2009 AWS Educational Programs
Return to ALL Education Program Information
| Session | Member (AWS, FMA,SME, PMA, NAM) |
Non-Member |
|---|---|---|
| Welding Education Conference. (W20) | $149 |
$149 |
| One Day Conference or Seminar (W21, W22, W23, W24, W25, W26, W27) |
$345 |
$480 |
| Two Day Conference or Seminar (W28, W29) |
$550 |
$685 |
| Two Day RWMA Welding School (W30) | $475 |
$695 |
| One Day Professional Program (W31, W32, W33) |
$150 |
$285 |
| Three Day Professional Program (W34) | $225 |
$360 |
| Three Day Student Professional Program (W35) | $75 |
$95** |
| ** Nonmember Student Professional Program price includes a one-year AWS Student Membership. | ||
The American Welding Society and The International Thermal Spray Association are organizing the first Thermal Spray and Coatings Conference, to be held in conjunction with the 2009 Fabtech & AWS Welding Show. This one-day event is intended to introduce the process and its uses to new potential users with morning and afternoon sessions focusing on actual applications and new developments in thermal spray technology. For more details, see the conference web page at aws.org/conferences.
In addition, on Sunday, November 15, 11 AM to 5 PM, a free half-day tutorial on thermal spray fundamentals is scheduled, sponsored by the International Thermal Spray Association, titled "What Is Thermal Spray?"
Monday, November 16, 2009 • 9:00 AM – 4:30 PM
Member of AWS, FMA, SME, NAM, or PMA: $345
Nonmembers: $480 • Registration Code: W22
Session 1: Plenary Session
9:00 AM
Welcome and Opening Remarks
Bob Unger, Polymet Corporation
9:00 – 9:30 AM
An Overview of Thermal Spray Processes & Applications
Richard Thorpe, Praxair TAFA
9:30 – 10:00 AM
Practical Understanding of Materials for Thermal Spray Applications
Mitch Dorfman, Sulzer Metco
10:00 – 10:25 AM
Comparison of Hardcoating Processes
Daniel Hayden, Hayden Corp.
Session 2: Successful Applications
10:40 – 11:00 AM
Wire Arc Sprayed Anti-Corrosion and Wear-Resistant Coatings for Waste Incineration Plants
J. Wilden, TU Berlin
11:00 – 11:20 AM
Tungsten-Based Coatings to Enhance the Performance of Casting Molds
V.E. Drescher, Berlin Institute of Technology
11:20 – 11:40 AM
A Review on Cold Gas Dynamic Sprayed Coatings
Tarun Goyal, Punjab
11:40 AM – 12:00 PM
Practical Applications of Cold Gas-Dynamic Spray (Low Pressure Cold Spray)
David W. Wright, Accuwright Industries
Session 3: New Developments in Thermal Spray Processes and Materials
1:00 – 1:20 PM
Shockwave Induced Cold Spraying: Evaluation of a New Solid-State Spraying Process
Eric Irissou, National Research Council, IMI
1:20 – 1:40 PM
Carbide Based Thermal Spray Powders with Alternative Matrix Alloys - The Only Choice to Protect Your Health and Environment
Stefan Zimmerman, H.C. Starck
1:40 – 2:00 PM
Optimization of Cold Sprayed Titanium Coatings on Adhesion Strength
W. Wong, McGill University
2:00 – 2:20 PM
Advanced Deposition Characteristics of Atmospheric Plasma Sprayed Bronze/Diamond Composite by Thermal Barrier Effect of Nickel Protective Thin Film
Hyunteak Na, Kinetic Spray Coating Laboratory
Session 4: New Developments in Thermal Spray Coatings and Equipment
2:35 – 2:55PM
Dense Ceramic Coatings Produced by Slurry Axial Plasma Spraying
Michael Molnar, Mettech
2:55 – 3:15 PM
Cermet and Ceramic Coatings with Novel Thermal Spraying Methods
Junya Kitamura, Fujimi Incorporated
3:15 – 3:35 PM
Advanced Vacuum Plasma Spray (VPS) for Rapid and Safe Closeout of Cooling Channels for Liquid Rocket Engine Combustion Chambers
Chris Power, Genie Products
3:55 – 4:15 PM
Methods and Effects of Cooling Work Parts During WC-CoCr HVOF Coating
Zbig Zurecki, Air Products & Chemicals, Inc.
4:15 – 4:25 PM
Gun Mounts for the Articulated Robot; Fibonacci Comes Through Again
Dale Moody, Plasma Powders and Systems
4:30 PM – Adjournment
The welding of chrome-moly steel goes way back to the days when tubing was oxyacetylene welded to make up the fuselages of the early pre-aluminum airplanes. It all required outstanding precision on the part of the welder. Believe it or not, even though the methods have changed, the welding of 4130 steel still requires utmost precision on the part of the welder. The welding of chrome-moly steels requires great skills from all parties involved. Not just the welding, either. To weld any of these steels for the first time, the engineer and the welder actually have to go back to school and start all over again. For full descriptions of presentations, see the conference web page at aws.org/conferences.
Tuesday, November 17, 2009 • 9:00 AM – 3:15 PM
Member of AWS, FMA, SME, NAM, or PMA: $345
Nonmembers: $480 • Registration Code: W23
9:00 AM - 9:30 AM
Welding of the 1 1/4Cr-1/2Mo Steels
Ben Pletcher, Welding Engineer/Metallurgist, Chicago Bridge & Iron Co. (This paper is co-authored by James Brennan, Senior Welding Engineer.)
Many of the high-temperature pressure vessels used in refining operations today depend on the use of chrome-moly steels. The requirements for the material and welding have evolved to included temper embrittlement, low temperature impacts, and low hardness values. The joining of these alloys requires planning, control and execution in all phases of the welding operation.
9:35 AM – 10:05 AM
Induction Heating as a Tool for Minimizing the Risk of Weld Cracking
Steve Latvis, Regional Manager, North & South America,
Global Pipe Systems, Miller Electric Manufacturing Co.
Relatively new induction heating equipment is finding use in various industries for preheat and stress relief. The technology appears to be more cost-effective than either resistance heating or flame heating.
Air-cooled equipment is available for temperatures up to 400 deg F and liquid-cooled equipment for work up
to 1,450 deg F.
10:10 AM – 10:40 AM
Pipe Welding for the Offshore Petroleum Industry
Embry Murphy, Welding Engineer, FGA Consulting Engineers Ltd.
Chrome-moly steel represented a considerable amount of pipe to be welded and inspected in the expanding oil production industry off the coast of Newfoundland, in the Jeanne d'Arc Basin. Most of the work was done using gas tungsten arc and shielded metal arc welding processes. The welding was performed in local area fabrication shops and on the drilling platforms.
10:45 AM – 11:15 AM
Welding 4130 Cr-Mo Steel in the Motorsports World
Richard Gostautas, Infrastructure Group Leader, Physical Acoustics Corp.
The fabrication and welding pitfalls of 4130 Cr-Mo when used for motorsports applications. Top fuel dragsters are now exceeding 7,500 HP, and special welding techniques and filler materials will be discussed to avoid weld failures. This interactive talk will highlight the 10 most-asked questions for 4130 Cr-Mo and will assist anyone involved with racing structures or lightweight aircraft.
11:20 AM – 11:50 AM
The Welding of 2 1/4 Cr–1 Mo–V: A Challenge
Russel Fuchs, Senior Technical Manager, Bohler Welding Group USA, Inc. Co-authors: Volker Gross and Martin Schmitz-Niederau
The use of 2 1/4 Cr-1 Mo-V steels (Grade 22V) has become more popular for the fabrication of heavy-wall pressure vessels due to its higher strength and creep resistance as compared to the conventional 2 1/4 Cr–1 Mo steel. However, it has not been without its share of challenges when it comes to welding. High toughness of the weld deposit is desirable both in the as-welded condition and after PWHT; as-welded in order to handle the component during fabrication without fear of cracking and after PWHT to insure in-service requirements are satisfied with respect to startup and shutdown. Issues with reheat cracking have been experienced, especially in the highly restrained weldments using the SAW process. Filler metals have been developed to meet these challenges.
11:55 AM – 1:00 PM lunch break
1:00 PM – 1:30 PM
High-Temperature Mechanical Performance of 2 1/4Cr-1Mo Steel Weldments
Robert W. Warke, Associate Professor of Welding and Materials Joining, LeTourneau University
Experience has demonstrated the relative vulnerability of welded joints to localized creep damage in high-temperature service. An extensive database of weldment test data was assembled and evaluated for a variety of welding processes, joint geometries, heat treatment conditions, and test configurations. Performance trends were assessed in light of base metal data and current design rules for pressure vessels and piping.
1:35 PM – 2:05 PM
Welding and PWHT of P91 Steel
William F. Newell, President, Euroweld Ltd.
Use of P(T)91 components is experiencing worldwide usage. Premature failures are being encountered due to design, inadequate attention to following procedures, or improper post-weld heat treatment. Heat treatment of both component manufacture and completed welds appears to be the number-one cause of premature failure. Factors that influence these failures will be presented.
2:10 PM – 2:40 PM
Time of Flight Diffraction Testing
Ronald W. Kruzic, Corporate QA/NDE Consultant, Chicago Bridge & Iron Company
ASME Code Case 2235 is for the use of an ultrasonic examination in lieu of a radiographic examination for pressure vessels and boilers. This talk is concerning the use of this Code Case utilizing the Time of Flight Diffraction technique for examination of coke drums fabricated from Cr-Mo alloys which have been clad with Type 410s stainless steel.
2:45 PM – 3:15 PM
A New Advancement in Chrome-Moly Flux Cored Wires
Keith Packard, Welding Engineer, Hobart Brothers Co. Co-author is Joe Bundy, Tubular Wire R&D Engineering Manager
A challenge to meet low-temperature impact toughness properties with gas-shielded flux cored filler metals in chrome-moly applications has led to a new patented technology in flux cored electrode design. This technology can provide impact toughness of 50-100 ft/lbs at -40 deg F. These new filler metals can now provide toughness that far exceeds even shielded metal arc welding or submerged arc welding.
3:15 PM – Adjournment
The most perplexing problem in the welding industry has to be weld cracking. Back by popular demand, this one-day conference is for those who want or need to get a handle on any weld cracking situation. The 2009 conference will also include networking opportunities to talk to welding cracking experts and others in the industry that face the challenges weld cracking can present. For more details, see the conference web page at aws.org/conferences.
Monday, November 16, 2009 • 9:00 AM – 4:00 PM
Member of AWS, FMA, SME, NAM, or PMA: $345
Nonmembers: $480 • Registration Code: W21
9:00 AM – 9:30 AM
Keynote Address
William A. "Bud" Baeslack III, Provost and Executive Vice President, and Professor of Materials Science and Engineering, Case Western Reserve University, and formerly, Dean, College of Engineering, Executive Dean for the Professional Colleges, Professor of Industrial, Welding and Systems Engineering and Professor of Materials Science and Engineering, Ohio State University
The metallurgical origins of weld cracking in such high-performance alloys as nickel-base materials and such high-performance nonferrous alloys as aluminum and titanium, and how those materials compare to weld cracking behavior in conventional and advanced steels.
9:35AM –10:05 AM
New Technique Determines Solid-Liquid and Solid-State Phase Transformations During Processing
Boian T. Alexandrov, Research Scientist, Welding Engineering Program, Dept. of Industrial, Welding, and Systems Engineering, The Ohio State University
A new technique for in-situ determination of solidification ranges and solid-state phase transformation temperatures in welded joints of various alloy steels, non-ferrous alloys and Ni-base superalloys, and for development of continuous cooling transformation diagrams.
10:10 AM –10:40 AM
Cracking Problems with Grade 91 and Other Creep-Strength Enhanced Ferritic Steels
Jeffrey Henry, President, Energy Solutions Group, LLC
Failure to control the processing steps, and particularly the post-weld heat treat temperature, can substantially increase the risk of brittle fracture and/or stress-corrosion cracking in the weld. Other factors that can promote cracking at the weldment include deficient design (e.g., saddle welded branch connections), improper support of components, and poor choice of filler metal for dissimilar metal combinations.
10:45 AM – 11:15 AM
Measuring Residual Stress Using X-Ray Diffraction
Robert Drake, Lab Sales, Proto Manufacturing Ltd
Residual stresses in weldments can lead to such problems as stress corrosion cracking or even fatigue cracking. But it is often difficult to determine whether heat treatment or shot peening can be used to cure such conditions without prior knowledge of the residual stress state. X-ray diffraction is being used to provide the information needed.
11:20 AM – 11:45 AM
Quality Improvements in Heat Treatment
Gary Lewis, Director of Business Development, Superheat FGH
Advancements in heat-treatment equipment technology, software and process control solutions, with renewed emphasis on shoring-up weld procedures and industry codes, are revolutionizing traditional business models and enhancing quality assurance.
11:45 AM – 1:00 PM lunch on your own
1:00 PM – 1:30 PM
Reheat Cracking in Weldments
Jose E. Ramirez, Principal Engineer, Edison Welding Institute
Reheat cracking has been observed in low-alloy steels, stainless steels, and nickel-base superalloys weldments. Understanding the effect of material chemical composition and microstructure, joint design, welding procedures, and post-weld heat treatment conditions on reheat cracking is of paramount importance to obtaining crack-free weldments.
1:35 PM – 2:05 PM
Hot Cracking in Welding of Austenitic Stainless Steels
Damian Kotecki, Damian Kotecki Welding Consultants, Inc.
Focus on solidification cracking, liquation cracking and ductility dip cracking, plus the role of ferrite in preventing hot cracking and means of lessening hot cracking tendencies when ferrite cannot be obtained in the weld metal.
2:10 PM – 2:40 PM
Fracture Mechanics – Operating with Defects
Kyle Koppenhoefer, Principal, AltaSim Technologies
Structural welding defects cannot always be avoided or removed and some may develop during in-service loading. In these situations, applied fracture mechanics can determine the effect of these defects on service life. Advancements in fracture mechanics, coupled with improved computational capabilities, have extended the application of fracture mechanics to practical problems of interest to welding engineers.
2:45 PM – 3:15 PM
Hot Cracking in Aluminum Welds
Thom Burns, Director of Technical Services and Business Development, AlcoTec Wire Corp.
Hot cracking of aluminum welds can be a function of contraction stresses or the hot-short tendency of certain weld compositions. The problem of hot cracking due to contraction stresses may be avoided by applying welding techniques that overcome the natural volume change that occurs during the heating and cooling of aluminum. It is necessary to understand the effects that alloying elements have on crack sensitivity and how the choice of joint design and the selection of a filler alloy can eliminate it.
3:20 PM – 3:55 PM
The Rewards in Purchasing Filler Metal by the AWS 5.01 Specification
William F. Newell, President, Euroweld Ltd.
The AWS A5.01 specification is organized in a logical order and is user friendly. Whether or not all or part of the criteria listed in the document for actual lot testing are used depends on the extent to which special criteria are needed to adequately describe the product(s) desired and to reduce the uncertainty of receiving a product that may not meet the procurer's specific needs. As a minimum, the manufacturer is required to have an established quality assurance system and is required to trace the product to some known lot that is unique to that manufacturer. This requirement also applies to those who repackage, relabel and resell another manufacturer's product that is identified as meeting AWS specification and classification or having the AWS classification imprinted on the electrode.
Corrosion-Resistant Alloys Conference
The interest level is extraordinarily high when it comes to the welding of corrosion-resistant alloys. The overall activity is immense. Cladding and strip overlay processes have become a more popular means of protecting parts exposed to heavy corrosion. Duplex stainless is now being welded for over-the-road tankage. New processes like friction stir welding and t thermal stir welding will be discussed as well. Also, improvements in weld properties are being realized by increasing the weld interpass temperatures for conventional austenitic stainless steels.
Wednesday, November 18, 2009 • 9:00 AM – 4:00 PM
Member of AWS, FMA, SME, NAM, or PMA: $345
Nonmembers: $480 • Registration Code: W24
9:00 AM – 9:30 AM
Lean Duplex Stainless Steel Chemical Cargo Tanks
Ralph Davison, Vice President, Technical Marketing Resources
A lean duplex stainless 2101 has been developed with low addition of nickel to reduce costs. Low nickel content is compensated by an increase in manganese and nitrogen to assure a balanced microstructure with approximately equal amounts of ferrite and austenite, for a yield strength more than twice that of 316 and 304 stainless steels. Lean duplex is also resistant to stress corrosion cracking, has better pitting resistance, and is being welded by the gas metal arc process.
9:35 AM – 10:05 AM
The Thermal Stir Welding Process
Jeff Ding, Aerospace Welding Engineer, NASA Marshall Space Flight Center
The thermal stir welding, developed by the NASA's Marshall Space Flight Center, is similar to friction stir welding in that the weld seam is consolidated without liquefying the parent material. Unlike FSW, the heating, stirring, and forging elements of the process are decoupled, allowing independent, dynamic control of each process element.
9:30 AM – 10:05 AM
Friction Stir Welding and Processing
Murray Mahoney, Consultant
General discussion of FSW including metal flow and defect avoidance, temperature gradient issues, lap vs. butt joints, some tool material and tool design considerations, current applications, FSW limitations, benefits such as properties and the solid state benefits of welding unweldable alloys and zero emissions, all as they apply to Al, Cu, and Fe based alloys. Friction stir processing will also be covered.
10:10 AM – 10:40 AM
Evaluation of Higher Interpass Temperatures When Welding 304L and 316L Austenitic Material
Matthew Yarmuch, co-authors are Iulian Radu and Ken Armstrong of PCL Industrial Constructors.Yarmuch is Program Leader, Welding Engineering, Advanced Materials Business Unit
A reassessment was made of maximum interpass temperature limits while welding 304L and 316L pressure equipment materials, to significantly improve welding productivity. Higher interpass temperatures can be tolerated without compromising the sensitization-corrosion resistance of the weldment. Not exceeding the critical threshold of "time at the sensitization temperature" is paramount to ensure weldment quality.
10:45 AM – 11:15 AM
Strip Overlay Weld Cladding of Specialty Stainless Steel Alloys Sandvik
Frank S. Babish, Technical Manager Welding Products, Sandvik Materials Technology, Welding & Wire Products Division
The presentation covers strip overlay welding of specialty stainless steel alloys using the electroslag welding process, allowing high deposition rates of metallurgically clean weld deposits. Alloys include duplex and superaustenitic alloys. Applications for the nuclear industry will be included.
11:20 AM – 11:50 PM
Alternative Welding Processes for the Fabrication of Titanium Structures
Nick Kapustka, Applications Engineer, Arc Welding, Lasers & Automation, Edison Welding Institute; co-authors: Suhas Vaze and Chris Conrardy
Work is underway at Edison Welding Institute to make the gas metal arc welding process a useful and effective means for welding Ti-6Al-4V. It was necessary to provide adequate inert gas shielding, arc stability, and contact tip life. Other processes include friction stir welding and hybrid laser welding.
11:50 AM – 1:00 PM Lunch on your own
1:00 PM – 1:30 PM
Welding Metallurgy of Duplex Stainless Steels
Damian Kotecki, President, Damian Kotecki Welding Consultants, Inc.
Duplex stainless steel weld metal solidifies as 100% ferrite, and the HAZ near the fusion boundary also forms 100% ferrite. It is essential that austenite nucleates and grows in both areas in order for proper properties to be obtained. The critical role of nitrogen in this process is explained. Then remaining ferrite can transform to undesirable phases such as sigma.
1:35 PM – 2:05 PM
Explosion Welding to Join Dissimilar Metals
Michael Blakely , Director of Market Development, Dynamic Materials Corp.
Explosion welding focuses on joining both similar and dissimilar metals. A value proposition exists when certain materials are required in specific applications for corrosion resistance, light-weighting or temperature distribution, and solid material is impractical.
2:10 PM – 2:40 PM
The 200 Series Stainless Steels and the Lean Duplex Stainless Steels: Why They Should Be Considered
Cheryl A. Botti, Manager, Market and Product Development, ATI Allegheny Ludlum
Popularity in the use of 200 series stainless steels where 300 series stainless have been traditionally specified continues. Advantages exist with respect to raw material volatility. This talk will address the issues involved with switching to another grade of stainless steel. The popularity of lean duplex stainless steels to replace 300 series stainless steels also continues to grow.
2:45 PM – 3:15 PM
PCBN Tools for Friction Stir Welding
Jeff Defalco, Business Manager, ESAB Welding & Cutting Products
With the development of pin tools produced from polycrystalline cubic boron nitride and its associative composites, the range of corrosion-resistant, high melting temperature materials joined by FSW has grown, including austenitic and superduplex stainless steels and various nickel-base alloys. Pin tool technology and its impact on joining these alloys is presented.
3:20 PM – 3:55 PM
Corrosion Resistance of New Ni-Cr-Mo and Ni-Mo-Cr Alloys
Jeff Defalco, Henry J. White, Senior Staff Engineer, Welding Metallurgist, Haynes International, Inc.; co-authors: N. S. Meck, N. Koon, and P. Manning
Alloys Ni-21Cr-17Mo and Ni-22Mo-17Cr are two new materials from Haynes International for use in the chemical process and oil and gas industries, respectively. We will discuss the corrosion properties of the base materials, arc weldments, and laser weldments, each being exposed to a variety of conditions.
National Welding Education Conference
Monday, November 16, 2009 • 9:15 AM – 4:30 PM
Conference fee: $149 • Registration Code: W20
Presented by the National Center for Welding Education and Training (Weld-Ed), this conference is designed to bring together educators for professional development and networking opportunities. Weld-Ed's focus is on the preparation of welders, welding technicians, and welding engineers to meet the needs of industry. This conference will include presentations on topics such as Weld-Ed accomplishments in the last year, the partnership between Weld-Ed and AWS, welding industry workforce needs, recruitment tips and tools for educators, competency models, externship programs for educators, tips on partnering with other secondary and post-secondary schools, welding education trends, curriculum, materials science education and applications, distance learning updates, new technology applications, how the economic stimulus package will affect educators, and presentations from welding educators who will share their best practices.
9:15 AM – 9:30 AM
Weld-Ed and What It Can Do for You
9:45 AM – 10:30 AM.
Skill Panel Update
10:45 AM – 12:00 PM.
Best Practices of Welding Educators
12:00 PM– 1:00 PM.
Lunch and Speaker from Industry
1:00 PM– 2:00 PM.
Advanced Manufacturing and Process Showcase
2:00 PM – 2:30 PM.
Problem-Based Learning Applications and Competency Models
2:45 PM – 3:30 PM.
Student Recruitment and Retention
3:30 PM– 4:15 PM.
Funding and Grant Opportunities
4:15 PM– 4:30 PM .
Wrap-up and Evaluations
Electron Beam Welding Conference
The American Welding Society, DVS (German Welding Society), and The International Institute of Welding are organizing their first International Electron Beam Welding Conference. This event will be held in conjunction with the Fabtech International & AWS Welding Show. It will include a two-day technical program plus a half-day tutorial sponsored by the Pro-beam foundation. IEBW will bring together scientists, engineers and technical personnel from around the globe involved in the research, development, and application of electron beam welding processes. For full descriptions of presentations, see the conference web page at aws.org/conferences.
Tuesday — Wednesday, November 17-18, 2009 • 9:00 AM – 4:15 PM
Member of AWS, FMA, SME, NAM, or PMA: $550
Nonmembers: $685 • Registration Code: W28
Tuesday, November 17
Session 1: General Assembly
9:00-9:15 AM
Welcome Address
9:15-9:45 AM
Keynote IIW
EBW Technology Overviews Commission IV Business Plan
Ernest Levert (IIW)
9:45-10:15 AM
Keynote Europe: Europe Business Developments
Current Development of the Electron Beam Technology in Europe
Dr. Phil Thorsten Löwer, pro-beam AG & Co. KGaA (Germany)
The number of producers of electron beam equipment in the world is the highest in Europe. Today, there are CVE in Great Britain; SAF and Techmeta in France; and AWT, pro-beam and Focus in Germany. The concurrence situation in Europe stimulated development work so that nowadays the different firms can offer a large variety of equipment specialized on each application. Due to this situation, the equipment from European sellers takes the highest share in all equipment worldwide.
A typical classification of electron beam machines is made by dividing them into low-voltage and high-voltage machines. 60kV machines for simple applications are available for low prices as well as for high production, highly automated applications, or in combination with other processes as a complete production cell. 150kV equipment is used as very flexible equipment, for highly sophisticated applications or on very sensitive products, for example in space and aircraft industry.
The revival of deep penetration welding that more and more is applied in heavy industry, thanks to new capabilities of EB-equipment, will also be reported.
10:15-10:30 AM — Break
Session 2: Research and Development Trends
10:30-10:50 AM
The Electron Beam as a Tool of Both Nano Science and Micro Technology: From UHV Evaporation to Micro Electron Beam Welding
M.Merkel*, K.Wrobel*, M.Escher*, M.Zobac**, I.Vlcek**, L.Dupak**, F.-H. Roegner***, G.Mattausch***, A.Reichmann***
*FOCUS GmbH, Huenstetten, Germany
**Institute of Scientific Instruments of the ASCR, Brno, Czech Republic
***Fraunhofer Institute for Electron Beam and Plasma Technology, Dresden, Germany
The electron beam as a highly efficient heating source is well known since its first use for the melting of tantalum at the end of the 19th century. During the first half of the last century, its ability to evaporate, to drill, and to weld of even refractive metals has been discovered. After the Second World War people started to use this exciting properties for a wide range of industrial applications commercially.
We started to use the electron beam for ultra-clean vapor deposition of very small amounts of numerous materials in 1990. Our ultra-high-vacuum electron beam evaporator is today a standard tool in nanoscience laboratories . We will show how it works together with some application examples.
A growing request for new joining methods applicable to micro technology did encourage us to develop a dedicated micro-electron beam welder during the last years. We ended up with a desktop-sized instrument looking more similar to an electron microscope than to a common e-beam welder. This is not only a formal difference. Its design philosophy follows a number of technical solutions what are commonly used for scanning electron microscopes. Based on a long-erm experience on the field of electron optics, it is suitable to match the needs of a wide range of challenging joining tasks: from micro-mechanical and microsystem technological ones to a lot of precision technological applications, how they are common nowadays e.g. for medical technology or sensor industry. We will present some examples and will give a brief outlook in terms of the challenges of the future in this field.
10:50-11:10 AM
Prediction and Control of Distortion and Residual Stresses in Electron Beam Welding
Nick Bagshaw and Chris Punshon TWI Ltd.
Electron beam welding is recognized as an attractive method for minimizing distortion during welding, and is used frequently to join parts which are already finally machined or close to finished size. In such cases, before EB welding, it is of great value to be able to estimate the level of accuracy that will be achieved and the dimensional stability of the assembly throughout its service life. This presentation describes the development of a finite element (FE) modeling technique, validated by experiment, for predicting and understanding the development of residual stresses and distortion during EB welding, particularly in circular components. The use of this method for optimization of welding procedures and residual stress mitigation methods is described and illustrated through a number of practical examples.
11:10-11:30 AM
Development of Local Vacuum Electron Beam Welding for Rapid Fabrication of Large Structures
Chris Punshon TWI Ltd.
Electron beam welding is generally carried out in a vacuum chamber, which is an attractive process characteristic offering many advantages in terms of containment, avoidance of contamination, and minimal metallurgical disturbance. To date, however, the necessity to conduct processing in a high vacuum atmosphere has largely restricted the application of the process to components and structures that can be entirely contained within a vacuum chamber.
This paper describes the innovative development of systems allowing the generation of high-power electron beams for use at "reduced pressure"(~1 mbar), uniquely combined with developments in mobile, local seals. The requirements for sealing and pumping at this pressure are much less onerous than with high-vacuum EBW, thus facilitating the application of the process to much larger structures and components. A number of practical examples are described of how these process developments have been used successfully, illustrating the potential for application in a range of industry sectors and materials.
11:30-11:50 AM
Developments in Sub-10kW Electron Beam Equipment, Processes and Monitoring
Bruce Dance, TWI Ltd
When first developed, electron beam process equipment was limited in beam power. Developments in equipment mean that processing is now possible over a huge range of beam powers and qualities. However, despite the possibilities of higher beam powers, a huge amount of commercial EB processing is still carried out at low powers (<10kW). In addition, although benefitting from modern control systems, the majority of EB process hardware still uses electron gun generator designs that are apparently little changed in the last 20 years, in stark contrast to laser equipments.
This paper reviews electron beam generator performance in relation to common process requirements, as well as the demands of more recently developed EB processes. Beam probing and measurement data are presented. Examples are given in which processes that demand specific beam qualities have been made possible by improved beam generation and control.
11:50 AM-12:10 PM
Investigations Relating to Electron Beam Welding of Dissimilar Metal Welds Based on Cast Iron
Karsten Rüthrich, TU Bergakademie Freiberg, Germany; Martina Mangler, TU Bergakademie Freiberg, Germany; Rolf Zenker, Zenker Consult Mittweida, Germany
The combination of casting and welding in hybrid designs is a very interesting direction of development, especially in the automotive industry. Cast iron materials are either not weldable at all or weldable only with large-scale additional technological measures (pre-heating, post-heating, filler material).
Electron beams are characterized by good deflectability, thus making it possible to realize multi-spot and/or multi-process technologies. This means that different processes influencing the thermal regimes in the welding zone may be carried out in one processing step.
First will be presented what EB multi-spot techniques and multi-process technologies mean and which opportunities are provided by them in connection with welding.
Furthermore, results of investigations relating to multi-spot welding of dissimilar metal welds based on cast iron (same-type, related-type) and unrelated-type welds of cast iron with steel will be presented. In addition, actual results of welding obtained using multi-process technologies (pre- and/or post-heating) in one processing step will be presented.
12:10-1:10 PM — Lunch
Hosted by AWS C7B Committee
1:10-1:30 PM
Joint Tracking with the Electron Beam Offline and Online – An Important Welding Automation Tool
Dr. Michael Mücke, Carsten Scheiblich, All Welding Technologies AG (Germany)
The electron beam is used in electron microscopy to image the smallest of structures. Highly dependent on surface structure, it capitalizes on the angle of backscatter from electrons reflected off the target material. This process is often used for imaging purposes in electron beam welding systems. The viewing advantages over photo-optical methods such as telescopes or CCD cameras include a markedly superior depth of field and elimination of the need to illuminate the target surface. The quality of these images has sufficient resolution for viewing typical joint forms.
The electron beam in EB welding systems is already being employed to identify joints for some welding projects. This process does not require a complete image of the surface. The signal provided by backscattered electrons from a single deflection line perpendicular to the joint is sufficient. The position of the joint can be ascertained by a change in the signal that occurs when the beam is reflected differently off the joint.
This process is customarily used to statically determine the joint position on one or a few points before the welding begins. Errors in the positioning of the target piece are measured and the welding process is adjusted accordingly. Even small tolerances in the assembly of a target piece can be offset. Other processes use a search beam to probe multiple points along the entire course of the joint before welding begins (offline). Measurable deviations from the reference position are saved and corrected during the welding process. In so doing, even residual magnetic fields in the target piece or clamping fixture can be compensated for.
Deflection technology in electron beam welding system hardware and software has seen significant improvements during the past several years. Using deflection frequencies as high as 200 kHz, it is now possible to conduct joint tracking during the welding process (online). The electron beam periodically springs out of the weld pool to perform a nearly continuous scan perpendicular to the weld. It moves far enough forward to take measurements ahead of the melt zone. If the weld focus is not on the surface of the target piece, the focus position is switched to joint identification in order to receive a clear surface joint signal. While the beam continues to weld after rebounding into the weld pool, the CPU calculates the deviation from the programmed reference position and corrects the weld position by deflecting the electron beam.
Examples will be used to illustrate the individual processes. The results document the current state of this technology. A view of prospective opportunities in electron beam process automation will be provided.
1:30-1:50 PM
Fast Beam Deflection and Beam Quality– Keys to Economic High Quality Electron Beam Applications
Uwe Clauß, pro-beam AG & Co. KGaA (Germany)
Since its first introduction to the industry the control systems of electron beam machines have gone through an enormous development. With the availability of fast amplifier components and digital beam controllers, the advantages of the electron beam have further increased, making it a truly software-controlled thermal processing tool.
Modern beam controllers enable multi-beam and multi-focus technologies, where the beam is split in up to 60 or more individual beams. These technologies can reduce the processing time by parallel processing or improve the quality by optimized thermal expansion of the part. Multi-process technologies, where several processes are performed in one run (e.g. welding and cosmetic treatment), further extend the application range of the electron beam process.
Fast beam deflection in conjunction with electron-optical monitoring is the fundamental component for advanced seam tracking systems. They allow automating the EB application in order to optimize the process costs and improve the quality of the results in a reproducible manner.
Basis for a high quality of the EB process is the condition of the tool the electron beam itself. By introducing the beam parameter product to the electron beam, reliable information about the quality of the beam can be derived. Implemented into automatic beam alignment systems, repeatable results with high quality can be achieved.
1:50-2:00 PM -- Break
2:00-2:20 PM
Reconstitution of Fracture Mechanics Test Specimens by Electron Beam Welding
Peter Petrov, Institute of Electronics
Changes in the material properties due to neutron irradiation are monitored by means of surveillance programs. Specimensurveillance programs for reactor pressure vessel (RPV) materials are among the most important parts of inspection programms that are necessary for realistic evaluation of RPV lifetime.
In nuclear power plants (NPP), Charpy - Cv specimens are used to assess the RPV embrittlement. The surveillance capsule assemblies in each capsule contain typically 12 Cv and 3 tensile specimens. However, to address future plant life management, especially for older NPP's, it is necessary to obtain more statistics on the pressure vessel embrittlement. Reconstitution technology allows performing additional Cv or fracture toughness tests on a limited amount of available material and can contribute to a better characterization of the material and, therefore, to a better evaluation of the embrittlement degree of RPV steel due to neutron irradiation.
This presentation reports results from reconstitution of Cv-type and CT specimens by electron beam welding. The experiments were carried out using a 15 kW Leybold Heraeus welding unit. The material used in this study is 18MND5 steel. Investigations were made of structural changes of metal in welds and heat-affected zones. Cv impact tests showed good agreement between the original and reconstituted specimens.
2:20-2:40 PM
Non-Vacuum Electron Beam Cutting
N. Murray, A. Beniach, R. Konya, Dr. Th. Hassel, Prof. Dr-Ing. Fr.-W. Bach, Institut für Werkstoffkunde (Germany)
The main domain of non-vacuum electron beam (NVEB) technology has so far been high-speed and high-quality joining. It is of great interest to find further uses for this efficient technology. Current research by the NVEB-group of the Institute of Material Science at the Leibniz University of Hannover focuses on the implementation of the NVEB process to the cutting of metal plates. Experiments are conducted on a PTR NVEB welding system with an acceleration voltage of 175 kV and a maximum power of 25 kW. First experiments with this equipment showed that it is possible to cut 20-mm-thick plates of mild steel. A cutting speed of 1 m/min at a beam current of 140 mA was achieved. Despite the well-known widening of the electron beam due to the scattering of the electrons in atmosphere, the resulting face is straight and of high quality, with only little residual melt drops at the lower edge. At the moment, preparations are being done to use a gas jet to blow away molten material from the cutting area to further improve surface finish of the cut. To evaluate the possibilities of expanding the work domain of the NVEB, process experiments will be done using the electron beam for weld preparation and welding within two steps on the same equipment.
2:40-3:00 PM
Modeling of Heat Transfer and Fluid Flow during Keyhole Mode Electron Beam Welding
R. Rai, T.A. Palmer, J.W. Elmer*, and T. DebRoy, Department of Materials Science and Engineering, Pennsylvania State University; *Lawrence Livermore National Laboratory, Livermore (USA)
A three-dimensional numerical model of the turbulent heat transfer and fluid flow in keyhole-mode electron beam welding has been developed and validated. In addition to solving for the enhanced heat and mass transport due to turbulence, this model also considers the heat balance at the keyhole walls and the variation of vapor pressure in the keyhole and the keyhole wall temperature with depth. Since the model takes into account these various physical processes, it can be applied to materials with different thermo-physical properties. In this work, the model was validated using several 304L stainless steel welds made at fixed input power but different power densities achieved by variation in the focal spot size, and the calculated and experimental weld geometries were in reasonable agreement. Peclet number calculations show that convective heat transfer is very significant, and computations performed in the presence and absence of convection also demonstrate the important role of convection on the formation of the resulting weld geometry.
3:00– 3:20 PM
Welding of an Anaesthesia Tank of Aluminum Die Casting with Multi-Jet Electron Beam
O.Krahn, H. Pries, K. Dilger, Institute of Joining- and Welding-Technology of the Technical University (Germany)
The process of aluminum die casting, which produces near-net-shape, complex, and thin-walled prefabricated parts of aluminum, finds more and more applications in all areas of the industry because it has economic advantages compared to other processes in productivity. The technically most-used molding process of aluminum die casting products is fusion welding, which shows multiple problems. The safe production of pore-free welding seams requires an expensive optimization all over the die casting process as well as the choice of a qualified welding process.
An innovative approach to solve these problems is the integration of the electron multi-jet beam welding in the manufacturing chain.
To avoid distortion at small welding seams, high-frequency deflection of the electron beam is used, to connect the welded joint and the local successive fusing in one process step to reduce the porosity. This aided project shows successfully that it is possible to qualify the welding of an anaesthesia tank in normal die casting quality with the electron multi-jet beam as an economic and applicable operation of mass production for premium, pressure-tight units.
It was shown that an optimization of the welding parameter and the welding sequence over the multijet electron beam can reduce the porosity of the welding seam under 8%. That puts us in a position to fulfill the technical requirements for medical products.
3:20– 3:40 PM
Micro Electron Beam Welding of Metal Foils and Wires
Backhaus, Dorfmüller, Dr. Olschok, Prof. Dr.-Ing. Reisgen, ISF - Welding and Joining Institute, RWTH Aachen University
3:40– 4:15 PM
The Electron Beam as Versatile Tool for the MEMS and Precision Engineering Technology
Dr.-Ing. Klaus Dilger, Universitätsprofessor, Materialprüfstelle für Schweißtechnik und Werkstoffe, Dr.-Ing. Prof. h.c. Stefan Böhm, Professor, Fachgebiet Mikrofügen
Under the framework of a public sponsored project, an electron beam -based production line for micro systems was developed and built. Different processes like structuring, joining, material removal, measuring and visualization can be performed in one installation without tool changes in a precise and flexible manner.
The electron beam is not only providing the machining capabilities, but also the opportunity to observe the work piece and production steps by the use of backscattered electrons, presenting a flexible tool for quality assurance.
In the last years, detailed studies about micromachining processes using an electron beam were performed on different types of machines, like a scanning electron microscope or conventional electron beam welding machines. But in comparison to this attempts our built micro-electron beam machine is much more stable, more precise, the power is between 1 watt and 500 watts and the beam diameter less than 50 microns.
The latest results of the machine development and the experiments will be presented.
Wednesday, November 18
Session 3: Application Trends
9:00-9:45 AM
Keynote Asia: Asia Business Developments Electron Beam Welding in Japan
Hirosada Irie, The Japan Welding Technology Center
Since the 1970s, considerable researchand development in the electron beam welding technology have been carried out in Japan. Owing to the long-term recession of the Japanese economy since the 1990's collapse of the bubble and the R&D activities of new technologies -- laser technology, FSW -- the R&D activities in electron beam welding technology have scarcely been published. However EBW technology has walked with steady steps in industries. As well known, the feature of EBW is deep penetration and low distortion. Since the bubble collapse, usage of EBW in Japan completely divided two extreme fields; that is, one is the construction of heavy gauge facilities and the other in mass production of small automotive and machine parts. The shipment of EB welders for the latter applications has been still active. In big construction, recently, the development of EBW of high-pressure gas pipe and the development of the welding process of overpack (container) for high level radioactive waste, and others, have been carried out. A brief introduction of electron beam welding technologies in Japan will be presented.
9:45-10:15 AM
Keynote America: America Business Developments
10:15-10:40 AM — Break
10:40-11:00 AM
Fabrication and Closure Welding of Containers for Long Term Storage of High Level Nuclear Waste Using Reduced Pressure Electron Beam Welding
Jim Dorsch, Ed Savage, Chris Punshon and Nick Bagshaw, TWI Ltd.
The growing demand for new base-load electricity generation will see an expanding role for nuclear energy as a major component. In consequence, increasing demands will be placed on the safe treatment and storage of high level nuclear waste (HLW). The current proposal for the USA is currently under review, but it is likely that spent fuel will be stored in a geological repository for a period of the order of a million years. The use of multiple-barriers to safely isolate HLW has been proposed, and the use of welding for fabrication and final closure of the containers considered. This paper describes a program of work carried out to examine the potential benefits of employing local vacuum, reduced pressure EB welding for both fabrication and sealing of containers for HLW, taking into account the demanding requirements for reliability, productivity, and concerns related to welding-induced distortion and residual stress.
11:00-11:20 AM
EB Surface Engineering for High Performance Heat Exchangers
A. L. Buxton, TWI Ltd; R. J. McGlen, Thermacore Europe Ltd.
From aircraft engines to electronic devices, current thermal management systems are limiting product performance. Heat exchanger designs have been constrained by the available production technologies, eg. machining or chemical etching, but a newly developed electron beam manufacturing process (Surfi-Sculpt) offers the potential to bring about a step-change in heat exchanger efficiency.
An electron beam in conjunction with a sophisticated beam deflection system is used to move material around the surface in a controlled manner to rapidly create a wide variety of complex surface structures, many of which are impossible to produce via any other processing route. New heat exchange surfaces and structures have been modelled to understand how different designs of surface feature can influence the flow behavior over a surface, and a parallel set of wind tunnel tests have been used to verify results. Ultimately this will enable the optimization of surface geometries for heat transfer and allow revolutionary changes in heat exchanger design.
This paper describes the background and scope of a new electron beam manufacturing process. The results of both modeling and wind tunnel testing are presented to demonstrate the impact of this technology on heat exchanger design and efficiency.
11:20-11:40 AM
The Use of Filler Metal Shims to Improve Electron Beam Weldability
Daniel Nowak, GE Energy; Gary LaFlamme and John Rugh, PTR-Precision Technologies, Inc.
Electron beam welding is normally considered an autogenous welding process and is typically used to join components with tight-fitting faying surfaces. Welding autogenously using the electron beam is ideal for producing the lowest possible heat input and minimal distortion by virtue of the processes narrow fusion zone. However, there are materials that cannot be fusion welded autogenously, such as 6000 series aluminum alloys. In these cases, a filler material must be used to change the weld metal chemistry to prevent cracking. The normal method for adding filler metal in conventional arc welding processes is to feed wire into the molten weld pool. This wire feeding method is suitable for the relatively shallow and wide welds produced by conventional non-keyhole welding processes, but it does not provide an adequate distribution of filler metal in the narrow, deep, rapidly solidifying welds produced by the EB welding process. To overcome this lack of filler metal distribution problem, it is possible to pre-place shim material between the faying surfaces prior to welding. This provides an even distribution of filler throughout the depth of the weld. However, the electron beam profile needs to be modified to accommodate the wider fusion zone and some of the inconsistencies of a shimmed joint.
This paper presents the use of filler shims in a number of applications in aluminum alloys and 300 series stainless steel. Properties data are also presented for select applications.
11:40 AM-12:00 PM
Electron-Beam Welding for Big Science
Dr.-Ing. Wilfried Behr, Zentralabteilung Technologie (ZAT)
The ISF (Institut for Welding Engineering and Joining Technology) at the RWTH Aachen (Aachen University) and the ZAT (Central Department of Technology) at the Forschungszentrum Jülich have worked for decades successfully in the development and application research of the joining technology. The FEZ (Excellency Center for Joining Technology) connects the technical authority of the RWTH Aachen and the Forschungszentrum Jülich. The combined use of personnel and machine resources offers a complete joining technology specialized authority unique in Europe. Both for the industrial site in Germany and in the global competition of the engineer-scientific research, this is very useful, since the FEZ can solve questions made of industry and research as a competent development partner.
The ZAT in the Forschungszentrum Jülich transfers the tasks of the non-university research, development and manufacturing for research establishments and major items of scientific equipment cooperating world-wide in the FEZ. Current joining tasks e.g. for the international fusion experiment ITER in Cadarache/F, for the Spallation Neutron Source SNS in Oak Ridge/USA, for the research reactor FRM II in München/D and for FAIR (Facility for antiproton and ion Research) experiment in Darmstadt/D. The section "beam welding technology" of the ZAT can offer the necessary machine equipment and specialized authority to the research partners with its decades of experience in the processing of special metals as ideal development partner. Embedded into the range special joining and inspection technique can the ZAT a comprehensive research and manufacturing service offer, which are necessary to the solution of more complex joining and technical questions. Electron-beam welding is frequent with the solution of these joining technology questions of central importance. Only with the unique characteristics of this process, the almost boundless deflection technology, the outstanding protection of the melt against atmospheric influences by the vacuum and the highly precise power control material can be worked on such as niobium, molybdenum and titanium in addition, copper and aluminium in the necessary quality.
12:00 PM-1:20 PM — Lunch
Hosted by AWS C7B Committee
1:20-1:40 PM
Electron Beam Welding of Aluminum Alloys for the Automotive and Aircraft Industry
Prof. Dr.-Ing. Stefan Böhm, Christian Börner, Kai Noack, Prof. Dr.-Ing. Klaus Dilger, Institute of Joining and Welding Technique, Technische Universität Braunschweig (Germany)
In an actual project sponsored by the EU, the electron beam is used for the welding of ductile aluminum die cast alloys for crash-optimized lightweight components for the automotive industry and aluminum wrought alloys for helium-proof chassis of aeronautic and aerospace instruments. For welding of ductile aluminum alloys, the challenges are the mechanic-technological joint properties, because ductile aluminum die cast is difficult to cast and so the hydrogen induced porosity is high. For welding of chassis made of aluminum wrought alloys, the shape of the chassis are not symmetrical rotationally, but complicated. The components are made by precision-casting. Here the heat transfer into the material, the welding order, and the start and stop craters are the challenge.
The paper will show how modern electron beam technology is able to fulfill the requirements of the welding tasks using multiple beams and multiple focuses.
1:40-2:00 PM
Applications of Electron Beam Diagnostics in Characterizing Low and High Voltage Electron Beam Welders
K.W. Lachenberg, T.A. Palmer**, A.T. Teruya*, and J.W. Elmer*, Sciaky Inc., * Lawrence Livermore National Laboratory; **Applied Research Laboratory, Pennsylvania State University (USA)
Over the past two decades, the development of diagnostic tools for characterizing electron beams has been growing in prominence. The Enhanced Modified Faraday Cup (EMFC), developed at Lawrence Livermore National Laboratory (LLNL), provides measurements of the general size and shape of the beam and the power density distribution across its width. This tool has been utilized in a number of common applications, including the characterization of machine performance for high- and low-voltage electron beam welders, the transfer of parameters between welders at remote locations, and as a process control tool. Because of its capability to quantify beam characteristics, the EMFC can also prove to be a useful tool in diagnosing differences in machine performance related to differences in machine construction. By employing the EMFC diagnostic tool, the power density distribution of the beam from a given electron beam gun configuration can be determined. This quantitative information can then be used as a baseline for providing a better understanding of how different features of the electron gun or power supply affect the resulting beam power. The use of the diagnostic tool will provide a better understanding of the operation of these machines and prove instrumental in producing improved designs for the next generation of electron beam guns and power supplies without extensive visual and destructive testing.
2:00-2:20 PM — Break
2:20-2:40 PM
Electron Beam Welding – Process, Applications, Equipment and Future Developments
Dr. Schubert, G. PTR-Precision Technologies, Inc. (USA)
This presentation gives a technical overview of unique features of the electron beam welding process. Applications from different types of industries and different materials will be discussed and technical challenges will be highlighted, as well as how they can be solved with the EB process. Weld cross sections of production parts will be shown to demonstrate weld shapes obtainable. In addition, an overview of today's welding equipment will be provided, ranging from universal chamber welders to flexible and dedicated production welders with short cycle times. Integration of high production welders into fully automated production lines will also be reviewed. A brief outlook will be given into future developments.
2:40- 3:00 PM
New Capabilities for Efficient Application of Electron Beam Welding for the Fabrication of Large-Scale Parts in Series Production
Volker Adam, pro-beam AG & Co. KgaA (Germany)
One domain of the electron beam is the possibility to join finished or near-net-shape machined parts distortion-minimized. This technology was field-tested and applied for more then 50 years for safety-related parts in space, aviation, military and nuclear applications. Simultaneously the technique is predestined for deep penetration welding of wall thicknesses up to 100mm and more. Possibilities in this field have been discussed in the past, but so far, hardly any equipment was available for flexible and economic operations.
Machines and control systems have been continuously developed by pro-beam. As a result, fast and economic machines with chamber volumes up to 600 m3 for welding of large-scale parts with weights above 50 tons are available.
Enormously increasing or fluctuating commodity prices, especially for high-alloyed steels and noble metals, force up the importance of EB-welding in vacuum without filler material. The low energy consumption of modern EB systems, the matured technology, and the high availability of the systems have turned the technology into an economic production method for semi-finished products.
Large-volume cast or forged parts, as well as large-sized sheets can be subdivided into smaller components, faster and better available, and joined economically with high-quality by EB in the vacuum. New applications in the areas of shipbuilding, aviation and offshore wind power as well as for system and machine building are in pre-series or series production.
The paper reflects the current status of the production and will give future prospects of EB welding in the area of large-scale parts. Besides technical aspects, in particular, economic aspects are discussed.
3:00- 3:20 PM
Studies on the Electron Beam Welding Behavior of Different Lightweight Materials
Marco Klemm, SZF Stahlzentrum and Rolf Zenker, TU Bergakademie
For modern lightweight design, it is becoming more and more necessary to produce welding constructions of lightweight materials as well as same-type design and also multi-material design. This makes high demands on the welding technologies itself, but also on additional thermal pre- and post-processes
in connection with the welding process.
The electron beam (EB) can meet the requirements for realizing such complex welding tasks. By using high-frequency beam deflection, it is possible to realize multi-spot welding and/or multi-process technologies in connection with welding.
The paper deals with results relating to EB welding of several Al and Mg alloys and different combinations of these materials. EB welding was realized without filler materials to connect components up to 25 mm in
thickness.
The quality of the weld (porosity, sensitivity to cracking), the microstructure and hardness of the welding seam, and the HAZ and the tensile behavior in comparison to the base materials were investigated.
Same-type and related-type welds of lightweight joints have a good quality and mostly very good properties. In case of unrelated-type welds, the welding results depend on the kinds of welding partners used.
3:20- 3:40 PM
Electron Beam Weldability of Aluminum-Based Dissimilar Alloy Joints
Michinori OKUBO, Toshiyuki HASEGAWA, Nihon University, Japan; Nobuyuki ABE, Osaka University, Japan
Aluminum alloy joints of dissimilar composition will give problems due to difference properties. The electron beam machine is 6 kW for high voltage type. Joint configuration is I type and without filler metal. Electron beam welds are produced on dissimilar aluminum alloys of 10 mm in thickness.
Al-Si alloy shave good performance. Main aluminum alloy is extruded Al-Si plate. Combination wrought alloys are Al-Mg, Al-Mg-Si and Al-Zn-Cu alloy plates. Hardness of Al-Si/Al-Mg and Al-Si/Al-Mg-Si weld metals is same level as both alloys. Tensile strength becomes about 200MPa. In case of Al-Si/Al-Zn-Cu joint, joint elongation is the lowest shown, and they are 80% of the base metal. Impact value shows a tendency to decrease. Micro-segregation of Mg, Si and Cu in weld metals is recognized for Al-Si/Al-Mg-Si joint.
Nanostructure aluminum alloy have high strength and good performance. The main alloy is nanostructure aluminum alloy. Combination aluminum-based alloys were extruded Al-Si plate and wrought Al-Mg, Al-Mg-Si and Al-Zn-Cu alloy plates. Dissimilar welding for nanostructure aluminum alloy to various aluminum-based alloys by electron beam welding process can be possible and crack-free. But some porosity is recognized in weld metal. As for hardness of the weld metal, they become 107 to 124HV with each joints. The high energy density processes such as electron beam welding are suitable because the heat-affected zone width is very narrow.
3:40-4:00 PM
Panel Discussions
Monday, November 16
EBW Student Tutorial
9:00 AM-2:45 AM
Student Tutorial
Pro-Beam Foundation (Germany)
- Basics of beam generation (beam source, influence of high voltage and magnetic fields, vacuum, deep penetration welding effect)
- Rules for design (theory and practical examples, EB conform design, parts preparation)
- Weldability of metallic materials (rules and practical applications)
- The multifunctional EB (quality assurance, seam tracking, online process control, automatic beam adjustment, multi-spot and multiprocess technologies)
- EB machines (single machines, production cells, EB welding of large parts, product life cycle)
- Criteria for EBW applications (examples for industrial applications)
2:45 PM
Adjournment
Pick and choose between concurrent sessions for the latest in welding research and commercial developments. Pay by the day or attend the entire three-day program, with special discounts for students and members of AWS, SME, FMA, NAM, or PMA.
3-day Professional Program
Member of AWS, FMA, SME, NAM, or PMA: $225
Nonmember: $360 (Code W34)
3-day Student Professional Program
Member of AWS, FMA, SME, NAM, or PMA: $75 Nonmember: $90 (Code W35)
1-day Professional Program
(Monday [W31], Tuesday [W32] or Wednesday [W33] only) Member of AWS, FMA, SME, NAM, or PMA: $150 • Nonmember: $285
Monday, November 16, 2009 — 8:30 AM – 5:00 PM
SESSION 1: International Trends in Welding Research
A. 8:30 AM Status and Trends of Welding Technology and Industry in China Ping Shan, Chinese Welding Society and Tianjin University
B. 9:15 AM Status and Trends of Welding Technology and Industry in Taiwan Jong-Ning Aoh, Taiwan Welding Association and National Chun Cheng University
C. 10:00 AM Welding Research in Canada Patricio Mendez, N.Zhou, A. Gerlich, and M. Yarmuch, University of Alberta
SESSION 2: Friction Stir Welding
A. 1:30 PM Effect of Joint Design on Strength of Dissimilar Mg-to-Al Friction-Stir Welds Vahid Firouzdor, and Sindo Kou;University of Wisconsin
B. 2:00 PM Friction Stir Spot Welding and Its Application for Magnesium Blair E. Carlson, Cameron Dasch, Robert Szymanski and Mark T. Hall; General Motors R & D
C. 2:30 PM Material Flow and Deformation Mechanisms During Friction Stir Welding Adrian Gerlech, University of Alberta
D. 3:00 PM Synthesis of Experimental and Simulation FSW Results Using Scaling Techniques Karem Tello and Patricio Mendez; Colorado School of Mines
E. 3:30 PM Ferrous Alloy Friction Stir Welding and Microstructure Simulation David M. Failla II and John Lippold; The Ohio State University
F. 4:00 PM Conparison of Joining Thin Sheet TRIP 780 to CRIF Steels Using FSW and GTAW Processes Scott Gordon and Stephen Liu; Colorado School of Mines
SESSION 3: Welding Metallurgy
A. 1:30 PM Optimizing Corrosion Performance of Welds Andrew Stockdale and John DuPont; Lehigh University
B. 2:00 PM Loading, Heat Treatment and Welding Parameters Influence on Wear Resistance Estela S. Surian, Agustin Gualco, Hernan Gabriel Svoboda and Luis Alberto de Vedia
C. 2:30 PM Development of a Chromium-Free Ni-Base Consumable for Joining Stainless Steel Jeffrey Sowards, Boian T. Alexandrov, Dong Liang, Gerald S. Frankel and John Lippold; The Ohio State University
D. 3:00 PM Gas Tungsten Arc Welding of Titanium: Complex Fluoride-Containing Flux Pastes and Flux-Cored Wires Christine Hillier, Michael Liu and Stephen Liu; Colorado School of Mines
E. 3:30 PM In-situ Thermite Welding of Boiler Tubing John Nickell, Stephen Liu and Kent Coleman; Colorado School of Mines
F. 4:00 PM Magnetic Stirring of High Chromium Nickel Based Weld Metals Steve McCracken, Suresh Babu, Dave Farson, Yong Chae Lin and Xinghua Yu; Electric Power Research Institute
G. 4:30 PM Microstructure Control in HSLA Steel Welds Boian T. Alexandrov and John C. Lippold; The Ohio State University
SESSION 4: High Energy Density Beam Processes
A . 1:30 PM Laser Hybrid Welding/Brazing of Al to Ti Alloys with Filler Wire Liqun Li, Shuhai Chen, YanBin Chen and Norman Zhou; Centre for Advanced Materials Joining, University of Waterloo and Harbin Institute of Technology
B. 2:00 PM Laser Welding of Open Root Thin Foil Materials for Producing Lattice Structures Andrew Deceuster, Chunbo Zhangand Leijun Li; Utah State University
C. 2:30 PM Energy Transfer in Laser Spot Welding - Effect of Joint Geometry Charles V. Robino, Jerome T. Norris and Gerald A. Knorovsky; Sandia National Laboratories
D. 3:00 PM The Use of Filler Metal Shims to Improve Electron Beam Weldability John Rugh, Gary LaFlamme and Daniel Nowak; PTR-Precision Technologies, Inc.
E .3:30 PM Fiber Laser Beam Oscillation Techniques for Spiking Suppression Dave Farson, Matt Reiter and Junho Cho; The Ohio State University
F. 4:00 PM Comparison of High Deposition Rate Laser Cladding with Yb Fiber and Direct Diode Lasers Todd A. Palmer, Kenneth Meinert and Keith Parker; Applied Research Laboratory
G. 4:30 PM Bead Geometry Control for Repair of Directionally Soldifified Nickel-Based Superalloy Andrew Deceuster, Chunbo Zhangand Leijun Li; Utah State University
Tuesday, November 18, 2009 8:00 AM – 5:30 PM
SESSION 5: Arc Processes
A .8:00 AM New Advancements in AC GMAW for Steel Construction Matthew Brooks, Ken Takahashi, Hideo Shiozaki, Tetsuo Era and Tomoyuki Ueyama; OTC Daihen, Inc.
B. 8:30 AM A Compact, Low Cost, In-Process Welding Defects Detection System Based on Thermal Plasma Emission Pengcheng Lv, Binglin Miao, Seun Hwan Lee, Jyoti Mazumder and Matthew Sinfield; AlphaSense, Inc.
C. 9:00 AM Laser Enhanced GMAW Metal Transfer Yi Huang and YuMing Zhang; Department of Electrical and Computer Engineering and Centre for Manufacturing
D. 9:30 AM Reflection of Illumination Laser from Gas Metal Arc Weld Pool Surface Xiaoji Ma and YuMing Zhang; Department of Electrical and Computer Engineering and Centre for Manufacturing
E .10:00 AM Droplet Heat Content in Various Transfer Modes in Gas Metal Arc Welding Erik James Soderstrom, Kevin Michael Scott and Patricio F. Mendez; Colorado School of Mines
F. 10:30 AM Radial Composition of Fume Particles by STEM-EDS Neil T. Jenkins and Thomas W. Eager; The Ohio State University
G 11:00 AM Influence of Behavioral Parameters on Duplex Weldments Carolian Payares-Asprino, John P. Steele and Homan Galezo; Universidad Simon Bolivar
SESSION 6: Industrial Technology
A. 8:00 AM Construction and Weld Overlay of Pipelines for the Petrochemical Industry Borja Saiz Sanchez and Roberto Saiz Juarez; Edison Welding Institute
B. 8:30 AM Evaluation of Arc Burning Behavior and Process-Intergrated Quality Assurance in Pulse GMA Welding Al-Mg Alloys S. Rajasekaran; Vinayaka Missions University
C. 9:00 AM Thermal Sprayed Aluminum Against Corrosion Under Insulation Fred van Rodijnen; Sulzer Metco OSU GmbH
D. 9:30 AM Reducing the Noise Generated when Air-Arc Gouging Can Be as Simple as Flipping A Switch George Durkt, Jr., U.S. Dept. of Labor - Mine Safety & Health Administration
E. 10:00 AM DeltaSpot - Real Time Resistance Welding Stefan Mayr; Fronius USA
SESSION 7: Welding Modeling
A. 8:00 AM A Distortion Prediction Tool for Weld Sequence Optimization Yu-Ping Yang and Bradrinarayan P. Athreya; Edison Welding Institute
B. 8:30 AM Preventing Dissimilar Metal Weld Failures: Application of New Functionally Graded Transition Joints Gregory Brentrup, Brett Leister and John DuPont; Lehigh University
C. 9:00 AM Analytical Three-Dimensional Temperature Field in Keyhole Welding C.C. Chiang and P.S. Wei
D. 9:30 AM Experimental and Simulation Study of Laser-Stimulated Electrical Discharges in Nanoscale Gaps Jian Chen and Dave Farson; The Ohio State University
E. 10:00 AM Bilinear Model Predictive Control of Plasma Pipe Welding Process Kun Qian and YuMing Zhang; University of Kentucky
F. 10:30 AM Maximum Post-Weld Heat Treating Temperatures for 9-12 Cr-Mo Steels Michael Santella
G. 11:00 AM Weld Profile Prediction of GMAW of Duplex Stainless Steel John P.H. Steele and Carolina Payares-Asprino; Colorado School of Mines
SESSION 8: Properties/Design
A .2:00 PM FCMAW Welding of Stainless Steels for 4.2 K Service Edward N. Dalder; Dalder Materials Consulting, Inc.
B. 2:30 PM Influence of Material Properties and Weld Geometry on Fatigue Performance of DP780 and Mild Steel GMAW Lap Joints David Anderson, Yan (Jack) Sang, Justin Hunt and Chonghua (Cindy) Jiang; American Iron and Steel Institute
C. 3:00 PM Welding Specifications: What Makes for a Good One? Gerald A. Knorovsky; Sandia National Laboratories
D. 3:30 PM Effect of Submerged Arc Welding Parameters on Weld Microstructure and Mechnical Properties of AISI 304 Welded Joints for Cryogenic Applications Rafael Eiji Toma, Antonio Cordeiro Souza, Zorailde Morais and Sergio Duarte Brandi; Promon Tecnologia
E. 4:00 PM Impact Reliability of Hybrid Laser Arc (HLA) Welds on Mild Steels and High Strength Steels Caleb Roepke and Stephen Liu; Colorado School of Mines
F. 4:30 PM Effect of Welding Parameters on Duplex Stainless Steel Performance Matthew Yarmuch, Kimberley Sandy and Galen Wright; Alberta Research Council
G. 5:00 PM Differences in Hardness Testing Techniques for Characterizing Wellhead Cladding Joshua Sleigh, Martin Hukle and Brian Newbury; ExxonMobil Development Co.
SESSION 9: Solid-State Processes
A. 2:00 PM An Explosion in the Uses of Explosion Welding Michael Blakely; Dynamic Materials Corporation
B. 2:30 PM Explosive Bond Interface Characterization Stephen Liu, Vilem Petr, Collin Trickel, Brandon Dugan, Scott Gordon, Dan Andrews and Chris Paul; Colorado School of Mines
C. 3:00 PM Diffusion-Welded Superconducting Joints of Bi-2223 / Ag Multifilamentary Tapes Gui Sheng Zou, Wei Guo, Fang Big, Zhou, Ai Ping Wu and Norman Zhou; Centre for Adanvced Materials Joining, Univeristy of Waterloo, and Harbin Institute of Technology
D. 3:30 PM Interfacial Microstructure Characterization in Magnetic Pulse Welds Yuan Zhang, Suresh Babu and Glenn Daehn; The Ohio State University
E. 4:00 PM Transient Thermal Response in Ultrasonic Additive Manufacturing David Schick; The Ohio State University
F. 4:30 PM Very High Power Ultrasonic Additive Manufacturing Siriraman Melatheru Ramanujam, Sudarsanam Suresh Babu, Matt Short and Karl Graff; The Ohio State University
G. 5:00 PM High-Resolution Transmission Electron Microscopy of Interfaces in UAM Bonds Ryan Dehoff, David Schick, Ryan Hahnien and Suresh Babu; The Ohio State University
SESSION 10: Automotive
A. 2:00 PM Failure Mode and Heat Affected Zone Microstructure of AHSS Victor H. Baltazar Hernandez, Yasuaki Okita and Y. Zhou; University of Waterloo/Centre for Advanced Materials Joining
B. 2:30 PM Effects of Surface Conditions On Resistance Spot Welding of Mg-Alloy AZ31 Lei Liu, Jicai Feng, Yanhong Tian and Norman Zhou; Centre for Advanced Materials Joining, Univeristy of Waterloo, and Harbin Institute of Technology
C. 3:00 PM Corrosion and Corrosion-Fatigue of AZ31 Magnesium Weldments Carl E. Cross and Suzanne Bender; BAM
D. 3:30 PM A Comparative Study of Joint Efficiency for Advanced High Strength Steels John Bohr, Ted Coon and Justin Hunt; General Motors R & D
E. 4:00 PM The Effect of Alloying Elements on the Resistance Spot Weld Performance in High Strength Dual Phase Steels Murali Tumuluru and Takahiro Kashima; U.S. Steel
F. 4:30 PM Evaluation of the Partial Interfacial Fracture During Mechanical Testing for Spot-Welded Advanced High Strength Steels Yeong-Do Park, Sang-Min Lee, Du-Youl Choi and Ji-Ho Lim; Dong-Eui University
Wednesday, November 18, 2009 — 8:00 AM – 12:00 PM
SESSION 11: Weldability
A. 8:00 AM Arc Waveform and Ni-Cr-Fe Weld Overlay Quality Yoni Adonyi, Steve Wolbert and Jordan Smith; LeTourneau University
B. 8:30 AM Failure Analysis of Welded Pipe Supports Mikal C. Balmforth and John Wise; Exponent, Inc.
C. 9:00 AM High Chromium Nickel-Base Weld Filler Metals Steve McCracken, Boian Alexandrov, John Lippold, Jeffrey Sowards and Adam Hope; Electric Power Research Institute
D. 9:30 AM Diffusible Hydrogen Characteristics of Hybrid Laser Arc Welding Paul A. Blomquist, Stan Ferree, Dale Anderson and Brian Marx; Applied Thermal Sciences
E. 10:00 AM A Comparison of the High Temperature Corrosion Resistance of Co-Extruded and Weld Overlay Coatings for Corrosion Protection in Coal Fired Boilers John N. DuPont and William Van Geertruyden; Lehigh University
F. 10:30 AM Welding Technology for Reeled Linepipe Used in Offshore Sour Service Applications Germanique Pickens, Craig Monahan and Rick Noecker; ExxonMobil Development Co.
G. 11:00 AM GTAW and LBW of 304 to 304L Stainless Steels P.W. Hochnanadel, M.Q Johnson, T.J. Lienert, J. Martinez and R. Martinez; Los Alamos National Laboratory
H. 11:30 AM Effects of Local Cr Additions on Solidification Mode and Cracking in Pulsed Laser Welds on 304L Stainless Steel T. J. Lienert, P.A. Papin, C.T. Necker and D.J. Alexander; Los Alamos National Laboratory
SESSION 12: Shipbuilding
A. 8:00 AM Microstuctural Evolution and Mechnical Properties of a New High Strength Steel for Defense Applications Jeff D. Farren and John DuPont; Lehigh University
B .8:30 AM Atom Probe Tomography of Cu Precipitates in HAZ of Steel Xinghua Yu, Jeremy Caron, Suresh Babu and John Lippold; The Ohio State University
C. 9:00 AM Qualification of HLAW of HSLA-80 Under Naval Vessel Rules Paul A. Blomquist, Erik Oller, Carl Chretien and Brian Marx; Applied Thermal Sciences
D. 9:30 AM Weldability Evaluation of Blast-Resistant Naval Steel Jeremy Caron and John Lippold; The Ohio State University
E. 10:00 AM Airborne Weld Fume Emission Profiles of HLAW Paul A. Blomquist and Dan Chute; Applied Thermal Sciences
F. 10:30 AM Size-Fractionated Stainless Steel Welding Fumes Emissions in an Isokinetic Chamber and in the Breathing Zone S. Erdal,J.J Schauer, J. Breskey and E. Indacochea; UIC-UW-M
This two-day resistance welding school is sponsored by the American Welding Society and the Resistance Welding Manufacturing Alliance, and conducted by industry specialists. The basics of resistance welding and real-life application of the process are covered. Participants learn at their own pace and discuss specific welding concerns with the instructors. You are invited to bring your own samples for discussion.
Please plan to be present for both days of the school. The program is limited to 100 students. The registration fee includes a copy of the Resistance Welding Manual, Revised Fourth Edition (a $125 value) and a course binder containing all instructor presentations. Participants will also receive a certificate of completion. In addition, there will be tabletop exhibits both days, demonstrating the latest resistance welding products offered by RWMA-member companies.
Tuesday, November 17, 2009 — 7:45 AM – 5:30 PM
Wednesday, November 18, 2009 — 8:00 AM – 4:00 PM
Member AWS, FMA, SME, NAM, or PMA: $475
Nonmembers: $695 • Registration Code: W35
Chair: Bruce Kelly, President, Kelly Welding Solutions, Grand Ledge, MI
Tuesday, November 17, 2009
7:45 AM – 8:00 AM
Welcome and Introduction to Resistance Welding
Bill Brafford, Technical Liaison Manager; Tuffaloy Products, Inc., Greer, SC
8:00 AM – 8:30 AM
Basics of Resistance Welding Video – Part I
8:30 AM – 11:00 AM
Electrodes and Tooling
Bill Brafford, Technical Liaison Manager
Focus on the classification, selection and maintenance of electrodes and fixtures as they pertain to numerous applications. By revealing some problem-solving techniques and suggestions, Bill Brafford will familiarize you with some powerful problem/evaluation/solution techniques that will keep your production process running longer – and operation more efficient.
11:10 AM – 12:15 PM.
Welding Controls
Don Sorenson, Director of Engineering, ENTRON Controls, LLC, Greer, SC
This discussion focuses on the selection, descriptions and applications of welding timers, contactors, and accessories. Packed with a punch, Don Sorenson drives home H = I2 RT in a way you'll never forget. He shows you how this invaluable formula is used in every resistance welding application – every day – every cycle – all the time!
12:15 PM – 1:45 PM
Lunch Served & Tabletop Exhibits
1:50 PM – 2:50 PM
Welding Controls (continued…)
3:00 PM – 5:30 PM
Electrical Power Systems
Mark Siehling, Vice President, Engineering, RoMan Engineering Services, Grand Rapids, MI
This session reviews the descriptions and maintenance of electrical power components and conductors from the weld control to the electrode. This lively presentation has something for everybody. Utilizing several small demonstrations, Mark Siehling helps you understand this very important part of the resistance welding process which will keep you on the edge of your seat!
Wednesday, November 18, 2009
7:00 AM – 8:00 AM — Sign-in
8:00 AM – 10:00 AM
Welding Processes & Machines
Tim Foley, Sr. Applications Engineer, Automation International, Inc., Danville, IL
This session will reinforce the very essence of how the resistance welding process works and how the process relates to each of the four resistance welding processes. This session will be full of application examples from each process and how machinery utilizes the individual components and elements illustrated in the other sessions.
10:15 AM – 10:45 AM .
Basics of Resistance Welding Video – Part II
11:00 AM – 12:15 PM.
Troubleshooting and Maintenance
Bruce Kelly, President, Kelly Welding Solutions, Grand Ledge, MI
With over 30 years experience in the auto industry, specifying, installing and troubleshooting resistance welding systems, Bruce Kelly will give you tips on how to find the reasons why welds don't turn out the way you would like. This presentation is filled with real life examples of problems that baffled maintenance persons.
12:15 PM – 1:45 PM
Lunch Served & Tabletop Exhibits
1:45 PM – 3:45 PM
Initial Machine Set–Up
Robert Matteson, Director – Product Development, Taylor-Winfield, Inc., Brookfield, OH
Robert Matteson takes you through the selection and maintenance procedures of proper weld schedules and preventive maintenance programs designed to make your resistance welding operations profitable. Hands-on demonstrations peak this presentation.
3:45 PM – 4:00 PM
Question and Answer Session
Five unique seminars will give you opportunities to gain practical knowledge on welding and inspection in a lively forum with expert instructors. Seminars are discounted for members of AWS, SME, FMA, NAM, or PMA.
THE WHY AND HOW OF WELDING PROCEDURE SPECIFICATIONS
Monday, November 16, 2009 — 9:00 AM – 4:30 PM
Member of AWS, FMA, SME, NAM, or PMA: $345 Nonmember: $480
Registration Code: W25
If you are responsible for planning a welding operation, which of the following items are most critical: base metal, welding process, filler metal, current and range, voltage and travel speed, joint design tolerances, joint and surface preparation, tack welding, welding position, preheat and interpass temperature, or shielding gas? This course provides the answers. This program will benefit owners, managers, engineers, and supervisors who must qualify, write, or revise their own welding procedure specifications to satisfy codes and contract documents.
Topics covered:
• Proper preparation and qualification of welding procedure specifications
• Selecting and documenting welding variables
• Documenting standard procedure qualification testing for commonly used processes for joining ferrous plate and pipe materials.
You can learn:
• Specifying essential and nonessential variables commonly used in sample AWS, ASME, and API code formats
• Using standards when preparing procedures
• Documenting welding variables and qualification tests
• Avoiding the pitfalls in revising previously qualified procedures.
VISUAL INSPECTION WORKSHOP
Monday, November 16 – Tuesday, November 17, 2009 — 9:00 AM – 4:30 PM
Member of AWS, FMA, SME, NAM, or PMA: $550
Nonmember: $685
Registration Code: W32
A 16-hour course for CWI exam candidates to review the basic concepts and applications of visual inspection. After a discussion of the limitations and advantages of visual inspection, types of weld data that may be obtained by visual inspection are presented and discussed. Includes the many types of discontinuities encountered during the visual inspection of welds. To help the prospective CWI be better prepared for the Part "B" Practical portion of the exam, common tools used for visual inspection are presented and discussed: a machinist's scale, dial calipers, micrometers, fillet weld gages, the Palmgren gage, and the V-WAC Undercut gage. Students will use these gages to make measurements on weld replicas. A sample weld specification containing acceptance criteria is presented and discussed, after which students use the specification and visual inspection tools to evaluate the weld replicas using a series of specific questions and scenarios.
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By attending, you can learn:
• How to use weld measuring instruments
• Compliance to a specific code
• Do's and don'ts of documentation
• When a discontinuity is OK
• When a defect is rejectable
• Why visual inspection can be the most effective NDE technique
CERTIFIED WELDING SALES REPRESENTATIVE SEMINAR
Monday, Nov. 16 – Wednesday, Nov. 18, 2009 — 9:00 AM – 5:00 PM
Member of AWS, FMA, SME, NAM, or PMA: $575 Nonmember: $655
Apply at aws.org/certification/CWSR Designed for the welding distributor and manufacturer sales representatives with the intent of introducing basic welding knowledge. This three-day program is not intended to help the participants become practicing welders, but rather gain an understanding of basic processes and equipment that is generic to all manufactures. The workshop focuses on safety, fundamental principles of general welding operations and processes, basic arc equipment, shielding gases, consumables, and related components. To qualify, you must be a high school graduate and have two years of experience in direct relation to sales of welding and cutting equipment, supplies and other related services. A study guide will be provided for those registering for the workshop and exam which will provide reading assignments necessary to be successful in the workshop activities. An exam (extra cost) is given on the third day leading to certification as an AWS Certified Welding Sales Representative.
METALLURGY APPLIED TO EVERYDAY WELDING
Tuesday, November 17, 2009 — 9:00 AM – 4:30 PM
Member of AWS, FMA, SME, NAM, or PMA: $345 Nonmember: $480
Registration Code: W26
Metallurgy of welds in carbon and low-alloy steels doesn't need to be complicated. This short course will help you understand how welding affects the properties of base materials, and how weld defects occur. Owners, inspectors, engineers, and supervisors who specify welding and need to understand the interaction of base, filler, and welding processes should attend.
ROADMAP THROUGH THE D1.1/D1.1M:2008 STRUCTURAL WELDING CODE–STEEL
Wednesday, November 18, 2009 —9:00 AM – 4:30 PM
Member of AWS, FMA, SME, NAM, or PMA: $345
Nonmember: $480
Registration Code: W34
This one-day program provides a comprehensive overview of the new AWS D1.1:2008, Structural Welding Code–Steel. Each code section, including General Requirements, Design of Welded Connections, Pre-qualification, Qualification, Fabrication, Inspection, Stud Welding, and Strengthening and Repair of Existing Structures, will be summarized with emphasis on their interrelationships and usage. In addition, the role of mandatory and non-mandatory annexes will be reviewed, along with tips on using the code Commentary. This program will benefit managers, engineers, supervisors, inspectors, and other decision-makers who need comprehensive understanding of what is, and what is not, covered by AWS D1.1:2008 to improve their job effectiveness. Attendees must bring their own copy of D1.1:2008, Structural Welding Code–Steel. Order it online at http://www.awspubs.com or call (888) 935-3464.
Free sessions that highlight the latest developments in welding education and training programs.
Tuesday, November 17, 2009— 9:00 AM – 4:00 PM
Wednesday, November 18, 2009— 9:00 AM – 11:00 AM
Registration Code: W12 • FREE
Tuesday, November 17, 2009 — 9:00 AM – 10:00 AM
Competency Model Used to Build a Career Ladder in Welding
Dr. Dave Dickenson, consultant (formerly with Ohio States University and past president of AWS)
10:00 AM – 11:00 AM
Plummer Memorial Lecture (see below)
11:00 AM – 11:45 AM
Novel Teaching Approach for Welding Using Augmented Reality
Victor Mata Alegre, Bernd Hillers and Axel Graser, Friedrich Wilhelm Bessel Institute
2:00 PM – 2:45 PM
Higher Education Update
Prof. S. Suresh Babu, Ohio State University
2:45 PM – 3:30 PM
AWS SOS
Monica Pfarr, Corporate Director, Solutions Opportunity Squad, AWS Foundation
3:30 PM – 4:00 PM
Update on the AWS S.E.N.S.E. and Accreditation Programs
Ed Norman, Education Committee Chair, and Steve Houston, Development Subcommittee Chair
Plummer Memorial Education Lecture
Tuesday, November 17, 2009 — 10:00 AM – 11:00 AM
Room S213 • FREE
The Plummer Memorial Education Lecture Award has been established by the American Welding Society to recognize an outstanding individual who has made significant contributions to welding education and training, and to recognize Fred L. Plummer's service to the society as president from 1952 to 1954 and executive director from 1957 to 1969. The recipient of this award will deliver a lecture and receive this educational distinction.
This year's presenter is Professor Jack D. Compton, of the College of the Canyons. His topic will be "Teaching Human Development Skills to Welders – 20 Years Later." This talk will be based on the Plummer Lecture given by Richard Sabo 20 years ago, with perspective on what Mr. Sabo proposed in 1989 compared to the art and science of welding education today.
Wednesday, November 18, 2009
9:00 AM – 9:30 AM
Perkins IV Presentation
Steve Parrott, Technology and Engineering Education Principal Consultant, Illinois State Board of Education
9:30 AM – 10:00 AM
Status on NSF Grant for National Center of Excellence in Welding Training and Education
Ken Smith, MBA, CPP, Manager of Training Projects & Principal Investigator, NSF DUE 0703018, Lorain County Community College/Weld-Ed National Center for Welding Education & Training
10:00 AM – 10:30 AM
Effective Teaching Laboratory
Dr. W. Richard Polanin, Professor and Program Chair, Manufacturing Engineering Technology, Welding Technology, Illinois Central College
10:30 AM – 11:00 AM
A Recipe for Homegrown Welders
Philip McNew, Pittsburg State
Guidance Counselor Workshop
Wednesday, November 18, 2009
9:00 AM – 11:45 AM
FREE
Monica Pfarr; Dr. Tom Lienert; Sam Gentry; H. Briggs Smith, Director of Career and Technical Education for the Hamilton County Department of Education
Sunday, November 15, 2009
What Is Thermal Spray?
11:00 AM – 5:00 PM
Registration Code: W10 • FREE
Free session sponsored by the International Thermal Spray Association.This basic introduction to thermal spray benefits will cover four major areas: processes, equipment, applications, and industry usage. Processes covered will include molten metal flame spraying, powder flame spraying, wire flame spraying, ceramic rod flame spraying, detonation flame spraying, high velocity oxy/fuel spraying (HVOF), cold spraying, plasma spraying, electric arc spraying, and RF plasma spraying. Equipment will be on display. Several spray guns will be available for attendees to handle and discuss throughout the class. Other larger items such as complex systems and spray booths will be illustrated and discussed. Application examples will be presented for a variety of requirements from several different industries. Industry usage charts will be reviewed listing several processes and coating applications used by various industries. Monday, November 16, 2009
AWS Opening Session & Annual Business Meeting
9:00 AM – 10:30 AM
During the AWS Opening Session and 90th Annual Business Meeting, 2009 AWS President Victor Y. Matthews will give the Presidential Report and John Bruskotter will be inducted as AWS President for 2010. Following the induction, the 2009 Class of AWS Counselors and Fellows will also be introduced. This meeting is open to all AWS Members and Show registrants.
Comfort A. Adams Lecture – Innovative Developments in Friction Stir Welding
10:30 AM – 11:30 AM
Wayne Thomas has considerable industrial experience. For the last 23 years he has worked in research and development at TWI. He is the author of over 100 technical papers and has been responsible for the invention and development of a number of emergent technologies, including friction stir welding. He has been awarded the Sir William J. Larke Medal, the Japanese Welding Society Welding Process Technology Award, the AWS Samuel Wylie Miller Memorial Medal Award, the IIW Evgenij Paton Medal, and the American Society of Manufacturing Engineers Award. The Comfort A. Adams Lecture is named after the founder and first president of AWS. This annual lecture is made by an outstanding scientist or engineer, honored by the AWS Board of Directors.
Image of Welding Awards Ceremony
11:15 AM – 1:30 PM
Join the AWS Image of Welding Committee (a subcommittee of the Welding Equipment Manufacturers Committee) and special guests as they salute this year's heroes of welding. Individuals and organizations will be honored at this special ceremony for their outstanding public initiatives and programs that promote the image of welding throughout their communities. To reserve your seat, RSVP by October 16 to AWS Image of Welding Awards at 800-443-9353, or e-mail image@aws.org.
AWS Officers/Presidents/Counterparts Reception
6:30 – 8:00 PM • Hilton Chicago Ballroom
This reception is held annually during the Show and is open to all registrants. Take advantage of this opportunity to meet the AWS officers, network with members and prospects. A complimentary hors d'oeuvres buffet is included, along with a cash bar. Evening business attire, please.
Tuesday, November 17, 2009
AWS Awards/AWS Foundation Recognition Ceremony & Luncheon
Noon – 1:30 PM
Registration Code: W13 • Price: $30
The first AWS award, the Samuel Wyllie Miller Memorial Medal, was presented to Comfort A. Adams in 1927. As the Society and the industry it serves have grown, so has the need to recognize outstanding scientists, engineers, educators, and researchers. Join an assembly of distinguished award presenters, recipients, and guests for a well-paced ceremony and a delicious lunch. The cost for attending the ceremony and luncheon is $30, and is open to all registrants. Tickets will also be available at the door.
AWS National Nominating Committee – Open Meeting
2:00 – 3:00 PM
AWS Members are requested to submit their recommendations for National Officers to serve during 2011. Nominations must be accompanied by 16 copies of biographical material on each candidate, including a written statement by the candidate as to his/her willingness and ability to serve if nominated and elected.
Wednesday, November 18, 2009
R. D. Thomas, Jr., International Lecture
10:00 AM (American Council of IIW meeting immediately following lecture at 10:30 AM)
This year's R. D. Thomas, Jr., International Lecture Award recipient, Dr. David Wiggery, will speak on "Standardization – Brake on Innovation or Engine for Change?" The R. D. Thomas, Jr., International Lecture Award was created to honor R. D. Thomas, Jr., for his participation in IIW/ISO activities and is presented by AWS to an individual who is also involved in IIW/ISO international activities. The recipient is invited to deliver a lecture illustrating the incorporation of global studies in the standardization of welding technology during the AWS Welding Show and at the Annual Assembly of the IIW.
After taking a degree in metallurgy at Cambridge University, David Widgery joined the British Welding Research Association, later to become TWI, in 1964. He was awarded the AWS Lincoln Gold Medal for his 1976 paper "Deoxidation practice for mild steel weld metal."
In 1976, he left TWI to join GKN Lincoln Electric Ltd as Development Manager. In 1982, the GKN welding companies were acquired by the ESAB Group. He published a book, Tubular Wire Welding, in 1994. David Widgery became chairman of IIW SC II-E in 2001. The main work of this committee over the following years was to bring together the CEN and ISO standards by developing the so-called "cohabitation" drafts, many of which have now been adopted by CEN and ISO and published as national standards. Following retirement from ESAB in 2007, he now works as a consultant.
American Council of IIW
10:30 AM (immediately following the R.D. Thomas, Jr., International Lecture)
Professional Welders Competition Award Ceremony
1:00 PM North Hall competition area
AWS Board of Directors Meetings
2:30 - 7:30 PM Wednesday and 8 AM Thursday
For other AWS committee meeting times and locations, please visit www.aws.org/show