Welding Journal - April 2012

156 Pages·2012·28.24 MB·English

by  American Welding Society

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April 2012
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Welder Training
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Precision Laser
Cutting
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
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CONTENTS
April 2012 (cid:129) Volume 91 (cid:129) Number 4
AWS Web sitewww.aws.org
Features Departments
28 Unlocking Your Gas Metal Arc Welding Potential
A study sponsored by the National Shipbuilding Research
Program investigated low-cost modifications to equipment Editorial............................4
28
or parameters that improved welding performance Washington Watchword..........6
P. A. Blomquist
Press Time News..................8
33 Community College Welding Program Update News of the Industry............10
Many community colleges around the country are equipping Aluminum Q&A..................14
future workers with the skills manufacturers need
Brazing Q&A......................18
D. Postlethwaite
Product & Print Spotlight......22
38 Modern Power Source Technology Drives Process
Coming Events....................58
Improvement
New technology in weld monitoring is making it easier to Certification Schedule..........68
access the data by all the appropriate personnel and Welding Workbook..............70
understand how it should be applied to benefit weld quality
Society News....................73
T. McEllis
Interpretations D1.1 ..........74
33 45 Building a Welding Career from the Ground Up Guide to AWS Services........94
A thirty-two-year career welder shares her passion for the Personnel........................104
profession with others in hopes of inspiring them to expand
Welding School Profiles......108
their skills and knowledge
Classifieds......................122
Advertiser Index................125
48 How Today’s Power Sources Aid Pulsed GMAW
The advanced welding machines of today can deliver power
to the arc in almost any form and can react with split-second
timing to avoid adverse arc phenomena
L. Barley
52 Fiber Lasers Perform Precision Cutting for Medical Devices
There are many methods to cut thin tubular structures often
38 used in medical devices, but fiber lasers are emerging as the
precision machines of choice
Welding Research Supplement
101-s Arc Characteristics in Pulsed-GMA Welding with Acute
Groove Angles
The characteristics of a joint tracking sensor were monitored
Welding Journal (ISSN 0043-2296) is published
under conditions of different groove angles and root openings monthly by the American Welding Society for
R-H. Kim et al. $120.00 per year in the United States and posses-
sions, $160 per year in foreign countries: $7.50
106-s Design of Experiment and Goal Programming per single issue for domestic AWS members and
Application for the GMAW Process $10.00 per single issue for nonmembers and
$14.00 single issue for international. American
This study was conducted to determine critical gas metal arc
Welding Society is located at 550 NW LeJeune Rd.,
welding variables and ways to optimize them Miami, FL 33126-5671; telephone [phone].
Y. T. Iç et al. Periodicals postage paid in Miami, Fla., and addi-
tional mailing offices. POSTMASTER: Send address
113-s Predictive and Measurement Methods for Delta Ferrite changes to Welding Journal, 550 NW LeJeune Rd.,
Determination in Stainless Steels Miami, FL 33126-5671. Canada Post:Publications
Mail Agreement #40612608 Canada Returns to be
The advantages and limitations of predictive measurement sent to Bleuchip International, P.O. Box 25542,
methods for δferrite are outlined London, ON N6C 6B2
M. A. Valiente Bermejo
Readers of Welding Journal may make copies of
122-s Susceptibility of IN740 to HAZ Liquation Cracking and articles for personal, archival, educational or
research purposes, and which are not for sale or
Ductility-Dip Cracking
resale. Permission is granted to quote from arti-
Conditions that lead to cracking susceptibility of nickel-based cles, provided customary acknowledgment of
IN740 were simulated to determine an action for its prevention authors and sources is made. Starred (*) items
J. E. Ramirez excluded from copyright.
On the cover: To attract and educate the skilled workforce of the future, it is
beneficial for community colleges and industry leaders to work together to
develop training programs. (Photo courtesy of The Lincoln Electric Co.,
Cleveland, Ohio.)
WELDING JOURNAL 3
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EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
The Welding Education
Officers
Challenge President William A. Rice Jr.
OKI Bering
Vice President Nancy C. Cole
To get a clear visual of welding education today, we must take a look at the past. I was
NCC Engineering
told many years ago that technology didn’t really matter because “welding could be
taught with a ‘cracker box’ power source.” I guess it’s all about the perspective one takes Vice President Dean R. Wilson
on the issue. As I reflect over the last three decades of welding education, I have good Kimberly-Clark Global Safety
memories of student successes and the challenges that educators have faced.
Vice President David J. Landon
One thing has not changed: the never-ending challenge of getting adequate funding
Vermeer Mfg. Co.
for our programs. Twenty-eight years ago, my program had a $10,000 training supply
budget for 40 students. This year it was just over $7000 for, you guessed it, 40 students. Treasurer Robert G. Pali
If you can understand that logic, please let me know. However, we must also realize that
J. P. Nissen Co.
welding is the most expensive program our administrators have to operate. Therefore, it
is our responsibility as welding instructors to be proactive and willing to work side by side Executive Director Ray W. Shook
with local industry leaders. We must educate industry on the advantages of helping us American Welding Society
produce a well-rounded welding graduate who not only has the needed welding skills,
but the math, science, and literacy skills necessary to become an asset to the employer.
Directors
If you do that, you may find that your program can be self-sustaining.
Now, let’s take a look at a few of the changes we have faced over the last 30 years: T. Anderson (At Large), ITW Global Welding Tech. Center
Technology has impacted our industry just as it has every other industry sector. J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
Remember the previously mentioned quote about technology? Most see this for what it
J. C. Bruskotter (Past President), Bruskotter Consulting Services
is, “change,” and most of us fear change. But, if we, as welding educators, refuse to
embrace change, we will fail our students. We must challenge every student to be the very G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
best he or she can be whether they’re under the hood or in the classroom. It is also imper- T. A. Ferri (Dist. 1), Thermadyne Industries
ative that we set high expectations for every student and make sure they understand why
D. A. Flood (Dist. 22), Tri Tool, Inc.
we expect so much of them. I’m confident that when we realize these technological
R. A. Harris (Dist. 10), Total Quality Testing
advancements have impacted our industry in a positive way, we can get on with the busi-
ness of welding education as it impacts our students. D. C. Howard (Dist. 7), Concurrent Technologies Corp.
The AWS Education Committee has made some important advancements in order J. Jones (Dist. 17), Thermadyne Industries
for welding educators to be able to utilize industry standards. For example, AWS SENSE
W. A. Komlos (Dist. 20), ArcTech, LLC
Levels I and II have been completely revised. We now have AWS accreditation available
R. C. Lanier (Dist. 4), Pitt C.C.
for welding programs similar to what ASE/NATIF offers for automotive programs. The
committee believes that with these programs in place, AWS will be well positioned to T. J. Lienert (At Large), Los Alamos National Laboratory
assist welding programs throughout the country. The committee is extremely fortunate J. Livesay (Dist. 8), Tennessee Technology Center
to have the industry’s skilled trades leaders helping to keep us current with these revi-
M. J. Lucas Jr. (At Large), Belcan Corp.
sions. Without these individuals and their leadership, our work would be in vain.
When we look at welding education, we must look at it at all levels. It could start as D. E. Lynnes (Dist. 15), Lynnes Welding Training
young as members of the Boy Scouts or 4-H, or in a high school FFA class or welding pro- C. Matricardi (Dist. 5), Welding Solutions, Inc.
gram. We have community/technical two-year postsecondary welding programs that may D. L. McQuaid (At Large), DL McQuaid & Associates
offer a certificate or an associate degree and four-year welding programs that offer weld-
J. L. Mendoza (Past President), Lone Star Welding
ing engineering degrees. Welding manufacturers realized early on that welding education
was and continues to be an important part of what they do. We also have excellent private S. P. Moran (At Large), ESAB Welding & Cutting Products
welding schools throughout the country. My point is when you hear the phrase “welding K. A. Phy (Dist. 6), KA Phy Services, Inc.
education,” it emcompasses much more than you might, at first, realize.
W. R. Polanin (Dist. 13), Illinois Central College
The AWS Welding Education Services department does an outstanding job of offer-
R. L. Richwine (Dist. 14), Ivy Tech State College
ing conferences and seminars, as well as developing new programs and products to meet
industry needs, such as the popular CWI seminars and many more. It is also developing D. J. Roland (Dist. 12), Marinette Marine Corp.
customized online courses that meet the needs of those willing to learn on their own N. Saminich (Dist. 21), Desert Rose H.S. and Career Center
time. With a strategic, aggressive marketing campaign, these conferences, seminars, and
N. S. Shannon (Dist. 19), Carlson Testing of Portland
programs will continue to enhance the lives of those in
T. A. Siewert (At Large), NIST (ret.)
the welding industry.
I believe the American Welding Society is well H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
positioned as we move forward with welding educa- R. P. Wilcox (Dist. 11), ACH Co.
tion. I hope the Society will continue to put welding
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
education and, more specifically, welding students
high on its list of priorities because they are the future D. Wright (Dist. 16), Zephyr Products, Inc.
of the Society.
Ed Norman
Chair, AWS Education Committee
4 APRIL 2012
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WASHINGTON
BY HUGH K. WEBSTER
WATCHWORD
AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
OSHA Continues Progress on Injury and and agreed to file all of its outstanding lobbying reports.
Illness Prevention Program
Ban on Campaign Participation by Foreign
The U.S. Occupational Safety and Health Administration Nationals Upheld
(OSHA) has announced plans to convene a small business re-
view panel to explore the establishment of an Injury and Illness In February, the U.S. Supreme Court upheld the constitution-
Prevention Program standard. This standard would require em- ality of a federal statute that prohibits foreign citizens who are
ployers to develop and implement a process that identifies haz- legally living in the United States from spending or contributing
ards in the workplace, and then establish a plan to eliminate those money in connection with U.S. elections for any government of-
hazards. The panel, whose members will be appointed by the fice. Under the federal Bipartisan Campaign Reform Act, for-
Small Business Administration, is the first step toward imple- eign nationals are prohibited from making expenditures or cam-
mentation of this proposed new rule. paign contributions to political parties, candidates, or political
action committees.
Federal Regulatory Portal Redesigned
Agencies Continue Plain Language Efforts
Regulations.gov, the federal government Web site intended to
make regulatory activity more accessible to the public, has un- After the passage of the Plain Writing Act of 2010, federal
dergone a major redesign, with improvements in functionality, agencies began efforts to produce regulations, or at least ver-
search capabilities, and organization. In particular, for the first sions of regulations, that are written in a more understandable
time, users are now able to browse by categories of regulations, manner. Many agencies now have Web sites dedicated to plain
such as aerospace, defense, labor, and education. language. Building on these efforts, in January, the federal Of-
fice of Information and Regulatory Affairs directed agencies to
Federal Lobbying Expenditures Decrease provide straightforward executive summaries of all rules, includ-
for First Time in a Decade ing separate descriptions of all key provisions and policy choices,
as well as an explanation of the need and legal basis for all rules.
More than $3.27 billion was spent on lobbying Congress in
Government Issues First Competitiveness
2011, according to lobbying reports filed with the House and Sen-
ate, down from $3.5 billion in 2010. This makes 2011 the first and Innovation Report
year in a decade that such lobbying expenditures have decreased
from the prior year. The number of federally registered lobbyists The America COMPETES Reauthorization Act of 2010 man-
also decreased, but this continues a trend that began in 2008. dates that the Secretary of Commerce complete a study that ad-
There were more than 12,500 registered lobbyists in 2011, com- dresses the economic competitiveness and innovative capacity of
pared to a high of nearly 14,900 in 2007, the year before new reg- the United States and, in January, the Department of Commerce
ulations and restrictions on lobbyists were implemented. issued that report. It is available at the following link: www.com-
The top-spending industries in 2011 were the pharmaceuti- merce.gov/sites/default/files/documents/2012/january/com-
cal/health products industry (at least $236 million), the insurance petes_010511_0.pdf.
industry ($158 million), the oil and gas industry ($146 million), The report concludes that “some [key] elements of the U.S.
and electric utilities ($144 million). The U.S. Chamber of Com- economy are losing their competitive edge, which may mean that
merce reported spending more than $66 million on lobbying, future generations of Americans will not enjoy a higher standard
more than any other organization or company. of living than is enjoyed in the United States today.” Observing
that “innovation is the key driver of competitiveness, wage and
R & D Tax Credit Featured in job growth, and long term, economic growth,” the report identi-
Administration Proposals fies the three “pillars” of innovation to be federal support for
basic research, education, and infrastructure.
Both the president’s 2013 budget and his separate corporate
Export-Import Bank Offers Revolving
tax proposals would not only renew the expired federal research-
and-development tax credit, but also make it permanent, and in- Credit for Small Business Exporters
crease the credit’s lower option of a 14% rate in excess of a base
amount to 17%. This generally has bipartisan support. Through a newly established initiative, “Global Credit Ex-
press,” small business exporters may be eligible for a revolving
First Prosecution Ever under Federal line of credit from the U.S. Export Import Bank, at amounts of
Lobbying Statute up to $500,000 for 6 to 12 months. During the program’s pilot
phase, an initial $100 million in financing will be made available
through a select number of lenders nationwide. Following the
In January, the U.S. Attorney’s Office for the District of Co-
pilot, the bank will evaluate the results of this direct loan pro-
lumbia announced that it had entered into a negotiated settle-
gram and determine whether to increase the available amount.
ment under the federal Lobbying Disclosure Act. This is the first
The product is specially designed to finance the business of ex-
enforcement action since passage of the act in 1995. In 2007, the porting rather than specific export transactions.♦
act was amended to significantly increase civil penalties and im-
pose criminal sanctions for violations.
The Department of Justice alleged that a lobbying firm failed Contact the AWS Washington Government Affairs Office at
to timely file its quarterly lobbying activity and semiannual con- 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail
tribution reports. The firm reportedly settled the case for $45,000 [email protected]; FAX [phone].
6 APRIL 2012
esab_FP_TEMP 3/7/12 7:41 AM Page 7
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PRESS TIME
NEWS
Publisher Andrew Cullison
North American Robotics Industry Achieves Record Year
Editorial
North American robotics companies sold more robots in 2011 than ever before, ac- Editorial Director Andrew Cullison
cording to new statistics from the Robotic Industries Association (RIA), Ann Arbor, Editor Mary Ruth Johnsen
Associate Editor Howard M. Woodward
Mich. A total of 19,337 robots valued at $1.17 billion were sold to companies in North
Associate Editor Kristin Campbell
America, beating the previous record. When sales by North American robot suppliers
Peer Review Coordinator Melissa Gomez
to companies outside North America are included, the totals are 22,126 robots valued
at $1.35 billion. Compared to 2010, North American orders were up 47% in units and
Publisher Emeritus Jeff Weber
38% in dollars.
According to Paul Kellett, RIA’s director of market analysis, a revitalized demand by
Design and Production
the automotive industry helped fuel the increase. Large surges were also seen in spot
Managing Editor Zaida Chavez
and arc welding; assembly; coating and dispensing; and material handling applications.
Senior Production Coordinator Brenda Flores
In addition, the fourth quarter of 2011 was the strongest quarter recorded by RIA in
Manager of International Periodicals and
terms of units ordered with 5721 robots valued at $317.5 million.
Electronic Media Carlos Guzman
Advertising
Lincoln Electric Acquires Weartech Intʼl
National SalesDirector Rob Saltzstein
Advertising Sales Representative Lea Paneca
Lincoln Electric Holdings, Inc., Cleveland, Ohio, has acquired Weartech Int’l, Inc.,
Senior Advertising Production Manager Frank Wilson
Anaheim, Calif., a privately held producer of cobalt-based hardfacing and wear-resist-
ant welding consumables with manufacturing plants in Anaheim and Port Talbot, Wales. Subscriptions
The company has annual sales of approximately $40 million and employs 140 people Subscriptions Representative Sylvia Ferreira
combined at both locations. Terms of the transaction were not disclosed. [email protected]
Texas Colleges Awarded Nearly $600,000 for New American Welding Society
550 NW LeJeune Rd., Miami, FL 33126
Welding Equipment
[phone] or [phone]
Texas Comptroller Susan Combs recently announced 11 community colleges and Publications, Expositions, Marketing Committee
technical institutes will receive $3 million in grants to buy equipment for training stu- D. L. Doench, Chair
dents in critical workforce skills. For its welding technician programs, Hill College has Hobart Brothers Co.
S. Bartholomew, Vice Chair
been awarded $282,281, and Texarkana College is collecting $289,248. This new round
ESAB Welding & Cutting Prod.
of grants comes from the Jobs and Education for Texans, a career training grant pro-
J. D. Weber, Secretary
gram administered by the comptroller’s office since 2009.
American Welding Society
T. Birky, Lincoln Electric Co.
JM Eagle Extends Deadline for $10,000 Scholarship D. Brown, Weiler Brush
J. Deckrow, Hypertherm
JM Eagle, Los Angeles, Calif., will extend the contest deadline awarding $10,000 to D. DeCorte, RoMan Mfg.
the student who submits the most compelling paper about the advantages of plastic pipe J. R. Franklin, Sellstrom Mfg. Co.
in a modern infrastructure. The company has changed the required submission date to F. H. Kasnick, Praxair
D. Levin, Airgas
June 30. It is open to junior- and senior-year as well as graduate students.
E. C. Lipphardt, Consultant
Contestants are required to submit 2500- to 5000-words describing the benefits of
R. Madden, Hypertherm
using plastic pipe vs. other materials in building and municipal waterworks systems. En-
D. Marquard, IBEDA Superflash
tries will be judged on vision, understanding of issues, originality, and emphasis on ma-
J. Mueller, Thermadyne Industries
terial solutions. Entrants must complete an online form along with their paper submis- J. F. Saenger Jr., Consultant
sions. The form, rules and regulations, and more details can be found at S. Smith, Weld-Aid Products
www.jmeagle.com/scholarship. The winner will be announced Aug. 1. N. C. Cole, Ex Off., NCC Engineering
J. N. DuPont, Ex Off., Lehigh University
Prima Power Laserdyne Expands Operations L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems
S. P. Moran, Ex Off., ESAB Welding & Cutting Prod.
E. Norman, Ex Off., Southwest Area Career Center
Prima Power Laserdyne, Champlin, Minn., a supplier of multiaxis laser systems to
R. G. Pali, Ex Off., J. P. Nissen Co.
the global aerospace industry, is hiring personnel for 20 newly created job positions.
R. Ranc, Ex Off., Superior Products
The company has recently increased its position in industries requiring laser cutting and
W. A. Rice, Ex Off., OKI Bering
welding fine mechanical and medical components and assemblies. Also, the manufac- R. W. Shook, Ex Off., American Welding Society
turing challenges of new lightweight automobiles, more efficient jet aircraft engines, D. Wilson, Ex Off., Kimberly-Clark Global Safety
and other fine mechanical items have increased demand for other products.
According to Terry VanderWert, company president, new positions include assembly, Copyright © 2012 by American Welding Society in both printed and elec-
installation, and service technicians; applications and design engineers; and customer tronic formats. The Society is not responsible for any statement made or
◆ opinion expressed herein. Data and information developed by the authors
service representatives. More information can be found at www.prima-na.com. of specific articles are for informational purposes only and are not in-
tended for use without independent, substantiating investigation on the
part of potential users.
MEMBER
8 APRIL 2012