opera-
tors, to learn the exact process of mov-
ing parts from pre- to postweld opera-
tions. This insight prevents any mis-
conceptions that could hinder results.
Regularly engaging welding operators
can help identify additional ways to
improve the welding operation. Man-
agement may find an employee in one
weld cell has discovered a way to
streamline an activity that could be
added to other weld cells.
Don’t be afraid of internal
pushback.
It is not uncommon for any type of
change to be met with resistance.
Every company has its own culture
that is determined by the personalities
of the employees — not everyone will
respond the same to the presence of a
welding information management
system.
Position this technology appropri-
ately from the start and involve every-
one. Top management should be aware
they can receive ongoing updates on
the improvements in the welding op-
eration. This can happen even if the
leadership team is remote (via a secure
Internet connection). The progress
and success they see will help foster
ongoing support and confidence in the
long-term benefits, including a better
bottom line.
Pushback from the plant floor may
also happen, but it doesn’t mean the
technology can’t be successful or that
the welding operators will never em-
brace it. Internal project champions
should help show the ways in which
the systems can improve and expedite
training, and help everyone do a better
job.
Conclusion
As with most changes to a welding
operation, implementing a welding in-
formation management solution
should be executed with careful con-
sideration and planning. It is an in-
vestment. As such, the technology
needs to position the welding opera-
tion for success by delivering results.
Keep open lines of communication
with all stakeholders as a best practice.
Ultimately, the end goal is to generate
collective interest in making the weld-
ing operation more productive, pro-
ducing higher quality parts, and in-
creasing profitability. WJ
RYAN LINDEMAN is product specialist —
Insight Systems, Miller Electric Mfg. Co.,
Appleton, Wis., millerwelds.com.
THE AMERICAN WELDER FACT SHEET

Joint Geometry for Arc Welding of Aluminum

R
A B A

C D

E F

G H

Fig. 2 — Special joint geometry for complete joint penetration for

arc welding from one side only.

I J K

Fig. 1 — Typical joint geometries for arc welds in aluminum.

Properties of the specific aluminum alloy, joint configura-

tion, strength requirement, appearance, and cost are factors
that determine the choice of the welding process or joining
method. Each method has advantages and limitations. For
most applications, the conventional equipment and tech-
niques used to join other metals can be used to join alu-
minum. Occasionally, specialized equipment or techniques,
or both, may be required.
Fig. 3 — Special joint geometries for welding aluminum in the hor­
Joint Geometry izontal position using arc welding processes.

Aluminum joints require smaller root openings and larg-
er groove angles than those generally used for steel. This is
because aluminum weld metal is more fluid and the welding
gun nozzles are larger. Figure 1 shows typical joint geome-
tries for arc welds in aluminum.
Figure 2 shows a special joint geometry that is recom-
mended for gas tungsten arc welding or gas metal arc weld-
ing when only one side of the joint is accessible and a
smooth root surface is required. The effectiveness of this de-
sign for complete joint penetration depends on the surface
tension of the weld metal. This design can be used with sec-
tion thicknesses greater than 3.2 mm (0.125 in.) and in all
welding positions. The abutting sections are designed so
that complete joint penetration is possible with the first
weld pass. This design has a large groove area and requires a
relatively large amount of filler metal to fill the joint. The
principal application is for circumferential joints in alu-
minum pipe.
For thick plate, U-groove or double V-groove welds are
preferred over the V-groove design to minimize the amount
of deposited metal and to permit access to the weld root.
Special joint geometries, as shown in Fig. 3, may be needed
to minimize porosity caused by entrapment of hydrogen
while welding in the horizontal position. WJ

Excerpted from the Welding Handbook, Ninth Edition, Volume 5, Materials and Applications, Part 2.

96 WELDING JOURNAL / FEBRUARY 2016

THE AMERICAN WELDER
Schoolcraft College Welding Program
Encourages Entrepreneurship
A revamped program offers a unique curriculum
and gives students a head start on industry trends
Schoolcraft College, Livonia, Mich.,
is located in the northwest part of
Wayne County, a large suburb of De-
troit. The college recently gained na-
tional recognition when it won the
2015 Clips & Clamps Industries Edu-
cational Institution Award of Excel-
lence in Metalforming from the Preci-
sion Metalforming Association. Com-
plementing Schoolcraft’s machining/
CNC program is a newly revamped
welding program, under the leadership
of Coley McLean, who joined the col-
lege’s full-time faculty a year ago.
McLean and five part-time instructors
provide training for 250 welding stu-
dents, with individual class sizes of 15
students — Fig. 1.
McLean started her career as a full-
time welding instructor at Washtenaw
Community College, Ann Arbor, Mich.,
but she had spent six years teaching
technology before that, and so will fin-
ish her 18th year of teaching at the
Welding students at work in the shop.
98 WELDING JOURNAL / FEBRUARY 2016
end of the 2015–2016 academic year.
McLean is certified as an AWS
CWI/CWE, and she is an OSHA-autho-
rized instructor for general industry
and construction, as well as an NCCER
instructor. She has certified more than
300 welders.
New Leadership
In just one year, McLean has imple-
mented changes to Schoolcraft’s pro-
gram that have resulted in credit hours
rising 120% and enrollment increasing
more than 100%. Some of these
changes include making the program a
SENSE-authorized facility for Levels 1
and 2, and accrediting the facility for
testing. In April 2015, the program
completed its first batch of in-house
certifications for its students, who
must now pass two certifications in
order to graduate.
McLean also made physical changes
LEARNING TRACK
BY ANNIK BABINSKI
to the program facility. She put in five
more workstations, and acquired new
equipment that resembles what stu-
dents will see in the industry, so they
are prepared once they join the work-
force — Fig. 2.
McLean has also brought an appre-
ciation for digital technologies to the
program. She meets her students
where they are, on their phones, and
“gently forces” them to explore weld-
ing applications for extra credit. She
also uses Blackboard, an online teach-
ing platform, to post course informa-
tion and stay connected with students.
Another innovation for the pro-
gram is McLean’s introduction of
video into the classroom. She uses
cameras to film instructors demon-
strating the techniques they use for
various processes and posts them on
YouTube so that students can see
equally good welds can be achieved in
different ways. The program was re-
cently awarded a grant to purchase a
professional-grade camera to capture
videos of the actual welding process,
and McLean hopes the video replays
will help learners.
Moving forward, McLean is work-
ing on setting up an articulation pro-
gram for four-year colleges so that she
can push her students to go on and
complete bachelor’s degrees in weld-
ing. That is where the money is, she
said, and so she encourages her stu-
dents to pursue higher education. She
is also forging connections with the lo-
cal Ironworkers Union and making in-
dustry partnerships to help her stu-
dents find employment once they
leave the program. For McLean, it’s all
about the one on one with students.
She enjoys watching her students
learn and grow, and giving her stu-
dents a head start in the industry.
 THE AMERICAN WELDER

Fig. 1 — Department Head Coley McLean speaks with a student Fig. 2 — The welding program recently acquired five more work­
during a laboratory class. stations and new equipment.

Instructors
Schoolcraft’s part-time instructors
include Christopher Olsen, an
AWS/ASME certified welder and own-
er of Exact Fabrication, LLC, who has
more than 12 years of industry experi-
ence. He teaches basic and advanced
welding courses, which also includes
blueprint reading. Donald Neilson is
an AWS-certified welder and owner of
GT Fabrication. He has more than 25
years of industry experience and in-
structs basic and advanced welding
courses, including fabrication and
blueprint reading. Jim Fowler is an
AWS-certified welder and welding in-
structor at Flat Rock High School. He
has more than 12 years of industry ex-
perience and teaches all levels of weld-
ing courses. Clyde Hall is a CWI/CWE
welding instructor and has been for
more than 30 years. Hall instructs
AWS certification preparation courses,

For info, go to www.aws.org/ad­index

FEBRUARY 2016 / WELDING JOURNAL 99

THE AMERICAN WELDER
Fig. 3 — Melissa Machnee’s sculptural
welding class made a sculpture for an
art competition to celebrate Henry
Ford’s 150th birthday. Seen is their prize­
winning entry.
among others. Dan Ondrus works for
the Ford Motor Co. and instructs in
adhesive joining, and Melissa Mach-
nee, an AWS-certified welder, CWE,
and CAWI, teaches GMAW and two
metal sculpture classes that she devel-
oped (see lead photo).
Sculpture Certificate
In 2010, Machnee developed the
sculptural welding certificate program
at Schoolcraft and ran it out of the
continuing education program. The
courses caught on, and were incorpo-
rated as a certificate into the program.
Machnee found that entering a weld-
ing class under the guise of art was an
easy in for some students who might
be intimidated to enter the industry.
Today, the program is available to
welding students as an elective, and
also to graphic design and art majors.
The result is that most classes have a
combination of welding and art stu-
dents, creating a great atmosphere for
creative problem solving. Welding stu-
dents are exposed to different equip-
ment in the sculpture classes, because
they use fabrication equipment. Stu-
dents in the welding sculpture class use
gas metal arc welding (GMAW), gas
tungsten arc welding (GTAW), oxyfuel
cutting, and plasma arc cutting (PAC).
100 WELDING JOURNAL / FEBRUARY 2016
Fig. 4 — Student Sasha Bennett started
his own lamp business, Dangerous
Lamps, after taking the sculptural weld­
ing class at Schoolcraft.
Machnee came to sculptural welding
on a unique path. She completed her
bachelor of fine arts at Wayne State in
Detroit, Mich., and began welding in
college to make sculptures. She later
went on to complete her master of fine
arts in sculpture at Eastern Michigan
University, Ypsilanti, Mich., where she
primarily used welding and metal cast-
ing for her work.
Machnee is a graduate of School-
craft’s program, having earned its
welding fabrication certificate in 2007,
and she has welded in the industry for
automotive prototype and production
welding custom fabrications.
Encouraging
Entrepreneurship
Schoolcraft was open to developing
the sculpture program, Machnee said,
because it promotes entrepreneurship.
The sculpture class gives students
many ways to take the skills they’ve
learned and go forward with their own
business. The class entered and won
an art competition to celebrate Henry
Ford’s 150th birthday, which familiar-
ized students with designing for a
client — Fig. 3. Student Sasha Bennett
started his own lamp business, Dan-
gerous Lamps. He can be seen powder
Fig. 5 — Student Kelly O’Neill exhibits
and sells her welded art at local Livonia,
Mich., galleries.
coating one of his lamps in Fig. 4. Kel-
ly O’Neill (Fig. 5) and Doug Cannell,
both graduates of the program, exhibit
and sell their art locally.
Program Offerings
Welding Fabrication Certificate
This 33-credit certificate prepares
students for jobs involving shielded
metal arc (SMA), gas metal arc (GMA),
and gas tungsten arc (GTA) welding
processes, and knowledge of plasma
arc and oxyfuel cutting technologies is
offered. Students acquire skills in
welding and fabrication processes with
an emphasis on technical support sub-
jects such as mathematics and science
courses, blueprint reading classes, and
courses to prepare for welder certifica-
tion exams.
Joining Technology AAS Degree
This 67-credit associate’s degree
covers the hands-on welding courses
found in the fabrication certificate,
and also provides an emphasis on met-
allurgy and business operations. Be-
side the courses listed under the weld-
ing fabrication certificate, the associ-
ate’s degree offers classes like business

English, human relations, communica-
tion skills, introduction to art and mu-
sic, and a few different welding cours-
es. This degree prepares graduates for
jobs in industrial, prototype, and ma-
chine tool building, heavy equipment,
construction, and emerging green and
sustainable technologies.
Pre­Apprenticeship Certificate
In order to qualify as a welding
journeyman, one must complete ap-
prenticeship training. Schoolcraft has
partnerships with local trade unions,
and trains students for union appren-
ticeship with this 24-credit certificate
by providing instruction in fundamen-
tal welding equipment and techniques,
Fig. 6 — Michelle Riley decided to trade
an office job for a career in welding.
Fig. 7 — A graduate of the program,
Cory Cummings said he appreciated the
one­on­one attention he got in class.
project planning, layout, fabrication,
safety, and math. Students who suc-
cessfully complete coursework will also
earn AWS certification in at least one
procedure. This certificate creates an
option for entry into the welding fab-
rication certificate and the welding
joining technology associate degree.
Welding Sculptural Skills
Certificate
This 19-credit certificate helps stu-
dents learn basic and advanced skills
in welding with the GMAW and GTAW
processes, as well as fabrication tech-
niques to give students an under-
standing of how to problem solve in
unique situations. An emphasis is
Student Voices
Michelle Riley
Michelle Riley went to a Big Ten
university and earned her bachelor’s
degree in English. Riley always enjoyed
working with her hands, and took con-
struction trades courses in high
school, but moved away from it in col-
lege. She had been working in an office
for the last eight years and decided to
take night classes in welding when she
heard that welders were in high de-
mand. Now a year into her degree, she
has fallen in love with the trade, hopes
to graduate sometime in 2017 with a
dual associate’s degree in welding/join-
ing technology and metallurgy, and
has started working full-time doing
pipe fitting and fabrication — Fig. 6.
Riley decided to take courses at
Schoolcraft out of convenience; it
was close to her home and it offered
night and weekend classes. She stayed
because of the small class sizes, the
“phenomenal staff,” the high level
of instructor one-on-one time, and
the program’s small community
atmosphere.
“We have an awesome team of in-
structors at Schoolcraft,” said Riley.
“Our full-time instructor [Coley
McLean] started the same semester I
did and she has totally turned the en-
tire program around (revised curricu-
lum, new classes, renovations, new
THE AMERICAN WELDER
placed on thinking and working cre-
atively, and on the ability to discuss
one’s work conceptually and objective-
ly. The certificate opens the student
to the possibility of completing the
welding fabrication certificate or the
welding joining technology associate
degree. It is a good choice for the pro-
fessional sculptor or the aspiring
welder. WJ
For More Information
To learn more about Schoolcraft
College’s welding program, contact Co-
ley McLean at (734) 462-4683 or e-
mail admissions@schoolcraft.edu.
equipment, new field contacts, etc.).
We are now more focused on industry
needs and skills training. We have
even added a pre-apprenticeship pro-
gram for the Ironworkers Union with-
in the last year. The focus at School-
craft is really toward industry and
manufacturing. Many of our part-time
instructors have both teaching experi-
ence and field experience, so they have
a wealth of knowledge and contacts for
all the students to use.”
Once she completes her associate’s
degree, Riley hopes to go on to earn
her CWI/CWE credentials, and possi-
bly complete a four-year degree in
welding engineering. She has thoughts
of becoming an OSHA-certified in-
structor, and of opening her own fab-
rication shop. As she said, “The possi-
bilities are endless.”
Cory Cummings
Cory Cummings completed his as-
sociates degree in liberal arts with a
certificate in welding in the summer of
2015 — Fig. 7. His interest in welding
built over many years. His father took
a welding class when Cummings was
young, and Cummings still has the
name plate his father made for him.
“I thought it was so cool that he
wrote “Cory” on a little weld coupon
and gave it to me one day.”
In high school, Cummings took an
auto shop class where Schoolcraft’s
FEBRUARY 2016 / WELDING JOURNAL 101
THE AMERICAN WELDER
welding program director spoke to the
students one day. Cummings liked
that Schoolcraft allowed its students
to study a trade at the same time as
they earned an associate’s degree.
“There is so much that I enjoyed
about Schoolcraft’s welding program
that it’s hard to say what my favorite
part was,” Cummings said. “The shop
is clean, well organized, and has the
For info, go to www.aws.org/ad­index
102 WELDING JOURNAL / FEBRUARY 2016
most up-to-date machines I have yet
to come across in industry. The in-
structors are always willing to give you
input on what to do differently and
will even come into the booth with you
and give you dedicated one-on-one
time during class. It blew me away that
they are willing to do that. Another
thing I enjoyed is classmates will try to
work together to solve an issue if a
student is having difficulty. The in-
structors and training are top notch…
They will do whatever it takes to help
out a student who is willing and eager
to learn, whether it’s staying later
after class or opening a lab on a
weekend.”
Since finishing his degree, Cum-
mings has started the OSHA safety
course and he is planning to continue
taking classes at Schoolcraft to im-
prove his craft. He found the job hunt
in Michigan very easy after gradua-
tion. At the time of production, he was
performing a weld test and had inter-
viewed with a company that rebuilds
aircraft engines. He would ultimately
like to work in the aerospace or rail-
road industries.
ANNIK BABINSKI (ababinski@aws.org)
is assistant editor
of the Welding Journal.
For info, go to www.aws.org/ad­index
BRAZING AND SOLDERING PROFILES (ADVERTISEMENTS)

Aimtek, Inc. Bellman Melcor Inc.

Established in 1973, Aimtek Founded by Richard Campbell,
is a manufacturer and value- Bellman-Melcor, LLC was
added supplier of Aerospace- created with one goal: to pro-
grade Brazing and Welding vide high quality products and
Alloys. Aimtek specializes in deliver them at a lower overall
precious metal-based brazing cost than any other supplier of brazing and soldering alloys.
alloys, as well as nickel, Since our inception in 1963, we have worked closely with the
titanium, and high tempera- engineering staff at some of the world’s largest companies to design
ture superalloys. Aimtek is and fabricate custom preforms and comprehensive solutions for
the exclusive North American use in a wide range of brazing applications. Focusing on process
distributor for Soudax, a respected European manufacturer of improvement and cost-saving solutions, we routinely provide
resistance microwelding equipment and hand tools for ball tack support on the entire brazing process.
welding, honeycomb, and numerous other set-up operations.
Aimtek’s quality certifications include AS9100, ISO9001, Pratt & 7575 West 183rd St
Whitney LCS, UTC Supplier Gold, Rolls Royce, Honeywell, and GE. Tinley Park, IL 60477
201 Washington St. (800) 367­6024
Auburn, MA 01501 USA Fax: 1­888­BRAZE­IT­272­9348
(508) 832­5035 www.bellmanmelcor.com
jkapur@aimtek.com
www.aimtek.com

Empower Materials, Inc.

New Improved Workhorse
2nd GENERATION
Vacuum Brazing
Vacuum Diffusion Bonding Furnaces
• All Stainless Steel chamber.
• Larger high-vacuum pumping system.
• Improved hot zone design.
• New HMI control strategy.
• Temperature Uniformity of +/- 3°C.
• Highest Quality at an affordable price.
Centorr Vacuum Industries manufactures
custom vacuum furnaces for High-
performance sintering, pressure
densification, and heat-treat of alloy
steels, stainless steels, high-speed steels,
hardmetals and ceramics.
Vacuum furnaces can be designed
with Graphite or carbon-free hot zones
with Sweepgas™ synthetic or natural
binder and lubricant removal systems
available for pressed or injection molded
Over 400 metal and ceramic parts.
Workhorse Furnaces
Built Since 1954
Centorr Vacuum Industries, Inc.
55 Northeastern Blvd., Nashua NH
Toll free: 800-962-8631
603-595-7233
Fax: 603-595-9220 • sales@centorr.com
Empower Materials is the
world leading manufacturer of
QPAC®Polyalkylene Carbonate.
QPAC® is used as a binder in
brazing applications because
it burns out very cleanly with
virtually no residue after
decomposition. QPAC®’s debind
process also produces higher
density seals. This results in
excellent joint sealing properties. Good adhesion and mechanical
strength also contribute to making QPAC® an ideal binder for
brazing applications.
91 Lukens Drive
New Castle, DE 19720
(302) 225­0100
www.empowermaterials.com
Fusion, Inc.
Fusion produces a wide
variety of brazing and
soldering alloys in paste
form. Each contains
atomized filler metal,
appropriate flux, and special
binders which facilitate
automatic application. Thus,
all the ingredients for a strong, reliable brazed or soldered joint are
delivered in one step. Fusion also designs and builds automatic
brazing and soldering machines. These custom-built systems convey
fixtured parts through a timed sequence of filler metal application,
heating, and cooling. Typically, 200-700 assemblies per hour can be
joined with just one operator.
4658 E 355th St
Willoughby, OH 44094
(800) 626­9501, ext. 510
(440) 602­5510 (Direct)
www.fusion­inc.com
FEBRUARY 2016 / WELDING JOURNAL 103
BRAZING AND SOLDERING PROFILES (ADVERTISEMENTS)

Harris Products Group Oerlikon Metco

The Harris Products Group Oerlikon Metco's innovative solutions

has been manufacturing improve the life, reliability and
quality braze filler metals in performance of your manufactured
the United States for over components and industrial processes.
50 years. We are leaders in Customers benefit from a broad range
developing brazing and of surface solutions that include
soldering products to meet the industry needs for new metal joining thermal spray and laser cladding
methods. We are certified to ISO 9001 and ISO 14000, and have advanced materials, integrated
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4501 Quality Pl. 1101 Prospect Ave.
Mason, OH 45040 Westbury, NY 11590
(800) 733­4043 (516) 334­1300
www.harrisproductsgroup.com Fax: (516) 338­2414
Info.Metco@oerlikon.com
www.oerlikon.com/metco

Lucas­Milhaupt, Saint­Gobain
Global Brazing Solutions Founded 1920

Lucas-Milhaupt is your single Saint-Gobain is a world class

supplier for the most comprehensive manufacturer of equipment and
selection of silver, gold, copper, consumables for the thermal
nickel, and aluminum brazing spray coatings industry. Our
supplies. We can provide you expansive equipment experience
technical support and materials dates back to 1920 with the
globally, wherever your company development of the first oxyacteylene flame wire gun followed by
manufactures your product. We are Rokide® Spray Systems, Plasma Spray Systems, PTA and many
your one source for brazing materials including Handy One® innovative materials. We offer a wide range of consumables in the
flux cored products, silver and aluminum coated products, Sil-Fos®, form of powder, ingots, flexible cords, Rokide® rods and wire for use in
Easy-Flo®, Braze™, Silvaloy®, Silvabrite®, Ultra Flux®, and many different applications and industries. We supply our own raw
Handy® Flux. materials and this enables us to develop a product to meet your
exact needs.
5656 S. Pennsylvania Ave.
Milwaukee, WI 53110 U.S.A. 1 New Bond Street,
(414) 769­6000 Worcester, MA 01615
info@lucasmilhaupt.com (800) 243­0028 • (508) 795­2380
www.lucasmilhaupt.com coatingsolutions@saint­gobain.com
www.coatingsolutions.saint­gobain.com
Metglas®, Inc. Thermo­Calc Software
Metglas® is a subsidiary of Hitachi Thermo-Calc Software is a leading
Metals America and is a worldwide developer of software and databases
leader in the production of for computational thermodynamics
amorphous metal brazing foils. and diffusion controlled simulations.
Metglas Brazing Foils are a solution Thermo-Calc: powerful software for
to produce virtually reject-free joints thermodynamic calculations for
with high strength and superior multicomponent systems. DICTRA:
resistance to corrosion and high tem- a unique tool for accurate simulations
perature oxidation. Metglas Brazing of diffusion in multicomponent alloys. TC-PRISMA: new software
Foils are available in various alloy for modeling concurrent nucleation, growth and coarsening of
compositions and widths and can be precipitates. Databases available for steels, Ti, Al, Ni-superalloys,
cut or stamped into exact shapes for the most demanding solders and other materials.
applications. For further information visit Metglas Inc. on the
web at: www.metglas.com or contact us at 1-800-581-7654.

Jimmy Jordan
(843) 349­7319 4160 Washington Rd Suite 230
McMurray, PA 15317
Metglas@metglas.com (724) 731­0074
www.metglas.com paul@thermocalc.com
www.thermocalc.com

104 WELDING JOURNAL / FEBRUARY 2016

Friends andd Colleagues:

The Ameriican Welding Society established the honor of Coun nselor of the Society to recognize
members for
f a career of distinguisheed leadership contributionss in the advancement of welding
science andd technology. Election as a Counselor is based upon an individual’s career of
outstandingg achievements and accommpplishments. The selection
o committee is seeking qualified
individuals who can demonstrate their leadership in the weldinng industry as evidenced by:

• Sustained service and performance in the advancement of welding science and

technology
•• Publication of papers, articles and books which enh hance knowledge of welding
• Innovative development of welding technology
• Society, National and Section contributions
•• Professional recognition
• Leadership in AWS or other corporate levels, particularly as it impacts the
advancement of welding technology
• Facilitating others to participate as a volunteer in the
h advancement of welding
technology

For specifics on the nomination requirements, please contact Che

C lsea Lewis at clewis@aws.org
at AWS headquarters in Miami, or simply follow the instructions
o on the Counselor nomination
form located at go.aws.org/appcounselor. Please remember, we all benefit in the honoring of
those who have made major contributions to our chosen profession and livelihood. The deadline
for submission is July 1, 2016. The Counselor Committee loo oks forward to receiving numerous
Counselor nominations for 2017 consideration.

Sincerely,

Lee Kvidahl
Chair, Counselor Committee




Friends and Colleagues:

The American Welding Society, in 1990, established the honor of Fellow of the Society to recognize
members for distinguished contributions to the field of welding science and technology, and for
n sustaining the proffessional stature of the field. Election as a Fellow of the Society is
promoting and
n ng accomplishment and technical impact off the individual. Such accomplishments
based on outstandi
will have advance the science, technology and application of w welding, as evidenced by:

• Sustained service and perfoormance in the advanc

n ement of welding science and
technology
• Publication of papers, articles and books which enhaannce knowledge of welding
• Innovative development of welding technology
•
• Society and Section contributions
• Proffessional recognitions

I want to encourage you to submit nomination packages for those individuals whom you feel have a
history of accomplishments and contributions to our proffession consistent with the standards set by
the existing Fellows. In particular, I would make uest that you look in to the most senior
k a special requ
members of your Section or District in considering members for nomination. In many cases, the
colleagues and peers of these individuals who are the most faam miliar with their contributions, and w
whho
would normally nominate the candidate, are no longer with us. I waant to be sure that we take the
extra efffort required to make sure that those truly worthy are not overlooked because no obvious
individual was available to start the nominating process.

For specifics on nomination requirements, please contact Chelsea Lewis at clewis@aws.org at AWS
headquarters in Miami, or simply fol
o low the instructions on the
h Fellow nomination for
o m located at
go.aws.org/appffellow. Please remember, we all benefit in the honor
h ing of those who have made
maajor contributions to our chosen profession and livelihood. The deadline for submission is August
1, 2016. The Fellows Committee looks forward to receiving numerous Fellow nominations for 2017
consideration.

Sincerely,
Dr. John Elmer
Chair, AWS Fellows Committee
NEWS OF THE INDUSTRY
— continued from page 17
will feature the company’s up-to-date technologies. Addi-
tionally, the facility will combine an automation center with
research and development, driving toward “one piece flow”
sheet metal production capabilities.
The technology center will be about 50,000 sq ft, based
on recent plans. Worldwide visitors will see system and ma-
chine demonstrations as well as observe and be part of live
sheet metal production with automated and flexible ma-
chine tools and processes.
Innovative Fuel Selected to be Part of
$100 Million Kennedy Space Center Project
MagneGas Corp., Tampa, Fla., a technology company that
counts among its inventions a patented process that con-
verts liquid waste into MagneGas2® fuel, recently an-
nounced a lead subcontractor for a Kennedy Space Center
build-out project has placed its first order for this fuel. It
will be used for metal cutting.
S&R Enterprises LLC, a lead subcontractor for the $100+
million Kennedy Space Center project that will last approxi-
mately 2 years, was introduced to MagneGas® during a
demonstration arranged by Suwannee Ironworks. As a re-
sult, the company chose to switch to the gas.
Metal Shark Delivers 55­ft Port Security Fireboat
A product of Metal Shark’s Franklin, La., shipyard, the 55­ft Defi­
ant can be custom­configured to suit a range of mission profiles.
Metal Shark, Jeanerette, La., has delivered a 55-ft multi-
purpose port security vessel to the Plaquemines Port Harbor
and Terminal District in Louisiana.
Based on the company’s Defiant-class monohull pilot-
house design, this welded aluminum vessel is meant to sup-
port port security efforts and firefighting missions at the
port district located 20 miles south of New Orleans at the
mouth of the Mississippi River.
Additionally, to meet the customer’s fire fighting require-
ments, the shipbuilder employed twin Darley fire pumps.
Water is pumped to an oversized main where it is distrib-
uted via electronic valves to three radio frequency-con-
trolled monitors; in this configuration, the vessel delivers
water flow of up to 10,000 gal/min.
With below-decks quarters offering enclosed head, galley,
and bunking capacity for a crew of four, the 55 Defiant is
equipped to stay on station for extended periods and accom-
modate crews during lengthy patrols.
A product of Metal Shark’s Franklin, La., shipyard, the
vessel can be custom-configured to suit a range of mission
profiles. It’s also offered with many power and propulsion
systems to meet various performance requirements.
Industry Notes
• Austin Community College, Austin, Tex., has finished
its previously contracted purchase of about 124 acres in
southeast Travis County. The college plans to use the site
for a career-technical training center that will provide space
for many programs, including welding. The $10.5 million
purchase is financed through bonds approved by voters in
November 2014.
• California Brazing, Newark, Calif., has purchased its
third vacuum aluminum brazing furnace from Ipsen, Cher-
ry Valley, Ill. It features a 38 ¥ 40 ¥ 62 in. all-metal hot
zone with a 1500-lb load capacity and operates at 500° to
1200°F with ±5°F temperature uniformity.
• WFW Industries, San Diego, Calif., a U.S. veteran-run
provider of manufacturing, welding/fabrication, machinery
repair, and customized training, has received the San Diego
Business Journal’s 2015 Manufacturing Award for best com-
munity service. Profits support Workshops for Warriors,
a nonprofit that provides veterans and injured vets with
skilled training. Also, Workshops for Warriors has re-
ceived a $37,000 donation from tooling manufacturer Core
Powered, Inc. The company contributed a vending ma-
chine for students and launched 70 Veterans at the
Table, a fundraising challenge to provide students with a
meal daily.
• Evana Automation Specialists, Evansville, Ind., has
shipped an off-line fluxing and soldering cell to an automo-
tive electronics manufacturer. It will permit rework of
failed occupant classification system sensor products, prod-
uct design, and production. WJ
Do You Have Some News to Tell Us?
If you have a news item that might interest the readers of
the Welding Journal, send it to the following address:
Welding Journal Dept.
Attn: Kristin Campbell
8669 NW 36th St., #130
Miami, FL 33166.
Items can also be sent via FAX to (305) 443-7404 or by
e-mail to kcampbell@aws.org.
FEBRUARY 2016 / WELDING JOURNAL 109
CLASSIFIEDS

FOR SALE OR RENT

MITROWSKI RENTS
Made in U.S.A.
Welding Positioners
1­Ton thru 60­Ton
Tank Turning Rolls
BIG
ON SAVINGS
USED EQUIPMENT
An Excellent Selection of Used
Welders, Welding Positioners,
Welding-Related Specialty
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Used Equipment for Sale

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View available equipment on our

website or call us toll-free.
JOE FULLER LLC
reddarc.com 1-866-733-3272 We manufacture tank turning rolls
sales@mitrowskiwelding.com 3-ton through 120-ton rolls
(800) 218-9620 www.joefuller.com
(713) 943-8032
Put Your Products and
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& TRAINING
email: joe@joefuller.com
Phone: (979) 277-8343
Fax: (281) 290-6184
Our products are made in the USA
2016
BUSINESS FOR SALE
CWI PREPARATORY
Generate new sales leads by showcasing 80+ HOUR COURSE
your full-color product photo with a MORE HANDS­ON/PRACTICAL APPLICATIONS For Sale
product description, website, or other Ellijay, GA Apr. 25–May 6
sales literature. Welding Marketplace Pascagoula, MS Mar. 7–18, May 9–20
Marksville, LA May 23–June 3 Established Custom Metal
reaches 80,000 qualified buyers. It’s
great exposure for just pennies per
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Closing date is ASME U, S and NB R stamp holder.
FOR DETAILS, CALL OR E­MAIL:
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(800) 489­2890
Call the AWS sales team at engineer who wants to own his or
info@realeducational.com her business.
(800) 443­9353
Sandra Jorgensen, ext. 254 Also offering: RT Film Interpretation,
sjorgensen@aws.org Applications of Welding Inspection, Training and terms negotiable.
MT/PT/UT Thickness, CWS, SCWI,
Annette Delagrange, ext. 332 Welding Procedure Fundamentals, Contact: workhere@earthlink.net
adelagrange@aws.org and Advanced Inspection Courses

110 WELDING JOURNAL / FEBRUARY 2016

 ADVERTISER INDEX

ALM Positioners 99 Intercon Enterprises, Inc. 27

almmh.com (855) 750­4295 intercon1978.com (800) 665­6655

Arcos Industries, LLC Inside Back Cover K.I.W.O.T.O., Inc. 55

arcos.us (800) 233­8460 rodguard.net (269) 944­1552

Atlas Welding Accessories, Inc. 87 KMT Saw/Kalamazoo Machine Tool 52

atlaswelding.com (800) 962­9353 kmtsaw.com (269) 321­8860

AWS Education Services 58, 106 Lincoln Electric Co. Outside Back Cover
aws.org/education (800) 443­9353, ext. 455 lincolnelectric.com (216) 481­8100

AWS Member Services 97, 108 Lucas Milhaupt 16

aws.org/membership (800) 443­9353, ext. 480 lucasmilhaupt.com (414) 769­6000

AWS Publication Services 57, 95 MIdalloy 26

aws.org/publications (800) 443­9353, ext. 275 midalloy.com (800) 776­3300

AWS Technical Services 95 National University Polytechnic Institute (NUPI) 48

aws.org/technical (800) 443­9353, ext. 340 nupolytech.org (800) 432­3483

Camfil Air Pollution Control 2 Nippon Steel & Sumikin Welding Co., Ltd. 9
camfilapc.com (800) 479­6801 welding.nssmc.com/en/ +81 3 6388 9000

CDA Technical Institute 21 North Orange County Community College District 102
commercialdivingacademy.com (888) 974­2232 apptrkr.com/719738 web contact only

Cor­Met 34 Oerlikon Metco 29

cor­met.com (800) 848­2719 oerlikon.com/metco (866) 828­7929

Diamond Ground Products, Inc. 15, 17 OTC Daihen, Inc. 31

diamondground.com (805) 498­3837 daihen­usa.com (888) 682­7626

Divers Academy International 25 Polysoude SAS/Astro Arc Polysoude 30

diversacademy.edu (800) 238­3483 polysoude.com 33 (0) 2 40 68 57 61

Donaldson Torit 35 Postle Industries/Postalloy 53

donaldsontorit.com/combustibledust (800) 365­1331 E­mail: ksmith@postle.com (216) 265­9000

Electron Beam Technologies, Inc. 17 Red­D­Arc Weldrentals 28

electronbeam.com (815) 935­2211 reddarc.com (866) 733­3272

FABTECH Mexico 54 Select­Arc, Inc. Inside Front Cover

fabtechmexico.com (800) 443­9353, ext. 297 select­arc.com (937) 295­5215

Fischer Technology 49 Superflash Compressed Gas Equipment/IBEDA, Inc. 11

fischer­technology.com (860) 683­0781 oxyfuelsafety.com (888) 327­7306

Fronius USA, LLC 1 Superior Consumables Inc. 102

fronius­usa.com (877) 376­6487 superiorconsumables.com (800) 567­1362

Fusion, Inc. 42 Triangle Engineering, Inc. 52

fusion­inc.com (800) 626­9501 trieng.com (781) 878­1500

Gradient Lens 22 TRUMPF 19

gradientlens.com (800) 536­0790 us.trumpf.com web contact only

Gullco International, Inc., U.S.A. 15 Voestalpine Bohler Welding USA, Inc. 49, 51, 53, 55
gullco.com (440) 439­8333 voestalpine.com/welding (800) 527­0791

Hobart 43 Weiler Corp. 13

HobartBrothers.com/tiethatbinds (800) 424­1543 weilercorp.com (800) 835­9999

Hobart Institute of Welding Technology 48 Weld Engineering 7

welding.org (800) 332­9448 weldengineering.com (508) 842­2224

Hodgson Custom Rolling, Inc. 5

Visit the AWS Interactive Ad Index: www.aws.org/ad­index
hcrsteel.com (905) 356­6025
FEBRUARY 2016 / WELDING JOURNAL 111
COMING EVENTS Plastics Welding School. A two-day course for certification
to European plastics welding standards. Malcom Hot Air
— continued from page 55 Systems; plasticweldingtools.com.

and on request, include tutorials and practical training. Pre-
sented at Servo-Robot, Inc., St. Bruno, QC, Canada. For
schedule, cost, and availability, send your request to
info@servorobot.com.
Machine Safeguarding Seminars. Rockford Systems, Inc.;
(800) 922-7533; rockfordsystems.com.
Machining and Grinding Courses. TechSolve, techsolve.org.
NACE International Training and Certification Courses. Na-
tional Assoc. of Corrosion Engineers; (281) 228-6223;
nace.org.
NDT Courses and Exams. Brea, Calif., and customers’ loca-
tions. Level I and II and refresher courses in PA, UT, MP, ra-
diation safety, radiography, visual, etc. Test NDT, LLC; (714)
255-1500; testndt.com.
Online Education Courses. Topics include Introduction to
Die Casting ($99), Metal Melting and Handling ($99), Prod-
uct Design ($59), Energy Training ($19), Dross Training
($19), Managing Dust Hazards ($19), Safety (free). North
American Die Casting Assoc.; (847) 808-3161;
diecasting.org/education/online.
Protective Coatings Training and Certification Courses. At
various locations and online. The Society for Protective
Coatings; (877) 281-7772; sspc.org.
Robotics Operator Training. Presented by ABB University at
13 locations nationwide. For course titles and locations:
(800) 435-7365, opt. 2, opt. 4; abb.us/abbuniversity.
Robotic Welding Training. Offers a variety of courses to en-
hance productivity and product quality, presented on site at
your facility or at the address shown below. Wolf Robotics,
LLC, 4600 Innovation Dr., Fort Collins, Colo.; (970) 225-
7600; wolfrobotics.com.
Safety Training Online. Unlimited training on myriad indus-
trial safety course titles. Visit website for complete informa-
tion and previews of several courses; safety99.com.
Service Manager Course. Designed for sheet metal workers
and HVAC service shop owners. Various locations and dates.
International Training Institute. (703) 739-7200;
sheetmetal-iti.org.
Shielded Metal Arc Welding of 2­in. Pipe in the 6G Position
— Uphill. Troy, Ohio. Hobart Institute of Welding Technolo-
gy; (800) 332-9448; welding.org.

PERSONNEL Muscat as industry director. The insti-

— continued from page 87
James Hussin Jeffrey Hill
appointment, Hussin served as direc-
tor for Hayward Baker, Inc., one of the
Keller companies. Jeffrey Hill, P.E.,
was promoted to director for Hayward
Baker. Hill has worked in the specialty
geotechnical field since graduating
from the University of Illinois.
New Industry Director for
Tauber Institute
The University of Michigan Tauber
Institute for Global Operations, Ann
Arbor, Mich., has welcomed Raymond
tute is a joint venture betwen the
school of business, the college of engi-
neering, and industry partners to fa-
cilitate cross-disciplinary education in
global operations management. In
this role, Muscat will participate in
strategic planning and lead strategic
initiatives. Muscat has 37 years of ex-
perience, having worked for the Ford
Motor Co., Raytheon Co., and Ball
Aerospace. He currently serves as vice
president of manufacturing for
Cignys, a precision-engineered prod-
ucts company in Saginaw, Mich.
Mathey Dearman Announces
New Account Manager
Mathey Dearman, Tulsa, Okla., a
pipe and vessel tool company, has an-
nounced the addition of Mike Brace as
key account manager. Brace brings
more than 20 years of sales and opera-
tional experience to his new role,
which will include supporting and
working with the entire sales team in
developing relationships with key cus-
tomers. An AWS Certified Welding In-
spector and Welding Sales Representa-
tive, he was formerly with Miller
Electric.
OBITUARY
Joseph F. Engelberger
Joseph F. Engelberger, an engineer
and entrepreneur, died peacefully at
his Newton, Conn., home on Decem-
ber 1, 2015. He was 90 years old.
Born in Brooklyn, N.Y., Engelberger
earned a bachelor’s degree in physics
and a master’s degree in electrical en-
gineering from Columbia University.
Engelberger was widely known as the
“Father of Robotics” for his creation of
the world’s first industrial robot. In
1956, Engelberger founded Unima-
tion, Inc., the world’s first industrial
robotics manufacturer, and later went
on to found HelpMate Robotics, a
manufacturer of hospital courier ro-
bots. Engelberger was inducted into
the U.S. Manufacturers Hall of Fame
in 2009. Throughout his career, he
won numerous awards, including the
Society of Manufacturing Engineers’
Progress Award, the American Society
of Mechanical Engineers’ Leonardo da
Vinci Award, and the American Ma-
chinist Award. WJ

112 WELDING JOURNAL / FEBRUARY 2016

 WELDING RESEARCH
SUPPLEMENT TO THE WELDING JOURNAL, FEBRUARY 2016
Sponsored by the American Welding Society and the Welding Research Council

Effect of Torch Height on Arc Stability

in Divided­Arc Processes
The distance between the contact tube and the workpiece has a significant
impact on the arc behavior in double­electrode gas metal arc welding

BY S. J. CHEN, L. ZHANG, G. Q. MEN, Y. X. SONG, S. SU, AND L. W. WANG

lishes an arc with the workpiece al-

ABSTRACT though there may be multiple elec-
trodes and parallel arcs. The weld pool
In conventional arc welding processes, an electrode only establishes an arc with the
is not only heated by several arcs, but
workpiece. As such, the current through the electrode and workpiece is the same. As has
been demonstrated, this mechanism fundamentally restricts the ability to decouple the also at a common terminal where arcs
heat input and deposition. In order to separately control the mass and heat inputs, double­ are coupled. All these modified
electrode gas metal arc welding (DE­GMAW), which modifies the GMAW by also establish­ processes share a fundamental princi-
ing a second arc from the electrode to an added second electrode, and arcing­wire gas ple in the arcing mechanism; the work-
tungsten arc welding (GTAW), which modifies the GTAW by establishing a second arc from pieces to be heated by all the arcs in
the electrode to the welding wire, have been proposed. Since both processes break the the system and the heat input are cou-
conventional arc, this paper refers to them as the divided­arc welding process. While the pled with the mass deposition pro-
divided­arc welding process promises a new mechanism to provide an ability to decouple duced. Novel modifications are still
the mass and heat inputs as will be demonstrated in this paper, maintaining a stable arc di­ needed to increase the deposition
vision is the key to ensuring the promised decoupling ability from this novel arc welding
without increasing the heat input in a
process. Studies are needed to determine how the ability to maintain the arc division is
affected by typical variations in manufacturing conditions. Unfortunately, no such studies certain range.
have been reported. In this paper, the effect from the variation in the distance between the In order to separately control the
torch and workpiece (simply the torch height) is experimentally studied. Since the variation mass and heat inputs, the divided-arc
in the torch height is probably the most commonly encountered variation in welding condi­ welding processes have been proposed
tions, such a study is significant in helping to transition the divided­arc welding processes at the University of Kentucky (Refs.
from laboratory to manufacturing. 10–12), and it has gained applications
in various industries including auto-
motive and shipbuilding (Ref. 13)
KEYWORDS among others (Refs. 14–17). Research
from Wu et al. (Ref. 14) demonstrated
• GMAW • GTAW • Arc Behavior • Metal Transfer • Divided Arc that double-electrode gas metal arc
welding (DE-GMAW) can enhance the
Introduction Gas metal arc welding (GMAW) and welding speed compared with conven-
gas tungsten arc welding (GTAW) are tional GMAW. Shi et al. (Ref. 15) ana-
Global competition in manufactur- two major arc welding processes wide- lyzed the DE-GMAW as a high-speed
ing demands welding processes for ly used in manufacturing industries. welding method for lap joints on zinc-
high efficiency and high quality. Con- Continuous efforts have been made to coated steel sheets for which the zinc
ventional welding processes often do improve their productivity without coating is less melted by the DE-
not satisfy such needs in modern man- compromising the quality. Many new GMAW than by GMAW with the same
ufacturing. Manufacturing industries modifications have been invented, in- deposition. Lu et al. (Refs. 18, 19) pro-
continuously look for novel arc weld- cluding tandem GMAW, plasma- posed and developed DE-SAW as a
ing processes to increase or improve GMAW, multiwire GMAW, and GTAW- variant/modification of the DE-
welding productivity/quality (Refs. GMAW (Refs. 5–9). Despite their GMAW to increase welding speed.
1–4) as arc welding is still and will con- demonstrated advantages, all of them This is because the DE-GMAW di-
tinue to be the most adopted process are based on the conventional arcing vides the arc and establishes arcs with
for welding. mechanism. Each electrode only estab- both the workpiece and another added

S. J. CHEN (sjchen@bjut.edu.cn), L. ZHANG, G. Q. MEN, Y. X. SONG, S. SU, and L. W. WANG are with the Engineering Research Center of Advanced Manufac­
turing Technology for Automotive Components, Ministry of Education, Beijing University of Technology, Beijing, China. L. ZHANG is with Hebei Key Laboratory
of Material Near­Net Forming Technology, Hebei University of Science and Technology, Shijiazhuang, Hebei, China.

FEBRUARY 2016 / WELDING JOURNAL 47-s

WELDING RESEARCH
Fig. 1 — DE­GMAW system.
Fig. 2 — Arcing­wire GTAW system.
electrode (Refs. 10, 12). As such, the
arc is no longer established between
the electrode and workpiece. Part of
the current that would otherwise flow
into the workpiece now flows to the
added electrode as a result of the arc
dividing. The resultant process, i.e.,
DE-GMAW, is thus a modification of
GMAW through arc dividing.
Another modification through arc di-
viding has been made for the GTAW
process, resulting in arcing-wire
GTAW (Ref. 12). The arc dividing al-
lows a second arc to be established be-
tween the tungsten electrode and the
filler metal, which melts the wire at a
high speed while the current on the
workpiece is still controlled at the de-
sired level. That is, while the heat in-
put is controlled by the current be-
tween the tungsten electrode and
workpiece, the deposition speed is in-
creased/controlled by the arc divided
from the original gas tungsten arc.
48-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95
Since the currents through the work-
piece and the filler metal are freely ad-
justable, the heat input and mass dep-
osition are separately controlled.
As can be seen, the arc dividing re-
lieves the inherent coupling between
the heat input and deposition in con-
ventional arc processes, resulting in
the advantages of high efficiency, high
speed, and low heat input with desir-
able coupled controls. However, these
advantages depend on the success in
the arc dividing. The arc dividing has
to be successfully maintained against
possible variations in manufacturing
conditions that may occur in industri-
al settings. Unfortunately, despite ex-
tensive various efforts on the divided-
arc processes (Refs. 20–23), effects
from possible variations in manufac-
turing conditions on the successful op-
erations of the divided-arc processes
have not been addressed. Without
studying the effects from manufactur-
ing variations, the applicability of the
divided-arc processes would not be en-
sured to actually deliver their distin-
guished advantages for decoupled
mass and heat input control. This pa-
per studies the effect of the most en-
countered variation in welding condi-
tions — the variation in the distance
from the torch to the work, which will
be referred to as to the torch height.
In particular, past studies have fo-
cused on modeling, monitoring, and
control of the divided-arc processes.
No mention has been made of the ef-
fect on the arc stability of coupled arcs
(Refs. 10, 12, 20, 22) from any welding
condition variations, including that of
the torch height. Gas metal arc and gas
tungsten arc welding are the results of
the effects from many parameters that
are coupled and interacted. These pa-
rameters also affect the success of the
arc dividing, thus the stability of the
coupled arcs, the controls on the heat
input and mass deposition, and there-
by the quality of produced welds. In
many studies, especially in DE-GMAW,
the torch height is abnormally high
compared with conventional GMAW.
For manufacturing applications, the
torch height may change significantly
due to the uneven surface of the work-
piece. In this investigation, experi-
ments were conducted and analyzed to
study how the torch height affects the
arc stability in two major divided-arc
welding processes, DE-GMAW and arc-
ing-wire GTAW, to help transition
these processes to manufacturing
applications.
Divided­Arc Welding
Processes
Double electrode GMAW (Refs. 10,
20, 21) and arcing-wire GTAW (Ref.
12) are presently the two major divid-
ed-arc welding processes. This paper
will focus on these two processes,
whose principles are discussed below.
DE­GMAW
Double electrode gas metal arc
welding (DE-GMAW) was proposed at
the University of Kentucky in 2004
(Ref. 10) as a modification to the
GMAW process. It separately controls
the heat input and deposition by
adding a second electrode (noncon-

Fig. 3 — Experimental system for arcing­wire GTAW.
Fig. 4 — High­speed images of DE­GMAW in Experiment 1.
Table 1 — Experimental System Components
Equipment and Accessories
GTA power supply
GTA torch
GMA power supply
GMA gun
Diameter of tungsten
High­speed camera
Shielding gas
sumable electrode) to bypass part of
the current, which otherwise would
flow to the workpiece. As shown in
Fig. 1, the main power supply, the
main welding gun, and the main arc
are the same as in the conventional
GMAW welding process. The bypass
electrode, a tungsten electrode, is
added to provide the condition to es-
tablish a bypass arc with the wire,
which is the electrode in GMAW. The
wire serves as a common positive ter-
minal for the two power supplies and
there are two currents flowing into the
wire: GMAW current (through the
workpiece) and GTAW current (bypass
current). These two currents are
“summed” to melt the wire and then
divided at the end of the wire, which is
the positive terminal of the two arcs.
The bypass gun and workpiece are
connected by the negative terminal of
Model, Material, or Size
Time WSM­400
WP­18
Kemppi FastMig 350
Kemppi MMT 30W
5 mm
IDT motion Y4
Pure Argon
the bypass power supply, and main
power supply, respectively. Gas metal
arc welding current and GTA current
together form the current to melt the
wire, but only the GMAW current con-
tributes directly to heat the workpiece.
With the DE-GMAW process, GMA
current and GTA current can be ad-
justed individually such that the depo-
sition and heat input can be adjusted
individually during welding.
Arcing­Wire GTAW
Gas tungsten arc welding is typical-
ly used for precision joining. However,
its productivity in depositing filler
metal is much lower than that of
GMAW because the wire is not melted
directly by an arc as in GMAW. In or-
der to increase the deposition speed in
GTAW, the wire melting in cold-wire
FEBRUARY 2016/ WELDING JOURNAL 49-s
WELDING RESEARCH
GTAW and hot-wire GTAW was stud-
ied by Chen et al. at the University of
Kentucky, and an innovatively modi-
fied GTAW, namely the arcing-wire
GTAW process, was proposed in 2012
(Ref. 12). As shown in Fig. 2, the arc-
ing-wire GTAW process is formed by
establishing a second arc between the
tungsten electrode and the wire such
that the wire becomes an arc terminal
that can melt the wire at high speeds
similarly to GMAW. As a result, there
are two coupled arcs: the arc between
the tungsten electrode and the work-
piece, which can be considered the
original gas tungsten arc, and the sec-
ond arc between the tungsten and
wire, which can be considered as an arc
divided from the original GTA. With
the second arc, the wire melting is no
longer dominated by the weld pool and
resistance heat. As a result, the filler
metal can not only be melted at high
speeds by the second arc, but also at a
desirable, adjustable speed by adjust-
ing the current through the wire. This
desirable adjustability does not de-
pend on the amperage of the current
through the workpiece, which directly
controls the heat input and penetra-
tion on the workpiece.
In particular, the tungsten elec-
trode (GTA torch) serves as a common
negative terminal to form the two di-
vided arcs. The GTA current is the cur-
rent to control the direct heating of
the workpiece and the wire current
(simply the GMA current hereafter be-
cause the wire is an arc terminal as in
the GMAW process) is the current to
control the direct melting of the wire.
The heat and mass inputs are thus
separately controlled and the high-
speed deposition in GTA becomes sim-
ilar to GMAW.
Experimental Procedure
A divided-arc process has at least
two arcs coupled to each other, al-
though there may be more than two
divided arcs (Refs. 23, 24). This study
tries to find how the torch height af-
fects the arc behaviors in the divided-
arc processes and the stability of the
arc dividing. To this end, the experi-
mental system will be able to record
necessary signals/information to ob-
serve and analyze the arc behaviors in
the two major divided-arc welding
processes being studied.
WELDING RESEARCH
Fig. 5 — Voltage waveforms of DE­GMAW in Experiment 1.
Fig. 6 — High­speed images of DE­GMAW in Experiment 2.
Table 2 — Parameters of Divided­Arc Welding Experiments
Welding Experiments
Process Height (mm) Current (A)
#1
DE­GMAW #2
#3
#4
Arcing­wire #5
GTAW #6
In the experimental system, GTA is
established using a DC-CC (direct cur-
rent-constant current) power supply
and GMA is established using a syner-
gically controlled DC power supply in
which the welding current and voltage
are adjusted in relation to the wire
feed without separate settings.
The experimental system shown in
Fig. 3 is the setting for the arcing-wire
GTAW. There are four sensors to de-
tect the voltages and currents of the
two divided-arcs and a high-speed
camera to record the arc images. The
high-speed camera (without an optical
filter) records the arc behaviors at
3000 frames per second (f/s), while
the current and voltage sensors sam-
ple at a higher frequency. However,
the timing for the images from the
high-speed camera and electrical arc
50-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95
from the tip of the contact tube to the
workpiece in DE-GMAW or the dis-
tance from the tip of the tungsten to
the workpiece in the arcing-wire
GTAW. Hence, experiments were con-
ducted to examine how the torch
height affected the stability of the arc
dividing, as shown in Table 2. The ex-
planation and detailed parameters/
conditions are given below.
In Table 2, GTA current (IGTA) refers
to the current between the tungsten
electrode and the workpiece in the arc-
ing-wire GTAW or the bypass current
between the main wire and the bypass
(tungsten) electrode in DE-GMAW. The
GMA current (IGMA) refers to the cur-
rent between the wire and workpiece in
the DE-GMAW or the current between
the tungsten and filler metal in the arc-
ing-wire GTAW. Because of the use of
the synergic DC power supply, the GMA
current is not a constant parameter but
controlled by the wire feed speed. Of
course, the change in other conditions
will affect the actual GMA current, as in
conventional GMAW. In the experi-
ments to be performed, the GTA cur-
rent is fixed at 100 A and the wire feed
speed varies between two levels. The
IGTA Wire Feed Exposure wire for both the DE-GMAW and arc-
ing-wire GTAW is low-carbon steel with
Torch GTA Speed (m/min) Time
(s) a 1.2 mm diameter. The shield gas is
pure argon. The flow rate was 12 L/min.
20 100 2.3 200 All the experiments were conducted as
15 100 2.3 200
15 100 1.2 160 bead-on-plate.
10 100 2.3 200 For the arcing-wire GTAW, the wire
6 100 2.3 200 was fixed at 3 mm below the tungsten
6 100 1.3 160 tip at the tungsten axis. The wire was
fed at 40 deg with the tungsten behind
signals were still synchronized in order the torch without optimization. For
to observe and analyze the behaviors the DE-GMAW, the actual extension of
of the divided arcs with information wire was variable as the wire feed
from multiple sources. Table 1 shows speed was a variable parameter (Table
the details of the experimental system. 2), but the distance between tungsten
With the divided-arc welding and contact cube was fixed at 7 mm,
processes, there are many parameters and the tungsten was fixed at 30 deg
affecting the behavior of the divided with the wire.
arcs. However, many of them may be
fixed at their experimentally deter- Experimental Results
mined values. For example, the posi-
tion of the bypass torch (or the filler
metal for the arcing-wire GTAW) in re- DE­GMAW
lation to the main torch may be opti-
mized and retained by a fixture. As There were three experiments in
such, the focus should be on parame- DE-GMAW. The GTA (bypass arc) cur-
ters that may easily be subjected to rent (IGTA) was fixed at 100 A and the
variations. A main parameter that de- other two parameters (wire feed speed
termines the stability of the coupled and torch height) were both changed.
arc and is easily subjected to variations In particular, the wire feed speed was
is the torch height — the distance decreased from 2.3 to 1.2 m/min in

Fig. 7 — Voltage waveforms of DE­GMAW in Experiment 2.
Fig. 8 — High­speed images of DE­GMAW in Experiment 3.
Fig. 9 — Voltage waveforms of DE­GMAW in Experiment 3.
Experiment 3; the torch height (the
distance from the tip of contact tube
to workpiece) decreased from 20 to 15
mm in Experiments 2 and 3.
In Experiment 1, the wire feed
speed was 2.3 m/min, which was in
the common range for industrial man-
ufacturing. The metal transfer for con-
ventional GMAW under this wire feed
speed and wire extension is the short
circuiting transfer. As can be seen in
Fig. 4, after the GTA (bypass arc) was
added, such that the process changes
from GMAW into DE-GMAW, the met-
al transfer changed to a free-flight
globular transfer. In this experiment,
the torch height was approximately 20
mm, slightly longer than typical in
conventional GMAW. As can be seen,
the anodes of the two arcs are both on
the wire. The heat melting wire was
thus determined by the sum currents
of GMA and GTA. As can be seen from
Fig. 4, the process and the arc dividing
were stable.
While the GTA (bypass arc) can be
established and maintained as expect-
ed, its arc column was bent, becoming
curved as can be seen in all images in
Fig. 4. The coupling between the GMA
FEBRUARY 2016 / WELDING JOURNAL 51-s
WELDING RESEARCH
and GTA is apparent. Although the
GMA was established between the
wire and workpiece as conventional
GMAW, the GMA deviated to the tung-
sten. There was a bright zone that in-
dicated the overlapping of the two arc
columns. The GMA and GTA were di-
vided at the end of this overlapping
zone. The role of the wire as the com-
mon anode changed the wire melting
speed and the mode of the metal
transfer. In the series of images in Fig.
4, the droplet gradually grew. When its
diameter became large enough, it was
transferred to the weld pool under the
influence of the gravity and the unique
electromagnetic forces associated with
divided current flows despite the sur-
face tension. In the entire process of
metal transfer, the arcs were stable
and the metal transfer was smooth.
There were no observations that the
two coupled arcs could affect the sta-
bility in this experiment.
For Experiment 1, the voltage
waveforms were given in Fig. 5. The
desirable stability of the DE-GMAW
arc can be seen in its relatively smooth
voltage waveforms. The amplitude of
GMA voltage was approximately 30 V
(CH2), which was higher than typical
in conventional GMAW in this condi-
tion. The simultaneous effects from
the two currents melted the wire at a
higher speed such that the arc length
became longer. As such, a higher wire
tip position was maintained. The GTA
voltage was approximately 20 V (CH4),
as the position of the tungsten relative
to the GMA torch was not changed.
The waveform for this voltage was also
smooth without fluctuations, suggest-
ing that the arc length of the GTA is
stable. The position of the wire tip,
from which the GTA is established to
the stationary tungsten, is thus stable.
The stable position of the common an-
odes as well as the stationary cathodes
(workpiece and tungsten electrode)
can ensure the stability of the two, di-
vided arcs.
In Experiment 2, all the parameters
were the same as Experiment 1, except
the torch height was decreased from
20 to 15 mm. Comparing Fig. 4 and
Fig. 6, there were some significant dif-
ferences in the behaviors of two cou-
pled arcs, especially in the mode of the
metal transfer. The transfer mode
changed from the globular transfer
back to the short circuiting transfer.
WELDING RESEARCH
Fig. 10 — High­speed images of arcing­wire GTAW in Experiment 4.
Fig. 11 — Voltage waveforms of arcing­wire GTAW in Experiment 4.
Fig. 12 — High­speed images of arcing­wire GTAW in Experiment 5.
As can be seen in Fig. 6, the process
became unstable just by changing the
torch height. The droplets grew up-
ward, fell, and touched the weld pool
and exploded at the end of the metal
transfer process. The whole process
was similar to the CO2 welding
process. Careful analysis and study on
Experiment 2 showed that the changes
were so obvious, not only on the mode
of metal transfer, but also on the be-
haviors of arcs. The GMA established
between the wire and workpiece devi-
ated to the left by GTA (bypass arc).
The GTA was not established directly
between the wire and the tungsten in
the last two images in Fig. 6. The an-
ode of the GTA looked like it was es-
tablished on the workpiece. The GTA
(bypass arc) heated the workpiece di-
rectly and decreased the heat that
melted the wire. The wire melting rate
52-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95
was reduced and GMA current adapted
that automatically. The actual exten-
sion of the wire was longer than that
in Experiment 1. The behavior of GTA
and GMA were both changed, leading
to an unstable process for DE-GMAW.
The significant changes in compari-
son with Experiment 1 would also be
reflected in the voltage waveforms.
Figure 7 shows the voltage waveforms
of Experiment 2. The most obvious
change was that the waveforms were
no longer smooth, but had many large
fluctuations. The GMA voltage wave-
form (CH2) can match with the wave-
form in the short circuiting transfer
(Ref. 25). During the short circuit
time, the GTA deviated further to the
left in the fifth image in Fig. 6. The
electromagnetic forces should be re-
sponsible because the two currents
flowed in the opposite directions. In
this case, the electromagnetic forces
can push the two arcs away further.
When a short circuit occurred, the
GMA current increased sharply and
reached its greatest at the end of the
short circuit. In the meantime, the
GTA always existed. The magnitude of
the electromagnetic force acted on the
GTA depends on the GMA current.
The GTA thus deviated farther at the
end of the short circuit time. This de-
viation caused the voltage of the GTA
to further increase. The GTA voltage
waveform (CH4) thus had about 50 V
at the end of short circuit time. At this
time, the droplet transferred to the
workpiece and the GMA reignited,
while the GTA was still established be-
tween the tungsten and workpiece.
The voltage of the GTA was actually
the sum of GTA and GMA, which was
abnormally high.
In Experiment 3, in order to make
the GMA maintain a certain arc length
and the two arcs to be in a stable state
despite the reduced torch height, the
wire feed speed was decreased from
2.3 to 1.2 m/min, while other parame-
ters were kept the same as in Experi-
ment 2. The exposure time was re-
duced to 160 ms to further reduce the
interference of the arc in order to ob-
serve the behaviors of the droplets
more clearly. In this experiment,
changing the wire feed speed brought
some obvious changes. As shown by
the high-speed images in Fig. 8, the
GMA current decreased and the heat
melting the wire also reduced. The
length of the GMA was shorter than
that in Experiment 2. The metal trans-
fer mode was still the short circuiting
rather than the globular transfer as
was intended by reducing the wire feed
speed. After the droplet transferred to
the workpiece, the GMA and GTA
could be resumed, respectively. Obser-
vation of the series of images in Fig. 8
showed that the GTA successfully es-
tablished the tungsten and wire on re-
suming. However, as the wire melted,
forming a small droplet at the wire tip,
the GTA (bypass arc) changed immedi-
ately. It was no longer established
from the tungsten to the wire directly.
The arc column was bent and deviated
from the original direction to the
workpiece instead. The change was
very obvious, especially when the
droplet was being detached and trans-
ferred from the wire to the weld pool

Fig. 13 — Voltage waveforms of arcing­wire GTAW in Experiment 5.
Fig. 14 — High­speed images of arcing­wire GTAW in Experiment 6.
Fig. 15 — Voltage waveforms of arcing­wire GTAW in Experiment 6.
as in the last image in Fig. 8. The GMA
extinguished during the short circuit-
ing time, during which the deviation
of GTA was serious. In Figs. 4, 6, and
8, there is a common phenomenon:
the GTA was not a straight arc, but a
curved arc that bent toward the work-
piece. The stability of the GTA must
determine the stability of DE-GMAW.
How to obtain/maintain a desirable
bypass arc is the key to ensuring a suc-
cessful arc dividing to maintain a sta-
ble process.
Figure 9 is the voltage waveforms
in Experiment 3. The significant dif-
ferences were that the waveforms were
never smooth compared with Fig. 5.
The GMA voltage waveform was a typ-
ical short circuiting transfer voltage
waveform. The voltage was almost 0 V
during the short circuiting time and
near 20 V in the open-circuiting time.
The GTA voltage waveform was also
unstable. GMA experienced reestab-
lishment and the cycle started over
again periodically. As such, the at-
FEBRUARY 2016 / WELDING JOURNAL 53-s
WELDING RESEARCH
tempt to resume the arc stability by re-
ducing the wire feed speed without in-
creasing the torch height failed.
Arcing­Wire GTAW
There were three experiments con-
ducted using the arcing-wire GTAW. The
distance between the tungsten and wire
was fixed at 3 mm. The main arc was a
GTA and the second arc was a GMA.
The GTA current (IGTA) was fixed at 100
A. The major difference in the parame-
ters was the torch height, which de-
creased from 10 mm in Experiment 4 to
6 mm in Experiments 5 and 6. The wire
feed speed decreased from 2.3 to 1.3
m/min in Experiment 6.
For Experiment 4, the high-speed
images are shown in Fig. 10. The GTA
(main arc) was established between
the tungsten electrode and the work-
piece. The GMA (the second arc) was
established between the tungsten and
the wire. In Fig. 10, the droplet grew
uniformly when the wire was fed into
the GTA. It was similar to the cold wire
GTAW, except there was a second arc.
The current flowing into the tungsten
electrode was the sum of the GTA cur-
rent and GMA current. The tip of the
tungsten was the common cathode
where the arc divided into two arcs.
The directions of the two currents
were approximately the same. In theo-
ry, the GTA and GMA (the second arc)
should attract each other. However, it
was observed that the GTA deviated to
the left rather than toward the GMA
on the right. To explain this phenome-
non, we begin with the positive ions
emitted from the wire that must flow
to the tungsten at high speeds
through the GMA. These ions weighed
much more than the electrons and col-
lided with the particles in the GTA. As
such, the ions in the GMA are impact-
ed. In the meantime, any area in the
entire workpiece could be the anode
for the GTA and the additional energy
consumption is less sensitive to the
change of the anode position on the
flat workpiece surface. The GTA thus
tended to deviate to the left as can be
seen in the macroscopic phenomenon
observed in Fig. 10.
From the high-speed images in Fig.
10, there was no evidence that GMA
could be established between the wire
and workpiece, even when the droplet
transferred to the workpiece, and even
WELDING RESEARCH
Fig. 16 — Arc behaviors of DE­GMAW.
Fig. 17 — Arc behaviors of arcing­wire GTAW.
when there was no arc between the
droplet and workpiece, and even when
the distance between the droplet and
workpiece was only 1 or 2 mm. As
aforementioned, the GTA and GMA
would tend to attract each other. For
the GMA, the effect from the GTA is
minimal because only a small portion
of the GTA is coupled with the GMA
due to the wide spread of the GTA.
The impact from the GTA ions on the
GMA ions is thus minimal. As a result,
the GMA was stable as desired. The
droplet transferred to the workpiece in
the mode of globular transfer. Howev-
er, the arc behaviors were not affected
because the droplets did not affect the
distances between any arc terminals
and travel across any arc columns.
Figure 11 details the voltage wave-
forms for the GTA and GMA. Despite
that there were fluctuations in the
waveforms, they were much smoother
than those in Experiment 3. When the
droplet transferred to the workpiece,
there was an approximate increase of 3
V in the waveforms. However, the arc
stability and arc dividing were not af-
fected. Further, the GMA voltage was
smooth and was about 20 V. This fur-
ther illustrated that the GMA was
stable, as shown in the high-speed
54-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95
images.
While the torch height was an im-
portant parameter for the stability of
the DE-GMAW process, Experiment 4
showed a stable arcing-wire GTAW
process with a torch height of approxi-
mately 10 mm. To verify whether the
torch height had a significant impact
on the stability of arcing-wire GTAW,
it was decreased from 10 to 6 mm in
Experiment 5.
Figure 12 shows high-speed images
from Experiment 5. As can be seen,
the whole process was stable. The GTA
and GMA were established as desired.
The wire was fed and melted, forming
the droplet. When the droplet became
large enough, it touched the work-
piece. Then the droplet transferred
into the workpiece immediately. The
mode of the metal transfer was similar
to conventional short circuiting trans-
fer, but there were some fundamental
differences. There was no phenome-
non of short circuiting in the arcing-
wire GTAW. Although the droplet
touched the workpiece, the wire and
workpiece are not anode-cathode such
that there was no current to flow
through the bridging droplet. As such,
while touching the droplet to the
workpiece in GMAW results in short
circuiting, which may generate an ex-
plosion at the end of the short circuit
process, for the arcing-wire GTAW,
there was no explosion in the whole
process.
The electromagnetic force could also
have contributed to the observed stabil-
ity of the arc dividing and the divided
arcs despite the reduced torch height.
As aforementioned, because the GMA
current is approximately in parallel with
the GTA current, the electromagnetic
forces will tend to attract the two cur-
rents to each other. Since the impact
from the GTA ions on the GMA ions is
minimal, this attraction will not be sig-
nificantly neutralized. As a result, there
is a trend that the GMA is attracted to
the GTA such that the ionized particles
produced by the GTA will improve the
conductivity needed to maintain the
GMA. As such, the stability of the GMA
is enhanced. The stability of the arc di-
viding and the arc-wire GTAW process is
thus enhanced by the favorable way
how the electromagnetic forces are pro-
duced as in the arcing-wire GTAW
process. The strong arc stability over-
came the possible effect from the torch
height variation.
The voltage waveforms from Experi-
ment 5 are shown in Fig. 13. The GTA
voltage (CH2) was stabilized at 15 V,
which was less than that in Experiment
4, as the torch height was decreased
such that the arc length for the GTA was
reduced. The GMA voltage (CH4) was
also stabilized at 12 V, also lower than
that in Experiment 4. Careful compari-
son with Fig. 10 showed that the re-
duced arc length made the GTA more
concentrated. As a result, the conductiv-
ity of the GTA provided a conductive
channel needed to establish and main-
tain the GMA increase. The GMA volt-
age was thus reduced.
In Experiment 3 for DE-GMAW, de-
creasing the wire feed speed made the
mode of metal transfer less stable. To
check the possible effect from the re-
duced wire feed speed on the stability in
the arcing-wire GTAW, the wire feed
speed was reduced from 2.3 to
1.3m/min in Experiment 6. Experimen-
tal results showed no effect on the sta-
bility as can be seen from Fig. 14. In Fig.
14, the exposure time was reduced to
160 ms with the hope to reduce the in-
terference of the arc and observe the arc
behavior more clearly. In this case, the
wire further extended toward the GTA.

The droplet was still transferred into
the workpiece after touching, but the
droplet was reduced. It appeared that
the reduced distance from the wire to
the workpiece, due to the increased ex-
tension of the wire, which was fed with
an angle, reduced the gap for the
droplet to grow before touching the
workpiece. As a result, the droplet
transferred into the workpiece at re-
duced sizes as can be seen from Fig. 14
in comparison with the droplets in Fig.
10 and Fig. 12. The waveforms for the
voltages as shown in Fig. 15 also indi-
cated the stability of the arcs.
Analysis and Discussion
The major conclusion from this
study on the sensitivity of the arc di-
viding stability to the torch height is
that the DE-GMAW is sensitive while
the arcing-wire GTAW is not. DE-
GMAW and arcing-wire GTAW are
both based on the arc dividing. How-
ever, while the arc is divided at a con-
sumable (wire) in DE-GTAW, the arc-
ing dividing occurs at a nonconsum-
able (tungsten electrode) in the arcing-
wire GTAW. This difference causes the
difference in their sensitivity to the
variation in the torch height.
In DE-GMAW, the position of the arc
dividing root (wire tip) changes in rela-
tion to the GMAW torch due to the con-
sumable nature of the wire. The bypass
electrode/GTA torch is attached/fixed to
the GMAW torch. The relative position-
ing between the root and destination
thus changes. When the torch height re-
duces, the root would tend to move to-
ward the tip because the tip of the wire
is supposed to keep a constant distance
from the workpiece in the constant volt-
age (CV) mode. (A synergic control de-
termines the voltage setting based on
the wire feed speed but the current is
still adjusted to maintain this voltage.
The arc voltage, thus the arc length, is
still controlled similarly as in CV mode.)
The main arc that provides the needed
conductive channel to maintain the de-
sired arc dividing at the wire tip would
move toward the wire tip. The destina-
tion (bypass tungsten electrode) would
better immerse the needed conductive
channel. In this case, reducing the torch
in a certain range may benefit the stabi-
lization of the arc dividing.
However, the metal transfer associ-
ated with the consumable wire compli-
cates the physical process. The droplet
needs to be detached from the wire tip
by a sufficient electromagnetic force.
When the wire feed speed is relatively
small, the current is relatively small.
The electromagnetic force that con-
tributes to detaching the droplet is rel-
atively small and would be insufficient
to effectively detach the droplet by it-
self. As a result, the droplet grows. If
the distance between the contact tip
and the workpiece is relatively small,
the droplet may touch the workpiece,
forming the short circuiting. This can
be seen by comparing Fig. 16A with B.
In this case, the main arc extinguishes
and the condition for the arc dividing
is no longer maintained. As a result,
the workpiece becomes the anode to
establish the arc with the tungsten.
The arc no longer divides at the wire
tip. The process deviates from the de-
sired DE-GMAW.
Of course, the occurrence of the
short circuiting is the only cause that
affects the arc dividing. If the arc
length of the main GMA is too short,
the GMA would contract (image 5 in
Fig. 6) such that it would not be able
to immerse the bypass tungsten elec-
trode. The DE-GMAW would still not
be maintained. As such, maintaining a
sufficient torch height and a sufficient
arc length is needed to maintain the
arc dividing in the DE-GMAW.
For the arcing-wire GTAW, the case
is simpler. The “root” where the arc is
divided is stationary in relation to the
wire where the “destination” resides.
The length of the added arc is main-
tained constant by the CV mode used.
The relative position between the
“root” and “destination” thus tends to
be maintained stationary — Fig. 17.
The droplet formed on the wire would
no longer extinguish the main arc or
break the condition to maintain the
needed conductive channel for the
added arc, despite possibly touching
the workpiece. Changing the torch
height appears to have limited affect
on the successful maintainance of the
arc dividing as long as the torch is not
extremely low such that the wire
points to the workpiece before it can
immerse into the GTA. The stability of
the arcing-wire GTAW can thus be eas-
ily maintained and is much less sensi-
tive to the variation in the torch
height, as observed from Experiments
4 to 6.
FEBRUARY 2016 / WELDING JOURNAL 55-s
WELDING RESEARCH
Conclusion
This experiment studied and ana-
lyzed the effect of the torch height on
the stability in two innovative divided-
arc processes: DE-GMAW and arcing-
wire GTAW. The authors found the fol-
lowing:
1) The torch height has a signifi-
cant impact on the arc behavior in DE-
GMAW. Maintaining a stable (bypass)
GTA means a successful arc dividing and
stable welding process. When the torch
height is sufficient, the droplet may
transfer in globular transfer mode. The
bypass arc can be established stably be-
tween the bypass tungsten electrode
and the main wire. Decreasing the torch
height may cause the short circuiting
transfer for the main GMA such that
the condition to divide the arc at the
wire tip is no longer maintained. The
process would switch between the suc-
cessful arc dividing (desired DE-GMAW)
and unsuccessful arc dividing (deviating
from the DE-GMAW), which would be
unstable.
2) The torch height has less impact
on the stability of the arcing-wire
GTAW. The stationary position of the
arc dividing root in relation to the
wire, and the CV mode for the added
GMA that tend to maintain a con-
stant distance between the arc divid-
ing “root” and “destination,” are
largely responsible for this desirable
stability. The independence of the
main GTA from possible short circuit-
ing between the wire and workpiece
also contributes to this desirable sta-
bility and insensitivity to the varia-
tion in the arc length.
Acknowledgments
This work is supported by the Nation-
al Science Foundation of China
(51375021) and the National Science
and Technology Major Project
(20142x04001171).
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56-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95

 WELDING RESEARCH

Liquation and Liquation Cracking in Partially

Melted Zones of Magnesium Welds
Magnesium alloys are susceptible to liquation cracking, but the crack susceptibility
can be predicted and eliminated based on a simple criterion

BY X. CHAI, T. YUAN, AND S. KOU

(Ref. 9), Wagner et al. (Ref. 8) kept the

ABSTRACT current from rising sharply and effec-
tively eliminated spatter.
Liquation, that is, liquid formation, can occur in the partially melted zone of a Mg alloy dur­
Wagner et al. (Ref. 8) and Chai et al.
ing welding and the liquid formed along grain boundaries can weaken them to cause intergran­
ular cracking, that is, liquation cracking. The present study investigated liquation and liquation (Ref. 10) discovered that more defects
cracking in arc welding of Mg alloys. The Mg alloys investigated were the most widely used Mg can occur persistently in GMAW of Mg
wrought alloy, AZ31 Mg, and the most widely used Mg casting alloy, AZ91 Mg. The filler metals alloys (even with CSC), including hy-
were AZ31 Mg, AZ61 Mg, and AZ92 Mg. To evaluate the susceptibility to liquation cracking, drogen porosity, oxide-film entrap-
bead­on­plate circular welds were made by gas metal arc welding. The microstructure of the ment inside butt-joint welds, high
partially melted zone was examined to check for evidence of liquation and liquation cracking. crowns on butt-joint welds. and fin-
AZ91 Mg was found to be much more susceptible to liquation than AZ31 Mg, and the gers from lap-joint welds. They estab-
difference was explained based on their distinctly different microstructures. The curves of tem­ lished mechanisms to explain how the
perature T vs. fraction solid fS during solidification were plotted for the workpiece and the weld unusual physical and chemical proper-
based on their compositions. The prediction and elimination of the crack susceptibility based
ties of Mg cause these defects and how
on comparing T­fS curves were demonstrated.
to eliminate them effectively. These
Mg properties include the high reac-
tivity with moisture in air to form
KEYWORDS Mg(OH)2 (hydrogen porosity), low
formability (sheets chipping along
• Liquation Cracking • Partially Melted Zone • Magnesium Alloys • AZ31 Mg edges during shearing before welding),
• AZ91 Mg • Gas Metal Arc Welding (GMAW) and high reactivity with oxygen in air
to form MgO (oxide-film entrapment
Introduction ule is too light to detach by gravity. inside butt-joint welds), low density
When the globule finally touches the and hence low fluidity (high crowns),
weld pool and causes short circuiting, and low density (fingers).
Magnesium (Mg) alloys have been the current rises sharply, causing the With these five defects eliminated
increasingly used for vehicle weight re- reinitiating arc to heat up suddenly, effectively, the potential of GMAW as
duction (Refs. 1–3), the density of Mg expand (explode), and expel the glob- a versatile process for welding Mg al-
(1.7 g/cm3) being about one-third less ule as spatter. In conventional GMAW, loys has greatly increased. Gas metal
than that of Al (2.7 g/cm3), and the it is not unusual for short circuiting to arc welding is simple, inexpensive, and
weldability of Mg alloys has become an cause spatter. However, it is the huge capable of mass producing high-
important issue in welding (Refs. 4–7). Mg globule providing extra liquid Mg quality welds. Unlike friction stir weld-
Gas metal arc welding (GMAW) has for the arc to expel that makes the ing, it requires no rigid clamping or
been widely used for welding sheet spatter so severe. Although the surface backing and it makes fillet welds easi-
metals, such as Al alloys, steels, and tension of Mg is relatively low (lower ly. It can help accelerate the use of Mg
stainless steels. But its use for welding than that of Al), the very large but alloys as the lightest structural metal.
Mg sheets has long been delayed by se- light globule can be pushed by the arc The present study focuses on a sixth
vere spatter. Wagner et al. (Ref. 8) to become nearly horizontal and con- defect in welding Mg alloys — liqua-
showed recently that, due to the low tinue to grow bigger before short cir- tion cracking.
Mg density, the Mg filler metal melts cuiting. With a process controller, Since Mg alloys are similar to Al al-
easily to form a globule and the glob- called controlled short circuiting (CSC) loys in several physical and metallurgi-

X. CHAI is graduate student and S. KOU is professor, Department of Materials Science and Engineering, the University of Wisconsin, Madison, Wis. T. YUAN is
graduate student, School of Materials Science and Engineering, Tianjin University, Tianjin, China.

FEBRUARY 2016 / WELDING JOURNAL 57-s

WELDING RESEARCH

high thermal dif- present study involved no dissimilar

fusivity, wide Mg welding. Instead, a workpiece
melting tempera- without a hole was welded by bead-on-
ture range with plate welding to study both liquation
respect to their and the effect of the filler metal on li-
relatively low liq- quation cracking.
uidus tempera-
ture, and low eu- Experimental Procedure
tectic tempera-
ture (Refs. 15, Both wrought and cast Mg alloys
16). Thus, like Al were investigated, including the most
alloys, Mg alloys widely used Mg wrought alloy AZ31
are likely to be and the most widely used Mg casting
susceptible to li- alloy AZ91. Magnesium alloys are
quation and liqua- known to have low formability because
tion cracking. of their hexagonal closed packed (hcp)
Liquation structure (Ref. 24). Thus, the availabil-
cracking in Mg al- ity of Mg wrought alloys is limited,
loys has been re- and Mg casting alloys often have to be
Fig. 1 — Top view of workpiece before welding. ported (Refs. used. This is why it is desirable, in
17–20) even in studying the weldability of Mg alloys,
cal properties, the studies of Kou and friction stir weld- to include Mg casting alloys. The com-
coworkers on liquation and liquation ing (Refs. 21, 22). Recently, Yuan et al. positions of the materials used for
cracking of Al alloys (Refs. 11–14) can (Ref. 23) studied liquation cracking in welding are listed in Table 1 (Refs. 25,
help explain liquation and liquation butt-joint welds between dissimilar 26). Plates of AZ31 Mg were cut from
cracking in Mg alloys. Like Al alloys, Mg alloys by circular-patch welding. A a 3.2-mm-thick AZ31 Mg sheet while
Mg alloys tend to have low tempera- circular patch of one Mg alloy was plates of AZ91 Mg were cut from an
ture gradients normal to the fusion placed inside a round hole in the work- as-cast ingot. They were machined to
boundary and hence a wide partially piece of a different Mg alloy and weld- desired dimensions.
melted zone because of their relatively ed in a butt-joint configuration. The A Jetline Engineering weld process
controller called CSC-MIG (Ref. 9) was
Table 1 — Nominal Compositions of Materials Used for Welding (Refs. 25, 26) connected to a Miller Electric Invision
456P, a power source for conventional
Al (wt­%) Zn (wt­%) Mn (wt­%) Mg (wt­%) GMAW. The parameters used in CSC-
GMAW are shown in Table 2. The wave-
Workpiece
AZ31 3.0 1.0 0.6 balance forms of the welding current and arc
AZ91 9.0 0.7 0.2 balance voltage were recorded using a computer-
based data acquisition system and the
Welding wires
AZ31 3.0 1.0 0.6 balance software LabView. The data-sampling
AZ61 6.5 1.0 0.3 balance rate for each signal was 15,000 Hz.
AZ92 9.0 2.0 0.3 balance It was found that a workpiece of
102  102  1.6 mm tended to distort

Table 2 — Parameters Selected for CSC Welding

CSC Welding Parameters

Arc Phase Short Circuit Phase Wire Feeding Preheating P Delay Arc
(ms) Length
(mm)
Feed
Current Delay Current Delay Rate Delay Current (A) 0 0.2
(A) (ms) (A) (ms) (m/min) (ms)

start 44 4 start 96 2.5 down 8 0 58 CT Opening Argon

(mm) Flow
(L/min)
mid 54 6 mid 106 3.0 up 1 8 6 Delay (ms)
end 46 end 85 up 2 8 90 16 16.5

P Delay: penetration delay

CT Opening: distance between contact tube and workpiece
ms: millisecond
m/min: meter per minute
L/min: liter per minute

58-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95


A B
Fig. 2 — Bead­on­plate circular welding experiment: A — Workpiece; B — vertical cross
section of the apparatus.
Fig. 3 — Volume of the workpiece Vworkpiece and volume of the filler metal Vfiller in the
weld. The broken lines indicate the boundaries of the workpiece before welding.
Table 3 — Conditions for Circular Welding Experiments
Workpiece Filler Metal
AZ91 AZ31
AZ91 AZ92
AZ31 AZ61
AZ31 AZ92
after welding. So, beyond the thinner
inner square of 70  70  1.6 mm, the
workpiece was 3.2 mm thick to pre-
vent distortion, as shown in Fig. 1.
Figure 2 shows schematically the
circular welding test. To keep the
workpiece from contracting during
welding, it was bolted down tightly
with a torque wrench to a thick copper
plate and the thick stainless steel base
plate below it. This allowed severe ten-
sion to be induced along the outer
WELDING RESEARCH
welding gun was stationary with its tip
positioned 25.4 mm away from the cen-
ter of the workpiece, so, while the
turntable rotated, a circular weld was
made with the radius of 25.4 mm.
The diameters of the wires are also
shown in Table 3. The diameter of the
AZ31 welding wire was 1.2 mm. How-
ever, welding wires AZ61 and AZ92
were older and had to be cleaned with
sandpaper and washed with acetone
before welding in order to avoid gas
porosity. This reduced the wire diame-
ters slightly. The AZ61 wire diameter
was 1.16 mm, and the AZ92 wire 1.19
mm.
The linear travel speed in mm/min
was 2  25.4 mm  (rotation speed in
rpm). Since the rotation speed was 1.6
rpm, the linear travel speed was 255
mm/min in all experiments. The val-
ues of the average power P in Table 3
were calculated using the following
equation:
t
P= ( I E )dt / t ( 1)
0
where I is the current, E is the voltage,
and t is the welding time. The differ-
ences in the wire physical properties
and diameter contributed to the dif-
ferences in the power.
Figure 3 shows the volume of the
workpiece in the weld Vworkpiece and that
of the filler metal in the weld Vfiller. The
total volume of the weld Vweld = Vworkpiece
+ Vfiller. Thus, the ratios Vworkpiece/Vweld
and Vfiller/Vweld represent the volume
fractions of the workpiece and the
filler metal in the weld, respectively.
The ratio Vworkpiece/Vweld is called the di-
Wire Size Travel Speed Power lution of the filler metal by the work-
(mm) (mm/min) (W) piece (Ref. 15). The higher it is, the
1.20 255 686 more the filler metal is diluted by the
1.19 255 710 base metal. Based on these volume
1.16 255 935 fractions and the compositions of the
1.19 255 819
workpiece and filler metal (shown in
Table 1), the composition of the weld
weld edge to cause cracking. No can be calculated as follows:
cracking occurred along the inner
edge of the weld because it was in (wt-% E)weld = (Vworkpiece/Vweld)
compression. (wt-% E)workpiece + (Vfiller/Vweld)
Table 3 shows the conditions used (wt-% E)filler (2)
for circular welding experiments. The
apparatus was laid flat on a positioner where (wt-% E)weld, (wt-% E)workpiece, and
to rotate at the predetermined speed (wt-% E)filler are the wt-% of element E
during welding. The welding position in the weld, workpiece, and filler met-
was flat and the welding gun was verti- al, respectively.
cal with a distance of 16 mm between It should be pointed out that Equa-
its contact tube and the workpiece. The tion 2 is based on the assumption of
FEBRUARY 2016 / WELDING JOURNAL 59-s
WELDING RESEARCH

satisfactorily. volume of the weld Vweld. The volume

A were cut in the
B acetic acid + 5 g
Fig. 4 — Top views of example welds: A — Weld showing liquation
cracking along the outer weld edge; B — weld showing no cracking.
complete mixing in the weld pool,
which has been verified by Houldcroft
(Ref. 27) in single-pass welds made by
GMAW, and which is used routinely in
the calculation of the weld composi-
tion. The very fast Lorentz force-
driven flow (~ 10 cm/s) and Marango-
ni flow (~ 1 m/s) (Refs. 28–31) suggest
mixing across the weld pool tens or
hundreds of times before solidifica-
tion. In the previous studies of Kou
and coworkers (Refs. 16, 32–34) on
liquation cracking of Al alloys, this
assumption was found to work
The welds of the filler metal in the weld can be
calculated by Vfiller = Vweld – Vworkpiece. The
transverse direc- cross sections were also examined by
tion, polished, optical microscopy and scanning elec-
and etched in or- tron microscopy (SEM) to show liqua-
der to determine tion inside the partially melted zone.
volumes Vworkpiece,
Vweld, and Vfiller.
For AZ91 Mg, Results and Discussion
they were then
first etched for 3 Liquation
s in a solution of
3 mL HCl (con- Two examples of the circular welds
centrated) + 100 made in the present study are shown
mL ethanol and in Fig. 4. Figure 4A shows the weld
then etched for made by welding AZ91 Mg alloy with
another 3 s in a an AZ31 Mg filler metal. Cracking is
solution of 5 mL clear along the outer edge of the weld.
However, no cracking is visible along
picric acid + 10 the inner edge. This is because, as the
mL distilled wa- weld shrank during welding, the outer
ter + 100 mL edge was in tension and the inner edge
ethanol. As for in compression. Figure 4B, on the oth-
AZ31B, they er hand, shows the weld made by weld-
were etched for ing AZ31 Mg alloy with an AZ92 filler
15 s in a solu- metal. No cracking is visible either
tion of 5 mL along the outer or inner edge. The
acetic acid + 6 g weld is narrower as compared to that
picric acid + 10 in Fig. 4A mainly because the AZ31
mL distilled wa- Mg workpiece has a higher liquidus
ter + 100 mL temperature than the AZ91 Mg
ethanol. After workpiece.
etching, trans- The microstructure of the partially
verse macro- melted zone in AZ91 Mg alloy is
graphs of the shown in Fig. 5. The weld was made by
welds were tak- welding AZ91 Mg with an AZ31 Mg
en using a digital filler metal. In Fig. 5A, the boundary
camera with a between the fusion zone and the par-
close-up lens and bellows. With the tially melted zone is indicated by the
help of computer software, the macro- broken line. Near the fusion boundary,
graph was used to determine Vworkpiece cracking along grain boundaries is visi-
and Vweld. The thickness of the work- ble. A SEM image of the base metal
piece Hworkpiece was measured and used taken far away from the fusion bound-
respectively in the calculations of ary, beyond the right-hand side of the
Vworkpiece, that is, Vworkpiece = Hworkpiece area covered by Fig. 5A, is shown in
((Rb)2 – (R a)2). In view of the fact the Fig. 5B. Figure 5C shows a SEM image
vertical thickness of the weld varied in of the partially melted zone. An opti-
the radial direction R, the weld was di- cal micrograph at the borderline be-
vided into about a dozen rings of equal tween the partially melted zone and
DR. The volume of each ring was calcu- the base metal is shown in Fig. 5D
lated. The summation of the volumes (where the peak temperature during
of these rings was used to calculate the welding was the eutectic temperature).

Table 4 — Fractions of Phases in As­Cast AZ31 Mg Alloy

Phase Al12Mg17 AlMgZn_phi Al8Mn5 AlMgZn_tau MgZn Al11Mn4 Al4Mn

Fraction 2.10  10–2 5.5  10–3 3.87  10–3 3.20  10–4 9.66  10–4 1.19  10–5 5.65  10–6

60-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95

 WELDING RESEARCH

Based on the phase diagram, the mi-

A crostructure of an as-cast binary Mg-
9Al alloy should be a matrix of the Mg-
rich phase  embedded with an eutec-
tic consisting of  and  (Mg17Al12).
The SEM image of the base metal in
Fig. 5B shows a divorced eutectic in
the form of coarse  (Mg17Al12) parti-
cles instead of an ordinary composite-
like structure of the / (Mg17Al12) eu-
tectic. In other words, the  phase of
the eutectic is connected to and thus
indistinguishable from the surround-
ing  matrix. The fine needle-like pre-
cipitates are the  (Mg17Al12) phase
B that forms from the  phase, not from
the liquid, along some specific orienta-
C tions as temperature falls below the
solvus line. The composition analysis
by EDS indicates that point 1 is close
to the Mg-rich  phase in composition
and point 2 close to  (Mg17Al12). Ac-
cording to the Mg-Al phase diagram,
the  phase consists of about 58 wt-%
Mg and 42 wt-% Al.
The SEM image of the partially
melted zone in Fig. 5C shows the ma-
trix of the Mg-rich phase  is embed-
ded with an ordinary composite-like
structure of the / (Mg17Al12) eutec-
tic. The composition analysis by EDS
indicates that point 3 is close to the
Mg-rich  phase in composition and
point 4 close to eutectic / (Mg17Al12)
D in composition, which consists of
about 67 wt-% Mg and 33 wt-% Al.
The eutectic formed here by the con-
stitutional liquation mechanism was
originally proposed by Pepe and Sav-
age (Refs. 36, 37). Essentially, due to
rapid heating during arc welding, the
coarse  (Mg17Al12) particles did not
have time to dissolve completely when
the local temperature rose above the
solvus. The fine  (Mg17Al12) precipi-
tates most likely dissolved completely
before reaching the eutectic tempera-
ture. Upon reaching the eutectic tem-
perature TE, the remaining coarse 
(Mg17Al12) particles reacted with the
surrounding  matrix to form liquid,
that is, to cause liquation. This is indi-
Fig. 5 — Transverse micrographs of as­cast AZ91 Mg weld made with AZ31 Mg welding cated by the eutectic reaction in the
wire: A — Optical micrograph (broken line indicating fusion boundary); B, C — SEM im­ phase diagram as  +   LE, where LE
ages and results of EDS analysis; D — optical micrograph at border line between partially is the eutectic liquid. Thus, the coarse
melted zone and base metal, which is beyond the right­hand side of A.  (Mg17Al12) particles can be consid-
ered as the low melting point segre-
Figure 5D was taken from an area be- binary Mg-Al phase diagram (Ref. 35) gates along grain boundaries (and
yond the right-hand side of Fig. 5A. in Fig. 6 will be used as an approxima- within grains). Upon further heating
In order to explain the microstruc- tion. According to the phase diagram, to above TE, more  dissolves into the
ture in Fig. 5, the Mg-rich side of the the eutectic temperature is 437°C. eutectic liquid to make it hypoeutectic

FEBRUARY 2016 / WELDING JOURNAL 61-s

WELDING RESEARCH

(less solute than the eutectic composi-

tion). Upon subsequent cooling,
the hypoeutectic liquid solidified
first as the  phase and last as the
/ (Mg17Al12) eutectic.
The microstructure of the partially
melted zone in AZ31 Mg alloy is
shown in Fig. 7. The weld was made
with an AZ92 Mg filler metal. Figure
7A is a transverse macrograph of part
of the weld, again with a broken line
indicating the fusion boundary. No
cracking is visible. The fractions of in-
termetallic phases that form during
the solidification of AZ31 Mg, calcu-
lated using Pandat (Ref. 38) and Pan-
Magnesium (Ref. 39), are summarized
in Table 4. As shown, about 2% of
 (Mg17Al12) can be present in an as-
cast AZ31 Mg. However, no 
(Mg17Al12) could be found in the base
Fig. 6 — Binary Mg­Al phase diagram (Ref. 35). metal by optical or scanning electron
microscopy. This is because the AZ31
Mg is a wrought alloy, and it is nor-
A mally heat treated after casting to
dissolve  (Mg17Al12). The phase dia-
gram in Fig. 6 shows that AZ31 Mg,
which is essentially Mg-3Al alloy, can
be solutionized in the Mg-rich phase 
to dissolve  (Mg17Al12). Some particles
are visible in the partially melted zone
in Fig. 7A and the inset enlarges the
boxed area in the same figure to show
the particles more clearly. In the inset
the region to the right of the broken
line that contains scattered particles
represents the partially melted zone
and the particles were liquid during
welding. Figure 7B shows the SEM im-
C B age of the AZ31 Mg base metal. No
 (Mg17Al12) is visible. The composition
analysis by EDS indicates that point 1
is close to the Mg-rich  phase in com-
position and point 2 an intermetallic
compound consisting of essentially Al
and Mn alone. According to Table 4,
the Al-Mn intermetallic compound at
point 2 is most likely Al8Mn5. Al11Mn4
and Al4Mn are two and three orders of
magnitude lower in quantity, respec-
tively. Based on the atomic weights of
Al (26.98 g/mole) and Mn (54.94
g/mole), Al8Mn5 consists of 44 wt-% Al
and 56 wt-% Mn, which are close to
the values of 44.52 wt-% Al and 52.9
wt-% Mn measured by EDS.
Fig. 7 — Transverse micrographs of a circular weld of AZ31 made with AZ92 welding wire:
Figure 7C is a SEM image taken
A — Transverse cross section (the inset enlarging the boxed area and broken lines indicating close to the fusion boundary. Both
fusion boundary); B — SEM image of base metal; C — SEM image near fusion boundary. particles are composite-like, suggest-
ing liquation by eutectic reactions be-
tween the Mg-rich  matrix and some

62-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95

 WELDING RESEARCH

A positions of the welds. In the case of

B crostructure around the weld pool illus-
Fig. 8 — Criterion for susceptibility to cracking along weld edge: A — Phase diagram
showing alloy Co (workpiece); B — microstructure around weld pool in welding of alloy
Co; C — cracking likely in welding of an alloy; D — cracking unlikely in welding another
alloy with another filler metal. Rectangular box in B is enlarged in C, D.
very small intermetallic particles. The
composition analysis by EDS indicates
that point 3 is rich in Mg, Zn, and Al.
It is likely to be the eutectic reaction
product between the  matrix and an
AlMgZn-phi or AlMgZn-tau particle
that still existed in the workpiece be-
fore welding. It is more likely to be the
former because it is about ten times
more abundant according to Table 4.
The particle at point 4 consists of
much Al and Mn and some Mg. It is
perhaps the reaction product between
the  matrix and an Al8Mn5 particle.
In any case, there is much less liqua-
tion in the partially melted zone of
AZ31 Mg than that of AZ91 Mg. There
is no evidence of constitutional liqua-
tion caused by  (Mg17Al12) particles as
in the case of AZ91 Mg.
As explained above, the differences
between Figs. 5C and 7C are mainly
C welding AZ91 Mg with filler metal AZ31
D that illustrated in Fig. 8C, cracking can
caused by coarse  (Mg17Al12) particles
reacting with the Mg-rich  matrix to
form much liquid, which is present in
the as-cast AZ91 Mg alloy but not the
wrought AZ31 Mg alloy. The liquid is
enough to form continuous films
along grain boundaries to separate
grains and weaken the partially melted
zone of AZ91 Mg. In the case of AZ31
Mg, if any liquid forms in the partially
melted zone, it is very small in quanti-
ty and discontinuous, thus still allow-
ing firm bonding between grains.
Thus, the as-cast AZ91 Mg alloy
can be expected to be more susceptible
to liquation cracking.
Liquation Cracking
The extents of cracking in the circu-
lar welds are shown in Table 5, along
with the levels of dilution and the com-
Mg, the outer edge cracked along 66.7%
of its circumference. In order to explain
the results, Fig. 8 illustrates the interac-
tion between weld (S+L), i.e., the mushy
zone, and workpiece (S+L), i.e., the par-
tially melted zone. Kou and Le (Refs. 16,
40) established the semisolid mi-
trated in Fig. 8B by quenching the weld
pool and its surrounding area with wa-
ter during welding and by using the
phase diagram.
The mechanism of liquation crack-
ing in the partially melted zone can be
explained based on the semisolid
microstructure around the weld pool.
With the bonding between grains
weakened by significant liquid forma-
tion along grain boundaries, such as
occur in the partially melted zone if
significant tension exists. This crack-
ing is called liquation cracking. It oc-
curs along the edge of the weld and
hence can also be called weld-edge
cracking. The tension in the partially
melted zone is induced by the solidify-
ing and contracting weld pool that is
much larger than and immediately
next to the partially melted zone. Con-
traction of the weld pool, in turn, is in-
duced by solidification shrinkage and
thermal contraction. When the weld
pool solidifies, it shrinks because the
solid has a higher density than the liq-
uid, about 6.6% for Al and 4.2% for
Mg (Ref. 41). The solidified weld metal
contracts during cooling because of
contraction due to its thermal expan-
sion coefficient.
Based on the liquation cracking
mechanism, Kou and coworkers (Refs.
32–34) proposed the following criteri-
on for the susceptibility of Al alloys to
liquation cracking:
Susceptible if weld fS > workpiece fS (3)
This criterion is illustrated in Fig.

Table 5 — Cracking Extent, Dilution Levels, and Compositions of Welds

Workpiece Filler Cracking Dilution by Al in Zn in Weld Mn in Weld Mg in Weld

Metal along Outer Edge Workpiece (%) Weld (wt­%) (wt­%) (wt­%) (wt­%)
AZ91 AZ31 66.7% cracked 36.9 5.21 0.89 0.45 balance
AZ91 AZ92 no cracking 44.2 9.0 1.43 0.26 balance
AZ31 AZ92 no cracking 36.5 6.81 1.64 0.41 balance
AZ31 AZ61 no cracking 45.5 4.91 1.0 0.44 balance

FEBRUARY 2016 / WELDING JOURNAL 63-s

WELDING RESEARCH
Fig. 9 — AZ91 Mg welded with AZ31 Mg welding wire: A — T­fS curves predicting crack
susceptibility; B — verification of predicted crack susceptibility. T­fS curves calculated
using Pandat (Ref. 38) and PanMagnesium (Ref. 39) of CompuTherm, LLC.
8C, D. The assumption was that the
strength and hence the crack resist-
ance of a semisolid increases with in-
creasing fraction solid, which has been
verified experimentally (Ref. 42). For
simplicity, it was also assumed that
the morphology of the semisolid, e.g.,
dendritic or granular, is not as impor-
tant as the fraction solid. The same as-
sumption also implies that the grain
size of the semisolid is not as impor-
tant as the fraction solid. With a larger
grain size and hence a smaller grain
boundary area, the grain boundary liq-
uid and tensile strains are concentrat-
ed in a smaller area to make cracks
open wider. A larger grain size can also
reduce the number of changes in direc-
tion per unit distance along the crack
path, thus making it easier for crack
propagation. However, the effect of
fraction solid is still expected to domi-
nate. The prerequisites for liquation
cracking are significant liquation and
64-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95
A reaches about 0.3. Thus, Equation 3
D weld composition.
B be calculated based on their composi-
tension in the partially melted zone.
Without them a larger grain size alone
cannot cause cracking. In circular
welding, the prerequisites can be met
by welding with a sufficient heat input
to cause significant liquation in the
partially melted zone and tightly
clamping the workpiece to keep it
from contracting so that significant
strain can be induced normal to the
weld. Surprisingly, this criterion,
though very simple, works very well
for Al alloys as verified against numer-
ous welding experiments reported in
the literature, including those con-
ducted by The Welding Institute and
in the authors’ laboratory (Ref. 33).
Naturally, the susceptibility to li-
quation cracking is more significant
when the weld fS is significantly higher
than the workpiece fS. In general, a dif-
ference of 0.05 in fS is considered sig-
nificant enough. According to Flem-
ings (Ref. 41), significant strength de-
velops during solidification after fS
applies after some strength has devel-
oped in the semisolid, say after fS
reaches 0.3.
The criterion is easy to use as the
curve of temperature T vs. fraction
solid fS of the weld and that of the
workpiece can be calculated based on
their compositions using commercial
software and databases. The composi-
tion of the weld depends not only on
the compositions of the workpiece and
the filler metal but also on the dilu-
tion, as shown in Fig. 3 previously.
Therefore, when a proper filler metal
is selected, a proper dilution level may
still be needed to obtain the desired
The T-fS curves of the weld and the
workpiece (which has the same compo-
sition as the partially melted zone) can
tions. The simple Scheil solidification
model is valid because cracking occurs
shortly after solidification starts (no
time for solid diffusion), e.g., 5 to 7 s as
measured in permanent-mold casting of
Mg alloys (Refs. 43–45) and even short-
er in arc welding. According to Flemings
(Ref. 41), solid-state diffusion can be
neglected when 4kDStf/(d2) < 0.1, where
k is the equilibrium segregation ratio, DS
the coefficient of diffusion in solid, tf
the solidification time, and d the sec-
ondary dendrite arm spacing (DAS).
Based on the data of DAS of Al alloys vs.
the cooling rate (Ref. 41), with a second-
ary DAS of 1  10–5 m, the cooling rate
is about 100°C/s. With a typical freezing
temperature range of about 125°C for Al
alloys (such as the average of 2014,
2024, 2219, 6061, 7075 Al), the local
freezing time tf is about 1.25 s. DS is typ-
ically 1  10–12 m2/s and k around 0.15
(0.125 for Al-Si and 0.170 for Al-Cu).
Thus, 4kDStf/(d2) is around 0.0075 < 0.1,
which suggests negligible solid-state dif-
fusion. Thus, the cooling rate is fast
enough to make diffusion negligible and
the fS calculation is not affected by dif-
fusion, which is significant only at rela-
tively slow cooling rates. The T-fS curves
were calculated using the thermody-
namic software Pandat (Ref. 38) and the
Mg database PanMagnesium (Ref. 39)
of CompuTherm, LLC, in Madison, Wis.
The compositions of the welds calculat-
ed according to Fig. 3 are shown in Table
5, along with the dilution of the welding
wire by the workpiece measured based
 WELDING RESEARCH

the transverse cross section, as shown

A in Fig. 10B. Thus, the crack suscepti-
bility can be eliminated by selecting a
proper filler metal and dilution level,
and the simple criterion can be used as
a guide for the selection.
The weld made with AZ31 Mg as the
workpiece and AZ92 Mg as the welding
wire is shown in Fig. 11. The T-fS curves
in Fig. 11A show the weld fS is signifi-
cantly less than the workpiece fS up to
about fS = 0.96, beyond which they be-
come almost identical to each other.
The absence of crack susceptibility pre-
dicted by the T-fS curves is verified by
the absence of cracking in the trans-
verse cross section in Fig. 11B.
Figure 12 shows the weld made
with AZ31 Mg as the workpiece and
AZ61 Mg as the welding wire. The T-fS
curves in Fig. 12A show that weld fS is
significantly less than the workpiece
B fS, up to about fS = 0.96. So, no crack-
ing is expected up to this point. Be-
yond fS = 0.96, the weld fS becomes
slightly higher than the workpiece fS,
by less than about 0.02. Thus, the
curves suggest no significant suscepti-
bility to cracking. No cracks can be ob-
served on the transverse cross section,
as shown in Fig. 12B.

Conclusions
Fig. 10 — AZ91 Mg welded with AZ92 Mg welding wire: A — T­fS curves predicting no
crack susceptibility; B — verification of predicted no crack susceptibility. T­fS curves calcu­ 1. The crack susceptibility of Mg
lated using Pandat (Ref. 38) and PanMagnesium (Ref. 39) of CompuTherm, LLC. welds can be predicted by comparing
the T-fS curves of the weld and the
on the weld transverse cross section. is significantly greater than the work- workpiece, that is, susceptible if weld
Since weld (S+L) and workpiece piece fS up to about fS = 0.92 as indicat- fS > workpiece fS. The susceptibility is
(S+L) are in intimate contact with each ed by the region encircled by the dot- significant if the difference is signifi-
other along the weld edge, at any given ted oval. For instance, when the AZ91 cant, e.g., 0.05 and above.
point along the weld edge the thermal Mg workpiece fS reaches 0.70 (at about 2. This simple criterion can be used
cycles (temperature T vs. time t) they 525°C), the weld fS is about 0.86, that as a useful guide to selecting a proper
experience are identical. Thus, when a is, higher by about 0.16. Thus, the Mg filler metal and dilution level to
different heat input or travel speed is curves suggest a significant suscepti- avoid liquation cracking.
used, the thermal cycles both change bility to cracking. Beyond 0.92, the 3. As-cast AZ91Mg can be highly
but are still identical to each other. In weld fS becomes slightly lower than the susceptible to liquation during welding
fact, the thermal cycles of the two workpiece fS, but this is too late to due to the presence of numerous
semisolids are still identical even if the keep cracking from occurring. The coarse  (Mg17Al12) particles in the Mg-
cooling rate becomes slow enough to crack susceptibility predicted by the rich matrix , causing liquation by  +
cause significant solid-state diffusion, T-fS curves in Fig. 9A is verified by the   LE at a eutectic temperature as low
which can be considered by using a so- cracks visible in the transverse cross- as 437°C. The large amount of liquid
lidification model that includes solid- section of the weld in Fig. 9B. formed separates grains and causes
state diffusion. Consequently, compar- Figure 10 shows the weld made cracking under the tension induced by
ing the T-fS curves of the two semi- with AZ91 Mg as the workpiece and the solidifying and contracting weld
solids is equivalent to comparing their AZ92 Mg as the welding wire. The T-fS metal nearby. The use of a proper filler
t-fS curves. curves in Fig. 10A show the weld fS is metal and dilution is essential for
Figure 9 shows the weld made with less than the workpiece fS at any time avoiding cracking in AZ91 Mg.
AZ91 Mg as the workpiece and the during solidification. Thus, the curves 4. Wrought AZ31 Mg alloy is much
AZ31 Mg as welding wire. The T-fS suggest no significant susceptibility to less susceptible to liquation due to its
curves in Fig. 9A show that the weld fS cracking. No crack can be observed on solution heat treatment during produc-

FEBRUARY 2016 / WELDING JOURNAL 65-s

WELDING RESEARCH
Fig. 11 — AZ31 Mg welded with AZ92 Mg welding wire: A — T­fS curves predicting no
crack susceptibility; B — verification of predicted no crack susceptibility. T­fS curves cal­
culated using Pandat (Ref. 38) and PanMagnesium (Ref. 39) of CompuTherm, LLC.
tion, which dissolves  (Mg17Al12) and
raises the liquation temperature from
the eutectic temperature to the much
higher solidus temperature of 600°C.
This work was supported by the Na-
tional Science Foundation under Grant
No. IIP-1034695, the American Welding
Society Foundation (the AWS Founda-
tion Fellowship Program for Xiao Chai),
and the University of Wisconsin Foun-
dation through the Industry/University
Collaborative Research Center (I/UCRC)
for Integrated Materials Joining Science
for Energy Applications.
Acknowledgments
The authors would like to thank: 1)
CompuTherm, LLC, in Madison, Wis.,
and Professor Rainer Schmid-Fetzer,
Clausthal University of Technology,
Clausthal-Zellerfeld, Germany, for the
66-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95
A try. International Journal of Advanced Man-
B arc welding of magnesium alloys: Mecha-
software package Pandat and the data-
base PanMagnesium; 2) Tom Kurilich
of US Magnesium, LLC, Salt Lake City,
Utah, for donating 45 kg (100 lb) of
pure Mg ingots; 3) Derek Landwehr
for machining numerous specimens
for the circular-patch test.
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WELDING RESEARCH

TLP Bonding of Dissimilar FSX­414/IN738 System

with MBF80 Interlayer: Optimization of the
Bonding Time and Temperature
The effect of bonding temperature on the microstructure and mechanical properties
of the TLP­bonded FSX­414/MBF80/IN738 system is investigated

BY B. ABBASI-KHAZAEI, G. ASGHARI, AND R. BAKHTIARI

MPD diffusion into the base metal as

ABSTRACT well as diffusion of base metal alloying
elements into the interlayer during
In this research, the effect of bonding temperature (1050°–1200°C) on the joint
bonding.
microstructure and mechanical properties was studied for dissimilar transient liquid
phase bonded FSX­414/IN738 superalloys using MBF­80 interlayer. The width of There are many studies about TLP
diffusion­affected zone (DAZ) increased with increasing bonding temperature or bonding bonding of Ni-based superalloys. For
time. Also, the DAZ width in the IN738 half was higher than that of the FSX­414 half, example, Ojo et al. (Ref. 6) reported on
which showed more effective diffusion of melting point depressant elements into the the effect of joint clearance size and
IN738 half. For joints made at 1200°C, isothermal solidification was not complete even bonding parameters on diffusion braz-
after 10 min and secondary eutectics were formed at the joint centerline. Maximum ing of IN738 superalloy. The results
hardness of DAZ at the IN738 half was higher than that of the FSX­414 half at various showed that appropriate optimization
bonding temperatures. Furthermore, hardness values of both halves were reduced with of the TLP bonding variables, such as
increasing bonding temperature. The hardness of isothermal solidification zone as well bonding temperature, bonding time,
as the joint’s shear strength increased with increasing the bonding temperature.
and thickness and composition of the
interlayer, resulted in a joint which
properties are close to the base metal.
KEYWORDS Based on the work of Cook et al. (Ref.
• Superalloys • Dissimilar Transient Liquid Phase Bonding • Diffusion
7), a minimum isothermal solidifica-
• Scanning Electron Microscope tion time can be achieved at each
bonding temperature. However, Ab-
delfatah et al. (Ref. 8) and Mosallaee et
bines. In comparison with diffusion al. (Ref. 9) reported a critical bonding
bonding, TLP needs lower levels of temperature, above which the time of
Introduction pressure during bonding and there is complete isothermal solidification in-
no limitation of joint width. However, creases. Therefore, determining the
The Co-based FSX-414 and Ni- the effect of bonding pressure on TLP critical temperature is necessary to
based IN738 superalloys are especially joint’s microstructure and mechanical achieve reasonable bonding time.
used for first-stage nozzles and blades properties has been reported (Refs. 3, Idowu et al. (Ref. 10) studied the
of gas turbines, respectively, which are 4). In this process, an interlayer is TLP bonding of IN738 LC using Ni-Cr-
subjected to the highest gas path tem- used that contains melting point de- B interlayer. The results showed that
perature, as reported by Schilke. From pressant (MPD) elements such as B, P, the isothermal solidification occurs
an industrial point of view, high- and Si. The TLP bonding temperature under two separate regimes, depend-
quality joining of these blades and is selected higher than the interlayer ing on the bonding temperature. This
nozzles is necessary to repair the serv- melting point and lower than the base led to a different isothermal solidifica-
ice damages (Ref. 1). metal solidus temperature. Ghoneim tion rate and time, which was attrib-
Transient liquid phase (TLP) bond- et al. (Ref. 5) showed that the bonding uted to the substantial enrichment of
ing, as was reported by Duvall et al. time should be sufficient to cause the liquid interlayer with the base
(Ref. 2), is a combination of diffusion complete isothermal solidification of metal solute elements and its continu-
bonding and liquid phase joining the joint due to the compositional ous modification during isothermal
processes developed for joining of changes between the joint region and solidification. Research by Jalilvand et
high-temperature parts of gas tur- base alloy. These changes are results of al. (Ref. 11) about TLP bonding of

B. ABBASI­KHAZAEI (b.abbasi@razi.ac.ir), G. ASGHARI, and R. BAKHTIARI are assistant professors, Department of Materials Engineering, Razi University,
Kermanshah, Iran.

68-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95


Fig. 1 — Temperature profile used during bonding.
IN738 LC using AMS 4776 interlayer
showed that the rate of isothermal so-
lidification decreases as the bonding
temperature increases to 1150°C.
There is less research about TLP
bonding of Co-based superalloys in
comparison to the Ni-based ones.
Bakhtiari et al. (Ref. 12) investigated
the effect of TLP bonding temperature
on microstructural and mechanical
properties of joints made using FSX-
414 superalloy. The results showed
that 1190°C was the critical tempera-
ture of base metal liquefaction. Re-
search by Bakhtiari et al. (Ref. 13)
about TLP bonding of FSX-414 super-
alloy showed that the time of complete
isothermal solidification increased
with increasing root opening size.
Also, at complete isothermal solidifica-
tion condition, the shear strength and
the hardness of the isothermal solidifi-
cation zone decreased with an increase
of the root opening size.
Dissimilar TLP bonding of FSX-
414/IN738 superalloys using MBF80
interlayer has been investigated by Ab-
basi et al. (Ref. 14). They predicted sol-
id/liquid interface location using the
finite difference method. It seems the
effect of bonding temperature and
time on the bonding properties has
not been investigated so far. There-
fore, the main purpose of this research
is to investigate the effect of bonding
temperature on the microstructure
Table 1 — Chemical Composition of the IN738 and FSX­414 Superalloys and MBF­80 Interlayer
Ni Co Cr Mo W Nb
IN738 Bal. 8.5 15.84 1.88 2.48
FSX­414 10.32 Bal. 30.25 0.03 6.76
MBF­80 Bal. — 15.2 — —
Fig. 2 — Schematic diagram of the shear test fixture.
and mechanical
properties of the
TLP-bonded FSX-
414/MBF80/IN738
system.
Materials and
Experimental Procedure
As-cast FSX-414 and IN738 super-
alloys, with chemical compositions
shown in Table 1, were used in the
form of 10 × 10 × 5 mm coupons. Be-
fore TLP bonding, the mate surfaces
were ground using 600 grade SiC pa-
per and then ultrasonically cleaned in
an acetone bath. MBF-80 interlayer
(Table 1) with thickness of 50 μm was
inserted between two parts of the base
metal and a steel fixture was used to
hold the assembly and reduce metal
flow during TLP bonding. By the fix-
ture, the force applied on the samples
was just to keep them from sliding
during bonding. Therefore, the force
on the samples was limited to the
weight of the upper sample. Bondings
were conducted in a vacuum furnace
(with operating vacuum of 2 × 10–5
torr) at 1050°, 1100°, 1150°, and
1200°C temperatures for holding
times of 1, 5, and 10 min. The temper-
ature profile of the furnace during
bonding is schematically shown in Fig.
1. Selecting different times at various
temperatures was due to the fact that
the time of complete isothermal solidi-
fication is reduced with increasing
bonding temperature. Selection of
bonding temperature was due to the
wt­%
Al Ti Fe
0.92 3.46 3.47 0.07
— — — 0.52
— — — —
WELDING RESEARCH
melting temperature range of the FSX-
414 and IN738 superalloys as
1385°–1407°C and 1232°–1315°C, re-
spectively. Also, the bonding tempera-
ture must be higher than the interlay-
er liquidus temperature, which is
1054°C for MBF-80 interlayer. Bond-
ing temperature of 1050°C, with no
superheating above the interlayer liq-
uidus temperature, was selected to in-
vestigate the effect of superheating
during bonding at 1100° and 1150°C
on the joint’s properties.
The bonded samples were sectioned
perpendicular to the bond interface
and the mate surfaces were prepared
using standard metallographic tech-
niques. Microstructural studies were
conducted on an optical microscope
and a scanning electron microscope
(SEM). For this purpose, Murakami
and Kallings’ etchants were used.
Quantitative analysis was performed
using wavelength-dispersive x-ray
spectroscopy (WDS) on a Philips XL-
30 SEM device. The x-ray diffraction
patterns were achieved using an x-ray
diffractometer equipped with mono-
chromatic Cuk1 radiation, with a
wavelength of 1.540A° and diffraction
angle between 0 and 120 deg.
Microhardness profiles were ob-
tained across the joint using a MMT-7
Buehler microhardness tester with a
25-g load. An Instron tensile test ma-
chine with a cross-head speed of 1
mm/min was used to perform the
shear tests at room temperature. A fix-
ture was used to convert the applied
tensile stress to shear stress on the
Ta C B Zr S Si Mn
1.69 0.11 0.009 0.04 0.001 — —
0.14 0.15 0.006 — — 0.72 0.59
— 0.06 4 — — — —
FEBRUARY 2016 / WELDING JOURNAL 69-s
WELDING RESEARCH

A B

Fig. 3 — Light micrographs taken from joints bonded at 1050°C for holding times of A — 1 min; B — 10 min.

A B

Fig. 4 — Light micrographs taken from joints bonded at 1100°C for holding times of A — 1 min; B — 5 min.

joints. A schematic diagram of the
shear test fixture is shown in Fig. 2.
The fracture surfaces were studied us-
ing a stereo microscope and SEM.
Results and Discussion
Bonding at 1050°C
The microstructure of joints made at
1050°C for 1 and 10 min are shown in
Fig. 3. At the joint of this figure, contin-
uous centerline eutectic compounds are
visible, which formed due to incomplete
isothermal solidification. 1050°C is low-
er than the liquidus temperature of the
interlayer (1054°C); therefore, there was
no superheating (temperature differ-
ence higher than the melting point)
during melting of the interlayer, espe-
cially at a short bonding time of 1 min.
This could limit the diffusion of melting creased after a holding time of 10 min,
point depressant (MPD) elements from which can be indicative of isothermal
the interlayer into the base metal and solidification progression. Therefore,
cause the isothermal solidification rate occurrence of isothermal solidification
to be reduced. was possible at 1050°C, with no super-
Isolated centerline eutectics were vis- heating in the interlayer.
ible at the joints made at 1050°C for 10
min — Fig. 3B. With increasing bonding Bonding at 1100°C
time, more effective diffusion of MPD
elements of the interlayer into the base Micrographs of joints made at
metal occurred. Therefore, isothermal 1100°C for bonding times of 1 and 5
solidification was developed, and the min are shown in Fig. 4. At the joints
amount of eutectic constituents de- made for 1 min, isolated eutectic con-
Table 2 — Comparison of DAZ Width for Joints Made at Various Bonding Conditions
Bonding Temperature (C) 1050 1100 1150
Bonding Time (min) 1 10 1 5 1 5
DAZ Width in IN738 half (m) 40.19 50.97 44.24 54.33 70.45 85.04
DAZ Width in FSX­414 Half (m) 23.53 27.68 26.62 30.61 40.72 42.50

70-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95

 WELDING RESEARCH

A B

Fig. 5 — Micrographs taken from joints bonded at 1150°C for holding times of A — 1 min; B — 5 min.

terlayer is more width of the molten interlayer at sol-

Fig. 6 — Light micrograph taken from joints bonded at 1200°C for
10 min.
stituents are visible. In comparison
with the joints made at 1050°C for the
same bonding time, the isolated eutec-
tics were formed with less width. The
reason is superheating applied at
1100°C and also a higher diffusion rate
at this bonding temperature.
At the joints made at the same tem-
perature for 5 min, no eutectic con-
stituents were visible (Fig. 4B), which
was indicative of complete isothermal
solidification. Therefore, the time of
complete isothermal solidification re-
duced from 10 to 5 min, with an in-
crease of the bonding temperature
from 1050° to 1100°C. Furthermore,
some fine isolated eutectic constituents
were seen at the joints made at 1050°C
for 10 min — Fig. 3B. The diffusion of
boron to the outside of the molten in-
effective at a high-
er temperature of
1100°C and
caused even com-
plete isothermal
solidification at as
low a time as 5
min.
Bonding at
1150°C
Figure 5 shows
micrographs of
joints made at
1150°C for 1 and 5
min. Very fine iso-
lated eutectic con-
stituents were vis-
ible at the joint
made for 1 min, but these constituents
were completely removed after 5 min.
The eutectic-free bonding zone shows
complete isothermal solidification oc-
curred at the joint. Therefore, the time
of complete isothermal solidification at
1150°C was less than 5 min. To estimate
the time of complete isothermal solidifi-
cation, a model based on the diffusion-
induced solid/liquid interface motion
was used by Zhou (Ref. 15) as follows:
1
2 2h
t = 1
(1)
f almost spherical at the IN738 half.
4D 2
where D is the diffusion coefficient of
the MPD element in the solid base
metal, 2h is the equilibrium maximum
id/liquid interface, and  is a dimen-
sionless parameter.
According to Equation 1, tf is a
function of diffusion coefficient of the
MPD element in the solid base metal.
This diffusivity and the phase relation-
ship between the interlayer and the
base metal, as reported by Bakhtiari et
al. (Ref. 16), are dependent on the
bonding temperature. Therefore, tf re-
duces by increasing the bonding tem-
perature, which is in agreement with
the experimental results of this inves-
tigation. At 1050°C, the time of com-
plete isothermal solidification was 10
min, which was reduced to less than 5
min at 1150°C. Furthermore, Abbasi
et al. (Ref. 14) predicted the time of
complete isothermal solidification for
the FSX-414/MBF-80/IN738 system
using a numerical solution. The results
showed the same trend for variation of
complete isothermal solidification
time with increasing bonding tempera-
ture. Also, for complete isothermal so-
lidification time at all bonding temper-
atures, a good correlation between the
experimental and numerical results
was reported.
According to Fig. 5, there are some
intermetallics with different mor-
phologies at both sides of the diffu-
sion-affected zone (DAZ). In the FSX-
414 half, these intermetallics are
mostly needle-like, whereas they are
The width of the DAZ for joints
made at various conditions was meas-
ured using an image analyzer software
as the mean of 40 measurements at

FEBRUARY 2016 / WELDING JOURNAL 71-s

WELDING RESEARCH
A B
Fig. 7 — Light micrographs taken from joints bonded at A — 1050°C for 10 min; B — 1200°C for 10 min.
A B
Fig. 8 — WDS analysis profile of alloying elements across the joints made at A — 1150°C
for 5 min (with complete isothermal solidification); B — 1200°C for 10 min.
each condition. The DAZ was deter-
mined according to the existence of
phases. The results are shown in Table
2. According to the results, DAZ width
increased with rising bonding temper-
ature or bonding time, which was due
to the increased diffusion rate as well
as diffusion distance at higher bond-
ing temperature or time. Table 2 also
shows the DAZ width in the IN738
half was higher than that of the FSX-
414 half, which was related to a higher
boron diffusion coefficient in IN738 in
comparison with FSX-414.
Abbasi et al. (Ref. 14) reported, for
TLP joints of a FSX-414/MBF-80/
IN738 system, the ratio of interface lo-
cation (from the IN738 half with re-
spect to the FSX-414 half) at various
bonding temperatures was higher than
unity, according to both the experi-
72-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95
mental and numerical results. This is
in agreement with the higher DAZ
width of the IN738 half at all bonding
temperatures and times (Table 2). The
reason could be higher boron diffusion
coefficient in the IN738 half, which
controls the isothermal solidification.
Bonding at 1200°C
A micrograph of a joint made at
1200°C for 10 min is shown in Fig. 6.
Microstructural features of this joint
are different in comparison with the
joints made at lower temperatures.
Continuous centerline eutectics at the
joint of Fig. 4 show isothermal solidifi-
cation is incomplete even after 10 min,
whereas the complete isothermal so-
lidification time at 1150°C bonding
temperature was less than 5 min.
Therefore, there must be a critical
temperature (between 1150° and
1200°C) up to which isothermal solidi-
fication rate decreases. Various mecha-
nisms were reported about this critical
temperature as follows:
• Increase of base metal alloying ele-
ments concentration in the melted in-
terlayer with increasing bonding tem-
perature up to the critical temperature
caused the formation of secondary eu-
tectics and a reduction of isothermal
solidification rate, as reported by Id-
owu et al. (Ref. 10).
• Based on the work by Ghoneim et
al. (Ref. 5), a reduction of MPD ele-
ments’ diffusion rate from the inter-
layer into the base metal with increas-
ing bonding temperature up to the
critical temperature caused significant
reduction in element concentration
gradient and deviation of parabolic re-
lationship between solid/liquid inter-
face displacement and bonding time.
• Diffusion of secondary elements
between the interlayer and base metal
at the temperatures higher than the
critical value affected the isothermal
solidification rate, as reported by Sin-
clair et al. (Ref. 17).
According to Fig. 6, there are no in-
termetallics at the DAZ of joints made
at 1200°C. Furthermore, a wavy
boundary is visible between the bond-
ing zone and the DAZ. In the FSX-414
half, dissolution of base metal grain
boundaries is obvious, whereas partial
liquefaction of IN738 grain bound-
aries occurred adjacent to the bonding
zone. Interdiffusion between the base
metal, and the joint occurred at

Fig. 9 — Hardness profile across the joints made at 1050°C
for 1 and 10 min.
Fig. 11 — Variation of joint’s shear strength as a function of
bonding temperature.
1200°C and caused formation of sec-
ondary eutectics and liquefaction
phases, but the DAZ phases were un-
able to form at this temperature.
Figure 7 shows the eutectic mor-
phology at the bonding temperature of
1200°C for 10 min is layered and very
different in comparison with the
bonding temperature of 1050°C and
the same time. Average hardness of
the eutectic constituents are 582 and
334 HVN at 1050° and 1200°C, respec-
tively. The reduction of hardness at
1200°C can be related to the formation
of the secondary eutectics.
The wavelength-dispersive x-ray
spectroscopy analysis profiles of alloy-
ing elements across the joints made at
1150°C/5 min with complete isother-
mal solidification and 1200°C/10 min
are shown in Fig. 8. Distribution of al-
loying elements such as Ni, Cr, W, and
Ti is more uniform at 1200°C in com-
parison with the 1150°C bonding tem-
perature. Also, the concentration of W
in the bonding zone reached 3.27 wt-%
at 1200°C, which was zero at 1150°C.
Fig. 10 — Comparison of maximum hardness of DAZ and aver­
age hardness of ISZ for different bonding temperatures.
Therefore, significant
diffusion of base metal
alloying elements oc-
curred into the bonding
zone at 1200°C. The
segregation coefficient
of W and Ti is lower
than unity, which
caused a reduction of
the interlayer melting
temperature below the
critical bonding tem-
perature. This is against
increased interlayer
melting temperature
with the diffusion of
boron from interlayer
into the base metal, which reduced the
isothermal solidification rate and
caused eutectics formation at 1200°C.
Therefore, there are two regimes in TLP
bonding of the FSX-414/MBF-80/
IN738 system. The first regime, which
is controlled by Boron diffusion from
the interlayer into the base metal, is
predominant at the bonding tempera-
tures (1050°–1150°C) below the critical
value. The second regime is true at the
temperatures higher than the critical
value (1200°C), which is controlled by
diffusion of Ti and W from the base
metal into the bonding zone. The criti-
cal bonding temperature for similar TLP
bonding of the superalloys has been re-
ported by Bakhtiari et al. (Ref. 12),
Mosallaee et al. (Ref. 9), and Wikstrom
et al. (Ref. 18), which was 1190°C for
TLP bonding of FSX-414 superalloy.
Microhardness
Figure 9 shows the hardness profile
across the joints made at 1050°C for 1
FEBRUARY 2016/ WELDING JOURNAL 73-s
WELDING RESEARCH
and 10 min. A distinct peak is seen at
the profile of joints made for 1 min,
which is related to eutectic con-
stituents formed during isothermal
solidification. Also, the maximum
hardness of DAZ at the IN738 half is
higher than that of the FSX-414 half
for both bonding times. The diffusion
coefficient of boron is higher in the
IN738 half (Ref. 14), which caused
more effective diffusion and therefore
higher hardness of DAZ constituents,
in comparison with the FSX-414 half.
This is in agreement with the higher
diffusion distance of boron in the
IN738 half and therefore higher DAZ
width (Table 2). The hardness profiles
across the joints made at the other
temperatures were the same as
1050°C. According to Fig. 9 and the
hardness profiles of other bonding
temperatures, the hardness of isother-
mal solidification zone (ISZ) was lower
than that of the base metal for both
bonding times, which showed that dif-
fusion of base metal alloying elements
into the joint was not sufficient to in-
crease the ISZ hardness. This indicates
the need for a homogenization proce-
dure to increase the mechanical prop-
erties of the joints.
The comparison of maximum hard-
ness of DAZ and average hardness of
ISZ for joints made at different bonding
temperatures with complete isothermal
solidification is shown in Fig. 10. Maxi-
mum hardness of DAZ at the IN738
half was higher than that of the FSX-
414 half at various bonding tempera-
tures. But the hardness values of both
halves were reduced with increasing
bonding temperature. This was due to
more effective diffusion of boron into
WELDING RESEARCH

A1 A2

B1 B2

C1 C2

Fig. 12 — Stereomicrographs of shear tested samples bonded at A — 1100°C; B — 1150°C; C — 1200°C for 10 min.

A B C

Fig. 13 — SEM micrographs of shear­tested samples bonded at A — 1100°C for 1 min; B — 1100°C for 10 min; C — 1200°C for 10 min.

the DAZ and base metal at higher tem-
peratures, which reduced the formation
of DAZ constituents as well as the DAZ
hardness. According to Fig. 10, the ISZ
hardness increased with increasing
bonding temperature. Because diffusion
of the alloying elements (such as Co, Cr
and Ti) into the joint was more effective
at higher temperatures, which caused
higher strengthening of the joint due to
the solid solution strengthening. Solid
solution strengthening as well as car-
bides strengthening is the effective
strengthening mechanism for FSX-414
superalloy, as reported by Saha et al.
(Ref. 4).
Shear Test
Figure 11 shows shear strength of
the joints made at various tempera-
tures for 10 min in comparison with
those of the base metals. As can be
seen, the shear strength increased
with rising bonding temperature. The
same trend was seen for the variation
of ISZ hardness with increasing bond-
ing temperature — Fig. 10. This could
be related to more effective diffusion
of alloying elements from the base
metal into the joint at higher tempera-
tures and therefore more effective
solid-solution strengthening. Simulta-
neous increase of ISZ hardness and
the joint’s shear strength has been re-
ported for similar TLP joints of FSX-
414 superalloy (Ref. 12).
The highest shear strength of the
joints (1200°C/10 min) was obtained by
about 59 and 58% of the IN-738 and
FSX-414 base metals, respectively. This
shows that the joint should be homoge-
nized in order to remove the deleterious
DAZ phases and enhance the shear
strength. The effect of homogenizing
procedure (at 1150°, 1175°, 1200°, and
1225°C) on the mechanical properties
of the same system (IN738/MBF-
80/FSX-414) was studied in an unpub-
lished work. The results showed carbide
dissolving, recrystallization, partial
melting, and precipitation coarsening
occurred in the base metal and at the
joints during homogenizing at 1225°C.
However, maximum shear strength of
the joints was obtained at the homoge-
nizing temperature of 1200°C, about
twice in respect to the as-bonded sam-
ple (Ref. 19).
Figure 12 shows stereomicrographs

74-s WELDING JOURNAL / FEBRUARY 2016, VOL. 95


Fig. 14 — XRD pattern of shear fracture surface for joints made at 1100°C for 1 min.
of shear fracture surfaces of the joints
made at various temperatures for 10
min. For 1100° and 1150°C bonding
temperatures, the fracture path was
through the DAZ of the IN738 half.
Therefore, the intermetallics in DAZ
of the IN738 half was more brittle
than that of the FSX-414 half, which
was in agreement with the results of
microhardness — Fig. 9. The fracture
path of the joints made at 1200°C was
through the IN738 base metal and also
through the centerline eutectics of the
joint, which caused a nonuniform frac-
ture path. The hardness of secondary
eutectics was not high enough to make
a uniform fracture path though.
Therefore, these secondary eutectics
were not highly effective on fracture
since the joints made at 1200°C
had the highest shear strength, in
comparison with the other bonding
temperatures.
Scanning electron microscope mi-
crographs of shear fracture surfaces of
the joints made at various tempera-
tures are shown in Fig. 13. The cleav-
ages were predominant at the fracture
surface of Fig. 13A. This was due to in-
complete isothermal solidification as
well as eutectics formation at the
joints made at 1100°C for 1 min. X-ray
diffraction pattern of this fracture sur-
face (Fig. 14) revealed the formation of
Ni- and Cr-enriched eutectics such as
Ni4B3 and CrB that were formed dur-
ing athermal solidification of the
molten interlayer. For joints made at
the same temperature for 10 min (Fig.
13B), some dimples were seen at the
fracture surface, which were strained
in the direction of shear force during
the test. These dimples are finer in
comparison with the dimples shown
for bonding time of 1 min. This was
attributed to complete isothermal so-
lidification and no eutectic formation
occurring for the 10 min bonding
time. Furthermore, strained dimples
for 10 min bonding time shows plastic
deformation occurred before fracture,
while brittle fracture, without strain-
ing for 1 min bonding time, shows the
dominant role of eutectic compounds
on fracture. This trend was in agree-
ment with increase of the joint’s shear
strength with increasing bonding
time. According to Fig. 13C, dimples
are dominant and are finer in compari-
son with Fig. 13A, B, which is in agree-
ment with the joint’s higher shear
strength — Fig. 11. Also, some sec-
ondary cracks are visible at the frac-
ture surfaces of samples bonded at
1200°C for 10 min. These cracks could
be formed at the secondary eutectics.
Conclusion
TLP bonding of dissimilar FSX-
414/MBF80/IN738 system was con-
ducted at different temperatures. The
results of microstructural studies and
mechanical tests showed that
• The DAZ width, which was higher
in the IN738 half than in the FSX-414
half, increased with increasing bond-
ing temperature or bonding time.
• For joints made at 1200°C for 10
min, isothermal solidification was not
complete even after 10 min, and sec-
ondary eutectics were formed at the
joint centerline. These are indicative of
a second regime for isothermal solidi-
FEBRUARY 2016/ WELDING JOURNAL
WELDING RESEARCH
fication. In the FSX-414 half, dissolu-
tion of base metal grain boundaries
was obvious, whereas partial melting
of IN738 grain boundaries occurred
adjacent to the joint.
• WDS analysis showed that the sec-
ond regime for isothermal solidifica-
tion at 1200°C was controlled by diffu-
sion of Ti and W from the base metal
into the bonding zone.
• Maximum hardness of DAZ at the
IN738 half was higher than that of the
FSX-414 half at various bonding tem-
peratures and the hardness values of
both halves were reduced with increas-
ing bonding temperature. Also, the ISZ
hardness increased with increasing
bonding temperature and the maxi-
mum value was obtained for the joint
made at 1200°C/10 min.
• The joint’s shear strength in-
creased with increasing bonding tem-
perature. The highest shear strength
of the joints made at 1200°C/10 min
was obtained by about 59 and 58% of
those of the IN738 and FSX-414 base
metals, respectively. This condition
was selected as the optimum bonding
condition in spite of forming second-
ary eutectics at the joint.
• At the fracture surface of joints
made at 1100°C, the size of the dimples
was reduced with increasing bonding
time. Finer dimples, as well as microc-
racks formed at the secondary eutectics,
were seen at the fracture surfaces of the
samples with the highest shear strength
(made at 1200°C/10 min).
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rate during transient liquid phase bonding
of Inconel 738LC superalloy. Materials Sci-
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11. Jalilvand, V., Omidvar, H.,
Rahimipour, M. R., and Shakeri, H. R.
2013. Influence of bonding variables on
transient liquid phase bonding behavior of
nickel based superalloy IN-738LC. Materi-
als and Design 52: 36–46.
12. Bakhtiari, R., Ekrami, A., and Khan,
T. I. 2012. The effect of TLP bonding tem-
perature on microstructural and mechanical
property of joints made using FSX-414 su-
peralloy. Materials Science and Engineering A
546: 291–300.
13. Bakhtiari, R., and Ekrami, A. 2012.
The effect of gap size on the microstruc-
ture and mechanical properties of the tran-
sient liquid phase bonded FSX-414 super-
alloy. Materials and Design 40: 130–137.
14. Abbasi-Khazaei, B., Asghari, G., and
Bakhtiari, R. 2014. TLP bonding of dissim-
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15. Zhou, Y. 2001. Analytical modeling
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of isothermal solidification during tran-
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Transient liquid phase bonding of FSX-414
superalloy at the standard heat treatment
condition. Materials Characterization 66:
38–45.
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Morral, J. E. 2000. Transient liquid phase
bonding in two-phase ternary systems.
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Chaturvedi, M. C. 2006. Influence of
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layer. Materials Science and Engineering A
417(1): 299–306.
19. Jahanbakhsh, A. 2014. Investiga-
tion of microstructural evolution during
homogenization of dissimilar TLP joints of
a nickel and cobalt based superalloys. M.Sc.
thesis. Faculty of Engineering. Razi Uni-
versity.
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