welding journal | june 2019 · the decline in our investment portfolio, result-ing in a flat effect...

PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDINGAND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING

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JUNE 2019

Industry Spotlight: MaritimeAmerican Welder: GMAW/FCAW

AWS Centennial Festivities

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66 Making Waves in the Gulf Coast Shipbuilding and Repair Industry Four members of the Gulf States Shipbuilders Consortium offered their take on the state of the maritime industry — R. Blythe

70 Tips for Cutting and Grinding in Shipbuilding Applications These key practices can help shipbuilders gain optimal results in their cutting and grinding operations — T. Hufford and D. Jescovitch

74 They Say It’s Your Birthday: AWS Celebrates 100 Years AWS World Headquarters marked the Society’s centennial at a festive event — R. Pascal and K. Pacheco

78 Keeping the Coast Guard on Course How plasma cutting and nesting software aid the shipbuilding process — M. Avila

JUNE 2019 / WELDING JOURNAL 3

CONTENTS

165-s Assessment of Thermoplastic Weldability Using the Deformation Technique A new method for joining polymers without the use of additive materials helped avoid product overweight — P. Kumar and S. S. Panda

172-s Laser Wire Deposition of a Large Ti-6Al-4V Space Component The additive manufacturing methodology and

manufacturing strategy for printing a large space component with varying wall thicknesses are described — N. Chekir et al.

181-s Joining Alumina to the TZM Alloy by Hot Pressing A two-step process produced a strong joint in a ceramic-to-metal assembly — R. Berkouch et al.

WELDING RESEARCH SUPPLEMENT

June 2019 • Volume 98 • Number 6

FEATURES

66

118 Making Bigger Better in Texas A fabricator found a larger diameter, advanced formula electrode provides a jump in productivity B. Gulas 123 Gas Metal Arc Welding Fundamentals Good GMAW techniques produce positive results D. Weimer

THE AMERICAN WELDER

118

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6 Editorial8 AWS at 100

10 Press Time News12 News of the Industry18 Business Briefs20 Washington Watchword22 International Update26 Letters to the Editor28 Aluminum Q&A30 Brazing Q&A32 Product & Print Spotlight36 Centennial Stories38 AWS Financial Report

82 Coming Events90 Certification Schedule91 Society News

92 Member Profiles94 Tech Topics101 Section News113 Guide to AWS Services114 Personnel

The American Welder126 Learning Track129 Fact Sheet130 Classifieds130 Advertiser Index

OFFICERSPresident Thomas J. LienertConsultant

Vice President Robert W. RothRoMan Manufacturing Inc.

Vice President W. Richard PolaninWRP Associates

Vice President Dennis K. EckPraxair Distribution Inc.

Treasurer Carey ChenCincinnati Incorporated

Executive Director and CEO Matt MillerAmerican Welding Society

DIRECTORST. Anderson (At Large), ITW Welding North AmericaR. Ashelford (Dist. 13), Rock Valley CollegeJ. R. Bray (Past President), Affiliated Machinery Inc.T. Brosio (Dist. 14), Major Tool & MachineJ. Burgess (Dist. 8), General ElectricD. A. Desrochers (Dist. 1), Old Colony RVTHSD. L. Doench (At Large), Hobart Bros. Co.D. A. Flood (Past President), Tri Tool Inc.K. Fogleman (Dist. 16), ConsultantP. H. Gorman (Dist. 20), RetiredM. Hanson (Dist. 15), Consolidated Precision ProductsL. Heckendorn (Dist. 7)R. L. Holdren (At Large), ARC SpecialtiesT. Holt (Dist. 18), Tech Corr USA ManagementJ Jones (Dist. 17), Harris Products GroupM. Krupnicki (Dist. 6), Mahany Welding Supply Co. Inc.D. Lange (Dist. 12), Northeast Wisconsin Tech. College S. Lindsey (Dist. 21), City of San DiegoS. M. McDaniel (Dist. 19), Big Bend Community CollegeD. K. Miller (At Large), Lincoln ElectricS. Moran (Dist. 3), American Hydro Corp.R. Purvis (Dist. 22), Purvis Welding InspectionS. Raghunathan (At Large), Saudi AramcoH. Record (Dist. 5), Townley Foundry & MachineM. Sherman (Dist. 10), SW&E LLCL. E. Showalter (Dist. 4), Newport News ShipbuildingM. Skiles (Dist. 9), Airgas Inc.W. J. Sperko (At Large), Sperko Engineering ServicesK. Temme (Dist. 2), Matrix NACP. I. Temple (Dist. 11), Welding Consultant

WELDING JOURNALPublisher/Editor Mary Ruth JohnsenEditorialSr. Editor Cindy WeihlFeatures Editor Kristin CampbellAssociate Editor Katie PachecoAssistant Editor Roline PascalPeer Review Coord. Lea OwenPublisher Emeritus Jeff Weber

Design and ProductionProduction Manager Zaida ChavezAssistant Production Manager Brenda FloresManager of International Periodicals andElectronic Media Carlos Guzman

AdvertisingMedia Sales Executives Jeff Rhodes and Kim DanieleProduction Specialists Megan Lebo and Amy Gosen

SubscriptionsSubscriptions Representative Thomas [email protected]

MARKETING ADVISORY COUNCIL(MAC)D. Doench, Chair, Hobart Brothers Co.A. Sepulveda, Vice Chair, Hypertherm Inc.S. Samuels, Secretary, American Welding SocietyD. Brown, Astaras Inc.C. Coffey, The Lincoln Electric Co.D. DeCorte, RoMan Mfg. Inc.D. Marquard, IBEDA Superflash CompressedS. Molenda, ESAB Welding & CuttingM. Muenzer, ORS NascoW. Newell Jr., Euroweld Ltd.N. Schmid, Weiler Abrasives GroupS. Smith, Weld-Aid ProductsD. Wilson, Wilson and AssociatesC. Chen, Ex Officio, Cincinnati IncorporatedS. Fyffe, Ex Officio, Astaras Inc.L. Kvidahl, Ex Officio, Ingalls ShipbuildingT. Lienert, Ex Officio, ConsultantM. Miller, Ex Officio, American Welding SocietyS. Moran, Ex Officio, American Hydro Corp.R. Polanin, Ex Officio, WRP AssociatesR. Roth, Ex Officio, RoMan Mfg. Inc.Y. M. Zhang, Ex Officio, University of Kentucky

On the Cover: The Sentinel-classfast response cutters being builtby Bollinger Shipyards for theU.S. Coast Guard measure 154 ftlong and 26 ft wide.

Welding Journal (ISSN 0043-2296) is published monthlyby the American Welding Society for $120.00 per year in theUnited States and possessions, $160 per year in foreigncountries: $7.50 per single issue for domestic AWS membersand $10.00 per single issue for nonmembers and $14.00 sin-gle issue for international. Not available for resale in eitherprint or electronic form. American Welding Society is locatedat 8669 NW 36 St., # 130, Miami, FL 33166-6672; telephone(305) 443-9353. Periodicals postage paid in Miami, Fla., andadditional mailing offices. POSTMASTER: Send addresschanges to Welding Journal, 8669 NW 36 St., # 130, Miami, FL33166-6672. Canada Post: Publications Mail Agreement#40612608 Canada Returns to be sent to Bleuchip Interna-tional, P.O. Box 25542, London, ON N6C 6B2, Canada.

Readers of Welding Journal may make copies of articlesfor personal, archival, educational or research purposes, andwhich are not for sale or resale. Permission is granted toquote from articles, provided customary acknowledgment ofauthors and sources is made. Starred (*) items excludedfrom copyright.

Copyright © 2019 by American Welding Society in bothprinted and electronic formats. The Society is not responsiblefor any statement made or opinion expressed herein. Dataand information developed by the authors of specific articlesare for informational purposes only and are not intended foruse without independent, substantiating investigation on thepart of potential users.

WELDING JOURNAL / JUNE 20194

AWS Promotes Diversity

AWS values diversity, advocates equitable andinclusive practices, and engages its members andstakeholders in establishing a culture in thewelding community that welcomes, learns from,and celebrates differences among people. AWSrecognizes that a commitment to diversity, equity,and inclusion is essential to achieving excellencefor the Association, its members, and employees.

DEPARTMENTS

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When I wrote my Treasurer’s Report tothe American Welding Society (AWS) boardearlier in January, the northern half of thecountry was experiencing a “polar vortex,”with temperatures, including wind chill, dip-ping well below 0˚F in many places. The U.S.economy, too, felt like it was in a polar vor-tex, with a number of chilling economictrends from the end of 2018 extending intoearly 2019. Below are examples: • Stock market volatility created the worstDecember performance since the Great Depression. • Unemployment reached a 49-year low at3.7%, making it difficult for many high-techcompanies to find and hire needed talent. • After four painful interest rate increasesin 2018, the Fed kept rates unchanged inearly 2019, as the housing market weakened. • The bond market flashed a recessionarywarning sign. The yield curve inverted, withthe yield of 5-year Treasury notes falling be-hind that of 3-year Treasury notes. • Uncertainty over the U.S.-China tradepolicy continued to stew, though the G20Summit held in December 2018 produced atemporary 90-day halt to new tariffs. All of this was reflected in a modest fi-nancial decrease for AWS, continuingthrough the end of 2018. AWS revenues for2018 were $38.9 million, a slight (2.6%) de-crease from the previous year. This softnessin 2018 revenues compared to the previousyear was also driven by decreases in interna-tional certification activities, domestic Certi-fied Welding Inspector exam activities, andeducation, along with (to a lesser degree) ad-vertising in AWS publications. Surplus for the same period was $8.5 mil-lion, down 11.8% from the prior year. Com-bined with lower revenues, nonrecurring expenses compressed year-to-year perform-ance. These expenses included internal AWS restructuring, ongoing enterprise re-source planning/customer relationship management implementation expenses, and centralizing and automating customerservice functions. The AWS Foundation’s assets on Decem-ber 31, 2018, dropped to $67.8 million,down $1.6 million or 2.3% from the year-endbalance in 2017. Despite positive transfersto the Foundation of $3.5 million from oper-ations, its expenses of $2.9 million and nega-tive market investment changes of $3 mil-lion resulted in the overall decline in Foun-dation assets. (Fortunately, the negativemarket investment changes in December

completely reversed in the first quarter of2019.) In 2018, the Foundation awardedmore than $1.4 million in scholarships andother programs, benefiting close to 1000 re-cipients. Additionally, under the new WelderWorkforce Grant program, the Foundationawarded more than half a million dollarssince 2017. AWS total net assets at year-end stood at$155.4 million, a slight increase of $53,900over 2018. Surplus generated in fiscal year2018 did not increase our net assets as in oth-er years, as operating results were absorbed bythe decline in our investment portfolio, result-ing in a flat effect on net assets. Despite these less-than-desirable num-bers for AWS, the reserve fund on December31, 2018, was $53.2 million, an increase of$3.1 million or 6.1% greater than the 2017year-end balance. On the positive side, AWS was involved inseveral new and successful operational pro-grams during 2018. The AWS Welding Sum-mit in League City, Tex., in October included13 professional presentations, a job fair, anda colocated meeting with the AWS HoustonSection. We also attained International Asso-ciation for Continuing Education and Train-ing (IACET) and Accreditation Board for En-gineering and Technology (ABET) accredita-tion, which will help us position our educa-tional offerings. Our 2018 FABTECH Show in Atlanta, Ga.,was the largest even-year FABTECH everheld. Attendance was 33,755, up 9.5% fromAtlanta 2014, and up 8.5% from Las Vegas in2016. At 650,060 net square feet (NSF) ofexhibit space, the 2018 Atlanta show was up17.4% from Atlanta 2014 and 14% from LasVegas 2016. The 198,925 NSF in weldingrepresented an increase of 10.6% from At-lanta 2014 and 13.85% from Las Vegas2016. International show increases followedsuit; the 2018 WELDMEX Show in MexicoCity occupied 49,350 NSF compared to49,000 NSF in 2017 in Monterrey, Mexico. The AWS membership count at year-endwas 68,404, down 1863 or 2.7% over a one-year period. However, membership revenuesgrew by $387,500 or 8.5% compared to 2017,resulting from a revised transfer allocationfrom combo seminar and exam packages. In early December, AWS hosted the inau-gural meeting of the Skilled Trades Coalition,which included senior executives from 17professional associations and unions. A recapstory was published in the March 2019 Weld-ing Journal (see page 63 in Society News).


EDITORIAL

Carey ChenAWS Treasurer

“AWS felt theimpact of achallenging andmixed economicenvironment thathas stronglyaffected industryand advocacyinterests through-out the country.”

Staying Strong in a Shaky Economy

— continued on page 115

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1980s

Arc welding robots make their presence felt in U.S. manu-facturing plants.

1980 Use of power transistors allows replacement of largetransformers in welding power supplies. These inverter sys-

tems allowed small, efficient transformers to replace largertransformers operating at 60 cycles.

Welding filler metals continued to evolve to meet the de-mands of higher-strength and higher-toughness steels. Sig-nificant advances occured in the development of flux-coredelectrodes.

1984

The self-shielded version of flux cored arc welding seesbroad use in the erection of high-rise buildings throughoutthe United States.

Soviet Cosmonaut Svetlana Savitskaya uses a hand-heldelectron beam gun to conduct welding, brazing, and spray-ing experiments in space.


AWS AT 100

In celebration of the AmericanWelding Society’s 100th anniversary,here are some historical highlights ofthe Society and industry. In this issue,we feature the 1980s.

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1985

AWS educational offerings for welding inspection certifi-cation preparation and skills improvement were established.

1988

Resistance and arc welding robots see widespread use onautomotive assembly lines throughout the world.

1989

The AWS Foundation was established to promote post-secondary welding education. To date, more than $7 millionin scholarships and fellowships have been awarded to students.

The first AWS Section outside North America was established — the AWS Emirates Welding International Section.


Learn about the 1990s in the July Welding Journal.

WJ

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Excitement filled the air on April10, 2019, as the American Weld-ing Society (AWS) commemorat-ed a landmark 100 years of service.Celebrating on the 100th day of its100th year, AWS observed the occasionat its World Headquarters in Miami,Fla., along with local schools, organi-zations, Society members, and theSouth Florida community. To bolster its centennial theme of“Honoring our Past, Embracing theFuture,” AWS treated guests to fingerfoods, music delivered by a DJ, educa-tional desserts, a digital photo booth,live demonstrations, interactive activi-ties for both kids and adults, and pre-sentations from government officials.

Welding Trailer Rolls Backto Town

One of the major highlights of thecentennial event was the AWS Careersin Welding Trailer (Fig. 1), which lastvisited AWS Headquarters in 2012.The 53-ft interactive trailer travels thecountry for 18 weeks of the year and iscomprised of four Lincoln Electric VRTEX® 360 virtual reality weldingsimulators (two for shielded metal arcwelding and two for gas metal arcwelding), plus a mini unit; weldingtrivia tablets; videos; a social mediakiosk; career/salary data; scholarshipinformation; and more. During the centennial celebration,Welding Instructor Stephanie Hoff-man, along with various AWS staffmembers, led visitors around the trail-er, informing them about the many ca-reers in welding and assisting them inperfecting their virtual welds. Approximately 511 people visitedthe trailer, with 343 welds made onthe welding simulators. Attendees

ranging from students to staff mem-bers to government officials were ex-cited to jump in and try the craft.Some even got into a friendly competi-tion to get the highest score. In honor of the Society turning 100years old, a $1000 scholarship wasawarded to the person with the high-est score on the virtual reality weldingsimulators for that day. High SchoolStudent Susan Nelson, 17, won thescholarship — Fig. 2. The interactive trailer made a lasting

impression on those who entered it. Greater Miami Service Corps(GMSC) Teacher Andre Miller enjoyedseeing his students gain first-handknowledge and experience on a newcareer option. “We’re a construction training pro-gram and we’re always looking for av-enues and career opportunities thatinterest the young people,” he said.“I’m hoping the ones who like weldingwill go ahead and pursue a career inthe field.”


They Say It’s Your Birthday: AWS Celebrates 100 Years

AWS marks the 100th day of its 100th yearwith festivities at World Headquarters

BY ROLINE PASCAL AND KATIE PACHECO

Fig. 1 — The 53-ft Careers in Welding Trailer was one of the biggest attractions atAWS’s centennial celebration.

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All of the GMSC students in atten-dance tried welding for the first timeon the simulator, and described it asan enjoyable activity. “I had never welded before. I lovedusing it because it teaches you how toweld and lets you learn from your mis-takes so that you can weld better,” saidGMSC Student John Watson, 21. “Idon’t know yet if I want to go intowelding, but I am thinking of it. It wasfun.” Mayor of Doral Juan Carlos Ber-mudez was impressed with the trailer’suse of technology as a teaching tool inthe skilled trades. “I was truly honored to be part ofthe American Welding Society centen-nial celebration, where I had the op-portunity to experience the virtualwelding machine and witness, first-hand, the actual application of tech-nology into the welding field,” he said.

Booth Activities Make Learning a Fun and Tasty Treat

In celebration of AWS’s 100th birth-day, event-goers were treated to a vari-ety of activities that entertained, in-formed, and satisfied taste buds. One such activity included “edible

electrodes,” which gave guests a basicunderstanding of what goes into awelding electrode as they created a delicious treat. The edible materialsincluded pretzel rods (electrodes), ic-ing (manganese), sprinkles (silicon),rice krispies (carbon), and cookiecrumbs (chromium). Many guestswere surprised to learn how elementsplay an important role in welding. Uwe Aschemeier, senior weldingengineer at Subsea Global Solutions,past AWS District 7 director, and con-tributing author of the Welding Jour-nal, was present for the festivities togive guests information on underwa-ter welding. He exhibited a video ofunderwater welding, articles he haswritten, and various underwater weld-ing equipment, including a new com-mercial diving helmet, electrodes, anda communication box used to speakwith the submerged diver. Aschemeierallowed guests to hold a 30-lb divinghelmet while answering various ques-tions, such as what it takes to becomea commercial diver/underwaterwelder, the amount of money under-water welders earn, and whether ornot underwater welding is dangerous— Fig. 3. “I’ve heard a lot about underwater

welding, but to see it in person is mindblowing,” said GMSC Student EdwinBueso, 21. Representatives from MathesonGas, Harris Products Group, and Lin-coln Electric were also on hand to per-form live welding and cutting demon-strations. Lincoln Electric Welding En-gineer Lou Kleinsmith wowed guestsas he displayed the shielded metal arcwelding process — Fig. 4. Harris Rep-resentative Ozzie Sejas demonstratedhow to cut 1⁄2-in. mild steel with oxygenand propane, and allowed guests togive it a try as he guided them on theproper technique. It was my first time welding and I’mexcited I tried it because I had a greatexperience,” said GMSC StudentLadarius Reid, 20. “I liked burning themetal and talking to him about whatschools teach welding.” Additionally, Marie Theodore-Pharel from Girl Scouts of TropicalFlorida was in attendance to spreadthe word about the organization’sSTEM Badge opportunities for younggirls. “As the premier organization foryoung girl’s empowerment and devel-opment, learning about AWS will en-able us to provide and suggest AWS as


Fig. 2 — Welding Instructor Stephanie Hoffman teaches highschool student Susan Nelson (wearing helmet) how to virtuallyperform shielded metal arc welding. Nelson was awarded a$1000 scholarship for earning the day’s top score.

Fig. 3 — Uwe Aschemeier, senior welding engineer at SubseaGlobal Solutions, shows GMSC students a diving helmet usedfor underwater welding.

Fig. 4 — Lincoln Electric Welding Engineer Lou Kleinsmithdemonstrates shielded metal arc welding.

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a resource to girls with a proclivity forhands-on engineering and otherSTEM-related [science, technology, en-gineering, and mathematics] inter-ests,” said Theodore-Pharel. The Girl Scouts booth offeredguests a bracelet-making activityaimed at teaching the concept behindbasic binary codes that make up com-puter language. Also present was Florida Interna-tional University’s Department of En-gineering, which showcased theschool’s 3D-printed components, andSkillsUSA Representative Dave Wor-den, who answered questions aboutmembership and discussed the bene-fits of competing. To cement memories, a photobooth was available for guests to takesnapshots of themselves with weldinghelmets, hard hats, safety goggles, andother amusing props.

City of Doral Honors AWSwith Proclamations

With government officials joiningin on the festivities, AWS’s centennialcelebration featured presentationsfrom Mayor of Doral Juan CarlosBermudez, County Commissioner José“Pepe” Diaz, and representatives fromthe office of Congressman Mario Díaz-Balart. The program kicked off with AWSExecutive Director and CEO MattMiller, who highlighted AWS’s missionto serve communities.

“April 10 actually marks the 100thday of our 100th year, and we couldn’tthink of a better place to celebrate thanright here in our headquarters and inthis local community,” affirmed Miller.“From the very beginning, when AWSwas formed back during World War I,our enduring mission has been to pro-tect and improve lives by advancing thescience and technology of welding.That mission now extends to morecommunities all around the world.” Miller also thanked all the men andwomen in the industry who havehelped shape the Society and under-scored the importance of educatingthe public about the dire need forwelders. Highlighting the deficit of weldingprofessionals, AWS Foundation Execu-tive Director Monica Pfarr identifiedthe numerous ways the AWS Founda-tion is helping to rectify the shortage,such as offering $1.3 million annuallyin scholarships. During his presentation, Mayor ofDoral Bermudez discussed the histori-cal role welding played in World War I,and pointed out that AWS’s WorldHeadquarters almost became Miami-Dade’s City Hall building several yearsago. Proclaiming April 10 as AmericanWelding Centennial Day, he praisedthe organization for its contributionto society — Fig. 5A. “The men and women of your Soci-ety are the people who make a lot ofthings we enjoy every day possible,”Bermudez declared. Miami-Dade County Commissioner

José “Pepe” Diaz concurred with Mayor Bermudez and acknowledgedthat reaching 100 years is an incredi-ble milestone for a company. He pro-claimed April 10 as American WeldingSociety Day — Fig. 5B. “One hundred years in anything is along time, but when 100 years of ex-cellence takes place, that’s a great rea-son to celebrate, and that’s what we’redoing here today,” said Diaz. “Thatplane that just flew over us hadwelders working on it; that truck thatjust went by had welders working onit. Basically, everything that is aroundus, you guys touched.” Glorianne Oliveros, district directorfor the office of Congressman MarioDíaz-Balart, thanked AWS for helpingto educate the community. “It’s great to raise awareness of anorganization such as this one that is soimportant to bringing so many skillsto individuals in our society,” she said. Oliveros gifted AWS an Americanflag that was flown over the U.S. Capi-tol in honor of AWS’s 100th anniver-sary, along with a certificate of authen-ticity — Fig. 5C. She also announcedthat AWS had been entered into theCongressional Record, saying, “TheAmerican Welding Society is now apart of U.S. history and can be consult-ed in the Library of Congress for alltime.”


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Fig. 5 — A — AWS Executive Director and CEO Matt Miller (right) receives a proclamation of AWS Centennial Day from Mayor ofDoral Juan Carlos Bermudez; B — Miller (right) accepts a proclamation of AWS Day from Miami-Dade County Commissioner José“Pepe” Diaz; C — Glorianne Oliveros (left), district director for the office of Congressman Mario Díaz-Balart, bestowed AWS with anAmerican flag that flew over the U.S. Capitol, and announced that AWS has been entered into the Congressional Record.

ROLINE PASCAL ([email protected]) isassistant editor and KATIE PACHECO([email protected]) is associate editor ofthe Welding Journal.

A B C


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MenuSearchTable of ContentFeaturesThey Say It’s Your Birthday: AWS Celebrates 100 Years

DepartmentsEditorialAWS @ 100

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welding journal | june 2019 · the decline in our investment portfolio, result-ing in a flat effect...

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