JANUARY 2019

Brazing &
Soldering
Today
2018 FABTECH
Recap
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
January 2019 • Volume 98 • Number 1 CONTENTS
FEATURES
32 The Peach State Welcomed FABTECH 2018
Attendees from around the world came to 32
network with other welding professionals, view
the latest product innovations, and experience a
wide array of educational opportunities
M. R. Johnsen et al.

BRAZING & SOLDERING TODAY

44 Brazing 101: Induction Heating
The basics of this heating method, often used 44 56
as a step in the brazing process, are explained
W. A. Morrison

50 Filler Metal Control in Sinter Brazing

The ability to join two components while
sintering has enabled the industry to broaden
its capabilities — K. H. Bear et al.

54 Brazing with Photochemical-Etched Amorphous

Filler Metal Preforms
Amorphous brazing foils in a range of
thicknesses are ideal candidates for utilizing the
photochemical etching process to manufacture
preforms — W. Coughlan and E. Theisen

56 Resistance Microwelding Best Practices in

Braze Setup
Resistance microwelding can be a useful and
powerful tool in brazing setup operations
J. Kapur

WELDING RESEARCH SUPPLEMENT

1-s The Mechanical Performance of Sn-Pb Solder
Joints on LTCC Substrates
This study evaluated the properties of a thin-film
metallization layer deposited on low-temperature
co-fired ceramic base materials — P. Vianco et al.
14-s Corrosion Behaviors of CMT Spot-Joined
AA6022-T4 to Galvanized DC03
Postweld e-coating of cold metal transfer welded
aluminum to steel joints provide a high level of
corrosion protection — H. Y. Lei et al.

JANUARY 2019 / WELDING JOURNAL 3

DEPARTMENTS
6 Editorial 64 Coming Events
8 Press Time News 67 Certification Schedule
10 International Update 68 Welding Workbook
12 News of the Industry 69 Society News
16 Business Briefs 70 Tech Topics
18 AWS 100 78 Section News
20 Stainless Q&A 92 Guide to AWS Services
22 RWMA Q&A 94 Personnel
26 Product & Print Spotlight 100 Classifieds
30 Point of View 101 Advertiser Index
Brazing & Soldering Today On the cover: Hand brazing an
60 Technology News aluminum evaporator coil
featuring Harris twin tips and
Aluxcor™ flux cored brazing rod.
(Courtesy of Harris Products
Group.)

OFFICERS WELDING JOURNAL

President Thomas J. Lienert
Consultant
Vice President Robert W. Roth
RoMan Manufacturing Inc.
Vice President W. Richard Polanin
WRP Associates
Vice President Dennis K. Eck
Praxair Distribution Inc.
Treasurer Carey Chen
Cincinnati Incorporated
Executive Director and CEO Matt Miller
American Welding Society
DIRECTORS
T. Anderson (At Large), ITW Welding North America
R. Ashelford (Dist. 13), Rock Valley College
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. A. Flood (Past President), Tri Tool Inc.
K. Fogleman (Dist. 16), Consultant
P. H. Gorman (Dist. 20), Retired
M. Hanson (Dist. 15), Consolidated Precision Products
L. Heckendorn (Dist. 7)
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. K. Miller (At Large), Lincoln Electric
S. Moran (Dist. 3), American Hydro Corp.
R. Purvis (Dist. 22), Purvis Welding Inspection
S. Raghunathan (At Large), Saudi Aramco
H. Record (Dist. 5), Townley Foundry & Machine
M. Sherman (Dist. 10), SW&E LLC
L. E. Showalter (Dist. 4), Newport News Shipbuilding
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), Retired
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
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inclusive practices, and engages its members and
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and celebrates differences among people. AWS
recognizes that a commitment to diversity, equity,
and inclusion is essential to achieving excellence
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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 / JANUARY 2019

EDITORIAL
AWS Members: We Value Your Feedback
Happy 100th birthday to the American
Welding Society (AWS)! As everyone surely
knows by now, 2019 marks the 100th year
anniversary of the founding of AWS. You will
see articles and other editorials on this topic
in future Welding Journal issues.
Now, let’s discuss the matter at hand. In
2016, AWS conducted a member survey
aimed at providing guidance for developing a
strategic plan for the 2017 to 2019 period.
The web-based survey involved questions on
the importance and performance of AWS
programs, opportunities, threats, and barri-
ers for growth. It was sent to various groups
of AWS stakeholders (~ 13,000), including
Section chairpersons, members of standing
T. J. Lienert and technical committees, welder members,
AWS President corporate members, student chapter advi-
sors, selected industry leaders, and AWS in-
ternational agents.
Members of the AWS board of directors
(BOD) and the Foundation board of trustees
were also included in the survey, as were
senior-level AWS staff. About 22% of all
stakeholders responded to the survey. Many
thanks to those who took the time to pro-
vide valuable feedback.
Results of the survey were subsequently
discussed by the AWS BOD and staff. Then,
we listened to you and used your feedback to
design improvements in several areas. More-
“In 2016, AWS over, many of the steps toward improvement
conducted a were incorporated into the strategic plan.
member survey One small detail that caught my eye in-
aimed at providing volved low scores by many respondents on a
question of the importance of the BOD in
guidance for helping AWS achieve its mission. Leadership
developing a strate- of the BOD interpreted this as a call to do a
gic plan for the 2017 better job in helping achieve our mission and
to 2019 period... to communicate more effectively with all
results of the survey members. In response, new and expanded
training courses have been developed and in-
were subsequently stituted for new BOD members, with a men-
discussed by the tor program for incoming members.
AWS BOD and staff. Survey responses involving issues related
Then, we listened to to customer service in certification and re-
you and used your newal were common. As a result, efforts are
feedback to design being made by AWS to improve testing, pro-
vide quicker turn around of exam results,
improvements in and broaden test accessibility through the
several areas.” implementation of a new IT system that has
the ability to submit and track certification
applications electronically. Moreover, migra-
tion to computer-based testing that will pro-
vide for more rapid grading, allow more con-
venient scheduling for tests, and will contin-
ue with the Certified Welding Inspector pro-
gram in 2019.
The shortage of properly trained welding
6 WELDING JOURNAL / JANUARY 2019
personnel was identified in the survey as one
of the top threats and barriers for growth for
AWS. The work by the staff and board of
trustees of the AWS Foundation in address-
ing this threat has been nothing short of
phenomenal. The number of scholarships
available to attract and retain students into
the welding field has exploded over the last
several years. By the end of 2018, the Foun-
dation will have awarded more than $1.2
million for that year alone. In addition, the
Foundation has initiated and awarded work-
force development grants.
Concerns over the level of exposure and
support of early career individuals were an-
other common theme from the survey.
These issues prompted developments in two
specific areas aimed at promoting greater en-
gagement of early career members with AWS
and the welding industry. The first involved
the formation of the AWS Diversity and In-
clusion Committee to ensure a diversity of
viewpoints reflective of the entire member-
ship, including early career members. The
second initiative is called the Future Leaders
Program. You may recall my recent editorial
on this topic in the September 2018 Welding
Journal. The program was begun to help de-
velop the next generation of AWS leaders,
and offers opportunities for early career
members of the welding community to inter-
act with members of the AWS BOD at their
board meetings. While only two participants
will be chosen for the program each year, we
envision the program will have a profound
and burgeoning effect on the participants
peers, colleagues, and coworkers back home.
So, why is this discussion pertinent? As I
write this editorial in late November, AWS
staff are preparing to send emails to each of
you with an invitation to participate in the
next member survey. This survey will now go
out to ~ 90,000 AWS members and stake-
holders (many more than the last one), and
several of the same questions used previous-
ly will be utilized again to allow direct com-
parisons with prior results. Findings of this
new survey will be used to gauge improve-
ments in areas discussed above (and others),
and will provide direct input to the revised
strategic plan (2020–2022). By the time you
read this editorial, “data crunching” will be
underway, and construction of aspects of the
new strategic plan will begin in February.
The takeaway message here is that AWS
values and appreciates your feedback, and is
using it to drive improvements at the Society
and the welding industry. We appreciate
your continued support. WJ
INTERNATIONAL UPDATE
Metal My Way Contest Winners Include
Dragon, Library Door, and More
Metal Supermar-
kets, Mississauga,
Ontario, Canada, a
small-quantity met-
als supplier, has an-
nounced the five
winners of the 2018
annual Metal My
Way contest. The
online contest show-
cased creative metal
projects from across
the United States,
Grand Prize Winner Damian Summer- Canada, and the
hayes, from Victoria, British Colum-
United Kingdom.
bia, Canada, impressed the Metal
My Way contest judges with his Here’s a list of the
fire-breathing dragon. award recipients,
along with their cate-
gories and projects:
• Grand Prize: Damian Summerhayes from Victoria,
British Columbia, Canada. His fire-breathing dragon was
made from round stock, sheet metal, and minimal tools, in-
cluding a grinder and welding machine, as well as expelled
real fire.
• Automotive and Vehicle Project: Bob Eyler of Alvin,
Tex., built a custom front-end loader using the chassis of an
old lawnmower and building out the frame using a variety of
metals.
• Around the Home Project: Brian Gingras of Woburn,
Mass., constructed a smoker trailer that featured two smok-
ers, a smoker/grill combo, hand sink with hot and cold run-
ning water, two-burner stove, folding stainless work table,
dry storage, and a propane fuel system.
• Industrial and Shop Project: Jacques Asselin-Kowalsky
from Ayr, Ontario, assembled an industrial heat exchanger for
a food processing plant. He used 306 Stainless Steel and other
high-pressure, high-heat stainless steels with processes includ-
ing gas tungsten arc welding, orbital welding with purging,
and acid treatment of welds.
• Art and Design Project: William Bush and John Miller
from Amsterdam, N.Y., fabricated an intricately designed li-
brary door. Created for the Carnegie Library, the door was
made using a 16-oz copper sheet, brass, and copper rods. It
was made entirely by hand.
The grand prize winner received a Weber Genesis II S-310
BBQ grill. The four category prize winners were each award-
ed a Lincoln Electric 180-A Weld-Pak® 180 HD gas metal arc
wire feed welding machines.
“We were thrilled with the response to this year’s contest
with a record number of projects submitted,” said Stephen
Schober, president and CEO of Metal Supermarkets. “We
love to see all the incredible projects people are working on
and think Metal My Way is a great platform to showcase
their work. We’re already thinking about how we can make
next year’s contest even bigger.”
Winning projects as well as hundreds of other submis-
sions can be seen on metalmyway.com.
10 WELDING JOURNAL / JANUARY 2019
EuroBLECH 2018 Attracts More Than 56,000
Visitors to Hanover, Germany
Digitalization set the tone at EuroBLECH 2018 with innovative
technologies for the sheet metal working industry.
The 25th International Sheet Metal Working Technology
Exhibition, EuroBLECH 2018, in Hanover, Germany, attract-
ed a total of 56,301 visitors from around the world to view
the latest innovations and digital technologies for sheet
metal working and to also invest in new manufacturing ma-
chinery. A total of 1507 companies from 40 countries exhib-
ited at the show. The theme of the exhibition was “Step into
the digital reality.”
“There was a noticeable technological advancement within
the last two years. Many exhibitors demonstrated how well the
industry is prepared for digitalization and how these new tech-
nologies can be used within a manufacturing environment,”
said Evelyn Warwick, EuroBLECH exhibition director.
A total of 58% of exhibitors were reported to come from
outside Germany at this year’s show. More than 70% of all
exhibitors stated that they intended to exhibit again at the
next EuroBLECH in 2020.
Southern African Institute Receives Robot-
Welding System from Yaskawa
Yaskawa Southern Africa, a Japanese automation and ro-
botic company, donated a complete robot welding system to
the Southern African Institute of Welding (SAIW) for its
new robot-welding training program. The program includes
the training of robotic-welding operators, skilled welders,
and welding engineers.
“What we are trying to achieve together with the SAIW is
to give students an opportunity to complete a basic welder
training course, whereafter those who obtain good marks in
their exams will be offered the opportunity to enroll in a ro-
botic welding course,” said Terry Rosenberg, Yaskawa South-
ern Africa chairperson and key account manager.
Rosenberg also mentioned that Yaskawa will train the
SAIW trainers, who, in turn, will train others. Upon gradua-
tion from robot welding school at SAIW, Yaskawa will offer
them an advanced course in robot-welding software
programming at its robotic academy in Longmeadow,
Johannesburg. WJ
NEWS OF THE INDUSTRY

Air Liquide Opens Advanced Fabrication
Center in Delaware
Air Liquide and its U.S. subsidiary, Airgas, recently inau-
gurated the Advanced Fabrication Center at the company’s
Delaware Innovation Campus in Newark, Del. The center
will focus on helping industrial customers adopt new manu-
facturing technologies and more efficient and cost-effective
production processes.
The center features dedicated “R&D studios” equipped
for specialized research and staffed with experts who will be
devoted to key segments such as welding and cutting, digiti-
zation and visualization, additive manufacturing, cryo-
assisted manufacturing, as well as robotics and cobotics au-
tomation. Utilizing the expertise at the campus, the center
opens its doors to original equipment manufacturers
(OEMs) to test state-of-the-art equipment and will serve as
a collaboration space for end-users, OEMs, as well as aca-
demic and research institutes, to develop and optimize new
fabrication technologies.
The Delaware Innovation Campus is one of five such cen-
ters the company operates around the world. The largest is
in France; the others are in Japan, Germany, and China.
By concentrating on metal fabrication, “this new lab rep-
resents a new area for us,” explained Michael Graff, chair-
man and CEO, executive vice president and executive com-
mittee member, Air Liquide S.A. He called the center an “in-
novation ecosystem” and added that it was developed to
“meet the needs of customers today and anticipate needs for
later.” In describing the staff at the Delaware campus, Graff
noted that it employed about 140 individuals from 20 coun-
tries of whom 50% hold PhDs. There is “deep technical tal-
ent” here, he said.
Graff explained the company has grown in recent years to
where revenue in 2017 was between $23 and $24 billion.
The United States represents 40% of the revenue base and is
the largest metal fabrication market in the world.
Andy Cichocki, Airgas chief operating officer, noted the
center is “an excellent example of opportunities available
through the combination of Air Liquide and Airgas.” (Air
Liquide’s acquisition of Airgas, one of the largest welding
distributor networks in the United States, was finalized in
May 2016.) Cichocki mentioned the skilled labor shortage
and how the work done at the Advanced Fabrication Center
will be able to help customers cope with that shortage.
Dave Lambert of Miller Electric Mfg. Co./ITW, said, “We
have a unique relationship with Airgas. We are both a suppli-
er and a customer.” Through both relationships, he added, “I
have witnessed Airgas’s commitment to solving customer
problems.” The new center is another venue for doing so, he
noted.
“The Innovation Center will bridge the gap with cus-
tomers who don’t have the time or personnel for research
and development,” explained Pascal Vinet, Airgas chief exec-
utive officer and Air Liquide executive committee member.
“This is what Air Liquide has always been about,” Graff
said. “We don’t celebrate the date the company started in
1902; we celebrate Innovation Day, the people who have
done the most innovation over the past year.”
— Mary Ruth Johnsen, publisher

Air Liquide and its U.S. subsidiary, Airgas, inaugurated the Advanced Fabrication Center at the Air Liquide Delaware Innovation
Campus. Ceremonially cutting the ribbon to open the center are (from left): Ron Stark, Airgas sr. vice president, sales and market-
ing; Olivier Letessier, Air Liquide vice president, research and development; Francois Darchis, Air Liquide sr. vice president and ex-
ecutive committee member; Michael Graff, Air Liquide executive vice president and executive committee member; Pascal Vinet,
Airgas chief executive officer and Air Liquide executive committee member; Andy Cichocki, Airgas chief operating officer; and
Bertrand Masselot, president, Air Liquide Canada.

12 WELDING JOURNAL / JANUARY 2019

 specific operator, so we take the variables out of the
process,” he said.
“Our students who are graduating with good technical
skills and the proper certifications have their choice of jobs,”
added Ronnie Teague, the district’s director of career and
technical education.

Westinghouse Utilizes Computerized

Plasma Transferred Arc Welding

The automated plasma transferred arc welding process by

Westinghouse uses powder instead of traditional solid rods.

Westinghouse Electric Co., Newington, N.H., has suc-

ceeded in the first application of its optimized process of ap-
plying hardfacing overlay for wear resistance through using
computerized plasma transferred arc welding.
The first two products that have been delivered were pro-
duced in one-third of the time it would take with conven-
tional methods, reducing the schedule to complete each by
several days. The automated plasma transferred arc welding
process uses powder instead of traditional solid rods and is
applied in consistent bands, which reduces the amount of
filler metal required, the need for postweld machining, and
the waste generated from both. The process can be applied
to many metals, including carbon and stainless steel, plus
nickel and cobalt alloys. In addition, it can be applied on
outside or inside surfaces on round products of more than
30 in. in diameter.

New $3-Million Program Could Help

Close Skills Gap in Advanced
Manufacturing
A skills gap that could leave as many as 2 million manu-
facturing jobs unfilled by 2025 is one of the driving forces
behind a program at Clemson University in South Carolina
that matches graduate students with technical college stu-

14 WELDING JOURNAL / JANUARY 2019

BUSINESS BRIEFS
TRUMPF to Open Technology Center on the
West Coast
TRUMPF will open a 20,000-sq-ft technology center in Costa
Mesa, Calif. The facility will offer operator and programmer
training, machine demonstrations, and technology seminars
to users in the western United States.
During FABTECH 2018, TRUMPF Inc., a global manufac-
turer in fabricating machinery and industrial lasers, an-
nounced that it will open a 20,000-sq-ft facility in Costa
Mesta, Calif., in early 2019. The new technology center will
be located within close proximity to the John Wayne Airport
in Orange County.
At the new center, West Coast customers will have the
opportunity to attend operator and programming training,
machine demonstrations, and technology seminars; experi-
ence the manufacturer’s latest technology advancements
and Industry 4.0 solutions for sheet metal fabrication; as
well as learn about the company’s TruServices and TruCon-
nect solutions for their manufacturing processes.
A 13,000-sq-ft showroom will be equipped with six
TRUMPF machines and a 650-sq-ft training room will be set
up to optimize customers’ knowledge and skillset on the
company’s equipment and TruTops software. Additional
space will be occupied by employee offices and customer
meeting rooms.
New Hampshire Honors Hypertherm for
Excellence in Work-Based Learning
Hypertherm,
Hanover, N.H., an
industrial cutting
systems and soft-
ware manufacturer,
has been honored
with the Work-
Based Learning
Award. New Hamp-
shire Governor
Chris Sununu pre-
Hypertherm’s Barbara Couch (far sented the company
right), with New Hampshire Governor and President of
Chris Sununu (second from left) and Hypertherm Own-
representatives from Lebanon High ers’ Philanthropic
School and Hypertherm, pose for a Endeavors (HOPE)
photo.
Foundation Barbara
Couch with the
award during a ceremony in Concord, N.H.
Couch was recognized for her leadership in promoting
16 WELDING JOURNAL / JANUARY 2019
work-based learning across the state, for encouraging associ-
ates to volunteer, and sponsoring events through the HOPE
Foundation. Hypertherm was recognized for its science, tech-
nology, engineering, and math (STEM) internship program for
high school seniors, as well as its SHAPE for STEM initiative,
which includes sponsorships of STEM camps and clubs for
middle and elementary school students, respectively.
“We are humbled by this award...it is of great strategic im-
portance to us that upcoming generations are engaged and ca-
pable in all areas of science, technology, engineering, and math
(STEM) and programs like SHAPE for STEM, combined with
giving through the HOPE Foundation, and volunteering by
our associates is one way we can do that,” said Couch.
Louisiana-Based Metal Shark Acquires
Alabama-Based Horizon Shipbuilding
Shipbuilder Metal
Shark, Jeanerette,
La., has acquired Ala-
bama-based Horizon
Shipbuilding. Metal
Shark’s new Alabama
yard is situated just
minutes from the In-
tracoastal Waterway
with access to the
Gulf of Mexico.
Pictured is a steel tug built by Hori- With the acquisition,
zon Shipbuilding on the 660-ton the Lousiana-based
Travelift at Metal Shark’s newly ac- shipbuilder assumes
quired Alabama shipyard. (Photo ownership of a 35-
credit: Metal Shark.) acre shipbuilding fa-
cility in the Mobile
Bay region, with sepa-
rate east and west yards fronting a dredged deepwater inlet.
The facility boasts a total of nine assembly buildings, a
660-ton Travelift, multiple cranes, CNC plasma cutting
units, welding machines, and other fixtures supporting the
construction of steel and aluminum vessels up to 300 in. in
length and 1500 tons launch weight.
“This acquisition will dramatically expand Metal Shark, as
we add an impressive Alabama facility to our growing portfolio
of shipyards and leverage Horizon’s expertise in the construc-
tion of steel vessels,” said Metal Shark’s CEO Chris Allard.
CGW-Camel Grinding Wheels Becomes
CGW Abrasives
Camel Grinding Wheels (CGW), Niles, Ill., a producer of
vitrified grinding wheels since 1956, has changed its name
to CGW Abrasives. With more than 140,000 sq ft of manu-
facturing and distribution space, the company also produces
resin grinding and cutting wheels, flap discs, coated abrasive
belts, and paper sanding discs.
We changed our name to CGW Abrasives to tell everyone
what we’re all about — abrasives,” said Mike Sullivan, presi-
dent. He added the company is the place where quality, per-
formance, and value come together. WJ
AWS AT 100

In celebration of the American Welding Society’s 100th

anniversary, here are some historical highlights of the
Society and industry

1919 Electric arc welding was starting to be used in the field

to make repairs on costly equipment. In the below right
When the United States entered World War I, American picture, a welder used bare wire steel electrodes to make a
industry needed to produce war and transport ships quickly repair in a steam shovel dragline bucket. The bare electrode
and in quantity. Welding, which at that time was a newly remained the main tool for electric welding until the early
emerging metal joining process, was called upon to meet 1930s when it started to be replaced by the covered or
those needs. President Woodrow Wilson asked Harvard Pro- shielded manual arc electrode.
fessor Comfort Avery Adams to chair the Welding Commit-
tee of the Emergency Fleet Corp.
Welding performed well in the war effort. That success
motivated Adams to bring together industry leaders for the
purpose of merging the Welding Committee of the Emer-
gency Fleet Corp. and the National Welding Council into a
new organization, the purpose of which was to provide de-
pendable and objective information on the developing tech-
nology of welding. On March 28, 1919, the American Welding
Society (AWS) was born. Adams served as its first president,
and, by year’s end, the Society had grown to 217 members.
AWS published the first Journal of the American Welding
Society in October 1919. Because of cost factors, only the in-
augural issue was published.
1922
A pipe laying crew
sets out for a day’s
work. Pipeline activity
had undoubtedly been
triggered by the 1918
and 1919 discovery of
the Panhandle natural
gas field in Potters
County, Tex., and the
Hugoton field in south-
west Kansas. The Pan-
handle field contained
1.6-million acres. By
1920, the first commer-
cially produced pipe
having electric welded
1920s longitudinal seams
made its debut in the
In the early 1920s, the Pressure Vessel Committee of the marketplace.
American Society of Mechanical Engineers evaluated numer- The first issue of the
ous methods for testing tanks made in the shop. On some Journal of the American
tanks, hand hammers were used, as specified in the Code. In Welding Society, now
the upcoming left photo, the blows were struck 3 in. apart known as the Welding
and within 2 or 3 in. of the joint at the rate of 50 to 60 per Journal, was published.
min. A 12-lb sledge, with a 24-in. handle was used on some of It has been in continu-
the tanks. In the end, it was found that the hammer test was ous publication since
only effective on tanks having exceptional defective welds. that time.

18 WELDING JOURNAL / JANUARY 2019

 Butt-joint welds and 1925
sleeve welds were used in
the fabrication of Philadel-
phia Electric Co.’s 2200-ft-
long steam line in 1922.
Electric welding was used
on 33 sleeve welds for the
flange joints, while the 92
butt joints were made using
oxyacetylene welding. The
entire line consisted of a
12-in.-diameter steam line
and a 3-in.-diameter water
return line.
The first AWS Welding Show was held in Boston, Mass.

1928

Code 1, Part A, was first

First AWS Education First AWS Annual Meet- published. This was the pred-
Committee established. ing held. ecessor of D1.1, Structural
Welding Code — Steel.

1924
The sign speaks for itself in this gathering of welding pro-
fessionals in 1924. The assemblage was about to board two
buses for tours of three facilities in Cleveland. The first was
the local utility where they witnessed oxyacetylene welding
of a 16-in.-diameter, high-pressure steam line. The next 1929
stop was a tour of the Collingswood Shops for the New York
Central Railroad. Third on the list was a visit to The Lincoln
Electric Co. The editor of the November 1924 Journal noted
the following: “This plant is taking its own ‘medicine’ in that
it is using welding wherever possible in the construction of
its motors and generators.”
In 1929, pipelines were
welded using the oxyacety-
lene process. The necessary
cylinders of oxygen and
acetylene are shown here be-
ing delivered by what could
very well have been one of
the earliest welding distribu-
tors in the United States.

Issuance of Welding and

AWS membership reached Nomenclature, Definitions and
the 1000 mark. Symbols. WJ

JANUARY 2019 / WELDING JOURNAL 19

as for the G 19 9 L — the steelmaking
practice does not produce 0% Si. The
Sandvik online datasheet indicates
0.4% Si as typical for its G 19 12 3 L.
The Mo story is the main difference —
the ER316L Mo range is 2.0 to 3.0%
while the G 19 12 3 L Mo range is 2.5
to 3.0%, within the ER316L range. The
tramp element limits for S and Cu are
more restrictive for G 19 12 3 L than
for ER316L. Most, if not all, European
filler metal producers list compliance
with ER316L and G 19 12 3 L wire re-
quirements. I contend that real com-
mercial ER316L and real commercial G
19 12 3 L are interchangeable.
There is another difference be-
tween the traditional AWS A5.9/
A5.9M classification designations and
the ISO classification designations
that came into the 2017 version of
AWS A5.9/A5.9M. This difference is
the indication of the product/process.
The traditional AWS product/process
symbol is either ER for round products
(wires or rods) or EQ for strip prod-
ucts. But the new ISO classification
designations that came into A5.9/
A5.9M can carry any of the following
for the product/process symbol:
• G for gas metal arc welding
• W for gas tungsten arc welding
• P for plasma arc welding
• S for submerged arc welding
• B for submerged arc strip cladding or
electroslag strip cladding
• L for laser beam welding.
There are no differences in compo-
sition when the product/process sym-
bol is changed. Accordingly, a small di-
ameter wire can be interchangeable
given G, W, P, or L. Larger diameter
wire would be given S. Cut lengths
would be given W. Strip would be giv-
en B. For the comparisons I made
above, I chose G for the discussion vs.
the traditional ER because GMAW is
by far the dominant process in terms
of consumption of solid stainless steel
filler metal. Interestingly, for example,
the Sandvik online datasheets for 19 9
L and 19 12 3 L wires do not use the
product/process symbol at all.
Before deciding if an ISO or Euro-
pean classification is interchangeable
with a traditional AWS A5.9/A5.9M
classification, one should look not
only at the composition ranges for
the respective classifications in the
specification, but also at the commer-
cial practice. In many cases, the suppli-
er’s datasheet will indicate compliance
with both the traditional AWS classifi-
cation and the ISO or European
classification. WJ
DAMIAN J. KOTECKI is president, Damian
Kotecki Welding Consultants Inc. He is
chair of the AWS A5D Subcommittee on
Stainless Steel Filler Metals, and member
of the 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, past treasurer of the IIW,
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.
JANUARY 2019 / WELDING JOURNAL 21
RWMA Q&A
BY ROGER HIRSCH

the circuit breaker setting for a rela-

Q: We started to install a new resistance welding machine that has a
tively long period of time.
built-in circuit breaker. The circuit breaker is marked 250 A. My electri-
Typically, a resistance welding ma-
cian says that the circuit breaker on our power panel that feeds this
chine uses a magnetic-only, high-
welding machine has to be at least 250 A. This seems very large for our
speed, trip-style circuit breaker. This
100-KVA welding machine operating on 440 V.
means that it will almost instantly trip
if the current going through it exceeds
A: The problem is that you are working panel that feeds this welding control is the breaker setting. It is designed to
with two different types of circuit a thermal type. This type of circuit protect the solid-state switch (SCR or
breakers. breaker is designed to trip (open) if IGBT contactor) from a catastrophic
The circuit breaker on your power the current going through it exceeds high-current short.
Typical setting of the magnetic-
only circuit breaker is three times
higher than the maximum expected
continuous current from the resist-
ance welding unit. This trip value is
set by turning a dial on the magnetic
trip circuit breaker. The 250-A rating
of this circuit breaker only says that
this circuit breaker’s mechanism can
sustain 250 A continuously, but does
not select what amperage will cause
the circuit breaker to trip.
One good sizing chart for resistance
welding machined is in the RWMA
Bulletin 16, Chart 1.7.15. This will se-
lect the appropriate fuse disconnect or
panel circuit breaker to back up a weld-
ing machine regardless of the magnet-
ic-only circuit breaker that is furnished
with the welding control.

Q: We just starting using our first

capacitive discharge (CD) resist-
ance welding machine. Does this
type of equipment require the same
water cooling as our standard spot
welding machines?

A: Capacitive discharge (CD) resistance

welding machines build a high-voltage
charge in a capacitor bank and then
dump this stored electrical energy
through the welding electrodes very
rapidly. Because of this, current con-
duction time is very short compared to
normal resistance welding. There is lit-
tle time to heat the actual electrodes.
As a result, many companies do not
use water to cool the electrodes. How-
ever, the secondary conducting com-
ponents should have some water cool-
ing. And if you are using very high cur-
rents, having some water cooling will
extend electrode life.
In addition, multiple CD welds can’t
be made as quickly since the capacitor
bank has to charge up between welds.
This allows more time for any heat
built up in the electrodes to dissipate.

22 WELDING JOURNAL / JANUARY 2019

Forge force = (50 × 78.50) = 3925 lb

Head weight: To either of these elec-

trode force numbers, you have to add
the dead weight of the moving welding
machine ram. This is the weight pro-
duced between the electrodes when all
air is removed from the machinery. For
larger welding machines, this can be
100 to 200 lb. The calculated value
should then match the actual force be-
tween electrodes during the weld and
forge portions of the sequence.

Q: We just built a welding machine

to weld filter bag frames (Fig. 2).
Twenty 18-in.-diameter wires form
the cage with rings spaced every 5
in. The first joining sequence is to
weld one end of each wire to the
inside of a drawn sheet metal end
cap. I have no problem welding the
rings, but securely welding the end
cap is a hit-or-miss proposition.
We are using a welding machine
with ten welding cylinders that are
in a radial positioning, and we weld
two opposite cylinders at a time
with an expanded mandrel on the
inside connected to one side of the
welding transformer. Each cylinder
welds two wires to the end cup
with the same electrode. The inside
expanding mandrel connects to the
other side of the welding trans-
former for direct welds.
Fig. 2 — Filter bag frame.
A: I looked at the drawing you sent
(Fig. 3) showing the ten welding guns
and electrode layout that joins two
wires per electrode. After discussing
the electrode geometry shown in 3A, I
found the first problem. If you look at
3A, you will see that the welding cur-
rent path is not directly from end cup
to wire but is through the surface of
the metal back to the wire. Change the
geometry of the electrodes to that
shown in 3B so that the current path
Fig. 3 — Weld gun arrangement.
is directly from cup to wire, and you
will see a major improvement in weld
strength and consistency.
Second, I was told that the firing
sequence has pairs of welding guns lo-
cated opposite of each other going for-
ward and welding at the same time.
For example, in Fig. 3, one weld se-
quence uses SV1 and SV6 guns at the
same time. By closing the electrodes
from opposite sides of the part, there
is no way to maintain full force be-
tween the inside of the end cup and
the wire. The end cup will not yield.
The answer here is to either close and
weld one electrode at a time or weld
two next to each other. This will allow
the end cup to float during the weld
sequence to keep full force between
the end cup and the wires.
Q: Our company just recently
changed over from arc welding of a
16-gauge cold rolled sheet metal
tool box to spot welding. Our first
100-kVA spot welding machine was
delivered, and we have not been
able to get good welds. The welds
either flash metal with deep holes
in the weld area, or they fall apart.
We made our own electrodes from
copper bar in our tool room and
think the shape is okay. Our weld-
ing schedule is the following:
3A 3B
Squeeze time = 60 cycles
Weld time = 49 cycles
Weld percent heat = 47%
Hold time = 25 cycles
Electrode force = 350 lb
A: You have two different problems.
First, electrodes have to be made from
special resistance welding alloy copper.
You are probably using C110 copper
rod. This copper does not have the al-
loyed material needed to maintain
shape under the high welding forces
and temperatures inherent in the re-
sistance welding process. Purchase
commercially available electrodes
made of RWMA Class 2 alloy for your
cold rolled steel welding.
The next problem is that your weld
time is way too long. You are trying to
melt the parts together. But by having
relatively low welding current from
the low heat % for a relatively long
time, you will just end up heating not
only the nugget area but also the met-
al around it. The resistance welding
process depends on high current for
the shortest possible time to create a
concentrated melt zone and good forg-
ing together of the two parts. You also
need enough electrode force to keep
the molten metal from blowing out
from under the electrode face (expul-
sion) and from between the sheets.

24 WELDING JOURNAL / JANUARY 2019

Handheld Brazing Machine Self-Monitoring System
Comes in Two Models Facilitates Compliance with
Heat Treatment Standards

easy to pick up and dump, especially if

using a forklift that has rotating forks.
The full depth of the legs also permits
the container to be stored on pallet The S.M.A.R.T. system helps ease
racking. The industrial, general- the stringent requirements of heat
purpose container showcases heavy, treatment standards like AIAG CQI9
corrugated steel sides and deck to and others that require data collection
The Perfect Flame® brazing machine maximize durability. Providing both as well as monthly or quarterly tests to
comes in two models to deliver consis- two- and four-way entries, the con- validate equipment performance. It
tent results for repetitive, high-volume, tainer is a cost-effective solution for saves furnace trend data like tempera-
handheld brazing applications. The bulk storage of parts. tures, belt and fan speed, along with
Model ST offers a single-torch configu- any other relevant data the customer
ration that allows the braze operator to Steel King Industries Inc. may want. Collecting the required data,
toggle between five different settings, steelking.com the system sends daily reports for
so that he or she can quickly switch be- (800) 826-0203 management review and has the ability
tween different preset flames for differ-
ent braze connections. Hands-free
technology allows the user to switch
between flames via a foot pedal, select-
ing up to five preset flames from a li-
brary of up to 100. This configuration
is ideal for the brazing operator who
has multiple but different braze joints
per job and needs to quickly adjust the
flame settings. The Model MT provides
a multi-torch configuration that is best
suited for high-production operations
where individual operators are brazing
the same or different joints. Three op-
erators can use the same or different
flames, each controlled by one Model
MT unit. Both models include torches,
tips, flow-control devices, and software
that work together to improve brazing
quality and increase productivity.

Harris Products Group

harrisperfectflame.com
(800) 733-4043

Industrial Containers Boost

Storage with Roll-Over Legs
The round corner container fea-
tures roll-over legs that allow it to be
stacked four containers high while
loaded. Made of 1⁄4-in. steel, the univer-
sal stacking legs make the container

JANUARY 2019 / WELDING JOURNAL 27

 to send text messages or emails to
maintenance or quality personnel. Re-
minders can be programmed for in-
strument calibration and annual ther-
mal uniformity tests. It also has the
ability to automate the system accura-
cy test and deliver the report via email.
Abbott Furnace Co.
abbottfurnaceco.com
(814) 781-6355
Pen-Sized Soldering Iron
Delivers Fast Heating
The portable and easy-to-use TS80
smart soldering iron provides accurate
temperature control and fast heating
speed. Its soldering tip uses a 3.5-mm,
gold-plated audio plug and an internal
thermal ceramic heating core. Through
pure copper-heat conduction, it can
quickly transfer heat to the soldering
tip. Its STM32 chip ensures smart con-
trol in the rise and fall of the tip tem-
perature. The pen-sized soldering iron
is equipped with a USB type-C power
jack, and can be directly powered by
power banks and a smartphone quick
charger. This makes it convenient
for bench working and field repairs.
Its controller is built with a CNC-
machined aluminum alloy shell, and
features a digital OLED screen display,
so users can monitor the status of the
soldering iron at a glance.
e-Design
miniware.com.cn
(8620) 83720503
Report Forecasts Growth for
the Global Brazing Market
Global Brazing Materials Market
2018 by Manufacturers, Regions, Type
and Application, Forecast to 2023 posits
that this market is expected to grow at
a compound annual growth rate of
roughly 3.3% over the next five years,
reaching $1380 million in 2023. The
28 WELDING JOURNAL / JANUARY 2019
146-page report identifies end-user
industries as major drivers, such as
the automotive, aviation, oil and gas,
electrical, household appliance, and
power distribution industries. Addi-
tionally, it states that the world’s
largest brazing enterprises are mainly
concentrated in Asia, but China’s pro-
duction technology is relatively slow.
As such, the country is mainly produc-
ing low-end products, causing it to rely
on import for high-end products. The
report also states that the following
barriers may make entry into the glob-
al brazing market difficult: product de-
velopment costs, capital requirements,
intellectual property rights, regulatory
requirements, and transition methods
of competition. However, it concludes
that the investors are optimistic de-
spite these barriers.
Market Study Report
marketstudyreport.com
(866) 764-2150
Report Analyzes the Global
2018–2023 Solder Market
Global Solder Market 2018 by Manu-
facturers, Regions, Type and Application,
Forecast to 2023 states that this mar-
ket is expected to grow at a compound
annual growth rate of roughly 0.3%
over the next five years, and will reach
$5900 million in 2023. The 149-page
report provides a basic overview of the
industry, including definitions, classi-
fications, applications, and industry
chain structure. It also offers an analy-
sis for international markets, includ-
ing development trends, competitive
landscape analysis, and development
status of key regions. Overall, the re-
port finds that China and North
America are the major production
bases of solder; the two regions con-
tributed about 72% share in the global
production market in 2017. As for
consumption, Asia-Pacific and North
America are also the major consumers
of this market, with a total share of
87% in 2017.
Orion Research Consultants
orionresearch.com
(415) 830-3727
Exothermic Cutting System
Features Upgrades
The Arcair® Slice exothermic cut-
WELDING JOURNAL
WELDING JOURNAL
WELDING JOURNAL
WELDING JOURNAL
WELDING JOURNAL
WELDING JOURNAL
WELDING JOURNAL
 WCM low-manganese elec-
trodes
suhner.com

TruLaser
Cell 5030

mo-
toman.com

weldcotemetals.com

Fig. 16 — The line of WCM low-

manganese shielded metal arc weld-
ing electrodes reduces manganese
emissions by up to 50%.
trumpf.com

ArcWorld
1200
Fig. 17 — The backside of Yaskawa’s
ArcWorld robotic welding cells has
been reduced in size.

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Fig. 15 — The TruLaser Cell 5030

comes equipped with a solid-state
TruDisk laser, flying optics, and NC
controller and motion unit. fabtechexpo.com

Plummer Lecture

JANUARY 2019 / WELDING JOURNAL 39

enhance flexibility as key attributes
for the increased use of robots and in-
telligent systems in various industries,
including e-commerce. Kara also
pointed out that the manufacturing
industry’s need to automate and move
goods quickly will continue to fuel the
use of robotics. Looking ahead, he list-
ed robotic exoskeletons as the future
of manufacturing, as “companies ex-
plore how to integrate human opera-
tors with the strength and endurance
of industrial robots.”
Aaron Kaufman, owner of Arclight
Fabrication autoshop and television
personality on Discovery Channel’s
Shifting Gears, concluded FABx with
anecdotes on how he began working in
manufacturing, as well as how he con-
tinues to strive in the industry. Ac-
cording to Kaufman, to be the best,
one must never become complacent, FABx Tech Talks inspired attendees with six motivational speeches on innovation.
but must always work to be better Pictured (from left) are FABx speakers Aaron Kaufman, Dan Kara, Eric Wilson, Charlie
than he or she was the previous day. Covert, Julia Crews, and Dennis Adamovich.
He also stressed fearlessness as an es-
sential attribute, always saying “yes” building cars, I was always in the same portunities for me,” he explained.
to new opportunities, and networking circle. When I got into racing, I met “There are advantages to meeting new
across various industries. “When I was new people and that opened new op- people who have more experience.”

Expert Panel Discusses Gen Z and the

Manufacturing Workforce
It’s a fact: Millennials will make up
the majority of the workforce in com-
ing years. FABTECH 2018 presented a
lively discussion with a panel of ex-
perts to share their perspective and
help companies understand how to
adapt and attract this new generation
of employees. Titled “Manufacturing
and the New Generation Workforce,”
topics covered included best practices
in areas such as creating a culture of
care, communication, engagement,
technology, and teamwork.
The panel of experts were David
Stillman, generations expert and best
selling author; Jacob Wilson, CEO,
Morrison Industries; and Lee Ann
(Schwope) Cochran, vice president of
sales and marketing, PRADCO; along
with Jonah Stillman, moderator and
Gen Z ambassador (see lead photo).
Jonah Stillman led the panel with
his first question: “What needs to hap-
pen to put the industry in the Gen Z
radar?”
Cochran responded that the first
organic step is to bring man (industry)
to the digital world. Wilson agreed
adding that companies need to be
good at PR and marketing because
“Gen Z is not reading the newspaper.”
He asserted how companies have had
success in employing young people by
using social media platforms such as
Facebook.
David Stillman asserted that de-
tailed communication is key. Essential-
ly, explaining what a typical day would
be like in the job’s position, from the
moment he or she clocks in until
clock-out stating, “Don’t just describe
what the job does, but what they [Gen
Z] will be doing on a daily basis.”
Another talking point was engage-
ment. What will it take to engage mil-
lenials? Wilson responded, “Don’t just
stick them to entry level. Show them
and make sure that they are part of
something important.”
Cochran believed that engagement
should be looked at differently to
make an impact for millenials. “En-
gagement is being excited to go to
work,” she said. “They should want to
get up and go to work everyday.”
The idea of figital, fear of missing
out from not being on a digital device,
was another topic of discussion. Jonah
Stillman explained Gen Z has been
categorized as digital natives and
asked the panel, “What is currently
the biggest trend in your industry that
will not work with Gen Z? Is there
anything you’ve heard of that is hap-
pening in your industry that will not
necessarily be appealing to the next
generation that is changing?”
Wilson used an example in the suc-
cess he has had in his company em-
ploying young people, while explaining
the new generation does not want to
simply “go through the motions” and
be “a number on a piece of paper.”
Cochran looked at the question
through a different perspective. She

JANUARY 2019 / WELDING JOURNAL 41

 A panel of experts, led by (from left) Moderator Jonah Stillman, Gen Z ambassador; David Stillman, generations expert and best
selling author; Jacob Wilson, CEO, Morrison Industries; and Lee Ann (Schwope) Cochran, vice president of sales and marketing,
PRADCO, shared their perspective on how to adapt and attract this new generation of employees.
stated, “Even as a Gen X-er, we have
people that have been in industries for
a very long time. After you’re in it for
5, 10 years or so, you kind of start to
know everyone, and I think that’s go-
ing to change with Gen Z.” She went
on to explain that millenials will not
work in a specific marketplace for 5,
10, 15, or 30 plus years. They are go-
ing to want change, and they are going
to want to figure out how to solve dif-
ferent problems across marketplaces.
“It’s going to be important for us to
think about how that industry knowl-
edge is shared, how associations and
societies are growing because of that,
and making sure that data is accessible
to brand new members within a mar-
ket space or an industry or someone
that’s been there for a long time,” she
concluded.
David Stillman chimed in explain-
ing that although he does not work in
the industry, he has worked with the
industry long enough to know that in
manufacturing and family-owned
42 WELDING JOURNAL / JANUARY 2019
businesses, oftentimes he hears, “It’s
the way it’s always been done.” While
previous generations have been okay
with the response, as he goes on to
state, “We are going to have a genera-
tion that’ll say, ‘I don’t think this is go-
ing to work. Just because it’s not bro-
ken in their eyes doesn’t mean it can’t
be better.’” He added that industries
need to explain how it’s done and why,
but to also be prepared for a genera-
tion that might have some input,
whether they’ve been in the company
for two days or two years, and to wel-
come the input.
Afterwards, Jonah Stillman opened
the floor to questions from the audi-
ence. One individual brought up a con-
cern regarding the lack of industry ex-
posure in schools. He said, “Agricultur-
al arts is not given an option in high
schools. How can that be changed?”
Jonah Stillman wholeheartedly
agreed with the individual’s observa-
tion as he related his high school years
and the little to no exposure to agri-
cultural arts. Most schools place stu-
dents success on getting accepted into
a four-year college. “If you don’t go to
a four-year college, you’ve failed as a
high school student. The four years
was a waste,” he said. He went on to
implore companies to reach out to the
schools and have students go on tours,
career fairs, and so on. “It’s up to you
to go to the schools because the
schools won’t do it,” he ended.
A recurring message throughout
the session was communication. The
panelists agreed that the new genera-
tion can and will connect with the pre-
vious generation because they want to
learn. It’s up to the industry and the
new generation to be open to change,
technology, and understanding each
other’s points of view. WJ
MARY RUTH JOHNSEN (mjohnsen@aws.org)
is publisher, KATIE PACHECO (kpacheco@
aws.org) is associate editor, ROLINE PASCAL
(rpascal@aws.org) is assistant editor, and
CINDY WEIHL (cweihl@aws.org) is senior
editor of the Welding Journal.
BRAZING & SOLDERING TODAY

Brazing 101: Induction Heating

BY W. ADAM MORRISON
The basics of induction brazing are
provided to dispel common misconceptions

I
nduction heating is a well-estab-
lished heating method that many
still consider new technology. Al-
though induction heating technology
is approaching 100 years of commer-
cialization, questions and misconcep-
tions surrounding its application still
exist. For example, one common mis-
understanding is that induction heat-
ing will only heat magnetic compo-
nents. However, induction heating can
be used to heat any electrically con-
ductive material.
It is also important to consider
both brazing and induction heating as
separate and different processes to un-
derstand and apply them. Brazing is a
joining process, while induction heat-
ing is a heating process that is often
used as a single step of the brazing
process.
Numerous texts and studies have
been published about brazing and
other metal-joining techniques. It is
not the intent of this paper to present
all the details associated with brazing
processes. Instead, general rules of
thumb will be presented for a detailed Pictured is an induction coil with a brazed tube and flange.
discussion on induction heating tech-
nology. This article also addresses magnetic field is generated by an alter- key difference associated when heat-
common misconceptions of induction nating current (AC) being passed ing a magnetic part vs. a nonmagnetic
heating in relation to its brazing- through an electrical winding (coil/ part. Magnetic parts, such as iron,
related applications. inductor). Induction heating is a non- have magnetic particles within their
contact heating method that is ex- atomic structure called domains.
Induction Heating Defined tremely fast and efficient when com- These domains are like small bar mag-
pared to other heating technologies nets. The domains physically align
Induction heating is a thermal used for brazing. themselves with the polarity of the
process in which an electrically con- magnetic field applied to the part. As
ductive material is placed within a Hysteresis Heating the magnetic field reverses, the do-
varying magnetic field and heated via mains physically reverse direction.
hysteresis (magnetic materials only) Induction heating can heat any This constant reversing of direction
and/or induced electrical current (all electrically conductive material, mag- results in internal friction heating.
conductive materials). The changing netic and nonmagnetic. There is one This heating through magnetic do-

44 WELDING JOURNAL / JANUARY 2019

BRAZING & SOLDERING TODAY

Filler Metal Control in Sinter Brazing

This method is applied to control the flow BY KYLE H. BEAR, GLENN RISHEL,
BRIAN SMITH, AND
and retention of the filler metal at the STEPHEN L. FELDBAUER

sinter braze joint

S
inter brazing has become a sig-
nificant tool in the manufactur-
ing of many complex powder
metal components. Although the com-
paction technology has advanced sub-
stantially over the years, the ability to
bond two components while sintering
has enabled the industry to broaden
its capabilities and remain competitive
in many markets.
The primary issue with the brazing
of two powder metal components, in ei-
ther the green or sintered states, is the
competition between the capillary ef-
fect that draws the filler metal into the
joint clearance and the capillary effect
produced by the porosity of the com-
pact, which results in the filler metal contact angle, and is the radius of the that is stronger than the base metal.
being pulled away from the joint clear- capillary. The joint clearance, through which
ance and into the part. If this filler met- There are a few key steps that must the filler metal is pulled via the capil-
al is pulled into the part, the bond may be followed to produce a good braze lary force and is a strong function of
be compromised or not formed at all. joint, as detailed below. the , must be 0.05 mm (0.002 in.) to
This article reviews the fundamen- 0.20 mm (0.008 in.) wide at the braz-
tals of brazing and applies them in a Surface Preparation ing temperature. This means that the
way that better controls the flow and
retention of the filler metal at the sin- When the filler metal melts, the Braze Filler Metal
ter braze joint. This is achieved by re- wetting of the filler metal is strongly
viewing key variables and their effect affected by the cleanliness of the sur-
on the wetting of the filler metal. The face — Fig. 1.
sintering atmosphere, flux content of Figure 1 shows the effect of a car-
the filler metal, and the density of the bon ring on the filler metal flow (AB-
components are all important to filler 72) on a carbon steel plate. If the sur-
metal control. face is not free of dirt, oxides, and oils,
the filler metal will not wet the base
Fundamentals of Brazing metal and will not be pulled into the
braze joint.
The fundamental driving forces for
the formation of a good braze joint are Braze Joint Design
the wetting of the base metal by the
filler metal and the capillary force that Proper braze joint design is critical
results and pulls the filler metal to achieving the desired strength in the
through the braze root opening, component. The total length of the
braze joint should be three times the Braze Joint Clearance
Capillary Force = 2 cos / thickness of the thinnest cross section
being joined — Fig. 2. This will ensure
where is the surface tension, is the that a good braze will result in a joint

50 WELDING JOURNAL / JANUARY 2019

WELDING JOURNAL
WELDING JOURNAL
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Authors from the National Re-
search Council (CNR)-ICMATE and Po-
litecnico di Torino-DISAT, Italy, inves-
tigated two approaches to joining SiC
to SiC: 1) infiltration of the opening
between adjoining materials by Al3Ti,
and 2) placing a 50-μm Ti foil between
the SiC surfaces coated with an Al3Ti
paste (Ref. 5).
Wetting of SiC by Al-3 at.-% Ti, Al-
25 at.-% Ti, and Al-46 at.-% Ti was
studied at 1500°C. All the studied sys-
tems exhibited good wetting; the con-
tact angles ranged from 10 to 14 deg,
and the kinetics lasted < 100 s. In con-
tact with SiC, the liquid Al3Ti formed a
well-bonded Ti3Si(Al)C2 interfacial lay-
er. The Al-C-Si-Ti phase diagram
demonstrated that the liquid Al-25
at.-% alloy (Al3Ti) formed some inter-
facial Ti3Si(Al)C2.
Interest in this particular phase is
largely explained by its unique combi-
nation of metallic and ceramic proper-
ties, such as its high melting point and
oxidation, wear, and irradiation resist-
ance. Moreover, its lattice matching to
SiC at basal and nonbasal planes
makes its presence appealing in the
brazed joint; and also because of its
lattice matching to SiC at basal and
nonbasal planes.
In addition, Ti3SiC2 has a unique
high-temperature plastic deformation
behavior at temperatures above 1200°C,
which can help to release thermal
stresses. Single lap offset tests showed a
relatively high shear strength of 296 ±
20 MPa for the joints manufactured by
capillary infiltration.
In-Situ Investigation of
Microwelding and Brazing
Aluminum Cast
A large chamber scanning electron
microscope (LC-SEM) was developed
as a tool suitable for the study of large
technological parts, so they would not
have to be sectioned. This approach
also allowed visual inspection and con-
trol of any micromechanical manufac-
turing, assembling, or the observation
of processes. Examples of this include
formation and solidification of the
melt of a tin-copper brazing filler on
an aluminum cast alloy, and laser mi-
crowelding of stainless steel, both
done at RWTH Aachen University,
Germany.
BRAZING & SOLDERING TODAY
It was possible by encapsulation in
a LC-SEM, for the first time, to ob-
serve in in-situ wetting experiments
all the stages of melting and wetting
of an aluminum alloy, that is, includ-
ing the removal of the alumina layer
directly in the electron microscope
(Ref. 6).
Subsequent analytical studies
would provide an accurate insight
regarding the composition of the
individual phases and their local
distribution.
The wetting experiments were as
follows: melt-spinned 78Sn22Cu
(wt-%) braze ribbons were placed on
an Al7Si0.3Mg (wt-%) aluminum cast
alloy. This was done at thixotropic
temperatures. At temperatures above
250°C, the shape of the soldering tape
began to shrink. This happens due to
sufficiently high surface tension. After
shrinking, the braze ribbon deformed
more and more into a partially liqui-
fied sphere, and this without wetting
the base metal. A probable reason for
the liquid filler metal not wetting the
aluminum in this context may be due
to the alumina layer on top.
At 380°C, the braze ribbon sudden-
ly began to flow on the substrate sur-
face. The braze material was almost
completely spread out at 390°C. There
it remained virtually unchanged dur-
ing the holding time of 30 min. The
SEM-energy-dispersive x-ray spec-
troscopy element maps revealed
that the tin spreads beyond the braze
point. It goes along the silicon-
enriched grain boundaries of the base
metal.
A New Method for
Bonding Alumina to TZM
A titanium-zirconium-molybdenum
(TZM) alloy in the form of polished
discs was joined, with alumina by an
unconventional and much shorter
process than brazing, at the University
of Limoges, Limoges Cedex, France
(Ref. 7).
The alloy was first preoxidized in a
furnace at 795°C in air for 30 min.
Then, it was hot pressed with alumina
at 1700°C in argon under pressure
(~ 22 MPa) for 3 h with heating and
cooling rates of 0.25°C/s. During the
first step of preoxidation, molybde-
num oxide attacked and sufficiently
roughened the alumina and TZM sur-
face such that the resulting irregulari-
ty, even without an interlayer, pro-
duced sufficient adherence after hot
pressing.
Because secondary phases, primari-
ly of the MoO2 type, penetrated into
both materials, holding them together
as if one was nailed to the other, the
resulting joints had relatively signifi-
cant adherence (> 45 MPa).
Typically, brazing is used for joining
these materials. In that case, ceramics
are coated with a layer, and possibly
with other layers, until a layer suitable
for joining with the metal part is top-
most. The issue is the cost of this
method, even if it produces relatively
high-strength joints. If joining as com-
monly done, the resulting assembly
cannot be used at high temperatures
because molybdenum trioxide has a
melting point at 795°C. That excludes
it from many important prospective
applications.
Something different was sought for
high-temperature applications where
good adherence is also necessary. The
TZM has a much higher 2620°C melt-
ing point, and the carbides of Zr and
Ti behave such that they increase the
recrystallization temperature of the
assembly. It also has thermal expan-
sion close enough to alumina. Molyb-
denum oxide attacked and sufficiently
roughened the alumina surface such
that the resulting irregularity, even
without an interlayer, produced suffi-
cient adherence. The fewer, simpler
steps involved make the process re-
duce typical industrial production
costs, but the hot-pressing use limits
the applications to flat pieces.
Thermal Fatigue on W-W
Brazed Joints for Divertor
Components
Plasma facing divertor components
of the DEMO fusion reactor are ex-
posed to thermal loads and neutron ir-
radiation. Therefore, brazed joints
should be tested accordingly to with-
stand the same conditions. The effect
of steady-state loads on the quality of
tungsten brazed joints by exposure to
different thermal loads was explored
by Rey Juan Carlos University,
Madrid, Spain, and Forschungscen-
trum Jülich, Germany.
JANUARY 2019 / WELDING JOURNAL 61
BRAZING & SOLDERING TODAY
Fe-14Ti powder mixture in the
form of transfer tape 250 μm thick
was used as the filler metal at brazing
temperature 1350°C. After brazing,
tungsten joints were brazed on top of
a copper cooling system by
Ag28Cu2Ge0.2Ni wt-% braze alloy at
850°C (Ref. 8). A high-heat flux test
was carried out by applying scanning
electron beam heating to the surface
of samples, while at the same time,
water was used as a coolant of the
cooling structure. Tested samples were
monitored with an infrared camera
during 100–1000 cycles.
The W-W joints exhibited 1000°C
surface temperature as a heat limit in
the DEMO reactor. The microstructure
of brazed joints was stable for all heat-
ing cycles, while the shear strength
dropped from 43 MPa after brazing to
26 MPa after 100 cycles and was not
deteriorated by further heat cycling.
Interfacial cracks appeared only during
heating to 1250°C, after 100 cycles.
62 WELDING JOURNAL / JANUARY 2019
This resulted in a significant drop of ting of SiC by Al-Ti alloys and joining by in-
strength down to 8 MPa. WJ situ formation of interfacial Ti3Si(Al)C2.
J. of the European Ceramic Society 38:
3727–3734.
6. Aretz, A., Ehle, L., Haeusler, A.,
Bobzin, K., Öte, M., Wiesner, S., Schmidt,
1. Lin, C.-Z., and Shiue, R.-K. 2018.
A., Gillner, A., Poprawe, R., and Mayer, J.
Vacuum brazing niobium using the clad
2018. In situ investigation of production
50Ti-35Ni-15Nb foil. Int. J. of Refractory
processes in a large chamber scanning elec-
Metals & Hard Materials 71: 206–210.
tron microscope. Ultramicroscopy 193:
2. Esmaeili, N., and Ojo, O. A. 2018.
Analysis of brazed effect on hot corrosion
151–158.
7. Berkouch, R., Valette, S., Absi, J., and
behavior of a nickel-based aerospace. Met-
Lefort, P. 2018. A new method for bonding
allurgical and Materials Transactions B 49B:
alumina to the alloy titanium-zirconium-
912–918.
molybdenum. J. of European Ceramic Society
3. Kral, M. V., Maher, C. M., and Mc-
38: 2462–2466.
Swain, R. H. 2018. Failure analysis of a
8. de Prado, J., Sanchez, M., Wirtz, M.,
brazed, stainless steel fuel injection line.
Pintsuk, G., Du, J., Linke, J., and Ureña, A.
Engineering Failure Analysis 88: 54–62.
2018. Impact of thermal fatigue on W-W
4. Benedetti, A., Gambaro, S., Valenza,
brazed joints for divertor components. J. of
F., Faimali, M., Colli, M., Hostasa, J., and
Materials Processing Technology 252:
Delucchi, M. 2018. Ag and AgCu as brazing
materials for Ti6Al4V-Y3Al5O12 joints: Does
211–216.
ennoblement affect the galvanic behavior
in seawater? Electrochemical Acta 283: Information provided by ALEXANDER E.
SHAPIRO (ashapiro@titanium-brazing.com)
155–166.
and LEO A. SHAPIRO, Titanium Brazing Inc.,
5. Valenza, F., Gambaro, S., Muolo, M. Columbus, Ohio.
L., Salvo, M., and Casalegno, V. 2018. Wet-


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COMING EVENTS
U.S., CANADA, MEXICO EVENTS
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64 WELDING JOURNAL / JANUARY 2019
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CERTIFICATION SEMINARS, CODE CLINICS, AND EXAMINATIONS CERTIFICATION SCHEDULE

Note: The 2019 schedule for all certifications is posted online at 9-Year Recertification Seminar for CWI/SCWI
aws.org/w/a/registrations/prices_schedules.html. For current CWIs and SCWIs needing to meet education re-
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at any site listed under Certified Welding Inspector.
Certified Welding Inspector (CWI)
Location Seminar Dates Exam Date Location Seminar Dates
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Phoenix, AZ July 7–12 July 13
Houston, TX Sept. 30–Oct. 4 Oct. 5
Nofolk, VA July 14–19 July 20
Milwaukee, WI July 21–26 July 27
Orlando, FL July 21–26 July 27 Certified Robotic Arc Welding (CRAW)
Cleveland, OH July 28–Aug. 2 Aug. 3 OTC Daihen Inc., Tipp City, OH; (937) 667-0800, ext. 218
Los Angeles, CA July 28–Aug. 2 Aug. 3 Lincoln Electric Co., Cleveland, OH; (216) 383-4723
Denver, CO Aug. 4–9 Aug. 10 Wolf Robotics, Fort Collins, CO; (970) 225-7667
Philadelphia, PA Aug. 4–9 Aug. 10 Milwaukee Area Technical College, Milwaukee, WI;
Chicago, IL Aug. 11–16 Aug. 17 (414) 456-5454
San Diego, CA Aug. 11–16 Aug. 17 College of the Canyons, Santa Clarita, CA; (651) 259-7800,
Salt Lake City, UT Aug. 11–16 Aug. 17 ext. 3062
Charlotte, NC Aug. 18–23 Aug. 24 Ogden-Weber Applied Technology College, Ogden, UT;
Sacramento, CA Aug. 18–23 Aug. 24 (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.

JANUARY 2019 / WELDING JOURNAL 67

WELDING WORKBOOK
DATASHEET 386

Introduction to Torch Brazing

Torch brazing is accomplished by heating the assembly
with a fuel-gas flame, using one or more gas torches. De-
pending on the temperature and the amount of heat re-
quired, the fuel gas (e.g., acetylene, propane, or natural gas)
can be burned with air, compressed air, or oxygen. Addition-
al information on torch brazing is presented in the Ameri-
can Welding Society (AWS) Standard C3.4.3, Specification for
Torch Brazing.
Manual torch brazing, totally without automation, repre-
sents the simplest brazing technique — Fig. 1. While torch
brazing is labor intensive and low in productivity, it has
some practical and economic justification. First, the braze
joint is visible to the operator, who adjusts the process based
on observation. Second, heat is directed only to the joint
area. This is an important consideration when energy costs
represent a large fraction of the cost of a brazed joint.
Equipment
torch brazing require fluxes. For certain applications, even
the self-fluxing copper-phosphorus filler metals require
added flux.
The brazing filler metal can be preplaced in the joint as
the joint is prepared for brazing and fluxed before heating,
or it can be face-fed into the joint. Heat is applied to the
joint first to melt the flux, then continuing until the filler
metal melts and flows into the joint. Overheating of the
base metal and brazing filler metal should be carefully avoid-
ed, as it may cause dropthrough, undesirable sagging, or
surface irregularity. Natural gas is well suited for torch braz-
ing because its relatively low flame temperature reduces the
risk of overheating.
Brazing filler metal can be preplaced at the joint in the
form of rings, washers, strips, slugs, or powder, or it can be
fed by hand, typically in the form of wire or rod. It should be
noted that silver filler metals do not diffuse in iron. In any
case, proper cleaning and fluxing are essential.

Of the torches used in brazing, air-natural gas torches Techniques

provide the lowest flame temperature and the least heat.
Acetylene under pressure is used in the air-acetylene torch
with air at atmospheric pressure. Both air-natural gas and
air-acetylene torches can be used on small components and
thin sections.
Torches that use oxygen with natural gas or other gases
(such as propane or butane) produce higher flame tempera-
tures. When properly applied as a neutral flame or a slightly
reducing flame, excellent results are obtainable for many
brazing applications.
Oxyhydrogen torches are often used for brazing alu-
minum and nonferrous alloys because they operate at lower
temperatures, which reduces the possibility of overheating
the assembly during brazing. An excess of hydrogen pro-
vides the joint with additional cleaning and protection.
Specially designed torches with multiple tips or multiple
flames can be used to increase the rate of heat input; howev-
er, local overheating must be carefully avoided. This can be
accomplished by constantly moving the torch relative to the
assembly to disperse the heat. Fig. 1 — Generic setup for manual torch brazing. (Photograph
For manual torch brazing, the torch can be equipped with courtesy of Fusion Inc.)
a single tip that provides either a single flame or multiple
flames. Manual torch brazing is particularly useful on as-
semblies involving sections of unequal mass. When the vol- Torch brazing techniques with oxyfuel gas welding equip-
ume and rate of production warrants, mechanized opera- ment differ from those used for oxyfuel gas welding. Opera-
tions can be set up using torches. One or more torches tors experienced only in welding techniques may require in-
equipped with single- or multiple-flame tips may be an ac- struction in brazing techniques. It is good practice, for ex-
ceptable option. Machines can be designed to move either ample, to prevent the inner cone of the flame from coming
the workpieces or the torches, or both. For premixed natural in contact with the joint, potentially causing overheating.
gas-air flames, a refractory type of nozzle or tip is used. Overheating could result in the melting of the base metal
Torch heating for brazing with filler metal rods can be and dilution with the filler metal. This may increase its liq-
accomplished with flux-covered or -cored rods. Only copper- uidus temperature and cause the flow to stop or be more
phosphorus filler metals are self-fluxing; they are used for sluggish. In addition, the flux may become overheated and
brazing in air without flux. With the exception of these thus lose its ability to promote capillary flow, and the low-
copper-phosphorus filler metals, all other filler metals for melting constituents of the filler metal may evaporate. WJ

Excerpted from the Welding Handbook, Ninth edition, Volume 2, Welding Processes, Part 1.

68 WELDING JOURNAL / JANUARY 2019

BY KATIE PACHECO —
National and District Officers Nominated for 2019
The American Welding Society
(AWS) has elected national and Dis-
trict officers to serve terms beginning
January 1, 2019.
Thomas Lienert, elected to serve as
president, was formerly a technical
staff member and a R&D engineer 4 at
Los Alamos National Laboratory for
more than 16 years. He is also an ac-
tive member and officer of several
national-level committees, has served
as chairman of the AWS New Mexico
Section, and has been named an AWS
Fellow.
Robert Roth, elected to serve as
vice president, is a member of the
AWS Executive and Finance Commit-
tees, WEMCO, and RWMA. He is pres-
ident and CEO of RoMan Manufactur-
ing Inc., an AWS sustaining member
company. He also serves on the boards
of various organizations and nonprofit
corporations.
Richard Polanin, elected to serve as
vice president, is a retired professor and
program chair of the manufacturing en-
gineering technology and welding tech-
nology programs at Illinois Central Col-
lege. He is currently coprincipal investi-
gator for Weld-Ed and chair of the AWS
Peoria Section. He is also an active
member of several AWS committees.
SOCIETY NEWS
Dennis Eck, elected to serve as vice
president, is general sales manager for
Praxair in the greater Houston area.
He has been involved with the AWS
Houston Section for 27 years, serving
as chairman, first and second vice
chairman, treasurer, and secretary. He
was also a part of the Membership
Committee for seven years.
Carey Chen, elected to serve as
treasurer, is president, CEO, and board
vice chairman of Cincinnati Incorpo-
rated, and currently serves as treasur-
er on the AWS Board of Directors and
the Foundation Board of Trustees. He
is also a member of the AWS Audit and
Compensation Committees, as well as
chair of the Finance Committee.
Walter Sperko, elected to serve as
director-at-large, is president of
Sperko Engineering Services Inc. He
has been involved with the AWS Car-
olina Section since the 1970s, serving
as chair several times, and is currently
an officer of that Section. He is also a
member of the D10 Committee on
Piping and Tubing as well as vice chair
of the Technical Activities Committee.
Sayee Raghunathan, elected to
serve as director-at-large, is an engi-
neering specialist at Saudi Aramco in
Saudi Arabia. He was the chair of the
AWS Saudi Arabia Section and credited
with reinvigorating that Section,
which is 200 members strong. He is
also the Fellow of seven institutes. He
has worked for TWI Ltd. in Cambridge,
UK; J. Ray McDermott Middle East
Inc. in Dubai; and Advani-Oerlikon
Ltd. in India.
Douglas Desrochers, elected to
serve as Dist. 1 director, has worked as
a welding instructor at Old Colony Re-
gional Vocational Technical High
School for 23 years. He is also an AWS
Certified Welding Inspector (CWI) and
an AWS Certified Welding Educator
(CWE). An AWS member since 2000,
he has served as the chair, secretary,
treasurer, and technical representative
of the AWS Central Massachusetts/
Rhode Island Section.
Lynn Showalter, elected to serve as
Dist. 4 director, is a welding engineer 4
with Newport News Shipbuilding, a di-
vision of Huntington Ingalls Indus-
tries. He has served on the AWS Tide-
water Section since 1992, with two
terms as chairman and six years as the
District’s deputy director. He has also
been an AWS CWI test supervisor for
26 years.
Howard Record, elected to serve as
Dist. 5 director Aug. 31–Dec. 1 follow-
JANUARY 2019 / WELDING JOURNAL 69
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NORTHERN NEW YORK
October 6
Location: Tech Valley Center of Gravi-
ty, Troy, N.Y.
Presenter: Daniel Falkenstrom, facili-
ties specialist, Tech Valley Center of
Gravity
Summary: Members had the opportu-
nity to tour Tech Valley Center of
Gravity, a makerspace, creative com-
munity, prototyping center, and man-
ufacturing business incubator. Falken-
strom showed attendees the space’s
3D printers, industrial sewing ma-
chines, laser cutting unit, electronics,
wood and metal working facilities,
weld shop, and prototyping. Attendees
were also treated to pizza and chicken
wings.

NIAGARA FRONTIER — Section trustee

CENTRAL FLORIDA-ORLANDO — Students (from left) Miguel Mata, Eric Sheller, Jesse Shawn Woodward (left) presented a
Rigel, Cody Padron, and Mark Siddens received free AWS student memberships speaker’s gift to Junjie Ma of Praxair.
sponsored by the Section.

CENTRAL FLORIDA-ORLANDO — Section members and Valencia College students are seen at the October meeting.

NORTHERN NEW YORK — Makerspace tour attendees included (from left) Daisy Canaan, Christopher Lanese, Ralph Viola, Connor
Meehan, Dan Falkenstrom, Dave Parker, Tori Rodriguez, Max Faulkner, Brandon Brenno, and Erich Haun.

80 WELDING JOURNAL / JANUARY 2019


ROCHESTER
September 26
Location: Rochester, N.Y.
Summary: AWS 2018 President Dale
Flood and his wife Svetlana visited
with District 6 members. The Floods
toured Paley Studios, Protech Sno
Pushers, Paul and Christine
Knoblauch’s studio, Feldmeier Equip-
ment’s new manufacturing facility,
Corning Community College’s Welding
SECTION NEWS
Technology Department, Cameron COLUMBUS
Manufacturing & Design, and U. A. October 23
Local 773. Location: The Ohio State University,
Columbus, Ohio
Presenter: Darrin Orr, project and stu-
District 7 dent coordinator, The Ohio State Uni-
versity, Center for Automotive
Larry Heckendorn, director Research
(614) 292-1220 Summary: Members toured The Ohio
heckendorn.4@osu.edu State University’s Center for Automo-
tive Research (CAR). The facility is the

ROCHESTER — AWS 2018 President Dale Flood and his wife, Svetlana, posed with the staff of Protech Sno Pushers following a
tour.

COLUMBUS — Tour Guide Darrin Orr (second from left) explained the Venturi Astrolab solar powered car.

JANUARY 2019 / WELDING JOURNAL 83


NEW ORLEANS
October 16
Location: Copland Towers & Confer-
ence Center, Metairie, La.
Presenter: Matthew Howerton, region-
al sales engineer, Lincoln Electric Co.
Summary: The meeting was sponsored
by Plumbers & Steamfitters UA Local
60. Local 60 Business Manager Curtis
Mezzic and AWS District 9 Director
Mike Skiles were in attendance and
presided over the meeting. Howerton
gave a presentation on using a modi-
NEW ORLEANS — Guest speaker
Matthew Howerton (center) is seen
with Section Treasurer Travis Moore
(left) and Section 1st Vice Chair Bruce
Hallila.
SECTION NEWS
fied short-circuit welding process.
Door prizes for attendees were donat-
ed by Lincoln Electric and a 50/50 raf-
fle was held with proceeds dedicated
toward Section student activities. The
Section’s officers are thankful that
Skiles took the time to travel and par-
ticipate in the meeting.
District 10
Mike Sherman, director
(216) 570-9348
mike@shermanswelding.com
District 11
Phillip Temple, director
(734) 546-4298
nwcllc_ptemple@att.net
PINCKNEY COMMUNITY HIGH
SCHOOL STUDENT CHAPTER
October 4
Location: Pinckney, Mich.
Summary: Student Chapter Advisor
and Welding Instructor Mark Stein
took welding students to visit local
manufacturers C&B Machinery, Flexi-
ble Metal, and TG Fluid Systems.
District 12
Dale Lange, director
(715) 732-3645
dale.lange@nwtc.edu
MADISON-BELOIT /
BLACKHAWK TECHNICAL
COLLEGE STUDENT CHAPTER
October 7
Location: Stoughton, Wis.
Summary: The Blackhawk Technical
College AWS Student Chapter attend-
ed Zalk Josephs Fabricators’s Manu-
facturing Day events at its facility. Ac-
tivities included a tour and demon-
stration stations set up by American
Bolt Co. and Lincoln Electric. Local
vendors provided food and drinks for
all attendees.
District 13
Ronald Ashelford director
(815) 218-8766
r.ashelford@rockvalleycollege.edu

Pinckney Community High School Student Chapter — Welding Instructor Mark Stein and his students toured TG Fluid Systems as
part of annual Manufacturing Day celebrations.

MADISON-BELOIT / Blackhawk Technical College Student Chapter — Student Chapter Advisor Dan Crifase (far left) and his weld-
ing students toured Zalk Josephs Fabricators LLC.

JANUARY 2019 / WELDING JOURNAL 85


NEBRASKA
September 12
Location: Metro Community College,
Omaha, Neb.
Presenter: Uwe Aschemeier, senior
welding engineer, Subsea Global
Solutions
Summary: Aschemeier spoke to Sec-
tion members about underwater wet
welding, including an overview of un-
derwater repair projects.
October 10
Location: Metro Community College,
Omaha, Neb.
Summary: The Section hosted AWS
2018 President Dale Flood and his
wife Svetlana. Flood provided an
overview of the current state of the
welding industry and how it is expect-
ed to change in the next ten years.
District 17
J Jones, director
(832) 506-5986
jjones6@lincolnelectric.com
NEBRASKA — Guest Speaker Uwe As-
chemeier (left) shared stories and in-
sight on underwater welding. District
16 Director Karl Fogleman (right) also
addressed attendees.
NEBRASKA — District Director Karl Fogleman (standing) and Section members en-
joyed a presentation from AWS 2018 President Dale Flood.
SECTION NEWS
He turned 100 years old on December
District 18 28, 2018, and still goes to work every
Thomas Holt, director day. Participating schools included
(409) 721-5777 Newton ISD, Dayton ISD, West Hardin
tholt@techcorr.com ISD, Hampshire-Fannett ISD, Orange-
field ISD, Evadale ISD, Buna ISD,
SABINE Hardin ISD, Liberty ISD, Lovelady ISD,
September 18 Barbers Hill ISD, East Chambers ISD,
Location: Coastal Welding, Magnolia West ISD, Burkeville ISD,
Beaumont, Tex. Taylor Career Center–Beaumont ISD,
Summary: During its September meet- Bridge City ISD, Silsbee ISD, Vidor ISD,
ing, the Section recognized items that Anahuac ISD, Hardin–Jefferson ISD,
were donated by AWS Headquarters to Port Neches Groves ISD, Woodville
Vidor ISD after Hurricane Harvey ru- ISD, and Deweyville ISD.
ined students’ welding gear.
October 3
Location: Lamar Institute of Technolo-
gy (L. I. T.), Tex., Beaumont, Tex.
Summary: Twenty-three schools par-
ticipated in the Texas Rice Festival
High School Welding Competition. Lil-
ton Sonnier of Winnie Welding Works
assisted as a judge, a job he has been
doing since the first competition 19
years ago. Sonnier started Winnie
Welding Works in 1946 and has been a
mentor to young welding students.
SABINE — Standing with items do-
nated by AWS Headquarters are (from
left) District 17 Director J Jones, District
18 Director Tom Holt, Vidor High School
Instructor Garrett Smith, and AWS
Past President John Bray.
NEBRASKA — Section Chair Greg
Schroeter presented guest speaker
and AWS 2018 President Dale Flood
(left) and his wife Svetlana with a
token of appreciation.
SABINE — Lilton Sonnier (left) and
Section Chair John McKeehan served
as judges during the Texas Rice Festi-
val High School Welding Competition.
One-hundred-year-old Sonnier has
been a judge for the competition
since it began 19 years ago.
JANUARY 2019 / WELDING JOURNAL 89
SECTION NEWS
SABINE — Members participated in the Texas Rice Festival High School Welding Competition.
BRITISH COLUMBIA — Section 1st Vice
Chair Kyle Bramhoff (left) presented a
speaker gift to Paul Murray.
BRITISH COLUMBIA — Section 1st Vice
Chair Kyle Bramhoff (right) is seen
with Guest Speaker Tristan Warren.
COLORADO — Member Steve Pineiro
(left) received the Section Dalton E.
Hamilton CWI of the Year Award.
90 WELDING JOURNAL / JANUARY 2019
District 19
Shawn McDaniel, director
(509) 793-5182
shawnm@bigbend.edu
BRITISH COLUMBIA
September 27
Location: UAPIC Delta, British Colum-
bia, Canada
Presenter: Paul Murray, Lincoln Elec-
tric Co.
Summary: Members gathered for a
catered dinner and presentation by
Murray titled, “Back to Basic Flux Core
Welding and Consumables.”
October 22
Location: Central City Brewers & Dis-
tillers, Surrey, British Columbia,
Canada
Presenter: Tristan Warren, brewmas-
ter, Central City Brewers & Distillers
Summary: Warren led Section mem-
bers on an operation and maintenance
tour of Central City Brewers & Dis-
tillers. Dinner was catered on-site fol-
lowing the tour.
COLORADO — Guest speaker Patrick Hickey (far left) is seen with Section Board
members (left to right) Tom Kienbaum, AWS Past President Bob Teuscher, Jesse
Grantham, and Juan Carlos Madeni.
District 20
Pierrette H. Gorman, director
(505) 440-6284
pierrette@comcast.net
COLORADO
April 5
Location: Lakewood, Colo.
Summary: The Section presented the
Dalton E. Hamilton Memorial CWI of
the Year Award to Steve Pineiro.
October 11
Location: Denver, Colo.
Presenter: Patrick Hickey, Newmont
Mining Corp., PT Newmont Nusa
Tenggara
Summary: Hickey presented an in-
depth discussion on the Batu Hijau
Mine project in Sumbawa, Indonesia.
He spoke about issues of logistics, hu-
man resources, some of the construc-
tion challenges in a wet jungle/ocean
environment with different types of
materials, special challenges with
welding many of the components in

that environment, and changes that
were required to the original material
selections when necessary due to ma-
terial failures. Also discussed were
some of the unique fabrication solu-
tions for welding and transporting un-
dersea pipelines in various material
combinations.
NEW MEXICO
October 18
Location: Gallup, N.Mex.
Presenter: Joe Sanchez, instructor,
University of New Mexico – Gallup
Summary: Sanchez discussed educa-
tional opportunities for students in
welding and the trades. He explained
that both an associate of applied sci-
ence and certificate of program com-
pletion are offered in the welding pro-
gram at the University of New Mexi-
co – Gallup campus.
District 21
Sam Lindsey, director
(858) 740-1917
slindsey@sandiego.gov
SAN FRANCISCO — AWS 2018 President Dale Flood (center) and his wife Svetlana
(second from left) are seen with (from left) Section Secretary May Ung and Co-
Chairs Liisa Pine and Jennifer Bernard.
NEW MEXICO — Section Chair Pat Bauman (standing, far left) joined Assistant Welding Instructor Jim Bostic (standing, sixth from
left), Instructor Joe Sanchez (kneeling, first from left) and students from the University of New Mexico – Gallup campus.
SECTION NEWS
Presenter: Randy Thomas, coordina-
District 22 tor, Boilermakers Local #549
Robert Purvis, director Topic: Introduction to the Internation-
(916) 599-5561 al Brotherhood of Boilermakers (IBB)
purviswelds@gmail.com Summary: Thomas spoke to members
about the history of the Brotherhood
CENTRAL VALLEY and its relationship to welding. Fol-
October 25 lowing a Q&A session, attendees were
Location: College of the Sequoias, taken on a tour of the training
Tulare, Calif. facilities.
Summary: Past District Director Kerry
Shattell outlined current AWS Scholar-
ship opportunities available to welding
students in the area prior to introduc-
ing AWS 2018 President Dale Flood.
SAN FRANCISCO
October 23
Location: Plumbers & Pipefitters Local
342 Union Hall, Concord, Calif.
Summary: AWS 2018 President Dale
Flood spoke to members and welding
students from Laney College, Los
Medanos College, and San Francisco
CENTRAL VALLEY — Seen at the Octo-
State University. Flood’s presentation
was followed by a tour of Local 342’s
ber meeting are (from left) Section
Chair Randy Emery, AWS 2018 Presi-
updated training facility. dent Dale Flood, Past District Director
Kerry Shattell, and Section Officer
October 23 Chris Huff.
Location: Boilermakers Local #549
Lodge, Pittsburg, Calif.
SAN FRANCISCO — Section Co-Chair
Jennifer Bernard (left) thanked IBB
Coordinator Randy Thomas for his
presentation.
JANUARY 2019 / WELDING JOURNAL 91
 GUIDE TO AWS SERVICES
American Welding Society® INFORMATION SYSTEMS Program Managers II
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CONFERENCES & EVENTS Executive Director, Foundation
GOVERNMENT LIAISON SERVICES Director Monica Pfarr.. mpfarr@aws.org . . . . . . . . . . . . . . . . . .(461)
Hugh Webster .... hwebster@wc-b.com CaLae Browne..cbrowne@aws.org . . . . . . . . . . . .(213)
Webster, Chamberlain & Bean, Washington, D.C. Associate Director, Foundation Services
(202) 785-9500; Fax: (202) 835-0243 SALES & PUBLISHING John Douglass.. jdouglass@aws.org . . . . . . . . . . . . . . .(212)
Monitors federal issues of importance to the Managing Director
industry. Michael Walsh...mwalsh@aws.org . . . . . . . . . . .(350)
The AWS Foundation is a not-for-profit 501(c)(3)
CONVENTION AND EXPOSITIONS Senior Sales Executive, Academia charitable organization established to provide support
Director, Expositions Efram Abrams....eabrams@aws.org . . . . . . . . . .(333) for the educational and scientific endeavors of the Amer-
Matthew Rubin.....mrubin@aws.org . . . . . . . . . .(239) ican Welding Society. Promote the Foundation’s work
Senior Sales Executive, Corporate with your financial support.
Senior Sales Executive, Expositions Sandra Jorgensen.....sjorgensen@aws.org . . . . .(254)
Sarah Dickson.....sdickson@aws.org . . . . . . . . . .(297)
STANDARDS DEVELOPMENT
ITSA — INTERNATIONAL THERMAL Dept. information . . . . . . . . . . . . . . . . . . . . . . . .(340)
SPRAY ASSOCIATION
Program Manager Director — Standards Development
Alfred Nieves....anieves@aws.org . . . . . . . . . . . .(467) Peter Portela.. pportela@aws.org . . . . . . . . . . . .(311)
Technical Committee Activities, Additive
RWMA — RESISTANCE WELDING MANUFACTUR- Manufacturing, High-Energy Beam Welding, Ro-
ING ALLIANCE botics Welding, Welding in Sanitary Applications,
Program Manager Structural Subcommittees on Bridge Welding and
Adrian Bustillo....abustillo@aws.org . . . . . . . . . .(295) Titanium

WEMCO — ASSOCIATION OF WELDING Director — International Activities

MANUFACTURERS Andrew Davis.. adavis@aws.org . . . . . . . . . . . . . .(466)
Program Manager International Standards Activities, American
Keila DeMoraes....kdemoraes@aws.org . . . . . . .(444) Council of the International Institute of Welding

GLOBAL OPERATIONS Manager, Safety and Health

Corporate Director Stephen Hedrick.. steveh@aws.org . . . . . . . . . . .(305)
Jeff Kamentz..jkamentz@aws.org . . . . . . . . . . .(233) Metric Practice, Safety and Health, Joining of
Oversees international business activities; Plastics and Composites, Personnel and Facilities
certification, publications, and membership. Qualification, Mechanical Testing of Welds

92 WELDING JOURNAL / JANUARY 2019

PERSONNEL
Walter Surface Technologies
Appoints Senior Positions
M.-A. Aubé D. Wright
Walter Surface Technologies, Mon-
treal, Canada, has recently announced
two senior-level appointments. The
company has promoted Marc-André
Aubé to the CEO position from his for-
mer role of president and COO. Prior
to joining Walter in February 2017,
Aubé was president and COO of Gar-
daWorld Protective Services, where his
main responsibilities included driving
the company’s annual growth and en-
suring operational standards within
the team of 26,000 Canadian security
professionals. He has also worked for
Nalco Canada, Petro-Canada, Caisse de
dépôt et placement du Québec, and
Scotia Capital Inc. Additionally, David
Wright has been promoted to vice
president of corporate development.
He joined the company in 2015 as the
business development manager.
Ford Expands
Leadership Team
E. Ford J. Savona
Ford Motor Co., Dearborn, Mich.,
has named Elena Ford as chief cus-
94 WELDING JOURNAL / JANUARY 2019
tomer experience officer. In her role,
she will continue to be closely inte-
grated with the sales and marketing
organization and global dealer net-
work as well as work with the Ford
customer service division and the
quality organization team. She will
also lead a team to identify key cus-
tomer pain points that can drive im-
proved business results, from digital
sites to call centers and service bays.
The company has also named John
Savona as vice president of North
American manufacturing. Additional-
ly, Savona has been elected as a com-
pany officer. In this role, he will be re-
sponsible for the company’s North
America manufacturing footprint.
Savona began his career with the au-
tomaker in 1989 as a security officer
at its Wayne, Mich., assembly plant
after three years of service in the U.S.
Army. Throughout his time at the
company, he has held a variety of roles
with increasing responsibility, includ-
ing his most recent position as direc-
tor of global manufacturing quality.
Chicago Pneumatic Names
Business Line Manager
Chicago Pneumatic, an internation-
al manufacturer of professional auto-
motive and industrial tools, has ap-
pointed Philip Warmbier as business
line manager at the company’s head-
quarters located in Rock Hill, S.C.
Warmbier will direct the sales teams in
the North American territory, which
includes the United States, Canada,
and Mexico. The team services indus-
trial and vehicle service clients.
Obituary
Bernhard Joseph “Bernie” Bastian
Bernhard Joseph “Bernie” Bastian
passed away of natural causes on Nov.
4, 2018. He was 90. A welding consult-
ant, teacher, writer, mentor, and con-
tributor to the technology of automo-
tive welding, Bastian built a 50-plus-
year career in the welding industry.
Born in Poughkeepsie, N.Y., he
earned his bachelor of science degree
in mechanical engineering and a mas-
ter’s degree in metallurgical engineer-
ing from Rensselaer Polytechnic Insti-
tute in Troy, N.Y.
He served in the
U.S. Army during
the Korean War
and was stationed
at Fort Riley mili-
tary base. Bastian
went on to work
as a metallurgical
engineer for near-
ly 40 years, begin-
ning his career
B. J. Bastian
with IBM and the
Edison Institute
in New York and
New Jersey, before moving to Detroit
in 1957. He worked for Chrysler Corp.
and Ford Motor Co. in welding engi-
neering and management. He was also
an instructor and coach for welders
and technicians. He taught welding
and related courses at Henry Ford
Community College for 17 years and
has written instructive articles for a
number of technical publications.
Bastian was very active in the
American Welding Society (AWS),
holding multiple positions, while re-
ceiving numerous awards. He served
on the Welding Handbook Committee,
providing guidance on the organiza-
tion and technical content of the Weld-
ing Handbook. He was also responsible
for oversight and final reviews of vari-
ous chapters of each of the five vol-
umes of the 9th Edition. He is a Fellow
of AWS and was honored as a Life
Member in 2018.
He is survived by his wife, Marta,
11 children, 31 grandchildren, and nu-
merous great grandchildren.
Glenn M. Nally
Glenn M. Nally passed away on No-
vember 13, 2018. He was 91. Nally
contributed to the welding community
and industry for more than 50 years as
a specialist in communications, adver-
tising, literature, public relations,
trade show, and product styling.
He joined Hobart Brothers Co. in
1967, then went on to retire from the
company in 1990. From beginning to
end, he was involved in the creation of
the Gallery of Welding History at the
Hobart Institute of Welding Technolo-
gy. He created a 3D model of the
gallery based on the architectural
drawings, assisted in the research of
pictures, as well as created many of the
pictorial displays and collages and ad-
vised how to place them.
Additionlly, Nally served the Ameri-
can Welding Society (AWS) as a mem-
ber of its board of directors, twice
elected as director-at-large. He was
also a member and chairman of the
Welding Journal Committee for 21
years. He received the AWS National
Meritorious Certificate Award for his
“counsel, loyalty, and devotion to the
B. Leibinger
affairs of the Society.”
He is survived by his wife of 63
years, Beverly, five children, and nine
grandchildren. Under his leadership, the company
evolved into one of the world’s leading
machine manufacturers. He is regarded
Berthold Leibinger as one of the pioneers in the industrial
application of lasers. In 2005, he hand-
Berthold Leibinger, a TRUMPF sen- ed over the reins of the company to his
ior figure and partner, passed away on eldest daughter.
NEWS OF THE INDUSTRY
continued from page 15
At a ribbon cutting for the new Toyota welding lab at Ivy Tech
Community College’s (ITCC) Columbus, Ind., campus were
(from left) Jesse Brand, member, ITCC state board of trustees;
Steven Coffman, dean, schools of advanced manufacturing,
engineering, and applied science, ITCC Columbus; Cindy Frey,
president, Columbus Area Chamber of Commerce; Joe Otte,
department chair, advanced automation and robotics tech-
nology, design technology, and industrial technology, ITCC
Columbus; Tony Miller, senior vice president, Toyota Industrial
Equipment Manufacturing (TIEM); Steven Combs, chancellor,
ITCC Columbus; Steve Pride, former director of human re-
sources, training, and customs compliance, TIEM; Jim Lien-
hoop, mayor, City of Columbus; Takafumi Zensho, president/
CEO, TIEM; Michael Kelley, welding instructor, ITCC Columbus;
Josh Linnemann, director of design engineering, production
engineering, and information technology, TIEM; and Trunnis
Goggins, workforce development consultant, ITCC Columbus.
October 16, 2018, In addition to his work at TRUMPF,
following a long ill- he has held numerous positions in the
ness. He was 87. German business community, includ-
After studying en- ing membership of the supervisory
gineering in boards of Deutsche Bank AG and
Stuttgart, Baden- BMW AG, as well as chair of the super-
Württemberg, Ger- visory board of BASF SE. He was presi-
many, and spend- dent of the Chamber of Industry and
ing two years in Commerce of the Stuttgart Region
the United States, and, from 1990 to 1992, president of
Leibinger joined the German Mechanical Engineering
TRUMPF in 1961. Industry Association. In 1992,
He became a part- Leibinger established the Berthold
ner and managing Leibinger Stiftung, a not-for-profit
director in 1966. foundation that dedicates its proceeds
to cultural, scientific, religious, and
charitable purposes. In 2000, the
foundation established the Berthold
Leibinger Innovation Prize, which is
awarded once every two years. WJ
“At Toyota, we believe that our best hope for the future is
right here in our local people,” said Tony Miller, TIEM senior
vice president.
A ribbon-cutting ceremony on September 25 served as
the official unveiling. Many attendees from TIEM and the
community college were present (see the group photo).
Industry Notes
• Progress is continuing on the proposed welding training
facility at the Port of West St. Mary in Louisiana, which
will aid local companies in filling needs for skilled aluminum
welders. A finalized design is expected in early 2019. Last
year, the Port Commission of West St. Mary revealed a
$1.3-million grant from the U.S. Economic Development
Administration to aid in building a welding training facil-
ity on port grounds; this will be combined with $450,000
in state capital outlay funds.
• The U.S. Department of Energy has awarded Brimrose
Technology, Sparks, Md., with a Phase 1 Small Business In-
novation Research award worth $149,995 to improve the
manufacturing of small modular reactors via nondestructive
examination. The focus is to demonstrate the feasibility of an
ultrasonic scattering technique used to characterize the mi-
crostructure and material properties for components made
with various additive manufacturing characteristics.
• Randolph Community College, Asheboro, N.C., hosted
225 eighth-grade students from nine Randolph County
middle schools as part of Manufacturing Day on October 5.
They participated in a mock assembly line, created badges,
and enjoyed hands-on activities/demonstrations in the
Gene Haas Computer-Integrated Machining Institute, elec-
trical systems, mechatronics, and welding areas. According
to mfgday.com, 2786 events were planned in 2018. WJ
JANUARY 2019 / WELDING JOURNAL 95


9







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CLASSIFIEDS

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Procedure Specifications
This three-day seminar/workshop on the
subject of developing welding procedure
specifications, procedure qualification
records, and welder qualification records is
being offered once again. The three-day
workshop/seminar is scheduled for March
25 through March 27, 2019 in Simsbury,
Connecticut. The seminar provides a
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100 WELDING JOURNAL / JANUARY 2019


and provide interconnections that meet long-term reliability
requirements. The reliability limitation became particularly
apparent in the development of thick film/LTCC PCBs for
multi-chip module (MCM) sub-assemblies (Ref. 4).
An alternative approach is to replace thick film conductors
with thin film layers. The thin films are deposited by physical
vapor deposition (PVD) techniques — evaporation or sputter-
ing. The glass adhesion layer is replaced with a thin-film met-
allization such as titanium (Ti) or chromium (Cr). The solder-
able finish is deposited on top of the adhesion layer. The sol-
derable finish is the layer to which the solder joint is made.
Common solderable finishes include copper (Cu), nickel (Ni),
and platinum (Pt). The solderability of the layer is maintained
by adding a protective finish on top of it. Often-used protec-
tive finishes include gold (Au), silver (Ag), and tin (Sn). While
the adhesion layer is typically only fractions of a micron thick,
the other layers can have thicknesses that vary over several
microns, depending upon the soldering process, signal trans-
mission properties, and long-term reliability requirements.
The particular advantage of thin film conductors is that
the corresponding circuit pattern can be made with increas-
ingly finer features to support further miniaturization. Cir-
cuit definition can be achieved by one of three methodolo-
WELDING RESEARCH
gies: a) shadow masks, b) photoimaging as is similarly used
in the microelectronics industry, and c) laser ablation. The
use of shadow masks provides a rapid means to define the
metallization pattern. However, its drawback is a limitation
on feature definition due to the combination of minimum
mask feature dimensions and proximity of the mask to the
substrate surface.
The photoimaging process can realize considerably finer
lines and spaces. Ultraviolet light passes through a glass
mask to define the pattern on a photosensitive film or resist
covering the thin-film metallization. The unexposed film is
removed by chemicals. The exposed metallization is re-
moved by plasma etching, leaving behind the desired circuit
pattern under the exposed photosensitive layer. The latter
layer is removed by a different chemical removal step. Draw-
backs include capital equipment costs and time duration to
plasma etch away the thin film, which increases with the lat-
ter’s thickness. Also, prolonged etching times can expose the
substrate surface to temperatures of 150°–200°C.
The third technique is laser ablation (Ref. 5). The particu-
lar advantage comes with thicker film layers because it re-
duces both process time and temperature rise at the sub-
strate while still providing feature resolution equivalent to
that of photoimaging techniques. Aside from capital equip-
ment costs, its other drawbacks include metal and substrate
spatter as well as surface microcracks and general roughness
that may impact high-frequency, RF signal performance. See
Fig. 3 for an example of a laser-ablated surface.
Hybrid microcircuit products have been developed at
Sandia National Laboratories using a thin film-on-LTCC
technology. The metallization stack was as follows: 0.200-
 m Ti adhesion layer, 4.0- m copper (Cu) signal layer, 2.0-
 m Pt solderable finish, and 0.250- m Au protective finish.
The relatively thick metallization required plasma etching as
the photo definition process. Titanium was selected as the
adhesion layer based upon its success on alumina ceramics.
An extensive study was conducted that is similar to that re-
ported below, which examined the adhesion strength of the
Ti-Cu-Pt-Au system when soldered with the 63Sn-37Pb sol-
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A B

A B

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 The mixed use of aluminum and steel is increasing in light-
weight automotive bodies. The cold metal transfer (CMT) arc
spot welding of aluminum alloy to steel has recently been de-
veloped. However, the electrochemical potential difference of
dissimilar materials will inevitably degrade weld performance.
Thus, this study investigated the corrosion behavior of CMT
spot-welded 1-mm AA6022-T4 sheet to 1.5-mm hot dipped
galvanized (HDG) low-carbon steel, DC03. The open circuit po-
tential (OCP) of the base materials and varying positions with-
in the welds was measured, and the results showed that the
OCP of the zinc coating on the steel substrate and zinc-rich
zone at the weld root were the most negative and likely to
corrode. Salt spray exposure was conducted specifically on
the welds with and without e-coating. The results indicated a
similar fracture mode after 20 cycles as with the as-welded
condition, i.e., fracture in the weld metal, though with a slight-
ly reduced lap-shear strength. After an exposure of 63 cycles,
the weld strength decreased nearly 38%, and the fracture
mode transitioned to interfacial fracture due to the corroded
Fe-Al IMC layer, whereas postweld e-coating of the CMT Al-
steel joints provided a high level of corrosion protection.

• Aluminum • Steel • Zinc • Intermetallics • Welding

• Corrosion

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A B

Fig. 4 — Electrochemical test workstation: A — Modulab potentiostat; B — flat cell with three electrodes.

B C

Fig. 5 — OCP testing: A — Relative positions within the weld; B — section through the aluminum weld; C — section through the
base steel substrate.

nal properties of the base materials are listed in Tables 1 and
2, respectively. The composition of zinc coating on the steel
was zinc + 0.15–0.20% Al + 0–0.1% Pb or 0–0.5% Sb, and
the layer thickness was typically less than 10 m.
The aluminum alloy and zinc-coated steel were fabricated
into 304.8-  127-mm panels, and the aluminum alloy panel
was positioned as the top sheet closest to the CMT torch
with an overlap width of 20 mm, as presented in Fig. 2. All
the panels were cleaned using acetone to remove any surface
contamination.
The EPW mode (Refs. 8, 9) (refer to Fig. 3) was adopted to
spot weld aluminum alloy to galvanized steel. This process re-
quires a predrilled hole in the top aluminum sheet. The diame-
ter of the hole used in the study was 6.5 mm with a 50.8-mm
interval on the panel (refer to Fig. 2). The welding torch was
kept perpendicular to the aluminum sheet with an extension
of 12 mm, and the center of the wire was aligned to the edge of
the hole. The welding torch moved along the edge of the
predrilled hole at a translation speed of 27 mm/s. Upon reach-
ing an angle of 337.5 deg from the starting position, the torch
changed direction toward the center of the hole. The arc was
extinguished upon reaching the center of the hole. The wire

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Fig. 6 — Heat treatment of non e-coated panels. A — Temperature profile used in e-coating; B — heat-treatment oven and thermo-
couple fastened to the welded assembly.
feed speed was 5.6 m/min, the welding current was 116 A, and
the voltage was 14.0 V. A shielding gas of 99.999% pure argon
was adopted at a flow rate of 20 L/min.
Electrochemical Measurements
The open circuit potential (OCP) measurements were tak-
en using a Modulab potentiostat, as shown in Fig. 4A. A
three-electrode PAR flat cell was employed, which used a sat-
urated calomel reference electrode (RE) and a pure Pt-mesh
counter electrode (CE). A photo of the apparatus is presented
in Fig. 4B. The electrolyte was a 3.5% NaCl solution. A base-
line measurement of the bare steel substrate was desired.
Thus, to eliminate any batch-to-batch variation, the zinc-
coated DC03 steel surface was ground using a 180-, 600-, and
1200-grit SiC abrasive paper to expose the underlying steel
substrate for OCP measurements.
Figure 5A is a drawing of the CMT Al-steel weld with vari-
ous positions in the stackup, indicating where specimens
were extracted for OCP measurements. Position 1 is the top
WELDING RESEARCH
surface of the weld, and then sections were taken through
the stackup until position 7, which is the bottom surface of
the zinc-coated steel. Electrical discharge machining (EDM)
was used to section the weld stackup to remove slices of ma-
terial, as exemplified by the two in Fig. 5B and C. The circu-
lar CMT weld can be clearly seen within the aluminum sub-
strate material in Fig. 5B. If the steel slice in Fig. 5C were
polished, it would exhibit a circular heat-affected zone be-
cause no nugget is formed within the steel. Positions 2 and
3, which were the top and bottom surfaces of the Al slice,
were the filler metal in the nugget on the aluminum side.
The diameter of the area of filler metal was larger than the
working electrode on the flat cell to make sure that only the
filler metal was exposed to the electrolyte when the OCP
testing was conducted. Position 4 is intended to enable OCP
measurements of the IMC layer. Because of the difficulty in
accurate positioning of the EDM process in relation to the
very thin IMC layer, it was decided to load the weld to frac-
ture and thereby expose the IMC layer. This had the advan-
tage of isolating the IMC layer though introducing a certain
JANUARY 2019 / WELDING JOURNAL 17-s
WELDING RESEARCH

A B

Fig. 7 — Cyclic corrosion test: A — Test chamber; B — positioning of welded panels in the chamber.

A B C

Fig. 8 — Weld morphology and microstructure: A — Cross section of the weld; B — enlarged view of the region b presented in A; C
— enlarged view of the region c presented in A (Ref. 10).

A B

Fig. 9 — Morphology of the CMT spot-welded panels: A — As-welded and without e-coating; B — e-coated following welding.

amount of surface texture, which is not consistent with the
other positions. Three specimens were measured for each
position.
E-Coating of Samples
An electrophoretic deposition process, e-coat, is a coating
process within the automotive assembly paint process that
deposits particles onto the surface of the aluminum and/or
steel body in white prior to painting. As such, e-coating does
provide a level of corrosion protection and, therefore, needs
to be considered in the experimental plan especially for dis-
similar material joints. Thus, welded panels were e-coated to
simulate the industrial body in white process. However, be-
cause the e-coating process consists of immersion in a wa-
ter-based solution containing paint epoxy-based emulsion
followed by curing, referred to here as “paint bake,” all weld-
ed panels underwent a paint bake process to eliminate any
potential heat treatment effects. The maximum tempera-
ture of the bake process was about 190˚C (375˚F). The red,
green, and blue plots in Fig. 6A are experimental measure-
ments from the e-coating process with the blue plot based
upon data from a thermocouple affixed to an actual welded

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A B
Fig. 10 — OCP testing of the substrate and different positions of the weld: A — Positions tested in the weld; B — potential curves
as a function of time for various substrates and weld positions.
Fig. 11 — EPMA analysis of zinc distribution within the weld.
panel assembly. This data was used to generate a heat-treat-
ment schedule for non e-coated coupons in the furnace seen
in the photo (refer to Fig. 6B). The black plot in Fig. 6A is
the experimental thermal history of a non e-coated coupon
affixed with a thermocouple in the furnace, which exhibits
good correlation to the thermal history inherent in the e-
coating process. The probe of the thermocouple was fas-
tened on the weld surface with heat-resistant adhesive tape,
as shown in Fig. 6B.
Salt Spray Test
Typical automotive environmental exposure testing em-
ploys some form of salt spray exposure. The current study
followed the standard GMW14872 and carried out the test-
ing using an auto technology cyclic corrosion test chamber.
The welded panels were placed at an angle of 30 deg to the
vertical reference line with the steel sheet at the bottom (re-
Table 3 — Salt Spray Exposure Cycle Based on GMW14872 (Ref. 14)
Control Variable Ambient Stage
Temperature 25 ± 3
C
Humidity ~ 45 ± 10% RH
Duration 8h
WELDING RESEARCH
fer to Fig. 7). The water solution within the chamber was
composed of 0.9% NaCl, 0.1% CaCl2, and 0.075% NaHCO3.
Because the GMW14872 was an internal standard from
General Motors, the salt spray exposure cycle was listed in
Table 3, which consisted of three stages, e.g., ambient, hu-
mid, and dry off (Ref. 14). Two different exposure cycles,
i.e., 20 and 63 days, were adopted to investigate the influ-
ence of exposure time. Although GMW14872 stipulates a
targeted mass reduction, this was not measured because the
corrosion products found at the notch root are difficult to
remove, and their presence would cause significant error in
the mass loss measurements.
Microstructural Analysis and Mechanical
Testing
Because any welded assembly would be e-coated, the
greatest concern is not the top or bottom sheet surfaces but
the area of the notch root where e-coating penetration may
not reach and dissimilar materials of the Al-steel joint are in
intimate contact. Thus, individual welds of a panel were ex-
tracted and cross sectioned to examine the effect of corro-
sion on weld macro- and microstructure. The weld cross sec-
tions were mounted and first ground with 180-, 600-, and
1200-grit SiC abrasive paper followed by polishing with sus-
pension liquids on a Presi polishing machine. Keller’s
reagent (1 mL HF + 1.5 mL HCl + 2.5 mL HNO3 + 95 mL
H2O) was used to etch the aluminum side for 15 s, and 4%
nital was used to etch the steel side for 20 s to highlight the
Humid Stage Dry-Off Stage
49 ± 2
C 60 ± 2
C
~ 100% RH  30% RH
8h 8h
JANUARY 2019 / WELDING JOURNAL 19-s

Fig. 13 — Lap shear strength of CMT Al-steel welds (with and
without e-coating) measured as-welded and following envi-
ronmental exposure for 20 and 63 cycles.
ning electron microscope with accompanying EDS analysis.
Results are shown in Table 4.
Position 1 located at the Fe-Al IMC layer was identified as
Fe2Al5. Because the beam spot of EDS was too close to the
steel substrate, the reflections of the Fe element were picked
up from the steel. Positions 2 and 3 were the Al–Zn mixture,
indicating that a zinc-rich zone existed between the alu-
minum weld metal and Fe-Al IMC layer. Farther into the
weld, though still along the faying interface, a thin IMC layer,
i.e., Fe2Al5, with very little zinc was detected at position 4.
Figure 9A is a photo of the as-welded panel, and Fig. 9B is
a photo of the welded and e-coated panels, which appear
black.
Electrochemical Measurements
As a measurement of the corrosion tendency for the dif-
ferent alloy compositions making up the Al-steel joint (refer
to Fig. 5), the OCP was plotted as a function of time (refer to
Fig. 10A). The majority of positions exhibit a trend of de-
creasing OCP values with time. However, for those positions
(1 and 2) exhibiting an increase of the OCP over time, the
authors attribute this to an increasing protective property
of a passive AlxOy film during the exposure to the elec-
Table 4 — Chemical Compositions of Different Points (at.-%)
Elements
Positions
Al Fe
1 58.12 25.19
2 49.38 2.91
3 59.50 2.42
4 64.63 26.12
WELDING RESEARCH
trolyte. To compare these values, an average OCP was calcu-
lated by averaging the values in the time frame of 1800–
3600 s. This was done for three replicates per position, and
the average OCP values were then plotted as a function of
relative position within the joint stackup (refer to Fig. 10B).
The OCP for the zinc coating on the steel substrate was the
most negative, which is similar to the bottom surface of the
weld, position 7, as would be expected assuming that the sur-
face temperature at the bottom surface of the steel does not
reach the melting point of zinc during welding. The OCP of
the Fe-Al IMC layer mixed with zinc, position 4, was also very
low, about –1.0 V, compared with the weld metal in the alu-
minum side. Thus, this would drive the IMC layer to corrode
after the corrosion of the zinc-rich zone. The OCP of the alu-
minum base alloy was relatively higher and OCP of the Al
weld decreased in OCP value from the surface of the weld to
the faying interface, especially positions 2 to 3, which is at-
tributed to a greater zinc-alloying content closer to the faying
interface (refer to Fig. 10A). This can be explained by the fact
that the zinc coating has a low boiling point of 906˚C, such
that when it is exposed to the heat from the welding arc, it
will evaporate and become trapped at the weld root.
This was detected by EPMA analysis of zinc distribution
in the weld nugget, as shown in Fig. 11. The OCP of the steel
substrate and positions 5 and 6 within the steel substrate
were the most positive, indicating the greatest corrosion re-
sistance. The OCP of positions 2, 3, and 4 was the result of
mixed potentials.
Therefore, according to the OCP results, it is proposed
that the zinc coating on the steel surface will corrode first
during the corrosion process. However, the zinc coating on
the steel in the vicinity of the weld notch root corroded
slowly because of the difficulty for the electrolyte solution
to penetrate into this overlapped area. Once the solution
penetrated into the overlapped area and following extended
exposure times, the zinc-rich zone at the weld notch root
corroded and the corrosion propagated into the aluminum
weld metal through the zinc distribution at the notch root.
The existence of e-coating on the panels provides a barrier
to the invasion of electrolyte solution into the overlapped
area, and the corrosion rate is slowed, highlighting the bene-
ficial attributes of e-coating.
Macro Morphology of the Corroded Panels
Photos exhibiting the morphologies of the welded panels
with and without e-coating after salt spray exposure for dif-
ferent cycles are presented in Fig. 12. The uncoated welded
Phases
Zn Si
6.65 10.04 Fe2Al5
45.40 2.32 Al–Zn mixture
36.61 1.46 Al–Zn mixture
0.27 8.98 Fe2Al5
JANUARY 2019 / WELDING JOURNAL 21-s
WELDING RESEARCH

A B

C D

Fig. 14 — Fractography of the weld under applied load: A — Uncoated weld after 20 cycles; B — e-coated weld after 20 cycles; C
— uncoated weld after 63 cycles; D — e-coated weld after 63 cycles.

A B C

Fig. 15 — Fractographies and lap-shear strengths of non e-coated coupons with a different % of corroded weld nugget fracture
surface following 63 cycles of GM14872 environmental exposure testing: A — 2.3%; B — 18.5%; C — 67.7%; D — weld strength with
different percentage of corrosion weld nugget fracture surface shown in A, B, and C.

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A B

C D

Fig. 16 — Photomicrographs of polished cross sections of the Al-steel weld following environmental exposure: A — Uncoated weld
after 20 cycles; B — e-coated weld after 20 cycles; C — uncoated weld after 63 cycles; D — e-coated weld after 63 cycles.

panels exhibit a white color indicating oxidation of the zinc
coating and areas of brown rust after 20 cycles of environ-
mental exposure (refer to Fig. 12A). Brown rust can also be
observed in some locations, which indicates full oxidation of
the zinc coating and oxidation of the base steel substrate
has begun. Conversely, the e-coated panels (refer to Fig.
12B) were well protected and no obvious corrosion was de-
tected. The white drops on the surface in the photo are dried
electrolyte solution left on the panels. After 63 cycles of en-
vironmental exposure, the uncoated steel panel exhibited
severe corrosion as evidenced by a thick layer of brown rust
(refer to Fig. 12C). For the same exposure, the aluminum
panel exhibits a white corrosion product covering the sheet
in contrast to the darker grey color of the aluminum panel
seen in Fig. 12A. After 63 cycles, the e-coating was still pro-
viding corrosion protection; however, evidence of white cor-
rosion product could be found in the vicinity of the over-
lapped region.
Lap-Shear Strength
For the investigation of corrosion on the mechanical
property of the welds, lap-shear testing was conducted fol-
lowing 20 and 63 cycles of salt spray exposure. The results
are summarized in Fig. 13. As a baseline, coupons were test-
ed prior to any environmental exposure and measured a lap-
shear strength of approximately 4.1 kN independent of the
presence of e-coating or not.
The fracture mode was crack initiation at the weld
notch root progressing into and through the weld to create
a partial button similar to that presented in Fig. 14A and
B. Following 20 cycles of salt spray exposure, there was no
measurable effect for coupons that were e-coated. Based
upon observation of a clear demarcation in Fig. 14B be-
tween the black e-coated steel surface and the oxidized
steel surface in the overlap area, it was concluded that the
e-coating did not penetrate fully around the welds. For
those welds without e-coating, the lap strength after 20
cycles of exposure was reduced to a value of 3.6 kN, retain-
ing the same fracture mode as the baseline — Fig. 13.
Again, after 63 cycles, there was no degradation of lap-
shear strength for the e-coated coupons; however, for
coupons without e-coating, the strength reduction was sig-
nificant, measuring an average strength of 2.6 kN. Fur-
thermore, the fracture mode changed to one of interfacial
fracture along the IMC layer. This can be understood in the
observation of a thick oxidation layer in the region of over-
lap and corrosion directly on the weld fracture surface (re-
fer to Fig. 14C), which also caused the large fluctuation of
the weld strength shown in Fig. 13. Thus, e-coating ex-
hibits an ability to provide significant corrosion protection
for coupon-level testing even without complete joint pene-
tration into the Al-steel overlapped area (refer to Fig.
14D). Further work under conditions of durability type
testing would be required to represent in-use conditions
for automotive applications.
Observation of the fracture surfaces for the welds with-
out e-coating tested after 63 cycles of environmental expo-
sure (refer to Fig. 15A–C) led to the correlation of the %
area of weld nugget corroded during the salt spray test,
i.e., extent of corrosion, to the lap-shear strength (refer to
Fig. 15D). This implies that as the corrosion progresses,
the bond between the Al and steel is destroyed, thereby re-
ducing the overall load-bearing area of the joint. For the

JANUARY 2019 / WELDING JOURNAL 23-s

WELDING RESEARCH

Fig. 17 — Microstructure of the corroded weld notch root without e-coating: A — Corrosion propagation in the weld notch root after
20 cycles; B — IMC layer near the weld notch root without corrosion after 20 cycles; C — corrosion propagation in the weld notch
root after 63 cycles; D — corroded IMC layer near the weld notch root after 63 cycles.

welds shown in Fig. 15A–C, the percentage of corroded
weld nugget fracture surface increased greatly from 2 to
57% (refer to Fig. 15D) because the weld with the largest
corrosion area was close to the edge of the panel, as shown
in Fig. 9A and exposed much more to the corrosion solu-
tion; the weld adjacent to the panel center corroded slight-
ly. As the percentage of the corroded weld nugget area in-
creased to 57%, corresponding to the fractography pre-
sented in Fig. 15C, the weld strength per unit area de-
creased from 38 N/mm2 for the as-welded and e-coated
condition to approximately 23 N/mm2, which implies there
is another mechanism beyond the load-bearing area at
play. As the square of corrosion area increased, which
caused a smaller load-bearing area, the reduction of the
lap-shear strength also became larger simultaneously (re-
fer to Fig. 15D), which was calculated by the lap-shear
strength of the weld without corrosion subtracted by the
value of the weld strength after corrosion, then divided by
the area of corroded interface. This could very well have to
do with the stress state at the faying interface/notch root,
which requires further investigation beyond the current
body of work.

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trolyte penetrates, it would attack the zinc-rich zone at the
weld notch root.
3) Considering the as-welded condition as the baseline lap-
shear strength with a nugget pullout through the Al as the
fracture mode, the average strength dropped 12% following
20 cycles of salt spray exposure and 41% following 63 cycles
coupled with a change in fracture mode to interfacial.
4) E-coating has a very positive effect upon corrosion of the
CMT Al-steel welds. The e-coating provides a barrier to the
penetration of the electrolyte solution into the overlapped
area between the top and bottom sheets. Resulting lap-shear
strengths exhibited no statistical difference between the as-
welded and post-environmentally exposed conditions.
The authors would like to acknowledge the support of
GM Research and Development Center and National Natural
Science Foundation of China (Grant Nos. U1564204,
U1764251, and 51322504).
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Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, School of Mechanical Engineering, Shanghai Jiao Tong
University, Shanghai, China. YANG GUO is with the Advanced Materials Lab, General Motors China Advanced Technical Center, Pudong,
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WELDING RESEARCH
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