NOVEMBER 2018

STEM Education
Developments in
Power Sources

Safety & Health

American Welder:
Celebrating Welding’s
Diverse Population
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
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November 2018 • Volume 97 • Number 11 CONTENTS
FEATURES
30 How to Combat Hexavalent Chromium
What you need to know to protect yourself from 30
exposure — K. Richardson

36 USA Science & Engineering Festival Sparks

Interest in All Things STEM
Huge festival engages youngsters to learn
about science, technology, engineering, and
mathematics topics — C. Weihl

40 Weld Surfacing Improves the Life Cycle of

Components
This green process improves the longevity of
components even in severe wear environments
R. Chattopadhyay

THE AMERICAN WELDER

70 Welding Power Sources Shorten Training and
Reduce Rework 70
One key to addressing the challenges users of
welding face is to make welding power sources
easier to use — B. Hammers

74 Commemorating Welding’s Native Voices

Three welders of Native American heritage share
their stories — K. Pacheco

WELDING RESEARCH SUPPLEMENT

301-s Microstructure Evolution and Solidification
Cracking in Austenitic Stainless Steel Welds
A novel quenching technique helped to gain a
better understanding of solidification cracking
P. Yu et al.
315-s Exploring the Cooling Process for Residual
Stress Reduction in Dissimilar Welds
Carbon dioxide rapid cooling was found to
eliminate stresses in gas tungsten arc welds
H. Eisazadeh et al.

NOVEMBER 2018 / WELDING JOURNAL 3

DEPARTMENTS
6 Editorial 51 Society News
8 Press Time News 53 Tech Topics
10 International Update 60 Section News
12 News of the Industry 67 Guide to AWS Services
16 Business Briefs 68 Personnel
18 Stainless Q&A The American Welder
20 Laser Q&A 78 Learning Track
24 Product & Print Spotlight 83 Fact Sheet
44 Coming Events 86 Classifieds
50 Certification Schedule 87 Advertiser Index
On the cover: Making welding
power sources easier to use is
one key to addressing the
challenges faced by the welding
industry. (Credit: Miller Electric
Mfg. LLC.)

OFFICERS WELDING JOURNAL

President Dale Flood
TRI TOOL Inc.
Vice President Thomas J. Lienert
Consultant
Vice President Robert Roth
RoMan Manufacturing Inc.
Vice President Richard Polanin
Illinois Central College
Treasurer Carey Chen
Cincinnati Incorporated
Executive Director and CEO Matt Miller
American Welding Society
DIRECTORS
T. Anderson (At Large), ITW Welding North America
U. Aschemeier (Dist. 7), Subsea Global Solutions
J. R. Bray (Past President), Affiliated Machinery Inc.
T. Brosio (Dist. 14), Major Tool & Machine
J. Burgess (Dist. 8), General Electric
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), Retired
M. Hanson (Dist. 15), Consolidated Precision Products
S. A. Harris (Dist. 4), Altec Industries
R. L. Holdren (At Large), ARC Specialties
T. Holt (Dist. 18), Tech Corr USA Management
J Jones (Dist. 17), Harris Products Group
M. Krupnicki (Dist. 6), Mahany Welding Supply Co. Inc.
D. Lange (Dist. 12), Northeast Wisconsin Tech. College
S. Lindsey (Dist. 21), City of San Diego
S. M. McDaniel (Dist. 19), Big Bend Community College
D. L. McQuaid (Past President), D. L. McQuaid and
Associates Inc.
D. K. Miller (At Large), Lincoln Electric
S. Moran (Dist. 3), American Hydro Corp.
H. Record (Dist. 5), Townley Foundry & Machine
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
M. Sherman (Dist. 10), SW&E LLC
M. Skiles (Dist. 9), Airgas Inc.
W. J. Sperko (At Large), Sperko Engineering Services
K. Temme (Dist. 2), Matrix NAC
P. I. Temple (Dist. 11), Energy Wise Consulting LLC
J. A. Willard (Dist. 13), Kankakee Community College
Publisher/Editor Mary Ruth Johnsen
Editorial
Sr. Editor Cindy Weihl
Features Editor Kristin Campbell
Associate Editor Katie Pacheco
Assistant Editor Roline Pascal
Peer Review Coord. Sonia Aleman
Publisher Emeritus Jeff Weber
Design and Production
Production Manager Zaida Chavez
Assistant Production Manager Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
Media Sales Executives Jeff Rhodes
and Kim Daniele
Production Specialists Megan Lebo
and Amy Gosen
Subscriptions
Subscriptions Representative Sonia Aleman
saleman@aws.org
MARKETING ADVISORY COUNCIL
(MAC)
D. Doench, Chair, Hobart Brothers Co.
S. Bartholomew, Vice Chair, ESAB Cutting Systems
S. Samuels, Secretary, American Welding Society
D. Brown, AGONOW
C. Coffey, The Lincoln Electric Co.
D. DeCorte, RoMan Mfg. Inc.
S. Fyffe, Astaras Inc.
L. Kvidahl, Ingalls Shipbuilding
D. Marquard, IBEDA Superflash Compressed
S. Moran, American Hydro
M. Muenzer, ORS Nasco
E. Norman, EDCO Industries LLC
R. Roth, RoMan Mfg. Inc.
F. Saenger, Consultant
M. Smickenbecker, Matheson
S. Smith, Weld-Aid Products
E. Stone, Weiler Corp.
A. Sepulveda, Hypertherm
D. Wilson, Wilson and Associates
T. Lienert, Consultant
J. Bray, Ex Officio, Affiliated Machinery Inc.
C. Chen, Ex Officio, Cincinnati Incorporated
M. Miller, Ex Officio, American Welding Society
aws.org
8669 NW 36 St., # 130, Miami, FL 33166-6672
(305) 443-9353 or (800) 443-9353
AWS Promotes Diversity
AWS values diversity, advocates equitable and
inclusive practices, and engages its members and
stakeholders in establishing a culture in the
welding community that welcomes, learns from,
and celebrates differences among people. AWS
recognizes that a commitment to diversity, equity,
and inclusion is essential to achieving excellence
for the Association, its members, and employees.
Welding Journal (ISSN 0043-2296) 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 sin-
gle issue for international. Not available for resale in either
print or electronic form. American Welding Society is located
at 8669 NW 36 St., # 130, Miami, FL 33166-6672; telephone
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additional mailing offices. POSTMASTER: Send address
changes to Welding Journal, 8669 NW 36 St., # 130, Miami, FL
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Readers of Welding Journal may make copies of articles
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quote from articles, provided customary acknowledgment of
authors and sources is made. Starred (*) items excluded
from copyright.
Copyright © 2018 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 information developed by the authors of specific articles
are for informational purposes only and are not intended for
use without independent, substantiating investigation on the
part of potential users.

4 WELDING JOURNAL / NOVEMBER 2018

EDITORIAL
The AWS Foundation
Continues Its Critical Work
The staff and volunteers working on be-
half of the American Welding Society’s
(AWS) Foundation are always thinking of
new ways to support welding education
throughout North America. For instance, the
Foundation Grants Program introduced in
2017 is one of the latest efforts to ensure a
skilled workforce is on call when industry
needs it.
This year, the Foundation will award up to
$300,000 to improve and expand training
programs and institutions, as well as build
the number of welding graduates nation-
William Rice wide. Individual grants of up to $25,000 are
Chairman, available for secondary and post-secondary
AWS Foundation education/training institutions to enhance
and improve welding programs, resulting in
more welding graduates and placement of
those grads in welding-related jobs. Funds
can be used for capital equipment, classroom
or lab materials and supplies, facilities im-
provements, computer systems, metalwork-
ing equipment, and expanding staff.
In addition, a special AWS Detroit Section
Welder Workforce Grant will be considered
for any training institution within the Sec-
tion boundaries. This annual grant will
award $15,000 to the selected candidate
from the Detroit Section.
As a further step, the AWS Grants Com-
mittee is considering allocating funds for a
grants program aimed exclusively at high
“We’re all working schools that do not presently have a welding
toward the same program, and which want to offer an intro-
goal of getting the ductory welding course or courses for its stu-
word out about the dents. This will be discussed at the Grants
tremendous career Committee meeting this month, and, if ap-
proved, limited grants would be available to
opportunities in our these types of schools in 2019.
field.” While administering and considering
these new programs is important, the basic
work of the Foundation continues to set new
6 WELDING JOURNAL / NOVEMBER 2018
records. In 2017, we surpassed the $1-
million mark in scholarship dollars awarded
in one year. Nearly 900 scholarships were
awarded to students at more than 250 aca-
demic and training institutions. The more
than $1 million awarded represents a steady
and increasing climb over the past 25 years.
Beyond this, grants totaling $250,000
were made to high schools, trade/technical
schools, and community colleges. In addi-
tion, $100,000 in Graduate Research Fellow-
ships went to fund research into cutting-
edge technologies in welding and
manufacturing.
To promote future employment in weld-
ing, the AWS Careers in Welding Trailer also
went to 18 events in 11 states, drawing
25,860 visitors who tested themselves by
making nearly 40,000 virtual welds.
In support of the AWS 100th anniversary
in 2019, the AWS Foundation Board will dis-
cuss several new initiatives at their meeting
this month in Atlanta, Ga. If approved, these
initiatives would provide funding for new
scholarships at both the District and Nation-
al levels. Stay tuned for more information on
these new programs. Updates will be an-
nounced in connection with the upcoming
AWS Centennial Celebration.
Promoting the profession we all know to
be so critical to the U.S. economy, and the
safety and well-being of our citizens, is what
the AWS Foundation is all about. If you have
any thoughts on ways we can further help
build the welding workforce, we would defi-
nitely like to hear them. You can contact the
Foundation’s Executive Director, Monica
Pfarr, at mpfarr@aws.org.
Remember, we’re all working toward the
same goal of getting the word out about the
tremendous career opportunities in our
field. WJ
PRESS TIME NEWS
Fullerton College’s Welding Program to
Benefit from $1-Million Investment
Assemblywoman
Sharon Quirk-Silva,
who represents the
65th District of the
California State As-
sembly, has secured
$1 million in funding
from the 2018–19
State Budget for
Welding faculty and Assembly- Fullerton College’s
woman Sharon Quirk-Silva pose welding program in
during the ceremonial check pres- Fullerton, Calif.
entation in honor of Fullerton Col- This investment
lege receiving $1 million to expand
from the state will al-
its welding technology program.
low the college to
better equip students
with the skills need-
ed to meet the growing needs of industry.
“American manufacturing is the bedrock of our economy,
and students with the technical skills learned in this depart-
ment will find a wide variety of manufacturing opportuni-
ties and technical positions in today’s job market,” Quirk-
Silva said.
On October 4, she visited the welding department for a
ceremonial check presentation, reiterated the importance of
the college’s workforce training programs, and thanked fac-
ulty and students for the positive impact they make in Or-
ange County’s economy and job market. More than 80 indi-
viduals attended the event.
“This funding support for our welding and manufactur-
ing programs will allow Fullerton College to be more respon-
sive to the significant demand for certified welders, welding
inspectors, and manufacturing technicians in Orange Coun-
ty and beyond,” said Fullerton College President Greg
Schulz. “We are so grateful for this support and the doors it
will help us open for students. These funds will help us serve
a greater number of women, minorities, veterans, unem-
ployed, and underemployed individuals.”
The funds will be used for upgrading equipment, pur-
chasing new fabrication and cutting equipment, adding ro-
botic technology, and installing welding inspection instruc-
tion and lab spaces.
In addition, the college has engaged in talks with Chip
Foose and Mitch Lanzini from the TV show Overhaulin’ to
help the department build a functional welding vehicle to
bring welding education to area schools and businesses.
ESAB Acquires Gas Control Equipment
ESAB Welding & Cutting Products, Annapolis Junction,
Md., has acquired Gas Control Equipment (GCE), Malmö, Swe-
den, which offers solutions for general industrial, healthcare,
high-purity, and science and research applications. It also em-
ploys more than 900 people.
“GCE businesses have more than 100 years of experience
developing, manufacturing, and distributing equipment for
pressure and flow control of high-pressure gases, as well as
cutting and welding equipment,” said Shyam Kambeyanda,
8 WELDING JOURNAL / NOVEMBER 2018
president, ESAB. “The opportunities created by combining
GCE with ESAB’s global presence and continuous improve-
ment culture will drive both businesses to achieve new heights
of success.”
Randolph Community College Earns
AWS Accredited Test Facility Status
Students in the newest welding technology class at the
Randolph Community College (RCC) Archdale Welding Center
pose with RCC President Bob Shackleford (standing fifth
from right), Welding Department Head Michael Ford (holding
the accreditation certificate), and Instructor Allan Bechel
(standing first from right).
Randolph Community College’s Archdale Welding Center in
North Carolina has been named an Accredited Test Facility by
the American Welding Society (AWS), Miami, Fla. This distinc-
tion establishes minimum requirements for test facilities, their
personnel, and equipment to qualify for accreditation to test
and qualify welders.
The college’s program can test welders from any one of
eight different codes and standards. In addition, its Certi-
fied Welding Inspector can test welders for AWS certifica-
tions that are recognized worldwide, according to Michael
Ford, department head and Certified Welding Inspector for
welding technology at the college. Ford noted it took more
than a year of work to earn the status, which included im-
plementing a quality assurance program and writing a quali-
ty manual.
Randolph Community College is one of five AWS Accredit-
ed Test Facilities in North Carolina. Students earning AWS
Certified Welder certification will be in high demand from lo-
cal companies; all graduating diploma and certificate students
will be tested.
This welding center is also getting ready to add about ten
more welding booths. Approximately 2000 sq ft of classroom
and office space will be converted into a lab. The college’s cur-
riculum welding technology program has experienced high en-
rollment in the last several years and is at maximum enroll-
ment for the fall 2018 semester, Ford added.
TRUMPF to Hold Consignment Contest
To support the growth of additive manufacturing research,
TRUMPF, Farmington, Conn., will hold a contest to consign
TruPrint 1000 laser metal fusion systems. The deadline for
submissions is December 15. It will be open to colleges, uni-
versities, and research institutes in North America; up to three
winners will be selected to receive a system for a period of 12
months. To apply, applicants must submit a paper explaining
their research objectives if they were to receive a system for
their research lab. For more details, send an email to
additivemanufacturingUS@trumpf.com. WJ
INTERNATIONAL UPDATE
Shipyard Donates Equipment and Recruits
Students at AWS SENSE Program in Indonesia
PT. Karimun Sembawang Shipyard’s visit to SMKN 2 Ban-
dung, in Indonesia, was followed with donations from the
shipyard and a job contract for five AWS SENSE pilot pro-
gram students.
Sekolah Menengah Kejuruan Negeri (SMKN) 2 Bandung,
in Indonesia, recently received a visit from PT. Karimun
Sembawang Shipyard (PT. KSS), a shipbuilding company lo-
cated in Kepulauan Karimun, Riau, Indonesia. This visit was
carried out in cooperation between SMKN 2 Bandung and
PT. Asian Welding Specialist (PT. AWS).
During the visit, PT. KSS donated about $14,500 worth
of welding power sources and consumables. In a symbolic
gesture, the donation was handed to the Principal of SMKN
2 Bandung, Tatang Gunawan, by Lim Wei Tat, president di-
rector of PT. KSS; Kiw Chee Siam, general deputy of PT. KSS;
and Eka Santoso, human resource manager. Teachers and
students, along with Dina Septriana, director of PT. AWS,
and Steve T. Snyder, an American Welding Society (AWS)
Senior Certified Welding Inspector and test supervisor of
PT. AWS, witnessed the occasion.
The shipyard also recruited five AWS SENSE pilot program
students at the school, who signed a contract with PT. KSS.
Upon graduation, they will work directly for the company.
Xiris Appoints Turkish Representative
Canada-based Xiris selected Pruftechnik STI as its exclusive
distributor in Turkey.
Xiris Automation, Burlington, Ontario, Canada, a developer
of machine vision camera systems and image inspection soft-
ware, recently appointed Pruftechnik STI as its exclusive dis-
tributor of Xiris products for both the metal fabrication and
tube and pipe industries in Turkey.
Pruftechnik STI, a sales representative of nondestructive
examination equipment for the tube industry and other met-
alworking fields, will be able to distribute and support the
Xiris WI2000/3000 postweld inspection systems used to de-
tect quality issues related to tube welding and forming.
“We are excited to work with an excellent partner who
10 WELDING JOURNAL / NOVEMBER 2018
has many years of experience in the tube market in Turkey,
combining operations experience with extensive test equip-
ment knowledge. They share our values of a high level of
commitment to ensuring customer satisfaction and continu-
ous improvement of technical knowledge,” said Cameron
Serles, president of Xiris Automation.
Kemper GmbH Expands to Norway with
iTec AS Partnership
Kemper GmbH has expanded into Scandinavia via a partner-
ship with iTec AS.
Kemper GmbH, Vreden, Germany, a manufacturer of ex-
traction and filter systems for the metal-processing indus-
try, has expanded into Norway with new sales partner, iTec
AS, which is now exclusively distributing Kemper’s entire
product portfolio.
This partnership will give metalworkers in Norway easier
and faster access to the extraction/filter company’s prod-
ucts, including cutting and machine tools, as well as laser
systems. For iTec, the partnership represents a comprehen-
sive expansion of its occupational safety portfolio. In the fu-
ture, employees will be trained in all technical issues at the
Vreden site.
Australian Government Funds 3D Welding
Simulators to Secure Jobs for Queenslanders
The Palaszczuk Government in Australia has funded
equipment to train Queenslanders faster in welding qualifi-
cations, which are in high demand by defense and manufac-
turing industries, to secure future jobs.
Cameron Dick, minister for state development, manufac-
turing, infrastructure, and planning, joined Shannon Fenti-
man, minister for training and skills development, at the
Parliament House to demonstrate the 3D augmented reality
systems for training welders.
“Our government is helping Queenslanders to keep pace
with industry demand for qualified welders by purchasing ten
state-of-the-art augmented reality welding training simulators
at a total cost of up to $800,000,” said Dick. “These simulators
will enable TAFE SkillsTech to increase the speed at which stu-
dents can become qualified to the ISO 9606 welding standard.”
According to Dick, the investment will help address a na-
tional shortage of ISO 9606-qualified welders. Five welding
simulator units will be based at SkillsTech in Acacia Ridge,
with the remaining five to be based in regional areas such as
North and Far North Queensland. WJ
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NEWS OF THE INDUSTRY
Salt Lake Community College Opens
Westpointe Workforce Training &
Education Center
Posing in front of The Sam Gentry Welding Computer Lab at
Salt Lake Community College’s workforce facility are (from
left) Pierrette Gorman, American Welding Society (AWS) Dis-
trict 20 director; Monica Pfarr, executive director, AWS Foun-
dation; and Eric Heiser, the college’s dean for the School of
Applied Technology and Technical Specialties.
Utah lawmakers, along with industry, business, and edu-
cation leaders, received their first glimpse of Salt Lake Com-
munity College’s 121,000-sq-ft Westpointe Workforce Train-
ing & Education Center during a recent celebration.
“I need this as a father,” said Utah House Speaker Greg
Hughes, gesturing to the Westpointe building behind him. “I
need to have a state where I know my children will have
good jobs and will be able to raise families. It’s things like
today, moments like today, that are going to make sure we
have those opportunities.”
The facility’s welding computer lab has been named in
memory of Sam Gentry, former executive director of the
American Welding Society’s Foundation, who passed away
last year.
Located in Salt Lake City’s industrial northwest quad-
rant, the facility is designed to support the community by
providing education and training in key industries critical to
the region’s economic success. This includes welding, ma-
12 WELDING JOURNAL / NOVEMBER 2018
The new workforce facility at Salt Lake Community College
provides education and training in key industries critical to
the region’s economic success, including welding.
chining, diesel systems technology, injection molding, com-
posites manufacturing, and commercial driving.
The center houses eight classrooms, 34 lab spaces, and a
three-acre lot for commercial truck driving, as well as more
than 100 welding bays, a large diesel maintenance facility,
and an injection molding lab.
“I’m so pleased with what we’re seeing happening in this
state and an increased emphasis on technical education,”
said Utah Governor’s Office Education Advisor Tami Pyfer.
“Let me tell you, technical education is for everyone.”
Westpointe also allows the college to fulfill its mission as
Salt Lake County’s primary postsecondary provider of work-
force education.
“At Westpointe, students will receive hands-on education
and experience in a number of important trades,” said Salt
Lake Community College President Deneece G. Huftalin. “It
will not only be a boon to students but also to our region by
allowing us to maintain our economic prosperity through
the development of a top-notch workforce.”
In addition, there’s space for collaboration with industry
partners, allowing students to interface with Utah’s compa-
nies in the industrial trades.
“Now with this building and the commitment of our com-
munity college,” Davis concluded, “it’s going to be vocation,
vocation, vocation, which is the most important thing we
can do for Utah.”
ESAB Changes Sandvik Welding
Consumables Name to Exaton™
For more than 80 years, Sandvik Welding Consumables
has been a developer and manufacturer of advanced stain-
less steels and nickel filler metals. ESAB Welding & Cutting
Products, Annapolis Junction, Md., recently acquired its
welding consumables business, finalizing the transaction
earlier this year. Beginning November 1, these products will
go to market under the name Exaton™, an ESAB brand.
Product packaging will be updated to reflect the new Exa-
ton brand and logo. In addition, the product itself will retain
current labeling; contents of the Sandvik website will be trans-
ferred to the ESAB website; and the Sandvik Welding Hand-
book mobile app will be transferred to the ESAB website.

COMBUSTIBLE
Yaskawa Motoman and RAMTEC Join
Forces for Manufacturing Partnership

Yaskawa Motoman and RAMTEC recently announced a new
manufacturing enterprise. At the press conference were
(back row, from left) Bob Graff, senior sales manager, educa-
tion, Yaskawa Motoman; Rob Brundrett, director, public policy
services, the Ohio Manufacturers’ Association; Jon Husted,
secretary of state, Ohio; and (speaking) Ritch Ramey,
RAMTEC coordinator for Tri-Rivers Career Center.
Yaskawa Motoman, Dayton, Ohio, a robotics company,
and RAMTEC (Robotics & Advanced Manufacturing Tech-
nology Education Collaborative), Marion, Ohio, an accredi-
tor of high school and adult robotics manufacturing licen-
sures and certifications, have formed the Ohio Manufactur-
ing Workforce Partnership. This collaboration will not only
support the state in creating a highly sustainable workforce
development model, but will also provide Ohio educators
and students with science, technology, engineering, and
mathematics aligned curriculum and training to be profi-
cient in Industry 4.0 technologies.
“Data reveals that within ten years, nearly 3.5 million
manufacturing jobs will sit empty, with the skills gap being
responsible for 2 million of those jobs going unfilled,” said
Ritch Ramey, RAMTEC coordinator and engineering in-
structor. “Forming mutually beneficial relationships with
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NOVEMBER 2018 / WELDING JOURNAL 13

 Partnership will create the foundation needed to move
MONITOR ROBOT WATER Ohio’s workforce forward.”
WITH ROCON NO-DRIP The entire project development funding is earmarked for
$400,000 to provide a comprehensive training and applica-
CAP CHANGE SYSTEM tion development model that will reach thousands of incum-
bent workers and students statewide.
“Our workforce-driven training and research partnership
z Water Saver with Venturi with RAMTEC is a solid step to providing students with
WET system means NO work-based learning opportunities in the field of robotics,”
water on plant floor during
added Doug Burnside, Yaskawa Motoman’s vice president of
cap change
sales and marketing.
z Uses cooling water to Highlights of the partnership will include developing ad-
create a vacuum, no need vanced, industry-recognized robotic certifications and uti-
for air lizing augmented and virtual-reality technologies to develop
z Independent flow &
a new class of training tools and curriculum.
temperature circuits –
Weld gun & transformer
flow, and temperature (up to 3 temp sensors). Joining of Advanced and Specialty
z Devicenet, Ethernet/IP and Profinet available Materials Conference Celebrates
z Robot Teach Pendant monitoring and configuring of 20th Anniversary
water saver gun & transformer flow settings available
The Joining Critical Technology Sector (JCTS), formed in
z Ease of maintenance 1998 within the American Society for Metals (ASM) Inter-
national Technical Programming Board, is currently in its
20th year. As the first chair, Mrityunjay Singh organized the
Joining of Advanced and Specialty Materials I (JASM I) Con-
ference, held on October 12–15, 1998. Twenty-three papers
were published in that year’s proceedings.
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presentation awards were given in three categories. In 2017,
JASM XIX set participation records, with 60 oral and poster
presentations by speakers from academia and industry.
This year, JCTS organized the JASM XX symposium on
October 14–18 in Columbus, Ohio, as part of the Materials
Science & Technology Conference and Exhibition. Papers ac-
cepted there focused on fundamentals and applications, in
addition to experimental, analytical, and computational
studies related to several welding subjects. Celebrating two
decades of contributions to the joining research community,
JASM XX highlighted its members, who have been recog-
nized by ASM as fellows of the society, as keynote speakers.
In addition, starting in 2000, JCTS has cooperated with
the American Welding Society to organize the International
Brazing and Soldering Conference. The first event was host-
ed by Sandia National Laboratories, Albuquerque, N.Mex.,
on April 2–5, 2000; the latest was held this year on April
15–18 in New Orleans, La. The platform has provided pro-
fessionals, scientists, and engineers in the research, develop-
ment, and application of brazing and soldering, a unique
networking and idea-exchange forum.
The JCTS committee wishes to thank the organizing
committee, session chairs, and proceeding editors for their
service. It would also like to express gratitude to the presen-
ters for participating in JASM conferences over the past 20
years and looks forward to continued success. — Zhenzhen
Yu, Department of Metallurgical and Materials Engineering,
Colorado School of Mines, Golden, Colo.; Carolin Fink and Boian
— continued on page 84
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BUSINESS BRIEFS
Innovation Center Opens at Lockheed Martin
in Orlando
Melinda Anthony, information technology assistant, and AJ
Tate, electrical engineer, engage with augmented reality at
Lockheed Martin’s Innovation Center in Orlando.
Lockheed Martin, Bethesda, Md., has opened an Innova-
tion Center at the company’s Missiles and Fire Control
(MFC) facility in Orlando, Fla. The 6500-sq-ft space will pro-
vide employees with the technology and tools to develop
new technology solutions to complex problems.
Virtual reality, robotics, computer-simulated environ-
ments, 3D printing, and more are available at workers’ fin-
gertips to encourage new ways of thinking and approaching
business needs. The space will also host monthly hands-on
demonstrations and live webcasts.
“The Innovation Center is a destination for our program
teams to explore what’s possible with the use of high technolo-
gy,” said Tom Mirek, vice president deputy of engineering and
technology at MFC. “Like we already have in Dallas, we’re go-
ing to recognize Orlando’s Innovation Center for being a vital
resource to the success of our company for years to come.”
The center is comprised of these five labs: the Applica-
tion Research Experimentation and Simulation facility, Gen-
esis Lab, Iris Lab, Engineering Visualization Environment
Lab, and the Polaris Lab, which will open in early 2019.
ASTM International to Host December
Workshop on Ships and Marine Technology
The ASTM International committee on ships and marine
technology (F25) is sponsoring the Workshop on Au-
tonomous Shipping, Vessel Automation, and Maritime Cy-
ber Security, Dec. 5, at the Washington Hilton, Washington,
D.C. The workshop will take place in conjunction with the
standards development meetings of the committee.
The workshop will provide a forum for the exchange of
ideas related to the operation of autonomous vessels in the
maritime sector, as well as automation and cyber security in
maritime domain. The objective of this workshop will be to
identify potential new opportunities for standards and re-
lated products applicable to advancements in automation,
autonomous shipping, and maritime-specific cyber security
issues.
Topics will include, but are not limited to, autonomous
shipping, vessels, and shipping operations; cyber risk man-
agement; automation; and more. To register for the work-
shop, visit astm.org.
16 WELDING JOURNAL / NOVEMBER 2018
Mahlo America Celebrates 50th Anniversary
Located in Spartan-
burg, S.C., Mahlo Amer-
ica Inc., a subsidiary of
the German machine
manufacturer, Mahlo
GmbH, is celebrating its
50th anniversay.
The company is
known for its straight-
A subsidiary of the German- ening machines and
based machine manufacturer,
straight-edged
Mahlo America Inc. celebrates
50 years in business. products.
“The many years of
experience of our engi-
neers and the constant development of the systems are re-
flected in our success,” said Executive Vice President Alan
Lavore. “The future looks bright if we keep working hard.”
Laboratory Testing Acquires TAC Technical
Instrument Corp. of New Jersey
Fred Beck, president of TAC Technical Instrument Corp. (left),
and Mike McVaugh, president and CEO of Laboratory Testing
Inc., shake hands following the transfer of ownership.
Laboratory Testing Inc. (LTI), Hatfield, Pa., has pur-
chased TAC Technical Instrument Corp. (TACTIC), Trenton,
N.J., a provider of ultrasonic inspection systems and acces-
sories. Laboratory Testing runs seven TACTIC immersion ul-
trasonic testing inspection systems under one roof and is
one of the company’s largest customers.
“TACTIC is a perfect fit for our growing business, and
our companies have a long history together,” said Mike
McVaugh, LTI president and CEO. “LTI was started as a nonde-
structive testing lab in 1984, and we have been using TACTIC
equipment to perform ultrasonic testing since the beginning.
They were the leader in the industry back then and still are.”
TACTIC will stay at its current location and will operate
as a subsidiary of LTI. The company’s president, Fred Beck,
and the other employees will remain in their positions.
Quoting and sales of all products and services will continue
to be handled by the New Jersey facility, with the exception
of ultrasonic testing services, which will be consolidated
into LTI’s NDT Department. WJ
STAINLESS Q&A
Q: What is the appropriate mini-
mum ferrite content for Type 347
stainless steel and weld metal?
We weld by autogenous gas
tungsten arc welding, so the
base metal ferrite content mat-
ters a great deal. We are having
difficulty locating a 347 base
metal that complies with API RP
582, Welding Guidelines for the
Chemical, Oil, and Gas Industries.
We have been receiving heats
that barely comply with a 3 Fer-
rite Number (FN) minimum. Our
most recent heat does not
comply.
A: In API RP 582, Welding Guidelines
for the Chemical, Oil, and Gas Industries,
second edition, Clause 6.4.2.2 states
the following:
“The minimum FN for deposited
weld metal should be 3 FN except for
the following (FN shall be measured
prior to PWHT).
“a) The minimum FN for Type 347
weld deposits shall be 5 FN. The mini-
mum FN may be reduced to 3 FN pro-
vided the fabricator submits data veri-
fying that hot cracking will not occur
using the lower FN consumable to be
used in production and this is ap-
proved by the purchaser.”
This clause is preceded by the fol-
lowing note: “Whenever FN measure-
ments are required in this document,
they are to be taken prior to any
PWHT and shall be measured with an
instrument calibrated to, and listed in,
AWS A4.2M or by actual, as-deposited
chemical composition using WRC
1992 (FN) or DeLong (FN) Diagrams.”
I requested, and received from the
inquirer, certified chemical composi-
Table 1 — Tye 347 Compositions
Steel C Mn P S
ASTM 0.08 2.00 0.045
A240 max. max. max.
347
Old Heat 0.06 1.80 0.033
New Heat 0.055 1.75 0.024
N.S. = Not Specified
18 WELDING JOURNAL / NOVEMBER 2018
Fig. 1 — Type 347 heats on the WRC-1992 Diagram.
tions for the most recent heat and
for another heat that was accepted.
These results are shown in Table 1,
along with the requirements for Type
347 base metal in ASTM A240, Stan-
dard Specification for Chromium and
Chromium-Nickel Stainless Steel Plate,
Sheet, and Strip for Pressure Vessels and
for General Applications.
I note that the chromium and nick-
el contents of the two heats are very
similar, and are at the very bottom of
the range specified by ASTM A240.
This reflects common steelmaking
practice all over the world. I also note
that the sulfur content of the new heat
is very low. This may cause difficulty
in achieving desired weld penetration
in autogenous gas tungsten arc weld-
ing (GTAW) due to the Marangoni ef-
fect (see this column in the Welding
Journal’s September 2018 issue).
I further note that the API Recom-
mended Practice calls for 3 FN mini-
mum, not 3.0 FN. Rounding rules
(e.g., ASTM E29 or ISO 80000-1:2009)
say that 3.1 FN and 2.8 FN are both 3
Composition, wt-%
Si Cr Ni Mo
0.030 0.75 17.0–19.0 9.0–13.0 N.S.
max. max.
0.023 0.71 17.24 9.12 0.46
0.002 0.26 17.32 9.16 0.27
BY DAMIAN J. KOTECKI
FN. It is not appropriate to state more
precision than is called for by the stan-
dard in determining compliance.
Figure 1 plots the old heat and the
new heat on the WRC-1992 Diagram.
The two heats lie very close together,
and both lie comfortably within the
area bounded by two dashed lines and
labeled “FA.” FA means compositions
within those boundaries will solidify
as primary ferrite and therefore
should be very resistant to solidifica-
tion cracking. In my opinion, both
heats fulfill the intent of API RP 582.
However, there is another consider-
ation. Metal adjacent to the fusion
boundary can be susceptible to mi-
crofissuring. This consists of very
short cracks in the heat-affected zone
(HAZ), generally perpendicular to the
fusion boundary. Lundin et al. studied
the ferrite level necessary to eliminate
microfissures from various weld met-
als and found that 347 requires more
ferrite than other austenitic stainless
steel compositions to eliminate mi-
crofissures, using the fissure bend test
Cu Nb N WRC 1992 FN
N.S 10 x C min.–1.0 N.S. N.S.
0.47 0.72 0.02 3.1
0.27 0.69 0.028 2.8

Fig. 2 — Ferrite-fissuring relationship.
(Ref. 1). Figure 2 summarizes their
findings. About 6 FN was found to be
necessary to eliminate microfissures
from 347, vs. 2 to 3 FN for 308, 308L,
316, and 316L. The microfissures were
found to be generally between 1 and 2
mm in length in the 347, shorter in
other alloys.
Microfissures are considered to
be promoted by phosphorus (P), sulfur
(S), and niobium (Nb). Li and Messler
examined P and S effects (but not Nb)
in 308 weld metal, and they concluded
that P is more important for promot-
ing weld metal solidification cracking,
while S is more important for promot-
ing HAZ microfissuring (Ref. 2).
Note, from Table 1, the new heat of
the inquirer is much lower in sulfur
and somewhat lower in phosphorus
than the old heat. I note that Li and
Messler’s study was of weld metal,
not of the HAZ in base metal, so their
conclusions must be considered in
that light.
In conclusion, it is my opinion that
the new heat is not significantly differ-
ent from the old heat. If the old heat
gave acceptable performance, the new
heat should also. I would not expect
solidification cracking in autogenous
GTAW of either heat, although I would
be careful to taper off the welding cur-
rent to avoid a depression in the crater
at the end of the weld. I do think there
will be some sensitivity to microfissur-
ing at the fusion boundary in the HAZ
with either heat. Many austenitic
stainless steel welds with very low or
no ferrite can be found to contain mi-
crofissures and still give satisfactory
service. WJ
NOVEMBER 2018 / WELDING JOURNAL 19
References
1. Lundin, C. D., DeLong, W. T.,
and Spond, D. F. 1975. Ferrite-fissur-
ing relationship in austenitic stainless
steel weld metals. Welding Journal
54(8): 241-s to 246-s.
2. Li, L., and Messler, R. W. 1999.
The effects of phosphorus and sulfur
on susceptibility to weld hot cracking
in austenitic stainless steels. Welding
Journal 78(12): 387-s to 396-s.
DAMIAN J. KOTECKI is president, Damian
Kotecki Welding Consultants Inc. He is a
past treasurer of the IIW and a member of
the AWS A5D Subcommittee on Stainless
Steel Filler Metals, D1K Subcommittee on
Stainless Steel Structural Welding, and
WRC Subcommittee on Welding Stainless
Steels and Nickel-Base Alloys. He is a
past chair of the A5 Committee on Filler
Metals and Allied Materials, and served as
AWS president (2005–2006). Questions
may be sent to Damian J. Kotecki c/o
Welding Journal, 8669 NW 36 St., # 130,
Miami, FL 33166-6672, or via email at
damian@damiankotecki.com.
LASER WELDING Q&A
BY SIMON L. ENGEL

A: According to Encyclopedia Britannica

Q: We read in an earlier column
(Ref. 1), “Blackbody, in physics, [is] a
that during laser welding, the
surface that absorbs all radiant energy
metal behaves like a “black-
falling on it. The term arises because
body.” Can you please explain
incident visible light will be absorbed
this statement and tell us how it
rather than reflected, and therefore
relates to and affects laser weld-
the surface will appear black…The best
ing? We use both pulsed and
practical blackbody is a small hole in a
continuous-wave lasers.
box with a blackened interior, because

Fig. 1 — Schematic of a two-sector

pulse shape for welding class I metals
using a flash-lamp-pumped Nd:YAG
laser. The values of power density on
the graph are the power density re-
quired to couple the beam into the
metal (Sector 1), then to keep it
molten (Sector 2). The main features
of this pulse shape and the complete

ITS POTENTIAL IS LIMITLESS. weld schedule may be computed

using the algorithms in Laser Welding

THE POSSIBILITIES ARE INFINITE.

Technology — Engineering Manual
(Ref. 3).

practically none of the radiation enter-

ing such a hole could escape again, and
it would be absorbed inside…Polished
metal surfaces…absorb only about 6
percent of the incident radiation, re-
flecting the rest.”
In laser welding, we create a black-
body by vaporizing the surface of the
metal and creating a small hole. The
laser-created hole acts like a blackbody
and it “couples” all the energy of the
laser, irrespective of the wavelength of
the laser. It takes approximately a few
picoseconds (10-9 s) to couple the laser
beam into the material. Once the laser
beam is absorbed into the material,
the power density may be lowered to
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pulsed laser power. This subject was
covered in the March 2017 issue of the
Welding Journal (Ref. 2).
Aside from efficient coupling of the
laser beam and heating the bulk metal,
pulsing the laser power and pulse
P LAS MA | LAS E R | WATE R J ET | AUTO MATI O N | S O FTWAR E | C O N S U MAB LE S shaping offer other significant bene-
fits that are available to improve the

20 WELDING JOURNAL / NOVEMBER 2018

laser welding process:
1. Select the laser that is able to de-
liver the desirable characteristics.
2. Control the total heat generated
during welding.
3. Control the transient heat —
reduce the damage to heat-sensitive
components.
4. Increase process efficiency, pro-
ductivity, and welded-product quality.
The full description of the pulse
shape shown in Fig. 1 is found in Table

Table 1 — Summary of the Computations Performed to Optimize the Initial Pulse Shape

Change
Nd:YAG SS [3] % of original

Penetration in. 0.030 0.030 0.00%

Energy J 36.6 24.1 66%
Pulse width s 0.0041 0.0027 66%

Sector 1 Fig. 2 — Nd:YAG lasers, Sector 1: Cou-

Sector width s 0.0005 0.000005 1.00% pling of the laser energy into the
Peak power W 25,000 10,000 40.00% metal does not happen until the
Power density W/in.2 5.5E + 07 600E + 07 ok power density reaches a certain
Energy J 12.5 0.05 0.40% value. The energy that’s not coupled
is reflected off the surface and is lost.
Sector 2 The rest of the energy in Sector 1 may
Sector width s 0.0036 0.0027 75.00% cause vaporization of the metal and
Peak power W 6694 2900 43.32% some of it will blend into Sector 2. The
Power density W/in.2 1.5E + 07 2.0E + 07 ok rise time (RT) of the pulse may be as
Energy J 24.1 24.1 0.00% high as 250 μs and therefore the
width of Sector 1 (minimum sector
width) is 500 μs. By choosing a laser
*The information in column SS [3] is for a solid-state laser capable of delivering an RT of l μs and a sector with faster RT (and shorter minimum
width of 5 μs. The energy used in Sector 1 is only 0.05 Joules. The results are shown graphically in Fig. 4. For sector width), the lost energy may be
the same weld quality and results, you see much reduction in peak power values, less energy used, and the
transient heat has been reduced dramatically.
minimized (see Fig. 3).

NOVEMBER 2018 / WELDING JOURNAL 21

 Fig. 3 — Fiber lasers, Sector 1: Less en-
ergy is lost when the RT of the pulse
is 50 μs and the width of Sector 1 is
100 μs. The power density values in
both sectors are maintained to ensure
coupling of the laser and sustaining
the melt-weld process.
Fig. 4 — Transient temperature as a function of the peak power of Sector 1. The tem-
perature is measured about ½ bead width away from the edge of the weld joint.
Experience indicates that damage to plastic, seals, glass feedthroughs, and elec-
trolyte (as in batteries) is caused by the transient heat. The lower peak power and
the shorter Sector 1 creates a significantly lower transient heat wave.

1. We will use this pulse as a model to
show the added benefits of pulsed
power laser welding and shaping the
laser pulses.
Fiber Lasers
Using a fiber laser, we may change
the width of Sector 1 from 500 to 100
μs to reduce energy in Sector 1 from
12.5 to 1.25 joules (J). At the same
time, the energy in Sector 2 is in-
creased from 24.1 to 35.5 J. Typical
fiber lasers are able to provide this
pulse rise time (RT) and widths —
Fig. 2.
Solid-State Lasers
Some solid-state lasers are capable
of delivering a RT of 1 μs and a pulse
width of 5 μs, using only 0.11 J in Sec-
tor 1; hence, essentially all the energy
in the pulse is used in Sector 2 to melt
metal. We can compute a new weld
schedule, essentially ignoring the
small amount of energy used in
Sector 1.
The Optimized Weld Schedule
Looking at the original pulse pa-
rameters (see Fig. 1), we see that, in
Sector 2, only 24.1 J were used to melt
the volume of metal. A new weld
schedule may be computed using only
24.1 J (not 36.6 J) and the correspon-
ding values of peak power for Sector 1
and 2 to achieve the required power
density during the two sectors. The
laser used must have a RT of a few mi-
croseconds — Fig. 3. See Table 1 and
Fig. 4 for the summary and compari-
son of the weld schedule for the origi-
nal pulse and the optimized pulse.
Conclusion
The take home is the following:
1) Select a solid-state laser that
features Sector 1 that is only a few
microseconds long to reduce the heat
input by 34% as shown.
2) The total heat input may be
further reduced by lowering the duty
cycle and the overlap of the weld
nuggets.
3) The transient heat was reduced
significantly by reducing the peak
power by 60%.
4) By using shorter pulse widths (by
34%), the pulse rate and productivity
may be increased.
5) The cooling time was decreased
to 75%, and the cooling rate increased
by 52%. This change may cause prob-
lems welding metal alloys that have
marginal composition for laser
welding.
6) With the right laser and a laser
that is in calibration (Ref. 4), along
with some desk work (computation),
the weld schedule may as well be the
optimal as shown in this Q&A. The
time to compute the initial pulse
shape and its optimized version took
about 10 min. Time well spent. WJ
References
1. Encyclopedia Britannica. britanni-
ca.com/science/blackbody.
2. Engel, S. L. 2017. Laser welding
Q&A. Welding Journal 96(3): 18, 19.
3. Engel, S. L. 2018. Laser Welding
Technology — Engineering Manual.
HDE Technologies Inc., Elk Grove,
Calif.
4. American Welding Society. 2017.
AWS C7.4/C7.4M:2017, Process Specifi-
cation and Operator Qualification for
Laser Beam Welding. Miami, Fla.
SIMON L. ENGEL is president of HDE Tech-
nologies Inc., Elk Grove, Calif. He serves as
vice chair of the AWS C7C Subcommittee
on Laser Beam Welding and Cutting and is
a member of the US TAG for ISO/TC44/
SC10/WG9 on Hybrid Welding. He is also a
senior member of the Laser Institute of
America and a life member of the Society
of Manufacturing Engineers. He is consid-
ered a specialist in industrial laser applica-
tions and has been in the business for 40
years. Questions may be sent to Simon En-
gel, c/o Welding Journal, 8669 NW 36 St.,
#130, Miami, FL 33166-6672, or via email at
simon_of_hde@yahoo.com.

22 WELDING JOURNAL / NOVEMBER 2018

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24 WELDING JOURNAL / NOVEMBER 2018
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A welder uses a portable fume extractor with
an extra flexible capture hose that enables
placement in hard-to-reach areas.

How to Combat
Hexavalent Chromium

U
tilizing local ventilation systems or fume extractors for welding work-
Safety organizations spaces helps protect employee health, improves workplace safety, and pre-
provide regulations vents violations set by the Occupational Safety and Health Administration
(OSHA) (see lead photo).
and guidelines to Welding produces fumes when heating is applied to various metals, such as
stainless steel and chrome, nickel, or copper alloys (Ref. 1). Stainless steel,
protect workers from chrome alloys, or chrome-coated metals create the largest health risks due to
the presence of chromium, in particular hexavalent chromium.
this exposure Employers must ensure employee safety through the use of welding fume ex-
tractors, as seen in Fig. 1, coupled with respirators. However, respirators alone
do not provide enough respiratory protection. The National Institute for Occu-
BY KATIE RICHARDSON
pational Safety and Health (NIOSH) also recommends using other control
methods, such as fume extractors, as the primary fume control device (Ref. 2,
p. 99).

What is Hexavalent Chromium?

Hexavalent chromium is one of the oxidations or valence states of the ele-
ment chromium (Ref. 1).
Primarily, chromium is consumed by the steel industry with alloys of stain-
less steel and chromium containing about 11.5–30% chromium by weight (Ref.
3). When welding chromium alloy steels or stainless steel, heat is applied, and
chromium turns into hexavalent chromium (Ref. 1).
Hexavalent chromium is a more unstable, hazardous, and easily absorbed

30 WELDING JOURNAL / NOVEMBER 2018

form of chromium (Ref. 4, p. 159). Be-
cause of its unstable quality, once
hexavalent chromium enters the hu-
man body, it must be reduced to an-
other more stable form of chromium
(Ref. 4, p. 159). This process creates
free radicals that structurally damage
DNA, causing the toxicity and carcino-
genic properties of hexavalent chromi-
um (Ref. 4, p. 159).
Hexavalent Chromium
Exposure
Exposure to hexavalent chromium
during welding depends on the
amount of chromium in the metal and
the welding process being performed.
Typical chromium airborne concentra-
tions for welding range from 50 to
400 μg/m3 (Ref. 3). For example, the
Electric Power Research Institute
measured the chromium exposure dur-
ing various welding operations at an
electric utility operation. Mean expo-
sures are listed in Table 1.
The mean exposures are below the
OSHA permissible exposure limit
Fig. 1 — A worker welds
next to a dual-operator,
portable welding fume
extractor featuring
heavy-duty arms and a
cleanable filter.
Table 1 — Mean Hexavalent Chromium
Exposure by Welding Type (Department of
Health, Criteria, p. 22)
Welding Mean
Type Exposure
Shielded Metal Arc Welding 1.4 μg/m3
Gas Metal Arc Welding 1.3 μg/m3
Gas Tungsten Arc Welding 0.14 μg/m3
(PEL), but for shielded metal arc weld-
ing (SMAW), the exposure level was
only below the PEL when ventilation
was used, and the chromium content
of the metal was less than 3% (Ref. 2,
p. 22).
A study was also conducted testing
biological samples from welders and
showed that manual metal arc weld-
ing, or SMAW, produced the highest
concentration of chromium (Ref. 3). In
a different study, air measurements
were collected to confirm that SMAW
produced the highest amount of
chromium (Ref. 5, p. 48).
Other types of welding, such as flux
cored arc welding and short circuit weld-
ing, produce less chromium than
NOVEMBER 2018 / WELDING JOURNAL 31
SMAW. Pulsed spray welding has been
shown to emit the least amount of
chromium out of all types (Ref. 5, p. 48).
Health Factors
The International Agency for Re-
search on Cancer (IARC) classifies
hexavalent chromium as a carcinogen
in humans (Ref. 3). The most com-
monly caused cancer from hexavalent
chromium is lung cancer, due to the
inhalation of fumes. Inhalation cancer
risks depend on personal health as
well as the intensity and duration of
the exposure (Ref. 6, p. 667). In an
analysis of 30 Iranian welders in the
oil and gas industry, researchers found
the cancer risk to vary depending on
whether the worker welds mainly for
maintenance in a less often basis, or as
a project welding full time, as well as if
the welder had prior respiratory condi-
tions. Although the difference is mini-
mal between asthma and healthy indi-
viduals, the main contributing factor
is whether the worker only welded oc-
casionally or full time (Ref. 6, p. 670).
In a population study conducted by
 Fig. 2 — Two welders benefit from using a dual-arm
portable fume extractor with a cleanable filter.

the IARC, 11,092 European welders

were analyzed, and 116 lung cancer
deaths occurred in this study group
(Ref. 2, p. 38). This is approximately
1.05% of the study population, which
could mean there is a 1/100 chance of
welders developing lung cancer. How-
ever, this study did not provide data
about the level of chromium concen-
tration exposure, which is an impor-
tant contributing factor.
Not only does hexavalent chromium
increase the risk for lung cancer, it can
also cause sinonasal, oral, liver, and
esophagus cancers. However, the risks
for these types of cancers are much less,
with little evidence to prove that the
cancer was caused from hexavalent
chromium exposure (Ref. 4, p. 163).
In addition, exposure to airborne
hexavalent chromium has been shown
to cause irritation to the nose and
throat, with symptoms such as a run-
ny nose and nose bleeds (Ref. 7). Nasal
symptoms should be closely moni-
tored because they can signify devel-
oping cancer in the nasal area (Ref. 4,
p. 168). In severe cases, the nasal sep-
tum can develop a hole in it (Ref. 7).
However, small concentrations do
not cause most people respiratory side
effects. Employees may become aller- Fig. 3 — This picture, taken at a distance, reflects the full size of a rugged air
gic to hexavalent chromium and devel- portable fume extractor with a cleanable filter.
op wheezing or shortness of breath
(Ref. 7). Exposure can result in bron- skin, eyes, kidney, and liver (Ref. 8). pain, and teeth irritation or yellowing
chitis, asthma, and damage to the Pulmonary congestion, abdominal may also occur from exposure (Ref. 8).

32 WELDING JOURNAL / NOVEMBER 2018


Fig. 4 — Hanging ambient air cleaners, such as the models seen here, are advised to
be used with a source capture fume extractor.
Table 2 — Industrial Hygienist Testing Report on Sentry Air Systems Products for
Hexavalent Chromium Removal Efficiency
Product Filter Reading
Source
Model 300 HEPA Inlet
Ambient Air
Welder
Model 450 Micro-Pleat Inlet
Ambient Air
Welder
Regulations and
Guidelines
The Occupational Safety and
Health Administration and other or-
ganizations provide regulations, along
with guidelines, for hexavalent
chromium exposure to protect worker
safety and health — Fig. 2.
The Occupational Safety and
Health Administration legally requires
employers to keep the PEL below 5
μg/m3 for 8 h of work five days a week
(Ref. 7). Employers must conduct
monitoring assessments to check the
level of airborne hexavalent chromi-
um. If the level is at or above 2.5
μg/m3, OSHA requires that action
must be taken to ensure the level does
not exceed the PEL (Ref. 7).
The National Institute for Occupa-
tional Safety and Health has much
stricter recommended exposure limits
Cr(VI) Reading Approximate
(μg/m3) Efficiency
94
0.27 99.9%
1.3
16
≤ 0.2 > 97%
≤ 0.2
(REL) of 0.2 μg/m3 for 8 h of work five
days a week (Ref. 2, p. 2). This limit is
not legally enforced but provides the
ultimate safety for employees and
helps reduce the risk of cancer. The or-
ganization selected this limit on the
basis that this exposure level had a
1/1000 cancer risk, as found from data
of a quantitative risk assessment of
lung cancer deaths from a Maryland
chromate production facility over a 45-
year lifetime exposure (Ref. 2, p. 84). It
considers cancer risks above 1/1000 to
be significant and worthy of requiring
action by OSHA. Also, NIOSH defined
the immediate danger to life and
health level as 15 mg/m3 (Ref. 2, p. 84).
The American Conference of Govern-
mental Industrial Hygienists (ACGIH)
recently decreased their threshold limit
value to 0.2 mg/m3, which is the same
level as NIOSH’s REL. The ACGIH also
recommends a short term exposure lim-
it of 0.5 μg/m3.
NOVEMBER 2018 / WELDING JOURNAL 33
Exposure Prevention
and Welding Safety
To keep hexavalent chromium lev-
els below the OSHA PEL and/or
NIOSH’s REL, employers can take sev-
eral precautions, including changing
the welding type, reducing the amount
of chromium in the material, utilizing
personal protection equipment, and
installing local exhaust or fume extrac-
tors (Ref. 7) — Fig. 3.
In all situations, it is vital for em-
ployers to provide respirators and
welding fume extractors. Respirators
do not provide enough protection
alone, and NIOSH warns against using
them as a primary control method
(Ref. 2, p. 99).
Welding Fume Extractors
The most functional and versatile
fume extractors are portable units.
Portability allows the system to be
easily installed and moved to a differ-
ent welding location. Portable fume
extractors do not require exterior
ducting or makeup air. With a flame-
based application like welding, flame-
retardant capture hoses and filter me-
dia provide optimized safety. Flame-
retardant hoses are available as self-
supporting flexible hoses, allowing the
operator to move the capture source
closer to the weld, or extra long, flexi-
ble hoses, which allow fumes to be ex-
tracted in hard-to-reach areas.
Most welding fume extractors uti-
lize high-efficiency particulate air
(HEPA) or cleanable micropleat filters.
The HEPA filters are best suited for
lower-volume welding and provide up
to 99.97% efficiency on particles as
small as 0.3 microns. Cleanable filter
media, such as micropleat filters, pro-
vide a solution for high-volume appli-
cations by allowing the operator to
clean and reuse the filter without re-
moving it from the system. The clean-
able filter media systems are usually
larger in size but do not require duct-
work or makeup air, making them easy
to move if needed. Multiple operator
systems provide two or four capture
hoses to allow multiple employees to
use the same system.
Ambient air cleaners provide added
protection to collect fumes and partic-
ulate from the room’s air. Hanging am-
bient air cleaners are recommended to
be used with a source capture fume ex-
 tractor to ensure maximum protection
— Fig. 4.
Workspace Monitoring
Once the hexavalent chromium ex-
posure is at the action level, employers
must monitor the workspace every six
months to ensure the hexavalent
chromium exposure is below the
OSHA PEL (Ref. 7).
At Sentry Air Systems Inc., Cypress,
Tex., the company tested the Model
300 welding fume extractor with a
HEPA filter, and Model 450 welding
fume extractor with a micropleat filter
to ensure high efficiency. The results
are shown in Table 2. Both systems
maintained an airborne level of
chromium below the OSHA PEL, pro-
viding employee health protection.
Conclusion
After learning more about hexava-
lent chromium, including exposure
statistics, health factors, regulations
and guidelines, welding safety, extrac-
tor units, and workspace observations,
you should now have a better under-
standing of the importance of safe-
guarding workers from exposure. WJ
References
1. Occupational Safety and Health
Administration. Overview. Hexavalent
Chromium. osha.gov/SLTC/
hexavalentchromium/.
2. Department of Health and Hu-
man Services. Sept. 2013. Criteria for a
Recommended Standard: Occupational
Exposure to Hexavalent Chromium. pp.
2, 22, 38, 84, and 99.
3. U.S. Department of Health and
Human Services. Nov. 3, 2016. Chromi-
um Hexavalent Compounds. Report on
Carcinogens, 14th ed. ntp.niehs.nih.gov/
ntp/roc/content/profiles/
chromiumhexavalentcompounds.pdf.
4. Higashi, T., Kawaguchi, T., Mori-
moto, Y., Noguchi, S., Suzuki, H.,
Tanaka, F., Ueno, S., and Yatera, K.
2018. Cancer risks of hexavalent
chromium in the respiratory tract.
Journal of UOEH, The University of Oc-
cupational and Environmental Health
Japan 40(2): pp. 159, 163, and 168.
5. Keane, M. J. 2014. An evaluation
of welding processes to reduce hexava-
lent chromium exposures and reduce
costs by using better welding tech-
niques. Environmental Health Insights
34 WELDING JOURNAL / NOVEMBER 2018
8(1): 47–50. ncbi.nlm.nih.gov/pmc/arti-
cles/PMC4270263/.
6. Barkhordari, A., et al. 2014. Can-
cer risk assessment in welder’s under
different exposure scenarios. Iranian
Journal of Public Health 43.5: 666–673.
ncbi.nlm.nih.gov/pmc/articles/PMC444
9415/.
7. Occupational Safety and Health
Administration. July 2006. Health Ef-
fects of Hexavalent Chromium. OSHA
Fact Sheet. osha.gov/OshDoc/data_
General_Facts/hexavalent_chromium.
pdf.
8. Occupational Safety and Health
Administration. Health Effects. Hexa-
valent Chromium. osha.gov/SLTC/
hexavalentchromium/healtheffects.html.
KATIE RICHARDSON
(krichardson@sentryair.com) is the
marketing coordinator for Sentry Air
Systems Inc., Cypress, Tex.
Permissible and
Recommended
Exposure Limits
Matter
To access the permissible
exposure limits — annotated tables,
visit the Occupational Safety
and Health Administration’s
(OSHA) website at osha.gov/dsg/
annotated-pels/index.html.
As stated, “To provide employers,
workers, and other interested par-
ties with a list of alternate occupa-
tional exposure limits that may
serve to better protect workers,
OSHA has annotated the existing
Z-Tables with other selected occupa-
tional exposure limits.”
Additional information found on
that website consists of the Nation-
al Institute for Occupational Safety
and Health’s (NIOSH) recommend-
ed exposure limits (RELs), including
these details.
“In developing RELs and other
recommendations to protect worker
health, NIOSH evaluates all avail-
able medical, biological, engineer-
ing, chemical, and trade informa-
tion relevant to the hazard. NIOSH
transmits its recommendations to
OSHA for use in developing legally
enforceable standards.”
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USA Science & Engineering
Festival Sparks Interest in
All Things STEM
BY CINDY WEIHL
Science enthusiasts of all ages engaged
their minds and fueled their curiosity at
this biennial event

F
rom engineering to space explo-
ration, chemistry to military
service, and veterinary science to
3D printing technology, just about any
topic of interest in the science, tech-
nology, engineering, and mathematics
(STEM) sector covered 2.3 million sq
ft of space at the Walter E. Washing-
ton Convention Center in Washington,
D.C., on April 7 and 8 during the 5th
USA Science & Engineering Festival.
The nation’s largest celebration of
STEM brought in more than 370,000
attendees, the festival’s biggest event
to date — Fig. 1. Its other crowd-
drawing events included X-STEM, a
symposium “TED Talk”-like day geared
to engage middle and high school stu-
dents with STEM professionals, and
Sneak Peak Friday. Roger Russel, director and cofounder of SMILE camp (left), explained the electrifying
reason nine-year-old Claire Ransom’s hair is standing up.
Sneak Peak Friday
The biennial festival kicked off on
Friday, April 6, with Sneak Peak Fri-
day, sponsored by Chevron. The pre-
view day is only open for schools,
homeschoolers, and military families.
Khary Parker and his family, wife
Jennifer and daughters Naomi, 8, and
Mykah, 7, from Arnold, Md., made the
hour drive to the festival to provide a
hands-on opportunity for the girls to
strengthen their home schooling rou-
tine — Fig. 2.
“It’s our first year attending, and as
an engineer, I know how much I enjoy
science, and both girls are into science,
so we are always looking for an opportu- Fig. 1 — More than 370,000 people attended the 5th USA Science & Engineering Festi-
nity for them to experience it,” said val in Washington, D.C. In this photo, attendees watch a presentation by Honda Ro-
Parker. botics featuring its humanoid robot, ASIMO.

36 WELDING JOURNAL / NOVEMBER 2018


Fig. 2 — Sisters Naomi (left) and Mykah Parker learned how to simulate an earth-
quake at the Incorporated Research Institutions for Seismology (IRIS) booth as their
parents, Jennifer and Khary, look on.
Fig. 3 — Shannon Varcoe, founder of ZYX Sticks, helped young festival visitors create
a wooden structure.
Something for Everyone
With more than 650 participating
organizations and companies, visitors
to the 2018 festival were able to en-
gage their minds, be inspired, fuel
their curiosity, and explore all things
STEM.
NASA was on hand with an interac-
tive and informative exhibit, which in-
cluded learning about x-rays and gam-
ma rays, living and working on the In-
ternational Space Station, and lunar
exploration today and in the future.
Lockheed Martin allowed visitors
to try their luck with a career predic-
tor, fly a full-scale Raider helicopter,
virtually visit Mars Base Camp, and
climb on board an F-35 fighter jet.
At the exhibit sponsored by the In-
ternational Society of Automation,
visitors competed in a computerized
game based on an actual industrial au-
tomation and control system.
How important are standards to
our daily life? The American National
Standards Institute (ANSI) was on
hand to show attendees just how much
we unknowingly rely on standards
every day. One example, a basketball
NOVEMBER 2018 / WELDING JOURNAL 37
game visitors could participate in for
the organization to showcase how bas-
ketballs reliably fit in the rim thanks
to ASTM F1882, Standard Specification
For Residential Basketball Systems.
Some exhibitors were also hoping
to attract the next generation of job
seekers to careers they may not have
even known were out there. Phil
Trach, ASNT NDT Level III (UT), was
at the ASNT booth showing visitors
how nondestructive examination
works.
“Nondestructive testing is the most
important industry you’ve never heard
of,” said Trach. He explained to atten-
dees how it is used to find cracks, de-
fects, corrosion, and other potential
damage in structures, such as build-
ings, bridges, airplanes, and cars.
Start-up companies attracting engi-
neering enthusiasts also made a pres-
ence at the festival. Shannon Varcoe,
founder of ZYX Sticks, saw her booth
surrounded by young boys and girls
for the duration of the event — Fig. 3.
The open-ended, wooden building
sticks promote creative and collabora-
tive play. The idea for the toy came to
Varcoe while she was a mechanical en-
gineering student creating a sculpture
with interlocking pieces. With notched
joints cut into the sides, three dimen-
sional building is possible.
“It may seem simple at first, but the
more sticks you add, the more complex
it becomes,” said Varcoe. “The struc-
tures can be geometrically organized
or built into something competely ab-
stract. They don’t come with instruc-
tions because what you build is driven
by your creativity.”
Universities Get Young
Visitors Thinking About
the Future
As students walked around the con-
vention center exploring all things
STEM, there was no shortage of uni-
versities from across the United States
hoping to get them thinking about
where they want to attend school by
wooing them with their engineering,
science, and research programs. Some
schools, like Michigan Technological
University, made sure their program
stood out from the rest by showcasing
its Mind Trekkers Road Show. The
Mind Trekkers team consisted of un-
dergraduate and graduate students
showing booth visitors how science
can be fun, from making ice cream in
less than 60 s to how the motion of a
spinning plate creates a vortex of fire
— Fig. 4.
North Carolina State University’s
Engineering program and Women in
Science & Engineering (WISE) pro-
gram were also on hand with Roger
Russel, director and cofounder of
SMILE Camp (Science and Math Inter-
active Learning Experience), who drew
in a crowd with a Van de Graaff gener-
ator (a large metal ball) creating static
electricity. The electrons move up a
rubber band to the metal ball and into
the person touching it. The electrons
repel each other, causing the hair of
the person touching it to move as far
away from the body as it can (see lead
photo).

Special Guests Connect

with Attendees
Fair attendees also had the privi-
lege of meeting a slew of special guests
who shared their love of science with
them. Danni Washington, who is a ma-
rine biologist, TV host, and ocean ad-
vocate, spoke to attendees about her
deep passion for the ocean. Guy Raz
and Mindy Thomas, hosts of NPR’s
Wow the World, a podcast for kids and
families, chatted with visitors and
signed autographs both days of the
festival. Other special guests included
Mathmagician Art Benjamin; Steve
Spangler, host of DIY Sci; and NASA Fig. 4 — A Michigan Technological University student demonstrates how to make a
Astronaut Jessica Meir. fire tornado.

Career Fair Attracts

Students and Job
Seekers of All Ages
In addition to the many exhibitors
and special guests showcasing STEM
careers, as an extension of the 2018
expo, the festival hosted its first-ever
STEM Career Fair Night. The goal was
to connect employers with potential
recruits and to showcase future oppor-
tunities for employment.
Current students and college gradu-
ates had the opportunity to meet with
more than 50 companies and govern-
ment agencies looking to recruit new
talent. More than 1000 students par-
ticipated, some as young as high
schoolers — Fig. 5.
Natalie Gainer and Alexandra
“Sasha” Dodzin, now high school soph-
omores, traveled from their home in Fig. 5 — Career fair attendees waited in line to speak to job recruiters.

38 WELDING JOURNAL / NOVEMBER 2018

Reston, Va., to the career fair in hopes
of finding more information about

STOP Reverse Flow

summer internships, colleges, and ca-
reers. Gainer was interested in com-
puter sciences, coding, and engineer-
ing while Dodzin was interested in
econometrics and mathematics.
Margaret Ardillo, university rela-
tions and recruiting, Lockheed Martin,
Flashback Fires
was hoping to meet with mechanical
and electrical engineers as well as soft- IN STEEL MILLS & SHIP YARDS
ware, business, and finance majors in-
terested in internships and co-ops all SuperFlash Flashback Arrestors
across the United States. prevent costly OSHA fines
“We’re looking to meet current stu-
dents and create a talent profile,” she
said. SuperFlash Flashback Arrestors
The profiles, Ardillo explained, are prevent downtime, accidents and injuries
used to pair students with open in-
ternship positions.
David Burge, integrated controls di-
SuperFlash Flashback Arrestors are available
vision operations manager, Honda in many different connections and flow rates
R&D Americas, was also at the career
fair hoping to find not only interns
but future employees. The company CLAIM YOUR “Safety Tips to Prevent Downtime & Injuries”
was hiring electrical and mechanical
engineers for more than 30 open posi-
FREE GUIDE: bscheetz@oxyfuelsafety.com ƒ (866) 324-0036
tions, including hybrid electric vehicle
systems engineer and vehicle control FABTECH Booth: # C11129
safety engineer.
Fair attendees looking for jobs and oxyfuelsafety.com
internships were pleased with the
companies participating in the career
fair. Mohammed Abu Sharifa, a me-
chanical engineering graduate from
Catholic University of America, was
happy to meet with Pam Herman, a re-
cruiter with Marathon Petroleum Co.
Herman was accepting résumés but
also looking for interns for spring
2019. She said the company hires
about 300 to 400 interns per year.

Festival Encore
Based on the success of this year’s
X-STEM symposium, X-STEM DC
2019, presented by the NCR Founda-
tion, will return to the Walter E. Wash-
ington Convention Center on March
19, 2019. Meanwhile, the festival’s bi-
ennial expo weekend will return in
spring 2020. For more information,
visit usasciencefestival.org. WJ

CINDY WEIHL (cweihl@aws.org) is senior

editor of the Welding Journal.

NOVEMBER 2018 / WELDING JOURNAL 39

Weld Surfacing Improves the
Life Cycle of Components
This process helps machines and
equipment last longer while saving energy
W
eld surfacing is a green
process that saves energy and
reduces material loss due to
wear and friction. The objective of
green weld surfacing is to form a pro-
tective coating to resist wear, friction,
and corrosion in the working environ-
ment of the component. The protec-
tive coating improves the life cycle of
the critical component’s performance
over a long period of time even in se-
vere wear environments. The process
is used during original equipment
manufacturing and in successive main-
tenance and repairs of worn compo-
nents, thus extending the life cycle by
several folds.
Processes
All common welding processes,
including gas, manual metal arc
(MMAW), gas metal arc (GMAW), gas
tungsten arc (GTAW), submerged arc
(SAW), and flux cored arc welding
(FCAW), are used for fusion weld sur-
facing. The metallurgical bonding of
welds allows heavy build-up and repair
of damaged, worn components.
However, advanced processes based
on plasma, laser, and spark are being
increasingly used because they are
faster, high-energy operations. These
processes produce low-dilution welds,
with a low heat-affected zone (HAZ)
base metal, and are capable of making
thin, single-layer overlays, thus retain-
ing the composition of the consumable
in the transfer process and deposit
(Ref. 1).
Dilution and HAZ are two impor-
tant factors in selecting the welding
parameters and process by picking up
elements from the base metal, which
leads to dilution in composition of the
weld overlay from that of the original
consumable. High dilution of the weld
overlay in arc welding processes, such
as MMAW or FCAW, significantly al-
40 WELDING JOURNAL / NOVEMBER 2018
Fig. 1 — Laser deposition process on
boiler tubes (Ref. 8).
ters the wear and corrosion properties
(Ref. 2). Plasma transferred arc weld-
ing (PTAW) using powder consum-
ables can restrict dilution to 5%. Dilu-
tion in the laser weld overlay using
powder alloys is negligible. No dilution
occurs in the microwelding process in
electrospark deposition (ESD). Low di-
lution enables single-layer instead of
three-layer deposits in high-dilution
processes, such as MMAW, to arrive at
a wear-resistance alloy composition in
the top layer. Faster welding by high-
energy beam or plasma results in a
lower HAZ in the base metal.
The most widely used consumable
alloys are based on Fe-Cr-C (stainless
steels, white cast iron), Ni-Cr-M
(Inconel, Hastelloy, Nimonic),
Co-Cr-C-M (Stellite 21, 6, 32, 12)
systems (M stands for additional ele-
ments), where Cr ≥ 11% provides cor-
rosion protection. Also used are metal
matrix composites, such as WC-Co and
NiCrBSiC + WC. These are used in the
form of wire, rod, tube, or powder.
Selected Industries
and Green Welding
Applications
Green welding applications in in-
dustries, including steel, transporta-
BY RAM CHATTOPADHYAY
tion (automotive and railway), power
(thermal and hydro), mineral process-
ing, and machine tools, are discussed
in the following sections.
Steel
Concast Rolls
A single operation of continuous
casting of molten steel to produce a
solidified, semifinished billet, bloom,
or slab replaces the four older process-
es, such as ingot mold casting, mold
stripping, soaking pit heating, and pri-
mary rolling, to form the same prod-
uct. Energy savings by continuous
casting over ingot mold practice is ap-
proximately one million BTU per ton
of cast steel (Ref. 3).
In continuous casting, the molten
metal is poured into a bottomless
mold, where skin formation occurs be-
fore being drawn through a series of
caster rolls to form a slab, billet, or
bloom. With progressive solidification,
the caster roll size increases from 6 to
12 in. in diameter to support a higher
forming load.
Rolls are subjected to thermal fa-
tigue, ionized hydrogen and halogen
corrosion, and stress corrosion crack-
ing. Pits and crevices formed on the
surface is known as fire cracking or
checking (Ref. 1). New rolls are sur-
faced by the SAW process with 400 se-
ries stainless steel (AISI 410, 420, or
414). Rolls require resurfacing at regu-
lar intervals. The life of the cladded
rolls is six months to a year and can
make more than a million ton steel
slabs during that period. A metal cored
tubular-flux combination for weld sur-
facing has been found to prolong the
life cycle by two to three folds com-
pared to strip cladding (Ref. 4). A pro-
tective weld overlay on a castor roll en-
ables the energy saving process to run
in a severe wear environment.
Table 1 — Hot Microhardness (HV) at Elevated Temperature (‘K)

Alloy 303’K 698’K 773’K 813’K 923’K 973’K 1033’K 1143’K

1 213 — 185 — 180 145 100 —

2 300 — 260 — — 257 — 210
3 380 290 — 265 245 — 166 —
4 270 — 222 — 150 — 110 —

*PTA deposits of Alloy 1 (Hastelloy® 276), Alloy 2 (Udimet® 520), Alloy 3 (Stellites™ 6), Alloy 4 (Stellite™ 21) (Ref. 5).

Bar Forging Hammer

Repeated impact results in thermal
fatigue wear in a bar forging hammer.
The fatigue wear life of the hammer
is expressed in terms of cycles to start
the wear process. The Zero Impact
Wear equation (IBM model) correlates
the number of cycles to wear with
shear yield stress or hardness (Ref. 5).
In this case, a die steel hammer
(0.56 C, 1.1 Cr, 0.5 Mo, 1.7 Ni, and 0.1
V) is coated with a top layer of high
hot hardness Nimonic® alloy (Udimet®
520/18.73 Cr, 12 Co, 5.8 Mo, 1.0 W,
1.7 Al, 2.86 Ti, and Rest Ni), an inter-
mediate layer of Hastelloy® C276 (C <
0.04, 16 Cr, 16 Mo, 4 W, Co > 2.5)
with good hot hardness, followed by a
buffer and buildup layer(s) of Inconel®
625 (21.5 Cr, 9 Mo, 3.6 Cb, 0.2 Ti, and
0.2 Al) on the hammer. Gas tungsten Fig. 2 — A typical cross section photo (50×) of a process qualification sample for
arc welding is used to avoid loss of Al ASME Section IX. Base material is SA-213-T22. The photo shows good overlay den-
in direct arc transfer processes. Service sity, no cracking, no incomplete fusion, very low dilution, and minimal HAZ (Ref. 8).
life improves 700 times compared to
die steel base metals.
2N, are valve materials. steel and modified AISI 410 showed
Table 1 shows the hot hardness of
Plasma arc welded Stellite™ 6 over- the life span increased by two and four
PTA deposits with increasing tempera-
lay retains high hot hardness (Table 1) times, respectively, with respect to
ture. Nimonic® alloy has the unique
and, thus, wear resistance properties bare rail steel (Ref. 7).
property of retaining high-tempera-
at 700°C. Wear resistant coating of the
ture strength due to the presence of
the gamma prime phase (Ni3AI).
valve face with Stellite™ 6 minimizes Power
erosion-corrosion wear and improves
Based on hot hardness data at 1043 ‘K
thermal fatigue life by tenfold (Ref. 6). Waste Heat Boiler
and using the Zero Impact Wear equa-
Substitutes showing a similar life span In the power generation industry,
tion, the calculated ratio for the num-
include Stellite™ 32 (Co-1.75C-25Cr- one of the most inhospitable opera-
ber of cycles to wear for Udimet® 520
11.8W-22Ni) and Ni-11 (Ni-0.45C- tional environments occurs within the
and Hastelloy® 276 is 512. Hence, PTA
3.5Si-16.7Cr-12.5Fe). boilers operating at “waste-to-energy”
overlay of Udimet® 520 will improve
service life more than 700 times com- facilities. The most common fuel
pared to a much lower hot hardness of Railroad Frog source ranges from wood or construc-
a base metal (Ref. 5). Railroad frogs, crossings where tion debris to municipal solid waste.
train wheels are guided to change Pressurized boiler components are
tracks, undergo severe surface fatigue subjected to high temperatures
Transportation wear due to repetitive impact loading. (1600°–2000°F), high pressures
Failure occurs due to rolling contact fa- (850–1200 lb/in.2), and fuel that is
Engine Valve tigue, which results in crack initiation both highly corrosive and erosive. Ma-
Engine valves are subjected to com- and growth in the subsurface region, jor wear problems, including corrosion
bined thermal fatigue, erosion, and causing material removal by flaking. by chlorine, erosion by fly ash, buildup
corrosion. Wear on the sealing face can Railroad frogs require regular repair by fly ash, plus wear debris, reduces
cause hot gas to escape and conse- and resurfacing to build up worn areas heat transfer and creates “hot spots.”
quently decrease in effective cylinder for safe changeover without derail- Inconel 625 overlay resists high tem-
output and performance. Austenitic ment. Results of wear simulation tests perature erosion-corrosion.
stainless steels, such as 21-4N and 21- on a 15Cr-15Mn austenitic manganese Benefits of laser weld coating (Fig.

NOVEMBER 2018 / WELDING JOURNAL 41

1) include higher hardness (60–70
HRC), which results in a reduction in
fly ash erosion, thus SH tube shielding
can be partly or fully eliminated. This
would reduce hot spot formation and
failure points. Soot blower cleaning cy-
cle frequency has reported a 79% reduc-
tion. Low heat input and dilution lead
to full material properties within 0.005
in. from the substrate. A coating thick-
ness of ≥ 0.030 in. is ideal. Thinner
coating improves thermal efficiency.
For continuous in-line shoot blower
lances, component life extends six
times their preexisting lifespan (Ref. 8).
Hydroturbine
Hydroturbines in the Himalayan re-
gions face severe wear due to high silt
in its river water. The high wear rate
can cause the removal of half of the
runner blades within six months (Ref.
9). Re-blading takes three months.
The high kinetic energy of impact by
slurry-containing abrasive quartz par-
ticles results in heavy loss of material
from the component surface. Wear
scars in the form of ripples grow in
size and depth (Fig. 3) and reduce
power generation efficiency progres-
sively. The thin, worn leading edge of
the runner blade breaks due to water
pressure. Failure in trials with high-ve-
locity oxygen fuel and plasma nitrid-
ing has led to ongoing research for al-
ternative base material (Ref. 9).
Results of long time wear simula-
tion tests were conducted on weld de-
posits of three alloys and base material
showed a decreasing steady state wear
rate in this order: AISI 316 → CA6NM
(turbine material) → Fe-15Mn-15Cr-
0.4C alloy → Stellite™ 6. The PTAW-
deposited Stellite™ 6 overlay showed
an almost flat steady state wear while
others showed a higher rate with time
(Ref. 10). Wear data indicates a poten-
tial life cycle extension by several folds
with PTA overlay of Stellite™ 6.
Mining and Mineral
Processing
An estimated energy loss directly
through friction and wear in the min-
ing and mineral processing industries
is equivalent to 15 × 109 kWh, ac-
counting for half of the wear losses in
the industrial sector in the United
States (Ref. 11). In this sector, high
wear leads to higher maintenance
costs of up to 40% of the operating
cost (Ref. 9).
42 WELDING JOURNAL / NOVEMBER 2018
Tricone Bit
Rock cutters require different sur-
facing treatments for their compo-
nents. For example, rolling rock cutter
bits consist of three major compo-
nents: cones, bearing pins, and bit
body. All steel teeth cones require
hardfacing in the gauge surfaces.
Hardfacing improves wear resistance
to teeth but reduces resistance to chip-
ping. Hence, for hard-formation cones,
only the gauge is coated and not the
teeth. For soft-formation cones, usual-
ly both teeth and gauge are coated.
Nose bearing and thrust surface areas
are coated and grounded to provide
precision low-friction bearing sur-
faces.
Normal practice is gas welding with
Stellite™ 190. The PTA overlay of
NiCrBSiC + WC has an extended serv-
ice life in this application by several
folds (Refs. 9, 12) and that of sand
mining equipment by 500% (Ref. 13).
Mineral Processing Equipment
High abrasive wear of mineral pro-
cessing equipment requires a heavy
buildup of wear-resistant overlay alloy.
Normal practice includes fusion weld- Fig. 3 — High-silt wear pattern in a
ing by MMAW or FCAW. A series of Pelton wheel component.
high-chromium white irons are used
as coating material for crushers, ham- material by momentarily short circuit-
mers, and liners. The addition of 2 to ing with the substrate (Ref. 1). It is
3% Mo improves toughness and resist- used to deposit high- hardness, thin
ance to spalling, pitting, and hot weld overlay (up to 1 mm or 0.04 in.)
checking. White iron 15-2-1 (Fe-2.8C- on machine tools in both original
16Cr-2Mo-1Cu) with a highest hard- equipment manufacturing as well as
ness of 776HV showed the lowest maintenance and repairs. There is no
wear in a crusher test (Ref. 12). The al- need for stripping of worn coatings in
loy is widely used for crushing ham- repairs by ESD.
mer, impact bar, and small jaw. Plas- Overlay of super-hard materials,
ma-transferred arc deposits of white such as W, Ti, Cr carbides, and ultra-
iron showed an improved wear resist- fine diamond particles (Ref. 9), im-
ance in comparison to those obtained proves tool life. The use of graphite
by other welding processes (Ref. 14). electrode increases the carbon content
of the steel surface, and, with a very
Machine Tool Industry high cooling rate, a thin, carbon-
Huge energy loss to the tune of 28 enriched surface layer transforms to
× 1012 BTU occurs due to wear and hard martensite (Ref. 9).
friction in the machine tool sector. Although cutting tool wear can oc-
Another green objective is to minimize cur at both the rake and clearance
the use of lubricants by reducing fic- sides of cutting edges, carbide impreg-
tion with an appropriate low-friction nation at the rake face of a milling cut-
coating. ter is sufficient to improve tool wear
Metal deposition by reversing the life (Ref. 15). Similarly, the flutes of
polarity of a spark-erosion machine is taps and drills, top surfaces of dies,
used both for correcting machining er- and the ends of punches are carbide
rors and for wear facing of difficult- impregnated to improve wear life
to-weld hard machine tools. Electro- (Ref. 15).
spark deposition is a microwelding Summary of the applications dis-
process in which a moving consumable cussed in this article is tabulated in
electrode deposits minute amounts of Table 2.
Table 2 — Summary of Selected Applications

Application/Wear Type Alloy Welding System Life Expectancy

Concast rolls/high T corrosion AISI 410, 412, 420 SAW 6 months–1 year
Metal cored wire flux combination 3× above

Bar forging hammer/ 3 layers/Inconel® 600, GTAW 700× more cycles than
thermal fatigue Hastelloy® 276, and die steel basel 1000×
top Udimet® 500 PTAW than die steel

Engine valve/erosion-corrosion Stellite™ 6, Stellite™ 32, and Ni11 PTAW 10×

at high T

Waste heat boiler/high T Inconel® 625 Laser 6×

erosion/corrosion

Hydroturbine/high-silt erosion Stellite™ 6 PTAW Several folds over CA6NM

Tricone bit/oil sand mining NiCrBSi + WC PTAW 5×

tools/abrasion Stellite™ 1 or 190 Gas welding

Crusher, hammer, impact White Iron 15-2-1 MMAW/FCAW Several times

bars/impact-abrasion

Machine tools/diffusion- Carbides Electrospark deposition Several times

friction-abrasion

Future
Electrically driven polariton laser
operates using one hundredth of the
power of conventional laser and may
save an enormous amount of energy in
laser surfacing processes (Ref. 16). The
concentrated solar flux has been found
to be the fastest and cheapest green
heat source for fusion. For example, it
takes 0.089 seconds to reach 2900°C
melting point of ZrO2.
Conclusion
Thermal spraying and weld surfac-
ing are two main green processes for
improving the life cycle of critical com-
ponents in machines or equipment in
use. Both can save 1) quadrillion BTUs
in energy loss due to wear and friction;
2) millions in tons of minerals and
other resources required to make new
components for frequent replacement
of worn parts; 3) billions of dollars re-
quired to compensate energy loss in
operation, frequent maintenance
downtime, and replacement of worn
components; and 4) billions in tons
of carbon dioxide emission through
energy savings (Ref. 1), with the po-
tential to save the ecology, climate,
and environment. WJ
References
1. Chattopadhyay, R. 2004. Ad-
vanced Thermally Assisted Surface Engi-
neering Processes. Kluwer Academic
Publishing (now Springer): New York.,
N.Y.
2. Chattopadhyay, R., and Kammer,
P. A. 1992. International Conference on
Trends in Welding Research. Gatlinburg,
Tenn., American Welding Society and
ASM International, pp. 455–460.
3. Benefits of Increased Use of Con-
tinuous Casting by the U.S. Steel In-
dustry. 1979. princeton.edu/~ota/disk3/
1979/7902/790203.pdf.
4. The Lincoln Electric Co. 1996.
Cored wires add life to caster rolls.
Welding Journal 75(6): 55-s to 57-s.
5. Chattopadhyay, R. 1991. Proc.
Conf. Structure-Property Relationships
Correlations with the Environmental
Degradation of Engineering Materials.
ASM-IMS, Monterey, Calif., p.
477–504.
6. Chattopadhyay, R. 1995. Proc.
ITSC’95, Seminar on Automobile Indus-
try. Kobe, Japan, pp. 31–34.
7. Chattopadhyay, R. 1993. Proc.
Int. Symp., Tribology. Beijing, National
Science Foundation, China.
8. Whittaker, J. Private communica-
tion. Overview: Laser Metal Deposi-
tion — For Waste to Energy, Pressur-
ized Boiler Components. American
Cladding Technologies Inc.
9. Chattopadhyay, R. 2014. Green
Tribology, Green Surface Engineering
and Global Warming. Materials Park,
Ohio: ASM International.
10. Chattopadhyay, R. 1993. Proc.
Int. Conf. on Wear of Materials. San Fran-
cisco, Part B, ASME, pp. 1040–1044.
11. Imhoff, C. H. 1985. A Review of
Tribological Sinks in the Six Major In-
dustries, Technical Report 5535. Pacif-
ic Northwest Lab, pp. 199–213.
12. Chattopadhyay, R. 2001. Surface
Wear, Analysis, Treatment, and Preven-
tion. Materials Park, Ohio: ASM
International.
13. Deuis, R. L., et al. 1998. Metal-
matrix composite coatings by PTA sur-
facing. Composites Science and Technolo-
gy 58(2): 299–309.
14. Flores, J. F., et al. 2009. An
experimental study of the erosion-
corrosion behavior of plasma trans-
ferred arc MMCs. Wear 267(1): 213–
222.
15. Reynolds, J. L., et al. 2003.
Electro-spark deposition. Advanced
Materials & Processes: 35–37.
16. Schneider, C., et al. 2013. An
electrically pumped polariton laser.
Nature #497: 348–352.
RAM CHATTOPADHYAY
(ramchattopadhyay@gmail.com) is an emi-
nent author of books on green engineering
and environment, member of UN
Environment on Life Cycle Initiative,
honorary professor at Simon Bolivar Univer-
sity, Caracas, and adviser for American
Cladding Technologies, East Granby, Conn.

NOVEMBER 2018 / WELDING JOURNAL 43

COMING EVENTS

this event focuses on robotic grinding and finishing

AWS-SPONSORED EVENTS
2018 AWS Professional Program. Nov. 6–8. World
Congress Center, Atlanta, Ga. The American Welding Soci-
ety’s 2018 annual conference, known as the 2018 AWS
Professional Program, welcomes presentations on novel
developments and research areas related to materials join-
ing, including surfacing and additive manufacturing. Visit
aws.org.
U.S., CANADA, MEXICO EVENTS
FABTECH. Nov. 6–8. Georgia World Congress Center,
Atlanta, Ga. This trade show provides a one-stop shop venue
where visitors can meet with world-class suppliers; see the
latest industry products and developments; find the tools to
improve productivity; increase profits; and discover new so-
lutions to metal forming, fabricating, welding, and finishing
needs. This year’s event is expected to have more than
35,000 attendees and 1500 exhibiting companies. Visit
fabtechexpo.com.
processes. Topics will include best practices, key parameters
for success, implementation techniques, tooling, and more.
Visit robotics.org.
INTERNATIONAL EVENTS
India Essen Welding & Cutting — 8th International Trade
Fair Joining – Cutting – Surfacing. Nov. 27–29. Bombay
Convention & Exhibition Centre, Mumbai, India. The trade
show will be a platform for exhibitors to present their latest
products, services, and technologies related to the automa-
tion industry, robotics, CNC machines, cutting machines,
surfacing, laser cutting machines, safety equipment, health
and safety, quality assurance, measurement, and testing
technology. The biennial event is scheduled concurrent to
Metallurgy India, Tube India, and Wire & Cable India. An-
other highlight will be a specialized supporting program, In-
ternational Welding Symposium (IWS 2K18), staged by the
Indian Welding Society and DVS–German Welding Society.
Visit iewc.in.

RIA Robotic Grinding and Finishing Conference. Nov. 28, GCMM 2018 — 14th Global Congress on Manufacturing
29. 3M Innovation Center, St. Paul, Minn. Presented by 3M, and Management. Dec. 5–7. Brisbane, Australia. The global

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44 WELDING JOURNAL / NOVEMBER 2018

forum to exchange knowledge on materials, manufacturing,
digital technologies, and business management. Topics fo-
cus on sustainable digital manufacturing, innovative use of
environment-friendly materials, faster production methods,
and predictive maintenance of manufacturing systems. Visit
gcmm2018.org.

ICAPPM 2018 — International Conference on Applied

Physics, Power and Material Science. Dec. 5, 6. Swami
Vivekananda Institute of Technology, Hyderabad, India.
This conference is a platform for researchers, academicians,
as well as professionals from around the world to discuss
and promote advances in knowledge, research, and practice
in the field of engineering and science. All registered and
presented papers will be published in the volume of Ameri-
can Institute of Physics: Conference Proceedings. Visit
icappm.com.

2nd International Conference on Mechanical Engineering

and Applied Composite Materials. Dec. 7, 8. Harbin, Chi-
na. The conference brings together leaders from mechanical
engineering and applied composite materials to exchange
and share their experiences, present research results, ex-
plore collaborations, and to spark new ideas with the aim of
developing new projects and exploiting new technology in
this field. Prospective authors are invited to submit original
papers by Nov. 17. Visit meacm.org.

Best in Class Performance

Abrasive Products for the Professional
Visit us at Booth C12174

flexovitabrasives.com
1-800-268-7476
NOVEMBER 2018 / WELDING JOURNAL 45
 EDUCATIONAL OPPORTUNITIES
Advanced Fundamentals & Brazing by Design. Philadel-
phia, Pa. Two-and-a-half days of classes covering the essen-
tial theoretical aspects of brazing technology combined
with real-life applications and case studies. Visit
lucasmilhaupt.com.

Amada Miyachi Educational Resources/Training. Person-

alized training services on resistance and laser welding fun-
damentals, laser marking, custom programs, material selec-
tion and joint design, and more. Visit amadamiyachi.com, or
call (626) 303-5676.

ASME Section IX Seminar. Learn how to use ASME Section

IX quickly and cost effectively. This three-day ASME-
sponsored course is scheduled for the following dates and
locations: New Orleans, La., Dec. 10–12; Portland, Ore.,
April 8–10, 2019; and Houston, Tex., June 10–12, 2019.
Contact Marion Hess, hessm@asme.org, (212) 591-7161,
or register at asme.org/products/courses/bpv-code-section-ix-
welding-brazing-fusing.

Brazing Training — Fundamentals to Advanced Con-

cepts. Simsbury, Conn. Intensive, hands-on, three-day pro-
grams, held Nov. 13–15, designed to help you improve pro-
ductivity and reduce scrap/rework. Contact Kay & Associ-

ATTENTION CONTRACTORS!
IMPACT’S PROJECT OF THE YEAR AWARDS
ARE OPEN FOR SUBMISSIONS!
Is this your year? Submit today!

Project of the Year Award recognizes signatory contractors who achieve outstanding SAFETY performance.
Contractors and their Ironworkers complete countless, complex projects throughout the United States and Canada
each year and truly deserve to be recognized nationally for their amazing efforts and dedication.

THESE ARE THE SIX CATEGORIES TO SUBMIT FOR TODAY:

1) Architectural/Ornamental 2) Bridge/Structural 3) Fabrication
4) Industrial/Rigging/Machinery Moving 5) Reinforcing 6) Metal Buildings

VISIT WWW.IMPACT-NET.ORG TO SUMBIT UNDER PROJECT OF THE YEAR

Projects need to have been completed within the calendar year January 1 - December 31, 2018

46 WELDING JOURNAL / NOVEMBER 2018

ates to register, or for more information, (860) 651-5595;
kaybrazing.com; dan.kay@kaybrazing.com.
Business Electronics Soldering Technology. Classes held
in Chicago, Ill.; Detroit, Mich.; Minneapolis, Minn.; Cleve-
land, Ohio; and Huntsville, Ala., or can be coordinated onsite
at your facility. Contact BEST at (847) 797-9250 to register.
Certification Classes and Seminar. Steel Tank Institute/
Steel Plate Fabricators Association offer the upcoming
STI/SP001 Aboveground Tank System Inspector Training,
Dec. 10–14. Visit steeltank.com.
CPCC NDE Continuing Education Courses. Central Pied-
mont Community College presents the following 2019
spring courses: Online: Introduction to NDE, Jan. 14–May
10; NDE Visual Testing Level I & II, Jan. 14–May 10. Class-
room: Magnetic Particle Testing Level I & II, Jan. 14–Feb.
11; Level I & II Penetrant Testing, March 18–April 1; Ultra-
sonic Testing Level 1, Jan. 23–Feb. 27; Ultrasonic Testing
Level 2, March 18–April 24. To register, visit
cpcc.edu/cce/register-now.
CWB Online/Classroom Courses. Courses in NDE disci-
plines to meet certifications to Canadian General Standards
Board or Canadian Nuclear Safety Commission. The Canadi-
an Welding Bureau; (800) 844-6790; cwbgroup.org;
info@cwbgroup.org.
MEGAFLO GLASS
™
NOZZLES
WT-20 Shown
(250 Amps -
Water Cooled)
• Better weld visibility
• Maximum weld zone protection
• Light weight with replaceable screens
From the company who introduced clear glass
nozzles to TIG welding . . . comes Megaflo™
The Megaflo™ nozzles provide complete weld zone
protection for critical welding of reactive metals
such as titanium, molybdenum, nickel and
stainless alloys.
Available for 1/16, 3/32 and 1/8 electrode sizes and useable on
most hand held or machine TIG torches. Order individually by
electrode size or in handy kits for all three electrode sizes.
Order yours today! Contact your welding products distributor or
TEC Welding Products at (760)747-3700, info@tectorch.com
TEC Welding Products Inc. ©TEC Welding Products 2015
1-866-733-3272
NOVEMBER 2018 / WELDING JOURNAL 47
E-Courses in Destructive and Nondestructive Testing of
Welds and Other Welding-Related Topics. Online video
courses taken at one’s own pace offer certificates of comple-
tion and continuing education units. Contact Hobart Insti-
tute of Welding Technology; (800) 332-9448;
welding.org/product-category/online-courses/.
ESAB Welding and Cutting Instructor-Led Training. Year-
round training at Denton, Tex.; West Lebanon, N.H.; Tra-
verse City, Mich.; Hanover, Pa.; and Salt Lake City, Utah.
Online e-Learning training available at training.
victortechnologies.com; email trainingteam@esab.com.
Hypertherm Cutting Institute Online. Includes video tuto-
rials, interactive e-Learning courses, discussion forums, we-
binars, and blogs. Visit hypertherm.com; hyperthermcutting
institute.com.
Industrial Laser Training. Technical training and support
offered for users of industrial lasers in manufacturing,
education, and research. Regularly scheduled classes in laser
welding, laser cutting, and drilling. HDE Technologies Inc.;
(916) 714-4944; laserweldtraining.com.
Laser Safety Training Courses. Laser training courses for
personnel in research, industrial, and medical laser facilities.
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 Vision Training Seminars. Two-day classes, offered
monthly and on request, include tutorials and practical
training. Presented at Servo-Robot Inc., St. Bruno, QC,
Canada. For schedule, cost, and availability, email info@
servorobot.com.
NDE Classes. Moraine Valley Community College, Palos
Hills, Ill., offers NDE classes in PT, MT, UT, RT, radiation
safety, and eddy current, as well as API 510 exam prep and
weld inspection. (708) 974-5735; ccce@morainevalley.edu;
morainevalley.edu.
NDT Classroom Training and e-Learning Course. Offer
courses in UT, RT, MT, PT, eddy current, and remote visual
inspection. Onsite training also available. (855) 232-7470;
geinspectionacademy.com; inspection.academy@ge.com.
NDT Courses and Exams. Brea, Calif., and customers’ loca-
tions. Level I, II, and III 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 (free), Safety (free), Metal Melting and Han-
dling, Product Design, Energy Training, Dross Training,
Managing Dust Hazards, and more. North American Die
Casting Assoc.; diecasting.org/education/online;
(847) 808-3161.
OSHA Training Courses. Rockford, Ill. Rockford Systems
has added OSHA-authorized health and safety courses to its
48 WELDING JOURNAL / NOVEMBER 2018
training curriculum: OSHA 10-Hour General Industry
Course, OSHA 30-Hour General Industry Course, OSHA
1910.1200 Hazard Communication Course, and an ongoing
2½-day Machine Safeguarding Seminar. Contact
(800) 922-7533; rockfordsystems.com.
Preparation for AWS® — CWI®/CWE® Examination.
Troy, Ohio. This two-week class offers nine days of instruc-
tion with the test being administered on the tenth day. In-
cludes a backpack for the convenience of carrying your
books and other study materials. Contact Hobart Institute
of Welding Technology; (800) 332-9448; welding.org.
Protective Coatings Training and Certification Courses.
At various locations and online. The Society for Protective
Coatings; (877) 281-7772; sspc.org.
Veterans Goodwill Weld Training Program. South Burling-
ton, Vt., and Eagle River, Wis. AWI and Veterans of
Foreign Wars (VFW) have partnered to offer veterans
complimentary two-day training at AWI facilities. Contact
(802) 660-0600, (715) 337-0122, or awi.edu.
Welding Courses. The Lincoln Electric Co. presents a wide
range of specialized courses throughout the year at its
Cleveland, Ohio, headquarters. Upcoming courses include
REALWELD® Customer Training: Dec. 13. VRTEX®
Customer Training: Dec. 11. Aluminum Solutions,
Advanced Training: Nov. 6. The Lincoln Electric Co.,
lincolnelectric.com. WJ
Looking for a Welding Job?
The American Welding Society has enhanced its Jobs
In Welding website at jobsinwelding.com.
The redesigned career portal includes additional capa-
bilities for companies seeking workers and individuals
looking for jobs.
Through relationships with many job boards and dis-
tributors, it offers direct access to more than 88% of the
welding-related jobs posted on the Internet.
Users may search various openings for welders, Certi-
fied Welding Inspectors, engineers, technicians, and man-
agers/supervisors.
In addition, the website contains the following
highlights:
• The home page displays featured welding jobs along
with the companies looking to fill them and city/state
locations.
• The job seeker section connects individuals to new
career opportunities by allowing them to post an anony-
mous résumé, view jobs, and make personal job alerts.
This area has résumé tips, certification information, and a
school locator.
• The employer area enables association with qualified
applicants. Résumés, job postings, and products/pricing
options may be viewed here.
Visit the website to create or access job seeker and
employer accounts.
American Welding Society®
FOUNDAATTION
aws.org

2018 Careerss in Welding Trailer

r Toour
Sparking Intterest in Our Industry

53-FOOT TRAILER

R
5 VIRTUAL WEELDING
E STTATTIONS

11
1 STA
ATTES
22 EV
VENTS
44 DAY
YS
22,000 VISITOR RS
IT’S BEEEN A GOOD YEAR.
Thee AWWS Foundation wouuld like to thank our vissitors and volunteers foor
theeir contributions to the success of our 2018 Careers
C in Welding Toourr.
2019 Dates Coming Sooon!
I have volunteered for thhe last five years and It’s fun to
t engage people with the virtual weldding
d The American Welding Socciety (AWS) trailer is an
every year it gets betterr. Watching a person experiennce, talk to them about their scores and experience unlike any otheer. It provides students
making a weld for the firsst time on a simulator watch thhem improve those with a few more tries.
r an opportunity to learn thee history and principles
that has never welded beefore and realize that It’s reallly fun when friends/families come in and of welding. A virtual reaality simulator allows
this is something they coould actually do for a have a friendly
f competition between each othher!
h students to participate in w
welding in a hazard free
living or a hobby. Givingg them that spark to environment. During the B Boy Scouts of America
become a welder is what it is all about and I am Taana Errbes Jamboree, scouts from alll over the world visited
proud to be part of that. Progrraam
m Outreeachh Coorddinator the AWS trailer. It provided a wonderful, hands-on
Weeldingg Teechhnology Progrraam experience and gave atteendees a glimpse into
Teed Nelson North D Dakoota State College of Science – the world of welding.
AWS Member,, Northwest Section Waahpetton, ND/Farggo,, ND
Justin Rowley
Student Utah State Univeersity
Student,

For moree information, visit aws.org/foundation/c

/ccareers-in-welding--trailer
CERTIFICATION SCHEDULE
Certification Seminars, Code Clinics, And Examinations

Note: The 2018 and 2019 schedule for all certifications is posted 9-Year Recertification Seminar for CWI/SCWI
online at 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 taken
at any site listed under Certified Welding Inspector.
Certified Welding Inspector (CWI)
Location Seminar Dates
Location Seminar Dates Exam Date Houston, TX Nov. 25–30
Charlotte, NC Nov. 11–16 Nov. 17 Miami, FL Dec. 9–14
Reno, NV Nov. 25–30 Dec. 1 Miami, FL Jan. 20–25
Orlando, FL Nov. 25–30 Dec. 1 Houston, TX Feb. 10–15
Houston, TX Dec. 2–7 Dec. 8 San Diego, CA Feb. 17–22
Los Angeles, CA Dec. 2–7 Dec. 8 New Orleans, LA March 10–15
Richmond, VA Dec. 9–14 Dec. 15 Dallas, TX March 24–29
Miami, FL Dec. 9–14 Dec. 15
Charlotte, NC Jan. 13–18 Jan. 19
Dallas, TX Jan. 13–18 Jan. 19 Certified Welding Educator (CWE)
Denver, CO Jan. 20–25 Jan. 26 Seminar and exam are given at all sites listed under Certified
Long Beach, CA Jan. 20–25 Jan. 26 Welding Inspector. Seminar attendees will not attend the Code
Houston, TX Jan. 27–Feb. 1 Feb. 2 Clinic portion of the seminar (usually the first two days).
Milwaukee, WI Jan. 27–Feb. 1 Feb. 2
Los Angeles, CA Feb. 10–15 Feb. 16
Pittsburgh, PA Feb. 10–15 Feb. 16 Certified Welding Sales Representative
Orlando, FL Feb. 17–22 Feb. 23 (CWSR)
Seattle, WA Feb. 17–22 Feb. 23 CWSR exams are given at Prometric testing centers. More
New Orleans, LA Feb. 24–March 1 March 2 information at aws.org/certification/detail/certified-welding-
San Diego, CA Feb. 24–March 1 March 2 sales-representative.
Atlanta, GA March 3–8 March 9
Salt Lake City, UT March 10–15 March 16
Annapolis, MD March 10–15 March 16 Certified Welding Supervisor (CWS)
Houston, TX March 10–15 March 16 CWS exams are given at Prometric testing centers. More infor-
Chicago, IL March 17–22 March 23 mation at aws.org/certification/detail/certified-welding-supervisor.
Phoenix, AZ March 17–22 March 23
Boston, MA March 24–29 March 30
Portland, OR March 24–29 March 30 Certified Radiographic Interpreter (CRI)
Miami, FL March 31–April 5 April 6 The CRI certification can be a stand-alone credential or can
Minneapolis, MN March 31–April 5 April 6 exempt you from your next 9-Year Recertification. More in-
Dallas, TX April 7–12 April 13 formation at aws.org/certification/detail/certified-radiographic-
Las Vegas, NV April 7–12 April 13 interpreter.
Bakersfield, CA April 28–May 3 May 4
St. Louis, MO April 28–May 3 May 4 Location Seminar Dates Exam Date
Baton Rouge, LA May 5–10 May 11 Cleveland, OH Jan. 28–Feb. 1 Feb. 2
Detroit, MI May 5–10 May 11 Dallas, TX April 1–5 April 6
Denver, CO May 19–24 May 25 Las Vegas, NV June 3–7 June 8
Nasvhille, TN May 19–24 May 25 Pittsburgh, PA July 29–Aug. 2 Aug. 3
Birmingham, AL June 2–7 June 8 Houston, TX Sept. 30–Oct. 4 Oct. 5
Kansas City, MO June 2–7 June 8
Pittsburgh, PA June 9–14 June 15
Spokane, WA June 9–14 June 15
Beaumont, TX June 16–21 June 22 Certified Robotic Arc Welding (CRAW)
Hartford, CT June 16–21 June 22 OTC Daihen Inc., Tipp City, OH; (937) 667-0800, ext. 218
Newark, NJ June 23–28 June 29 Lincoln Electric Co., Cleveland, OH; (216) 383-4723
Omaha, NE June 23–28 June 29 Wolf Robotics, Fort Collins, CO; (970) 225-7667
Louisville, KY July 7–12 July 13 Milwaukee Area Technical College, Milwaukee, WI;
Phoenix, AZ July 7–12 July 13 (414) 456-5454
Norfolk, VA July 14–19 July 20 College of the Canyons, Santa Clarita, CA; (651) 259-7800,
Milwaukee, WI July 21–26 July 27 ext. 3062
Orlando, FL July 21–26 July 27 Ogden-Weber Applied Technology College, Ogden, UT;
Cleveland, OH July 28–Aug. 2 Aug. 3 (800) 627-8448

IMPORTANT: This schedule is subject to change without notice. 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
$250 Fast Track fee. Please verify application deadline dates by visiting our website at 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) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.

50 WELDING JOURNAL / NOVEMBER 2018

BY KATIE PACHECO — kpacheco@aws.org
ICONWELD 2018 Draws Industry to Peru
Fig. 1 — More than 1000 professionals attended the ICONWELD 2018 International
Conference on Welding and Joining of Materials, including its trade show, held
August 6–8 in Lima, Peru.
Known famously for the Incan city
of Machu Picchu and the mountain-
ous, 26-mile Incan Trail, Peru recently
established itself as a manufacturing
hub when it hosted the ICONWELD
2018 International Conference on
Welding and Joining of Materials,
along with its trade show. Held August
6–8 in Lima’s Pontificia Universidad
Católica del Perú (PUCP), the event at-
tracted more than 1000 attendees
from more than 13 countries — Fig. 1.
The three-day event provided the
local and international welding indus-
try a platform to network, report find-
ings, share ideas, and learn new infor-
mation related to metallurgy, welding
engineering, and joining technology.
“ICONWELD, already in its fourth
edition, is a space that promotes inte-
gration between professionals and
technicians linked to the different
fields of welding,” affirmed Paul Lean
Sifuentes, professor, Mechanical Engi-
neering department, PUCP.
The event was organized by the
PUCP; supported by the Peruvian In-
stitute of Production and Soldex S.A.;
and sponsored by the American Weld-
ing Society (AWS), International
Institute of Welding, and Spanish
Association of Welding and Joining
Technology.
Conference Offers a Diverse
Technical Program
More than 300 professionals at-
SOCIETY NEWS
tended the conference, which offered
43 technical presentations related to
process methods, joint performance,
and materials characterization. Some
of the topics covered included the fol-
lowing: Preprocessing of data obtained
in gas metal arc welding using machine
learning techniques; evaluating poly-
mer as an ingredient in submerged arc
welding flux; influence of the preheat-
ing temperature in the welding of
white cast iron; wire and arc additive
manufacture systems for production
of large-scale engineering parts; and
effect of welding parameters in the
thermal cycles of high-hardness steel.
The conference’s technical program
was also comprised of 11 keynote
Fig. 2 — AWS President Dale Flood delivers his keynote speech on mechanizing the
welding industry at ICONWELD 2018.
NOVEMBER 2018 / WELDING JOURNAL 51
speeches, followed by Q&A sessions.
Some of the keynote speakers included
Dale Flood, AWS president and project
manager of Tri Tool Inc.; Walter
Sperko, AWS board member and presi-
dent of Sperko Engineering Services
Inc.; Stephen Liu, AWS Fellow and pro-
fessor of metallurgical engineering,
Colorado School of Mines; and Patricio
F. Mendez, AWS Fellow and professor
for the Chemical and Materials Engi-
neering department, University of
Alberta.
Flood’s speech, titled “Mechanizing
the Welding Industry,” discussed how
mechanization can significantly im-
prove productivity during welding op-
erations, thus increasing profitability
and keeping companies competitive
within a global economy — Fig. 2.
“On a professional level, my passion
to help companies and workers in our
industry drives me to deliver this edu-
cational information that will level the
‘playing field’ when ‘cheap labor’ com-
petes with industrialized nations with
an advanced labor workforce,” Flood
explained.
In his speech titled “Qualification
of Welding Procedures and Welders,”
Sperko provided a historical review of
the requirements of Section IX from
when it was first issued in 1941
through 1974, when it was revised
into today’s format.
“I thought it was important to pres-
ent the historical development of Sec-
SOCIETY NEWS
Fig. 3 — Occurring concurrently with the conference, the 2018 ICONWELD trade show
hosted 17 exhibitors, some of which also provided product demonstrations. Pictured
is Ingesold PUCP’s booth.
tion IX at a technical conference...to il-
lustrate to researchers that their work
allows those who write codes to base
code requirements on a sound techni-
cal basis,” Sperko explained. “Illustrat-
ing how the code has changed over
time with the introduction of new
technologies and concepts encourages
researchers to keep up the good work,
even if their work appears to be of lit-
tle consequence.”
Liu presented a speech titled “Un-
derstanding Laser Based & Electron
Beam Based Additive Manufacturing,”
where he discussed case studies that
demonstrate the need for interdiscipli-
nary expertise and the integration of
materials and mechanical models to
produce 3D printed components that
satisfy the process-structure-property-
performance material tetrahedron.
“As a welding scientist, it is very
important for me to participate in an
event like ICONWELD 2018 to wit-
ness the stage of scientific and techno-
logical growth in the industrial sector
of the country. In fact, I have partici-
pated in every one of the previous In-
ternational Conference in Welding and
Joining of Materials...in Peru in the
years of 2003, 2007, and 2010, and
was able to gauge real and successful
progress,” Liu affirmed. “Peru is an
emerging country in terms of GDP
[gross domestic product] and growth
in South America. Its manufacturing
and fabrication industries have experi-
enced vibrant growth in recent years.
Its large natural resources are also un-
52 WELDING JOURNAL / NOVEMBER 2018
der development.”
Mendez’s speech, “Mechanisms
Present in Welding Processes,” covered
the mechanisms present during weld
deposition of wear-resistant coatings,
and how the performance of these
coatings vary depending on how they
are made.
“Presenting at this event was im-
portant on two levels,” Mendez said.
“First, to help the Peruvian welding
community by sharing what we have
learned in North America that could
be of use to them. Second, in this con-
ference, I met excellent practitioners,
engineers, and researchers who sel-
dom attend main events such as
FABTECH. I learned much from them
and started new lines of collaboration
based on these new acquaintances.”
Fig. 4 — Pictured in front of the AWS Peru Section’s booth at the ICONWELD 2018
trade show are Francisco Rumiche, professor, Mechanical Engineering department,
PUCP; Dale Flood, AWS president; Paul Lean Sifuentes, professor, Welding Labora-
tory, PUCP; and Carlos Gomez, AWS business development manager for Latin
America.
Trade Show Features
Products and Services
The ICONWELD 2018 trade show
took place concurrently with the con-
ference and hosted 17 exhibitors —
Fig. 3. It provided a space for welding
and material joining companies to
present their services, products, and
projects. According to Sifuentes, the
event highlighted the “main suppliers
of machines, accessories, and consum-
ables for welding work, as well as im-
portant companies that offer services
for the quality control of welded
joints.”
Some of the companies represented
at the show included ESAB, Miller
Electric, JLZ Logística, Ingesold PUCP,
Instituto Tecnológico de la Producció,
Niro S.A.C., Soldamundo, FICEP Corp.,
S&H Representaciones, CITE Materi-
ales PUCP, voestalpine Böhler Welding,
3M, Indura, Reactor S.A.C., and AWS
Peru Section — Fig. 4.
The trade show also featured vari-
ous commercial presentations. For in-
stance, Soldex S.A. performed techni-
cal demonstrations of Gullco’s automa-
tion equipment as well as ESAB’s ICE™
for submerged arc welding. Miller Elec-
tric’s XMT® Field ProTM, DimensionTM
650, and Big Blue® 800 welding ma-
chines were also demonstrated.
Conclusion
To learn more about ICONWELD
2018’s conference and trade show, plus
view photos from past events, visit
iconweldperu.com. WJ

TECH TOPICS
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/
library/doclib/Technical-Committee-
Application.pdf.
S. Borrero, sborrero@aws.org, ext.
334. Definitions and symbols, A2
Committee (E). Titanium and zirco-
nium filler metals, A5K Subcommit-
tee. Piping and tubing, D10 Com-
mittee (C, E, U). Welding practices
and procedures for austenitic
steels, D10C Subcommittee. Alu-
minum piping, D10H Subcommittee.
Chromium molybdenum steel pip-
ing, D10I Subcommittee. Welding of
titanium piping, D10K Subcommit-
tee. Purging and root pass welding,
D10S Subcommittee. Low-carbon
steel pipe, D10T Subcommittee. Or-
bital pipe welding, D10U Subcom-
mittee. Duplex pipe welding, D10Y
Wolf Robotics Hosts AWS Technical Activities Committee Meeting
Members of the Technical Activities Committee (TAC) posed for a photo during their August 22 and 23 meeting in Fort Collins, Colo.
The event was hosted by Wolf Robotics, a Lincoln Electric company.
SOCIETY NEWS
Subcommittee. Joining metals and
alloys, G2 Committee (E, G, U). Reac-
tive alloys, G2D Subcommittee (G).
R. Gupta, gupta@aws.org, ext. 301.
Filler metals and allied materials,
A5 Committee (E). Magnesium alloy
filler metals, A5L Subcommittee.
P. Portela, pportela@aws.org, ext.
311. High energy beam welding
and cutting, C7 Committee (C, E, G).
Hybrid welding, C7D Subcommittee
(G). Robotic and automatic weld-
ing, D16 Committee (C, E). Welding
in sanitary applications, D18 Com-
mittee (C, E, G). Additive manufac-
turing, D20 Committee (C, E, G). The
D1N Subcommittee on Titanium
Welding is recruiting all interest
groups.
J. Molin, jmolin@aws.org, ext. 304.
Structural welding, D1 Committee
(E). Sheet metal welding, D9 Com-
mittee (C, G). The D9 Committee on
Sheet Metal is recruiting consultants,
producers, and general interest
members.
K. Bulger, kbulger@aws.org, ext.
306. Methods of weld inspection,
B1 Committee (C, E). Brazing and
soldering, C3 Committee (C, E, G).
Welding in marine construction,
D3 Committee (C, E, G, U). Welding
NOVEMBER 2018 / WELDING JOURNAL 53
of machinery and equipment, D14
Committee (C, E, G, U).
M. Diaz, mdiaz@aws.org, ext. 310.
Resistance welding, C1 Committee
(C, E, G, U). Friction welding, C6
Committee (C, E). Automotive weld-
ing, D8 Committee (C, E, G, U). Re-
sistance welding equipment, J1
Committee (C, E, G, U). Welding in
the aircraft and aerospace indus-
try, D17 Subcommittee (C, E, G).
S. Hedrick, steveh@aws.org, ext.
305. Metric practice, A1 Committee
(C, E). Mechanical testing of welds,
B4 Committee (E, G, P). Joining of
plastics and composites, G1 Com-
mittee (C, E, G). Personal and facili-
ties qualification, PFQC Committee
(C, E, G). Safety and health com-
mittee, SHC Committee (E, G).
J. Rosario, jrosario@aws.org, ext.
308. Procedure and performance
qualification, B2 Committee (E, G).
Thermal spraying, C2 Committee (C,
E, G, U). Oxyfuel gas welding and
cutting, C4 Committee (C, E, G).
Welding iron castings, D11 (C, E, G,
P, U). Railroad welding, D15 (C, E, G,
U). The D15 Committee on Railroad
Welding is recruiting educators, users,
consultants, and general interest
members.
SOCIETY NEWS
TECH TOPICS
Technical Committee
Meetings
All AWS Technical Committee
meetings are open to the public. Con-
tact staff members listed below or call
(800/305) 443-9353 for information.
Nov. 4. C7 Committee on High En-
ergy Beam Welding and Cutting.
Atlanta, Ga. Contact: P. Portela, ext.
311, pportela@aws.org.
Nov. 4. C7B Subcommittee on Elec-
tron Beam Welding and Cutting.
Atlanta, Ga. Contact: P. Portela, ext.
311, pportela@aws.org.
Nov. 4. C7C Subcommittee on Laser
Beam Welding and Cutting. Atlanta,
Ga. Contact: P. Portela, ext. 311,
pportela@aws.org.
Nov. 4. C7D Subcommittee on Hy-
brid Welding. Atlanta, Ga. Contact: P.
Portela, pportela@aws.org, ext. 311.
Nov. 5. B1 Committee on Methods
of Inspection. Atlanta, Ga. Contact: K.
Bulger, kbulger@aws.org, ext. 306.
Nov. 5. C2 Committee and Subcom-
mittees on Thermal Spraying. Atlanta,
Ga. Contact: J. Rosario, ext. 308,
jrosario@aws.org.
Nov. 5. D9 Committee on Sheet
Metal. Atlanta, Ga. Contact: J. Molin,
jmolin@aws.org, ext. 304.
Nov. 6. D14 Committee and
Subcommittees on Machinery and
Equipment. Atlanta, Ga. Contact: K.
Bulger, kbulger@aws.org, ext. 306.
Nov. 6. D15C Subcommittee on
Track Welding. Atlanta, Ga. Contact: J.
Rosario, jrosario@aws.org, ext. 308.
Nov. 6. D17D Subcommittee on Re-
sistance Welding. Atlanta, Ga. Con-
tact: M. Diaz, mdiaz@aws.org, ext. 310.
Nov. 6. D17J Subcommittee on
Friction Stir Welding for Aerospace.
Atlanta, Ga. Contact: M. Diaz, ext.
310, mdiaz@aws.org.
Nov. 7. D11 Committee on Welding
Iron Castings. Atlanta, Ga. Contact: J.
Rosario, jrosario@aws.org, ext. 308.
Nov. 7. D14 Committee and
Subcommittees on Machinery and
Equipment. Atlanta, Ga. Contact: K.
Bulger, kbulger@aws.org, ext. 306.
Nov. 7. D17K Subcommittee on Fu-
sion Welding. Atlanta, Ga. Contact: M.
Diaz, mdiaz@aws.org, ext. 310.
Nov. 8. D16 Committee on Robotic
54 WELDING JOURNAL / NOVEMBER 2018
and Automatic Welding. Atlanta, Ga.
Contact: P. Portela, pportela@aws.org,
ext. 311.
Nov. 8. D17 Committee on Welding
in the Aircraft and Aerospace
Industries. Atlanta, Ga. Contact: M.
Diaz, mdiaz@aws.org, ext. 310.
Standards for Public Review
AWS was approved as an accredited
standards-preparing organization by
the American National Standards In-
stitute (ANSI) in 1979. AWS rules, as
approved by ANSI, require that all
standards be open to public review for
comment during the approval process.
This column also advises of ANSI ap-
proval of documents.
B2.1-1-201:20XX, Standard Welding
Procedure Specification (SWPS) for
Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1, Group 1 or 2), 1⁄8 inch [3
mm] through 3⁄4 inch [19 mm] Thick,
E6010 (Vertical Uphill) Followed by
E7018 (Vertical Uphill), in the As-
Welded Condition, Primarily Pipe Appli-
cations. New Standard. $136.00. ANSI
public review expires 10/15/18. Con-
tact: J. Rosario, jrosario@aws.org, ext.
308.
B2.1-1-202:20XX, Standard Welding
Procedure Specification (SWPS) for
Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1, Group 1 or 2), 1⁄8 inch [3
mm] through 3⁄4 inch [19 mm] Thick,
E6010 (Vertical Downhill) Followed by
E7018 (Vertical Uphill), in the As-
Welded Condition, Primarily Pipe Appli-
cations. New Standard. $136.00. ANSI
public review expires 10/15/18. Con-
tact: J. Rosario, jrosario@aws.org, ext.
308.
B2.1-1-203:20XX, Standard Welding
Procedure Specification (SWPS) for
Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1, Group 1 or 2), 1⁄8 inch [3
mm] through 3⁄4 inch [19 mm] Thick,
E6010 (Vertical Uphill), in the As-
Welded Condition, Primarily Pipe Appli-
cations. New Standard. $136.00. ANSI
public review expires 10/15/18. Con-
tact: J. Rosario, jrosario@aws.org, ext.
308.
B2.1-1-204:20XX, Standard Welding
Procedure Specification (SWPS) for
Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1, Group 1 or 2), 1⁄8 inch [3
mm] through 3⁄4 inch [19 mm] Thick,
E6010 (Vertical Downhill Root with the
Balance Vertical Uphill), in the As-
Welded Condition, Primarily Pipe Appli-
cations. New Standard. $136.00. ANSI
public review expires 10/15/18. Con-
tact: J. Rosario, jrosario@aws.org, ext.
308.
B2.1-1-205:20XX, Standard Welding
Procedure Specification (SWPS) for
Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1, Group 1 or 2), 1⁄8 inch [3
mm] through 1-1⁄2 inch [38 mm] Thick,
E6010 (Vertical Uphill) Followed by
E7018 (Vertical Uphill), in the As-
Welded or PWHT Condition, Primarily
Pipe Applications. New Standard.
$136.00. ANSI public review expires
10/15/18. Contact: J. Rosario, ext.
308, jrosario@aws.org.
B2.1-1-206:20XX, Standard Welding
Procedure Specification (SWPS) for
Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1, Group 1 or 2), 1⁄8 inch [3
mm] through 1-1⁄2 inch [38 mm] Thick,
E6010 (Vertical Downhill) Followed by
E7018 (Vertical Uphill), in the As-
Welded or PWHT Condition, Primarily
Pipe Applications. New Standard.
$136.00. ANSI public review expires
10/15/18. Contact: J. Rosario, ext.
308, jrosario@aws.org.
B2.1-1-207:20XX, Standard Welding
Procedure Specification (SWPS) for Gas
Tungsten Arc Welding of Carbon Steel
(M-1/P-1, Group 1 or 2), 1⁄8 inch [3 mm]
through 1-1⁄2 inch [38 mm] Thick, ER70S-
2, in the As-Welded or PWHT Condition,
Primarily Pipe Applications. New Stan-
dard. $136.00. ANSI public review ex-
pires 10/15/18. Contact: J. Rosario,
jrosario@aws.org, ext. 308.
B2.1-1-208:20XX, Standard Welding
Procedure Specification (SWPS) for
Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1, Group 1 or 2), 1⁄8 inch [3
mm] through 1-1⁄2 inch [38 mm] Thick,
E7018, in the As-Welded or PWHT Con-
dition, Primarily Pipe Applications. New
Standard. $136.00. ANSI public review
expires 10/15/18. Contact: J. Rosario,
jrosario@aws.org, ext. 308.
B2.1-1-209:20XX, Standard Welding
Procedure Specification (SWPS) for Gas
Tungsten Arc Welding Followed by

Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1, Group 1 or 2), 1⁄8 inch [3
mm] through 1-1⁄2 inch [38 mm] Thick,
ER70S-2 and E7018, in the As-Welded or
PWHT Condition, Primarily Pipe Appli-
cations. New Standard. $136.00. ANSI
public review expires 10/15/18. Con-
tact: J. Rosario, jrosario@aws.org, ext.
308.
B2.5/B2.5M:20XX (ISO/TR 18491:
2015 MOD), Specification for Measure-
ment and Calculation of Welding Energy.
New Standard. $25.00. ANSI public re-
view expires 10/22/18. Contact: J.
Rosario, jrosario@aws.org, ext. 308.
C4.7/C4.7M:20XX, Recommended
Practices for Oxyfuel Gas Welding of
Steel. New Standard. $25.00. ANSI
public review expires 11/12/18. Con-
tact: J. Rosario, jrosario@aws.org, ext.
308.
New Standards Approved by
ANSI
B2.1-1-314:2018, Standard Welding
Procedure Specification for Naval Appli-
cations (SWPS-N) for Gas Tungsten Arc
Welding with Consumable Insert Root of
Carbon Steel (S-1), 1⁄8 inch [3 mm]
through 1-1⁄2 inch [38 mm] Thick, MIL-
MS-1 and MIL-70S-2, in the As-Welded
or PWHT Condition, Primarily Pipe for
AWS Board Executive Committee Meeting Held in New Hampshire
The AWS Board of Directors Executive Committee, along with AWS staff and family members, came together for its August 19
meeting in Bretton Woods, N.H.
SOCIETY NEWS
Naval Applications. Approval date:
8/3/2018.
B2.1-1-315:2018, Standard Welding
Procedure Specification for Naval Appli-
cations (SWPS-N) for Gas Tungsten Arc
Welding with Consumable Insert Root
Followed by Shielded Metal Arc Welding
of Carbon Steel (S-1), 1⁄8 inch [3 mm]
through 1-1⁄2 inch [38 mm] Thick, MIL-
MS-1 MIL-70S-2, and MIL-7018-M in
the As-Welded or PWHT Condition, Pri-
marily Pipe for Naval Applications. Ap-
proval date: 8/3/2018.
B2.1-8-321:2018, Standard Welding
Procedure Specification for Naval Appli-
cations (SWPS-N) for Gas Tungsten Arc
Welding with Consumable Insert Root of
Austenitic Stainless Steel (S-8), 1⁄8 inch [3
mm] through 1-1⁄2 inch [38 mm] Thick,
MIL-3XX, in the As-Welded Condition,
Primarily Pipe for Naval Applications.
Approval date: 8/3/2018.
B2.1-8-322:2018, Standard Welding
Procedure Specification for Naval Appli-
cations (SWPS-N) for Gas Tungsten Arc
Welding with Consumable Insert Root
Followed by Shielded Metal Arc Welding
of Austenitic Stainless Steel (S-8), 1⁄8 inch
[3 mm] through 1-1⁄2 inch [38 mm] Thick,
MIL-3XX and MIL-3XX-XX, in the As-
Welded Condition, Primarily Pipe for
Naval Applications. Approval date:
8/3/2018.
D16.6M/D16.6:2018, Specification
NOVEMBER 2018 / WELDING JOURNAL 55
for Robot Arc Welding Training and Test-
ing Cell. Approval date: 8/22/2018.
Interpretation
AWS D15.1/D15.1M:2012-AMD1
Subject: PQR essential variable
changes requiring WPS requalification
for SMAW, SAW, GMAW, FCAW, and
GTAW — Process parameters
Code Edition: D15.1:2012-AMD1 (Ed.
5)
Code Provision: Subclause 10.1 and
Table 10.1 (17)
AWS Log: D15.1-12-I02
Inquiry: Table 10.1, Item 17 specifies if
there is “A change in amperage or volt-
age that is not within a range recomm-
ended by the electrode supplier,” then
WPSs must be requalified.
1. If a WPS is outside of these set-
tings, is the range that may be
produced from a PQR similar to item
18?
2. Is the term supplier intended to
be the manufacturer of the wire?
Response: 1. No. The only ranges
qualified are those recorded on the
PQR(s). 2. Yes.
SOCIETY NEWS
MEMBERSHIP ACTIVITIES
T. A. Harris, Johnstown-Altoona — 18 D & S Construction Inc.
AWS Member Counts D. A. Saunders, Lakeshore — 16 13312 Ranchero Rd.
October 1, 2018 R. Young, Iowa — 16 Ste. 18-270
D. Melton, Greater Huntsville — 15 Oak Hills, CA 92344
Sustaining.................................594 J. L. Stokes, Dayton — 15
Supporting ...............................355 S. Toops, Central Texas — 15 Greenville Fabrication LLC
Educational...............................841 C. A. Renfro, Chattanooga — 14 200 Carrington Wy.
Affiliate.....................................659 M. J. Jones, Saginaw Valley — 14 Simpsonville, SC 29681
Welding Distributor ...................68 O. Serrano, Ecuador — 14
Total Corporate .......................2517 B. M. Scherer, Cincinnati — 13 Gullet Welding & Fabrication/
Individual ...........................58,131 B. A. Cheatham, Columbia — 12 Gullet’s Hard Art LLC
Student + Transitional ...........11,958 G. T. Rolla, Los Angeles/Inland 1167 Finney Rd.
Total Members .....................70,089 Empire — 12 Robertsville, MO 63072
E. R. Krestakos-Fromson,
Indiana — 11 HR Mechanical Services
Member-Get-A-Member S. Smalley, Mid-Plains — 11 42556 Island Inn Dr.
Campaign Lebanon, OR 97355

Listed here are the members parti- New AWS Supporters Holland LP
cipating in the 2018 Member-Get-A- 750 Central Ave.
Member Campaign. The campaign University Park, IL 60484
runs from Jan. 1 to Dec. 31, 2018. Sustaining Company Members
Members receive 5 points for each In- JC Steel Fabricators Inc.
dividual Member and 1 point for every JADCO Manufacturing Inc. 295 Sunpac Ave.
Student Member they recruit. P.O. Box 465 Henderson, NV 89011
For campaign rules and a prize list, Zelienople, PA 16063
please see page 65 of this Welding Jour- jadcomfg.com Manufacturing Resources
nal. Standings as of Sept. 13. For more International
information, call the AWS Member- American Steel & Precast 6415 Shiloh Rd. East
ship Dept. at (800) 443-9353, ext. Erectors Inc. Alpharetta, GA 30005
480. 328 Sawmill Rd.
Greenfield, NH 03047 Ramprem Enterprises Ltd.
J. W. Morris, Mobile — 80 aspe-nh.com LP# 9 Chatee St., Warren Rd.,
M. D. Box, Pascagoula — 75 Off Uriah Butler Hwy.
D. S. Beecher, San Diego — 72 American Steel & Precast Erectors Cunupia 00000
M. Krupnicki, Rochester — 60 (ASPE) serve the steel erection, pre- Trinidad and Tobago
F. A. Cea, Columbus — 60 cast erection, and lifting markets with
A. D. Dillon, Detroit — 59 a commitment to service, quality
M. A. Centeno, Nevada — 59 workmanship, customer satisfaction, Educational Institution
J. P. Theberge, Boston — 48 and safety. The company can provide Members
B. Newcomb, Madison-Beloit — 39 all of its capabilities or just one service
W. L. Harris, Pascagoula — 36 to help customers complete projects. Al-Joud Co. for Engineering
C. Cosentino, Pittsburgh — 35 The company is located in Greenfield, Inspection Service
H. H. Hughes, Wheeling Section — 35 N.H., and Graham, N.C., and serves Az Zubair St.
V. Craven, Pascagoula — 30 customers throughout the East Coast Basra, Iraq 00964
B. P. Brandmeir, Lehigh Valley — 29 and Canada.
M. D. Stein, Detroit — 29 Arclabs Welding School
A. M. Young, Detroit — 27 2615 Hwy. 153, Bldg. B-3
R. Riggs, Tulsa — 24 Affiliate Company Members Piedmont, SC 29673
O. N. Boylan, Cleveland — 23
M. J. Lannom, Long Beach/Orange Apparent Technologies Inc. Bingham High School
County — 23 11202 Georgian Dr., Unit A 2160 W. Jordan Pkwy.
D. R. Jacobs, Northwestern Austin, TX 78753 South Jordan, UT 84095
Pennsylvania — 20
G. L. Gammil, NE Mississippi — 20 Callington Inc. East Davidson High School
C. A. Donnell, Northwest Ohio — 19 1170 Tree Swallow Dr., Ste. 402 1408 Lake Rd.
G. D. Wentland, Sacramento — 18 Winter Springs, FL 32708 Thomasville, NC 27360

56 WELDING JOURNAL / NOVEMBER 2018

 SOCIETY NEWS
Elgin Community College
1700 Spartan Dr.
Student Recognized for Chapter Successes
Elgin, IL 60123

Indian Hills Community College

525 Grandview Ave.
Ottumwa, IA 52501

Lincoln College of Technology —

Indianapolis
7225 Winton Dr.
Indianapolis, IN 46268

Lincoln College of Technology —

Nashville
1524 Gallatin Ave.
Nashville, TN 37206

Lincoln Technical Institute —

East Windsor
97 Newberry Rd.
East Windsor, CT 06088

Lincoln Technical Institute —

Denver
11194 E. 45 Ave.
Denver, CO 80239

Mandan High School

905 8th Ave. NW
Mandan, ND 58559

North Valley Career and Technology

Center
1540 School Rd.
Grafton, ND 58237

Operating Engineers Local 324

JATF Inc.
275 E. Highland Rd.
Howell, MI 48843
Craig Donnell (right) awards Justin Robinette of the AWS Whitmer Career and Tech-
Public Schools of Robeson County nology Center Student Chapter with the Student Chapter Member Award in recogni-
1339 Hilly Branch Rd. tion of his community achievements.
Lumberton, NC 28360

Warren County High School Supporting Company Praxair Surface Technologies

199 Pioneer Ln.
McMinnville, TN 37110
Welding Distributor Company
Members
Astrolite Alloys
3225 West Old Lincoln Wy.
Wooster, OH 44691
Superior Recreational Products
1050 Columbia Dr.
Carrollton, GA 30117
Members 1500 Polco St.
Indianapolis, IN 46222
Cardinal Fabrication & Welding
23 Yellowbrook Rd. CWI of the Year Award
Howell, NJ 07728
The Dalton E. Hamilton Memorial
CWI of the Year District Award is pre-
Ibis Tek Inc. sented in recognition of outstanding
912 Pittsburgh Rd. performance in the practice of welding
Butler, PA 16002 inspection.
This award has recently been pre-
Metcut Research Inc. sented to Al Garcia, District 1, Con-
3980 Rosslyn Dr. necticut Section; and Paul Wittenbach,
Cincinnati, OH 45209 District 17, Tulsa Section.

NOVEMBER 2018 / WELDING JOURNAL 57

SOCIETY NEWS
AWS Membership Committee Visits Mississippi

The AWS Membership Committee, chaired by Lee Kvidahl, had their fall meeting on August 30 at the Beau Rivage Resort and
Casino in Biloxi, Miss. Prior to the meeting, the committee visited Ingalls Shipbuilding, Pascagoula, Miss., the largest supplier of
U.S. Navy surface combatants, where they saw a LHA amphibious assault ship.

Candidates Sought to Receive the MIT Masubuchi Award

The Prof. Koichi Masubuchi award,
with a $5000 honorarium, is present-
ed to one person, 40 or younger, who
has made significant contributions to
the advancement of materials joining
through research and development.
Send a list of your candidate’s experi-
ence, publications, honors, awards,
and at least three letters of recommen-
dation from fellow researchers to Prof.
Todd Palmer, tap103@psu.edu. This
award is sponsored annually by the
Massachusetts Institute of Technolo-
gy, Dept. of Ocean Engineering.

Nominate AWS Members to be Profiled

The Welding Journal is celebrating the diversity of its To nominate an AWS member, submit a statement about
members by profiling two AWS members each month in its what makes the nominee a noteworthy member, the nomi-
Society News section. Michael Thomas and Miranda nee’s contact information, and a photo of the nominee to
Williams are profiled on the next page. Katie Pacheco, kpacheco@aws.org.

58 WELDING JOURNAL / NOVEMBER 2018


AWS Member Profile
Michael Thomas
Born and raised on the Navajo
reservation in western New Mexico,
Michael Thomas got his first taste of
welding in high school, where he took
industrial courses that included nine
weeks of welding.
“I seemed to have a knack for mak-
ing a good bead,” he said.
The first person in his family to at-
tend college, Thomas honed his weld-
ing skills at LeTourneau University in
Longview, Tex. In 1972, his education
AWS Member Profile
Miranda Williams
Born and raised in New Mexico,
and hailing from the Navajo tribe, Mi-
randa Williams became intrigued by
welding at the age of 16 when her old-
er brother brought home a welded
stove he made.
“I wanted to understand how that
worked and what processes were in-
volved in getting metals to bond to-
gether,” she said.
In 2013, Williams made a life-alter-
SOCIETY NEWS
was put on hold when he was drafted
into the military. After serving two
years, he returned to school and
earned a bachelor’s in welding engi-
neering technology.
Thomas got his start in the indus-
try as a factory representative, made
his way up to a sales engineer, and
eventually became the regional sales
manager.
In 2004, after 25 years in sales,
Thomas started his own business,
Thomas Sales Co., which became Rocky
Mountain Testing LLC. As the AWS
Senior Certified Welding Inspector in
his “one-man business,” he performs
welding inspections, welder qualifica-
tions, training, and consulting.
An AWS member since 1992,
Thomas has worn many hats for the
Society. He served the AWS New Mexi-
co Section as vice chair and chair, and
currently serves as program chair. He
is also a member of the AWS B2 Com-
mittee on Procedure and Performance
Qualification, as well as the B2A Braz-
ing Qualification and B2B Welding
Qualification Subcommittees.
Thomas’s additional volunteer work
ing contact at an AWS New Mexico
Section meeting and was offered an in-
ternship at Los Alamos National Labo-
ratory, where she worked her way up
to a full-time position as a research
tech with the materials property team.
“I like it because it helps me under-
stand material properties and how it’s
used in the field,” she explained.
Through her involvement with the
AWS New Mexico Section, Williams
has also volunteered in the SkillsUSA
competition. One year she helped
teachers corral their teams, and anoth-
er year she served as secretary. During
downtime, she and the SkillsUSA team
performed community service by help-
ing to build and remodel houses.
“It was rewarding. I got to travel to
see all the competitions and meet a lot
of people, and we helped a lot of com-
munities,” she said.
Having completed her associate’s
degree in welding from Central New
Mexico Community College (CNM),
Williams now has her sights on earn-
ing a bachelor’s in welding engineer-
ing. She credits two people for encour-
NOVEMBER 2018 / WELDING JOURNAL 59
involves chairing SkillsUSA’s sculpture
welding contest held at Central New
Mexico Community College, as well as
serving on the college’s welding advi-
sory committee.
His contributions to the industry
have been recognized with several ac-
colades, including the District Director
Certificate Award, Dalton E. Hamilton
Memorial CWI of the Year Section
Award, and Dalton E. Hamilton Me-
morial CWI of the Year District Award.
“I enjoy it. Welding is my life. I
don’t know about anything else. If it
has to do with metallurgy or welding,
I’m there,” he said. “Welding makes my
world go round.”
A true busy bee, Thomas plays vol-
leyball twice a week and builds homes
as a hobby; he is currently building his
fourth house.
His success extends beyond his
work life. Thomas has been married to
his wife, Martha, for 45 years, and has
three children plus seven grandchil-
dren. His life motto is simple:
“God first, family second, and then
country and welding,” he affirmed.
“Welding holds America together.”
aging her continued education — Ron
Hackney, her welding instructor; and
Pierrette Gorman, retired welding en-
gineer and AWS District 20 director.
“Pierrette has had a huge influence
on my career. When I met Pierrette, I
didn’t know anything about welding
engineering. She told me how long it
took her to get her degree; she was in
her 40s, but she never gave up,” said
Williams. “That inspired me to keep
pushing myself and keep at it.”
With the help of AWS scholarships,
Williams is currently taking classes at
CNM and plans to transfer to New
Mexico Tech to complete her bache-
lor’s degree. Because of her full-time
job, she admits it will take her some
time to graduate.
“It’ll take a while, but I’ll get there,”
she affirmed.
Williams hopes to follow in Gor-
man’s footsteps by working as a weld-
ing engineer at Sandia National Labo-
ratories, New Mexico.
“I love welding. It’s something I find
interesting,” she said. “I hope I get the
opportunity to be a welding engineer.”
SECTION NEWS BY BY
CINDY WEIHL
CINDY — cweihl@aws.org
— CWEIHL@AWS.ORG
WEIHL

District 1 District 4 ATLANTA

August 29
Douglas A. Desrochers, director Stewart A. Harris, director Location: Lithia Springs, Ga.
(508) 763-8011 (919) 824-0520 Presenter: Dale Flood, AWS president
dadaws@comcast.net stewart.harris@altec.com Summary: Past District 5 Director J. T.
Mahoney introduced 2018 AWS Presi-
dent Dale Flood to attendees of the
Section’s August meeting. Flood gave a
District 2 District 5 presentation on mechanized welding
Howard Record, director and highlighted his travel to foreign
Ken Temme, director
(352) 816-0835 countries to demonstrate welding
(856) 264-8377
howard@rtdtools.com procedures.
kenneth.temme@gmail.com
CENTRAL FLORIDA-ORLANDO
August 16
District 3 Location: Valencia College Advanced
Manufacturing Training Center
Sean Moran, director Presenter: Jason Becker, Section chair
(717) 885-5039
sean.moran@ahydro.com

LANCASTER
August 25
Location: Landisville, Pa.
Summary: The Section’s executive
board gathered to discuss plans for
tours, events, fundraising, speakers,
and other activities for 2018–2019.
Board members’ families were also in-
ATLANTA — Seen at the Section’s Au-
vited to a picnic following the meet- gust meeting are (from left) AWS
ing, so everyone could get to know one CENTRAL FLORIDA-ORLANDO — Sec-
President Dale Flood, Host Tony Hoyle, tion members Justin Burt and Jason
an other better. and Section Chair René Engeron. Becker are seen during the raffle.

LANCASTER — The Section’s executive board members and their families gathered for a photo.

60 WELDING JOURNAL / NOVEMBER 2018


and senior welding instructor
Summary: The Section held its first of-
ficial meeting as a networking event to
let members know that Orlando is
once again active in the District. More
than 40 people attended. Several
prizes donated by Lincoln Electric, Va-
lencia College, and Roberts Oxygen
were raffled.
District 6
Michael Krupnicki, director
(585) 705-1764
mkrup@mahanyweld.com
District 7
Uwe Aschemeier, director
(786) 473-9540
uwe@sgsdiving.com
COLUMBUS
September 19
Location: Crowne Plaza Columbus,
Columbus, Ohio
Presenter: Alex Leybovich, founder
and chief technology specialist, NDT
Custom Programming & Applications
Engineering LLC
Summary: Leybovich spoke to meeting
attendees about advances in ultrason-
ics testing of metallic bonds. He has
more than 35 years of experience
working in cross-disciplinary fields of
semiconductor thin film technology,
material science, and nondestructive
testing applied to R&D and manufac-
turing of electronic devices and elec-
tronic consumables. He holds 16 pri-
mary and numerous secondary
JOHNSTOWN/ALTOONA — Section members are pictured outside the Elliott Group following their facility tour.
SECTION NEWS
patents and has authored multiple sci-
entific and technical articles. District 9
Michael Skiles, director
JOHNSTOWN/ALTOONA (337) 501-0304
September 18 michaelskiles@cox.net
Location: Jeannette, Pa.
Summary: Members toured the Elliott
Group facility. The company designs
and manufactures centrifugal com-
pressors and steam turbines. The com-
pany uses various welding processes
throughout several stages of its manu-
facturing process.
District 8
D. Joshua Burgess, director
(931) 260-7039
djoshuaburgess@gmail.com
NASHVILLE COLUMBUS — Donny Didion (left)
August 30 presented a speaker gift to Alex
Leybovich.
Location: Tennessee College of Applied
Technology, Lebanon, Tenn.
Summary: Several members received
honors for their years of membership.
District 8 Director Josh Burgess was in
attendance to join Section Chair Rick
Tidwell and AWS President Dale Flood
in awarding those individuals. Flood
was also presented an honorary Ten-
nessee sign by David Porter, chair of
education and student affairs. Addi-
tionally, Flood received an AWS
Nashville Section member shirt from
the group. Members receiving their
NASHVILLE — David Porter, welding
25-Year Silver Member Award were technology instructor at TCAT–
Joe Livesay, Robert O’Neal, and Mari- Hartsville (left), presented AWS Presi-
on Brown. Phil Thomas and Frank dent Dale Flood with an honorary Ten-
Lake received Life Member certificates nessee sign, making him an “official”
and pins. Tennessean.
NOVEMBER 2018 / WELDING JOURNAL 61
SECTION NEWS
MOBILE
September 17
Location: Original Oyster House,
Spanish Fort, Ala.
Presenter: Mike Biggs, ESAB
Summary: The Section held a Scholar-
ship Night and Weld Trivia contest.
The meeting kicked off with announce-
ments by Section Chair Mike Magazzu,
followed by a buffet-style dinner.
Scholarship recipients were recognized
and presented with certificates. Maga-
zzu then introduced speaker Mike Big-
gs, who hosted a welding trivia contest.
Phil Wickersham, also of ESAB, was
present to assist Biggs with the trivia
questions and answers. The company
provided t-shirts and hats for members
who correctly answered the trivia ques-
tions. A split-the-pot drawing was also
held and door prizes were awarded. To-
tal attedance was 106, including 68
students and nine instructors from
area schools.
NEW ORLEANS
May 15
Location: Copeland Towers and Con-
ference, Metairie, La.
Presenter: Tyler Vial, territory repre-
sentative, ESAB Welding and Cutting
Products
Summary: The Section’s May meeting
was sponsored by ESAB, and Vial con-
ducted an interactive presentation on
welding trivia. Participating attendees
were awarded prizes for answering

NASHVILLE — District 8 Director Josh Burgess (far left) and AWS President Dale Flood (third from left) are pictured with members
receiving anniversary awards for their long-standing membership.

MOBILE — Female Section members gathered for a group photo.

MOBILE — The Section had a great turnout for its first meeting of the 2018–2019 season.

62 WELDING JOURNAL / NOVEMBER 2018


questions. This was the final Section
general meeting for the 2017–2018
schedule, which awards a lucky Section
student for best participation in meet-
ings. This year’s winner was Eric Fu-
nez, an apprentice in the Ironworkers
Local Union #58 Apprenticeship Pro-
gram. He has received the award three
years in a row. Door prizes were donat-
ed by ESAB and a 50/50 raffle was
held with proceeds dedicated to Sec-
tion student activities.
District 10
Mike Sherman, director
(216) 570-9348
mike@shermanswelding.com
District 11
Phillip Temple, director
(734) 546-4298
nwcllc_ptemple@att.net
District 12
Dale Lange, director
(715) 732-3645
dale.lange@nwtc.edu
NEW ORLEANS — Guest speaker Tyler
Vial (left) is seen with Section Chair
Aldo Duron.
SECTION NEWS
Summary: The Section’s board met to
District 13 discuss the Bass Tournament held on
John Willard, director August 25. Members also discussed
(815) 954-4838 the development of a scholarship for
kustom_bilt@msn.com Arkansas welding students to attend
accredited colleges in the state.
August 25
District 14 Location: Hot Springs, Ark.
Tony Brosio, director Summary: The Section held its 1st of
(765) 215-7506 what is to be annual Bass Tournament.
tbrosio@yahoo.com Several sponsors and boats entered
the competition, which included a
division for high school students to
compete.
District 15
Michael Hanson, director
(763) 221-5951
mikhan318@comcast.com
District 18
Thomas Holt, director
(409) 721-5777
tholt@techcorr.com
District 16
Karl Fogleman, director
(402) 677-2490
fogleman3@cox.net
District 17
J Jones, director
(832) 506-5986
jjones6@lincolnelectric.com
CENTRAL ARKANSAS
August 16 CENTRAL ARKANSAS — Highest fin-
Location: Cajun’s Wharf, Little Rock, ishing high school angler Caleb
Ark. Thompson received a Yeti® cooler.
CENTRAL ARKANSAS — Pictured are CENTRAL ARKANSAS — Mark Harrison
the first-place winners of the Sec- and Brendon Haynes were the highest
tion’s first-ever bass tournament. finishing AWS members.
NOVEMBER 2018 / WELDING JOURNAL 63
SECTION NEWS
from start to turn key. Several cars funds received in Arizona history for
District 19 that had been transformed from “mild 2017–2018.
Shawn McDaniel, director to wild” were on display.
(509) 793-5182
shawnm@bigbend.edu
District 22
District 21 Kerry E. Shatell, director
District 20 Sam Lindsey, director
(858) 740-1917
(925) 866-5434
kesia@pge.com
Pierrette H. Gorman, director slindsey@sandiego.gov
(505) 440-6284 CENTRAL VALLEY
pierrette@comcast.net ARIZONA August 23
May 19 Location: Tulare, Calif.
NEW MEXICO Location: Top Golf, Scottsdale, Ariz. Presenter: Clayton Rutti, technical
September 13 Summary: The Section hosted its 3rd sales and support representative, Lin-
Location: Albuquerque, N.Mex. Annual Top Golf event. The cost of ad- coln Electric
Presenter: Eric Kos, second-generation mission will go toward the Section’s Summary: Rutti gave a presentation
owner, Mild Wild Inc. “Halls of Knowledge” scholarship. Sec- on modern welding equipment cur-
Summary: Kos spoke to Section mem- tion officers reported that Arizona rently used in the industry, including
bers about the automotive restoration students set a record for most scholar- automation and advanced welding
procedures necessary to restore a car ship applicants and most scholarship processes.

NEW MEXICO — Automotive restoration expert Eric Kos (far left, standing) and Section members posed for a photo.

CENTRAL VALLEY — Section Chair Randy Emery (center, left) presented a speaker’s gift to Lincoln Electric’s Clayton Rutti.

64 WELDING JOURNAL / NOVEMBER 2018


Join or Renew:
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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)
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NOTE: Dues include $17.30 for Welding Journal subscription and $4.00 for the AWS Foundation.
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REV. 11/16
 GUIDE TO AWS SERVICES
American Welding Society® certification, publications, and membership. Metric Practice, Safety and Health, Joining of
8669 NW 36 St., #130 Plastics and Composites, Personnel and Facilities
Miami, FL 33166-6672 INFORMATION SYSTEMS Qualification, Mechanical Testing of Welds
(800/305) 443-9353; Fax: (305) 443-7559 Managing Director
Phone extensions are in parentheses. John Perry .. jperry@aws.org . . . . . . . . . . . . . . .(247) Program Managers II
Stephen Borrero... sborrero@aws.org . . . . . . . . .(334)
AWS PRESIDENT PUBLISHING & EDITORIAL Definitions and Symbols, Structural Subcom-
Dale Flood. . . . . . . .floodaws@tritool.com Dept. information . . . . . . . . . . . . . . . . . . . . . . . .(275) mittees on Reinforcing Steel and Stainless Steel,
Tri Tool Inc. Joining of Metals and Alloys, Piping and Tubing
3041 Sunrise Blvd., Rancho Cordova, CA 95742 Welding Journal
Publisher/Editor Rakesh Gupta.. gupta@aws.org . . . . . . . . . . . . .(301)
SENIOR LEADERSHIP TEAM Mary Ruth Johnsen.. mjohnsen@aws.org . . . . .(238) Filler Metals and Allied Materials, International
Executive Director/ Filler Metals, UNS Numbers Assignment, Arc Weld-
Chief Executive Officer Society News Editor ing and Cutting Processes, Computational Weld
Matt Miller.. mmiller@aws.org . . . . . . . . . . . . . .(207) Katie Pacheco.. kpacheco@aws.org . . . . . . . . . . .(275) Mechanics

Chief Financial Officer/ Section News Editor Jennifer Molin.. jmolin@aws.org . . . . . . . . . . . .(304)
Chief Administrative Officer Cindy Weihl..cweihl@aws.org . . . . . . . . . . . . . . .(256) Structural Welding, Sheet Metal Welding
Gesana Villegas.. gvillegas@aws.org . . . . . . . . . .(252)
Inspection Trends Editor
Chief Marketing Officer Carlos Guzman..cguzman@aws.org . . . . . . . . . .(348) Program Managers
Sofia Samuels..ssamuels@aws.org . . . . . . . . . . . .(419) Mario Diaz..mdiaz@aws.org . . . . . . . . . . . . . . . .(310)
MARKETING Automotive, Resistance Welding, Resistance
Senior Vice Presidents Chief Marketing Officer Welding Equipment, Welding and Brazing in Aero-
Cassie Burrell.. cburrell@aws.org . . . . . . . . . . . .(253) Sofia Samuels.. ssamuels@aws.org . . . . . . . . . . .(419) space, Friction Welding
Research, Strategy, and Membership
MEMBER SERVICES Kevin Bulger..kbulger@aws.org . . . . . . . . . . . . . .(306)
John Gayler.. gayler@aws.org . . . . . . . . . . . . . . .(472) Dept. information . . . . . . . . . . . . . . . . . . . . . . . .(480) Brazing and Soldering, Methods of Weld In-
Welding & Technology spection, Welding in Marine Construction, Welding
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Annette Alonso.. aalonso@aws.org . . . . . . . . . . .(299) Serves as a liaison between members and AWS Jennifer Rosario.. jrosario@aws.org . . . . . . . . . .(308)
Talent headquarters. Oxyfuel Gas Welding and Cutting, Railroad
Welding, Thermal Spraying, Welding Iron Castings,
Patrick Henry.. phenry@aws.org . . . . . . . . . . . . .(226) Senior Manager, Volunteer Engagement Welding Qualification
Society Programs and Support
Darrill Gaschler.. dgaschler@aws.org . . . . . . . . .(306) Welding Handbook Editor
EXECUTIVE OFFICE Kathy Sinnes.. ksinnes@aws.org . . . . . . . . . . . .(255)
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Director
HUMAN RESOURCES Managing Director Hosea Carter...hcarter@aws.org . . . . . . . . . . . . .(413)
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ACCREDITATION
INTERNATIONAL INSTITUTE OF WELDING Senior Manager AWS FOUNDATION INC.
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Liaison services with other national and interna- EDUCATION & TRAINING (800/305) 443-9353, ext. 212, jdouglass@aws.org
tional societies and standards organizations. Director
Alicia Garcia..agarcia@aws.org . . . . . . . . . . . . . .(229) Chairman, Board of Trustees
GOVERNMENT LIAISON SERVICES William A. Rice.. brice@oki-bering.com
Hugh Webster .... hwebster@wc-b.com CONFERENCES & EVENTS
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International Standards Activities, American
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Oversees international business activities; Stephen Hedrick.. steveh@aws.org . . . . . . . . . . .(305)

NOVEMBER 2018 / WELDING JOURNAL 67

PERSONNEL

Camel Grinding Wheels National Tooling and CenterLine Chooses

Announces President Machining Association Vice President and
Appoints President General Counsel
Camel Grinding
Wheels (CGW), The National Tooling and Machining CenterLine
Niles, Ill., a manu- Association, Cleveland, Ohio, has elect- (Windsor) Ltd.,
facturer of vitri- ed Dean Bartles as its president. Bartles Windsor, Ontario,
fied grinding brings 40 years of experience in the Canada, a
wheels, has ap- manufacturing sector, most recently as provider of fas-
pointed Mike Sul- the director of the John Olson Ad- tener and resist-
livan as president vanced Manufacturing Center at the ance spot welding
for CGW and Pa- University of New Hampshire. Previ- technology and
cific Abrasive Sup- ously, he served as president of the So- advanced produc-
ply Co. in the ciety of Manufacturing Engineers, pres- tion systems for
United States and ident of the North American Research the automotive
M. Sullivan Canada. He will be Institute, founding executive director industry, has
responsible for of the Digital Manufacturing & Design D. Mueller added David
overall manage- Innovation Institute, and founding Mueller to the po-
ment and profitability. Sullivan brings chairman of the Smart Manufacturing sition of vice pres-
35 years of abrasives experience to the Leadership Coalition. Bartles also has ident and general counsel. In his role,
position. He previously served as vice extensive corporate experience. For 13 he will lead all legal and risk manage-
president at United Abrasives/SAIT years, he was vice president and general ment matters, steer various global
and director of industrial coated abra- manager of the ordnance and tactical growth initiatives, and help drive
sives product management and mar- systems division at General Dynamics, strategic planning for the company.
keting at Saint-Gobain. Sullivan re- and earlier in his career held positions Previously, Mueller spent nearly five
cently completed a two-year term as at Primex Technologies, Olin Ordnance, years at Valiant TMS, a global tooling
the president of the Coated Abrasives General Defense Corp., and Fairchild and automation company, as a mem-
Fabricators Association. Republic Co. ber of its executive leadership team in
a corporate development and general
counsel role. He started his legal ca-
reer at Fasken Martineau DuMoulin
LLP in Toronto before joining Shibley
Righton LLP in Windsor, Ontario,
where he worked as a business law as-
sociate advising clients on a variety of
commerical matters.

AMETEK Enhances Senior

Management Team

S. McMahon J. Zyglis

AMETEK Surface Vision, Hayward,

Calif., a company that offers automat-
ed online surface inspection solutions,
has hired Shean McMahon as division-

68 WELDING JOURNAL / NOVEMBER 2018

al vice president of R&D. McMahon is
an experienced director of innovation
with a background in developing solu-
tions, creating more than 20 digital
and information technology products.
He will head up the company’s R&D
teams and build on its reputation
for providing market- and industry-
focused solutions. Additionally, the
company has promoted Jason Zyglis
to the position of divisional vice presi-
dent of project and product manage-
ment. He previously had the role of di-
rector of sales, Americas, and brings
two decades of experience focused on
strategic product marketing, sales,
and business development.
Imperial Systems Welcomes
Director of Sales and
Marketing
Imperial Systems, Mercer, Pa., an
industrial dust and fume collection
company, has welcomed Tomm
Frungillo as director of sales and mar-
keting to lead a group of sales profes-
sionals. Frungillo comes with a 25-year
career in industrial dust and fume col-
lection equipment. Most recently, he
held the position of director of sales at
The Systems Group and was responsi-
ble for growing sales globally. Prior, he
led many divisions of Camfil APC, in-
cluding vice president of the Americas.
He also led teams in charge of growing
the Latin America mining market, cre-
ating strategy and equipment for the
pharmaceutical and biotechnology
market, and growing the thermal spray
market for the APC division.
TRUMPF Expands Product
Management Group
Masoud Harooni has been named
product manager of TruLaser Weld for
TRUMPF, Farmington, Conn., a global
provider of fabricating machinery and
industrial lasers. Harooni will be re-
sponsible for the day-to-day opera-
tions of the TruLaser Weld Group. He
will work to develop resources and
processes to enhance the company’s
customer product demonstrations as
well as its training to further advance
customers’ knowledge and proficiency
on the TruLaser Weld. Harooni began
his career with the machine tools
provider at the Smart Factory in
Chicago as a senior advanced technol-
ogy engineer.
In addition, the company has
WOORK
RK
M. Harooni A. Buerkler
SSM
MART
M ART
RT
named Adi Buerkler as product man-
ager of TruLaser Tube for the Laser
Product Group. In this position, he
will be responsible for expanding the
company’s market share by helping
fabricators realize the benefits of laser
tube processing. He will work together
with customers to help optimize their
tube cutting capabilities and will serve
as a technology expert providing prod-
uct and process support. Buerkler
started at TRUMPF in Gruesch,
Switzerland, as a mechanical engineer
in 1998. Following his time in Switzer- Model 200 Positioner
land, he joined TRUMPF in Farming- 3 models av
ton in 2001 where he held a couple of ,
positions, prior to becoming the man- .
ager of the International Service Com-
petence Center and technical manager.
Chemcoaters Director Retires
Bill Krippes, di-
rector of new
product develop-
ment at Chem-
coaters, Gary, Ind.,
has retired from Mode el 1200 Pipemate
the company after Rottates pipe and tube
16 years of serv- from 1 ½” to 17” diameter,,
ice. He will contin-
ue to serve as a
new business de-
velopment con-
B. Krippes sultant. His ex-
pertise in dry-film
lubes for stamping
and product-development skills have
helped advance the company’s core
business and aided in educating em-
ployees. Krippes has been in the coil
and mill-applied coating industry for
more than 46 years, serving in R&D,
technical service, and sales roles. He
started his career developing products
for JM Eltzroth, before moving on to
PPG and specializing in mill-applied
coatings, where he spent more than a
decade.
NOVEMBER 2018 / WELDING JOURNAL 69
THE AMERICAN WELDER

Welding Power Sources Shorten

Training and Reduce Rework
Newer power source technologies are offering easy-to- BY BRIAN HAMMERS
use setups to not only address the welder experience
gap but also improve efficiency

T
he welding industry is currently
faced with many challenges, in-
cluding the shortage of skilled
welders, the need to get new welders
trained and on the job faster, and
greater pressure to improve productivi-
ty and reduce costs. One key to ad-
dressing these challenges is making
welding power sources easier to use —
Fig. 1.
For years, many technologies fo-
cused on a simplified setup system,
and ease of use had been incorporated
in machines designed for the home
hobbyist or do-it-yourself welder.
Now, those solutions are migrating to
more power sources used in industrial
and heavy manufacturing applications,
as those industries look for ways to ad-
dress the welder experience gap and
improve efficiency.
What exactly does it mean to make
a welding power source easier to use?
This article will discuss technologies
that simplify setup, shorten training
time, and help even inexperienced
welders produce high-quality welds.

Single User Interface

A simplified power source starts
with easier setup. Where previously
welders had to input some parameters
at the power source and some parame-
ters at the wire feeder (or whatever in-
terface is used at the weld joint), more
machines now put all controls on a
single user interface.
When every knob or button the
welder needs to set up the process and Fig. 1 — Making welding power sources easier to use is one key to addressing the
control parameters is on the interface challenges faced by the welding industry, including the shortage of skilled welders,
at the wire feeder, this eliminates set- the need to get new welders trained faster, and greater pressure to improve produc-
ting up parameters on two separate in- tivity and reduce costs.

70 WELDING JOURNAL / NOVEMBER 2018

terfaces. The welder no longer needs to
return to the power source to make
changes. This single interface setup
also streamlines training time for new
welders and saves time during welding.
The displays on the user interface
are also getting bigger, making it easi-
er for welders to read and understand
the settings. Where displays previous-
ly used small digital screens and were
often limited to a few letters in each
word, requiring words to be abbreviat-
ed, new larger LCD displays show full
words and sentences — Fig. 2.
One-Step Setup
Requiring fewer steps to start weld-
ing simplifies the process and also
makes training new welders faster.
Some newer welding systems offer
an “easy button” for machine setup.
Less experienced welders may not
know the correct voltage or wire feed
speed settings for the application.
With this technology, the only param-
eter a welder needs to input is material
thickness. Once that is set, the power
source automatically sets the other pa-
rameters appropriately.
This not only saves time in setup, it
also eliminates the risk that incorrect
parameters might inadvertently be
set, which could lead to weld defects
or rework.
Customized Weld Programs
More welding systems provide the
ability to customize the weld program
during machine setup, which results in
an arc that’s tailored to the specific
variables of that weld. In the past,
this option was limited to advanced
welding systems and required expert-
ise to set up. Now, customizable weld
programs are available in a broader
range of power sources, and the
process is simplified, so even welders
with less experience can tailor the
weld program.
When a welding system offers only
one weld program, it must be designed
broadly enough to produce quality
welds no matter what type of shielding
gas, filler metal, material, or weld
process is being used. With the ability
to customize the weld program,
welders can fine-tune it to match their
specific variables, resulting in a better
weld arc for the application.
On some welding systems, the weld
program can be customized by toggling
through a series of prompts on the in-
terface screen. The welder first selects
the weld process, followed by the weld-
ing wire type and size. The last variable
is gas type. Based on the previously en-
tered variables, the machine narrows
down possible shielding gases to a
handful of options, which are listed on
the screen for the welder to choose. The
welding system then automatically sets
a weld program best suited to the vari-
ables input by the welder, so there’s no
compromising on arc quality.
Dial-In Arc Control
As machine setup and adjustment
are simplified, more power sources
also provide welders with greater arc
control, so they can adjust the arc
based on variations in their technique
or the material.
This arc control feature is often a
knob on the user interface that can be
dialed up or down. Adjusting the arc
control knob doesn’t change the main
weld parameters, but it does allow
welders to fine-tune the arc to their
preferences. Welders can compensate
for variations in their technique, while
still staying within the wire feed speed
and voltage windows required by the
application’s weld procedures.
Less experienced welders may use
an arc length that is too long, for ex-
ample. Adjusting the arc control knob
can help produce a better weld in this
situation.
Fig. 2 — More welding systems are placing all setup functions and parameter con-
trols on a single user interface at the wire feeder for simplified setup and parameter
changes. Display screens are also getting bigger, making it easier for welders to
read and understand settings.
NOVEMBER 2018 / WELDING JOURNAL 71
This technology also delivers bene-
fits for experienced welders, providing
them the ability to make an already
good welding arc even better.
More Forgiving Weld
Processes
Today’s welding systems also offer
more pulsed welding capabilities.
Pulsed welding processes are more for-
giving to variations in technique, mak-
ing it easier for all welders to produce
high-quality welds. In lab testing, one
advanced pulsed gas metal arc welding
(GMAW-P) process offered a 28%
wider operating window compared to
standard constant-voltage GMAW.
This wider window helps less experi-
enced welders produce high-quality
welds and reduce rework, saving time
and money in the operation.
There are different types of pulsed
processes, from standard GMAW-P to
various advanced pulsed processes,
and the technology continues to
evolve. In general, advanced pulsed
arcs compensate for a lack of experi-
ence and/or consistency, because they
bridge the gap between varying travel
speeds and contact-to-work distances,
making it easier for welders to consis-
tently produce a high-quality weld —
Fig. 3. This is valuable as welding oper-
ations struggle to find skilled welders
to rebuild the workforce as experi-
enced welders retire.
 vanced monitoring software that de-
tects welding mistakes, tracks parts,
and delivers real-time feedback to
welders.
Where previously these weld moni-
toring solutions were often an extra
module attached to the welding power
source, new technologies can be incor-
porated inside the power source for an
easier, more streamlined weld moni-
toring option.

Simplified Machines Save

Fig. 3 — Pulsed welding processes, which are available in more power sources to-
day, are more forgiving to variations in technique, making it easier for welders of all
skills levels to produce high-quality welds.
Productivity and Quality
Tracking
Digital weld monitoring is growing
in use and is available on more power
sources today, making the technology
accessible for welding operations of all
Time and Money
Welding systems are becoming easi-
er than ever to use, with simplified in-
terfaces, automatic parameter adjust-
ments, push-button capabilities, and
greater arc control. These smarter ma-
chines offer more capabilities that
make it easier for welders of all skill
levels to save time, reduce mistakes,
and produce high-quality welds. WJ
sizes. Weld data monitoring systems
can measure and track performance
metrics to help companies improve
BRIAN HAMMERS
productivity and weld quality. (brian.hammers@millerwelds.com) is an
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systems that verify weld parameters LLC, Appleton, Wis.
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 An Association of We
elding Manuffacturers
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THE AMERICAN WELDER

Commemorating Welding’s Native Voices

BY KATIE PACHECO
Three welders share their stories in honor
of Native American Heritage Month

O
bserved every November, Native From there, Dru began doing struc- As fate would have it, there was a
American Heritage Month cele- tural welding, as well as working on job fair taking place the day he toured
brates the rich cultures and vast boat docks and in muffler shops. the Tulsa, Okla., school campus. After
achievements of more than 500 Native “At that point, I thought I was a speaking to several of the companies
American tribes. Officially proclaimed welder when I really wasn’t,” he said that were hiring students, he was sold
in 1990 by Former President George with a laugh. “I didn’t understand all on the idea of pursuing a formal weld-
H. W. Bush, the observance provides the welding procedures and how welds ing education.
an opportunity for learning about the are actually supposed to look. I was “They were offering welders a lot of
traditions and histories of Native just sticking two pieces of metal money. That did it for me,” he af-
people. together.” firmed. “I used my G.I. bill and went to
In honor of Native American Her- After performing odd jobs for years, school.”
itage Month, the Welding Journal Dru began working in the marine indus- Dru completed the seven-month
reached out to three welders from the try as a mechanic and boat salesman. professional welder program and
Cheyenne, Arikara, Navajo, and He noticed that many of the people quickly landed a job as a boilermaker.
Choctaw nations to tell their unique coming in to buy boats were welders. “A company hired me right out of
stories. “I could see what their finances Tulsa Welding School, and I learned the
were, and these welders were making a weld they required me to do on the job,”
Isaac “Ike” Dru: The Pupil lot of money,” he explained. “I went he said. “I traveled all over the United
from welding shop to welding shop, States welding as a boilermaker.”
Becomes the Teacher but no one would give me a chance, so After many years in the boilermak-
that’s when I went to Tulsa Welding ing industry, Dru decided to change
Half Cheyenne and Arikara, Isaac School.” careers and buy a house in Tulsa,
“Ike” Dru had an idyllic upbringing on
a Native American reservation in
Oklahoma.
“There wasn’t anything out there;
no running water and no restroom fa-
cilities. We didn’t have electricity ei-
ther; we used oil lanterns. We got
around on horseback, and my grandfa-
ther used his pickup truck to get
things from town,” he recalled. “It was
really quiet. You could hear coyotes
howling every so often. It sure was
peaceful.”
Even though he has two older uncles
who are welders, Dru didn’t take up the
craft until he returned from serving in
the U.S. Army. His roommate, who was
welding in muffler shops for a living,
showed him the ropes.
“I liked the craft aspect of it. You
can sit back and see your work. If you
put an ugly bead on there, that’s what
it’ll look like, so you do your best to
make it look as beautiful as possible,”
he said. “It becomes an obsession. If
you put an ugly bead on there, you Fig. 1 — Welding Instructor Isaac “Ike” Dru stands in Tulsa Welding School’s welding
want to grind it off and put a prettier facility in Oklahoma, where he has taught for five years. (Photo courtesy of Tulsa
Welding School.)
one back on it.”

74 WELDING JOURNAL / NOVEMBER 2018

 Fig. 2 — Pictured with her welding instructor, Ryan Gold- Fig. 3 — Thomas Newman, pictured in snowy Grandby, Colo.,
tooth (left), Danielle Lopez holds up the welding helmet she took a risk when he left his ten-year job in the transporta-
won at the NAVIT trades competition. tion industry to pursue a career in welding.

Okla., to better care for his ailing
mother. With the help of Tulsa Weld-
ing School’s Career Services depart-
ment, he got a job with American Air-
lines performing high-frequency weld-
ing on Boeing 717 and 767 aircraft.
When the company moved to Mexico,
he returned to Career Services, which
helped him secure a job welding hair-
pin heat exchangers. After his mother
passed away, he again solicited the
help of Career Services to find a job in
offshore welding. Returning to the
school to practice for his weld test, the
instructors took notice of his high-
quality work and offered him a job.
“Some of the instructors looked at
my welds and said they were good
enough to be an instructor if I wanted
a job there,” he recalled. “It was quite a
shock to me that I am that good of a
welder to be an instructor.”
Passing the educator test, Dru be-
came a welding instructor at Tulsa
Welding School’s Oklahoma campus,
where he has been teaching for five
years — Fig. 1. He describes teaching
as the most enjoyable and fulfilling job
he has ever had.
“The students start off having a dif-
ficult time, but by the time they test
on that weld, they can do it, and you
see in their eyes that they’re excited to
achieve that level,” he explained. “And
it’s great to see them graduate and
come back to the school with their
brand-new truck or motorcycle to tell
me about all the money they are mak-
ing now.”
He describes the school’s Oklahoma
campus as having a significant Native
American population. As a Native
American himself, he serves as a role
model for them.
“They see that I can do it. I’ve been
there, done that; it gives them the
feeling that they can do it as well,” he
affirmed. “It’s a hard seven months,
but I tell them when they finish it,
they’ll get paid for it, which they do.”
Danielle Lopez: The Product
of a Dedicated Teacher
Danielle Lopez wasn’t thrilled
about having to take a welding course
to satisfy the career and technical edu-
cation (CTE) requirement at Tuba City
High School, located on the Arizona
Navajo Reservation. After the very
first day of class, she took measures to
distance herself from welding.
“I saw welding on my schedule, and
I was confused. I got into that class,
and just sat there not knowing what
my teacher was talking about,” she re-
called. “When school was over, I tried
to change my CTE class, but they
wouldn’t let me because other stu-
dents were trying to change it, too.”
Lopez describes her first few weeks
of welding class as being “pretty bad.”
“I didn’t know what anything in the
shop was called, or how to work the
machine, or what the amperages do,”
she explained. “I didn’t know how fast
to move my hand or how wide my
stringer beads were supposed to be.”
Her naïveté was swiftly replaced by
skill, dedication, and a love for the
craft.
“I got the hang of it fast, and it be-
came a lot of fun,” she said. “I took in-
tro to welding, then welding 1, then 2,
and 3. I took welding classes all
throughout high school. I was the top
student in all my welding classes.”
Taking notice of her welding
prowess, Welding Instructor Ryan
Goldtooth selected Lopez in her junior
year to compete on behalf of her
school at a trades competition hosted
by Northern Arizona Vocational Insti-
tute of Technology (NAVIT). The two-
part competition included fabrication
and an exam. To get competition-

NOVEMBER 2018 / WELDING JOURNAL 75

ready, Lopez practiced gas metal arc
welding for a month using the compe-
tition’s project blueprints.
“It was my first welding competi-
tion. I was so nervous, but Ryan
wasn’t worried about me because he
knew I had it all down. He believed I’d
win something,” she recalled.
Goldtooth was right. Lopez won
third place and a $2500 scholarship
to Tulsa Welding School. The win
also garnered her attention from
classmates.
“The next day in school, they men-
tioned it on the intercom, and my
friends and peers congratulated me,”
she said.
The following year, Goldtooth again
chose Lopez to represent the school at
the NAVIT competition. To her aston-
ishment, she took first place, which
came with a $10,000 scholarship to
Tulsa Welding School, welding gloves,
and a welding helmet.
With a portion of her education
paid for, Lopez is currently in the Tul-
sa Welding School’s professional
welder program in Tulsa, Okla. She
credits her high school welding in-
structor for the strong foundation in
welding she brings to the program. Al-
though he’s 13 hours away on the Ari-
zona Navajo Reservation, Goldtooth
continues to dedicate himself to
Lopez’s education.
“People at Tulsa [Welding School]
ask me if I welded back home, and I
tell them my teacher taught me every-
thing I know about welding,” she af-
firmed. “To this day, I still ask him for
tips, and he checks up on me to ask
about my next welding project. Some-
times I send pictures of what I’m
working on, and he coaches me
through text.”
Despite her advantage, Lopez has
had to overcome gender stereotypes
on her journey to becoming a welder.
She finds that her welding skills are of-
ten doubted within her community
even though she has completed proj-
ects and built welded sculptures for
the Navajo Reservation.
“There aren’t a lot of welders in my
community, and there’s a bias that
women can’t weld,” she said. “When
they see me they ask, ‘Are you actually
good?’ They’re amazed when they
learn I can weld.”
The diversity offered by Tulsa
Welding School’s Oklahoma campus
has played a role in helping Lopez to
overcome misconceptions about
women in manufacturing.
76 WELDING JOURNAL / NOVEMBER 2018
“I’m meeting new people, and I’m
learning how to be with different
types of people,” she said. “I feel ac-
cepted as a female welder.”
Slated to graduate this year, Lopez
looks forward to her future as a welder
and has both a plan A and B. Plan A is
to weld in the field and travel to “see
the real world.” In contrast, plan B is
to stay near the Arizona Navajo Reser-
vation to teach.
“Ryan told me, ‘I taught you good,
and I am always here to help you,’” she
said. “I would like to be a teacher like
him.”
Thomas Newman: Grabbing
Life by the Horns
Not many people have the courage
to leave a steady job to follow their
dream career. After working in the
transportation industry for a decade,
Thomas Newman decided it was time
for a change — Fig. 3.
“My whole working career, I was ei-
ther in construction or transportation.
I held the same job for a transporta-
tion company for ten years, and I just
wanted to do something more exciting
than sit behind a desk for 8 to 10
hours a day directing people around
the country,” he explained. “I wanted
to do something completely different.”
Born in Amarillo, Tex., but raised in
Houston, and from the Choctaw Na-
tion on his mother’s side, Newman
was inherently drawn to welding even
though he had never tried it himself.
“My interest lies in building things.
I like taking nothing and turning it
into something,” he affirmed.
With the encouragement of his
wife, Francesca, he quit his job and be-
came a full-time student in Tulsa
Welding School’s seven-month welding
specialist program in Houston, Tex.
Trying welding for the first time on
the first day of class, Newman discov-
ered that his gut instinct was right.
“I took a chance and rolled the dice
on something I had never done before.
Luckily, I liked it,” he recalled with a
laugh. “As nervous as I was, it was very
exhilarating to be able to take the
hardest material known to man and do
with it as I pleased.”
Having learned various processes,
Newman lists shielded metal arc weld-
ing (SMAW) as his favorite.
“As simple as the process is, it’s still
very technical,” he explained. “There’s
such a small room for error in any type
of welding you do, but SMAW is more
of a primitive art form.”
He credits the program’s hands-on
methodology and accessible instruc-
tional staff for preparing him for the
manufacturing industry.
“What I like about the program is
the ability to be able to learn as you go
and to have an unlimited amount of
knowledge you can obtain from in-
structors and their resources,” he said.
Graduating from the program in
September, Newman feels confident in
his ability to weld. He hopes to en-
hance his knowledge in diagnosing
and troubleshooting problems once in
the field.
“There isn’t even one thing I feel I
could run up against that I couldn’t
produce a sound, structural weld on,”
he said. “But if something was wrong
with my machine, or if someone threw
a curve ball at me, it would take me
some time to figure out what to do.
Things of that nature will come in
time. You can’t learn everything in
seven months.”
Newman is currently working with
the school’s Career Services depart-
ment to locate his first welding job. He
also recently attended a career fair for
Union Tank Car Co., a railway equip-
ment leasing company.
In the future, Newman hopes to
one day work on motorcycles, which
are his passion. However, he states
that supporting his family financially
is his greatest priority at the moment.
Newman points out that his dream of
being a welder would have gone unful-
filled if it weren’t for the encourage-
ment of his wife and three sons —
Everett, Charles, and James.
“Luckily, I have an amazing wife
who really pushed me to make a
change,” he affirmed.
Excited for this new chapter in his
life, Newman advises anyone consider-
ing a similar life change to set fear
aside and take the leap.
“For me, it was getting past the sta-
bility of a normal job and being able to
put faith in myself and take a chance, ”
he said. “In life, we either stay the
same or take a chance in doing some-
thing new. I would tell anyone not to
be afraid to take that chance.” WJ
KATIE PACHECO (kpacheco@aws.org) is
associate editor of the Welding Journal.
American Welding Society®
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THE AMERICAN WELDER LEARNING TRACK

Sitting Bull College Looks to Expand Its Welding Program

On and Off the Standing Rock Reservation

Despite challenges, this welding program at the tribal BY ROLINE PASCAL

college continues to persevere as it works to fill the
industry with its students

S
tanding Rock Reservation takes
its name from a natural forma-
tion that resembles a woman
with a child on her back. Straddling
the border between northern South
Dakota and southern North Dakota, it
is the fifth largest reservation in the
United States covering 2.3-million
acres. It stretches across tall grass
plains, rolling hills, and buttes that
border the Missouri River.
Taking the Standing Rock National
Native American Scenic Byway, you
would likely journey where Lewis and
Clark stopped 14 times and mountain
men like Jim Bridger and Jedediah
Smith passed through. You’ll also
venture through the birthplace of Sit-
ting Bull, one of the most widely rec-
ognized Native American historical
figures who advocated for maintaining
the land, rights, and ways of the
people.
In the Native American reserva-
tions, tribes invest on and off their
lands to generate revenues and ensure
economic opportunities. The results
have been tribal-controlled programs
emerging. While dependence on the
federal government is still a norm,
reservations are developing skills to
continually build their economies,
and they are doing it through higher
education.
The Timeline of Sitting
Bull College
College classes were first offered on
the Standing Rock Reservation in
1968 through the Division of Continu-

Welding Instructor Joe McMullen (left), Sitting Bull College, demonstrates proper setup for shielded metal arc welding to a student
who has never welded before.

78 WELDING JOURNAL / NOVEMBER 2018


A U.S. Department of Labor’s grant pro-
Fig. 1 — A — A welding student attempts to strike an arc for the first time with an
E7018 electrode to perform shielded metal arc welding; B — a welding student pro-
duces oxyacetylene welds in the flat position with an ER70S6 filler rod. Oxyacety-
lene welding is used as an introduction to the gas tungsten arc welding process.
ing Education at then-named Bismar-
ck Junior College. Recognizing the
need for a higher education institution
that could provide opportunities for
people in the area, several movers and
shakers on the reservation began the
process of establishing one of the na-
tion’s first tribal colleges, Sitting Bull
College, which was originally named
Standing Rock Community College.
The institution, located in Fort Yates,
N.Dak., began operation on Sept. 21,
1973. At its inception, there were only
three full-time people on staff.
The process of seeking accredita-
tion was initiated in 1975, and in
1984, the college received full accredi-
tation. To mark this achievement and
recognize their continued growth, the
college officially changed its name to
Standing Rock College.
More than a decade later, the
Standing Rock Sioux Tribal Council
voted to officially amend the charter,
changing the college’s name to Sitting
Bull College (SBC) on March 6, 1996.
The objectives were not altered, and
the college continues to operate as the
charter specifies. Currently, there are
more than 70 full-time faculty, admin-
istrative, and support staff. The origi-
nal enrollment of 90 students has
grown to approximately 300 each
semester.
Sitting Bull College not only meets
the standards of the higher education
B institution), to become involved in a
agencies, but also provides services to
the Native American community. It is
tribally controlled, and advisory
boards, made up of community mem-
bers, provide input for program con-
tinuation and/or changes.
Sitting Bull College is the primary
educational institution on the reserva-
tion providing academic and career as
well as technical education training.
Students can obtain a master of sci-
ence, bachelor of science, associate of
science/applied science, and associate
of arts degrees, as well as certificates
of completion of a vocational training
program.
Amongst courses such as electrical,
entrepreneurship, information tech-
nology, and construction trades, the
certification program offers welding,
which was originally created to fulfill
the need for specialized workers in
various parts of North Dakota.
The Inception of the
Welding Program
In 2013, SBC began the process of
negotiating and receiving a grant from
the North Dakota TREND program.
The TREND program is a partnership
between the state and tribal institu-
tions in North Dakota that came to-
gether as a consortium. The college
joined forces with four other colleges,
including Bismarck State College (lead
NOVEMBER 2018 / WELDING JOURNAL 79
gram that would allow SBC to expand
and improve its education and career
training programs that can be com-
pleted in two years or less. The grant
helps the tribal college to add equip-
ment, train faculty and staff, and pro-
vide more services to students to in-
crease their success at college and in
the job market.
Looking to expand the trades pro-
grams and given the welding labor
market in North Dakota, as well as a
local need for people skilled in the
trade, SBC introduced the welding
engineering technology program in
2014.
“At that time, there was a local
native-owned company employing
welders and having a hard time find-
ing skilled people. The welding pro-
gram was formed with consultation
from Bismarck State College,” said Joe
McMullen, SBC welding instructor.
That said, the start of the program
was rocky. During its first year, 2013–
2014, the welding program had no
full-time instructor and ran for one se-
mester in the summer. The 2014–
2015 year was the first time it was of-
fered full time. The following school
year was again without an instructor.
The welding program had been consid-
ered one of the most successful in the
trades program with enrollees, but the
number of completers was low. Stu-
dents enrolled in the welding program
were dedicated to the field of work,
but they largely gave up on it because
it was not fully staffed, and it was in-
consistent. Hoping to see a shift, the
college hired Joe McMullen as its full-
time welding instructor for the
2016–2017 school year, and he is now
running the program. Since his hire,
the program has advanced.
The Welding Program
Progresses
The welding program provides edu-
cation and hands-on training in com-
mon welding processes, operations, in-
spection, and plate welding along with
other aspects of general welding. The
curriculum provides students with cer-
tification in oxyacetylene, shielded
metal arc, and gas metal arc welding
gases and processes. Students in the
program also gain knowledge of the
Occupational Safety and Health Ad-
ministration standards for welding
 Fig. 3 — A welding student tests for
limited thickness overhead based on
the AWS D1.1 Code using shielded
Fig. 2 — A welding student produces flat bead-on-plate welds using an E6010 elec- metal arc welding with an 7018 elec-
trode during shielded metal arc welding. trode.

safety practices. They are required to

attend a minimum of one job/career
fair and apply for two jobs in their
field of study. Career opportunities in
North Dakota offer a wide array of em-
ployment potential from manufactur-
ing, steel construction, mining, ener-
gy, petroleum, and other production
areas.
The certificate course runs for 16
weeks with a focus on training stu-
dents to get into an apprenticeship or
entry-level position. To be enrolled
full-time in the welding program, stu-
dents must take safety, gas cutting and
welding, gas metal arc welding, flux
cored arc welding, shielded metal arc
welding, and an individual practicum
course to meet the requirements —
Fig. 1A. Classes cover oxyfuel welding
and cutting, plasma cutting, and, al-
though not covered in depth, gas tung- Fig. 4 — Welding Instructor McMullen (fourth from left) poses with his welding
students.
sten arc welding — Fig. 1B.
“We spend two hours a day in the
classroom discussing each process and of American Welding Society (AWS) testing on, first, a limited thickness
how to use them properly. We then D1.1, Structural Welding Code — Steel, and then an unlimited thickness plate
spend four hours in the shop putting on a scale similar to that used for scor- test in 3G vertical and 4G overhead
what we discussed in the classroom to ing in the SkillsUSA competition — welding test positions.
use,” said McMullen. Figs. 2, 3. “This semester, I will begin using
Students are graded just as heavily “Once we have covered the very ba- the Miller open book online curricu-
on attendance as they are on class- sics with each process, students are lum mixed with what I have already
room studies or workmanship in the given daily shop assignments, which been using in the classroom,” said
shop. Lab work ranges from the cor- are usually a shop drawing with weld McMullen.
rectness of weld size and placement, symbols and a welding procedure spec- Despite its shaky start, the past five
according to the shop’s drawings and ification to follow,” said McMullen. years have seen the young program
the welding procedure specification After midterms and having a gradually progress. Enrollment has
they’re given, moving up to grading chance to use all of the processes cov- been fairly steady with 10–12 students
based on the visual acceptance criteria ered, the welding students pick one or during the fall and 6–8 students dur-
two processes to use for qualification ing the spring semesters — Fig. 4. Ad-

80 WELDING JOURNAL / NOVEMBER 2018


Fig. 5 — The laboratory carries a variety of welding machines to prepare students
for anything they may encounter in the field. A — Classroom with welding simula-
tors; B — welding shop.
ditionally, McMullen has continually
worked to increase enrollment by go-
ing to local high schools to recruit,
even though most of these schools of-
fer very limited to no welding courses.
The hard work has been met with suc-
cess stories. Several of SBC’s welding
graduates have gone on to work in the
construction/building trades field. For
example, a recent welding graduate is
now working as a manufacturing
welder in Bismarck. Realizing the po-
tential, plans are being initiated to
lengthen the program.
“This year, I will be working to
implement a second semester ad-
vanced certificate course, which will
give students the freedom to either
look for work after completing the
first certificate or stick around for the
advanced certificate,” said McMullen.
“This also gives previous students who
have had a chance to spend some time
in the job market to come back and re-
focus their study to a specific area or
process and build on skills they’ve
already developed.”
Welding students are also focused
on achieving their qualifications
through AWS and have only one se-
mester to do so. Expanding the pro-
gram from one to two semesters will
allow students to go on more job sites
without a tight time frame.
McMullen added that the program
is also working to become an AWS
SENSE Level II school. He hopes this
feat will bring even more credibility to
what they are accomplishing at SBC.
Welding Facility Offers a
Variety of Machines
The welding laboratory at the col-
lege has been designed to facilitate
the students’ learning. The 1280-sq-ft
facility contains an attached 900-sq-ft
classroom. The classroom includes two
Lincoln Electric VRTEX® welding sim-
ulators — Fig. 5A. The shop includes
NOVEMBER 2018 / WELDING JOURNAL 81
seven cross-flow ventilated welding
booths, three Miller Electric XMT®
350 welding machines, and from Lin-
coln Electric, two Power Wave® 350s,
two Flextec® 350Xs, a Square Wave®
TIG 200, and two Ranger® portable
units — Fig. 5B.
“We have tried to keep as much va-
riety in the shop as possible to encom-
pass anything a student may en-
counter once they leave. We even
utilize suitcase wire feeders on some
of our [welding machines], since that
is common to find in many construc-
tion and repair applications,” said
McMullen.
The machines run from the most
high-tech welding machines to the
tried and true standard. For personal
protective equipment, students are
provided with a Lincoln Electric Tradi-
tional Welding Gear Ready-Pak® as
part of their tuition.
The Instructor Behind
the Program
The welding program runs on the
fuel of its instructor. With the pro-
gram working to fill the industry with
its students, McMullen uses his ex-
pertise to teach his students the in-
dustry — Fig. 6.
“Having very little formal training
as a teacher, I run the program more
like I am training people in the field
and on a job site than really a class-
room,” he said.
McMullen began welding in high-
school but never really thought of it as
a career.
“At 24 years old, I found myself
married with a two year old and a baby
on the way. We were barely scraping by
with me working construction in my
hometown of Klamath Falls, Ore.,” he
said.
McMullen decided to take welding
courses at Klamath Community Col-
lege, and immediately started looking
for work upon completion.
McMullen was first hired at P&H
MinePro, which is now Komatsu Min-
ing Corp., in Gillette, Wyo., doing re-
pair work on shovels and draglines in
coal mines. After two years, he moved
on to Wyoming Machinery Co., the lo-
cal Caterpillar Inc. (CAT) dealer. This
time, he was contracted to the Black
Thunder mine doing frame repair
mainly on offroad mining trucks.
“With CAT, I worked closely with
their engineers on several large proj-
ects since the mine was a proving
ground for prototype equipment,” he
explained.
Due to a slump in coal, McMullen,
along with more than 1500 miners
and contractors, was laid off. This un-
fortunate event led him to SBC’s
doorstep.
“My friend had been trying for a
couple of years to get me to move and
start teaching at Sitting Bull College.
He lives in the area and felt I had a
knack for teaching, since I was the guy
who trained most of the new hires be-
fore being laid off. I applied and ac-
cepted the teaching position with real-
ly very little formal teaching experi-
ence,” he explained.
Since being hired, McMullen has
earned a career and technical educa-
tion teaching certificate for welding
technology from Valley City State Uni-
versity and Bismarck State College. He
has also earned AWS Certified Welding
Instructor and Certified Welding Edu-
cator certifications.
Establishing Partnerships to
Build Future Welders
Given the remote setting of the
school and the area, in general, the
welding program has faced challenges,
specifically exposing its students to
real-world experiences in the industry.
“We have been trying very hard to
get work placement/apprenticeship
agreements going,” said McMullen.
“But there is some new industry mov-
ing in locally that should help with at
least temporary work placement or a
kicking-off point for our students to
get some form of experience as soon
as they leave.”
Many of the students recruited stay
locally and are hired to do part-time
work, such as repairs and projects, for
local ranchers and other members of
the community in which they live.
Where this may not be considered tra-
ditional job placement or employment,
McMullen is happy they are utilizing
the skills they learned in the class-
room and lab to help bring needed
skills to the area, including the tribal
work department and local trans-
portation.
The students give back to their
community by doing projects such as
building an anti break-in door latch to
help protect the equipment for the
wildland fire crews. They’ve also done
repairs to bumper mounts, stair
mounts, gates, and more for Standing
Rock Public Transit. For the tribal
82 WELDING JOURNAL / NOVEMBER 2018
Fig. 6 — Welding Instructor McMullen
explains how to examine a finished
weld for proper bead profile and travel
speed.
roads department, the welding pro-
gram repaired and rebuilt snow plow
mounts for their plow trucks. At SBC’s
own maintenance department, the
program have completed several
equipment repairs and fabrication
projects.
“We repaired a bunch of old cast-
iron wood stoves that were donated to
the local Catholic Church. This semes-
ter, we will be rebuilding a handicap
ramp for one of the local offices. I am
also working with our preengineering
course to design a welded metal sculp-
ture of some sort that students can
work on that will be installed on cam-
pus,” McMullen said.
McMullen is working to keep ex-
panding the program. He continues to
reach out for support and interest
from the local industry to expose his
students to the welding field.
Another challenge the program
faces is the lack of donations, especial-
ly with rising material costs.
“I actually began looking for dona-
tions after talking with both Bismarck
State and NDSCS colleges, because
they rely heavily on donations. How-
ever, in my search for donations, even
utilizing the contacts provided by both
of these other programs, our requests
have gone unanswered and even un-
replied to,” said McMullen.
As for funding, the program has
been able to work under a Department
of Labor grant for the past few years.
Other grants have been applied for to
continue to, or help, fund the welding
program. McMullen conveyed the
school’s willingness to try and keep
the program running as long as possi-
ble even if the grants do not go
through.
“The value of the program for the
students and community is fully un-
derstood by our administration. Our
biggest concern, and really the main
reason for seeking the material dona-
tions to begin with, is simply to keep
the program as cost effective as possi-
ble and not to have to raise tuition
rates, which could very easily make
many students unable to participate in
the program,” said McMullen.
From the start, SBC and McMullen
never lost sight on the most important
aspect of the program, and that is to
arm its students with the training and
skills necessary to succeed in the
workforce.
“My hope for our students moving
on is that we can provide them with a
source of confidence and accomplish-
ment even if they don’t go into the
welding field,” he affirmed.
For many reasons, career training
programs at a reservation is different
than these programs elsewhere. Mc-
Mullen knows what the success of this
program means to not just the stu-
dents or the tribal college, but to their
tribal land as well.
“It means independence, hopefully
bringing manufacturing and jobs to the
area as we progress forward so that lo-
cals don’t have to go to Bismarck for a
good job, and so that local residents are
not at the mercy of outside contractors
from 75–100 miles away when they
need repair work done or something
built,” he said. “Many times it can take
weeks and/or a lot of money to get any
type of welding repair done. It can be
done here on the reservation by people
trained here on the reservation, moving
the people of Standing Rock closer to
the end goal of independence as op-
posed to dependence.” WJ
To inquire about the welding pro-
gram or ways to donate, contact Joe
McMullen, welding instructor, Sit-
ting Bull College, at (701) 854-8066
or joe.mcmullen@sittingbull.edu.
ROLINE PASCAL (rpascal@aws.org) is
assistant editor of the Welding Journal.
 FACT SHEET
Introduction to Arc Welding Power Sources
Fig. 1 — Shown are the basic elements of an arc welding power source.
Welding has a long and rich history. Commercial arc weld-
ing is more than a hundred years old, and scores of processes
and variations have been developed. Over the years, power
sources have been produced or modified by equipment manu-
facturers in response to the changes and improvements in
these processes. As welding processes continue to evolve, pow-
er sources continue to provide the means of controlling the
welding current, voltage, and power.
Fundamentals of Arc Welding Power Sources
The voltage supplied by power companies for industrial
purposes — 120, 230, 380, or 480 V — is too high for use in
arc welding. Therefore, the first function of an arc welding
power source is to reduce the high input or line voltage to a
suitable output voltage range, 20 to 80 V. A transformer, a
solid-state inverter, or an electric motor-generator can be
used to reduce the utility power to terminal or open-circuit
voltage appropriate for arc welding.
Alternatively, a power source for arc welding may derive
its power from a prime mover, such as an internal combus-
tion engine. The rotating power from an internal combus-
tion engine is used to rotate a generator or an alternator for
the source of electrical current.
Welding transformers, inverters, or generator/alternators
provide high-amperage welding current, generally ranging
from 30 to 1500 A. The output of a power source may be alter-
nating current (AC), direct current (DC), or both. It may be
constant current, constant voltage, or both. Welding power
sources may also provide pulsed output of voltage or current.
Some power source configurations deliver only certain
types of current. For example, transformer power sources
deliver AC only. Transformer-rectifier power sources can de-
liver either alternating or direct current, as selected by the
operator. Electric motor-generator power sources usually de-
liver DC output. A motor-alternator delivers AC, or when
equipped with rectifiers, DC.
Power sources can also be classified into subcategories.
For example, a gas tungsten arc welding power source might
be identified as follows: transformer-rectifier, constant-
Excerpted from the Welding Handbook, Ninth edition, Volume 2, Welding Processes, Part 1.
THE AMERICAN WELDER
current, AC/DC. A complete description of any power source
should include welding current rating, duty cycle rating,
service classification, and input power requirements. Special
features can also be included, such as remote control, high-
frequency stabilization, current-pulsing capability, stating
and finishing current versus time programming, wave bal-
ancing capabilities, and line-voltage compensation. Conven-
tional magnetic controls include movable shunts, saturable
reactors, magnetic amplifiers, series impedance, or tapped
windings. Solid-state electronic controls may be phased-
controlled, silicon-controlled rectifiers or inverter-
controlled semiconductors. Electronic logic or microproces-
sor circuits may control these elements.
Figure 1 shows the basic elements of a welding power
source with power supplied from utility lines. The arc weld-
ing power source itself does not usually include the fused
disconnect switch; however, this is a necessary protective
and safety element.
An engine-driven power source would require elements
different from those shown in Fig. 1. It would require an in-
ternal combustion engine, an engine speed regulator, and an
alternator, with or without a rectifier, or a generator and an
output control.
Before the advent of pulsed current welding processes in
the 1970s, welding power sources were commonly classified
as constant current or constant voltage. These classifica-
tions are based on the static volt-ampere characteristics of
the power source, not the dynamic characteristic or arc
characteristics. The term constant is true only in a general
sense. A constant-voltage output actually reduces or droops
slightly as the arc current increases, whereas a constant-
current output gradually increases as the arc length and arc
voltage decrease. In either case, specialized power sources
are available that can hold output voltage or current truly
constant. Constant-current power sources are also known
as variable-voltage power sources, and constant-voltage
power sources are often referred to as constant-potential
power sources. These fast-response, solid-state power
sources can provide power in pulses over a broad range of
frequencies. WJ
NOVEMBER 2018 / WELDING JOURNAL 83
NEWS OF THE INDUSTRY
— continued from page 15
Alexandrov, Department of Materials Science and Engineering,
The Ohio State University, Columbus, Ohio; and Judith Schnei-
der, Department of Mechanical and Aerospace Engineering, The
University of Alabama in Huntsville, Huntsville, Ala.
Interest in STEM, Technical Careers
Raise Female Ranks at Ranken
Summer Camp
Ranken Technical College’s Summer Adventure Academy ex-
poses youth to technical education, including welding. This
year, girls filled almost half of the heavy metals camp. (Photo
courtesy of Ranken Technical College.)
The student makeup at Ranken Technical College’s Sum-
mer Adventure Academy was a pleasant surprise this year.
Females represented 25 to 50% of camp participants.
Ranken, St. Louis, Mo., opens its doors for several weeks
every summer to hundreds of middle- and high-school stu-
dents to spur their interest in science, technology, engineer-
ing, and mathematics (STEM), as well as encourage their de-
cisions to pursue technical careers. This year, of the 123
84 WELDING JOURNAL / NOVEMBER 2018
middle schoolers participating in the camps, 42 were girls.
In particular, the heavy metals (welding) camp was popular.
High-school students were offered different programs.
Of those 142 participants, 38 were females. A camp dedicat-
ed to women in engineering was filled. Other top choices
among female high schoolers (25–40%) were robotics and
racing along with design and engineering.
The program, which charges minimal fees and offers
scholarships, is funded in part by a National Science Foun-
dation grant and many local donors.
Industry Notes
• The welding technology program at Texas State Techni-
cal College in Harlingen was ranked number seven this
year as one of the best welding programs in the United
States by Washington Monthly, a bimonthly nonprofit mag-
azine in Washington, D.C. “Instructors give 110% of them-
selves every day to ensure that our students are successful,
and this recognition goes to show how their work and dedi-
cation has paid off,” said Welding Technology and Precision
Machining Technology Lead Instructor Isaac Gonzalez.
• The National Association of Manufacturers’ Manu-
facturing Institute, Washington, D.C., is expanding its
service member training program into Fort Hood, Tex.
While 80% of manufacturers report difficulty filling open
positions, more than 200,000 service members return to
civilian life each year in search of a new career. The Heroes
MAKE America program connects them to modern manu-
facturing by providing skills and helping them find a job.
• The National Institute of Standards and Technology,
Gaithersburg, Md., has awarded a grant to Senvol, New
York, N.Y., for continuous learning for additive manufactur-
ing processes through advanced data analytics. Work will
focus on demonstrating data analytics can be applied to
additive manufacturing data to establish process-structure-
property relationships. Senvol will also parameterize in-
situ monitoring and nondestructive examination data.
• Sussex County Community College is adding a second-
ary location to provide students interested in career and
technical programs, such as welding, a place to gain hands-
on experience. A former car dealership in Newton, N.J., will
be renamed the McGuire Technical Education Center. The
new welding technology program will provide pupils with
the knowledge to gain employment either as an entry-level
technician in the field or work in adjacent fields.
• All four Solar Atmospheres facilities, located in eastern
and western Pennsylvania, California, and South Carolina,
have obtained certifications to AS9100 Revision D and
ISO9001:2015. “A key portion of this latest revision high-
lights the need for top management’s commitment and risk
assessment,” said Edward Engelhard, corporate quality
manager. He added that the company has a daily commit-
ment to quality vacuum thermal processing. WJ
WELLDIN
D uN
JournG
rna
al 2019 Editorial Calendar
CLASSIFIEDS

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NOVEMBER 2018 / WELDING JOURNAL 87

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88 WELDING JOURNAL / NOVEMBER 2018


SUPPLEMENT TO THE WELDING JOURNAL, NOVEMBER 2018
Sponsored by the American Welding Society
Microstructure Evolution and Solidification
Cracking in Austenitic Stainless Steel Welds
Using a novel quenching technique to simultaneously reveal
microstructure evolution and induce cracking, a new fundamental
understanding of solidification cracking was gained
BY P. YU, K. J. THOMPSON, J. MCCARTHY, AND S. KOU
ABSTRACT
Two austenitic stainless steels representing different re-
sistance to solidification cracking were investigated: 304,
which solidifies as -ferrite dendrites (bcc), and 310, which
solidifies as austenite  dendrites (fcc). They were quenched
during gas tungsten arc welding with liquid Wood’s metal (at
75°C). Quenching induced much more cracking in 310 than
304, consistent with the much higher crack susceptibility of
310 observed in conventional solidification cracking tests. In
304, the L +  +  reaction consumed interdendritic liquid (L)
and formed  continuously between -ferrite dendrites,
bonding the dendrites together to resist cracking. In 310, the
L +  +  reaction did not form continuous -ferrite to bond 
dendrites together to resist cracking, and the  dendrites
were coarse with long, straight boundaries to make cracking
easy to occur. The well-known room-temperature mi-
crostructure consisting of vermicular/lacy -ferrite in a ma-
trix of , which often exists in welds of austenitic stainless
steels with good crack resistance (such as 304), was not
found in the mushy zone, neither in 304 nor 310. This mi-
crostructure, though widely used to explain the crack resist-
ance, cannot resist cracking because it does not even exist
in the mushy zone, where solidification cracking occurs dur-
ing welding. The present study demonstrated that, to under-
stand solidification cracking in austenitic stainless steels, re-
vealing the elevated-temperature microstructure of the
mushy zone during welding is much more useful than exam-
ining the room-temperature microstructure of the fusion
zone after welding.
KEYWORDS
• Solidification Cracking • Austenitic Stainless Steel
• Alloy 304 • Alloy 310 • Microstructural Evolution
• Gas Tungsten Arc Welding
https://doi.org/10.29391/2018.97.026
WELDING RESEARCH
Introduction
Austenitic stainless steels are known to be susceptible to
solidification cracking, cracking that occurs inside the
mushy zone during welding and leaves behind open cracks
in the fusion zone of the resultant weld. The mushy zone is
a weak semisolid region immediately behind the advancing
weld pool (Ref. 1). According to Novikov (Ref. 2), cracking
during solidification is caused by obstructed shrinkage. The
higher density of the solid metal than the liquid metal caus-
es the solidifying mushy zone to shrink. For instance, solid
aluminum is 6.6% higher in density than liquid aluminum
(Refs. 3, 4). The thermal expansion coefficient of metals
also causes the solidifying mushy zone to shrink, but to a
lesser extent. However, the mushy zone cannot shrink freely
because it is connected to the workpiece, which is much big-
ger and more rigid than the mushy zone. Tight clamping of
the workpiece can make it worse. Obstructed shrinkage can
induce significant tension in the lateral direction of the
mushy zone to cause cracking. Cracking occurs along grain
boundaries during the terminal stage of solidification,
where a small amount of liquid remains along grain bound-
aries, enough to keep grains from bonding together but not
enough to fill the intergranular space (i.e., crack) formed
when the grains are separated under tension.
Solidification Cracking of Austenitic
Stainless Steels
Various factors affecting the crack susceptibility of
austenitic stainless steels have been investigated (Refs.
5–11). In general, as shown by Masumoto et al. (Ref. 6),
austenitic stainless steels tend to be less susceptible to solid-
ification cracking if the primary solidification phase (the
first solid to form from the liquid) is -ferrite (bcc) instead
of austenite  (fcc). The widely cited review of Shankar et al.
(Ref. 5) summarized many factors that have been proposed
NOVEMBER 2018 / WELDING JOURNAL 301-s
WELDING RESEARCH
A ing between dendrites and increase the resistance to crack-
B tive heat transfer between water and stainless steel. So, Kou
C quench stainless steels during welding. It is a eutectic alloy of
Fig. 1 — A novel technique for quenching during welding: A
— Top view of weld pool and surroundings; B — side view; C
— quenching weld pool surroundings. Welding from below
the workpiece makes room for quenching. Gas lens keeps
liquid Wood’s metal from entering the torch. Wood’s metal
(70°C melting point) can be poured from a glass beaker and
separated from the quenched workpiece and gas lens in
hot water after welding.
to explain the beneficial effect of -ferrite on the cracking
behavior (Refs. 12–18).
Bonding between Grains to Resist
Solidification Cracking
Kou’s solidification model (Refs. 19, 20) showed the earli-
er dendrites bond together during solidification, the higher
the resistance to solidification cracking. Liu and Kou (Refs.
302-s WELDING JOURNAL / NOVEMBER 2018, VOL. 97
21–25) further showed in Al alloys, backdiffusion during so-
lidification (e.g., Mg in Al-4Mg alloy) can cause earlier bond-
ing. Bonding between growing grains can also play a signifi-
cant role in the solidification cracking of austenitic stainless
steels, as will be shown subsequently. However, unlike in Al
alloys, it can be affected significantly by the L +  +  reac-
tion during solidification.
Quenching Stainless Steels with Sn
Ice-water quenching of stainless steel during welding
does not work well because steam and bubbles prevent effec-
and Le (Ref. 26) first used liquid Sn to quench stainless
steels during welding. Sn quenching worked much better
than ice-water quenching and was also used by subsequent
investigators to study phase transformations in stainless
steels during welding (Refs. 27, 28). Matsuda et al. (Ref. 9)
used Sn quenching to study solidification cracking in stain-
less steels. This is the only solidification cracking study
known to the authors that revealed the mushy-zone
microstructure.
Experimental Procedure
A Novel Quenching Technique for Welding
To further improve quenching, Wood’s metal was used to
50% Bi, 26.7% Pb, 13.3% Sn, and 10% Cd by weight (Ref.
29). Like Ga or In, it melts at a very low temperature (70°C)
but is much less expensive. Because of the lower pouring
temperature of Wood’s metal (75°C) than Sn (300°C), Wood’s
metal quenching was much easier to conduct and significant-
ly more effective than Sn quenching. It revealed the mi-
crostructure more clearly and induced cracking more easily.
Figure 1A is a top view showing the weld pool and the
mushy zone behind it during the welding of an alloy (Ref. 1).
Figure 1B is a vertical cross section (through the weld cen-
terline and the axis of the tungsten electrode) showing the
position of the welding arc relative to the weld pool and the
mushy zone. Welding from below the workpiece provided
more room for quenching from above. Molten Wood’s metal
was poured onto the weld pool and its surroundings to
quench the mushy zone behind it, as illustrated in Fig. 1C.
The arc was turned off immediately after quenching. The
torch continued to travel for 2 to 3 s before it was stopped.
For comparison, welding was also conducted under identical
conditions without quenching.
About 50 mL of liquid Wood’s metal was held in a 100-
mL Pyrex glass beaker and poured at 75°C. With an ordinary
glove, the glass beaker can be picked up directly to pour
without using crucible tongs. After welding, the solidified
Wood’s metal was separated from the workpiece by heating
in hot water. This quenching technique was recently tried on
Al alloys (Ref. 25) because liquid Sn is too warm for quench-
ing Al. No elements in Wood’s metal were detected in the Al
welds. Wood’s metal quenching was further improved in the
present study, including the use of a gas lens to keep the
 WELDING RESEARCH

etched. In-situ x-ray diffraction by

A B
Fig. 2 — Vertical sections of ternary Fe-Cr-Ni phase diagram: A — Fe-18Cr-8Ni (close to 304
stainless steel), which solidifies as primary -ferrite (Ref. 34); B — Fe-25Cr-20Ni (close to
310 stainless steel), which solidifies as primary austenite  (Ref. 35).
Wood’s metal from entering and damaging the torch. Since
the Wood’s metal could be separated from the gas lens in hot
water, the same gas lens was used over and over again.
The chemical compositions of the 304 and 310 stainless
steels used are shown in Table 1. The workpiece was 102
mm (4 in.) long, 51 mm (2 in.) wide, and 1.6 mm (1⁄16 in.)
thick. Bead-on-plate gas tungsten arc welding without a
filler metal was conducted in the length direction of the
workpiece along its centerline. Direct current electrode neg-
ative (DCEN) was used with Ar shielding. The torch travel
speed was 1.35 to 1.48 mm/s (3.2 to 3.5 in./min), the weld-
ing current was 48 to 55 A, and the voltage was 7.8 to 10 V.
The arc length was initially set at 2.3 mm.
Analysis of Welds
The resultant welds were cut, polished, and electrochemi-
cally etched with a solution consisting of 60 g of oxalic acid
in 600 mL of water. For 304 stainless steel, the voltage was
10 V and the etching time 15 s. For 310 stainless steel, the
voltage was 5 V and the etching time 7 s. Mixed acids were
also used for etching, consisting of 10 mL HNO3, 20 mL
HCl, and 30 mL H2O. The etched samples were examined by
optical microscopy, with or without differential interference
contrast (DIC), and scanning electron microscopy (SEM).
The phases present in the microstructure were identified by
electron backscatter diffraction (EBSD). This was conducted
using a Thermo Scientific Quasor EBSD installed on a JEOL
JSM-7001F scanning electron microscope at Thermo Fisher
Scientific in Fitchburg, Wis. The samples were sequentially
hand polished down to a 20-nm colloidal slurry but not
synchrotron radiation, pioneered
by Elmer (Ref. 30) for studying
phase transformations during
welding, is an advanced tech-
nique. However, Wood’s metal
quenching is simple and inexpen-
sive enough to be used in any
welding lab. An additional advan-
tage is that it can induce solidifi-
cation cracking as well as reveal
microstructural evolution during
welding.
The composition analysis was
conducted by an electron probe mi-
croanalyzer (EPMA). SXFiveFE, a
state-of-the-art field emission
EPMA for quantitative analysis and
x-ray mapping at high spatial reso-
lution, was used (Ref. 31). Wave-
length dispersive spectrometers
(WDS), up to five, could be fitted
into the microprobe for high-precision quantitative analysis.
The beam was fully focused with an approximate diameter of
80–100 nm. The voltage and current were 8 kV and 20 nA, re-
spectively. The volume below the sample surface affected by
the beam was about 250 nm in diameter (Refs. 32, 33). The
samples were polished and very lightly etched.
Results and Discussion
For convenience of discussion, the vertical sections of the
ternary Fe-Cr-Ni phase diagram are shown at 74 wt-% Fe in
Fig. 2A for 304 (~ Fe-18Cr-8Ni) (Ref. 34) and at 55 wt-% Fe
(~ Fe-25Cr-20Ni) in Fig. 2B for 310 (Ref. 35). They show 304
solidifies as primary  and transforms to  upon further
cooling after solidification, while 310 solidifies as primary 
without postsolidification phase transformation.
Welds Made without Quenching
Figure 3A shows the fusion-zone microstructure of an un-
quenched 304 weld that was electroetched. It consists of a thin
dark-etching -ferrite in a light-etching matrix of austenite ,
either vermicular (also called skeletal) ferrite or lacy ferrite.
Figure 3B shows the fusion-zone microstructure of an un-
quenched 310 weld that was etched with mixed acids. The mi-
crograph, taken with DIC, shows light-etching  dendrites and
some dark-etching -ferrite. Unlike in Fig. 3A, -ferrite is ab-
sent from most areas occupied by . A minimum of about 5%
-ferrite is usually considered as a requirement for a weld of
austenitic stainless steel to resist solidification cracking.

Table 1 — Chemical Compositions of Stainless Steels Used in the Present Study (in wt-%)

C% Cr% Ni% Mn% Si% Cu% Mo% N% P% S%

304 0.055 18.17 8.07 1.00 0.045 — — 0.048 0.031 0.002

310 0.05 25.55 19.22 0.84 0.57 0.22 0.25 0.0 0.02 0.001

NOVEMBER 2018 / WELDING JOURNAL 303-s

WELDING RESEARCH
A 1), Fig. 3A and B suggest the microstructure of
B quenched and electroetched. As shown by Fig. 4A,
C width of the mushy zone. The main crack runs
Fig. 3 — The -ferrite content in welds of austenitic stainless steels: A —
304 showing vermicular/lacy  in ; B — 310 showing a little  but not ver-
micular/lacy ; C — factors explaining the beneficial effect of microstruc-
ture consisting of vermicular/lacy  in , summarized from the review by
Shankar et al. (Ref. 5).
304-s WELDING JOURNAL / NOVEMBER 2018, VOL. 97
Since 304 stainless steel is known to resist so-
lidification cracking much better than 310 (Ref.
vermicular/lacy  in  is associated with the good
resistance to solidification cracking. In fact, the
room-temperature, fusion-zone microstructure of
vermicular/lacy  in  has been widely used to ex-
plain the crack resistance of austenitic stainless
steels (Ref. 5). To the best knowledge of the au-
thors, the elevated-temperature, mushy-zone mi-
crostructure has not been shown so far in studies
on solidification cracking of stainless steels, ex-
cept for that by Matsuda et al. (Ref. 9) using Sn-
quenching. Figure 3C summarizes the factors that
have been proposed to explain the beneficial ef-
fect of the microstructure of vermicular/lacy  in
 on reducing solidification cracking (Refs. 5,
12–18).
304 Solidification Cracking
Figure 4 shows a 304 stainless steel weld
most of the liquid in the weld pool was pushed out
by Wood’s metal during quenching. Figure 4B shows
the mushy zone. Solidification cracking occurs
mainly in three different areas, as shown in Fig.
4C–E. Columnar dendrites of the primary solidifica-
tion phase -ferrite are clear in the mushy zone.
Cracking occurs mainly along boundaries between
dendrites, typical of solidification cracking. The
quenched pool boundary, that is, the beginning of
the mushy zone, is indicated by a white broken line.
A dark broken line indicates the beginning of the
postsolidification    phase transformation. It
forms  along boundaries between -ferrite den-
drites. In Fig. 4D, the distance between the two bro-
ken lines is 225 m, i.e., the maximum possible
across the entire width of the mushy zone and prop-
agates slightly beyond it.
Identification of Phases in 304 Mushy
Zone
Figure 5 shows a 304 weld quenched and
etched with mixed acids, which reveal  in the 304
mushy zone more clearly than electroetching. The
sample was prepared for electron beam backscat-
ter diffraction (EBSD) without etching. After
EBSD, it was etched with mixed acids and then
photographed. The micrograph in Fig. 5B is locat-
ed in the middle of the mushy zone, away from
the pool boundary. The broken line indicates the
beginning of  formation by the    phase
transformation after solidification.
The microstructure in the white box in Fig. 5B
is enlarged in Fig. 5C, and the corresponding
EBSD map is shown in Fig. 5D. The green areas in
Fig. 5D indicate -ferrite (bcc), and they corre-
spond to the main bodies of the -ferrite den-
 WELDING RESEARCH

Fig. 4 — Mushy zone microstructure of a 304 weld quenched and electroetched: A — Macrograph; B — mushy zone; C, D, E — mi-
crostructure near cracks.

NOVEMBER 2018 / WELDING JOURNAL 305-s

WELDING RESEARCH

drites in Fig. 5C. The blue areas

in Fig. 5D, on the other hand, in-
A B dicate austenite  (fcc). This sug-
gests the presence of  along the
boundaries between the -ferrite
dendrites. As can be seen in Fig.
5C, austenite  exists along the
boundaries between -ferrite
dendrites and is light yellow in
color. This is the  that forms
during the L +  +  stage of solid-
ification. The thin purple phase
in  is the residual liquid during
the L +  +  stage of solidifica-
tion that was quenched. Fu et al.
(Refs. 36–38) identified by TEM
the phases in a 304 stainless
steel that was quenched in water
during directional solidification
in an Al2O3 tube. They also
showed grain boundary  and
quenched residual liquid in .
Figure 6 shows the composi-
tions of the phases in the 304
mushy zone determined by
EPMA. As shown, the three phas-
es differ in the Ni content. The
Ni content is lowest in -ferrite
(~ 7 wt-%), higher in  (~ 8 wt-
D C %), and highest in the quenched
residual liquid (~ 9–11 wt-%). In
the studies by Fu et al. (Refs.
36–38), the Ni content was also
lowest in -ferrite (F), higher in 
(A) and highest in the quenched
residual liquid (L).

304 Microstructure
Evolution
Figure 7A shows a 304 weld
quenched and electroetched,
about 4 mm wide. The mi-
crostructure in the rectangular
box is shown in Fig. 7B and con-
tinued in Fig. 7C. As shown, mi-
crostructure evolution begins
with primary solidification L 
, that is, -ferrite dendrites
growing at the weld pool bound-
ary, which is indicated by the up-
per broken line in Fig. 7B. The
L +  +  reaction is next. In the
boxed areas in Fig. 7B, evidence
of this three-phase reaction can
Fig. 5 — Phases in the 304 mushy zone (etched with mixed acids): A — Macrograph; B — mi- be seen, as will be shown subse-
crograph in the boxed area in A; C — micrograph enlarged, showing  that formed along the
quently in Figs. 8 and 9. As indi-
boundaries between -ferrite dendrites during the L +  +  stage of solidification and resid-
ual liquid (purple, richer in Cr and Ni) that solidified upon quenching; D — EBSD map of C. cated by the two broken lines in
Fig. 7B, the mushy zone is at
most 275 m wide. The postso-
lidification    transformation

306-s WELDING JOURNAL / NOVEMBER 2018, VOL. 97


A tually, only a small amount of -ferrite is left, either as
B boundary  divides and surrounds the grain boundary
Fig. 6 — Compositions of phases in the 304 mushy zone deter-
mined by electron probe microanalysis (EPMA): A — Locations of
measurements; B — measured compositions.
WELDING RESEARCH
is the next microstructure evolution. The -ferrite den-
drites begin to transform to  (lower broken line). Even-
vermicular or lacy ferrite as can be seen in Fig. 7D, which
is located far behind the end of Fig. 7C. This microstruc-
ture is similar to that in the un-quenched weld in Fig.
3A. This indicates that the well-known microstructure of
vermicular/lacy -ferrite in  does not exist in the mushy
zone during welding but forms in the fusion zone after
solidification is over. Thus, it cannot resist solidification
cracking as often suggested.
Before leaving this section, it is perhaps worth men-
tioning that near the bottom of Fig. 7C, some  appears to
grow into neighboring -ferrite at an angle similar to the
angle of the  in the lacy ferrite in Fig. 7D. According to In-
oue et al. (Ref. 28), if the Kurdjumov-Sachs orientation re-
lationships, i.e., (-110)//(-111) and [-1-11]//[-1-10], ex-
ist between -ferrite and , the - transformation occurs
along the  habit plane into-ferrite dendrites. Otherwise,
vermicular ferrite can form.
304 Crack Resistance
According to Fig. 2A,  can form when the three-
phase triangle L + +  is reached during solidification.
Both peritectic reaction and eutectic reaction have been
proposed for austenitic stainless steels (Refs. 28, 37).
The peritectic reaction is L +   and the eutectic reac-
tion L  + . However, it is not the intention of the
present study to determine which reaction occurs. For
convenience of discussion, both reactions will be called
the L + + reaction. Fu et al. (Refs. 36–38) observed
coupled / growth from undercooled liquid.
Figure 8 shows some dendrites in the middle of Fig.
7B. Between the two thick arrowheads is a grain bound-
ary between two columnar dendritic grains of -ferrite.
The L + + reaction causes  (light-etching) to form
continuously along the grain boundary. This grain-
liquid L (dark etching). The upper thick arrowhead is not
far behind the tips of the dendrites. This suggests the
grains are bonded together early during solidification to
resist solidification cracking.
The mushy-zone microstructure in the two dotted
boxes in Fig. 7B is enlarged in Fig. 9A, B. Two distinct
phases are visible along the grain boundary. The lighter-
etching continuous phase is , and the darker-etching
discontinuous phase (gold or brown in color) is the
quenched residual liquid. This microstructure is consis-
tent with Fig. 5C, which shows  and residual liquid coex-
ist along the boundaries between -ferrite dendrites.
The simultaneous presence of L, , and indicates the L
+ + reaction.
The SEM images of the microstructure in the boxed
areas in Fig. 9A and B are shown in Fig. 9C and D, respec-
tively. Continuous  forms along boundaries of -ferrite
dendrites to bond them together and divide/surround
the residual liquid, which appears to be etched out as
holes or grooves during electroetching. In the SEM im-
age of a 304 stainless steel quenched during directional
solidification and electroetched with oxalic acid,  also
NOVEMBER 2018 / WELDING JOURNAL 307-s
WELDING RESEARCH

appeared smooth, and the quenched

residual liquid was also etched out as A C
holes or grooves (Refs. 36–38).

310 Stainless Steel

Figure 10 shows a quenched 310

weld in which the phases present were
identified by EBSD. The weld was elec-
troetched, and the macrograph is
shown in Fig. 10A. As shown, signifi-
cant cracking was induced by quench-
ing, much more cracking than in the
304 welds. This is consistent with the
much higher crack susceptibility of 310
than 304 observed in conventional
crack susceptibility tests (Refs. 39, 40).
Thus, Wood’s-metal quenching can dis-
criminate the solidification cracking
susceptibility between different alloys.
However, the big crack along the cen-
terline, about 1.2 mm long, is obvious-
ly longer than the centerline of the
mushy zone. In other words, this solid-
ification crack propagates not just
through the entire mushy zone but
further into the fusion zone as a ductil-
ity-dip crack. Also, 310 stainless steel
is known to be susceptible to ductility-
dip cracking as well as solidification
cracking (Refs. 41, 42). Ductility-dip
cracking in stainless steels, however, is D
beyond the scope of the present study.
As mentioned previously, EBSD was
conducted without etching. After EBSD
the sample was etched with mixed
acids to reveal -ferrite. Figure 10B
shows the mushy-zone microstructure B
in the upper boxed area near the weld
pool in Fig. 10A. Figure 10C shows the Fig. 7 — Microstructural evolution in a 304 weld quenched and electroetched: A —
EBSD maps of the boxed area in Fig. Macrograph; B — mushy zone and    transformation; C — continuation from the
10B. Except for a few small dots, the bottom of B; D — far behind mushy zone and C, showing vermicular  and lacy  like
entire area is  (fcc). Thus, near the those in Fig. 3A.
pool boundary the mushy zone mi-
crostructure is mainly dendrites of . drites growing from the side toward the centerline of the
This confirms the primary- solidification mode of 310 mushy zone, Fig. 11C was taken by first shifting somewhat to
stainless steel, consistent with Fig. 2B. The dominating crys- the right. As shown by Fig. 11B, many primary dendrite arms
tal orientation (represented by red color) is <001>, which is (about a dozen) grow in the same direction. They belong to the
the easy growth direction of fcc metals. The microstructure same grain that grows essentially along the welding direction.
in the lower boxed area in Fig. 10A is shown in Fig. 10D, This indicates  dendrites tend to form coarse grains with
whose EBSD map is shown in Fig. 10E. Thus, the fusion- long, straight grain boundaries as shown more clearly in Fig.
zone microstructure consists of -ferrite in a matrix of . 10A by electroetching. These grains can promote solidification
This -ferrite forms by the L +  +  reaction. According to cracking because long, straight grain boundaries are easy for
Fig. 2B, there is no    postsolidification phase transfor- liquid to remain continuous and for cracks to propagate.
mation in 310 to form -ferrite from . In Fig. 11B, the location where liquid films disappear is tak-
Figure 11A shows a 310 weld quenched and etched with en as the end of the mushy zone and marked with a broken
mixed acids, again showing significant cracking. As compared line. This is because the mushy zone, by definition, is the re-
to electro etching, etching with mixed acids reveals -ferrite gion where solid and liquid both exist during solidification.
more clearly but the macrostructure of the weld less clearly. The mushy zone is about 440 m wide. This is significantly
The microstructure in the rectangular box is shown in Fig. 11B wider than the 304 mushy zone shown previously in Fig. 7B,
and continued in Fig. 11C. To also include some of the den- which is at most 275 m wide. The wider mushy zone of 310

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 WELDING RESEARCH

may also contribute to its higher crack susceptibility than 304.

Figure 11D shows the fusion-zone microstructure far behind
the box in Fig. 11A. Its similarity to that in Fig. 11C suggests
no postsolidification phase transformation, consistent with
the vertical section shown in Fig. 2B. It is also similar to that in
the 310 weld made without quenching — Fig. 3B.
Figure 12A shows the microstructure in the boxed area in
Fig. 11B. The residual quenched liquid (L) indicates liquid films
are present along boundaries of  dendrites, which are en-
larged in in the SEM image in Fig. 12C. Sometimes, Wood’s
metal might touch a long, continuous liquid film. Fig. 12B is
the microstructure in the boxed area in Fig. 11C, showing
elongated -ferrite particles along boundaries of  dendrites,
which are enlarged in the SEM image in Fig. 12D.
The microstructure evolution shown in Fig. 11 indicates
that the L +  +  reaction does not form continuous -ferrite
to bond  dendrites together or consume interdendritic liquid
enough to make it discontinuous. Thus, the L +  +  reaction
cannot help 310 reduce the high crack susceptibility caused by
its coarse  dendrites with long, straight boundaries. This ex-
plains its high crack susceptibility.

New Explanations for Crack Resistance vs. Old

Figure 13 summarizes the explanations for the resistance
to solidification cracking observed in welds of 304 and 310.
Based on the elevated-temperature microstructure of the
mushy zone revealed by quenching, the new explanation for
the good crack resistance of 304 stainless steel is shown in
Fig. 13A. It includes 1) the L +  +  reaction in 304 forms
continuous  along boundaries between  dendrites to bond
them together early during solidification, and consumes in-
terdendritic liquid to make it discontinuous, and 2) the
mushy zone is narrow.
The new explanation for the much worse crack resistance
of 310 stainless steel, as shown in Fig. 13B, includes 1) the
L +  +  reaction in 310 neither forms continuous  along
boundaries between  dendrites to bond them together nor
consumes interdendritic liquid significantly to make it dis-
continuous; 2) coarse  dendrites with long, straight bound-
aries help residual liquid remains as continuous films and
cracks propagate; and 3) the mushy zone is significantly
wider in 310 than 304.
The old explanations, on the other hand, are based on the
room-temperature microstructure of the fusion zone (Refs.
5, 12–18). As shown by Fig. 13C, a microstructure consist-
ing of vermicular/lacy  in a  matrix (Fig. 3A) is believed to
resist cracking well. However, Wood’s metal quenching
showed such a microstructure does not even exist in the
mushy zone (Figs. 7B and 4C, E), where solidification crack-
ing occurs. Thus, even though such a microstructure can
correlate well with good crack resistance (Fig. 3A), it cannot
explain solidification cracking. As for 310, as shown in Fig.
13D, the old explanation for its poor crack resistance is the
absence of such a microstructure.
Before closing, it should be mentioned that the results of
the present study do not necessarily contradict the constitu-

Fig. 8 — The -dendrites in Fig. 7B enlarged to show L +  +  reaction

forms continuous  to bond -grains along the grain boundary (between
two thick arrowheads) and divide liquid L to resist cracking.

NOVEMBER 2018 / WELDING JOURNAL 309-s

WELDING RESEARCH

C cracking by forming continuous  to

bond -ferrite dendrites together
early during solidification and con-
A suming the interdendritic liquid to
make it less continuous and hence
less able to separate the dendrites.
3. As shown by the quenched
welds of 304, the well-known mi-
crostructure consisting of vermicu-
lar/lacy -ferrite in a  matrix
forms in the fusion zone after so-
lidification is over — not in the
mushy zone during welding. This
microstructure (Fig. 3A), though
widely used to explain the crack re-
sistance of welds of austenitic
stainless steels such as 304, cannot
explain the crack resistance as
widely believed because it does not
even exist in the mushy zone,
D where solidification cracking occurs
during welding.
4. In 310, the L +  +  reaction
B neither forms continuous -ferrite
to bond  dendrites together nor
consumes the interdendritic liquid
enough to make it discontinuous.
To make it worse, the  dendrites
are often coarse with long,
straight boundaries to help liquid
films remain continuous and
cracks propagate.
5. Wood’s metal quenching can
induce much more cracking in 310
than 304, consistent with results
of conventional crack susceptibili-
ty tests.
6. The EPMA composition
measurements in the L +  +  re-
Fig. 9 — Bonding of -ferrite grains in the 304 mushy zone by  to resist cracking, which gion of the quenched 304 mushy
forms along grain boundaries by L +  +  reaction (electroetched): A — Left boxed area in zone showed the Ni content is low-
Fig. 7B; B — right boxed area in Fig. 7B; C, D — SEM image of boxes in A, B. est in -ferrite (about 7 wt-%),
higher in  (about 8 wt %), and
tion diagrams, such as Schaeffler’s diagram (Ref. 43) or the highest in the quenched residual
WRC-1992 diagram (Ref. 45). These diagrams are empirical liquid (about 9-11 wt-%).
data that correlate the solidification modes and the composi-
tions of the weld metals. The effect of the solidification modes Acknowledgments
on the solidification cracking susceptibility suggested by the
constitution diagrams can still be consistent with that ob-
served in the present study. This work was supported by the National Science Founda-
tion under Grant No. DMR 1500367 and the University of
Conclusions Wisconsin Foundation. The authors thank Dr. John Fournelle
of the Department of Geoscience, the University of Wisconsin,
Madison, Wis., for composition measurements by EPMA.
1. Wood’s metal quenching can be a useful novel technique
for studying solidification cracking in austenitic stainless steel
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B A

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mushy zone; C — continuation from bottom of B; D — far behind mushy zone and C, still showing  in the inter-
dendritic space between  dendrites, i.e., no evidence of postsolidification phase transformation. Compare with
304 in Fig. 7.

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A
C

D
B

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area in Fig. 11C; C — SEM image in boxed area in A; D — SEM image in the boxed area in B.
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A B

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PING YU, J. MCCARTHY, and SINDO KOU are, respectively, assistant scientist, adjunct professor, and professor in the Department of Materials
Science and Engineering, University of Wisconsin, Madison, Wis. K. J. THOMPSON is manager, Thermo Fisher Scientific, Madison, Wis.

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Exploring the Cooling Process for Residual
Stress Reduction in Dissimilar Welds
CO2 cooling is found to be an effective technique for eliminating
stresses in gas tungsten arc welding similar and dissimilar metals
BY H. EISAZADEH, E. A. PAYZANT, P. A. CORNWELL, J. R. BUNN, AND D. K. AIDUN
ABSTRACT
Dissimilar metal welds are currently used in various in-
dustry applications; however, a significant number of fail-
ures have been reported in these joints due to the exis-
tence of large tensile residual stresses induced by arc
welding processes. Hence, it is crucial to reduce or elimi-
nate such residual stresses in dissimilar metal welds. Re-
cently, modern techniques such as CO2 rapid cooling have
received attention by scholars to reduce residual stress in
similar metal welds. Nevertheless, the effectivity of this
technique has not been explored in dissimilar metal welds.
In this paper, the impact of in-situ rapid local cooling in dis-
similar metal welds is studied experimentally. The residual
stresses of CO2-cooled welds were measured using the
neutron diffraction technique. The effect of rapid cooling on
the microstructure of the weld and heat-affected zones
were examined. It is shown that for certain cases, in-situ
rapid cooling during the arc welding process can minimize
tensile residual stresses in dissimilar metal welds.
KEYWORDS
• Residual Stress Reduction • Dissimilar Metal Welds
• Rapid Cooling
Introduction
Residual stress (RS) induced by dissimilar metal welds
(DMW) is undesirable since it contributes to premature fail-
ures in welded structures. Hence, reducing RS in DMW is of
primary concern. A wide variety of techniques are intro-
duced for the reduction or modification of residual stress
distributions in similar metal welds, such as heat treatment
and peening processes. These are the common (convention-
al) techniques used nowadays, but their effectiveness on
DMW is still questionable (Ref. 1). In addition, not only do
such methods demand expensive equipment and energy, but
some of them, such as the heat treatment method, are not
applicable when a large welded structure is the case for RS
reduction.
Recently, two modern methods, so-called in-situ rapid
https://doi.org/10.29391/2018.97.027
WELDING RESEARCH
cooling (Ref. 2) and global mechanical tensioning (GMT)
(Refs. 3, 4), were designed to work against the formation of
RS during the welding process. These methods have received
significant attention over the past two decades because they
are more economical and effective compared to the conven-
tional methods. Particularly, the in-situ cooling method
sounds more promising than GMT because of its easy adap-
tation to industrial applications.
The RS reduction in the in-situ cooling method, as the
name suggests, can be achieved through modifying the ther-
mal field induced via welding by applying an external cool-
ing source. This method was introduced and implemented
by Guan et al. (Ref. 5), and was later named dynamically
controlled low stress non-distortion (DC-LSND) welding,
where an intense cooling source is applied behind the weld
pool (WP). This cooling source induces thermal tensioning
near the weld zone (WZ) and reverses the incompatible plas-
tic strain that occurs during the heating stage. The method
was also applied by others, Li et al. (Refs. 2, 6), to mitigate
RS and distortion. Both their experimental and numerical
outcomes indicated that the RS along the longitudinal direc-
tion was reduced by 50%. Moreover, the welding distortion
was entirely eliminated.
In their attempt to improve RS reduction in the welding
process, van der Aa et al. (Ref. 7) found that the cooling
source has to be tuned to generate intense cooling power
and be located as close to the WP as possible.
Through numerical modeling, Richards et al. tested the
DC-LSND method in friction stir welding (FSW) of AA 2024-
T3 plates. Richards et al. also concluded that the location of
the cooling source has a great impact on the amount of re-
duced RS (Ref. 8).
Over the last decade, the DC-LSND or CO2 cooling
method has been employed to reduce and eliminate RS and
distortions in welding processes (Refs. 9–11). However, at
present, the potential benefits of this technique have not
been explored on DMWs, where mixture of dissimilar metals
makes a fresh composition, and this consequently leads to
metal phase transformation.
This study focuses on the experimental implementation
of the CO2 cooling method for gas tungsten arc welding
(GTAW) of similar and DMWs. The RS distributions of in-
NOVEMBER 2018 / WELDING JOURNAL 315-s
WELDING RESEARCH
Fig. 1 — Schematic of CO2 welding.
situ rapidly cooled welds (using CO2) were investigated using
the neutron diffraction (ND) technique. Distortion in 304-
304 and 1018-1018 similar welds, and their dissimilar metal
welds (304-1018), were measured and compared with their
corresponding CO2-cooled welds. Microhardness and mi-
crostructure changes were also evaluated to explore the ef-
fect of the in-situ rapid cooling method at the microstruc-
ture level.
Experimental Method
CO2 Cooling (DC-LSND)
The technology developed by Li et al. (Ref. 6) was used in
this study to reduce the RS and distortion induced by the arc
welding process. The schematic used for this method is
shown in Fig. 1. In this method, a CO2 cooling source is em-
ployed during the GTAW process, which is located 40 mm
behind the welding torch. As the welding torch travels along
the weld path (shown by the red arrow), the cooling nozzle
travels at the same velocity along with the welding torch
while spraying the coolant on the surface of the hot metal
behind the WP.
It is necessary that the cooling source behind the welding
torch meets essential requirements. The first important key
is that it must be capable of cooling the hot region behind
the WP fast with a high cooling rate. The second key is that
the cooling source needs to be applied to a relatively small
area behind the torch to provide a typical temperature dis-
tribution — Fig. 2B. Additionally, it is crucial that the cool-
ing source does not interfere with the flow of the shielding
gas and the arc, otherwise the arc will become unstable.
As shown in Fig. 2, the highest temperature at the center of
the heat sources was approximately the same in both conven-
tional and CO2 welding processes. However, the temperature
behind the heat source for the case of CO2 did not drop
smoothly in the same pattern as the conventional welding
process, as shown by arrows in Fig. 2A and B, respectively. Fig-
ure 2B shows that a sharp temperature drop occurred behind
the peak temperature for the CO2 case. The steepness is de-
pendent on the power of the CO2 cooling source.
316-s WELDING JOURNAL / NOVEMBER 2018, VOL. 97
B
Fig. 2 — Typical temperature distribution: A — Conventional
GTAW; B — CO2 GTAW.
The generated power can be quantified by the uniform
convective cooling heat flux, qcooling. The heat flux (qcooling) be-
tween a hot plate at temperature, T, and the cooling source
can be described by Newton’s law of cooling:
qcooling = hcooling •(T – Tcooling) (1)
where the interfacial heat transfer (hcooling) and the cooling
source temperature (Tcooling) are two variables associated
with the cooling source characteristics. Based on Equation
1, the most effective coolant for the CO2 cooling method,
in terms of cooling source strength, should have a large
heat transfer coefficient (h), while having a low tempera-
ture (Tcooling). Some of the existing coolants are liquid argon,
liquid CO2, and liquid nitrogen. Among these coolants, liq-
uid CO2 is very notable and prominent because of its sub-
stantial latent heat during phase change. Since the phase
change of liquid CO2 takes place at atmospheric pressure,
the cooling power can be significantly high. Normally, the
CO2 is filled in tanks as a liquid at –18°C and 18 bar pres-
sure. While spraying this liquid out into one bar pressure
(atmospheric pressure), it turns into dry ice with a temper-
ature around –78°C. Such low temperature makes the CO2
one of the best coolants and cleaning agents for the CO2
cooling method.
 WELDING RESEARCH

A B

Fig. 3 — A — Dimensions and measurement directions of the specimen (dimensions are in mm); B — experimental setup for the
DMW with CO2 cooling and mechanical restraints.

CO2 Cooling Welding Temperature Measurements

Experiments were carried out with single-pass, autoge-
nous GTA butt joint welding of 1018 steel to 304 stainless
steel. Dimensions of the plates were 300 × 300 × 3 mm —
Fig. 3A. Compositions of these alloys are shown in Table 1.
The welding parameters (displayed in Table 2) were designed
so as to produce partial penetration, because no auxiliary ar-
gon gas was accommodated for weld protection underneath.
After welding, the specimens were allowed to cool for 2000
s. This time allows the weldments to cool completely to am-
bient temperature before being released from the fixture.
The active cooling source consisted of a CO2 snow jet that
followed the welding torch at a distance of 40 mm with the
same velocity — Fig. 3B.
In this research, there is a modest amount of practical de-
velopment on the CO2 cooling method. The nozzle and pow-
er of the cooling source were not varied in the present study.
In addition, the cooling source properties were not perfectly
constant for all welds because the setup was a home-made
apparatus. Consequently, there can be some variations in
cooling between the different CO2 weldments. The main
goal of this research was not to develop an ideal CO2 cooling
setup, but to prove its effectiveness in reducing tensile RS in
DMWs.
Temperatures were recorded during the GTAW process
using K-type thermocouples that were spot welded to the
upper surface of the plates. An array of three thermocouples
(T/C) was applied on a line perpendicular to the weld zone,
with distances of 30, 40, and 50 mm away from the weld
centerline. Measurements were taken during both conven-
tional and CO2 welding processes.
Stress Measurement Using the Neutron
Diffraction Method
In this study, the ND method was used to nondestruc-
tively measure the residual elastic stresses in the weld-
ments (Ref. 12). These measurements were performed us-
ing the High Flux Isotope Reactor at Oak Ridge National
Laboratory’s (ORNL) 2nd Generation Neutron Residual
Stress Facility (Ref. 16). At each measurement point, lat-
tice strains were calculated from the corresponding meas-
ured d-spacing changes in three orthogonal directions.
Then the stress fields were calculated from the strain val-
ues. Full details of this measurement are given elsewhere
(Ref. 12).

Table 1 — Chemical Composition of Steel Plates (wt-%)

Composition C Mn Si P S Cr Ni Balance Nieq Creq

1018 steel 0.13–0.20 0.30–0.90 0.15–0.30 0–0.04 0–0.05 — — Fe 6 0.3
(average)
304 stainless 0–0.08 1.7 0.52 0–0.045 0–0.035 18.9 7.5 Fe  10  20
(average)
1018-304 — 1.14 0.12 — — 7.58 4.32 Fe 7 8
WZ
(EDAX)

NOVEMBER 2018 / WELDING JOURNAL 317-s

WELDING RESEARCH

A B
Temperature

Temperature
Fig. 4 — Temperature measurement in conventional GTA DMW: A — 1018 side; B — 304 side.

A B

Temperature
Temperature

Fig. 5 — Temperature measurement in CO2 GTA DMW: A — 1018 side; B — 304 side.

Microstructure Study nificantly drop temperatures on both sides of the DMW

It is important to analyze the microstructure of the weld-
ments due to the increased cooling rate taking place using the
CO2 cooling method. Optical microscopy and microhardness
mesurements were used to identify the possible phases pres-
ent in the weldments.
even at locations 30, 40, and 50 mm away from the weld
centerline. Figure 5 shows that the temperature drop in the
1018 side is larger than that of the 304 side. This is because
the thermal conductivity of 1018 steel is greater than that
of 304. Hence, heating/cooling dissipation is faster in the
1018 weldment when compared to the 304 weldment.

Results and Discussions Effect of the CO2 Rapid Cooling Technique on

Weld Distortion
Figures 4 and 5 present temperature measurements of
conventional and CO2 welding processes, respectively. These Welding of thin base metals (BM) with low stiffness gen-
results show that the CO2 cooling was robust enough to sig- erally produces distortions due to formation of residual

Table 2 — GTAW (DCEN) Parameters Used in This Study

Arc Voltage Arc Current Electrode Diameter Arc Length Travel Speed Argon Gas
(V) (A) (mm) (mm) (mm/s) (m3/s)
18 150 2.4 1.5 4 0.0136

318-s WELDING JOURNAL / NOVEMBER 2018, VOL. 97


Fig. 6 — Distortion observed in similar and dissimilar metal welds; A — Conventional weld; B — CO2 weld.
plastic strains around weldments (Ref. 13). Different de-
grees of distortion can occur depending on the gradient
forces/moments caused by longitudinal and transverse
shrinkages (Ref. 14). In this section, curvatures, measured
along the longitudinal and transverse edges with a dial
gauge (see Fig. 3A), are addressed for both the conventional
and CO2 weldments.
Figure 6 depicts distorted weldments for conventional
and CO2 cooling along the longitudinal and transverse direc-
tions. As shown in Fig. 6A, a large distortion can be ob-
served in the conventional welding process of all three weld
cases, namely 1018-1018 similar, 304-304 similar, and 304-
1018 dissimilar weldments. Distortions in both directions
(longitudinal and transverse) are large. However, these
large distortions almost disappeared in the CO2-cooled
weldments for all three cases — Fig. 6B.
Figure 7 shows the measured values of distortion in longi-
tudinal (Fig. 7A) and transverse (Fig. 7B) directions with and
without CO2 cooling for the similar and dissimilar weldments.
From Fig. 7A and B, it can be concluded that CO2 cooling re-
duces the amount of distortion in 304-1018 DMWs from 3.5
to 0.5 mm for both longitudinal and transverse directions. It is
worth noting that if excessive cooling power is used in this
technique, it may reverse the direction of distortion. With the
employment of the CO2 cooling technique, a large positive cur-
vature in the longitudinal direction and a negative curvature in
the transverse direction, which are a result of volume expan-
WELDING RESEARCH
sion due to the formation of martensite in the 1018-304 WZ
(Ref. 12), were minimized.
Weld Microstructure
Figures 8 through 9 show microstructures of the WZ and
HAZ in both conventional and CO2 weldments. The BM of
the 1018 conventional weldment has microstructures of
mainly ferrite and some pearlite; the HAZ contains fine
pearlites due to the faster cooling rate, while the WZ con-
tains coarse ferrite/pearlite as a result of the intermediate
cooling rate — Fig. 8A and C. As depicted in Fig. 8B and D,
the microstructure of the HAZ and WZ in the 1018 CO2
weldment did not change to a degree where the difference
between conventional and CO2 welds was noticeable. Figure
9A and C show the microstructure of the conventional 304
weldment. It is well known that the microstructure of 304 is
mainly composed of single-phase austenite. It shows a
columnar dendritic structure within the WZ. Figure 9B and
D show that by implementing CO2 rapid cooling during the
welding process, the microstructure of the 304 similar weld-
ment was not significantly influenced.
Figures 10 and 11 show the microstructure of the 304-
1018 weldment in conventional and CO2 rapid cooling con-
ditions, respectively. According to the Schaeffler diagram
(Ref. 12), the WZ of the 1018-304 weldment is martensitic.
Similarly, it predicts that the WZ microstructure of the
NOVEMBER 2018 / WELDING JOURNAL 319-s
WELDING RESEARCH
Fig. 7 — Measured distortion in similar and dissimilar metal welds with and without CO2 cooling: A — Longitudinal; B — transverse.
1018-304 weldment made by the CO2 rapid cooling method
is also martensitic.
Microhardness Evaluation
Hardness profiles can assist the interpretation of weld
microstructure changes affected by the CO2 cooling tech-
nique. Microhardness tests were performed by measuring
values across the weld cross section, crossing both the HAZ
and WZ for the three cases (1018-1018, 304-304, and 1018-
304 weldments). The Vickers test was done with a load of
500 gf and a loading time of 10 s. Microhardness profiles
across the six weldments are shown in Fig. 12.
Figure 12A shows that the hardness of the similar 1018
weldments made by the conventional and CO2 rapid cooling
methods slightly increased from BM to HAZ to WZ. This is
due to the increase in density of the fine ferrite phase. Hard-
ness in the 304 weldments (Fig. 12B) made by the conven-
tional and CO2 rapid cooling technique showed very similar
values across both weldments. However, in the case of the
304-1018 weldments (Fig. 12C), a sharp increase in hard-
ness (about 200 HV) was seen from the HAZ to the WZ. The
reason behind this increase is the formation of martensite
320-s WELDING JOURNAL / NOVEMBER 2018, VOL. 97
in the WZ, which confirms the microstructure predicted
by the Schaeffler diagram. Implementation of CO2 rapid
cooling did not significantly influence the hardness
magnitude/distribution in the 1018 and 304 similar weld-
ments. However, it did affect the hardness of the 1018-304
weldment. No visible cracks were observed in all the welds
subjected to the CO2 rapid cooling process.
Residual Stresses
The main purpose of using the DC-LSND technique, such
as the CO2 rapid cooling process, is to reduce RS during the
welding process. The RS distribution for both the conven-
tional and CO2 cooling weldments, measured using the ND
technique, are shown in Figs. 13 to 16. It is important to
note that the accuracy of strain measurements by the ND
method is on the order of ± 50 , resulting in a RS resolu-
tion of ± 10 ~ 15 MPa.
According to Fig. 13A, the maximum longitudinal stress
of 300 and 350 MPa occurs in the WZ and the HAZ of the
304-304 weldment, respectively, which then decreases
sharply with the increasing distance from the weld center-
line. In the case of the 304-304 CO2 weldment (Fig. 13B),

A B
C D
Fig. 8 — Microstructure of conventional 1018 weldments,
etchant 2% nital.
A B
C D
Fig. 10 — Microstructure of the conventional dissimilar weld,
etchants 2% nital and 87% glyceregia.
the maximum longitudinal stress drops to 100 MPa in the
WZ. The asymmetric RS distribution across the 304-304
CO2 weldment is attributed to asymmetrical cooling due to
misalignment of the CO2 nozzle.
Figure 14 shows the distribution of RS across the 1018-
1018 conventional weldment (Fig. 14A) versus the 1018-
1018 CO2 weldment (Fig. 14B). In this case, the maximum
longitudinal RS drops from 400 to 200 MPa in the WZ by
the CO2 cooling technique. Also, a 100-MPa RS reduction
was observed in the transverse and normal directions for
the 1018 CO2 weldment. These results confirm the effec-
tiveness of the CO2 rapid cooling process for the 1018 simi-
lar weldments.
The magnitude of longitudinal RS in the 1018 similar
weld is larger compared to that of the 304 similar weld. Also,
the RS evens out with a smaller gradient in the 1018 similar
WELDING RESEARCH
A B
C D
Fig. 9 — Microstructure of the conventional 304 similar weld
(left) and 304 similar CO2 weld (right), etchant 87% glyceregia.
A B
C D
Fig. 11 — Microstructure of the CO2 DMW, etchants 2% nital
and 87% glyceregia.
weld. The reason is that 1018 alloy has a lower coefficient of
thermal expansion (CTE) and a larger yield strength (YS)
compared to the 304.
Generally, when a DMW is carried out, induced RS by the
arc welding process could produce different RS distribu-
tions, especially near the WZ — Fig. 15A. This is due to the
different CTE and YS of the base metals. Aside from materi-
al properties, the microstructure of the WZ in this DMW
can contribute significantly to RS formation near the fusion
boundary. It is shown that the microstructure of the WZ in
the 304-1018 weldment is mainly martensitic because of the
varied composition and rapid cooling (Ref. 15). When the
face-centered cubic (FCC) structure of the WZ (austenite)
transforms to the body-centered tetragonal (BCT) structure
(martensite) during cooling, a volume expansion is experi-
enced. This expansion produces a compressive stress within
NOVEMBER 2018 / WELDING JOURNAL 321-s
WELDING RESEARCH

the WZ; however, it induces a tensile stress to the surround-

ing area outside of the WZ. It is interesting to note that the
RS in the transverse direction undergoes a sharp increase A
near the WZ (± 5 mm). The reason for this drastic change is
again the existence of martensite at the top surface of the
WZ (Ref. 15). The question then becomes the following:
Why does experimental measurement show only tensile
stress near the weld center? Given that the ND facility at
ORNL measured only one phase on each side of the DMW
(FCC on the 304 side and BCC on the 1018 side), the stress
within the WZ, which is martensite (BCT), was not meas-
ured. It has been shown in previous numerical studies that
the overall stress within the WZ of the 1018-304 DMW is
mainly compressive (Refs. 12, 15).
Figure 15B shows RS distribution in the 304-1018 weld- B
ment exposed to the CO2 rapid cooling process. It shows
that RS reduction took place effectively in the longitudinal
and transverse directions, in which the RS dropped from
400 (Fig. 15A) to 250 MPa (Fig. 15B) and from 300 (Fig.
15A) to 100 MPa (Fig. 15B), respectively.
Several studies (Refs. 2, 7, 8) concentrated on the effec-
tiveness of DC-LSND on RS distribution in the past two
decades. With their experimental and numerical investiga-
tion, they successfully demonstrated that CO2 rapid cooling
is capable of reducing RS significantly if proper parameters
are used, such as distance between the cooling nozzle and C
the torch (arc), size of nozzle, and type of coolant. In this
study, implementation of this technique on the 1018 similar
weld can be another proof of principle.
In addition, the RS distribution of the 304 similar weld
under the CO2 rapid cooling condition conveys the same be-
lief, while neglecting the asymmetric behavior due to incon-
sistent experimental setup. Two common facts about all pre-
vious studies (Ref. 14) are that in-situ cooling was imple-
mented on welded samples that were neither DMW nor sub-
jected to undergo phase transformation. When similar metal
welds (1018-1018 or 304-304 welds) are carried out under
this rapid cooling condition, ideally the amount of RS re-
duced is constant through thickness (normal direction) if
these welds do not undergo any phase transformation. Fig- Fig. 12 — Microhardness profiles for welds made with and with-
ure 16A and B shows the schematics of the tensile and com- out the CO2 cooling method: blue circle — conventional weld;
pressive stress distribution inside and outside of the WZ for red rectangle — CO2-cooled weld.

A B

Fig. 13 — Longitudinal, transverse, and normal stress distributions in convectional 304-304 (left) and 304-304 CO2 (right) weldments.

322-s WELDING JOURNAL / NOVEMBER 2018, VOL. 97

 WELDING RESEARCH

A B

Fig. 14 — Longitudinal, transverse, and normal stress distributions in convectional 1018-1018 (left) and 1018-1018 CO2 (right) weldments.

A B

Fig. 15 — Longitudinal, transverse, and normal stress distributions in convectional (left) and CO2 cooling (right) of the 304-1018 weld.

similar and dissimilar metal welds.
In this study, application of the CO2 rapid cooling technique
was extended to 304-1018 DMWs, which have three phases:
ferrite in the BM, and the HAZ on the 1018 side; austenite in
the BM, and the HAZ on the 304 side; and mainly martensite
in the WZ. It is of interest to examine the interaction of these
phases with CO2 cooling welds. Normally, in the WZ of con-
ventional 304-1018 DMWs, martensite forms because of the
varied composition and rapid cooling. The martensite forma-
tion induces compressive stress within the WZ, resulting in
tensile stress to the surrounding area — Fig. 16C.
As shown in Fig. 16, dark arrows are a representation of
RS formed purely due to heating and cooling during the
welding process. However, the red arrows represent the
stress due to formation of martensite. It is believed that un-
der the rapid cooling condition, the magnitude of compres-
sive/tensile stress due to formation of martensite does not
change. All red arrows in Fig. 16C and D display the same
magnitude of stress. However, the black arrows outside the
WZ show that RS due to welding should drop with the im-
plementation of rapid cooling. These hypotheses were con-
firmed by ND measurements — Figs. 13 and 15. According
to these results, it can be concluded that the CO2 rapid cool-
ing technique is not only effective on similar welds, but also
effective on selected DMWs.
Conclusions
This study focused on the implementation of the CO2
rapid cooling technique on 1018 and 304 similar and 304-
1018 DMWs. For this purpose, a setup was designed at
Clarkson University, Potsdam, N.Y., to make welds under
controlled conditions.
The cooling source size and heat transfer coefficient could

NOVEMBER 2018 / WELDING JOURNAL 323-s

WELDING RESEARCH
Fig. 16 — Longitudinal, transverse, and normal stress distributions in the conventional weld and CO2 DMW (304-1018
dissimilar): A — Conventional weld; B — CO2 cooling weld; C — conventional weld; D — CO2 cooling weld.
not be changed. Spraying dry ice CO2 during welding resulted
in a drastic drop in temperature, localized at the cooling
source position. During the conventional welding process of
thin plates, the samples showed an out-of-plane deformation
and severe buckling deformation. Distortion of 304 and 1018
similar and their DMW were measured and compared with
their corresponding CO2 rapid cooled welds. It was experi-
mentally shown that the CO2 rapid cooling welding process
can be exceptionally successful in the elimination of buckling
distortion in thin plates.
The influence of such active cooling was investigated on
the microstructures of similar and DMW. In the 1018 and 304
similar welds, no significant influence of CO2 on the weld mi-
crostructure was found. However, this technique led to a
modest increase in hardness in the DMWs.
The RS distributions of conventional and CO2-cooled
weldments were investigated by ND technique. According to
these results, it can be found that the CO2 cooling technique
is not only effective on similar welds, but it is also successful
on DMWs.
Improvement of the CO2 rapid cooling technique is im-
portant to deliver the desired hardness and microstructure
in the DMWs.
Acknowledgments
This research used resources from the High Flux Isotope
Reactor, a Department of Energy Office of Science user facility
324-s WELDING JOURNAL / NOVEMBER 2018, VOL. 97
operated by the Oak Ridge National Laboratory, Oak Ridge,
Tenn. The authors would like to thank John Goldak for his
valuable suggestions.
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HAMID EISAZADEH is with the Mechanical Engineering Technology, Old Dominion University, Norfolk, Va. E. ANDREW PAYZANT, PARIS A.
CORNWELL, and JEFF R. BUNN are with the Chemical and Engineering Materials Division, Oak Ridge National Laboratory, Oak Ridge,
Tenn. DARYUSH K. AIDUN is with the Department of Mechanical and Aeronautical Engineering, Clarkson University, Potsdam, N.Y.

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