Welding Journal | August 2016 Journal readers know about our aging workforce and the need for hundreds of thousands of new welders. With millions of service members leaving the military

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

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30 The Cat Way Building One Trike at a Time A Florida manufacturer depends on welding to fabricate its unique recumbent trikes (low-to- ground tricycles) M. Gomez

*36 From the Lab to Your Driveway: Aluminum Tailor Welded Blanks To meet impending fuel economy mandates, auto makers are turning more and more to aluminum G. A. Kunkel and Y. Hovanski

40 Rethinking Football Goal Post Manufacturing A small four-person operation specializing in sports construction equipment has grown into a 100-employee operation as the interest in sporting events continues to expand C. Wood

AUGUST 2016 / WELDING JOURNAL 3

CONTENTS

273s Effect of ArCO2 Gas Blends on Droplet Temperature in GMAW Higher concentrations of CO2 in an argon-CO2 mix do not appear to change the shape of the temperature curve C. McIntosh et al.

*280s Evolution of WeldingFume Aerosols with Time and Distance from the Source Number size and particle mass distributions were measured from welding fumes generated near the arc (30 cm) and farther from the arc (200 cm) to assess the degree of welder exposure L. G. Cena et al.

286s Projection Welding with Pneumatic and Servo mechanical Electrode Operating Force Systems

A comparative analysis of the systems was performed using finite element calculations and destructive and nondestructive testing of the welds Z. Mikno

300s UltraNarrowGroove Laser Welding for Heavy Sections in ITER Defect-free welds were made on 60-mm-thick stainless steel plates using a wire-fed fiber laser S. K. Wu et al.

309s Temperature and Stress Simulation of the Hardfacing for Cr5Mo1VRE Alloy Experimental results indicate the computational temperature field and stress field agree well for the alloys J. Yang et al.

WELDING RESEARCH SUPPLEMENT

August 2016 Volume 95 Number 8

FEATURES30

74 84

80

THE AMERICAN WELDER74 Reporting for Duty as an Army Welder A Soldier tells his story how the military exposed him to welding and how it has now become his passion C. C. Wheeler

80 Using Technology to Help You Teach Online instruction, computerized welding machines, and virtual reality simulated welding are all technologies that drive modern welding instruction J. McIntosh

84 Antispatter Compound Helps Extend Consumable Life Reducing excess spatter buildup in the nozzle can minimize the risk of porosity and restricted gas flow, as well as extend contact tip life A. Marchand

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6 Editorial8 Press Time News

10 Washington Watchword12 International Update14 News of the Industry18 Business Briefs20 Aluminum Q&A24 Brazing Q&A26 Product & Print Spotlight44 Coming Events50 Certification Schedule

53 Society News54 Tech Topics58 Section News69 Guide to AWS Services70 Personnel

The American Welder88 Learning Track91 Fact Sheet92 Classifieds94 Advertiser Index

OFFICERSPresident David L. McQuaidD. L. McQuaid and Associates, Inc.

Vice President John R. BrayAffiliated Machinery, Inc.

Vice President Dale FloodTri Tool, Inc.

Vice President Thomas J. LienertLos Alamos National Laboratory

Treasurer Carey ChenCincinnati, Inc.

Executive Director Ray W. ShookAmerican Welding Society

DIRECTORST. Anderson (At Large), ITW Welding North AmericaU. Aschemeier (Dist. 7), Subsea Global SolutionsD. J. Burgess (Dist. 8), Alstom PowerD. A. Desrochers (Dist. 1), Old Colony RVTHSD. L. Doench (At Large), Hobart Bros. Co.D. K. Eck (At Large), Praxair Distribution, Inc.K. Fogleman (Dist. 16), ConsultantP. H. Gorman (Dist. 20), Sandia National LaboratoriesS. A. Harris (Dist. 4), Altec IndustriesJ. Knapp (Dist. 17), ConsultantM. Krupnicki (Dist. 6), Mahany Welding SupplyD. J. Landon (Past President), Vermeer Mfg. Co.S. Lindsey (Dist. 21), City of San DiegoD. E. Lynnes (Dist. 15), Lynnes Welding TrainingC. Matricardi (Dist. 5), Welding Solutions, Inc.S. M. McDaniel (Dist. 19), Big Bend Community CollegeW. R. Polanin (At Large), Illinois Central CollegeR. L. Richwine (Dist. 14), Ivy Tech State CollegeD. J. Roland (Dist. 12), Airgas USA, LLC,

NorthCentral RegionR. W. Roth (At Large), RoMan ManufacturingM. Sebergandio (Dist. 3), CNH AmericaK. E. Shatell (Dist. 22), Pacific Gas & Electric Co.M. Sherman (Dist. 10), SW&E, LLC

M. Skiles (Dist. 9), ConsultantW. J. Sperko (At Large), Sperko Engineering ServicesJ. Stoll (Dist. 18), The Bohler Welding Group U.S.H. W. Thompson (Dist. 2), UL, Inc.R. P. Wilcox (Dist. 11), ConsultantJ. A. Willard (Dist. 13), Kankakee Community CollegeD. R. Wilson (Past President), Wilson and Associates

WELDING JOURNALPublisher Andrew CullisonEditorialEditorial Director Andrew CullisonEditor Mary Ruth JohnsenFeatures Editor Kristin CampbellAssistant Editor Melissa GomezAssistant Editor Annik BabinskiPeer Review Coord. Sonia AlemanPublisher Emeritus Jeff Weber

Design and ProductionProduction Manager Zaida ChavezSr. Production Coordinator Brenda FloresManager of International Periodicals andElectronic Media Carlos Guzman

AdvertisingSr. Advertising Sales Exec. Sandra JorgensenSr. Advertising Sales Exec. Annette DelagrangeManager of Sales Operations Lea OwenSr. Advertising Production Manager Frank Wilson

SubscriptionsSubscriptions Representative Evelyn [email protected]

MARKETING ADVISORY COUNCIL(MAC)D. L. Doench, Chair, Hobart Brothers Co.S. Bartholomew, Vice Chair, ESAB Welding

& Cutting Prod.Lorena Cora, Secretary, American Welding SocietyD. Brown, Weiler BrushC. Coffey, Lincoln ElectricD. DeCorte, RoMan ManufacturingS. Fyffe, Astaras, Inc.D. Levin, AirgasR. Madden, Hypertherm

D. Marquard, IBEDA SuperflashJ. F. Saenger Jr., ConsultantS. Smith, WeldAid ProductsD. Wilson, Wilson and AssociatesJ. N. DuPont, Ex Off., Lehigh UniversityL. G. Kvidahl, Ex Off., Northrop Grumman

Ship SystemsD. J. Landon, Ex Off., Vermeer Mfg.S. P. Moran, Ex Off., Weir American HydroE. Norman, Ex Off., Southwest Area Career CenterR. G. Pali, Ex Off., J. P. Nissen Co.N. Scotchmer, Ex Off., Huys IndustriesR. W. Shook, Ex Off., American Welding Society

American Welding Society8669 NW 36 St., # 130, Miami, FL 331666672(305) 4439353 or (800) 4439353

On the cover: A welder gas tungstenarc welds a recumbent trike at Catrikesmanufacturing facility in Orlando, Fla.(Photo by Assistant Editor MelissaGomez.)

Welding Journal (ISSN 00432296) is published monthly bythe American Welding Society for $120.00 per year in the UnitedStates and possessions, $160 per year in foreign countries: $7.50per single issue for domestic AWS members and $10.00 per singleissue for nonmembers and $14.00 single issue for international.American Welding Society is located at 8669 NW 36th St., # 130,Miami, FL 331666672; telephone (305) 4439353. Periodicalspostage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 8669 NW36th St., # 130, Miami, FL 331666672. Canada Post: PublicationsMail Agreement #40612608 Canada Returns to be sent toBleuchip International, P.O. Box 25542, London, ON N6C 6B2,Canada.

Readers of Welding Journal may make copies of articles forpersonal, archival, educational or research purposes, and whichare not for sale or resale. Permission is granted to quote from articles, provided customary acknowledgment of authors and sourcesis made. Starred (*) items excluded from copyright.

Copyright 2016 by American Welding Society in bothprinted and electronic formats. The Society is not responsible forany statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

DEPARTMENTS

WELDING JOURNAL / AUGUST 20164

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In his book Wealth of Nations, EconomistAdam Smith described an invisible handof the market that guides the action of indi-viduals, but produces an unintended eco-nomic benefit for society. Society has changed a bit since Smithwrote Wealth of Nations in 1776. Today, so-cial responsibility is no longer an option.Companies cannot remain isolated. Theymust give back to the industries, communi-ties, and people they affect. In the case ofthe welding industry, the hand of the mar-ket is quite visible; good corporate citizen-ship produces direct benefits and creates aself-reciprocating relationship between theindustry and those we help.

WEMCO Importance

As a 20-year member and past presidentof WEMCO, an association of welding man-ufacturers and a standing committee of theAmerican Welding Society (AWS), I am aproud member of an organization dedicatedto promoting the welding community. WEMCOs membership roster includesroughly 80 manufacturers in the welding in-dustry who care about its future. A primarytenet is its focus on education. WEMCOwants to make an impact by positively influ-encing people to consider welding careers. Each year at FABTECH, WEMCO andAWS honor the industry by announcing thewinners of their Excellence in WeldingAwards. These recognize individuals, busi-nesses, AWS Sections, distributors, media,educators, and others for their unique andexceptional contributions. For the second year, the Excellence inWelding Awards has included a veteran cate-gory to honor those who help active serviceforces, civilians, and veterans acquire skillsand pursue careers in welding. I had thepleasure of spending time with the winnerof the 2015 veteran award, Lyle Palm, whowas able to offer some additional insights. Palm teaches welding skills to activeduty, veterans, and wounded warriors forthe nonprofit organization Workshops forWarriors in San Diego, Calif. He has takenthis program to the next level with his ex-pertise and dedication. As dean of welding,Palm helped develop the curriculum, weld-ing processes, and implementation of Work-shops for Warriors and continues to workclosely with business and industry to devel-op partnerships and ensure the program

meets various needs. The program hastrained hundreds of veterans, its job place-ment rate is nearly 100%, and veterans at-tend for free.

Reinvesting in the Future

The Workshops for Warriors facility con-tains 18 welding booths, but Palm wouldlike to see it expand into a full welding tech-nical center that contains 40 to 60 booths. Welding Journal readers know about ouraging workforce and the need for hundredsof thousands of new welders. With millionsof service members leaving the military inthe next five years, the welding industry hasa huge opportunity to transform intowelders those who want to learn a new setof skills for civilian society. Palm pointed out that veterans demon-strate a remarkable work ethic and under-stand what it takes to work as a team. Theymake great welders, he said. I visited Palms workshop and witnesseda dozen young Marines under their hoodslearning my industrys trade. They made meproud of my industry and country. Howev-er, we have to do more. Whether its Work-shops for Warriors, a local training facility,or your nearest technical college, weldingequipment manufacturers need to becomemore involved so that schools can keepoverhead low and tuition affordable. As Palm explained, We want the weldingcommunity to get excited with us and investin our graduates. Funding is our biggestchallenge, and we are working toward ourCapital Campaign to build a new facilitythat will train five times as many veteranswho can go into advanced manufacturingcareers each year. Actions, however small or large, canliterally change the arc of a persons life,

whether a veteran or someone else whowants an opportunity to earn a decent liv-ing. Actions, each and every one, will directthe future of the welding industry. Paying itforward takes on a very literal meaning inthe welding community. By giving, we liter-ally create the next generation of our owncustomers. As a final thought, ask yourself what thewelding community means to you. The an-swer may not be simple, but it will undoubt-edly lead to the unintended benefit of aninvisible hand that improves society whenwe pursue what matters most to us.

EDITORIAL

Good Corporate Citizenship in theWelding Community


Jim HorvathVP DistributorRelations, ESABWelding & CuttingProducts, and PastWEMCO President

Paying it forwardtakes on a very literal meaning in thewelding community.By giving, we literally create the nextgeneration of ourown customers.

WJ

EDITORIAL AUG 2016_Layout 1 7/14/16 3:05 PM Page 6

Welding may not be the firstjob considered when a personintends to join the military,but for some, like me, welding in themilitary can become both a career anda passion. I have been in the welding field myentire military service, which spans 19years. I have been stationed in Iraq,Korea, and Alaska, among other places Fig. 1. Currently, I am a Chief War-rant Officer Three (CW3), Active DutyArmy 914A, Allied Trades Warrant Officer. The purpose of this article is toshare my experience. In doing so,welding educators can become moreinformed about a welding career in theU.S. Army and pass on that knowledgeto students who might be interested ina military career. It is based on theWelding in the Military lecture I de-livered as part of the American Weld-ing Society (AWS) Education Program at FABTECH 2015 in Chicago, Ill. Fig. 2.

Basic Entry Requirements

In general, applicants to the Armyare required to have strong moral char-acter, be able to pass a thorough physi-cal and mental examination, and passthe Armed Services Vocational Apti-tude Battery.*

The Army also has strict regula-tions on tattoos and piercings, as wellas hair and beards, but this should notdiscourage an otherwise qualified ap-

plicant from visiting a recruiter. Onlythe local recruiter or other authorizedpersonnel can determine whether ornot a person is qualified.


Reporting for Duty as an Army WelderA long-time Soldier describes thejourney of his welding career in the U.S. Army, including training,responsibilities, and opportunities

BY CHARLES C. WHEELER

THE AMERICAN WELDERTHE AMERICAN WELDER

*Information presented in this section should beverified with a recruiter. Fig. 1 The author performing a fabrication near Tikrit, Iraq, in 2003.

WHEELER AW ARTICLE AUG 2016.qxp_Layout 1 7/12/16 1:18 PM Page 74


THE AMERICAN WELDER

Many recruiters may not want totalk about specific jobs the applicant isinterested in. This is partly becausethere are always high-demand MilitaryOccupational Specialties (MOSs) thatneed to be filled. For metalworking,MOS 91E Allied Trades Specialists aregenerally not in that category.

If applicants get through their localrecruiter, Military Entrance ProcessingStation, and enlist as a 91E, they canexpect to go to Basic Combat Trainingfor 10 weeks. Once individuals com-plete that stage, they will be shippedto Fort Lee in Virginia for AdvancedIndividual Training as an Allied TradesSpecialist.

Allied Trades Training Welding and machining togetherare Allied Trades. At one point,welders and machinists were separatejobs in the Army. A few years ago, aspart of a larger restructuring effort,the two jobs were combined to formone MOS. So, if a school-trainedwelder joins the Army as a 91E, he orshe will also be a trained machinistonce training is complete. For most people, this is a huge ben-efit, especially those who already havea background in the trades. Personally,I have found it easier for skilledwelders to learn how to be machiniststhan the other way around. Having theskills, experience, and knowledge ofboth trades can be a valuable asset to

the Army as well as individual servicemembers when they prepare to leavethe service and begin searching forwork. Training for Allied Trades Special-ists is currently 19 weeks, 2 days andis conducted at Fort Lee in Virginia.The Ordnance Corps, which is theArmy corps that oversees most main-tenance-related fields, was movedaround 2010 from Aberdeen ProvingGround in Maryland to Fort Lee. TheAllied Trades hall, located on the Ord-nance Center and School campus,houses modern equipment for Soldiersto train on. The course is laid out asfollows: Introduction to Machining (23 h) Bench Layout Operations (52 h) Lathe Operations (192 h) Milling Operations (82 h) Introduction to Welding (35 h) Oxyfuel Operations (38 h) Gas Tungsten Arc Welding (GTAW) (54 h) Gas Metal Arc Welding (GMAW) (62 h) Shielded Metal Arc Welding (SMAW) (88 h) Army Unique (69 h).

Fig. 3 An Army welding trailer in the Army Unique portion of the school at Fort Lee. Soldiers practice setting up and using this equipmentbefore completing training.

Fig. 2 Last year at FABTECH, I presentedWelding in the Military to a group of at-tendees as part of the AWS EducationProgram.



THE AMERICAN WELDER

Currently, in the initial entryphase, Soldiers learn machining onmanual lathes and mills. The Armydoes use computer numerical controltechnology, but the initial entrycourse is not long enough to accom-modate that type of training. It istaught later in a Soldiers career. The Army welding school at FortLee is an AWS SENSE accredited facili-ty. During the courses welding phases,Soldiers weld in all positions, normallyon steel, standard weldable grades ofaluminum, and stainless steel. Thecourse is designed for those who havenever welded. The students start on a LincolnElectric VRTEX 360 virtual reality arcwelding training simulator before per-forming actual welds in the booth. TheMarine Corps uses the same school;therefore, the courses portion calledArmy Unique is training unique to theArmy. This is where the Soldiers learnhow to set up and use our weldingtrailer, plus other Army-specific equip-ment Fig. 3.

Ability to Earn Credentials

For those who come to the schoolas trained welders, there are opportu-nities to advance through the coursefaster than their peers. In addition tomoving ahead and getting out of train-ing quicker, another advantage is theArmy has recently begun credentialingwelders and machinists at the school.This is an area I am especially proud ofas it brings even more validity to ourtraining. From AWS, this consists of achiev-ing credentials in SMAW, GMAW, fluxcored arc welding, GTAW, and oxyfuelcutting/plasma cutting. Also, from theNational Institute for MetalworkingSkills (NIMS), this includes the follow-ing: Measurement, Materials, and Safe-ty; Job Planning, Benchwork, and Lay-out; Drill Press Skills I; Manual MillingSkills I; and Lathe Turning Skills I. Credentials are becoming more andmore important as technology and theneed for greater skill increases. Theseare free of charge to the individual.With further experience and mainte-nance of earned credentials, the op-portunities are further increased whenthe person leaves the service. Not everyone can leave the schoolwith a folder full of certificates. Each

person is evaluated throughout theduration of the course and only indi-viduals with demonstrated ability are

allowed to take credentialing tests, butthe opportunity for a person who al-ready has demonstrated welding skills

Fig. 4 Two Warrant Officers train on a computer numerical control mill at Fort Lee.

Fig. 5 A Soldier makes a weld on a fabrication in South Korea in 2008.


to earn credentials can be far greaterthan for someone learning eachprocess for the first time.

Equipment Used

The equipment Soldiers train withare mostly commercially availablewelding machines, generally moderninverter-based models, and cuttingequipment. Most students start on avirtual reality arc welding trainingsimulator. Once the students get to the ArmyUnique portion of the course, theylearn how to set up and use our weld-ing trailer, otherwise known as ShopEquipment, Welding (SEW). The SEW is a small trailer that canbe pulled behind a 2.5-ton vehicle. Ithas a diesel-driven welding powersource, suitcase-style GMAW machine,300-A GTAW machine, along with as-sociated tools, cutting apparatuses,and all the basics needed for a fieldwelding job. Nothing else being guar-anteed, anywhere in the Army that a91E will go, there will be at least oneSEW.

Service Details

A common question among new re-cruits is, Where am I going to be sta-tioned? The Army has duty stationsthroughout the continental UnitedStates, Alaska, Hawaii, and around theworld. There is virtually no way to beable to say a certain person will be sta-tioned at a particular location. I recommend Soldiers embrace adifferent environment and take advan-tage of the opportunities presentedthere. Youll never know if you loveKorean food without being stationedin South Korea or know what thenorthern lights truly look like fromAlaska without actually being there.

Solving Problems with Welding

It is difficult for me to state specifi-cally what Army welders do, becausewe do a little bit of everything. I say,We solve problems. I have repairedradiators, weldments on tracked vehi-cle hulls, and a plethora of other ran-dom items. Anyone with a little bit of skill can

replace a transmission, yet only some-one with great attention to detail candrill, tap, and insert 17 holes strippedin an aluminum transmission housing,all while it is attached to the vehicleand the person is lying in the sand inthe deserts of California. I have repaired and fabricated moreparts and equipment than I can re-member. Each time, I learned some-thing new and gained invaluable expe-rience. Im still sometimes surprisedby the metal components Soldiersmanage to break or the special tools Iam frequently asked to fabricate.

In-Service Opportunities There are many reasons why peopledecide to enlist in the military, but one of the most popular is educationbenefits. All Soldiers who serve honorablyhave access to the Post 9/11 GI Bill.The benefits in this bill can be trans-ferred to spouses or other familymembers. One of the more popular educationbenefits while in service is Tuition As-sistance. This allows a person who hasat least one year of service to receiveup to $250 per credit hour to take col-lege classes. The cap is $4500 per yearor 16 credit hours, whichever comesfirst. I have personally used TuitionAssistance to its maximum extent andearned associate and bachelor degrees. There are multiple other benefitsthat really depend on how long a per-son stays in the service. The Post 9/11 GI Bill can also pay

for credentialing programs, like fur-ther AWS and NIMS certifications. Asan example, I earned my AWS Certi-fied Welding Inspector (CWI) distinc-tion while on station at Training withIndustry. If a person stays in the Army longenough, he or she can submit an appli-cation to become an Allied TradesWarrant Officer. Generally, candidateswill be a promotable Sergeant E5, haveat least 60 months of documented ex-cellence in the form of evaluations,and have at least the AdvancedLeaders Course completed. The Warrant Officer program ishighly competitive Fig. 4. WarrantOfficers make up only about 1% of thetotal Army population, and there areonly around 80 Allied Trades WarrantOfficers on active duty at any giventime. A program called Training with In-dustry is also an option for those whochoose to make a career out of the mil-itary. This is a collaboration betweenthe U.S. Army and The Lincoln ElectricCo. Soldiers competitively selected re-ceive a one-year assignment at Lin-colns headquarters in Cleveland,Ohio. They have the opportunity tolearn from welding experts, attendseminars, and go to the companyswelding school, as well as other events.The program is designed so Soldiersgain knowledge that helps advancewelding practices and procedures inthe Army. Currently, Im on this assignment.As a career military member, the op-portunity for me to get out and experi-


THE AMERICAN WELDER

Fig. 6 A GTAW row at the school in Fort Lee.


ence more of the greater metalworkingindustry has been invaluable.

Post Service Life

Whether a person enlists for fouryears and leaves the service, or choos-es to make it a career, there are manyemployment avenues available for sep-arating service members. Many businesses have veteran-preferred hiring procedures, unions of-fer a variety of training and job place-ment services, and the Army man-dates that all service members who areseparating complete the Soldier forLife transition program, which helpsteach skills such as interviewing andrsum writing. In addition, the Department of De-fense Skillbridge program connectsseparating service members with em-ployers and training opportunities.

Conclusion

Whatever the reasons for joiningthe Army, ultimately the experience isirreplaceable. The variety of fabrica-tions, repairs, materials, and experi-ences in different locations are almostcountless and ultimately invaluable Figs. 5, 6. I highly encourage educators withstudents who seem like a good fit forthe Army to encourage them to con-sider the military as a career option.We are in a time of reduction of forces,but there are always people leaving the service who need to be replaced.Students who have at least some education in the trades and who aremotivated, self-starters are ideal can-didates to become an Allied TradesSpecialist.


CHARLES C. WHEELER([email protected]) is anActive Duty Army 914A, Allied TradesWarrant Officer.

This article is based on the Welding inthe Military presentation given atFABTECH 2015 in Chicago, Ill.

All information contained herein regard-ing educational programs, credential-ing/certification, and other information iscurrent as of this writing; however, theseprograms are continually under reviewand subject to change.

THE AMERICAN WELDER

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/CreateJDFFile false /Description > /Namespace [ (Adobe) (Common) (1.0) ] /OtherNamespaces [ > /FormElements false /GenerateStructure false /IncludeBookmarks false /IncludeHyperlinks false /IncludeInteractive false /IncludeLayers fal

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Welding Journal | August 2016 Journal readers know about our aging workforce and the need for hundreds of thousands of new welders. With millions of service members leaving the military