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VICTOR MODEL “DEMS”
A big money-maker for anyone rebuild-
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duction basis. Double-ended. multiple
spindle mounts 8 track rollers, or 2
idiers, at a single loading. 360° rota
tion permits rebuilding all faces and
flanges without additional handling
Automatic move-over assures uniform
build-up. Dual wire feed cuts rebuilding
time in half. Comes complete with
power-saving power unit, specially engi
neered for automatic welding
ROLLER FLANGE
FLAME HARDENER
prevents flange wear and roll over
(cause of many premature failures) by
flame hardening renewed area to ap-
VicTOR
proximately 50 Rockwell C. Dual
torches flame harden both inside and
outside of flanges simultaneously
For details, circle Ne. 1 on Reader information Card
for hardfacing
these
Economy Size
ROLLER AND IDLER REBUILDER
VICTOR MODEL B
Rebuilding
r contractors and smail repair
Produces same high quality
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only two rollers or idlers at a loading
Machines
Has same type double wire feed, auto
matic move-over, and motorized posi-
tioning of work. Built-in jib crane (rated
¥4-ton capacity) enables operator to
handle rollers and large idlers with
ease. Price includes power supply
VICTOR FLUX GRINDER
processes 1500 pounds or more of
fused flux per hour with very low flux
oss. Sizes flux to factory specifica-
EQUIPMEN] COMPANY tions. Savings made by reclaiming only
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rdfacing rods; blasting nozzles;
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 Welding

Journal

Conception, Design and Fabrication of a Welded Rigid-frame Railroad Bridge, by R. T. Blewitt

Technical Papers
Specific Problems Associated with Oxygen Cutting of Bevels, by G. R. Spies, Jr
Items and Multiple Brazing Process, by George D. Cremer and Richard S. Mueller. .
Reports Micro-wire Welding, by Harley J. Orr and John H. Headapohl

Practical Welder Natural-gas Cutting Used in Fabrication of Pipes, by L. H. Paines and H. Cutler...
Production in Modern Railroading. ..High-iron Heavyweights, by C. N. Strutz and E. D. Uecker
and Designer

Press-Time News. Section News and Events

Society
Welding Zones New Members.....
and Related World-Wide Welding News News of the Industry...
Events Editorial—Productivity: Are We Doing Our Part Personnel
by R. David Thomas, Jr
New Literature.
Society News
New Products..
4)isi Annual Meeting
si Reader Information Card
Technical Papers Sessions—1960 AWS :
National Fall Meeting... eens 618 Index to Advertisers

1959 Adams Lecture—The Science of Arc Weiding, Part II!, by Clarence E. Jackson...
Welding
Effect of Elevated-temperature Exposure on Heavy-section Pressure-vessel Steels, by A. W. Pense, J. H.
Research Gross and R. D. Stout
Supplement Weld Metals in Nicke!-base Alloys, by J. Heuschkel.
Resistance Seam Welding of Terne Plate, by H. F. Greer and M. L.Begeman.
Arc Welding of 5% Cr—0.5% Mo Alloy-steel Pipe, by J. Bland and G. F. Tisinai.....
Submerged-arc Welding HY-80 Steel, by W. J. Lewis, G. E. Faulkner, D. C. Martin and P. J. Rieppel

Published for the advancement

of the science and art of welding
by the American Welding Society
Published monthly by the American Welding Society. Publication office, 20th and Northampton Streets,
Pa. Editorial and general offices, 33 West 39th St., New York 18, N. Y. Subscription $8.00 per year in the
United States and possessions; foreign countries $10.00. Single copies, nonmembers $1.50; members $1.00.
Second-class privileges authorized at Easton, Penna. This publication is authorized to be mailed at the special
rates of postage prescribed by Section 132. 122 Copyright 1960, by the American jos yy
s not responsible for any statement made nion expressed in its publications Permis
any article after its date of publication provided credit is given

Technical Papers Chosen for Presentation
National Fall Meeting in Pittsburgh
As technical developments in
welding continue unabated, the
AMERICAN WELDING SOCIETY has
scheduled a fall meeting to review
recent progress in research, develop-
ment and applications. This year’s
National Fall Meeting will be held
in Pittsburgh, Sept. 26-29th, at
the Penn Sheraton Hotel. During
this week, the steel center of the
United States will be host to AWS
members and guests participating
in a well-rounded program ar-
ranged by the Technical Papers
Committee. A total of 51 papers
have been grouped into 17 sessions,
each session having three papers
related to it: subject.
The major interests of the steel
center of America are reflected in
the selection of subjects of timely
importance to the steel industry but
many other important topics are
included. Four sessions are under
the sponsorship of the Structural
Division of the American Society of
Civil Engineers. Two of these are
co-sponsored by the Column Re-
search Council of the Engineering
Foundation. In addition, a_ ses-
sion of nondestructive testing is
co-sponsored by the Society for
Nondestructive Testing. In _par-
ticular, the four sessions on welded
structures will deal with welding of
the higher-strength steels in bridges,
the behavior of built-up beams
and thin-web girders under loads,
the fatigue strength of stiffened
beams, design of columns, a study
of beam-to-column connections and
other related topics.
Other sessions will cover missile
construction, electrodes and _ tech-
niques, brazing, research and weld-
566 JUNE 1960
Branson Demonstrates
Ultrasonic Equipment
A press conference was held by
Branson Instruments, Inc., at their
Stamford, Conn., plant on Apr. 12,
1960. A brief address by Peter K.
Bloch, president, revealed that the
company is riding high on a wave of
increased sales due principally to
rapid growth in the industrial appli-
cations of ultrasonic cleaning. This
was followed by a talk by Henry
Osterman on the service-engineered
approach used by Branson in the
cleaning field and a description of
the advantages obtained by the
newest transducer elements. A short
talk by John Bobbin covered the
newest developments in the ultra-
sonic testing field.
During a quick plant tour, the
at 1960 AWS group witnessed applications of the
latest thickness testing and flaw-
detection apparatus: the Audigage,
the Vidigage, the Sonoray 5 and a
ability, new processes and rebuild- recently developed rail-flaw detector
ing and surfacing. The simulta- carried about like a walking stick.
neous sessions have been so arranged Also viewed during the tour were
that different presentations on the numerous applications of ultrasonic
same topic will not be made at the
cleaning, pickling and degreasing.
same time.
There will be no welding show Thickness readings on the Vidi-
at the Fall Meeting program. The gage tester run about 1“; of nominal
detailed program of events appears wall thickness in accuracy while the
on pages 618-620 of this issue of the figure for the Audigage model is
Journal. between 1 and 2%.
“TREASURAMA” CONTEST EVOKES EXHIBIT INTEREST
Jim Norcross, vice president of Arcos Corporation, dips his hand into a drum and selects
the winner of the Welding Journal's Welders’ Treasurama contest. Looking on are
Bonney Rossi, left, and Fred Talento of the Journal Staff. This contest was held in
conjunction with the 1960 Welding Show in Los Angeles. The Journal offered a chance
to win a tape recorder to any person who filled in a brief description of each exhibit at the
Show on a special contest form distributed to those who registered at the convention.
The winning form was submitted by Don Howard of A.C.F. Industries. The drawing was
held on Thursday, April 28, the last day of the exhibit
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f WELDING ZONES

Giant diesel-electric-pow-
ered ore carrier, with its
55-ton load, maneuvers
‘like a small car."" Made
by Unit Rig and Equip-
ment Co., Tulsa, Okla.,
body is of '/,- and 5/s-in
T-1 steel. Welding was
by semiautomatic, gas-
shielded, flux-cored-elec-
trode process. (Cour-
tesy NCG Div., Che-
metron Corp.)

Fourteen __liquid-oxygen
converters, each yielding
300,000 scf oxygen at 260
psi, nearing completion
at Standard Steel Corp.'s
Cambridge Div., Lowell,
Mass. Vacuum-jacketed
vessels have _ stainless-
steel interior, carbon-
steel exterior

World's largest ditcher

the Gar Wood-Buckeye
300, digs irrigation canals
up to 22 ft wide for a vast
project in Cameron Co.,
Texas

as
y\
‘
| JUNE 1960 a*
Py
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A
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eeet -> >
 welding costs

cut 317% to 51%

A recent test matched Pureco CO. Weld Shielding

against three other methods: Two with manual stick
electrodes—one with manual submerged arc. Each
made an identical 100 ft., 14" fillet weld. COs trav-
eled 40 inches per minute against 21.4 ipm for the
fastest stick electrode. CO2 deposited 21 lbs. of metal
per hour compared to 11.4 lbs. for submerged arc
WITH Py RECO CO and 9.81 lbs. for the fastest stick electrode. Consid-
ering all cost elements, including overhead—Pureco
as 2 CO. Weld Shielding was 31 to 51% less than the
others.
44 97
Pureco CO, Weld Shielding Faster!
The continuous wire welding process provides sev-
eral advantages over other welding methods. It needs
no flux . . . provides an easily controlled are. Welds
are deep rooted and ductile. No time lost changing
electrodes.
Gas Cost Lower... Current Higher
The cost of Pureco COz is less than that of other
shielding gases . . . gas consumption is low. Welds
are slag free . . . no cleaning or chipping necessary.
Currents frequently used on mild steel are about
25% higher, causing higher burn-off rates and faster
welding . . . deposition efficiency ranges from 90%
to 95‘ O-
Speeds Automatic Set-Ups
Pureco CO. Weld Shielding is ideal for both single
and multi-pass applications, manual or automatic,
with large or small diameter wires . . . CO2 can now
be used for position manual welding, too!
For complete information on the proper Pureco
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nearest Pureco representative—see your Yellow
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For details, circle No. 3 on Reader Information Card
WELDING JOURNAL 569
 WORLD-WIDE
EAST GERMANY
The September issue of the East
German Schweisstechnik reports
plans in Russia for automation and
specialized factories. Reference is
made to the specialized plant for
welding 325,000 ft of plate girders
. per year that was designed in 1956
for East Germany, but has not yet
been erected.
Fatigue Tests
Pulsating-bend fatigue tests were
made on five designs for trusses.
The specimens were tested mainly
on a span of 4 ft, the height of the
trusses being about 1 ft. Upper and
lower members were angles, tubes or
fabricated hollow sections. Diag-
onals were channels, tubes or angles.
Whether mild or low-alloy steel
was used, the fatigue strength was
low, 7000-i8,000 psi despite the
use of low-hydrogen electrodes.
Rounded gussets and machined welds
were essential to avoid unusually
low fatigue strength.
Tests showed that CO, for weld-
ing steel may contain up to the
commercial limit of 3 g/m’ of
moisture without sacrifice in weld
quality. The butt welds were made
with a 1'/,% Mn, 1% Si electrode in
s-in. mild steel. The root layer
was made with 0.047-in. wire at 100
amp, the upper layers with ' /,;-in.
electrode at 200 amp. Porosity
was not encountered at 13.2 g of
water’m’ of CO, but was observed
at 17.0 g/m‘.
A flash-welding machine is used at
the Meerane boiler plant in East
Germany to butt weld economizer
tubes 1' .-in. OD, -in. wall.
The upset force is 3 tons. Welding
creates a heated zone only */,-in.
long. Reheating is done in the
machine to create a zone 2-in. long
at 1650° F to avoid hardening.
Flash on the interior of the joint is
removed by a plug which is blown
through the pipe by compressed
air at 85 psi. Flash welds require
no radiography and therefore are
Dr. GERARD E. CLAUSSEN is associated with
Arcrods Corporation, Sparrows Point, Md
570 | JUNE 1960
WELDING NEWS
less expensive than gas welds, which
must be radiographed.
FRANCE
Quality Control
The July-August, 1959, issue of
Soudage, the French welding maga-
zine, contains five papers presented
at the joint meeting in London of
the French Society of Welding
Engineers and the British Institute
of Welding on Nov. 3-6, 1959.
1. Nondestructive test methods
for welded hydroelectric equipment
and penstocks are described by the
fabricator. In the shop, radiogra-
phy is used for turbine casings for
only those welds which show a
doubtful pattern on the ultrasonic
reflectoscope. For penstocks in the
field, a radioactive source such as
iridium 192 inside the penstock is
positioned ata weld. Ascintillation
detector with sodium iodide crystal
picks up the radiation on the out-
side of the weld. The signal is
read 25 ft away on a microammeter.
2. Quality control specifications
for spot welds in aluminum air-
craft, such as the caravelle jet, are
given in detail. The American
MIL-W6860 and French AIR 9100
specifications were used as a basis.
The specification controls contact
resistance, shear strength, macro-
structure, radiography, internal de-
fects and dimensions. Repair of
defective spot welds also is dis-
cussed.
3. The quality control organiza-
tion of a French shipyard employing
800 arc welders, 120 gas welders and
40 submerged-arc welders is de-
scribed. For nondestructive testing
there are 4 X-ray machines (150 and
260 kv), 7 iridium 192 sources; one
cobalt 60, one cesium 137, 5 magna-
flux units, 4 ultrasonic reflecto-
scopes, one trepanner, 1 freon leak
detector and two endoscopes for the
reverse side of inaccessible welds.
4. The relation between radio-
graphic image quality and thickness
is plotted. For the wire and hole
indicators of the IIW, an index of
required quality of image is specified
depending on thickness.
\e
By Gerard E. Claussen |
5. Quality control for welded
pipe lines for oil and gas, in France
is described in detail. API code
requirements for steel, dimensional
tolerances and joint designs have
been adopted with some reserva-
tions. On completed pipe lines,
inspection consists of transverse
tensile tests for pipes under 14 in.
diam., or radiography for larger
diameters. The large diameter
pipes themselves are made from
plate by submerged-arc welding
with tandem electrodes. These
welds are required to exhibit 17 ft-
lb Charpy V at +32° F
This issue contains a recommen-
dation to standardize an aluminum-
alloy containing 3.70-4.50% Mg,
0.05-0.35°, Cr, which has better
corrosion resistance than the 3°,
Mg alloy. The presence of chro-
mium was shown to be essential for
good crack resistance.
RUSSIA
The July 1959 issue of the Ukrain-
ian welding magazine Avtomatiches-
kaya Svarka contains the following
papers.
1. Mild-steel fatigue specimens
l-in. thick containing fatigue cracks
of various depths in base metal and
weld metal were tested in tension
with and without impact at —85° F.
If the crack did not exceed a depth
of in., it did not affect the
behavior at —85° F. Deeper cracks
lowered the strength at low tem-
peratures.
2. The strength of seam welds in
mild steel made by the foil process
0.008-in foil on upper and lower
sides of a butt joint in sheets 0.032
0.16 in. thick) was found to vary
with current, pressure and seam-
welding speed. Machine settings
for highest strength were worked
out.
3. The need is pointed out for a
resistance butt-welding machine to
weld -in. diam rods of alloy and
stainless steel with provision for
removal of upset in the hot, plastic
condition, and for heat treatment
by resistance in the welding machine.
4. The electrical calculations are
presented for a very simple, direct-
 HW-9 110 amp., Air cooled. Weighs
only 3 oz. Interchangeable collet body
and torch cap provide 120° or 60°
working angles for torch head. Screw-
on connections for cable and hoses. AC
or DC. Self-aligning electrodes. Elec-
trode sizes: .020 to 1/16 in.
HW-9 110 amp. Pencil torch. Air
cooled. For welding thin gauge materi-
als. In-line design for welding in hard-
to-reach joints. Handle is high impact
phenolic tube over bronze torch body.
AC or DC. Self-aligning electrodes
Electrode sizes: .020 to 1/16 in
HW-17 130 amps. AC or DC. High-
est rated air cooled manual torch avail-
able. Self-aligning electrodes. Design
eliminates high-frequency leaks. Col-
lets, collet bodies, caps and cups inter-
changeable with HW-18. Electrode
sizes: .020 to 3/32 in.

——

HW-20 200 amps. AC or DC. Water
cooled. Weighs only 3.3 oz. This small-
size torch can actually weld inside a
3-in. tube. No chance of water leaks
(same design as HW-18). Self-aligning
electrodes. Electrode sizes: .020 through
1/8 in
HW-18 300 amps. AC or DC. Water
cooled. Torch body is molded around
water passages to form closed cooling
system—no chance of leakage. Improved
collet bodies for better shielding with
less gas. Torch designed for welding
metals with a wide range of thicknesses
Self-aligning electrodes. Electrode
sizes: .020 to 1/8 in
HW-12 500 amps. AC or DC. Water
cooled. For heavy-duty manual weld-
ing. Includes two collet bodies, one
from 10 to 300 amps., the other, 300
to 500. Straight-line water passages are
easily cleaned. Entire torch quickly dis-
assembled. Electrode sizes: .040
through 1/4 in

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Linde Company, Division of Union Carbide Corporation, UNION
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Hastelloy,”’ “Linde,” “‘Heliarc,” and “Union Carbide” are registered trade marks of Union Carbide Corporation
For details, circle No. 4 on Reader Information Card
WELDING JOURNAL 571
acting voltage regulator for auto-
matic arc welding. A part of the
arc voltage is impressed on the shunt
winding of the wire-feed motor.
5. The effect of cold working
Type 310 submerged-arc weld metal
in promoting conversion of austenite
to sigma phase was determined
after heating 500 hr at 1470° F.
Conversion to sigma was estimated
in the microstructure and in notch-
impact results. Up to 5% cold
work inhibited sigma formation,
but 10-30°% cold work accelerated
it.
6. In tungsten-arc welding of
copper, the addition of 0.2-1% Ni,
0.01-4% Si, 0.2-1.5% Co or 0.3
1.2% Cr improved weldability, while
0.2-1% Al, 0.05-0.5% Be, 0.1
0.3% Zr and 0.02-0.035% Ti was
disadvantageous. Cadmium (0.09
0.6%) promoted weld cracking.
7. The application of spot welding
to steel railroad-car doors is dis-
cussed.
8. The CO. welding of thin-gage
steel for automobiles is described.
The electrode was 0.032-0.039-in.
diam and contained 0.07% C,
1.0% Mn and 0.96% Si. A travel
speed of 44 ipm was used at 110
amp on one application.
The August 1959 issue of the
Russian welding journal Avtoma-
ticheskaya Svarka contains the fol-
lowing articles.
1. Apparatus for electron-beam
welding is described. Stainless steel
0.059-in. thick and copper 0.039-in.
thick were welded at 30,000 v, 30
For low-frequency resistance-
SWEDEN
Welded frame of the stator for a 10,500 KVA alternator
$72 | JUNE 1960
welding machines, the best frequency
of current for aluminum was found
to be 5 cps, whereas for steel the
best frequency was 10 cps.
3. Electroslag welds were made
in a low-alloy steel 2°,,, 3'/. and
6'/, in. thick with an electrode con-
taining 0.10% C, 1.75% Mn and
0.05% Si. At —4° F the notch im-
pact value was low for the as-welded
joint, but was high for normalized
specimens.
4. Stress-rupture tests on welded
joints in 1% Cr-—'/.% Mo steel
with and without 0.24% V were
made at 930 and 1020° F on welds
made by the CO, process. The
fractures were attributed to viscous
slip on the grain boundaries and the
segregation of vacancies there.
5. The rate of corrosion of welded
aluminum in nitric acid (10-80%
was found to attain a maximum at
30° concentration.
6. Micrographic evidence is pre-
sented for and against the theory
that polygonization of the solidified
metal is the cause of hot cracking in
austenitic steels.
7. An automatic submerged-arc
welding head is described using strip
steel electrode.
8. A line of all-metal ignitrons for
spot welding is described.
9. The hydrogen content of CO
weld metal was found to be almost
directly proportional to the moisture
content of the gas. A silica-gel
dryer is described.
SWITZERLAND
Two articles of particular interest
(Courtesy I1W)
have appeared in the Swiss welding
magazine Zeitschrift fur Schweiss-
technik. In the August 1959 issue
is a discussion of the design of tables
to support work for oxygen cutting.
The relative merits of copper and
cast iron saddles and pins for direct
support of the work are explained.
The second article in the September
and October issues describes the gas-
shielded arc welding of aluminum
components of dams for hydroelec-
tric power, including piling, dam
gates and penstocks. There are 600
gas tungsten-arc units and 50 gas
metal-arc units in service in Switzer-
land consuming 2,500,000 cu ft of
argon per year, of which 5% contain
oxygen for welding steel. About
20 tons of wire is used per year for
gas metal-arc welding and proba-
bly a similar amount for gas tung-
sten-arc welding. For oxyacetylene
welding of aluminum, about 3 tons
of flux are used every year. For the
aluminum hydroelectric fabrication,
starting plates were used to avoid
porosity. Several alloys were used,
including an experimental Al-Zn-Mg
composition for which an electrode
of different composition was re-
quired for gas metal-arc welding
to avoid cracks. The welds in the
dam gates had a tensile strength of
38,000-40,000 psi.
WEST GERMANY
The progress of research on
weldable low-alloy steels at the
Mannesmann Research Institute in
West Germany is reported in the
Aug. 6, 1959, issue of Stahl Und
Eisen. The preferred open hearth
steel to develop minimum yield
strengths of 64,000 psi at room
temperature and 50,000 psi at
662° F in the normalized condition
‘/, to 4 in. thick contained 0.16
0.24% C, 0.43-0.50% Si, 1.45
1.71% Mn, 0.10-0.15% V, 0.015
0.041% total Al, 0.015-0.026% total
nitrogen. Tests on 40 heats showed
that nitrogen could be controlled in
the open hearth. The vanadium
made it possible to secure desired
properties and nitride precipitate by
normalizing without recourse to
quenching. Good tensile, notch-
impact and bead-bend results were
secured with low-hydrogen elec-
trodes, with the automatic helical
contact electrode process and sub-
merged-arc welding. Submerged
arc welds in 4-in. thick plates of this
steel containing 0.26% V_ (weld
metal analyzed 0.03-0.12% V,
0.020% N, 0.37% Mo) had good
tensile, impact, and bend properties
at room temperature and 67,000-psi
yield strength at 662° F.
 Boscobel weldor is attaching Jalloy +1 steel wear
plates to Bucyrus Erie alloy body and manganese
steel lip with Wear-O-Matic WH wire.

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“We ar-O-Mati WH 15 the most versatilej we le le wu }f buc p; mainte- the abrasion o1 impact resi alloy
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and has excellent resistance to impact when used your weldor can apply build-up deposits
in time and labor through the semi-automatic ope to lesser worn areas such as latch pins,
keepers and lips . . . a deposit that will
wire have resulted in less bucket down time and lower
work harden to outwear manganese steel.
L. ARDEN HENLEY, SUPT. [o put more service life in > business
BOSCOBEL GRANITE CORP., MANAKIN, VA. end of your shovels and drag lines, in-
vestigate today the semi-automatic open
Ww" about bucket maintenance in trodes to obtain the necessary high arc application of Wear-O-Matic WH
your shops? Costs too high due to strength attachment welds for their rug- wires. You'll lower your maintenance
too many manual welding applications? ged rock handling chores [hese benefits costs decrease down time and in-
Ihe important benefit gained by Bos- can be yours whether you are welding crease working life. For complete de-
cobel Granite was the elimination of manganese to manganese, manganese to tails, request Bulletin AR-21 Alloy Rods
manual welding with stainless steel elec - carbon steel or either of these to any of Company, P. O. Box 1828, York 3, Pa.

ALLOY RODS COMPANY

YORK, PENNSYLVANIA
SALES OFFICES AND WAREHOUSES ©NEWARK, PITTSBURGH, PHILADELPHIA, BOSTON, CHICAGO, SAN FRANCISCO, EL SEGUNDO, CALIFORNIA — DISTRIBUTORS IN ALL OTHER PRINCIPAL CITIES

TWENTY YEARS OF LEADERSHIP IN THE DEVELOPMENT OF QUALITY ALLOY ARC WELDING ELECTRODES
For details, circle No. 5 on Reader Information Card
 Lewis Welding & Engineering Company of Bedford, Ohio, welded this annulus for
Clark Bros. Co. of Olean, New York, producers of industrial gas turbine engines.
Here’s
that’s
When this liner for an industrial gas
turbine annulus is hooked up to a com-
bustion chamber, it will face tempera-
tures over 1000°F. That’s how hot its
metal surfaces get when they channel
high temperature combustion gases to-
ward whirling turbine blades.
The welding of these dissimilar alloy
parts, one heavy, the other light, be-
comes really important when operating
conditions are considered. Shutdowns
are rare in industrial gas turbine ser-
vice, and welds must last for years. But
the Inco-Weld* “A” Electrodes used
here eliminate the possibility of weld
failure.
No heat problems
That’s because the Inco-Weld “A” de-
posit is both ductile and strong. In all
likely combinations, it is compatible
with high-temperature-type base metals.
Inco-Weld “A” Electrode, remark-
able for its ability to weld 97% of all
4~.
INCO
TRADE MARK
574 | JUNE 1960
a dissimilar alloy weld
reliable above 1000° F...
dissimilar alloy combinations, is equally
remarkable for its ability to provide
dissimilar alloy joints capable of long-
term resistance to heat and corrosion.
Operability is excellent
With Inco-Weld “A” Electrode it’s easy
to produce ductile X-ray quality welds.
You can weld in all positions, the arc is
spray-type, slag removal is good, and
spatter is at a minimum.
Inco-Weld “A” Electrode is supplied
in 3/32, 1/8, 5/32 and 3/16 inch diam-
eters, packed in 5-Ilb sealed asphalt-
lined containers for convenience and
protection.
Plan to use Inco-Weld “A” Electrode
Combustion chamber liner is made of In-
the next time you weld dissimilar alloys. conel* nickel-chromium alloy and other
For information on the weld properties high temperature alloys, production welded
you can expect, write for our 6-page with Inco-Weld “A” Electrodes.
brochure, “Now You Can Weld 97% HUNTINGTON ALLOY PRODUCTS DIVISION
of All Dissimilar Alloy Combinations The International Nickel Company, Inc.
with One Electrode.” *Inco trademar! Huntington 17, West Virginia
WELDING PRODUCTS
electrodes * wires * fluxes
For details, circle No. 6 on Reader information Card
 Productivity: Are We Doing Our Part?

“To whom much is given, of him shall much be
required.”
We have been given a wealth of knowledge and
technical skills. We have been shown how to
construct pressure vessels by welding to with-
stand extremes of heat and cold, high pressures
and high vacuums. We have been shown how to
weld all sorts of new materials. We have been
shown how to design for welding, so as to use less
or cheaper materials. We have been shown how
to use assembly-line techniques for welded struc-
tures of many sorts.
Over the years our Society has prepared and
published standards, codes and recommended
practices. These standards have become impor-
tant adjuncts to mass production. Our codes
have provided our regulatory bodies an assur-
ance in the reliability of welding. And our rec-
ommended practice manuals have been the media
by which many thousands of engineers and de-
signers from different branches of industry have
been shown how to make productive uses of weld-
ing.
As a result of efforts of those who went before
us, we have been given much. But, are we now
doing our part?
Have we become satisfied to maintain the sta-
tus quo? Are the new ideas, the new processes
and the new materials, which are pouring forth
from our research establishments, being put to
work? Are we opening our minds to the new
techniques being studied and used abroad? Or,
having taught the world techniques of mass pro-
duction, are we now content to let the world out-
produce us?
We have it in our power to see that compla-
cency does not set in. Both as individuals and as
a SOCIETY, we must see that we continue to do
our share toward the attainment of still higher
productivity. The opportunities in the welding
field are still enormous.
We must educate more and more technical, vo-
cational and engineering students in the knowl-
edge and skills that we have acquired. We must
constantly study and revise our publications so
that they never impede the use of new and better
techniques. Above all, we must let the public
know that through increased use of welding lies
still greater productivity.
The responsibility upon us is great The public
has a right to expect much from us. Let none of
us lessen his effort.

R. David Thomas, -Jr.

PRESIDENT
4MERICAN WELDING SOCIETY

EDITOR ASST. EDITOR PRODUCTION MANAGER ADVERTISING ART

B. E. Rossi Carl H. Willer Catherine M. O'Leary F. J. Talento Gil Miller

OFFICERS OF THE SOCIETY

R. D. Thomas, Jr. J. H. Blankenbuehler A. F. Chouinard C. E. Jackson H. E. Rockefeller
Welding
President Vice-President Vice-President Vice-President Treasurer
F. L. Plummer F. J. Mooney E. A. Fenton A. L. Phillips
Secretary Asst. Secretary Technical Secretary Info.-Ed. Sec
Journal
WELDING JOURNAL COMMITTEE
J. E. Norcross Chairman 0. B. J. Fraser A. G. Oehler R. D. Stout
H. R. Clauser Vice-Chairman John Haydock A. V. Scherer E. J. Tangerman
|. E. Boberg J. N. McCracken R. E. Somers
 CP-3-VS

Complete specifications, as 2I| as recommendations for your particular

application problems, -will be sent promptly upon request

rk 19 NY e Dp tributed anada
For details, circle Ne. 7 on Reader Information Card
576 | JUNE 1960
 Fig. 1—Four-track bridge on main line of Nickel Plate Railroad in Cleveland
Ohio, is United States’ first welded rigid-frame railroad bridge
Conception, Design and Fabrication
Welded Rigid-Frame Railroad
results in a structure that is clean lined, economical
maintain and free from hazardous columns
BY R.T. BLEWITT, H. T. BORTON AND
ABSTRACT. A_ rigid-frame welded-steel bridge was
selected as the railroad supporting structure for a grade
separation project at E. 222nd St. and the Nickel Plate
Railroad in Euclid, Ohio. The bridge is divided into
three parallel structures: the center bridge carries the
east- and west-bound main tracks; each outside bridge
supports an industrial track and a 4-ft 4-in. sidewalk
with steel railing. Structural-steel elements comprise a
series of parallel welded-steel ribs or frames of 91-ft
1' .-in. span and 37-deg, 59-min, 10-sec skew, covered
with composite reinforced-concrete deck. The bridge
was designed for Cooper’s E-72 loading in accordance
with AREA Specifications. Alloy steel was used to
reduce weight of sections and thickness of material to be
welded. The completed bridge provides a clean-lined
structure, economical to build, easy to maintain and free
from hazardous columns in the underpass
General Details
Elimination of a grade crossing at E. 222nd St. and
the Nickel Plate Railroad in Euclid, Ohio, pro-
grammed for completion in November 1959, is fea-
tured by a four-track, rigid-frame, welded-steel
bridge with 68-ft clear span and 91-ft girder frames,
one of the few structures of its kind in the United
States. The $1.6 million project includes, in addi-
tion to the bridge, 12,000 sq yd of 9-in. concrete
R. T BLEWITT is Bridge Engineer New York, Chicago & St. Louis
tailroad Co Cleveland, Ohio. H.T BORTON is President of Osborn
Engineering Co., Cleveland, Ohio, and J P. JASO is Welding Engineer
of the Lincoln Electric Co Chicago, Ill
Paper presented at AWS 1959 National Fall Meeting held in Detroit
Mich., Sept. 28-Oct. 1, 1959
of a
Bridge
to build, easy to
in underpass
J JASO
highway pavement, 23,200 sq ft of concrete sidewalk
and 1400 lineal ft of retaining walls of varying heights
see Fig. 1
A traffic count prior to the start of construction
indicated that, during a 24-hr period, about 8400
highway vehicles and 80 trains cleared the crossing.
In addition, many of the trains were switching rail
movements because of the presence of a nearby
classification yard in the midst of a highly industrial-
ized area.
Location of an existing sanitary sewer, a desired
15-ft vertical clearance and the objection to raising
existing tracks more than 18 in. predetermined that
the maximum depth from top of rail to the clearance
point would be limited to 6 ft. Highway require-
ments dictated a 68-ft clear span at right angles to a
roadway having a 37-deg, 59 min, 10-sec left forward
skew. No obstruction could be permitted above the
top of rail due to trainmen performing switching
operations.
Highway traffic at the crossing was shut off com-
pletely during the construction period, although rail
traffic was maintained by installing runaround tracks
on each side of the new bridge structure. This per-
mitted the contractor to build three-fourths of the
bridge before the railroad shifted three tracks back to
their permanent location. The entire job was
handled without interference to rail movements,
other than occasional speed restrictions.
WELDING JOURNAL 577
 Design Requirements since the presence of columns in the underpass was
The track-supporting structure was designed for felt to be hazardous to vehicular traffic. Test bor-
Cooper’s E-72 loading in accordance with AREA ings at the site disclosed shale near the surface, ex-
Specifications. Structural steel, designed for a tending to a depth well below the bottom of the
tensile stress of 24,000 psi, was required to conform to proposed footing. Preliminary calculations of hori-
ASTM A-242-55_ specifications. Required clear zontal frame thrust indicated that all reactions could
span and minimum vertical clearance were 86 ft be transferred directly to the shale. This condition
4 in. and 15 ft, res~9r-egtiice This span was neces- eliminated the need for tension ties between the
sary to clear the 52-ft roadway plus two 8-ft side- columns, thereby making a rigid-frame stru°ture
walks because of the skew in the alignment of the suitable. The vertical-clearance problem dicatated a
street and the railroad right-of-way. A total width maximum bridge-depth limitation from the top of
of 63 ft 8 in. was necessary to accommodate the rail to the clearance point of slightly more than 6 ft.
mainline tracks, the two switching tracks and the Preliminary designs proved that a reinforced-con-
two steel-railed sidewalks (see Fig. 2). crete frame would not provide adequate vertical
clearance. <A steel frame could feasibly meet the
Selection of Span Type rigid-strength and clearance requirements and, there-
The use of a single-span structure was specified, fore, was selected as the type of structure to be used.
Rounded knees at the girder ends
met strength, fabrication and ap-
pearance demands more satisfac-
torily than straight tapered knees
and were accordingly approved.
A study of welded vs. riveted
frames favored the former in respect
to weight of material, appearance
and over-all economy.
Field splices were decided upon
since one complete span frame was
dimensionally too large to be
¢
SWITCHING shipped by rail. High-strength
/ ee LEAD
ree bolts were used for these field con-
a, 4 Ar WEST BOUND nections. The girder and knees
/37°59 10", if F a head MAIN
LA ¢ EAST BOUND could be shipped in one piece, so the
a MAIN logical location for each field splice
¢ SWITCHING was in the column just below the
LEAD knee-to-column section. Spiral shear
connectors were field welded to the
top flanges of the girders.
Choice of Alloy Steel
The use of A-242 steel was ana-
TOP OF RAIL
7 lyzed and was found to offer two
T > n TOP OF SHALE
@ 36W 230 particular advantages. First, the
2 higher allowable stresses permitted
thinner sections and plate thick-
66-0 nesses, which were a definite aid
o'- 4% c/C COLS from the standpoint of reducing
SECTION A-A welding costs. For the knee where
_. = 3 most of the shop welding was con-
63'- 8" centrated, A-242 steel made possible
_15-0" 6-6" 6-6" 5-0" 5-4 4-4, 1*/,-in. flange plates in. web),
as compared to 2-in. plates for
ASTM A-373-58T steel. Second
salts jest seins cstaich item, with A-242 steel the girder
ITitd friiiiiil LT LLL
L bsew and column sections required were
36 WF 230 and 36 WF 260 respec-
SPA.
@ 2-6"| 5-0" 4SPA@ 2-6" Nilewnone; 5-0"42 SPA.@ 2-¢
0-0" tively while the sections required
-O 10-0" 10-0" for A-373 steel would have been 36
SECTION B-8 WF 260 and 36 WF 300 respectively.
°—EE=_5S a
° Preliminary cost studies indicated
Fig. 2—Plan and sections of bridge comprised of twenty 91-ft that the savings in material more
rigid frames. Skew angle is about 38 deg than compensated for the premium

578 JUNE 1960

 —Jop fla ng¢ splice
aaa "TF"
oe ————— =
:

™ ~S
mee—i
| Deta; “BE
5
= Bottom flange splice
Cut web to permit -
| Continuous weld

“60
Detai/ BF”
Bottom flange splice

——
Fig Drawing of welded knee showing details of splices in top and bottom flanges
joining knee to center-section beam Note web cutouts to 5 ermit contir US welds

paid for the higher-strength alloy steel, resulting in
over-all economy. An additional consideration on
the positive side was the increased resistance to cor-
rosion of the high-strength steel.
Design Conclusions
The choice of rigid steel frames for the bridge struc-
ture solved the problems imposed by severe space
limitations. The suitability of the frames for situa-
tions requiring minimum girder depth, coupled with
the presence of good foundation conditions, made the
selection of this type of structure an obvious one.
General economy, ease of fabrication and erection,
and appearance requirements favored the use of
welded frames of high-strength steel. Deflections
and stresses were reduced by making use of composite
action.
Welding Details
Shop fabrication and welding of the 20 frames were
worked out carefully to hold dimensional require-
ments and to avoid post-welding distortion. As-
sembled pieces were clamped down rigidly and stif-
fener plates were welded in place before welding the
flanges to the web plate on the knees. As mentioned
previously, principal welding was confined to these
knee or haunch sections, since the center portion of
the span was a wide-flange beam of 36-in. depth,
requiring only the addition of a few stiffener plates
at about 8-ft intervals. Stiffeners were omitted on
the outside web faces of the two outer frames on each
five-member unit, this in the interest of appearance
and conformance with Ohio highway-bridge speci-
fications
Splices between the knee-flange plates and the
center section are detailed herewith. They are
double-vee joints, connecting the 1 -in. flange of
the center beam to the 1*/,-in. flange of the knee.
Top-filange splice is set back 2 ft from the bottom-
flange splice, and the web-plate splice is between
them. There are three full-depth radially disposed
stiffener plates on each side at the corner of the knee,
flanked by two triangular stiffener plates 18-in. deep
and welded to the web and bottom flange (see Fig. 3
All splices were X-rayed. A few defects were
found and were corrected by compressed-air carbon-
arc gouging out and rewelding. Actually less than
5% of all welds X-rayed showed any defects. Joints
were oxygen cut and ground. Stringer passes were
made with iron-powder type AWS E-7016 electrode,
as were fillet welds on stiffener plates. Fill-in passes
were made with fast-travel iron-powder electrode,
AWS E-6027. All welding was done manually.
Assembly procedure, briefly, was to fabricate the
knee in a jig, using templates to insure proper curva-
ture: then to weld in the stiffeners on the wide-

WELDING JOURNAL 579

 Fig. 4—Joint edges in cut web plates and formed flange Fig. 5—Web and flange plates were assembled in this
plates were ground to insure best fit-up. Webs were given jig for tack welding
double bevel to provide 100% penetration. Note web tem-
plate in background
form a 45-deg joint on both sides of the web. They
were fitted tight with an allowable gap of ' , in.
Once again, the welding started in the center of the
knee and progressed outward with two men doing the
welding. The compression flange was welded to the
web using s-in. low-hydrogen electrode and then
filling in with ' ,-in. E-6027. The tension flange was
then welded to the web using the same procedure
see Figs. 5 and 6).
The center-beam span was a continuous beam and
the only welding required was on the stiffeners.
Low-hydrogen electrodes were used, first, to weld
stiffeners to web of beam; second, to weld stiffener
to compression flange; and, third, to weld stifferer
Fig. 6—Assembled knees were removed from jig after tack- to tension flange.
ing for welding of stiffeners and web-to-flange joints. E-7018 The knee and center-beam span were then spliced
electrodes were used for root passes, and E-6027 for filler together. Welding proceeded at both ends of the
passes. Prescribed sequence was used to control distor- frame simultaneously, duplicating the following pro-
tion
cedure at each end (see Fig. 7).
The pieces were laid flat and the top and bottom
flange splices were welded on the outside using low-
hydrogen electrode E-7018, welding vertically up.
The web splice was then welded on one side with a
low-hydrogen electrode for stringer pass and then
filled in with type E-6027 electrode.
The whole section was then turned with legs up as
in Fig. 8. The unwelded side of the top-flange splice
was arc gouged on both sides of the web and then
welded to complete the top-flange splice. The top
flange-to-web fillets, now in the horizontal position,
were welded first on one side, then arc gouged from
the other side and completed. E-7018 and E-6027
Fig. 7—Knees were welded to center-section rolled beam electrodes were used.
beginning in this position. Welding vertically up, top- and Next, the section was laid flat, again continuing
bottom-flange splices were welded on outside. Web joint rotation so that the unwelded side of the web was
was also welded on one side
now up. The web splice was completed using the
same procedure as before, after arc gouging to good,
flange-beam center section, and then to hook up the sound weld metal.
knee to the center section in the flat position see The section was then further rotated to the legs-
Fig. 4). down position. The inside of the bottom-fiange
The welding procedure on the knee sections was as splice, now in the downhand position, was gouged and
follows: 1) fit and tack stiffener tight to the tension welded. The bottom flange-to-web fillet welds were
flange; (2) weld stiffeners to the web starting from also completed, using the same procedure as on the
the center and working out; (3) weld stiffener to top.
compression flange; (4) weld stiffener to tension The flange and web welds were all X-rayed. Care-
flange. ful edge preparation, proper welding procedure and
The web plates were then welded to the flange correct electrode selection resulted in high-quality
plates. Web plates were given a double bevel to welding.

580 JUNE 1960

 Ay
Ae

ITE,
LLIN

™~ > 7°
Fig. 8—Assembly was turned up to weld inside of top-flange Fig. 9—Three rail cars were required to
splice and both sides of web-to-top-flange joint. Next, ship three frames to the bridge site
frame was rotated around to flat position and then to legs-
down position to complete all weids

A 50-ton overhead crane and supplementary 5-ton

hoists aided in shop handling of the lengthy and
heavy frame sections. When completed, three of the
frames were placed on three railroad cars for ship-
ment to the bridge site. Long-boom crawler cranes
at the site handled unloading and positioning on the
stub columns for bolting in place (see Fig. 9).
Spiral shear connectors are formed from */,-in.
diameter plain round rod, the spirals having varying
pitch over the length of the frame. The spirals are
attached to the top flange with two ‘/,,-in. fillet
welds of 2'/, in., effective length at each point of
contact with the top flange, one weld on each side of
the bar. Welding was started at either end of the
frame and progressed toward the center (see Figs.
10, 11 and 12).
The fabricated frames weigh 15.6 tonseach. Add-
ing to this the 40 stub columns, total weight of steel
in the project was 422 tons, not counting railings and
other minor details (see Fig. 13).

Arrangement of Frames Fig. 10—Frames were unioaded from cars and put into ex-
The structure was divided into three separate cavation which was not completely dug out to permit trains
bridges. The center one carries the east- and west- to detour around site. Site was prepared with footings and
stub ends of columns to receive frames
bound main tracks, while each of the other side
bridges carries an industrial track and a sidewalk.
This arrangement permitted a construction sequence
that allowed restoration of normal railroad-traffic
conditions with the least delay after start of construc-
tion.
Five frames spaced on 2-ft 6-in. centers, were
needed for each track—-20 frames in all. The sup-
porting columns are 91 ft 4'/, in. center to center,
and hinges were assumed at the base of the founda-
tions. Vertical loads were assumed carried uni-
formly by each set of frames.
Design Analysis
The frames were analyzed by the method of virtual
work for the following effects:
. Dead load (1.30 kips per foot per frame).
. E-72 live load.
3. Impact for steam locomotive and rolling effect
(57% LL). Fig. 1l—Frames are bolted to columns which were covered
. Longitudinal braking force (15% LL). with concrete. Shipping restrictions on height of leg re-
. Lateral earth pressure. quired field splice. Each frame weighed about 15.6 tons

WELDING JOURNAL | 581

 6. Surcharge of axle loads. method based on the wedge theory as presented by
7. Temperature effects. H. C. Olander in the 1954 Transactions of the ASCE.
The effects of the 37-deg plus skew were deemed to Maximum moment and direct load were 2460-ft kips
be insufficient in magnitude to warrant alteration of and 240 kips, respectively, at the deepest section, but
this was not the critical section.
the design.
Design moments and direct loads for the girders Stresses were higher in all other sections of the
are: knee, with the critical stress occurring 15 deg from
the column-to-knee location. A combined stress
M + 1538-ft kips and P 144 kips at mid- of 22,600 psi at this section resulted in the sum of
span. stress to allowable ratios, fa/Fa + /fb/Fb, of 0.974.
M 1456-ft kips and P 153 kips at the All design moments, direct loads and shears are based
knee-to-girder section. on the critical combination of load effects for each
Critical condition in the column is at the column- particular section.
to-knee section and is designed for M 1750-ft kips Foundation dimensions were based on an allowable
and P = 197 kips. The knee was analyzed using a bearing pressure of 5 tons psf. Total vertical load

s
bie al I . oe f\
* _ —_—

Fig. 12—Spiral sheer connectors were welded to top flanges to tie into reinforced-concrete deck
Fig. 13—Completed bridge before excavation was completed. No stiffeners were used on outside of end frames

ee -
et ae
.
Fig. 14—Finished structure has low, clean lines from track side
at the base of the concrete foundation was 200 kips
per frame and resulted in a bearing pressure of 4.53
kips psf. Horizontal thrust of the frames was re-
sisted by friction at the base of the foundation, as well
as by bearing on the vertical face of the shale. Re-
sulting horizontal bearing pressure was 4.34 tons
psf.
Reinforced Concrete Action
The columns were encased in concrete to a point
above the knee-to-column section. This was done
to eliminate the undesirable niches between the
columns at pedestrian level which were considered to
constitute a maintenance problem. The resulting
composite action stiffened the column sections to
provide a more rigid structure. The concrete deck
is secured to the girders by spiral shear connectors
to effect the composite action for that part of the
frame. This also increases the stiffness of the frame
and serves to reduce live-load stresses and deflections.
Another advantage of the composite action is that
separation of the deck from the girders is prevented.
Camber
A camber of 3! in. was provided which allowed
for a total dead-plus-live-load deflection of 1 in.,
plus a 2-in. residual. Such a large residual was con-
sidered necessary to counterbalance the visual effects
of sag which may be more pronounced than usual due
to the long approaches of the highway.
Deflection
A series of deflection observations were taken on
one bridge during pouring of the concrete deck. The
concrete encasement of the columns had cured by the
time the deck was poured. Results of the deflection
calculations, based on the bare girder section and
composite action of the columns, were compared to
observed values. Assuming no interaction of the
frames, the calculated midspan deflection at the end
of the pouring operations was 0.313 in. for the outside
frame and 0.168 for the first interior and center
frames. Measured deflections were 0.209 in. for
the outside frame, 0.171 in. for the first interior
frame and 0.156 for the center frame. The greater
deflection of the outside frame was caused by a heavy
curb on the deck.
Full composite action was considered for all loads
added after the deck had cured. Deflection of one
completed bridge was measured under a static load
of a light switcher locomotive and loaded hopper cars
having axle loads of approximately 58 and 34 kips,
respectively. The maximum observed static defiec-
tion was 0.155 in., or approximately 5% of the
theoretical value for the applied loads.
The foregoing tests indicate that the assumptions
for the design for effectiveness of composite action
were conservative, but nonetheless satisfactory.
Deck curbs were provided with expansion joints
every 15ft6 in. The joints are intended primarily
to eliminate cracking of the curbs due to excessive
strain under deflection.
Approach Detail
Concrete approach blocks perpendicular to the
tracks are provided at each abutment. The ballast
covering these blocks varies in thickness from that of
the roadbed to that on the bridge deck. The blocks
serve to ease the train onto and off the bridge without
imparting a rolling action. Both wheels of an axle
meet and leave the edge of the block simultaneously.
Acknowledgments
Project costs were borne by Cuyahoga County,
the City of Euclid and the railroad in the ratio of
42' .,42'/,and 15%, respectively. The general con-
tract was prepared by the County under the direc-
tion of A. S. Porter, County Engineer, with the assist-
ance of A. V. Dollard and M. Friedman. National
Engineering and Contracting Co. was awarded the
general contract. Fabrication of structural steel was
the responsibility of Allied Structural Steel Co.,
Chicago. Welding sequence and procedure were de-
veloped in cooperation with the Lincoln Electric
Co. Steel erection was handled by Vogt and
Conant Co. Inspection of steel fabrication and erec-
tion was performed by the Pittsburgh Testing Labo-
ratories and by the railroad, respectively, the railroad
being the designated owner of the structure.
The over-all design was worked out by Osborn
Engineering in consultation with bridge engineers of
both the railroad and the County. Structural anal-
ysis was prepared by John B. Scalzi, Ralph Scott and
Gregory Chacos, Osborn Structural engineers, with
the assistance of Paul Montgomery of the Nickel
Plate Railroad.
WELDING JOURNAL 583
 preparation of bevels is an important aspect of the
oxygen-cutting process, yet very little information
has been published concerning it. If the requirements
of bevel cutting were principally the same as perpen-
dicular cutting this would be understandable, but
such is not true. The characteristics of bevel cut-
ting are, in many respects, very different from those
of perpendicular cutting, and therefore much of the
available data are not applicable.
The purpose of this paper is to discuss the specific
problems of bevel cutting and to develop information
parallel to that already available for perpendicular
cutting.
The paper discusses the requirements of preheat,
cutting oxygen and cutting speed in bevel cutting
and compares these functions to their corresponding
values in perpendicular cutting. It offers practical
information on adjustments of torches and operating
techniques to obtain quality results, and it compares
the relative ability and economy of several common
preheat fuels in beveling.

The Relationship of the Cutting

Variables in Bevel Cutting
The significant variables of any oxygen-cutting
process are preheat, cutting oxygen and cutting
Fig. 1—General view of bevel cutting speed. The establishment of these generally defines
the process.
Preheat
In bevel cutting, the most significant variation
Specific Problems Associated from perpendicular cutting occurs in the preheat.
As would be suspected, the glancing angle at which
the flames strike the work causes a loss of heat-input
with Oxygen Cutting of efficiency. ‘The greater the bevel angle, the greater
the efficiency loss. In order to maintain sufficient
heat for beveling, this loss must be compensated by a
corresponding increase in heat input, usually in the
Bevels form of greater preheat flow.
At angles less than 15 deg from the vertical, the loss
are discussed and information parallel of preheat efficiency is slight and, in most cases, can
be neglected. As the angle increases above 15 deg,
to that already available for however, the loss becomes noticeable and, at angles
of 45 deg and higher, the preheat requirement in
perpendicular cutting is developed beveling may be six to ten times that needed for
ordinary perpendicular cutting.
SY @ 8. SPIES, JR Figure 2 shows the relationship between preheat
flow, bevel angle and material thickness. It is pre-
sumed in this figure that all cuts on a particular ma-
terial thickness, regardless of bevel angle, are made
Oxygen cutting of steel is a process so well established
at the same speed as generally recommended for per-
in industry that it needs no introduction. A great
pendicular cutting of that thickness. This speed is
deal of information has been developed concerning
also shown on the horizontal axis.
the process and much of it has been published. It
It is seen that the greater the bevel angle, the
will be found, however, that virtually all of this
greater the required preheat flow. This is as would
material covering cutting speeds, oxygen and fuel
be expected. It is also seen, however, that at a
flows, fuel comparisons, etc., is based upon perpen-
constant bevel angle, the thinner materials require
dicular or square-edge cutting. heavier preheat than the thicker. This is peculiar
From the standpoint of production tonnage, the
because it is exactly the opposite of perpendicular
G. R. SPIES, JR. is associated with the Air Reduction Sales Co., New cutting. Directly related to this same effect is the
York, N. Y
amount of increase of heat needed for beveling, as
Paper presented at the AWS 4ist Annual Meeting held in Los Angeles,
Calif., April 25-29, 1960 compared to perpendicular cutting. The flow

584 | JUNE 1960

needed for perpendicular cutting is shown in this cutting, becomes less. For materials in the '/, to
figure in the form of a dotted line which is seen to be 1/.-in. thick range, beveling flows may run six to ten
almost level. This figure shows that, for thinner times corresponding perpendicular flows. When
materials, the flow needed for beveling is many times thickness reaches 4 to 5 in., the bevel flows are essen-
greater than that needed for perpendicular cutting, tially equal to the perpendicular flows.
but, as the thickness increases, the amount of flow The reason why the preheat-flow requirements for
increase for beveling, as compared to perpendicular beveling increase with increasing bevel angle is
readily apparent. The more obliquely the flames
strike the work, the greater is the actual area being
heated by these flames and, hence, the lower is the
temperature attained. This is illustrated in Fig. 3.
It is the same as the loss in effectiveness of the sun’s
radiation in winter when the greater slant of the
rays spreads them over a larger area of the earth.
To heat a larger area to the same temperature re-
quires a greater amount of heat input.
Also, the efficiency of the preheat is reduced, as
bevel angle increases, by the reduced impingement
force of the gas stream as it strikes the work. It is
FLOW well known that the purely kinetic impingement force
of the gas stream on a body has an important bearing
on the heat-transfer efficiency of any flames. The
loss in heat input from flames at an oblique angle may
be likened to the lower force that is realized from a
FUEL
PREHEAT garden hose when the stream impingement is oblique
to a surface instead of perpendicular. ‘These reasons
explain why more preheat flow is required as bevel
angle increases for any given thickness of material.
The reason why the amount of this increase is less
for thicker materials than for thin, or why thinner
materials require more preheat than thicker for the
same bevel angle, is not quite as apparent. How-
(8) IN. </MIN ever, it can be explained if we consider the cutting
[SPEED 00) | ee—
172 2 3 speed which is used for the various thicknesses.
BEVEL FACE WIDTH (MTL. THICKNESS) It is shown in Fig. 4, and will be further discussed
later, that the cutting speed has a very marked effect
Fig. 2—Typical preheat requirements for bevel on preheat flow at any bevel angle. When we ob-
cutting various material thicknesses
serve that a higher flow is needed for beveling
-in. material than for 2-in. material at the same
angle, we are really observing only the difference in
flow required between cutting at 18 ipm and at 10
ipm. The faster speed for the thinner material re-
quires the higher flow. Actually, as will be pointed
out later, the material thickness itself has no effect on
preheat flow in beveling; therefore, any difference
that is observed is solely the effect of speed.
The only difficulty that arises in accepting this
theory is that it does not seem to apply to perpen-
dicular cutting. In perpendicular cutting, thinner
materials usually require equal or less preheat than
thicker, even in spite of their higher cutting speeds.
The reason for this exactly opposite behavior between
/5 bevel cutting and perpendicular cutting cannot be
( explained with scientific proof at this time, but one
)
rd possible theory is advanced. This theory presumes
Q () that the function of preheat in cutting fulfills two
<
purposes: (1) heating of the work to kindling temper-
$
ature, which is essentially a surface effect, and (2)
RELATIVE AREA OF HEAT INPUT forming or “‘disciplining”’ the cutting-oxygen stream
Fig. 3—Comparison of preheat area in perpendicular so that it maintains its “‘strength” through the full
and bevel cutting cut, to give smooth quality to the cut. This may be

WELDING JOURNAL | 585

 30° BEVEL ANGLE
CUTTING
SPEED
100 60
PREHEAT
(A) NATURAL GAS (B) PROPANE
Fig. 4—The relationship between preheat fuei flow and bevel-cutting speed
considered a thickness effect. That part of the pre-
heat which is concerned with the thickness effect
might be expected to require increased flow with in-
creased thickness, and that part which is concerned
with the surface effect might be expected to require
increased flow with increased surface (surface per
minute being heated) which is, of course, directly re-
lated to increased speed.
In perpendicular cutting, it may be supposed that,
because surface conditions are more favorable to
heat transfer (minimum area being heated and per-
pendicular impingement of flames), the proportion of
the total preheat, which is used in the surface func-
tion, is relatively small. Consequently, that portion
entering into the thickness function will be relatively
large. Therefore, as material becomes thinner and
speeds increase, the increased requirement of preheat
in the surface function is counterbalanced, or even
exceeded, by the reduced requirement for preheat in
the thickness function. The net result in total pre-
heat, therefore, is no change, or even a slight reduc-
tion for the thinner materials.
In bevel cutting, however, it may be supposed that
because surface conditions are less favorable to heat
transfer (increased area being heated and lower im-
pingement efficiency), the surface-function require-
ment will become much larger while the thickness-
function requirement increases only slightly or not at
all. Hence, it may be supposed that almost all of
the large increase in preheat needed for beveling over
perpendicular cutting goes into the surface function,
and thus this function in bevel cutting is now a very
large proportion of the total preheat, and the thick-
ness function is a relatively small proportion.
Therefore changes such as speed, which affect the
586 | JUNE 1960
20 40
FUEL FLOW
ACETYLENE
surface function of the preheat, will be so large as to
override any counteracting opposite changes re-
sulting from the thickness-function requirements,
and thus the total effect on preheat in beveling will
be a marked increase in fuel flow as thicknesses be-
come less. Let us restate that the above is merely a
theory postulated to explain observed facts, but it
does appear to fit the results.
It is apparent then, from the foregoing, that for
beveling materials over 4 in. no unusual preheat
problems are generally posed, but for materials
lighter than this and especially for those less than
1 in., much heavier preheats are often required.
When gas-supply pressures are high, there is no
problem in obtaining the flows necessary. There
are cases, however, when gas pressures are limited
and the required high flows cannot be obtained.
This is especially true in the case of natural gas,
which is frequently supplied at inches of water
pressure. When preheat flows are inadequate, it is
still possible to obtain good bevel cuts, but it is
necessary to increase preheat input by the alternate
method of slowing down the cutting speed.
Figure 4 shows the relationship between cutting
speed and preheat flow for various bevel angles.
It is seen from this figure that satisfactory bevel
cuts can be made at almost all reasonable preheat
flows provided that a corresponding adjustment to
speed is made. It must be borne in mind, of course,
that slowing down the cutting speed almost always
adversely affects production costs. Therefore, from
the standpoint of economics, it is usually more favor-
able to increase gas flows, if possible, rather than re-
duce cutting speed.
It is of interest to note that in Fig. 4, no reference
 is made to material thickness. In the range of mate-
rials under 4 in. in thickness, it was found that the
fuel flow for bevel cutting is not affected by material
thickness itself. This was determined by series of
cuts which were made at the same angle and speed on
various material thicknesses. It was determined
that, so long as the angle and speed were held con-
stant, the preheat did not vary for the different mate-
rial thicknesses. On the other hand, when speed or
angle were varied, the effect on preheat flow was
found to be the same for all thicknesses. Apparently
the problem of heat transfer into the surface of the
work is so dominant in bevel cutting that all other
functions of the preheat through the depth of the
cut are overridden.
Cutting Oxygen
It has been noted that preheat is the most signifi-
cantly affected variable in bevel cutting, and the
nature and extent of its variations from perpendicular
cutting have been discussed. The second important
function in any oxygen-cutting process is the cutting
oxygen.
Unlike preheat, the requirements of cutting oxygen
in beveling are very similar to those of perpendicular
cutting. The cutting-oxygen requirements in bevel-
ing are found to be solely a function of the thickness
of cut through which the cutting stream passes.
They are not affected by the angularity of the bevel
cut, except as such angularity affects the total length
of actual material penetration.
As an example, let us consider 1-in. material. A tips.
perpendicular cut through this material is obviously
lin. long. If a cut is made at 45 deg, however, and
the cut extends completely from top to bottom of the
plate, then the actual length of stream penetration
through the material is 1.41 in. The cutting-oxygen
flow needed for this cut is the same as to cut 1.41
thick material perpendicularly. If, however, the
45 deg bevel is made at the edge of the plate, in such
a manner as to form a bevel and land in which the
actual length of the cut penetration is 1 in., then the
cutting oxygen flow will be the same as to cut the 1-
in. material perpendicularly.
In order to determine the correct cutting oxygen
for bevel cutting, therefore, it is necessary to deter-
mine, either by scale measurement or calculation,
the actual thickness of material through which the
cutting stream will penetrate. The correct adjust-
ment will be the same as for perpendicular cutting
material of that thickness.
It is interesting to note the directly opposite
characteristics of preheat and cutting oxygen in
bevel cutting. While preheat varies with bevel
angle and is not affected by material thickness, the
cutting oxygen on the contrary varies only with
thickness penetration and is not affected by bevel
angle.
Cutting Speed
The remaining variable defining the cutting process
is speed. It has already been shown in Fig. 2 that
bevel cutting can be accomplished at the same cut-
ting speed as an equivalent perpendicular cut.
The adjustment of speed follows the same formula
as cutting oxygen; that is, determine the actual
thickness penetration of the cutting stream and ad-
just the cutting speed to that specified for an equiva-
lent perpendicular cut. Sufficient preheat, of course,
must be available to satisfy this speed. If such pre-
heat is not available, speed will have to be reduced,
as previously described.
Sometimes a bevel made at full speed, however,
does not give the smoothness of finish desired. As
in perpendicular cutting, smoothness of the cut face
in beveling is improved by slowing down the cutting
speed. Often an accompanying slight reduction in
cutting-oxygen pressure also further improves qual-
ity. When seeking high-quality bevels, therefore,
speed should be reduced and cutting-oxygen pressure
adjusted until the desired finish is achieved.
When speed is reduced in order to obtain improved
quality, a corresponding reduction in preheat must
be made to avoid excessive melting of the material.
Equipment and Operating Techniques
Although many variations of torch holding,
angling and traversing mechanisms are available for
both single- and multiple-torch beveling, the actual
torch and tip equipment itself need be no different
than for conventional perpendicular cutting. The
previous discussion of flows, speeds and thicknesses
is based upon the use of conventional torches and
It has been mentioned, however, how the glancing
angle of the preheat in beveling causes a loss of heat-
input efficiency and thus requires the use of greater
fuel flows or the slowing of cutting speeds. It is
possible to minimize this loss of efficiency and im-
prove the economy of beveling by the observance of
proper operating techniques and the use of some
special equipment.
Auxiliary Preheat Torches and Adapters
In order to counteract the effect of the glancing
preheat, it is advantageous to apply a portion of the
preheat at as nearly right angles to the work as possi-
ble. This is often done by providing an additional
torch with flames striking the work in advance of the
main cutting tip and at right angles to the material.
The auxiliary torch does no cutting but provides only
a leading preheat. This technique, although using
preheat at two locations, actually consumes less
total gas than does a single, angled tip and allows
faster beveling speeds, but it is rather cumbersome.
The same result can be accomplished with an
adapter used in a single torch which divides the pre-
heat and applies a portion of it at right angles to the
material. Figure 5 shows such a device. The
savings in fuel or increase in speed which is obtained
by use of this device is shown in Fig. 6.
This device is less cumbersome than the two-torch
procedure. Unfortunately, a disadvantage is its
directional limitation. Because of the fixed arrange-
WELDING JOURNAL | 587
 ment of the auxiliary tip, there is only one direction
of cutting in which it correctly leads the cutting tip.
Therefore, it is necessary to have a left-handed and
right-handed model of this adapter to cut in both
directions as shown in Fig. 7.
Tip Adjustment and Flame Ratio
Also in connection with operating technique, it is
important in bevel cutting to carry the tip close to
the work and to use a hot oxygen-fuel gas ratio.
Both of these adjustments must be determined by
trial by the operator. In tip spacing it is usually
found that the top flames of the preheat circle, having
the greatest tip-to-work distance, should just touch
the work, while the underneath flames are “buried”’
in the work. Bevel cutting is very sensitive to the
tip spacing and small variations cause large differ-
ences in results. If, for some reason, the tip cannot
be carried close to the work, auxiliary preheat or a
bevel adapter will have further advantage in main-
taining good efficiency.
. 5—Photo of auxiliary preheat bevel adapter The hottest flame, and consequently the best for
beveling, is usually found to be more oxidizing than
= that usually used for perpendicular cutting. The
flame ratio giving the best results will have to be
found by trial, but the operator should expect to
look for the more oxidizing adjustment.
WITH ADAPTER Recognizing Correct Adjustments
Preheat. The correctness of cutting oxygen, pre-
heat and speed in any beveling application is best
judged by the appearance of the cut. If the cut is
a alternately good and then gouged or even if it is
a
Ww mostly good but is intermittently gouged, it is a
a WITHOUT ADAPTER
yn sign of insufficient preheat or too-high speed, both of
oO which are essentially the same problem. In order to
z
- maintain speed, the preheat flow must be increased
i
2 sufficiently to give a continuous cut without gouges.
oO
If preheat cannot be increased and gouging is still
present, the speed must be reduced. Preheat should
be increased or speed reduced just enough to elimi-
nate all gouging.
Because the preheat required for beveling is often
SEVEL ANGLE = 52° so much greater than that used for perpendicular
MATERIAL THICKNESS UP TO 4 cutting, it is frequently the tendency of operators to
work with too little heat. Operators must be in-
eBDies d ae Pe
30 40 50 60 70 80 structed in the heavy heat requirements for beveling
PREHEAT FUEL FLOW so that they become accustomed to use of the proper .
(PROPANE) flames.
Fig. 6—Typical savings in preheat through the Too-much preheat or too-slow speed is indicated
use of the adapter shown in Fig. 5 by excessive melting of the top edge of the good plate.
Speed should be increased or preheat reduced until
the top edge issharp and clean. No attention should
be paid to the top edge of the opposite or waste sec-
tion of the plate as this usually melts out severely
under conditions which give good bevel results.
Speed. The best speed adjustment is recognized
by the smoothness of finish desired. As previously
~ noted, speed can be as high as in equivalent perpen-
»
~ NY vA J; dicular cutting; however, this often results in a fairly
RIGHT HAND LEFT HAND coarse finish of cut face. A good-quality, smooth
Fig. 7—Left- and right-bevel adapters required for bevel is usually obtained at 75 to 80% of the chart
cutting in both directions speeds for perpendicular cutting. Still smoother

588 | JUNE 1960

 PROPANE

ACETYLEWE

SPEED

CUTTING
SPEED
CUTTING
P084 1%
\¥e FUEL i
weutmay."atOxY
22% 1.04LS
SEVEL ANGLE « 52°
MATERIAL THICKNESS UP TO 4°
| | | BEVEL ANGLE: 45°
es oe oe ee MATERIAL THICKNESS UP TO 4
50 60 70
PREHEAT FUEL FLOW SS on ee Oe oe
(ACETYLENE) 30 40 50 60 70 80 90 100
Fig. 8—Typical comparison of preheat performance PREHEAT FUEL FLOW c.AM.
at different oxy—fuel-gas combustion ratios
Fig. 9—Comparison of preheat consumption for beveling
with acetylene, propane and natural gas

results are obtained by further slowing down.

When the correct speed has been determined by the
smoothness desired, the preheat must be adjusted to
give the desired sharp top edge and no gouging.
Cutting Oxygen. Cutting oxygen and speed are so
interrelated, that it is impossible to completely
separate their effects. The correct cutting-oxygen
adjustment is recognized by a smooth, even cut face
without excessive drag lines or concavity. Initial
cutting-oxygen adjustment is best obtained from the
manufacturer’s chart for the corresponding thickness
of perpendicular cutting. When using divergent
(high-speed) type tips, cutting-oxygen pressure
should be set at manufacturer’s recommendations,
plus or minus 10 psi.
When using straight drilled tips it is usually ad-
vantageous to set as low a cutting-oxygen pressure as
possible, while still being able to penetrate the full
thickness of the material. A pressure in the range of
35 to 65 psi is usually found best. If the drag lines
are excessively swept to the rear, or if they curl for-
ward at the bottom of the cut, it is usually a sign of
too-low pressure. If the cut face is concave it is
usually a sign of too-high pressure.
A Comparison of Fuels
The previous discussion has been concerned with
the effect of preheat, speed and cutting oxygen on
bevel cutting, and with the practical "techniques for
obtaining good-quality results.
It was noted in the discussion that the function of
preheat is much more dominant in bevel cutting than
it is in perpendicular cutting. Asa result, beveling is
an appropriate tool for studying details of preheat.
One of the most important aspects of such a study
is a comparison of fuels. It is found that although
the principal effects are similar in beveling with all
of the common fuels, the extent of these effects is not
always equivalent.
Before making any comparison among fuels, it is
is important to determine the best oxy-fuel-gas
ratios for each.
Figure 8 shows a typical set of curves for deter-
mining such ratio, in this case for acetylene. From
a composite of many curves of this type, it was found
that the most favorable ratios for bevel cutting were
obtained at oxygen-fuel ratios approximately as
follows:
1*/, oxygen to 1 acetylene
5 oxygen to 1 propane
2'/, oxygen to 1 natural gas
All of these are seen to be more oxidizing than those
generally recommended for perpendicular cutting,
and it is important to recognize this difference in
adjusting flames for bevel cutting. If the more fuel-
rich adjustments generally used for perpendicular
cutting are used for beveling, the operation will be
considerably slower and less efficient, with a conse-
quent increase in cost. With the optimum oxy-fuel-
gas ratios established, Fig. 9 is a graph of speed vs.
fuel flow for each of the fuels, i.e., acetylene, propane
and natural gas. The difference between flows for
the various gases to make the same bevel cut is
clearly shown.
It is seen that in the lower speed range, the flows of
acetylene and propane are closely equal. At the

WELDING JOURNAL | 589

 higher speeds, however, propane requires about 20%
more flow than acetylene. The flow of natural gas
at all speeds is seen to be considerably greater than
for either propane or acetylene. Over the full range
of speed the flow of natural gas averages approxi-
mately four times that of the other fuels.
Another view of the comparative performance of
fuels is shown in Fig. 10. Sections (a), (6) and (c) of
this figure compare the flow for 30, 45 and 52 deg
bevels with that recommended for perpendicular
cutting for each of the fuel gases.
The charts show the amount of increase of fuel
flow for bevel cutting over that needed for perpen-
dicular cutting.
Acetylene is seen to have the least increase; the
flow for beveling '/.-in. material at 45 deg being ap-
proximately 1*/, times that needed for perpendicular
cutting. Natural gas, on the other hand, requires
the greatest flow increase and for the same bevel, re-
quires approximately 6'/, times as much flow as for
perpendicular cutting.
Similarly, acetylene requires no greater flows for
beveling, as compared to perpendicular cutting, as
soon as thicknesses reach 1 in. and greater. On the
other hand, beveling and perpendicular flows are not
equal for natural gas until thicknesses reach ap-
proximately 5 in.
The performance of propane falls between acety-
lene and natural gas. This difference among fuels in
52° BEVEL ANGLE
PREHEAT FOR
PERPENDICULAR
CUTTING
FUEL
PREHEAT
FLOW
BEVEL FACE
(A) NATURAL GAS
Fig. 10--Comparison of the increased preheat for beveling compared to perpendicular cutting for various fuels
590 | JUNE 1960
the amount of additional flow needed for beveling
probably accounts for the usual operator’s impression
that beveling is easiest with acetylene and hardest
with natural gas.
The reason for this difference is not readily ex-
plained, although a number of theories based upon
flame temperature, combustion intensity and burning
velocity have been advanced by various authors.
It appears in observing the beveling operation that
each individual acetylene flame has the ability to
generate an intense localized hot spot under it
sufficient to carry the reaction. The natural-gas
and propane flames, even though ringing the tip in a
more closely packed circle, provide a more diffuse
heat at the tip of each individual flame and thus re-
quire the concerted effort of several flames to actually
carry the reaction.
The principal importance of any comparison of
fuels is in the economic analysis. In comparing the
economics of fuels in bevel cutting, it is not so much
the differences in fuel-gas consumption which affect
the economic picture as it is the difference in pre-
heat-oxygen consumption which the fuel flows entail.
Since natural gas requires 2 to 2'/, cu ft of oxygen
for each cubic foot of fuel consumed, and since the
hottest acetylene flame requires 1'/, to 1°/, cu ft of
oxygen for each cubic foot of fuel, the four-times
quantity of natural gas required from Fig. 9 involves
about six times the preheat-oxygen consumption.
°
i 3
| J |
.e) 3 3
WIDTH (MT'L. THICKNESS) INCHES
(B) PROPANE (C) ACETYLENE
 Table 1—Cost Comparison for Beveling with Acetylene, Propane and Natural Gas
Basis of example: Assumed prices:
Type of bevel, 45 deg Acetylene, $2.75/C cu ft
Basic fuel consumption, 100 cu ft acetylene Propane, 0.80/C cu ft
Combustion ratios: Natural gas, 0.05/C cu ft
Acetylene, 13/,:1 Oxygen
Natural gas, 2'/,:1 0.50/C cu ft
Propane, 5:1 1.00/C cu ft
—_—_———Acetylene——_—_—_ Propane Natural gas—————
Quantity Quantity Quantity
required, required, required,
cu ft Cost cu ft cu ft Cost
Oxygen @ $0.50/C
Fuel 100 $2.75 120 , 400 $ 0.20
Oxygen 175 0.88 600 R 1000 5.00
Total gas cost 3.63
Oxygen @ $1.00/C
Fuel 2.75
Oxygen £.35
Total gas cost 4.50

In the case of propane, for which the oxygen-fuel
ratio is 5:1, a similar comparison shows a consump-
tion of 3'/, times the preheat oxygen for equivalent
results as compared to acetylene.
This leads to the economic comparison shown in
Table 1.
It is seen that these cost comparisons are quite
_ different from those which are often established for
perpendicular cutting and which often show savings
in favor of natural gas. We do not claim to refute
the results of perpendicular tests with the above
data. It is true that in many shape cutting and
similar perpendicular operations, natural gas offers
the cheapest operating cost.
We wish to show, however, the difference in the
economic picture between perpendicular and bevel
cutting. We wish to show the importance of ana-
lyzing all operations in a shop when making a com-
parison among fuels. The shop whose operations
are principally shape cutting and perpendicular work
may find one fuel advantageous; the shop whose
operations are in large measure beveling and edge
preparation often finds another most advantageous.
Conclusions
In the foregoing text, the subject of bevel cutting
has been discussed with emphasis on three main
headings:
a) The relationship of preheat, cutting oxygen
and speed in bevel cutting.
6) The practical technique for obtaining good-
quality bevel results.
(c) The comparison of common fuel gases in
bevel cutting.
The following conclusions are presented:
1. Good-quality bevel cuts can be made with all
common fuel gases.
2. In bevel cutting, the adjustments of cutting
oxygen and cutting speed are not greatly different
from perpendicular cutting. However, the adjust-
ment of preheat is markedly different.
3. In bevel cutting, thinner materials require
heavier preheat than thicker materials. Those
under 1 in. require very heavy preheat.
4. The heavy preheat required can be supplied by
increased preheat-gas flows or by slowing down cut-
ting speed.
5. For thinner materials, the preheat required for
beveling is much greater than that needed for per-
pendicular cutting. As thickness increases, the
difference in preheat between beveling and per-
pendicular cutting becomes less. At thicknesses
over 4 to 5 in., the preheat for beveling and per-
pendicular cutting are essentially equal.
6. The cutting-oxygen and cutting-speed adjust-
ments in beveling are generally equal to those for a
perpendicular cut whose thickness equals the actual
cutting-stream penetration of the bevel.
7. The heavy preheat requirements for beveling
can be minimized by the use of auxiliary preheat
traveling in advance of the cutting tip and disposed
at a more nearly 90-deg angle to the work.
8. Quality and economy in bevel cutting are very
sensitive to oxy-fuel gas combustion ratio and tip-to-
work spacing. Careful attention must be given to
determining the best adjustment of these items and
operators must be informed as to their importance.
9. Although all of the common fuel gases will give
good results in beveling, they are not all equal in
efficiency. Acetylene is the most efficient, followed
by propane and natural gas in that order.
10. The economics of fuel cost in beveling are con-
siderably different from the economics of perpen-
dicular cutting. Shops in which bevel cutting is a
significant item of the budget must be sure to make
comparative fuel studies on actual beveling opera-
tions, as results from perpendicular cutting are not
applicable.

WELDING JOURNAL | 591

 Many complex metal components can be fabricated by

Multiple

Brazing

Process

BY GEORGE D. CREMER AND

RICHARD S. MUELLER

_d
Space-age brazing demands highly specialized furnace and
muffle equipment. This 9-ft high by 6-ft diam welded seal
muffle encloses a giant rocket thrust chamber. Argon or
hydrogen is flowed internally to maintain clean tube joints
and insure complete braze flow
Multiple Brazing
Since World War II, new manufacturing techniques
have been evolved for fabricating complex metal
parts for aircraft and missiles. Many of these
processes will find use in building hardware for the
coming “space age.”
In all cases, the design criterion is maximum
strength-to-weight ratio. If temperature require-
ments on the order of 1000 to 2000° F are added,
the design, materials selection and fabrication prob- -
lems become really formidable.
Components for airframe, control surfaces, engine
and accessories have metamorphosed as a result of
these technological demands. In order to find solu-
tions, it has been necessary to re-evaluate, redesign
and apply new and improved manufacturing
methods. Quality-control standards have been
drastically tightened. ‘‘Producibility’’ has become
a milestone to progress.
One postwar technique that has advanced rapidly
and continues to show amazing growth potential is
high-temperature corrosion-resistant brazing. Engi-
neers and designers herald joining by brazing as the
ultimate for precision assembly of complex, light-
weight, strong metal components. One very useful
application of high-temperature brazing is “multiple
brazing.”
High-temperature corrosion-resistant brazing is a
metallurgical joining process employing a molten
filler metal which has a melting point in excess of
1600° F but below that of the base metal. Atomic
diffusion between filler metal and base metal must
occur.
Multiple-brazing processes (occasionally referred
to as “double brazing’’) utilize two, three or some-
times more separate and distinct brazing operations.
During each brazing cycle, new components or sub-
assemblies are added in building up the final struc-
GEORGE D. CREMER is Senior Staff Engineer and RICHARD S.
MUELLER is Research Engineer at Solar Aircraft Co., San Diego,
Calif.

592 | JUNE 1960

ture. With this technique, extremely complex, generally requires specialized equipment and tool-
dimensionally stable, lightweight structures are being ing, the costs of which would be prohibitive if the
manufactured. This paper will emphasize only entire structure were brazed together in a single
metal structures joined by corrosion-resistant brazing operation.
alloys of the nickel-base type. Such brazing applica-
tions are today being exploited commercially on a Material Considerations
large scale. Predictions of the future by “realistic The designer has available an increasingly wide
optimists,’’ engineers, designers and technical manu- range of engineering alloys that have been used
facturing men, foretell a dominant position for high- extensively in high-temperature brazing manufac-
temperature corrosion-resistant brazing processes. turing processes. Chemical, metallurgical and engi-
Numerous successful applications have demon- neering process controls and production specifica-
strated the remarkable versatility of the high-tem- tions have been established. A few representative
perature corrosion-resistant brazing process and commercially available alloys are listed in Table 1 to
designers are currently taking full advantage of the indicate the broad scope of the high-temperature
following salient factors: brazing field. In all instances, the service tempera-
ture limitation is based upon oxidation tests. The
(a)Practical, economical means for fabrication figures under the heading of “‘lightweight sandwich”
of complex and multicomponent assemblies. are less exact, yet may offer the designer and engi-
(6) Precision production-tolerance capability. neer an over-all capability of this type of structure.
(c) Relatively simple means for achieving exten- It should be noted that thin foil-gage metals are
sive joint area or joint length. particularly sensitive to effects of oxidation, corro-
(d) Natural braze-filleting action which insures sion, brazing filler-metal diffusion, local imperfec-
good stress distribution and excellent fatigue tions and variations in manufacturing technique
resistance. and processing method.
Ability to preserve protective metal coating or These figures must be further qualified by saying
cladding. that in actual brazing applications, additional factors
Ability to join cast materials to wrought that should be considered include:
metals.
Base-metal physical properties desired.
Ability to join widely dissimilar metal thick-
2. Base metal—brazing alloy reaction.
nesses.
3. Joint type (Fig, 1).
Ability to join dissimilar metals.
4. Joint thickness.
Means for preserving desired uniform metallur-
Material gages used.
gical characteristics of the metals being
3. Joint-surface preparation.
joined.
. Corrosion factors: oxidation, nitriding, com-
A reproducible, metallurgical joining process
bustion-gas reaction.
that can be kept under close process control.
. Fatigue considerations.
Multiple brazing not only incorporates all of these . Superimposed stresses due to dynamic thermal
features but also provides opportunities for increased effects.
production control and manufacturing economies. 10. Metallurgical heat-treatment effects.
By using brazed subassemblies or a sequence of 11. Use of oxidation inhibitors and fluxes.
brazing operations in building up a metal assembly,
the following manufacturing advantages are para- Table 1—Service Temperatures of
High-strength Brazed Metal Assemblies
mount:
Massive Lightweight
1. Subassemblies are simple in relation to the Metal alloy assemblies, ° F sandwich, ° F
final part. 17-7 PH 700-800 750
2. Annealed, brazed subassemblies insure preci- PH 15-7 MO 800-900 800
sion final assemblies. AM 355 800-900 900
3. Diffusion of brazing filler metal prevents T-410 800-900
reflow, joint shrinkage, joint loosening, permitting Tool steel’ 800-1100
A-286 1000-1350
succeeding brazing operations to be made with Inconel ‘‘X”’ 1000-1400
minimum of support fixturing. Hastelloy B 1200-1500
4. Inspection is greatly simplified. Quality and T-321 1200-1600 1500
reliability are thereby assured. 19-9DL 1200-1700 1500
5. Minor braze repairs can be made during subse- T-310 1200-1800 1700
R-235 1300-1700 1500
quent brazing cycles. N-155 1400-1900 1700
6. More economical fabrication is frequently Inconel 1500-2000 1800
possible. L-605 1500-2200 1900
In many applications requiring numerous small Hastelloy X 1600-2200 2000
subassemblies, brazing can be accomplished readily 1 Approximate upper temperature limit for exposures of 100 hr
using small production-type equipment. The inte- Short time use at higher heats is possible
> Air-hardening tool and die steel of 5% chromium type Protection
gration of these subassemblies into a large part coating may be required

WELDING JOURNAL | 593

 LAP
qe ___ All-purpose joint

PIERCED PLUG
Blades—-Vanes, tubes, etc.
—~

NSO int,22
“wre |S Sad- sr Rh Pot

SIMPLE “T”’
Bosses, flanges, honey-
comb core

BUTT/LAP
Sac * Transitions
Fig. 1—Types of high-temperature brazed joints used
Joint Diffusion Principle
A fundamental requirement of all high-tempera-
ture corrosion-resistant brazing is metallurgical
diffusion in the joint areas. A review of the consid-
erations involved is pertinent to an understanding of
multiple-brazing principles.
The three cross-sectional honeycomb joint micro-
structures, shown in Fig. 2, represent the progressive
effects of brazing alloy-base metal diffusion. Time
at temperature is the driving energy source. The
original joint clearances of approximately 0.001 in.
are indicative of good quality control.
Fig. 2A is representative of the initial joint struc-
ture after a rapid brazing cycle involving one minute
at 1950° F. Brazing alloy was still largely molten
at the maximum brazing temperature as evidenced
by the dendritic or cast-alloy appearance. Dark
diffusion bands near base-metal surfaces are typical
when boron-containing brazing alloys are used.
Only a superficial amount of “undercutting” or
“erosion’”’ is discernible with this special brazing-alloy
system. Primary grains, rich in nickel, chromium
and iron, are seen in the fillet as a massive white
phase.
Metallographic etchants were selected to favor the
braze joint over the base metal.
Diffusion is very rapid during the early stages of
high-temperature brazing due to the relatively large
amount of liquid brazing filler metal available and
C. Soaked for 88 hr at temperature of 1800° F
the steep element compositional gradient.
If the joint in Fig. 2A had been held an additional
Fig. 2—Photomicrographs showing progressive effects of
nine minutes at brazing temperature, diffusion would braze metal—base metal diffusion
produce a metallographic structure as seen in Fig.
Material:
2B. Here all evidences of dendrites, and a signifi- Core, 0.005-in. Inconel
cant liquid phase, are absent. Diffusion between Facing, 0.100-in. Inconel
High temp., corrosion-resistant braze alloy
Inconel and brazing filler metal is advanced and has Magnification, X 275 approx.

594 | JUNE 1960


Fig. 3—Gas-turbine nozzle diaphragm with
air-cooled vane subassemblies
obliterated the original profile of the vertical core
leg.
Commercial production brazing of Inconel honey-
comb sandwich is frequently specified to be ten
minutes at maximum temperature. Figure 2B
therefore closely approximates a typical joint struc-
ture.
Continued diffusion at high temperature of the
Inconel-brazing metal system under consideration
will produce a solid-solution type joint that indicates
an advanced state of homogenization. This condi-
tion is represented by Fig. 2C. Grain growth has
occurred throughout the joint and _ base-metal
volume. Minute, well-distributed porosity is evi-
denced by the nearly spherical black spots. The
result is a strong, corrosion-resistant, well-filleted
““Tee”’-type joint that joins easily at 1950° F but
exhibits useful physical and chemical properties at
2100° F.
The technique for producing homogenized diffused
joints shows how to achieve maximum performance
of brazed structures at extreme temperatures.
Also, it serves to emphasize the necessity of the
scientific approach in manufacturing development
and production of multiple-brazed assemblies.
Multiple-brazing Applications
Gas-turbine Diaphragm
Brazing of small gas-turbine nozzle diaphragms,
compressor stators, turbine stators and inlet guide
vane sections is becoming increasingly popular.
Several of the country’s top performance engines
have been efficiently designed to incorporate high-
temperature, multiple-brazed assemblies. Corro-
sion-resistant brazing alloys are being used to join:
Vane: Sheet-metal vane halves, trailing edges,
internal hat stiffners, heat-exchanger corrugations
and passages for coolant airflow, and end trunions
or vane supports.
Shroud:—-Vanes-to-shrouds, built-up sheet-metal
shroud, shroud bosses, diffuser sections, mounting
flanges, seal supports and plumbing fittings.
Most frequently, the vanes are fabricated by
brazing in one or two brazing cycles. Because they
are small identical parts, precision production tech-
niques are used to lay-up, braze, inspect joints and
contour check.
Both outer and inner shrouds are also being de-
signed as brazed fabrications. Thin, double wall
or sandwich-type construction is sometimes used
to obtain maximum shroud stiffness. Bosses, flanges
tubing connectors, etc., may be incorporated at this
stage.
As high-temperature brazing operations stress
relieve and/or anneal the complex subassemblies,
a simple sizing operation usually permits a very
high degree of precision to be obtained prior to the
final assembly. Specialized skill and experience is
necessary to insure unstressed components as the
complex (and by now expensive) assembly is pre-
pared for another cycle in the multiple-brazing
schedule.
After final braze, it is sometimes desirable to run
an additional brazing cycle. This may be occasioned
by the necessity for building up of braze-fillet
size, sealing of fluid passages, correcting parts
mishandled during a machining operation, realigning
out-of-tolerance conditions reclaimable only by ther-
mal creeping or, finally, accommodating a minor
design change.
Figure 3 shows a complex precision gas-turbine
nozzle-vane diaphragm fabricated by the multiple-
brazing technique.
Honeycomb Shroud
Fuselage sections, nose and tail cones and engine
air ducting present an excellent example of multiple-
brazed structures.
All-metal honeycomb sandwich is favored for its
high strength-to-weight ratio, stiffness and thermal-
insulation properties.
Large, intricate ducts and cones, in cylindrical,
elliptical and irregular cross sections, are frequently
required for elevated-temperature applications. By
designing a special framework as part of the basic
structure, a practical manufacturing technique
has been evolved and has been used successfully in a
variety of applications.
An afterburner heat shroud is illustrative of this
design-fabrication concept.
An all-metal honeycomb sandwich high-strength
framework or “picture frame’? for a cylindrical
component may be seen in Fig. 4. Facings are
perforated stainless steel, bonded during the first
brazing operation to high density core of '/;-in.
square cell, 0.005-in. T-321 stainless steel. Strips of
WELDING JOURNAL | 595
 Fig. 4—Afterburner heat shroud in lay-up stage
prior to second brazing operation
this sandwich are then machine cut and gas-shielded
tungsten-arc welded to assemble the frame. Perfor-
ations lighten the structure and, more significantly,
serve as a means of preloading granular brazing
alloy. This insures high-quality, continuous lap
joints between framework facings and final sandwich
facings during the second brazing operation.
The precision framework is shown on the lay-up
mandrel together with low-density honeycomb
which, of course, constitutes the main structure.
Core is 0.002—'/,-in. square-cell T-321 material
and carefully machined to be level with the surface
of the framework structure. Shear ties are made
by spot welding the lightweight core to the high-
density core.
After loading with brazing alloy, 0.004-in. T-321
facings will be tightly laid up over the entire ID and
OD surface. The composite assembly is then united
into a strong honeycomb structure during a second
high-temperature brazing operation.
In this illustration of the multiple-brazing process,
the same brazing alloy is used for joining sub-
assembly and final assembly.
For extreme-temperature shroud applications,
the structures designer might consider Inconel
honeycomb core and facings joined with a controlled-
diffusion-type brazing alloy. The joint structure
shown in Fig 2B would permit service exposures up
to 1800° F, while the homogeneous solid solution
type joint of Fig 2C should exhibit structural strength
to at least 2100° F.
Figure 5 shows an afterburner heat shroud made
in half sections. Each section incorporates high-
density framework for all edges, ports and access
doors.
Gas-turbine Honeycomb Seal
The experimental lightweight sheet-metal honey-
comb turbine seal shown in Fig. 6 is a fine example of
employing a slight modification of the original
brazing alloy in a double-braze cycle. The inner
0.093-in. Inconel band and the 0.005- x '/,-i11. square
59% | JUNE 1960
Fig. 5—Completed afterburner honeycomb structure
assembled by multiple-brazing process
cell honeycomb were first brazed to make an “‘open-
face honeycomb sandwich.”
The outer shroud shown was fabricated on a
special bellows forming machine. Material is
Inconel W, 0.043-in. gage.
After brazing at 2050° F, the open-face seal ring
was expanded to fit the outer shroud and then
braze joined to it using a slightly lower melting
brazing alloy.
The composition of the brazing alloy used for this
second brazing operation contained an additional
0.5% boron and 0.8% silicon over the original
Ni-Cr-Mn-Si-B composition. This modification per-
mitted the second brazing operation to be readily
performed at 1900° F.
The high physical properties of heat-treated
Inconel W make this double-brazed sheet-metal
seal design very attractive from the standpoint of
strength-to-weight ratio and production economy.
High-temperature Control Instrument
Figure 7A shows a well-engineered brazed pneu-
matic control instrument designed for turbojet
applications. This unit is functionally actuated
by engine combustion gases up to 1500° F. Require-
ments involving corrosion, oxidation and high-
strength joint operation at extreme temperatures,
dictated the use of corrosion-resistant brazing.
Through efficient application of the high-temperature
corrosion-resistant brazing principles discussed, this
intricate assembly was designed and manufactured
without difficulty to exacting standards. A single
high-temperature nickel-base brazing alloy contain-

Fig. 6—Completed sheet-metal honeycomb seal
for large jet engine
Fig. 7—(A, left) Multicomponent brazed assembly formed from brazed subassemblies.
sectioned. Brazed joints and brazing operation sequence are noted
ing 1.4% boron was used in a multiple-brazing se-
quence.
Braze-joint clearances were held within 0.0005 to
0.0025 in. This condition must be maintained to
insure joint reliability. Keeping the amounts of
brazing alloy required to a minimum enables rapid
metallurgical diffusion and precludes the danger of
brazing-alloy drip and reflow. Precision fit-up of
the assembly also allows the use of simple staking
and minimum fixturing of parts for brazing.
The components are relatively simple parts
which by the brazing sequence developed can be
built up into subassemblies and final assemblies
with attendant reliability and manufacturing econ-
omy. The brazing method of joining permits sheet-
metal stampings, bar stock, machined forgings and
precision castings to be designed into an efficient,
complex, yet lightweight, structure such as this
pneumatic control unit represents.
During the first furnace-brazing cycle, the orifice
parts were joined in the subassembly halves, Fig. 7B.
By holding the assemblies for thirty minutes at
brazing temperature of 1900° F, partial homo-
genization of the brazed joints was achieved. The
resulting increase in the braze remelt temperature
allowed further brazing cycles without the need for
support fixturing of the first brazed joints. Inspec-
tion for continuous fillets at the opposite sides of
the joints from where the brazing alloy was loaded
is an indication of soundness of the joint. Should
an unsound joint be found, a simple braze repair is
performed. In this manner, subassemblies can be
built to close dimensional tolerances, machined if
necessary, and thoroughly inspected. Joints which
subsequently will become inaccessible can be exam-
BRAZE SEQUENCE
=
cose
Li
(B, right) The same assembly as
ined and accepted with an assurance of permanent
quality.
The precision castings of Type 347 at the base,
the machined tubing and the side-located orifice
control nozzle were joined in the second brazing
operation at 1900° F for fifteen minutes. This
second brazing cycle utilized simple, “super alloy”
external holding clamps to hold the component parts
in proper contact to complete and join the sub-
assembly.
The third furnace-brazing cycle completed the
assembly by joining of the three subassembly units.
After preplacing of the powder brazing alloy at the
joint areas, alignment and clamping pressure were
WELDING JOURNAL | 597
achieved by external, yoke-type spring clamps which
straddled the over-all assembly.
Preheating the complete assembly to 1750° F and
soaking to stabilize the parts is a desirable pre-
caution. At this temperature, fresh brazing alloy
does not begin to flow. The furnace temperature is
then rapidly raised bringing the part to 1875° F for
fifteen minutes, as specified for the third and final
brazing cycle. This final joining of the three main
components at the two center joint areas completes
the assembly. After final visual inspection, accept-
ance tests are then performed using high-pressure
water.
The pneumatic control unit described dramatically
illustrates the advantages of multiple brazing.
Close coordination between designer, engineer,
fabricator and customer has literally insured a suc-
cessful brazing application.
Honeycomb-sandwich Wedges
Tapered or wedge-shaped steel honeycomb struc-
tures will be widely used in high-speed aircraft for
wings, control surfaces, leading edges, trailing edges
Fig. 8—Honeycomb-sandwich wedge-type structures;
full-depth core and box-panel assembly
Fig. 9—Stock panel concept has low-cost potential. Basic brazed sandwich structure is
manufactured on a boardfoot basis, then cut and framed as required
im
yl as Pity “Fy % y,
and flaps. Two applicable honeycomb-sandwich
designs are shown in Fig. 8.
Both designs have been successfully applied to
multiple-brazing methods.
From a producibility standpoint, the built-up
panel-type assembly has received more manu-
facturing development and so is generally preferred.
Mechanical fasteners make final assemblies feasible
even for very large-size box-beam type structures.
Full-depth core sandwich, on the other hand, is more
economical for small tapered parts and panels up to
several inches in thickness. Considerations of
thermal-stress resistance also favor full-depth con-
struction.
The extreme edge in finely tapered sandwich has
always been a critical area. Solid inserts are fre-
quently used but these are heavy, expensive to
machine and may require a prolonged brazing cycle.
The use of dense (small cell) core in the thin edge
areas has proved very successful. A high-strength,
continuous skin support is provided right up to a
feather edge if desired. When used in multiple
brazing, this high-density frame-type sandwich
construction gives the designer new versatility in
honeycomb structures. This concept permits direct
joining of attachments by arc welding, resistance
welding, bolting, riveting or hand brazing.
Honeycomb-sandwich Stock Panel
Another development is a low-cost, all-metal
honeycomb-sandwich fabricating process termed
“stock panel.’”” One version of this manufacturing
technique incorporates multiple brazing. Production
development has verified the feasibility of this
approach.
A special brazing furnace is moved continuously
over long slabs of flat or slightly curved honeycomb
sandwich. A typical slab would measure, say,
13 ft long by 2 ft wide. Edge attachments, if any,
must be simple and of lightweight design. Small
cell core or simple “‘Zee’’ or ““U’’ channel-type edge
reinforcements have been successfully brazed in
place.
In some cases, as illustrated in Fig. 9, it has proved
most practical to first braze a basic honeycomb slab
consisting only of low-density honeycomb core and
plain facing sheets. Inspection of this simple sand-
wich by ultrasonic or X-ray methods is rapid and
reliable.
Such slabs may be fabricated in quantity and
stored as “stock panels.”
As shown in Fig. 9, top, a 3-ft long wedge plan has
been cut out from a rectangular stock honeycomb
panel. Honeycomb core is 0.0015—'/,-in. square
cell by '/.-in. thick; facings are 0.010-in. 17-7PH
precipitation-hardening stainless steel. A corrosion-
resistant brazing alloy joins the assembly as well as
reinforcing the core nodes.
Typical 0.016-in. brake-formed “‘Zee”’ sections and
lap strips are shown in the lower view. This
hardware is securely attached to the basic sandwich
by a second high-temperature furnace-brazing opera-
tion. In the particular instance described, the same
braze alloy was used in a multiple-brazing sequence.
Further developments of interest to the designer
and being investigated include:
1. Increasing stock panel width to 30 in.
2. Evaluating stretch-form and stretch-level tech-
niques.
3. Evolving simple means of assemblying long
stock panels into wide honeycomb sheets.
. Perfecting techniques for reliably obtaining
shear ties in secondary brazed attachments.
Fig. 10—Photomicrograph of powder-braze metal
mixture showing large joint forming capability of
“insitu brazing technique”
Insitu Braze Technique
A useful development that has shown great pro-
duction significance for multiple-brazing processes
has been dubbed “‘insitu technique.’”’ To date, the
method has been applicable only to joints where a
brazing alloy powder is used. A sintered form or
insert, however, may offer additional design latitude.
By mechanically mixing a selected metal powder
with the brazing-alloy powder, it is possible to pro-
duce brazed joints with special characteristics.
The principle involved is to effect braze diffusion
““insitu.””
For example, consider a metal powder such as
nickel or nickel-chromium-iron alloy being thoroughly
admixed with a high-temperature brazing powder
and brazed in a ““T’’ type joint, a portion of which is
represented by Fig. 10. When the braze metal
flows at, say, 1950° F, it immediately wets and
begins to alloy with the refractory powder filler
as well as the base metal of the joint itself. Rapid
diffusion between braze and filler occurs due to the
large interfacial surface area involved. This de-
sirable metallurgical phenomena and the sponge-
like nature of the undissolved filler hold the braze in
place and effectively prevents flow-out. Only a
small amount of braze metal fills the actual joint
faying-surface volume, the bulk remains where
originally applied in the fillet areas.
Advantages of “‘insitu”’ brazing technique include:
1. Higher-temperature joint service capabilities.
2. Large fillets mean higher impact and fatigue
properties.
3. Tougher, thicker joints can be made even with
nonductile braze alloys.
Large fillets and “‘braze puddle”’ volumes can
be controlled where desired.
Lesser base-metal erosion effects due to
shortened time in liquidus range.
>. Less critical maximum temperature-time
brazing requirements.
. Restricted braze flow, little or no “‘stop-off”
needed.
Extends repair techniques.
. Many multiple-brazing cycles can be carried
out.
It should be noted that this method requires an
increased understanding of nonequilibrium metal-
lurgy and diffusion kinetics. The potential applica-
tion for the “‘insitu technique” is great; however,
the brazing metallurgist must supply the answers for
its practical utilization.
Conclusions
Multiple brazing offers greatly enhanced design
opportunities for manufacture of brazed metal
assemblies.
Numerous quality control benefits and production
economies are available with this new technique
for high-temperature corrosion-resistant brazing.
The scope of applications for braze-joining tech-
nology is rapidly expanding. Continued research
and manufacturing development are establishing
new standards of process and quality control. New
brazing concepts now being applied are successfully
providing solutions for materials and fabrication
problems posed by ultrasonic aircraft.
It is safe to predict that multiple-brazing processes
will also figure prominently in the building of ad-
vanced missile and space-vehicle structures.
WELDING JOURNAL | 599
 Micro-wire welding of thick-to-thin metal application. A fitting with a heavier
wall thickness is welded to the 14-gage steel shell of an air tank
Micro-Wire Welding
joins sheet metal and wide joint gaps by small-wire
with carbon-dioxide shielding utilizing lightweight equipment
BY HARLEY J. ORR AND JOHN H. HEADAPOHL
The welding industry has needed a practical process
for welding thin gage metals and joining metals
where good metal-to-metal fit-up cannot be ob-
tained or is impractical economically. The micro-
wire welding process was introduced to provide a
semiautomatic methed for welding in this large and
important area of metal joining.
The name ‘“micro-wire’’ describes briefly the
process and equipment components. The micro-wire
process is a new dimension in the welding industry.
The equipment offers smaller, lighter and more
reliable equipment components than previously
used. Micro-wire welding is a low-amperage elec-
tric-arc process which continuously feeds a small-
diameter bare-wire electrode into a welding zone
shielded by a gas. This open-arc process produces a
high-quality weld on various metals, particularly
those in the sheet-metal classification or where poor
joint fit-up is encountered. This paper offers data,
HARLEY J. ORR is Project Engineer and JOHN H. HEADAPOHL
is Sales Manager of the Automatic Welding Division of Hobart Brothers
Co., Troy, Ohio
Paper presented at AWS 4ist Annual Meeting held in Los Angeles,
Calif., April 25-29, 1960
600 | JUNE 1960
welding
research and development background on the micro-
wire process as it is applied in the welding industry.
Although the micro-wire welding process may be
used on carbon and alloy steels, stainless steels,
aluminum and some other nonferrous metals, the
studies presented in this paper cover so-called mild
steels with carbon-dioxide shielding gas.
Process Components
Assuming that a material can be welded satis-
factorily, the success or failure of a process depends
upon the ease with which weld metal can be applied
economically. Ease of application is particularly
important when a process is applied manually or
semiautomatically since the welding operator con-
trols the weld deposit. The operator must be con-
vinced of the utility and reliability of the equipment.
Micro-wire equipment is simple in design and op-
eration. The main components are shown in Fig. 1.
Welding wire is fed through a cable and gun from a
spool of wire by means of a wire feeder. The elec-
tric arc is powered from a welding machine of the
constant-voltage or variable-slope type. Gas supply
and regulation apparatus are not shown in Fig. 1.
 ARC STABILIZER

AL WELDING POWER CONNECTION

Fig. 1—Components of CO-.shielded micro-wire process

Micro-wire Equipment
The lightweight gun-cable assembly and improved
arc-transfer characteristics are the heart of the micro-
wire process. This waterless (atmospheric air-
cooled, no water required) gun is shown in com-
parison with a stick-electrode holder in Fig. 2.
It weighs less than 1 lb. By use of an ex-
tremely flexible cable which is new to the welding Fig. 2—Lightweight CO.-shielded micro-wire gun
industry, an operator can manipulate the gun and standard covered-electrode holder
with ease. All wire-feeding facilities, gas tubes and
wires are contained inside one extruded jacket which
measures *4 in. diam. Without additions or LOAD CHARACTERISTIC CURVES
(CV MOTOR-GENERATOR WELDER)
changes, this cable will feed 0.020 in. through 0.045-
in. diam welding wires.
The welding wire is pushed through the wire-
feed cable from the wire feeder. The wire is fed
by a four-roll driving system which makes positive
contact with the wire at two different pairs of rolls.
By “‘spreading”’ the force necessary to drive the wire,
a more positive and controlled driving force is im- —+-
0¢VOLTS
parted to the wire as it passes through the cable.
The four rolls are powered by a d-c shunt motor
and gearbox. This type motor and gear reduction,
200 300 400
plus dynamic motor braking, gives instantaneous LOAD CURRENT (OC. AMPERES)
and accurate starting and stopping of the welding
wire. Once the welding conditions are determined, Fig. 3—Constant-voltage motor-generator welding
the system feeds wire at a constant rate which is machine volt-ampere load characteristic curves
most important to the success of micro-wire welding.
Equipment—Power Sources LOAD CHARACTERISTIC CURVES
(C.V. RECTIFIER WELDERS
Both the constant-voltage motor-generator ma-
chine and the variable-slope rectifier are suitable
power sources for micro-wire welding. The con-
stant-voltage motor-generator usually has a rela-
tively flat volt-ampere load characteristic, whereas
the variable-slope rectifier has a more drooping
characteristic. Typical volt-ampere load character-
istics for these types of motor generators and rec-
tifiers are shown in Figs. 3 and 4.
Both motor-generator and rectifier welding ma-
chines must be capable of accurately adjusting the 100 200
arc voltage between approximately 14 and 28 v. LOAD CURRENT (0.C. AMPERES)
With a motor-generator machine, an _ infinite
number of voltage selections can be made by a Fig. 4—Variable-slope rectifier welding machine
voltage-control rheostat. Slope of the volt-ampere volt-ampere load characteristic curves

WELDING JOURNAL | 601

 WELDING CONDITIONS WELDING CONDITIONS
O35 INCH DIA. ELECTRODE 035 INCH DIA. ELECTRODE
75 IPM WIRE FEED SPEED 75 1PM ors FEED SPEED
CO, SHIELD CO2 SHIELD
MOTOR-GENERATOR CV WELDER RESTIFIER CV WELDE
35 TRANSFERS PER SECOND 79 TRANSFERS PER SEC
—_—_}—____ 4

WATTSg waTTs AVERAGE POWER

__ AVERAGE POWER ARC
POWER 875 WATTS
ARC
POWER ~*~952 WATTS
°

oo
AMPSoo
WELDING
CURRENT AVERAGE CURRENT
° 50.8 AMPS
30
AVERAGE VOLTAGE
18 19.0 VOLTS
Q O16 SEC.
TiMeE —>
Fig. 5—Oscillograph curve reproduction of motor-generator
CV welding machine, CO, arc-welding conditions
curve can be varied slightly by shifting the generator
brushes.
The rectifier welding machine has a wide range of
volt-ampere slope control from 2 v droop to 16 v
droop per 100 amp. The 2 v droop per 100-amp
curve is not shown in Fig. 4. Arc voltage is selected
with a vernier rheostat control.
Although both the constant-voltage and variable-
slope welding machine give relatively stable welding
arcs, additional arc stabilizers are added to the circuit
to obtain the excellent welding characteristics of the
micro-wire welding process. Welding-circuit induc-
tive reactance and resistance are the main factors
added for arc stabilization.
The use of inductive reactors in the welding indus-
try is over 40 years old. In the early days of weld-
ing, proper circuit inductance enabled the operator to
hold a short 20-v arc using a bare electrode. How-
ever, it is the proper selection of reactance and resist-
ance which is important. Selective amounts of
resistance are available from the ballast resistor.
These factors smooth out the peaks and valleys of
the welding current and supply energy to the arc
during the melting and transfer of the electrode wire.
The design of micro-wire equipment components
was determined by instrumentation of the dynamic
and static characteristics and by performance appeal
to the operator. The opinions of both experienced
and inexperienced operators were considered very
valuable. The operators considered such arc qual-
ities as: ease of sustaining an arc, feel of the arc
(soft or harsh), sound of the arc, visual amount of
weld spatter produced, ability to make and break
the arc, travel speed and relative performance in all
welding positions.
These rectifier and motor-generator welding ma-
chines supply power which controls burn-off of the
electrode. If the operator moves his gun away from
the arc, welding current automatically decreases. If
he moves his gun toward the arc, the welding current
increases. The constant-voltage type welding
machine delivers current to satisfy conditions at the
arc.
AMPS 2 AVERAGE CURRENT
CURRENT
WELDING 49. 5AMPS
o_o. +apes
*—~ 17.6 VOLT
TIME —e
Fig. 6—Oscillograph curve reproduction of variable-slope
rectifier welding machine, CO, arc-welding conditions
Tests demonstrated that the static slope of the
welding machine can vary considerably and yet
produce satisfactory welds. Oscillographs were
taken of the motor-generator machine and rectifier
voltage and current during the welding operation.
Horizontal fillet welds were made using a 0.035-
in. silicon-killed wire fed at a constant rate of 75
ipm wire speed. Carbon dioxide was used as the
shielding gas.
The oscillograph of voltage and current delivered
by the motor-generator machine (Fig. 5) shows an
average voltage value of 19.0 v DCRP. The weld-
ing current average value is 50.5 amp. Average arc
power is 952 w.
Pulse rate of metal transfer to the work is 35
per second. Transfer pulse rate is periodic. The
welding machine delivers current to meet arc de-
mands. The welding current trace shows the weld-
ing current does not drop to zero. The calculated
power trace indicates that there are no arc power
outages.
The rectifier-circuit oscillographs show an average
voltage value of 17.6 v DCRP. Average welding
current is 49.5 amp. Average power delivered to
the arc is 875 w (see Fig. 6). Weld-metal transfer
pulse rate is 79 per second. The increase in transfer
pulse rate over the motor-generator machine in-
dicates less inductance in the rectifier circuit.
Although comparative values between the rectifier
and motor-generator machine were different, both
produced good welds.
The current density for micro-wire welding is usu-
ally between 50,000 and 250,000 amp per square
inch electrode. Thus, for a 0.035-in. diam electrode
at 50.5 amp, the current density is 50,000 amp per
square inch (see Fig. 7). For some welding applica-
tions, it is entirely practical to use this same wire
at 200 amp or more which approaches a current
density of 250,000 amp per square inch. Such usage
illustrates the wide welding range possible with the
micro-wire process.

602 | JUNE 1960

 BURNOFF RATE CURVES
#25 ELECTRODE CO SHIELD
CURRENT DENSITY
WELDING CURRENT VS ELECTRODE DIA |
||

® rs)

~~ 50,000
8
8 AMPERES
D.C
“20/000 WELDING
CURRENT
CURRENT
(AMPERES)
WELDING et 8,0/00
?
|
010 020 030 040 050 060 ELECTRODE WIRE SPEED
ELECTRODE WIRE DIAMETER (INCHES) INCHES PER MINUTE
Fig. 7—Current density of small-diameter electrodes Fig, 8—Burn-off rate curves of ‘‘C’”’
operating at various welding currents electrode using CO.-gas shield

Table 1—Mechanical Properties and Chemical Composition of Steel-electrode Wires

Yield Tensile Elonga-
strength, strength, _ tion,
Type psi psi % C Mn Si Other
_ 58 ,500 79,000 24 0.11/0.17 1.75/2.10 0.65/0.85 0.40/0.60
B 55,000 75,000 0.13/0.19 0.95/1.30 0.15/0.30
“~~” 60 ,000 75,000 0.13/0.19 0.95/1.30 0.45/0.60
D 60,000 75,000 0.13/0.19 1.00/1.30 0.30/0.50 0.55/0.90 Al

Welding Wire and Gas processes is difficult because many applications

For most mild-steel welding applications, the weld-
ing wire size will be between 0.020 and 0.045 in. diam.
A 0.035-in. diam wire is very popular due to its
wide current range and ability to weld different gage
thicknesses. Then, too, this size wire offers good
wire-feeding qualities at reasonable product cost.
Wire smaller in diameter has a higher product cost
and is more difficult to feed through the system.
For metal thinner than 20 gage, a smaller wire is
preferred, such as 0.020-in. diam wire.
Welding wires are developed and are readily
available for use with this process (see Table 1).
““A”’ is a low-alloy wire used for high-quality welds
on low- and medium-carbon steels, also sulfur steels.
““B” and “‘C”’ are used on low- and medium-quality
steels. ‘‘C’’ contains more silicon than “‘B” and
is especially good for out-of-position welding.
“D” is an aluminum-killed wire for superior-quality
welds on poorly deoxidized steels.
The principal gas used for this study of the micro-
wire process was welding-grade (dry) carbon dioxide.
This gas was selected because of its shielding and arc
properties, its commercial availability in standard
cylinders and its low cost. Argon-carbon dioxide
mixtures may also be used with this process.
Economics
The costs of the micro-wire process are somewhat
difficult to figure for general welding applications.
Likewise, economic comparison with older welding
could not be welded practically before the advent of
micro-wire welding. If covered-electrode welding
was impossible or impractical, tungsten-arc welding
with an argon-gas shield was usually employed.
Tungsten-arc process produced a satisfactory weld,
but was slow and too expensive for most mild-steel
weldments. However, assuming that a gage-thick-
ness mild steel can be welded by any arc- or gas-
welding method, including covered electrode, the
economics favor the micro-wire process.
Although micro-wire speeds may be equal to or
faster than covered electrode, this factor is not the
greatest influence on weld costs. Minimum weld
cleaning time is most important. By actual experi-
ence, some companies spend more money for weld
cleaning than for welding. For many weldments
cleaning is eliminated with micro-wire process.
It is possible to deposit up to 96% of the electrode
wire in the weld with micro-wire process. Effective
electrode deposition of 70% is considered good for
the covered-electrode process. Weld spatter was
checked on various applications at different arc-
energy levels. Spatter losses ranged between 4 and
12% for micro-wire with most losses less than 8%.
Spatter consisted of small particles of solidified
metal which appeared dust-like on the work. High
deposition efficiency and lack of weld spatter offset
the higher electrode-wire costs of micro-wire process
as compared to covered-electrode process.
Figures 8 and 9 show wire burn-off rate and deposi-

WELDING JOURNAL | 603

 ELECTRODE DEPOSITION CURVES
RP-*25 ELECTRODE -COo

POUNDS
OF
METAL
DEPOSITED
PER.
MIN
2 4d0
ELECTRODE WIRE SPEED
INCHES PER MINUTE
Fig. 9—Deposit rate curves for small-diameter
electrodes operating at various wire-feed speeds Fig. 12—Application of CO.-shielded micro-wire welding;
3/\.-in. gap on 11-gage vertical-down butt weld

tion data for the micro-wire process with carbon-

Fig. 1l—Pipe multipass welded with CO,-
shielded micro-wire process
dioxide gas shielding. For example, welding at 50
amp., an 0.035-in. wire is fed at 75 ipm, depositing
0.02 lb per minute of metal. If the job is applicable,
this same 0.035-in. wire at 250 amp is fed at 600 ipm
for a metal deposition rate of 0.15 lb per minute.
Thus, attractive deposition rates and weld speeds
are possible with the micro-wire process.
The cost of the carbon-dioxide gas and the power
costs are usually negligible factors when considering
costs. Welding-grade carbon-dioxide gas usually
costs between '/.¢ and 2¢ per cubic foot or less than
30¢ per arc hour. Of course, labor and overhead
costs are most important, but will vary with each
plant or shop. Labor costs are largely dependent
on welding speed and cleaning time.
Some factors are difficult to analyze, such as
joint fit-up, bridging of gaps, reject-repair time and
others. Micro-wire is outstanding in its ability to
bridge gaps which may be impossible with any other
process.
Applications of Micro-wire Process
Applications for the micro-wire process are virtu-
ally unlimited due to precise control of the arc for
low- or high-current density welding. Welds may
be accomplished in all positions: overhead, vertical
up and down, horizontal and flat on metal thick-
nesses from 24 gage to '/, in. and greater. A combi-
nation of metal thicknesses is also practical—that is,
thin-to-thick and thick-to-thin. Most welding will
be accomplished by semiautomatic equipment, but
the process is also feasible for fully automatic opera-
tion.
The ability of the micro-wire process to weld in all
positions is best demonstrated by welding pipe.
Figure 10 shows the semiautomatic welding of a 4-in.
pipe section.
Test requirements of the ASME Boiler and Pres-
sure Vessel Code show that the process and procedure

604 | JUNE 1960


Fig. 13—Thin-gage furnace heat exchangers CO,-
shielded micro-wire welded with either semiauto-
matic (inset)or fully automatic equipment
can be qualified. Semiautomatic multipass welding
of pipe is illustrated in Fig. 11. Four weld passes
completed the 6-in. OD pipe, 0.432-in. wall thickness.
No backing ring or cleaning between passes was
necessary. Welds were run at 100 amp, 19 v, with
0.035-in. wire at 6 ipm average welding speed. No
adjustments were required when changing from
down-hand to overhead or vertical welding.
Figure 12 illustrates the ability of the micro-wire
process to weld gaps. This is a vertical down weld
on 11-gage steel, s-in. gap.
A difficult-to-weld edge joint used on a furnace
heat exchanger successfully welded by micro-wire
is pictured in Fig. 13. This manufacturer used such
Fig. 14—CO, welding of 11-gage fuel tanks with semiautomatic micro-wire process.
Minimum of weld cleaning necessary on this earth-moving-equipment weldment
&.
\
an edge-weld design to take advantage of the “‘bel-
lows” effect of the exchanger for maximum expan-
sion and contraction. The 16- and 18-gage steel
materials were edge-welded with automatic mechan-
ical equipment. The corners and repair welding
were done with semiautomatic equipment.
Weld cleaning is drastically reduced with the
micro-wire process. Figure 14 shows the carbon
dioxide gas-shielded semiautomatic welding of an
11-gage steel fuel tank used on earth-moving equip-
ment. There is a very minimum of weld slag and
spatter.
Summary
The micro-wire process should prove most valuable
to the welding industry, particularly in the sheet-
metal field and in overcoming poor joint fit-up or
excessive joint gaps. It will be most widely used on
metals ranging from 24 gage to '/,-in. thickness.
The small 0.020-in. to 0.045-in. diam welding
wires offer excellent stability and control of the
electric arc by means of ballast resistance and
inductive reactance added to a constant-voltage-type
power source. Inexpensive carbon-dioxide gas
shields the arc and welding zone for low- and me-
dium-carbon steels.
A flexible, waterless gun and cable provides for
welding in all positions, as typified by the welding
of steel pipe in a fixed position. High quality of
welds permits micro-wire to meet test requirements
of the ASME Boiler and Pressure Vessel Code.
The bare-wire electrode deposits sound weld metal
with a very minimum of weld slag and spatter.
Various weld-cost factors, especially a minimum of
weld-cleaning time, make the micro-wire process
attractive economically.
 Practical Welder

and Designer

Natural-Gas Cutting Used in Fabrication of Pipes

By L. H. PAINES AND H. CUTLER

In the production of pipe for high-pressure gas and
oil lines, the Cal-Metal Pipe Corp. of Louisiana at
Baton Rouge ranks high among Gulf South Area
producers though still a virtual ““newcomer”’ to the
L. H. PAINES, is Assistant Manager, Engineering Services, Air Re-
duction Sales Co., Baton Rouge, La., and H.CUTLER is Plant Superin-
tendent, Cal-Metal Pipe Corp
Fig. 1.—Twin-cutting torches are mounted on a
radiograph to bevel and cut edges
before pipe is rolled and formed
; %
field. Starting in business in 1952 with a small con-
tinuous roll-forming mill designed to make pipe from
4 to 8 in. in diam in lightweight only, the company to-
day has extensive facilities which produce around
200,000 tons of pipe per year. Sizes of present out-
put range from 4',. to 42 in. OD while wall thick-
nesses vary from 0.109 to 1.000 in.
Cal-Metal’s newest addition to its pipe-milling
operation at Baton Rouge, completed only last year,
incorporates what the management feels to be some
of the latest refinements. One of the refinements is
the use of natural-gas cutting equipment in the
cutting to size and beveling of mild-steel plates
prior to rolling (see Figs. 1 and 2), and in the squar-
ing-up and beveling of pipe section ends once they
have been formed (see Fig 3). For both operations,
torches specifically designed for use with propane or
natural gas are used.
In the preforming operation, twin-style torches
mounted on oxygen-cutting machines simultaneously
cut and bevel the mild-steel plates which are pro-
duced in varying thicknesses. In the squaring-up
operation, completed pipe is straightened and outer
edges are beveled by single torches mounted at each
end of the finished pipe. Bevelers use a floating-
head principal, wherein the bevel remains true to
the wall of the pipe regardless of minute out-of-
roundness or of wall thickness variations.

Fig. 3.—Natural-gas torch used to bevel

ends of pipe after forming and shearing
~

Fig. 2—Mild-steel sheets, cut and beveled with natural-

gas torches are rolled and ready to enter the forming mill

606 | JUNE 1960

Production in Modern Railroading. . .

High-Iron Heavyweights
The railroad industry, fascinating to men and boys
BY C. R. STRUTZ AND E D. UECKER alike, still retains much of its legendary glory. But
to the managers of today’s railroads, it is a dollar-
and-cents struggle to maintain efficiency against
rising cost.
A prime example is railroad rolling stock, which
contains some of the biggest and heaviest equipment
in use by any industry. Freight cars, for instance,
range from “shorty” 36-ft tank cars to 88-ft de-
pressed-center flat cars, and weigh anywhere from 20
to 120 tons. In nearly all cases these weights would
be at least 5% greater, and railroad fuel and mainte-
nance costs considerably higher, if it were not for the
industry-wide use of welded car components.
The workhorse process that has practically elimi-
nated riveted designs is automatic submerged-arc
welding. At Norfolk and Western Railway Co.’s
Roanoke freight car shop, for example, as many as 20
coal-hauling hopper cars can roll off the production
line each day with the help of submerged-arc welding
equipment.
In one of the most-successful operations of its
kind, the submerged-arc welding machines join two
‘“‘zee’’ bars to form the hopper-car center sill. In
designing their own hold-down fixture, N. & W. in-
Fig. 1—Submerged-arc welding a hopper-car corporated the welding-carriage track in the re-
CONDE OE a8 HHEeREN & Vepnteon tractable hold-down bars, and mounted 12 air-brake
cylinders as “‘muscle”’ for the fixture.
& wy Parallel welding heads travel on a carriage at a
welding speed of 27 ipm. An oxyacetylene torch
; 1
a with a No. 50 single-flame tip, also mounted on the
. i carriage, cleans and dries the edges of the ‘‘zee’’ bars
C. R. STRUTZ is Eastern Zone Sales Manager, Oxweld Railroad Dept.
Linde Co., New York, N. Y. and E. D. UECKER is a Welding Sales
Engineer, Linde Co., Houston, Tex

WELD
1€2

& 16 "x Ke“

I2"-C-25.0/r

WEIGHT OF WELDED
SECTION 89.4/r
>
Fig. 2—Multiple-electrode submerged-arc
welding on center sill at Kaiser Steel Fig. 3—Alternate center-sill design

WELDING JOURNAL | 607


bolster in a dual fixture
Fig. 4—Depositing four fillet welds
simultaneously on alternate center sill
ahead of the welding operation, helping to insure
porosity-free welds (Fig. 1).
Kaiser Steel Corp. fabricates their standard hop-
per-car center sills from two “‘zee’’ bars welded toe-
to-toe. In this case, the company uses multiple-
electrode submerged-arc welding, because the ''/ ».-
to in. thick flanges have high filler-metal re-
quirements and poor fit-up.
The “zee”? bars are clamped in a hydraulic jig
using a preset camber for distortion allowance (Fig.
2). Welding is done from one side only, against a flux
backing which permits complete penetration and
supports the molten metal where poor fit-up occurs.
The lead arc uses a */y.-in. diam electrode carrying
1200 amp at 30 v, D.C.R.P. The trailing arc uses
two '/;-in. diam electrodes carrying 750 amp at 38 v,
ac. Welding speed is 45 ipm.
When a steel shortage cut off their supply of “‘zee”’
bars, Kaiser devised an alternate center sill, using
two 12-in. channels. a °/\.-in. top cover plate, and
two 4- by °/;-in. flatbar stiffeners (Fig. 3).
A system of magnets holds the components in
proper position during welding. Two automatic
submerged-arc welding heads make the four outer
fillets simultaneously (Fig. 4). The sill is then
flipped over onto another fixture and the last two
joints are welded. The same heads operate at both
fixtures, welding at one fixture while the other is
being loaded.
608 JUNE 1960
Fig. 5—Dual submerged-arc heads join a
Many Parts, Same Principle
The combination of automatic submerged-arc
welding with custom-built tooling is a principle which
applies to fabricating many different railroad-car
components of varying sizes and shapes.
Iron-ore-car side panels, for instance, are fabricated
by Kaiser Steel using five submerged-arc welding
stations. At the first three stations, the top bulb
angle and bottom-side sill are attached to the side
sheet. The side-post stiffeners are attached at
station four, where gantries straddling the assembly
not only carry the welding machines, but serve as
huge “C”’ clamps to hold the stiffeners against the
side sheet. The small I-beam stiffeners are attached
at station five, completing the assembly of the sides.
Railroad-car bolsters, the parts of the underframe
which pivot on the trucks, are other complex items to
fabricate because bolster designs vary according to
the total car weight and the relative cost of suitable
steel shapes. Bolsters are roughly in the form of a
square tube and are fabricated either by welding
together two channels or four flat plates, or by cap-
ping one channel with a flat plate.
Normally this requires welding every seam indi-
vidually, resulting in excessive materials handling.
But the fabricator uses two automatic submerged-
arc welding heads and dual holding fixtures to permit
maximum use of welding equipment. The welding
gantry serves both fixtures, thus allowing one fixture
to be loaded while welding proceeds at the other
Don’t Forget Aluminum
A major factor in the railroad’s modernization
program has been the extensive use of light-weight
aluminum. However, before the inert-gas shielded-
arc welding processes were introduced in the 1940’s,
Fig. 6—Inert-gas tungsten-arc cutting slices man-way
opening in dome of aluminum tank car
Fig. 8—Tungsten-arc welding aluminum heating coils for special tank cars
the use of aluminum was necessarily restricted be-
cause of the contamination problems encountered
when welding the metal with the previous flux-
coated welding processes.
Today, however, aluminum railroad tank cars,
such as those fabricated at General American Trans-
portation Corp., Sharon, Pa., are essential for car-
rying many corrosive acids and chemicals which
attack a carbon-steel tank.
One of the major bottlenecks in making the tanks
was the cutting of manways and other openings,
which had to be burned through with metal-arc
welding rods, then chipped to the correct diameter.
But General American switched to tungsten-arc
cutting and one man was able to do in 30 min what
Fig. 7—Tack-welding tank-car plates with
inert-gas metal-arc welding at General American
four men did previously in 3'/, hr (Fig. 6). In addi-
tion, the smooth cuts required no chipping, grinding
or other finishing operations.
Welding mobility is the keynote at this company’s
plant—-seams must be completed both inside and
outside the tanks, and heating coils must be installed
inside many special-purpose tanks. Automatic gas
metal-are (consumabie-electrode) welding machines
are used to tack-weld and complete seams, and to
attach fittings and sub-assemblies (Fig. 7 For
fabricating the heating coils, manual gas tungsten-
arc welding torches are used (Fig. 8). The fiexi-
bility of inert-gas shielded-arc welding enables
General American to do a variety of jobs at highest
speed with only a minimum of welding equipment.
WELDING JOURNAL | 609
 Society News

Excellent Exhibits Feature Welding Convention on West Coast

Technical Sessions Attract Interested Audiences as Research, Development and Applications

Reveal New Welding Progress

The first national meeting of the Convention Chairman J. E. Dato,

Silla
' became the world’s market place
hea Y a
24 aed
Fig. 1—President-elect R. D. Thomas, Jr.,
cuts the chain, officially opening the 1960
Welding Exhibition at the Great Western
Exhibit Center, Los Angeles, Calif. As-
sisting are California's Lt. Governor Glenn
Anderson (left) and R. D. Huff
Fig. 2—Busy scene at a section of the
Welding Show reveals lively interest
in the huge display
Fig. 3—Opening session on Monday with President C. |. MacGuffie
addressing the group and National Secretary Fred Plummer seated at right
AMERICAN WELDING SOCIETY ever
to be held on the West Coast was
a successful one, as Los Angeles
of welding during the week of
April 25—29th.
At the Biltmore Hotel, the regis-
tration figures showed that over 900
members and guests attended the
various technical sessions, while more
than 9,000 witnessed the record-
breaking display of welding equip-
ment which filled the entire exhibit
area of the Great Western Exhibit
Center. Visitors from European
countries, the Near East and Asia
included England, France, Norway,
Sweden, Switzerland, Belgium,
Germany, Turkey, Japan and many
others. In addition, a large group
from neighboring Canada attended.
This wide interest in the 4lst
Annual Meeting and Exposition
is ample evidence of the increasing
importance of welding in today’s
technology.
Opening Session Features Addresses,
Awards, Adams Lecture
The opening session was officially
called to order in the Grand Ball-
room of the Biltmore Hotel by
before a large audience on Mon-
day morning. President C. I. Mac-
Guffie welcomed members and their
guests to the Los Angeles meeting
and then delivered the annual
‘**President’s Address” in which he
made a stirring appeal for continued
growth in AWS activities. (The
tull text of President MacGuffie’s
address appears on pages 614-617.
Presentation of Annual Awards
Following the president’s ad-
dress, the members who have
made outstanding contributions to
welding and to the SocrETy were
called forth to receive their awards.
District Meritorious Awards,
given in recognition of unusual serv-
ice to a section or district, were
presented to Sidney Low, District 1;
Walter Begerow, Richard K. Lee
and Edward W. Moles, District 2;
G. O. Hoglund and Harry E. Miller,
District 3; James C. Thompson,
Jr., District 4; William G. Morgan
and Perry J. Rieppel, District 5;
R. H. Hoefler, District 6; William
N. Norton, District 7; and Frank
G. Singleton, District 8.
The Adams Memorial Member-
ship Awards were presented, for the
first time this year, to members
of the teaching profession for out-
standing work at the college level.
Four-year memberships were
awarded to Professors W. H. Bruck-
ner, University of Illinois; A. E.
Flanigan, University of California;
R. B. McCauley, Ohio State Univer-
sity; G. S. Schaller University of
Washington; and R. S. Wyant,
Clarkson College of Technology.
Singled out for National Meri-
torious Certificate Awards were
J. E. Dato, national chairman of the
 AWS Convention Committee and
F. W. Davis, presently staff consult-
ant with the Southwest Research
Institute. These awards are given
in recognition of the counsel, loyalty
and devotion to the affairs of the
Society given by the recipients.
The Henry Nietzel National
Membership award for the greatest
net percentage increase in section
membership went to the Nashville,
Tenn., Section. The corresponding
award for the greatest net numerical
increase in section membership was
given to the Pittsburgh, Pa., Sec-
tion.
Selected for distinction as persons
of eminence in the welding profes-
sion, Honorary Membership was
conferred on Royal D. Thomas, Sr.,
chairman of the board of Arcos
Corp., and Fred L. Plummer, na-
tional secretary of AWS and previous
winner of the outstanding Miller
Memoria] Award.
The A. F. Davis Silver Medal
Awards are given to the authors
of papers judged to make the best
contribution in three different fields
of welding and published in the
WELDING JOURNAL. Co-authors of
the best paper on structural design
are Charles S. Matiock of the
Fig. 4—President MacGuffie reviews 40
years of AWS progress as he delivers
the annual President’s Address
Fig. 7—President MacGuffie presents District Meritorious Awards to (left to right) W.
Begerow, R. H. Hoefler, G. O. Hoglund, R. K. Lee, H. E. Miller, E.W. Moles, W. C
Morgan, W. N. Norton, P. J. Rieppel, F. G. Singleton, J.C. Thompson, Jr.
2 ©2985by
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Bridge Division, Texas Highway
Dept., and Farland C. Bundy,
consulting engineer with Julian
Montgomery and Associates, Aus-
tin, Tex. Winner of the award for
machine design is Gordon M. Som-
mer, vice-president, Clearing Divi-
sion, U.S. Industries, Inc., Chicago,
Ill. The award for maintenance
and hard surfacing went to co-
authors A. M. Hill, superintendent,
and F. W. Zilm, contract admin-
istrator, both of Service Pipe Line
Co., Tulsa, Okla.
A gold medal and certificate,
known as the James F. Lincoln
Gold Medal Award, is awarded
each year for the best paper, with
one author, which makes the great-
est original contribution to the
advancement and the use of welding
and is published in the WELDING
JOURNAL. This year’s recipient is
Kenneth R. Notvest, welding engi-
neer with Willamette Iron and
Steel Co., Portland, Ore.
To Boniface E. Rossi, editor of
the WELDING JOURNAL, went the
distinction of receiving the Society’s
highest technical honor—the Samuel
Wylie Miller Memorial Award for
meritorious achievement in advanc-
ing the art and science of welding.
Fig. 5—President MacGuffie (left) trans-
fers the symbol of his office to President-
elect Thomas. The new term officially
begins June 1
aA 2
r
:= - -
New Officers
The new officers and members
of the board of directors were an-
nounced by Secretary Plummer.
The entire slate, as reported in the
May issue of WELDING JOURNAL,
was elected to office as follows:
R. David Thomas, Jr., president;
John H. Blankenbuehler, A. F.
Chouinard and Clarence E. Jackson,
the three vice-presidents without
seniority; H. E. Rockefeller (ap-
pointed for 3-year term), treasurer.
President-elect R. D. Thomas, Jr.,
who assumes office on June Ist,
received the gavel, symbol of his new
post and then made a short accept-
ance speech during which he af-
firmed his dedication to the Soct-
ETY’s highest post of honor. Later,
the audience was greeted briefly by
W. C. Heath, vice-president of the
American Society of Mechanical
Engineers and A. C. Axtell, presi-
dent of the National Welding Supply
Assn., who presented a check to
the United Engineering Center.
The directors - at - large newly
elected to office are R. B. McCauley,
John Mikulak, Ernest F. Nippes
and Robert D. Stout. District
directors for the new term are
Fig. 6—During his acceptance address,
President-elect Thomas affirmed his
dedication to the aims of AWS
Fig. 8—Professors A. E. Flanigan (center),
of the University of California, and R. B.
McCauley (right), of Ohio State, receive
their Adams Memorial Membership
Award certificates
Fig. 9—Congratulations are in order as
J. E. Dato (center), National Conven-
tion chairman, and F. W. Davis (right) re-
ceive National Meritorious Awards
%
ae
Fig. 12—National Secretary Fred L.
Plummer (right) is greeted by President
MacGuffie upon receiving his Honorary
Membership certificate
Fig. 14—K. R. Notvest is the proud re-
cipient of the James F. Lincoln Gold
Medal and Certificate as President Mac-
Guffie makes the award
George W. Kirkley, District 1
New England; James M. Shilstone,
District 4—Southeast; Lester L.
Baugh, District 7—West Central;
and David P. O’Connor, District
10—Western. The National Nomi-
nating Committee, in addition to
C. I. MacGuffie, chairman, will
consist of G. O. Hoglund, R. W.
Clark, B. Gates and the district
representatives who are as follows:
Helmut Thielsch, S. T. Walter,
D. H. St. Louis, G. M. Slaughter,
E. T. Scott, Sr., R. H. Hoefler,
L. C. Monroe, J. R. Warn, J. M.
Barnes, F. R. Drahos and Eric
Kinnaird.
As a fitting climax to the award
ceremonies, Past-president G. O.
Hoglund gave the Past-president
612 | JUNE 1960
Fig. 10—The Pittsburgh Section, win-
ner of the Henry Nietzel National Mem-
bership Award for greatest numerical
increase, is represented by Paul Masters
Fig. 13—President MacGuffie passes out the A. F. Davis Silver Medals and Certifi-
cates to the authors (left to right) A. M. Hill, C. S.Matlock and G. M. Sommer
Fig. 15—B. E. Rossi is greeted by Presi-
dent MacGuffie as the editor of the
Welding Journal receives the coveted
Samuel Wylie Miller Medal and Certifi-
cate
Award to Mr. MacGuffie for his un-
tiring service to the Socrety during
his tenure as president.
Adams Lecture
The Adams Lecture, presented
annually by an outstanding engi-
neer, scientist or educator, this year
was given by Robert D. Stout, head
of Metallurgy Department, Lehigh
University. Dr. Stout, who has
made many notable contributions
in the field of welding research, se-
lected as his subject ‘“Higher-
Strength Steels for Welded Struc-
tures.”” His excellent presentation
covered valuable research findings
in one of the most important trends
in modern fabrication.
After the traditional lecture, Dr.
Fig. 1l—A charter member is honored
as Royal D. Thomas is presented with
certificate of Honorary Membership by
President MacGuffie
Fig. 16—After his delivery of the Annual
Adams Lecture, the noted educator and
scientist Robert D. Stout was presented
with the Adams Certificate, emblem of
the occasion
Stout was presented with the
Adams Certificate and Honorarium
by President MacGuffie.
President's Reception and Annual Banquet
On Monday evening, a large
turnout of members and guests
crowded the Galeria Room for the
President’s Reception where they
were introduced to the national
officers and staff members. The
occasion afforded a welcome oppor-
tunity for relaxation, renewing old
acquaintances as well as making
new ones, in the informal atmosphere
of refreshments and the music of
the popular Jose Nieto Trio. Fol-
lowing the reception, the Annual
Banquet was held in the Ball-

Fig. 17—A group of authors gather for breakfast and last-
minute instructions before presenting their technical
papers at the Annual Meeting
Fig. 19—Harry Schwartzbart was the principal speaker at the Educational
Lecture Series at the 41st Annual Meeting. The topic, ‘‘New
Welding Processes,’ "was presented in two sessions
room where, in a pleasant break
with tradition, no formal speeches
were scheduled. As more than 400
enjoyed the excellent banquet, a
gay note was struck by the antics
and jokes of Don Rice who took
over as Master of Ceremonies.
Jack Benny’s favorite quartet, the
Sportsmen, regaled the group with
many delightful songs, old and
new.
Varied Technical Program
Includes Sessions by ASME
From Monday afternoon through
Friday morning, a total of 23 tech-
nical sessions included the presenta-
tion of 69 papers on varied aspects
of welding. In tune with the
dominant interests of the area, a
number of papers were related to
the aircraft industry and to missile
and rocketry applications. The
Metals Engineering Division of the
American Society of Mechanical
Engineers sponsored four sessions
covering the important fields of
welding and fabrication of the
Ni-Cr-Fe alloys, fracture mechan-
ics and nonmetallic structural ma-
terials. Chairman of the ASME
Coordination Committee was C. E.
Bowman of the University of IIli-
nois. The AWS-sponsored sessions
ranged from wmicro-wire to the
largest girders and from pure re-
search to. practical fabrication.
Other subjects included heat effects
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Fig. 18—An attentive audience listens to the presentation
of a technical paper at a typical session held in
the Galeria Room of the Hotel Biltmore
on weldments, resistance welding,
structures, aluminum alloys, fabrica-
tion procedures, weldments, welda-
bility, ductility of steels, brazing,
columbium, titanium, zirconium,
pipe lines and processes.
Plant Tours Reveal Unusual Facilities
On Wednesday and Thursday
the two plant tours arranged by the
Los Angeles Section turned out to
be popular side attractions of inter-
est. The Wednesday tour included
a double visit to the McCulloch
Motors Corp., and Airline Welding
and Manufacturing Co. The for-
mer, a large plant specializing in
chain saws and outboard motors,
showed a number of other diversified
products. Airline Welding demon-
strated the approach adopted by
modern shops handling the latest
high-quality products demanded by
the aircraft and missile industry.
The Thursday tour to the U. S.
Consolidated Steel Division of the
U. S. Steel Corp. was a revelation,
to many, of the extensive fabricating
operations handled on the West
Coast. One of the largest combina-
tion production—job shops, the
widely diversified operations in-
cluded all types of welding.
Ladies’ Program Exceptional
An attractive ladies’ program
kept the distaff side enjoyably
occupied from Monday through
Fig. 20—At the completion of his lecture,
Mr. Schwartzbart is presented with the
Educational Lecturer Certificate by Presi-
dent MacGuffie
Friday. Under the guiding hand
of a committee of 21 ladies from
the Los Angeles Section, organized
by Chairman J. B. Ross, each day
started out with a continental break-
fast and then proceeded with the
day’s tour. Among the interesting
places visited were TV and movie
studios, LaBrea Pits, Hollywood,
Beverly Hills, Marineland, Hunt-
ington Museum and Library and
Disneyland.
Welding Show Bigger Than Ever
The most impressive Welding
Show the Socrety has ever pre-
sented got underway Tuesday morn
ing as President-elect ‘Dave’
Thomas severed the chain across the
entrance to the exhibits at the
Great Western Exhibit Center.
From the time of the chain-cutting
ceremony until Thursday evening,
a crowd of over §$,000 visitors
streamed through the vast arena.
The display area covered over
70,000 sq ft—more than double
the amount required last year.
Besides new equipment unveiled
to the public for the first time, many
live demonstrations added to the
attractions. Those attending the
show voiced their praises for the ex-
cellence of the various displays.
Maintenance Panel Held at Exhibit
On Wednesday afternoon,
WELDING JOURNAL | 613
informal panel on maintenance weld-
ing at the Exhibit Center featured
five experts from different fields.
These informative discussions drew
a lively interest as the following
leaders held forth: R. Haines,
atomic reactors; S. Tossetti, rail-
roads; R. Wiliets, refineries; W.
Lester, ships; and R. Norris, steel
companies.
Educational Lectures
Numerous other activities
crowded the busy week-long calen-
dar. Among these was the Educa-
tional Lecture Series, in two parts,
during which Harry Schwartzbart
of the Armour Research Foundation
explained new welding processes.
Mr. Schwartzbart was given the
Educational Lecturer Certificate
for his highly valued lecture pre-
sentations at the annual meeting
of the Society.
Other Activities
An important meeting was held
of the various groups of the Missiles
and Rockets Welded Fabrication
Committee under the chairmanship
Fig. 21—At the President’s Reception—a happy group meets and greets the
national officers during an informal cocktail hour
Fig. 22—The Grand Baliroom of the Biltmore is crowded with diners as the Annual
Meeting and Exposition of the AWS
Dg
of D. B. Howard of American Car
and Foundry, Division of ACF
Industries.
Also, there were meetings by
several other committees and
groups, notably the National Mem-
bership Committee, the Districts
Council meeting, the Section Offi-
cer’s meeting, the Resistance Weld-
ing Committee’s group on Alumi-
num, the WRC Aircraft Advisory
Committee, the Section Technical
Representatives meeting, the Na-
tional Nominating Committee, the
WRC University Research Confer-
ence, the Board of Directors Meet-
ing and the Welding Handbook
Chapter Committee Meeting. The
author’s breakfasts were held each
morning and last minute instructions
were given to prepare the numerous
authors for their task ahead.
To the Los Angeles Section: Plaudits
Behind the general scene of in-
tense activity lay the careful plan-
ning, through months of prepara-
tion, by the Los Angeles Section.
To the many members and friends,
too numerous to mention, goes the
Banquet celebrates the 41st Annual
credit for most. of the succses
achieved in the smooth-running
program. The gratitude of the
SocrETYy and a sense of a job well-
done must be shared by all members
and committee men. The Arrange-
ments Committee was divided as
follows: General Chairman, C. P.
Sander; Secretary, D. A. Elmer;
Subcommittee chairmen, F. V. Mc-
Ginley, Banquet; D. P. O’Connor,
Hospitality; J. B. Ross, Ladies
Entertainment; R. J. Frick, Meet-
ing Sessions; J. B. Wiley, Panel
Discussions; A. M. Thompson,
Plant Tours; E. D. Williams, Presi-
dent’s Reception; L. M. West,
Publicity; J. M. Sayers, Signs;
S. E. Hickman, Technical; A. L.
Collin, Welded Products.
Presidential Address
By C. |. MacGuffie
President, 1959-60, American Welding Society
The 1959-60 year of the AMERI-
CAN WELDING SOCIETY will soon be
history. It will be recorded as the
first full year of operation under our
new By-laws which were designed
for more efficient and _ effective
management of our large organiza-
tion. Under these new By-laws,
four Councils, each consisting of
members of our Board of Directors,
have promoted and supervised the
operations of our many working
committees. They have carried out
their newly established responsi-
bilities faithfully and diligently. I
believe that history will record the
results of their efforts benevolently
as a year of progress on many
fronts. Time will probably endorse
 these new By-laws as a substantial
forward-looking step in the story
of our growth.
The past year will be remembered
as our Fortieth Anniversary Year.
Just forty years ago, our AMERICAN
WELDING SOCIETY was incorporated
as a group of individuals working
through an organized society dedi-
cated to the principles set forth in
our Constitution to “‘encourage in
the broadest and most liberal sense
the advancement of welding’’...
“thereby fostering public welfare
and education, aiding in the develop-
ment of our country’s industries
and adding to the material pros-
perity and well being of our people.”’
It is fitting that on our Fortieth
Anniversary we take a short time
here to appraise briefly our per-
formance and our progress. Perhaps
such an appraisal may give us a
clearer picture of the tasks which
lie just ahead.
In our appraisal, we will dispense
with activities of our past year, as
such. Their details you can read
from our National Secretary’s re-
port which contains summaries of
our many committee activities.
mean, rather, that we should now
take a long range look backward at
the results of the work of our many
predecessors in charting the course
of this Socrety over the past four
decades and thus obtain a better
background to plot our future
course.
During the forty-year period,
membership has grown from 219 in
1919 until at the present time it
numbers over 12,600. It has
doubled in the last fifteen years,
thus showing an accelerating growth
in more recent years. These mem-
bers now constitute 84 Sections,
covering all major industrial areas,
and are strategically located to carry
on SocIETy activities at the local
Fig. 23—President MacGuffie registers a big smile as he is pre
sented a check for the United Engineering Center building funa
on behalf of the National Welding Supply Assn., by NWSA Presi
dentA. C. Axtell
area in all parts of our country.
Several more sections are in the
formative stage.
Our operating budget has grown
yearly until it now is about $650,000
surely an amount which wisely
administered should support and
speed the work necessary to ap-
proach our objectives. Income has
grown much faster than our mem-
bership. Members’ dues account
for less than 50% of income. The
remainder is derived from the serv-
ices now rendered, such as Journal
advertising, sale of codes, standards,
reprints and national meetings such
as the one we are now officially
opening. It is gratifying to note
that over the years, most of the
services to industry which have
been initiated and sponsored by our
Society have soon been accepted
to a degree that has permitted them
to be established on close to a self-
supporting basis.
Headquarter’s staff has increased
from two individuals in 1919 to a
present staff of 36 loyal, competent
individuals devoting full time to the
support of our SociETy’s efforts.
| They spark the work of more than
one hundred committees operating
in the technical, educational and ad-
ministrative areas. They edit and
promote our WELDING JOURNAL,
our WELDING HANDBOOK, and they
service our growing membership.
The WELDING JOURNAL, our offi-
cial organ, has reached a circulation
of over 16,000 copies monthly, about
2000 of which carry results of our
activities to foreign countries. It
is internationally accepted as the
outstanding technical journal in the
welding field.
The WELDING HANDBOOK in 22
years has come to be regarded inter-
nationally as the bible of the weld-
ing industry. Orders are received
from every country in the world.
Fig. 24—Douglas Latimer, Jr., a student from
La., is congratulated on receiving the Special
Award from Jack Holifield of the Los Angeles
of Supervisors. The winning entry demonstrated
making steel
Our yearly distribution is approach-
ing 15,000.
We are now sponsoring our own
Exposition and holding two national
technical sessions each year to pro-
vide for presentation and discussion
of the new developments in our
rapidly growing fund of technical
knowledge, thus speeding the edu-
cation of both our members and our
interested co-workers in related
fields of engineering.
As co-sponsor of the American
Council of the International Insti-
tute of Welding, our Socrerty is be-
coming a greater factor in promot-
ing the advancement of welding on
an international basis.
Through our education and infor-
mation activities during recent
years, we have made a modest start
to get word of the results of our
technical progress beyond our So-
CIETY’s boundaries to the outside
world, thus attracting new, in-
terested talent to the welding field
and spreading the use of proved
welding techniques in industrial
practice.
We could go into much greater
detail in this forty year summary.
For instance, we could mention the
part played in World War II when
many of our members, organized
under the sponsorship of and guided
by our Society, helped solve many
ship building problems and sped
production of tanks and planes.
Perhaps we should not leave out
some of the specific work being done
currently by our Educational Com-
mittees. But I _ believe this
“‘thumb-nail”’ sketch gives us a true
foundation upon which to judge.
It is interesting to note that the
growth in size and influence of the
AMERICAN WELDING SOCIETY has
been closely related to the increased
acceptance of welding as a means of
joining by American industry. It
Baton Rouge,
Achievement
County Board
a method for
is, therefore, a safe assumption that
the work of the Society has been an
influential factor in the increased
use of the many welding processes.
Truly, this brief look backward
presents a picture of progress of
which our predecessors can justly
be proud. Behind it is a story of
hard work and dedication to a
principle so clearly stated in our
original By-laws. It confirms be-
yond any question of a doubt the
need for services the AMERICAN
WELDING Society can and should
render to its members, to the engi-
neering profession and to the Ameri-
can economy.
But to those of us on the current
scene, it should mean much more.
It should impress upon us the fact
that we are now part of a mature or-
ganization wielding a _ substantial
influence on engineering progress
and in our national economy. It
should give us an awareness of the
increased responsibilities we now
shoulder to carry our SOCIETY on-
ward toward those same objectives
that time has proved to be so
worthy and so valid.
It should raise in our minds the
question, “where do we go from
here?”’
Part of the answer to such a
question is obvious. We must con-
tinue to provide, within our means,
those services that have contrib-
uted heavily to this long-term,
healthy growth.
We must continue the same dili-
gent attention to our JOURNAL that
has been evidenced in the past
to keep its format attractive, its
circulation list broad and its content
alert to the needs of our members.
We must continue the fine work
being done by our many Technical
Committees in developing new
codes, standards, recommended
practices and handbooks. The list
of those still required grows longer
and more urgent. Many of those
issued years ago must be brought up
to date to reflect current needs and
recent technology. Probably no
phase of our activity is more vital
to continued progress. Therefore,
in no phase of activity is the answer
to our question more evident.
The same enthusiastic planning
and programming that have been
evidenced in the many Sections
visited during the past year should
be continued and increased. This
means of exchanging ideas has
proved invaluable in servicing mem-
bership, improving their technical
competence and rapidly taking the
new and novel of our industry to
the user. The continuing effort of
our Sections to interest potential
members in our enterprise becomes
616 | JUNE 1960
more important with the years. As
the demand for new codes and
standards grows, so does our need
for members with experience to pre-
pare them.
Even though the courses of action
mentioned are reasonably clear, the
facilities for properly sponsoring our
efforts to obtain results may not
be so well defined. We are ex-
tremely fortunate that our several
preceding Boards of Directors have
spent so much time on depth studies
of Headquarter’s needs and have
completed the arrangements for
housing in the new Engineering
Center. In this modern office build-
ing, we will have offices, library and
committee rooms to carry on this
work on an extremely economical
and efficient basis. Continued close
association and using the same
facilities with the management of
seventeen other engineering organi-
zations with whom we have many
common interests carries with it the
intangible assets of a working cli-
mate that should improve com-
munications and be helpful in many
ways.
But we have so far only partially
answered the question. The rest of
the answer is not quite as obvious.
1, therefore, offer these suggestions
for your consideration and future
action.
I am firmly convinced that the
rate of growth of our Society during
coming years—the speed at which
we move toward our stated objec-
tives—and the degree to which we
“aid in the development of our
country’s industries’’ will depend
heavily upon the initiative we take
on informational and educational
activities. Perhaps we should use
these words synonymously and
Fig. 25—The ladies had a grand time. Here a group prepares to embark on one of
the daily tours of the Los Angeles area which proved extremely successful
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simply state we must concentrate
on a broad educational program.
This educational program must
effectively reach four separate and
distinct groups.
The first group consists of the
youth in the high schools or second-
ary schools of our nation. They
must be told of the many interesting
and challenging fields of work that
lie in the many facets of the welding
industry. An excellent start has
been made by recent Educational
Committees and Sections, but we
have just begun the work in earnest.
Such work must be strengthened
and expanded. Our very future as
a SOCIETY or as an industry will be
heavily influenced by the effective-
ness of this program. From the
youth we are trying to reach must
come the scientists, engineers and
technicians to carry on our work
tomorrow.
Next it will be necessary that
welding be more effectively pre-
sented in the colleges so that the
engineers reaching industry have a
better comprehension of and more
confidence in the proper use of the
right welding process. Improved
education of this group can acceler-
ate greatly our Societry’s future
progress.
The third group to whom we must
direct our educational efforts is the
engineering profession as a whole
the members of the other engineer-
ing societies who design and build
the structures, machinery and other
products where metal is joined to
metal and upon whose shoulders
rests the prime responsibility for the
greatest use of welding. Our engi-
neers today are usually specialists.
The one designing mechanical struc-
tures often does not have the time,
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 if he does have the inclination, to be-
come an authority on all of the
thirty-odd welding processes avail-
able. The latest advancements in
our science presented to our mem-
bers at meetings such as this must
be made available in usable form to
all members of the engineering pro-
fession. Our jointly sponsored, na-
tional technical sessions are a big
step in this direction. The several
educational courses and seminars
sponsored nationally and locally are
effectively starting this phase of
education. We must educate these
engineers to confidence in the tools
and techniques that welding has to
offer. During the past forty years,
the AMERICAN WELDING SOCIETY
has obtained from the ranks of the
mechanical, civil, electrical and
others the individuals who have
carried on the work we have re-
viewed earlier here. We owe these
same engineering organizations the
service of continually keeping them
up to date on the advantages of our
new-found knowledge in a form they
can use and of educating them in
its proper application.
Last and not least is the general
public. In the capitalist economy
of which we are now a major part,
the general public has a large voice
in determining our future course and
timing. When the American con-
sumer fully realizes the part that
welding plays in his everyday life, he
will demand more welded products.
When he knows his _ purchases
can be made lighter, or stronger,
or more pleasing in appearance
through welding, he will insist on its
use. An increased effort on our part
to tell our public about some of the
basic advantages of welding can,
Fig. 26—A fitting climax to the presentation of awards—President Mac Guffie
receives from the hands of Past-president G. O. Hoglund the Past-
president's Certificate, Pin and Life Membership
therefore, accelerate their growing
confidence in its application and use.
What does this mean to us?
It means that during the years just
ahead, we must spend a larger por-
tion of our resources of income and
talent to educate our youth, our co-
workers in engineering and our
general public in the many advan-
tages we have to offer. All of these
groups can help us along the path
we have chosen. They can make
easier, smoother and faster our
journey toward our stated goals.
Acceptance Address
By R. D. Thomas, Jr.
President-elect, 1960-61
American Welding Society
President MacGuffie, Fellow Mem-
bers of the AMERICAN WELDING
SocrETy and Guests: You have
conferred on me a great honor
an honor to serve you as head of this
fine organization. You have placed
on me a responsibility—a respon-
sibility to promote the objectives of
our Socrety for the benefit of its
members, and in so doing contribute
to the industrial and economic
health of our nation. You have
given me a task-—to represent you
before various technical, engineer-
ing and educational groups, and
thereby carry to them the message
of the benefits which our Socrety
has to offer to groups outside our
midst.
Our President has outlined for us
a program for the coming years.
For background, he has reviewed
the past and acknowledged the
tremendous advances made by the
outstanding men who preceded him
in the office of President. In pre-
senting to us a program for the
future, he has laid the cornerstone
for the information and education
project, to which he, himself, over
the past decade has contributed
so much of his time and attention.
We shall always be indebted to you,
Charlie MacGuffie, for your per-
sistent efforts to construct a sound
foundation for bringing the benefits
of welding to the attention of our
youth, our engineering students,
our fellow engineers and the general
public. I know that I speak for
all the national officers when I say
that we are dedicated to build on
this foundation a structure of which
all of us can be proud.
In our enthusiasm for this new
educational approach for reaching
our objectives, we must not over-
look our Technical and Section
Activities. These are the heart-
beats of our Socrety. ‘These are
the grass roots of our organization.
All of us whom you have elected
to national office will endeavor to
maintain a sense of proportion, so
that the new may fit in appro-
priately with the old.
Our President also remarked on
the growing importance of our
Society in the international councils
of the engineering profession. In
April 1961, we will serve as host to
the Annual Assembly of the In-
ternational Institute of Welding,
the first meeting of this group out-
side of Europe. The choice of our
country for this meeting is a recog-
nition of the importance of our
SociETy in the world engineering
circles.
The IIW Assembly will precede
our Annual Meeting and Welding
Exposition in New York, permitting
their delegates to share also in
our convention. This will give our
next year’s meeting an international
flavor and will provide an oppor-
tunity to all of our members to
meet and to talk with recognized
authorities from abroad.
The immediate year ahead pre-
sents to one in my position a chal-
lenge and a fascination. As I
look at the task before me, I would
be overwhelmed, if it were not
for the confidence I have in the
officers whom you have elected
to serve with me and the fine staff
of men at our headquarters in New
York. I look forward, therefore,
to the absorbing task ahead of me
and will be forever grateful to you
for this opportunity to serve as
President of so fine an organization.
WELDING JOURNAL | 617
TECHNICAL PAPERS SESSIONS

1960

AWS

NATIONAL REGISTRATION

HOTEL PENN-SHERATON
FALL
Sunday, Sept. 25 e 3:00 P.M. to 6:00 P.M.
Monday, Sept. 26 e 8:00 A.M. to 4:00 P.M.
MEETING
Tuesday, Sept 27 e 8:00 A.M. to 4:00 P.M.
Wednesday, Sept 28 e 8:30 A.M. to 3:00 P.M
SEPTEMBER 26-29, HOTEL PENN-SHERATON, PITTSBURGH, PA.
Thursday, Sept. 29 e 8:30 A.M. to 3:00 P.M.

SEPTEMBER 26, MONDAY MORNING

10:00 A.M.—Official Opening Session

WELCOME ADDRESS
R. D. Thomas, Jr., President, AWS
KEYNOTE ADDRESS
(Speaker to be announced later)

SEPTEMBER 26, MONDAY AFTERNOON THREE SIMULTANEOUS SESSIONS, 2:00 P.M. Papers “A” Start at 2 00 P.M
Papers “B’’ Start at 2 50 P.M.
Papers “C”’ Start at 3 40 P.M.

l. Welded Structures 2. Resistance Welding x Brazing

(Sponsored by ASCE)
A. Welding of High-strength Low-alloy
Structural Steels for Bridges
by John L. Beaton and Paul G. Jonas,
California Division of Highways
. Behavior of Welded Built-up Beams
Under Repeated Loads
by J. E. Stallmeyer, L. R. Hall and W. H.
Munse, University of Illinois
. The Flexural Fatigue Strength of Stif-
fened Beams
by J. E. Stallmeyer and W. H. Munse,
University of Illinois
A. Spot Welding of Wrought HK31A,
HM21A and ZE10A Magnesium Alloys
by Lloyd F. Lockwood, The Dow Metal
Products Co.
. Projection Welding of Low-carbon
Steel Using Embossed Projections
by J. F. Harris and J. J. Riley, The
Taylor-Winfield Corp.
. Percussion Welding, Using Magnetic
Force, A Production Process
by Robert Manning, Cutler-Hammer,
Inc.
A. Recent Progress in Development of
Self-fluxing, Airproof Brazing Alloys
by N. Bredzs and H. Schwartzbart
Armour Research Foundation of Illinois
Institute of Technology
. A New High-temperature Manganese-
base Brazing Alloy
by R. C. Kopituk, Thiokol Chemical
Corp.
C. “Wide-gap” Brazing for High-tempera-
ture Service
by P. R. Mobley and G. S. Hoppin III,
General Electric Co.

618 | JUNE 1960

SEPTEMBER 27, TUESDAY MORNING
4. Welded Structures
(Sponsored by CRC and ASCE)
A. Tests of Welded Plate Girders
by B. T. Yen, Lehigh University
B. Design of Columns in Multi-story
Frames
by J. S. Ellis, Royal Military College of
Canada
. Welded Interior Beam-to-column Con
nections
by J. D. Graham, A. N. Sherbourne, R.
N. Khabbaz and C. D. Jensen, Lehigh
University
SEPTEMBER 27, TUESDAY AFTERNOON
6. Welded Structures
(Sponsored by CRC and ASCE)
A. Design Features for Welded Joints in
Space Trusses for Retractable-roof
Auditorium
by Edward Cohen, Ammann & Whitney
. Plastic Design of Fixed-base, Gabled
Frames
by S. P. Prawel, Jr., and R. L. Ketter,
University of Buffalo
,. Behavior of Haunched Connections
by G. C. Lee, J. W. Fisher and G. C.
Driscoll, Jr., Lehigh University
SEPTEMBER 28, WEDNESDAY MORNING
9. Rebuilding and Surfacing
A. Rebuilding a 20-ton Box-girder Crane
to a 45-ton Capacity
by Y. T. Smith, Lakeside Bridge &
Steel Co.
. Welding Repairs of Cavitation on Large
Hydro-electric Turbines
by M. Friedmann, Jr., Martin Fried-
mann Co.
. Hard Surfacing of Blast-furnace Bells
and Hoppers
by F. J. Gaydos and N. Fragasse, U. S.
Steel Corp.
TWO SIMULTANEOUS SESSIONS, 9:30 A.M. Papers “A” Start at 9:30 A
Papers “B”’ Start at 10:2(
Papers “C’’ Start at 11:10
d. Electrodes and Techniques
A. Evaluating Crack-resistant Electrodes
for Welding HY80 Steel
by Stanley |. Roberts, Portsmouth
Naval Shipyard
. Low-hydrogen Electrodes for Out-of-
position Welding
by J. E. Hinkel, The Lincoln Electric Co.
C. Zircaloy-welding Techniques De-
veloped for Nuclear Ceramic-fuel-ele-
ment Fabrication
by L. E. Mills, General Electric Co.
THREE SIMULTANEOUS SESSIONS, 2:00 P.M. Papers ‘ A’ Start at 2:00 P.M
Papers ““B” Start at 2:50 P.M.
Papers “‘C’’ Start at 3:40 P.M
/. Research and Weldability 8. Processes
A. Some Factors Affecting the Notch A. Advances in Electron-beam Welding
Toughness of Steel Weld Metal
Techniques
by K. E. Dorschu, Air Reduction Co. by R. R. Banks, Air Reduction Sales Co.
and R. D. Stout, Lehigh University
. A Comparative Study of Underbead B. Today’s Industrial Role of Magnetic-
and Weld-metal Cracking flux Gas-shielded Arc Welding
by Z. P. Saperstein, C. F. Braun & Co., by R. T. Telford, Linde Co.
and A. E. Flanigan, University of Cali-
fornia C. High-vacuum System Fabrication
. Brittle Fracture Tests of Six-foot Wide by E. P. Cornwall, Boeing Airplane Co.
Prestressed Steel Plates
by F. W. Barton and W. J. Hall, Uni-
versity of Illinois
TWO SIMULTANEOUS SESSIONS, 9:30 A.M Papers ‘‘A”’ Start at 9:30 A.M.
Papers ““B”’ Start at 10:20 A.M.
Papers “C”’ Start at 11:10 A.M.
10. Research and Weldability
A. Mechanical Properties of Electroslag
Welds
by W. H. Wooding and H. C. Campbell,
Arcos Corp.
. New Approach to Problem of Residual
Stresses and Distortions Due to Weld-
ing
by Koichi Masubuchi, Battelle Me-
morial Institute
C. Fundamentals of Weld Behavior Under
Hindered Contractions
by C. M. Adams, Jr., R. E. Travis,
W. G. Moffatt and J. V. Robinson,
Massachusetts Institute of Technology
WELDING JOURNAL | 619
 SEPTEMBER 28, WEDNESDAY
11. Welded Structures
(Sponsored by ASCE)
A. Strength of Welded Aluminum-alloy
Box Beams
by R. J. Brungraber, Alcoa Research
Laboratories
. Research and Development of Con-
tinuous Welded Rail
by G. M. Magee, Association of Ameri-
can Railroads
. Painting of Welds
by J. D. Keane, Steel Structures
Painting Council
SEPTEMBER 29, THURSDAY
14. Cutting
A. Single-pass “J” Grooving in Heavy
Plate with an Oxy-fuel Gas Flame
by C. B. Milton, Linde Co.
. Principles of Template Preparation
for the Oxygen-cutting Process
by L. M. Layden, Air Reduction Co.
. Heavy-duty Constricted Tungsten-arc
Cutting of All Metals
by W. A. Geideman, Jr., Linde Co.
SEPTEMBER 29, THURSDAY AFTERNOON
16. High Alloys
A. Fabrication Principles for Welded In-
conel “X”’ Structures
by H. P. Schane and E. E. Weismantel
The Budd Co.
. Studies of Repair Welding Age-hard-
enable Nickel-base Alloys
by W. J. Lepkowski, R. E. Monroe and
P. J. Rieppel, Battelle Memorial Insti-
tute
. Joint Characteristics of Welded Cold-
worked Stainless Steel
by L. Stemann and E. E. Weismantel
The Budd Co.
620 | JUNE 1960
AFTERNOON THREE SIMULTANEOUS SESSIONS, 2:00 P.M. Papers “A’’ Start at 2:0
Papers “B”’ Start at 2:5
Papers ‘‘C’’ Start at 3:4
12. Nondestructive Testing 13. Missiles
(Co-sponsored by SNT) A. Welded Fabrication of Solid-fuel Rocket
A. What the Welding Industry Requires Motor Cases
from Nondestructive Testing by M. D. Randall, R. E. Monroe and
by Jay Bland, General Electric Co. P. J. Rieppel, Battelle Memorial Insti-
. Activities of Commission V, Inter- tute
national Institute of Welding . Weldability of Ultra-high-strength
by R. A. Pulk, Physical Sciences La- Steels for Missiles
boratory by M. J. Albom and C. C. Titherington,
. Practical Use of Magnetic Inspection Aerojet General Corp.
of Welding in Industry . Production Welding of Thin-walled
by Fred Boehm, Schutte and Koerting Pressure Vessels
Co. by T. J. Bosworth and D. S. Hem-
minger, Boeing Airplane Co.
MORNING TWO SIMULTANEOUS SESSIONS, 9:30 A.M. Papers ‘‘A”’ Start at 9:30 A.M
Papers “B” Start at 10:20 A.M.
Papers “C” Start at 11:10 A.M
15. Aluminum
A. Assembly-line Fabrication of All-
welded Aluminum Covered Hopper
Cars
by D. V. Wilcox, Reynolds Metals Co.
and R. P. Hubbard, Magor Car Corp.
. Inert-gas-shielded Metal-arc Spot
Welding Aluminum
by S. E. McFall, Aluminium Labora-
tories Ltd.
. Fusion-zone Structures and Properties
in Aluminum Alloys
by C. M. Adams and P. E. Brown, Mas-
sachusetts Institute of Technology
TWO SIMULTANEOUS SESSIONS, 2:00 P.M. Papers “A” Start at 2:00 P.M.
Papers “B” Start at 2:50 P.M.
Papers “C” Start at 3:40 P.M
17. Fabrication of Weldments
A. A New Method of Fusion Welding
Tapered Sheets
by A. Sciaky and M. Sommeria, Sciaky
Brothers, Inc.
. Fabrication of Primary Piping System
of the Yankee Atomic Electric Plant
by R. R. Rothermel, National Valve
and Manufacturing Co. and R. A.
Loose, Westinghouse Electric Corp. This schedule of technical
papers is not necessarily
. Welding Centrifugal-compressor Im- final. Amore complete and de-
peller Wheels tailed program, including an
by J. H. Matheny and E. L. Aul, Clark account of other activities, will
be published in the September
Brothers Co. issue of the WELDING
JOURNAL.
 KEEPING YOU POSTED

by Fred L. Plummer

e@ A cable from Dr. Charles Keel of stitute of Welding which will be Rockefeller discussing staff per-
Switzerland dated March 22nd an- held in New York during April sonnel requirements and estimates
nounced that he and his charming 1961. This event will bring to the of income and expense for the 1960
wife would attend the AWS Annual United States many world famous 61 fiscal year; and the usual weekly
Meeting in Los Angeles prior to scientists, engineers and industrial- conferences of department heads.
participation in the San Francisco ists interested in all types of welded
Meeting of the International Acety- e A special committee consisting of
design and fabrication.
lene Assn. at which he will be Past-president O. B. J. Fraser as
e@ Important conferences during the chairman, Past-president H. W
awarded the important Morehead next few days included: a half day
Medal. Pierce, President-elect R. D.
with President C. I. MacGuffie; a Thomas, Jr., Treasurer H. E. Rocke-
e@ The following day A. Haeger and luncheon with WRC Director W. feller and WRC Director W. Sprara-
I. Stromberg of Sweden reported to Spraragen who retires on June Ist gen held its first meeting in your
your Secretary concerning an ex- after more than forty years of dis- Secretary’s office on April 7th to
tended inspection trip in the United tinguished activities associated with consider the need for revision of the
States and Canada which they had welding; a discussion with Holiday pension plan, insurance and medical
just completed. They wished to House President Abrams and repre- protection, vacation policies and
express their appreciation for the sentative Ryan concerning final other benefits made available to
courtesies and cooperation extended plans for the AWS Mid Pacific Con- AWS staff members.
to them in the many plants which ference in Hawaii; an inspection
they had visited. with Exposition Manager Ken- @ The week of April 11th included
worthy and N. Y. Coliseum Man- the climax of preparation for the
@ On March 24th your Secretary ager Strong of facilities to be used for Annual Meeting and Welding Ex-
was guest, through the courtesy of position: completing and mailing of
the 1961 Welding Exposition; a
AWS Director Don Howard, of agendas for meetings of the Exposi-
long telephone conversation with
officials of American Car and Foun- tion, Manufacturers and other com-
Indianapolis Section officer Fred
dry Division of ACF Industries at a Watts concerning a proclamation to mittees, the Technical Council,
luncheon meeting of the National be signed by the Governor desig- Board of Directors and other groups;
Security and Industrial Assn. at printing of the final programs, the
nating April as Welded Products
which President H. H. Rogge of President’s address, registration
Month in Indiana (one of many
AC and F Div. presided and Major such proclamations signed by Gov- badges and supplies; preparation
General S. T. Wray of Wright Air ernors and Mayors); an afternoon and distribution of news releases
Development Division, ARDC, de- covering meetings, exposition, ex-
with President MacGuffie, Presi-
scribed problems involved in sending hibitors, authors, awardees and
dent-elect Thomas and ‘Treasurer
men into space.
@ This same day your Secretary
met with L. Manne, Decorating
Contractor for the Welding Ex-
position in Los Angeles, and with
Dr. Wundt of General Electric Co.,
expert on the subject of brittle AWS DIRECTORS-AT-LARGE
fracture, who will join other rep- Term Expires 1961 1962 1963
resentatives of the United States
at the Annual Assembly of the A. A. Holzbaur Jay Bland R. B. McCauley
IIW in Liege, Belgium, during June. D. B. Howard F. G. Singleton John Mikulak
J. L. York C. B. Smith E. F. Nippes
@ The next day Technical Secre- W. H. Hobart, Jr. J. R. Stitt R. D. Stout
tary Fenton and your Secretary
traveled to Philadelphia to join
President-elect R. D. Thomas, Jr., AWS DISTRICT DIRECTORS
in a conference with ASTM repre-
sentatives R. E. Hess, N. L. Mochel District No. leNew England G. W. Kirkley District No. 6eCentral J. N. Alcock
and J. Caum concerning joint AWS- District No. 2eMiddle Eastern E. E. Goehringer District No. 7eWest Central L.L. Baugh
ASTM activities in the preparation District No. 3eNorth Central J. W. Kehoe District No. 8eMidwest G. 0. Bland
and publication of specifications District No. 4eSoutheast J. M. Shilstone District No. 9eSouthwest C.L. Moss III
and other technical papers. District No. 5eEast Central H. E. Schulz District No. 10eWestern D. P. O Connor
District No. 1leNorthwest C . Robinson
@ Convention Manager = Frank
Mooney and your Secretary had a
long conference on March 29th with AWS PAST-PRESIDENT DIRECTORS
representatives of the Sheraton-
Atlantic Hotel discussing facilities C. |. MacGuffie G. 0. Hoglund
and arrangements for the Annual
Assembly of the International In-

WELDING JOURNAL | 621

 special events; securing medals,
SYVZRON
certificates and other awards to be
presented at the meeting; col-
lecting, packing and shipping signs,
SELENIUM equipment, technical publications,
programs and various supplies re-
quired for the meeting and exposi-
tion; and preparing and _ repro-
WELDING ducing a detailed program of ac-
tivities for officers of the SocrEery.
@ Each member of the staff has im-
portant assignments which must
coordinated through frequent
STACKS
conferences within the group and
with others who perform services
for the Socrery.
e@ Constitution and By-laws Com-
mittee Chairman I. O. Oehler met
with your Secretary on April 12th
to discuss several minor changes in
the By-laws and Board of Directors
“‘rules”” which may be submitted for
consideration later this year.
e This same day your Secretary
discussed with NWSA President
A. C. Axtell plans for more careful
coordination of regional and national
meetings, and of other activities
and interests of the two groups.
e@ The following day Past-president
J. H. Humberstone discussed with
your Secretary the activities of a
group of industry leaders who are
organizing support for the 1961
Assembly of the ITW which will be
held in conjunction with the 1961
AWS Annual Meeting and Welding
Exposition. The possibility of in-
--the industry cluding in the AWS meeting pro-
gram several panel discussions de-
standard for
voted to specific industries such as
more than shipbuilding, automobile assembly,
aircraft manufacture, pressure-
seven years
vessel construction, fabrication and
erection of structures and others,
with prominent representatives from
other countries forming the panels
and discussing equipment, pro-
cedures, materials, inspection, costs
and other design and fabricating
factors, was explored.
Experience by seven major manu-
facturers since 1952 shows less @ On Easter Sunday, April 17th,
than 2°% have failed in field service. your Secretary met with Lincoln Co.
SYNTRON Welding Rectifier Board Chairman J. F. Lincoln at
Specialists are ready to serve you. the New York Engineers Club, prior
to his departure for a business trip
Write for information and specifications in Europe, to discuss a series of
articles, intended for general dis-
SYNTRON RECTIFIER DIVISION tribution and the encouragement of
the greater use of welding by re-
258. Lexington Ave Homer City, Penna porting outstanding examples of
simple, economical, serviceable ap-
Sales Engineers in: New York, Chicag plications requiring a minimum of
geles and Canada
Canadian Manufacturing Plant inspection or other quality controls.
Ltd., Stoney Creek, Ontario
Export ) Representat ve: Dage Corporat e@ These notes are being written
44th Street, New York, N. Y during the evening of April 20th.
ies end Snaten nq Representat Robert O
Wh tsell and Associatees 6620 Eos Bypay President MacGuffie is devoting
reet, Indianapolis 15 indiana Offic n Cleve- this week to a series of AWS Section
land, Dayton and Cincinnat
For details, circie No. 8 on Reader information Card meetings including San Francisco
622 | JUNE 1960
on Monday, April 18th, Santa Clara
at San Jose on Tuesday, San Diego
on Wednesday, Salt Lake City on
Thursday and Long Beach on Fri-
day. District Director McGinley
and your secretary will join Presi-
dent MacGuffie and Harnischfeger’s
D. C. Smith (technical speaker) for
the meeting at Long Beach on
April 22nd.
@ Technical Secretary Fenton is in
Sacramento for meetings of the
AWS Conference Committee on
Welded Bridges and a tour of fabri-
cating shops in the San Francisco
Bay Area.
@ Exposition Manager Kenworthy
and Publicity Manager Phillips are
in Los Angeles completing arrange-
ments for meetings and exposition
to be held there next week.
@ Convention Manager Mooney is
flying to Los Angeles tonight and
will be joined there later by Jour-
NAL Editor Rossi, Advertising Man-
ager Talento and Office Manager
Krisman.
@ Los Angeles Section Chairman
Hayes and Arrangements Chairman
Sander and their associates have
completed months of preparation
for our annual convention. Else-
where in this issue you may read
the first reports of these events.
@ At the opening session, President’s
Reception and Banquet, ASME
Vice-president H. W. Heath and
NWSA President A. C. Axtell offi-
cially represented their respective
organizations. President Axtell
presented a substantial gift from
NWSA to the United Engineering
Center Building Fund.
@ Past-president Humberstone, who
was principal speaker at the April
7th meeting of the Detroit Section,
President-elect Thomas, Vice-presi-
dents-elect Blankenbuehler and
Chouinard together with their wives
will head a large delegation of mem-
bers and their ladies to Hawaii for
the Mid-Pacific Conference which
follows the meetings in Los An-
geles.
Welcome
e Supporting Company
Effective Apr. 1, 1960:
Horton Steel Works Ltd.
P. O. Box 190
Fort Erie, Ontario, Canada
 EDUCATIONAL ACTIVITIES

Welding: Technicians Information and Education, and

Dave Holster, representative of Air
There is an ever-increasing need Reduction Co.
for a new classification in the weld- Mr. McLaughlin outlined his NOW AVAILABLE
ing industry. The graduate en- tentative plans. He explained the
gineer is asked to perform many change in the industrial approach,
duties which could easily be and how changing times have WELDING HAND-
delegated to someone who does not brought about the need for an in- BOOK SECTION III
possess the engineer’s specialized dividual with these skills. He
knowledge. Consequently, much of Miscellaneous Metal
pointed out that in this highly
the engineer’s time is relatively un- technological age, a great deal more Joining and Cutting
productive, since it is spent in de- skill and knowledge are required Processes.
tailed work that could be handled than in any part of our history.
by someone who has been trained for He visualized a two-year course
this particular job. In its pages is found
with emphasis upon theory, but
There is a definite need today for with sufficient practical instruction the most accurate, up-
some person to act as a liaison be- to enable the graduate to develop to-date knowledge on
tween the graduate engineer and adequate manipulative skills.
the welder. This individual would welding, cutting and al-
The Superintendent of the school
carry out the ideas of the welding requested help from the AWS lied joming methods ob-
engineer, and could do much of the Educational Committees in prepar-
paper work that takes so much of tainable.
ing a curriculum which could be used
the engineer’s time. to develop men with the type of This Section contains
On April 13th, a meeting was held knowledge and skill to fulfill this
at the New York Trade School, with job classification. When such a chapters on: Forge
a view to discussing the need for this curriculum has been established, it Welding, Thermit
new classification, and also the em- was felt that it could conceivably
ployment possibilities for such a become the pattern for all similar Welding, Induction
person after graduation. courses throughout the country. Welding, Surfacing,
The meeting was called at the One point was raised during the Metallizing, Brazing,
request of George McLaughlin, discussion which is of vital impor-
Superintendent of the New York tance to the welding industry. This Soldering, Welding of
Trade School. It was attended by point was whether industry itself Plastics,* Adhesive
Clarence E. Jackson, Chairman of is aware of the need for this new
the Educational Activities Com- classification, which, for want of a Bonding of Metals,*
mittee, A. L. Phillips, Secretary of better word, is termed “‘technician.”’ Oxygen Cutting and
Auxiliary Oxygen Cut-
ting Processes, Arc Cut-
EDUCATIONAL ACTIVITIES COMMITTEE MEETS IN TROY
ting, Ultrasonic Weld-
te
ing,* Welding by Cold
Workings, * Stud Welding.

Section IIT contains over

500 pages and 400 illus-
trations
and tables. Cop-
ies may be obtained from
the American Welding
Society, 33 West 39th
Street, New York 18,
N. Y. List price $9.00
per copy.
Members and guests attending the Feb. 2, 1960, meeting of the Educational Activities
Committee, held at Hobart Brothers Technical School, Troy, Ohio. (Left to right) C.
Turnquist, Cass Apprentice School, Detroit; H. A. Sosnin, Nibco, Inc.; H. Hogan, U. S. * These subjects have never before been
included in an AWS Welding Handbook
Department of Education; A. L. Phillips, Secretary of Information and Education; C. E.
Jackson, Linde Co., R. B. McCauley, Ohio State University; J. Blankenbuehler, Hobart
Brothers Co.; J. Light, Arcos Corp.; and H. B. Cary, Hobart Brothers Co.

WELDING JOURNAL | 623

 SECTION NEWS AND EVENTS

As reported to Catherine M. O'Leary

NATURAL-GAS CUTTING for conversions to obtain the re-

LECTURE SERIES
Birmingham—tThe first annual
lecture series sponsored by the
Birmingham Section has met with
outstanding success. There was a
total of 73 registered for the series,
but registration was required for
only the first two of the five ses-
sions. Thus, the total number in
attendance was considerably greater
than this. The first lecture was
held on February 16th. The pro-
gram of lectures was as follows:
First Lecture—Fundamentals of
Arc Welding Mild and Low-alloy
Steels, by A. E. Pearson, manager,
Research and Development, The
Ingalls Iron Works Co.
Second Lecture—Inert-gas Weld-
ing of Stainless Steels, by R. T.
Telford, Laboratory Div. head,
Linde Co., and Arc Welding of
Stainless Steel, by R. K. Lee, vice
president, Alloy Rods Co.
Third Lecture—The Cutting
Processes, by J. R. McFarland,
steel mill specialist, Air Reduction
Sales Co.
Fourth Lecture-—Automatic
Welding, by Robert A. Wilson,
vice-president, The Lincoln Elec-
tric Co.
Fifth Lecture—-Welding Costs
and Controls, by John E. Durstine,
district manager, The Lincoln Elec-
tric Co.
The lectures were held in Febru-
ary and March and are planned as
annual series.
Birmingham—tThe April 12th
meeting of the Birmingham Sec-
tion was held at the Salem’s Res-
taurant. There were 68 members
and guests in attendance.
Roy Rasmussen of the Harris
Calorific Co., Cleveland, Ohio, pre-
sented an interesting paper on the
subject of “‘Natural-gas Flame Cut-
ting.” His talk covered applica-
tions, cost factors, current develop-
ments, equipment and special ap-
paratus involved with the use of
natural gas.
The subject, treated in a prac-
tical manner, was of great interest
to those present.
ELECTRON-BEAM WELDING
Los Angeles—The Los Angeles
Section was privileged to have as
their guest speaker at the March
17th meeting, held at the Rodger
Young Auditorium, William J. Far-
rell, chief application engineer for
Sciaky Bros, Inc. of Chicago, II.
Mr. Farrell’s subject, which was
exceptionally well presented before
an audience of approximately 130
members and guests, covered the
principles and practices of electron-
beam welding. With the use of a
blackboard, he showed what the
equipment and instrumentation con-
sist of, including the equations
quired settings. This was followed
by a series of slides that showed
how the welding structure was built
into an atmosphere chamber and
its mechanics. Samples of the type
of welding accomplished by the
process were displayed by Mr.
Farrell at the conclusion of his talk.
STAINLESS STEEL
San Diego—On February 16th,
a joint meeting of the American
Society for Metals and the AWS
San Diego Section was held in the
Lafayette Hotel. A short welcome
speech was given by the chairman
of the ASM.
The speaker of the evening was
Ray A. Lula, chief metallurgist,
Stainless Steel Division, Allegheny
Ludlum Steel Corp. His subject
was: “Recent Developments in
High-strength Stainless Steel.”” A
most interesting question-and-an-
swer period followed the presenta-
tion.
FLAME SPRAYING
San Diego—The March meeting
of the San Diego Section was held
on the 16th at the Midway Chuck
Wagon. During ‘Engineering
Week,” the San Diego Section
participated in the welding ex-
hibitions shown in Balboa Park.
The display managed by the mem-
bers received a Gold Certificate
Award.

BIRMINGHAM SECTION SPONSORS LECTURE SERIES

Shown, left to right, at the March 8th lecture sponsored by the This is a small part of the crowd that attended the meeting.
Birmingham Section are C. T. Estock (standing), J. E. Durstine, Some 73 men registered for the five-lecture course
A. E. Pearson and speaker R. A. Wilson at the head table

624 | JUNE 1960

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Send for free sample Tempil° Pellets,
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the N EW
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WELDING JOURNAL | 625
William J. Farrell speaks on the principles and practices Among those present to hear Mr. Farrell were, left to
of electron-beam welding at the March 17th meeting right, Bob Frick, J. M. Soyars and Past-chairman John Ross
of the Los Angeles Section. Chairman Dick Hayes is at left

The speaker at the March meeting
was George Hrach, field representa-
tive for the Metallizing Engineering
Co., Utica, N. Y. His talk was on
“Oxyacetylene and Plasma-jet
Flame Spraying.” He supple-
mented his talk with many in-
teresting slides.
FURNACE BRAZING
Berkeley—On Monday evening,
February 29th, the San Francisco
Section met for dinner and regular
meeting at Spengers Fish Grotto
in Berkeley.
Technical speaker was Robert L.
Ray, vice-president and metallur-
gist of the Pyromet Co. of South
San Francisco. His subject was
“Furnace Brazing—Industrial Ap-
plications and Considerations.”
Through a well-prepared talk and
with good application of slides,
the speaker covered the subject
well.. Points considered were ma-
terials used, joint preparation, types
of furnaces, atmosphere require-
ments, heating method, heating
and cooling cycles and applica-
tion of the brazing alloy. A good
display of sample brazements made
for a well-rounded presentation.
Of significance was the disclosure
of brazing temperatures in excess
of 2300°F. Such applications are
usually associated with the high-
temperature requirements of mis-
siles.
One of the honored visitors at
this meeting was Mitsuo Hasegowa,
director of Welding Division, Osaka
Transformer Co., Osaka, Japan.
FAILURE CAUSES
Berkeley—On Monday evening,
March 28th, the San Francisco
Section met for dinner and regular
meeting at Spengers Fish Grotto
in Berkeley.
Technical speaker was Helmut
Thielsch, metallurgical engineer of
the Grinnell Co., Inc., of Prov-
idence, R. I. His subject was
“Why Welds Fail.”” He discussed
the factors which must be considered
if a satisfactory welded product is
to be expected. The following items
were considered: (1) Inspection
as applied to filler materials and to
base materials. (2) Welding ma-
terials, that is, the selection of the
proper material for the job. (3)
Base materials, those items that
must be considered in so far as
weldability and intended service.
4) In weld deposits, consideration
was given to proper joint prepara-
tion with stress placed on proper
fit-up. (5) For service conditions
those items considered were cor-
rosive service, high-pressure serv-
ice, high-temperature service and
combination of these services. (6
With regard to welding technique,
stress was placed on well-regulated,
proper technique as associated with
the particular application.

EXPLAINS WELD FAILURES AT SAN FRANCISCO MEETING

This smiling speaker is Helmut Thielsch There was a large crowd on hand to hear the speaker as can be seen from the above
shown addressing the March 28th meet-
ing of the San Francisco Section. His
topic: ‘‘Why Welds Fail’’

626 | JUNE 1960

REASONS FOR WELD FAILURES ARE DISCUSSED
Members and guests of Santa Clara Valley Section enjoying dinner
at the March 29th meeting Later, they heard Helmut
Thielsch explain the reasons why some welds fail
Good use of slides and a clever
application of humor kept the at-
tention of all.
CAUSES OF FAILURES
Sunnyvale—About 70 members
and guests of the Santa Clara
Valley Section met on March 29th
to hear a talk on “‘Why Welds
Fail” as given in a very under-
standable manner by Helmut
Thielsch, metallurgical engineer for
the Grinnell Co. of Providence, R.
I. During his lecture he discussed
the principal causes which, he feels,
are of major importance for weld
failures, namely, improper joint
design, improper selection of base
material or filler metal, defective
base material or filler metal, im-
proper techniques or practices un-
known to the welding engineer
and excessive service conditions
for which the weldment was not
designed or fabricated.
Mr. Thielsch’s manner of de-
livery was most entertaining and
BRAZING IS HIS SUBJECT
The subject of furnace-brazing applica-
tions was discussed by Robert L. Ray at
the February 29th meeting of the San
Francisco Section
enlightening, and was thoroughly
enjoyed by those in attendance.
The meeting was held at Sabell’s
Restaurant in Sunnyvale and was
preceded by a dinner and _ short
business meeting.
MANUAL ARC WELDING
Denver—The Colorado Section
held its April meeting on the 12th
at Cavaleri’s Restaurant. The
group gathered at about 6 : 30 P.M.
for an appetizer until 7:00 P.M.,
when dinner was served.
The coffee speaker for the even-
ing was Edward Malin of the Denver
Juvenile Court who gave an insight
into some of the problems of this
busy and important court in the
community.
A. A. “Scotty” Lambrecht of
the Denver office of the Lincoln
Electric Co. was the main speaker
for the evening. His topic was
“‘New Trends and the Direction in
Which We Are Going in Manual
Welding.”” This talk, augmented
with slides, dealt with weld-rod
coverings and classifications. ‘The
presentation was very interesting.
The meeting was concluded at
10: 00 P.M.
CLAD STEELS
Bridgeport——The Bridgeport Sec-
tion met on March 17th at the Fair-
way Restaurant. The speaker was
Louis K. Keay of the Lukens Steel
Co., Coatesville, Pa. He presented
an illustrated talk on the ‘‘Fabrica-
tion and Welding of Clad Steels.”’
PIPE WELDING
Glastonbury—The Hartford Sec-
tion held its regular monthly meet-
Speaker Thielsch, facing camera, listens
attentively while one of the section
officers raises a question
ing on March 15th at the Villa
Maria Restaurant in Glastonbury.
W. D. Oldershaw of the Linde
Co.’s Development Laboratory in
Newark, N. J., presented an il-
lustrated talk on ‘“‘Pipe Welding
with Tungsten and _ Short-arc
Processes.”
SILVER BRAZING
Joliet—The April 14th meeting
of the J. A. K. Section was held
in D’Amicos Restaurant, with 41
members and guests in attendance.
The principal speaker of the evening
was Ward Dawdy of Central Steel
and Wire Co., Chicago, Ill.
Mr. Dawdy spoke on “Silver
Brazing’ and his talk was aug-
mented by movies furnished by
Handy & Harman.
At this same meeting, the nomi-
nating committee presented a new
slate of officers consisting of Robert
Lincoln, chairman; Robert Barnet,
first vice-chairman; Peter Vander-
ploeg, second vice-chairman; Ken-
neth Hanks, secretary; Len Nielsen,
treasurer.
ELECTION OF OFFICERS
Peoria The Peoria Section held
its annual business meeting at
Vonachen’s Junction on Friday,
March 23rd. The main order of
business was the election of officers
for 1960-61 as follows: chairman,
H. Smith; first vice-chairman,
D. Hawes; second vice-chairman,
E. Savant; secretary. E. Bogart;
treasurer, W. Callaway; and ex-
ecutive committee Members-at-
large, G. Swift, T. Morrow, J.
Philyaw and R. Nelson.
The meeting closed with the
showing of the movie ‘“‘Man Into
Outer Space.”’
WELDING JOURNAL | 627
 When You Weld Cast Iron
Select the Correct
TRAVELOGUE
Fort Wayne—The Anthony
CAST IRON WELDING RODS Wayne Section held its March
OR ELECTRODES
meeting on Thursday, the 17th,
beginning with a dinner for mem-
bers, wives and guests at Hobby
’ Ranch House Restaurant.
FUSE-WELL No. 11, Squere—Gray Cast
Iron Welding Rod for Acetylene use in This was followed by a Trave-
filling or building up new or worn logue given by William A. Orr,
castings producing machineable welds. manager of the Kosciusko County
REMC at Warsaw, Ind.
Mr. Orr was one of 15 men from
FUSE-WELL No. 12, Round—Has the this area, who last August took a
same uses and analytical ingredients 21-day tour of England, Germany
as Fuse-Well No. 11. and Russia. He showed a great
number of slides taken on this
tour, commenting on same as he
FUSE-WELL No. 14, Moly—An Iron went along. Keen interest was
Base Rod with alloys added for finer evident among all present.
grain structure and greater strength.
ELECTRODE COVERINGS
FUSE-WELL No. 22, Electrode — Light | Indianapolis—A dinner meeting
coated Rod to be used for AC or DC of the Indiana Section was held in
welding in the fabricating and repair- | Room 412 of the Indiana State
ing of cast iron castings.
Teacher’s Building on March 25th.
Forty members and guests were
THE CHICAGO HARDWARE FOUNDRY CO. present. A short business meeting
NOR a CMICAGO, NLINOHS was held followed by introduction of
the speaker, Harry F. Reid, Jr.,
For details, circle No. 11 on Reader Information Card
manager of the Technical Service
Division of the McKay Co., York,
Pa.
Mr. Reid’s subject, “It Isn’t
Mud,” a_ semitechnical talk on
electrode coverings, was very inter-
esting and well delivered. Slides
were also used.
WELDING SYMBOLS
South Bend—lIt has been said
that a picture is worth a thousand
words. A welding symbol may
Yes, the swing is not represent quite that many, but
it can be replaced only by a much
on and here’s why: larger note. The Michiana Section
delved into this method of specify-
ing welds on drawings with a talk
SPEAKS ON BRAZING
@ 30% More Heat Resistant than any
other make.
@ Brilliant Red and Yellow Gloss Fibre
Colors insures identification of Holder
anywhere in plant—Valuable Safety
Feature.
@ Low initial cost, easy and economical
to maintain.
Sold only through Weld-
ing Supply Distrib-
utors throughout the U.S.
and Canada.
wa Al
LENCO, Inc. Uebel
with | Ward Dawdy spoke on silver brazing at
the April 14th meeting of J. A. K. Section.
JACKSON, MISSOURI HI-AMP
Left to right are R. Lincoln, Mr. Dawdy
For details, circle No. 12 on Reader information Card and Chairman J. J. Wolf
628 | JUNE 1960
ATTENTION
SECTION SECRETARIES:
Notices for November
1960 meetings must reach
JOURNAL office prior to
August 20th so that they
may be published in the Oc-
tober Section Meeting Cal-
endar. Please give full in-
formation concerning time,
place, topic and speaker for
each meeting.
by Virgil Young, senior engineer,
Airframe Group, at the Mishawaka
Division of the Bendix Corp. Mr.
Young said many people shy away
from the use of the AWS standard
symbols because they look strange
and impress them as being difficult
to learn. In reality, it is a quite
simple and logical process to use and,
once a few conventions are learned,
the symbols can give clear and con-
cise instructions for a large variety
of welding conditions.
Too often, said Mr. Young, the
engineer relies on the welder to put
the proper size, shape, kind and
analysis of weld on a product when,
in truth, the engineer should be
telling the welder what to do.
By means of the AWS welding
symbol chart and a simple welding
drawing, the speaker showed how
a rather complex weld could be
accurately described in a minimum
drawing space.
PLANT TOUR
Des Moines—Following a buffet
dinner at the Hotel Kirkwood, 39
members and guests of the Jowa
Section enjoyed a visit to the
Firestone Plant on February 18th.
The tour was conducted by mem-
bers of the Firestone Engineering
staff. Those who attended were
impressed by the modern equipment
employed by this company in the
manufacturing of automobile and
truck tires.
HIGH FREQUENCY
Des Moines—The March 17th
meeting of the Jowa Section was
held in the Garden Room of the
Hotel Kirkwood. Thirty-three
members and guests were present
for the dinner and meeting.
Speaker was R. E. Purkhiser,
section head, Electrical Control
Section of the Development Depart-
ment, Air Reduction Sales Co..,
New York.
His talk was a presentation of
ideas that have actually been used
in practice. It covered the need
for high frequency, characteristics
of its performance with helium
and argon, and discussion of tech-
niques used in the field to improve
the reliability of high-frequency
starting.
Melt tielate!
SCIENCE PROJECT
Baton Rouge—The Baton Rouge
Section conducted its annual High
School Science Project at the Belle-
mont Motor Hotel, Thursday, April
14th. Douglas Latimer, Jr., a sen-
ior at Baton Rouge High School,
was selected as the winner with
a project entitled, “‘Steel for Weld-
ing Products.” Jack York was his
technical advisor. During his dis-
cussion of the exhibit, young Mr.
Latimer explained the various pro-
cedures for making steel which were
shown pictorially on the project.
After his discussion, he inserted the
various materials necessary for the
production of steel into a_ lined
crucible and ignited thermite. The
crucible glowed brightly under the
intense heat and sputtered sparks.
PROJECT WINNER eeSS
COMPLETE ACCESSIBILITY
DUAL WORK POSITIONS
Photo
courtesy
Pfaudier Co.,
a Division of
Pfaudier Permutit, inc
PROVEN DESIGN
High-school senior Douglas Latimer, Jr.,
was selected winner of Science Project VACUUM-PURGE, INERT GAS
WELDING CHAMBER
sponsored by Baton Rouge Section. He
is shown above, left, with his technical For manual welding in laboratory or limited
advisor Jack York production work. A variety of pumping sys-
tems for required purging. Foot operated
welding shields. Internal lighting. Feed-
throughs for power, water, gas.
As the flame died, he opened the c Ample space
bottom and molten steel poured w= : for positioner
into the sand pad beneath. The and work.
prize for the contest was a trip to
California to attend the Weld-
ing Show where the project was
exhibited. Write or call
Officers for the year 1960-61 were for details
elected as follows: chairman, Ed
Edley, Nadler Foundry; first vice-
chairman, M. V. Christesen, Delta GENERAL VACUUM
Tank Mfg. Co.; second vice-chair- CORPORATION
400 BORDER ST., EAST BOSTON 28, MASS.
man, Craig Kennedy, Air Reduction
Sales Co.; secretary, Gil Black, For details, circle Ne. 14 on Reader information Card
General Dynamics; treasurer, Louis

Mire, Ormet Corp.; executive com-

mittee—Louis Bergeron, Esso Divi-
sion of Humble Refining Co.; Rob-
ert Daniel, Woodward Wight; O. J.
Templet, Action Welding Supply
Co.; Herbert Boxhill, W. R. Grace
Co.
Authors...- Dr. Beverly J. Covington, Profes-
sor of Civil Engineering at Louisiana
State University, discussed the in-
please uote! creasing importance of welding, its
effect upon college curricula and
the possibility of a welding-engineer-
All authors interested in presenting papers at the ing course at LSU.
AWS 42nd Annual Meeting to be held in New York City
on April 17-21, 1961 are advised of a change in pre-
liminary arrangements.
The usual forms, ‘An Invitation to Authors” and “Authors
BRAZING
Application Form,” were printed as a detachable insert
in the May issue of the Welding Journal instead of Baltimore—The regular monthly
meeting of the Maryland Section
being sent through the mails. was held on March 18th at the
Additional copies of the forms may be obtained by Engineers Club of Baltimore. After
writing to AWS Headquarters, 33 West 39th St., New dinner, there was a very interesting
York 18, New York. talk by Keene Roadman, marketing
manager for the McCormick Co.
His talk was on ‘““Multiple Manage-
ment.”” He explained the setup
that brings management to lower
levels. Constructive meetings are
held for improvements; the results
are referred to upper levels for
evaluation.

WELDING JOURNAL | 629


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For details, circle No. 15 on Reader Information Card
The technical meeting speaker
for the evening was Donald C.
Herrschaft, assistant manager, Braz-
ing Products Division, Handy &
Harman. His subject was ‘“‘Braz-
ing Challenges the Thermal Bar-
rier.” He gave an interesting talk
accompanied by slides, and covered
the story of how brazing alloys for
elevated-temperature service are
solving a variety of problems in the
elevated-temperature fields, with
particular emphasis on applications
in the aircraft industry. With the
aid of slides, he discussed the
properties of gold, nickel, chromium
brazing alloy for elevated tem-
peratures, and the brazing for ele-
vated temperature, of 304 stainless
steel to Inconel, with Au, Ni, Cr
brazing alloy after exposure to air
at 1600° F for 80 hr. The talk
concluded with a prediction con-
cerning the superbrazing alloys of
tomorrow.
Massachusetts
PRODUCT DESIGN
Springfield——A regular meeting
of the Western Massachusetts Section
630 | JUNE 1960
WORCESTER SECTION VISITS MACHINE PLANT
Members and guests gathered in the conference room at Heald Machine
Co. in Worcester, Mass., following a tour of the plant
was held at the Crossroads Restau- internal burners and plasma jets
rant in Springfield on Tuesday in such fields as metal cutting,
evening, April 5th. metallizing and flame hardening.
The speaker of the evening was The talk was presented by James A.
John Mikulak, assistant to the vice- Browning of the Thermal Dynamics
president of manufacturing for Wor- Corp. It was entitled “‘Applica-
thington Corp., Harrison, N. J. tion of Rocket Energy in Welding
His subject was “Product Design Industry.”
for Welding.”’ It was very interest- There were many questions dur-
ing and educational. ing and after the talk, and Mr.
Browning was kept very busy sup-
plying additional information. The
PLANT TOUR
audience was a most interested
Worcester Fifty-four members one.
and guests of the Worcester Section
had the pleasure of touring the
plant of The Heald Machine Co. on
March 14th. The conducted tour
took one hour. It was followed by INDUSTRIAL PROGRESS
the showing of a colored motion
picture of the Heald products, and Detroit——The Detroit Section was
by a question-and-answer period. given an impressive send-off for the
It proved to be a most successful Welded Products Month activity
evening. when it was addressed by AWS
Past-President J. H. Humberstone
at the April 8th meeting. The
ROCKET ENERGY topic of his talk was ‘“‘Welding
Worcester— At the April meeting Magic Wand of Industrial Prog-
of the Worcester Section, the mem- ress.”
bers and guests present heard an Illustrated with slides, Mr. Hum-
excellent discussion on the uses of berstone’s presentation depicted and
ROCKET ENERGY IS THEIR SUBJECT
; sf
~ oy”
git. . €
i
- a a ; - ae: Yt & 4% —
The Worcester Section was addressed by James A. Browning at their April meeting.
His subject dealt with the application of rocket energy in the welding industry. Seated
at the head table are, left to right, J. Belisle, Mr. Browning, Distric tDirector G. A.
Kirkley and Section Chairman E. Hall
PAST PRESIDENT ADDRESSES
Past-president Joe H. Humberstone
was the principal speaker at April 8th
meeting of Detroit Section
emphasized the indispensability of
welding in this modern world. It
included many examples of welded
fabrication that could not be ac-
cepted as efficiently and effectively
as other fabrication methods, if at
all. Acknowledging the significance
of National Welded Products
Month, this talk also pointed up
that more people, the general public
and manufacturing top management
included, should and must be made
to appreciate the importance and
advantages of welding in industrial
progress.
The guest speaker also told briefly
about his recent trip abroad and
expressed the view that the Euro-
peans are apparently ahead of us in
some areas of research.
As so often in the past, those who
heard Mr. Humberstone’ were
quickly impressed by his dedication
to welding and his deep feeling for
the AWS, to which he has contrib-
uted so much.
The members and guests present
expressed their appreciation for the
inspirational message provided by
Mr. Humberstone.
WELDING CONTROLS
Detroit—The April 14th special
meeting held by the Detroit Section
featured an address by Karl Sarafian
on the topic of “Resistance Welding
Controls Used by Fisher Body, Past
and Present.”” Mr. Sarafian de-
scribed his plant’s early methods of
controlling the time elements of
the welding cycles and parallel
development of more efficient con-
tactors. Using slides, he illustrated
the types of equipment which have
been used by the largest builder of
automotive bodies through the years
DETROIT SECTION
Section Chairman Ray Wilcoxson con-
gratulates Mr. Humberstone on his talk
on ‘“‘Welding—the Magic Wand of iIn-
dustrial Progress"’
and explained the successful applica-
tion which lead to a conservative
approach to the adoption of new
developments. He stated that the
displacement of the pneumatic timer
by electronic timers in welding func-
tions has followed as the latter have
approached the repetitive accuracy
of the former, especially under
fluctuating line conditions, while
the pneumatic has not been able to
maintain calibration over long peri-
ods of use. A spirited question-
and-answer period followed Mr.
Sarafian’s talk.
PLANT TOUR
Muskegon—The Western Mich-
igan Section held its regular monthly
meeting on March 28th with a dinner
at Bill Sterns Restaurant in Muske-
gon Heights and a plant tour THOMSON manufacturing capabili-
through the West Michigan Steel ties have resulted in reduced costs
Foundry in Muskegon. on their resistance welding machines
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The resistance welding controls used by
Fisher Body were explained by Karl HOMSON ELECTRIC WELDER COMPANY
Sarafian at the April 14th special tech- 161 PLEASANT STREET, 2.7710
LYNN, MASSACHUSETTS
UY nn 2
nical meeting of the Detroit Section For details, circle No. 16 on Reader information Card
WELDING JOURNAL | 631
NEW JERSEY SECTION HOLDS WELDING EDUCATIONAL SEMINAR

T. McElrath, left, and T. Smith register for the Welding Educational Seminar spon- Clarence E. Jackson spoke on
sored by the New Jersey Section on March 16th and 17th destructive testing

After dinner, the 66 members and
guests present journeyed to the
Foundry where they were divided
into groups of 8 each for the tour.
They were shown where molds and
cores were being made, the actual
pouring of the metal and, next, the
cleaning and preparing of the cast-
ings for the market. Several weld-
ing and air-gouging operations were
used in preparing the castings for
shipment.
All who attended this unusual
plant tour agreed that it was one
of the most interesting meetings to Jersey Section monthly meeting held
date. on March 15th at the Essex House
in Newark. The speaker pointed
out that such things as missiles,
nuclear reactors and high-tempera-
ture boilers would all be impossible
without welding, and he emphasized
WELDING EDUCATION
the need for a realization of these
Newark—Howard B. Cary of facts by the public and educators
Hobart Bros. Technical School, alike. The various activities of
Troy, Ohio, spoke on ‘Welding the SocrETy to promote welding
Technician Education” at the New education were outlined, and the
talk concluded with one of a series
of motion pictures used in training
welding technicians.

WELDING SEMINAR
Newark—Nearly 200 welders,
technicians, engineers, and super-
visors attended the New Jersey
Section 1960 Welding Educational
Seminar on March 16th and 17th
at the Essex House in Newark.
Sixteen speakers during the series
of sessions covered Quality Control,
Recent Advances, Mechanization
and Automation, Codes, Standards
They mean and Welder Qualification and the
Always Big and Little in Welding—consid-
National Carbide's \
calcium carbide nearby— erations in joining massive sections
) in the and miniature assemblies. Plant
— gets ten
BIG tours to the Linde Development
Laboratory, Magor Car Corp. and
RED
General Motors Linden Assembly
DRUM. Plant provided an opportunity to
Wire for witness various production-welding
supplier... operations as well as new welding
techniques and methods.

WELDING OF SUBMARINES
Bellmore—The April 14th meet-
NATIONAL CARBIDE COMPANY | ing of the Long Island Section was
A DIVISION OF AIR REDUCTION COMPANY, INC, held at the Sunrise Village. The
150 East 42nd Street, New York 17,N.Y. guest speaker, George W. Kirkley
For details, circle No. 17 on Reader Information Card of the Electric Boat Division of

632 | JUNE 1960

WELDING EDUCATION unique and unusual techniques that
have been developed at Electric
Boat for the welding of nuclear
piping systems. These techniques
are presently being used by all the
reactor fabricators in the country
as well as by many central steam
station constructors. Welding prob-
lems associated with thick hull
plating were also discussed.
The talk was accompanied by
slides and 16-mm sound movies.
WELDED STRUCTURES
New York—On April 12th, the
New York Section had its largest
turnout of the season. Almost 100
members and guests heard W. H.
Heidtmann and H. Winters describe
the ‘““Welded Design Features of the
Western Electric Building.’”’ This
44-story building, still under con-
struction, is located at Fulton St.
and Broadway in downtown Man-

REPORTS ON WELDING OF TRITON

Howard B. Cary spoke on the subject of
“Welding Technician Education” at the
March 15th meeting of the New Jersey
Section

General Dynamics Corp., covered

“‘Welding the World’s Largest Un-
dersea Craft —U.S:S. Triton.”
There were 45 members and guests
in attendance.
Mr. Kirkley outlined the welding
andfa brication problem encoun-
tered in nuclear power propulsion
systems and explained the many
proved techniques developed during
the building of the first A-sub The welding of the world’s largest undersea craft, the USS Triton, was described by
Nautilus and subsequent ships. Par- George W. Kirkley at the April 14th meeting of Long Island Section. Seated at head
ticular emphasis was placed on table, left to right, are Mr. Kirkley, Section-Chairman K. Berry, A. Esgro and R. Harris

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WELDING JOURNAL | 633
DESCRIBE WELDING DESIGN FEATURES OF NEW BUILDING

A portion of the capacity crowd at the April 12th meeting of New Mr. Heidtmann points out one of the de-
York Section. The members and guests present are listening sign features in the welded frame of the
to guest speaker W. H. Heidtmann new Western Electric Building in New
York

hattan. It is the tallest building the steel fabricator and did the
in New York City which utilizes erection on the site.
welding in the fabrication and erec- Mr. Heidtmann explained to the
tion of the structural steel frame. group the unusual design features
This building is 390 ft high with the of the building. Many of these are
first floor dimensions, 140 x 240 brought about by the desire to
ft, and has three basement levels. utilize the maximum volume as
It will be occupied almost exclu- permitted by the building set-back
sively by Western Electric Co. requirement of the City of New
executive offices. Structurally, the York. This resulted in irregular
building is a nonrigid frame with symmetry at various levels and
brick facing. Although the original therefore unusual structural config-
plans called for bolts or rivets, Purdy urations.
and Henderson Associates, Inc., Mr. Heidtmann showed an excel-
consulting structural engineers, re- lent group of slides illustrating each
designed the joints to accommodate joint or structural detail in a draw-
welding. Mr. Heidtmann, the ing, and then actual photographs of
speaker, is president of Purdy and the detail in place in the structure.
Henderson. The Drier Structural Mr. Winters described briefly the
Steel Co., Inc., for whom Mr. fabrication of the steel in the shops
Winters is project coordinator, was and on the site. He explained that,
for almost all welding, E6013 iron-
powder electrodes were used on this
Now you can check job. Low-hydrogen electrodes were
used on some very heavy sections
WELD TIME with used for column supports. From
7 to 9 welders were used on the site
new PORTA-COUNT during the erection. Welding power
cycle counter was supplied by a separate rectifier
welding machine fed by a diesel
generator set.
In conclusion, the speakers said
that it is estimated that $50,000
was saved in using welding rather
only $282 than bolts or rivets for this building.
Counts actual weld time during firing. They agreed that if the building
PORTA-COUNT is light and small enough had been redesigned to take full
to carry easily—keep right on the job. advantage of welding, a much larger
Completely portable and self-contained
with long life (up to 2 years) batteries. saving would result.
Counts single phase. This subject was of particular
No Plug In No Clips No Clamps interest to many of the New York
PORTA-COUNT uses an inductive pick up Section members since many of
to count, sensing magnetic field around them have worked on code com-
power line, welding buss, transformer or mittees and with municipal engi-
electrodes. neers to obtain approval to use
INSTRUMENT CONTROL CO. welding on structures in New York
1554 Nicollet Avenue City. This is a realization of some
Minneapolis 3, Minnesota of that past effort.
For details, circle No. 20 on Reader information Card This was also a preview of
methods to be used on the new
home of the AWS, since Dreier
Structural Steel Co. will fabricate
the steel for the United Engineer-
ing Building.
Many guests were present from
sister engineering societies including
American Society of Civil Engineers,
New York Society of Consulting
Engineers, Society of Naval Archi-
tects & Marine Engineers and The
Construction Specification Writers
Association. Other distinguished
guests who were introduced to the
group were: P. J. Reidy, Com-
missioner of Buildings of New York
City and J. E. Ruth, Superintendent
of Plant Engineering for Western
Electric Co.
This was the last technical meet-
ing of the 1959-60 season.
MAINTENANCE WELDING
Buffalo—-For the second time
this year, the weather tested the
spirit of the Niagara Frontier Sec-
tion. Nevertheless, 45 members
braved the worst blizzard of the
year to attend the March 24th
meeting of the LaSalle Yacht Club,
Niagara Falls.
The speaker, Dick Rectenwald,
of Maintenance Engineering Co.,
Pittsburgh, described the rewelding
of large cracked machine members.
Mr. Rectenwald illustrated, with
slides, the repair of a crack in a
large cast-iron steam-hammer base.
After the crack was grooved out,
the base was preheated to 1300° F
using charcoal and coke in a tem-
porary furnace built around it.
Then 10 men took turns using five
torches to apply 2400 lb of bronze
rod.
For cast steels, his company de-
veloped a technique which Mr.
Rectenwald termed “cyclic weld-
ing.”’ Following a preheat of about

634 | JUNE 1960

 700° F, the welding is done by metal
arc using low-hydrogen electrodes.
The feature which explains the
name “cyclic” is that welding is
interrupted after each 1-to-2 in.
of increase in weld thickness and
the temperature is raised to 1200° F
to relieve stresses and reduce dis-
tortion. After this, the temperature
is lowered and welding is resumed.
He stated that this procedure is
almost a foolproof method for joints
of great thickness, that is 3 or 4
ft. thick. The welding is often
done in the vertical position so
that slag will runnoff freely. The
questions from the audience showed
a lively interest.
WELDING CONTROLS
Rochester—The March 2lst
meeting of the Rochester Section
consisted principally of a lecture
entitled ‘““The Control of Resistance
Welding” by Glenn B. Heck of
Weltronic Co. Mr. Heck very
ably summed up the types of con-
trols that can be used for resistance-
welding application. Each type
was discussed thoroughly and the
advantages and disadvantages of
each type were stated. Although
most of the group is concerned
more closely with arc welding, it
was a refreshing and educational
meeting for all.
This meeting was also in honor of
the sustaining and supporting mem-
bers of the Rochester Section of the
AMERICAN WELDING Society. The
section was very pleased to welcome
Foster-Wheeler Corp., Eastman
Kodak Co. and Rochester Gas &
Electric Corp. as sustaining mem-
bers and Jackson Welding Supply
and Delco Appliance Corp. as
supporting members.
The most successful dinner dance
in the history of the section was
held at the Party House in Roch-
ester on Apr. 2, 1960. There were
over 100 people there for the cock-
tail party, dinner and the dance.
It was a good sign of the spirit and
enthusiasm that the membership
has for Soctety affairs.
WELDING ELECTRODES
Liverpool—The February 10th
meeting of the Syracuse Section
was held at LaMoyne Manor,
Liverpool, N.Y. After a very good
chicken dinner, the diners were
entertained by a brief talk on the
life of Dr. Albert Schweitzer.
The main speaker of the evening
was E. H. Turnock, manager of the
Electrode Engineering Division,
Westinghouse Corp., Montevallo,
SPEAKS ON ELECTRODES N. Y. A coffee-hour film, ‘‘Music
oar in Motion,” was shown through
the courtesy of the Bell Telephone
Laboratories.
The meeting consisted of a panel
discussion on resistance welding
and related fields. The panel con-
sisted of Bob Greer, Carl Hirsch-
man, Al Myrdeck and Bill Hughes.
A general presentation of the process
made up the first hour, followed by a
short discussion on spike welding.
WELDING ALUMINUM ALLOYS
Syracuse—The regular monthly
meeting of the Syracuse Section
was held on April 13th at the Le
Development and application of manual Moyne Manor Restaurant. Cock-
electrodes were discussed by E. H. tails were served at the bar from
Turnock at the February 10th meeting of 6:00 to 6:30 P.M. followed by
Syracuse Section an excellent chicken dinner. The
coffee speaker was Mrs. Dorothy
Riester from the Syracuse Univer-
sity Art Dept. who discussed her
work in “Welded Sculpture.”’ Her
Ala. He discussed the character-
talk was very interesting.
istics of various electrodes and
A short business meeting followed
showed an interesting slow-motion
and was highlighted by the nom-
movie on welding. The topic of his
inating committee report for of-
talk was “‘Present Day Trends in the
Development and Application of ficers for the coming year. It was
read by Jack Helmer, committee
Manual Electrodes.” Approxi-
mately 60 members and guests were chairman.
The technical speaker was W. M.
present for the talk.
Rogerson, welding engineer for the
District Director J. W. Kehoe
attended this meeting and the Aluminum Company of America,
Process Development Lab., New
Section was pleased to present him
with their check for the new United Kensington, Pa. Mr. Rogerson dis-
cussed the welding of aluminum by
Engineering Center building. The
check covers 100% of the member- the various available processes in-
cluding inert-gas-shielded arc weld-
ship of this Section.
After the meeting, a light repast ing. He also showed a 16-mm
film and a number of slides dealing
was served and the monthly door
prize was drawn. with the subject in general. Among
the topics discussed were the selec-
tion of proper alloys and _ filler
RESISTANCE WELDING
metals, work preparation, cleaning
Liverpool The March 9th meet- and the like. The speaker’s mes-
ing of the Syracuse Section was held sage made a fine impression on the
at LeMoyne Manor, Liverpool, 40 members and guests.
FLAME STRAIGHTENING DISCUSSED BY PANEL
The subject of flame straightening of structural and plate fabrications was discussed
at the April 13th meeting of Cleveland Section by a panel consisting of, left
to right, W. J. Gallo, H. Sikorski, Lou Hardnack, Ross Yarrow and Omer Blodgett
WELDING JOURNAL | 635
 To identify a strange fish...

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R~ . \
2 % . > \
* —
.

. ‘ -
_*-
‘a ‘ — . . r
YOY, ae si
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a- ~ _~ -
= -
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you call in an ICHTHYOLOGIST

(specialist in fish life)

-
For details, circle Ne. 21 on Reader information Card
636 | JUNE 1960
to cut production costs...

you call in LINCOLN

(specialists in arc welding)

ee of high operating costs a Maryland barge builder had trouble meeting

competitive prices. The LINCOLN Field Engineer recommended a semi-
automatic ‘‘Squirt’’ welder. On heavy plate it was four times faster and reduced
overall costs due to reduced plate preparation and cleaning time.
As a matter of fact, right there is a good reason for doing business with
LINCOLN. Cost reduction is a sort of religion at LINCOLN where production costs
have dropped as much as 50% in the last 20 years. It’s the result of LINCOLN’S
world-famous cooperation between employees and management where every-
body gets paid according to his own contribution to the company’s goal—superior
products and service to you at continually decreasing costs.
That's why we Say it’s a good idea to do business with LINCOLN where arc
welding is a specialty and cost reduction comes to you as a “‘plus” at no charge.

To learn how LINCOLN can be of service to you, write today

THE LINCOLN ELECTRIC COMPANY

WELDERS

For details, circle No. 21 on Reader Information Card

WELDING
NORTH AMERICAN AVIATION PLANT TOURED BY COLUMBUS SECTION

On April 8th the members of the Columbus Section toured the Mr. Meinhart, extreme left, shows arc-spot welding equip-
North American Aviation plant. Here Charlies Meinhart of ment to three fellow Section officers, H. Mishler, R. Ryan and
NAA explains the operation of honeycomb brazing furnace to Wm. Green. They are treasurer, chairman, secretary and vice-
visitors chairman, respectively

teresting one, was preceded by a colored slides and emphasized the

FLAME STRAIGHTENING
Cleveland— Well over 100 mem-
bers of the Cleveland Section were
on hand on April 13th to hear a
panel of local experts discuss the
subject ‘“‘Flame Straightening of
Structural and Plate Fabrications.”
This fine attendance indicates a
never-ending interest in solutions
for handling this ever-present prob-
lem.
After preliminary remarks were
made by Lou Hardnack, meeting
technical chairman, outlining the
scope of the discussion, each panel
member presented a short dis-
course on his subject matter. The
subject matter was arranged to
permit all panel members to draw
from personal practical experience.
Omer Blodgett, Lincoln Electric
Co., introduced the subject with a
discussion on the physical reactions
that heat produces in steel. Werner
J. Gallo, Thew Shovel Co.; Ross J.
Yarrow, Republic Structural Iron
Works; and Henry Sikorski, Cleve-
land Trencher Co. related this
theoretical analysis to practical
experience in flame straightening
and prevention of distortion on
structural shapes, plate weldments
and pipe weldments respectively.
Numerous questions following the
formal presentation directed the
panel’s practical experience to spe-
cific applications of local interest.
PLANT TOUR
Columbus ~The April 8th meet-
ing of the Columbus Section con-
sisted principally of a plant tour of
the North American Aviation weld-
ing facilities. The tour, a most in-
dinner held at the Desert Inn.
There were 106 members and guests
in attendance.
AUTOMATIC-WELDING
SEMINAR
Dayton— One hundred and
ninety men from the Miami Valley
area have completed a_ six-week
‘“‘Automatic-Welding Seminar”
sponsored by the Dayton Section
at the Engineers Club.
Recognized experts in each field
discussed the principle and applica-
tion of the following processes:
“Submerged Arc,”’ W. F. Hoffman,
Linde Co.; ‘“‘Inert-gas Shielding,”
R. W. Tuthill, Air Reduction Sales;
‘*Tubular Electrode,’”’ R. K. Wilson,
Lincoln Electric Co.; “‘Carbondiox-
ide Shielding,’ J. H. Headapohl,
Hobart Brothers Co.; ‘Tooling
for Automation,” Lee Farns-
worth, Automated Machines and
Equipment Co.; ‘“‘Power Sources,”
G. O. Williams, Hobart Brothers
Co.
Members of the Section’s Ed-
ucational Committee were
troduced at the final seminar and
plans were revealed for future courses
in the different processes of metal
joining.
BRAZING
Dayton— Thirty-five members
and guests enjoyed a baked ham
dinner and social period prior to
the Dayton Section’s April meeting
held at Kuntz’s Cafe, Tuesday
evening, the 12th.
Speaker for the evening was D. C.
Herschaft, assistant manager of
the Brazing Products Division of
Handy and Harmon Co. Mr.
Herschaft illustrated his talk with
importance of design for a good
brazed joint. An excellent film giv-
ing examples of production braz-
ing and proper procedures was also
shown.
The meeting was opened with a
film, ‘““The Leading Roll,” on the
welding of steel tubing.
FUSION WELDING
Youngstown—The March 17th
meeting of the Mahoning Valley
Section was a memorable St. Pat-
rick’s Day event with National
President C. I. MacGuffie and
National Secretary Fred L. Plum-
mer as guest speakers.
Over 50 members and guests
attended this dinner meeting at the
Victoria Restaurant in Youngstown
to hear Mr. Plummer’s excellent
coffee-hour talk on the work of the
staff at national headquarters, and
Mr. MacGuffie’s excellent presen-
tation of ‘A Glimpse at the Future
of Fusion Welding.” After the
presentation by the national of-
ficers, the group was entertained by
in- a film on the 1959 World Series
obtained from the Cleveland In-
dians Baseball Club.
A cocktail hour was held pre-
ceding the meeting. After dinner,
two prominent guests were in-
troduced; J. F. Deffenbaugh, direc-
tor-at-large, and J. W. Kehoe,
District No. 3 director.
Mr. Kehoe emphasized the im-
portance of the Educational Pro-
gram presently being conducted
by the Section, and congratulated
the members of the tremendous
interest shown over the past few
years.
The remarks made by Mr. Plum-
mer on the work of the national

638 JUNE 1960

DAYTON HOLDS AUTOMATIC-WELDING SEMINAR

Some of the 190 men who attended the six-week auto- These are the members of the Educational Committee, left to
matic-welding seminar sponsored by Dayton Section. The right, C. O. Adams, O. Martin, F. L. Hofman, T. Falter, L. L.
principles and application of several processes were covered Hahn, H. Cary, G. Prass and W. R. Schober

headquarters staff included the in-
come from various activities such
as membership dues, WELDING
JOURNAL, sale of technical litera-
ture and the Annual Welding Show.
He also mentioned the latest addi-
tion to the headquarters operation
which was the Welding Informa-
tion Service which handled such
events as National Welded Prod-
ucts Month. The work of the
SociETY with respect to the In-
ternational Institute of Welding
was also covered by Mr. Plummer.
In addition, he noted that the 1961
National Meeting of the SocretTy
will be held in New York City,
in conjunction with the first meet-
ing in this country of the IIW.
Mr. Plummer concluded his dis-
cussion with a background of the
drive for funds for the United
Engineering Center Building Fund
Drive.
Mr. MacGuffie’s talk was ac-
companied by slides on the latest
fusion welding processes that have
been developed. He mentioned
that more and more machine weld-
ing is now being used rather than
the older manual style. He em-
phasized that welding engineers
should use the proper tooling avail-
able for the various welding proc-
esses and the accurate controls
that are presently being developed.
Some of the latest fusion welding
applications described by Mr. Mac-
Guffie included the welding in
controlled atmosphere chambers,
electron-beam welding, the arc-
plasma flame type of cutting and
spraying and also adhesive bonding.
The Section officers expressed
their appreciation for the oppor-
tunity of having these National
officers present.
officers for the 1960-61 season were
announced as follows: chairman,
Walter R. Edwards, Marion Power
Shovel Co.; first vice-chairman,
Walter J. Corrigan, Marion Power
Shovel Co.; second vice-chairman,
Gerald Adams, Webster Mfg. Co.;
secretary, Al Tozer, Lincoln Elec-
tric Co.; treasurer, Wayne Dawson,
Ohio Seamless Tube Co.; direc-
tors—Robert Poole, Glenn Toms,
Rene Nueman and William Kaiser.
After a fine dinner served by the
auxiliary of the American Legion,
Thomas J. Dawson of the Ingalls
Shipbuilding Corp., Pascagoula,
Miss., gave a very interesting and
informative talk on “Modern Ad-
vances in Heavy Welded Struc-
tures.”
A film showing the construction
and planning behind the develop-
ment of facilities for the Winter
Olympics was presented for the
members’ enjoyment.
ARC CUTTING
Canton—William (Bill) Cough-
lin of the Arcair Corp. of Lan-
caster, Ohio, was the speaker at
the March 9th meeting of the
MACGUFFIE AND PLUMMER
= t.
Stark Central Section.
Starting with the early develop-
ment of the compressed-air carbon-
arc cutting process, the speaker
brought the audience up to date
on the refinements and _ special
applications of the process and some
of the ways it works in everyday
production.
His knowledge of his subject was
excellent and his wit was of the
highest order.
@)afelateliite
Oklahoma City—-The Okla-
homa City Section has made pro-
vision for three awards to be made
in successive years, starting in 1960
through 1962. This _ scholarship
award will be $100 a year to a
student who has completed the
first three semesters’ credits and
who anticipates completing all cred-
its required for a Metalworking
Technology Certificate, at the Okla-
homa State University and to a
student who has completed three
years of credits toward a BS.
VISIT SCHOOL
‘

HEAVY WELDED STRUCTURES

Bucyrus The April meeting of
the North Central Ohio Section was
held at the American Legion Home
in Bucyrus on Thursday, April 7th.
The results of the election of
President C. |. MacGuffie and Secretary F. L. Plummer visited the welding labora-
tory facilities at the Warren G. Harding High School in Warren, Ohio, on March 18th. Left
to right, above, are M. Bushwach, Department head; R. Haynes, instructor; Principal M.
Mollenkopf; Mr. MacGuffie; Mr. Plummer; and R. H. Foxall

WELDING JOURNAL | 639

Degree in the Metallurgical En- AUTOMATIC WELDING EXPLAINED
gineering School at the University
of Oklahoma.
The 1960 Scholarship awards
were presented to John Allen Smith
of Oklahoma State University and
Steve Conner of the University of
Oklahoma. The presentation was
made by Marvin J. Barnes, Chair-
man of the Scholarship Committee
during the April 6th AWS meeting
that was held at W & W Steel Co.

Pennsylvania
Johnstown—The Pittsburgh
Sub-Section located in Johnstown
held their scheduled meeting on
March 17th at the Elks Home.
Dinner was served at 6 : 30 P.M. and
was followed by a brief business
meeting.
The technical presentation was
made by H. W. Speicher, industrial
hygiene administrator, Westing-
house Electric Corp.
Mr. Speicher’s coverage of tox-
icity dangers and preventions, es-
pecially in inert-gas and _iron-
powder welding applications, was
pertinent to local operations and
was very well received.
AUTOMATIC WELDING
Philadelphia—‘‘Machinery for
Automatic Welding’’ proved to be
a very interesting subject at the
March 21st meeting of the Phila-
delphia Section. H. J. Lange, of
the National Electric Welding Ma-
chines Co., with the help of three
excellent films, demonstrated the
progress made by welding-machin-
ery manufacturers.
These machines are so thoroughly
developed that it is only necessary,
in many cases, for one operator
to dump the necessary material
into hoppers and let the automa-
tion form, fit and weld utilizing
Machinery for automatic welding was the E. Wolfgang looks over the display
topic of H. J. Lange's talk at the March of AWS literature during a free mo-
24th meeting of Philadelphia Section. ment at the meeting
Mr. Lange, left, shown in the company of
H. F. Merchant and W. Neely
either CO, welding, submerged melt Johnson’s Hummocks.
or resistance welding. The featured speaker was Emil F.
Mr. Lange cited one case where Steinert of the Westinghouse Elec-
one welding machine producing tric Corp., Buffalo, N. Y. He gave
1250 pieces, with one operator, a brief summary of the history of
every eight hours for the auto- arc welding and arc-welding equip-
mobile industry replaced 9 machines ment. He also discussed, in detail,
using 2 operators per machine with power supplies of the constant-
a total production of only 650 current and constant-voltage types.
pieces. With the aid of slides, he showed
Typical products are automotive the various electrical character-
brake drums, air-compressor cyl- istics of static-type arc-welding
inders and specialty parts. He machines.
emphasized two very important The Section was privileged to
items a customer must decide upon have District Director George Kirk-
before design of automatic ma- ley, as a guest. Mr. Kirkley
chinery is begun, namely the elec- spoke on the National Welded
tric power available and how many Products Month.
pieces are wanted per unit per time.
ditete“MaCitelate Tennessee
POWER SOURCES FUTURE OF WELDING
Providence—-The monthly din- Nashville—The Nashville Sec-
ner meeting of the Providence Sec- tion met for dinner and meeting
tion was held on March 16th at on March 16th at Konnard’s Res-

NATIONAL OFFICERS VISIT MAHONING VALLEY SECTION

National Secretary F. L. Plummer and President C. !. MacGuffie
were the guests of the Mahoning Valley Section at the March
17th meeting. Shown above are, left to right, R. H. Foxall, Jack
Huna Mr. Plummer, Mr. MacGuffie and Section Chairman E. A.
Craig
Here Secretary Plummer and President MacGuffie pose with
District No. 3 Director Joe Kehoe, second from left, and
Director-at-large James F. Deffenbaugh, extreme right

640 | JUNE 1960

 HOW TO
and get extra
Two teeth with same number of hours
on same machine. At left, sharpness is
retained with STOODY 100; at right,
edge of unprotected tooth is blunted.
1 Line up several teeth against a tilted
carbon block. Cutting edges should be
approximately level and teeth closely
butted.
KEEP DITCHER TEETH
footage with STOODY
Dull teeth and frequent changes take
the profit out of ditching operations.
The answer —hard-face teeth before
they are installed and repeat the
hard-facing as they wear.
2 Now make a continuous pass of
STOODY 100 applied semi-automati-
cally along cutting edge, tieing all teeth
together. Second pass of STOODY 100
is molded to sharp edge by carbon block
beneath. Dropping teeth flat on con-
crete floor breaks them apart. This
welding technique saves time, keeps
sides square without individual welding
attention. Same system can be used with
standard Stoody manual electrodes.
For details, circle No. 22 on Reader Information Card
SHARP...
ALLOYS!
A Texas contractor follows this plan,
uses the semi-automatic welder
applying STOODY 100 to keep teeth
sharp longer and reduce time out for
changes. The photos show how it’s
done. This contractor has found that
teeth protected with STOODY 100
working in limestone and shale are
good for better than 150 hours, while
unprotected teeth are worn to de-
struction in 30 hours with several
sharpenings necessary in-between.
Many operators of ditching equip-
ment operating in extremely abra-
sive soils find that one or two passes
of STOODY TUBE BORIUM, a
tungsten carbide material, on tooth
points give an amazing increase in
service life—outlasting all ordinary
alloys.
Your Stoody dealer will be glad to
demonstrate the semi-automatic
welder in your shop. Check the Yellow
Pages in your phone book for his
name and address or write for
dealer’s name and complete informa-
tion to
STOODY COMPANY
11986 East Slauson Avenue
Whittier, California
WELDING JOURNAL | 641
taurant The meeting was at-
tended by some 52 members and
guests.
President C. I. MacGuffie gave a
short talk on Socrety affairs, in-
cluding its accomplishments during
the past 40 years of service. He
also stated that universities are be-
coming aware of the need for weld-
ing engineers.
Mr. MacGuffie also gave a tech-
nical talk on ‘‘A Glimpse in the
Future of Welding.’”’ He touched
on fully automatic welding of 0.030
stainless steel, electron-beam weld-
ing and plasma cutting of various
metals and cement blocks.
FUSION OF METALS
Nashville—The Nashville Sec-
tion met at Kinnards Restaurant at
6:30 P.M., April 14th, at which
time a social hour was enjoyed by
some 25 members and guests.
After dinner, at 7:00 P.M., a
very informative talk was made by
Herbert Kuinzel, Head of the Me-
chanical Engineering Department at
the University of Alabama. Prof.
Kuinzel spoke on “The Metal-
lurgical Aspects of the Fusion of
Metals.”” Some of the _ points
covered were the advantage of
temperature distribution; how tem-
peratures directly affect stresses;
how grain structure affects the
strength of metals; how grain sizes
are obtained; the Martensite for-
mation in the weld zone and how
various types of tests are conducted
on steel.
CONTAINMENT SPHERE
Knoxville—The Northeast Ten-
nessee Section monthly meeting
was held on March 15th at the
Regas Restaurant. Approximately
DESCRIBES FABRICATION OF CONTAINMENT
Erection and welding of the 190-ft Dresden Nuclear Power Station Containment Sphere
was discussed by Perry C. Arnold at the March 15th meeting of the Northeast Tennes-
see Section. Left to right are: E. C. Miller, District Chairman; R. M. Fuller, Mr. Arnold
and C. H. Wodtke, Section Chairman
642 | JUNE 1960
50 members and guests were on
hand to hear Perry C. Arnold,
chief field-welding engineer of the
Chicago Bridge and Iron Co.,
Chicago, give a most interesting
and informative talk on “The
Erection and Welding of the 190
Ft Dresden Nuclear Power Station
Containment Sphere.”
His talk was prefaced by an ex-
cellent color film which followed the
fabrication and erection step by
step from the initial forming of the
plates in the shop to the final pres-
sure testing of the vessel in the
field.
The vessel is fabricated from A-
201 Grade B firebox material meet-
ing a Charpy-keyhole notch-tough-
ness value of 15 ft-lb at —50° F.
The sphere is self supporting, free
of internals, capable of resisting
an external load of 1 psig plus
dead load and an internal working
pressure of 29.5 psig. Pre-erection
welds were made using the twin-
arc automatic submerged-are proc-
ess with the electrodes spaced two
to four inches apart in trail.
The in-place welds were made with
E-7018 low-hydrogen electrodes.
All of the butt-welded main
joints in the vessel wall were 100%
radiographed and less than 1.4%
of the 15,000 ft of welds made re-
quired repair.
Texas
PLANT TOUR
Houston—For the February
meeting, approximately 100 mem-
bers of the Houston Section visited
the plant of Hughes Tool Co.,
manufacturers of specialized oil-
well drilling tools.
SPHERE
AT NASHVILLE MEETING
At the March 16th meeting of Nash-
ville Section, President C. |. MacGuffie
spoke on the future of welding
The visitors were divided into
small groups and were shown
through the plant by company
personnel, who pointed out many of
the varied welding applications, as
well as many other interesting opera-
tions performed at the plant.
The plant covers approximately
75 acres with more than 30 acres
under cover and its employees
number about 4000. The visitors
were able to see submerged-arc,
atomic-hydrogen, electric, acety-
lene, flash, and tungsten-carbide
hard-surfacing welding.
The tour began at 6:00 P.M.,
and at 7:15 P.M. all groups met
in the Cafeteria where they en-
joyed a very tasty dinner. The
tour was made after dinner. This
was a very interesting and worth-
while visit.
PANEL DISCUSSION
Houston—The March meeting
of the Houston Section was held at
the Houston Engineering and Scien-
tific Society on March 16th and
was devoted to a panel discussion
on ‘“Welding.”” This discussion
covered all phases of welding from
metallurgy to inspection. The mod-
erator was Larry Megow of Hahn
and Clay and the panel consisted
of the following: J. H. Walker,
Sheffield Steel Corp.; J. R. Pratt,
Hughes Tool Co.; W. H. McGrew,
Air Reduction Sales Co.; J. Earth-
man, Wyatt Industries, Inc.; H.
F. Crick, Mosher Steel Co.; W. H.
Greer, Southwestern Laboratories.
Approximately 100 were in at-
tendance and enjoyed the movie
“Bimini Blues’; which is a film
on deep sea fishing, and dinner prior
to the panel discussion. This was
an excellent meeting.
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For details, circle No. 23 on Reader information Card

WELDING ELECTRODES
Fort Worth—On Tuesday,
April 12th, 48 members and guests
of the North Texas Section met at
the Western Hills Inn for their
regular monthly meeting.
Jerry Hinkel, applications en-
gineer for The Lincoln Electric
Co., was the guest speaker. His
talk, ‘‘Mild-steel Electrode Ap-
plication,” was enlightening and
very interesting to all those pres-
ent. Illustrating his presentation
with a series of slides, Mr. Hinkel
discussed the developments in the
field of mild-steel welding elec-
trodes during the past few years.
The lively question-and-answer
session which followed showed that
there was great deal of interest
in Mr. Hinkel’s subject.
AUTOMATIC WELDING
San Antonio—Sixty-eight mem-
bers and guests attended the April
4th meeting of the San Antonio
Section of AWS held at Cap’t.
Jim’s honoring Clarence E. Hosier.
Mr. Hosier retired March 30th
after completing more than 41
years of service with the Linde Co.
He is a charter member of the San
Antonio Section, and has held the
office of treasurer for two years. At
present he is the 2nd vice-chairman. MILWAUKEE SPEAKER
Duke Wiley and Jack Bostick of
the Texas Highway Department,
Bridge Division, presented a talk
at this meeting on the subject of
“‘Automatic Welding of Bridges,
Boats or Buildings.’”’ Mr. Wiley, a
member of AWS since 1923, brought
out numerous factors that are im-
portant in making a good weld-
ment. Some of these are: (1)
survey the operation; (2) take a
few tests; (3) what results are re-
quired; (4) what results are ob-
tained and (5) design a joint to
fit the process.
Mr. Bostick presented a very
informative series of slides on what
constitutes a good or a bad weld, Louis J. Larson addressed the Milwaukee
with different types of joint prep- Section at the April 15th meeting. He
aration. spoke on the subject of stress reliev-
To conclude the program for the ing
evening, the Section-sponsored weld-
ing student, Fernando Flores, of ing of the Fox Valley Section, held
San Antonio Technical and Voca- on the 18th, was in the nature of
tional High School, was presented the annual spring plant tour. The
with the trophy awarded to the many members in attendance toured
most outstanding welding student the Pulliam plant of the Wisconsin
in the South Texas Area. Public Service Corp. in Green Bay.
This plant is actually the generat-
ing station and those who made the
Wisconsin
tour learned some of the aspects of
current generation. Dinner at
PLANT TOUR
Manci’s Supper Club followed the
Green Bay—-The March meet- tour.

STRESS RELIEVING
Milwaukee—The Milwaukee
Section held its monthly meeting
at the Ambassador Hotel on Apr.
“ACRO WELDER MEG. CO. 15, 1960. Fifty members and guests
attended the buffet dinner, and
MILWAUKEE heard William N. Lathrop, Coun-
selor Industrial Dept. of the Mil-
WELDING MACHINERY waukee Vocational & Adult School
outline the activities of the school
ENGINEERS BUILDERS and, in particular, what was being
done in training men for the welding
ESTABLISHED 1926 industry. After a short break,
L. J. Larson, Welding Engineer of
Allis-Chalmers Mfg. Co., West Allis,
presented an excellent technical
talk on ‘““The Case for and Against
Stress Relieving.”” Mr. Larson was
very clear in his talk as to the
ACR@©® general purpose spot-projection-butt-seam re- reasons for stress relieving, and where
sistance welding machines. it was applicable. A spirited ques-
tion-and-answer period after Mr.
ACRO-ARC ® special purpose production welding ma- Larson’s talk was helpful to many
chinery employing automatic arc welding members as far as their own shop
processes. problems were concerned.

ACROMATIC® special purpose production welding

machinery employing resistance welding
processes. Plan Now To Attend
ACRO-MAGNETIC ® magnetic force spot, projec- 1960 National Fall Meeting
tion, and percussion welding machines. September 26-29
Pittsburgh, Pa.

For details, circle No. 24 on Reader Information Card For details, circle Ne. 25 on Reader information Card
644 | JUNE 1960
NOW, WATER-COOLED WELDING! What!

Water quench cast iron? Never, according

to Conventional theory. But now, our

extensive field research brings you new

QuenchT rode* 24 and a quick-quench,

pre-neat process. Result: permanent c

iron repairs. With this discovery, and si

application techniques, you can wel

iron in as little as 1/10 of the usual ti

No special equipment needed. =

EUTECTIC)
For details, case histo v. (Ufc. on
NEVER SAY “CAN’T WELD IT”... Case in

point: Midwest shop was given a broken

cast Iron oil sump to repair. Conventional

weld attempts failed due to oi! and crack-

sensitivity. Porosity and voids resulted.

Then they called in Eutectic. Our man-on-

the-spot prescribed the cure: our trouble-

shooting trio of ChamferTrode; EutecT rode’

2/, and QuenchTrode* 24. _ Watch them!

& Nv bi)

he: “paints’’ over entire yee
sitesee EutecTrode a filling
s he goes. EutecTrode ee
iee She oiliest surface, giv
ase for joining.
Final step: weldor makes joint with
QuenchTrode 24, using stringer
sses and cold-to-hot back-step
thod, He quenches with wet rag
after each pass, till complete fill is
made

RESULT: A strong, permanent, machinable weld, ina

fraction of the usual time. No distortion, stress, oF
cracking. NOTE: the “Quench Weld” process: is
equally effective for building up missing metal sec-
tions or joining steel to cast iron. This is but one
example of how Eutectic helps you
For the-finest in quality products, always turn to
Cutectic. Service, on the job, any time, anywhere.
Reg. 1.M. Edtectic Weldin:ng Alloys Corp.

Urectic 40-40 172nd Street, Flushing 58; New York

——_}] EUTECTIC WELDING ALLOYS CORPORATION


ANTHONY WAYNE
Cowles, Edward Elmer
ATLANTA
Garner, James (B
BATON ROUGE
Gresham, Leroy (B
BIRMINGHAM
Rienks, Frits (B
BOSTON
Camorali, Louis (B
Knight, Frederick T. (B
O’Malley, William J. (B
Rios, Pedro Augustin (D
CANADA
Dunnet, Eric (B
Menlove, B. P. (B
CAROLINA
Dail, Ellsworth H.
CHICAGO
Hissong, Alfred L. (B
Kaufhold, John A. (C
CLEVELAND
Reed, Janet Rose (C
Schindler, Jack R. (C
Sipe, R. C. (B
Vorhis, Frederick H. (B
COLORADO
Horovitz, Paul (B
COLUMBUS
Helder, Earl C. (D
Merryman, Glen A.
DETROIT
Bakewell, Elton W. (B
Grove, Bud (B
Hahn, Clayton E. (B
La May, Lawrence (B
McKee, W. A. (B
Muscott, Arthur Roy (B
Novitke, Ervin R. (B
EASTERN ILLINOIS
Eggett, Joe (B
Peklay, William P. (B
Shoufler, Herbert E. (B
Thompson, Joseph W. (B
FOX VALLEY
Lytikainen, Lauri J. (B
HOUSTON
Dauphine, Claude (B
Hall, Charles E. (B)
Hays, Marvin E. (B
Lyday, Bryan L. (B
New Members
Putnam, Walter Floyd
(B Webb, H. E. (C
INDIANA
Campbell, Robert (B
J. A. K.
Anzelc, Charles E. (B
Russell, Richard G. (B
Stefko, Michael Stephen
LONG BEACH
Goodwin, Tommie C. (C
Perry, Al (B
LONG ISLAND
Mazurkiewicz, Robert (C
Siebel, M. P. L. (B
Tedesco, Robert (D
LOS ANGELES
Fleek, L. William (C
Froehlich, Robert (D
Grenci, Carl A. (C
Pruss, Gene N. (D
(C
Steinmetz, Lloyd E. (D
Tucker, Frank C. (C
Wright, Stewart A. (C
MARYLAND
Marshall, Vernon L., Jr. (C
Thompson, Richard W. (C
MICHIANA
Dettman, Norman (B
MILWAUKEE
Hinkley, Frederick Eugene
Schultz, Lee (B
MOBILE
Pierce, Ronald C. (B
(C
NEW JERSEY
Craig, Thomas A. (C
Cutro, Peter A. (C
Dunzelman, Raymond (B
Hecht, Frederick M. (C
Koch, Eugene (C
Lotti, Gilbert (C
McClure, Arthur C. (B
McKay, E. O. (B
Richter, Eduard C. (C
Rosenbchm, Edward (C
NEW ORLEANS
Gordon, Clyde H. (B
NEW YORK
Drier, Philip (B
NIAGARA FRONTIER
Ketter, Robert L. (B
Klingel, Theodore W. (C
Lorenzo, Ormond (C
Rainey, Richard (B
Reifel, Eston (C
Teschemacher, Alfred (B
EFFECTIVE APRIL 1, 1960
MEMBERSHIP CLASSIFICATION
A—Sustaining Member C—Associate Member
B-—Member D—Student Member
TOTAL NATIONAL MEMBERSHIP
Sustaining Members.
Members
(B Associate Members.
Students
Honorary Members. . .
Life Members
AWS Builds Men of Welding
(C
NORTH TEXAS
ST. LOUIS
Cresswell, V. E. (B Bennett, Clarence (B
Malone, Grady H. (C Hendrix, Lee (C
Jacobsmeyer, Roland (B
NORTHERN NEW YORK Lemler, Willard A. (C
MacLaren, Henry, Jr. (C Wright, Robert (C
Stachura, Stanley Edwin (C
SALT LAKE CITY
NORTHWEST Hirschi, Scott (D
Turner, Daniel L. (C Jefferson, James M. (D
Pitcher, Richard (D
NORTHWESTERN PA. Wilkins, Vern G. (D
Zollinger, Dennis (D
Mytinger, Richard (B
OKLAHOMA CITY SAN ANTONIO
Eddy. Lial (B Bullion, Richard W. (B
Heimer, Robert G. (C
Fagin, Carl (C
Kennedy. Ellis L. (C McKnight, Charles (C
Ramos, Henry (D
Short, Roy D. (C
Wyrick, W. D. (C Tindell, Allen P. (B
PHILADELPHIA SAN FRANCISCO
Hoetger, Ralph L. (B Mellott. Ned (B
Patton, Fay (C
SANGAMON VALLEY
(B Mack, Budd L. (C
Wilfong, Evan C. (B Edwards, William R. (C
Frederick, David C. (C
PITTSBURGH Frank, Charley (C
Birtle, Leonard M. (B Niebler, Donald E. (B)
Chappell, E L. (C Standerfer, Jack M. (¢
Christie, Robert B. (C SANTA CLARA VALLEY
Daley, Paul L. (B
Doerrer. C. L. (C Cochran, Robert L. (B
Dybas, Robert J. (B Marley, Craig (D
Gregory, Jack Wilbert (B Pierce, Mike (D)
Lucci, Henry J. (C Wasmund, Fred A. (C
Miller, Herbert F. (B Young, Alan D. (B
Young, Kelsie (C
SHREVEPORT
PORTLAND
Le Grand, Clifton (B
Hewitt, H. H., Jr. (B
Spencer, Donald B. (C SOUTH FLORIDA
Todd, Robert R. (B
Foran, Peter (B
Vannier, Maurice I. (B
Wilson, Sharon (D
SUSQUEHANNA VALLEY
PUGET SOUND Cotterman, Almon Q. (B
Hartman, Edgar J. (B
Hill, Leslie A. (B
Leonard, Raymond B. (C
RICHMOND
SYRACUSE
Barlow, George S., Jr. (B
Lochner, Roy G. (C Leyburn, John T. (B
ROCHESTER TULSA
Olds, Bernard A. (B Derrick, Dan M. (B
WELDING JOURNAL | 647

WELDING
ENGINEER
Experienced aluminum welding engineer to
advise and assist manufacturers and fab-
ricators on aluminum welding problems.
Knowledge of equipment and procedures
essential for demonstrating welding tech-
niques and occasionally training customer
welders. Most activity in fusion processes
but some resistance welding, brazing, and
soldering also involved. Metallurgical de-
gree or training desirable. Travel approxi-
mately 50 per cent of working days limited
primarily to U.S. Rarely out over weekend,
Salary, open. Location, Richmond, Vir-
ginia.
Address reply to Sales Personnel Depart-
ment, Reynolds Metals Company, Rich-
mond, Virginia.
WICHITA CHICAGO
Filler, Lester W. (B) Copuano, Richard J. (C to B)
Garner, Robert E. (B)
Kice, James V. (C) COLUMBUS
Marler, Irvin P. (C) Barta, Irvin M. (B to A)
Moore, Bill R. (C)
DAYTON
WORCESTER Kolb, Albert W., Jr. (C to B)
Clark, Joel E. (C DETROIT
YORK-CENTRAL PA. Appleby, Gordon (C to B)
Smith, Herbert L., Jr. (C to B)
Dyblie, Harry G. (B) Waggener, Max H. (C to B)
MEMBERS NOT IN SECTIONS Weiss, Jerry L. (C to B)
Pizzini, Vincenzo (B) LOS ANGELES
Applegate, Robert R. (C to B)
Dull, V. L. (C to B)
Members Reclassified O’Connor, David P. (C to B)
During April McPherson, Robert F. (C to B)
Schnabel, Robert L. (C to B)
CANADA MILWAUKEE
Asplin, A. G. (C to B) Cox, D. E. (C to B)
Carolina Section Co-sponsors Carolina Section of the AWS.
In conjunction with the exhibit,
Southeastern Show
which will display the products
The second annual maintenance and services of about 300 companies,
and engineering show to be held
three seminars will be held. One
at the State Fair Arena, Raleigh,
N. C., September 14-17, will be of these will be a “Welding and
sponsored by the American Insti- Maintenance Seminar’ during
tute of Plant Engineers, the Main- which technical papers will be pre-
tenance Council of the North Caro- sented followed by general discus-
lina Motor Carriers Assn. and the sion periods.

CHANGE OF RESIDENCE ADDRESS

WELDING OR COMPANY AFFILIATION

ENGINEER
DATE

Fine opportunity for young gradu- NAME

LAST MIDDLE
ate engineer interested in research
RESIDENCE ADDRESS
and development in welding. This
position offers a challenge to a STREET
creative minded young man. This
man should be a self-started indi- CITY
vidual who is seeking a future with
COMPANY NAME
a research oriented company well
known for its achievements in the COMPANY ADDRESS
STREET
welding field. Excellent laboratory
working conditions. Good starting cITY
salary and fringe benefits.
Title of position held
Mail should be sent to my residence company (check one)
Contact: D. H. Devine
A. 0. SMITH CORP. | wish to be affiliated with the AWS Section
Box 584
NOTE: To assure that your copy of the Welding Journal is mailed to your new address, this
Milwaukee 1, Wis. change of address notice must be received at American Welding Society, 33 West 39th
Street, New York 18, N.Y., no later than the 25th of the month previous to issue mailing.

648 | JUNE 1960

 Mi NO. 6 OF A SERIES
\F “How to Design Welded Aluminum Structures”

Choice of Proper Filler Alloy

Can Increase Strength

of Welded Aluminum 40%

Mr. Harry N. Hill,

Engineering Design
Division Chief,
Alcoa Research
Laboratories,
Aluminum Company
of America, reports
research findings
presented at the 1959
annual meeting
of the American
Society of Civil
Engineers.

Use of a filler alloy nominally the same

composition as the parent metal is
common practice in joining aluminum
alloys. Investigation at the Alcoa Re-
search Laboratories, however, reveals
that this widely accepted technique
rather seriously penalizes the strength
of welded joints!
Strength is most frequently the con
trolling factor in selecting a particular
filler alloy. For maximum strength,
apply the following general rule: Whers
possible, use a filler alloy that will be
stronger in the weld than the parent metal
adjacent to the weld. An investigation
of fillet-weld strength reveals why.
A fillet weld transmits load by shear
... particularly longitudinal fillet welds,
where the shearing force is along the
length of the weld.
Minimum shear area occurs at the
throat depth. Since shear area at the
sides of the fillet is about 40 per cent
greater than at the throat area, a longi-
tudinal fillet weld will fail in shear at
the throat section unless the weld is
stronger than the adjacent metal by
about 40 per cent or more. Use of a
higher strength filler alloy can there-
fore increase the strength of a longitu-
dinal fillet weld by about 40 per cent.
In a transverse fillet weld, the com-
plex stress state makes a simple analy-
sis impossible. The accompanying chart
demonstrates the increased strength
actually realized with the use of higher
strength filler alloy in transverse fillet
welds. Fillet welds in alloy 5154 were
35 per cent stronger when made with
filler alloy 5556 than when made with
filler alloy of the same composition as
+—— + —~
LINES SHOW AVERAGE STRENGTHS
BASED ON TESTS WITH PARE?
Y THE SAME COMPOSITIO
aw L
FILLET SIZE, INCH
SHEAR STRENGTH OF TRANSVERSE FILLET WELDS
OF 5154 PLATE—USING 5556 FILLER
that of the parent metal. available free on request.
The increased strength of fillet welds The next article in this series will
thus obtained permits use of less weld present basic design data for the most
for a given load with consequent sav- important of the weldable aluminum
ings in both material and welding costs. alloys. A final article dealing with the
Although the advantages of higher fatigue strength of welded aluminum
strength filler alloy are greatest in fillet alloys will conclude the series.
welds, tests indicate some improvement For top-quality aluminum welding
with welded butt joints. products such as consumable elec-
In selecting the best combination of trodes, welding and brazing rods and
parent and filler alloys, the designer fluxes, and solder and soldering fluxes,
must consider such matters as ease of contact your nearest Alcoa sales office.
welding, corrosion resistance, operating For more complete information on
temperature, ductility, and sometimes “Designing Welded Aluminum Struc-
color .. . in addition to strength. Alcoa tures,’”” write Aluminum Company of
has prepared a handy filler metal se- America, 1762-F Alcoa Building, Pitts-
lection chart to help you, which is burgh 19, Pennsylvania.
VaLcoa ALUMINUM
WELDING MATERIALS
For details, circle No. 28 on Reader information Card
WELDING JOURNAL | 649

Ransome Opens Regional Office
The Ransome Co., Scotch Plains,
N. J., announces the opening of a
new office in Pittsburgh, Pa., at
345 Mount Lebanon Blvd., to serve
its central sales region. P. J.
Patton is the regional manager,
covering Pennsylvania, Ohio, Ten-
nessee, Kentucky, Michigan and
upstate New York.
Linde Builds Plant
A new plant for Linde’s Flame-
Plating process will be built at
North Haven, Conn., it was an-
nounced recently by W. B. Nichol-
son, president of Linde Co., Division
of Union Carbide Corp. Ground
was broken for the new plant in
May, and completion is scheduled
for December 1960. The North
Haven plant is being built primarily
to serve industries in New England
and the Central Atlantic States.
Other Flame-Plating facilities are
located now at Speedway (Indian-
apolis), Ind., and Los Angeles, Calif.
Flame-Plating, introduced
1953, is Linde’s process in which
coatings of hard materials (such as
tungsten carbide and aluminum
oxide) are applied to parts made
from a variety of base metals and
other materials, providing them
with far greater resistance to wear,
abrasion, erosion and corrosion.
NWSA Holds Meetings
The National Welding Supply As-
sociation has held two conventions.
The Southeastern Zone Meeting was
held Monday and Tuesday, Novem-
ber 30-December 1 at the Atlantic
Biltimore Hotel, Atlanta, Ga.
The Southwestern Zone Meeting
was held at the Hotel Texas, Fort
Worth, Texas, on December 3-4.
Programs included “‘Buzz Sessions”
and panel discussions on manage-
ment problems.
650 | JUNE 1960
of the industry
Harris Calorific Reports
Harris Calorific Co., Cleveland
manufacturer of gas welding and
cutting apparatus. reported 1959
was the best year in its 55-year
history. The reason according to
C. M. Taylor, president: sales
activity combined with research
initiative resulted in marketing sev-
eral new products.
Domestic sales were 52% over
1958. With enlarged production
facilities and new welding equip-
ment scheduled, a continued in-
crease is forecast for 1960.
Air Reduction Opens
California Plant
Air Reduction Pacific Co., a
division of Air Reduction Co., Inc.,
has opened in Richmond, Calif., a
liquid air separation plant. In-
cluding related distribution equip-
ment, the installation cost approxi-
in
mately $3,000,000, and will produce
30 tons per day of liquid oxygen,
nitrogen and argon. The plant is
designed to accommodate three
additional installations.
Westinghouse Income Up
Net income of the Westinghouse
Electric Corp. after taxes increased
35% in the first quarter of 1960
over the corresponding period a
year ago to $19,496,000 on billings
of $458,817,000, a 4% increase
over the first quarter of 1959.
Earnings of 55 cents a common
share was the second highest ever
reported by Westinghouse in a first
quarter, being exceeded only in
1954, and compared with earnings
equal to 41 cents a common share
a year ago. Net sales billed were
also the second highest for a first
quarter.
Robotron Groups Products
Robotron Corp., Detroit manu-
facturers of industrial electronic
control systems, has regrouped its
product lines into four divisions:
Resistance Welding, Automation
Devices, Regulators and Induction
Heating. For practical operating
purposes, each division now func-
tions within the corporation under
production, sales and shipping poli-
cies peculiar to its needs.
COMING
EVENTS
A Calendar of Welding Activity
AWS National Meetings
1960 National Fall Meeting. Sep-
tember 26-29. Penn-Sheraton
Hotel, Pittsburgh, Pa.
1961 Annual Meeting & Exposi-
tion: April 17-21. Hotel Com-
modore, New York, N. Y.
ASM
Oct. 17-21. 42nd Annual] Metal
Show. Trade and Convention
Center, Philadelphia, Pa.
 © Copyright 1960

TREK
ndustries,
Inc.

Home Plant and Offices:

9701 $.E. McLoughlin Bivd., Olive 4-653]
Portland 22, Oregon
Eastern Distribution Center
10515 Reading Road, PRinceton 1-313]
Cincinnati 41, Ohio
OMARK Industries (1959), Ltd.
165 York Road, Guelph, Ontario, Canada
Sporting Arms, Ltd
Adelaide, South Australia
Svenska-OREGON AB
{ : Kopparberg, Sweden

P é; ON-THE-JOB, SINGLE-SOURCE SERVICE

FROM FACTORY BRANCHES
oe = IN MAJOR CITIES 2
2 ‘ . . ‘ ! OMARK-Midwest, Inc.
If fastening to ferrous or nonferrous metal is your responsibility ... 5404 West Fullerton St., Chicago 39, Ill.
TUxedo 9-2662
whether accurately to position and secure small parts and thin plates, 7 "
free from burn or distortion, in industry ... or to carry heavy loads over GARE,
8610 Natura!Leake,Bridge,tne St. Louis, Mo.
2 . e
big areas in building and construction... a talk with your OMARK HArrison 83702
Stud Welding System representative is certain to prove worthwhile. anes OMARK-Wisconsin, Inc
~ 100 West Bluemound Rd Milwaukee, Wis.
He will get together with you in your plant or on the job, offer you sound ny
OMARK-Ohio, Inc
counsel and service, come up with a ready, standard solution to your 5 Reading Rd Cte s ]
problem, or one quickly engineered to meet your specifications. PRinceton 1-3849
OMARK-Northeast, Inc
Either way, you will get helpful, dependable answers. Start now, with Southwest Park, Routes |
: : = > - ‘ : Westwood, Massachusetts
a call to your nearest OMARK factory branch. You'll finish your fasten-
; 3 : OMARK-Northeast, Inc
ing job with greater profit. Steet Had aes.
Long Island City, N
OMARK-Mideast, Inc
SPEED THE JOB, CUT THE COST — WITH QUALITY 4153 He Dr., Baltimore
OMARK STUD WELDING SYSTEM EQUIPMENT AND STUDS eet. Soars
OMARK-Southeast, Inc
aA st Platt Street, Tampa, Florid
OMARK Stud Welding System Single-And-Multiple-Gun Bench Machines
for Industrial Use 3333}:
a) OMARK-Southeast, Inc
1543 N.W. 54th Street, Miami, Fi
OMARK Stud Welding System Portable Machines for Building, Construction Oxford 1-67
and Shipyard Use t OMARK-Southeast, Inc
1500 West Church Street, Orlando,
OMARK Stud Welding System Quality Studs Standard or Custom Design . GArden 4-0815
Unlimited Variety in Size, Configuration and Metal Content : OMARK-Southern, Inc
1 Jefferson Hwy., New Orleans, La.
3-641
’ yi OMARK-Southern, Inc
AVP WV; 2039 Grant Street, Mobile, Ala.
GRant 9-0315
- OMARK-West Coast, Inc
A DR F = 401 E. Washingtor 4., Los Angeles 15, Calif
. T eee ‘ Richmond 7
OMARK-West Coast, Inc
746 E Street, San Francisco 9, Ca
PRospect 5-6243
“e OMARK-Southwest, Inc
1305 Akard Street, Dallas, Texas
Riverside 7-700]
dddddddd
OMARK-Southeast, inc
Atlanta Divisio 440 Nort!
Atlanta, Ga., JAckson 5-6426
Construction Tool & Supply Co
OMARK Direct Factory Branct
1815 Hancock St., San Diego
CYpress 6-6146

SEE THE YELLOW PA

WELDING EQL
YOUR MARK [I

For details, circle No. 30 on Reader Information Card

 ATTEND WELDING COURSE
BATEMAN

BANTAM
IRON WORKER

THE ONLY IRON WORKER OF ITS

KIND ON THE MARKET TODAY
No Grinding Neces-
sary After Cut. One
Stroke Cycle Clutch
Operated by Hand
or Foot.
+a ss The Bateman “‘Ban-
tam” cuts 2” x 2” x
Members of the group successfully completing the welding course sponsored by Ali- ” angles and %4" x
State Welding Alloys Co. of White Plains, N. Y. The course covered the latest methods i” flats. Standard
of joining and salvaging metal parts. Second from the left, front row is Jack Donnelly, punches will fit this
instructor. machine. The Coper
will cope 1%”
through '4” material
Aero Supply Acquires Interest in new ultrasonic continuous seam- It will punch 2”
International Ultrasonics welding machine for aluminum foil hole through '4” ma-
and other thin metals. The first terial. With the clutch
open, the Bantam wil!
Acquisition of an interest in such unit will be installed soon at the make 44 strokes per minute. It is made of
International Utrasonics, Inc., Rah- Richmond, Va., foil plant of Reyn- high-grade cast iron, with the clutch, pin
olds Metals Co. The unit is said to and dog made of hardened steel. The blades
way, N. J., by Aero Supply Mfg. are made with tool steel. Ic is powered with
Co., Inec., Corry, Pa., has been an- be capable of welding aluminum foil a fly wheel and gear drive, and uses a small
nounced by Thomas J. Scarpa, as thin as 0.00025 in. %4 hp motor, 1750 rpm.
president of International Ultra- Air Reduction Releases Bateman Bantam with punch _$575.00
sonics. The agreement includes op- Shear only : $495.00
tions for Aero to acquire up to 40% 1959 Annual Report Shipping wt. 750 Ibs.
of International Ultrasonics. Air Reduction Co., Inc., released
Mr. Scarpa said Aero will as- its 1959 annual report in which BATEMAN FOUNDRY & MACHINE
sist in financing production of a President John A. Hill stated that ee ee ee a
For details, circle No. 27 on Reader Information Card

Are YOU the

man who pays despite the adverse effect of the steel

the trucking
Then Consider this
money saving fact !
You get more gas in every
Coyne Cylinder because each
Coyne Acetylene Cylinder
has the Coyne “92” high
porosity filler! You need to
haul less tanks (for the same
amount of gas) which means
lower trucking costs.
Write or call now!
COYNE
cylinder company
224 Ryan Way,
South San Francisco, California « Plaza 6-6910
155 West Bodley Avenue,
Memphis, Tennessee - WHitehall 8-7789
3800 Springdale Avenue,
Glenview, Illinois « PArk 4-3828
24 Commerce Street,
Newark, New Jersey « Mitchell 2-1618
For details, circle No. 26 on Reader information Card
strike, sales rose to a record level of
: $200,603,636, compared with sales
in 1958 of $175,307,384, an increase
of 14.4%. Net income after taxes
in 1959 was $14,850,600, compared
with 1958 net income of $13,349,885,
an increase of 11.2%. Earnings per
share of common stock were $3.81 in
1959, compared with $3.47 in 1958,
an increase of 9.87
Disaster Control Conference
The 4th Annual Industrial Mutual
Aid & Disaster Control Conference
was held May 18-20, 1960, at the
Netherland-Hilton Hotel, Cincin-
nati, Ohio.
Sponsored by the National Insti-
tute for Disaster Mobilization, Inc.
NIDM,), the office of Civil Defense
Mobilization (OCDM) and the Air
Materiel Command (AMC)—U. S.
Air Force, the conference is held for
industrial plants and communities
having preparedness interests. The
host group is the Evendale Industrial
Mutual Aid Association (EMA),
P. O. Box 151, Cincinnati 15, Ohio,
from whom further information may
be obtained.

652 | JUNE 1960

 —
a

—=

You can slash welding labor and

overhead costs as much as 50% by
just pressing the control button on
a P&H welding positioner. It’s
being done every day.
P&H weldment-positioning is a one-
man, fingertip-controlled operation.
Once the piece is secured, the oper-
ator can raise and tilt it at the most
convenient angle through 135° ~—
without extra help or equipment.
Weldors can work in the less tiring
and much more efficient downhand
position. They can use “hotter” rods
for heavier, smoother first-run beads.
In most cases, the number of passes
drops from three to one.
to cut welding costs There are 14 P&H positioner
models. Capacities from 100 lbs. to
100,000 Ibs. — with variable speed,
if desired. Write for information on
in half! the capacity you need.
P<
bas!
For details, circle No. 31 on Reader information Card HARNISCHFEGER
Milwavkee 46, Wisconsin
Export Division:
4329 W. National Ave., Milwaukee, Wis.
P&H welding equipment is manufactured and sold in Canada
by REGENT EQUIPMENT MANUFACTURING COMPANY, Ltd
455 King St. West © Toronto, Ontario, Canada
Lincoln Makes Service Awards
Four top executives of The Lin-
coln Electric Co., Cleveland, Ohio,
were among the 106 employees
recognized at the company’s 43rd
Annual Employees Assn. Banquet.
Over 900 employees gathered to
observe the awarding of service
pins to employees having service
records of 10 years and over, in 5-
year intervals.
The service awards were high-
lighted when William Irrgang, presi-
dent, received his 30-year pin.
Mr. Lincoln, chairman of the board,
presented pins to those employees
who have served 25 years or over. J. F. Lincoln, center, presents service pins to four executives. They are, left
to right, George Clipsham, William Irrgang, M. N. Vuchnich and J. S. Roscoe
J. S. Roscoe, executive vice-presi-
dent and sales manager, received a
35-year pin and George Clipsham, Shipments also reflect this upward and office facilities at 703-37th Ave.,
secretary, received 30-year recogni- trend and show a gain of 25% over Oakland, Calif., is announced by
tion. M. N. ‘‘Mickey’”’ Vuchnich, last year’s figures. With shipments Glenn Pacific Power Suppiy Corp.
president of Lincoln Electric of for October at slightly over two
Canada, Ltd., received a gold watch million dollars, it was the eighth |AA Honors Dr. Keel
and a pin for 25 years of service. consecutive month that this figure Dr. Charles G. Keel, managing
has been attained. director of the Swiss Welding Assn.
RWMA Reports Business Rise Backlogs at the end of October and ‘father’ of the progressive
The monthly statistics compiled amounted to more than nine million Swiss regulations on carbide, acety-
by the Resistance Welder Manu- dollars, the highest figure this year. lene and oxygen, was awarded the
facturers’ Assn. indicate that new 1960 Morehead Medal of the Inter-
business for the first ten months of Glenn Pacific Expands national Acetylene Assn. The
1959 is 38°, ahead of orders for the Construction of a new building on award, which was presented at the
same period in 1958. property adjoining present plant [AA’s 62nd Anniversary Convention
in San Francisco on May 9th and
10th, is presented annually to the
individual who, in the opinion of the
+ the MODERN METHOD Association’s directors, has contrib-
of Transporting Compressed Gases uted most toward advancement of
the art of producing or utilizing
calcium carbide or acetylene.

wr” Ls

gr
gas supply TRAILERS
() C3 Ce Ca
Ren
aileted just for Y OU

@ MANIFOLD & CONTROLS — for YOUR Gas and Handling Requirements

© CAPACITY — to meet YOUR Requirements A graduate of the Swiss Federal
Institute of Technology in Zurich,
@ SAFETY — Cylinders, Safety Devices, Controls etc., All in accordance with ICC Requirements
Dr. Keel is also president of the
for YOUR Protection. Swiss Federation of the Technical
© CHASSIS — by leading Chassis Manufacturers with Service Branches throughout the United and Periodical Press, Editor of the
States for YOUR Convenience. Swiss Welding Journal, a member
of the Swiss Chamber of Scientific
and Technical Experts for Judicial
SEND YOUR INDEPENDENT ENGINEERING COMPANY, Inc. Inquiries and a member of the
INQUIRIES” aa fi, —— f AMERICAN WELDING Society. He
CONSULTING 0 CEO DESIGNING CYLINDERS AND GAS PRODUCING EQUIPMENT has written numerous articles on
“TODAY TO* ACETYLENE + OXYGEN - NITROGEN~ ARGON
“geen a RESEARCH welding problems and is the author
O'FALLON 2, ILLINOIS of Welding Techniques and Inert Gas
For details, circle No. 29 on Reader Information Card Welding.

654 | JUNE 1960

 5 = bes

Modern welding processes ™

wa like these demand a

oak
| modern power supply!

: Week 1G ("=") *MIG(=)

Nth\** Short Arc * Submerged Arca

aL ‘+t mee“S Magnetic Flux -

. + ie >- ae= ot- eee ‘ ae< ee Et

Never underestimate the importance of the power

supply to the proper operation of today’s improved
welding processes.
Weld quality, appearance, speed and economy all
depend on matching arc characteristics to the re-
quirements of the process and the material. If your
power supply can’t produce the required character-
istics, you're sure to lose some or all of the perform-
ance you want.
Glenn Pacific, working closely with major welding
process development engineers, has kept pace with
process requirements. For example, GLENN con-
stant voltage power supplies with linear slope con-
trol have solved major problems in MIG and Short
Arc welding on aluminum and ferrous alloys, and
many exotic “space age” metals.

Get the facts now about GLENN Power Sup-

plies matched to your welding needs—you'll be
hours and dollars ahead! For details, please
address Dept. 138.

7 bi Y a D q q 7
GLENN PACIFI¢
Glenn Constant Vo/tage Power Supply POWER SUPPLY CORPORATION
with Stepless Vernier Slope Contro/ 703-37th Avenue « Oakland 1, California
Originators of CV Power Supplies
Eastern Office Midwestern Office
221 Dukes Rd., Rahway, N. J. 640 So. York, Eimhurst, Ill.

wer Supply 3 GLENN Arc Gouger Power Supply GLENN

| Welder for “Gang” Manual Welding >» GLENN Industrial
: an:spam ee Voltage Transformers

For details, circle No. 33 on Reader Information Card

WELDING JOURNAL | 655

PERSONNEL
Fallon and Whiting Advance
Thomas J. Fallon WS has been
named Boston district manager for
the National Cylinder Gas Division
of Chemetron Corp. Chester E.
Whiting 3, a former NCG sales-
man, has been appointed to succeed
Fallon as South Meriden, Conn.,
branch manager.
Crockett Made Vice President
J. M. Crockett has been appointed
vice president—gases of Air Re-
duction Sales Co., it was announced
recently. Mr. Crockett, a graduate
of the South Dakota School of
Mines, has been associated with
Air Reduction since 1945. Most
recently, he served as manager of
Airco’s Birmingham district office.
He will now be responsible for the
production and distribution of Air
Reduction Sales Co.’s complete
line of industrial gases.
A member of the American In-
stitute of Mining, Metallurgical
and Petroleum Engineers, the Amer-
ican Foundrymen’s Assn., and the
AMERICAN WELDING Socrety, Mr.
Crockett resides at 16 Moraine
Rd., Metuchen, N. J.
J. M. Crockett
656 | JUNE 1960
Schetky Assumes New Duties
Appointment of L. McD. Schetky
as vice president and _ technical
director of the Alloyd Corp. has
been announced by B. L. Averbach,
chairman. In this new post, Dr.
Schetky will be responsible for the
company’s government and com-
mercial research programs. Dr.
Averbach previously served as both
chairman and technical director of
the corporation.
Appointment of D. W. Morgan
Linde Co., Division of Union
Carbide Corp., announces the ap-
pointment of D. W. Morgan as
manager, Essington Electric Weld-
ing Apparatus Factory, Essington,
Pa. His previous assignment was
assistant manager, Tonawanda Fac-
tory, Tonawanda, N. Y. He holds
the degrees of M.S. in Business
Administration from the University
of Buffalo, and B.S. in Mechanical
Engineering from Cornell Univer-
sity.
Kaluzny Joins AMF Co.
The American Machine and
Foundry Co., Buffalo, N. Y., has
announced that John C. Kaluzny
has joined the organization as
welding engineer. Mr. Kaluzny
formerly was process engineer, Spe-
cial Products Department of the Air
Reduction Sales Co., Union, N. J.
In his new position, Mr. Kaluzny
will direct the welding activities
at the AMF Co., Buffalo Works.
The company is presently concerned
with the fabrication of the Sergeant
ground support mechanism and the
Titan and Atlas ICBM Launcher
Systems.
A member of the AMERICAN
WELDING Society, Mr. Kaluzny
is Chairman of the Niagara Frontier
Section.
J.C. Kaluzny
Smith Returns from Abroad
Donald W. Smith, Chief Engineer
of the Sight Feed Generator Co.,
West Alexandria, Ohio, has made
an extensive trip abroad, in North
Africa and Europe.
The primary purpose of the trip
was to train the personnel of the
Caterpilar dealership in Algiers
to use automatic welding machines
and positioners for the rebuilding
of worn tractor rails, rollers and
idlers.
Leston is Research Director
T. I. Leston is now associated
as technical director of research of
the Certanium Alloys and Research
Corp. He was formerly vice presi-
dent in charge of products and re-
search for the Eutectic Welding
Alloys Corp.
Dr. Leston is a chemical and
metallurgical engineer having had
extensive scientific and practical
experience in metal-working in-
dustries of Europe and the United
States. He has contributed to the
development of many types of weld-
ing electrodes and the development
of a number of fluxes to be used in
connection with gas welding and for
the covering of electrodes.
Burnett Assigned District
C. M. Burnett has been named
district representative of the south
central states for Hobart Brothers
Co., Troy, Ohio. Mr. Burnett will
supervise the distribution of Hobart
arc welding equipment and elec-
trodes in Louisiana, Texas and
New Mexico. He is an active
member of the AMERICAN WELDING
Society and is a past-chairman of
the Worcester, Mass., Section.
Presently, he is serving on the Board
of Directors of St. Louis Section.
C. M. Burnett
alloys for outer space

Solving the difficult problem of joining light metals for outer space vehicles is just one of
many new uses for TIG welding. And for this kind of critical application, no finer Tungsten
Electrode is made than by Sylvania.
Sylvania makes every kind of Tungsten Electrode available: Puretung®, Zirtung®, 1%
Thoriated, 2% Thoriated. And each comes in the desired finish—cleaned or ground, and There's a
color-coded to save valuable time, prevent costly errors. Chemical & Metallurgical Division, es! , ani Tungsten
: ‘ . : - ‘ trode for every
Sylvania Electric Products Inc., Towanda, Pennsylvania. e
welding need.d

Subsidiary of GENERAL TELEPHONE & ELECTRONICS

For details, circle No. 34 on Reader Information Card
WELDING JOURNAL | 657
 Busby Becomes Supervisor
John T. Busby has been named
field supervisor by Eutectic Weld-
ing Alloys Corp., Flushing, N. Y..,
according to an announcement by
Rene D. Wasserman, president.
He was previously a technical rep-
resentative with the company.
Prior to joining Eutectic, Mr.
Busby was a Navy welding in-
structor. In his new position, he
will be responsible for the training
of Eutectic’s technical representa-
tives.
Stratton, Haas Join Lincoln
The Lincoln Electric Co. has
expanded field forces with the addi-
tion of two field welding engineers.
Charles A. Stratton, a [MW
graduate of Northeastern Univer-
sity of Boston, Mass., has been
assigned to the Kansas City office.
Robert E. Haas, Jr. [3/9], a grad-
uate of Case Institute of Tech-
nology, was assigned to Chicago.
Both men are graduate engineers
and have undergone a_ year-long
training program to equip them to
serve their respective areas in en-
gineering, the application of arc
welding processes and equipment.
Roper Sales Representative
Earl Roper has been appointed
southern factory sales representative
for Sellstrom Manufacturing Co.,
Palatine, Ill., manufacturers of weld-
ing and safety equipment. He will
cover Alabama, Florida, Georgia,
Mississippi, North and South Caro-
lina and Tennessee.
Mr. Roper comes to Sellstrom
with an extensive background in
selling safety equipment. In addi-
tion, he studied safety management
at the University Center in Bir-
mingham, Ala.
Baltzegar Named Manager
Cecil Baltzegar has been named
manager of the newly created mar-
ket research department of Omark
Industries, Inc.
Mr. Baltzegar has been with
Omark since 1953, serving as as-
sistant to the chain sales manager
and market research analyst. He
is a graduate of the U. S. Merchant
Marine Academy.
Neilson Appointed Manager
Robert T. Neilson, of Berkeley,
Calif., has been appointed plant
manager of National Welding
Equipment Co., San _ Francisco.
Mr. Neilson was formerly employed
as chief engineer for Prescolite
Mfg. Corp.
Rhodes Fills New Post
E. E. (Dusty) Rhodes 3, for the
past 8 years service engineer for
National Electric Welding Ma-
chines Co., Bay City, Mich., has
joined the staff of the K. Wm.
Ostrom Co., Inc., Drexel Hill,
Pa., as a sales engineer.
Ostrom is exclusive sales repre-
sentative for National Electric in
New Jersey, Maryland, Delaware,
Virginia, eastern Pennsylvania and
Washington, D. C.
Mr. Rhodes will specialize in
container manufacturers’ problems.
Salesmen Honored
Five field engineers, each having
sold more than $1,000,000 worth of
equipment, were honored recently
by Gregory Industries, Inc., and its
Nelson Stud Welding Division, Lo-
raine, Ohio. The Nelson repre-
sentatives became charter members
of a new ‘‘President’s Million Dollar
Club.”
Certificates were presented to
Walter E McArthur, of the Los
Angeles branch office; James E

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You get an economy package of exclusive TEC time-saving

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TEC Spot Gun with built in dual timing; the easy to read,
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MANUFACTURERS OF VISUWELD EQUIPMENT
For details, circle No. 35 on Reader Information Card
658 JUNE 1960
 Stone, Jr., Philadelphia; E. W.
Pat) Smith WS, Cincinnati; Samuel
B. Murphy, Pittsburgh, and Rich-
ard O. Blankmeyer, Syracuse, N. Y. New Hi-Impact Plastic Insulated
Coltman Sales Representative
John P. Coltman has been ap- Panel Receptacles and Mating Plugs
pointed eastern sales representative
for Norris-Thermador Corp., Los
Angeles, Calif., manufacturer of
compressed-gas cylinders. His ap-
_ Mount’ directly
pointment was announced recently
by R. J. Mastick, manager of cylin- b ——s Zz *e d
der sales. Ween) Onany
Mr. Coltman, who is well known Electrical =~
in the industry, will represent .
Norris-Thermador in the eastern Panel
United States and Canada. His
office will be located at 185 Ller
Drive, Middletown, N. J.
Bennett Heads Sales 2
aoe ghee
Clarence Bennett {@/3| has been .
os * «
appointed sales section head of the
Welder Product Group at Vickers 2
Inc., Electric Products Division, St.
Louis. He was formerly head of cam-lok
the Welder Engineering Design Sec-
a
tion.
Mr. Bennett, who joined Vickers
Electric Products Division in 1951,
graduated from the University of
Missouri in 1949 with the degree Now, you can make fast, positive power connections to any
B.S., E.E. He is also a member metal panel or housing without special insulating materials.
of the AIEE.
Simply punch outa hole and insert a Cam-Lok self-insulated
Receptacle! Uses standard electrical lock-nuts, affords
OBITUARY
‘“‘dead-front” protection. Push in and twist Cam-Lok
Lockwood Hill mating Plug and you've made a locked connection, which
Lockwood Hill, 73, founder and can be released quickly.
chairman of the board of the Hill
Equipment Co., 1413 Pennsylvania
New Cam-Lok Receptacles eliminate costs of special
Ave., St. Louis, Miss., died sud-
denly of a heart attack on Mar. 24, insulating panels and reduce assembly time. Patented,
1960. high-pressure contact assures minimum resistance and
Mr. Hill, a long time member of heating.
AWS, was an electrical engineering
graduate of Cornell University in Cam-Lok has a complete line of Receptacles and Plugs in
1909. He founded his firm, which
many sizes and designs. Standard and special purpose
handles welding equipment and
supplies, in November of 1929. Power Distribution Connections are available. W rite today
Surviving are his widow, Mrs. for new Bulletin No. 301.
Katherine G. Hill, a daughter,
Mrs. Louis A. Hoerr, a son Stuart
Hill, and a brother, Maury Hill. “Dead Front” design tor fast

William F. Farnham direct mounting on...

William F. Farnham, 51, partner © ELECTRICAL DISTRIBUTION PANELS © SWITCHGEAR
in the bridge designing firm of
Modjeski and Masters of Harris- ¢ BUS DUCT © JUNCTION BOXES
burg, Pa., died Mar. 22, 1960, at e WIREWAY or any electrical cubicle
Cornell University, his alma mater,
after a bridge project conference.
Mr. Farnham was a member of
the American Society of Civil En-
gineers, American Railway En-
gineering Assn., National Society
for Professional Engineers, Penn- EMPIRE PRODUCTS, INC,
sylvania Society of Professional Coe] Gonollalix P.O. BOX J-98
Engineers, and the AMERICAN DIVISION CINCINNATI 36, OHIO
WELDING SOCIETY.
For details, circle No. 36 on Reader Information Card
WELDING JOURNAL 659

Flame-spray Process
An engineering data bulletin on
basic flame-spray processes is of-
fered by Metallizing Engineering
Co., 1101 Prospect Ave., Westbury,
L. 1., N. Y. This 16-page bulletin
covers techniques and equipment
used in spray-bonding metals and
refractory materials. Three
methods are described: Metallizing,
Thermospray and Plasma Flame.
THE METCO
FLAME SPRAYING PROCESSES
In addition to covering the basic
engineering for each process, the
bulletin includes tables and charts
on properties of these coatings; such
as hardness, tensile strength, bond
strength, etc.
For your free copy, circle No. 51
on Reader Information Card.
Fusion Welding Aluminum
Available from Reynolds Metals
Co., Dept. PRD-31, Richmond, Va.,
is a 32-page technical handbook
entitled ‘“‘Fusion Welding Alumi-
num.’ The booklet describes joint
design and the various gas and arc-
welding techniques used in joining
aluminum.
For your free copy, circle No. 52
on Reader Information Card.
Welding-rod Data Sheets
New data sheets for 12 NCG
welding filler rods, which include
specifications, welding and brazing
characteristics, physical properties
and a color identification guide, are
available from National Cylinder
Gas Division of Chemetron Corp.,
840 N. Michigan Ave., Chicago 11,
Ill. Procedures for welding and
brazing, as well as typical applica-
660 | JUNE 1960
tions, are included in the sheets.
Data sheets are available for the
following welding rods (sheet code
number in parenthesis):
NCG _ Redifluxed 30, Naval
Bronze (N-103A); NCG Redi-
fluxed 35, High Strength Bronze
N-103B); NCG Redifluxed 52,
Nickel Bronze (103C); NCG 1, 0.06
Carbon Steel (N-103D); NCG 2,
Low Carbon Steel (N-103E); and
NCG 6, Medium Carbon Steel
N-103F).
Others are NCG 1232, Silicon-
Copper (N-103H); NCG 3000, Na-
val Bronze (N-1031); NCG 3101,
Bronze (N-103J); NCG 3500,
Bronze (N-103K); NCG_ 5200,
Nickel Bronze (N-103L); and
NCG 99, Gray Iron (N-103M).
For your free copy, circle No. 53
on Reader Information Card.
Carbon-dioxide Booklet
A twenty-four page booklet on
carbon dioxide and its value to in-
dustry has been issued by the Pure
Carbonic Co., 150 E. 42nd St., New
York 17, N. Y. The colorfully
illustrated booklet tells the history,
principal applications, properties,
manufacture, supply and distribu-
tion of carbon dioxide in gaseous,
liquid and solid form.
For your free copy, circle No. 54
on Reader Information Card.
Automated Welding
““Weld-It” (No. 602), a 4-page
bulletin by The Taylor-Winfield
Corp., Warren, Ohio, describes auto-
mated welding processes in current
use.
For your free copy, circle No. 55
on Reader Information Card.
Fusion Facts
The quarterly bulletin, Fusion
Facts, issued by the Stoody Co.,
11920 E. Slanson Ave., Whitteir,
Calif., contains, in the 22 pages of
the Fall number, six articles on
applications of hard surfacing.
For your free copy, circle No. 56
on Reader Information Card.
Aluminum-joining Manual
A 40-page illustrated manual
surveys the physical properties of
aluminum, its alloys and methods
used in joining.
Prepared by All-State Welding
Alloys Co., Inc., 249-55 Ferris Ave.,
White Plains, N. Y., the booklet
presents general descriptions, arc-
and gas-welding methods, brazing
and soldering. Charts and tables
list pertinent data on All-States’
aluminum joining products.
For your free copy, circle No. 57
on Reader Information Card.
Air-cooled Electrode Holder
An air-cooled electrode holder
for heavy-duty metallic arc welding
is described in a data sheet by J. B.
Nottingham & Co., Inc., 441 Lex-
ington Ave., New York 17, N. Y.
Results of two years’ field testing
in heavy construction and manu-
facturing are cited, including a
large shipyard’s estimate of one full
man-hour gained per eight-hour
shift. The air-cooled unit is said
to let a man weld a full shift without
changing holders.
For your free copy, circle No. 58
on Reader Information Card.
Resistance Welding
A 12-page brochure describes 32
multi-spot and projection resist-
ance welding machines in detail.
Data include: end product, type
of operation, production rate, weld-
ing machine specifications and ma-
terial handling equipment. The
bulletin describes such special fea-
tures as: automatic loading, inspec-
tion, special welding techniques,
spot, projection and seam welds,
resistance brazing and hot upsetting
operations, automatic transfer, as-
sociated forming operations and
automatic unloading. Bulletin
8-413 is published by the Taylor
Winfield Corp., Warren, Ohio.
For your free copy, circle No. 59
on Reader Information Card.
Fused-coating Data
A 2-page engineering data sheet
(No. 4.5) describing the Nicrocoat
process for oxidation, corrosion and
abrasion resistance is now available
from the Stainless Processing Di-
vision, Wall Colmonoy Corp., 19345
John R St., Detroit 3, Mich.
The new data sheet discusses
physical, chemical and fabrication
properties of the surface protection
provided by the Nicrocoat process.
For your free copy, circle No. 60
on Reader Information Card.

Temperature Measuring
A revised data sheet giving in-
structions for the use of Tempil-
stiks® under various working situa-
tions is available from Tempil
Corp., 132 W. 22nd St., New York

11, N. Y. The heat-sensitive cray-

ons come in 80 temperature ratings.
For your free copy, circle No. 61
on Reader Information Card.
Long-life overlay

Flash-butt Welding ...5,000 FEET OF IT!

A 16-page brochure (No. 7-913
describes the resistance flash-butt
welding process and illustrates types
of clamping, flash and upset mecha-
nisms. Designed by Taylor-Win-
field Corp., Warren, Ohio, for spe-
cific applications, 40 butt-welding
machines are shown and described,
together with the welding job done.
Applications include the flash-butt
welding of aircraft components,
automotive parts, window frames
and small electronic components:
germanium diodes, etc.
For your free copy, circle No 62
on Reader Information Card.
Typical AMPCO-TRODE’
application with
submerged arc or MIG
To protect against wear caused by
sliding friction — to get years of
extra service—this 7,500-ton forging-
press ram was overlaid with Ampco-
Trode 10 bare wire. Two submerged-
arc heads were used, instead of one,
to double the rate of deposit.
There are three Ampco bronze elec-
trodes especially suited for auto-
matic welding processes: Ampco-
Trode 10, Ampco-Trode 160, and
Phos-Trode, They give you a range
of deposit hardnesses resistant to
sliding wear, shock, squashing out,
erosion, cavitation-pitting, and cor-
rosion,
All are available also as bare and
coated filler rods. Ask your Ampco
distributor torecommend the Ampco-
Trode that is right for you. Send
coupon for bulletin. Do it today.

All-weather Welding Units AMPCO METAL, INC.

‘‘Sureweld”’ d-c arc-welding unit; MILWAUKEE 46, WISCONSIN
West Coast: Burbank, California
that are completely weatherproofed Southwest: Gariand (Dalias County), Tex,
for use by shipbuilders, contractors
and metal fabricators are described
in a new bulletin (NH-162) avail-
able from National Cylinder Gas
Division of Chemetron Corp., 840 AMPCO METAL, INC.
N. Michigan Ave., Chicago 11, IIl. Dept. 186F, Milwaukee 46, Wisconsin
The bulletin gives features and Send me Bulletin W-17.
specifications for the three models
in the DRH series: 222A, with Name
200-amp rated welding current; Company————————______
33A, with a 300-amp rated welding
current; and 44A, with 400-amp Address——
Bare wire availabie in
rated current. colls and level-wound City——— —Zone $6000
For your free copy, circle No. 63 spools W-1SS 4
eee
on Reader Information Card.
For details, circle No. 37 on Reader Information Card
WELDING JOURNAL | 661
Welding Power Supplies
Features, applications and speci-
fications of Glenn Pacific constant-
voltage power supplies with “slope
control” for precision welding of
space-age materials are contained
in a 4-page brochure available from
Glenn Pacific Power Supply Corp.,
703 37th Ave., Oakland, Calif.
For your free copy, circle No. 64
on Reader Information Card.
Hard-surfacing News
The winter 1959-60 edition of
‘‘Fusion Facts”’ published by Stoody
Co., 11920 E. Slfuson Ave., Whit-
tier, Calif., contains a number of
interestingly presented articles on
hard surfacing.
For your free copy, circle No. 65
on Reader Information Card.
Resistance-welding Transformers
A 20-page technical brochure
SP-23) contains data on resistance-
welding transformers. Offered by
The Taylor-Winfield Corp., Warren,
Ohio, the bulletin describes con-
struction techniques, transformer
rating and load demand, magnetiz-
ing and load transients, applica-
tions and duty cycles. Formulas
are provided for calculating kva
at various duty cycles, with con-
to get the best joint, use the right
FLUX
sideration of series-parallel winding,
eight step windings, etc. Sche-
matic diagrams, drawings, charts and
graphs aid in providing a_ basic
understanding of resistance-welding-
machine transformer design.
For your free copy, circle No. 66
on Reader Information Card.
Welding-hose Data
Literature detailing the complete
line of single and double welding
hose is available from Swan Rubber
Co., Bucyrus, Ohio.
Various types of welding hose are
described and information on appli-
cations, cover, reinforcement tube,
length, packaging and recommended
couplings is outlined.
For your free copy, circle No. 67
on Reader Information Card.
Dial-feed Welding Machines
A 12-page brochure (8-213) de-
scribes Taylor-Winfield’s dial-feed
mechanism for dial-feed resistance-
welding machines. Included are
drawings and photographs of the
Geneva index mechanism, and a
graph s!:owing recommended rate
of indexing for various numbers of
stations. Numerous machine pho-
tographs and case histories outline:
product, operation, production rate,
etc., for these high-production ma-
chines which are particularly suit-
able for assembly of smaller com-
ponents. Automatic loading, un-
loading, inspection operations are
illustrated.
For your free copy, circle No. 68
on Reader Information Card.
Flux-cored Welding
Process and Equipment
A completely revised booklet
NH-137) describing the Dual Shield
arc-welding process, and new equip-
ment and Dual Shield flux-cored
electrodes used in the process, is
available from National Cylinder
Gas Division of Chemetron Corp.,
840 N. Michigan Ave., Chicago 11,
Ill.
The new WC-1 welding control
and AM-1 torch are pictured and
described, and Dual Shield elec-
trodes and the types of welding for
which the process is effective are
listed. Also discussed are the ad-
vantages of Dual Shield welding,
including production increases, high
electrode efficiency, elimination of
metal cleaning preparation, self-
removing slag and clear visibility
during welding. Pictures show
cross sections of butt and fillet welds
made with the process.
For your free copy, circle No. 69
on Reader Information Card.
Bulletins Describe
Welding Machines
Features, specifications and op-
tional equipment available with four

‘‘Sureweld”’ SU series a-c arc-welding

you name it—ALL-STATE has it
ALL-STATE makes quality fluxes for torch and solder-
ing iron applications on all commercial metals. . . in
the form you prefer: liquid, paste, powder, flux cored
solders, flux coated rods. Working temperatures range
from 300F to 2200F. Designed for maximum wetting
action, minimum fuming. For instance:
DUZALL . . a new liquid flux for all soft solders, all
metals (except light metals). DUZALL eliminates
pre-cleaning, increases capillary action, leaves mini-
mum deposit. Comes in handy 4 oz. refillable dispenser-
type plastic containers, and in larger units.
=11 BRAZALOY®.. .a paste or powder flux for use
on 14 ferrous and bronze alloys. Wide temperature
range: 1200F to 2200F. Non-corrosive, non-fuming.
Also available extruded on Nickel Silver welding rods.
#31 BRAZALOY®... a highly active aluminum
brazing flux that gives maximum wetting action,
All-State’s JET FLUX® and excellent capillary flow. Protects surfaces from dis-
JET FLUX DISPENSER® coloration, requires less after-cleaning. An outstanding
on production line at temperature indicator.
Griggs Manufacturing Co. $200 SILVER BRAZING FLUX .. . melts at 600F,
Acetylene and Jet Flux becomes transparent at 1100F, protects heated base
mixed and fed automati- metal to 1800F. Induces excellent capillary action and
cally from Dispenser. flow of silver alloys.
Send for free copy of 54-page Instruction Manual and
for information on custom coating your welding
Distributor-Stocked, convenient to buy. Economical to use
Kefrusun WELDING ALLOYS CO., INC., White Plains, N. Y.
Call WHite Plains 8-4646 or write for nearest distributor
For details, circle No. 38 on Reader information Card
machines are presented in two new
illustrated bulletins available from
National Cylinder Gas Division of
Chemetron Corp., 840 N. Michigan
Ave., Chicago 11, IIl.
One bulletin (NH-175) contains
information on the SU-180 and the
SU-180P (with power factor correc-
tion) 180-amp welding machines
designed for general repair work and
light-duty service in garages, hobby
shops and farms. The other (NH-
178) gives data on the SU-295 and
SU-295P (power factor correction)
units with 295-amp rated welding
current for use on the production
line and for shop and general main-
tenance welding.
For your free copy, circle No. 70
on Reader Information Card.
Alloy News
Published by the Wall Colmonoy
Corp., 19345 John R St., Detroit 3,
Mich., “‘Alloy News,” vol. 5, no. 1,
is a 4-page folder describing prod-
ucts of the company and applica-
tions to specific jobs.
For your free copy, circle No. 71
on Reader Information Card.

662 | JUNE 1960

 HEADQUARTERS
FOR

RESISTANCE WELDING SUPPLIES

R. W. M. A. CLASSES OF ALLOYS
IN CASTINGS, FORGINGS AND BAR STOCK &
COPPER TUNGSTEN ALLOYS

WELDER WHEELS IN ALL ALLOYS

AND SIZES TO SUIT YOUR REQUIREMENTS

ALL TYPES OF STRAIGHT AND OFFSET HOLDERS

STANDARD ELECTRODES

AND SPECIAL TO YOUR SPECIFICATIONS

ADJUST-A-PRESSURE HOLDERS

ADJUST-A-ANGLE ADAPTERS

FOR MULTIPLE SPOT AND INDIRECT SPOT WELDING

TIP DRESSERS, REAMERS AND CONTOUR DRESSERS

WE DESIGN AND BUILD SPECIAL ELECTRODES

AND FIXTURES

S-M-S CORPORATION

2254 COLE AVENUE « BIRMINGHAM, MICHIGAN

For details, circle No. 39 on Reader Information Card

 New
Portable Spot-welding Machine
Two new portable spot-welding
machines for use on mild steel,
stainless steel and galvanized iron
up to 1,/8-in. combined thickness
have been announced by Metal &
Thermit Corp., Rahway, N. J.
They are designed for use on sheet
metal or wire.
Model 11 operates from 115 v ac
and requires 3.3 kva. Model 23
requires 230 v a-c power and is
rated at 4.4 kva. The 24-lb units
have a fixed top tong which permits
one-hand operation of the unit, re-
lieving the other to position the
work.
For details, circle No. 101 on
Reader Information Card.
Flux-cored, Gas-shielded
Welding Equipment
A Dual Shield arc-welding control
with wire drive, and a Dual Shield
arc-welding torch have been intro-
duced by National Cylinder Gas
Division of Chemetron Corp., 840
N. Michigan Ave., Chicago 11, Ill.
Both are designed for consumable-
electrode welding processes using
shielding gases such as argon, helium
or carbon dioxide in making hori-
zontal fillets and flat-position welds.
The new units, designated as the
WC-1 welding control and the AM-1
torch, can be used with d-c welding
current and may also be used in
other semiautomatic welding proc-
esses.
The skid-mounted WC-1 control
weighs 55 lb, will clear an 18-in.
664 | JUNE 19
Products
manhole, and has a wire-feed rate of
from 55 to 500 ipm for 3 °64- to
3/32-in. diam wire.
For details, circle No. 102 on
Reader Information Card.
Three Products Feature
Design Improvements
Several improvements in design
plus a competitive price structure
have been incorporated into three
products manufactured by A. O.
Smith Corp., Welding Products
Division, Milwaukee, Wis.
A new Premier line of a-c welding
machines, replacing the Challenger
models, have the transformer on its
side, resulting in a lateral coil move-
ment rather than vertical. This
saves a foot of height enabling the
machines to be stacked 3 high. The
coil is easier to move, making hand-
wheel adjustment easier.
A. O. Smith’s SW 612 mild steel
electrode (E 6012) has a new cover-
ing formulation which is claimed to
cut spatter loss by60°,. Therutile-
type covering is said to increase
deposition efficiency by 15°; at high
currents, to increase crack resist-
ance and to reduce cleaning time
by 50°.
The firm’s portable d-c welding
machine now offers a 2000-w boost
in auxiliary 60 cycle, single-phase
a-c power. The “Bug’’ now gener-
ates 3500 w and in, addition, offers
optional electric starting and several
other innovations.
For details, circle No. 103 on
Reader Information Card.
Hard-surfacing Electrode
Tufanhard 375, offered by Hobart
Bros. Co., Troy, Ohio, is an ex-
truded, heavily covered arc-welding
electrode yielding wear resistance
under medium impact conditions.
The weld deposit is nonmachinable
but can be forged at a bright cherry-
red heat. It has a stable covering
to which iron powder has been added
for increased deposition. The ap-
proximate hardness of the weld de-
posit is Brinnell 375; Rockwell ‘*C”’
40. Standard package is 50 lb per
box.
For details, circle No. 104 on
Reader Information Card.
Arc-welding Machine
Miller Electric Mfg. Co., Inc., of
Appleton, Wis., announces a_bal-
anced-wave tungsten inert-gas weld-
ing machine, model BWC-300MAP,
for which is claimed:
1. Perfect balance throughout the
entire welding range even during
crater elimination, plus arc stability
without high frequency at as low as
18 amp.
2. The d-c component is com-
pletely removed. This results from
a new concept in balanced-wave
welding circuits and a-specially de-
signed transformer. Arc-outs dur-
ing the weld cycle are impossible.
 3. Electrical control gives simple,
safe and accurate low voltage reg-
ulation from panel or any remote
station.

‘|

ati:Ihe
eR d

4. “‘Fail-safe’’ voltage reducer

automatically lowers the open cir-
cuit voltage when arc is struck or
broken. This feature remains oper-
ative even if a partial failure occurs
in voltage reducer circuit.
5. Five separate welding ranges,
with wide overlap, insure the proper
current range for any job.
For details, circle No. 105 on
Reader Information Card.

Push-button Tube Welding

A mobile welding-machine as-
sembly which is said to permit push-
button welding of stainless-steel
tubes and fittings, 1' . to 4 in. diam,
is offered by Cycl-O-Magic, Inc., Here the light-weight transformer head of a 300 KV Model is being positioned
1736 N. Second St., Milwaukee 12, to X-ray a circumferential weld in an airliner landing gear strut.
Wis.
High KV X-ray

with 100% Duty Cycle

Triplett & Barton 100% duty cycle X-ray

<@perry >
~ naa”
ULTRASONIC TESTING
may double the number of exposures a day
save vital time and dollars.
The fully loaded, ready to operate Triplett
& Barton head on the 275 KV Model weighs
only 65 Ibs. That light weight means easier
portability, quicker setups more time and
dollars saved.

oe And Triplett & Barton’s high KV (up to 300

A tricycle-mounted gas metal-arc KV with a full 10 milleamperes output) al-
welding machine, with a timing con- NOUSTRIAL X-RAY
— lows for shorter exposures with the required
trol box, accommodates the required
definition more time and dollars saved.
gas cylinder, regulators and flow
meter. An automatic welding-head MAGNETIC PARTICLE Call on Sperry Sales Engineers for the best in
fixture is designed to clamp on the
nondestructive testing systems and equipment.
tubing and is driven from the control-
box circuit. Machine settings are
tabulated according to pipe size
and, after setup, the operator pushes Sperry Products Company
a “‘start’’ button and waits for the DIVISION OF HOWE SOUND COMPANY
machine to complete the weld.
For details, circle No. 106 on 2406 Shelter Rock Road, Danbury. Connecticut
Reader Information Card. For details, circle No. 40 on Reader Information Card

WELDING JOURNAL | 665

 Coiled Tube Rods
Haynes Stellite Co., Division of
Union Carbide Corp., announces
that copper-coated tube rods are
now available for semiautomatic
open-arc hardsurfacing. ‘“‘Haynes”’
90, 94 and 4560; ‘“‘Haynes” Nickel-
Manganese; *‘Hascrome’”’; and
‘“‘Haystellite”’ tube rods are all sup-
plied in the 7/,-in. diam. drawn

size, in convenient coils. The tube

rod contains an internal flux to make
open-arc deposition possible and in-
sure a sound, slag-free deposit. The
copper coating reportedly helps pre-
Job Report Courtesy of vent rusting, makes feeding easier
Ingersoll-Rand Co., Phillipsburg, N. J. and provides better electrical con-
tact through the welding head.
When low alloy welds For details, circle No. 107 on
Reader Information Card.
must withstand 2000 psi
Heavy-duty Cutting Torch
This centrifugal compressor is one of many used in offshore gas repressuring. A rugged-duty cutting torch with
The pressure of nearly 2000 psi is nearly twice the highest former working flow capacity which enables it to
pressure. Arcos Tensilend 70 Electrodes were used to produce the high cut 24-in. steel has been introduced
strength welds required. When you need sound, high strength weld metal, by Smith Welding Equipment Corp.,
2633 Fourth St., S. E., Minneapolis
use Arcos Low Alloy quality controlled electrodes for reliable performance. 14, Minn., under the trade name of
““Tuf-Tony.”’
Primarily designed for heavy
cutting under all conditions, this
torch adapts to a wide variety of
less demanding applications by use
WELD WITH, of different “‘slip-in’”’ tips. A fea-
ture of Tuf-Tony is the oxygen
control valve which permits gradual
LOW ALLOY ELECTRODES introduction of cutting oxygen.
for quality weld metal This reduces slag spray and facili-

SEMI-AUTOMATIC AND AUTOMATIC EQUIPMENT FOR WELDING

STAINLESS + LOW ALLOY + ALUMINUM + MILD STEEL
tates control in such processes as
ARCOS CORPORATION «+ 1500 South 50th St., Philadelphia 43, Pa. piercing, rivet washing and heavy
For details, circle No. 41 on Reader Information Card cutting. The torch is equipped

666 | JUNE 1960

Trackless Welding-head Carriage either head. The PG 140 tube head

is 7'/, x 11°/, x 16'/: in. and
The Lincoln Electric Co. of weighs 55 Ib and the PG 200
Cleveland, Ohio, announces the tube head is 7'/, x 13°/, x 19*/, in.
development of a_ self-propelled weighing 88 lb. Rated for steel
trackless carriage for operation in components up to 2'/» in. in thick-
conjunction with their ML-3 Mech- ness, voltage is continuously ad-
anized Squirt Welder. The new justable from 35 to 140 kv for the
‘“‘Squirtmobile”’ supports, advances, PG 140 head and 50-200 kv for the
guides the welding gun along the
joint and, in effect, is said to produce eTf z
full automatic submerged-arc welds.
Designed to produce long welds
continuously, thereby increasing op-
erating factor, this 37-lb, compact
tractor requires no supporting fix-
Moisture ‘messes up’’ tures. The equipment can be easily
moved to the job site and quickly
electrodes, too, cuts placed in operation thus elimin-
ating the time loss and cost of
welding profits. moving bulky assemblies to fixtured
welding equipment. The company
End costly reworks believes that the Squirtmobile will
be useful in structural fabricating, PG 200 head. Current is 5 ma at
by drying rods in shipbuilding and machinery manu- all voltages. Duty cycle is 100°,
facture where long welds are in- continuous with water cooling, in-
volved in the manufacture of the termittent with air.
product. For details, circle No. 112 on
Reader Information Card.
DryRiod:
Cylinder Valve
OVEN
Less than 4° ;,-in., overall height,
this field-proved cylinder valve, has
been announced by Rego Division,
the Bastian-Blessing Co., 4201 W.
Peterson Ave., Chicago 46, Ill. Ex-
treme high efficiency is said to be
achieved through its low silhouette
body design. The original cost and
The carriage travels on a pair of shipping charges of this valve are
magnetized rollers. These rollers less than others because it is 20°,
prevent slipping and bouncing and lighter than valves of an older style.
yet move the trackless Squirtmobile
at speeds ranging from 7 to 70 ipm.
The magnetic force is great enough
to support the weight of the unit,
Mineral coated electrodes are ML-3 gun and cable assembly, for
thirsty. The instant you unpack out-of-position welding. ‘Trackless
them they start soaking up mois- travel along the inclined leg of a
ture .. . within 2 hours often as flat position fillet or the vertical
leg of a horizontal fillet is a simple
much as 13 times US allowable matter, and uphill travel is practical
specifications. Moist rods cause within the limitations of the sub-
porosity, under-bead cracking, merged-arc process, according to
rough welds, etc. Rod scrap runs the manufacturer.
high Production slows down. For details, circle No. 111 on
Reader Information Card.
Reworks eat up profits.
Storing rods in DRY -ROD
Two X-ray Units
OVEN prevents such losses, in-
sures faster, finer workmanship Two Norelco industrial X-ray The manufacturer reports that a
units (PG 140 and PG 200), de- longer, maintenance-free life is
at less cost. signed for minimum weight are insured by the nylon packing, and
available from Philips Electronic automatic take up which never re-
Write for new literature / Instruments, 750 S. Fulton Ave., quires adjustment. Thoroughly
on latest rod-drying Mount Vernon, N. Y. proved safety devices are offered
methods, “Dry Rod as
Standard Welding The units are reported as shock- for every rating and application.
Equipment.” proofed, rayproofed and weather- If desired, company symbol or name
proofed for outdoor operation. The may be embossed on the valve
PHOENIX PRODUCTS COMPANY two tube heads (140 and 200 kv, body.
4753 N. 27th St. * Milwaukee 9, Wis. respectively) are companion units For details, circle No. 113 on
For details circle No. 43 on Reader information Card and one control cabinet serves Reader Information Card.

668 | JUNE 1960

 June, 1960
READER INFORMATION CARD Cordvl oni! August31, 1960
Please send me, without cost or obligation, further ©
information and literature on items circled belows
76 101
77 102
78 103
7? 104
80 105
81 106
82 107
83 108
84 109
85
846 11}
87 112
88
89
90
91
92
93
O8
95
96
97
98
99
100

$$

Information

and >.

Literature...

PERMIT
NO.
9286
FIRST
CLASS

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 PERMIT
NO.
9266NEW
FIRST
CLASS YORK,
Y.
N. Acro Welder Mfg. Co.
Air Reduction Sales Co.
All-State Welding Alloys Co., Inc.
Alloy Rods Company
Aluminum Company of America
The American Brass Company
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 Welding
Research
SUPPLEMENT TO THE
The Science of Arc
Evaluation of the present knowledge
and the research man with basic concepts
relationship, distribution of field intensities
transfer, spatter, arc forces and motion, melting rate,
weld area, melting ratio and other related factors
BY CLARENCE E. JACKSON
Part I11*—What the Arc Does
So far in this discussion, the
physical characteristics of the tung-
sten-arc and consumable-electrode
arc-welding processes have been con-
sidered. In order to provide a basis
for a practical engineering approach
to the selection of welding tech-
niques, it will be useful to consider
the performance of the arc. In
projecting welding techniques for
any application, a number of funda-
mental measurements are required.
These essentially relate the effect of
welding current, voltage and speed of
CLARENCE E. JACKSON is Associate Man
ager, Electric Welding Department, at the De-
velopment Laboratory, Linde Co., Division of
Union Carbide Corp., Newark, N. J.
* Part I—Definition of Arc’’ and Part II
“Consumable-electrode Welding Arc’”’ appeared
on pages 129-s-140-s and 177-8-190-s, respectively
of the April and May 1960 issues of the WeLpING
JOURNAL Research Supplement
Sponsored
of the
WELDING JOURNAL,
Welding
provides the engineer
of volt-ampere
and temperatures,
travel on the performance of the
welding process.
Volume or Area of Weld
Metal Deposited
The fact that the melting rate of
an electrode is expressed in many
different units, sometimes is con-
fusing. Such units as pounds per
minute or hour, grams per second,
and inches per minute, appear to
be favored by individual workers.
It is suggested that a more practi-
cal designation for melting rate is
based on the volume deposited per
unit time (Fig. 25). This engineer-
ing designation is even more con-
venient when measurements of elec-
trode melting rates are taken in
inches per minute. The volume
of metal deposited per linear inch
is easily obtained by dividing the
t See page 178-s of May 1960 issue of WELDING
JOURNAL Research Supplement
WELDING
by e Welding Research Council
Engineering Foundation
JUNE 1960
1959 ADAMS LECTURE
metal
melting rate in cubic inches by the
speed of travel. It has been pointed
out by Wilson, et al.,* that in
consumable-electrode arc welding,
the total melting rate of the elec-
trode is the melting rate caused by
the arc to which is added the in-
crease in melting rate due to the
I°R heating of the length of elec-
trode that extends beyond the con-
tact tip. The melting rate has
also been found to be dependent
upon the electrode diameter in
both the inert-gas and submerged-
arc processes. In order to fill a
groove or to produce a fillet with a
given dimension, a definite volume
of weld metal per inch of length of
weld is required. In order to de-
posit this volume or cross-sectional
area of weld metal, the ratio of the
current to the speed of travel is
useful (Fig. 51). For a given
melting rate in pounds per minute,
the cross-sectional area of the
RESEARCH SUPPLEMENT | 225-s
deposited weld metal can be pre- which influence penetration for any weld, from a fundamental study, it is
dicted. given welding process indicates that assumed that penetration is the
current, voltage and travel are im- distance below the level of molten
Penetration
portant in the results which are ob- metal in the crater which the base
The penetration of a weld depos- metal is melted. Figure 52 shows
ited in a groove or on the surface tained. Of these three items, the
welding current is the most signifi- the combined effect of current,
of a plate is generally recognized welding voltage, speed of travel on
as the distance below the original cant, while the travel and voltage
penetration for a series of experi-
surface to which the molten metal are less important. In determining ments with covered electrodes. A
progresses. A study of the factors the penetration for any particular similar relationship is noted with
submerged-are welding and also
with inert-gas consumable-elec-
trode for mild steel; these results
3 shown in Figs. 53 and 54 indicate
the general application of the weld-
ing-technique performance factor.
In a series of tests using the sub-
] merged-arc process, the results re-
< ported by Hayashi** covering a
| ne
as wide range of welding conditions
f=) gave the relation shown in Fig.
Ww
= vo.
In applying empirical relation-
ships, the level of the crater is
WwW important. In many cases, the
a
penetration is roughly the pene-
ad tration below the surface of the plate
a
Ee
WwW — since the crater is essentially level
= nwun with the surface. The true arc
Qa length cannot be measured directly
J except when there is negligible
Ww
penetration because, although a
= . B./MIN./1000 AMP. projected image of the arc may be
uw B./MIN./1000 AMP.
o readily recorded, a fraction of the arc
B./MIN./ 1000 AMP
B./MIN./ |OOOAMP. may be below the plate level. It
e has been suggested by Needham
a + + ooo + and Smith, that the extension of the
+ + + be He +——+— + + THT arc below the plate may be nearly
.a equal to the penetration in etched
i; itil
©
88
Rs Lt Lif} i macrospecimens. Certainly the arc
50 100 200 500 1000 cannot extend beyond the fused
zone. Fusing of the plate material
by heat flow is limited by the steep
thermal gradient at the crater
Fig. 5l1—Area of weld metal deposited is determined by the ratio of periphery.
current (1) to the speed of travel (S) for any electrode melting rate Very few data have been reported
which show the effect of welding
technique on crater formation.
From a theoretical standpoint, the
force acting toward the crater will
be given by the following relation:

F = KI? log -

radius of arc at crater

radius of arc at electrode
= current, amperes
= constant
K- 0.00130 = force toward crater
RANGE OF WELDING CONDITIONS:
CURRENT (1),85 TO 350 AMPS From this it is seen that the force
TRAVEL (S), 6 TO 18 INCHES/MIN. at the crater will increase with an
VOLTAGE(E), 23 TO25 VOLTS
ELECTRODE DIAMETER 4 To Z In increase in current with a given
PENETRATION,
INCHES TYPE E-6015 ELECTRODE electrode or with a decrease in the
diameter of the electrode for a given
current. This suggests that pene-
joo 750 tration should increase with current
density; McElrath”? reports a series
3/14 WELDING TECHNIQUE of tests which substantiates this
ES PERFORMANCE FACTOR conclusion (Fig. 56). Such in-
Fig. 52—Effect of current, welding voltage and speed of travel on crease in penetration is more likely
penetration in the covered-electrode process accompanied by an increase in

226-s | JUNE 1960

Table 8—Comparison of Effect of Welding Technique on Melting Rate, Nugget Area,
Melting Ratio and Penetration; Both Measured and Calculated Values Are Shown
—NMelting rate-——
——Welding technique electrode Ib/min Nugget area, in —Melting ratio, % Penetration, in.
Amp Vv Measured Calculated Measured Calculated Measured Calculated Measured Calculated
290 12 09 51.0 55.4 12 0.18
800 42 18 60.7 73.2 39 0.42
900 49 65.5 71.0 ee
500 22 72.0 73.0 0.28
580 25 68.7 69.1 26 mr:
435 19 60.4 56.3 27
420 16 70.6 68.0 0.22
290 li 52.0 55.4
500 22 74.3 78.6
135 .04 eooooocooococo aooococo0coco
ecoooocoooococeo 46.0 31.2 Hh
ONE
WOCOPOW™

crater depth. Further investiga- the welding current. In a like Log A 0.903 log IC
tion is needed in order to study all manner, as the speed of travel is
the factors which control crater increased for a given current, this Where:
formation and the resulting pene- area will decrease. The area from
tration. many tests seems to be relatively ? z area of weld nugget, sq. in.
welding current, amp
unaffected by normal changes in the oa travel, ipm
Weld-metal Nugget Area welding voltage. The weld-metal
In any study of electric-arc area is controlled by the current and
welding, some indication of the total speed of travel used, and, for the Melting Ratio
quality of metal which is fused is data which are available, is related Wilson, et al..*° have suggested an
important. The quantity of base directly to the 1.716 power of the equation for the melting rate for a
metal fused, together with the current and inversely to the first steel electrode for the submerged-
electrode consumed, provides the power of the speed of travel as arc process as follows:
molten metal which, properly po- Ir
shown in Fig. 57 for the submerged- d? + 2.08
sitioned by the welding process, MR = 1000 |
must necessarily form the weld arc process. A_ similar relation-
joint. In the fused-metal area, ship also is applicable to the inert-
both the molten metal transferred gas consumable-electrode process
from the electrode and the quantity as shown in Fig. 58. An equation Where:
of base metal fused increases with for the data in Fig. 57 is as follows: MR = melting rate, lb/min

POLARITY
STRAIGHT REWERSE
°
INCHES e
imcnes 7

PENETRATION,
PEmETeaTion,

k= 0.00115
RANGE OF WELDING CONDITIONS
CURRENT (1), 350 TO 1200 AMPERES ac
TRAVEL (S), 5.7 TO $3.3 INCHES min.
VOLTAGE (E). 28 TO SS VOLTS
ELECTRODE DIAMETER 5/32 TO 1/8 ImCH
—— 20 GRADE UMIOMMELT, 12 = 200 MESH

i
300 400 0
3 x L*
se? 3 $E2
WELDING TECHMIQUE PERFORMARCE FACTOR WELDING TECHMIQUE PERFORMANCE FACTOR
Fig. 53—Effect of welding technique on penetration in the Fig. 54—Effect of technique on penetration in the inert-gas
submerged-arc process consumable-electrode process

WELDING RESEARCH SUPPLEMENT | 227-s

 8 3

PENETRATION~INCH ° & ra) on . -

PLATE THICKNESS -7/16 IN.
WELDING CURRENT — 300 AMP. DCRP
WELDING VOLTAGE — 25 VOLTS
Ye WELDING SPEED— 15 IN. PER. MIN.
PENETRATION
BELOW
SURFACE
IN.
- °
10 30 50 70 90 10 130 150 170

CURRENT DENSITY
- THOUSAND AMP PER. SQ IN.
a
se? WITH 3/6, '4, 342, Vie and 344 IN. ROD DIAMETERS
WELDING TECHNIQUE PERFORMANCE FACTOR
Fig. 55—Penetration for submerged-arc Fig. 56—Penetration vs. current density”
welding

d = electrode diameter, in.

I = current, amp
L = electrode extension, in.
It is now possible to estimate the
ratio of the volume of the base
metal melted to total weld metal
melted for a range of welding tech-
niques. The results of such a cal-
culation are compared with actual
measurements for a series of sub-
merged-arc welding tests in Table 8;
the agreement is reasonable.
Heat Effect of Weld Nugget
The electric-arc welding process
fuses a volume of weld metal. In
order to produce this volume of
weld metal, energy is consumed.
From studies of the energy distri-
bution in electric-arc welding, it
has been pointed out that improved
efficiency of energy utilization is
expected with higher currents and
higher speeds. The weld-nugget
area increases at a rate faster than
the first power of current. In weld-
ing literature, the total energy in-
put is often expressed as joules per
linear inch. In these days of in-
creased use of automatic welding
processes, with higher speeds and
higher-strength steels, it is impor-
tant to recognize that comparisons
based on total energy may not be
applicable** and that the factors
affecting the energy distribution
must be considered.
In order to determine the ef-
fect of current and travel on the
weld-metal nugget area, fifteen welds
were deposited using the submerged-
arc process on the surface of a
steel plate (A212). These surface
beads were deposited with currents
from 135 to 800 amp with the
travel adjusted to give an energy
input of 45,000 joules per linear
inch. The area of cross section
taken from these welds ranged from
0.044 to 0.186 sq in., Table 9.
Two cross sections are shown in
Fig. 59. The maximum cooling

EQUATION OF LIWE -£
LOG A= 0.903 LOG FI 1.716 )- 3.95 + ——>—+4
|
4
SUBMERGED- ARC

POLARITY
STRAIGHT REVERSE
° e
2 a
c
RATIO
CURRENT
WELDING
OF
1.716
THE
TO
|SPEED
POWER
TRAVEL
($)
Ms
0.10 -O1 +02 08
-06 .08 .10 -20
NUGGET AREA, (A) SQUARE INCHES MUGGET AREA, SQUARE INCHES
Fig. 57—Effect of current and speed of travel on nugget area Fig. 58—Effect of technique on nugget area with inert-gas
in the submerged-arc process consumable-electrode arc welding

228-s | JUNE 1960

Table 9—Effect of Welding Technique on Nugget Area
Energy input,
-Welding technique joules per Nugget area, sq in.
Amp Vv Ipm linear inch Actual Calculated
290 26 ,290 084 0.092
435 26 ,000 115 149
580 26 ,000 160 143
580 26 ,000 . 165 143
500 30 , 800 . 138 .143
420 36 , 100 102 087
503 30 ,000 117 143
580 26 ,000 .143 143
580 26 ,000 143 ).143
800 26 ,500 . 186 178
800 26 >bee
ee , 900 185 ).178
800 26 — 5,500 173 178
290 26 ,400 .087 092
135 26 ™~ , 800 .044 0.059

rate in the heat-affected zone is a fair understanding exists of the fac-

determined by the volume of mol-
ten metal in the weld bead; the
hardness in the heat-affected zone
for any steel is controlled by this
cooling rate. As shown in Fig. 60,
the maximum hardness in the heat-
affected zone decreases as the nug-
get area increases even though the
power input in joules per linear
inch is constant.
Data are gradually being accumu-
lated covering the performance of
the various factors which may be
controlled in the application of any
arc-welding process. The welding
engineer is now able to go to the
drawing board and establish ap-
proximate welding techniques for
initial tests and further predict
the effects of specified changes in
welding conditions.
tors which control the melting rate of
the electrode, there is need for
further data in order to provide
engineering scope over the entire Fig. 59—(a) Weld deposited using 800
field. The techniques which are amp, 26 v and 27.4-ipm travel at 45,500
joules per linear inch, (b) weld deposited
available for studying the spatial using 135 amp, 26 v and 4.7-ipm travel at
relation in the submerged-arc proc- 44,800 joules per linear inch P
ess will be useful in systematically
investigating the effects of current 600
density, electrode diameters, flux
compositions and other factors.
The new processes using carbon
dioxide have not been studied from
a fundamental standpoint.
The welding fraternity is ap-
proaching a clear-cut scientific un-
derstanding of the many factors
which control arc welding. Many
investigators have contributed;
many investigators will continue to
contribute.

Discussion
Useful concepts for the engi-
neering application of the welding
arc have been proposed. The melt-
ing rate of an electrode depends
upon the electrode diameter, ex-
tension and current level. Pene-
tration below the level of the crater
increases with current and decreases
with speed of travel and welding
voltage. The effect of welding tech-
nique on melting ratio and nugget
area has been pointed out.
Because of the fact that the
consumable-electrode arc-welding
processes include such a wide range
of conditions, many questions re-
main to be answered, in spite of the
extensive investigations reported.
There is need for a more compre-
hensive study of crater mechanics.
The factors which control the solid-
ification pattern of the molten
weld metal will aid in understanding
such phenomena as undercutting and
molten-metal viscosity. Although
Closure
Engineering knowledge starts with
the accumulation of empirical data,
which to begin with, can only be
qualitative. As new approaches HARDNESS
MAXIMUM
ZONE
INHEAT-AFFECTED
-KNOOP
are used, and especially when new
methods of measurements or new I
techniques for studying the phenom- % 05 10 5 20 25
ena become available, these quali- NUGGET AREA- IN?
tative data gradually develop into
quantitative data which serve as a Fig. 60—The maximum hardness in the
basis for the theoretical analysis of heat-affected zone decreases as the
the phenomena which we are study- nugget area increases even though all
deposited with approximately 45,000
ing. Only when the engineering joules per linear inch
data become quantitive, can we
deal with the why and wherefore
of the field. A special plea is made
for a broadening of the range of
arc-welding data which are studied; gas-shielded tungsten-arc process.
often a small amount of data taken Considerable data have been pre-
in order to extrapolate restricted sented for the consumable-elec-
data will establish trends, and will trode processes, although these are
be useful in developing a pattern. more complicated and will require
The physical description of the ingenious approaches in future in-
arc-welding zone is rapidly becoming vestigations. The _ relationships
more exact, particular for the inert- which exist for the inert-gas and

WELDING RESEARCH SUPPLEMENT | 229-s

submerged-arc consumable-elec-
trode arc-welding processes will
be useful in developing new tech-
niques for applications using modern
materials.
It is hoped that this presentation
will stimulate investigation in some
of the fields where the data are
meager. Although a good practical
understanding exists, there are large
areas which will require further
attention. As new welding proc-
esses are introduced, new basic prob-
lems will be raised. Although many
welding engineers have a sound
intuitive approach to welding prob-
lems, as more basic data become
available, welding engineering will
continue to grow into an exact
science—that engineering ‘“‘science
of welding’ envisioned by Dr.
Adams.
References
53. Hayashi, K., Private communication, 1953
4. Jackson, C. E., and Goodwin, W. J.,
‘Effect of Variations in Welding Technique on the
Transition Behavior of Welded Specimens,”
Part Il, THe WeLpInG JouRNAL, 27 (5), Research
Suppl., 234-s to 266-s (1948)
55. Alexander, P., ““The Abridgement of the
Stability of the Welding Arc,”’ -/. Am. Inst. Elec
Engrs., 47, 109-112, February 1928
56. Benner, R. H., and Jones, T. B., “‘Atmos-
pheric Water Vapor Effects on D-C Arc Electrode
Burn-Off Rates,” THe WeLpInG JouRNAL, 36
0), Research Suppl., 263-s to 264-s (1957).
57. Boulton, N. S., and Martin, H. E. L.,
“Temperature Distribution During Welding,”
Proc. Inst. Mech. Engrs., 133, 295-339, 1936.
58. Breymeier, R. T., “‘Metal Transfer in
Sigma Welding,”” THe Wetpinc JourNaL, 31
5), 393-399 (1952).
59. Busz-Peuckert, G., and Finkelnburg, W.,
“On Anode Mechanisms of Thermal Argon
Ares,” Z. Physik, 144, 244-251, 1956.
60. d’Herbemont, G., “‘Deep Penetration Weld-
ing with Covered Electrodes,”’ Soudage et Tech-
niques Connexes, Vol. 12, pp. 15-20, January-
February 1958
61. Fett, G. H., “Cathode Drop of an Arc,”
Welding Journal, Vol. 21, pp. 27s-29s, January
1942
62. Gaubert, A., ““Deep Penetration Welding
with Covered Electrodes,”” Soudage et Techniques
Connexes, 12, 5-14, January-February 1958.
63. Gunnert, R., “Penetration and Travel
Speed in Metal-Arc Welding,”” AMERICAN WELD-
Inc Society JOURNAL, 27 (1), 542 (1935)
64. Hazlett, T. H., “Coating Ingredients”
Influence on Surface Tension, Arc Stability and
Bead Shape,” THe WELDING JouRNAL, 36 (1),
Research Suppl., 18-s to 22-s (1957).
65. Helmbrecht, W. H., and Oyler, G. W.,
“Shielding Gases for Inert-Gas Welding,” Tue
WELDING JOURNAL, 36 (10), 969-979 (1957).
66. Hull, W. G., and Needham, J. C., “‘Self-
Adjusting Arc and Controlled-Arc Welding
Processes,”"" Welding Research, 7, 80-95, August
1953
67. Jackson, C. E., and Shrubsall, A. E., ““Con-
trol of Penetration and Melting Ratio with Weld-
ing Technique,” THE WELDING JOURNAL, 32 (4),
Research Suppl., 172-s to 178-s (1953)
68. Jones, T. B., Kouwenhoven, W. B., and
Skolnik, M., “Heat Effects in Anode Spots of
High-Current Arcs,”’ Jbid., 28 (10), Research
Suppl., 461-s to 465-s (1949)
69. Keller, R. J., and Koss, J., ““The Carbon-
Dioxide-Shielded Metal-Arc Welding Process,’’
Ibid., 35 (2), 145-151 (1956).
70. Larson, L. J., “‘Metal Transfer in the Metal-
lic Arc,”’ Jbid., 21 (2), Research Suppl., 107-s to
112-s (1942)
71. Needham, J. C., The Transfer of Material,
Temperature and Stability in the Electric Welding
Arc, British Welding Association Report R27,
London, 1946
72. Needham, J. C., and Smith, A. A., “Arc
and Bead Characteristics of the Aluminum Self-
Adjusting Arc,” British Welding Journal, 5, 66-76,
1958
73. Orton, L. H., and Needham, J. C., Micro-
second Phenomena in the Steel Welding Arc, Elec-
trical Research Association Report Z/T79, Lon-
don, 1949
74. Paschkis, V., “Establishment of Cooling
Curves of Welds by Means of Electrical Analogy.”’
THe Wetpinc JouRNAL, 22 (10), Research
Suppl, 462-s to 483-s (1943).
75. Richter, K. E., and Essig, J. F. M., “Con
sumable-Electrode Inert-Gas Welding with
Small-Diameter Wires,” Ibid., 36 (9), 893-899
1957
76. Rosenthal, D., and Schmerber, R., ““Ther
mal Study of Are Welding Experimental Verifica
tion of Theoretical Formulas,”’ /bid., 17 (4), Re-
search Suppl., 2-8 to 8-s (1938)
77. Rothschild, G = *“Carbon-Dioxide-
Shielded Consumable-Electrode Arc Welding,”
Ibid., 35 (1), 19-29 (1956
78. Spraragen, W., and Claussen, G. E.,
“Temperature Distribution During Welding, a
Review of the Literature to January 1, 1937,”"
Ibid., 16 (9), Research Suppl., 4-¢ to 10-8 (1937
79. Von Conrady, H., ““The Transfer of Ma-
terial in the Welding Arc,”’ Elektroschweissung, 11,
109-114, 1940
80. Wienecke, R., ‘‘Concerning Physical Proc-
esses in Electric Arcs,’ Schweissen und Schneiden,
9, 428-434, September 1957

A Request for Corrosion Complaints Involving 316L Weld Metal

Service exposure of Type 316L stainless steel, in the as-welded condition, seems to
lead to weld corrosion under a variety of conditions. Too little information has been
published to permit prediction of this attack.
The WRC High Alloys Subcommittee investigating this subject are soliciting information
about any such experience which the readers of this journal can report. A post card to
1500 S. 50th St., Philadelphia 43, Pa., will initiate the correspondence necessary to ex-
plore the conditions under which the weld corrosion occurred.

230-s | JUNE 1960

 Effect of Elevated-Temperature
Heavy-Section Pressure-Vessel
PVRC-sponsored investigation
of aging at room temperature,
of carbon and alloy pressure-vessel
Sy A. W. PENSE, J. H. GROSS
ABSTRACT. Previous PVRC _investi-
gations have indicated the suitability
of high-strength steels for pressure-
vessel applications in conventional
thicknesses and also in heavy sections,
particularly if the heavy sections are
spray-quenched and _stress-relieved.
However, concern has been expressed
regarding the effect of extended expo-
sure at elevated temperatures on the
mechanical properties of heavy-section
pressure-vessel steels in applications
such as power boilers and nuclear and
chemical reactors.
The present investigation describes
the effect of exposure at room tempera-
ture, 500, and 700° F for times up
to 16,000 hr on the tensile properties
and the notch ductility of simulated
spray-quenched and normalized heavy-
section pressure-vessel steels.
The results of the study indicate
that no. significant embrittlement
(greater than 25° F increase in transi-
tion temperature) occurred in any of
the steels after aging at room tempera-
ture or 500° F for times up to 16,000 hr.
After aging at 700° F, certain alloy
steels (T-1, HY80, HY65 and A203
exhibited an embrittlement of 40 to
100° F increase in the transition tem-
perature. The maximum embrittle-
ment, which occurred at about 8000
hr at 700° F, appeared to be inde-
pendent of the condition of the steel
spray-quenched or normalized and
stress-relieved or stress-relieved,
strained and restress-relieved. After
16,000 hr at 700° F the stress-relieved
steels showed the same embrittlement
as after 8000 hr, whereas the strained
and restress-relieved specimens exhib-
ited a tendency to recover from the
maximum embrittlement. The 700
F embrittlement was accompanied by
a corresponding increase in the tensile
strength.
The results obtained did not suggest
A. W. PENSE, J. H. GROSS and R. D. STOUT
are associated with the Department of Metallur-
gical Engineering, Lehigh University, Bethlehem,
Pa
Paper presented at AWS 4ist Annual Meeting
held in Los Angeles, Calif., April 25-29, 1960
Exposure
Steels
describes the effect
500 and 700° F on the embrittlement
steels
AND R. D. STOUT
a specific mechanism by which the em-
brittlement occurs. However, only the
steels containing nickel were observed
to embrittle.
Introduction
During the past ten years, the
Pressure Vessel Research Committee
has sponsored investigations to de-
termine the suitability of high-
strength steels for pressure-vessel
construction. The interest in high-
strength steels stems from the in-
creased pressure and temperature
requirements for modern pressure-
vessel applications and the problems
encountered in meeting these re-
quirements with conventional car-
bon-steel plate materials. Initial
studies' on selected - and 1-
in. thick high-strength steels indi-
cated that the plastic fatigue
strength, room and elevated-tem-
perature tensile strength and notch
toughness were superior to the cor-
responding properties of the carbon
steels, and that the ductility and
weldability were only slightly re-
duced. Similar results were also
obtained in a comparison‘ of 4-in.
thick carbon- and _ high-strength
steels. A subsequent investigation
indicated that a further improve-
ment in mechanical properties of the
4-in. thick high-strength steels was
obtained by accelerated cooling
spray quenching—providing a stress-
relieving treatment followed the
spray quenching. The most recent
study® showed that the _ spray-
quenched steels exhibited about the
same susceptibility to embrittle-
ment from cold-forming, cold-form-
ing and aging and extended stress-
relieving as the conventionally
treated steels. Thus, the superiority
of the spray-quenched steels should
be retained after normal fabrication
operations.
The preceding studies demon-
WELDING
on
strated the general suitability of
high-strength steels, spray-quenched
and conventionally treated, for am-
bient-temperature pressure-vessel
applications. However, boilers,
chemical pressure vessels and
nuclear-reaction pressure vessels
commonly operate at elevated tem-
peratures for extended periods of
time. At present, little or no in-
formation is available on the effect
of extended elevated-temperature
exposure on the mechanical proper-
ties of heavy-section steels, par-
ticularly on heavy-section high-
strength steels in the spray-
quenched condition. Of particular
interest are changes in the tensile
properties that might affect con-
tinued operation at elevated tem-
peratures and changes in notch
toughness that may influence safety
during shut-down operations. ‘The
present investigation extends the
available information on extended
exposure at room temperature, 500
and 700° F on the tensile properties
and notch ductility of these steels
in the spray-quenched and in the
normalized condition.
Experimental Procedure
The experimental procedure con-
sisted of exposing two carbon steels
A285 and A212) and seven alloy
high-strength steels (48s5, A302,
A203, HY65, A387, HY80, and T-1)
to elevated temperatures of 500 and
700° F for periods of 2000, 8000,
and 16,000 hr. The steels were ex-
posed as -in. thick plates which
were either oil quenched (to simu-
late the microstructure near the
surface of a spray-quenched 4-in.
thick plate) and stress relieved at
the recommended §stress-relieving
temperatures, or were cooled in a
foil-lined box (to simulate the micro-
structure of a normalized 4-in. thick
plate) and stress relieved. Addi-
RESEARCH SUPPLEMENT 231-s
Table 1—Chemical Analysis (%) and Heat-treating Temperatures
Stress re-
Austenitiz- lief or tem-
ing tem- pering
perature, tempera-
Steel Grade*® C Mn P S uel ture, ° F
ASTM A285 C . 0.53 0.020 0.016 1650 1150
48s5 HT , 1.09 0.033 0.028 1650 1150
ASTM A212 B : 0.70 0.010 0.021 1650 1150
ASTM A203. D , 0.64 0.010 0.026 1650 1150
HY 65 , 0.48 0.013 0.032 1750 1200
ASTM A302 B ; 1.32 0.022 0.030 1650 1150
ASTM A387. _D .09 0.44 0.013 0.011 oe 1700 1350
- 0.93 0.015 0.022 0.0031 1700 1200
0.28 0.016 0.015 eceoooooco$n.
KPNMMNMMYNRe!
SOO
NY
AHeE
OI 1650 1150
@ All steels were firebox quality where applicable.

tional specimens of all steels in the
same two base conditions were
strained 5% after heat treatment,
restress relieved and then exposed
at 500 and 700° F. Specimens of
each steel were also prepared in the
base conditions, strained 5% and ex-
posed at room temperature for
1, 13, 26, 52 and 104 weeks (168,
2184, 4368, 8736 and 17,472 hr).
Following exposure, the tensile
properties and notch ductility of the
steels were evaluated. Standard
0.252 - inch - diameter tension - test
specimens cut parallel to the rolling
direction of the plate and Charpy
V-notch impact specimens cut par-
allel to the rolling direction and
notched transversely to the surface
of the plate were prepared from each
test plate. The chemical composition
and the temperatures of heat treat-
Spray -quenched , Stress-relieved
Strained 5%
- 200+
oO L a387 -©
Bea
i unoO
oO
\5-
Charpy
Mil
Transtion
Notch
Temperature
-F
+ on2)
A.
4000 8000 12000
Aging Time At Room Temperature - Hours
Fig. 1—Effect of room-temperature aging on the notch toughness of spray-quenched
and normalized pressure-vessel steels after 5% plastic strain
ment for each steel are given in Table Figure 1 shows the transition
o temperatures of the spray-quenched
and stress-relieved and the normal-
Experimental Results ized and stress-relieved steels after
and Discussion 5° plastic strain and aging at room
The tensile properties—yield and temperature for periods of one week
tensile strength, elongation and re- to two years. The results indicate
duction of area—and the impact that there is little or no tendency
properties—transition temperature for these steels to strain age at room
based on 15 ft-lb, 15 mil and 50° temperature for times up to two
fibrous fracture—for the nine steels years. Since the spray-quenched
in their various conditions of pro- as well as the normalized steels were
longed exposure at room tempera- insensitive to the room-temperature
ture, 500 and 700° F are presented aging treatment, any initial superi-
in complete tabular form in WRC ority in notch ductility for the
Reports of Progress, June issue. To spray-quenched steels was retained
allow a convenient comparison of after the aging treatment.
the effect of the aging treatments on
the nine steels, the impact properties The effect of aging at 500° F for
and selected tensile properties are times up to 16,000 hr on the notch
presented graphically in Figs. 1 ductility of the normalized and
through 8. stress-relieved steels is presented in
Fig. 2. Also shown is the effect
of the 500° F aging on the steels in
the stress-relieved, strained 5° and
restress-relieved condition. For the
Normalized, Stress-relieved most part, the changes in transition
Strained 5% temperature after the various aging
times are within 25° F of the value
prior to aging. The observed
A203, ~/\oO changes in notch toughness are not
considered significant since they are
typical of the scatter commonly
encountered in transition-tempera-
ture determinations. Figure 3 illus-
trates the effect of the 500° F aging
treatment on the notch ductility of
the spray-quenched steels. The re-
SS. sults are similar to those presented
yp in Fig. 2 and confirm the observa-
a eo
EBs __ 4885 __— tion that these steels in the stress-
<6 —q— — relieved condition or in the stress-
relieved, strained and restress-re-
lieved condition are not significantly
embrittled by exposure at 500° F
a p22 ——& for times up to 16,000 hr (approxi-
4285 mately two years).
U
4 A i l After aging at 700° F, the carbon
6000 O 4000 8000 12000 16000 steels and certain of the alloy steels
(4885, A302 and A387) again ex-
hibited no significant susceptibility
to embrittlement as illustrated in

232-s | JUNE 1960

 Figs. 4 and 5 for the same conditions reported in fully hardened alloy tion of the chemical composition
as the 500° aging. However, the steels of the type studied in this of the four alloy steels that exhibited
other alloy steels (HY65, T-1, HY80 program but usually at higher car- embrittlement after aging at 700° F
and A203) showed a _ substantial bon contents, Jaffe’s interpretive reveals that nickel is the only ele-
embrittlement in all conditions report’ indicates that essentially no ment common to these four steels
spray-quenched or normalized and information is available on time- and not present in the other five
stress-relieved or _ stress-relieved, temperature embrittlement of pres- steels. The role that nickel may
strained and restress-relieved. In sure-vessel steels, particularly in the play, if any, in the observed embrit-
general, the steels in all conditions unhardened condition. Examina- tlement is not clear. For example,
exhibited significant embrittlement
after 2000 hr at 700° F and reached
a maximum by 8000 hr at 700° F.
Although the maximum embrittle- 1
ment varied for the four steels (40 to i Normalized, Stress-relieve Normalized,Stress-relieved
100° F increase in the 15-mil Charpy Strained 5%, Restress-relieved
V-notch transition temperature) the + oO
condition of the steel had no appreci-
able effect on the general pattern of emperature
embrittlement or the maximum +
embrittlement. One exception to
this observation is the tendency for
Transition
the stress-relieved, strained and
restress-relieved material to recover
some notch ductility between 8000
and 16,000 hr, whereas the stress- Niytch
V
relieved material exhibited about n an
the same embrittlement after 8000
and 16,000 hr at 700° F.
Figure 6 reveals that the increase MilCharpy
in transition temperature for the
four embrittled steels was accom-
panied by a proportionate increase
in the tensile strength. Examina- hange
if
tion of the data obtained also shows
that the yield strength increased and a 7 ee e
the elongation and reduction of area 16000 = fo (O00
decreased as the embrittlement at yng Time = at = SO0°F - Hours
700° F increased. The increase in Fig. 2—Effect of aging at 500° F on the notch toughness of normalized pressure-vessel
tensile strength with embrittlement steels in the stress-relieved con dilions and in the stress-relieved, strained and
is great enough so that the embrittle- restress-relieved condition
ment could probably be detected
by hardness measurements. This
behavior is interesting because many
embrittling phenomena cannot be
detected readily by changes in Sproy-quenched, Stress-relieved Spray-quenched , Stress-relieved
tensile properties. Strained 5% , Restress-relieved
In spite of the embrittlement ob-
served in four of the alloy steels,
all of the alloy steels, except HY65,
exhibited better notch toughness
than the carbon steels in all condi-
tions including exposure at 700° F.
This behavior is illustrated in Fig. 7
for the stress-relieved condition
and in Fig. 8 for the stress-relieved,
strained and restress-relieved condi-
tion. These graphs again show that
the maximum embrittlement (cross-
hatched part) after aging at 700° F
varies with the steels but is essen-
tially independent of the treatment
imposed upon the steels.
The results obtained to date have
not indicated any specific mecha- Change
I5-Mil
Transition
V-Notch
Charpy
Temperature
°F
in
nism by which the embrittlement
occurs. Limited additional studies
at higher aging temperatures suggest
that the 700° F embrittlement may Aging Time At 500°F -Hours
be an extension of temper embrittle- Fig. 3—Effect of aging at 500° F on the notch toughness of spray-quenched pressure-
ment to lower temperatures. A\l- vessel steels in the stress-relieved condition and in the stress-relieved, strained and
though embrittlement has _ been restress-relieved condition

WELDING RESEARCH SUPPLEMENT | 233-s

 4en"S j www seu"

the nonnickel-bearing steels may Summary resulted in no additional

exhibit embrittlement at a slightly embrittlement.
The results of the present investi-
higher aging temperature. Thus, Exposure at 500° F for
gation on the effect of aging at room
the effect of nickel could be related times up to 16,000 hr pro-
temperature, 500 and 700° F on the
to a lowering of the embrittling duced no significant em-
embrittlement of carbon and alloy
temperature in the same way nickel brittlement for any of the
pressure-vessel steels may be sum-
lowers the critical temperature. steels in any condition.
marized as follows:
This and similar approaches to the Exposure at 700° F re-
cause and elimination of the ob- 1. Effect of temperature and time. sulted in embrittlement as
served embrittlement are currently (a) Prolonged aging at room great as 100° F increase in
under study. temperature after straining transition temperature for
certain alloy steels.
At 700° F the maximum
+125 embrittlement occurred at
w° Normalized, Stress-relieved Normalized, Stress-relieved about 8000-hr exposure.
' Strained 5%,Restress-relieved Beyond 8000-hr exposure
no additional embrittle-
° fe ment was observed and the
strained and _restress-re-
4e lieved condition tended to
+ ~“ co] ie
| + recover.
d a 2. Effect of heat treatment and
—5 i | cold work.
+ uo (2) / ©i a) After stress relieving, the
c—
2(2) | / _ - spray-quenched steels ex-
2; hibited about the same
> + le eo gy " e
™m oO sensitivity to embrittle-
a=> ment as the normalized
°] |/O< \ pa
©£ // >_> n2i2 steels. Therefore, any in-
Ca oso itial superiority in notch
= toughness for the spray-
© \@ 4885 >= 2 quenched steels over the
¢ . —s normalized steels was re-
@ ' ay)uw tained after exposure.
o>
=o The maximum embrittle-
ment at 700° F exhibited
uw > j | by steels in the strained
4000 8000 _= [2000 4000
16000 © 8000 12000 16000
and restress-relieved condi-
Aging Time at
700°F - Hours tion was essentially the
Fig. 4—Effect of aging at 700° F on the notch toughness of normalized pressure- same as in the stress-
vessel steels in the stress-relieved condition and in the stress-relieved, strained and relieved condition. How-
restress-relieved condition ever, steels in the strained
and restress-relieved condi-
tion showed a greater ten-
Spray-quenched,Stress-relieved Spray-quenched,Stress-relieved, dency to recover from the
Strained 5%,Restress-relieved embrittlement.
——203. A. Effect of steel composition.
r c / 4 a) The carbon steels and cer-
/ <03
tain alloy steels were not
significantly embrittled by
n
any of the exposure treat-
ments.
Only the alloy steels con-
+ wnJ taining nickel exhibited
embrittlement greater than
30° F increase in the tran-
nD On sition temperature.
The embrittlement of the alloy
steels at 700° F was accompanied
by a proportional increase in the
tensile strength.
The specific mechanism of em-
Temperature
Charpy
|5-Mil
Transition
change
V-Notch
in brittlement that resulted from aging
at 700° F was not established.
However, limited additional studies
indicate a similarity to temper em-
4000 8000 200C 600C 0 G00 000 12000 16000 brittlement.
Aging at 700°F - Hours
Acknowledgment
Fig. 5—Effect of aging at 700° F on the notch toughness of spray-quenched pressure-
vessel steels in the stress-relieved condition and in stress-relieved, strained and The investigation reported herein
restress-relieved condition was sponsored by the Materials

234-s | JUNE 1960

 Stress-relieved,
Aged 7O00°F

G Unembrittled Value
| | -Embrittled Value
=
ve) O
Transition
Temperature-°F S- Spray -quenched
N- Normalized
Z

V-Notch

LLLLMALMLL
LL
YY,
V1
Fig. 6—Increase in tensile strength Z
accompanying 700° F embrittlement of
certain pressure-vessel steels 5-Mil
Charpy
sin

+100L 285] |azi2| |48s5| |az02 sq) |HY65|

Division of the Pressure Vessel Fig. 7—Maximum embrittlement exhibited by spray-quenched and normalized
Research Committee and guided pressure-vessel steels in the stress-relieved condition after aging at 700° F
by the Subcommittee on Research
on High-Strength Steels, F. Eberle, 200
Chairman. The authors are _ in- Stress-relieved ,Strained 5%, Restress-relieved,
Aged 700°F
debted to PVRC for support of the
investigation and to the subcom- SASASS
mittee for direction and encou’age- ao O 77a Unemorittied Vaiue f
ment. SA |
<4..-Embrittled Value || a
| Xx Z
References
1. Gross, J. H., and Stout Eee The ro)O SSS
aes
Performance of High-Strength Pressure-Veasel S- Spray-quenched
Steels,’ THE Wetpinc JOURNAL. 35 (3), Research
Suppl. 115-s to 119-s (1956 N -Normalized — hhh
2. Bunk, A. P., “Welding Procedure Qualifica hh
heheheh
tion Tests for Six High-Yield-Strength Steels
Ibid., 34 (4 Research Suppl., 197-s to 206-s
1955). WL:
3. Kooistra, L. F., “Effect of Plastic Fatigueon J/
Pressure-Vessel Materials and Design,”’ Jhid CL.
36 (3), Research Suppl., 121-6 to 130-8 (195
4. Gross, J. H.. and Stout, R. D., “Properties ©
and «=Weldability of High-Strength Pressure 4
Vessel Steels in Heavy Sections,’ Jbid., 36 SS / LLL
7—""
» MMMM.
Research Suppl., 157-s to 167-8 (1957 » fe me
5. Gross, J. H., Kottcamp, E. H., and Stout
R. D., “Effect of Heat Treatment on the Micro + ul 2)
structure and Low-Temperature Properties of ISIN |S <<“
—' ! ' ' | SIN
Pressure-Vessel Steels,”’ Jbid.. 37 (4), Research | |
Suppl., 160-s to 168-s (1958 °F
-
IS-Mil
Temperature
Transition
V-Notch
Charpy
6. Rubin, A. L., Gross, J. H., and Stout, R. D |A387} bn | i465) |a203
“Effect of Heat Treatment and Fabrication +100
on Heavy-Section Pressure- Vessel Steels,”’ [bid
38 (4), Research Suppl., 182-s to 187-s (1959 Fig. 8—Maximum embrittlement exhibited by spray-quenched and normalized
Jaffe, L. D., “Temper Brittleness of Pres
sure- Vessel Steels,”’ Ibid., 34 (3), Research Suppl., pressure-vessel steels in the stress-relieved, strained and restress-relieved condition
141-8 to 150-s (1955) after aging at 700° F

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FOR are invited to send for a free copy of the booklet “‘Instructions and Suggestions
for Authors.”’ All requests should be addressed to Editor, WELDING JOURNAL,
PROSPECTIVE
American Welding Society, 33 W. 39th St., New York 18, N. Y
AUTHORS

WELDING RESEARCH SUPPLEMENT | 235-s

Weld Metals in Nickel-Base Alloys

Laboratory investigation indicates that sound welds

in these alloys tend to have good strength, ductility and

toughness at normal and low temperatures. Best results are

secured from argon-shielded Ni-Cr-Fe-Cb type welds

BY J. HEUSCHKEL

Introduction
Nickel-base alloy structures are
being fabricated by welding, al-
though such alloys were not origi-
nally designed for that specific mode
of joining. The resulting products
are widely used in industry for cor-
rosion-resistant and elevated-tem-
perature applications. Some poros-
ity or cracking may occur during the
welding operations.'~* The welds
contain from 64 to 97% nickel;
that is, pure-nickel weld metals are
not used commercially. All but the
Ni-Ti type alloy compositions are
nonmagnetic. No suitable pub-
lished data exist on the elevated-
temperature properties of these weld
metals to serve as a guide in de-
fining the regions wherein they are
weak and /or brittle.
Within the nuclear-power in-
dustry there has been a recent tend-
ency to shift, or to consider shift-
ing, from the use of AISI 300 aus-
tenitic stainless steels to such nickel-
base alloys as the Ni-Cr-Fe type,
largely because of expected im-
proved resistance to stress-corrosion
cracking. Following the marginal
difficulties already experienced in
the welding of some of the AISI
300 series of commercially available
austenitic stainless steels,‘~* it is
appropriate that the temperature
effects on the properties of sound,
nickel-base alloy weld metals be
firmly established. Such _infor-
mation provides a basis for judging
the susceptibility to hot cracking
during welding, subsequent heat
treatments and service. It also
provides further perspective on the
J. HEUSCHKEL is Consulting Welding En-
i Westinghouse Research Laboratories,
Pittsburgh 35, Pa.
Paper presented at the AWS National Fall
Meeting held in Detroit, Mich., Sept. 28-Oct. 1,
1959.
general problem of hot brittleness
in metals. Accordingly, tests were
conducted on all-weld-metal tensile
specimens in the as-deposited con-
dition, made with existing nickel-
titanium, nickel-chromium-iron-
columbium, _ nickel-chromium-iron-
titanium and nickel-copper type
electrodes.
The deposits contain nickel,
chromium, iron, copper, titanium,
columbium (= niobium), tantalum,
manganese, silicon, molybdenum,
carbon and/or aluminum.'~
Sound welds, in these alloys, tend
to have good strength, ductility and
toughness at normal and low tem-
peratures. They also tend to have
low ductility, as little as 4% total
elongation, across a_ several-hun-
dred-degree temperature range,
which varies with alloy type, from
1200 to 2200° F. In these alloy
systems, the conditions are once
more encountered where marginal
success in welding operations may be
experienced because of the inherent
characteristics of the metals.
Knowing these characteristics, how-
ever, permits a more rational ap-
proach to the selection of composi-
tion limits, joint designs, welding
procedures and heat treatments for
particular service conditions. Best
results were secured from argon-
shielded Ni-Cr-Fe-Cb type welds,
where a minimum total elongation of
34% was secured.
Experimental Objectives
The tests described were con-
ducted to provide basic technical
and engineering information on
the compositions, short-time tensile
properties, microstructures and hard-
nesses of as-deposited weld metals,
and to observe how those properties
are altered by temperature. It is
recognized that designers need other
information but as a guide for re-
commendations in welded appli-
cations, it was first necessary to
determine if brittle ranges exist and,
if so, to define those ranges.
Except for welds in the Ni-Cr-
Fe-Ti type alloy, conventional 25-
degree included-angle, U-grooved,
unrestrained, flat butt joints were
made, double thickness bars being
used as an expedient because the ° /;-
in. thick stock desired was not
readily available. Ni-Cr-Fe-Ti type
alloy flats were not available in any
thickness and longitudinally U-
grooved pipe was used for making
these welds. Test welds in this
case were, therefore, subject to more
restraint during initial cool-down
than those in the other alloy sys-
tems. Ten welds were made (see
Figs. 1 to 10). Two others, not
being reported in detail, involved
dissimilar-metal combinations, a Ni-
Cr-Fe alloy welded to plain-carbon
steel, but, in general, the base metal
was of the same composition type as
the electrode. Both argon and
covered-electrode shielded arcs were
used. Tensile specimens 0.357 in.
in diam were prepared with their
longitudinal axes coincident with
the longitudinal axes of the welds.
Chemical analyses were secured
from the ruptured shanks of these
specimens. In no case was the
weld-metal sulfur content more than
0.009%, or the phosphorus content
over 0.007%. The cobalt contents
were less than 0.05%.
Chemistry of Arc Transfer
of Metal
Argon-shielded Arcs
Five bare-wire electrode welds
were made with the argon-shielded
arc (see Figs. 1, 3,6 and10). Data
were secured to provide a_ back-

236-s | JUNE 1960

 t
|
| Proportional Limit

dritic Fractures fe Many T

Area Reductior

Fig. 1—Temperature-stress-ductility relations for Ni-Ti Fig. 2—Temperature-stress-ductility relations for

type welds (argon shielded) Ni-Ti type welds (covered-electrode shielded)

be Dendritic F
Lu de Crocks
o Reduction

2 5
- ect Ty emperature
nt Test Temperature

Fig. 3—Temperature-stress-ductility relations for Fig. 4—Temperature-stress-ductility relations for

Ni-Cr-Fe-Cb type welds (argon shielded) Ni-Cr-Fe-Cb type welds (covered-electrode shielded)

WELDING RESEARCH SUPPLEMENT | 237-s

ground for evaluating the amount
of each element lost in the gross
transfer of metal across the arc
where the argon envelope is sur-
rounded by air. This is the normal
production condition.
The nickel mass is the same, rel-
atively, in the weld deposit as in the
wire; i.e., the weight loss suffered
from oxidization, evaporation and
spatter of molten globules does not
alter the total percentage of nickel.
If the ratio of the alloying element
present in the weld, in weight per-
cent, to the corresponding amount
originally present in the wire is
called the are transfer ratio, the
lowest value of that ratio, for the
several more prominent elements
in the argon-shielded nickel-base
alloy arc welds, is:
Iron
Chromium
Manganese
Carbon
Titanium
Silicon
Aluminum
Columbium
Tantalum
The lower the order in which an
element appears on this list, the
more effective it is as a deoxidizer,
or the more susceptible it is to
evaporation.
Because of the losses of other ele-
ments, there is a slight relative gain
in copper content in the Ni-Cu type
weld metals over the percentage
present in the bare wire.
There is no general increase in
nitrogen and oxygen contents, in-
dicating that efficient arc shielding
is obtained.
When joining base metals of
similar composition with the argon-
shielded process, if that composition
is to be maintained, all of the alloy-
ing elements desired in the deposited
weld metal must be present in the
wire in an amount inversely pro-
portional to the ratios listed in the
above tabulation.
Covered Electrodes
The electrode coverings contain
Ca, Na, or Na;Al fluorides. Ade-
quate ventilation should be pro-
98
vided when using these materials.
96
In this respect, they are no different
95
from the stainless steels.
95
Oxides of Ti, Al, Si, Mg, Mo, Cr
82
and /or Ca, ferroalloys, organic ma-
81
terials and binders are also present
79
in the coverings. Only two of the
78
electrode coverings contain more
65
than 10°% of organic materials.
Transfer of alloying elements across
the covered-electrode arc is a com-
plex phenomenon. All, part, or
none of the alloying element found
in the weld may come from the wire;
the other source is the covering.
Chromium and copper, where
used, are added through the core
wire, the average transfer ratio
being 0.95 for chromium. Some
copper in the Ni-Cu type alloys is
brought over from the electrode
covering as impurities in the ferro-
alloys.
Iron, where used as an alloy,
comes basically from the core wire,
but some is added via the ferro-
alloys in the covering.
Carbon, manganese and silicon are
usually higher in the weld deposit
than in the core wire, indicating
that all three elements are present
in the electrode coverings in sig-
nificant amounts.
Aluminum is transferred from the
core wire, but the transfer ratio is
only about 0.51.
Titanium is transferred from the
core wire in full amount, partly
because enough is placed in the
covering to compensate for transfer
losses. This contrasts with the
circulated opinion of the manu-
facturers of covered stainless-steel
electrodes, who claim that titanium
cannot be effectively transferred
across the covered-electrode arc.
There is little difference between
the oxygen, nitrogen, phosphorus
and sulfur contents of the welds;
all are low. The low oxygen con-
tents of the nickel-base alloy weld
metals are partially related to the

+——=Side Cracks

Nm oO
s;)S

p000 Ambient 00
psi)
ti = (IOC
S
1 Nominal Nominol
Ultimate Ultimate
‘ tt

stress
Volue Stress
Values
. 0.2% Yield,
Fa t
. Proportional Limit x
Proportional Limit
ritic Fractures} a.2ge——
T
Area Reduction I Area Elongations
| Reduction Total
Elongations 1
Total u
Ductility
Uniform [esx| | | tinifewen
Unito | '
71 les]
4 8 12 16 20 24 4 8 6 20 24
Test Temperature (1O0°F
\ ) Test Temperature (|OO°F )
Fig. 5—Temperature-stress-ductility relations for Fig. 6—Temperature-stress-ductility relations for
annealed Ni-Cr-Fe-Ti type base metal Ni-Cr-Fe-Ti type weld metal (argon shielded)

238-s | JUNE 1960

high amounts of deoxidizers present
in the electrode wires as alloys, and
in the coverings as ferroalloys or
metallic powders.
Temperature Dependence of
Tensile Properties
Tensile tests on 0.357-in. diam
unnotched tensile specimens, cut
from the center of the welds, were
made at a 750% per hour constant
strain rate across a temperature
range from —320 to +2200° F for
all but three of the welds. One
series was tested down to —452° F.
The other two exceptions were not
tested below room’ temperature.
Load-strain curves to rupture were
recorded automatically in every
case.
The temperature dependence of
the short-time tensile strength and
ductility of the as-deposited weld-
metal specimens are shown graphi-
cally in Figs. 1 to 10 inclusive.
Basically, these welds show about
the same temperature response as
was found previously for welds in
the AISI 300 series stainless
steels.* With few exceptions, as
temperature decreases below normal
ambients down to liquid-nitrogen
levels, —320° F, there is little or no
change in ductility. There is a
slight (39°) rise in the proportional
limit and yield stresses, a modest
4e
rock
emperot
Fig. 7—Temperature-stress-ductility relations for
Ni-Cr-Fe-Cb type weld metal (covered-electrode shielded)
33%) increase in tensile strength
and from zero to a substantial (74%)
increase in fracture stress. These
are, in general, good metals for low-
temperature service. Of the several
compositions, the Ni-Cu type is best
for very low temperatures. But
significant decreases in ductility
were found in most of the elevated-
temperature tests. Also, welds in
the Ni-Cr-Fe-Ti compositions
showed a sharp increase in yield
strength at, or near, 1400° F, with
corresponding losses in ductility
see Figs. 5 and 6).
The detailed response secured
from the twelve welds tested was:
Ni-Ti Type Weld, Argon Shielded
The argon-shielded Ni-Ti type
alloy weld metal, with Si-Al-Mn
present in more than trivial amounts,
has subambient-temperature tensile
properties characteristic of f.c.c.
metals, Fig. 1. It is dendritic and
large-grained, with normal orienta-
tion, but is characterized by the
presence of many small particles
both within the grain matrix and at
the grain boundaries. The larger
particles are about 0.0001 in. in
actual diameter. For a commer-
cially available product, the phos-
phorus, sulfur, oxygen and nitrogen
contents are low.
As temperatures decrease from
the ambient down to —320° F, the
Dendritic
Froctures
Fig. 8—Temperature-stress-ductility relationsfor Ni-Cr-Fe-Cb-Mn
type weld metal (covered-electrode shielded)
WELDING
yield strength rises 37%, the nomi-
nal ultimate strength rises 39%, and
the fracture strength rises 18%.
There is no decrease in ductility
down to —320° F.
As temperature rises from the am-
bient to 600° F, the strength drops
slightly. Also, up to that tempera-
ture, the ductility, as measured by
elongation to reach maximum load
uniform elongation), total elonga-
tion to rupture, and area reduction
at fracture, are all about constant;
the average values being 38.6, 47.6
and 64.2% respectively. Between
+600 and —320° F, all of the
ruptured specimens exhibit a
mottled side surface appearance
see Fig. 11), and at 30 magnifi-
cation with the binocular microscope
under strong light there were no
visible evidences of side surface
cracks.
At 1000° F, the fracture strength
has dropped to slightly less than
50% of the room-temperature value
and, for all temperatures above
1000° F, the fractures are no longer
of the 45 deg “‘satin’’ to “‘unglazed
porcelain” type, but are instead of
the separated dendritic reed type
see Fig. 12). Full ductility is
maintained up to 1000° F (see
Fig. 1).
Above 1200° F, up to the maxi-
mum of 2200° F tested, all strength
values progressively approach zero,
=e [ee]
Test Temperature
RESEARCH SUPPLEMENT 239-s
 which would be expected for pure
nickel to be at about 2650° F.
For the 2.2°% Ti nickel alloy, this
zero-strength level is expected at a
slightly lower temperature.
Minimum ductility is reached be-
tween 1500 and 1900° F. All speci-
mens tested at and above 1000° F
exhibit numerous side cracks (see
Fig. 11), and the final fracture is
simply the one region where the
most and largest of such cracks con-
verged into acommon schism. The
total elongation values obtained
above 1000° F may be misleadingly
high because they include the sum
of all crack widths. For this reason
the ‘‘total-elongation’”’ curves are
hatched for those temperature
ranges across which such side cracks
were observed on the finally rup-
tured specimens.
Above 1800° F, all of the ductility
indices rise to reveal the character-
istic presence of the temperature-
ductility dip previously described
for similar deposits in austenitic
Cr-Ni steel weld metals.s There
are reasons to believe that this is
associated with internal microstruc-
tural changes in these metals. The
as-deposited hot-brittleness prob-
lem in austenitic steels is therefore
not circumvented by the lone ex-
pedient of changing from Fe-Cr-Ni
steels to a f.c.c. Ni-Ti alloy, even
when used with argon shielding
under ideal laboratory conditions.
Ni-Ti Type Weld, Covered-electrode
Shielded
The companion weld, deposited
with covered electrodes (see Fig.
2), reflects more than a change in
arc shielding. The argon-shielded
weld was made in three layers; the
covered-electrode weld in_ nine
beads. The microstructure is
correspondingly finer but the basic
dendritic grains are still “large.”
The covered-electrode weld also
contains more Ti (+0.91%), C
(+0.26), Si (+0.22), Al (+0.21) and
Mn (+0.05) than the argon-shielded
deposit. The P, S, O, and N con-
tents of this weld were low.
The stress-temperature relations
are roughly the same as for the
argon-shielded weld, but the welds
are generally stronger at any
selected temperature, probably be-
cause of the higher alloy contents.
A less-pronounced ductility dip
exists, and its location is shifted
down to between 1200 and 1600° F,
probably because of the higher ti-
tanium content. The ductility is
less across most of the temperature
range, but it is more ductile within
the 1600 to 2100° F range. At
—320° F, the ductility, by all cri-
teria, was decreasing.
The specimen appearances were
about the same, except that the
fracture surfaces revealed the den-
dritic structure at all test tempera-
tures. Side surface cracks, on the
ruptured specimens, were visible
only for tests made at and above
1000° F.
Except within the 1600—-2100° F
range, the ductility of the argon-
shielded weld is superior to the
covered-electrode one, but, in
general, the covered-electrode weld
is stronger. If it is assumed that,
on the first cool-down of the weld
metal, the same strength-ductility
relations exist at each temperature
as is shown by the test specimens,
the prevailing fracture strength-
elongation relations during that
cool-down would be as shown in
Fig. 13. As the temperature falls
below 2200° F, the fracture strength
rises (reading Figs. 1 and 2 from
right to left) and, when the ductility
also rises, the potential for cracking
is lower. But, when ductility falls
disproportionately with increasing
strength as the temperature is
lowered, one can expect cracking
in the presence of adequate local
strain. Note that strain hardening
does not occur at these high tem-
peratures and maximum resistance
to loading occurs at strains of about
1% in an unnotched specimen.
With the argon-shielded welds, one
could anticipate that cracking would
be most likely to occur at 1600° F
under restrained notched conditions,
and between 1300 and 1600° F with
the covered-electrode weld under
similar conditions. As__ both

~ '
Comp. (%) l Comp. (%)
+Normal Ambient Ni =66.07 ' + Normal Ambient Ni =6477
yw
' , , ,
Cu=31.93
Cu=29.68
Mn= | .8] t | T =
Al= 1.09 ) ~ | Tested in Liquid
) ™°° 1 Helium 2
Ti= 050 !
= 0.46 ! nNes)
@ Hw
SdNm
co) oO = 0.20 eo)o 2)) i
! , Fracture
Fracture = 0.064
= 0.004
nN > ! +
) 00022 Pe
Zowno
OO0O00000-
OO0O00
OOON
WW-
ON
1 0.0005
Nominal
1! Nominal
! Ultimate Stress
Values
(1000
psi = Ultimate
a
Stress
(IOOO
Values
psi
102% Yield " 0.2% Yieid

iL. . Proportional Limit

Proportional Limit Side Cracks
Side Cracks Deadritic Fractures
Dendritic TFractures
Area Reduction + Area Reduction
@ oO
:ot ss| Elongations
y :
Elongations Ductility Total
Py i + : +
Ductility Total ‘| Uniform
(%)
Values
0 G 8 l2 16 20
Leet
Helium Test Temperature (IOO°F )
Test Temperature (IOO°F) (-452°F)
Fig. 9—-Temperature-strength-ductility relations for Ni-Cu Fig. 10—Temperature-stress-ductility relations for
type weld metal (covered-electrode shielded) Ni-Cu type weld metal (argon shielded)

240-s | JUNE 1960

 << Cut for hardness readings

<+Tensile fracture

Typical of Typical of
Pl— — —- — ——_>
800° F to 320° F 1000° F
(Mottied flowed surface (Smooth surface with
with no detectable from few to many
cracks at X 30) surtace fissures)
Fig. 11—Typical appearance of
ruptured specimens

strength and ductility rise, with begins at 1100° F. The fracture

further decreasing temperatures, the
capacity of the metal to absorb
energy increases and cracking is not
expected to occur in these metals.
Ni-Cr-Fe-Cb Type Weld, Argon Shielded
The yield strength vs. tempera-
ture relations for the argon-shielded
Ni-Cr-Fe-Cb type weld metal (see
Fig. 3), are again typical of f.c.c.
metals. These include the low rise
in yield strength at the suppressed
temperatures, down to —320° F,
and the gradually drooping shelf
that extends as temperature in-
creases above the ambient, in this
case, up to 1600° F. Above 1600° F,
the yield strengths decrease rapidly
with increased temperatures.
The ultimate strength vs. tem-
perature curve is almost parallel to
the yield-stress curve except that
the fall-off on rising temperature
stress starts deteriorating at some
temperature near 1000° F.
The ductility of this metal is ex-
cellent from 320° F up to, and
including, 1200° F. There is a
slight dip in ductility between 1200
and 2000° F, but it is not severe;
at its lowest, the elongation is
34.3% and the area reduction is
41.5%, both at 1400° F. Strain
hardening occurs up to, and in-
cluding, 1200° F, but decreases
rapidly above that temperature toa
low amount at and above 1800° F.
Random transverse cracking oc-
curred on straining above the ulti-
mate load uniform elongation
value for all temperatures above
1000° F and fractures show the ir-
regular dendritic reed type for all
temperatures over 1200° F.
A feathery dendritic 10 macro-
structure reveals sharply delineated
1000° F
Fig. 12—Typical fractures
grain boundaries at Xx 100 and
1000 magnifications with sec-
ondary constituents distributed
throughout the grains. *
Ni-Cr-Fe-Cb Type Weld, Covered
Electrode
The covered-electrode Ni-Cr-Fe-
Cb type weld metal has the same
general characteristics as the argon-
shielded one, with which it is almost
identical chemically, but the duc-
tility is inferior across the entire
temperature range (see Fig. 4
The low-ductility point, 13.1% total
* These structures are not reproduced in this
paper to keep length within reasonable limit.

@ = Cov. Elec (8!) ——

© = Argon Shield (82 |
||
}

a °o
(%)
on
Elongation
(%)

Total
Total
Elongat:
Direction of Chonge
—————
on Initial Cool— Down
t +-2000°F

80 120 160 20 60 20 60
Fracture Stress (1000 psi) Fracture Stress (i000psi)
Fig. 13—Relation between fracture stress and Fig. 14—Relations between fracture stress and
elongation for Ni-Ti type weld metals elongation for Ni-Cr-Fe-Cb type weld metals

WELDING RESEARCH SUPPLEMENT | 24l-s


80°F
Fig. 15—Structures of Ni-Cr-Fe-Ti type base metal at X 1000.
unstrained ends of tensile specimens tested at temperatures
listed.) (Reduced by approx. ! » upon reproduction)
elongation, is between 1700 and
2100° F.
Treating the temperature-
strength-ductility relations for the
Ni-Cr-Fe-Cb type welds, as was
done for the Ni-Ti ones, it would be
expected that a minimum tendency
for cracking would exist with the
argon-shielded welds (see Fig. 14).
Covered-electrode welds would be
expected to crack only near the
2000° F level.
Ni-Cr-Fe-Ti-Type Alloys
The Ni-Cr-Fe-Ti type base, and
weld, metals and one variation of
the weld metal, have special charac-
teristics. For the base metal, a
slight increase occurs in yield
strength as the temperature in-
creases from 300 to 600° F, then
242-s | JUNE 1960
1000° F
(From
decreases as the temperature rises
to 1000° F, and then it rises sharply
to a maximum at 1400° F (see Fig.
5). As the strengths increase, the
ductility decreases disproportion-
ately. The minimum ductility at
1400° F is 7.4% total elongation and
13.4% area reduction. At 1600° F,
the fractures in the base metal had
the appearance of grain separations
in a compact of wet sand. At
1800° F, and above, the metal is
very ductile; >99.2% area re-
duction at 1800, 2000, and 2200° F.
At 1800° F, the total elongation is
107.9%.
The certified analysis (©) of the
tube stock involved is:
Nickel. . 73.10
Chromium 15.04
Iron :
Titanium 2
Cb + Ta 0
Aluminum 0
Manganese 0
Silicon 0
Copper 0
Carbon 0
A precipitation-hardening mech-
anism, effective in the annealed base
metal, is temperature dependent and
is effective at two levels. Between
>300 and <600° F and again be-
tween >1000 and <1600° F, the
mechanism causes increases in yield
strengths with minor increases in
tensile strength (see Fig. 5). Serra-
tions occur in the load-strain curves
only within the 600—1200° F range,
i.e., when there is a maximum gap
between fracture and yield
strengths. Such serrations are as-
sociated with precipitation-harden-
ing phenomena occurring during
strain hardening. This occurs in
low-carbon steel welds at about
300° F* and in some precipitation-
hardening stainless steels at 1200° F.
The titanium compounds that
precipitate within the <600 to
>1400° F range cause the increased
yield, ultimate and fracture
strengtinss (see Fig. 15). The over-
all increase in the grain strengthen-
ing components, caused by the
presence of the precipitate, without
a proportionate increase in cohesive
strength between the grains pro-
duces the low-ductility rupture at
1400° F. At 1600° F, the difference
between the fracture stress and the
yield and ultimate stresses is a
minimum. It is here that the sand-
compact type failure occurs (see
Fig 15 As the temperature in-
creases further, the return of the
precipitate into solution in the
matrix results in excellent ductility
at lowered strengths, normal for the
temperature levels. This effect, ex-
cept for the time scale, is analogous
to the formation and re-entry into
solution of the brittle sigma phase
in the austenitic matrix Fe-Cr-Ni
steels as temperatures progressively
increase.
Ni-Cr-Fe-Ti Type Welds, Argon- or
Covered-electrode Shielded
The argon-shielded Ni-Cr-Fe-Ti
type weld metal (Fig. 6) had tensile
characteristics roughly similar to
those of the base metal as related to
temperature, except that a rise in
yield strength does not occur at
600° F. A_ pronounced rise in
yield strength does occur at >1000
and <1600° F, with a corresponding
disproportionate drop in ductility,
4.2% total elongation on one speci-
men and only 2.8% on a recheck.
At 1800° F, and above, the duc-
 tility is good; >51% area reduction
and >44% total elongation. The
fracture stress is poor for all tem-
peratures above 1000° F.
The covered-electrode shielded
welds had similar characteristics,
except that the ductility across most
of the temperature range was poor.
This weld contained some cracks in
the as-deposited condition. At
1300° F, the total elongation was
1% and the area reduction 11.3%.
These data are not included in de-
tail. (See Fig. 16 for microstruc-
tures). 1900° F
A weld of similar composition
made between a Ni-Cr-Fe alloy and
plain-carbon structural steel with
argon shielding and a commercially
available electrode also exhibited a
rise in yield strength at 1400° F,
with the corresponding ductility dip,
7% total elongation.
Significantly, these three welds
are the only ones of the basic Ni-Cr-
Fe composition series studied that
contain high titanium, from 2.35 to
2.66%. Of the 12 welds covered by
this study, only these three ex-
hibited the high-yield-strength
characteristic at 1400° F. It is
therefore the titanium that makes
the difference in the Ni-Cr-Fe com-
bination, but the presence of ti-
tanium in nickel (see Figs. 1 and 2
and in the Ni-Cu alloys (see Fig 10
has no such effect in the short-time
tensile test. There is, however,
some evidence of this phenomenon
in the hardness data (see Fig. 18
for the unstrained metal.
Additional welds of the covered-
electrode Ni-Cr-Fe-Cb type (see 4*
Figs. 7 and 8) with low titanium
Ti 0.25/0.48), did not exhibit the ~
yield stress rise or the ductility dip 80 F
at 1400° F. A weld made with a Fig. 16—Structures of covered-electrode Ni-Cr-Fe-Cb-Ti-Ta type welds at X 1000.
covered electrode that is no longer (From unstrained ends of tensile specimens tested at temperatures listed).
commercially available (see Fig. 7 (Reduced by approx. '/, upon reproduction)
exhibits no anomalies in strength-
temperature relations and shows
good ductility up to and including
2200° F, with a ductility rise at
>1200 and <2000° F. Another T Fig. 17—Fracture
covered-electrode weld (see Fig. 8 | stress vs. elonga-
octiatmie tion relationships
containing 0.25°% titanium, also © = Argon Shielded (80) | | | for Ni-Cu type weld
exhibited no anomalies in the T ki he cna | metals
strength-temperature relations, but
it had a minimum ductility at Con
1900° F. At that temperature, the $—__$—$_+—_4__}__
total elongation was only 7.1%.
Both of these welds contained de-
fects of the porosity-cracking type
from their original solidification. Elongation
(%)
o °o
The first root bead of this deposit
Total
cracked _ badly. Unfortunately,
from a property determination point
of view, the variable restraint con-
ditions in the tube has had its in- Zi200°%F
fluence on these results, but that Decreasing
_ Temperatures |
condition has, at the same time, pro- 60 120 160
vided information to show that, in Fracture Stress (1000 psi)

WELDING RESEARCH SUPPLEMENT | 243-s

production, caution must be exer-
cised in the selection and use of these
compositions. A weld made with
the same electrode between two
flat pieces of Ni-Cr-Fe alloy and car-
bon steel had closely similar proper-
ties, but somewhat improved duc-
tility, 13.2°, minimum total elonga-
tion at 1800° F. The iron content
was higher and the nickel and
chromium contents lower because of
enrichment and dilution resulting
from the carbon-steel member.
The choice between Cb and Ti
as additions to the Ni-Cr-Fe alloy
series is therefore a delicate one.
More than 2° Ti, with or without
Cb, produces precipitation harden-
ing and 1400° F embrittlement;
less than 0.5% Ti with too high Cb,
>1.9°%, produces low ductility at
1800° F or higher.
Ni-Cu Type Welds, Covered Electrode
and Argon Shielded
Ni-Cu type weld metals (see Figs.
9 and 10) exhibit normal tempera-
ture-strength relations up to the
2200° F maximum investigated.
The fracture strengths are poor
above 600° F, but are excellent at
the very low temperatures. There
is little difference between the
covered-electrode and the argon-
shielded deposits. At 600° F and
lower, the ductility is excellent, but
a marked deterioration in ductility
is already in evidence as the tem-
perature increases up to 1000° F,
and these values continue to de-
ncrease of Shank
Test Temperature (\OO°F)
Fig. 18—Hardness data for Ni-Ti type welds
244-s | JUNE 1960
generate to a minimum between
1200 and 2000° F, being less than
15% total elongation for all but
one point within that range, and
having a minima of 6.2 and 7.1%
total elongation for the covered-
electrode and argon-shielded de-
posits at 1200 and 1600° F re-
spectively.
Of special academic interest are
the results secured at liquid helium
temperatures (—452° F) with the
argon-shielded Ni-Cu alloy weld
metal (see Fig. 10). The yield
strength maintained its relatively
low rate of rise down to that tem-
perature, only 4.5° above absolute
zero, while maintaining excellent
ductility, 47.3% total elongation
and 61.8% area reduction.
The fracture stress vs. elongation
values are shown for the Ni-Cu
welds in Fig.17. The critical crack-
ing temperatures appear to be at
1600 and 1200° F; 1600° F being
the most critical for both shielding
methods.
Hardness Variations
Hardness traverses were made on
the unstrained butt ends and in the
strained shanks 0.75 in. from the
ends of most of the tensile specimens
after rupture (see Fig. 11). This
provided independent information
on the effects of the thermal and of
the thermal-stress cycles (see Figs.
18 to 21).
The covered-electrode Ni-Ti type
DPH)
Hardness
———E——
over Butt
4 6 8 10 12
Fig. 19—Hardness data for Ni-Cr-Fe-Cb type welds
welds were softened when heated to
and above 1700° F (Fig. 18), but
the argon-shielded welds were es-
sentially unaffected by brief (20
min) exposure to any of the 2200° F
maximum test temperatures. For
both cases, there was evidence o
hardening at 1400° F. Strain hard-
ening occurred up to 1280 and
1440° F, respectively, lower curve,
but it was most appreciable below
1100° F.
Ni-Cr-Fe-Cb type welds (Fig. 19)
had essentially the same response,
regardless of shielding mechanism.
The as-deposited welds were
softened slightly upon exposure to
temperatures above 1600° F. The
strain hardening was about constant
up to 1000° F. It decreased rapidly
above that temperature, to very
small amounts at and _ above
1700° F.
The Ni-Cr-Fe-Ti type base metal
hardness-temperature responses re-
vealed softening of the strained
metal above 1400° F and hardening
of the unstrained metal after ex-
posure to temperatures of 1200° F
and above. The hardness increase
in the unstrained metal is the result
of a precipitation phenomenon pre-
viously discussed. These weld
metals, containing >2.0°% titanium,
respond, in general, in the same
manner as the base metal (see Fig.
20), but in a more pronounced man-
ner. The unstrained metal in-
creases in hardness after exposure
Shielding Code
@0= 83=+Cov. Elec
&4=84=Argon
ss.
+
“-Unstrained Butts
+ + +
f increase of Shank
1 over Butt
7
14 16
Test Temperature OO°F)
Fig. 20—Hardness data for Ni-Cr-Fe-Ti type welds
to temperatures above 1000° F.
This increases to a maximum at
1400° F, and for higher temperatures
the hardness progressively decreases
as the precipitate returns into solu-
tion. The net result is that there is
little difference between the hard-
ness of the strained and unstrained
metal for exposures to temperatures
of 1400° F and above. Modified
electrodes, producing welds con-
taining columbium, do not exhibit
the precipitation-hardening phenom-
enon. These metals are softened
somewhat by exposure to tempera-
tures above 1400° F and the maxi-
mum straining hardness decreases
as the temperatures exceed 1000° F.
No net increase in hardness occurs
from straining at temperatures of
1800° F and above.
A titanium-bearing deposit, made
between a Ni-Cr-Fe alloy and plain-
carbon steel, again shows the
1400° F increase in hardness in the
unstrained weld metal. This weld
is the only one of the entire series
that shows at least some strain
hardening at all test temperatures.
Ni-Cu type welds showed the
least sensitivity to strain hardness
(see Fig. 21 They were softened
by exposure to temperatures above
1800° F and revealed no precipita-
tion-hardening effects.
In general, all of the nickel-base
alloy welds, except the Ni-Cu group,
increased about 100 DPH in the
uniformly strained metal over that
in the unstrained butts, up to about
1000° F. This differential dropped
ig -Hardness data fo: Ni-Cu type welds
to from less than 25 DPH to a nega-
-Shielding———
tive value above 1200° F for the Covered
Ni-Ti and the Ni-Cu type welds Element Argon electrode
see Figs. 18 and 21); above 1400° F Fe 0.98 >1.
for the Ni-Cr-Fe-Cb and Ni-Cr-Fe- Cr 0.96 0.
Ti welds (see Figs. 19 and 20); and Mn 0.95es
above 1600° F for the Ni-Cr-Fe-Cb- C
Ti welds. Ti
There is a general near-linear re- Si
lation between the amount of strain Al
at uniform load and the strain Cb
hardening increase, although this is Ta
more pronounced in some composi- t Net for fortified covering
tions than in others. For a 40% > Net for unfortified covering
€ Independent of covering fortification
uniform strain, the hardness in-
crease ranges from 60 in the Ni-Cu 2. Any desired composition in
type welds to as high as 150 for the nickel-base alloy weld metals can be
Ni-Ti and the Ni-Cr-Fe-Ti welds. secured by either shielding tech-
In the high-temperature tests there nique by properly balancing wire
was little uniform, and total, strain; and covering compositions.
also, there is little increase in hard- 3. Ni-Cu type alloy welds are
ness at those temperatures. In low in ductility at all temperatures
general, for a given strain, the hard- above 1200° F, but are very ductile
ness increase is less in the argon- below 800° F and down to liquid-
shielded welds than in the covered- helium temperatures.
electrode ones. 4. Ni-Ti type alloy welds have a
low-ductility dip centered at
Magnetic Characteristics 1800° F.
Magne-gage readings showed all 5. Ni-Cr-Fe-Cb type alloy welds
the welds to be nonmagnetic, except have maximum hot ductility, par-
the Ni-Ti alloy series. These two ticularly when argon shielded.
welds had the magnetic equivalent 6. Welds in the Ni-Cr-Fe series
of more than 35% ferrite in the total become precipitation hardened and
mass. very brittle at 1400° F when more
than 2% Ti is added to the deposit,
regardless of the arc shielding media.
Conclusions 7. Ni-Cr-Fe-Ti type alloy welds
1. The transfer efficiencies of the are not only hot brittle but are crack
primary alloying elements across the sensitive under nominal levels of
welding arc in the nickel-base alloys restraint.
are: 8. Ni-Cu, Ni-Ti and WNi-Cr-
WELDING RESEARCH SUPPLEMENT 245-s
Fe-Cb type alloy welds have ex-
cellent ductility and strength at
extremely low temperatures. The
yield stress tends to rise with
lowered temperatures about in line
with accepted values for f.c.c.
metals.
9. Strain hardening below
1000° F is basically a function of the
amount of strain, and for a given
amount of strain it is a minimum in
the Ni-Cu alloys and a maximum in
the Ni-Ti and Ni-Cr-Fe-Ti alloys.
10. All welds in these alloys are
nonmagnetic except for the Ni-Ti
compositions.
Acknowledgments
Analyses of the weld deposits
were provided by the Westinghouse
Engineering Departments. Cover-
ing analyses were made by J. F.
Reed, and spectrographic analyses
by J. Senko, Technology Depart-
ment, Research Laboratories.
Welds were made by P. T. Ehr-
hardt; magnetic readings by C. J.
Dorsch, and hardness readings by
C. J. Dorsch and G. R. McGraw, all
of the Research Metals Joining
Section. Tensile tests were made
by W. H. Pryle and R. R. Hovan,
and metallographic examinations by
R. L. Anderson, all of the Research
Metallurgy Department.
References
;% R. “The Practical Welding
Metallurgy of Nickel and High Nickel Alloys,”
THE WELDING JOURNAL, 36 (7), Research Suppl.,
330 to 334-s (1957)
2. Pease, G. R., Brien, R. E., and Legrand
P. E. “The Control of Porosity in High Nickel
Alloy Welds,” Jbid., 37 (8), Research Suppl.,
354-s to 360-s (1958)
3. T. E. Kihlgren and C. E. Lacy. “The
Control of Weld Hot Cracking in Nickel-
Chromium-Iron Alloys,” Ibid., 25 (11), Research
Suppl., 769-s to 775-s (1946).
4. Poole, L. K. “The Incidence of Cracking
in Welding Type 347 Steels,” Jbid., 32 (8),
Research Suppl., 403-s to 412-s (1953)
§ Heuschkel, J. “Initial Characteristics of
Chromium-Nickel Steel Weld Metals,”’ [bid., 34
10), Research Suppl., 484-s to 504-s (1955).
6. Heuschkel, J. ‘*Time-Temperature De-
pendence of Austenitic Stainless Steel Welded
Joint Components,” Jbid., 35 Research Suppl.
12), 569-8 to 581-s (1956).
Heuschkel, J. “‘Dependence of Steel Weld
Properties on Lattice Structure,” Jbid., 35 (2),
82-s to 90-s (1956).
8. Heuschkel, J. “Effects of Temperature on
Weld Metal Properties,”’ Jbid., 33 (8), 388-s to
397-8 (1954

BULLETIN SERIES

Requests for single copies should be sent to the

AMERICAN WELDING SOCIETY, 29 W. 39th St., New York 18, N. Y.

Requests for bulk lots of ten or more, should be sent to the

WELDING RESEARCH COUNCIL, 29 W. 39th St., New York 18, N. Y.

Plastic Design of Pinned-Base ‘‘Lean-to’’ Type Frames, by Robert L. Ketter and Bung-Tseng Yen,
September 1959. $1.00.

Bending of 2:1 and 3:1 Open-Crown Ellipsoidal Shells, by G. D. Galletly, October 1959. $1.00.

Fourth Technical Progress Report of the Ship Structure Committee, November 1959. $1.00.

Interpretive Report on Welding Titanium and Titanium Alloys, by G. E. Faulkner and

C. B. Voldrich, December 1959. $1.00.

Some Observations on the Brittle Fracture, by G. M. Boyd, January 1960. $1.00.

Strength of Aluminum Alloy 6061-T4 Thick-Walled Cylindrical Vessels Subjected to Internal

Pressures, by J. Marin and Tu-Lung Weng, March 1960. $1.00.

Factors Which Affect Low-Alloy Weld Metal Notch-Toughness, by S. S. Sagan and H. C. Campbell,
April 1960. $1.00.

(1) Interpretive Commentary on the Application of Theory to Experimental Results for Stresses
and Deflections Due to Local Loads on Cylindrical Shells, by P. P. Bijlaard and E. T. Cranch;
(2) An Experimental Investigation of Stresses in the Neighborhood of Attachments to a Cylin-
drical Shell, by E. T. Cranch, May 1960. $2.00.

No. 61 Interpretive Report on Welding of Nickel Clad and Stainless Clad Steel Plate, by W. H. Funk,
June 1960. $1.00.

246-s | JUNE 1960

Resistance Seam Welding
The changes in welding variables necessary
and the welds produced are compared
BY HORACE F. GREER AND M.
Introduction
Coated-steel sheets have wide ap-
plication in industry for products
which must be resistant to corrosion
and have liquid-tight seams. This
report is one of several which deals
with the uses of resistance seam
welding as a method for producing
acceptable welded joints. The first
two reports compared the results
of welding uncoated and zinc-coated
low-carbon steel at the welding
conditions for uncoated steels, and
established the fact that coated
materials require different machine
settings to produce welds of con-
sistent high quality. This report
describes the changes in welding
variables necessary for seam welding
terne plate and compares the welds
produced with welds having a zinc
coating.
Terne plate is sheet steel which
has been coated with an alloy of
lead and tin. The normal composi-
tion of the terne-alloy coating is
75% lead and 25% tin; however,
wide variations in composition are
not uncommon. The reason for a
proportion of tin in terne metal is
that lead, by itself, is insoluble in
both solid and liquid iron, so there
is no tendency for lead to wet the
steel or to bond itself to a steel
surface by alloying. The addition
of 25% tin enhances the adhering
property of the lead-alloy coating
to such an extent that by weight,
only a half or a third as much is
required to achieve the same pro-
tection as would be required for
lead or zinc, respectively.
Effect of Metallic Coatings
on a Resistance Weld
The presence of any low-melting-
HORACE F. GREER is Research Engineer, Con
vair, Vandenburg Air Force Base, Calif.; formerly
a graduate student RWMA Fellowship, the Uni
versity of Texas, Austin, Texas, and M. L. BEGE-
MAN is Professor of Mechanical Engineering, the
University of Texas.
Paper presented at AWS 4lst Annual Meeting
held in Los Angeles, Calif., April 25-29, 1960.
of Terne Plate
for seam welding terne plate are described,
with welds having a zinc coating
L. BEGEMAN
point coating on the surface of a
weldment involves some difficulty
in seam welding in that the coating
tends to alloy with the wheel elec-
trodes, and some provision is neces-
sary for cleaning the wheel surface.
Another effect of coatings is to in-
crease the number of layers of
metal initially present between the
electrodes from two to six, thereby
increasing the electrical resistance
as compared to uncoated steel.
The melting of a coating in the
course of making a seam weld in-
troduces a third effect—that of
being a cooling medium or heat
sink for the area surrounding the
weld, tending to restrict the maxi-
mum temperature reached.
The problem of electrode pickup
may be countered by employing
a knurled driving roller to break
up the alloyed material on the elec-
trode face. This technique proved
reasonably satisfactory in welding
terne plate although the electrode
pickup was found to _ progress
rapidly.
A resistance weld is made by an
application of force and heat gen-
erated by resistance to the passage
of an electric current; the presence
of extra layers of metal in a weld
area affecting the manner in which
heat is produced in the weld region.
With uncoated weldments, the three
primary resistances are the contact
resistances between the electrodes
and weldments, plus the interface
resistance between the weldments.
The electrode-weldment contact re-
sistances are small, and heat gen-
erated at the outside surfaces is
dissipated by flood cooling. It is
the heat generated at the interface
which produces the weld.
For coated weldments, the major
resistances are still the contact
resistances; however, the distribu-
tion of resistance across the weld-
ments changes once the welding is
begun. With the first generation
of heat, the low-melting-point coat-
WELDING
ing liquefies and is squeezed away
from the weld area by the force
applied by the electrodes. Ideally,
the displacement of the liquid
coating results in a _ steel-to-steel
contact at the sheet interface, and
welding then proceeds as in un-
coated materials. There is, how-
ever, the possibility that some of
the coating will be trapped in the
weld area and remain as an inclusion
defect. The requirement that the
liquefied coating be forced from the
weld area dictates the use of higher
electrode forces when welding coated
materials.
The melting of the coating pro-
duces cooling in the weld area and
represents a heat loss to the base
metal. 'To compensate for the heat
deficit, either the electrical resist-
ance or the welding current must
be increased. No “extra” heat is
generated due to increased electrical
resistance because the initial re-
sistance decreases in accordance
with melting of the coating until
its value is that of the two steel weld-
ments in close contact. The in-
creased heating required for the weld-
ing of coated steel can be achieved
only by an increase in the welding
current.
In summary, it is seen that a
metallic coating introduces the fol-
lowing considerations to the seam-
welding process: (1) the problem
of the coating alloying with the
electrode; (2) the problem of se-
curing a steel-to-steel contact at
the interface; and (3) the problem
of countering the cooling effect
associated with melting of the
coating.
Equipment and Materials
A circular seam-welding machine
was employed to produce the seam
welds involved in this study. With
a power input of 440 v and 60
cycle current, the transformer for
the welding machine was rated at
250 kva. Control of the current
RESEARCH SUPPLEMENT | 247-s

Table 1—Information on Terne-coated Steel Sheet
Coating Coating ——
weight, class, C,
oz/ft? oz/ft? %N
0.48 0.55 0.06
0.37 0.45 0.07
0.33 0.35 0.05
0.45 0.55 0.05
variables associated with the weld-
ing process was provided by a
thyratron control unit. This fully
electronic control permitted the
selection of “‘on’’ and “‘off” times
of 1 to 32 cycles in one cycle incre-
ments, and provided for current
variation by means of a_ phase
control which adjusted the basic
sine wave to correspond to the
selected percent heat.
The copper-base electrodes em-
ployed were made of a RWMA
Class II alloy recommended for
seam welding coated steels. The
electrodes were 10 in. in diam
and '/, in. thick, with the face
width reduced to */\, in. by 10-deg
tapers, and '/,-in. radii provided
at the face edges. The resulting
electrode face was °/-in. wide
and fitted snugly into the driving
roller. Knurled driving rollers were
employed to rotate the electrodes.
Materials. Steel sheets for pro-
duction of terne-coated sheet steels
are supplied in three qualities;
namely, “commercial,” ‘“‘drawing”’
and “‘physical,”’ according to whether
ductility or mechanical tests are
specified. The materials used in
this investigation were hot-dip
coated 22-, 20- and 18-gage com-
mercial-quality steel sheets. This
means that the steel sheets were
produced from rimmed, capped or
semikilled steel, at the producer’s
option. Table 1 summarizes in-
formation given on the shipping
documents of the material used in
this investigation, and shows the
coating weight as determined by
ASTM triple-spot test, and corre-
Fig. 1—High welding speeds
produced ‘‘tear-drop”’ nugget shape
248-s | JUNE 1960
—— —Steel—-
Mn, P, Ss,
%N % %
sponding “coating class,” plus the
chemical analyses of the steel and
terne alloy.
Procedure
The resistance-seam-welding
process is complicated by interrela-
tion of its four major variables,
namely, electrode force, current tim-
ing, welding current and welding
speed. Toestablish optimum condi-
tions, a systematic variation of the
welding variables must be made us-
ing some arbitrarily selected initial
settings. The investigational proce-
dure described below proved satis-
factory and was applied to each of
the three gages investigated.
Selection of Welding Speeds and
Timing (for initial experiments).
A welding speed of 60 ipm was
selected because work with other
coated steels indicated that this
was the optimum speed. In addi-
tion, a speed of 100 ipm was investi-
gated because of the industrial
trend toward higher welding speeds.
A current timing for making the
first welds was selected by consult-
ing a welding schedule for uncoated
steels and increasing the recom-
mended heating time by one cycle.
This timing was used to establish
the optimum electrode force. The
optimum timing was not deter-
mined until later in the investiga-
tion.
Determination of Optimum Elec-
trode Force. Using the arbitrarily
selected welding speed and current
timing, welds were made at several
settings of electrode force, and for
each electrode force the welding
current was varied to produce a
series of welds. The welds pro-
duced in this manner were often
not of top quality, but a clearly
defined region of better-quality
welds was distinguishable in each
investigation made. The electrode
force that produced the better
welds was designated as “opti-
mum.”
The procedure described above
was applied uniformly to each of
the three gages of material; with
the exception that, for the 22-gage
material, optimum force investiga-
tionS were conducted at three
welding speeds, namely, 60, 100
and 150 ipm, to confirm that no
change in optimum electrode force
accompanied a change in welding
speed.
Determination of Optimum Tim-
ing and Welding Current. With
the established optimum electrode
force, welds were made with varia-
tion in welding current for each of
several current timings. From
these welds, the optimum current
timing and welding current were
determined.
Welding Technique. In prepara-
tion for the welding operation,
weldments were wiped free of loose
dirt and dust with a clean cloth.
No other preparation was deemed
necessary, for the surface was only
slightly oiled. The welds were
made by superimposing one 1-x
30-in. strip upon another and then
seam welding along the center of
the strips. From these welded
strips, specimens were taken for
metallurgical examination, X-ray
evaluation, and corrosion testing.
Metallurgical Examination. Met-
allurgical examination of the welds
consisted of measuring the nugget
penetration* and inspecting the
welds for defects. Both longitudi-
nal and transverse sections were
employed. The longitudinal sec-
tions were used in studying defects
such as microscopic and visual
transverse cracks, lack of nugget
overlap and the extent of porosity;
while transverse sections were
needed to reveal unsymmetrical
nuggets.
Corrosion Testing. 'To determine
the corrosion resistance of terne
plate after it was welded, speci-
mens possessing the heaviest coat-
ing of terne, 0.48 oz per sq ft,
were subjected to 100% humidity
at room temperature for four
months, November through Feb-
ruary, and inspected periodically
for corrosion.
Results
Percent nugget penetration was
used as the first criteria for evalua-
tion of weld quality, but complete
evaluation was based upon inspec-
tion for weld defects and upon
peel-and pillow-test performance.
Measurement of nugget penetration
was made using longitudinally sec-
tioned specimens, for this exposed
several nuggets in each seam weld
and allowed an average assessment of
penetration.
Effect of Welding-speed Varia-
* Nugget penetration is defined to be the ratio
of weld-nugget thickness to the total thickness of
the joint.
 22-GAUGE TERNE PLATE
WELDING SPEED: 100 IPM
TIMING 5 ON, 2 OFF

PENETRATION
%,

%
PENETRATION,
NUGGET 22-GAUGE TERNE PLATE NUGGET
WELDING SPEED: 60 iPm
TIMING 3 ON—2 OFF

12 14 16 18 20 22 13 1S 7 ig 2! 23
WELDING CURRENT IN THOUSANDS OF AMPERES WELDING CURRENT IN THOUSANDS OF AMPERES
Fig. 2—Effect of electrode force on nugget penetration Fig. 3—Effect of elecirode force on nugget penetration
and welding current for 22-gage terne plate and welding current for 22-gage terne plate welded at 100 ipm
welded at 60 ipm

tion. To determine the effect of
welding speed on optimum electrode
force, welds were made in 22-gage
material at speeds of 60, 100 and
150 ipm, with various electrode
forces, and a current timing of 4
cycles on and 2 off. It was found
that the optimum electrode force
was unaffected by changes in weld-
ing speed. For 22-gage sheet, the
optimum electrode force was 900
Ib. One effect of increased weld-
ing speed was that each increase
in speed required an increase in
current in order to achieve a given
nugget penetration. The increase
in current was required because
more material was passing between
the electrodes per unit time, due
to increased speed, and additional
heat (current) was required
weld the ‘“‘extra’’ material.
It was also found that an increase
in the welding speed increased
nugget spacing and altered nugget
shape. Nugget spacing was barely
sufficient to produce tangency of
the nuggets at 100 ipm, so this
speed was the upper linit for pro-
ducing seam welds. The effect
of increased welding speed on nug-
get shape was to change the con-
tour from oval to “tear drop”
as shown in Fig. 1. Large voids
occurred frequently in the thickest
portion of the weld nugget near the
plane of the interface due to pre-
mature release of electrode force
inherent with high welding speed.
The shape of the nugget shows
that, after the initial impulse of
current, the amount of heat gen-
erated decreased. The decrease in
nugget thickness was the result of
increased electrical resistance caused
by heating of the steel. After the
first impulse of current, the ma
terial adjacent to the weld area
was preheated by conduction, and
portions of the subsequent current
flow were diverted around the nug-
get region, thus reducing the heat
generated in the trailing weld area.
One effect of the diverted current
was the formation of twin projec-
tions at the interface periphery of
almost every nugget.
The fact that the *‘diverted-
current” phenomenon is common
to all welds was shown by the
presence of the projections on welds
made both at 150 and 60 ipm as
shown in Fig. 1 and later in Fig. 4,
respectively. The overlapping nug-
gets at low welding speeds obscure
to
7 : s
Del etka dey a ; rity: Cpe
ee Vp ee’s 4 AZ ¢!
Pee> aC aa wee ei a
a i
- ORS + Sw ew
the decreased heating effect, but
the wide nugget spacing of the
higher welding speeds distributes
the decrease in nugget thickness
and produces the “‘tear-drop”’ shape.
Effect of FElectrode-force Varia-
tion. Figures 2 and 3 show the
results of welds made in 22-gage
terne plate with variations in elec-
trode force at welding speeds of
60 and 100 ipm, respectively. The
maximum pentrations obtainable
without excessive flashing and elec-
trode sticking were 80° in 22-
gage, 70% in 20-gage and 50% in
18-gage terne plate which are ap-
proximately the maximum pene-
Fig. 4—Macrograph
showing the normal
15,000 increase in nugget
size which accompa-
nies increased weiding
current. Welds were
made in 22-gage terne
plate with 900-Ib elec-
trode force and weld-
ing speed of 60 ipm.
x 12. (Reduced by
20% upon reproduc-
tion)
. 17,000
,
—-_
ee tees ee

WELDING RESEARCH SUPPLEMENT 249-s

 | |
FLASHING AND SURFACE SCALDING | FLASHING , SURFACE SCALDING
TRANSVERSE CRACKS TRANSVERSE CRACKS TRANSVERSE CRACKS TRANSVERSE CRACKS
P i
PERRO al |
LARGE } POROSITY+ © SEE SEVERE SURFACE LARGE + POROSITY+ SURFACE
x tome) INDENTATION INDENTATION
EEK
x So oO T| |
RK XO 0
POROSITY LARGE POROSITY
POROSITY
PENETRATION,
% fetex : POROSITY
’
+INCONSISTENT AND INSUFFICIENT —
PENETRATION
} INSUFFICIENT PENETRATION
NUGGET
PENETRATION
%, 22 GAUGE TERNE PLATE NUGGET + + .
WELDING SPEED: 60 IPu 22 GAUGE TERNE PLATE
Timin@: SON — 2 OFF WELDING SPEED’ 100 1PM
| T Timing: SON, 2 OFF
1 |
12 14 16 18 20 22 13 15 17 19 2! 23
WELDING CURRENT IN THOUSANDS OF AMPERES WELDING CURRENT IN THOUSANDS OF AMPERES
Fig. 5—Region of optimum welds (shaded area) and Fig. 6—Region of optimum welds (shaded area) and
defects encountered outside the optimum region defects encountered outside the optimum region for
for 22-gage terne plate welded at 60 ipm 22-gage terne plate welded at 100 ipm

trations obtained in galvanized steel
of the same gage. Figures 2 and 3
also illustrate that an increase in
electrode force requires an increase
in current to maintain a given
penetration.
The macrographs in Fig. 4 show,
for 22-gage material welded at
60 ipm, the effect of current varia-
tion at an electrode force of 900
lb. The weld produced at 15,000
amp did not possess complete pene-
tration and was unsatisfactory un
der pillow testing. Welds made
with 16,000, 17,000, 18,000, 19,000
and 20,000 amp show the normal
increase in nugget size associated
with an increased current.
For the electrode forces investi-
gated, it was noted that the weld
defects could be grouped into zones
or regions in which a particular
weld defect predominated. The
shaded areas in Figs. 5 and 6 indi-
cate regions of optimum weld qual-
ity. The figures also point out
the defects encountered if condi-
tions are outside the optimum
zone. Figures 5 and 6 are 22-
gage material at welding speeds
of 60 and 100 ipm, respectively.
The limits of the optimum regions
for each of three gages were set
by excessive flashing and electrode
sticking at the higher penetrations
and by insufficient bonding or
joining at the lower penetrations.
The lateral boundaries of the opti-
mum region were not so easily
defined, for the change in weld
quality was gradual. The bound-
aries were drawn in the light of
the observation that acceptable
welds could be achieved with elec-
trode forces 100 lb. above or below
the designated optimum electrode
force. The optimum forces for
22-, 20- and 18-gage material were
found to be 900, 1000 and 1100 lb, With an electrode force of 900 lb
respectively, which are partially and a welding current of 17,000
the same as the electrode forces amp, 60% penetration was ob-
recommended by Volek! and tained at 60 ipm as compared to
Allen? for seam welding the corre- 48% at 100 ipm. It appears that
sponding gages of galvanized steel. intermediate welding speeds would
The only difference in recommended
electrode forces was that for 22-
gage material both Volek and Allen
recommended 1200-lb_ electrode
force; however, their welds were
essentially pressure welds with no
real nugget formation. Welds
made with 900-lb electrode force
possessed large well-defined nug-
gets as was shown in Fig. 4. PENETRATION,
%
Where defects were present, these
were similar in all gages of material
except that transverse cracks were NUGGET 22-GAUGE TERME PLATE
detected in the 22-gage material WELOMG SPEEDO 60 IPu
Tmime: 3 ON - & OFF %+.
and not in the 20- and 18-gage *
terne plate. A discussion of the $00 700 900 100
causes which produced these cracks ELECTRODE FORCE IN POUNDS
is presented under “‘Weld Defects.” Fig. 7—Effect of electrode force on nug-
Figures 7 and 8 show the effect get penetration with welding current
of a variation in electrode force on held constant. 22-gage terne plate;
nugget penetration when the weld- welding speed 60 ipm
ing current is held constant. They
pertain to 22-gage terne plate at
60 and 100 ipm, respectively. The 22-GAUGE TERWE PLATE
decrease in penetration obtained WELOING SPEEDO: 100 1PM
Timing 5 ON, 2 OFF
with higher electrode force is due
to decreased interface-contact re-
sistance causing less heat generation.
The macrographs in Fig. 9 illustrate
the decrease in penetration obtained
with increased electrode force in PENETRATION
%,
22-gage material at a constant cur-
rent of 17,000 amp.
As shown in Figs. 7 and 8, the NUGGET
curvature of the penetration lines
changed from convex to concave
when the welding speed was changed
from 60 to 100 ipm. It is believed ELECTRODE FORCE IN POUNDS
that this occurrence is due to the Fig. 8—Effect of electrode force on nug-
“tear-drop” nugget shape which get penetration with welding current
reduces the average nugget pene- held constant. 22-gage terne plate;
tration for high welding speeds. welding speed 100 ipm

250-s | JUNE 1960

 produce transition configurations Fig. 9—Macrograph
from convex to concave, and that showing the decrease
a particular welding speed would in nugget size pro-
produce a linear relationship be- duced by increased
electrode force in 22-
tween nugget penetration and elec- gage terne plate
trode force. welded at 60 ipm with
Effect of Current-timing Varia- a welding current of
tion. Briefly stated, the biggest 17,000 amp. X 12.
problem associated with seam weld- (Reduced by 20%
ing is control of the “heat input’ upon reproduction)
at the weld area. Selection of an
electrode force and a welding cur-
rent provides a certain amount of
heating control, but fine adjustment
can best be accomplished by current
timing. The effect of current tim-
ing is to distribute the current im-
pulses along the weld. Current
timing is referred to as “heat”
time and “cool” time or as ‘“‘on”’
time and “off” time. The heat
time governs the amount of heat
available to produce the weld nug-
get; while the cool time determines
the nugget-to-nugget. spacing and
allows time for heat dissipation,
which is necessary to prevent over-
heating in the weld areas. increase in nugget size which was
Heat-time Variation. Change in helpful in improving nugget over-
heat time (while holding the cool lap, but tended to cause large voids
time constant) was found to have in the nugget interior.
little effect on the penetration ob Cool-time Variation. For 22- and
tained in any of the three materials. 20-gage terne plates the effect of
Figures 10 and 11 show this result increasing the cool time, while
for 22-gage terne plate at speeds of holding the heat time constant,
60 and 100 ipm, respectively. This was to sharply reduce the amount
finding indicates that, for a given of current required to produce a %PENETRATION,
gage of terne plate, the amount of given nugget penetration. Figures
penetration obtained depends pri- 12 and 13 illustrate this result for
marily upon the welding current 22-gage terne plate at speeds of
NUGGET 22-GAUGE TERNE PLATE 7
used to make the weld. The weld- 60 and 100 ipm, respectively. This WELDING SPEED: 60 IP
ing current, however, is determined was the result expected because ELECTRODE FORCE: 900 ves |
by the current timing and the per- the increased cool time increased
cent heat setting. Percent heat nugget spacing thereby reducing 14 6 8
WELDING CURRENT IN
is the ratio of the heat produced shunting effects and allowing more THOUSANDS OF AMPERES
with an altered sine wave to the time for heat dissipation between Fig. 12—Effect of cool-time variation on
heat produced by an _ unaltered, current impulses. The time avail- nugget penetration and welding current.
full-sine wave. Increased heating able for heat dissipation is important 22-gage terne plate; 900-lb electrode
time was found to produce a slight for it lowers the temperature and force; welding speed, 60 ipm

| 22-GauGE TERWE PLATE

WELOING SPEED 100 1Pu
ELECTRODE FORCE 900 LBs

PENETRATION,
& PENETRATION,
% PENETRATION
&%,
22-GAUGE TERWE 60PLATE
WELOING SPEED: 1pm
ELECTRODE
© 30N,2 OFF 900 LSS
FORCE
NUGGET 4 40N,2 OFF NUGGET NUGGET 22-GAUGE TERNE PLATE
Oo SON, OFF WELDING SPEED’ 100 1pm
ELECTRODE FORCE 900 .6S
1S 17 19 21 15 7 19
WELDING CURRENT IN WELDING CURRENT N WELDING CURRENT N
THOUSANDS OF AMPERES THOUSANDS OF AMPERES THOUSANDS OF AMPERES
Fig. 10—Effect of heat-time variation on Fig. 11—Effect of heat-time variation on Fig. 13—Effect of cool-time variation on
nugget penetration and welding current. nugget penetration and welding current. nugget penetration and welding current.
22-gage terne plate; 900-lb. electrode 22-gage terne plate; 900-lb electrode 22-gage terne plate, 900-lb electrode
force; welding speed, 60 ipm force; welding speed, 100 ipm force; welding speed, 100 ipm

WELDING RESEARCH SUPPLEMENT 25l1-s

 T a combination of two of them might
18-GAUGE TERNE PLATE
WELDING SPEEDO’ 60 IPM
ELECTRODE
t FORCE
t ' 1100 ; L8S
PENETRATION,
% current was investigated because
NUGGET
15 17 19
WELDING CURRENT IN
THOUSANDS OF AMPERES
Fig. 14—Effect of cool-time variation on
nugget penetration and welding current.
18-gage terne plate; 1100-lb electrode
force; welding speed, 60 ipm
the electrical resistance of the weld-
ment at the point of the next cur-
rent impulse. The slight reduction
in resistance tends to cause less
total heat to be generated between
the electrodes; however, this loss
is more than offset by the heating
effect produced by the proportional
increase in the current which flows
through the weld area, since heat
is proportional to RI’.
The findings in the 18-gage ma-
terial were not at all similar to the
results obtained in the 22- and 20-
gage terne plate as may be seen in
Fig. 14. This is because increased
cool time increased the current
required to achieve a given pene
tration. Apparently, the heavier
gage material introduces some new
consideration to the welding opera-
tion; possibly an increase in elec-
trical resistance or an_ increase
in heat dissipation due to larger
amounts of surrounding metal.
Either one of these possibilities or
Fig. 15—Composite micrograph of weld defect found in a weld
produced in 22-gage terne plate with 900-lb electrode force,
welding speed of 150 ipm, and 22,000 amp of continuous current.
Nugget penetration was 35%. Micrograph shows less than
half of the actual defect. < 156. (Reduced by '/, upon re-
production)
252-s | JUNE 1960
account for the increase in current
required to obtain a given penetra-
tion, but they provide no ready
explanation for the transition range
in which penetration remained un-
changed by substantial increases
in current.
Continuous Current. Continuous
it offered a means of achieving
nugget overlap at high welding
speeds. It was found that nugget
overlap was consistent, but that
close control of the welding current
was mandatory to minimize weld
defects. Slight overheating of the
weld produced large voids and longi-
tudinal cracks as shown in Fig. 15.
The defects pictured in Fig. 15
occurred in a weld possessing only
35° penetration made with 900-lb
electrode force, at a welding speed
of 150 ipm, and with welding cur-
rent of 22,000 amp. Welds with
higher penetrations contained larger
voids.
Welds made with currents in-
sufficient to produce weld nuggets
were sporadic combinations of sol-
dering and solid phase bonding.
The solid-phase bonding appeared
very much as that pictured in Fig.
17. It appears that, if sound welds
are to be produced by continuous
current, the nugget formation should
be avoided, especially for high weld-
ing speeds where the release of
the electrode force is premature;
also, emphasis should be placed
on the pressure welding obtained
with low welding current.
The sporadic solid-phase bond
ing obtained might be improved
by reducing the width of the elec-
trode face or by increasing electrode
force. If dependable pressure weld-
ing were achieved, then it might
also be possible to increase welding
speed.
Weld Defects. Weld quality in
each of the three gages of terne
plate was found to be most affected
by electrode force and cool time.
Generally, welds made with less
than optimum electrode force were
degraded by the presence of inclu-
sions and widely distributed poros-
ity. Welds made with electrode
force above the optimum suffered
from surface indentation and severe
squeezing of the weld nugget.
The cool time employed to pro-
duce a weld was also a factor in
determining weld quality. Gener-
ally, reducing the cool time to one
cycle tended to overheat the weld
area and cause porosity and shrink-
age cracks in the nugget. A cool
time of two cycles normally pro-
duced welds with less porosity and
shrinkage defects. Welds made
with three cooling cycles were about
equal in quality to the two-cooling-
cycle welds except that nugget
overlap was lacking.
Fig. 16—Shrinkage defect caused by ex-
cessive heat time. Surface indentation
and bulging at center of weld due to de-
fective electrode face. x 12. (Reduced
by '/, upon reproduction)
The over-all effect of cool time,
however, must be judged with
consideration given to heat time,
materia] thickness and current mag-
nitude. Excessive current pro-
duces welds having porosity and
shrinkage defects. Figure 16 shows
a weld made with an excessive heat
time of 6 cycles which was partially
remedied by 2-cycles cool time;
but even so, the nugget in the 18-
gage specimen was overheated and
displayed a large shrinkage defect.
Lack of nugget overlap was a
problem associated with the 22-
and 20-gage terne plate at the higher
welding speed of 100 ipm. Nugget
overlap was found to be improved
with an increase in material thick-
ness, due to the increased heating
associated with the increase in
resistance. For this reason, nugget
overlap improved from marginal
in the 22-gage terne plate to mod-
erate in the 20-gage terne plate,
and to more than adequate in the
18-gage material.
Figure 17 is a micrograph of the
region between two of the layers or
bands of martensite, and reveals
that solid-phase bonding has been
accomplished. In _ pillow _ tests,
welds of this nature displayed no
pin-hole leaks up to 100 psi and
withstood pressure of over 200 psi
before failure occurred outside the
seam weld.
Transverse cracking was a weld
defect that was found rather fre-
quently in 22-gage terne plate,
occasionally in 20-gage terne plate
and not at all in the 18-gage ma-
terial. These cracks were detected
largely in welds of higher penetra-
tion, and occurred invariably in
the depressions which were formed
in the weld surface by the knurled
electrode faces. Figure 18 is a
macrograph of a longitudinal sec-
tion of two welds showing unusually
large cracks which pass completely
through the weld. It was found
that the cracks ranged in size from
the microscopically small to the
visibly large. The consistent loca-
tion of the transverse cracks in
the impressed furrows suggests that
these cracks are caused by thermal
and vibrational stresses. Depres-
sions would serve to concentrate
the stresses and trigger the crack
propagation. This view is some-
what supported by the routine
observation that the 22-gage weld-
ments were subjected to severe
vibration due to the fluctuating
magnetic field surrounding the weld-
ing operation.
To test this idea, a simple fixture
was added to the backup plate
used to guide the strips between
the electrodes. A small shelf was
placed about four inches to the side
and a quarter inch above the point
of contact with the electrodes.
The purpose of the shelf was to
lift the weldments and maintain
a slight spring tension in them as
they emerged between the elec-
trodes. With this device, welds
were made in the 22-gage material
at the same conditions which pro-
duced cracking in the first welds.
There was a definite reduction in
the vibration observed during the
welding operation, and no large
cracks were found in the metallur-
gical specimens. Some small trans-
verse cracking occurred, but magni-
fication was required to detect the
small and infrequently spaced cracks.
Nugget Hardness. A survey of
the hardness across a weld area
was made using a Knoop hardness
tester. It was found that the
dark etched layers at the upper and
lower surfaces of the weld were
harder than any other structure
in the weld area, possessing a Rock-
well “B” hardness of 108. This
exceeded the Rockwell “B”’ hard-
ness of 95, which is the maximum
hardness obtainable in steel with
the carbon content involved in this
investigation. A similar structure
and hardness had been encountered
by Volek' in his investigation of
galvanized steel, and an investiga-
tion into the source of the unex-
pected hardness found that carbon
concentration occurred in some areas
and produced the high hardness.
That a similar structure and
events occur in terne plate should be
expected, since the chemical analy-
ses for the terne-coated and gal-
vanized steels were very similar.
The fact that the structures and
hardness were similar, also detracts
from the idea that the ‘“extra’”’ Fig. 17—Micrograph of solid-phase bond-
hardness was due to alloying of ing achieved between the bands of
the coating with the steel. If this hard constituent which connect the nug-
were the case, then it would be get. xX 156. (Reduced by upon re-
expected that the hardness of the production)
“‘galvanized”’ dark areas would differ
from the “‘terne plate’’ dark areas.
For the welds made in this in-
vestigation there was a heat-affected
zone (HAZ) composed of large
grains in the region between the
dark etched layers and the nugget.
The hardness of the heat-affected
zone was about 72 on the Rock-
well “B”’ scale. Across the nugget
the hardness was near the maxi-
mum attainable with 0.06°-carbon
steel. The nugget hardness was
93 on the Rockwell “B” scale. Fig. 18—Longitudinal sections of two
Figure 19 presents the findings of welds possessing unusually large trans-
verse cracks completely through the
the hardness survey. A hard ma- weld. xX 10. (Reduced by upon re-
terial possesses high strength, but production)
it is also brittle; therefore, the
presence of the dark etched layers
near the surface was conducive to
cracking and contributed to the
production of transverse cracks.
Corrosion Resistance. For com-
parison, a few galvanized-steel speci-
mens were included with the terne-
plate specimens in the corrosion
test. The welds in the galvanized
material quickly developed a white
‘frosting’ over their entire surface;
while the terne-plate specimens in
the same interval developed rust
areas on and near the seam weld.
The corrosion specimens were
1-x 2-in. sections cut from the test
weld strips. In the 100°, humidity
room, the specimens were inclined
at an angle from the _ vertical.
Since a fine spray was ejected into ENTER
the test chamber near the ceiling,
the inclination of the specimens Fig. 19—Survey of the hardness
tended to produce a wet upper and across a weld nugget
a dry lower surface on each speci-
men. The abundance of water
on the upper surface caused ex- men was limited, and in the four-
tensive rusting, and the surface month test period appeared to do
was heavily coated with a layer of no great harm to the weld. How-
red and orange oxide. The lower ever, the aqueous attack on the
surface, however, was only locally upper side of the specimen was
attacked, with the rust areas de- severe and concentrated along the
veloping where there were irreg- edge of the weld. The welding
ularities in the weld surface. Cor- operation did not remove all of
rosion on the dry side of the speci the terne from the path of the weld,
WELDING RESEARCH SUP PLEMENT | 253-s
Table 2—Recommended Schedule for Seam
Welding 22-, 20- and 18-Gage Terne Plate
THICKNESS ELECTRODE} ELECTRODE
FACE FORCE
WIDTH,
inches | gouge MIN MAX
inches Ibs
/s2
*/s2
*/se
but enough was removed to expose
the steel to corrosion attack. The
corrosion resistance of welded terne
plate was only moderate and was
much less than that of welded gal-
vanized steel.
Electrode Life. Alloying of terne
metal with the electrodes occurred
in the seam-welding operation and
produced a marked change in weld-
surface appearance and electrode
contour. The first welds were made
with new and freshly machined
electrodes and were accompanied
by flashing and a tendency for
electrode sticking. As welding con-
tinued, the alloy coating on the elec-
trodes increased and the weld sur-
faces lost their sticky, melted ap-
pearance and began to show dis-
tinct ridge impressions from the
knurled electrode face. Flashing
and electrode sticking were reduced
even for high welding currents.
After 600 ft of welding, the alloy-
ing on the electrodes had produced
a line depression in the middle of
the electrode face which encircled
the electrode wheel. Also, the con-
tour of the electrode face had been
changed from flat to concave.
Other effects were increased elec-
trode indentation at the edge of
the weld and bulging at the center
of the weld. Reference is made to
Fig. 16 to illustrate the indentation
and bulging produced in the weld.
For the concave shape to have
developed, more alloying must have
occurred at the center of the elec-
trode face than at its edges. The
conditions surrounding the welding
event were such as to produce
254-s | JUNE 1960
WELDING CURRENT WELDING | PERCENT
SPEED, TIMING, CURRENT,| HEAT
ipm amperes
Ibs.
60 17,000
ae
18,000
17,500
18,500
18,000
19,000
increased wear at the center of the
electrode face. The heat generated
at the weld surfaces was dissipated
by conduction and water cooling.
The center of the electrode face
was less affected by these cooling
processes than were the _ edges;
therefore, its higher temperature
was conducive to more alloying
and wear.
Electrode life was not much
greater than 500 ft due to the bulge
in weld thickness. This compares
to an estimated electrode life of
over a thousand feet for galvanized
steel. The vaporization of zinc
removed it from the weld area so
that little remained to alloy with
the electrodes; whereas, with the
melting of terne alloy, the coating
remained in close contact with the
electrodes and was readily available
for electrode pickup. It is expected
that electrode life could be greatly
improved if additional cooling were
available.
Conclusions
Based upon an evaluation of the
results obtained in this investiga-
tion, the seam-welding schedule in
Table 2 is given as a guide for weld-
ing 22-, 20- and 18-gage terne plate,
and the following conclusions are
presented:
1. The optimum electrode force
for a given gage of terne plate is
independent of the welding speed.
2. For a given gage of material,
the optimum electrode force is the
same for terne plate and galvanized
steel.
3. The welding current recom-
mended for welding terne plate is
in line with that recommended for
galvanized steel.
4. The optimum current timing
is the most difficult evaluation to
make and the timings presented in
Table 2 should be interpreted as
being approximate rather than final
determinations.
5. A fitted knurled driving roller
is necessary to remove pickup from
the electrodes and to prevent mush-
rooming.
6. The most common weld de-
fect was porosity, which was pres-
ent, more or less, in all welds.
7. Transverse cracking can be
eliminated or greatly reduced by
restricting the vibration of the
weldments after passing between
the electrodes.
8. The corrosion resistance of
welded terne plate is much less than
that of welded galvanized steel,
and judgment should be exercised
in using such welds where they
would be exposed to water for long
periods.
9. Electrode life is limited in
seam welding terne plate, but this
difficulty might be removed if a
means were provided for increased
cooling.
10. Lack of nugget overlap does
not necessarily imply a “leaky”
seam weld, since “‘martensitic’”’ pres-
sure welds occur between the nug-
gets.
11. By employing continuous cur-
rent and higher interface pressures
to produce solid-phase bonding,
it seems likely that welding speed
could be increased.
Acknowledgment
The copper-base RWMA Class
II alloy electrodes were donated by
P. R. Mallory and Company;
the hot-dip coated 22-, 20- and 18-
gage commercial-quality steel sheets
were contributed by Republic Steel
Corp.
References
1. Volek, C. W. and Begeman, M. L., “Effect
of Zinc Coatings on Resistance Seam Welding of
Sheet Steel,” THe Wetpinc Journat, 38 (3)
Research Suppl., 113-s to 121-8 (1959)
2. Allen, W. J. and Begeman, M. L., “Seam
Welding Galvanized Steel,”’ [hid., 37 (4) Research
Suppl., 138-¢ to 143-8 (1958).
3. Resistance Welder Manufacturers’ Associa-
tion, Resistance Welding Manual, Revised Edition,
Philadelphia, Pa (1948).
Arc Welding of 5%
Wide use of low-chromium-molybdenum
prompts study on properties of weldments
particularly with reference to extent to which
treatments are required to obtain satisfactory
BY J. BLAND AND G. F. TISINAI
ABSTRACT. Unrestrained weldments
were made using 5°), Cr 2% Mo al-
loy-steel pipe and 5% Cr 2% Mo,
1'/,% Cr 2% Mo, 25% Cr - 12% Ni
or 25% Cr—-20% Ni electrodes. The
hardness and tensile properties were
correlated for both 5% Cr-—'/2% Mo
alloy-steel pipe material and 5% Cr
2% Mo alloy weld deposits. The
heat-affected zones of the 5% Cr — '/2%
Mo alloy-steel pipe had adequate duc-
tility even in the absence of preheat or
postheat treatments. Postheat tem-
peratures of 1250° F and above im
parted appreciable ductility to 5°
Cr 2% Mo weld metal; however, a
temperature of 1400° F gave markedly
more ductility and is preferred. if
1!/,% Cr—1/2% Mo, 25% Cr-12% Ni
or 25% Cr-—20% Ni electrodes were
used for unrestrained weldments of 5“;
Cr 2% Mo alloy-steel pipe, no pre-
heat or postheat treatments were
needed to obtain adequate weld duc-
tility. However, refinery experience
has indicated that austenitic stainless-
steel welds on ferritic base metals may
crack eventually when subjected to
thermal cycling.
Introduction
The wide use of low-chromium-
molybdenum steels in the petroleum
industry has prompted a series of
studies on the properties of weld-
ments of these steels, particularly
in reference to the extent to which
thermal treatments are required to
obtain satisfactory properties.
Three previous papers'~* have de-
scribed the results of welding 0.5%
Cr—0.5% Mo, 1.25% Cr-—0.5% Mo
and 2.25% Cr-1.0% Mo steels.
This paper will describe the results
J. BLAND, formerly with Standard Oil Company
Indiana), is Consulting Engineer, Welding Metal
lurgy and Development, Knolls Atomic Power
Laboratory, General Electric Co., Schenectady,
N. Y., and G. F. TISINAI is a Project Supervisor,
Engineering Research Department, Standard Oil
Co. (Indiana), Whiting, Ind
Alternate paper for AWS 4\ist Annual Meeting
held in Los Angeles, Calif., April 25-29, 1960
Cr—0.5% Mo Alloy-Steel
steels in petroleum industry
of these steels,
thermal
properties
of a similar study made on 5.0%
Cr—0.5% Mo steel. In the earlier
papers, particular reference was
made to the resistance of the
Cr— Mo steels both to graphitization
and to high-temperature hydrogen
attack.
The American Standard Code for
Pressure Piping‘ recommended a
minimum preheat temperature of
450° F and a minimum stress-
relieving temperature of 1200° F.
This treatment is accepted also by
the AMERICAN WELDING SOCIETY.
The Pipe Fabrication Institute’
recommends a 250° F minimum
preheat temperature before tack
welding, and a 400 to 700° F preheat
and interpass temperature or a
partial stress relief between 1200
and 1400° F for 30 min or more if
welding is interrupted. Postheat
treatment of 1325 to 1400° F for
1 hr per in. of thickness, but not
less than 1 hr, also is recommended
by the Institute. The AWS Stand-
ard for Interruption of Heat
Treatment’ states that the heating
cycle may be safely interrupted for
the 5.0% Cr-—0.5% Mo steel in
wall thicknesses 1 in. and below,
provided it is welded under con-
trolled procedures using low-hydro-
gen electrodes. However, the weld
deposit should never be less than
one-third the wall thickness or
two layers, whichever is greater.
Holmberg* reported on the weld-
ability of the ferritic 5 to 9% Cr
0.5 to 1% Mo steels and the use of
austenitic electrodes when post-
heating could not be done readily.
As in the past studies of this
series, particular emphasis was placed
on a correlation of the hardness
measurements of the weld metal
and heat-affected zones with the
ductility values exhibited in both
tensile and bend specimens. The
need of such a correlation is em-
WELDING
Pipe
phasized in particular when elec-
trodes depositing high-strength weld
metal are used, since deformation in
these specimens under load occurs
preferentially in the lower strength
base metal.
The mechanical property most
difficult to evaluate from the tests of
weldments is ductility. A butt-
weld tensile-test specimen, for ex-
ample, involves a composite volume
of metal including unaffected base
metal, deposited weld metal and
heat-affected base and weld metals.
Each portion contributes to the
over-all deformation to varying
degrees. The extent of such varia-
tion can be determined most readily
by a hardness survey across the weld
section, providing the ductility of
the particular zone can be cor-
related with the particular hardness
level. If this correlation is un-
known, there can be no sound basis
in using the hardness measurements
for the evaluation of the weld.
In the text of this paper, the fol-
lowing designations will be used:
1'/, Cr Mo for 1.25% Cr—0.5% Mo
steel, 5 Cr Mo for 5.0% Cr—0.5% Mo
steel, 25-12 Cr Ni for the 25% Cr
12% Ni austenitic stainless steel
and 25-20 Cr Ni for the 25% Cr
20% Ni austenitic stainless steel.
Experimental Procedures
Portions of 5 in.-schedule 160,
5 Cr Mo steel pipe were heat
treated to the 1700° F normalized,
1700° F water quenched, 1700° F
water quenched and _ tempered,
1900° F normalized, 1900° F water
quenched and _ 1900 F water
quenched and tempered states.
The analysis of the pipe is given in
Table 1. Button-head, 0.505-in.
diam tensile bars were made from
such heat-treated materials, as well
as from as-received stock, and tested
to failure in a hydraulic testing
RESEARCH SUPPLEMENT 255-s
Table 1—Chemical Composition of Deposited Weld Metal and Alloy Pipe Material
Brand AWS Covering - Chemical composition, %
code class type Mn P S Si
Electrode No. E502-15 Low hydrogen 0.011 0.013 0.87
Electrode No. E502-15 Low hydrogen 0.011 0.015 0.82
Electrode No. E502-15 Low hydrogen 0.014 0.012 0.24
Electrode No. E502-18 Iron powder-
low hydrogen 0.022 0.014 0.45
Pipe material 0.014 0.014 0.39

machine. The button heads of all
tensile specimens were cut off and
their hardnesses determined by
Rockwell B and C tests. These
hardness values then were converted
to Brinell hardness values. Equa-
tions correlating the hardness and
tensile data were obtained by ana-
lyzing the data on an IBM 705
digital computer. Particular em-
phasis wiil be placed on the equation
correlating hardness with percent
elongation im 2 in. (hereafter re-
ferred to as “‘ductility”’).
Test plates for all-weld-metal
specimens of four different brands of
5 Cr Mo electrodes were made in
accordance with AWS specifications.
Analyses of the as-deposited metals
are given in Table 1. The test
plates were made with combinations
of 300, 500° F and no preheats with
both 1350° F and no postheats.
Duplicate all-weld-metal, button-
head, 0.505-in. diam tensile bars
were made from each weld deposit
and tested to failure in a hydraulic
testing machine. The button heads
of all tensile specimens were cut off
and their hardnesses determined
by Rockwell B and C tests. These
hardness values then were converted
to Brinell hardness values. Equa-
tions correlating the hardness and
tensile data were obtained by ana-
lyzing the data on the digital com-
puter.
Full-thickness, multipass butt
welds were made between 2'/,-in.
long sections of the 5-in., schedule
160, 5 Cr Mosteel pipe with electrode
brand No. 1. All weld joints were
60-deg included-angle single vees
with a '/3. to '/\-in. root face and a
*/3. to '/s-in. root opening. Backing
straps were not used. One weld-
ment was made with each of 300° F,
500° F and no preheats. All welds
were made in the flat position (pipe
horizontally rolled) with welding
current in the range recommended
by the manufacturer ofthe electrode.
Each welded ring was cut longitu-
dinally into 16 pieces, and the
individual pieces were postheated
for '/», 1, 2 and 4 hr at each of the
temperatures 1250, 1300, 1350 and
1400° F. Hardness measurements
were made of the welds, heat-affected
zones and base metals on each of the
48 pieces after they had been pol-
ished suitably.
Full-thickness multipass butt
welds were made between 6-in. long
sections of the 5-in., schedule 160,
5 Cr Mo steel pipe with each of the
electrodes listed in Table 1. All
weld joints were 60 deg included-
angle single vees with a '/3. to '/i«-
in. root face and a */3. to '/s-in.
root opening. Backing straps were
not used. The welds were made
with four preheat-postheat combina-
tions, viz.,300—1250° F,500—1250° F,
300-1350° F and 500-1350° F.
All postheat times were 1 hr. All
welds were made in the flat position
pipe horizontally rolled) with weld-
ing currents in the range recom-
mended by the manufacturers of
the particular electrodes. Side-
bend, notch-bend, hardness-meas-
urement and Charpy V-notch impact
specimens were prepared from the
weldments. Longitudinal bend
specimens were prepared from full-
thickness longitudinal butt welds
made between 6-in. long quarter
sections of the pipe under similar
welding conditions described above.
Full-thickness multipass butt
welds were made between 6-in. long
sections of the 5-in., schedule 160,
5 Cr Mo pipe with austenitic stain-
less-steel electrodes of the 25-12
Cr Ni and 25-20 Cr Ni compositions
and the low-alloy ferritic electrode
of the 1'/, Cr Mo composition.
Conditions of welding were similar
to those described previously for
5 Cr Mo electrodes except for pre-
heat-postheat conditions. The
welds made with the austenitic
stainless-steel electrodes were made
both with no preheat and with a
500° F preheat. No postheats were
made. The welds made with the
1'/, Cr Mo electrode were made
with a 300° F preheat followed by
both no postheat and a 1250° F-
1 hr postheat. Side-bend, notch-
bend and _ hardness-measurement
specimens were prepared from the
weldments.
Results
Hardness- Tensile Properties of
5 Cr Mo Pipe Metal. The tensile
properties of heat-affected zones of
pipe welds are virtually impossible
to obtain directly because of their
small volume. However, the micro-
structures of such zones usually
are intermediate between the micro-
structures of the base metal in the
normalized and in the water-
quenched (from austenitizing tem-
peratures) conditions. Through the
heat treatments given this pipe
metal, a variety of microstructures
was obtained which had various
hardness values. The data ob-
tained in these experiments showed
that the hardness and tensile prop-
erties produced by any given tem-
pering treatment were very similar
whether the temperature from which
the sample was water quenched was
either 1700 or 1900° F (see Table 2
and Fig. 1). The correlation be-
tween the hardness and _ tensile
data obtained by the digital com-
puter analysis are given below. The
precision limits for the quadratic
equations were much better than
those for the linear equations:
Precision limits
for correspond-
ing linear
equations
Yield strength, psi +18,090 psi
= 1331.1 Bhn—1.73
(Bhn)? — 122,230
(+11,160 psi)
Tensile strength, psi +9,170 psi
= 246.52 Bhn + 0.503
(Bhn)? + 26,480
(+7120 psi)
%Y Elongation in 2 in.
= 69.92 — 0.314 Bhn
+ 0.00044 (Bhn)? (i.e.,
ductility) (+2.42%)
% Reduction of area
= 56.98 + 0.211 Bhn
— 0.00056 (Bhn)?
(+4.74%)
The curves for the above equations
were drawn by the 705 computer
and the one correlating ductility
and hardness is shown in Fig. 2.
By applying the equations to hard-
ness data obtained in heat-affected
zones of pipe welds, the tensile
properties of the heat-affected zones
can be approximated.

256-s | JUNE 1960

Table 2—Mechanical Properties of Heat-treated 5 Cr Mo Steel Pipe
Specimen Thermal Hardness, Yield Ultimate Elongation, % Reduction
no. treatment Bhn? strength, psi’ strength, psi in 2 in. of area, %
l As received 151 44,100 76,000 wa
2 1700 F—1 hr—air cool 362 121,000 190,000 n~
< an
1700 F—1 hr—H.O 372 140 ,000 190,000
1700 F, H.O, 1100 F—'/. hr 322 135,000 153,000 RO>
ODini
©
1700 F, , 1100 F—1 hr 283 122,000 138,000 >T
1700 F, 1100 F—2 hr 270 117,000 134,500
1700 F, 1100 F—4 hr 260 109,000 126,000
1700 F, 1200 F—'/. hr 250 102,800 121,000 ~~
1700 F, 1200 F—1 hr 240 95 ,000 112,700
1700 F, 1200 F—2 hr 222 89,000 108 ,000
1700 F, 5555056 1200 F—4 hr 222 84,500 104 ,000
1700 F, 1300 F—'/, hr 216 81,000 101,000
1700 F, 1300 F—1 hr 210 77,000 99,000
1700 F, 1300 F—2 hr 71,000 94 ,600
1700 F, 1300 F—4 hr 66 ,000 91,000
1700 F, 1400 F—'/. hr 69,500 93,700
1700 F, 1400 F—1 hr 64,500 89,000
1700 F, 1400 F—2 hr 60,000 86 ,000
1700 F, rtrrrrrriririr1iiiig24g
1400 F—4 hr 55,400 83,600
1900 F—1 hr—air cool 119,000 184,000
1900 F—1 hr—H.O 139,000 187 ,000
1900 F, 1100 F—'/. hr 133,000 150 ,000
1900 F, 1100 F—1 124,000 140,000
1900 F, 1100 F—2 hr 115,000 133,000
1900 F, 1100 F—4 hr 110,000 127 ,000
1900 F, 1200 F—'/, hr 103,000 120,000
1900 F, 1200 F—1 95 ,500 113,500
1900 F, 1200 F—2 hr 89,000 107 ,000
1900 F, 1200 F—4 hr ; J 104 ,000
1900 F, 1300 F— hr 2 81, 101,000
1900 F, 1300 F—1 hr 7 101,000
1900 F, 1300 F—2 hr 14,5 96 ,000
1900 F, 1300 F—4 hr § » 3 93,000 ont
6O
:nN ?}2.>
1900 F, 1400 F—'/. hr 7 95 ,500 COOUMMMOOCOOMOMOOMOCO
1900 F, 1400 F—1 hr 57 91,700 < Oo
1900 F, 1400 F—2 hr : 87,000
1900 F, FT
ee
oe
ff
et
t+ SOOOOOOOOoooooooszTOOOOOOOO
, 1400 F—4 hr : 83,000 inin i~jc
“ :j~; COOCOOMMOeCOCo
SOTTO

@ Converted from Rockwell hardness measurements

°0.2 permanent set

Table 3—Mechanical Properties of Deposited Weld Metal

Yield Ultimate
Electrode Preheat, Postheat, Hardness, strength, strength, Elongation, % Reduction of
no F F Bhn? psi psi in 2in area, %
l None None 290 91,500 118,000 8.0 15.0
l None None 245 97,500 119,000 53.5
l 300 1350 240 91,500 104,000
l 300 1350 228 ,600 102 ,000
None None 240 ,000 113,000 mmr
None None 240 ,600 115,000
None 1350 185 1,000 88,700 nm
None 1350 195 11,500 89,000 oOoOre
Mw
re~
300 None 223 89,600 114,500
300 None 240 91,500 114,500
300 1350 195 70,700 88,700
300 1350 195 2,500 89,500
500 None 220 83,500 114,000
500 None 240 87,500 118,000 FrRDAO_em™
None None 332 121,000 145,000
None None 322 116,000 148 ,000 NMoOODM
YM
VIS
300 1350 190 74,700 90 ,000
300 1350 190 77,500 92 ,100
300 1350 216 84,000 98 ,500
300 1350 210 83,700 98 ,500 Mme
Phhe
WM!

@ Converted from Rockwell hardness measurements.

° 0.2% permanent set.

WELDING RESEARCH SUPPLEMENT | 257-s

 Hardness-Tensile Properties of tions were drawn by the 705 com-
5 Cr Mo Weld Metal. The tensile Precision limits puter and the one correlating duc-
properties of weld metal in pipe for correspond- tility and hardness also is shown in
welds cannot be obtained readily by ing quadratic
equations Fig. 2. By applying the equations
direct tests because tensile bars to hardness data obtained from
Yield strength, psi =
made from weldments usually fail 300.14 Bhn + 17,400 weld metal in pipe welds, the tensile
in the base metal rather than in (+9360 psi) +9,590 psi properties of the weld metal can be
the weld metal. The hardness and Tensile strength, psi = approximated.
tensile data obtained from the 376.17 Bhn + 20,485 These data indicate that the
samples made from the all-weld- (+12,190 psi) +11,865 psi pipe metal has a greater ductility at
metal specimens are listed in Table 3. % Elongation in 2 in. a given hardness value than the
The correlation between the hard- = 51.88 — 0.154 Bhn weld metal. This difference is very
ness and tensile data obtained by the (i.e., ductility) pronounced at hardnesses above
digital computer analysis is given (+6.82%) +6.94% 225 Brinell. In comparing all of
% Reduction of area =
in adjacent column. The equations 154.15 — 0.451 Bhn the tensile properties at various
are given in linear form since the (+19.52%) +20.08% hardness levels, those of the pipe
precision limits for the corresponding metal generally show much less
quadratic equations are not much deviation from the curves than do
different. The curves for the above equa- those of the weld metal.

Table 4—Effect of Preheat and Postheat (Time and Temperature) on Hardness-Ductility of Welds Made on
5% Cr- % Mo Steel Pipe Using Brand No. 1 (5% Cr-'/:% Mo) Electrode
—Brinell hardness? Calculated ductility’ .
Preheat, Postheat, Heat-affected Heat-affected
F F and Hr zone zone
0 1250— 233 20.4
300 1250 237 20.2
500 1250 240 19.8
0 1250—1 235 20.
300 1250—1 233 20.
1250—1 229 21.
0 1250—2 235 20.
300 1250—2 237 20
1250—2 226
0 1250—4 233
300 1250—4 213
500 1250—4 224
0 1300— 215
300 1300— 199
1300— 209
0 1300—1 209
1300—1 210
1300—1 200
0 1300—2 212
300 1300—2 210
500 1300—2 213
0 1300—4 210 SONMNOMP
RED
RP
ODE
EBIDRPYUNMYHWEE
300 1300—4 213
500 1300—4 205
0 1350— 228
1350— 231
500 1350— 220
0 1350—1 218
300 1350—1 226
500 1350—1 210
0 1350—2 224
300 1350—2 210
1350—2 215
0 1350-—4 195
300 1350—4 215
1350—4 220
0 1400— 202
300 1400— 209
500 1400— 199 : s,soTaD<
0 1400—1 216
300 1400—1 215
500 1400—1 211
0 1400—2 187 ; . tnr
300 1400—2 185
500 1400—2 182
0 1400—4 182
300 1400—4 177 NOM HK
WWONWEPONEPOHREE
UNONNOWNNHWDWONKHONUNNDWO
RNR
500 1400—4 170

“ Converted from Rockwell C hardness

® As calculated from the appropriate equations

258-s | JUNE 1960

 1700 F, Water Quenched
1900 F, Water Quenched

300-!1250F 500-I250OF
#0 @0 100 880 840 260 280 300
SPINEL, HARONESS
Fig. 3—Longitudinal bend specimens of
weldments made on 5 Cr Mo pipe with
the 5 Cr Mo electrode No. 1. Approxi-
mately X
inches

1700 F, Water Quenched not affect the final hardnesses

Elongation 900 F, Water Quenched
inpercent
2 whereas postheats do. The calcu-
Temperature (Hre
Fig. 1—Effect of temperature and time of
tempering on hardness and ductility of
5 Cr Mo steel, water quenched from 1700
F and from 1900° F
Effect of Various Preheats and
Postheats on the Hardness of 5 Cr Mo
Weldments. The hardness measure-
ments and the calculated ductility
values of the welds and heat-affected
zones on each of the 48 pieces of
pipe weld made with electrode
brand No. 1 with the variety of
preheats and postheats are given in
Table 4.
The ductility of weld metal
using normal welding practice is
less for any given preheat-postheat
of welds and heat-affected zones
lated ductilities of welds is between
12.1 and 14.7% for a 1250° F post-
heat, 15.8 and 16.9% for a 1300° F
postheat, 14.7 and 16.1% for a
1350° F postheat and 15.5 and 23.0 %
for a 1400° F postheat. It must be
remembered that in the all-weld-
g ‘ © 800 300 metal samples, the measured duc-
“AROMESS
tilities of samples given a 1350° F
Fig. 2—The curves drawn by the 705 com- postheat were between 19.0 and
puter for the equations relating the hard- 25.0%. In comparing the data for
ness and ductility for the pipe and the the 1400° F postheat, an anomaly
weld metals appears. The '/»-hr treated samples
show ductilities of 18.7 to 18.9%
treatment than the ductility of whereas the 1-hr treated samples
weld metal made according to show ductilities of 15.5 to 16.1%.
AWS specifications for producing However, the ductilities of the 2
all weld-test samples. This dis- and 4-hr treated samples are all
crepancy is due to the differences in above 19.4%. The calculated duc-
techniques in making the welds and tilities of the heat-affected zones for
does not indicate that the pipe all postheats ranged between 19.8
welds are unacceptable. The data and 29.2%.
show that preheats up to 500° F do Weldments on 5 Cr Mo Pipe Made

Table 5—€ffect of Preheat and Postheat on Hardness—Ductility of 5 Cr Mo Steel Pipe Welds Using 5 Cr Mo Electrodes
—_——_—Brinell hardness? — Calculated ductility ~
Electrode Preheat, Postheat, Heat-affected Heat-affected
no. at ° Fa zone Pipe Weld zone
1 300 1250 210 132 13.5 23.6
500 1250 228 137 14. 21.
300 1350 210 132 15. 23
500 1350 222 135 14. 21
300 1250 210 132 16. 23.
500 1250 210 135 16. 23.
300 1350 260 141 10.9 17
500 1350 205 130 19. 23.
300 1250 210 135 16. 23.
500 1250 216 135 14. 22
300 1350 216 132 14. 22.
500 1350 210 130 19. 23.
300 1250 222 127 15. 21
500 1250 216 135 15. 22.POODLE
DAOUAMHAW®ONMH
300 1350 276 139 3. 16.
500 1350 222 135 17. 21. oan

@ Postheat treatment for 1 hr at temperature

> Converted from Rockwell B and C hardness values
€ As calculated from the appropriate equation.

WELDING RESEARCH SUPPLEMENT | 259-s

 Table 6—Bend Tests of Welds in 5 Cr Mo Steel Pipe Using 5 Cr Mo Electrodes
— —_——_—_———Longitudinal bend*- On
Elec Side bend?
trode, Preheat, Postheat' Bend Elonga- Bend Pass* or
no. wa °F angle, deg tion, % Remarks angle, deg fail Remarks
1 300 1250 180 22 180 4P One sample had a '/;¢-
tear at edge
1 1250 180 22 180 4P
1 300 1350 180 22 180 4P sin. tear in center of
finish pass on surface
500 1350 180 180 4P One sample had a '/;¢-in.
tear in final pass
1250 22 4P
1250 One very small pinhole 4P One sample had a small
opened up tear in finish pass
1350 One very small pinhole 4P
opened up
1350 2 4P
1250 Two-minute surface de- 4P
fects '/s2 to '/is-in. long
opened up
1250 4P
1350 4P Two samples show mi-
nor lack of penetra-
tion at root but did not
open up
One sample had a
‘/i¢-in. Opening in root
caused by lack of
penetration
300 1250
500 1250
300 1350
500 1350

@ Averages of two specimens.

> Postheat treatment for 1 hr at temperature.
© Elongation in outer fiber—percent in 2 in.
4 Averages of four specimens.
¢ Cracks or tears longer than '/; in. constitute failure.

eee? wea

S00 500 2 OO SOO

12S50OF :250F 1Z50F

ddeg 5 let

390-I250F SO00-/250F
Fig. 4—Side-bend specimens of weldments made on 5 Cr Mo Fig. 5—Notch-bend specimens of weldments made on 5 Cr Mo
= ® pipe with the 5 Cr Mo electrode No.1. Approximately x ?/s pipe with the 5 Cr Mo electrode No. 1. The top specimens con-
tained the notch in the heat-affected zone and the bottom speci-
mens contained the notch in the weld metal. Approximately
X 7/5

260-s | JUNE 1960

Table 7—Notch-bend Tests of Welds in 5 Cr Mo Steel Pipe
—Deflection-
Thermal treatment After Energy——— Extent of
Preheat, Postheat, Notch Max At max max To max After max cracking at
Specimen °F "7" location load, |b load, in. load, in. load, ft-lb load, ft-lb notch root
Base metal ime 1250 Base metal 1880 10 143.2 150.6 Slight
Base metal 1350 Base metal 1880 .10 143.2 150.6 Slight
Electrode no. 1 1250 Weld 2600 .25 170.3 234.0 Slight
1250 Weld 2600 che 25 170.3 234.0 Slight
1250 Heat-affected zone 2520 ‘ 200. Slight
1250 Heat-affected zone 2400 b 190. Moderate
1250 Weld 2780 oak 184 237. Severe
1250 Weld 2760 .08 184. 211. Severe
1250 Heat-affected zone 2620 26 173. 230. Severe
1250 Heat-affected zone 2440 16 184 196 Severe
1350 Weld 2550 24 166 431 Slight
1350 Weld 2550 24 166. Slight
1350 Heat-affected zone 2280 .23 131. Moderate
1350 Heat-affected zone 2420 .23 164 Severe
1350 Weld 2700 .62 180. Severe
1350 Weld 2600 52 173. Severe
1350 Heat-affected zone 2420 .20 166. Severe
1350 Heat-affected zone 2420 .20 166 Aonnwowwowoonrrn
qQooocooocoocorcocoorrOCorrH Severe
WDAWMOMNDSDWOWUN

Electrode 1250 Weld 2600 .26 166. on Severe

no. 2 3 1250 Weld 2540 .20 177 a Severe
1250 Heat-affected zone 2500 52 ’ 196. Slight
1250 Heat-affected zone 2500 J 196. Moderate
1250 Weld 2600 . 86 168. Severe
1250 Weld 2600 . 86 168. Severe
1250 Heat-affected zone 2400 .90 168. Severe
1250 Heat-affected zone 2340 COO
OOrFF
HR 15 176. ONfLPODOw Moderate
1350 Weld 2500 . Severe
1350 Weld 2500 24 169. Severe
1350 Heat-affected zone 2400 .22 166. Moderate
1350 Heat-affected zone 2400 ae 166. Moderate
1350 Weld 2460 .24 168. Severe
1350 Weld 2440 .28 168. Severe
1350 Heat-affected zone 2200 154. Moderate
1350 Heat-affected zone 2200 &OO°o°o
Rr 154 Co
coco
OO
ww Moderate

Electrode 1250 Weld 2680 Oo 175. Severe

no. 3 1250 Weld 2680 175 Severe
1250 Heat-affected zone 2470 192. Slight
1250 Heat-affected zone 2470 192. Moderate
1250 Weld 2750 173. Severe
1250 Weld 2750 171 Severe
1250 Heat-affected zone 2460 166. Severe
1250 Heat-affected zone 2400 166. Severe
1350 Weld 2500 163. Severe
1350 Weld 2460 159. Severe
1350 Heat-affected zone 2320 158. Slight
1350 Heat-affected zone 2360 158. Moderate
1350 Weld 2450 164 Slight
1350 Weld 2400 159. Slight
1350 Heat-affected zone 2320 165. Slight
1350 Heat-affected zone 2300 |el
Mo
ww
own165. UI
oConouwr
OO
CO
&OO
WO
OW
~ lL
Oo
Ww Slight
~WwWwoaanunn

Electrode 1250 Weld 2700 i] 169. ; Severe

no. 4 1250 Weld 2680 Le 169. Moderate
1250 Heat-affected zone 2360 154 Severe
1250 Heat-affected zone 2360 154. Severe
1250 Weld 2760 176. Severe
1250 Weld 2760 176. Severe
1250 Heat-affected zone 2500 191 Moderate
1250 Heat-affected zone 2500 191. Moderate
1350 Weld 2580 169. Severe
1350 Weld 2500 133 Severe
1350 Heat-affected zone 2420 163. Severe
1350 Heat-affected zone 2380 169 Moderate
1350 Weld 2500 184. Severe
1350 Weld 2420 176 Slight
1350 Heat-affected zone 2250 158. Moderate
1350 Heat-affected zone 2200 rODOOrKHOOCOO
ee
He OOOKRHOOHKOFH
ROK
HH NS
WO
OWNER
BRO Moderate
158. OUWAHRMNUHMHOWWOSOHWHOUUMN
MDOOUBRH

@ Postheat treatment for 1 hr.

> Recording instrument was improperly set to obtain the full deflection after maximum loading for these specimens
© Improper loading prevented the obtaining of these data

WELDING RESEARCH SUPPLEMENT | 26l-s

with Various 5 Cr Mo Electrodes.
The hardness measurements and the Table 8—Impact Properties of Weld Metal in 5 Cr Mo Steel Pipe Weldments”
calculated ductility values of the Transition temperature and energy ranges
welds and heat-affected zones of Room
the 16 weldments of 5 Cr Mo pipe Elec- Thermal treatment '‘/> energy level 15 ft-lb level, temperature
made with the four 5 Cr Mo elec- trode Preheat, Postheat, Temperature, temperature, energy,
trodes are given in Table 5. no. F °F Ft-Ib ft-lb
The calculated ductilities for all 300 1250 45 +90 + 20 30+ 1
16 weldments are on the order of 300 1250 45 +10+ 15 75
15°, for the weld metal and 20° 300 1250 55 +45+ 15 : 85
for the heat-affected zones. These 300 1250 45 +100 + 15 30
500 1250 45 +25 + 25 70
results, therefore, correspond closely 500 1250 45 —10+ 20 70
to those described in Table 4 for the 500 1250 50 +10+ 20 80
previous study on weldments made 500 1250 50 +100 + 40 ? 35
only with the No. 1 electrode. 300 1350 45 +60 + 25 50
Three discrepancies were noted, 300 1350 20 +15 + 60 40 - 30
however. In two instances (Nos. 2 300 1350 50 —15+ 10 90
and 4 electrodes with the 300 300 1350 35 +135 + 35 : 10
1350° F treatments), decided re- 500 1350 50 +60 + 30 ? 55 no weuno
ol RP
oe
NMmroOonnoOo
alll
lll
ductions in ductility occurred and in 500 1350 35 —20+ 25 7 65
500 1350 55 —15+ 15 95
one instance (No. 2 electrode with BwWh
PWM
BWM
BWNHe 500 1350 55 +50 + 55 65 HHHHHHHHHHEHHEHEHEH
_ Om
rm
the 500-1350° F treatment), a
decided increase in ductility oc-
curred. The reasons for the ? Averages of duplicate or triplicate specimens
» Postheat treatment for 1 hr at temperature
anomalies are not evident readily.
The longitudinal bend-test re-
sults (duplicates) for each weldment The side-bend test results (quad- given in Table 7 and illustrated for
are given in Table 6 and illustrated ruplicates) for each weldment are those made with electrode No. 1 in
for those made with electrode No. 1 given in Table 6 and illustrated for Fig. 5. The results indicate that
in Fig. 3. All samples responded those made with electrode No. 1 in all of the weld metals and base-metal
excellently to this test. The elon- Fig. 4. All weldments responded heat-affected zones could sustain
gation in the outer fibers of this excellently to this test. maximum loads greater than those
particular size sample was 22% at The notch-bend test results (dup- for the base metal. In all instances,
the zone of maximum straining. licates) for each weldment are there was a definite measurable

,)
a2 -— Electrode
lbs
r— Electrode
» + No, No. 2 Heat-affected
7 Zones
c—
te_—
2~”
Qbe
a
akeS Energy
Absorbed-ft Energy
Absorbed-ft
lbs
-100 -50 50 100 150 200 -100 -50 0 50 100 150 200
Temperature - F Temperature - F et a oe ee ee
-150 -100 -50 © 50 100
Temperature - F

Base Metal

[~= Electrode

|,CeurtitT Energy
lbs
Absorbed-ft
| P ad | J
| j J -200 -150 -100 -50 0 50 100
Absorbed-ft
Energy
lbs 8 lbs
Absorbed-tt
Energy
100 150 200 0 50 100 150 200
Temperature - F Temperature - F
Temperature - F
300 F = 1250 F Fig. 7—Charpy V-notch impact transition-
500F - 1250 F temperature curves for both heat-
300 F - 1350 F affected zone and base metals of the
500 F - 1359 F 5 Cr Mo pipe welded under the various
Fig. 6—Charpy V-notch impact transition-temperature curves for preheat-postheat conditions of 300-1250°
5 Cr Mo weld metals deposited in weldments on 5 Cr Mo steel pipe F, 500-1250° F, 300-1350° F and 500-1350° F

262-s | JUNE 1960

deflection (or energy absorption)
after maximum loading. As indi-
cated in Table 7, many of these
samples had severe cracks at the
completion of the test. It is not
known when these cracks were
initiated during the bend test but,
in no instance, did they prevent a
definite deflection after maximum
loading. This observation indicates
that these welds would not be
subject to a catastrophic failure
because of a notch brittleness of
the welds or heat-affected zones. On
this basis, both the 1250 and 1350° F
postheats were beneficial in pre-
venting notch embrittlement.
The impact-test results are given
in Table 8 and Fig. 6 for the weld
metals and in Fig. 7 for the heat-
affected zones and the base metal.
The data obtained for the weld
metals showed a considerable scat-
ter so that individual tests often
differed greatly from the aver-
age curves drawn in Fig. 7. There
was some suggestion that the weld
metal deposited by Electrode No.
4 had somewhat inferior impact-
resistance properties. Also, the
500-1350° F preheat-postheat com-
bination appeared to impart the
most consistently satisfactory im-
pact resistance to the weld metals.
The data obtained for heat-
affected zones and the base metal
showed that both zones have better
impact resistance than that of the
weld metal. Also, the various pre-
heat treatments had virtually no
effect in changing these impact
properties.
Weldments on 5 Cr Mo Steel Pipe
with 25-12 Cr Ni, 25-20 Cr Ni and
I',, Cr Mo Electrodes. The
hardness measurements and the
calculated ductility values of the
heat-affected zones (and weld metal
of the 1'/, Cr Mo electrode using an
equation developed in a previous
study”) and side-bend-test results
are given in Table 9 and Fig. 8.
As expected, the austenitic welds
are relatively soft and would be
expected to have excellent ductility.
The 1'/, Cr Mo weld metal also
has an excellent (calculated) duc-
tility even with no postheat treat-
rnent. The heat-affected zones of
the 5 Cr Mo pipe have excellent
calculated) ductilities even in the
absence of any preheat and postheat
treatments. The side-bend-test re-
sults on all weldments showed ex-
cellent responses with the only
failures being a lack of penetration
in a few of the weld roots; an effect
which preheat and postheat treat-
ments would not have prevented.
The notch-bend-test results are
given in Table 10. The results
show that all of the specimens ab-
sorbed appreciable energy after
maximum loading. As _ indicated
in Table 10, many of these samples
had severe cracks at the completion
of the test. It is not known when
these cracks were initiated during
the bend test but in no instance did
they prevent a definite deflection
after maximum loading. This ob-
servation indicates that these welds
would not be subject to a cata-
strophic failure because of a notch
brittleness of the welds or heat-
affected zones.
Conclusions
The hardness and _ tensile
properties can be correlated for both
5 Cr Mo alloy-steel pipe material and
for 5 Cr Mo weld deposits. At high
hardness values, the ductility of the
pipe metal (including heat-affected
zones) remains relatively high but
the ductility of weld metal becomes
rather low. This fact indicates
that postheat treatments of such
weldments are essential to impart
ductility to the 5 Cr Mo weld metal
but are not needed to impart duc-
tility to the heat-affected zones of
the 5 Cr Mo base metal. Evenata
Brinell hardness of 380, the pipe
metal has a ductility (as measured
by elongation) of about 12.5‘
2. Ductilities of weld metal of pipe
welds are less than those of all-weld-
metal specimens made according to
AWS specifications. Thisdifference
probably is due to the welding-
technique differences followed in
each instance.
SOOF-None oe on
cca ta
bed
dt
None-WNone None-None
Fig. 8—Side-bend specimens after testing. The tests were made in
quadruplicate and the identifications of welding-electrode composition,
preheat and postheat are given in the photograph. Approximately x !
WELDING
3. Preheating up to 500° F has
only a very slight effect in improving
the ductility of weld metal and
heat-affected zones in 5 Cr Mo
alloy-steel pipe welded with 5 Cr
Mo electrodes. Postheat treat-
ments of 1250 and 1350° F are
effective in imparting ductility to
5 Cr Mo weld metal but a 1400° F
treatment increases the ductility
markedly.
The ductility of all welds made
on 5 Cr Mo alloy steel pipe with
5 Cr Mo electrodes using postheats
of 1250 and 1350°F were entirely
satisfactory as evidenced by the
results of side-bend and longitudinal-
bend tests.
5. Notch-bend-test results indi-
cate that the 1250 and 1350° F
postheat treated weldments of 5
Cr Mo electrodes on 5 Cr Mo alloy-
steel pipes are not subject to notch
embrittlement during slow bending.
The impact properties of heat-
affected zones of 1250 and 1350° F
postheat treated 5 Cr Mo alloy-
steel pipe are as good as those of the
base metal. However, the 5 Cr Mo
weld metal has impact properties
substantially lower than those of the
heat-affected zones and base metal.
7. When unrestrained welds are
made in 5 Cr Mo alloy steel with
25-12 Cr Ni, 25-20 Cr Ni and 1'/,
Cr Mo electrodes, there appears to
be no need for either preheat or
postheat to obtain ductile weld-
ments. Previous studies have
shown that 1!/, Cr Mo weld metal
does not need either preheat or
300F-J250F
None
p nD)
DD
ZOOF-None
RESEARCH SUPPLEMENT 263-s
Table 9—Effect of Preheat or Postheat on Hardness—Ductility and Side-bend Tests of Welds Made on 5 Cr Mo Pipe
Using 25-12 Cr Ni, 25-20 Cr N and 1'/, Cr Mo Electrodes
—Brinell hardness*—. Calculated ——_————. Side-bend-test results‘
Heat- ductility, Bend
Preheat, Postheat, affected Heat-affected’ angle, Pass or
Electrode °F °F Weld zone Pipe zone deg fail? Remarks
25-12 Cr Ni None None 169 210 132 23.6 180 All passed No. 1—"/j.-in. open-
ing in root
500 None 169 228 130 21.2 180 3 passed No. 4—"'/, crack
1 failed in. root pass—not
lack of fusion
25-20 Cr Ni None 169 210 139 23.6 180 3 passed No. 3 lack of fusion
1 failed in root prop. into
weld !/,-in.
None 22.4 Al! passed Lack of fusion in
root stopped in
weld
Heat*
af-
fected
Welde zone
20.8 21.2 All passed Nos. 2, 3—slight lack
of fusion in root
—did not propa-
gate into weld
300 1250—1 hr 23.8 23.6 All passed

®@ Converted from Rockwell B hardness values.

> As calculated from the appropriate equation.
© Four side bends made for each condition.
4 Cracks or tears longer than '/s in. constitute failure
* This data obtained from equations developed in previous studies.

Table 10—Notch-bend Tests of Weldments of 5 Cr Mo Pipe with Various Electrodes

—Deflection-
After
Thermal treatment max ——Energy———..__ Extent of
Preheat, Postheat, Notch Max At max load To max After max cracking at
Specimen "Fr nt location load, Ib load, in. load,in. load, ft-lb load, ft-lb notch root
5 Cr Mo pipe None None Weid 2000 ; 0.50 81.6 64.8 Severe
welded with None None Weld 1900 : 0.% 47.6 79.3 Severe
25-20 Cr Ni None None Heat-affected 2200 . 0.96 144.0 138.7 Moderate
zone
None None Heat-affected 2180 ! 1.24 149.6 160.8 Moderate
zone
500 None Weld 2040 t 72 85.0 76.5 Severe
500 None Weld 2050 ‘ .68 86.3 71.2 Severe
500 None Heat-affected 2250 ‘ Rs 162.3 197.0 Moderate
zone
500 None Heat-affected 2170 , -44 113. 113.5 Severe
zone
5 Cr Mo pipe None Weld 2020 ' 72 78. 53.6 Severe
welded with None Weld 1900 : 65 67. 52.3 Severe
25-12 Cr Ni None Heat-affected 2200 , 18 ; 184.6 Moderate
zone
None Heat-affected 1940 } , 78. 47.2 Severe
zone
None Weld 2070 . F 86. Severe
None Weld 2000 ; , 84. Severe
None Heat-affected 2300 , ; Severe
zone
None Heat-affected ’ ; 166. Severe
zone
5 Cr Mo pipe None Weld . , 166. , Severe
welded with None Weld i , , : Severe
1'/, Cr Mo None Heat-affected , . ; " Severe
zone
None Heat-affected ? , ; Severe
zone
1250° F Weld : ; ' Severe
1250° F Weld , ‘ 3 Severe
1250° F Heat-affected J : Moderate
zone
1250° F Heat-affected ‘ ; Moderate
zone

| JUNE 1960
postheat for good ductility. It is
well known that 25-12 Cr Ni and
25-20 Cr Ni weld metals are
ductile. This study has shown that
heat-affected zones of 5 Cr Mo pipe
material are ductile even in the
absence of preheat and _ postheat
(although the 5 Cr Mo weld metal
does need the postheat treatment).
Therefore, it follows that when
unrestrained welds are made on
5 Cr Mo alloy-steel pipe with an
electrode which deposits ductile
weld metal, the weldment should
need no preheat or postheat treat-
ments. However, refinery ex-
perience has shown that weldments
of ferritic base metals with the
austenitic 25-12 Cr Ni and 25-20
Cr Ni electrodes may crack even-
tually in or adjacent to the weld
when subjected to thermal cycling.
The stresses causing such cracks are
developed because of the difference
in the coefficients of thermal ex-
pansion of the austenitic weld
metal and ferritic base metal. The
1'!/,Cr Mo weld metal, being ferritic,
will not cause this type of cracking
in 5 Cr Mo weldments exposed to
thermal cycling.
Acknowledgment
The authors wish to acknowledge
the assistance of C. F. Braun,
J. M. Backus and other personnel of
the Engineering Research Depart-
ment for the preparation of the
welds and test specimens and in
securing the data.
The permission of the Standard
Oil Company (Indiana) to publish
this paper is greatly appreciated,
as are the advice and encourage-
ment given by C. H. Samans,
Associate Director, Materials Divi-
sion, Engineering Research Depart-
ment.
References
1. Bland, J., Privoznik L. F., and Windsor, F
J., “The Arc Welding of Low Chromium-Molyb-
denum Steel Pipe,”” THE WELDING JouRNAL, 31
9), 783-791 (1952
2. Bland, J., “‘Arc Welding of Low Chromium-
Molybdenum Steel Pipe,”’ Jbid., 32 (9) 803-814
1953
3. Bland, J., “The Arc Welding of 2.25%
Cr-—1.0% Mo Alloy Steel Pipe,” Jbid., 35 (4
Research Suppl., 181-s to 194-s (1956
4. American Standard Code for Pressure Pip-
ing, ASME, ASA B31.1-1955
». “Rules for Welding Piping in Marine Con-
struction—Ferritic Alloy Steels AWS Std
D3.4-52 (tent.), p. 1
6. “‘Recommended Preheat and Postheat Weld-
ing Practices for Low Chromium-Molybdenum
Steel Pipe,”’ Pipe Fabrication Institute Standard
FS(M) 8-1955
7. “‘Recommended Practices for Interruption of
Heat Treatment Cycles for Low Chromium-
Molybdenum Steel Pipe Materials,’"”’ AWS Std
D-10.3-55 (tent
8. Holmberg, M. F., “‘Welding Alloy Steels for
High-Temperature Service,’ THE WELDING JoUR
NAL, 28 (2), 141-148 (1949

selection of Projects

The Welding Research Council is receptive to new ideas for research projects from any source.
Naturally before any project can be approved or undertaken, certain yardsticks have to be ap-
plied. Forthe most part there are rather obvious yardsticks developed over the years:

1. Is the Welding Research Council the best agency to undertake the work?
2. Is the problema ‘“‘doable”’ one?
3. Willit be possible to secure the necessary funds, talent and research facilities?
4. \Isthe problem of broad general interest?

The answer to question 1 is in most cases not too difficult as this question implies other ques-
tions:

(a) What other agencies are working in this general field?

(b) What work has already been done or is being done in the general field?
(c) Isthere some other agency that could be considered a more logical agency?

Problem 2 is sometimes more difficult. The Welding Research Council believes, however,
that before any experimental work is undertaken that a literature survey of existing information
should be made by the investigator to learn what has been done before—the successes and fail-
ures. A breakdown of the problem into its fundamental elements should help provide this
answer.
The answer to the third question, inasfar as funds are concerned, should be readily available.
A project should not be undertaken unless the sponsors are willing to put up a third of the funds.
In developing a program and budget one should have bids from at least two laboratories which in
itself would provide part of the answer to this question. However the ideas of Committee mem-
bers and the original sponsors should be secured.
The answer to the fourth question is generally availabie as the result of securing the answers to
the first three questions.

WELDING RESEARCH SUPPLEMENT | 265-s

Submerged-Arc Welding HY-80 Steel

Study is conducted to develop methods for

making submerged-arc welds capable of withstanding

severe impact loading at low temperatures

BY W. J. LEWIS, G. E. FAULKNER, D. C. MARTIN AND P. J. RIEPPEL

Introduction
Table 1—Composition of 1-in. Thick HY-80 Steel Plates
One of the prime considerations in
the construction of submarine hulls Heat
is the ability of the hull to withstand designation Cc Mn
severe impact loading at tempera- Heat 20120-15 0.15 0.36
tures of 30° F. Most of the sub- Heat 20739 0.16 0.23
marine hulls being fabricated today
are made from Grade HY-80 steel covered electrodes and filler wires
using standard low-hydrogen weld- for the inert-gas-shielded metal-arc
ing electrodes and preheating opera- process which produce weld metals
tions. The Grade HY-80 steel base with good Charpy V-notch-tough-
plate and the welded joints meet the ness properties. It was found that
property requirements for subma- submerged-arc welds made with
rine-hull construction. Although similar filler-metal compositions had
many of the joints in hull construc- lower V-notch toughness than that
tion are suitable for automatic reported for manual and inert-gas-
welding techniques such as the sub- shielded metal-arc welds.
merged-arc process, the properties In order to determine methods for
of weldments deposited with the
improving the notch toughness of
submerged-arc process with con- submerged-arc welds, studies were
ventional techniques are not satis-
made to compare the mechanical
factory for submarine applications. properties, metallurgical charac-
This study was conducted to
teristics and compositions of welds
develop methods for making sub- made by the submerged-arc process
merged-arc welds which will with-
with those made by the inert-gas-
stand severe impact loading at low shielded metal-arc process. The
temperatures. The specific ob-
information obtained from these
jectives were to obtain submerged- comparisons led to Phase II of this
arc weld metals with yield strengths
program in which the effects of flux
of at least 80,000 psi and Charpy composition on weld-metal proper-
V-notch toughness of 20 ft-lb at
ties were studied. For this phase
—100° F or a nil-ductility temper- of the program, experimental fluxes
ature of —100° F* in both the as-
were prepared and evaluated. The
welded and stress-relieved condi- information obtained in the flux
tions. Submarine hulls with notch
studies will be presented in a sub-
toughness and nil-ductility tem- sequent paper.
perature values in this range will This paper describes the results
withstand severe impact loading at obtained in evaluating several ex-
service temperatures. perimental filler wires for use in sub-
This program was conducted in
two phases. The first phase of the
program consisted of preparing and Table 2—Tension and Impact Properties of 1-in.-thick HY-80 Steel Plates® ”
evaluating several experimental filler Ultimate
wires. The compositions of the ex- Yield tensile
perimental wires were within the Heat strength, strength, Elongation
range of compositions of commercial designation psi psi in2in.,%
W. J. LEWIS, G. E. FAULKNER, D. C Heat 20120-15 82,000 98 ,000
MARTIN and P. J. RIEPPEL are associated Heat 20739 90 ,000 104,000
= Battelle Memorial Institute, Columbus,
@ Testing direction transverse to the direction of rolling.
Paper presented at AWS 40th Annual Meeting > Average of two specimens.
held in Chicago, Ill.. April 6-10, 1959. © Did not break.
Chemical composition, 9%
P Ss Si
0.020 0. 032 0.18
0.011 0. 028 0.19
merged-arc welding HY-80 steel.
The effects of nickel, manganese and
molybdenum on weld-metal prop-
erties are discussed and the prop-
erties of submerged-arc welds and
inert-gas-shielded metal-arc welds
made with the same filler wire and
conditions are compared.
HY-80 Steel Base Material
The base metal used in the weld-
ing studies was l-in. thick HY-80
steel plate. Plates from two dif-
ferent heats were obtained for these
studies. The compositions of these
plates were as given in Table 1.
Tension and impact tests were
made on the base metals. The re-
sults of these tests are listed in
Table 2. From the data obtained,
both plates met the requirements of
MIL-S-16216W (Navy). However,
Heat 20739 had superior tensile and
impact properties. Because tests
were concerned primarily with weld-
metal properties rather than base-
metal properties, both of the heats
were used during this program.
Experimental Procedures
Weld-metal studies were made on
V-notched Charpy
notch toughness,
Reduction ft-Ib
in area,% 78°F —40°F —100°F
23 63 84 80 57
21 66 c c c

266-s | JUNE 1960

 joints prepared with 9 experimental
filler wires. The welds were made
under closely controlled conditions
and were evaluated on the basis of
Charpy V-notch properties and
tensile properties.
The heats of steel for the experi-
mental filler wires were prepared in
a MgO-lined electric-induction fur-
—— nace under an argon atmosphere.
0.505-inch tension ~ , ee RS“ | ee The heats were prepared from high-
specimen a = ft grade melting stock, which included
electrolytic iron as the base to keep
ae sulfur and phosphorus contents at a
rif 7 minimum. The chemical composi-
tion of each of the additions was
known prior to the preparation of
| the heats, and the amount of each
1 element added to the heats of steel
was carefully weighed in preparing
these materials. Approximately
| \ 0.075% aluminum was added to
each heat as a deoxidizer. All alloy
and deoxidation additions were
made in the furnace.
;
The normal pouring temperature
for all experimental heats was
2980° F. Big-end-up ingot molds
a were used for all of the experimental
! A heats. The size of the heats varied
\ from 110 lb from which three 35-lb
a. a splits were made to 310-lb heats
-s al rs, which were subsequently divided
into three 100-lb splits.* The in-
gots were then forged, rolled and

I
Fig. 1—Joint design, pass sequence and location of tension . * Two foror variations
Except
more
; ingots cast from one heat
in one alloying element,
and impact specimens in a multipass weld each split had the same composition

“0
eZ T
Designation
A (1.4% Ni)
— B (1.9% Ni)
(2.8% Ni)

ft-lb
hness,
Toug!

Notch

-40
-4
Temperature, F
Temperature, F
Fig. 2—Effectof nickel on weld-metal Fig. 3—Effect of nickel on weld-metal
notch toughness (as-welded) notch toughness (stress relieved)

WELDING RESEARCH SUPPLEMENT 267-s

 which met the target requirements.
Table 3—Chemical Composition of Experimental Wires However, the results showed that
Wire —_——— Chemical composition, 4————_ increased nickel lowered notch
designation Cc Mn Si Ni Mo toughness and also increased yield
0.0 9 0.13 1.40 0.56 strength. The 2 and 3% nickel
0.0 8 0.26 1.91 0.57 wires were then modified for further
0.0 8 2.88 0.53 studies. First, the manganese con-
0.0 9 2.15 Trace tent of the 2°; nickel wire was in-
0.0 8 2.14 Trace creased with and without molyb-
0.1 l 3.44 Trace denum additions and, second,
0.0 8 3.16 0.52 molybdenum content of the 3%
0.1 0 nr> 3.40 0.62
-~IroO™m™ooa,p0.1 1 ee
Re
Meee 3.36 1.07 nickel wire was varied in an
effort to increase notch toughness
’ The wires were taken from split heats: heat No. 1—A and G; heat No. 2 B and C: heat No. without lowering the yield strength
3—D and E; heat No. 4—F, H and I too much. In addition, a 1'/.%
nickel wire was used to further
study the effects of nickel on weld
drawn to -in. diam wire for standard 0.505-in. tensile specimens properties.
welding. (Fig.1). The stress-relieving treat- The results presented in succeed-
All of the wires were used to make ment consisted of heating the welded ing sections are from single and
submerged-arc welds in 1-in. thick joints for 1 hr at 1200° F. duplicate tests. In most cases,
HY-80 steel plate. The joint geom- tensile data are obtained from single
etry was a single-vee 45-deg butt Experimental Results and specimens and Charpy V-notch-
joint with a ');-in. root opening toughness data are obtained from
(Fig. 1). Welding conditions which Discussion
duplicate specimens.
gave a 45,000 joules/in. heat input The compositions of the experi-
were used. This heat input was mental wires were selected on the Effect of Nickel on Weld-metal
selected on the basis of studies made basis of available information‘ on Properties
on weld metals and _ heat-affected welds made with manual electrodes.
The effect of nickel on weld-metal
zones of submerged-arc welds made This information showed that good
properties was studied over the
with various amounts of heat per Charpy V-notch-toughness proper-
range of 1.4 to 2.8% nickel. This
inch of weld. The aim was to use ties were obtained in weld deposits
study involved three different weld-
the highest heat input per inch of containing approximately 3%
ing wires designated A, B and C.
weld possible and still maintain nickel, 1°% manganese and 0.6%
Chemical compositions of sub-
good heat-affected-zone properties. molybdenum. However, it was
merged-arc welds made with these
In using 45,000 joules in., a rela- found in this program that sub- wires are given in Table 4. It can
tively narrow and _high-hardness merged-arc welds made with similar
be seen that the weld-metal compo-
heat-affected zone was obtained. compositions had lower notch tough-
sitions were similar except for the
It appeared that weld metals with ness than that reported for manual
nickel content.
better properties might be obtained welds. Attempts were made to
The effects of nickel on weld-
if lower heat inputs were used than obtain satisfactory weld properties
metal notch toughness and tensile
those made with 45,000 joules /in., by modifying the nickel, manganese
properties are shown in Fig. 2.
but the difference at low testing and molybdenum contents of the
The notch toughness of the weld
temperatures did not appear signifi- wires. None of the modified wires
metals decreased with increasing
cant. The welding conditions used produced satisfactory weld proper-
nickel contents, especially at tem-
to make submerged-are welds with ties. However, the selection of
peratures above -—40° F. For
experimental wires were: compositions allowed a study of the
example, at room temperature, the
effect of nickel, manganese and
Arc voltage, v 30 notch toughness of A weld metal
molybdenum on weld-metal proper-
Amperage, amp 550 1.4% nickel) was 52 ft-lb; whereas
ties.
Travel speed, ipm 22 the notch toughness of C weld
The chemical compositions of the
Preheat and interpass metal (2.8% nickel) was 22 ft-lb.
experimental filler wires studied are
temperature, ° F. 250 However, at subzero temperatures,
listed in Table 3. Of the first two
Flux Neutral the increased nickel did not appear
heats studied, one wire contained
to be harmful. At -—80° F, the
Weld-metal notch toughness and 2% nickel and the other contained
notch toughness of A and C weld
tensile properties were determined 3% nickel. Both wires had man-
metals was similar and at —100° F
in both the as-welded and stress- ganese contents of 1% and molyb-
the notch toughness of A _ weld
relieved conditions using standard denum contents of 0.50%. These
metal (1.4% nickel) was 7 ft-lb and
V-notch Charpy specimens and wires did not produce weld metals
that of C weld metal (2.8% nickel)
was 12 ft-lb.
The tensile properties of the welds
Table 4—Composition of Experimental Filler Wires and Weld Metals with Three were obtained from single tests.
Levels of Nickel Although the differences in proper-
ties are small, there is a trend that
Filler-wire Chemical composition, % tensile and yield strengths increased
designation Ni P slightly with increased nickel con-
A wire 1.40 tents, and the ductility was slightly
A weld metal 1.35 ve decreased. All of the welds had
B wire 1.91 0.012
B weld metal 1.92 0.012 yield strengths above the minimum
C wire 2.88 0.012 required 80,000 psi.
C weld metal 2.76 0.011 The effect of nickel on weld-metal
notch toughness and tensile proper-

268-s | JUNE 1960

 Table 5—Composition of Experimental Filler Wire and Metals
with Two Levels of Manganese
Filler-wire —_—————Chemical composition, %——
designation C Mn Si Ni
D wire 1.94 0.12
D weld metal 1.26 0.41
E wire 2.84 0. 04
E weld metal 1.81 0. 4

e'*
Fig. 4—Typical acicular as-welded
microstructure within the weld pass. X
500. (Reduced by '/; upon reproduction)
Fig. 5—Typical stress-relieved micro-
structure within the weld pass. X 500.
(Reduced by '/; upon reproduction)
ties in the stress-relieved condition
is shown in Fig. 3. The notch
toughness of the stress-relieved weld
metals were not affected appreciably
by nickel content. In comparing
Figs. 2 and 3, it can be seen that
weld-metal notch toughness was
higher and the tensile strength was
lower in the stress-relieved condition
than in the as-welded condition.
The change in properties was at-
tributed to the change in micro-
structure observed in the joints.
In the as-welded condition, carbide
occurred predominantly at the edge
of acicular ferrite plates, resulting in
an acicular pattern (Fig. 4). Dur-
ing stress-relieving operations (Fig.
5), the carbide was spheroidized and
this apparently improved notch
properties.
Effect of Manganese on Weld-metal
Properties
Two filler wires were fabricated
which allowed a study on the effects
of manganese on weld-metal prop-
erties. The compositions of the
wire and weld metals are listed in
Table 5. The nickel and molyb-
denum contents of the wires were
about 2 and 0%, respectively. The
manganese content ranged from 2 to
3% in the wire and 1.26 to 1.81% in
the deposited weld metals.
The notch toughness and tensile
properties of weld metals made with
wires D and E are shown in Fig. 6.
At temperatures above —40° F, the
notch toughness of weld metals with
high manganese (1.8%) was 10 to
20 ft-lb lower than the welds con-
taining low manganese (1.26%
However, at temperatures below
—40° F, the notch toughness of the
welds was essentially the same.
With increasing manganese con-
tent, the yield and tensile strengths
were increased, and the ductility
was decreased. ‘The yield strength
of both weld metals was above the
80,000-psi minimum yield require-
ments.
The effects of manganese on the
notch toughness and tensile prop-
erties of weld metals in the stress-

+
Designation
pind
hPL 2h
22% Mn
8% Wn

ft-lb ft-lt

oughness,

Notch
Toughness,

an
Temperature, fF Temperature, F
Fig. 6—Effect of manganese on weld- Fig. 7—Effect of manganese on weld-
metal notch toughness (as welded) metal notch toughness (stress relieved

WELDING RESEARCH SUPPLEMENT | 269s

 relieved condition are shown in
i 7. At temperatures above Table 6—Composition of Experimental Filler Wires and Weld Metals
F, the notch toughness of the with Four Levels of Molybdenum
weld metals was similar. However, Filler-wire Chemical composition, 4——__-
at low-testing temperatures the designation Mn Si Ni Mo
high-manganese content appears F wire 1.26 0.01 Trace
beneficial. At -—100° F, E weld F weld metal 0.93 0.34 0.05
metal (1.81°, manganese) was 10 G wire 1.34 0.10 0.52
ft-lb higher than D weld metal G weld metal 0.92 0.39 0.43
(1.26% manganese). In comparing H wire i, 0.05 0.62
Figs. 6 and 7, it can be seen that H weld metal 0.97 0.32 0.50
weld-metal notch toughness was | wire 1.20 0.02 1.07
| weld metal 0.86
cooocooooo]eo
Ore
CO
OO™
sR
COrPOKCCOK 0.28 NMRhWWW
Ww wo
Ww Soros. 0.76
improved and the yield strength was
lowered by stress relieving.
same welding conditions and the The tensile properties of welds
Effect of Molybdenum on Weld-metal microstructures and compositions deposited from experimental wires
Properties were similar. The tensile and yield F, G, H and I showed that increased
The effects of molybdenum were strengths of weld metal (G) were molybdenum content generally im-
studied in weld metal containing high, but the weld from which these proves yield and tensile properties
about 3° nickel —1° manganese. data were obtained was made with in both the as-welded and stress-re-
The chemical analysis of the wires an 80° F interpass temperature in- lieved conditions.
and weld metals are given in Table stead of the 250° F interpass tem-
6. The molybdenum content of the perature used for the other welds. Comparison of Submerged-
weld metals ranged from 0.05 to The effect of molybdenum on
arc and Inert-gas-shielded
0.76%. weld-metal notch toughness and
The effects of molybdenum on the tensile properties in the stress-re- Metal-arc Weld Metal
weld-metal notch toughness and lieved condition is shown in Fig. 9. In the filler-wire study, it was ex-
tensile properties of the 3% nickel The same trend that was observed pected that better notch toughness
wires are shown in Fig. 8. It can be on the welds in the as-welded condi- results than were observed would be
seen that, with increased molybde- tion prevailed in the stress-relieved obtained since the notch toughness
num contents, impact properties welds; that is, with increased of weld metals made with other
were generally lowered and the ten- molybdenum contents, weld-metal processes with similar compositions
sile and yield strengths were in- notch toughness decreased and ten- were good. Therefore, further
creased. The notch toughness, sile and yield strengths increased. studies were made to determine if
however, of (G) 0.43° molybdenum In comparing Figs. 8 and 9, it can the experimental filler wires in-
and (H) 0.50° molybdenum weld be seen again that weld-metal notch herently produced low notch tough-
metal were not comparable. The toughness was improved and tensile ness or whether the low notch tough-
reason for this is not known. Both strength was lowered by stress re- ness was due to some metallurgical
weld metals were made with the lieving. or chemical change that normally

T
Designation ¥s Designation
0.05% Mo)
0.05% Mo) 77,00 0.43% Mo)
S (0.43% Mo) 102,00¢ 0.50% Mo
0.76% Mo)

ft-lb
Toughness,
Notch
Toughness,
Notch
ft-lb

-40
Temperature, F Temperature, F
Fig. 8—Effect of molybdenum on weld- Fig. 9—Effect of molybdenum on weld-
metal notch toughness (as welded) metal notch toughness (stress relieved)

270-s | JUNE 1960

 occurs in using the submerged-arc ard V-notch Charpy specimens and
welding process. standard 0.505-in. tensile specimens.
Studies were made to compare the The welds were tested in the as-
mechanical properties, metallurgical welded condition. The results of
characteristics and composition of the notch-toughness tests are shown
weld metals deposited with the sub- in Fig. 10. As this figure shows, the
merged-arc and _ inert-gas-shielded notch toughness of the welds made
metal-arc processes. ‘These studies by the inert-gas-shielded process
were made to determine if dif- was considerably higher than that of
ferences in weld-joint properties the welds made by the submerged-
could be associated with micro- arc process. The tensile properties
structure or composition of the of the welds are shown in Table 7.
welds. The tensile properties of both welds
Submerged-arc and __inert-gas- were practically the same.
shielded metal-arc welds were made Metallographic examinations and
using the same base plate, joint de- chemical and vacuum-fusion anal-
sign, filler wire (B) and welding yses were made on both weld metals
conditions. The welding conditions to try to determine the causes of the
were: 450 amp, 26 arc v, 15.6-ipm difference in notch-toughness proper-
welding speed, and a 250° F inter- ties. Metallographic examinations
pass temperature. The submerged- showed that the microstructure of
arc welds were made with a neutral the welds made with both processes
flux. The inert-gas-shielded metal- was essentially thesame. However,
arc welds were made with argon the submerged-arc welds contained
Fig. 10—Comparison of notch toughness shielding. a considerable number of silicate in-
of weld metals made with the sub- Weld-metal notch toughness and clusions and the inert-gas welds were
merged-arc welding process and the in tensile properties were determined relatively clean (Fig. 11
ert-gas-shielded metal-arc process for both types of welds using stand- The results of chemical and vac-
uum-fusion analyses are shown in
Table 8. The wire composition is
included for comparison. As this
table shows, the major differences in
the compositions of the weld metal
are in silicon and oxygen contents.
The silicon content of the sub-
merged-arc welds was about twice
that of the inert-gas welds. The
oxygen content of the submerged-arc
welds was about 6 times that of the
argon-shielded welds.
This study showed that the major
differences between the submerged-
Submerged-arc weld Inert-gas-shielded metal-arc weld arc welds and the inert-gas-shielded
metal-arc welds were:
Fig 11—Comparison
i of cleanliness of submerged-arc and inert-gas-shielded 4
metal-arc weld metals 1500 (Reduced by upon reproduction) 1. Number of inclusions.
2. Oxygen content.
3. Silicon content.
Table 7—Tensile Properties of Submerged-arc and Inert-gas Welds Made On the basis of this information,
with the Same Filler Wire and Welding Conditions studies were made to improve weld-
metal notch toughness by modifying
Ultimate the neutral flux or developing a new
Yield strength tensile flux. The modifications were aimed
(0.2% offset), strength, Elongation Reduction
psi in2in.,% in area, % at altering the fluidity of the flux or
Welding process psi
52 6 changing arc characteristics so as to
Submerged arc 100 ,000 114,250 obtain less trapped silicates than
100 ,000 114,250 3
Inert gas 98 ,000 107 , 750 8 7 51 .0 were observed in weld metals made
102 ,500 111,750 é 58 .3 with the neutral flux. The informa-
tion obtained from the flux studies

Table 8—Composition of Experimental Filler Wire and Weld Metals

— ——_—_———Chemical composition, %
Mn P Ss Si Cr Ni Mo
Filler wire 1.18 0.002 0.26 1.91 0.57
Submerged-arc weld metal 0.81 0.016 0.44 0.43 2.15 0.32 0.007 0.00007
Inert-gas weld metal 0.74 0.021 0.22 é 2.13 0.36 0.006 0.00005

@ Total aluminum—aAl,O; and residual Al

WELDING RESEARCH SUPPLEMENT |} 27l-s

will be presented in a subsequent
paper.
Conclusions
Nine experimental filler wires were
prepared for submerged-arc welding
studies. The compositions of these
wires were such that a study of the
effects of nickel, manganese and
molybdenum could be made. The
ranges of alloy content studied were:
nickel, 1.4 to 3.0%; manganese, 1.2
to 1.8%; molybdenum, 0.05 to
0.80%. The weld metals were eval-
uated on the basis of notch tough-
ness and tension tests. In analyz-
ing the data, the following important
observations were made:
1. Increasing nickel content low-
ered weld-metal notch toughness,
especially at testing temperatures
above —40° F. However, at test-
ing temperatures below -40° F,
increased nickel appeared to be
beneficial.
2. Increasing manganese content
also lowered weld-metal notch
toughness at testing temperatures
above —40° F, but at testing
temperatures below —40° F, the
notch toughness of the welds was
about the same.
3. Increasing molybdenum con-
tent generally lowered weld-metal
notch toughness.
4. The tensile and yield strengths
of the weld metals were improved by
increasing the nickel, manganese or
molybdenum contents. However,
the improvement in strength ob-
tained by increasing the manganese
or molybdenum contents was greater
than that obtained by increasing the
nickel content.
5. The notch toughness of the
weld metals was improved and the
tensile and yield strengths were
lowered by stress-relieving opera-
tions.
Studies to find the differences be-
tween submerged-arc and inert-gas-
shielded metal-arc weld metals
showed the following:
1. The notch toughness of weld
metals made by the _inert-gas-
shielded metal-arc process was
higher than the notch toughness of
weld metals made by the submerged-
arc process.
2. The difference found in the
notch toughness of weld metals
made by the two processes was
attributed to the number of in-
clusions, oxygen content and silicon
content.
3. The tensile properties of weld
metals made by the two processes
were practically the same.
Acknowledgment
The authors wish to express their
appreciation to the Bureau of Ships
and to Battelle Memorial Institute
for permission to publish this paper.
The authors alsc wish to express
their appreciation for the technical
counsel offered by C. E. Sims, of the
Battelle staff.
Acknowledgment is also due to
J. A. Hincks and R. Pollock for the
preparation and testing of the weld-
joint specimens and to R. D.
Buchheit for the metallographic
work.
References
1. Rienbolt, J. A., and Harris, W. J., Jr.,
“Effect of Alloy Elements on Notch Toughness of
Pearlitic Steels,"" Am. Soc. Metals, Trans., 43
1175-1201 (1951
2. Boulger, F. W., Frazier, R. H., and Lorig,
C. H., Investigation of the Influence of Deoxidation
and Chemical Composition on Notched-Bar
Properties of Ship Plate Steel, Welding Research
Council, Bull. No. 26, April 1956.
3. Puzak, P. P., and Pellini, W. S., “Effect of
Temperature on the Ductility of High-Strength
Structural Steels Loaded in the Presence of Sharp
Crack,’ Naval Research Laboratory, Report
4545
4. Wepfer, G. S., “The Development and In-
vestigation of High-Tensile High-Impact Elec-
trode,”” THE WELDING JOURNAL, 35 (3), 229-235
1956
5. Hatch, W. P., Jr., and Hartbower, C. E.,
““Vee-Notch Charpy Impact Testing of Weld
Metal and Heat-Affected Zone Simultaneously,”
lbid., 35 (3), Research Suppl., 120-8 to 126-s
1956
6. Simon, W., “Effect of Silicon in Submerged-
Arc Welds,"’ Materials and Methods (July 1955)
7. Stern, I. L.. Kohn, N. A., and Nagler, H.,
**‘Notch-Toughness Characteristics of Submerged-
Arc Weld Deposits,” WELDING JOURNAL, 36 (5
Research Suppl., 226-s to 234-8 (1957
8. Battelle Memorial Institute, “Development
of Filler Wire for Welding Army Ordnance Armor
by the Inert-Gas-Shielded Consumable-Electrode
Process,"" Summary Report WAL 641/17, dated
March 31, 1956, to Watertown Arsenal Labora-
tory (Contract DAI-33-019-505-ORD-(P)-2, Sub-
contract TB4-31
9. Air Reduction Co., ““The Welding of HY-80
Steel by Inert-Gas-Shielded Metal-Arc Welding,”
Final Report dated Feb. 28, 1957, to Department
of the Navy (Contract NObs 72087

“To Prospective pbuthors for G2ud

AAunual Meeting!

All authors interested in presenting papers at the AWS 42nd Annual Meet-
ing to be held in New York City on April 17-21, 1961 are advised of a change
in preliminary arrangements.

The usual forms, ‘‘An Invitation to Authors’’ and ‘‘Authors Application

Form’’, have been printed as a detachable insert on pages 509-510 of the
May issue of the Welding Journal instead of being sent through the mails.

272-s | JUNE 1960

Anaconda Memo to Management

\
\

his is a penny’s \\ worth of bronze

YD
—

It’s a piece of Anaconda welding rod that could be worth its weight in gold to

you. It might save you a big capital investment or important production time by

salvaging equipment that seems beyond repair. Take the experience of Jessup
TOE Tho
Steel Co., for example. A while back their production stopped dead in its VA be r
“—

tracks when the 60-ton semisteel base of a big forging hammer fractured. A

replacement base? Of course—in nine months. Jessup called specialists in re-

pairing heavy machinery. The base was repaired by braze welding in a week

—at 20% of replacement cost. About a ton of Tobin Bronze*-481 rod was used.

But sometimes a few ounces can make equally significant savings in building

up worn surfaces or repairing a broken part that has immobilized 7 a big

Ba.aresrtad
machine. And don’t overlook braze welding in production. It’s a practical way

to get flexible, low-cost production assembly

of tubular and sheet steel products

—like =o furniture and appliances. American Motors usesit to add strength,

prevent sunenits. leaks, and rattles in unit construction of the Rambler’s body,
‘ ° ‘ , reek? ‘ va
supplementing electric welding in some aN 30 areas. Anaconda-997 (Low
Wt tb

Fuming) Bronze Rod has proved to be the best welding rod for these produc-

tion uses.

We'd be glad to send you (or anyone else in your

company) a copy of Publication B-13 which gives
detailed and practical information on Anaconda
Welding Rods in repair and production jobs. If you
have a special problem, the services of an Anaconda WELDING RODS
specialist are at your disposal. Write: The American roducts of The American Brass Cx
Brass Company, Waterbury 20, Conn. In Canada:
Anaconda American Brass Ltd., New Toronto, Ont.
For details, circle No. 46 on Reader information Card
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CYLINDER
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or at top of protective
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