April 08 Cover 1:4/06 Cover 3/10/08 1:25 PM Page C1 April 2008 W E L D I N G J O U R N A L • V O L U M E 8 7 N U M B E R 4 • A P R I L 2 0 0 8 ••PPllaassmmaa AArrcc CCuuttttiinngg ••CCrriittiiccaall EEvvaalluuaattiioonn ooff PPiippee WWeellddss ••FFrriiccttiioonn SSttiirr WWeellddiinngg SSpphheerriiccaall PPaarrttss ••BBoonnuuss:: TThhee AAmmeerriiccaann WWeellddeerr PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING AND ALLIED JOINING AND CUTTING PROCESSES, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING SELECT ARC:FP_TEMP 3/5/08 2:00 PM Page C2 For Info go to www.aws.org/ad-index NATIONAL STANDARD:FP_TEMP 3/5/08 1:58 PM Page 1 For Info go to www.aws.org/ad-index WELD MOLD:FP_TEMP 3/5/08 2:01 PM Page 2 For Info go to www.aws.org/ad-index April 08 Layout:Layout 1 3/7/08 8:40 AM Page 3 CONTENTS April 2008 • Volume 87 • Number 4 AWS Web sitewww.aws.org 30 Features Departments 30 Electrode Life: A Measure of System Performance in Washington Watchword..........4 Plasma Cutting Press Time News ................6 Reasons for electrode erosion and ways to prevent it are discussed Editorial............................8 N. Hussary and T. Renault News of the Industry............10 34 Pipeline Weld Discontinuities Too Small to Matter Brazing Q&A......................20 The use of Engineering Critical Assessment on pipeline Aluminum Q&A..................22 welds can help reduce costs and delays in large pipe construction projects New Products....................24 K. Y. Lee Coming Events....................48 36 Plasma Cutting Systems Combine Versatility with Efficiency Society News....................53 The plasma process offers manufacturers multiple options in metal fabrication Tech Topics ......................54 R. Madden Errata A5.22..................55 34 40 Friction Stir Welding of Thick-Walled Aluminum Pressure Guide to AWS Services..........73 Vessels New Literature....................76 The challenges of friction stir welding circumferential parts were met head on and resolved Personnel ........................80 E. Dalder et al. American Welder The American Welder Behind the Mask ............94 36 Learning Track................96 88 Addressing the Welder Shortage: Lessons from Alberta Fact Sheet....................98 Natural-resource-rich Alberta, Canada, is investing heavily in welding facilities and recruiting to meet the Classifieds......................111 growing demand for skilled welders Advertiser Index................114 M. Langier and S. MACKay 100 Welding Instruction More than 50 welding schools offer a glimpse at their programs and services Welding Research Supplement 85-s Measurement and Analysis of Three-Dimensional Specular Gas Tungsten Arc Weld Pool Surface A method of rebuilding a 3-D weld pool surface off-line was Welding Journal (ISSN 0043-2296) is published devised and verified 40 monthly by the American Welding Society for H. S. Song and Y. M. Zhang $120.00 per year in the United States and posses- sions, $160 per year in foreign countries: $7.50 96-s Predicting Resistance Spot Weld Failure Modes in per single issue for domestic AWS members and Shear Tension Tests of Advanced High-Strength $10.00 per single issue for nonmembers and Automotive Steels $14.00 single issue for international. American Welding Society is located at 550 NW LeJeune Rd., Experiments indicate that the mode of failure should not be the Miami, FL 33126-5671; telephone (305) 443-9353. only judge of spot weld quality in advanced high-strength steels Periodicals postage paid in Miami, Fla., and addi- D. J. Radakovic and M. Tumuluru tional mailing offices. POSTMASTER:Send address changes to Welding Journal, 550 NW LeJeune Rd., 106-s Characterization of Welding Fume from SMAW Miami, FL 33126-5671. Canada Post:Publications Mail Agreement #40612608 Canada Returns to be Electrodes — Part I sent to Bleuchip International, P.O. Box 25542, Lon- Fume particles and generation rates were characterized as don, ON N6C 6B2 a function of size for three different covered electrodes Readers of Welding Journal may make copies of J. W. Sowards et al. articles for personal, archival, educational or re- search purposes, and which are not for sale or re- On the cover: An apprentice at Southern Alberta Institute of Technology, sale. Permission is granted to quote from articles, Calgary, Canada, practices gas tungsten arc welding on stainless steel. (Photo provided customary acknowledgment of authors courtesy of Miller Electric Mfg. Co., Appleton, Wis.) and sources is made. Starred (*) items excluded from copyright. WELDING JOURNAL 3 Washington Watchword April 2008:Layout 1 3/6/08 4:27 PM Page 4 WASHINGTON BY HUGH K. WEBSTER WATCHWORD AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE Enforcement Procedures for Hexavalent Federal Regulations Recommended for Chromium Standards Review The U.S. Occupational Safety and Health Administration Small business owners and representatives have nominated (OSHA) has issued a new compliance directive for occupational more than 80 federal regulations for review and reform in re- exposure to hexavalent chromium (Cr(VI)) that provides guid- sponse to the U.S. Small Business Administration’s (SBA) Of- ance for enforcement of the final rule on hexavalent chromium fice of Advocacy’s Regulatory Review and Reform (r3) initiative. standards. The directive, OSHA Instruction CPL 02-02-074, In- The r3 program is designed to identify and address existing fed- spection Procedures for the Chromium (VI) Standards, became ef- eral regulations that should be revised because they are ineffec- fective Jan. 24, 2008. The Cr(VI) standards were originally pub- tive, duplicative, or out of date. It is a tool for small business lished in the Feb. 28, 2006, Federal Register. stakeholders to suggest needed reforms. The program includes The Cr(VI) standards, which lower the permissible exposure the process under Section 610 of the Regulatory Flexibility Act limit for hexavalent chromium to 5 micrograms of Cr(VI) per for agencies to consider whether their current regulations are cubic meter of air as an 8-h time-weighted average, are applica- still needed, and the degree to which technology, economic con- ble to general industry, construction, and shipyards (Sections 29 ditions, or other factors have changed since their rules were first CFR 1910.1026, 29 CFR 1926.1126, and 29 CFR 1915.1026, re- promulgated. Also, it includes a process by which interested stake- spectively). Highlights of the new Cr(VI) directive include pro- holders can nominate existing regulations for reform, and moni- cedures for reviewing an employer’s air sampling records to de- tor the progress that agencies make toward achieving those termine exposure levels; guidance on how employers can imple- reforms. ment effective engineering and work practice controls to reduce The SBA will transmit the Top 10 list to agencies in the spring and maintain exposure below approved permissible exposure lim- and will work to ensure that the listed rules will be reviewed and its; requirements for employers to provide hygiene areas to min- reformed. In order to track agency progress, the recommended imize employees’ exposure to Cr(VI); guidelines requiring em- reforms will be posted on the SBA’s Web site and an update on ployers to maintain exposure and medical surveillance records; the status of reforms will be published twice a year. SBA will ac- and a requirement that Compliance Safety and Health Officers cept r3 nominations for 2009 from now until Dec. 31. (CSHOs) evaluate portland cement wherever it is being used. The standards became effective May 30, 2006. Employers with 20 or more employees were given six months from the effective Paperwork Burden Unfairly Falls on Small date to comply with most of the provisions. Employers with fewer Business than 20 employees were allowed 12 months from the effective date to come into compliance with most of the provisions. All Recent hearings before the U.S. House Committee on Small employers were given four years from the effective date to install Business concluded that the requirements of the federal Paper- feasible engineering controls. work Reduction Act fall disproportionately on small businesses. In 2007, the Federal Registergrew to 70,000 pages, roughly the Stimulus Legislation Benefits Businesses equivalent of 39 New York City phone books. The committee es- timates that the federal regulatory burden translates into approx- imately $8000 per employee in annual costs. The Economic Stimulus Act of 2008, signed into law in early The Paperwork Reduction Act of 1980 was signed into law to February, has two provisions that may be beneficial to businesses. clarify government communications while easing related burdens First, the legislation gives companies a 50% bonus deduction on on U.S. business. The law established the Office of Information new equipment that would normally be depreciated over many and Regulatory Affairs at the Office of Management and Budget, years, and, second, the law increases — to $250,000 from $128,000 and charged the Small Business Administration with mitigating in 2008 — the limit on expenses that small businesses can deduct the impact of federal information requests. Despite this, small from annual income, with a total cap of $800,000. firms now spend 15% more time on paperwork than they did just Companies that purchase less than $800,000 of capital assets three years ago. in a year now can expense (i.e., deduct currently) the first $250,000 of capital investment, effective for purchases made in 2008 (the prior limits for 2008 were $128,000 and $510,000, respectively). Workplace Injury and Illness Rates at The new law also includes a new 50% expensing allowance Record Lows (also known as bonus or accelerated depreciation) that generally applies to capital equipment purchased and placed in service dur- ing 2008. This incentive is available to all companies, regardless The U.S. Department of Labor reports continued declines in of the size of their investment. serious workplace injuries and illnesses. The rates for calendar Under this provision, companies are eligible for a “bonus” year 2006 were the lowest ever reported. In calendar year 2005, first-year depreciation totaling 50% of the cost of the investment the rate of fatal work injuries was 4.0 fatalities per 100,000 em- and can depreciate the remaining basis of the asset under the ployees. In calendar year 2006, the rate of fatal work injuries was regular depreciation rules. Smaller companies get even more of 3.9 fatalities per 100,000 employees. This decreased rate is the a “bonus.” As described above, they can first take advantage of all-time low achieved since the Bureau of Labor Statistics insti- expensing and then also use the 50% expensing allowance. tuted its Census of Fatal Occupational Injuries in 1992. Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail [email protected]; FAX (202) 835-0243. 4 APRIL 2008 CM INDUSTRIES:FP_TEMP 3/5/08 1:53 PM Page 5 For Info go to www.aws.org/ad-index Press Time News April 2008:Layout 1 3/6/08 4:25 PM Page 6 PRESS TIME NEWS AWS Names World Engineering Xchange as Publisher Andrew Cullison International Auditor Editorial Editor/Editorial Director Andrew Cullison The American Welding Society (AWS), Miami, Fla., recently announced World En- Senior Editor Mary Ruth Johnsen gineering Xchange, Ltd. (WEX), has been engaged as the Society’s international audit- Associate Editor Howard M. Woodward ing agency, effective immediately. Assistant Editor Kristin Campbell WEX will be responsible for auditing AWS certification seminars and exams that Peer Review Coordinator Erin Adams take place outside of the United States. Additionally, the company will assist AWS’s in- ternational certification agencies with the development of strategies to improve and Publisher Emeritus Jeff Weber promote AWS interests within the international market. Graphics and Production “We have enjoyed a successful relationship with WEX since it became our fulfill- Managing Editor Zaida Chavez ment partner for AWS codes, standards, and other publications,” said Cassie Burrell, Senior Production Coordinator Brenda Flores AWS deputy executive director. “WEX’s focus on quality, dependable service, first-class reputation, and knowledge of our industry make them particularly well suited to take an Advertising additional role as AWS’s international auditor. We look forward to working with WEX National SalesDirector Rob Saltzstein in all phases of its auditing activities as we continue to expand and enhance our interna- Advertising Sales Representative Lea Garrigan Badwy tional certification base.” Advertising Production Manager Frank Wilson WEX will conduct ongoing quality control and technical compliance analyses of all Subscriptions AWS international agencies. Also, it will help to maintain open communication streams between AWS and its international agencies while ensuring that AWS best practices and [email protected] procedures are followed. American Welding Society Westinghouse Subsidiary Wins Machining and 550 NW LeJeune Rd., Miami, FL 33126 (305) 443-9353 or (800) 443-9353 Welding Services Contract Westinghouse Electric Co. subsidiary WEC Welding and Machining has won a major Publications, Expositions, Marketing Committee contract from CalEnergy, Calipatria, Calif., a large geothermal power producer, to com- D. L. Doench, Chair plete the 2507 Superduplex Pipe Replacement Project. Its Carolina Energy Solutions Hobart Brothers Co. (CES) will provide all machining and welding services for the assignment. T. A. Barry, Vice Chair Specifically, CES will provide orbital welding of 2507 superduplex stainless steel uti- Miller Electric Mfg. Co. J. D. Weber, Secretary lizing 686CPT Inconel™ filler material for the replacement of the customer’s existing American Welding Society carbon steel pipeline. The 14,000-ft-long pipeline will require more than 600 welds. The R. L. Arn, WELDtech International project will last approximately four months. S. Bartholomew, ESAB Welding & Cutting Prod. CES met the stringent weld properties established by CalEnergy for this project by J. Deckrow, Hypertherm repetitively producing 100% flawless welds. J. Dillhoff, OKI Bering J. R. Franklin, Sellstrom Mfg. Co. Kobe Steel to Establish Welding Company in China J. Horvath, Thermadyne Industries D. Levin, Airgas Kobe Steel, Ltd., plans to establish a company to produce welding materials in Qing- J. Mueller, Thermadyne Industries R. G. Pali, J. P. Nissen Co. dao, Shangdong Province, China. It will make flux cored welding wire for welding car- J. F. Saenger Jr., Consultant bon steel used in shipbuilding. S. Smith, Weld-Aid Products The joint venture, called Kobe Welding of Qingdao Co., Ltd., will be formed this D. Wilson, Wilson Industries month. Production is scheduled to begin in April 2009. The plant will have a capacity of J. C. Bruskotter, Ex Off., Bruskotter Consulting Services 1000 metric tons per month. H. Castner, Ex Off., Edison Welding Institute The new company will employ about 90 people and be capitalized at about $29 L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems million. G. E. Lawson, Ex Off., ESAB Welding & Cutting Prod. E. C. Lipphardt, Ex Off., Consultant Alcoa Completes Modernization Project in Hungary S. Liu, Ex Off., Colorado School of Mines C. Martin, Ex Off., Phoenix International E. Norman, Ex Off., Southwest Area Career Center Alcoa has completed a $83 million modernization investment project at Alcoa-Köfém, R. W. Shook,Ex Off., American Welding Society its operations in Székesfehérvár, Hungary. The project began in November 2005. The core of the investment is the modernization of Alcoa European Mill Products, involving expanding brazing sheet capability to offer a full range of gauges. Copyright © 2008 by American Welding Society in both printed and elec- Lincoln Electric Forms Agreement with Petty Enterprises tronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not in- The Lincoln Electric Co., Cleveland, Ohio, recently formed a team-supplier agree- tended for use without independent, substantiating investigation on the part of potential users. ment with Petty Enterprises, a two-car team with Kyle Petty driving the #45 Marathon Dodge and Bobby Labonte driving the #43 Cheerios/Betty Crocker Dodge. Lincoln is supplying the team with a full range of welding and cutting equipment, tech- nical training, and welding application support. The program will also help ensure the team maintains a high standard of safety, weld integrity, and performance both on the track and in the shop. MEMBER 6 APRIL 2008 MILLER:FP_TEMP 3/5/08 1:58 PM Page 7 For Info go to www.aws.org/ad-index Editorial April 2008:Layout 1 3/7/08 2:26 PM Page 8 EDITORIAL Founded in 1919 to Advance the Science, Technology and Application of Welding The Hands-on Experience: Is Officers President Gene E. Lawson It Losing Its Touch? ESAB Welding & Cutting Products Vice President Victor Y. Matthews The Lincoln Electric Co. There was once a vision that we would become a paperless society. That template never quite materialized, but we have moved a lot closer to its fulfillment with many busi- Vice President John C. Bruskotter ness and consumer transactions taking place electronically without a piece of paper in Bruskotter Consulting Services, LLC sight. The question that now looms is “will we become a printless society?” Will there be a time when a printed periodical is as obsolete as atomic hydrogen welding? Will there Vice President John L. Mendoza be a time when picking up the Welding Journal, flipping through its pages and resting CPS Energy comfortably to read what interests you will be as archaic as a 1000-lb welding machine? Treasurer Earl C. Lipphardt Four years ago, I would have said, “You’re crazy.” Three years ago it was “Never.” Consultant Two years ago I’m thinking, “Could it really happen?” Today, I see where reading publi- cations online is a foregone conclusion. I’m still old school enough to think that the tac- Executive Director Ray W. Shook tile “hands-on experience” still has appeal when it comes to reading the Welding Journal. American Welding Society Picking it up, sensing something of substance in your hands, feeling the texture of the page and hearing it rustle as it’s turned, carrying the whole of it to wherever you want, Directors all have an allure that is not quite dead. But, then again, I also think, “Am I kidding myself?” B. P. Albrecht (At Large), Miller Electric Mfg. Co. For someone who has used a slide rule and has had a large chunk of his life unadul- O. Al-Erhayem (At Large), JOM terated by personal computers, I may not be the best in gauging what a generation that has never been without the Internet might want. There is an age group that is used to A. J. Badeaux Sr. (Dist. 3), Charles Cty. Career & Tech. Center getting all its information from the Web, and who see anything not accessible electroni- J. R. Bray (Dist. 18), Affiliated Machinery, Inc. cally as “old generation,” and to be avoided. Text messaging, blogs, podcasts, webinars, H. R. Castner (At Large), Edison Welding Institute vlog, YouTube, all have become a common means of obtaining information in our evolv- N. A. Chapman (Dist. 6), Entergy Nuclear Northeast ing society. The pace of information access and the technology to deliver it are moving at mach speed. So it might not be so unbelievable that one day all periodicals will be read J. D. Compton (Dist. 21), College of the Canyons online and that printing will be obsolete. G. Fairbanks (Dist. 9), Gonzalez Industrial X-Ray Today, now, this minute, I still think a print publication is desirable and will be around D. A. Flood (Dist. 22), Tri Tool, Inc. for many years, but I am not ignorant of the multiple advantages a digital version of the M. V. Harris (Dist. 15), Reynolds Welding Supply Welding Journaloffers. For one, it is immediate — no waiting for delivery, no uncertain- ty of its availability. The digital page offers instant links to related information, is search- R. A. Harris (Dist. 10), Consultant able, archiveable, incorporates animation and video, and the list goes on and on. D. C. Howard (Dist. 7), Concurrent Technologies Corp. That is why I am investigating new ways to offer the Welding Journalin digital form J. Jones (Dist. 17), Thermadyne with all the unique features it affords. One of the core competencies of the American Welding Society is the dissemination of information and knowledge, and my goal is to do W. A. Komlos (Dist. 20), ArcTech LLC that with the Welding Journal in the most efficient way possible. The present printed D. J. Kotecki (Past President), The Lincoln Electric Co. Welding Journalwill remain the stalwart member benefit, but the future is a multimedia D. Landon (Dist. 16), Vermeer Mfg. Co. platform of presentation. R. C. Lanier (Dist. 4), Pitt C.C. Excuse me now while I find a nice cozy corner and a comfortable chair to sit down in and read my BlackBerry®. J. Livesay (Dist. 8), Tennessee Technology Center D. L. McQuaid (At Large), DL McQuaid & Associates S. Mattson (Dist. 5), Mattson Repair Service S. P. Moran (Dist. 12), Miller Electric Mfg. Co. R. L. Norris (Dist. 1), Merriam Graves Corp. T. C. Parker (Dist. 14), Miller Electric Mfg. Co. W. R. Polanin (Dist. 13), Illinois Central College W. A. Rice (At Large), OKI Bering, Inc. Andrew Cullison N. S. Shannon (Dist. 19), Carlson Testing of Portland Publisher, Welding Journal E. Siradakis (Dist. 11), Airgas Great Lakes K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv. G. D. Uttrachi (Past President), WA Technology, LLC D. R. Wilson (At Large), Wilson Industries 8 APRIL 2008