IN THIS tSSVUE

rpP FICIAL PUBLICATION OF T H-E AMERICAN WELOING SOCItiéetTty

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your most

With Victor’s wide variety of nozzles, tips, and cutting

flexible tools
attachments, and reliable, field-proven regulators,
you can handle all your jobs with ease.

See your Victor dealer’s complete stock of welding

VICTOR

and cutting units for industrial uses... or if you’re

looking for economy, Victor’s Super- Range unit
Combination (only $99.00, including accessories) is your best buy.
Helpful literature yours for the asking. Call
Welding and your Victor dealer today.

Cutting Units
VicIOR EQUIPMEN] COMPANY
844 Folsom St 3821 Santa Fe Avenue
San Francisco 7 os Angeles 58
1145 E. 76th St., Chicago 19
J. C. Menzies & Co., Wholly-Owned Subsidiary
H
for welding
and cutting
70
MFRS. OF HIGH PRESSURE AND LARGE VOLUME GAS REGULATORS; WELDING & CUTTING EQUIPMENT; HARDFACING ROD Ss BLASTING
NOZZLES; COBALT & TUNGSTEN CASTINGS; STRAIGHT-LINE AND SHAPE CUTTING MACHINES; ROLLER AND IDLER REBUILDING MACHINES
For details, circle No. 1 on Reader Information Card
 VOLUME 39 e NUMBER 12 e DECEMBER 1960 W ||

Technical Papers Evaluation of Weld Quality on a Submarine Pipe tine, by Paul W. Turner
New Techniques for Cladding with the Gas Shielded Process, by Ralph D. Engel...
Items and Inert-gas-shielded Metal-arc Spot Welding of Aluminum, by S. Eric McFall
Reports Properly Designed Weld Tooling and Fixturing Greatly Simplifies the Welding of Large Rocket
J. E. Bartley and R. E. Frala

Practical Welder Christmas Trees—Made to Order, by Robert E. Haas

Metallizing Protects Parts from Corrosion
and Designer Birth of a New Welding Torch, byby F. M. Simms and 1 J.
J V. Warinsky..
Superior Welds Make Superior Tanks, by F. A. Henninger and W. F. Beldon.

ress-Time News 4 New }

i ne Ive News ofthe Industry
Society F
Welding Zones 5 ~=—-Personnel
and Related : |
World-Wide Welding News | Employment Service Bulletin
Events Editorial: Shielding Gases—and How The Current Welding Literature
Grew, by R. E. Lenhard New Literature
New Products
n 1 NeNews andan Even te Reader Information Card
w Members 126 index to Advertisers

Welding Steel: Avant Garde, by Charles M. Parker

Fusion-zone Structures and Properties in Aluminum Alloys, by Paul E. Brown and C. M. Adams
Research Analytical Investigation of Residual Stresses and Distortions Due to Welding, by Koichi Masubuct
Supplement Design of Interior Columns in Multi-Story Frames, by J. S. Ellis.
Research News..
A Reversed-bend Test to Study Ductile to Brittle Transition, by J. H.Ludley and D. C. Drucke
Current Welding Research Problems

Published for the advancement

J y so sani Utena witli ties Pub cation office
, Pa ditor d general offices, 33 West 39th St ,_ New York 18, N. Y
of the science and art of welding nited States rivileges
and possessions; reig Single e ‘copies,es
authorized foreign
at Easton,countries
Penna. $10.00.
This publication is authorized
rescribed by Section 132.122. Copyright 1960,
for any statement made or opinion expressed in its publicat by the Amer
by the American Welding Society date of publication provided credit is given
 Lincoln Foundation Offers
$25,000 in Prizes
A $25,000 award program has
been announced by The James F.
Lincoln Arc Welding Foundation,
PRESS-TIME Cleveland.
The awards are being made to
advance progress in the develop-
ment of better machines and struc-
tures through more efficient use of
arc-welded steel and to recognize
individual contributions to this
NEWS
progress.
The competition is open to any
U. S. resident who has taken part
. People
in the design, planning or production
of the design described in his paper.
. Welding Separate awards will be made for
machines and structures. In the
. Products machine design competition papers
must present a discussion of the
use of arc-welded steel in the design
of either a complete machine or a
machine component, including
achieved or expected results relating
New Engiand Conterence Held at Boston
to performance, and /or appearance,
The New England Region held its this, an address by N. J. Grant, savings in material, time or money,
combined technical conference and Professor of Metallurgy, M.I.T., made possible through welded de-
welding show on October 13-14th was enthusiastically received. Pro- sign.
at the Commonwealth Armory in fessor Grant spoke on “Russian Awards totaling $12,500 will be
Boston, Mass. The event marked Technology and Education.” made to the 38 papers adjudged best
the fifth year for the conference At the welding show about 2000 in the mechanical division. A similar
and the second for the welding people saw a wide variety of equip- amount will be awarded to a
show, both of which were enthu- ment displayed by over 60 manu- like number of papers in the struc-
siastically described by Chairman facturers and distributors. Adding tural design group.
A. J. Rosenberg as_ successfully to the general attraction was the First award in machines will
fulfilling all expectations of the fact that most of the equipment was be $3000; second and third awards
sponsoring groups. This year, the set up to give live demonstrations. will total $1500 each; five fourth-
Boston Section, acted as host, and These included several types of place awards amount to $500 each;
was supported by the seven other gas metal-arc welding, spot-weld- ten fifth-place awards are $250
AWS Sections of the region. ing, flash welding, stud welding, each; while 20 persons will receive
About 200 were present at the all- metallizing, ultrasonic welding, sixth-place awards of $100 each.
day technical session where the forming, cutting, plasma-are torch Complete rules and related in-
theme, “‘Welding in Defense’ was and many other processes. The formation may be obtained from
developed ‘“‘underseas,” ‘‘on the booths were well staffed and the The James F. Lincoln Arc Welding
seas” and “in the air.”” The five demonstrations were ably pre- Foundation, P.O. Box 3035, Cleve-
technical presentations, luncheon sented. land 17, Ohio.
and the evening banquet were held
in rooms adjacent to the welding
exhibition, a convenient arrange-
BRIDGE COMMITTEE IN HOUSTON
ment made possible by the large
armory facilities. The papers pre-
sented were: ‘‘Welding of the Tri-
ton” by N. Pomptilio, Electric
Boat Division of General Dynamics;
‘“‘Welding in Surface Vessels” by
H. C. Von Blohm, Bethlehem Steel
Co.; “Welding in Marine and
Airborne Structures” by H. R.
Bullock. Raytheon Co.; ‘Welding
Missiles Too Large for Post Heat
Treatment” by C. E. Hartbower,
Watertown Arsenal; and “Ultra
High Pressure Research” by W.
G. Field, Hanscom Air Force Base.
At the banquet, the members
and guests were greeted by A. R.
Barilaro, chairman of the Boston Members and guests of the AWS Conference Committee on Welded Bridges visited
Section, Frank Mooney, assistant the Mosher Steel Co. during their meeting in Houston ,Tex. The committee is working on
secretary AWS, and C. E. Jackson, the next edition of the AWS specifications for Welded Highway and Railway Bridges to be
vice president AWS. Following issued next spring

1204 | DECEMBER 1960

 |

ys |

y}

Mode! 1259 ‘‘Micro-wire” welder

SQUEEZE THE TRIGGER ON THE GUN...

WELDING WIRE FEEDS AUTOMATICALLY

That’s Hobart’s new MICRO-WIRE welder package. Think what this means in cutting
costs! No time loss changing electrodes—no stub end loss—no clean up of welds necessary.
Joins sheet metal and heavier sections, using small diameter wire and inexpensive carbon
dioxide (COz) or argon and COz2 mixtures. Actual production economies will amaze you.
This new MICRO-WIRE package is an extremely versatile unit for all position welding and
can be used by inexperienced as well as experienced operators. For complete details, write
for bulletin DM-159.

HOBART BROTHERS CoQO., Box wWJ-120, Troy, Ohio

ee Ph. FE 2-1223 Manufacturers of the world’s most complete line of arc welding equipment.

For details, circle No. 2 on Reader infermation Card

WELDING ZONES

Welding is under way on the largest wet-process rotary Sidewalk bridge railing designed by Massachusetts High-
cement kiln in the Western Hemisphere. The kiln was way Dept. is made of all-welded wrought iron to resist corro
recently shipped in 59 sections from Allis-Chalmers shops sion. Fabricator is Fulton Railing Co., Lawrence, Mass
to Argentina (Courtesy A. M. Byers Co.)

Worm's-eye view ofa 90-ft boom lifting Transit concrete mixers are made of aluminum, hold 7-yd loads. In operation
a 150-ft high, 5-ft diam stack. The at Central Pre-Mix Concrete Co., Spokane, Wash., mixers were developed jointly
all-welded stack was made from x by Construction Machinery Co., Waterloo, lowa, and Kaiser Aluminum & Chemical
72 x 188-in. 4D wrought iron plate by Corp
Conn Welding Co., New Castle, Pa
(Courtesy A. M. Byers Co.)

12066 | DECEMBER 1960

 ©

WELD 50 STORIES UP...

OR 50 MILES FROM NOWHERE

with P&H Engine-Driven Welders

You can use these portable, self-contained weiders

to save time and work on any construction job
anywhere! They are ideal for buildings, pipe lines,
bridges, or maintenance — wherever you need cost-
cutting weld-power to join and strengthen metal
parts and sections. You simply haul, wheel, or hoist
the welders into position and start welding.
P&H offers you six machines for welding require-
ments ranging from 25 to 500 amps. Easy, precise
voltage control and arc stability enable operators
to lay down sounder, cleaner welds faster — prevent
burn-through and popouts, thus sparing you the
need for costly rewelds and call-backs.
You don’t have to pamper P&H welders. They’re
built to withstand hard use and rough handling in
the field. They need less care — and they are easier
to service. Rugged field-proved gas or diesel engines
meet your toughest demands with power and fuel
to spare,
You can choose skid- or wheel-mounted machines
— with manual or electric starting. Interested?
Write for Bulletin W-158.

HARNISCHFEGER
WELDERS + ELECTRODES - POSITIONERS
MILWAUKEE 46, WISCONSIN
Export Division:
4329 W. National Ave., Milwaukee, Wis
P&H welding equipment is manufactured and sold in
anada by REGENT EQUIPMENT MANUFACTURING CO
455 King St. West ¢ Toronto, Ontario, Canada
Fer details, circle Ne. 3 on Reader ‘afermation Card
 WORLD-WIDE WELDING NEWS

By Gerard E. Claussen

BELGIUM Classes II and III only up to 1 Sheet No. 98—Instructions for

in. thick. The high-transition tem- converting drooping characteristic
In the February 1960 issue of the perature of rimmed steel and its motor generators to flat charac-
Belgian magazine Revue Universelle tendency to produce cracked and teristic.
des Mines problems of welding in porous welds in the segregated core Sheet No. 96-—Porosity in CO,
the chemical industry were dis- also were pointed out. Fatigue welds in mild steel is observed only
cussed at a symposium on special tests and work on new specifica- with more than 0.5 g of water per
materials organized by the As- tions, more lenient toward rimmed cubic foot of CO, gas. Commercial
sociation of Engineering Graduates steel, are being rushed. For sev- CO, contains less than 0.1 g of water
of the University of Liege, Belgium. eral years welded railway cars of per cubic foot of gas.
Reference is made to a welded rimmed steel have been in opera- Sheet No. 82——Tests for brazing
cylinder 3 ft diam made by the tion on the German railroads. fluxes.
Ferrand autofrettage process for Automatic and semiautomatic proc-
oxygen at 2800 psi. Another lec- esses are believed to be most prom-
ising since productive capacity for RUSSIA
ture at the symposium illustrates
welded equipment in silver, tan- low-hydrogen electrodes is too small
to meet the expected demand, if the The Russian automatic welding
talum, titanium, and zirconium. magazine Avtomaticheskaya Svarka,
Silver-clad steel plate is made with use of rimmed steel becomes per-
missible. for January 1960 contains the fol-
the aid ofa thin foil of Monel, which lowing articles:
bonds the silver to the steel. An The Central Welding Institute of
East Germany issued 110 informa- 1. Manufacturing practices for
internally clad reactor 10 in. diam welded oil and gas line piping in
utilizes tantalum sheet welded to tion sheets. starting October 1956
to December 1959. These sheets USA, France, Germany and Russia
the inside of a centrifugally cast are compared. Travel speeds in
tube of 42° nickel-iron 10 ft long summarize useful information on
some particular phase of welding. submerged-arc tandem _ electrode
which has the same coefficient of welding average 92 ipm and ex-
thermal expansion as_ tantalum. A few examples are abstracted here-
with. No. 1 gives the composition pansion in diameter after welding
and method of application of sub- need not exceed 1.2%. The welded
merged-arc flux, THM Pie 18, pipe is not heat treated.
EAST GERMANY 2. Ultrasonic vibrations, 20 kc,
which was the first East German
flux to be made. It was produced applied to the weld puddle in elec-
The East German welding mag-
starting in August 1955 at the troslag welding Type 310 stainless
azine Schweisstechnik, for February steel refined the grain structure
1960 consists principally of papers Piesteritz nitrogen plant in arc
furnaces. The liquid flux was and reduced the tendency to
describing the applications of weld-
passed over water-cooled copper cracking.
ing and cutting to chemical ap- 3. A comparison was made of the
paratus, steam turbines and build- rolls, then sieved. It contains 45
46 SiO., 19-21 CaO, 17-19 MnO, power required to cause grain re-
ings. In tank and boiler fabrica-
6-7 MgO, 1.5-2.0 Al,O;, 5-6 CaF.,, finement by ultrasonic vibration in
tion the practical rate of deposit-
and is supplied in two meshes 0.008- submerged-arc and electroslag weld-
ing metal increases from 0.8 lb/hr
0.071 in. and 0.016-0.079 in. The ing of stainless steel, mild steel
for covered electrodes to 5.5 for
finer mesh is used for automatic and bronze at 10 to 50 ke. Elec-
submerged arc and CO,, to 25
welding of plain carbon structural troslag welding required 2 to 3 kw
75 lb/hr for electroslag welding. compared with only 1 kw for sub-
In October 1959 a conference was and boiler steels with 1% Mn wire.
The coarser mesh is for semi- merged-arc welding. The vibrations
held in Leipzig on the possibility were imparted to the consumable
of increasing the application of automatic work with rimmed steel
wire. The flux is applicable up to electrodes, thence to the weld
rimmed steel in welded construc-
1000 amp dc and, the slag is difficult puddle.
tion. Rimmed steel is more widely 4. The hot cracking of aluminum-
used in USA and Hungary than in to remove in fillet welds.
Sheet No. 110 compares Czech zine alloys (5% Zn) in the fusion
East Germany which has limited
and Hungarian low-hydrogen elec- zone of gas welds was related to
capacity for producing killed steel.
trodes with the domestic types, the the appearance of an intergranular
Killed steel costs 14 marks (about phase. Preliminary cold working
$3) more per ton than rimmed steel. latter being in short supply. The
Hungarian is equivalent to the of the zone to be partially fused
However, East German codes for-
East German, but the Czech elec- during welding was believed to be
bid rimmed steel for Class I con-
trode has lower strength. All three more effective in preventing crack-
struction, and allows its use for
electrodes must be dried 2 hr at 480 ing than addition of 0.1% Ti to
Dr. GERARD E. CLAUSSEN is associated with to 570° F before use to avoid the alloy.
Arcrétis Corporation, Sparrows Point, Md porosity. 5. The quality of seam welds in

1208 | DECEMBER 1960

 Fou jobs where only the best will do—

NEW GLENN Vigcc

CONSTANT VOLTAGE

POWER SUPPLIES

for all consummable-electrode automatic and

semi-automatic welding processes, including:

MIG - SHORT ARC

SUBMERGED ARC - MAGNETIC FLUX

New GLENN V/S power supplies are totally new from basic trans-
former design to their exclusive new linear siope control. They can
be precisely “tuned” to the exact arc characteristics needed to
produce any type of metal transfer and deposition desired. The
result is improved weld quality, appearance, speed and economy.

Baaic features

NEW TRANSFORMER DESIGN increases efficiency,

improves voltage regulation and minimizes effects
of line voltage fluctuations.

STEPLESS VERNIER SLOPE CONTROL provides con-

tinuous linear slope control from flat no-slope to
maximum slope; in two overlapping ranges.

EXTENDED OUTPUT VERNIER VOLTAGE RANGE pro-

vides effective dc welding (loaded) voltages from
approximately 8 to 42 volts, depending on slope
settings.

«6GLENN PACIFIC
comecses ,
POWER SUPPLY CORPORATION
quality, uniformity and appearance must be kept
hich. you'll be hours and dollars ahead to specify 703-37th Avenue + Oakiand 1, California
GLENN V/S power supplies. Why not get the Originators of CV Power Supplies
facts? Write us today for literature, specifications Eastern Office Midwestern Office
please address Dept. 138. 221 Dukes Rd., Rahway, N. J. 640 So. York, Eimhurst, ti!

%* GLENN Balanced Wave Power Supply for TIG Welding & GLENN Manual
and Stud Welder Power Supply % GLENN Arc Gouger Power Supply > GLENN
Constant Potential Welder for “Gang” Manual Welding % GLENN Industrial
Power Supplies and Heavy Duty Variable Voltage Transformers

For details, circle No. 4 on Reader Information Card

WELDING JOURNAL | 1209
Type 321 stainless-steel sheets 0.018 to the flux to insure transfer of sheet 0.08 in. thick with a slit 2
in. thick was found to depend pri- 0.12% Ti to the deposit. in. long perpendicular to the bend.
marily on energy input and time of 9. Electroslag welding has been The metal inert-gas process was
welding. The welds were made at a applied successfully to rail joints. used to weld the slit. The results
roller speed of 18 ipm. Joint re- 10. Accelerated corrosion tests of a crack test, thermal analysis
sistivity did not provide a safe in nitric acid were made on sub- of weld metal compositions, and
criterion for quality control. merged-are welds in aluminum ! metallographic examination showed
6. The equivalent resistance of in. thick made at 250 amp, 30 v, that the best commercial alloys
the material between the jaws of a 13 ipm. The weld corroded more for this welding were Al + 7 Mg,
flash welder during welding was rapidly than base metal. and Al + 8 Si. Both provided
found to depend not so much on the 11. A tractor for vertical welding sufficient alpha-Si-Mg.Si_ eutectic
size and specific resistance of the features a continuous chain of to minimize cracking. The pre-
parts to be welded, but on a num- magnets to climb vertically up- ferred base metal composition was
ber of thermal properties of the ward. <0.05 Cu, <0.2 Mn, >1.0 Meg,
material, the value of the secondary <0.3 Si, <0.3 Fe, 4.5 Zn, 0.1 Cr,
voltage of the transformer, the in- 0.1 Ti + B. Tensile strength
ductance of the machine and the SWITZERLAND over 43,000 psi was secured with
speed of fusion. Two Swiss standards on spot- the above electrodes and _ base
7. As the amperage was increased welding aluminum and its alloys metal.
from 1200 to 1800 in electroslag are reproduced in the March 1960 2. The views of a Swedish pro-
deposition of steel with steel elec- issue of Journal de la Soudure. ducer of stainless steel on welding
trodes 1° ,;, to 2°’, in. diam and The weldability standard defines problems coincide with American
CaQO-CaF.-Al.O; flux, the volume spot weldability and tabulates the experience. Ferrite must be pres-
of the molten bath increased from ent to prevent cracking. If, as in
degree of weldability of 16 stand-
6 to 16 cu in., and the bath depth ard aluminum alloys with each Type 310, ferrite cannot be pres-
increased from 1'/, to 2'/, in. The other. The standard on prepara- ent, then silicon and phosphorus
copper crucible was 4 in. diam. tion and execution of spot welds must be as low as possible.
With graphite electrodes the vol- specifies electrode designs, machine 3. A general review is given of the
ume of the bath of metal was only settings and minimum spacing of application of metallography to
20°;, of the bath volume with steel welds. Cleaning procedures _in- welds and heat-affected zones in
electrodes. clude steel wire brushing, pickling steel. The TTT and continuous
8. Cavitation damage of hydro- in NAF-HNO,-H,SO, solution, transformation diagrams for 1.0
electric turbine vanes weighing 22 and pickling in K,Cr.0O;-HNO, Cr—0.5 Mo steel with 0.16 C
tons was repaired by submerged- solution. are used to explain the presence of
arc welding using stainless steel martensite without preheat.
Type 321 strip as consumable 4. A new German standard for
electrode. The strip was 0.006 WEST GERMANY seam welder wheels (DIN 44754)
to 0.016 in. thick, 2°, in. wide, provides for four materials ranging
and was deposited at 750 amp. The West German magazine in conductivity and Vickers hard-
No cracks were observed, provided Schweissen und Schneiden contains ness from copper at 97° and 85
the ratio of Cr to Ni in the deposit the following articles in its Feb- Vickers to a material at 45°% and
did not fall below 190. The AN26 ruary 1960 issue: 180 Vickers, respectively. The
flux contained 32.4 SiO., 21.4 Al.Os, 1. The hot cracking tendency dimensions of the wheels are
8.1 CaO, 15.9 MgO, 4.0 MnO, of aluminum containing 4.5 Zn, standardized.
14.1 CaF,. An addition of 2.5 1.2 Mg, 0.5 Mn, 0.4 Si, 0.5 Fe,
to 3°, aluminum metal was made 0.01 Cu was evaluated by a bent The repair of cracked necks 11.5
in. diam of rolling mill rolls of steel
containing 1.3 C, 0.48 Si, 0.46
Mn, 2.08 Cr, 0.68 W, 0.13 Ni is
RUMANIA described in the February 1960
issue of ‘‘Der Pratiker,’’ the supple-
ment of the West German
Schweissen und Schneiden. The
cracks were flame gouged to produce
a circumferential groove 3.2 in. deep,
2.2 in. wide. An electrode con-
taining 0.08 C, 1.25 Si, 0.40 Mn,
10.0 Cr, 11.0 Ni, 2.6 Mo, 1.0 Ta +
Cb with lime coating was used to
fill the groove to within */; in. of
the top. The sides of the groove
were also buttered to the top. The
remainder of the groove was filled
with a low-hydrogen electrode con-
taining 0.10 C, 0.32 Si, 0.54 Mn,
2.2 Cr, 1.0 Mo. The roll was
maintained at 840° F throughout
the job, and the austenitic weld
metal was peened lightly. The
roll was cooled to 175° F over a
period of 72 hr, and was then heat
Welding shop for large fabrication Courtesy 11W) treated.

1210 | DECEMBER 1960

 NEW FEEDBACK CONTROL

makes every weld count

Now, with the new Monautronic

C ff N V-2 welding control, you can
rat 4 make consistently top-quality
welds over long stretches of time,
without stopping to test and inspect sample
welds. The control senses variations in line
voltage, electrode shape and tip force,
material thickness and surface finish . . . and
compensates for them immediately.

The Monautronic V-2 automatically com-

pares actual voltage across the weld with
command voltage, and adjusts current
accordingly to maintain voltage—and weld
quality—at a constant level. If weld resist-
ance is too high or too low to produce a
good weld, the control locks out until the
condition is corrected.

Although the Monautronic V-2 embodies

the latest advances in computer-type cir-
cuitry, it is quite simple to operate, and
easier to maintain than most conventional
controls. For complete details, contact
are ‘ THE BUDD COMPANY, Electronic Con-
tei yp eg tha iy ponte scanamtaneoagesccph spriender ee trols Section, Philadelphia 32, Pa., oF Cae
for single spot, roll spot and seam welding. of our regional offices.

Here’s a typical example of how Monautronic

Welding Controls pay off. The part at the left is
fastened by butt welding a piece of square cut mill
bar stock to the side of a section of thick-walled
tubular stock. With conventional control, 100%
inspection at 8000 pounds pull revealed that
approximately 5% of the assemblies ended up in the
scrap pile. With Monautronic Controls, failures were
cut to less than 14 of 1%. The few times failures
did occur, the Monautronic Control locked out auto-
matically indicating a low quality weld. The piece
at the left failed at 14,000 pounds. Notice that the
nugget is almost as large in diameter as the bar stock.

2450 Hunting Park Ave. 1515 N. Harlem Ave.

Philadelphia 32, Pa. Oak Park, Ill. ciecTRonic I BD y A yA

beth een Io aslo 3, Ga. HB

DEMEMED conseas
For details, circle No. 5 on Reader Information Card
WELDING JOURNAL 1211
 Lewis Welding & Engineering Company of Bedford, Ohio, welded this annulus for
Clark Bros. Co. of Olean, New York, producers of industrial gas turbine engines.

Here’s a dissimilar alloy weld

that’s reliable above 1000° F...

When this liner for an industrial gas dissimilar alloy combinations, is equally
turbine annulus is hooked up to a com- remarkable for its ability to provide
bustion chamber, it will face tempera- dissimilar alloy joints capable of long-
tures over 1000°F. That’s how hot its term resistance to heat and corrosion.
metal surfaces get when they channel
Operability is excellent
high temperature combustion gases to-
With Inco-Weld “A” Electrode it’s easy
ward whirling turbine blades.
to produce ductile X-ray quality welds.
The welding of these dissimilar alloy
You can weld in all positions, the arc is
parts, one heavy, the other light, be-
spray-type, slag removal is good, and
comes really important when operating
spatter is at a minimum.
conditions are considered. Shutdowns
are rare in industrial gas turbine ser- Inco-Weld “A” Electrode is supplied
vice, and welds must last for years. But in 3/32, 1/8, 5/32 and 3/16 inch diam-
the Inco-Weld* “A” Electrodes used eters, packed in 5-lb sealed asphalt-
here eliminate the possibility of weld lined containers for convenience and
failure. protection.
No heat problems Plan to use Inco-Weld “A” Electrode
Combustion chamber liner is made of In-
That’s because the Inco-Weld “A” de- the next time you weld dissimilar alloys. conel* nickel-chromium alloy and other
posit is both ductile and strong. In all For information on the weld properties high temperature alloys, production welded
likely combinations, it is compatible you can expect, write for our 6-page with Inco-Weld “A” Electrodes.
with high-temperature-type base metals. brochure, “Now You Can Weld 97% HUNTINGTON ALLOY PRODUCTS DIVISION
Inco-Weld “A” Electrode, remark- of All Dissimilar Alloy Combinations The International Nickel Company, Inc.
able for its ability to weld 97% of all with One Electrode.” *Inco trademark Huntington 17, West Virginia

4
INC O, WELD
fl": ING PRODUCTS
electrodes * wires * fluxes
TRADE MARK
For details, circle Ne. 6 on Reader Information Card
1212 | DECEMBER 1960
 Shielding Gases—and How They Grew

The fact that welding industry sales have construction appears to be a coming word in
recently passed the billion dollar mark can be the lexicon of the automobile builders. Every-
attributed largely to the industry’s strong em- thing from air-conditioning units and children’s
phasis on research and development —particu- swings to electrical power stations and nuclear
larly in the development of new processes using ships can be joined with one or more of the gas-
shielding gas. We in the welding industry can shielded arc welding processes.
be proud that the number of basic innovations The use of argon, helium, nitrogen and carbon
in techniques, equipment and materials have dioxide to shield the welding arc in the manu-
made important contributions to the success facture of thousands of industrial products is
and progress of many other major industries. opening up new areas for the welding industry
For example, look at the benefits accruing be- that were virtually unexplored a few years back.
cause of modern gas-shielded welding techniques. The protection against impurities during the
Today, shields of argon, helium and carbon welding process afforded by these gases has been
dioxide permit the almost routine welding of extended to the protection of many products,
aluminum, stainless steel and other “once themselves.
upon a time”’ problem materials. The same gases It is interesting to note that the same indus-
permit welding of many of the new “exotic tries that use industrial gases in welding have
metals” —columbium, rhenium, hafnium, etc. also learned to use them for many other shield-
whose names we had hardly heard of a few years ing and protective applications—for example,
ago. for electronic, food and chemical products.
What do these capabilities mean to other in- Industry after industry is being helped to ex-
dustries? To the missile and rocket builders, pand its markets and to improve its product
gas-shielded arc welding obviously means ef- through the use of these industrial gases. The
fective joining of space-age materials. They entire industrial complex is becoming increasingly
have used it to weld the orange peel sections of aware not only of the benefits of gas-shielded
the Titan ICBM, component parts of the Bo- welding but also of the advantages and ver-
marc interceptor, pressure vessels in the Atlas, satility of industrial gases, themselves. The
and all of the welding of titanium and Inconel X welding industry deserves a great deal of credit
for the first manned space craft to come off the for helping to pave the way to these advances in
production line—the X-15. our nation’s economy and technology.
In more prosaic areas, “‘unibody”’ (all-welded

R. E. Lenhard

PRESIDENT
AIR REDUCTION SALES CO.

Weldir

JO
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100% duty cycle. Ample open circuit voltage gives superior
GASOLINE ENGINE- results with a-c, d-c or a-c/d-c electrodes.
METALLIC INERT GAS WELDING. Using the d-c side of
the AD-225-L, and with new style hand guns feeding small
DRIVEN AC/DC diameter wire from spools, aluminum, mild or stainless steel
may be welded by the MIG process. Power for the gun is pro-
WELDER/POWER vided by the 115 volt d-c outlet.
A-C POWER PLANT. As an a-c power plant, this model
PLA NT produces 7 KW of 115/230v single phase 60 cycle current. In
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AUXILIARY D-C POWER. While welding, the AD-225-L
delivers 1 KW of 115v d-c which is ample for operation of
flood lights, power tools, etc. Other uses to which this versa-
tile model has been put most successfully include thawing of
frozen water pipes, warming of viscous fluid for pumping,
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Distributed in Canada by Canadian Liquid Air Co., Ltd, Montreal « EXPORT OFFICE: 250 West 57th St., New York 19, N. Y

For details, circle No. 7 on Reader Information Card

1214 | DECEMBER 1960
 Every weld is X-rayed and statistical

quality-control charts are used during

Evaluation of Weld Quality

ona

Submarine

Pipe Line

BY PAUL W. TURNER

ABSTRACT. This paper describes the inspection of weld-

ing on a submarine pipe line built in Iran for crude oil
service. Inspection was conducted in accordance with
the requirements of API Std. 1104, Standard for Field
Welding of Pipe Lines, 5th ed.
The design requirement and method used to install the
line are mentioned. The welding and radiography pro-
cedures, the method used to qualify welders for overseas
employment and the measures used to controi weld
quality are presented in detail.
Every weld was X-rayed. The control chart method
of analysis was used to maintain statistical control of
quality.
The various types of defects are discussed with respect
to their tendencies to occur at certain welding positions
and in particular weld beads.
The results indicated that high-quality welds were
made with the conventional procedures and techniques
employed by the pipe-line construction industry
Introduction
This paper covers the inspection of welding on a
30-in. diam submarine pipe line that is reputed to be
the longest one of its type ever built. This pipe line
is part of a 100 mile gravity-flow trunk line extending
from the Gach-Saran oil fields of southern Iran to a
crude oil loading terminal located 25 miles out in the
Persian Gulf on Kharg Island.
Except for being underwater, a submarine line is
similar to a land line. Special precautions, however,
must be taken to assure that conditions imposed by
the water environment and stresses inherent in the
method of installation do not cause failure. The
use of high-quality materials and ‘‘100% inspection”
of welds is specified because of the consequence of
failure during construction or in service.
In this paper, a brief description of design and
method of installation is presented first. Next,
View of submarine pipe line being pulled into the Persian
Gulf showing pulling barge in the background and PAUL W. TURNER is a Welding Engineer, [ranian Oil Exploration &
placement of temporary weights in the foreground Producing Co., Teheran, Iran

WELDING JOURNAL | 1215

 »
Fig. 1—Launchway and fabricated strings of 30-in OD pipe

those methods which were used to maintain quality

control are covered and will be followed by a dis-
cussion of the different types of defects that were
revealed by radiographic examination.

Design and Installation

The submarine line was designed to operate at
840 psig with a crude oil through-put of 330,000
bbl per day. It was built of seamless pipe made to
API Std. 5LX42 specification by a European manu-
facturer.
Pipe was welded into 4000-ft strings by the so-
called stove-pipe method and was coated and
wrapped with bitumen and fiber glass to protect it
from corrosion. Next, it was sheathed with rein-
forced concrete to provide a weight-in-water of 5 lb
per linear ft. The concrete also protected the pipe
line from marine borers and against abrasion during
launching. The total dead weight of the line in
water was approximately 500,000 Ib. A_ general
layout of the fabricated strings can be seen in Fig. 1.
The friction-transposition method was used to
launch the line—that is, the pipe was pulled along
the bottom of the sea to its destination. A barge
¥ equipped with a twin-drummed winch having a
; 1,000,000-lb capacity was used to pull the line across
Fig. 2—Welding station and a string being the gulf. A welding station was set up as shown in
aligned to one already pulled into the water Fig. 2 for joining one string to another as the line was
pulled into the water. Rubber-tired dollies, also
3C 70 35 Dé. visible in Fig. 2 were used to roll each string off the
shore. The pipe line, weighing considerably less
in water than in air, was dragged along the bottom
of the gulf with a pulling force ranging from 50,000
to 500,000 Ib.

Welding Procedure Specification

Before welding was commenced on the line, a
pipe joint welding procedure test was conducted to
prove the weldability of the pipe and the suitability
of materials, equipment, and methods. This test
was qualified in accordance with the requirements
of Par. 1.412 of Reference 1. The qualified pro-
cedure was recorded in detail and was adhered to
during construction. Herewith are the details of the
Fig. 3—Joint design procedure specification:

1216 | DECEMBER 1960

 1. Welding shall be done manually by the 10. At least two welders shall be used, working
shielded metal arc process. simultaneously and in opposite quarters of the pipe
2. Pipe material shall consist of seamless pipe to weld root beads. The number of second-bead
manufactured to API Std. 5LX42 with 30 in. OD welders shall be such that the second bead is com-
and 0.5 in. wall thickness. pleted within 15 min after the root bead is completed.
3. Filler metal shall comply with the require- 11. Hammering of pipe to obtain proper align-
ments of AWS-ASTM Specification for Iron and ment shall be held to a minimum. Heads of ham-
Steel Arc-Welding Electrodes. mers shall be built up with brass and maintained in
4. All welding shall be done in the horizontal- a soft, annealed condition.
fixed position with the pipe resting on skids so that 12. Welds shall be identified by marking with
the clearance around the pipe is not less than 16 in. a crayon having a noncorrosive base.
5. Joints shall be prepared by machine oxygen
cutting and grinding. Surfaces shall be smooth and Qualification of Welders
free of rust, scale and other foreign matter. Since each weld on the line was examined by radi-
ography, qualification of welders was not a great
problem. It was realized that welders who could
not follow the welding procedure would be discov-
ered very quickly in any case.
Testing was important, however, from the stand-
point of recruiting. It would have been rather
expensive to send unqualified welders halfway around
the world to find that their work did not comply
with field requirements. Consequently, welders
were tested before leaving their country of origin
Great Britain or USA) unless they could provide
test certificates indicating they had been recently
employed on a pipe-line project.
As soon as a new welder arrived in Iran, he was
required to make another test weld on the line.
After his test weld was X-rayed and approved, he
was allowed to continue as a qualified welder.

Radiography
Fig. 4—Radiography team with welders in background Two portable X-ray machines, rated at 170 kvp,
were operated close behind the welders. The ob-
6. The direction of welding shall be vertical jective was to discover and to control any adverse
down. trend in weld quality before it caused the rejection
7. Joint design is illustrated in Fig. 3. The of a large number of welds.
diameter of electrode for each bead and the range The radiographic procedure was set up to provide
of voltage and amperage values during welding of speed as well as good radiographs. High-speed
each bead are shown in Table 1. 17 x 3',.-in., film was sandwiched between calcium-
8. Internal electro-hydraulic line-up clamps shall tungstate intensifying screens and shielded from
be used whenever practical. External line-up back scatter by a 0.010-in. lead-foil screen. Six
clamps shall be used on tie-ins. films were positioned on each joint as shown in Table
9. Line-up clamps shall not be removed or loos- 2, but not more than two were exposed at a time.
ened until at least 50° of the root bead is completed This arrangement provided an overlap of about
in segments equidistant around the circumference 1 in. per film and a diagnostic film length of 32 in.
of the pipe. maximum. The double-wall exposure technique
as set up in Fig. 4 was employed.
The radiographs illustrated herein are representa-
Table 1—Number of Beads and Specifications tive of the lot. Films were exposed so that the
Bead Electrode Electrode Arc average density was not less than 1 Typical
No.* class size, in. Amperage volts exposure and processing conditions are shown below:
Root £6010 150-190 28-34
2 E7010 150-190 28-34 Exposure, ma at 1 min and 150 kvp 5
Source-to-film-distance, in 34
3-7 E7010 140-190 32-36 Development, min at 70° F 4
8 E7010 or 140-190 32-36 Fixing, min at 70° F 4
E6010 Washing, min manual agitation 20
* Each bead was welded completely around the pipe before a At least one radiograph of each weld bore the
successive one was commenced.
Measured at the machine terminals, cable length and size image of an ASME-type penetrameter having a
250 ft and 2/0. thickness of 2% of the wall thickness of the pipe.
NOTE: Extra ‘‘stripper beads’’ may be required at the 2-4 o'clock
position. The densities of the other five radiographs were

WELDING JOURNAL |} 1217

 economically feasible to find. The number of de-
Table 2—Location of Films with Respect to
Position of Welding fects attributable to chance was considered a measure
of the optimum performance of the welding organiza-
Identification Position by tion. Defects in excess of this number signified
of film clock notation
trouble and indicated that welding was out of sta-
5-7
7-9 tistical control.
9-11 Structure of Control Chart
11-1
1-3 The control chart method was used to analyze
3-5 daily batches of radiographs to determine whether
welding conditions were normal.
In developing the chart, it was convenient to
required to compare favorably with the one showing define a defective as a single radiograph showing at
the image of the penetrameter. least one weld defect. For the definitions and limi-
The penetrameter was located on the film side of tations of defects see Reference 1.
the pipe. A test made at the commencement of the The fraction defective for the first 955 welds was
job (with one penetrameter on the source side and adopted as a standard. Seventy-nine of the 5730
another on the film side) indicated that either loca- radiographs of these welds were classed as defectives.
tion was suitable for this work. The value of the standard was fixed at 0.011. It
A welding inspector of the client and a radi- should be noted that data believed to be out of con-
ographer of the contractor jointly interpreted each trol (15 of the 79 radiographs) were arbitrarily omit-
radiograph. In turn, the client’s welding engineer ted from the computation used to arrive at this
made supervisory checks to assure that their inter- standard. On the control chart (Fig. 5) the stand-
pretations conformed with the requirements of ard is represented by the central line.
Part II of Reference 1. Thereafter, the welding organization was ex-
pected to maintain this standard within the limits
Statistical Control
of three standard deviations. The following rela-
Obviously, every weld was not a good one. Some tionship was used to compute these control limits
had borderline defects; others had major defects for the chart:
that were removed at extra cost to comply with
Control limits for p = p + 34/)(1 — p)/n
requirements of specifications. A certain number
of defects occurred by chance. Such defects were where p and p were the daily fraction defective and
tolerated because the factors causing them were not the adopted standard, respectively, and n was valued

ae Rilelt
tS <cdiscaes
oe aneet |_
“a,
> 0.02

ul +r
DEFECTS
WELD
SHOWING
ui
° rere | yyA
38 40 70
BATCH NUMBER

RADIOGRAPHS
OF
FRACTION

110
BATCH NUMBER
Fig. 5—Control chart for fraction of radiographs showing weld defects

1218 | DECEMBER 1960

Fig. 6—Porosity due to improper Fig. 8—Root-bead defects caused
operation of a welding machine by poor welding technique

7 OD
Fig. 7—Slag inclusions resulting from
inadequate cleaning of successive beads Fig. 9—Inadequate penetration at the downhand position

at 330 when the number of radiographs in a batch

was greater than 260 and at 220 whenever the num-
ber was less than 260. These values of nwerechosen
arbitrarily to avoid the task of recalculating control
limits on each occasion that the size of a batch varied.
Since the sizes of batches ranged from 140 to 420
radiographs per day, the control limit error, due to
this arbitrary selection of values for n, never ex Fig. 10—Aggregates of small burn-through
areas at the 9-11 o'clock welding position
ceeded 0.005.
Use of Control Chart
Each day the chart was used to analyze the weld-
ing completed on the previous day. A fraction and filling the joint with fewer beads than designated
defective with a value exceeding the control limit in the procedure specification.
was a sign of trouble. The batch numbers denoting 4. Batches 79 to 82. During the absence of the
the times that trouble developed can be seen on the two regular root-bead welders, eleven welds were
chart, and what happened during these times may rejected mainly because of defects in the root beads.
be explained as follows: Figure 8 illustrates defects that were typical in this
1. Batches 46 and 47. Heavy porosity (Fig. 6 case. One of the two replacement welders was trans-
began to appear in radiographs of welds made by one ferred to other work.
welder. He attributed the cause to improper func- 5. Batch 89. Figure 9 shows inadequate pene-
tioning of his welding machine. The machine was tration that occurred when alignment procedure and
replaced. welding sequence for applying the root bead were
2. Batches 56 and 57. Seven welds were re- not followed.
jected in two days. There were 13 defectives, all 6. Batches 94 and 103. In Fig. 10 it can be seen
due to burn-through areas at the 7-11 o’clock posi- that burn-through areas occurred at the vertical
tion. The root-bead welder working at that position welding positions. Control was restored by in-
was instructed to be sure that bevels were cleaned creasing the width of the root gap and by assuring
properly and that root gaps were adjusted carefully that bevels were clean prior to applying the root
before welding. bead.
3. Batches 62 and 64. Slag inclusions as shown Also, the chart was used to check variations in the
in Fig. 7 began to appear when six new welders were interpretation of radiographs. For example, it was
employed. The inspector advised them about weld- considered improbable to have long periods without
ing procedure details, especially cleaning weld beads. defectives. Consequently, as periods without de-
One of them continued to produce defective work. fectives became extended, supervisory checks were
He was discharged for welding over uncleaned beads made more frequently than usual to assure that

WELDING JOURNAL | 1219

 radiographs were interpreted in accordance with the the root bead. Most of them probably were made
acceptability standard. ' as the root bead was applied. It is reasonable to
On the other hand, specific causes for defective assume, however, that some of the burn-through
work could not be found while the chart showed areas were made by welders who applied the second
control. This knowledge resulted in a saving of bead. It is not intended to put all the blame on
inspection time. Hours were not spent in hunting the root-bead welder. Nevertheless, the results are
nonexistent trouble. In addition, it assured every- conclusive enough to justify much closer supervision
one in a quantitative way that weld quality was the and inspection during pipe alignment and root-bead
best that could be economically obtained. welding than at any other stage of welding.
The fraction defective for the entire lot of welds Inadequate penetration and incomplete fusion
was 0.012. This value compares well with the occurred with such frequency at the 11-1 o’clock
standard used on the control chart. It is a standard position that both should be considered characteris-
with which any welding organization using similar tic top-of-the-pipe defects. The repeated occurrence
procedures should be able to work. of these defects at this position was related to the
alignment procedure and welding sequence of the
Type, Frequency and Location of Defects
root bead.
Table 3 shows the frequency of defects with ref- Whenever the pipe was lowered to the skids and
erence to welds and radiographs. The average the tension of the line-up clamps was released before
number of defectives per rejected weld was 2.6. enough of the root bead was completed at the 12
The types of defects encountered were slag inclusions, o’clock position, the moment developed at the joint
porosity, burn-through areas, incomplete fusion, tended to close the root gap and misalign the in-
inadequate penetration, undercutting and lack of ternal surfaces at the top of the pipe.
reinforcement. The limitations of these disconti- Aggregates of small burn-through areas tended
nuities are as defined in Reference 1. to occur at the 1-5 and 7-11 o’clock positions. This
Each type of defect was characteristic of a certain type of burn-through area is shown in Fig. 10. It
section of the weld and a particular welding position. has a characteristic shape like a small arrow pointing
A summary of all defectives is arranged in Table 4 in the direction opposite that of weld progression.
to show the frequency and location of each type of These arrow-shaped holes appeared on the internal
defect with respect to position and weld bead. side of the root bead and did not penetrate all the
Root-bead Defects way through the bead. Hence, these defects could
Approximately 70% of all defectives occurred in not be detected from the outside of the pipe. The
causes of this type of defect appeared to be improper
cleaning of bevels and insufficient root gap. These
Table 3—Disposition of Defective Work conditions produced internal piping cavities as the
No. with bead solidified. It is noteworthy that this defect
weld caused more rejections than any other type.
Total defects Repaired Cut-out Rejection,% Individual burn-through areas (Fig. 11) were
Welds 4,550 125 91 34 2.7 found more often at 5-7 o’clock than at other posi-
Radio-
graphs 27,300 329 iad ie 1.2 tions. The frequency of this type of defect at that
location can be attributed to the difficulty of making

Table 4—Analysis of Defects Showing the Frequency and Location of Each Type with Respect to Welding Position
Film positiona
Location Type” C D Total Total, %
Root bead IBT 1 54
ABT 45 1 138
IF 1 8 16
IP 21 24
31 232
Filler beads ISI 3 35
LSI
P

Finish bead EU pe—

LR

Total |bt
ee
=>—™Bla)
E> |;al
oust) w

*See Table 2 for welding position with respect to film position.

“1BT, individual burn-through area; ABT, aggregate of small burn-through areas; IF, incomplete fusion; IP, inadequate pene-
tration; ISI, isolated slag inclusion; LSI, linear slag inclusion; P, porosity; EU, external undercut; LR, low reinforcement.)

1220 | DECEMBER 1960

 After the line was pulled into the sea, it was sub-
jected to another hydrostatic test. This time the
line began to leak when the pressure reached 860
psig. ‘The leak was found about 9 miles off shore
in 83 ft of water. It was due to a circumferential
crack in a buckle 14 ft from the nearest weld.
The damaged section was raised to the surface,
cut from the line and replaced. Then, the repaired
@ 138A line was retested at 920 psig (110% of working pres-
Fig. 11—Individual burn-through area at the sure) for 24 hr. Before the line was commissioned,
overhead welding position a sizing disk was put through it again to make sure
that further damage had not occurred during the
the junction of the root bead at the 6 o’clock posi- pulling operation.
tion.
Filler-bead Defects Conclusions
About one-fourth of all defectives was due to 1. All welds on the pipe were X-rayed. It was
slag inclusions and porosity in the filler and second found that 125 of 4550 welds contained defects.
beads. These defects prevailed at the 3—9 o’clock The fraction of radiographs showing weld defects
segment of the weld. Some of the causes were (fraction defective) was 0.012.
faulty welding technique, inadequate cleaning of 2. It was found that 70% of all defectives oc-
weld beads, electrode covering with insufficient mois- curred in root beads, 28% in filler and second beads
ture and improper functioning of welding machines. and 2% in finish beads.
3. The type of defect occurring most frequently
External Defects was the burn-through area, particularly aggregates
There are only a few defectives due to undercutting of small areas at the 1-5 and 7-11 o’clock positions.
and low reinforcement. All of them, except a single 4. There was a tendency for other types of de-
case, occurred at the overhead position (5—7 o’clock) fects to occur at preferred locations. Isolated slag
These defects were caused primarily by poor welding inclusions, individual burn-through areas and de-
technique. fects in finish beads were found more often at the
overhead welding position than elsewhere. Inade-
Repair or Removal of Defects
quate penetration and incomplete fusion occurred
Whenever possible, repairs of defects in root with significant frequency only at the flat position.
beads were carried out by a welder who entered the 5. The over-all results indicated that high-
pipe on a garage-type trolley and applied a sealing quality welds were obtained with the conventional
bead. Access was usually made by cutting a re- welding procedures and techniques employed by
jected weld from the line. The maximum distance the pipe-line construction industry.
entered in this way was 900 ft. Insulated electrode
holders were used to guard against arcing the in- Acknowledgments
terior of the pipe. By utilizing this method it was The author acknowledges the work of R. M. Brown
possible to repair many welds that otherwise would of Welding Supervision Ltd., who interpreted radio-
have been cut out. graphs and the helpful suggestions of R. A. Peterson
Deep gouging and local repair of internal defects of Frederic R. Harris Corp., D. C. Smith of Gulf
were not authorized, since it was decided that locked- Oil Corp. and A. J. DiGennaro of the Standard
up stresses resulting from such repairs might cause Oil Co. (N. J.).
failure. Consequently, welds having deep internal Also, he expresses his appreciation to F. A. Mali-
defects were cut from the line and replaced. phant of the British Petroleum Co. Ltd. and N. M.
W. Vermeulen of Royal Dutch Shell for their counsel
Pressure Tests and guidance during the course of this work.
Each 4000-ft string of pipe was tested at 1260 psig He is grateful to the International Marine Con-
(90% of yield strength) with fresh water. This structors for supplying the lead photograph and
pressure was held for 3 hr. All welds and piping Figs. 1 to 3 and to the Iranian Oil Exploration and
were visually examined for leaks. All strings with- Producing Co. for granting permission to publish
stood the test without leakage. this paper.
In addition to this test, a sizing disk having a
1/, in. clearance was forced through each string to References
1. “Standard for Field Welding of Pipe Lines,’’ API Standard 1104
assure that obstructions such as buckles, excessive 5th edition (May 1958).
root penetration and loose objects were not in the 2. “ASTM Manual on Quality Control of Materials,’’ prepared by
ASTM Committee E-11, published by American Society for Testing
line. Materials (January 1951).

WELDING JOURNAL | i221

 1220 | DECEMBER 1960

Equipment for gas-shielded cladding features a welding barrel oscillator and wire feed on a welding manipulator

New Techniques for Cladding

with the Gas Shielded Process

produce high-quality overlays of stainless steel, nickel or copper base alloys

BY RALPH D. ENGEL

Fusion cladding of carbon and alloy steels to improve freedom in forming and stress relieving practices is
the corrosion wear and high-temperature properties enjoyed with these processes. In many instances,
of the base material has become established fab- large castings and forgings can be surfaced by fusion
ricating procedure. A vast area of application cladding to obtain corrosion and wear resistant prop-
exists for the fusion cladding of nuclear reactor shells, erties that could not be obtained in any other way.
steam generators, blast-furnace bells and hoppers, The variety of materials that can be applied by fu-
paper pulp digesters and various types of heavy sion cladding makes the process extremely versatile
industrial rolis. In most cases, the physical size of and broad in potential.
these parts makes the use of clad steel plate imprac-
tical from the standpoint of material cost and fab- History
rication procedures. The technique first employed for fusion cladding
Fusion cladding possesses some distinct advan- with the gas-shielded process was the stringer-bead
tages over the use of preclad material. Since fusion technique. This technique involved overlapping
cladding is usually applied after major forming and non-oscillating weld beads to form a continuous layer
fabrication operations have been completed, more of weld metal. In many instances, an auxiliary
cold filler wire was added to increase the weld metal
RALPH D. ENGEL is Project Engineer, Air Reduction Sales Co., deposition rate and to minimize dilution. The
Equipment Engineering and Development Department, Union, N. J
objection to this method is the characteristic deep
Paper presented at AWS 4lst Annual Meeting held in Los Angeles,
Calif., Apr. 25-29, 1960 papillary depression of the fusion line of each weld

1222 | DECEMBER 1960

 WELDING JOURNAL } 12221

Fig. 2-—Comparison of oscillation motion characteristics

in Fig. 2). The slope of the oscillation wave traces

in Fig. 2 indicates the relative oscillation velocity of
the electrode with respect to the workpiece. Ex-
amination of the sinusoidal motion patterns show
that, in each case, there is an inherent end-dwell of
the electrode at the bead edges. The effect of this
Fig. 1—The effect of oscillation motion inherent end-dwell is to increase the energy input
on weld bead penetration per inch_of weld in the localized area of the bead
edges.
To overcome oscillation end-dwell, a constant
bead (View A in Fig. 1 The deep depression of the velocity cam mechanism was developed to oscillate
fusion line into the base plate results in excessive the electrode. The motion pattern produced in this
dilution, which causes metallurgical difficulties. manner resembled an equilateral saw tooth wave
When subjected to side bend tests, the samples in- View C in Fig. 2). Examination of the motion
variably failed in the immediate area of the papillary pattern shows that there is no end-dwell at the bead
depression. edges. Constant velocity oscillation of the welding
In an effort to modify the characteristic pen- arcs, therefore, distributes the arc energy uni-
etration pattern obtained with the stringer bead formly over the entire bead width producing a uni-
technique, an oscillating technique employing cold form depth of penetration (View C in Fig. 1). It
wire addition was developed. This technique in- should be emphasized that the oscillation motion
volved oscillating the welding barrel as a sinusoidal characteristic and not the constant contact-tube-to-
pendulum with a cold wire positioner rigidly attached work distance feature of this process is the major
to the oscillating barrel. This procedure produced a factor in producing the uniform depth of penetration.
wider bead with less average dilution than was ob- The term “convelinear oscillation’”’ is used to refer
tained with the stringer bead technique. The ob- to the type of oscillation described above; this is
jections to the sinusoidal pendulum method of os- produced when the electrode is oscillated at constant
cillation with filler wire addition are: 1) the diffi- velocity while also maintaining a constant contact-
culty of adding a cold filler wire under an oscillating tube-to-work distance.
arc, (2) the continually changing arc length, (3) the
limited usable range of oscillation width, and (4 Oscillating Equipment
the localized areas of high dilution at the bead edges Special overlay equipment shown in the lead
which cause metallurgical difficulties (View B in photograph has been designed for cladding with the
Fig. 1 gas-shielded process. The equipment consists of
a welding barrel oscillator and wire feeding system
Oscillation Motion mounted on a welding manipulator. The oscillator
Overlay cross sections made with either a sinu- is capable of producing an oscillation motion that is
soidal pendulum-type electrode oscillator or a sin- convelinear or linear sinusoidal. (The term linear
usoidal linear horizontal type of electrode oscillator designates constant contact-tube-to-work-distance.
always exhibit deep localized penetration at the The oscillator also provides for a stepless range of
bead edges. With either type of motion, the os- oscillation width of '/; to 3-in. "Two welding barrels
cillation pattern traced on the workpiece by the are fixed to a sliding mount, which is oscillated by a
electrode is essentially a sine wave (Views A and B cam mechanism within the head. The electrode wire

WELDING JOURNAL | 1223

 1222 | DECEMBER 1960

is fed to the barrels by two standard welding heads electrically insulated from the barrel components,
mounted above the oscillator. The electrode wire which normally carry the welding current. The
can be fed from two large level wound coils or from guide tubes have been made in various lengths so
standard size spools or pay-off packs. that wire extensions up to 3 in. are possible. A
sketch of the new barrel is shown in Fig. 3.
Electrode Extensions An arc starting problem was encountered using
Conventional electrode extensions of '/; to */,-in. the specia! barrel. The wire during initial arc starting
used with d. c. reverse polarity current result in deep exploded (similar to an electrical fuse) just below the
penetration at relatively low deposition rates. Filler
wire additions to the weld pool have sometimes been
used to increase the deposition rate and reduce pen-
etration. The term “deposition rate’”’ refers to the
actual pounds of weld metal deposited per arc hour. || | +| |
Positioning problems associated with present eieeftooe|e XTENSION
methods of filler wire addition to an oscillating }_L]
arc necessitated a more practical solution. The — + +
solution was to take advantage of the effects of I°R STTANIUM STABILIZED
NICKEL) BA
heating of the electrode wire by lengthening the
a a
electrode extension. The term “electrode exten-
|Alryee 308 ELS
sion”’ refers to the distance from the end of the con- STAINLESB STEEL
tact tube to the work. A considerable increase in
deposition rate accompanied by an appreciable de-
crease in penetration was obtained in this way.
To take maximum advantage of resistance heating
of the electrode wire, electrode extensions up to 3-in.
were used. At these electrode extensions, it was +. +
necessary to guide the electrode below the contact
NOTE: ALL CURVES RUN RT 260 AMPS
tube to prevent wandering. A welding barrel was | |
designed with a water cooled copper guide tube + + + + + +
downstream of the contact tube. The guide tube is |

“1 De I% Pete 1% 1% Ie 2 2%
ELECTRODE EXTENSION IN INCHES
Fig. 4—Wire feed speed versus electrode extension
No | & No3 ARE for various '/\.-in. diam electrode wires
SHORT- CIRCUITED
THRU TIMER—
CONTROLLED WELD
CONTACTOR TO
START ARC.
‘0
SURRENT-CARRY!ING
WATER-COOLED
NNER BARREL

2
INSULATING SLEEVE

3
SURRENT-CARRY ING
OUTER WATER
JACKE T
6 300 AMPS
CONTACT TUBE
REPLACEABLE
COPPER MELT
RATE
OFF
HR
PER
LBS
IN
GUIDE TUBE
CERAMIC INSERT
WIRE
MINUTE
PER
INCHES
IN
SPEED
FEED 50 |
ok
1 th th 2 2% 2% 2%3 34 3% 3%
ELECTRODE EXTENSION IN INCHES
Fig. 5—Wire feed speed versus electrode
extension for */,-in. diam type 308 ELC stainless steel
Fig. 3—Extended electrode welding barrel electrode wire at 300, 350 and 400 amp

1224 | DECEMBER 1960

 WELUING JOURNAL | 1263

point of current pickup as the advancing wire made Arc length: '/, in.
contact with the plate. To overcome this problem, Shielding gas: Argon + 1% O, at 50 cfh/are.
the point of current pickup was moved to the guide Electrode wire: */3-in. diam/Type 308 ELC.
tube for initial arc starting. This, in effect, allows Weld bead thickness and edge contour.
the arc to be started with a short electrode extension
using the guide tube temporarily as a contact tube. The tests were divided into two separate groups.
Once the arc has been established, the point of cur- One group of tests was run at a traverse speed of
rent pickup is automatically switched from the guide 180 ipm, and the other group was run at a traverse
tube to the contact tube. speed of 270 ipm. The term “traverse speed”’ refers
Wire feed speed versus electrode extension data to the lateral surface speed of the arcs across the
were collected using the new extended electrode bead width measured in inches per minute. The
barrel. The data were collected by holding the cur- traverse speeds of 180 and 270 ipm are values that
rent and physical arc length constant and by pro- were obtained at oscillation rates of 60 and 90 cycles
gressively increasing the electrode extension from 1 per min respectively at an oscillation width of 1!
in. to a useable maximum. Data were taken with in. In both test groups the oscillation width was
several electrode wires using d. c. reverse polarity varied in '/,-in. increments from 1 to 2*/, in. The
current. Typical deposition rate versus electrode traverse speed for each group was maintained con-
extension curves for various '/\, in. diam wires are stant as the oscillation width was varied by adjusting
shown in Fig. 4. The effect of resistance heating on the oscillation rate. The term “oscillation rate”
3-in. diam Type 308 ELC stainless steel electrode refers to the number of cycles per minute that the
wire at several current levels is shown in Fig. 5. arc oscillates across the bead width. The forward
These curves show that the melt-off rate, at constant travel speed in these tests was considered as a de-
current, of various electrode wires can be increased pendent variable and was adjusted to maintain the
50 to 100% by resistance heating of the electrode arcs on the weld pool as the oscillation width was
wire. It also has been shown that, as the electrode varied. In order to show the effect of the test vari-
extension is increased at constant current, pene- ables on dilution, weld metal chips were taken for
tration is appreciably decreased. This fact is of chemical analysis from each test specimen at '/; in.
major importance, since it offers a practical method above the original plate surface.
of dilution control. The results of the tests are plotted in Fig.6. The
data show that as the oscillation width was increased
Physical Variables the percent chromium in the weld metal increased.
Tests were conducted to determine the effects of This indicates a decrease in dilution as the oscillation
oscillation width and oscillation rate on weld metal width was increased over the range tested. The
dilution. The following variables were held constant curves for the two test groups run at different trav-
during this series of dual-arc weld bead tests: erse speeds essentially coincide so that they appear
in Fig. 6 as one curve. The fact that the two curves
1. Welding current: 350 amp d-c reverse polarity.
coincide indicates that, within the range of traverse
2. Electrode extension: 2°/, in.
speed used, the oscillation rate had little or no effect
on dilution as detectable by the normal accuracy of
chemical analysis. The oscillation rates for each
oscillation width are shown in Fig. 6 for the two
traverse speeds used in these tests. It is not yet
known whether the hump in the curves at 2'/, in.
oscillation width has any particular significance.
General information for use in determining the
proper forward travel speed and oscillation rate for
the oscillating gas-shielded overlay process has also
been determined. Forward travel speed versus
oscillation width has been plotted in Fig. 7. The
graph indicates the approximate recommended
forward travel speed to be used over a range of oscil-
lation widths. The shaded area of the graph in-
~~ \u 2 ee ee ee ee | cludes the approximate forward travel speeds to be
lla th (@ 2 Bt 24 2
OSCLCLATION b//DTH (1 INCHES used at deposition rates of approximately 15 to 20 lb
per hour per arc. The graph in Fig. 7 can be used
athe — 4 Ew with electrode wire diameters of 0.045 to /32 in. and
90 72 60 arSP at 4S PY Fo-- 36 onoS > TRAVEL
pe 7
| OSH -CATIONPATE 1 CretES Pi 11, ( TERVEESE LSE © PEs is general enough to allow its use with most stainless
Ba I Neciectiilis 4 ‘ ‘ ‘ steel and nickel alloy electrode wires with either
GS #08 FIO 77 oa Oo = 43 TRAVE. single or dual arcs.
OSCILLATION FATE VERES PER ATIN ASbay yd SPLEO
Figure 8 is a graph of oscillation rate in cycles
Fig. 6—Effect of oscillation width and oscillation per minute versus oscillation width in inches and
rate on dilution at constant current gives the useable range of oscillation rate for various

WELDING JOURNAL | 1225

 4408 | VOEVCMOLCN L1970N

OF ENT Wwlid
"CL vi “ONE
7 REGULAR
CHAN VCE OF OFBEAD
ECTS 2

we CLCELRING

Fig. 8—-Recommended oscillation rates for stainless

steel and nickel alloy electrode wires used
Fig. 7—Recommended travel speeds for stainless with d-c reverse polarity
steel and nickel alloy electrode wires used
with d-c reverse polarity current

oscillation widths for most electrode wires. Figure

8 can also be applied with either single or dual arcs. J
Ni
y
Weld Metal Dilution
One of the major factors governing the success of
any fusion cladding application is the degree to which
the weld metal is diluted by the base metal. This
factor will be a major consideration in determining
the thickness of the overlay to be applied to obtain V2
OYMOAT
IVbv
the required weld metal chemistry at the working
surface. To investigate this dilution factor, dual- PER
arc overlays were made using predetermined combi-
nations of current, voltage, electrode extension,
forward travel speed, oscillation rate, and oscillation Fig. 9—Percent chromium versus overlay thickness for '/;.-in.
width. The overlays were made using '/j-in. diam electrode wire at 250 and 290 amp d-c reverse polarity
diam Type 308 ELC and */;.-in. diam Type 308 ELC
and Type 309 stainless steel electrode wires. The
overlays were two layers thick, and weld metal chips + 19.70% cr. FOR
were taken for chemical analysis every '/;, in. depth TYPE 3086 E.L.c
ELECT
down through thickness of the overlay. The
purpose of these tests was to determine the weld
metal chemistry that could be expected at various
thicknesses of an overlay made with the electrode
wires mentioned above.
Examination of the chemical analysis data showed
that a definite dilution gradient existed in each layer
of the overlay. This was significant, since the usual %CRIN
WELD
METAL>ooe
method of calculating weld metal dilution is area x
dependent. The area method of dilution calculation
e SURFACE
PLATE
on 32 a a a oe: a ae i 62
necessarily assumes uniform mixing throughout the pA LKRALARAHR?Z
thickness of the weld bead— in other words, a fairly DISTANCE ABOVE PLATE SURFACE INCHES
homogeneous chemistry throughout the weld cross Fig. 10—Percent chromium versus overlay thickness for */,2-
section. Therefore, since the convelinear oscillating in. diam electrode wire at 350 amp d-c reverse polarity

1226 | DECEMBER 1960

 process does not produce uniform mixing, the area shows almost no dilution gradient. The apparent
method of dilution calculation should not be applied lack of a dilution gradient in curve A is accountable
to this process. For this reason, the dilution results to the higher chromium and nickel content of the
were plotted as percent chromium in the weld metal Type 309 stainless electrode. The percent dilution
versus distance above the original plate surface. of the Type 309 electrode is approximately equal
The trend shown by the chromium analysis was also to that obtained with the Type 308 ELC electrode.
found to be representative of the nickel analysis. However, the resulting weld metal chemistry ob-
The carbon analysis for the 308 ELC overlay was tained with the Type 309 is higher in chromium and
found to show a reverse trend from the chromium and nickel. An examination of Curves A and B in Fig.
nickel analysis and ranged from approximately 0.10 10 shows that a Type 309 barrier layer is not needed
to 0.05% at '/3 and ''/ 3 in. respectively above the if it is necessary to apply two or more layers of weld
original plate surface. It is desirable to keep the metal on a particular application since the difference
carbon in the finished layer of the overlay below in chemistry at the top of the second layer is rela-
0.08% to avoid the formation of chromium carbide, tively small.
which promotes intergranular corrosion of the stain-
less steel overlay. Overlay Applications
A graph of the chromium analysis for the test over- The overlay quality obtained with the conve-
lays made with '/;,.-in. diam Type 308 ELC stainless linear oscillating gas-shielded process is consistently
steel electrode wire at 250 and 290 amp is shown in high. When the process is properly applied, virtu-
Fig. 9. Curve A in Fig. 9 has been approximated ally defect-free overlays can consistently be made
from two actual points and the general shape of under production conditions at high-deposition
Curve B. The curves show the dilution gradient rates with many types of electrode wires. A sur-
in each weld layer discussed previously. The gra- face photograph of a dual-arc overlay made with
dient is considered an advantage, since the overlay -in. diam Type 308 ELC electrode wire on ASTM
chemistry at the top of any layer will be superior A212B steel base plate is shown in Fig. 11. The
with this process than with processes that produce overlay was made using 350 amp d-c reverse polarity
uniform mixing. It can be concluded that an over- current with a 3 in. long electrode extension for each
lay of less total thickness can be applied with the electrode wire. The shielding gas used was argon
convelinear oscillating gas-shielded process than + 1% QO, at approximately 50 cfh per arc. The
with other non-oscillating processes. total weld metal deposition rate for the two arcs was
Graphs of the chromium analysis for two test 40 lb per arc hour. The smooth overlay and fiat
overlays made with */.-in. diam electrode wire are surface of the 3-in wide beads requires a minimum of
shown in Fig. 10. One specimen was made using machining to produce a defect-free machined surface.
Type 308 ELC stainless steel electrode wire for Typical side bend specimens of an overlay made
both layers of the overlay. The other specimen with the above conditions are shown in Fig. 12.
was made using a Type 309 stainless steel electrode The specimens were stress-relief-annealed at 1100°F
wire for the first layer and a Type 308 ELC electrode for 25 hr prior to bending and showed no defects at
wire for the second layer. Curve B in Fig. 10 repre- 50x after bending. The specimens in Fig. 12
sents the overlay made completely with Type 308 also show the uniform shallow penetration obtained
ELC stainless steel electrode wire and shows a defi- with this process.
nite dilution gradient in each layer. Curve A in The convelinear oscillating dual-arc gas shielded
Fig. 10 represents the overlay made with the Type process has also been applied to automatic hard sur-
309 and 308 ELC electrode wire combination and facing applications using fabricated hard surfacing
wires. A surface view of a hard surfacing overlay is
shown with accompanying welding data in Fig. 13.
Fig. 1l—Dual arc Type 308 ELC stainless steel overlay
Gas flow Total
Amp Volts TR. speed, W.F. speed, (A + 1), cfh dep. rate, Ib/hr
ipm ipm Fig. 12—Type 308 ELC stainless steel overlay side bend speci-
6 175 mens after stress relief annealing for 25 hr at 1100°F

” YE ER PIP Ge

74
>
--
 ‘ ube ee
YF Be Yan
aR as 7he .” 5 4
(ee ost ' ial . “e ;
“Sars rk ‘ = ai)
\ Jae roai » ies. }
Ss > . r.
> Grea Cee

Fig. 13—Hard surfaced test cylinder

lst layer (each barrel) Fig. 14—Center section overlay on Westinghouse high-
DCSP, Amp Volts W. F. speed, Tr. speed, ipm Gas flow pressure feedwater heater tube sheet face. First
ipm (A + 1), cfh
600 40 285 10 50 layer nickel, second and third layers monel
2nd layer (each barrel)
DCRP
500 35 150 50

Table 1—Data and Information for Hard Surfacing

Electrode wire... s-in. diam fabricated tube
wire
Base material ASTM 1020 cast steel
Welding head...... dual barrel, convelinear
oscillator
Power supply.... (2) 1000 amp d-c drooping
characteristic rectifiers
Deposit composition (%). . .C-1.25, Mn-0.37, Si-0.35, Ni-
7.10, Cr-22.27, Mo-0.57,
P-0.012
First layer deposition rate
(actual) 90 Ib ‘arc hr
Second layer deposition rate
(actual) 45 Ib/arc hr
Rate of surface coverage on
first layer (*/\, in. thick). .......11 sq ft/arc hr
Rate of surface coverage on
second layer (°/;, in. thick) 7 sq ft/arc hr
Fig. 15—Completed as-welded overlay on Westinghouse
As-welded hardness.... 28-30 RC high-pressure feedwater heater tube sheet face. First
Hardness after heat treatment. ..43-45 RC layer nickel, second and third layers monel
Heat treatment 1200° F for 20 hr FC

treated hardness values in Table 1 also indicate a

The two layer overlay was made by over-lapping 3-in. very desirable condition for applications such as
wide weld beads. The flat weld surface and the blast furnace bells and hoppers where weld surface
smooth overlap are clearly visible in the photograph. machining is required.
Supplementary information for Fig. 13 appears in The nickel base alloys also lend themselves to use
Table 1 and examination of this data indicates that with the convelinear oscillating gas-shielded process.
extremely high-deposition rates and rapid surface cov- The overlay welding techniques employed for the
erage can be obtained with the convelinear oscillat- nickel base alloys are similar to the techniques used
ing gas-shielded process. The as-welded and heat- for stainless steel ove-laying. The convelinear

1228 | DECEMBER 1960

 tube sheet overlay is shown ‘“‘as welded”’ in Fig. 15.
Copper and bronze overlays can also be made with
the gas-shielded overlay process using the same
basic welding techniques developed for stainless
steel and nickel alloys. Cross sections of dual-arc
deoxidized copper and 10% aluminum bronze over-
lays are shown in Fig. 16. The cross sections show
the typical uniform shallow penetration obtained
with this process. The overlays were made using
DEOXIDIZED COPPER
approximately 300 amp/arc d-c reverse polarity
current with '/j-in. diam electrode wires. The
shielding gases consisted of argon + 1% O, for the
deoxidized copper overlay and pure argon for the
10% aluminum bronze overlay. The deposition
rate tor both the aluminum bronze and the deox-
idized copper overlays was in the order of 30 lb per
arc hour total for the dual arcs.
Summary
High-deposition rates can be obtained with the
gas-shielded welding process used with d-c reverse
Fig. 16—Dual arc overlay cross sections of deoxidized copper polarity current and electrode extensions up to 3 in
and 10% aluminum bronze on mild steel base plate The long electrode extensions produce deposition
rates 50 to 100% higher than can be obtained with
normal extensions of '/, to */;-in. The use of long
oscillating process has been successfully applied in electrode extensions has also resulted in a substan-
the fabrication of commercial feed water heaters by tial reduction in weld metal dilution.
a leading fabricator in this field. The primary An improved fusion cladding process was de-
veloped by combining the extended-electrode gas-
application of the process, in this particular case,
was for cladding feed water heater tube sheets with shielded process with a convelinear oscillating device.
various nickel base alloys. The fabricator reports The resulting overlay process produces high-quality
that the production overlays were virtually defect overlays at high-deposition rates when used with
free as determined by ultrasonic inspection. A tube d-c reverse polarity. The process can be used to
sheet is shown in Fig. 14 with the first cladding deposit stainless steel, nickel and copper base alloys,
operation completed. The first operation consists and various other weldable materials. The versa-
of overlaying the center section of the tube sheet tility of the convelinear oscillating gas shielded
face with straight oscillating weld beads. The process makes it a valuable fabrication technique.
center section overlay has been machined to a circu- Acknowledgment
lar shape in preparation for the final cladding opera- Appreciation is expressed to the Westinghouse
tion. The tube sheet overlay is completed by over- Steam Division, Lester Pa., for the information and
laying the remainder of the tube sheet face circum- photographs concerning the commercial cladding of
ferentially with oscillating beads. The completed feed water heater tube sheets presented in this paper.

An Important Reminder

AUTHORS

January 15, 1961, is the deadline when application forms and abstracts must be postmarked in order
to receive consideration for presentation at the 1961 AWS National Fall Meeting to be held in Dallas,
Tex., Sept. 25-28, 1961.
The application form was included as a detachable insert in the October issue of the WELDING
JOURNAL. Additional copies of the application, as well as ‘Instructions and Suggestions for Authors,’
may be obtained by writing to AWS headquarters, 33 W. 39th St., New York 18, N. Y.

WELDING JOURNAL | 1229

 Inert-gas-shielded metal-arc spot welding process being used to produce spot fillets in aluminum

develop the metal-arc spot welding process so that

Inert-Gas-Shielded Metal-Arc it would become a reliable tool to join aluminum.
In adapting the process to aluminum most of the
commercially available metal-arc spot welding
accessory kits were investigated, and a selection was
Spot Welding made of equipment offering the best compromise of
advantages and disadvantages. Subsequently, the
limitations of the process were determined on the
basis of sheet thickness and alloys.
of Aluminum
The Process
In inert-gas-shielded metal-arc spot welding of
aluminum, the torch is placed with the nozzle di-
features ease of application and reliability rectly on the work. When the trigger is pulled, an
arc is established in a shield of inert gas between a
consumable aluminum electrode and the aluminum
workpiece. Current densities are high and a conical
BY S. ERIC McFALL zone of metal is melted, mixed with filler, and re-
solidified in a very short interval of time which must
be accurately controlled.
Equipment
Equipment required for inert-gas-shielded metal-
As early as 1949, the arc spot welding of aluminum
arc spot welding aluminum is essentially the same as
using the inert-gas-shielded tungsten-arc process
that normally used to weld aluminum, i.e., a
was discussed in a paper by F. J. Pilia.' This
welding power source, a wire drive unit, an inert gas
method is still being used to some extent but, since
supply. To this is added a timing device and other
no filler is added, its use is limited to those aluminum
special controls.
alloys which are not prone to hot short cracking. In
In the early phases of the work, several types of
1955, R. L. Hackman? and, in 1956, Kehoe and
equipment were tried and evaluated. These are
Bichsel’ discussed the adaptation of the inert-gas-
discussed in detail below. A typical laboratory set-
shielded metal-arc process to arc spot welding.
up is illustrated in Fig. 1.
However, most of their work was done on steel. The
object of work that this paper reports was to further Power Sources
With drooping characteristic (constant current)
S. ERIC McFALL is Welding Metallurgist, Aluminium Laboratories power sources, the nature of the arc in inert-gas-
Ltd., Kingston, Ont.
shielded metal-arc spot welding is such that, as the
Paper presented at 1960 AWS National Fall Meeting held in Pittsburgh,
Pa., Sept. 26-29, 1960. arc is extinguished, a comparatively large ball tends

1230 | DECEMBER 1960

Fig. 1—Typical equipment for inert-gas-shielded metal-arc spot welding of aluminum

to form on the end of the electrode. This ball makes Controls

restriking difficult, and consecutive spot welds can- Early controls consisted solely of a mechanical
not be made without snipping the end of the wire timing device to cut out the welding current at
between each spot. some preset time. Subsequently, manufacturers
Both rising-characteristic and constant-arc-volt- added further refinements to the control circuits, the
age power sources eliminate this problem. No ball is effects of which are discussed below under Process
formed on the end of the electrode, and restriking Variables.
presents no difficulty. Since there were more con-
stant-arc-voltage units readily available in Canadian Process Variables
shops and since the motor generator rising-character- Having chosen a suitable power source and wire
istic power source was noisy in the laboratory, the drive equipment and having established in a few
constant-arc-voltage unit was chosen for most of the ad hoc tests that the process could be adapted for
procedure development phase of the investigation. aluminum, the next step was to determine the
effect of the process variables. During the ex-
Wire Drive Units
ploratory and procedure development phases of this
Again in the early stages of adapting the process work, a recording oscillograph was used to measure
to aluminum, several commercially available wire arc voltage, current and time. Each trace presented
drive units were tried, at that time, however, only a diagram of the welding conditions from the instant
the push type of wire drive unit was available. All the trigger was pulled and the arc was initiated
units presented one major problem with alumi- until the arc was extinguished. It was thus asimple
num electrode wire. In a standard 10- or 12-ft matter to compare charts from a number of series of
flexible cable there was enough slack between the spot welds at various control settings and determine
electrode and the plastic liner so that if one were to the effect of each control and the effect of changes in
grasp the electrode at the end of the contact tube, it one or more variables. These controllable variables
could be pulled back and forth at least an inch and are discussed in detail below.
often even more. Since only 2- to 3-in. of electrode
wire are consumed in one spot weld, this slack in the Open Circuit Voltage
cable represented at least one-third of the volume of The open circuit voltage set on the constant arc
metal in the spot weld and hence resulted in a wide voltage power source in conjunction with the wire
scatter in size and strength of spot. By shortening speed determines the arc voltage during the welding
the cable length to about 30 in., welding conditions cycle. However, since the duration of the weld
and reproducibility were improved but the port- cycle is so short, a spot weld cannot be thought of as
ability and flexibility of the equipment were dras- a normal weld. Contrary to normal welding prac-
tically reduced. With the advent of the pull type of tice, a high are voltage in arc spot welding results in
wire drive equipment, the problem of slack in the better penetration than a low arc voltage. The
cable was eliminated. In this type of equipment, voltage required for adequate penetration is a func-
the electrode is pushed only about 4 to 6 in. and is tion of sheet thickness; hence as the top sheet
fully guided and supported. thickness is increased, so must the arc voltage setting

WELDING JOURNAL | 1233

 be increased. With */,,-in. diam electrode wire, small in diameter and tends to build-up excessively.
open-circuit voltages of less than 22 v usually result In relatively heavy thicknesses there is a tendency
in failure of the arc to strike, while settings of 36 v for large gas pockets to form in the nugget. If this
or higher generally result in a burnback. With condition occurs, it can be eliminated by an increase
'/,s-in. diam electrode, this range is narrowed to be- in the time cycle. This keeps the center of the
tween 26 and 36 v. nugget molten long enough for the gas pocket to
Electrode Wire Speed escape to the surface.
With a constant arc voltage power source, the rate Stub or Burn-off Control
of electrode wire feed determines the welding cur- In the absence of this control, the electrode would
rent. To provide sufficient arc force to melt and invariably stick in the button at the end of the arc
penetrate through two thicknesses of sheet in a very time period as the arc was extinguished. This
short interval of time requires welding currents, and control has the effect of decreasing the electrode
hence wire speeds, considerably in excess of those speed just before the arc is extinguished so that the
used in normal welding operations. As material electrode stops just short of the top of the button.
thicknesses are increased so must the current and Post-weld Shut-off Delays
hence the wire feed be increased. For example, a
The post-weld gas shut-off delay allows the shield-
wire feed speed of between 600 and 900 ipm is used
ing gas to flow after the arc is extinguished so that
for 0.047-in. diam electrode.
the button freezes in an inert atmosphere. Care
Slow Run-in must be taken on large spots in heavy materials to
If the wire is allowed to strike the plate at the high ensure that the torch is not lifted off the spot before
speed necessary for spot welding, one of a number of the button freezes. The water shut-off delay per-
things may happen: (1) The short length of wire mits the cooling water to flow and absorb the heat
between the end of the contact tube and the work from the spot welding nozzle. With high duty
may break off, resulting in a false start, (2) the sud- cycles it may be necessary with some torches to by-
den impact may jolt the operator’s hand so that the pass the water shut-off so that continuous coolingtis
torch moves off the desired location, or (3) the torch obtained.
itself may be damaged. To eliminate these possi-
Contact Tip-to-work Distance
bilities the equipment is provided with a means of
reducing the speed of the electrode so that it hits the Shortening the tip-to-work distance has the effect
sheet with sufficient force to strike an arc, but slowly of reducing the arc voltage. It has been found that a
enough to prevent the undesirable effects. distance of '/, in. is satisfactory. On light gage
There is a measurable interval of time between materials this may be reduced to */,; in. or, con-
when the electrode strikes at the reduced speed and versely with large spots on heavy materials, it may
when it reaches the preset speed. This time lag has be necessary to increase the distance to °/, in. to
little effect on the penetration of light gage sheet. avoid spatter or burnbacks.
When working with fairly heavy thicknesses how- Gas-nozzle Geometry
ever it may be necessary to let the electrode feed The standard gas nozzle supplied with the equip-
faster and thus hit the sheet harder than would be ment may not be satisfactory for all applications.
desired in order to obtain quickly enough the arc Special nozzles can be designed and machined to fit
force necessary to penetrate the sheet. most joint contours or for specific jigging require-
A secondary advantage of the slow run-in control ments. Examples of some special nozzles are shown
is that it provides an interval of time for the shielding in Fig. 2.
gas to purge the nozzle of entrapped air before the
arc strikes. Materials
Time Control Alloys
For arc spot welding aluminum, this investigation As a general rule, aluminum alloys which are
has shown that relatively short arc time intervals are considered weldable by the fusion welding processes
advantageous. Hence the timing mechanism must are weldable by inert-gas-shielded metal-arc spot
be accurate to the extent that, at any one setting, it welding. This includes the AA 1xxx, 5xxx and 6xxx
will reproduce the same arc time for each of hundreds series of alloys. Naturally, electrode alloys must be
or thousands of spot welds. It has been found that compatible with the sheet alloys. While a some-
arc times of less than '/, sec are not sufficient to what broader range of machine settings can be used
allow welding conditions to become fully established with an AI-Si type alloy electrode, the lower strength
and hence reproducibility suffers badly. On the or stiffness of this wire compared with one from the
other hand—except for heavier thicknesses—arc Al-Mg series sometimes results in kinking of the
times much in excess of 1 sec result in overheating electrode in the torch or buckling between the con-
and severe cracking of the top sheet under the edges tact tip and the work piece. Since most of the sheet
of the button. At high arc voltages and long arc materials used in this investigation were either Al-
times, the button tends to be very flat and spread Mg alloys or Al-Mg alloys in combination with
out while at low arc voltages and long arc times it is AA6061, the electrode alloys were generally in the

1232 | DECEMBER 1960

Al-Mg series. Several electrode alloys in this series
were tried ranging from 3'/.% Mg to 5% Mg, but
little difference in operating characteristics could be
detected except for spot fillets where there seemed
to be a tendency to increased cracking as the Mg
content decreased, especially when the alloy of one
or both members of a Tee joint was AA6061.
Shielding Gases
In the early stages of the investigation helium
was used as the shielding gas. As the supply of
helium became critical, however, readily available
argon was substituted with little effect on the Fig. 2—Spot welding nozzles for special applications
potential usage of the process.
Sheet Thickness
In order to determine the limitations of sheet thick-
nesses, it was necessary that a program be drawn up
to develop workable procedures for inert-gas-
shielded metal-arc spot welds in various combina-
tions of sheet thicknesses. The practical combina-
tions are given in Table 1. It appeared from early
work that combinations of a top sheet thickness of t
and a bottom sheet thickness of 2¢ would provide
the most ideal combination. Subsequent work
however, showed that joints between ¢ and 3¢ had
even better properties within a wide range of welding
procedures. —
It is obvious that the shear strengths of inert-gas-
shielded metal-arc spot welds are a function of the
diameter of the nugget at the interface between the
two sheets. There appears to be a maximum nugget
diameter which can be formed in the various thick-
nesses of top sheets. Fig. 3—Torque testing inert-gas-shielded metal-arc
It may be seen from Table 1 that, at the present Spot weld in two sheets of aluminum
state of development, the minimum top sheet thick-
ness is 0.032 in. and the maximum is 0.125 in. Ma-
terials with thicknesses less than 0.032 in. and
greater than 0.125 in. have been metal-arc spot
welded, but the reproducibility has left much to be
desired. On the thinner material there is a tendency
to burn away the sheet around the edge of the but-
ton, and on the very heavy gage material the conical
shape of the nugget results in a comparatively small
cross section and hence low strength at the sheet
interface.
The equipment being used at this stage of the in-

Table 1—Practical Thickness Combinations

Bottom
sheet Top sheet thickness, in. _ Fig. 4—Profile of inert-gas-shielded metal-arc spot weld in
thickness, in. 0.032 0.040 0.051 0.064 0.081 0.125 aluminum. (Note peripheral cracking of top sheet under
0.051 the button together with porosity and gas pockets)
0.064
0.091
0.125 Be
0.156 vestigation was not designed to drive electrode wire
0.187 with diameters greater than 0.062 in. In order to
0.250 round out the program, the drive mechanism and
wire guides were modified to take 0.093-in. electrode.
Legend: A—joints can be made with relative ease; B—joints possible
but control settings much more critical than “A”; X—not recommended However, this modification proved too hard on the

WELDING JOURNAL | 1233

 that reproducibility will not be as good as with a
single thickness top sheet. Also because of the
conical shape of the nugget, strengths will differ at
each interface.
One method of accomplishing inert-gas-shielded
metal-arc spot welds in heavier sheet is to partially
drill or countersink the top sheet so that a thickness
of about 0.125 in. of solid metal remains. This may
then be treated as though it were 0.125-in. sheet.
The disadvantage of this method is that it requires
some means of registering the torch over the hole.
It is poor practice in aluminum to drill right
through the top sheet and plug weld. Invariably
this leads to zones of incomplete fusion for some
portion of the periphery of the nugget.
Fig. 5—Profile of inert-gas-shielded metal-arc spot
fillet in aluminum—also illustrates porosity Spot Fillets. For tee joints, as would be expected
the best combination for inert-gas-shielded metal-
arc spot fillets is two sheets of equal thickness.
When other than equal thicknesses are involved,
then it becomes a problem to find a critical set of
conditions which avoid excessive penetration of the
lighter sheet while obtaining reasonable fusion to
the heavier sheet. Little success has been had with
sheet thicknesses less than 0.062 in., and joint
strengths are low. Two thicknesses of 0.25 in.
have been joined, but the incidence of throat cracks
is high and hence an upper limit of 0.187 in. is recom-
mended. For lap joints the same general comments
apply with the additional problem of a tendency of
the edge of the lap sheet to burn away from the
weld in light gages.
Fig. 6—Necessary reduction in spot weld size to In all spot fillet welding the most important single
eliminate cracks and gas pockets—compare to Fig. 4
variable is torch alignment. It is essential that the
electrode strikes in exactly the same place each time.
Failure to do so will invariably result in an undersize
off-center spot fillet and almost certain cracking.
. Bos For this reason the nozzle must be machined to fit
ae. % accurately into each joint and the sheets must be
= - ; a - jigged so that the original angle does not change.
In addition the contact tube in the torch must be
accurately centered.

Procedures
Typical procedures as developed for various thick-
ness combinations are given in Tables 2 and 3. It
Fig. 7—Standard tensile test piece machined
for fatigue testing equipment should be emphasized that these are given only as a
guide in setting up equipment. Various makes of
equipment will operate differently.

equipment and this part of the investigation was Preweld and Postweld Cleaning
halted. Results from this brief exploratory program Etching, wire brushing or disk sanding normal mill
and from early work with the push type of equipment finish surfaces are unnecessary. Preweld degreasing
indicate it should be possible to spot weld through or wiping of the faying surfaces with commercial
thicknesses greater than 0.187 in. with special equip- solvents is recommended. Any traces of anodizing,
ment. However, if strength requirements are such lacquering or any other artificially applied coating
that material thicknesses over 0.187 in. are required, must be completely removed from the faying surfaces
then it is reasonable to assume that strength require- before welding.
ments will be such that inert-gas-shielded metal-arc If necessary, the postweld removal of black smut
spot welding wil! be excluded as a joining method. around the button can be accomplished by wiping
Some exploratory work has been done on joining with a dry cloth. Occasionally soap and water or
two or more light gage sheets to a thicker sheet, but commercial solvents may be necessary to clean up
more work still needs to be done. Indications are all traces of the black deposit.

1244 | DECEMBER 1960

 Preweld caulking of a joint may be accomplished, metal-are spot fillets is to section the weld through
provided an area of about 1 in. in diam is kept com- the center and examine the profile. Figures 4 and 5
pletely clean and free from compound for each spot illustrate desirable profiles. In addition to profile,
weld and intimate contact of the faying surfaces is such a macrosample will reveal any undesirable
not prevented. defects such as cracks, gas pockets and porosity.
Cracks in the top sheet can usually be eliminated by
Safety a combination of reductions in time, voltage and
Since most of the arc is shielded by the welding current with—unfortunately—an accompanying re-
nozzle, the only protection required for eyes is duction in size and strength as illustrated in Fig. 6.
tinted safety glasses to guard against reflections and However, as discussed below under mechanical
spatter. properties some peripheral cracking may be toler-
ated. Gas pockets at the faying surfaces are very
Quality Control
detrimental and can usually be eliminated by an
Visual inspection of an arc spot weld can be very increase in time. Efforts to date to completely
misleading. In fact, destructive testing of sample eliminate porosity have been unsuccessful. It can
joints is the only safe way to maintain a periodic often be reduced by an increase in time which allows
check on joint quality. With this idea in mind, a it to end up as porosity on the surface of the button
simple “‘in the shop’”’ method of evaluating inert-gas- and detracts from the appearance.
shielded metal-arc spot welds was developed. The Use of the recording oscillograph is also a good
equipment consists of a standard torque wrench and method of checking that an established procedure is
a socket tool machined to a depth slightly less than being maintained. Any major deviation from an
the top sheet thickness. In use, samples of the top established trace pattern is cause for concern.
sheet sheared to fit the machined portion of the tool
are welded with single spot welds to samples of the Mechanical Properties
bottom sheet. The bottom sheet is then clamped in Shear tests have been performed on inert-gas-
a vise, and the maximum torque required to twist shielded metal-arc spot welds in a number of sheet
the sample apart is read on the torque wrench as thickness combinations. A standard test sample
illustrated in Fig. 3. It is important that torque developed to avoid any chance of premature twisting
values do not vary more than +1 ft-lb from the consisted of a top sheet attached by two spot welds
average value. to each of two bottom sheets. Typical values
Another method of checking spot-weld quality obtained from numerous tests are given in Table 4.
and the only way of checking inert-gas-shielded Also included in this table are the results of the
torque tests, and the minimum and minimum-
average resistance spot-weld strengths required by
Table 2—Typical Procedures for U. S. Military Specification MIL-W-6858A. It
Inert-gas-shielded Metal-arc Spot Welds may be seen that, except for heavy gages inert-gas-
Electrode Open Electrode shielded metal-arc spot-weld strengths exceed the
Bottom diameter, circuit speed Time minimum resistance spot-weld strength require-
Top sheet sheet in. voltage (ipm) cycles ments. Comparison of torque test values and shear
0.032 0.091 0.047 25 625 25 strengths show that the shear strength in pounds is
0.032 0.125 0.047 26 800 20 roughly equivalent to 90 times the torque values in
0.040 0.091 0.047 26 685 20
0.040 125 0.047 745 25 foot pounds.
0.040 156 0.047 3 745 25 A similar type of sample was machined as illus-
051 125 0.047 | 685 trated in Fig. 7 to fit Vibrophore fatigue testing
051 156 0.047 f 685
.051 187 0.047 ; 745
.064 125 0.062 385
064 156 0.062 445 Table 4—Typical Mechanical Properties of Arc Spot Welds
.064 187 0.062 565 Top Bottom Torque Shear -Spec. MIL-W-6858A-
081 0.062 625 sheet sheet ft-lb Ib/spot Min Min avg
0.062 685
0.062
ooooqcjooqcjoc”noo 685 032 091 660 235 295
032 125 820 235 295
040 .091 8 700 3 390
040 125 950 310 390
Table 3—Typical Procedures for 040 156 900
051 125 835 © oo
i
Inert-gas-shielded Metal-arc Spot Fillets
051 .156 1015
Electrode Open Electrode 051 187 ( 1030 &+>
Vertical diameter, circuit speed, Time 064 125 1010 noo
oon
Oo)Ina
Ww aan
leg Base leg in. voltage ipm _ cycles 064 156 1400 ana
0.064 0.064 0.047 21 385 25 064 187 1285 =n
0.125 0.125 0.047 27 685 30 081 187 1245
0.187 0.187 0.047 28 800 35 081 250 1580
125 250
eooooeoocoocoococoececeooco1230

WELDING JOURNAL
 — = INDICATES TESTPIECE REMAINED UNBROKEN
ANO RETESTED AT HIGHER STRESS

SEM/-RANGE
OF
LOAD

ENDURANCE ENDURANCE CYCLES

Fig. 8—Results of fatigue tests on joints of 0.081-in. thick Fig. 9—Results of fatigue tests on joints
Alcan B54S-H21 sheet spot welded to */,,-in. thick Alcan of 0.081-in. Alcan B54S-H21 sheet spot weided to */,,-in
65S-T6 extrusion with inert-gas-shielded metal-arc process— Alcan 65S-T6 extrusion—joints were not cracked
joints had peripheral cracks in top sheet around nugget

Table 5—Typical Shear Strengths of

Inert-gas-shielded Metal-arc Spot Fillets
Tee joint thicknesses, in..... 0.062to 0.125to 0.187 to
0.062 0.125 0.187
5356 alloy shear strengths
Ib/spot fillet 800 1100

num column covers for the new Sun Life building in

Toronto, Ont. Other developments are under way
for the attachment of aluminum panels in curtain
Fig. 10—Attachment of stiffening members to aluminum wall construction including vitreous enamelled sheet.
panels with inert-gas-shielded metal-arc spot welding Figure 10 illustrates the attachment of stiffening
members to aluminum panels.
Summary
equipment. In this investigation one series of sam- Adaptation of this process to aluminum has made
ples known to contain peripheral cracks was com- available a new, simple and reliable method for the
pared with a series of samples without cracks but of attachment of sheet to sheet and sheet to framing
lower strength. Figures 8 and 9 give the results of members. Once the equipment is setup and pro-
this test and, as can be seen, the stronger but cedures determined, little operator skill is required
cracked samples performed better than the less to produce consistently good welds. Cumbersome
strong uncracked samples. The peripheral crack protective shielding is unnecessary.
around the nugget of a spot weld may be considered Preweld and postweld cleaning is reduced to a
similar to the annular space between the hole in a minimum.
sheet and the shank of a rivet. Compared with resistance welding equipment,
Typical shear strengths of inert-gas-shielded metal- inert-gas-shielded metal-arc spot welding equipment
arc spot fillets on Al-Mg alloys are given in Table 5. is low in cost and is relatively portable and versatile.
Fatigue studies are under way on spot fillets, but in- Spot welds can be made from one side only. Spot
sufficient results are available to report at this time. fillets are possible for tee and lap joints. With a
Applications simple flip of a switch and an exchange of torch
barrels the spot welding equipment converts back
A number of applications employing inert-gas-
to standard inert-gas-shielded metal-arc welding
shielded metal-arc spot welding of aluminum are
equipment.
under development in the road transport and railway
fields. Both spot welds and spot fillets have been References
extensively used in the architectural field for fabri- 1. Pilia, F. J., “Inert Gas-Shielded Arc Spot Welding,” THe We.pina
JOURNAL,28 (1), 5-11 (1949).
cating aluminum column covers and light gage 2. Hackman, R. L., ““Consumable-Electrode Inert-Arc Spot Welding,”
corrugated building sheet. A current example of Ibid., 34 (9), 839-845 (1955).
3. Kehoe, J. W., and Bichsel, H. J., “‘Inert-Gas-Shielded Metal-Arc-
this process in use is in the fabrication of the alumi- Spot Process,” Ibid.,35 (9), 895-903 (1956).

1236 | DECEMBER 1960

 Solid rocket motors have, until recently, been limited
as to size and power. The advent of larger rocket
motors has been accompanied by problems not pre-
Properly designed weld tooling viously encountered in the fabrication of the smaller
and fixturing greatly simplifies the motors:
1. Size of tooling required by the large diameter.
2. Accuracy of fixturing and tooling to control
Welding of lq rge light-gage material to tight tolerances.
3. Preheat and postheat required by the use of
low-alloy high-strength steels.
4. Welding process required to obtain the de-
Rocket Moto rs sired weldment for a given thickness of metal.
These problems could not be solved through the
use of conventional weld fixturing. Instead, it was
BY J. E. BARTLEY AND R. E. FRALA necessary to obtain weld tooling and fixturing, which
incorporated entirely new concepts. It was also
necessary to incorporate high-temperature preheat
facilities and special postweld stress-relieving equip-
ment in the new fixturing. Furthermore, there was
A Navy Polaris test vehicle with an instrumentation need to equip each welding station so that it could
nose cone a few seconds after launch at the Air Force
Missile Test Center at Cape Canaveral, Fla. be operated with the tungsten-arc and submerged-
arc processes.
A final step was to centralize the various param-
eters involved in forming, welding, heat treatment
and inspection. This was done by placing an
operational plan sheet specifying shop procedures
with each job on the floor and was important in order
to minimize the effect of human error or judgment.
With a knowledge of operating parameters, it has
since been possible in some cases to effect improve-
ments from day to day.

Weld Tooling and Fixturing

Limitations of Conventional Weld Fixturing
Conventional weld fixturing was first considered
but was found to have certain disadvantages. When
a cylinder joint is preheated, the cylinder expands
away from the backing. Conversely, when it cools
and contracts, an internal mandrel restrains the
cylinder and sets up stress. An internally expanding
backing would have to be assembled in the part
and disassembled when using 600° F preheat. This
would be almost prohibitive without a period of
waiting for the mandrel to cool. Disassembly is
further complicated by the use of heavy actuating
cylinders used to expand the backing. These
cylinders unbalance the unit and require a large
speed-regulation unit. Elaborate scaffolding is
necessary with large diameters in order to place the
operator in welding position.
Selection of “‘Inside-out’”’ Approach
Because of the limitations of conventional weld
fixturing, it was necessary to utilize a new concept
in weld fixturing. This was tooling which entailed
an “inside-out” approach for welding the most
highly stressed welds on the motor case. Inside-
out welding consists of positioning and backing the
J. E. BARTLEY is Production Engineer, Aerojet-General Corp., and
R. E. FRALA is Electric Welding Sales Engineer, Linde Co., San Fran-
cisco, Calif.
Paper presented at AWS 41st Annual Meeting held in Los Angeles, Calif
April 25-29, 1960

WELDING JOURNAL | 1237

 Table 1—Joint Designs and Welding Conditions Used in Various Thickness of Steel
Gas tungsten-arc Root pass
Voltage 10
Amperage 200
Travel speed, ipm 8
Cold wire addition, ipm 27

Submerged-arc
Voltage
Amperage
Travel speed, ipm

Gas tungsten-arc
Voltage
Amperage
Travel speed, ipm
Cold wire addition, ipm

Gas tungsten-arc Root pass

Voltage 9
Amperage 130
Travel speed, ipm 9
Cold wire addition, ipm 24

Fig. 1—Longitudinal welding machine which has a Fig. 2—Welding torch and contact tip as
capacity of 60-in. course and from 38-in. diam located on front of longitudinal ram
to as large as there is material available

1238 | DECEMBER 1960

weld joint from the outside and welding from the a U-groove joint design is used as shown in Table 1.
inside of the case or cylinder. All welding is done from one side, using argon back-
When using an external clamp, the cylinder ex- ing. The root pass is made with the tungsten-arc
pands into the clamp and, upon cooling, contracts process with cold-wire addition in order to control
away from the clamp. Loading of the parts and base-metal penetration and give the joint enough
unloading of the case or assembly is greatly sim- body to support the following submerged-arc passes.
plified by the use of an external clamping device. Two-, three- or four-cover passes of submerged-
A head or cylinder is inserted into the clamp. A arc welding are made as required, using small-
mating part is inserted against the adjoining edge diameter wire and the stringer-type technique.
and the clamp is closed. On the lighter 0.093- and 0.062-in. gages, a V-
When the weld is completed, the clamp is opened groove joint design is used. Welding is done from
and the assembly removed. The outside-type clamp one side, with argon backing. These welds are also
is also easier to supply backing gas and preheat made with the tungsten-arc process using cold-
facilities, since it is essentially a fixed unit which wire addition.
does not require disassembly. This type of clamp On several components which are welded to the
also has a uniform weight distribution lending itself chamber head, short-arc welding with low arc
to simplified speed regulation. voltages and currents is used. The short-arc proc-
All welding can be done at operator level regardless ess makes it possible to pinpoint the arc, thereby
of cylinder diameter. This eliminates the necessity controlling penetration and producing a small
for elaborate scaffolding to fit various diameters. “‘cold’”’ puddle without the addition of excessive
Visual inspection and root-weld pickup are greatly filler metal.
simplified. With this approach, the bottom of the
root pass which is normally the most troublesome Welding-process Consumables
is now on the outside of the assembly or motor case. The filler metal selected to join the ASTM 6434
sheet was modified 1722AS. Vacuum-melted wire
The Welding Operation was selected in order to minimize inclusion content.
Automated Application of inside-out Approach The motor cases are subsequently heat treated to a
Two fixtures are used for the inside-out welding of strength ranging from 160,000 to 240,000 psi, de-
rocket-motor cases. These are a_ longitudinal- pending on the proposed application.
welding machine and a _ circumferential-welding The shielding gas was argon, with helium additions
machine. Welding with each is an automated proc- depending on the particular joint configuration.
ess. Both are utilized on low-alloy high-strength The argon is commercial grade supplied by pipe
ASTM 6434 steel, which was selected because of its line to the weld area from a liquid-argon converter.
properties with respect to heat-treatment response, Standard-purity helium is used and is supplied by
distortion, ductility, machinability, notch sensitivity, cylinder.
strength, workability, and—-most important—-weld- Standard commercial fused composition is used
ability. for submerged-arc welding.
The longitudinal machine is used for producing Quality Assurance
longitudinal welds at rates ranging from 8 ipm for
the gas-tungsten-arc process in 0.062-in. thick steel All welds are made in conformance with an opera-
to 25 ipm for the submerged-arc process in 0.350- tional plan sheet specifying the welding conditions.
in. thick material. The circumferential machine These conditions are determined by test welds and
is utilized with a welding lathe to weld circum- actual parts experience on the shop floor. If, for
ferential seams at rates up to 25 ipm in 54-in. any reason, the settings on the machine must be
diam cases. varied, the operator records the actual conditions and
the reason for the deviation. This is signed off on
Welding Process and Joint-design Selection the floor by the welding-shop foreman. In this
The motor cases range in thickness from 0.350 way, trouble areas are quickly found, and action can
in. down to 0.062 in. In order to cover the range of be taken to solve the problem. The planning sheets
metal thickness, types of material and joint con- are kept as a permanent record.
figurations, all welding stations were equipped with All welds are visually inspected before and after
gas-tungsten-arc with cold wire facilities, and sub- rough grinding. Pressure or circumferential welds
merged-arc welding equipment. All the processes are radiographically inspected 100°. When the
are connected and the controls integrated. This part passes, it is finish ground to a 0.012- +0.010-
enables the operator to change from one process to in. tolerance and magnetic-particle inspected. The
another with a single switch. Both pilot-arc and magnetic-particle inspection procedure applies to
high-frequency starting are employed with the tung- all welds as all the parts are assembled to a motor
sten-arc process. Conventional d-c power is used case. The case is furnace stress relieved and 100%
for the tungsten-arc process, and constant potential inspected by X-ray and magnetic-particle inspec-
power with slope control is used with the submerged- tion. The same inspection takes place after harden-
arc process. ing, so that each critical weld is inspected three
On heavier-walled 0.350- and 0.250-in. thick cases, times, or after any heat-treating operation.

WELDING JOURNAL | 1239

 t.. ; -

Cay

ri NY

+ Tr . inn

i
(Na,
«,
|

Fig. 3—Wire-feed motor and tungsten-arc voltage- Fig. 4—Front view of longitudinal machine shows copper
control motor located with wire spools on hold-down shoes connected to a stainless-steel segmented
opposite end of ram from torch and tip roll bar, which is actuated by a series of stainless-steel
springs connected to the torsion bars

Fig. 5—View shows machine loaded and Fig. 6—Circumferential welding machine which is 40 ft
ram in position to start weld long and has a capacity of 54 in. diam shells

Under present specifications, three repairs are welding facilities. This location is required because
allowed in one area before heat treatment. None of the high preheat temperatures.
are allowed after heat treatment without special By using the machine base as the backing when
consideration of the merits of each weld deficiency. welding an inside diameter, there is no deflection in
backing regardless of the clamping pressure. The
Welding Machines clamping pressure is applied through the use of two
Longitudinal-welding Machine hydraulically operated torsion bars that actuate the
Two of the fixtures used were specifically engi- hold-down shoes on the inside of the cylinder. The
neered and designed for inside-out welding. Oneisa copper hold-down shoes are connected to a stainless-
longitudinal-welding machine shown in Fig. 1, steel segmented roll bar, which is actuated by a series
which is a completely automatic machine and has a of stainless-steel springs connected to the torsion
capacity of 60 in. course from 38 in. in diameter to as bars as shown in Fig. 4. The cylinder has tabs
large as there is material available. The machine accurately aligned and tack welded with the hand
utilizes tungsten-arc and submerged-arc welding. tungsten-arc process at each end of the longitudinal
A welding torch and contact tip are located on the joints. These tabs serve for alignment of the joint
front of the ram as shown in Fig. 2. The wire- with the travel of the welding head, as a means of
feed motor and tungsten-arc voltage-control motor holding the cylinder together for handling, weld
are located on the opposite end of the ram along starts and run-off.
with the wire spools as shown in Fig. 3. Their When a cylinder is inserted into the fixture, the
service leads are shafted through the ram to the back tab nearest the control column fits into an

1240 | DECEMBER 1960

 Re A
Fig. 7—View shows control column and ram
of circumferential-welding machine

alignment fixture. The front tab is then centered

by two engaging blocks. The ram, which has elec-
tronic speed regulation, is run through the cylinder
to be welded as shown in Fig. 5. The weld is made Fig. 8—View of catshead which contains the hydraulically
from the operator’s position to the control column. operated external clamp with copper backing bar, tempera-
ture-controlled resistance-type preheat facilities, inert-gas
The operating controls are remotely located at the backing facilities, rotating speed-controlled power drive,
front of the machine. From the planning sheets, high-frequency stress-relieving coils, weld grounding brushes
the operator sets the welding current, arc voltage, and a short pen for locating the catshead for operation
cold-wire speed, and ram speed for the tungsten-
arc process. The welding current, arc voltage and ing. The parts are brought up to welding tempera-
ram speed are adjusted for the submerged-arc proc- ture, and the torch is moved over the weld seam.
ess. Process variables are locked in electrically, The machine is placed on ‘“‘automatic”’ and the weld
and by engaging one button the weld cycle is com- cycle begins.
pleted. The only added facility that is not a part of the
Circumferential-welding Machine longitudinal ram is vacuum equipment of melt pick-
The other special fixture is a circumferential- up. The operating controls are located in the face
welding machine shown in Fig. 6. This fixture has of the control column.
a 40-ft base with a control column and ram similar From the planning sheet, the operator sets the
to the longitudinal machine shown in Fig. 7. welding conditions. When the operator energizes
Mounted on the base are three major pieces of the weld start button in the automatic mode for
tooling: a tailstock, headstock and catshead. the tungsten arc, the following sequence takes place:
Each of the three major pieces of tooling has motor-
ized travel along the base as well as hand cranks for 1. Part rotates to a limit switch.
inching and brakes to lock them in place foroperation. 2. Part stops and torch travels down.
The catshead shown in Fig. 8, which can be con- 3. Arc is initiated at a current level lower than
sidered as the heart of the machine, contains the welding current.
Current up-slope time starts.
hydraulically operated external clamp with copper
backing bar, temperature-controlled resistance-type At approximately 50% of current up-slope,
preheat facilities, inert-gas backing facilities, rotat- the cold wire starts feeding into the weld
puddle.
ing speed-controlled power drive, high-frequency
stress-relieving coils, weld-grounding brushes and a At approximately 75% of current up-slope,
shot pen for locating the catshead for operation. travel starts.
For loading, the head is placed on the tailstock and Weld current reaches welding level.
Complete pass or passes are completed and a
moved into the clamping ring. There are removable
stops on the backing ring. The stops locate the limit switch is energized to start current decay.
head over the center of the backing. The torch is At approximately 50% down the current decay
then brought over the weld seam and the stops on slope, cold wire is timed out.
the ram are set. This permits the operator to locate At a low current, the arc is extinguished and
the torch over the weld seam when both parts are in torch-gas purge timed out.
the machine for welding. The ram is retracted, and 11. Control lights on the panel indicate com-
the chamber head is partially clamped. The other pletion of the weld.
component is placed on the headstock and moved The submerged-arc welding procedure is se-
into the clamp and against the head. The clamp is quenced the same as the tungsten-arc weld, with
then closed with a hydraulic cylinder and locked in the added feature of crater elimination.
place. The hydraulic cylinder is removed for weld- High-frequency induction stress-relieving coils

WELDING JOURNAL | 1241

 are permanently mounted on the opposite face of
the catshead from the weld clamp, as shown in
Fig. 9. Immediately after welding is completed,
the assembly is pulled by the tailstock to position
the weld joint into the coil. The assembly is stress
relieved for 10 min at 1150° F.
Auxiliary Equipment
Boom Manipulator
Boom-type manipulators shown in Fig. 10 were
selected for their flexibility. They have a 14-ft
boom with a 14-ft vertical traveler and a 360-deg
rotation movement. The welding positioners are
Fig. 9—High-frequency stress-relieving located at weld stations under each boom. Welding
coils mounted on back of the catshead fixtures shown in Fig. 11 are then used on the
positioners. Copper is used for backing and the
fixtures are equipped to be heated to a range of 400
a. =~ to 600° F. The backing is machined to introduce
argon gas behind the molten pool, and all welding is
done directly into gas from one side only.
The boom manipulator is used to weld auto-
matically the bosses into heads and various rings on
nozzles. The tungsten-arc and submerged-arc heads
are mounted on the booms. All the controls for the
two processes and positioning equipment are
mounted on one control] panel to reduce set-up time
and provide the flexibility required for handling the
parts and tooling. All of the motor controls and
relays are in a central console shown in Fig. 12.
The operational controls are in a 15 x 15 x 6-in.
control pendant where process, polarity, welding
variables anu conditions may be set up or changed.
These control pendants are on a pedestal which
will stand on the shop floor or fit into special holders
on the workstands around the welding positioners.
Precision dials are used on all the potentiometer
Fig. 10—View shows boom manipulator faces to assist in returning to the same settings.
with weld positioner located for welding The boom has also been utilized for inside-out weld-

Fig. 1l—Welding fixtures used for the Fig. 12—Motor controls and relays of boom manipulator
positioners under the boom manipulator and welding lathe are located in a central console
 Fig. 14—Welding lathe used for welding
circumferential parts from the outside

Fig. 13—View shows boom manipulator being utilized

for inside-out welding into a gas backing
on a special motor-case assembly

ing on special motor-case assemblies as seen in Fig.

13. In these instances, the parts are rotated on
precision turning rolls while the boom extends in-
side the parts, welding from one side only.
Welding Lathe
A welding lathe shown in Fig. 14 is utilized for
welding circumferential parts from the outside.
An example of this is the joining of the connection
skirt to the pressure vessel and heat-treatment holding
ring. A high-frequency induction stress-relieving
and preheat coil is mounted permanently on the ways
for stress relieving these welds immediately after
welding.
Stretch Press
The biggest aid to welding production is the 600-
ton stretch press shown in Fig. 15. This tool is
used to size the cylinders and the heads for welding.
The cylinders or barrel sections are normally welded
about 1°% smaller than the required diameter.
After welding and furnace stress relieving, the Fig. 15—View shows a 600-ton stretch
press used to size cylinders
sections are sized on the stretch press. A tolerance
of about +0.005 in. on the diameter can be main-
tained and out-of-round conditions are eliminated. lieving equipment is used to stress-relieve welds
The heads are spun on a mandrel and are ex- immediately after welding in order to minimize
plosively sized in a form die. In some cases, how- cracking in the alloy used. Coils specially designed
ever, the heads are set over the stretch press and to the contour of the part are used. In a few cases,
sized prior to welding. However, this requirement the coils are also used for preheating the parts.
is never more than about 0.030- to 0.040-in. stretch In some assemblies such as the cylinders which do
on the diameter. Coming into the picture more and not lend themselves to induction, stress relieving
more are the barrel sections which will be formed by is done in a furnace.
rolling and welding a thick section, then forming by Conclusions
the hydrospin process to the required thickness.
1. Properly designed weld tooling and fixturing
This cold work gives much better properties to the
greatly simplifies the welding of large-diameter thin-
cylindrical sections. The operation is done on a
walled vessels.
mandrel that has been turned to about 1% less than 2. The “‘inside-out’”’ welding approach is a major
the required size to allow a stretching operation
advance in reducing the complexity and cost of the
before welding to the heads.
weld tooling and fixturing.
induction-heating Coils 3. The quality of welds obtained is improved
High-frequency 3000-cycle induction stress-re- using this technique.

WELDING JOURNAL | 1243

 Practical Welder

and Designer

Christmas Trees—

Made to Order

How one community constructed a

/4-ft-high steel Christmas tree

that can be used for years to come

BY ROBERT E. HAAS

Using a jig-welded TV tower fora ‘“‘trunk,’’ Larry

Gehrlein, owner of Larry’s Welding Shop, Erie,
Pa., hung steel rings for ‘““‘branches’”’ to make a 74-
ft re-useable Christmas tree in a giant good will dis-
play for West Erie Plaza merchants last Christmas.
Air Force surplus tow cables supported nine rings
bearing 450 colored lights.
‘“‘We had to get flexibility into the tree design,”
it was explained, ‘‘so that the tree could withstand
winter winds and snow. The resilient tow cables
do the job, literally ‘floating’ the rings around the
Fig. 1—Seen by day—74-ft tower consisting of four diagonally steel tower and allowing play up to 12 in.” Flexi-
braced structural sections and rings with tinsel and ROBERT E. HAAS is District Engineer, The Lincoln Electric Co.,
holding lights Buffalo, N. Y

Fig. 2—Four winches—one each for the four cables suspend- Fig. 3—Bottom section of tower as welded to the cross chan-
ing the tree rings nel member—in turn bolted to heavy concrete footings
bility in the design permitted the tree to sway in
the breeze. This produced a beautiful, sparkling,
lifelike effect at night with the rings covered with
tinsel and the lights glowing.
Four tow cables suspended the nine rings that
ranged in diameter from 25 ft at the bottom to 18
in. at the top. Each cable ran through pulleys at
the tree top and down the tower to fabricated
winches near the tree base.
‘“‘We devised the four winches ourselves,” said
Gehrlein, “‘to suit the job. The rachet stop on each
winch can be locked in position so that tree cannot
be readily molested.”
Individual pieces of cable fastened the four '/s-in.
suspending cables to the steel rings through steel
loops welded to the rings. The rings were made by
bending sections of 1-in. electrical conduit to the
proper radius and welding them into half sections.
Field bolting was used for final assembly of each
half section.
Outdoor wire and sockets supported and supplied
power to the colored bulbs; the wire was taped and
tied to the rings at intervals. The rings were spaced
7 ft apart. A 4-ft aluminum star, also lighted,
topped the tree. Punching a hole in the star’s
center reduced wind load.
Corner members of the tower’s structural section
consisted of 2- and 1',.-in. angles; the lighter mem-
bers were used near the top. The angle iron used for
cross bracing was '/, x 1'/, in., and crossed 5-in.
channel iron members formed the base, which was
directly welded to the tower legs and braced with Fig. 4—Christmas tree seen by night
s-in. gusset plates. The base was anchored with
l-in. bolts to four individual footings positioned at guy cables tied them to the bottom ring of the tree.
each corner of the tower. These footings, each 4 ft Disposal of the tree at the end of the Christmas
high and tapering from a 24-in. square base to an season posed no problem. The rings could be
18-in. square top, were completely buried with only dropped in a matter of minutes. Dismantling the
the top protruding above ground. Concrete piers, tower was a simple matter, since it consisted of
each a 12-in. sq. column and 3 ft long, were also three 20-ft and one 10-ft section fastened together
buried around the perimeter of the tree; four safety with bolts.

Metallizing Protects Parts from Corrosion

Dix Engineering Co., Lincoln Park, Mich., sprays Fig. 1—Alloy wire is sprayed on 4-ft long piston r
deposits of Hastelloy alloys B and C on new and handling of sulfurous acid
worn machine parts to increase their service life
when exposed to hydrochloric acid, sulfuric acid,
ammonia, chlorine and other corrosives used in
the chemical industry.
These corrosion-resistant alloys, in the form of
1 s-in. diam wire, are applied with conventional
metallizing equipment to round or irregularly shaped
parts like the packing glands or bearing sections of
shafts, the hubs of impellers and the linings of new
pump casings.
After grit blasting or machine preparation, the

Based on story from the Haynes Stellite Co., Div. of Union Carbide
Corp., Kokomo, Ind
 WIRE ommended Metallizing Practices,” published by
OXY-FUEL GAS
the AMERICAN WELDING Society, Committee on
COMPRESSED
AIR Metallizing. )
FLAME The alloy wire is melted in the metallizing gun
MELTING WIR
with an oxyacetylene flame. Air converges where
the wire melts and atomizes the alloy. The alloy,
in a semiplastic state, strikes the workpiece under
AIR ENVELOPE an average air pressure of 65 lb. There is no fusion
PREPARED BASE after spraying. The metals bond mechanically.
WIRE AND GAS NOZZLE MATERIAL Both alloys can be easily machined or ground.
Fig. 2—Schematic view of metallizing process The sprayed metal deposit after finishing can be
0.040 in. thick or much more depending on the build-
base-metal area to be sprayed is heated to approxi- up required. In cases where the base metal is
mately 200° F to eliminate any condensate. Then not corrosion resistant, the sprayed deposit of alloy
the part is built up with the Hastelloy alloy sprayed is sealed with a micro-crystalline wax before finishing.
deposit. Other types of preparation are used, Sprayed alloys, while perhaps less efficient than
depending on the machinability of the base metal solid alloys in resisting severe corrosion, perform
and other variables. (For guidance, refer to “Rec- an excellent job in many corrosive environments.

Fig. 1— Telescoping handle permits extension of torch tip Fig. 2—Split-second head adjustment to any angle keeps
into recessed corner welder fatigue low and quality high

Birth of a New Welding Torch

BY FORDE M. SIMMS AND JOHN V. WARIN

It is called a controlled angle torch. As a new Thus, in our daily work with tungsten inert-gas arc
development, it was not born in a vacuum or in welding, it was necessary to explore a number of
a laboratory. Instead it was developed at the designs. Perhaps the problem was more acute than
Falstrom Co., in an attempt to do specific welding usually encountered, since Falstrom is a prime
jobs better, faster and more economically. To manufacturer of electronic and other quality type
understand the new torch fully, its historical per- cabinets, consoles and panels of aluminum, stainless
spective is worth looking at closely. steel and other special materials. Consoles and
The rapid development and universal acceptance cabinets provide very little room in which to work,
of electric arc welding has led to a number of in- and in some cases the corners and recesses which have
ventions covering electrode holders or torches. to be welded are almost impossible to reach.
At Falstrom, a number of straight torches in
FORDE M. SIMMS and JOHN V. WARINSKY are with Falstrom,
Passaic, N. J different head-lengths are used. The stockroom

1244 | DECEMBER 1960

 Fig. 4—Design of controlled angle torch

2. To develop a torch which would permit longi-

tudinal adjustment on the job so that recesses and
hard-to-get corners could be reached.
3. To find a means for accomplishing this com-
Fig. 3—The controlled angle torch—rating: 180 amp ac-dc plete flexibility and control which would not make
continuous duty; 350 amp ac-dc intermittent duty the torch heavy or unwieldy. Ruggedness was
important, but so was lightweight.
also includes anglehead torches which are familiar 4. To find a means for providing continuous
to most welding operators. The one shortcoming flexibility without the problem of work hardening.
of all the torches however, was the lack of flexibility 5. To produce a torch which would be com-
and adaptability. Whenever a different angle or petitive in price to conventional rigid straight or
a longer ‘‘reach’’ was required, it was necessary to angular torches.
break down and set up for a different torch. In 6. To create a design which would make it pos-
an operation such as encountered at Falstrom where sible to speed up production and to cut fabricating
quality is king and where high operating costs can costs on a wide variety of aluminum, stainless steel,
put one out of the competitive picture, the lost copper and other metal consoles, cabinets and panels.
production time required to obtain replacement Each objective has since been realized. Thus
torches, to change from one torch to another, to the torch now being used at Falstrom has a telescop-
adjust the new torch to proper operating conditions, ing handle as shown in Fig. 1 that makes it possible
etc., was a growing concern. A research project to extend the torch tip into recessed corners. More-
was, therefore, set up to find or develop a torch over, the torch head can be adjusted to reach around
with controlled an ilar movement as well as con- corners. Another feature is that the head can be
trolled longitudinal :novement. quickly adjusted to angles as illustrated in Fig. 2.
It was known that the torch had to be simple in The entire torch assembly may be seen in Fig. 3,
design, rugged in construction and light in weight. while reference to Fig. 4 illustrates its design.
Split-second head adjustments were also necessary, Continuous flexibility of the head is achieved by
and it was desirable that the adjusted position be the helix construction formed by inter-twining of
capable of being held without deviation. Going the copper cooling water and gas lines. This pro-
back to 1919, a complete investigation of past and vides a rigid yet flexible core which is brazed to the
existing torch designs which might be suitable was cooling head. The entire assembly is then integrally
made. No less than ten different attempts to molded and bonded with neoprene into a flexible
achieve some of the things being sought were found. insulated and heat resistant unit. This unit is
Innovations announced even as recently as two then inserted in a laminated phenolic handle suitable
years ago were not completely satisfactory. There- for manual or machine use.
fore, at Falstrom, design was undertaken on a new A ceramic cup is pressed over the upper portion
controlled-angle torch with the following objectives of the torch and firmly twisted so that the tungsten
in mind: electrode centers itself. The telescoping handle
1. To develop a torch which could be adjusted makes it possible to “extend” the torch into re-
on the job without the use of tools, and which would cessed areas; and the helix design permits continuous
hold the adjustment without slipping. controlled angle flexibility.

Outstanding weld quality and a production-time

Superior Welds saving of 60% are the results gained from submerged-
arc welding of storage tanks at Superior Tank Corp.,
Tucker, Ga.
Make Superior Tanks This company fabricates high-tensile, low-alloy
F. A. HENNINGER is General Superintendent, Superior Tank Corp.,
Tucker, Ga., and W. F.BELDON is a Welding Sales Engineer, Linde Co
SY Ff. A. HENNINGER AND W. F. BELDON Birmingham, Ala

WELDING JOURNAL | 1247

 war ‘c
ph
ad A) B
~
Fig. 1—Submerged-arc weld- Fig. 2—Joggling machine offsets edges of tank section,
ing head completes longi- prior to fitting of preformed heads
tudinal, square-butt weld on
sin. thick steel tank shell
Speed and Quality
Superior Tank receives its steel from the mill in
steel tanks, in 4- to 6000-gal capacities. They are two forms—preformed tank heads and flat plates
designed for everything from propane, and other for center sections.
liquefied-petroleum products, to hot water. Each plate is sheared to size, roll-formed and
The deep penetration of the submerged-arc welds square-butt welded along the longitudinal seam by a
permits all seams to be completed in just two passes. submerged-arc welding head mounted on a side-
And because of the penetration and the smooth weld beam carriage (Fig. 1). A water-cooled backing bar
bead, no pre- or postweld treatment is needed, ex- is incorporated in the welding fixture.
cept when specifically demanded by service re- Section edges, */; in. and less, are offset on a jog-
quirements of special tanks. gling machine (Fig. 2) to fit under the edges of the
tank heads. After this operation, the shells are
pressed into the heads on a special machine (Fig. 3).
The tank unit is then moved to a girth-seam weld-
ing station. Variable-speed turning rolls rotate
the tank under two submerged-arc welding heads,
mounted on a stationary carriage. The two tank
heads are simultaneously welded to the shell (Fig.
4). Approximate welding conditions for both the
longitudinal and girth seams are 650 amp, 34 v,
d-c constant potential.
This time-saving operation, combined with the
high welding speeds—24 ipm on longitudinal seams,
40 ipm on girth seams—add up to a 60% reduction
in total fabricating time, on the basis of the manu-
facturer’s production records.
Fig. 3—Hydraulic press forces preformed tank ends over off- To meet the ASME code for unfired pressure ves-
set edges of tank center section before welding sels, the tanks are subjected to 400-psi hydrostatic
tests, hammer tests with a 10-lb mall and spot X-ray
tests where girth and longitudinal seams intersect.
oe Fig. 4—Two sub- Only 0.008% of the completed tanks show any
merged-arc weld- sign of weld porosity. In fact, out of a total annual
eo ing heads simul-
taneously weld production of almost 6000 tanks, only three re-
/
both tank ends to quired any weld repair. Superior Tank attributes
center section this remarkable record to the unusually high weld
ges “” quality and general shop practices. Certainly it is a
7: ic 7. 9 record that proves a point—superior welds resuit
i | in superior products.

Fig. 5—Over 400 completed propane tanks are shown

awaiting shipment
 Society News

European Authorities to
Share Technical Program at

42nd Annual Meeting in New York City

What promises to be one of the that the AWS honor will be accorded Commission III) ‘“The Solutions
most unusual technical programs to an _ individual outside this Adopted in Some Difficult Applica-
ever to be presented by AWS has country. tions of Flash Welding’—M. E.
been scheduled for Apr. 17-21, 1961, Bylin, Sweden.
at the Commodore Hotel in New Educational Lectures Commission V “Inspection and
York City, when foreign experts Measurements of Properties of
from the International Institute of As an added attraction, two Welds on Plastics’’ G. A. Homes,
Welding will join American educational lectures will be given Belgium.
colleagues in technical presenta- over to a fundamental discussion (Commission IX and X) “The
tions at the 42nd Annual Meeting. by the noted Russian welding Influence of Residual Stresses and
The unprecedented arrangement authority, N. N. Rukalin of the Metallurgical Changes on Low
was made as a result of the over- National Committee on Welding of Stress Brittle Fractures in Welded
lapping of the two meetings—that the U.S.S.R. His subject, to be Steel Plates’—-A. A. Wells, United
of the IIW being scheduled from presented on consecutive days, will Kingdom.
April 11-19th. At this time, 300 be, “‘Heat Sources, Heat Flow and (Commission X1) ‘‘Pressure Vessel
top welding authorities from abroad Heat Effects in Welding.”’ Design Requirements in the Future”
will meet for the first time in this W. B. Carlson, United Kingdom.
country. In addition, a number of The IIW Papers Commission XII) ‘“‘Considera-
papers will be presented by members A special session devoted to tions on the Use of Gas Mixtures in
of the American Institute of electroslag welding is tentatively Shielded Arc Welding with Con-
Electrical Engineers. The result scheduled to be addressed by B. E. sumable Electrode’’—M. M.
bids fair to be an exceptional pro- Paton, director, Paton Institute of Komers, L. Wolff, West Germany.
gram. Electric Welding in Kiev (named Commission XIII) ‘“The Deter-
The Technical Papers Committee after his father) where the process mination of the Fatigue Limit by
has tentatively arranged for 22 was developed for industrial ap- Means of a Single Welded Specimen
sessions covering subjects from theo- plications. West European applica- or Assembly’—M. R. Cazaud,
retical research to practical applica- tions of this process will be discussed France.
tions. Fifteen sessions will be by F. G. Danhier of Belgium. An Commission XV) ‘“The Calcula-
sponsored by AWS, four sessions by idea of the scope and the variety of tion of Welded Assemblies: New
IIW and three by AIEE. The IIW the subjects to be covered in other Experimental Bases and Their In-
papers will be presented in English. sessions by IIW members may be fluence on Methods of Calculation”’
All but one session will have three gained from the following list which A. Van Douwen, Netherlands.
papers, making a total of 65 papers. is arranged in order of the commis-
A detailed program will be published sions giving rise to the investigation. Welding Exposition and Other Events
in the January issue of the JOURNAL. Commission |) “‘Problems in Con- The annual Welding Show will
nection with the Determination of be held in the New York Coliseum
Adams Lecture the Technological Characteristics of April 18-20th. Here, manufac-
As in previous years, the opening Brazing Filler Metals and Fluxes” turers and distributors will have an
day will feature the Adams C. G. Keel, G. M. A. Blanc, extraordinary opportunity for ex-
Memorial Lecture—this time to be Switzerland; J. Colbus, West hibiting to an anticipated record
given by H. Granjon of the French Germany. attendance.
Welding Institute. His topic will be Commission II “The Role [of Other events of interest will
“Studies on Cracking of and Trans- Hydrogen in Arc Welding with include plant tours, a well-rounded
formation in Steels During Weld- Coated Electrodes’—N. Christen- program for the ladies and many
ing.” This is the second time sen, Norway. committee and special meetings.

WELDING JOURNAL | 1249

UNITED ENGINEERING CENTER

Progress in Building Progress in Sections

To District No. 1 under Director George Kirkley goes
the distinction of being first “over the top.”” Every
section in the district has pledged 100% or more of its
goal.

Honor Sections
Section Goal, % Section
Oklahoma City 125 Eastern Illinois
Mahoning Valley 113 Holston Valley
Hartford 104 Long Beach
Kansas City 102 Louisville
N. E. Tennessee 102 New Hampshire
Puget Sound 102 N. Central Ohio
Tulsa 102 North Texas
Baton Rouge 101 Northern N.Y.
Colorado 101 Olean-Bradford
Detroit 101 Pascagoula
Niagara Frontier 101 San Antonio
Providence 101 Sangamon Valley
Rochester 101 Santa Clara Valley
St. Louis 101 Syracuse
Birmingham 100 Toledo
Boston 100 Western Mass.
Bridgeport 100 Wichita
Chattanooga 100 Worcester
Dayton 100

Pledges Needed to Meet Goal

Work forges ahead on the United Engineering Center as Section Needed Section Needed
stainless-steel mullions and column covers and the limestone
facing rise to sheath the new AWS headquarters. Soon the Philadelphia 82 Richmond 400
glass windows and spandrels will be installed to complete Mohawk Valley 100 Western Michigan
the gleaming curtain wall of the structure Tri-Cities 100 York-Central Pa.
Nashville 145 Cincinnati
Albuquerque 150 Saginaw Valley
Anthony Wayne 150 Salt Lake City
Shreveport 195 Portland
Ajizona 200 Indiana
Nebraska 200 Stark Central
Maryland 215 Fox Valley
New York 218 Washington, D. C.
Carolina 245 Lehigh Valley
Northwestern Pa. 280 Columbus
J. ALK. 295 Long Island
lowa 300 Northwest
Contribute Now to the Michiana 300 Milwaukee
Mobile 300 San Francisco
Peoria 340 New Jersey
San Diego 355 Houston
New Home jor AWS
Susquehanna (and Sabine)
Valley 355 Chicago
lowa-lllinois 370 Pittsburgh
New Orleans 390 Cleveland
South Florida 395 Los Angeles
Madison-Beloit 400

1250 | DECEMBER 1960

 directors are: C. L. Kreidler,
Dist. No. 2; P. J. Rieppel, Dist.
No. 5; George O Bland, Dist. No.
8; W. J. Erichsen, Dist. No. 11.
Chairman of this year’s nominat-
ing committee was Past-President
C. I. MacGuffie who was assisted
by eleven district representatives
and three members-at-large.

Nominated for President

A. F. Chouinard
Graduated from Purdue Univer-
sity in 1931 with a B.S. degree in elec-
trical engineering, Mr. Chouinard
has spent all of his professional life in
the engineering field.
He has worked in an engineering
capacity for the Chicago Surface
Lines, the Champion Chemical Co.
and Stewart-Warner Corp.
Since 1939 he has been employed
by National Cylinder Gas Co.
During this time, Mr. Chouinard
has designed many types of welding
and cutting equipment and ma-
chines, and has some 20 patents
issued in his name. For 14 years
manager of the Research and De-
velopment Department of NCG, he
is now director of research and
development for the Division. His
department is responsible for the
development and application of all
&

A. F. CHOUINARD of the company’s products and

processes.
Mr. Chouinard has been active
in the AWS in both local and na-
tional activities. He is a _ past
chairman of the Chicago Section
and is currently a national vice
president.
society Nominates National In 1957, Mr. Chouinard was ap-
pointed chairman of the Section
Advisory Committee. He is a
Officers for 1961-62 member of the Executive and Fi-
nance Committee, and is chairman
of the Technical Council.
The National Nominating Com- president and vice presidents (who He has presented many technical
mittee has submitted its choice of serve w'thout seniority) is one year talks to AWS sections throughout
candidates to serve as national and for the directors-at-large and the country. These talks include
officers in the eight elective posts of the district directors, three years, discussions on oxygen cutting,
president, three vice presidents and starting in June 1961. Provision metallurgical aspects of flame hard-
four directors-at-large. In addi- is made for the full complement of ening, specialized cutting applica-
tion, the District Nominating Com- directors by an annual rotation tions, foundry applications of many
mittees for Districts No. 2, 5, 8 and repeated every three years. oxyacetylene processes, etc. Mr.
11 have selected their candidates for Heading the list of candidates is Chouinard has also written several
district directors. A. F. Chouinard of National Cyl- technical articles which have ap-
According to AWS By-laws, the inder Gas Division of the Chemetron peared in different trade jounrals.
candidates, together with a brief Corp. He has been nominated for He was chairman of the commit-
biography, are to be submitted to the presidency. The three vice tee that prepared Chapter 4 (Gas
the National Secretary and then presidents nominated to serve with Welding Equipment and Materials),
published in the December issue Mr. Chouinard are Jay Bland, J. H. for the Third Edition of the WELD-
of the WELDING JoURNAL. Elec- Blankenbuehler and C. E. Jackson. ING HANDBOOK, published in 1948,
tion ballots are to be mailed to the For directors-at-large, the Com- and also was a member of commit-
corporate membership on or before mittee has submitted the names of tees preparing other chapters for
Dec. 26, 1960, and must be returned A. N. Kugler, E. C. Miller, J. E. this edition. Mr. Chouinard was
by Jan. 26, 1961, to be counted as Dato and T. E. Jones. Chosen chairman of the committee that
valid. The term of office for the as candidates to serve as district prepared Chapter 23 (Gas Welding

WELDING JOURNAL } 1251

Equipment and Materials) for the degree of Electrical Engineer. He tional Bureau of Standards (1930—
Fourth Edition of the WELDING was employed at the Westinghouse 36); U. S. Naval Gun Factory,
HANDBOOK. Electric Corp., in Pittsburgh, for Metallurgy and Testing Division
In addition to the AWS, Mr. 23 years, starting as a design engi- (1936-37); and Naval Research
Chouinard is a member of the IAA, neer. He was manager of welding Laboratory (1937-46). In 1946, he
AISE, ASM and is a registered apparatus engineering, in charge of accepted a position at the Metals
professional engineer in the state of all engineering on motor generator Research Laboratories of Union
Illinois. He is also a member of the sets, transformer welders, automatic Carbide Corp., and in 1956 was
Chicago Engineers Club. welding equipment and welding made manager of their welding
accessories at the time he left group.
Westinghouse in 1946. Since then In 1957, Mr. Jackson was trans-
Nominated for he has worked for Hobart Brothers ferred to the Development Labora-
Vice President Co., in Troy, Ohio, as design engi- tory of the Linde Co., at Newark,
neer. N.J. He is now associate manager
Jay Bland Mr. Blankenbuehler has 34 of Electric Welding Development.
patents on welding apparatus. He Mr. Jackson’s AWS activities
Jay Bland graduated from the is a member of the honorary engi- include: director for District No.
University of Rochester with a B.S. neering society, Tau Beta Pi, and 3 (1953-56); past chairman of the
in Chemical Engineering in 1933 honorary military society, Scabbard Washington, D. C., and Niagara
with the highest distinction in his and Blade, and is also a Fellow in Frontier Sections; chairman of the
class. After earning his M.S. in the American Institute of Electrical Educational Activities Committee;
Metallurgy at Columbia University Engineers. presently chairman of Publications
in 1934, he began employment with A member of the American Ord- and Promotion Council, and a Na-
the Sun Oil Co. at Marcus Hook, Pa. nance Association, American So- tional Vice President. He was also
In 1939 he entered the N. Y. Naval ciety for Metals, the Ohio Society a representative on Mission 250 of
Shipyard and served as welding of Professional Engineers, a regis- the Organization of European Eco-
section head, continuing in this tered Professional Engineer in Penn- nomic Cooperation in 1955, in
post until 1951. He then became sylvania and Ohio, he is also active Europe, under the sponsorship of
head of the Metals and Welding in the Troy Rotary Club. the Welding Research Council and
Section, Engineering Research Dept. During World War II he received the Ship Structures Committee.
of Standard Oil Co. of Indiana. a Certificate of Commendation from He has been active on a number of
From 1958 to date he has been em- the United States Navy for electri- committees of the Welding Research
ployed as manager, Welding De- cal design work done for the Navy. Council, particularly those which
velopment at the General Electric He has presented a number of pertain to weldability and interpre-
Co. Knolls Atomic Power Labora- papers before various sections of the tive reports. Mr. Jackson has pre-
tory, Schenectady, N. Y. AIEE and AWS. A past chairman sented numerous talks before various
Mr. Bland has been an active and secretary of the Dayton Section sections, and has authored more than
member of AWS, having served in of the AWS, he served from 1952 to 30 papers on welding and metallurgy.
the following capacities: (past) 1959 as a national director. His Mr. Jackson was given the Dis-
chairman of the Chicago Section; present offices include chairman tinguished Civilian Service Award
director-at-large on the Board of of the special committee on member in 1945 by the Secretary of the
Directors; member-at-large of the classes, member of the Technical Navy. Healso received the Samuel
National Nominating Committee; Papers Committee, Executive and Wylie Miller Memorial Medal in
and chairman of the Committee on Finance Committee, Honorary 1956 and delivered the Adams
Awards. He has been author or co- Membership Committee, Office As- Memorial Lecture in April 1959.
author of many technical papers signment Committee and the Weld-
covering welding and _ inspection, ing Handbook Committee. He was
and has addressed several AWS chairman of the committee that
sections on these subjects. A mem- wrote Chapter 30 on Arc Welding Nominated for
ber of the committee that prepared Equipment of the Fourth Edition Director-at-Large
the section on inspection in the of the WELDING HANDBOOK. He is
WELDING HANDBOOK, he was also now a vice president of the AWS and 1961-64
chairman of the committee that chairman of the Districts Council for
wrote the chapter on filler metals in the year 1960-61. J. E. Dato
the Fourth Edition. In 1956 he
won the Lincoln Gold Medal. Having learned the welding trade
Among his other affiliations are Nominated for in his father’s shop at Fort Worth,
ASM, SNT, Phi Beta Kappa, Vice President Tex., Mr. Dato joined the Linde
Sigma Xi, the Metal Science Club Co. in 1936 at the age of 21. In
(N. Y.) and several technical com- C. E. Jackson 1942 he became service supervisor,
mittees of the Welding Research rising to the position of assistant
Council. Clarence E. Jackson was born in manager of Process Service in 1952.
Graceville, Minn. He graduated He joined Linde’s Electric Welding
from Carleton College with honors Department in New York City when
Nominated for in physics in 1927, and engaged in it was formed in 1953 and has been
Vice President graduate work at George Washing- connected with this department
ton University. Upon completing since that time. He is now general
J. H. Blankenbuehler his studies, he joined the National sales manager of the department.
Bureau of Standards. Mr. Dato joined the Socrety in
John H. Blankenbuehler was born Mr. Jackson was associated with 1937 and since that time he has
in Elizabeth, Pa., and graduated the following branches of the govern- been active on various committees,
from Lehigh University with a ment: Metallurgy Division, Na- mostly in connection with the

1252 | DECEMBER 1960

promotion and arrangement of con- Nominated for Oak Ridge National Laboratory,
ventions and welding expositions Director-at-Large operated by Union Carbide Nuclear
and also as a district director. At Co., for the Atomic Energy Com-
the present time he is chairman of 1961-64 mission, Oak Ridge, Tenn.
the Convention Committee, mem- Associated with Union Carbide in
ber of the Exposition Committee T. E. Jones Oak Ridge since 1948, his prior ex-
and a member of the Sustaining perience included nonferrous metal-
Membership Committee. Born in Ilion, N. Y., Mr. Jones lurgical work in Montana and Penn-
He lives in Chappaqua, N. Y., is received his A.B. degree from Co- sylvania, teaching metallurgical en-
married and has two children. lumbia University in 1927 followed gineering at Purdue and Wayne
Among his many hobbies are golf by a BS. in 1929 and M.E. in 1930. Universities, and World War II
and square dance calling. He started employment’ with commissioned service with Navy.
Federal Machine & Welder Co. in He received a B.S. in Metallurgical
1930 as design engineer, becoming Engineering from Missouri School
chief engineer in 1933, sales manager of Mines and M.S. from University
Nominated for in 1935, assistant general manager of Idaho. He is a registered pro-
in 1939 and vice president and fessional engineer.
Director-at-Large manager of the Welding Division in He is actively engaged with
1961-64 1942. nuclear standardization committees
In 1945 Mr. Jones with E. W. of American Nuclear Society, ASM,
Forkner founded in Cincinnati the ASTM, ASME Boiler Code and
A. N. Kugler Precision Welder & Machine Co. of Code for Pressure Piping. He
which he is president and treas- served two terms as AWS district
urer. He holds the same offices in director and is chairman of AWS
Born in New York City, Mr. Precision Welder & Flexopress Corp. Educational Activities Committee
Kugler completed his early schooling and Precision Welder & Flexopress and AWS Committee on Piping and
in that city and graduated from Canada) Ltd. Tubing. Past chairman of local
Stevens Institute of Technology in Active in the resistance welding sections of AWS and ASM, member
1925 with an M.E. degree. He was industry for twenty years, Mr. of Tau Beta Pi, Phi Kappa Phi and
first employed with Barker and Jones has been chairman of the Sigma Xi, he published papers and
Wheeler, Consulting Engineers for technical committee and president has given talks on subjects pertain-
powerplant and utility installations, of the Resistance Welder Manufac- ing to zirconium, liquid metal cor-
and then with RCA Photophones, turers Association, member of the rosion, reactor safety codes, reactor
Inc., as engineer on sound motion Welding Equipment Industry Ad- fabrication and inspection. He is
picture installations. In 1929 he visory Committee during World married, has 4 children and resides
started with Air Reduction Sales Co. War II, and American delegate on in Knoxville, Tenn.
where he now holds the position of Commission III (Resistance Weld-
chief welding engineer, Marketing ing) of the International Institute
Department Equipment. Dur- of Welding from 1955 to date, at-
ing these years he was extensively tending the Assemblies in Madrid, Nominated for
engaged in many developments in Essen, Vienna, Opatija and Liege. District Director
the welding field. These include: A registered professional engineer
gas welding; brazing from early 1961-64
in the state of Ohio, Mr. Jones has
beginnings to present day com- been active on several national com-
plexes; covered-electrode and gas- mittees of the AMERICAN WELDING C. L. Kreidler
shielded arc-welding processes; all Society, including the Educational District 2, Middle Eastern
types of pipe welding; and design Activities Committee, vice chairman
of jigs, fixtures and machinery three years; Organization Structure C. L. Kreidler received his under-
components. He has been an in- Committee, advisory; Sustaining graduate engineering education at
structor at Pratt Institute, N. Y., Membership Committee, chairman Lehigh University, graduating in
and has served as consultant to the one year; Public Relations Com- 1930. Continuing at Lehigh he
U.S. Army Edgewood Arsenal. mittee and Technical Papers Com- earned his masters degree in 1932.
Mr. Kugler has written exten- mittee. He was given the Meri- From 1936 to date he has been em-
sively on the subject of welding. In torious Certificate Award of AWS in ployed by the Lehigh Structural
addition to many papers on gas and 1958. Steel Co., Allentown, Pa. where he
arc welding and brazing, his contri- Mr. Jones is a member of the Tau now holds the position of chief
butions include chapters, sections Beta Pi, Phi Kappa Psi and the engineer. A registered professional
and whole texts among the follow- Cincinnati Rotary Club and is engineer in the State of Pennsyl-
ing: WELDING HANDBOOK, Marks’ listed in ‘‘Who’s Who in Commerce vania, Mr. Kreidler is also a past
Mechanical Engineers’ Handbook, and Industry.”’ He is married, president of the Pennsylvania So-
American Machinists Handbook, resides in Cincinnati and is active ciety of Professional Engineers.
Tool Engineers’ Handbook, Standard in church and local affairs. His many activities with AWS be-
Manual on Pipe Welding, Inter- gan as a charter member of the Le-
national Correspondence Schools high Valley Section for which he has
texts and many others. Nominated for served as chairman and in other
In addition he has been and is capacities. In 1959 he received a
Director-at-Large
presently engaged with numerous District Meritorious Award. He is
technical committees of the ASA, 1961-64 chairman of the AWS Committee
IAA, ASME, API, SAE, ASPM and on Building Codes and is also chair-
the AWS. He is also past chairman E. C. Miller man of the committee preparing a
of the Technical Activities Com- chapter of the Welding Handbook
mittee of the AWS. E. C. Miller is inspection engineer, on the subject of Buildings.

WELDING JOURNAL | 1253

 Mr. Kreidler is a member of the Nominated for District Representatives
Technical Activities Committee and
Selected for the National
is active on various sub-committees District Director
of the Welding Research Council. Nominating Committee
1961-64
Eleven nominees to serve the 1961
Nominated for term as district representatives on
the National Nominating Commit-
District Director W. J. Erichsen
tee have been selected. Their
1961-64 names and addresses are listed as
District 11, Northwest follows:
P. J. Rieppel District
Born in Santa Clara Valley, No. Nominee
District 5, East Central Calif., Mr. Erichsen attended Stan- 1 G. W. Kirkley, 1086 Dryden
ford University where he won his Rd., Columbus 5, Ohio.
Graduating from Mansfield State engineering degree in 1944 and an James Cameron, ACF In-
‘College, Mansfield, Pa., with a M.S. in Metallurgical Engineering dustries, Inc., Berwick, Pa.
degree in mathematics and the in 1947. David Peterson, Air Pre-
physical sciences, P. J. Rieppel From 1944 to 1947 he was em- heater Co., Wellsville, N. Y.
continued further with graduate ployed with Joshua Hendy Iron
work at Cornell and the University Works as metallurgist. With the to be selected.
of Buffalo. He is a registered pro- Westinghouse Electric Corp., he R. J. Yarrow, 1324 Irene
fessional engineer in the State of continued in this capacity from 1947 Rd., Cleveland 24, Ohio.
Ohio. to 1950 when he became manager of Keith Sheren, Taylor Thomp-
From 1941-43 he was employed the Metallurgical Laboratory, the son Machinery Co., 8095
with the Curtiss Wright Corpora- position he now holds. Livernois, Detroit 4, Mich.
tion as a welding engineer. In 1943 His activities with AWS include L. C. Monroe, Publisher
he became associated with Battelle organizing membership with the Welder Digests, P.O. Box
Memorial Institute as welding re- Santa Clara Valley Section, vice 142, La Porte, Ind.
search engineer. He was assistant chairman and then chairman of the C. R. Rearden, Assigned
chief of the Division of Welding Section. He was a member of the Engineer, Sheffield Div.,
Engineering at Battelle from 1947 National Nominating Committee Armco Steel Corp., Kansas
53. Since then he has been chief of and since 1958 has been a member of City 25, Mo.
the Metals Joining Division. the Educational Activities Com-
D. J. Middlehurst, Big Three
Mr. Rieppel is well known for the mittee. A member of the ASM
Welding Equip. Co., P.O. Box
numerous lectures he has given at and the SNT, he has held the office
3047, Houston, Tex.
Section Meetings of AWS and for of vice chairman and chairman of
articles he has authored and co- the local chapters in both groups J. B. Ross, 11049 Kling St.,
authored for publication on welding and presently is chairman of the N. Hollywood, Calif.
research and developments. In 1962 Golden Gate Metals Con- R. E. McCormick, Sales
1947 he was co-author of a paper ference. He has presented a num- Manager, Pacific Metals
receiving the Lincoln Gold Medal. ber of technical talks before each of Co., 1900 3rd St., San
He is a member of the AWS Tech- the three societies. Francisco, Calif.
nical Papers Committee.

Nominated for AWS DIRECTORS-AT-LARGE

District Director
Term Expires 1961 1962 1963
1961-64 A. A. Holzbaur Jay Bland R. B. McCauley
D. B. Howard F. G. Singleton John Mikulak
George 0. Bland C. B. Smith E. F. Nippes
J. L. York
District 8, Midwest W. H. Hobart, Jr. J. R. Stitt R. D. Stout

G. O. Bland, who is president of AWS DISTRICT DIRECTORS

Hill Equipment Co., St. Louis, Mo.., District No. leNew England G. W. Kirkley District No. 6eCentral R. H. Hoefler
attended Lincoln College and Wash- District No. 2eMiddle Eastern E. E. Goehringer District No. 7eWest Central L. i Baugh
ing University. He first came to
District No. 3eNorth Central J. W. Kehoe District No. 8eMidwest G. 0. Bland
Hill Equipment Co., as a service
engineer in 1938. He was succes- District No. 4eSoutheast J. M. Shilstone District No. 9eSouthwest C.L. L. Moss, III
sively promoted to sales manager in District No. 5eEast Central H. E. Schulz District No. 10eWestern D. P.P. O'Connor
1947 and elected president in 1956. District No. 1leNorthwest C. B. Robinson
Mr. Bland has been an active
member of AWS since 1939. A past
chairman of the St. Louis Section he AWS PAST-PRESIDENT DIRECTORS
has also served as director of District C. |. MacGuffie G. 0. Hoglund
No. 8, the post for which he is now
candidate.

1254 | DECEMBER 1960

 KEEPING YOU POSTED

by Fred L. Plummer

e@ President R. D. Thomas, Jr., Brownrigg, Eschenburg, Hamilton, invitation to the SocrETy to hold
opened the National Fall Meeting Martin, F. Smith, Wagner, Wallace its 1963 Fall Meeting in New Or-
in Pittsburgh with an inspiring and and Woods asking questions for leans.
thought provoking address on Sep- San Antonio. Your Secretary en- On Monday October 10th, Presi-
tember 26th. The keynote address joyed a brief visit with Mr. and Mrs. dent Thomas arrived during the
was given by AISI Vice-President F. Smith at their home prior to the late afternoon at the San Antonio
C. M. Parker. Westinghouse Vice- dinner meeting. airport to join your Secretary (who
President W. W. Sproul, Jr., spoke The following day President had arrived on an earlier plane),
at the convention luncheon and pre- Thomas and your Secretary flew to Fred Smith and John Bergeron as
sented an optimsitic picture ‘““The New Orleans and drove with Clay well as a large delegation of local
New Face of America.”’ These three Birkhead to Baton Rouge for a leaders of the Democratic Party
addresses were highlights of the fine meeting of the AWS Section at the former President Harry Truman
technical program; the board, coun- Sherwood Forest Country Club arrived at the same time for a
cil and committee meetings; the ed- following a call at the home of political dinner and speech This
ucational, publicity and section offi- District Director J. M. Shilstone welcome was an appropriate prelude
cers open meetings; the plant tours; during which Mrs. Shilstone served to the evening social period, dinner
events planned for the ladies and delicious crayfish bisque, prepared and meeting at which your Secre-
other special events which were in accordance with her own special tary reviewed SociETy activities
included in the four-day program in recipe. Chairman Edley and Offi- and President Thomas discussed
which almost 700 AWS members cers Christenson, Kidman, Mire, stainless and low-alloy steel welding.
and guests participated. Cutler and Daniel presided at the Chairman Fred Smith, Secretary
Past-President G. O. Hoglund dinner meeting at which your Sec- John Bergeron and other officers
and Pittsburgh Section Members retary described Society activities including A. J. Bell, E. E. Wagner,
who assisted him in planning all and President Thomas discussed Bob Hamilton and most of the
local arrangements were perfect “Some Dramatic Applications of section directors assisted at this
hosts and must be highly compli- Stainless and Low-alloy Steel Weld- meeting.
mented on their outstanding per- ing.”’ Director Jack York and Sec- Arriving in Dallas the following
formance. All attending ladies paid tion Past-Chairmen Elborne (first morning, President Thomas and
tribute to Mr. and Mrs. W. H. Klug and Shilstone were included your Secretary were welcomed by
Kauffman and their associates who in the enthusiastic group in attend- TV cameras, convention bureau and
were responsible for the ladies’ ance. hotel representatives, Director Cliff
program. The following morning a tour of Moss, III, Section Chairman Ed
During the evening of October the Cal-Metal Pipe Corp. as a guest Mai and several other officers and
4th, President Thomas and your of Harman Cutler provided an members; presented with ‘“Texas”’
Secretary flew from New York to opportunity to inspect the high- hats and officially declared ‘“Tex-
San Antonio, Tex., for the annual frequency resistance welding of pipe ans’; and then escorted to the
meeting of the AEC Welding Forum in this new installation. Your Sec- Adolphus Hotel. Following lunch-
of which F. W. Davis is chairman. retary was pleased to meet Vernon eon with Director Moss in the
Arrangements for the meeting were Akers, winner of a Baton Rouge fabulous Ports O’ Call restaurant
made by Southwest Research Insti- Section High School Welding Com- near the top of Southland Center
tute. Participants in the sessions, petition, who displayed his project with a marvelous view of the city,
some of which were classified secret, at the Chicago Welding Exposition came a rewarding visit to the offices
included President Thomas, Past- and is now associated with this and plant of Texas Instruments
Presidents Chyle and Hoglund, company. with which one of your Secretary’s
Vice-President Jackson, Director President Thomas and your Sec- sons-in-law is associated (Nancy Lee
J. Bland and many other active retary then returned to New Orleans is Mrs. Wil T. Wakely.
AWS officers and members including with Mr. Birkhead for a late lunch The evening meeting of the North
L. J. Larson, R. E. Lorentz, M. A. with Bill Blackwell. Many mem- Texas Section (Fort Worth and
Scheil and K. Spicer. bers of the New Orleans Section Dallas) was held at the Amon
On October 5th your Secretary gathered that evening at the Engi- Carter Airport located between
joined Past-Director Percy Penny- neers Club for a social period and these two cities. Your Secretary
backer with several officers of the dinner followed by a meeting at outlined plans and activities of the
Austin Division of the Houston which President Thomas and your Society. President Thomas then
Section and ten members of the Secretary repeated their talks of discussed ‘‘Electroslag Welding for
Executive Committee of the San the previous night. Chairman L. Heavy Fabrication.”’ Chairman
Antonio Section for dinner at the E. Shirley presided, Vice-Chairman Ed Mai and Vice-Chairman J. C.
Seven Oaks Country Club and an >. Cockrell introduced the speakers Collins conducted the meeting which
evening-long discussion of section with officers C. Milford, G. Johnston followed a social period and excel-
activities. Officers Carroll, McBee, and L. Tanguis handling other lent dinner. Officers R. E. Key,
Pennybacker and M. Smith repre- meeting details. Officers and mem- R. E. Nye, V. E. Cresswell, D. M.
sented Austin with Bell, Bergeron, bers of the Section confirmed an Hoban as well as Mrs. Mai and Mrs.

WELDING JOURNAL | 1255

 Collins assisted in handling this
well-planned evening which was
concluded when most of those
present at the meeting crowded
around a T’'V set for the ten o’clock
news broadcast covering the “‘morn-
ing ceremony at the airport.”’ Pres-
ident Thomas wore his ‘Texas
Stetson” with distinction.
Activities the next day in Houston
included luncheon at the Rams
Club with Section Officers and an
afternoon at Wyatt Boiler as guests
of Jim Earthman. The Houston
Engineering and Science Society
was the site for the Section meeting
at which Chairman Don Middle-
hurst and Vice-Chairman Luther
Manchester, Jr., introduced your
Secretary and President Thomas to
speak about Society activities and
electroslag welding, respectively.
In addition to Officers Anderson,
Olson and Thompson, at least
eight other Directors of the Section
attended this meeting. David L.
Shall, who had charge of the very
successful education course given
last year with Welding Metallurgy
as the basic text, announced an
eight-lecture course to begin during
February 1961 with the WRC-AWS
book*on Weldability as a _ text.
Mr. Shall has established an out-
standing record in organizing and
conducting such courses. Hubert
Crick discussed arrangements for
the four-day meeting of the AWS
Bridge Specification Committee
Here the light-weight transformer head of a 300 KV Model is being positioned which met in Houston during the
to X-ray a circumferential weld in an airliner landing gear strut. week of October 17th with Tech-
nical Secretary Ed Fenton and
many TAC members in attendance.
High KV X-ray Your Secretary was pleased to
greet P. J. Gurklis, 30-year AWS
with 100% Duty Cycle member and graduate of Case
(while your Secretary was a pro-
Triplett & Barton 100% duty eyele X-ray fessor there).
may double the number of exposures a day Leaving Houston early on Oc-
tober 13th President Thomas and
save vital time and dollars.
your Secretary were driven to the
The fully loaded, ready to operate Triplett Beaumont-Orange-Port Arthur area
& Barton head on the 275 KV Model weighs J. J. Reilly and David Kegg for a
by tour of the Orange plant of the
only 65 Ibs. That light weight means easier American Bridge Division of U. S.
<Sperry>
~a se portability, quicker setups more time and Steel as guest of S. F. Valentine and
ULTRASONIC TESTING dollars saved. a second plant visit at the structural
shop of John Dollinger, Jr., Inc.,
And Triplett & Barton’s high KV (up to 300 where a large all-welded steel build-
comes
KV with a full 10 milleamperes output) al- ing frame was being fabricated
INDUSTRIAL X-RAY
lows for shorter exposures with the required under the direction of M. J.
definition more time and dollars saved. Williams and members of the Dol-
linger family. The new Sabine
MAGNETIC PARTICLE Call on Sperry Sales Engineers for the best in Section, formerly a Division of the
nondestructive testing systems and equipment. Houston Section, held their dinner
meeting at the Flying Chef Cafe,
Jefferson County Airport, opening
with a special session with President
Spefry Products Company Thomas and your Secretary prior
DIiVISsSIton oF HOWE SOUND COMPANY to a social period for the group which
enjoyed the generous buffet dinner
2412 Shelter Rock Road, Danbury. Connecticut and the well conducted meeting
For details, circle No. 8 on Reader information Card
1256 | DECEMBER 1960
at which the program of the previous Mooney officially represented na-
night was repeated. Chairman J. tional headquarters at the October
A. Mayo, Vice-Chairman S. W. 13-14th New England Regional Performance
Scurlock and Secretary-Treasurer Conference and Welding Show held
H. R. Johnston were assisted by in Boston with A. J. Rosenberg
seven of the ten remaining members serving as general chairman. Si- and
of their executive committee. multaneously on the west coast the
The following afternoon D. G. Santa Clara Section was sponsoring
Ellis met President Thomas and its large and successful conference
your Secretary at the Tulsa airport and exposition.
and later with R. H. Wainwright Frank B. Maxwell, managing
conducted them to the dinner director of J. F. Thompson Pty.
meeting of the Tulsa Section where Ltd. of Melbourne, Australia, was
Chairman L. Z. Johnson presided, a welcome visitor at headquarters |
Ellis introduced the speakers, H. R. on September 22nd and the follow-
Kretchmar reported on codes and ing day at a meeting of the PVRC
technical activities and J. H. Duerr Main Committee.
described the educational courses
Council Chairman C. E. Jackson
to be given by the AWS School of
and Convention Chairman J. E.
Welding Technology during the
Dato met with Convention Manager
current fiscal year. Following brief
F. J. Mooney and your Secretary
remarks by your Secretary, Presi-
on October 18th to discuss plans and
dent Thomas discussed ‘“‘Some Dra-
possible sites for future national
matic Applications of Stainless and
fall meetings.
Low-alloy Steel Welding.”’ Seven-
teen officers and directors of the The following day Canadian
Section including Floyd Silvers, Welding Society President A. V.
Dan Derrick and others in addition Phillips, Vice-President J. Weaver,
to those previously mentioned Past-President C. A. Sebastianovich
joined a large group of members to and Secretary W. T. Cherry came
form an appreciative audience for to New York to confer at AWS
President Thomas. headquarters with President R. D.
Vice-President C. E. Jackson, Thomas, Jr., and your Secretary
Convention Chairman J. E. Dato concerning further coordination and
and Assistant Secretary F. J. cooperation in planning the ac-
tivities of the two societies. Cer-
tain classes of members of CWS
When You Weld Cast Iron now receive a subscription to the
WELDING JOURNAL and enjoy spe-
Select the Correct cial discounts in purchasing other
AWS publications. Further co-
operation in promoting the use of
common standards, in education
activities, in planning meetings and
other activities is expected.
CAST IRON WELDING RODS
An important meeting of the
OR ELECTRODES
American Council of the Inter-
national Institute of Welding will
be held October 25th to complete SYNTRON
FUSE-WELL No. 11, Squore—Gray Cast | |all preliminary plans for the Assem-
Iron Welding Rod for Acetylene use in | bly to be held in New York next
filling or building up new or worn April. SELENIUM
castings producing machineable welds. |
I The following day AWS staff
FUSE-WELL NO, i2 members will meet with the Execu- WELDING
4 tive Group of our Missiles and
FUSE-WELL No. 12, Round—Has the |
same uses and analytical ingredients Rockets Welded Construction Com-
as Fuse-Well No. 17. mittee headed by Director Don STACKS
Howard.
Past-President C. I. MacGuffie
FUSE-WELL No. 14, Moly—An Iron| addressed an October meeting of
Base Rod with alloys added for finer the Lehigh Valley Section; Vice-
grain structure and greater strength. | President A. F. Chouinard met with
PUSE-WELL NO27 the Madison Section on October
22nd and presented an Adams rite for informatior
FUSE-WELL No. 22, Electrode — Light Memorial Membership Award to
coated Rod to be used for AC or DC | specifications
welding in the fabricating and repair- Prof. Walter H. Bruckner at a
ing of cast iron castings. meeting of the Eastern [Illinois SYNTRON RECTIFIER DIVISION
Section on October 26th; Vice-
President J. H. Blankenbuehler 258 Lexington Ave. ae a Te
THE CHICAGO HARDWARE FOUNDRY CO. presented a Neitzel Membership
Weld Rod Division Sales Engineers New York, Chicago
NORTH CHICAGO, ILLINOIS Award to the Nashville Section at Cleveland, Los Angeles and Canada
For details, circle No. 9 on Reader Information Card their meeting on October 13th. For details, circle No. 10 on Reader Information C ard

WELDING JOURNAL 1257

1256 | DECEMBER 1960

EDUCATIONAL ACTIVITIES

Section’s Day at Pittsburgh The afternoon session, which was afford to reserve space for lengthy
chairmanned by Ron Lawson, was meeting notices.
Section’s Day at Pittsburgh was devoted to Section publicity and Herb realized this and decided
an outstanding event. Every AWS promotion. that if a short format could be
educational chairman had _ been Ron opened the meeting and in- standardized and all local societies
alerted, and every publicity chair- troduced R. V. McGahey who spoke cooperated, then it might be possible
man received a program detailing on “The Value of Publicity.”” Bob to interest the newspapers in one
what subjects would be covered dur- McGahey knew his subject and ex- single release which would give de-
ing the meeting. plained how the publicity coming tails of every society meeting
The morning was to be devoted to from headquarters should be uti- throughout the month.
educational projects and the after- lized by the Sections for the benefit Accordingly, Herb contacted the
noon session to publicity and promo- of their own members. He pointed editor of one of the Pittsburgh
tion. out that nearly every release could papers and found the editor most
Ed Miller, Chairman of the Edu- be adapted for local consumption, receptive. The editor agreed to
cational Activities Committee, and explained how local Sections devote space to the activity pro-
opened the meeting and introduced could organize their own publicity vided Herb would organize the
the President, R. David Thomas, Jr. and make it very effective. various societies and get them to co-
Dave spoke with his usual elo- operate. Herb did that, and asked
quence of the need for education in each society to refrain from sending
the welding industry and brought Technical Society Meetings any news release concerning their
some classical examples to _ illus- At the conclusion of the formal meetings to the paper in question.
trate this particular need. He lik- afternoon meeting a period was de- Instead, they gave short copy of
ened those who were not aware of voted to solving problems and an- their meeting notices to him, and
the advantage of welding to those swering questions that section pub- Herb arranged with the society
who had lived in a cave all their licity chairmen might have. A technical writers and editors to put
lives, unable to catch more than a common problem and a unique solu- this into journalese and into the
glimpse of the daylight outside the tion was brought forth by Herb format which would be suitable for
cave. He explained how some of Cable, Publicity Chairman of the the newspaper in question.
them escaped from the cave and dis- Pittsburgh Section and son of Ed The result is that an entire column
covered the advantages of the world Cable, Publicity Chairrman of the is now devoted to meetings of tech-
outside, and how a few of these in- Pittsburgh Arrangements Commit- nical societies in the Pittsburgh area,
dividuals returned to bring the news tee. Herb gave a short talk on an and this will be a continuing opera-
to their unfortunate friends. activity that he himself developed. tion.
Dave Thomas suggested that He pointed out the difficulty of ob- At the close of the publicity meet-
there were many “‘prisoners”’ outside taining the cooperation of local ing the audience almost unani-
the welding industry who should be papers in publicizing technical so- mously requested copies of the talks
told of the advantages of welded ciety meetings. In many areas that had been given. It was de-
fabrication and construction. He there are many societies, each of cided that a booklet would be pre-
suggested that the more enlightened which would like to gain publicity pared that would contain pertinent
members of the engineering family for its own activity. There is only information discussed during the
should carry this news to the less a limited amount of space in any afternoon as well as during the
fortunate. newspaper, and a newspaper cannot question period.

Tea
‘i?
. , ¢
(ab, me 6 Perm,

\ =<

R. V. McGahey at the Publicity Open Meeting during the Fall E. C. Miller, Chairman, Educational Activities Committee,
Meeting; (left to right) Chairman R. E. Lawson, McGahey, addressing the Educational Open Meeting at Pittsburgh.
A. L. Phillips, Secretary of Information and Education, and Seated (left) President R. D. Thomas, Jr., and (right) A. L.
committee members F. X. Neary and M. D. Bellware Phillips, Secretary of Information and Education

1258 | DECEMBER 1960

 WELDING JOURNAL | 1257

SECTION NEWS AND EVENTS

As reported to Catherine M. O'Leary

problems in welding, welding se- cellent color slides of hard surfacing

quences, shaping and _ distortion applications, particularly in the
control of aluminum. fields of rock crushing, earth moving,
GAMMA RADIOGRAPHY pumps and steel mill maintenance.
Birmingham — The first meeting The meeting ended with a lively
of the 1960-61 season of the Bir- question and answer period.
mingham Section was held on Plans were announced for four
Tuesday, October 11th, at Salem’s ARC CUTTING seminars to be sponsored by the °
Restaurant Number Two. Section Educational Committee of
San Diego— The San Diego Sec- which William Ajello, president
A short business session followed tion dinner meeting was held at
the dinner at which time it was of the Reliable Welding Co., is
the Midway Chuck Wagon Res- chairman. Welding problems of
announced that National President taurant on September 21st.
R. D. Thomas and National Sec- interest in the West will be covered
An enlightening talk on ‘“‘Con- quite thoroughly by two or more
retary Fred Plummer would be stricted Arc Cutting and Plasma
the honored guests at the Novem- experts at each meeting with one
Arc Cutting” was given by Dick moderator presiding. The first
ber meeting. Simpson of the Linde Co.
The newly-elected Vice-chair- seminar will be a dinner meeting
A social hour and dinner pre- Feb. 20, 1961, at Spengers Fish
man, Tom Estock, introduced the ceded the meeting.
speaker of the evening, A. V. Grotto in Berkeley, Calif., and will
Kelley, sales manager, The Budd cover ‘“‘How to Choose a Welding
HARD SURFACING
Co., Instruments Div. Mr. Kelley’s Process.”” The last three will be
talk on “Gamma Radiography in Berkeley The San Francisco held at Contra Costa College, West
Modern Industry’ was well re- Section held its first meeting of the Campus, Students Lounge, Rich-
ceived and a great deal of discus- new term at Spenger’s Fish Grotto mond, and will deal respectively
sion resulted. in Berkeley on September 26th. with “‘How to Choose a Proper
Fabricating Procedure’ on Feb.
Robert A. Hand of the Stcody Co. 28th “How to Weld T-1 and
ALUMINUM WELDING spoke on “Hard Facing in Industry Similar Steels’ on March 7 and
Mobile—-Howard FE. Adkins, and Construction,” first covering ‘How to Choose the Proper Non-
welding specialist for the District the factors governing the choice Destructive Testing Procedure”’ on
Engineering Group of Kaiser Alu- of hard surfacing, wear, impact
March 14th. A turnout of 100 to
minum and Chemical Sales, Inc., heat and corrosion. He then dis- 150 is expected at each meeting,
was guest speaker at the Septem- cussed precautions in preparing and pre-registration will be required.
ber 20th meeting of the Mobile the worn surface. Cold worked
Section. The dinner and technical and fatigued metal is removed, and Sunnyvale—At the September
meeting was held at Korbet’s Res- an intermediate build-up material 27th meeting of the Santa Clara
taurant. is deposited to support the hard- Valley Section, R. A. Hand of the
Mr. Adkins covered many fields surfacing deposit under service Stoody Co., Whittier, discussed
of interest required in industry loading. The various methods of the general field of hard facing in
concerning the fabrication of alu- applying wear-resistant alloys were relation to the needs of industry
minum structures, vessels and fix- outlined, and the high-production and construction.
tures. The main topic of discussion rates obtainable with automatic The dinner meeting was held
was “Recommendations for Produc- welding were emphasized. High- at Sabella’s Restaurant in Sunny-
tion Use of Tungsten-arc and Gas- light of the talk was a series of ex- vale.
shielded Metal-arc Welding of
Aluminum.”
Mr. Adkins commenced with a
technical lecture on aluminum alloys FIRST MEETING OF SEASON FOR SAN FRANCISCO
and alloy selections. As pointed
out, the buyer for industries plays
the initial part in the final per-
formance of good fabrication and
welding.
Valuable information was con-
veyed to men of various positions
in industry from management,
buyer, welding engineer, shop su-
pervisors, welding supervisors and
the welder. Excellent slides, films
and welding samples on aluminum
were shown.
Immediately following the lec-
ture, a discussion from the floor Guest on the evening of September 26th was Robert A. Hand
brought out the multitude of local of the Stoody Co. who spoke on hard surfacing

WELDING JOURNAL | 1259

1258 | DECEMBER 1960

SECTION MEETING CALENDAR

DECEMBER 7 NORTHWEST Section. Minneapolis, Minn. PHILADELPHIA Section. Engineers Club.

SUSQUEHANNA VALLEY Section. Foot Hills “Factors Aiiecting the Properties of Stainless Dinner 6: 30. Meeting 8:00 P.M. “Automation
Manor, Shickshinny, Pa. Dinner 6:45 P.M. Weld Metal,” R. D. Thomas, Arcos Corp. the World Over,” R. 0. Wight.
“Nondestructive Testing of Weldments,’’ W. J. OKLAHOMA CITY Section. Cattleman’s Cafe, ROCHESTER Section. Liederkrantz Club.
McGonnagle, Argonne National Laboratory. Oklahoma City, Okla. Dinner 6:30. Meeting Dinner 7:00. Meeting 8:00. “Metallurgy of
7: 30 P.M. Welding,” G. E. Claussen, Arcrods Corp.
DECEMBER 9
COLUMBUS Section. Columbus, Ohio. Cutting JANUARY 10 JANUARY 17
Panel. Howard Balthasar. BIRMINGHAM Section. Joint meeting ASM. MOBILE Section. Korbet’s Restaurant. Social
DETROIT Section. Stag Christmas Party. 7: 30 “Manufacture, Metallurgy, Processes, and Applica- 6:30. Dinner 7:15. Session 8: 00 P.M.
P.M. Roboton Corp. plant. tions of Hard-facing Alloys,” A. J. Zvanut, Stoody NORTHWESTERN PENNSYLVANIA Section.
Co, “Hydrogen in Weld Metal.”
DECEMBER 12 ST. LOUIS Section. Union Electric Co. 12th
DAYTON Section. Kuntz’s Cafe, Dayton, Ohio.
BOSTON Section. Hotel Bostonian. Dinner Social6: 30. Dinner 7: 00. Meeting8: 00. “Safety and Locust Auditorium. Educational program
6:00. Quiz the Experts at 7: 30. in Welding and Cutting,” A. N. Kugler, Air Reduc- Part |: Processes.
DECEMBER 13 tion Sales Co. JANUARY 18
DAYTON Section. Kuntz’s Cafe, Dayton, Ohio. NORTHEAST TENNESSEE Section. Social 6: 30. HOUSTON Section. “Submerged-arc Welding,”
Social 6: 30. Dinner 7:00. Meeting 8:00 P.M. Dinner 7:00. Meeting 8:00P.M. “The Science R. D. Wilson, Lincoln Electric Co.
Annual Quiz Program. of Arc Welding,” Clarence Jackson, Linde Co. PEORIA Section. Vonachen’s Junction. Dinner
SANGAMON VALLEY Section. Decatur, Ill.
DECEMBER 14 “Weldability,”” B. R. Queneau, Tennessee Coal & 6:30. Meeting 8:30P.M. “Preheated Automatic
TOLEDO Section. The Toledo Yacht Club. Iron Div., U. S. Steel Corp. and Semi-automatic Welding Wires,” H. F. Reid,
Dinner 6:30. Meeting 7:45 P.M. ‘Welding of WESTERN MASSACHUSETTS Section. Oaks The McKay Co.
Piping, Refinery and Alloy Welding,” Robert Inn, Springfield, Mass. Dinner 6:30. Meeting TOLEDO Section. The Toledo Yacht Club.
Wylie, Babcock & Wilcox Co. 8:00 P.M. “Distortion Control of Large Welded Dinner 6: 30. Meeting7:45P.M. “Time Stand-
DECEMBER 19 Structures,” H. A. Sawyer, Jr., University of ards for Welding,” Phillip E. Sommer, LeTourneau
Westinghouse Co.
PHILADELPHIA Secticn. Engineers Club. Phila Connecticut.
delphia, Pa. 8:00 P.M. Joint meeting Society JANUARY 11 JANUARY 19
Naval Architects and Marine Engineers. ‘‘Polaris,”’ CLEVELAND Section. Executive Night. Cleve- BATON ROUGE Section. “A Progress Report
Comdr. Geo. F. Moran, U. S. Navy. land Scientific Center. on the Fluxed Cored CO, Welding Process.”
ROCHESTER Section. Liederkrantz Club. Din- NORTH TEXAS Section. Howard Johnson's BEAUMONT Section. “Submerged-arc Weld-
ner 7:00. Meeting 8:00. “Inert-gas Arc Weid- Turnpike Restaurant. Dinner and technical session ing,” R. D. Wilson, Lincoln Electric Co.
ing,” F. Nigro, Air Reduction Sales Co. 6: 30P.M. “Electron Beam Welding,” W. J. Farrell, MADISON Section. Evansville, Wis. “Hard
DECEMBER 27 Sciaky Bros. Inc. Surfacing and Its Characteristics, Applications and
SANTA CLARA VALLEY Section. Sabeila’s Methods,” H. V. Kouch, Coast Metals.
JANUARY 12
Restaurant “Ebb Tide Room,” Sunnyvale, Calif CHICAGO Section. Calumet Area Meeting JANUARY 20
Panel Discussion: Causes of Weld Failures. Jockey Club Restaurant, East Chicago, Ind. Social FOX VALLEY Section. Menasha Elks Club,
JANUARY 3 5:30. Dinner 6:30. Meeting 7:30. ‘“Fundamen- Menasha, Wis.
TUSLA Section. Danner’s Cafeteria, Tulsa, tals of Welding Power Sources,” Howard Cary or MARYLAND Section. Engineers Club, Bailti-
Okla. “Cutting of Stainless and Other Alloy J. H. Blankenbuehler, Hobart Bros. Co. more. Dinner 6:30. Meeting 8:00 P.M. “Why
Materials.” IOWA-iLLINOIS Section. Highland Park Bowl, Welds Fail," Helmut Thielsch, Grinnell Co.
JANUARY 4 Moline, Ill. Dinner 6:30. Meeting 7:30 P.M JANUARY 24
“Practical Aspects of Tungsten-arc and Gas- CENTRAL VALLEY Section. Sacramento, Calif.
SUSQUEHANNA VALLEY Section. Foot Hills shielded Metal-arc Welding of Aluminum,’’ Howard
Manor, Shickshinny, Pa. “Higher Strength “Pressure Vessel Welding,” P. C. Arnold, Chicago
Adkins, Kaiser Aluminum and Chemical Sales Bridge & Iron Co.
Steels for Welded Structures,” R. D. Stout, Lehigh Co.
University. ST. LOUIS Section. Union Electric Co. 12th
J). A. K. Section. Joliet, Ill. “Low-hydrogen and Locust Auditorium. Educational Program.
JANUARY 5 Electrodes,” D. C. Smith, Harnischfeger Corp. Part Il: Codes.
NORTH CENTRAL OHIO Section. “National MAHONING VALLEY Section. Joint meeting
Needs in Welding Education,” R. B. McCauley, with Warren A.S.M. Chapter. El Rio Restaurant, JANUARY 26
Ohio State University. Warren, Ohio. NIAGARA FRONTIER Section. The Cypress,
NORTHERN NEW YORK Section. Hot Shoppes, ST. LOUIS Section. Ruggeri’s Restaurant. Buffalo, N. Y. “New Developments in Welding,”
Route9, Albany, N.Y. Dinner7:00P.M. Session “Positioning as Applied to Weldments,” A. K. Harry Schwartzbart, Armour Research Foundation.
8:00 P.M. “Automated Welding Applications."’ Pandjiris, Pandjiris Weldments. JANUARY 27
SAGINAW VALLEY Section. “Oxyacetylene JANUARY 13
Processes,” E. Meincke, Linde Co. HOUSTON Section. Austin Division. Villa
COLUMBUS Section. OSU Student Meeting. Capri Restaurant. Social 6:30. Dinner 7: 00.
JANUARY 6 DETROIT SECTION. The Engineering Society Meeting 8:00 P.M. “Design of Structural Joints,”
LEHIGH VALLEY Section. Joint Meeting ASM. of Detroit (The Rackham Building). 8:00 P.M Ray Pechacek, Hahn & Clay.
Hotel Traylor. “Welding Metallurgy,” Henry “European Welding Processes and Progress,” INDIANA Section. Robert W. Kaunitz, United
Mason, Air Products, Inc. C. R. Bates, Progressive Welder Co. of Canada, Welders, Inc.
JANUARY 9 JANUARY 16 JANUARY 31
BOSTON Section. Hotel Bostonian. Dinner HOUSTON Section. Corpus Christi Division. ST. LOUIS Section. Union Electric Co. 12th
6:00. Technical Session 7:30. “Powder Torch “Inert-gas Welding of Stainless Steel,” C. W. Ferris, and Locust Auditorium. Educational Program.
Brazing,” H. Miller, Carrier Corp. Linde Co. Part Ill: Nondestructive Testing.

Editor's Note: Notices for March 1961 meetings must reach JOURNAL office prior to December 20th, so that they may be published in the February Calendar.
Give full information concerning time, place, topic and speaker for each meeting.

1260 | DECEMBER 1960

 He also discussed ultrasonic methods SOUTH FLORIDA MEETS
used on testing weldments and used
slides to illustrate this part of the
SHORT-ARC PROCESS talk.
Denver The first meeting of the COVERED ELECTRODES
1960-61 season of the Colorado
Section was held on September Bridgeport—The Bridgeport Sec-
13th at Cavaleri’s Restaurant. The tion met on October 19th at Fairway
group gathered at 6:30 P.M. Restaurant. John P. Broderick,
for an appetizer until 7:00 P.M. supervisorof Research and Develop-
when dinner was served. ment for Eutectic Welding Alloys Mar ,
Coffee speaker was Detective Corp., Flushing, N. Y., spoke on the Ap eee
John Moritzky of the Denver Police “Research and Development of , Tb bp
Morals Bureau. His talk gave a Covered Electfodes.’”’ He outlined
very interesting insight into some the step-by-step procedure involved,
of the problems and cases handled starting with the original concept
by this department. which could be an inquiry from a cus-
The main speaker was R. E. Scott tomer ora field representative. Mr. W. R. Barkiey discussed ‘‘Welding
of the Linde Co., Denver Region. Broderick explained that most of Design and Steel Structures”’
Mr. Scott’s subject was on the the research results from modifica- at Sept. 21st meeting
“Short-arc Consumable-electrode tions of basic types of electrodes.
Welding Process.”” The talk was He then covered the various steps
illustrated with slides and movies. in the development from chemical ent. The speaker was Everett
to physical tests before electrodes Cushman of Arcrods Corp., who
PLANT TOUR are finally put into production. discussed the theory behind the so-
called ‘“‘emissive’’ coverings on weld-
Denver—The October meeting MAGNESIUM ing wire and described in detail
of the Colorado Section was held much of the original research work
Glastonbury The HartfordSec-
on October 11th at Cavaleri’s Res- done by the Arcrods people. He
tion held its first regular meeting
taurant. The group met at 6:30 pointed out, in detail, both its
on September 20th at the Villa
P.M. for appetizers until 7:00 advantages and its shortcomings
Maria Restaurant in Glastonbury.
when dinner was served. The and concluded by stating that con-
coffee speaker was Reynold R. After a brief business meeting,
Robert L. Burns of Dow Chemical siderable work remains to be done
Akison of the Denver Div. of before this can be called a truly
Co. delivered a very interesting
Dow Chemical Co.; his topic was competitive system.
on “Colorado Indians and Arti- talk on the “Manufacture, Uses
and Fabrication of Magnesium.”
facts.”
Mr. Burns was assisted by a repre-
The technical portion of the meet-
ing was a tour of the Midwest sentative from A. R. Purdy Co.,
Inc. In conjunction with his dis-
Steel & Lron Works Co. in Denver, POWER SOURCES
cussion, Mr. Burns presented an
under the direction of Paul J.
excellent motion picture film on Fort Wayne—On September
Foehl, chief engineer. This com-
safety in handling magnesium. 15th, the Anthony Wayne Section
pany is at present fabricating a
large welded girder bridge to be held its first regular meeting of
located over the Powder River the season at Central High School.
near Buffalo, Wyo. This project Thirty-five members and guests
consists of two parallel bridges, were present to hear an interesting
each having spans of 160, 200 and WELDING DESIGN talk on “Power Sources for the
160 ft. Hialeah — The South Florida Sec- Arc Welding Machines” as given
A skeleton crew was on hand to tion held its regular monthly meet- by Emil F. Steinert of Westinghouse
show the welding method and pro- ing on September 21st at the Park Corp., Buffalo, N. Y.
cedure used on these girders, which Lane Cafeteria in Hialeah. Guest
vary in depth from 7 ft 8 in. at their speaker for the evening was W. R.
shallowest points to 15 ft 4 in. Barkley, who gave an interesting
deep over the piers, with flange talk on “Welding Design and Steel NEW SEASON
plates 2 in. thick. Structures.” This was followed FOR ANTHONY WAYNE
by the answering of questions per-
taining to relative costs of bolted
and welded structures. Mr. Barkely
has been a member of the SoctETy
ULTRASONICS for 20 yr. He is now semiretired
in Florida
Bridgeport—Philip R. Nute of
Sperry Products, Danbury, Conn.,
was the speaker at the September
2lst meeting of the Bridgeport
Section. Mr. Nute started his talk
with a brief history of nonde- WIRE COVERINGS
structive testing on weldments with Peoria—A dinner meeting of the
ultrasonics. This was followed by Pecria Section was held on Septem-
a film entitled, ‘Industry on Parade, ber 21st at Vonachen’s Junction, Fayette Jacobs, left, and Russel McNutt,
Variety of Ultrasonics Industry.” with 50 members and guests pres- right, with guest speaker, Ernie F. Steiner

WELDING JOURNAL | 1261

 FUEL GASES formation diagram of the particular
steel.
Cumberland-——-The September Mr. Aborn pointed out the func-
meeting of the Jndiana Section was tion and mechanism of preheating ELECTRON-BEAM WELDING
held on the 23rd at Buckley’s and postheating in relation to the
Restaurant, Cumberland, with 47 Detroit—On the evening of Octo-
cooling rate; the transformation
members attending. ber 14th, at the Engineering Society
and properties of the weldment;
The speaker of the evening was of Detroit, the Detroit Section was
and the influence of various ele-
Al Chouinard, Director of Research introduced to electron-beam weld-
ments in the weldment.
and Development Department of ing by Henry James, research en-
From a metallurgical viewpoint,
National Cylinder Gas Div., Cheme- gineer for Sciaky Bros., Inc.,
he took a brief look into the future of
tron Corp., and a vice-president of of Chicago, Ill.
welding and predicted the use of
the Society. After some initial This newest process makes pos-
nuclear power factors. The talk
comments on the new United En- sible the joining of heretofore dif-
was supplemented with slides and
gineering Center in New York, Mr. ficult-to-weld metals—namely _re-
a 10 min high-speed color film
Chouinard presented a very interest- fractory metals, metals with rel-
showing an initial study of welding
ing talk on ‘‘Fuel Gases for Weld- atively high-thermal conductivity,
arc behavior with four different
ing and Cutting Processes.””’ The highly reactive metals and the mak-
classes of electrodes.
various fuel gases available, their ing of certain special-situation welds
basic combustion reactions, heat not possible with conventional weld-
content and factors considered in ing processes. By use of this
selecting the appropriate fuel gas Massachusetts process any two different metals
were covered. The presentation was can be welded together, the limita-
supplemented with color slides and WELDING HISTORY tions and practicability of doing
followed by a lively discussion so will depend upon the metal-
period, Springfield—A very interesting lurgy of the resultant joint. The
meeting of the Western Massachu- process, which must be applied in a
setts Section was held at the Oaks chamber evacuated to a pressure
Inn on Tuesday evening, October of about 0.1 uw (1.3 x 10°" atm),
11th. utilizes an electron-gun emitting
METALLURGY OF FERROUS Harry Schwartzbart of Armour an electron-beam through a system
Research Foundation, entertained of simple aperture lenses and mag-
WELDING the group with an interesting and nets which shape and focus the
Des Moines—Robert H. Aborn, educational talk entitled ‘““One Hun- beam on a minute spot on the
director of the Research Center at dred Years of Welding.”” He began workpiece.
the United States Steel Corp. dis- with the start of arc welding in 1881 At a blackboard, Mr. James
cussed the “‘Metallurgy of Ferrous when the arc light was discovered outlined the system used and also
Welding” at the September 15th and which has been used for so took the audience back through
meeting of the Jowa Section, held many years in street lighting. their physics and calculus in de-
at the Hotel Kirkwood. Mr. Aborn He traced the history of arc veloping necessary formulas. ‘The
briefly explained the metallurgical welding, acetylene welding and braz- discussion was closed by a showing
principles involved in welding, and ing from their early beginnings of slides of diagrams and equipment.
then went on to apply them to the down to the present day, and then
making of welds. went on to ultrasonic welding, SPIKE WELDING
He discussed the factor control- high-frequency resistance welding,
ling the rate of heat input and dis- vacuum welding, high-voltage elec- Saginaw—-A dinner meeting of
sipation; why cooling rate is so tron beam welding and plasma the Saginaw Valley Section was held
important; and how its influence welding. The evening closed with at the Hi-Life Inn on October
may be estimated from a trans- a question and answer period. 6th with 67 members and guests
present. Program speaker was Ted
Thomsen, chief engineer at Robo-
tron Corp., Detroit. Mr. Thomsen
discussed the use and advantages
DISCUSSES FUEL GASES of a new kind of resistance welding
developed by his company, called
“Spike Welding.”’

JOB SHOP WELDING

St. Louis—-The October 13th
meeting of the St. Louis Section
was held at Ruggeri’s Restaurant.
A group of 66 members and guests
gathered at 6:00 P.M. for a fellow-
ship period; a “buffet style’’ din-
ner was served at 7:00 P.M.
Ed Bartz, technical sales man-
ager of Airline Welding and En-
Indiana Section officers are shown with A. F. Chouinard, third from right, gineering, Gardena, Calif., was the
who was guest speaker on Sept. 23rd speaker for the evening. His topic

1262 | DECEMBER 1960

DISCUSSES FUNDAMENTALS PLANT TOUR
Watervliet—A plant tour
through the Watervliet Arsenal
was the feature of the October
6th meeting of the Northern New
York Section. A short talk before
dinner in the Arsenal Cafeteria
was given by Colonel Tisdale,
commanding officer. Colonel Tis-
dale gave a brief history of the
arsenal, which was a military camp
in 1812 and established as an arsenal
in 1814. It was pointed out that
this is one of the few arsenals in
the free world concentrating on the
development of conventional can-
non.
Of interest to the members were
the prestressing, straightening, ma-
chining, refiling and heat-treating
At Oct. 13th Long Isiand Section meeting, guest speaker operations performed om the can-
E. A. Moles answers questions from two members—S. A. Greenberg, non barrels.
center, and Mr. Sciaky, right
LIMITATION OF PROCESS
Olean—Twenty-two members
and guests attended the September
was “Job Shop Welding in the The Section was happy to
welcome back Si Greenberg, who 20th meeting of the Olean-Bradford
Missile Age.’’ He pointed out
Section held at the Castle Res-
that we are now moving from a served as technical chairman. He
taurant in Olean.
period in which welding is an recalled the first meeting of the
Following the dinner, James
art to a period in which welding is Section at which time he was the
Matheny, chairman of the Section,
now a science. speaker and was introduced by
welcomed the new student members
His talk covered the accuracy and Ed Moles, the speaker at the cur-
and introduced the guest speaker,
intricate tooling needed to weld rent meeting.
John Mikulak, assistant to the
thin gage materials. Mr. Bartz
WELDING STAINLESS STEELS vice president of manufacturing,
also displayed several samples of
New York—tThe first meeting Worthington Corp., Harrison, N. J.
thin-welded materials. A movie
of the New York Section of the new Mr. Mikulak spoke on the sub-
shown by the speaker, “A Trip
to the Moon,” starring Art Baker, season was held at Victor’s Res- ject ‘“‘Limitations of Process.”’ The
taurant on Tuesday, September talk, accompanied by slides, was
was also well received. This film
13th. <A fine crowd turned out to very informative, educational and
will be edited and released for TV
hear Harry F. Reid, Jr., of the Mc- very well received.
in the near future.
Kay Co. lecture on the ‘Welding
of Stainless Steels.”’ Although the ARC CUTTING
subject is quite broad in scope, Mr. Olean—A dinner meeting of the
Reid’s emphasis was on manual Olean-Bradford Section was held
covered electrodes. on October 18th at the Castle
POWER SUPPLIES Following a definition of “‘stain- Restaurant in Olean, N. Y. Myron
Bellmore—The Long Island Sec- less steel,” Mr. Reid categorized D. Stepath, president of the Arcair
tion met on October 13th for dinner the 35 to 40 different available Co. spoke on the Arcair Process.
and meeting at Sunrise Village, electrodes into two basic groups His talk, accompanied by slides,
Bellmore. hardenable and nonhardenable was very informative and interest-
Using a condensed version of the and further into their three pri- ing. A question and answer period
material presented by him at the mary structures. This was fol- followed.
April 1960 AWS School of Welding lowed by a clear, comprehensive
Technology, Edward W. Moles of run-down of various typical grades
Grumman. Aijrcraft Engineering and a prepared slide presentation.
Corp., Bethpage, N. Y., introduced Dissimilar metal joining using
process and power supply funda- austenitic electrodes depositing
high-ferrite content was discussed. PANEL
mentals as applied to the gas
shielded-arc processes. Accom- Mr. Reid cited several case histories Cleveland—The Cleveland Sec-
panied by blackboard, visual of cracking problems in the field, tion opened its 1960-61 season with
aids and motion pictures, the par- solved with specialized or nonstand- a panel of local experts discussing
ticular characteristics of the var- ard electrodes. problems that are typical to heavy
ious processes and power supplies A lively question and answer ses- plate fabricators. The well-at-
were graphically represented in- sion followed the lecture, attesting tended meeting began with cock-
dividually and then interrelated to the interest aroused in the audi- tails and dinner at 6:00 P.M.
by superimposing one graph on ence by the speaker. Of particular at the Cleveland Engineering and
the other. The many questions note was Mr. Reid’s ability to Scientific Center. The panel dis-
and discussions on the floor were answer questions posed by those at cussion followed at 8:00 P.M.
evidence of the high interest in this both the welder and _ technician During the business portion of
subject. level. the meeting, Section Chairman

WELDING JOURNAL | 1263

 440e | VEevemoenmn savvy

CLEVELAND AWARDS AND PLANS Prior to the main feature, Chair-

man Edwards presented a 15 min
discussion about a practical weld-
ing problem. He discussed the
repair of a casting ring gear and
how cracking in the hardened area
was eliminated.
In order that the Technical Rep-
resentative and Educational Com-
mittee can better serve the group,
a monthly one- or two-page pub-
lication will be distributed at each
meeting. The first of this series
was “Heat Treatment Termi-
nology.”
Section chairman, Robert Pagenkopf, Discussing plans for the year—left to
left, and Ed Young, right, admire 5th right: Eva Karnatz, Loren Miller, Clayton PLANT TOUR
district membership trophy won and held Herrick, Wasil Romance, Janet Reed,
by Robert Mattoon Donald Schaefer, Ronald Andolsek and Toledo—On September 21st
Robert Pagenkopf the Toledo Section began its 1960
61 season with a tour of the Pas-
senger Transmission plant of the
Chevrolet Motor Div., General
Robert C. Pagenkopf introduced and discussed (1) how information Motors Corp.
the new executive officers: Wasil pertaining to welding can be con- More than 85 members witnessed
Roniance, lst vice chairman and veyed, (2) how the different welding the methods and processes em-
Charles Berka, 2nd vice chairman. methods fit into the over-all pro- ployed by this plant, which is one
Key men from several Cleveland duction schedule and (3) how the of the most modern and automated
concerns producing heavy weld- dimensions on some welding costs in the area.
ments made up the panel. They are derived. The welding processes observed
included Glen L. Johnson, Lewis included resistance welding, multi-
Welding and Engineering; Roy SPIKE WELDING ple spot welding, automatic seam
F. Flowers, Ohio State Fabrica- Dayton—The Dayton Section’s welding, automatic CO:, innershield
tors; Delbert D. Porter, Euclid first meeting of the 1960-61 fiscal and submerged-arc welding.
Division GMC; and Ross Yarrow, year was held at Kuntz’s Cafe on
Republic Structural Iron Works. Tuesday, October 11th. A _ one-
Panel chairman was Paul L. Holden half-hour social period preceded @)aielatelite!
of the Lincoln Electric Co. the dinner.
Opening remarks presented short Guest speaker for the evening NEW ALLOYS
cuts and rule-of-thumb production was Ted Thomsen, chief engineer Oklahoma City—The Oklahoma
approaches the panel members had of Robotron Corp. His talk, en- City Section met on October 3rd
developed from practical experience. titled ‘“Spike Welding Advantages at the Cattleman’s Cafe for dinner
After reviewing specific examples and Application Considerations,” and meeting. Guest speaker was
where good tooling, welding and was very well received. Slides Victor V. Lyon of Eutectic Welding
shop procedures achieved produc- illustrating actual welds performed Alloys Corp., Tulsa. His _ sub-
tion advantages, the meeting was using the recently developed spike ject was “‘Newly Developed Alloys
opened for informal audience par- welding technique were shown which for Welding, Brazing and Solder-
ticipation in a question-and-answer pointed out the advantages of the ing in Maintenance and Produc-
period. process. Basic theory of operation tion.”
of the control system was also In his opening remarks, Mr.
METHODS ENGINEERING discussed. A lively question-and- Lyon, stressed the importance of
Columbus—On Friday, October answer session followed. the welder and accurate judgment
14th, a meeting of the Columbus in the acetylene welding process.
Section was held at Carl’s Knotty WELD DISTORTION “Judgment” he pointed out, cov-
Pine Restaurant. A happy half- Bucyrus LaMotte Grover, ered not only the proper knowledge
hour of fellowship preceded the welding engineer for the Air Re- of the material to be welded but
dinner. duction Sales Co., New York, was also a basic and complete knowl-
The main speaker of the evening the guest speaker at the October edge of the equipment to accom-
was D. E. Cox, chief industrial 6th meeting of the North Central plish the job and the correct pro-
engineer, Caterpillar Tractor Co., Ohio Section held at the American cedure for carrying the job through
Milwaukee, Wis. His_ subject, Legion Home in Bucyrus. Mr. to completion.
which was exceptionally well pre- Grover gave an excellent presenta- Following these brief introductory
sented, covered ‘“‘Methods Engineer- tion of a subject of a very prac- remarks, he discussed and demon-
ing As Applied to Arc Welding.” tical nature, “Control and Cor- strated various rods. His initial
He discussed the general approach rection of Distortion in Steel Weld- demonstration covered both alumi-
to welding methods rather than ments.” He discussed first the num and magnesium samples; flux
the specific details of welding fundamentals of distortion with and the proper rod being stressed
techniques. simple weldments as examples, then by the speaker as essential in weld:
The importance of communica- integrated this idea in actual prac- ing of all white metals. This was
tions, methods control and costs tical applications. The lecture was followed in turn by welding of
were reviewed. Using slides to accompanied by slides, all of which steel and cast iron samples for the
illustrate the lecture, he showed were very well received. group.

1264 | DECEMBER 1960

 For his conclusion, Mr. Lyon the welding of rocket launching
presented a unique and new rod equipment except thermit welding.
which joins entirely dissimilar Applications of each were shown Lweuled by
metals. He stressed that, although and the entire equipment is made
this process was not too practical of T-1 steel.
in general industry, it has found THOMSON
limited, but very successful, ac- FALL FUN
ceptance in some plants.
Philadelphia—One hundred
members and guests of the PaAil-
adelphia Section thoroughly en-
Pennsylvania
Pfeilby

joyed a “Welcome Outing’ on

September 22nd at the Valley THOMSON
FUTURE OF WELDING Forge Golf Club.
Allentown—tThe Lehigh Valley The outing began in early after-
Section’s first meeting of the season noon with a golf tournament in Kewiilauce Weldlug
was held on October 3rd at Walp’s which 65 golfers participated.
Restaurant in Allentown. Nail driving, horseshoes, golf
* Press » Flash-Butt
The coffee speaker was Leslie L putting and various other contests * High-Frequency
Forster of Phillipsburg, N. J., who garnished with food and refresh-
gave an Englishman’s humorous ment added to a very busy and
impressions of America and com- entertaining afternoon and evening.
pared the living habits, foods and The committee in charge of this
television of typical Americans and very successful affair were: W. EXCLUSIVE
Englishmen. Morely, chairman; Earl Joseph,
Th technical meeting speaker Tom Kennelly, Brent Edwards, Synchro-matic
was C. I. MacGuffie, manager of Dave Buerkel, Tom Moore, Jerry
Special Products Dept. of Air Rapine, Bill Powers and Mr. Davies. and
Reduction Sales Co., New York,
N. Y. He spoke on the ‘“‘Future of PLANT TOUR Synchro-shear
Welding” and stated that there is a Conshohocken— Bill Brooks as
definite trend to fusion welding panel chairman of the Philadelphia ... for jobs no other
with machine welding techniques. Section this season stated that the resistance welders can do
Slides of precision weld machines meetings would follow a basic plan.
and articles welded by these ma- He could not have chosen a more
chines were shown. He also told basic start than the tour of the Alan
of the close tolerances that were Wood Steel Co.’s plant at Con-
possible with some of the units. shohocken on October 7th.
Mr. MacGuffie closed his talk by Three capable and_ congenial
stating that present welding proc- guides escorted 71 guests through
esses will expand and improve and the open hearth, machine shop
that new processes and machines and blooming mill. The tour was
will further expand welding in new timed so that everyone was able to
areas, but will not replace existing observe a heat being tapped in the
methods. open hearth. Another interesting
Chairman McGeady announced feature was the huge 250-ton fur-
that the Lehigh Valley Section is naces having capacity to fill two
cosponsoring a course in welding ladles simultaneously.
design with the ASCE local chapter The maintenance welding being
and that 22 men were taking the done in the machine shop was an
course one night a week at Liberty example of the extensive use of
High School in Bethlehem. welding employed in a steel mill
where heavy equipment is involved.
LAUNCHING SYSTEMS THOMSON QUALITY is so important
Erie—The Northwestern Penn- that we build our own transformers
sylvania Section held its first to assure maximum performance and
regular monthly meeting Septem- reliability. For all AUTOMATED and
ber 20th at Scheffner’s Grill. HIGH-PRODUCTION requirements —
J. C. Kaluzny, welding engineer PHILADELPHIA SKEPTICS either special or standard design —
with the American Machine & THOMSON QUALITY is within your
Foundry Co., Buffalo, N. Y., pre- budget. ATHOMSON quote will prove it.
sented a most interesting and ed- ce
ucational talk on the subject of patented
weld fabrication of Titan and Atlas
Look for our nearest representative
ICBM launching systems. A color
in the yellow pages or contact —
sound movie was shown on the
welding of the underground Titan
missile, which is retractable in case
of enemy retaliation. A movie Dale Bittenger, left, and Frank Liott,
and slides were shown on the smaller center, do not completely agree with
mobile Sargent launcher. Every HOMSON ELECTRIC WELDER COMPANY
Julian Miller during Philadelphia Section 161 PLEASANT STREET, LYNN, MASSACHUSETTS
welding process known is used in tour of Alan Wood Steel Co. on Oct. 7th
For details, circle No. 11 on Reader Information Card
WELDING JOURNAL | 1265
4409 | VEVECMOENR 1900

TENNESSEE MEETING positing out of position welds.

Another feature of CO, welding is
the ability to use the submerged-
arc welding process in depositing
welds without requiring the removal
of tack welds applied with the CO,
process. The resulting welds have
proved to be of acceptable X-ray
quality.

Rhode Island

HARD SURFACING
Providence The Providence
Section held their opening session
of the 1960-61 season with a dinner
meeting on Wednesday, September
Shown left to right at the Oct. 1lth Northeast Tennessee Section meeting are: Don 21st, at the Johnson’s Hummocks.
Scott, technical chairman for the evening; Henry Korner; Dave Kelliner, guest William L. Lutes, manager for
speaker; and Jay Marks of the Knoxville Welding Supply Co. which sponsored the the McKay Co., Hard Surfacing
social hour Electode Dept., presented an in-
teresting talk entitled ‘Facing
Facts.”
Mr. Lutes pointed out that until
some five years ago, very little
WELDED OFFICE BUILDING The dinner was held at the effort had been made to educate
Pittsburgh—on October 19th, Webster Hall Hotel. The meeting industry on the whys and where-
the Pittsburgh Section had _ the was in the auditorium of Mellon fores of hard surfacing weld metals.
unique privilege of hearing an Institute. He mentioned that a joint AWS-
illustrated address by W. H. Heidt- ASTM Committee is now working
mann, president of Purdy & Hender- CO, WELDING to set up specifications for hard-
son Associates, New York City. Shickshinny—The Susquehanna surfacing electrodes.
This company redesigned the 44- Valley Section held a dinner meeting Mr. Lutes’ talk covered five
story Western Electric Building on October 5th at the Foot Hills phases of hard surfacing: reasons
in New York from a totally riveted Manor, Schickshinny. for hard surfacing, welding processes
structure to a partially welded Guest speaker was Robert Mann most commonly employed for hard
structure. This design change re- of Air Reduction Sales Co., who surfacing, factors affecting alloy
sulted in savings of 20% on the addressed the meeting on the sub- selection, types of alloys and com-
cost of a riveted structure, and ject “CO, Welding and Its Ap- mon every-day applications.
from 11 to 21% on the cost of a plications.””. Mr. Mann _ covered
structure using only high-strength the development of CO, shielded
bolts. Approximately 10 tons of welding using only CO, as the shield. Tennessee
welding electrode were used in the He feels that results obtained with a
fabrication and erection of this shielding of CO, only are comparable HISTORY OF ELECTRODES
building. to argon-CO, combinations and Johnson City—The Holston
Mr. Heidtman’s talk was of flux-CO, type of shielding with Valley Section held its regular
particular interest to Pittsburgh respect to quality and cost per monthly dinner meeting at the
members, many of whom have been pound deposited. He stated that a Peerless Steak House on September
working with city and state officials primary advantage of CO, welding 20th.
on the revision of their own building with the short arc process is the Speaker of the evening was Julian
codes. greatly increased facility in de- S. Kobler, Head, Fabrication Pro-
cedures Section, U. S. Naval Weap-
ons Plant.
Mr. Kobler’s informative talk
BEFORE AND AFTER IN DALLAS on “History and Development of
Arc Welding Electrodes’’ was sup-
plemented by slides. His talk
included such important points as
development of electrodes, functions
of electrode coverings; electrode
design and manufacture, and recent
advance and future trends in elec-
trodes.

TOOLING FOR WELDING

Knoxville—The second meeting
R. D. Thomas and F. L. Plummer about to North Texas Section viewing Oct. 11th of the season of the Northeast
receive ‘‘Texas-style’’ hats upon arrival evening TV news coverage of R. D. Tennessee Section was held at the
in Dallas during afternoon of Oct. 11th Thomas and F. L. Plummer arrival at Regas Restaurant.
Dallas Speaker for the evening was

1266 | DECEMBER 1960

OCTOBER IN HOUSTON guests of the North Texas Section
assembled at Howard Johnson’s
Turnpike Restaurant for their first
meeting of the 1960-61 season.
J. F. O’Connell, chief welding
engineer at J. B. Beaird Co.,
Shreveport, La., was guest speaker.
Mr. O’Connell’s discussion of the
techniques employed by his com-
pany in welding aluminum tank
cars was enjoyed by all.

ELECTROSLAG WELDING
Forth Worth—On Tuesday, Oc-
tober 11th, the North Texas Section
Houston Section gathers to hear President R. D. Thomas was host to President R. D. Thomas,
and National Secretary F. L. Plummer Jr., and Secretary F. L. Plummer.
Greeted at the airport by a party
of twelve, Messrs. Thomas and
David Kelkner of Air Reduction missile industries were shown in an Plummer were presented Texas-
Sales Co., Louisville, Ky. The excellent movie. The solution of style hats by Miss Gay Sullivan
subject of his presentation was all of these particular problems was from the Dallas Chamber of Com-
“Machine Tools for Welding.”’ ingenious tooling with the various merce. At the meeting held at the
complementary welding processes greater Fort Worth International
Airport, Mr. Plummer reviewed the
ELECTROSLAG WELDING functions of the Society at both the
national and local levels. He also
Texas Houston—-The October meeting brought the section members up-
of the Houston Section was held to-date on the status of the various
on October 12th at the Houston projects of the SOCIETY.
PRESSURE VESSELS Engineering and Scientific Society Mr. Thomas, featured speaker for
Houston—-The September 21st with 79 members and_ guests the evening, presented an interesting
meeting of the Houston Section was present. and informative discussion of the
held at the Houston Engineering The speaker, R. D. Thomas, “Electroslag Welding Process.”
and Scientific Society with 115 president of the Arcos Corp. and This process, developed in Europe
members and guests in attendance. National President of the Society, for welding heavy sections, is rel-
Prior to the dinner and technical presented a very interesting talk atively new in this country. Il-
session, the group enjoyed the movie- on “Electroslag Welding for Heavy lustrating his talk with slides,
“Football Highlights of 1959”’ which Fabrication.” Mr. Thomas explained the op-
was furnished by Humble Oil and National Secretary Fred Plummer eration of electroslag welding equip-
Refining Co. gave a report on the activities of ment and the tremendous material
The speaker was Leonard P. the SOCIETY. and labor-saving potential of the
Zick, chief research engineer for Prior to the dinner and technical process compared to conventional
the Chicago Bridge and fron Co. session, the movie ‘Football Holi- processes when applied to heavy
Mr. Zick chose as his subject day,”’ was shown through the cour- sections.
‘‘Pressure Vessel Design.’’ A very tesy of the Humble Oil and Immediately after the meeting,
interesting question-and-answer Refining Co. some of the 59 members and guests
period followed. present gathered around a television
Production bottlenecks arising ALUMINUM TANK CARS set to view the news coverage of
from joining components in the Dallas—On Wednesday, the arrival at Dallas Love Field of
automotive, appliance, nuclear and tember 14th, 41 members Messrs. Thomas and Plummer on
KRLD-TV, Dallas.

STAINLESS STEEL
SAN ANTONIO FEAST FOR NATIONAL OFFICERS
San Antonio—The October 10th
meeting of the San Antonio Section
was held at Capt. Jim’s with 38
members present to hear R. D.
Thomas, National President, and
Fred L. Plummer, National Sec-
retary.
President Thomas was the prin-
cipal speaker, using as his topic
‘Some Dramatic Applications of
a ee «~ Stainless and Low-alloy Steel Weld-
-: ing.’ A series of slides was used
Sr to bring out the many applications
of stainless and low-alloy steel
welding of vessels for the chemical
Gathering of 38 San Antonio Section members who heard talks industry, citrus industry and nuclear
by R. D. Thomas and F. L. Plummer application for power. Mr. Thomas

WELDING JOURNAL | 1267

is also president of the Arcos Corp. Section held their monthly meeting
Mr. Plummer presented an in- on September 16th at the Am- BATEMAN
formative talk on the functions of bassador Hotel. There were 88
the national office and the various members and guests present. BANTAM
committees and programs that are The coffee speaker was E. F.
active in welding. It was interesting Katz, director of education, A. C. IRON WORKER
to note that the SocIETyY is very Spark Plug, Division of General
active in the International Institute Motors. His talk was entitled
THE ONLY IRON WORKER OF ITS
of Welding, with representation on “Inertial Guidance.’”’ He _ stated
the American Council. that due to the very high rate of KIND ON THE MARKET TODAY
speed missiles travel, a guidance No Grinding Neces-
system is necessary to keep the sary After Cut. One
missile on target. He explained Stroke Cycle Clutch
Operated by Hand
that once a guided missile was or Foof.
PLANT TOUR launched, there was nothing that The Bateman “Ban-
could interfere or compel it to go tam” cuts 2” x 2” x
Salt Lake City—-The September
off course. He also pointed out 4" angles and 44” x
meeting of the Salt Lake City Section 4” flats. Standard
that these and other developments
consisted of a plant tour through punches will fit this
are what keeps us a free people. machine. The Coper
Salt Lake City’s new water treat-
His talk created a great deal of will cope 1%”
ment plant. There were 35 mem- through 4” material
interest which was evident by the
bers and their wives on this very Ite will punch 2”
many questions asked. hole through 14” ma-
interesting tour. The plant was
The technical speaker was La- terial. With the clutch
built at a cost of seven million
Motte Grover, welding engineer open, the Bantam wil!
dollars, and has a capacity of one make 44 strokes per minute. It is made of
with the Air Reduction Co., New
hundred million gallons per day. high-grade cast iron, with the clutch, pin
York, N. Y. His topic was ‘‘Weld- and dog made of hardened steel. The blades
After the tour, a dinner and social
ing as a Modern Process for Bridge are made with tool steel. Ic is powered with
was enjoyed by all. a fly wheel and gear drive, and uses a small
Construction.”” Mr. Grover gave
statistics on welded bridge con- Y% hp motor, 1750 rpm.
Wisconsin struction throughout the United Bateman Bantam with punch _$575.00
States and some foreign countries. Shear only $495.00
Stress was put on the importance Shipping wt. 750 Ibs.
BRIDGE CONSTRUCTION of inspection of welds to prevent
Milwaukee The Milwaukee weld failures. It was pointed out BATEMAN FOUNDRY & MACHINE
MINERAL WELLS, TEXAS
For details, circle No. 13 on Reader information Card
now you can get
All-State Spoolarc

that welded construction was as

successful in cold climates of the
northern states as it is in the hot
SPOOLED

temperatures of the southern states.

He also pointed out that the
ALUMINUM
cement manufacturers were doing
much to educate the contractors
in all grades, all types and State Highway Commissions
Loading 10 |b. spool of #4043 aluminum wire at precision layer level in the advantages of prestressed
Michael Flynn Manufacturing Co., Philadelphia. wound on concrete bridges. He felt that, if
Aluminum in this particular spool was used in
welding curtain walls for skyscraper at 2 Broad- 1 Ib. and 10 Ib. spools welded construction is to progress
way, New York City. and more welded construction be
used, it would be necessary for the
Wire goes from extrusion and light draw to ALL-STATE’s precision spool- welding societies to present the
ing machines where it is layer level wound for smooth, trouble-free welds. advantages of the use of welded
Types available: 1100, 4043, 5052, 5154, 5183, 5356, 5556, 6061, 6063, construction.
*355,* 356, 716, 718. The Section invited the civil
Precision spooled in these sizes: .030, .040, 3/64, 1/16, 3/32, 1/8. engineers local chapter to attend
*down to 1/16 only the meeting in the interest of welded
ALL-STATE Spoolarc® spooled aluminum wire meets federal and industry bridge construction.
specifications. Spools are sealed in polyethylene bags plus desiccant to
retain top quality from spooling machine to welding machine. SCHOLARSHIP
Complete stocks available from factories at White Plains, N. Y. and Milwaukee — Richard J. Who-
South Gate, California . . . and from branches at St. Louis, Missouri and uley, mechanical engineering stu-
Toronto, Canada. On sale at over 1000 distributors here and abroad.
dent at the Milwaukee School of
Send for new free Aluminum Manual. Engineering, was recipient of a
$275 scholarship given by the Mil-
Distributor-Stocked, convenient to buy. Economical to use waukee Section. Mr. Whouley was
SGrsur WELDING ALLOYS CO., INC., White Plains, N. Y. selected by the Milwaukee School
~ Call WHite Plains 8-4646 or write for nearest? distributor of Engineering for his high-grade
For detais, circle Ne. 12 on Reader information Card average.

1268 | DECEMBER 1960

 New Members EFFECTIVE OCTOBER 1, 1960
MEMBERSHIP CLASSIFICATION
A—Sustaining Member D—Student Member
B—Member E—Honorary Member
C—Associate Member F—Life Member

TOTAL NATIONAL MEMBERSHIP

ARIZONA IOWA
Grant, William D. (C King, Elmer (C Sustaining Members
Hazzard, George E. (C Members
Morgan, John W. (C IOWA-ILLINOIS Associate Members
Tanner,' Bruce (C Black, Dewain J. (C Students.........
Pirages, Joe F. (B Honorary Members...
ATLANTA Vatt, David E. (B Life Members. . .
Peel, Harry Edward, Sr. (B J. A. K. Total...
Watson, Frank O. (B
Clark, Wilbur R. (B AWS Builds Men of Welding
BIRMINGHAM Bergeson, Harold B. (B
Kosecki, Eugene (C Mores, Edward S. (C
Roushar, Francis J. (C Mola, Antonio (C SALT LAKE CITY
Reaves, R. E. (C
Tach, George A. (C Tweet, Allan T. (C NORTH CENTRAL OHIO Robinson, C. Grant (B
Wall, A. G. (C Watling, Wilfred H., Sr. (C Sims, N. D. (B
Reichenbach, Robert (C
BOSTON- KANSAS CITY SAN ANTONIO
NORTH TEXAS
Gilchrist, Alan D. (B Dulany, James E., Jr. (B Alcorn, Joe D. (B
Alley, S. C. (B Kite, Lincoln (B
Gowen, Ralph H. (B LEHIGH VALLEY Freeman, Rex B. (C
Kirk, George A. (C Mann, Ivin ¥V. (B
Ziegler, Donald A. (B Mays, Bob L. (B Pattison, Burt O. (B
Moffatt, William G. (B
Murphy, Paul (C NORTHWEST Van Winkle, Pelra J. (B
Pardo, Patrick F. (B LOS ANGELES
Amerson, Roger H. (C SANTA CLARA VALLEY
Brown, Robert L. (B Cohen, Saul T. (B
CAROLINA Conrad, Alfred S. (B Mann, Jerome M. (C
Nelson, Gordon A. (C
Presley, Ernest H. (C Olsen, George V. (B Swanson, Richard A. (B SOUTH FLORIDA
Smith, Walter J. (C Van Brocklin, Philip G. (B
MADISON-BELOIT Barkley, William O. (C
CHICAGO Allen, T. W. (B NORTHWESTERN
PENNSYLVANIA SYRACUSE
Balaban, Timothy (C Becker, Donald A. (C
Janion, Harold J. (B Gilbertson, Allan V. (B Butcher, Clarence S B Axtell, Drew C. (D
Kaiser, Ferdinand (B Iverson, Lawrence E. (C Janes, Donald S. (C WESTERN MICHIGAN
Morehous, Myron O. (C Johnson, Leroy L. (C McNabb, James E. (C
Nadel, James (B Kramer, Walter I. (C McLenitham, Donald (C
Shoelson, Mitchell J. (B Peterson, Walter J. (C OKLAHOMA CITY Lord, Fred (C
Simms, Glen E. (C Petitt, Glen M. (C Koger, Russell L. Van Wingen, Roy Martin (C
Petrof, Charles R. (C WICHITA
CLEVELAND OLEAN BRADFORD
Heyman, Gustave C. (C MARYLAND Boyce, Daron E D Alberding, Albert F. (C
Kaderavek, Robert (C Broski, Chester M. (C Brown, George E. (C Hempler, Donald C. (C
Newhorter, Gillispe P. (B Gulley, Joseph F. (C Geuder, Duane D WORCESTER
Lawrence, William L. (C Gonska, John (B
COLORADO Place. Harold B. (C Dushner, Michael R. (B
Barone, Frank, Jr. (B MILWAUKEE Rice, Harold M. (C Rogers, William F., Jr. (B
Steck, Alfred B. (B Stannard, L. W. (C MEMBERS NOT IN SECTIONS
COLUMBUS
NASHVILLE ORANGE COUNTY Mc Connaughey, H. T. (B
Wilson, Charles Irwin (D
Brown, Clyde W. (B Martindale, Edward,’Jr. (B Nadkarni, S. V. (B
DETROIT Peyron, Francois (C
Combs, James M. (B PITTSBURGH "7
Treptav, Thomas E. (B
NEW JERSEY Barefoot, Thomas Glenn (B Members Reclassified
EASTERN ILLINOIS Deloskey, A. F. (B Gross, Alfred R. (C During October
Flora, Vaun R. (B Gehrmann, John (B Lyden, Joseph P. (C
MacFarlane, Douglas I. (C Schroeder, Kenneth J. (C DAYTON
FOX VALLEY Mc Cue, J. W. (B Terrill, James R. (D Headapohl, John H. (C to B
Cork, Ronald W. (C Schoonmaker, T. P. (B Scott, Gerald E. (C to B
PORTLAND
Metko, Clem (C Blanchard, Zane S. (B LOS ANGELES
Sullivan, Fred M. (C NEW ORLEANS
Jackson, Charles E. (B Rowen, Donald K. (C to B
Wilharms, Earl R. (C Kuiper, Johannes (C
PUGET SOUND NEW JERSEY
HARTFORD NEW YORK
Hamal, Eino E. (C Winsor, Frederick J. (C to B)
Glidden, Edmund T. (C Orrok, Neale Edgar (C Moyer, Walter L. (B
Scheidle, Frank J. (B Posnakoff, John (C Spooner, Jerry C. (B NIAGARA FRONTIER
Timby, Elmer K. (B Dillman, M. B. (C to B
HOUSTON Wagner, George Hoyt (B RICHMOND
Dotson, Clifford L. (B Lucy, Carlton H. (C OLEAN-BRADFORD
NIAGARA FRONTIER
Matheny, James H. (C to B)
INDIANA Giler, Roger R. (C ST. LOUIS
Green, Z. Elsworth (B Kaiser, Edward K. (C Lavelle, James C. (B RICHMOND
Maddock, M. O. (B) Kelley, Robert L. (C Roehrs, O. Aubrey (B) Williams, Robert S. (C to B)

WELDING JOURNAL | 1269

 of the industry

Engineering Students Win year’s most outstanding contribu- gases will be a permanent part of
Lincoln Foundation Prizes tions to advancing the use of copper the headquarters. One of the dis-
and its alloys. This year the Asso- play units is a liquid oxygen in-
The annual awards for engineering ciation will award first prizes in stallation capable of storing 150,000
undergraduate papers on welded two separate categories so _ that cu ft of oxygen at a temperature
machine and structural design were equal recognition may be given to around 300° F below zero and con-
announced today by the James F. the best industrial and architectural verting it automatically to a gas on
Lincoln Arce Welding Foundation applications of copper, brass, bronze demand.
of Cleveland, Ohio. A _ total of or other copper-base alloys. Win-
$5000 in 46 awards was made to ner in each category will receive United Welder Representative
engineering undergraduates in 21 $500 and a handsome bronze trophy
different engineering colleges. Stu- Robert E. Groening, general sales
to be presented May 17, 1961, at manager, United Welders, Inc.,
dents in the University of Wyoming the Association’s annual meeting in
made the best showing for any one Bay City, Mich., has announced the
Hot Springs, Va. Members of the appointment of the Thomas Kelle-
school, winning a total of 15 awards. copper and brass industry (pro-
University of Illinois students were her Co. as representative for the
ducers, brass mills, wire mills) are state of Minnesota and Northwest
second in total performance, taking not eligible for the awards, although
4 awards. Awards were made for Wisconsin. Kelleher maintains of-
these companies may nominate
papers explaining how the efficient other firms or individuals.
application of welded steel to the Entry forms and complete infor-
design of a machine or structure mation about the competition are
contributed to its improvement or available from the Copper & Brass
cost reduction. Research Assn., 420 Lexington Ave.,
First award of $1250 went to COMING
New York 17, N. Y.
G. F. Balfanz, Jr., of Cicero, IIl.,
for his paper on the redesign of a
pump discharge head. Second Linde Distributor Has Open House EVENTS
award of $1000 was received by J. R. Twenty manufacturers of welding
Cortelyou, Los Angeles, Calif., who equipment participated in a two- A Calendar of Welding Activity
submitted a paper on the redesign day industrial exposition and ‘‘open
of a foot bridge. D. Belz and M. house” which marked the Septem-
Skeer, of Glendale and Brooklyn, ber 14-15th grand opening of H. M. AWS
N. Y., shared third award of $500 Parker & Son’s new welding supply
for their joint paper on a marine Mar. 24—25, 1961. Kansas Weld-
headquarters in North Hollywood, ing Show. Kansas National
salvage float. The schools in which Calif.
these students were enrolled re- Guard Armory, Wichita.
The event featured displays and
ceived equal amounts to use as demonstrations of modern welding 42nd Annual Meeting & Welding
scholarships in the respective de- processes by the participating com- Show: April 17-21, 1961. Hotel
partments. panies and attracted more than 600 Commodore, New York, N. Y.
In addition, it was announced representatives of local industry
that the 1960-61 competition has ASM
and other visitors. Among the
been significantly increased in show’s highlights were demonstra- Mar. 20-24, 1961. 12th Western
amount. In each of the two non- tions of electric welding, copper Metal Congress and Exposition.
competing divisions of the program, enameling and oxygen lancing by Pan-Pacific Auditorium, Los An-
Machines and Structures, a total the Linde Co., Div. of Union Car- geles, Calif.
of 23 awards worth $5000 will be bide Corp.
made. The top award in each NWSA
H. M. Parker’s new $300,000
division is $1500, ranging down to headquarters include sales and ad- December 1, 2. Southwestern
10 sixth awards each worth $50. ministrative offices, a warehouse and Zone Meeting. Hotel Roosevelt,
a modern showroom for exhibition of New Orleans, La.
Annual Copper Competition
the latest welding equipment. May 810, 1961. Seventeenth
The Copper & Brass Research Facilities for demonstrating tech- Annual Convention, Hotel Com-
Association has launched its third niques of handling liquid and modore, New York, N. Y.
annual competition to honor *he gaseous oxygen, and other industrial

1270 | DECEMBER 1960

 CAN YOU—IN YOUR SHOP—

MAKE UP A WELD JOINT? | PORTABLE

, UME PRECISION

: / IN ULTRASONIC
2’’ STAINLESS PIPE
WELD

In less than 2 minutes? INSPECTION

CAN YOU THEN WITH NO DIE CHANGE

MAKE THIS SET-UP ?...

3” MILD STEEL PIPE

. and have both done in less than 4 minutes?

HOW WOULD YOU MAKE THIS ONE?!

THE NEW BRANSON

SONORA e MODEL 5
You could have made all 3 joints shown
for inspection of raw materials going into weld-
in less than 15 minutes with your ments, as well as of the finished weld itself, goes
4é De Witt Weld Joint Making Unit”! with you to the job wherever it may be... brings
. laboratory precision into the field and permits the
You should have one! Investigate! most accurate evaluations of internal! structure pos-
sible today. Simplified controls, easily mastered by
“How simple!’ one customer said.
non-technical personnel, are centralized on the
acai Sari i aaa aaa ; front panel. Skilled service by factory-trained
| specialists is always available across the nation.
|
| Phone me today! PORTABLE: Weighs only 37 pounds complete.
| Call me collect! SENSITIVE: Detects all cracks;
|
| BUCKINGHAM 1-7000 instrument response adjustable
| F ; to suit exact quality require-
| My job is to make your ments of any job.
job of weld joint preparation
, PRECISE: Completely locates,
| a and determfnes extent of, in-
| Or... write for a sample. ternal discontinuities.
| (Tell me what joints you make) ECONOMICAL: Costs $2750.
1}

BRANSON INSTRUMENTS INC.

WA LLA E 64 BROWN HOUSE ROAD + STAMFORD + CONN.
SUPPLIES MFG. COMPANY
3506 N Ravenswood Ave. = Chicago 13, Illinois
For details, circle No. 14 on Reader information Card For details, circle No. 15 on Reader information Card
WELDING JOURNAL | 1271

ag a a =
 1948, to build an on-site plant
Now you can check at Johnstown, Pa. Since then, the CHAIN REACTION
company has expanded on-site plant
WELD TIME with
construction in various locations.
new PORTA-COUNT Born in Calgary, Alberta, Dr.
Hugill graduated from Canada’s
cycle counter Royal Military College. He re-
ceived a B.S. and M.S. in chemical
engineering from the University of
Alberta, and a Ph.D. from McGill
University. In 1954, Dr. Hugill
only $282 was elected a fellow of the Chemical
Institute of Canada. In May 1960
Counts actual weld time during firing. he received the Plummer Medal
PORTA-COUNT is light and small enough
to carry easily—keep right on the job. from the Engineering Institute of
Completely portable and self-contained Canada—an award given for the Art Owens, manager of the Welding Sup-
with jong life (up to 2 years) batteries. best paper on a chemical or metal-
Counts single phase. ply Div. of H. M. Parker & Son, slices
lurgical engineering subject pub- through chain to mark opening of a two-
No Plug In No Clips No Clamps lished in the Engineering Institute day exposition held by the company at its
PORTA-COUNT uses an inductive pick up Journal. new $300,000 headquarters in North Holly-
to count, sensing magnetic field around wood, Calif. Left to right are H. M.
power line, welding buss, transformer or Parker, chairman of the board, Art Owens
electrodes. NCG Dealers Install and C. S. Richmond, distributor sales
INSTRUMENT CONTROL CO. Oxygen Converters manager in Los Angeles for the Linde Co.,
1554 Nicollet Avenue Div. of Union Carbide Corp.
Minneapolis 3, Minnesota Installation of liquid oxygen con-
verters at NCG dealerships in
Mansfield, Ohio, and Marinette,
For details, circle No. 16 on Reader information Card Wis., has been announced by Na-
tional Cylinder Gas Div., Cheme-
tron Corp. Budd to Build NASA Satellite
The units, which will enable the
fices at 1214 S. 3rd., Minneapolis, dealers to fill gaseous oxygen cylin- A contract to design and con-
Minn. struct the stainless steel structure of
ders to high pressure by converting
Within this new sales territory, the easily stored low-pressure liq- the S-6 Atmospheric Satellite has
Kelleher will sell United’s special uid, were obtained by Mansfield been awarded to the Budd Co. by
equipment concept that includes Oxygen Co., in Mansfield and the National Aeronautics and Space
welding operations in automatic Interstate Welding Sales Corp., in Administration.
processing lines. United pioneered Marinette. The liquid converters The S-6 Satellite program is a
the design and fabrication of such have the equivalent capacity of scientific space experiment designed
special equipment. 250,000 cu ft of gaseous oxygen, to measure the composition, density
yet take up a ground space of only and pressure of the atmosphere and
Airco Expands Tonnage 14 x 14 ft, it was said. the variation of these with latitude
Oxygen Activities The two firms provide oxygen and time of day up to altitudes of
for use by local industries in welding, approximately 680 miles. The
Formation of a department for cutting and brazing, and for medical Satellite is scheduled to be launched
tonnage, or on-site sales of in- use. by the Thor Delta vehicle.
dustrial gases—primarily oxygen, Under the contract, Budd will
nitrogen, hydrogen and argon IIl-Mo Opens Branch develop, design and fabricate the
has been announced by R. E. Len- structures to be launched. The
Ill-Mo Welding Products Co., Budd Co. will be directed by the
hard, president of Air Reduction
Jacksonville, Ill., announces the Goddard Space Flight Center,
Sales Co., New York, N. Y. Dr. completion of a new branch at 800
J. T. Hugill has been appointed Greenbelt, Md., which has over-all
E. Jefferson St. in Springfield, Ill. responsibility for developing and
manager of tonnage products sales
to direct the department’s opera- instrumenting the Satellite.
tions.
On-site, tonnage gas plants are
already of major importance in the Allis-Chalmers Consolidates Pumps
steel and chemical industries. Ac- and Compressor Departments
cording to Mr. Lenhard, “Cost of
tonnage oxygen in the steel industry Consolidation of the West Allis
has dropped some 80% in the past Centrifugal Pumps and Compressor
ten years, with the development of departments has been announced by
on-site plants. Advent of low cost the Allis-Chalmers Manufacturing
oxygen in tonnage quantities Co., Milwaukee, Wis.
through technological advances has The new department will be under
also made it attractive to the chemi- The new building features a demon- the management of E. F. Griewe.
cal and nonferrous metallurgical stration area as part of the main C. F. Codrington will be manager of
industries as an important and use- sales room. engineering.
ful raw material. Present daily Mr. Carl Shaw WS, who is R. J. Dineen succeeds E. F.
consumption by these industries manager of the Springfield opera- Griewe as manager of the Norwood
amounts to about 8000 tons.”’ tion, has been with the IIl-Mo (Ohio) Works Centrifugal Pumps
Airco was among the first, in organization over 35 years. Department.

1272 | DECEMBER 1960

 NEW Complete...

Welding Facilities Tempilstik:

Li
==

in: Se |

Vy |

"h

te

FOR TOUGH
WELDING
PROBLEMS

Rosemount Engineering Company announces the in-

stallation of a 36” chamber Electron Beam Welder in its
Welding Department. REC’s certified welding facilities
include:
e Electron Beam Welding—from .003” foil to .500” plate
—including exotic metals such as beryllium, molyb- Also Tempil® Pellets _
denum, tungsten and zirconium and Tempilagq® (liquid form
e Tungsten Inert Gas Welding Yj
e Metal Inert Gas Welding :
e Aircomatic Gun—permits rapid deposits of wire for - .
distortion control j Tempilstik’—. simple and
e Stake Seamer—for controlled arc penetration and accurate means of determining preheating
accurate positioning of parts and stress relieving temperatures in
WELDING SERVICE AVAILABLE—REC’s welding engi- welding operations. Wi ely used in all
neers provide consultation and establish welding pro- heat treating—as well as in hundreds
cedures for difficult problems on an R and D basis. REC’s of other heat-dependent processes
welding facilities are available for production work on an in industry. Available in 80 different
hourly or piece basis. Write, wire or call if we can be of temperature ratings from 113°F
service on jobs requiring broad R and D or production to 2500°F . . . $2.00 each.
experience.
Send for free sample Tempil® Pellets.
State temperature desired... Sorry,
no sample Tempilstiks .
Most industrial and Idi |
ROSEMOUNT heuies suas Gees ay 7 ieee
does not, write for information to:

ENGINEERING ACCESSORIES DIVISION

COMPANY Tempil® corporation

4900 West 78th Street * Minneapolis 24, Minnesota 132 West 22nd St., New York 11, N. Y
For details, circle No. 17 on Reader Information Card For details, circle No. 18 on Reader information Card
WELDING JOURNAL | 1273
Flying Laboratory Fibre-Metal Warehouse Welding Department for Kennedy
A flying laboratory for nonde- A southeastern warehouse has Formation of a Commercial
structive testing maintained by been announced by The Fibre- Welded Products Dept. has been
General Magnaplate Corp., Belle- Metal Products Co., of Chester, Pa. announced by D.S. Kennedy & Co.,
ville, N. J. is said to be unique. Fibre-Metal Southeast, Inc., of De- Cohasset, Mass. The move was
At a moment’s notice, plane, crew catur, Ga., will distribute Fibre- said to be part of the company’s
and technicians are prepared to Metal, Glendale Optical Co. and policy of diversification in commer-
fly anywhere in the U. S. with a J. M. Ragle Industries products to cial fields. It was stated that the
full line of equipment for nonde- welding and safety supply distrib-
utors of the Southeastern U. S.
To assist in distributor sales
effort, J. J.Hauser was recently ap-
pointed to the sales staff. His
territory will include Alabama,
North Carolina, South Caroline
and parts of Florida and Tennessee.

Eutectic Occupies New

Quarters in Southwest
Expanded and improved quarters
structive testing of materials, prod- for its welding service and training
ucts and components. The com- activities in the Southwest have
pany maintains a Beechcraft Bo- been occupied in Dallas, Tex., by
nanza plane at Teterboro Airport, Eutectic Welding Alloys Corp.,
N. J. Southwestern Div., Inc.—-to meet
A Baltospot x-ray unit is used to the increasing demand for Eutectic
perform radiographic testing be- products and services resulting from
cause of its portability. The 140- the rapid growth of industry in the
W. R. Schneider
kv unit is designed and fabricated by Southwest.
the Balteau Electric Corp., Stam- The center serves as a distribu-
ford, Conn. tion point for the more than 200 new department will do subcontract
welding rods, electrodes and chemi- work in aluminum and steel weld-
cal aids made by Eutectic, offers ments and has available complete
Awarded Welding Scholarships facilities for steel welding as well as
free consulting service on main-
Joseph Nunnikhoven of Burling- tenance and repair welding prob- one of the largest aluminum welding
ton, lowa, has been awarded a lems, and includes quarters for the shops in Massachusetts.
scholarship in welding engineering, Eutectic Welding Institute which The newly-created department
recently established by the Chicago offers welding training courses and will be under the direction of
Welding Sales Co. and its subsidiary clinics. The Dallas Center serves William R. Schneider, formerly
company, at Ohio State University. Texas, Oklahoma, Louisiana and manager of planning and control.
During the past summer Nun- parts of New Mexico and Arkansas. Schneider joined the company as
nikhoven worked for John Deere The center is one of a network of Chief Welding Engineer in 1959.
Ottawa Works in Ottawa, Iowa. such centers in principal cities of Before that he was Chief Welding
He is continuing his studies at the U. S. and Canada, established Engineer at Westinghouse Electric
Ohio State in his junior year in weld- by Eutectic which is observing its Corp., Sturtevent Div., Boston,
ing engineering. 20th anniversary in 1960. since 1951. He is a member of the
AMERICAN WELDING SOCIETY, the
Ransome Rents Positioners American Production and Inventory
BIG INCH BY THE MILE Control Society and is a registered
Welding positioning equipment professional engineer.
is now available on a rental basis
from the Ransome Co., Scotch A. 0. Smith Welding Shows
Plains, N. J. All the standard
models and many special models The latest techniques, machines
of the company’s positioners, manip- and electrodes were demonstrated
ulators, turning rolls and head by the A. O. Smith Corp. at two
and tail stocks, may be rented recent welding shows in Lubbock
directly from the company for and Odessa, Tex. The two-day
any desired period, according to a shows were sponsored by two weld-
recent announcement. ing distributors to bring their cus-
tomers up to date in welding de-
velopments and help solve specific
Weltronic Canadian Plant
welding problems.
A plant equipped to manufacture Western Air Products, Inc.,
resistance welding controls has been staged the Lubbock demonstration,
opened by Weltronic Co. in Wind- while the Odessa show was spon-
Twenty gas-shielded magnetic-flux arc-
sor, Ont., Canada. Known as the welding machines are employed at the sored by Western Oxygen Inc.
Weltronic-Canadian Div., it is un- Welland, Ont., plant of Welland Tubes A. O. Smith, welding machine and
der the direction of E. Small who Ltd., to fabricate miles of 20- to 36-in. oil electrode manufacturer, provided
has had 10 years’ experience in the and gas transmission pipe. Boom trav- instructor personnel and equipment
automotive welding field. els full internal length for both of the demonstrations.

1274 | DECEMBER 1960

Progressive Opens New Offices ELECTRON-BEAM UNIT Copper Tubing Produced
Progressive Welder and Machine by Electron Welding
Co., Pontiac, Mich., manufacturer Electronically welded copper tub-
of specialized resistance welding ing, the first to be produced com-
equipment, announces the expan- mercially in the U. S., has started
sion of their national sales organiza- rolling off the production line at
tion. Tubotron, Inc., Newark, N. J., an
A new west coast office has been affiliate of Eastern Rolling Mills,
opened at 5909 Melrose Ave., Los Inc., New York, N. Y. Equipment
Angeles 38, Calif., headed by R. for the operation will make tubing
Bever and R. Arkils, both former at up to 300 fpm with outside di-
Detroiters. Mr. Bever was gen- ameters from '/, to 3'/2 in. and wall
eral sales manager of Federal Screw thicknesses from 0.017 to 0.140 in.
in Detroit, while Mr. Arkils at- Recent $35,000 welding unit installed In addition to copper and brass
tended Wayne State University at Rosemount Engineering Co., tubing, the equipment can produce
and UCLA, earning his degree in Minneapolis, Minn electronically welded tubing, round
Industrial Engineering. and shaped, from all other metals
Progressive’s new representative including the exotic alloys.
for Ohio, Western Pennsylvania and The welding unit is said to have a
Western New York is D. Campion. power capacity equal to three
Formerly he was chief engineer of average television stations and can
a large welding concern and owner NCG Appoints Prisuta heat faces of cold copper strip to
of his own design engineering busi- 1700° F—ready for welding—in
ness. Mr. Campion’s offices are National Cylinder Gas Div. of less than '/ oth of a second; the
at 6604 Charles Rd., North Olm- Chemetron Corp. has announced heated faces are then electronically
sted, Ohio. the appointment of M. B. Prisuta welded together between squeeze
Frank Brainard and Associates, as supervisor of the technical serv- rolls. Pilot runs of light-wall cop-
Meetinghouse Rd., New Hope, Pa., ice section of NCG’s_ research per tubing have been certified by an
will handle Progressive’s sales on and development department. Mr. independent laboratory to with-
the northeastern seacoast and in the Prisuta formerly was in charge of stand pressures of more than 2000
eastern half of Pennsylvania. product development in the Nuclear psi, eight times the pressure re-
Reactor Div. of Westinghouse Elec- portedly required by the ASTM for
tric. the tubing involved. A _ special
New Clarkson Plant scarfing unit removés the external
and internal weld beads as desired;
The Clarkson Laboratories, Inc., Navy Sponsors Welding the finished tubing is cut into 25 ft
manufacturers of specialty chemi- Engineer Student lengths by a flying saw synchronized
cals for the aviation, metal finish- to the rate of production.
ing, dairy, institutional, welding and Charles Wilson, first welding en- The welding operation is carried
electronics industries, moved on gineer ‘“‘co-op’’ employed at the out with a process of the New
August Ist, from its old location in Portsmouth Naval Shipyard, Ports- Rochelle Thermotool Corp., New
Philadelphia, Pa., to its new plant mouth, N. H., entered Ohio State Rochelle, N. Y. A similar installa-
and administrative offices at 1450 University last September to engage tion for copper is in use in Canada;
Ferry Ave., Camden, N. J. The in a 5-yr program of studies leading about 100 installations for producing
new facilities will increase the space to a B.S. degree in welding engi- aluminum and stainless steel tubing
available for both research and neering. Wilson is from Greens- are operating throughout the U. S.
manufacturing. boro, Vt., where he established an and abroad.
enviable academic record in high
school.
Sonobond Names Executives The Navy is to be Wilson’s em-
ployer during the next 5 years. Wil-
The appointment of R. S. Ames FIRST WELDING ENGINEER
son will, however, be on leave status
to the position of General Manager to attend Ohio State for nine months “CO-OP”’ STUDENT
of Sonobond Corp., subsidiary of of each year and will work for a
Aeroprojects, Inc., was recently salary at the Portsmouth Naval
announced. Mr. Ames was for- Shipyard during summer months.
merly director of long-range plan- While at Ohio State, up to one-half
ning for Goodyear Aircraft Corp., of his schooling expenses will be
Akron, Ohio. Two other executive paid for by the Navy.
appointments are D. D. Kirkpat- This is the first time that an
rick as director of sales and W. N. employer has sponsored the uni-
Rosenberg as manager of engi- versity training of an employee in a
neering. Mr. Kirkpatrick, who has course of studies leading to a de-
been with Aeroprojects and Sono- gree in welding engineering. In-
bond sales development for several terested individuals, including high
such companies as Goodyear Air- school graduates, may obtain fur-
Raymond Rivers, training supervisor
craft Corp. and Automatic Trans- ther information concerning the (left) welcomes Charles Wilson, coopera-
portation. Mr. Rosenberg was for- welding engineering “co-op” plan tive welding engineering student, aboard
merly chief engineer for a Phila- by writing to the Industrial Rela- at the Portsmouth Naval Shipyard. Stan-
delphia industrial gas burner manu- tions Dept., Portsmouth Naval ley |. Roberts, head of Welding Engineer
facturer. Yard, Portsmouth, N. H. ing Branch, looks on

WELDING JOURNAL | 1275

 for this design are the elimination of telephone and reports his presence,
Who said: large and costly steam drums, and his clock and job number and the
constant steam temperature over time. The information ‘‘flashes”
a wider load range, giving higher to the accounting office where it is
“Un-weldable?” over-all plant efficiency. automatically transcribed on mag-
The absence of a weighty over- netic tape by a recorder that was
head steam drum represents an switched on when the worker picked
added advantage for Tokyo Elec- up the telephone. Later, when he
tric since the unit will be erected in finishes his job, the worker returns
an area prone to earthquakes. to the telephone, checks out the
When the boiler goes on-line in completed work and gives details
the fall of 1963 at Tokyo Electric’s on his next assignment. The pro-
new “Goi’’ station, it will produce cedure is repeated for each job
two million lb of high-pressure steam change during the day. Back in
per hr at 1060°F and 2500 psi, the accounting office, “‘loaded”’ tapes
Before you call it ““un-weldable” check it out with reheat to 1055° F. are placed on a playback recorder
on the NRC Electron Beam Welder. Prob Operating at full load, the unit and a timekeeper transfers the job
lems posed by reactive metals, dissimilar ma
terials, heat sensitivity, and unusual geometry will burn 17,000 gal of oil hourly data to the proper accounting record
ire being solved daily to provide 265,000 kw of electrical sheet.
«Tungsten, tantalum, columbium, zirconium power.
etc. are welded free of contamination and
porosity *« Finish machined parts are joined British to Meet in U. S.
without distortion « Sensitive instruments are Resistance Welding
evacuated and sealed + Precision welds are
made at the bottom of a 1/16” slot or between A financing plan that will allow For the first time since 1910,
two surfaces meeting at an acute angle « Depth purchasers of resistance welding the Iron and Steel Institute of
width ratios greater than 4 1 are attained. machines the option to lease instead Great Britain will hold a meeting
Try NRC E B Welding ... . a special Smal! of buy now has been finalized by in the United States in 1961.
Lot Welding Service is available at hourly rates Hosts will be The Metallurgical
or you can get a complete E/B installation for Thomson Electric Welder Co., Lynn,
less than $16,000! Call or write now Mass., and General Electric Credit Society of the American Institute
Corp. and has been incorporated of Mining, Metallurgical, and Pe-
into the company’s sales structure. troleum Engineers, and the Ameri-
A Subsidiary of National This option, according to R. P. can Society for Metals.
Research Corporation
Hedblom, president, is being offered The Metallurgical Society will
Dept J-12 so that metal working plants may hold its 1961 Fall Meeting in
160 Charlemont St Eourrment @
Newton 61, Massachusetts CORPORATION obtain modern, efficient welding Detroit, the week of October 23rd,
DEcatur 2.5800 machines and use them over a broad- in conjunction with the Annual
For details, circle Ne. 19 on Reader information Card er range of assembly operations Metal Congress sponsored by the
without materially increasing capi- American Society for Metals. Part
tal expenditures. of the British group will attend the
Nuclear Contracts Awarded The plan is similar to those Metal Congress following its ar-
currently in use in the machine tool rival earlier that October. During
The Nuclear Div., Midwest Pip- field. On request, welding ma- their visit, members of the British
ing Co., Inc., St. Louis, Mo., has been chines, either standard or modified party will be in various cities of the
awarded five contracts to produce slightly to suit a customer’s require- United States and Canada.
welding fittings and fabricated as- ments, are leased for a maximum
semblies for 20 atomic installations of 60 months. Fair value of the
of the U. S. Navy. The orders, equipment is calculated and the Dye Oxygen Expands
totaling $700,000, include welding leasing charges set accordingly.
elbows and special fabricated pip- G. V. Dye, president of Dye
Numerous options, are available,
ing in stainless steel and Inconel, Oxygen Co., Phoenix, Ariz., an-
including straight time-payment ar-
for use in sea-borne nuclear power nounced the recent opening of the
rangement in which a _ customer
plants and prototypes for sub- company’s newest branch at 221
obtains title to the unit.
marines, destroyers and aircraft Chelsea Drive in El Paso, Tex
carriers. Bert K. Marshall was named man-
Hi-Fi Cuts Cost at ager.
B&W Boiler for Japan National Electric Welding The addition of the El Paso
branch was said to be another step
The Babcock & Wilcox Co. re- Hi-fi and tape decks have been in the company’s policy of maintain-
ported a contract from the Tokyo togged out in coveralls at National ing fast, dependable service to its
Electric Power Co. to manufacture Electric Welding Machines Co., Bay customers in the Southwest.
what will be the largest steam gen- City, Mich., and put to work as
erating unit built in the United components in an automated time-
States for export to Japan. It is keeping and cost-accounting sys- Thomson Appoints Dealer
also the first unit of its design to be tem. The system is expected to pay
purchased by any utility operating for itself within 18 months. After The Addy and Luby Machinery
in a foreign country. a half year’s operation, the system Co. of Detroit has been appointed
B&W officials described the boiler is well on its way to a payoff in representative for Thomson Elec-
as one of its “Universal Pressure”’ terms of recaptured production time tric Welder Co. of Lynn, Mass.
series. Using the “once-through” plus greater timekeeping accuracy Addy and Luby will be the exclu-
method of generating steam, this and increased efficiency in account- sive dealer in the area for Thomson's
unit is designed to operate below ing processing. entire line and will maintain current
critical pressure at 2500 psi. When a production worker begins design information and appropriate
Among the advantages claimed an assignment, he picks up a special service facilities.

1276 | DECEMBER 1960

 New Secretary Cleveland and Detroit offices. He
Named for ASTM has been district manager in Lin-
coln’s Milwaukee and Detroit terri-
Thomas A. Marshall, Jr., has tories during 18 of the last 21 years
been elected Executive Secretary of with three years, 1942-45, spent in
the American Society for Testing military service.
Materials by its Board of Directors, Boucher was Lincoln’s Detroit
effective Oct. 15, 1960, it has been district manager at the time of this
announced by Dr. A. Allan Bates, appointment.
President of ASTM. Mr. Marshall
is currently senior assistant secre-
tary of the American Society of Eisenlohr and Poole Appointed
Mechanical Engineers.
Dr. Bates also announced that The Thermal Dynamics Corp.,
Lebanon, N. H., has announced two
Fred F. Van Atta, formerly As-
sistant Secretary of ASTM, was new appointments—Alfred Eisen-
lohr ®3 and manager of the re-
elected to the post of treasurer with
cently formed Plasma Bond Div.
responsibility for the business oper-
and John A. Poole as Sales En-
ations of the Society. Robert J.
Painter, formerly executive secre- gineer.
Mr. Eisenlohr was formerly asso-
tary and treasurer, will continue as
consultant to the executive secre- ciated with the Propulsion Labora-
tory of the General Electric Co. in
Tuthill Engineering Manager tary. He will be especially con-
cerned with the Society’s long-range Evandale, Ohio. Mr. Poole was
R. W. Tuthill 3 has been ap- previously with Bell Telephone
planning program. Raymond E.
pointed manager of engineering for Hess will continue as Associate Laboratories, Whippany, N. J
Air Reduction Sales Co.’s Special Executive Secretary. As Technical
Products Department, its depart- Secretary and Editor-in-Chief, Mr.
ment for making customized weld- Main Becomes Manager
Hess is responsible for the technical
ing systems, it was announced re- activities and publications of the Robert C. Main has joined Sperry
cently. In his new capacity, Mr. Society. Products Co., division of Howe
Tuthill will supervise the design and Sound Co., Danbury, Conn., as
construction of all Airco’s custom- Cresap and Nielson Elected Trustees manager of engineering. He is an
made equipment involving uses for engineering graduate of the U. S.
gases and the cutting and joining of M. W. Cresap, president of the
Westinghouse Electric Corp., Pitts- Naval Academy, Annapolis, and has
metals. done extensive graduate work in
burgh, Pa., and M. Nielson, presi-
He has been with Airco since electronics and business administra-
dent of Babcock & Wilcox Co.,
January 1958 and before his present tion at MIT, University of Southern
assignment was assistant manager New York, N. Y., were recently
elected trustees of the Carnegie In- California and Harvard. He holds
of the equipment engineering and a number of U. S. and foreign pat-
development department. stitute of Technology in Pittsburgh,
Pa. ents in the general field of electronics
Mr. Tuthill graduated fom Pratt and has co-authored several texts on
Institute with a B.S.E.E. degree. electronics and radar.
Boucher Promoted
He was employed by the General
Electric Co. for 16 years and did A. F. Boucher has been named
considerable work on gas-shielded assistant general sales manager by Burleson in New Position
methods of welding, both tungsten- The Lincoln Electric Co., Cleve-
arc and consumable-electrode meth- land, Ohio. Appointment of S. R. Burleson as
ods. During his career, Mr. Tut- Boucher, a graduate of Ohio application engineer has been an-
hill has delivered numerous lectures State University with a Bachelor of nounced by the Colmonoy Div.,
and contributed numerous articles Science Degree, came to Lincoln in Wall Colmonoy Corp., Detroit, Mich.
on the gas-shielded methods of weld- 1936 and was made a district man- producers of hard-surfacing alloys
ing, a field in which he holds several ager in 1939, after three years of and related application equipment.
patents. experience as a field engineer in the Burleson will have offices at 4323 N.

R. W. Tuthill A. F. Boucher A. Eisenlohr

WELDING JOURNAL
 )

A reindeer brings you Season’s Greetings

) when you write to

SANTA CLAUS

(specialist in world peace)

For details, circle No. 20 on Reader Information Card

1278 | DECEMBER 1960
A Field Engineer brings you profitable ideas

when you write to LINCOLN

(specialists in arc welding)

was to Santa Claus is an exciting experience for the whole family. Eager
faces... pencilled lists... crackling fire... and the air alive with expectancy.
And then the long, almost unending wait until Christmas, when miraculously St. Nick
generally delivers even a little more than was desired. This is why we have faith in
him. That's the spirit of Christmas!

Now, we don’t say our Field Engineers will arrive in sleighs filled with toys, but this
we can guarantee: if you write a letter to LINCOLN, the Field Engineer who calis will
be able to give you a good deal more help than you expected. Not only does he know
welding products but also the best procedure to use on each job. He understands
how to relate welding profitably to your total manufacturing operation.

That’s why so many companies who have had faith in LINCOLN for over fifty years
say, ‘‘It’s a good idea to do business with LINCOLN where arc welding is a specialty
and cost reduction comes to you as a ‘plus’ at no charge.”’

Merry Christmas!

THE LINCOLN ELECTRIC COMPANY LINCOLN

Dept. 15100 Cleveland 17, Ohio VV eB) St te

For details, circle No. 20 on Reader Information Card

WELDING JOURNAL 1279
W. 27th St., Oklahoma City, and West Virginia and parts of Pennsyl- cognizance over the total research
will serve Colmonoy customers vania, Indiana and Kentucky, are in and development effort of the com-
throughout Oklahoma. Detroit, Mich. Kilrain was pre- pany. He will also be responsible
Burleson is a graduate of Okla- viously Cardox sales representative for coordinating this work among all
homa University. He has a back in Memphis. Babcock & Wilcox divisions and
ground of more than 8 years’ ex- subsidiaries.
perience in welding including 6'/, Freeman Appointed Mr. Taber will make his head-
years with the Linde Co. The appointment of William M. quarters at the B&W Research
Freeman as New York district Center in Alliance, Ohio, but will
Rider Heads New Area sales manager has been announced also maintain an office in New York,
by the Chicago Bridge & Iron Co., m. f-
Bastian-Blessing Co., Chicago, Chicago, Ill. Mr. Freeman as-
lll., has announced that Alfred T. sumes his new position after two Baker and Sampson Advance
Rider will move to St. Louis and be- years as manager of the process
come district sales manager for A new plant superintendent and
equipment sales group. assistant have been named by the
Missouri, eastern Kansas, central A native of Chicago, Mr. Freeman
and southern Illinois and the western Bird Machine Co., South Walpole,
has been with Chicago Bridge & Iron
border counties of Tennessee. Mr. Mass.
for 19 years. In addition to sales The new superintendent is F. W.
Rider formerly lived in Memphis work, his experience includes several
and handled RegO accounts in Baker, Jr. @/3 and his assistant is
years in the company’s engineering W. P. Sampson. Both have been
Kentucky and in western Tennessee. and field construction departments.
In his new assignment he will with Bird Machine for 20 years. F.
handle much of the area which was Taber Advances W. Baker, Jr., replaces J. Lindsay,
covered by the late Harry Kaye. who is retiring.
The Babcock & Wilcox C~ has
announced the election of Alden P. Harbaugh Named
Cardox Names Kilrain
Taber as a vice president in charge
Frank J. Kilrain has been ap- of the Research and Development The appointment of Charles P.
pointed sales manager of the Cen- Division. Harbaugh as product line manager
tral region for the Cardox Div., Since joining the company in for machine tool sales for the elec-
Chemetron Corp., producer of liquid June 1959, Mr. Taber has been a tronics division of ACF Industries,
carbon dioxide, carbonic gas, dry ice member of the president’s staff, Inc., Riverdale, Md., has _ been
and fire extinguishing equipment. coordinating and directing research announced.
Headquarters of the Central region, and development activities. In his Harbaugh, who will be responsi-
which includes Michigan, Ohio, new position, Mr. Taber will have ble for ACF Electronic’s expanding

WANT TO MEASURE
WELDING ENGINEER

RESISTANCE WELDING
for large midwestern
SECONDARY CURRENT?
manufacturer

Experienced management now required to

handle Production Engineering responsibilities
in:
¥ Large Welding and Fabrication Opera-
tion

A qualified candidate must have an engineering

degree as well as thorough and extensive man-
agement experience. He must have the ability
to manage a Production Engineering Section
consisting of at least 50 technical and engineer-
ing employees. He will be responsible for:
¥ Planning of all production operations
¥ Specification of Machine Tools and Tool-
ing requirements
Battery powered, transistorized portable Model 260 meter
measures true RMS value of secondary current for single ¥ Manufacturing Cost Control of one or
more product lines
phase welders used with or without heat control. Seven
ranges to 250,000 Amps, +3% accuracy, down to one ENGINEERS (Ages 25-45) with these quali-
cycle weld time, uses special air core toroid requiring fications are invited to submit their personal,
no direct connection to welder. academic and experience background. Also,
salary expected.
DUFFERS ASSOCIATES, INC. Write Box V-394
P. O. Box 296, Troy, N. Y.

For details, circle No. 21 on Reader information Card

1280 | DECEMBER 1960

 RESISTANCE-WELDING
i

GALVANIZED *&
Ne
So

At Triangle Sheet Metal Works, Inc., Tips made of New rials other than AMZIRC consistently annealed
Copper-Zirconium Alloy Minimize Electrode Pickup, Reduce and mushroomed at these settings.
Dressing, and Triple Electrode Service Life
High Conductivity and Strength
Resistance-welding tips made of AMZIRC® Cop- at Elevated Temperatures
per Alloy retain strength and hardness at ele-
AMZIRC consists of OFHC® copper (oxygen-free,
vated temperatures where copper and conven-
high-conductivity) and a rigidly controlled addi-
tional alloy tips weaken and mushroom. Triangle
Sheet Metal Works of New Hyde Park, New tion of high-purity Zirconium. This unique com-
bination makes AMZIRC ideal for applications
York, switched to tips made of AMZIRC. They
requiring high electrical conductivity with high
find that AMZIRC’s superior high-heat proper-
mechanical strength, especially at elevated tem-
ties minimize electrode piekup, reduce frequency
peratures.
of dressing 30%, and shorten weld time. As a
result, Triangle now gets three times more welds For tips made of AMZIRC call your local welding
per tip than they did with tips formerly used! supplies distributor* For metallurgical infor-
Triangle is a leading sheet metal contractor and mation on AMZIRC contact AMCO’s Technical
Service Section.
manufacturer specializing in the installation of
industrial and commercial heating and cooling
systems. They spot-weld galvanized steel duct- AMCO DIVISION
work under the following conditions: current— American Metal Climax, Inc.
12,000 amps; pressure—1,100 lbs; heat cycle- 1270 Avenue of the Americas
5 secs; cool cycle—3 secs. Tips made of mate- Rockefeller Center, New York 20, N. Y.
*amzirc is also known as N-4.
For details, circle No. 38 on Reader Information Card
line of machine tools, joined the of sales of Welsh Manufacturing Co.
division from the Cosa Corp. in died suddenly on October 17, 1960,
New York where he was field sales while attending the 1960 National
manager for the company’s im- Safety Congress in Chicago, IIl.
ported machine tools. Before that He was 69 years old.
he was manager of government sales Mr. Luckey had been active for
for Delaware Valley Machinery, over 30 years in many capacities in
Inc. both the industrial safety and weld-
ing field. He was a member of
Nyburg Appointed Manager Veterans of Safety.
He is survived by his widow in
J. K. Nyburg @9 has been ap- Baltimore, Md.
pointed general sales manager of
Easton Metal Powder Co., Division
of American Mannex Corp., it was
announced recently. He will co-
ordinate sales and marketing
plans for the divisions covering EMPLOYMENT
molding, cutting and = scarfing
powders as well as powders for spec- SERVICE
ial applications. BULLETIN
Mr. Nyburg was formerly sales
manager for Republic Steel Corp.’s Mid
Metal Powder Division. He is a Mesh
member of the Board of Governors Services Available
of the Metal Powder Industries
A-742. Welding Supervisor. Twenty-
Federation, and a member of the
ASM, AWS, AIME and others.
six years of welding and supervision, Ulu /|
!ih
KAN
shipyard and field plate erection.
Home-study engineer; present shift Wiel
i
OBITUARY supervisor in small shipyard. Inspec-
tion, instruction or production, con-
Edgar N. Luckey stant or intermittent travel, domestic
or foreign acceptable. Position must
Edgar N. Luckey, former director offer challenge.

The Welding Journal is the

world’s most authoritative

welding and allied process

magazine; it has fully 2'>

limes the editorial conlent of

YOu
any compeling magazine;
CAN
it is unequalled in coverage of
SEE
welding engineering, research
THE
and application. If you
CAPACITY
HERE- have a product for the welding

or allied industries, the

Journal’s pages will reach

your market!

*30% MORE THAN THE AVERAGE ACETYLENE CYLINDER

224 Ryan Way, South San Francisco, Calif. e PLaza 6-6910
COYNE 155 West Bodley Ave., Memphis, Tenn. ¢ WHitehall 8-7789
3800 Springdale Ave., Glenview, Ill. ¢ PArk 4-3828
cylinder company 24 Commerce Street, Newark, N. J. e Mitchell 2-1618
For details, circle No. 22 on Reader Information Card

1282 | DECEMBER 1960

 For details, circle No. 38 on Reader Information Card

Which Brazing Alloys for Vacuum of Svarochnoe Proizvodstvo) Oct.

Systems?, W. Hack. Matis. in Design 1959), pp. 63—70.
Eng., vol. 52, no. 1 (July 1960), pp. Iron Castings
116-118.
Filler-Rod for Gas-Welding of S.-g.
Iron, R. H. T. Dixon, D. R. Thorney-
Carbon-dioxide Welding croft. Foundry Trade Jnl., vol. 108,
CO, Welding of Sheet Materials, A. G. no. 2266 (May 12, 1960), pp. 583-958.
Current Welding Brain, A. A. Smith. Brit. Welding Quenchable Deposits Speed Cast-Iron
inl., vol. 7, no. 7 (July 1960), pp. Repair. Welding Engr., vol. 45, no. 5
471. May 1960), p. 60.
Positional Welding of Steel with CO Missile Manufacture
LITERATURE Process, A. A. Smith. Brit. Welding
Jni., vol. 7, no. 7 July 1960), pp. Instrumentation for Better Welds,
158-463. D. J. Logan and W. K. Moen Metal
Progress, vol. 78, no. 1 (July 1960),
pp. 111-114.
Cobalt
Pipe Lines
Welding and Brazing of Certain Co-
balt-Containing Alloys, W. J. Lep- Pressure Welding for Pipelines, R. L.
kowski, R. E. Monroe. Cobalt, no. 7 Koppenhofer, W. J. Lewis, G. E.
June 1960), pp. 6-12. Faulkner, P. J. Rieppel, and H. C.
Cook. Oil & Gas Jni., vol. 58, no.
28 (July 11, 1960), pp. 114-117, 119
For copies of articles write directly to Die Repair
publications in which they appear. AA list of MISSILES
addresses is available on request Welding Renews Damaged Dies, O. /
Pfouts, C. F. Jatezak. Tool Engr., Superstrength Rocket Chambers Made
vol. 45, no. 1 (July 1960), pp. 77-80 From Paper-Thin Steel, C. O. Herb.
Aircraft Manufacture Macny N. Y.), vol. 66, no. 10 (June
Norair Method Slashes Brazing Time, 1965), pp. 174-177.
J. F. Judge. Missiles and Rockets, Electron-Beam Welding
Nickel! Piating
vol. 6, no. 18 (May 2, 1960), pp. 30-31 Electron Beam Welding, M. E. Harper, Corrosion Control Applications of Elec-
Aluminum E.G.Nunn. Brit. Welding Jni., vol. 7, troless Process for Chemical Nickel
no. 5 (May 1960), pp. 331-336. Plating, W. J.Crehan. Corrosion, vol.
Examination of Corroded Welds in
Aluminium Cooking Vessel, with Rec- 16, no. 4 (Apr. 1960), pp. 23-24.
ommendations for Improved Welding Is Electron Beam Welding Ready For Nuclear Reactors
Techniques, K. G. Latimer. Inst Production Line? M. Hablanian.
Iron Age, vol. 185, no. 2 (Jan. 14, 1960), Plug Welding on Fuel Guide Mech-
Metals—-Jnil., vol. 88, pt. 10 (June anism for Berkeley Nuclear Reactor,
1960), pp. 432-434. pp. 66-67.
C. Phillips. Welding & Metal Fabri-
Arc Welding cation, vol. 28, no. 6 (June 1960),
Progress in Electron-Beam Welding, pp. 216-228.
Dip Transfer Process: Low-spatter G. Burton, Jr., W. L. Frankhouser.
Welding in Any Position, A. Lesnewich. Engrs’ Digest, vol. 20, no. 11 (Nov. Welding of Stainless Steel Which
Metal Progress, vol. 78, no. 1 (July 1959), pp. 441-444, 467. Contains More than One Per Cent
1960), pp. 115-116. Boron, N. Balai. U. S. Atomic Energy
Arc Welding Commission—Tech. Information Serv-
Electroslag Welding ice Extension TID-7562 (Jan. 1959),
Droplet Transfer During Arc Welding Application of Electro-Slag Welding, pp. 15-31.
in Various Shielding Gases, L. F. A. M. Horseield Brit. Welding Jni.,
Defize, P. C. van der Willigen. Brit vol. 7, no. 5 (May 1960). pp 337-341. Oxygen-cutting Machines
Welding Jnil., vol. 7, no. 5 (May 1960), Join Thick Steel Sections with Elec- Better Controlled Dimensions with
pp. 297-305. troslag Welding Iron Age, vol. 184, Magnified Template Drawings, R. L
Arc Welding no. 25 (Dec. 17, 1959), pp. 170-172 Deily. Welding Engr., vol. 45, no. 5
May 1960), 42-43.
Fundamental Study of Tungsten Arc,
E. F. Gibbs. Metal Progress, vol. Note on Recent Experience with Oxygen Cutting
78, no. 1 (July 1960), pp. 84-92. Rockweld-Vus_ Electro-Slag Welding Distortion Problems in Oxygen-Cut
Arc Welding Machine, W. K. B. Marshall. Brit. ting, K. D. S. Semper. Welding &
Welding Jni., vol. 7, no. 6 (June 1960), Metal Fabrication, vol. 28, no. 8 (June
Percussion Welding Makes Quick; pp. 393-395
Low-Cost Wire Connections, J. S. 1960), pp. 229-234
Gellatly, K. F. Johnson and A. L. Pipe Lines
Quinlan. Metal Progress, vol. 7 Fatigue
Save Money with X52 Welded Re
no. 1 (July 1960), pp. 122-124. Flexural Fatigue Strength of sutt pairs, T. A. Ferguson. Oil & Gas J
Arc Welding Welds in N.P. 5/6 Type Aluminum vol. 58, no. 14 (Apr. 4, 1960), pp. 121,
Alloy, J. L. Wood. Brit. Welding Jni., 123
Semi-Automatic Welding with Fine vol. 7, no. 5 (May 1960), pp. 365
Wires, R. V. Brimble, J. A. Lucey, D 380. X-ray Testing in Pipeline Welding,
B. Tait. Brit. Welding Jnil., vol. 7, M. Sircon. Petroleum, vol. 23, no
no. 5 (May 1960), pp. 342-352. 3 (Mar. 1960), pp 95-96.
Friction Welding
Beryllium Pressure Vessels
Heating and Cooling of Rods Butt
Fusion Welding of Beryllium, T. J. Welded by Friction Process, N. N. Radiograph Welds and Cut Vessel
McDonald, N. F. Eaton and D. B. Rykalin, A. I. Pugin, V. A. Vasil’eva. Costs, R. Chuse Petroleum Re jiner,
Wright. Brit. Welding Jnil., vol. 7, Welding Production, (translation of vol. 39, no. 4 (Apr 1960), pp. 149
no. 7 (July 1960), pp. 441—450. Svarochnoe Proizvodstvo), (Oct. 1959), 150.
Brazing pp. 42-52 Pump Manufacture
New Method For Brazing Aluminum Don’t Wait for Tomorrow to Fabricate
and Magnesium, W. C. Rudd. Metal Power and Heat Parameters of Friction Titanium, B. Payne. Tooling & Pro-
Treating, vol. 11, no. 3 (June-July Welding, R. I. Zakson, V. D. Voznesen- duction, vol. 26, no. 2 (May 1960),
1960), pp. 19-22. skii. Welding Production (translation pp. 63-66.

WELDING JOURNAL | 1283

 New Literature Chemetron Corp., 840 N. Michigan
Ave., Chicago 11, Ill. Included are
diagrams of welding and cutting
tips, and specification tables for
tips, regulators and torches. The
catalog also lists uses for the in-
dustrial gases distributed by NCG,
and gives locations of NCG dealers
and distributors from coast to
coast.
For your free copy, circle No. 52
on Reader Information Card.

AWS Publishes Welding Metallurgy Booklet Silver Brazing Self Taught

A pocket-size booklet on welding are involved since it covers: tem- At-home or in-plant training in
metallurgy is announced by the perature changes in welding, struc- silver brazing is the subject of a
AMERICAN WELDING Society. It ture of metals, mechanical proper- new bulletin published by Handy &
is a condensed textbook on ferrous ties of metals, factors influencing Harman, 82 Fulton St., New York
and nonferrous welding metallurgy the properties of metals, fractures 38, N. Y. The bulletin describes in
prepared and reviewed by some of in metals, factors affecting weld- detail the packaged, self-study
the finest metallurgists in the United ability, plain steel and low-alloy course, introduced earlier this year,
States and containing 122 pages, steel, high-alloy steels (stainless and which is based upon a monthly
45 illustrations, 25 tables and 25 heat resisting), nickel and nickel al- three-day brazing class the com-
diagrams. loys, copper and copper alloys, alu- pany has used to train over 2500
The material is reprinted from minum and aluminum alloys, mag- industrial brazers during the past
the most recent edition of the WELD- nesium and magnesium alloys, tita- 13 years.
ING HANDBOOK in response to the nium and titanium alloys and bib- The brochure lists and illustrates
need for an _ inexpensive, short, liography. the complete contents of the pack-
comprehensive text on the subject. Copies may be obtained from the aged self-study course, including
It should prove invaluable for all AWS Information Center, 33 W. textbook and all materials required
training programs where the fun- 39th St., New York 18, N. Y. to complete the course exercises.
damentals of welding metallurgy Price $2.00. For your free copy, circle No. 53
on Reader Information Card.

ASA Pipe Thread Standards

Ultrasonic Welding teristics, quality control, equip-
ment and applications. In addi- *‘American Standard Pipe
The AMERICAN WELDING So- tion, a brief bibliography and Threads (except Dryseal), B2.1-
CIETY announces the publication of index are included. 1960,” and “American Standard
a new booklet, Ultrasonic Welding, Ultrasonic Welding is one of a Dryseal Pipe Threads, B2.2-1960,”’
containing 38 pages and 29 illus- series of AWS publications dealing have been approved by the Ameri-
trations. The booklet, a reprint of with specific processes or subjects can Standards Association and pub-
material published in Section III and designed to act as compact, lished by ASME.
of the WeLpING HANDBOOK (4th comprehensive guides te new proc- The previous edition of B2.1 was
Edition), contains sections discus- esses and methods. Copies at approved as an American Standard
sing fundamentals of the process, $1.50 each, may be obtained from by ASA in 1945. It contained
the metals which can be welded, the AMERICAN WELDING SOCIETY, standards for dryseal pressure-tight
welding techniques, weld charac- 33 W. 39th St., New York 18, N. Y. joints that are now published sepa-
rately as B2.2.
The standard for pipe threads
except Dryseal) covers specifica-
tions, dimensions and gaging for
Oxygen Cutting of Bevels the practical techniques for ob- taper and straight pipe threads in-
taining good-quality bevel results; cluding certain applications. There
Air Reduction Sales Co., 150 E. and the comparison of common fuel are 19 tables and 6 appendixes.
42nd St., New York 17, N. Y., has gases in bevel cutting. Informa-
just made available reprints of an tion on the cutting of bevels is
article by George Spies, “‘Specific related to published data on per- Fire Codes
Problems Associated with Oxygen pendicular cutting.
Cutting of Bevels.” The article For your free copy, circle No. 51 A new and revised edition of the
was delivered as a paper at the on Reader Information Card. National Fire Codes has just been
AWS 4ist Annual Meeting held in published by the National Fire
Los Angeles, Calif., Apr. 20—29, Protection Assn., 60 Batterymarch
Welding and Cutting Torches St., Boston 10, Mass.
1960, and appeared in the June
1960 issue of the WELDING JOURNAL. A new 16-page catalog (NTW-10) The 7-volume 1960-61 issue of
Complete with graphs and illus- describing and illustrating ‘“Torch- this authoritative reference work is
trations, the article discusses bevel weld” welding torches, cutting at- said to incorporate important
cutting under three main headings: tachments, tips, economizers, regu- changes in many fire safety stand-
the relationship of preheat, cutting lators and assemblies is available ards. Included is a compilation of
oxygen and speed in bevel cutting; from National Cylinder Gas Div., the 181 standards developed by

1284 | DECEMBER 1960

 /HANDY ALLOY DATA SHEET
HANDY & HARMAN’ ENGINEERING DEPARTMENT
82 FULTON STREET, NEW YORK 38, N.Y.

Handy & Harman Silver Brazing Alloys

...
he COMPLETE line that meets all specifications and production needs
Need to join any combinations of metals—ferrous and One Source of, and Authority On Brazing Alloys and
nonferrous? Investigate the vast number of products, Methods makes—and makes readily available —the fol-
assemblies and parts that are being joined better by lowing silver brazing alloys:
silver brazing alloys. Handy & Harman, the Number

HANDY & HARMAN SILVER BRAZING ALLOYS

COMPOSITION PERCENTAGE oe
Ag Cu Zn Other oF
50 1542 16¥2 1160

‘610 61 24 (15 In)

*A Solder—Not a Brazing Alloy. tFormer Names

Space does not permit listing the many special alloys, always ready to work closely with you on metal joining
formulated for a particular or unique application. Handy problems and methods.
& Harman Brazing Engineers and Technical Service are Comprehensive technical literature covering all aspects
of brazing methods and alloys awaits your request.
GET THE FACTS FROM Your No.1 Source of Supply and Authority on Brazing Alloys
BULLETIN 20 z
This informative booklet gives oa
a — re agg a | j
ing and its benefits...includes
details on alloys, heating — HANDY & HARMAN
Suction technigues’ Write foc (mmauuall General Offices: 82 Fulton St., New York 38, N.Y.
your copy. Offices and Plants: Bridgeport, Conn.+ Chicago, Ill. * Cleveland, Ohio* Dallas, Texas + Detroit, Mich
Los Angeles, Calif.- New York, N. ¥.» Providence, R. I.- San Francisco, Calif.- Montreal, Canada+* Toronto, Canada
DISTRIBUTORS IN PRINCIPAL CITIES
For details, circle No. 24 on Reader Information Card
WELDING JOURNAL 1285
NFPA in the fields of flammable RWMA Bulletins specifications as welded for principal
liquids and gases, combustible solids, alloying elements.
dusts, chemicals and _ explosives; The Resistance Welder Manufac- Specific case history studies on the
building construction and equip- turers’ Association has published use of stainless steel electrodes and
ment; extinguishing equipment; as association bulletins the follow- wires are also included.
electrical installations; and mobile ing three articles which appeared in In addition, pertinent information
fire equipment, transportation and the Welding Research Supplement: is given regarding the procedures to
management. No. 28, “Seam Welding Galva- follow for best results when welding
New material includes 42 new or nized Steel”; No. 29, “Tip Life stainless steel.
revised fire safety standards adopted Studies in the Spot Welding of For your free copy, circle No. 57
at the 1960 annual meeting of the 5052 Aluminum Alloy”; No. 30, on Reader Information Card.
Association, and incorporates all “Effect of Zinc Coatings on Resist-
amendments approved by _ the ance Seam Welding of Sheet Steel.’
NFPA Board of Directors up to and Copies are available from the
Dye Penetrant Movie
including July 30, 1960. Association’s headquarters, 1900
Arch St., Philadelphia 3, Pa., at a A full color and sound, 23 min
Vacuum Pump Catalog cost of 50¢ each. 16 mm motion picture entitled
“How to Locate Flaws with Dye
A new 12-page catalog that con- Penetrants” has been completed by
tains basic descriptive information Steel Water Tanks Turco Products, Inc., 24600 S.
on diffusion and booster pumps, Main St., Wilmington, Calif., and
shows speed curves for small, me- A 20-page brochure describing the is available for free showing to
dium and large models ranging from design and function of elevated steel interested organizations. The film
1 to 32-in. sizes, and _ includes tanks for water storage has been visually demonstrates every aspect
both tabular specifications and out- published by Chicago Bridge & Lron of dye penetrant inspection from
line drawings for each pump is now Co., 332 S. Michigan Ave., Chicago laboratory theory to authentic pro-
available from NRC Equipment 4, Ill. The brochure places particu- duction-line techniques actually
Corp., 160 Charlemont St., Newton, lar emphasis on Horton spheroidal, filmed on location during mass
Mass. The catalog is reportedly radial cone and ellipsoidal tank de- production dye penetrant inspec-
ideal for reference when designing signs in capacities ranging from tions. On-the-spot sequences
vacuum systems or checking on 15,000 to 3,000,000 gal. Illustrated shown include the inspection of
their performance. with photographs of structures now wing spars, small aircraft parts,
For your free copy, circle No. 54 in service, it also contains tables of truck wheels, valves, oil tool com-
on Reader Information Card. standard capacities. ponents, gears, spindles and pres-
For your free copy, circle No. 55 sure vessel weld seams.
on Reader Information Card. The laboratory sequence de-
scribes the theory behind dye pene-
Use the best ! ! trants in detail and outlines the
Resistance and Arc Welding proper methods of assuring com-
plete inspection accuracy. The
PACIFIC UW Capsule case histories of special viewer is enabled to see exactly
equipment, manufactured by Kirk- what action takes place when flaws
FOR UNDERWATER WELDING hof Manufacturing Corp., 2450 Bu-
are located in metal parts with
chanan Ave., S. W., Grand Rapids 7, dye penetrants.
For mild steel unde-water cutting Pacific Mich., to meet the special require-
A “Sneak Preview” folder de-
UW has no equal. Using the same ments of the metal working in-
scribing the film in detail is avail-
technique as applied on the surface, a dustry, are contained in a new 8-
able without charge or obligation.
skilled welder can produce 15 to 20 feet of page bulletin (E60-1). Illustrated For your free copy, circle No. 58
are resistance and arc welders, on Reader Information Card.
fillet welds per hour. Welds will develop welding guns and stations, jigs and
% of the original tensile strength. fixtures, mechanical handling equip-
ment, automation systems and as- High-temperature Tube Steels
sembly presses. Brief details of
machine design and methods are Those associated with the design,
PACIFIC UC given along with the production manufacture or purchase of equip-
rates and cost savings achieved. ment involving the high-tempera-
FOR UNDERWATER CUTTING For your free copy, circle No. 56 ture application of tubular products
on Reader Information Card. will be interested in a new brochure
Steel, cast iron, bronze, monel and other published by the Tubular Products
non-ferrous metals of ANY dimension can Div., Babcock & Wilcox Co., Beaver
be easily and quickly cut by any average New Reference Guide Falls, Pa. The 6-page folder (des-
operator. Pacific UC demands less skill, on Welding Stainless Steel ignated T-467) contains informa-
saves in operating costs. tion on 15 steels widely used in high-
A new 6-page folder has just been temperature service.
For information on the complete line issued by The McKay Co., 1005 Included is a chart containing
Liberty Ave., Pittsburgh 22, Pa., data on tensile properties, thermal
of Pacific electrodes write to and contains a valuable and handy conductivity and expansion, creep
chart on the chemical and physical strength, oxidation resistance and
specifications of McKay stainless other such mechanical and physical
Xo | ||
4 NORTH AVENUE . i) S ANGELES ALIF steel electrodes. The chart lists the properties of importance to appli-
grade of steel, AWS and AISI cation engineers.
identifications, principle properties For your free copy, circle No. 59
For details, circle No. 25 on Reader Information Card as welded, color codes and chemical on Reader Information Card.

1286 | DECEMBER 1960

 —,
baby
this
when

___heeds new shoes i

ee = REBUILD

THEM

FASTER...

MORE
ECONOMICALLY

eA
Nes

MANGANAL

NEAREST DISTRIBUTOR UPON REQUEST

WRITE
i
Sale ; for literature on the reclamation
‘ ae sb Sct of worn tra or parts

pt]
> oi et A -e
929\Julia Street @ Elizabeth, New Jersey

For details, circle No. 26 on Reader information Card

WELDING JOURNAL
Pipe Fitters Manual ings include semiconductors and that agent appears, a series of
diodes, transistors, panel meters, answers appear in another window.
Information expected to be at nuvistors, termisters, standard and These are color-coded comments
the finger tips of modern pipe fit- special-purpose electronic tubes, telling how each of the eight metals
ters and pipe welders is concen- miniature industrial fans, ultra- will react to that particular agent:
trated into the “‘Pipe Fitters Man- sonic cleaning equipment, test in- excellent, good, fair or not good.
ual,” a comprehensive 72-page struments, voltage stabilizers, trans- For your free copy, circle No. 64
handbook available from Tube formers, attenuators and controls, on Reader Information Card.
Turns Division of Chemetron Corp., resistors, capacitors, printed circuit
Louisville 1, Ky. components, potentiometers, rheo-
Text, tables and illustrations in stats, relays, switches, connectors,
the pocket-size field manual give rectifiers, fuses, tools, wire and
important mathematical, physical, cable, photoelectric components,
chemical and metallurgical data and two-way radio communications
related design, layout and mechani- equipment, closed-circuit TV sys-
cal information at a glance. tems, sound powered telephones,
Subjects covered include charac- counters, motors, program clocks,
teristics of welded and threaded timers, batteries, sockets, genera-
piping; basic mathematical formu- tors, power supplies, and a wide
las and conversion factors; dimen- variety of other electronic equip-
sions of welding fittings and flanges ment and components.
and commercial pipe sizes; elec- For your free copy, circle No. 62
trode data and practical tips on on Reader Information Card.
welding and properties of pipe,
metals and fluids. Illustrations
show methods of pipe alignment,
types of pipe hangers and commonly Epoxy-insulated Transformers
used drafting symbols for arc and An 8-page bulletin describing
gas welding and for pipe fittings. their complete line of Epoxy-Pak
For your free copy, circle No. 60 Resistance Welding Transformers is
on Reader Information Card. available from Kirkhof Manufac-
turing Corp., 2450 Buchanan Ave.,
S. W., Grand Rapids 7, Mich. Unfired Pressure Vessels. The
Plasma Bond Spraying Epoxy impregnation and encapsu- ASME Code Simplified. By Robert
lation is said to provide up to 33% Chuse. Hard Cover, 6 9 in.,
A 4-page bulletin, ““Plasma Bond
greater kva capacity, plus longer 154 pp., indexed. Published by F.
Spraying Service,” offered by Ther-
weld cycles, better overload pro- W. Dodge Corp., New York. Price
mal Dynamics Corp., Lebanon,
tection and longer operating life. $8.75.
N. H., describes the metallic and
ceramic coatings applied by their Bulletin T60-1 also contains capac- As a guide to the use of the sec-
plasma-spraying techniques. This ities and dimensions for each of tions of the ASME Code covering
process employs the principle of the 9 basic units. unfired pressure vessels, this book
feeding a powder into a high-ve- For your free copy, circle No. 63 fills a long-standing need. The
locity gas stream which has been on Reader Information Card. author praises the code as a sound
ionized by an electric arc. The body of rules. However, after some
ultra-high temperature ‘“‘plasma”’ 20 years’ experience as an inspector,
stream melts and carries the par- Slide-rule Corrosion Guide he finds that many estimators,
ticles and impinges them at high designers, shop men and even in-
speed upon the workpiece, producing A 4- by 8-in. card that works spectors often have difficulty in ap-
a dense, tightly bonded coating. like a slide rule and tells in seconds plying the proper rule. The result
For your free copy, circle No. 61 how each of eight types of metal is loss of time and added expense.
on Reader Information Card. withstands the corrosive effects One chapter of the book sets out
of 141 chemical agents is offered to overcome this situation by or-
by H. M. Harper Co., Morton ganizing the code rules around the
Electronics Catalog Grove, Ill. different acceptable components of
The metals are common in me- which pressure vessels are built.
Allied Radio Corp., 100 N. West- chanical work brass and naval The reader can see at a glance all
ern Ave., Chicago 80, Ill., an- bronze; silicon bronze; monel the rules that apply.
nounces the release of its 1961 metal; stainless types 410, 416 and Other chapters cover the range
catalog of electronic equipment. 430; stainless types 302, 303, 304 of fabrication, indicating the most
Special emphasis has been placed and 305; stainless type 316; copper, direct and economical means by
on electronic equipment for in- and aluminum. As a guide to which code requirements can be met.
dustry. The new 576-page catalog problem solving, this little computer The author carefully explains the
is stated to be the largest catalog lists for the user some 141 chemical reasons behind many requirements.
published by any electronics supply agents, any one of which may pose Instructions and suggestions are
house and lists over 48,000 items a problem because of the metals given on how best to qualify a
which include 240 pages in roto- it will contact. The problem is, shop, a welding procedure, a welder;
gravure. Covers are reproduced which metals best resist corrosion how to avoid pitfalls and what to
in 4 colors. by these agents. watch out for in joint preparation,
The catalog includes extensive To find out, the user slides the fit-up, welding and stress relieving.
listings of parts and equipment inner card of the computer so that A chapter is devoted to quality
for industrial maintenance, research the problem agent appears in a control methods. There are 66.
and production requirements. _List- window of the outer card. When charts, tables and diagrams.

1288 | DECEMBER 1960

MISSILE AGE PAUL BUNYAN

urFts 80,000 Pounps Hufford Corporation

specified all-welded
WITH THE STRENGTH OF construction for maximum
strength, minimum weight
iii: *
Transporting 80,000 pound rocket engine
/ | : and erecting them on test stands re-
units
. quires equipment that is unusual both in
, design and strength properties Hufford
Division of the Siegler Corporation met
this challenging project for Thiokol Chemi-
cal Corporation with this mobile handling
unit called the Transrector.
The first requirement as a transporter ne
cessitated the use of a minimum weight
material for fabrication to reduce the
overall hauling load. The use as an erector
made strength a highly important factor
This high strength to low weight ratio was
achieved through the exclusive use of T]
steel. To retain the inherent strength of
rl, the design engineers specified all-
welded construction.
Alloy Rods Company’s ATOM:ARC “J
more than satisfied Hufford’s needs
only electrode designed specifically
weld T1 steel in all applications, ATOM =
ARC “T” weld metal physical properties
eq ial or exceed those of T1 steel in the
“as welded” or “stress relieved” condition
for 100% design joint efficiency. ATOM +
ARC “T” electrodes are also excellent for
many other applications where high
strength welds are require d
Detailed application information about
ATOM:ARC “T” in data sheet form is
available by writing Alloy Rods Company,
P. O. Box 1828, York 3, Pennsylvania.

~~, ah ee

ATCT
‘

ALLOY RODS COMPANY

YORK, PENNSYLVANIA

SALES OFFICES & WAREHOUSES, BOSTON, NEWARK, PHILADELPHIA, PITTSBURGH, BIRMINGHAM, CHICAGO, SAN FRANCISCO & EL SEGUNDO, CALIF. —DISTRIBUTORS IN ALL OTHER PRINCIPAL CITIES

TWENTY YEARS OF LEADERSHIP IN THE DEVELOPMENT OF QUALITY ALLOY ARC WELDING ELECTRODES
For details, circle No. 27 on Reader information Card
WELDING JOURNAL | 1289
 New Products head support side beam carriage is
manually adjusted with a rack and
pinion and lock to cover the welding
area handled by the positioner table.
Other positioners and manipu-
lators can also be produced as single
units, if desired.
For details, circle No. 103 on
Reader Information Card.

Spot-welding Tip Holder

Lifting-clamp Adapter Eutec-TinWeld paste is made in four Tuffaloy paddle-type spot-weld-
formulations: (1) all-purpose, (2) ing tip holders of a unique design
A simple device recently made lead-free, nonblackening, for stain-
available by Merrill Brothers, Arctic are offered by Air Reduction Sales
less and nickel alloys, (3) neutral, Co., 150 E. 42nd St., New York 17,
St., Maspeth, N. Y., for those with noncorrosive flux, for electronic
using their special opening “‘G” N. Y. The company reports that
work, (4) special formulation for the new holders, designed for weld-
clamp, is said to increase the size copper, brass and bronze. Staintin
range of grips and eliminate the 157 PA paint-on solder paste is
formulated for high strength and
corrosion resistance on stainless steel
and other metals.
For details, circle No. 102 on
Reader Information Card.
r

Positioner-manipulator
Production of a new unit that is
actually a complete automatic weld-
ing station-—a 4-ft. x 4-ft. R manipu-
lator combined with a Model 25P
positioner—-has been announced by
the Ransome Co., Scotch Plains,
N. J., reportedly world’s largest
manufacturer of welding positioning
equipment. Joining the two units ing in confined areas, provide cost
accomplished by fitting the ma- savings for users because tee con-
need for another clamp where large
variance in grip would ordinarily nectors are not required. Holder
require it. comes with standard 4-in. offset,
The adapter unit, complete with and is available in hank diameters
pad, can be replaced when worn. of */, 7/s, 1 (shown) and 1!'/, in.
It slips in and out without use of
f

Tuffaloy socket-type tips are avail-

tools and does not interfere with the able in four nose designs and can
pad in clamp. be inserted on either side of paddle.
For details, circle No. 101 on For details, circle No. 104 on
Reader Information Card. Reader Information Card.

Long Life Solder Paste Welding-cable Reels

A new formulation for its Eutec- Two independently operating
TinWeld paint-on solder pastes units of different cable capacities
announced by Eutectic Welding are said to give a wide range of
Alloys Corp., is 40-40 172nd St., utility to the new Model EA-11
Flushing 58, N. Y. is said to combine “‘Weld-Reel’’ cable reel announced
an exact balance of alloy and flux, by United Specialties, Inc., El
and give long shelf life without Dorado, Ark. Recommended by
metallic elements settling, without the manufacturer for pipe lines,
flux separating and without hard- fabricating shops, road and bridge
nipulator mast into the positioner
ening in the jar. Eutectic Staintin construction, power plant main-
post—creates a single free standing
157 PA paste is also available in the tenance and steel erection, the
piece of equipment which performs
new “viscositized’”’ formulation.
the two basic welding positioning
operations.
The Model 25P positioner, capa-
ble of handling 2500 lb, features
precision electronic variable speed
drive, power operated tilt and re-
mote operator’s control station.
The manipulator is manually ele-
vated for arc height adjustment by
means of an Acme screw, and the “3
For details, circle No. 23 on Reader information Card——>
1290 | DECEMBER 1960
or"
%

Smith makes ind

Only extra-hea vy- ustry’s
duty welding ma
chine
 CAPACITORS
Smith Extra-Hez

S m ue ” < 1) 0) Zz = 0 0 0

To detach just tear along dotted lines

ONLY A. O. SMITH LETS YOU PAY YOUR

MONEY AND TAKE YOUR CHOICE!

Why pay your money and take a chance?

A. O. Smith lets you pay your money
and take your choice _ a value choice of
both Extra-Heavy-Duty and Standard-Duty
welding machines
The value gauge on the front of this
advertisement tells the inside story of
A. O. Smith Extra-Heavy-Duty welders. It
reveals that A. O. Smith is the only
manufacturer that still builds a real
Extra-Heavy-Duty welding machine — a
welder designed and constructed with
safety factors established 20 years ago
for long life under the most severe
operating conditions
But, of course, for standard duty,
A. O. Smith offers the MonArc shown at
left. Here is industry's quality, low-cost
welder. Available in 300, 400 and 500-
amp models. More copper in the coils
than any other competitive welder of the
standard class, means this rugged welder
will give you years of dependable
operation. The MonArc is the picture of
owe compactness. It racks! It stacks up to
a re three high! It slides under a bench. Fits
WELDING PRODUCTS DIVISION where others take up valuable floor space
Milwaukee
A. O. Smith INTERNATIONAL S.A See them both at your A. O. Smith
Milwaukee 1, Wis., U.S.A distributor. Or write for full details
Model EA-11 has one reel with
capacity for 50 ft of 2/0 cable on a
spring operated drum, and one
reel with capacity for 200 ft of 2/0
cable on a hand operated drum.
Current capacity is 300 amp, with
50% temporary overload factor.
Both operating sections are isolated
from each other and from the
supporting framework.
For details, circle No. 105 on
Reader Information Card.

Vacuum Metallizers
Adaptation of electron bombard-
ment heating sources to standard
and special vacuum coaters for
research into the evaporation of
ultra-pure metals and alloy systems,
as well as for depositing high-tem-
perature materials such as zir-
conium, tantalum and _ tungsten,
was announced by NRC Equipment
Corp., subsidiary of National Re- | Fast, high-quality
search Corp., 160 Charlemont St.,
Newton 61, Mass.
Reportedly, any of NRC standard
coaters can be supplied with electron all-position welds
bombardment evaporation sources.
However, the most popular units
are expected to consist of standard
Model 3144 coater with an electron difficult metals
beam gun or annular ring being
used as the heating source. Evap-
oration paths can be controlled by Easy to get with
the relative position of the gun and
of the metal to be evaporated.
The latter can be mounted either
as an ingot or button on a copper,
water-cooled support. The gun can
be located either on top or on the
side of the chamber and is rated at
Simplifies joining of cast iron, bronze,
up to 6 kw. A variety of power
brass, copper, galvanized iron, and malle-
supplies are available to meet user
able iron — or any one of these to another.
requirements.
For details, circle No. 106 on Dense deposits have high mechanical prop-
Reader Information Card. erties and are free from porosity and slag
inclusions. Beads are flat and smooth.
There is little splatter.
Resistance-welding Regulator Use Phos-Trode for overlays and general
A voltage-compensating regulator maintenance and repair welding. Order
for resistance-welding control is from your nearby Ampco distributor. Or
now available from General Electric. mail coupon below today.
The redesigned and improved
regulator will keep the welding heat AMPCO METAL, INC.
within +2° of the preset value MILWAUKEE 1, WISCONSIN
West Coast plant: Huntington Park, California
despite line voltage changes ranging Southwest plant: Gariand (Dallas County). Texas
from 20% to +10°%, according
to G.E.’s Detroit Service Shop,
which designs and builds the equip- AMPCO METAL, INC.
ment. Dept. 196L, Milwaukee1, Wis.
The voltage sensitive regulator Send me Bulletin W-17 describing
is said to be usually the most Phos-Trode and other Ampco Electrodes.
economical method of keeping weld Name
quality high when the power system
is subject to voltage variations. Company_
It does not correct for welding load Address
or reactance changes. Zone State
For details, circle No. 120 on
Reader Information Card. att ie ale ae Jee ae
For details, circle No. 28 on Reader information Card
WELDING JOURNAL | 1293
Power Supplies Gas-torch Outfits positioning equipment. The capca-
ity of each unit is 1000 lb; two or
An a-c /d-c silicon rectifier welding The Harris Calorific Co., 5501 more units can be ganged for greater
machine with a full 100° duty cycle Cass Ave., Cleveland, Ohio, an- capacity, or for handling short
reportedly first in the welding nounces four new welding and pieces.
industry——-was unveiled in October cutting outfits designed for the The unit is equipped with pilots
at the 1960 Metal Show in Phila- job shop, home or farm use. for automatic alignment, and a
delphia, Pa., by the A. O. Smith The 1225-C, the heavy-duty in- solid base is said to make it ideal for
Corp., Milwaukee, Wis. dustrial outfit shown, welds '/; in., field work. This unit can be used as
cuts 6 in. outboard support for a positioner or
The light weight 1900-C is de- head and tailstocks, as well as an
signed and built for precision auto- auxiliary support for turning rolls.
body and hobby-craft work and For details circle No. 109 on
comes complete with No. 19-B Reader Information Card.

Precision Welding Head

Model 1038 is a new, precision
welding head which is available
from Weldmatic, Div. of Unitek
Corp., 380 N. Halstead, Pasadena,
Calif. It is reported capable of
performing single, series or parallel
welds for electronic components
a-c/d-c silicon rectifier machine assembly; joining fine wire, ribbon
and foils; and for applications re-
Rated at 500 amp, 100° duty quiring a controllable fastening tech-
cycle, the machine is designed to nique without the use of an inter-
replace 600-amp motor-generator connecting or bonding material.
sets on semiautomatic submerged- Ball-race vertical action of the dual
arc welding applications. The ma- upper electrodes permits exact place-
chine’s a-c d-c capability reportedly ment of the welds with no electrode
runs the gamut of general welding welding torch with extra tips, two wiping action.
applications. The a-c section is said No. 25 regulators, No. 36 cutting
to be ideally suited for use with the attachment, and hose. This outfit
heavy iron-powder electrodes. The cuts up to 3 in. and welds up to
d-c side, in addition to its use on '/,in.
submerged-arc applications, can be The 7500 is a propane cutting
utilized where d-c hand arc welding outfit designed for scrapyard work.
is needed. It includes a No. 75 cutting torch
and tips, two No. 25 regulators, and
25 ft of '/, in. twin hose.
The 7800 is an acetylene cutting
outfit, also designed for scrapyard
work. This outfit includes a No.
78 cutting torch and extra tips,
two No. 25 regulators, and 25
ft of '/, in. twin hose.
These outfits also include a lighter
and goggles.
For details, circle No. 108 on
Reader Information Card.

New Pipe and Tube Rolls Operable with a complete range

New, adjustable pipe and tube of stored-energy power supplies, the
rolls featuring rubber tires, roller 1038 is said to feature 500 w-sec
bearings and all-steel construction, power rating, foot-pedal actuation,
and capable of handling from 2- to precisely controllable electrode pres-
36-in. diam cylinders have been sure and automatic firing. It re-
Constant potential d-c machine
announced by the Ransome Co., portedly requires no technical knowl-
Scotch Plains, N. J., reportedly the edge to operate. Its dimensions
Delivering up to 40 welding arcs, are 9'/,x6'/,x 10 in.
world’s largest producer of welding
a second unit is the constant-poten- For details, circle No. 110 on
tial d-c machine which is rated at Reader Information Card.
1500 amp, 100% duty cycle and
works in conjunction with series Controlled Angle Welding Torch
resistance grids to accommodate arc
welding, tack welding, stud welding, Development of a completely new
are air gouging and inert-arc weld- type of water-cooled welding torch
ing. for use in tungsten-arc welding, has
For details, circle No. 107 on been announced by A. W. Lindholm,
Reader Information Card. president of Falstrom Co., 147

1294 | DECEMBER 1960

 TIG WELDING

OUTFIT

e High operating efficiency; trouble-free performance

INCLUDING ¢ Better water cooling; up to three and a half quarts of water per
THESE minute through the head
* Better design; lightweight, rugged and watertightg
OUTSTANDING e Colorful; designed for safety with attractive finishes
FEATURES Complete; seven units designed to encompass the full range of
TIG welding requirements

ote Products.
-.- INCORPORATED

siiBe ilen gle] 4 4lei-t-fail-] 4, Mi, Meee -2°1¢)

3) deleleme ie Mac).
7 \. ihe eine @n 16 Sree ie ie) Am Air we we mel, ickl-im\.lene ke oa. he 4
SOUTH BEND, IND.-CHICAGO, ILL. ‘CREIGHTON, PA.- PARKERSBURG, W.VA.- CLEVELAND, OHIO- LOS ANGELES, CALIF.
For details, circle No. 29 on Reader information Card

WELDING JOURNAL | 1295

 erator can set torch angle for a par-
ticular job and loses no time in
changing torches, low torch inven-
tory, low maintenance and reduced
operator fatigue.
The torch has been rigidly service
tested for more than a year. The
model now available is rated at 180
amp ac-dc, continuous duty; 300
amp, intermittent duty.
For details, circle No. 111 on
Reader Information Card.

Clamp Connects Cable to Pipe

Falstrom Court, Passaic, N. J. The Connecting welding cable to a
new controlled angle torch features a pipeline is fastest and simplest with
flexible body that can be readily the Quick-Bond clamp according to thodic - protection pipe measure-
hand-adjusted to any angle as well the Pipetron Co., 12926 Saticoy ments, jumpering or any other
as extended to reach into difficult St., North Hollywood, Calif. The temporary electrical connection to
recesses. This development report- clamp consists of a high conductiv- pipelines. According to the manu-
edly makes it possible to use one ity bronze body equipped with a facturer, use of the clamps avoids
torch in place of many torches with chain and speed-screw for attaching arc-burns or other stress concen-
varying head angles, styles and to the pipe. trations to costly, high-pressure
sizes. Specially designed for pipe, the code piping, possible with make-
The torch was designed to answer one clamp takes all sizes from 2 in. shift field-fabricated devices; _ it
a costly and time-wasting welding up. It reportedly can be applied will handle 300 amp easily. The
production problem in the welding in less than 15 sec to give a positive, clamp has no loose parts and may be
of difficult-to-reach corners and low resistance contact. attached permanently to the cable
inaccessible interior joints. Ad- The clamp is said to provide a for ready use.
vantages are said to include better quick, ideal way of connecting any For details, circle No. 112 on
and faster welding in that the op- cable to pipe for arc welding, ca- Reader Information Card.

increase
Whatever the particular job
production you have to do—we have the
by automatic time measurement right FLUXINE you need. Be-
of manual and automatic / sides our 25 FLUXINES we
electric welding | carry a complete line of “KOP-
how much R-ARC" coated rods for weld-
performance \ 62 .
time should a yearsof ing copper and all copper
\ For Your Job , aeSentiic i alloys.
welding job take?
development
WELD-RECORD in welding
provides automatic, Write on company letterhead for chart and generous sample
permanent (paper stating which FLUXINE desired.
tape) records of pro-
ductive vs. non-pro- KREMBS & COMPANY
ductive welding time. (Est. 1875)
Dept. W, 669 W. Ohio St., Chicago 10, Ill.
Here’s how
WELD-RECORD For details, circle No. 30 on Reader Information Card
helps YOU:
1. Accurate time- WELDING JOURNAL
study data General Advertising Rates
2. Computing job Effective January 1, 1960
costs 12 times*
3. Reduces downtime
4. Setting job
standards EASY to install...
to use...to maintain!
1/8 page
write for brochure to *24 dense rate, for full page only: $330
*36 times rate, for full page only: $300
] 1) PREFERRED ene ™
| 1 450.00
« COVERS
Inside front cover
inside back cover
y| ] J Outside back cover
COLORS:
corporation Inside pages, standard AAAA color, extra
inside pages, special color, extra
Dept. J-12 2105 DAWSON ROAD ALBANY, GA. Color on cover, extra
For details, circle Ne. 37 on Reader information Card
1296 | DECEMBER1960
 ®

TIG weldila z

alloys for outer space

Solving the difficult problem of joining light metals for outer space vehicles is just one of
many new uses for TIG welding. And for this kind of critical application, no finer Tungsten
Electrode is made than by Sylvania.
Sylvania makes every kind of Tungsten Electrode available: Puretung®, Zirtung®, 1%
Thoriated, 2% Thoriated. And each comes in the desired finish—cleaned or ground, and
color-coded to save valuable time, prevent costly errors. Chemical & Metallurgical Division,
Dlectrode jor ¢ “?
Sylvania Electric Products Inc., Towanda, Pennsylvania. “ue“ ldlin . need

TA
AN
LV
SY

Subsioiary of GENERAL TELEPHONE & ELECTRONICS =)

For details, circle No. 31 on Reader information Card
WELDING JOURNAL | 1297
 recommended for d-c reverse po-
larity welding of aluminum railings,
tanks, pipe, truck and automobile
construction and repairs, for build-
up of missing sections, cladding and
reinforcing.
For details circle No. 114 on
Reader Information Card.

Ultra-high Heat Torches

The following advancements in
ultra-high heat applications are
claimed as the result of two new
electrode designs by Thermal Dy-
namics Corp., Lebanon, N. H.
Their Plasma Flame Torches are reversed by a relaxing pull on the
said to generate temperatures up to hose.
50,000° F. Up to now, the maxi- For details, circle No. 116 on
mum enthalpy, or heat content, of Reader Information Card.
nitrogen plasma produced by arc-
heated gas torches has been in the
Fixture Reduces Brazing Time
range of 16,000 Btu/lb. This new,
low-velocity flame operates con- Through the use of various sized
tinuously at enthalpies up to 60,000 work coils and their respectively
Btu/lb. In comparison, an oxy- fitting adapters, brazing different
acetylene flame has a maximum gas sized brass sleeves to cold-rolled
steel can now be done in one minute
‘Ow OWT on a single holding device, according
to Induction Heating Corp., Brook-
We Civ q Cepply House lyn, N. Y.

LENCO, INC.
BOX 192, JACKSON, MISSOURI
For details, circle No. 32 on Reader information Card

Flux-coated Aluminum Electrode

enthalpy of only 4700 Btu/lb, with
All-State Welding Alloys Co., a flame momentum twice that of the
Inc., White Plains, N. Y., has new plasma flame. Direct im-
announced a_ new _ all-position pingement of the new flame on a
Smoothcote #34 aluminum elec- molten substance causes no appre-
trode with a patented extruded ciable surface disturbance. In con-
trast to the high noise level of other A brass sleeve, with an undercut
flux coating.
plasma torches, this flame is silent. at one end allowing it to take a pre-
Developing tensile strengths up
A second electrode design permits formed silver alloy ring, is press
to 28,000 psi, the high-quality,
continuous operation with nitrogen fitted into the collar. Flux is used
aluminum alloy 4043 core wire is
at enthalpies up to 20,000 Btu/lb, on assembly to insure complete
combined with a_ velvet-smooth
with a Mach 1 velocity of approxi- cleanliness of joint area. The work
extruded flux coating, reportedly
mately 9000 ft/sec at an exhaust is placed on an elevating pin which
giving quiet welding and dense,
pressure of one atmosphere. has been raised to the loading posi-
spatter-free deposits at low amper-
For details, circle No. 115 on tion and the induction coils are
ages. Slag removal and deposition
Reader Information Card. energized for an automatic time
control are said to be far superior to
cycle.
standard dip-coated electrodes.
For details, circle No. 118 on
The #34 Smoothcote electrode is
Twin-hose Reel Reader Information Card.

Weighing less than 25 lb including Goggle for Welders

hose, the new Model OA-3 “‘Weld-
Reel” automatic hose reel, with A new goggle has been announced
capacity for 25 ft of */,.-in. twin by the Safety Products Department
hose or 20 ft of '/.-in. twin hose, is of Bausch & Lomb, Rochester 2,
offered by United Specialties, Inc., N.Y. It is made of molded rubber.
El] Dorado, Ark. Construction According to the manufacturer,
materials are stamped steel and the goggle is acid resistant, has soft-
cast aluminum, with brass shaft rolled edges, is completely comfort-
and connections. The spring-op- able, yet fits the face securely.
erated reel drum locks for 170 The goggle is said to feature a large
deg. of each turn, and is easily lens size with S-7 shape and pro-

1298 | DECEMBER 1960

 a> aa
DUT

A major oil company recently came to Budd Instru-

ments Division with rigorous specifications for a
Cobalt 60 irradiation facility. These included dual
irradiation chambers . . . high flux level . . . ex-
tremely low surfacé dose rate . . . provisions for
high temperature irradiation . . . large sample con-
tainment . . . variable diameter annular source . .
connections from lab utilities to the sample
source strength of 20,000 curies.
In addition, the unit had to be completely self-
contained, requiring no auxiliary shielding . . . and
completely mechanical in operation, with a series
of interlocks to make it foolproof.
The Instruments Division’s design amply met all
these specificdtfOns as well as A.E.C. and Bureau of
Explosives requirements. The unit has been pro-
duced, tested and delivered.
If you have a requirement for a
Cobalt 60 irradiation facility,
Budd Instruments Division
offers the most complete service in the field.

- Instruments Division products and services include...

Budd Nucletron
e@ Advanced-design gamma radiography equipment. Multi-
tron and Iriditron models for sources of all types and
strengths... for all methods of exposure.
@ Complete radiation facilities, including shielding, control
equipment, detection and warning systems.
Complete source service, including supply and encapsu-
lation, replacement and disposal.
A.E.C. approved safety training program for your per-
sonnel, offered without charge.
Radiation detection and monitoring instruments, includ-
ing survey meters, pocket dosimeters and dosimeter
wsTRUMENTS MD 7 A7 A chargers.

MDE EMER oision

THE BUDD COMPANY - P.O. Box 245 + Phoenixville, Pa.

Consult your phone book for sales offices in: Atlanta, Ga., Oak Park, Ill., Dallas, Tex.,
Los Angeles, Calif.
In Canada
Budd Instruments, Ltd., 170 Donway West, Don Mills, Ont.
For details, circle No. 33 on Reader Information Card
WELDING JOURNAL ; 1299
 Wide Vision Helmet Pipe-beveling Machine
The new, wide-vision welding C. A. Mathey Machine Works,
helmets, manufactured by Flood Inc., Tulsa, Okla., announces their
Safety Products Co., 3035 W. Lake
St., Chicago, 12, Ill., are said to °
,
have a large-view lens opening of
over 19 sq. in. Lenses are seated in
a leak proof, nonelectrical con-
ducting, neoprene holder and can
be taken out and replaced in a
matter of seconds.
Metal splash or spatter “‘bounces
off” and does not adhere to holder
which is both impact and fire re-
sistant. The helmets can be fur-

viding wide-angle vision. It will

reportedly fit over any modern eye-
glass frame with ease and is avail-
able with aluminum non-corrosive
vents (for welders and chippers).
For details, circle No. 117 on newly designed line of pipe beveling
Reader Information Card. machines. The improved design
features a shorter, balanced ring
Gas Metal-arc Welding Gun gear-saddle assembly, making it
now possible to cut shorter segments
Manual Aircomatic (gas-shielded of pipe. Storage space and weight
metal-arc welding) MIGet gun and have been reduced to make the unit
controls have recently been de- compact and easier to use.
veloped by Air Reduction Sales For details, circle No. 113 on
Co., 150 E 42nd St., New York Reader Information Card.
17, N. Y. The gun and controls
are designed for use in light to Safety Hat Winter Liners
heavy fabrication where numerous
short welds, off-the-ground welding, nished in fiberglass or vulcanized Six new safety hat winter liners
or emergency repairs are necessary. fiber and with snap-in Fit-Rite are now available from Jackson
headgear or safety cap which have Products, Air Reduction Sales Co.,
identical mountings and are quickly 31739 Mound Rd., Warren, Mich.
interchangeable. Ruggedly designed for outdoor in-
For details, circle No. 121 on dustrial activities, the liners are
Reader Information Card.

Weldment Stress-relieving Unit

A portable, two-in-one, combi-
nation heat-treating unit said to be
designed for exceptional flexibility
in the shop and field heat treatment
of weldments has been announced
by Electric Arc, Inc., 152 Jelliff
Ave., Newark 8, N. J.
The unit is the company’s new
80 kva Smith-Dolan Model BH-
The 2'/.-lb MIGet gun carries its DRS, and is a_ self-contained,
own compact reel of wire, wire- transformer-type electrical heater
feeding drive rolls and complete- equipped for both induction and re-
range wire-speed control. sistance heating. It mounts on
The welding control, weighing wheels for easy portability.
less than 20 lb, coordinates the Reportedly, the new Smith-Dolan
wire feed and welding current. unit will readily stress relieve pipe
The control is housed in a small welds in 2 to 14-in. OD pipe with
NEMA cabinet. wall thicknesses up to 2 in. at
The welding gun is rated at 200 temperatures to 1375° F, with each
amp dc reverse polarity at 100% of its two 40 kva sections, in ac- offered in a wide range of styles
duty cycle using argon or helium cordance with code requirements. and prices. The liners fit all hats,
as a shielding gas; and at 300 Operation is on four commercially all workers and feature lightweight
amp dc reverse polarity using carbon available voltages: 208, 220, 440 durable materials for warmth and
dioxide. The gunwill handle 0.030, and 550 v; a self-contained 120- ease of washing. They are com-
*/eg, and '/, in. diam aluminum volt, AC current supply for instru- pletely metal-free and may be used
wire and 0.030-, 0.035- and 0.045-in. mentation and control is included. by any workers exposed to electrical
hard wire. Booster units are available. shock hazards.
For details, circle No. 119 on For details, circle No. 122 on For details, circle No. 124 on
Reader Information Card. Reader Information Card. Reader Information Card.

1300 | DECEMBER 1960

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Please
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th Maintenance
Weldors

New Products... New Processes... New Plants...

New Service and Training Centers... New Program

of Packaging... New Expanded Services

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 THIS YEAR AND EVERY YEAR...

ON-THE-JOB SERVICE ANYWHERE, ANYTIME

What type services do you require? On-the-job demonstrations? Technical answers

on metal stress, tensile strength, elongation? Practical answers on torch or arc or solder
techniques? Information on product application? Personal training in basic
or advanced welding? All are available to you from EuTEctTIc, and you get these services
regardless of whether you’re a large or small operation.

Eutectic Welding Institute has the broad research and technological experience to
answer any questions and give expert personal instruction ...the Eutectic Welding Institute
supervises training at numerous local Service and Training Centers. In addition,
you get personal help and demonstrations on the job, anywhere, anytime, from EUTECTIC’s
factory-trained Technical Representatives. It’s yours for the asking.

= 40-40 172nd Street, Flushing 58, New York

“sere | EUTECTIC WELDING ALLOYS CORPORATION

(bess Originator of the Low Heat Input process... The ONLY welding alloy manufacturer in the world capable
EUTECTIC of producing welding rods and electrodes from virgin metals to finished products in ANY alloy.

Permit Please send further information on:

First 5104
Class No.
Y.
Filushing,N.
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“Learn what’s new in metal-joining”’

[] Service and Training Center nearest me

[ _] QuenchWeld Process

[ | EutecTrode 680

[_] EutecSil 1020 FC

FOLD
HERE [_] Neu-Tec-Tronic 157 BN
HERE
STAPLE
[| ChamferTrode AC-DC
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 FIRST
CLASS
Air Products Incorporated

Air Reduction Sales Company

All-State Welding Alloys Co., Inc.

Alloy Rods Company
The American Brass Company
American Metal Climax, Inc.
Ampco Metal, Inc.
Bateman Foundry & Machine
Branson Instruments Inc.
The Budd Company
Chicago Hardware Foundry Company
Coyne Cylinder Company
Welding
Journal
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York
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Stetes
United
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December, 1960 Harnischfeger Corporation

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Please send me, without cost or obligation, further instrument Control Company
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126 International Nickel! Co., Inc.
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129
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NRC Equipment Corporation

Pacific Welding Alloys

Rosemount Engineering Company

A. 0. Smith Corporation
auen-
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BSSTFEESE
Sperry Products Company
Stulz-Sickles Company
eK SSSVLSRRSSSSESEISRESsssysrz
SRAITISSSUSSMSSesseuserceas
SSSCSSESSASSSL
eSsresaay Sylvania Electric Products, !nc.
Syntron Rectifier Division
Tempil® Corporation
Thomson Electric Welder Company

Victor Equipment Company

Wallace Supplies Mfg. Company
Weld-Record Corporation
 Welding

Research Sponsored by the Welding Research Council

of the Engineering Foundation

SUPPLEMENT TO THE WELDING JOURNAL, DECEMBER 1960

Steel: Avant Garde

TALK PRESENTED AT 1960

AMERICAN WELDING SOCIETY
NATIONAL FALL MEETING

BY CHARLES M. PARKER

Mr. Parker delivers keynote address

It is an honor and a privilege to

be with you this morning to discuss Censures Steel Critics More recently there is a tendency
the role of the steel industry in the on the part of our gownless critics
future of the American economy. For the past two or three years, to use the Russian steel industry as
It is particularly gratifying to me to there has been a nebulous group of the ne plus ultra when discussing
have been invited to present this ungowned prophets sniping at the the steel industry of the United
discussion in Pittsburgh, the steel steel industry with artillery of States.
center of the world. microscopic caliber on every possible The steel industry of the United
The discussion will, of course, be occasion. If our plants run nearly States is neither backward nor com-
given in generalities. You will to capacity and delivery lags a placent. It is familiar with compet-
have enough of precise technology little, we do not have enough capac- itive materials, because it is a large
in your forthcoming technical ses- ity. If we slough off a bit because user of all of them and steel supple-
sions. I shall endeavor to present yur customers have fewer orders ments them and complements them
some ideas to you, in keeping with for their products, we have too much on every occasion of their use in
the title which I have chosen, which capacity. our economy. We know their
will be, I hope, rather startling. If a new product appears made strengths and we know their weak-
The results of some of them have of wood, a nonferrous metal, plastic, nesses. As a matter of fact, steel
reached the hardware stage, others giass or any other commercial ma- assists in the winning and manu-
are in preparation for it. terial, the cry is raised that steel is facture of every single one of them!
These ideas are presented with slipping and forecasts are made of Nothing is made without steel!
faith and with enthusiasm. Some the time, area of demise and burial. Moreover, we are keenly aware of
of them may be prejudiced by that When we in the steel industry take the methods used and the products
faith and enthusiasm because up to our competition in stride, we are made in all foreign countries—and
now the steel industry has been my accused of complacency. And some we can still beat them all produc-
entire life, and I hope, and expect, of our best customers are accused of tionwise and qualitywise. The
that my working life will end in the coinplacency, too, when they do not price differential between foreign
steel industry. immediately convert their superb and American products is the price
products made of steel to whatever we pay to live as free men under
C. M. PARKER is Vice-President, Research the faddish material of the moment our incomparable Constitution.
and Technology, American Iron and Steel In
stitute. may be. In the first quarter of this year,

WELDING RESEARCH SUPPLEMENT 513-5

our steel industry siaged its most “NEW METHODS OF DRILLING future. Oneschool of thought holds
spectacular performance producing FOR ORE...” that those processes will replace
34.7 million tons of ingots while the blast furnace. Another holds
utilizing only 93.8% of existing that the blast furnace will reign
capacity. To produce that tonnage supreme because of its high metal-
ten years ago would have required mn lurgical efficiency and its ability to
operating at an impossible 140% produce a satisfactory product for
of the capacity then existing. It steelmaking from a wide variety of
will take our competition, all added semisatisfactory raw materials.
together, nearly five years to pro- It is entirely possible that some
duce that tonnage, if they all work day both processes will be replaced
diligently. In respect to this per- by the distillation of ores using
formance our critics were strangely atomic energy as a source of heat
silent. and employing temperatures up to
6000°C. In such process all ele-
Past Progress and Tomorrow ments contained in an ore would be
This record breaking tonnage was carried off pure at temperatures
made with the existing equipment slightly above their respective boil-
of the industry which had been ing temperatures and steel would
brought to its high state of produc- be made simply by mixing the proper
tion, efficiecucy and quality during quantities of liquid metals and
the 1950’s by the expenditure of metalloids. This process is_ the-
over $10 billion of the industry’s oretically possible now but we lack
own money, and newly invested adequate containment materials.
capital.
During that decade, the industry Future of Basic Open Hearth
developed new sources of high-grade The basic open-hearth furnace,
shipping ore, new sources of high- Taconite is a low grade iron ore which is which makes close to 90°% of the
iron content beneficiated ore, new extremely hard and thus difficult to re- steel in this country, will continue to
methods of washing coal for coking, move. Jet piercing as shown here is a hold its top position in the next
new and improved methods of steel - relatively new flame process for drilling decade. Improved basic _refrac-
making to augment older yet su- blast holes in taconite to facilitate its tories have made possible the use of
perbly efficient methods, new and removal and ultimate benefication oxygen lances which have reduced
improved methods of heating and production time on individual heats
rolling steel and new methods of as much as 30%. In an experi-
thermally treating steel to make it substantially increase the output of mental crash program recently, one
the best possible material for its existing equipment at lower capital basic open-hearth furnace, with
intended use. costs than the building of new basic roof and three oxygen lances,
Every phase of steel industry equipment and release money for produced four heats of 350 tons
operation is, and has been, under the exploration of new fields. each in 24 hr. And that was
the closest scrutiny. New methods Among the new fields to be ex- specification steel, not remelt
of drilling for ore have been devised plored are the use of oxygen en- quality.
and faster methods of handling and riched blast, higher temperature The use of oxygen in basic open-
more efficient methods of blending blast, blast enriched by natural gas hearth furnaces has a_ beneficial
both domestic and foreigr ores or by hydrocarbons derived from effect on quality, too. The higher
have been employed. The entire oil and increased top pressure. turbulence generated in the bath
subject of handling bulk solids Some of these new features depend makes possible the removal of
such as coal, ore and limestone is for their success on the development greater quantities of some impuri-
under study in a research program and use of refractory materials ties as compared with conventional
at the University of Utah and which can sustain higher operating heats.
excellent results have been ob- temperatures and, at the same time, Oxygen is also used successfully
tained. resist successfully the more severe in electric furnaces, saving electric-
Projected for the future are more inroads of erosion and abrasion ity because of the higher tempera-
self-unloading ore boats and more imposed by higher driving rates. tures generated, decreasing time of
efficient railroad cars for hauling American Iron and Steel Institute heat and thus saving electrodes.
the ore, coal and limestone for the has under way an extensive research Once again, improved refractories
industry. program on refractory materials at will be necessary to extend these
The chemical composition, phys- Pennsylvania State University and benefits and again we place high
ical characteristics and sizing of the University of Michigan to assist hopes on our research.
raw materials for the blast furnaces, in solving those problems.
direct reduction processes and steel- The coking process will be im- Base Oxygen Process
making furnaces are under intensive proved, too. Recent researches in- Of the new processes which have
study. The future will bring sub- to the microstructure of coking appeared, the basic oxygen process
stantial increases in the amount of coals point clearly toward the seems to hold the lead. The United
agglomeration used, particularly probability of vastly increased qual- States now has four companies
self-fluxing sinter. Agglomeration ity and strength and decreased ash in production with a total annual
will make possible the use of high and sulfur. So hopeful are the capacity of over 4 million tons.
iron content ores of naturally poor results that a continuous coking Some are expanding, others have
physical characteristics and a sub- process may be envisioned. units under construction and others
stantial reduction in the quantity The new direct reduction proc- are in the planning stage.
of coke burned per ton produced. esses may be expected to find a The process is a flexible one.
These developments alone will place in the steel industry of the Some advocates say capital equip-

§l4-s | DECEMBER 1960

ment costs appear to be lower than ‘**.. OXYGEN IN BASIC OPEN-HEARTH FURNACES
capital costs for equivalent annual HAS A BENEFICIAL EFFECT...”
tonnages of new open-hearth or elec-
tric furnace capacity.
Economical small units are prac-
ticable, as has been proved in Eu-
rope, and the process delivers twice
as much steel per hour as the
conventional open hearth. The
open hearth with oxygen, however,
will give it a real run for supremacy.
It will be interesting to see where
they meet.
Basic oxygen furnaces require
high hot metal capacity, more per
ton than open-hearth furnaces be-
cause of their lower scrap utiliza-
tion. But that feature is under
study. The economy of the United
States generates something of the
order of 40 million tons of scrap
in an active year and such a quantity
of a usable material cannot be The use of oxygen in open hearths may require that oxygen be supplied in bulk
ignored. directly from on-site plants—or at least from plants that are nearby. Such
One of our companies, which a plant is shown here and supplies oxygen by pipeline to a nearby steel mill
does not have blast furnaces, is
successfully using basic hot blast
cupolas to supply hot metal to basic That is an awesome range of tem- they are not assuming, they are de-
oxygen furnaces. This suggests perature whiich clearly demonstrates manding. And their demands can-
that the basic oxygen process might the versatility of steel selected not be denied.
be successfully coupled to a direct properly for an intended use. The steel industry of the United
reduction process for limited pro- We have so-called ultrastrength States has a major interest in both
duction in remote areas. steels, up to 400,000 psi, and our education and research. It is a
research work tells us that the end highly technical industry which
Many other new processes are
is not yet in sight. We have found must have an ever increasing supply
now in daily use. We have vacuum
that pure iron retains considerable of men and women educated in
degassing of ingots for large forg-
ductility at; temperatures approach- many fields of science and tech-
ings, a rather spectacular employ-
ing absolute zero. But the pres- nology, the social sciences and the
ment of chemical methods made
ence of the slightest trace of phos- humanities. On the other hand it
possible by superb mechanical en-
phorus resu'ts in completely brittle must have the results of funda-
gineering. And we have several
behavior at the same temperature. mental research on which to build
exotic methods of melting steel in
We are stud ying substructures with- the iron and steelmaking processes
vacuum. We vacuum melt by
in individual metal crystals, plastic of the future.
either the arc or induction process
deformation, recrystallization and We are not always going to make
and for the highest purity we em-
diffusion. Through these studies steel by processing hot metal and
ploy the consumable electrode or
we hope'to learn why metals ex- scrap in conventional steelmaking
zone melting process in vacuum.
hibit only about one-tenth of their units. Already, the newer methods
These processes deliver product
theoretical mechanical strength. of steelmaking are more closely re-
of the highest purity and greatest
We have developed new struc- lated to the methods of chemical
density that we know how to make.
tural steels of greater yield strength engineering than they are to the
They are for specialty uses, mostly
and ultimate tensile strength and methods of conventional metal-
classified, and we can guess that
changes in nationally recognized lurgy. Nor are we going to produce
some of them are at this moment
specifications have been or are the finished steel products of the
flying around overhead.
being made: in order to make them future by casting ingots and working
These are only a few of the ad- commercially available. New
vances made by the steel industry them by conventional rolling and
grades of electrical steels have forging methods into the various
in the production of its product. been developed which promise newer
It is a superb record, but we are forms which will be required.
and smaller electrical equipment.
a restless people and we shall not We have even developed a_ por- The Russian Colossus
be content with it. The future celain enameled steel which emits But there is another and more
will bring more and ever more such light! immediate reason why we must in-
developments. In the future we may expect crease our efforts in education and
explosion welding and plasma melt- research. We are locked in a
Steel in the Future ing and welding to deliver com- struggle to the death with the
Our products have advanced, too. mercial products now only a dream Soviet Union and its satellite na-
The needs of American industry in a bald man’s mind. tions. They have bluntly told us
have caused the development of Up to now we have made little that they mean to bury us either
steels which will withstand stresses mention of men and their two most militarily or economically, or both.
at temperatures only 1000° F be- important intellectual activities, We are told by substantial citi-
low their melting points and steels education and research. But both zens, who have visited Russia and
which will withstand stresses some are assuming a more important have seen their universities and
3300° F below their melting points. aspect in our daily lives. In fact their research laboratories, that

WELDING RESEARCH SUPPLEMENT 515-s

their facilities are now equal to skills of draftsmen, machinists, complacency embracing us; we
ours but that they are building new welders and a myriad of other highly must arouse our feelings of discon-
laboratories and equipping them at skilled technical workers. It is tent with things as they are.
a much faster rate than we are doing. said that in one of our largest Two years ago Sir Winston
They tell us, too, that all over electrical manufacturing compan- Churchill said on announcing the
Europe, and especially in Russia, ies there are about forty highly College for Higher Scientific Ed-
there is a greater respect for learn- skilled technical workmen to back ucation at Cambridge University:
ing, a greater respect for teaching up every scientist or engineer on *‘Lands which we discovered and
and teachers and a greater respect the staff. ruled, developed and assisted, and
for research than there is in this others which not long ago were
country. This is an attitude which Lessons from History primitive and backward, today pro-
we must change and change fast, Once again, we are told that duce the goods which we, as pioneers
because not to change it could have Russia is graduating every year of the industrial revolution, man-
the most damaging effects on the some three times as many scien- ufactured and sold to them.
lives of all of us, and more par- tists, engineers and technicians as we “We are still a great trading
ticularly on the lives of our children. are. It is plain to be seen that they nation and still a great power.
are building an enormous industrial But it is only by leading mankind
Our Educational Needs organization as well as a frightening in the discovery of new worlds of
It is recognized in science and in- military organization. It is plain science and engineering that we
dustry that there is a time lag be- to be seen, too, that if we do not shall hold our position and con-
tween discovery in the laboratory take speedy, positive action it is tinue to earn our livelihood.”
to production for use which may be entirely possible that they can de- Another thing against which we
as much as seven to ten years. feat us economically and reduce us must guard is the idea that all
Between World War I and World to a second rate power without ever things can be bought with Ameri-
War II that time lag was fifteen to firing a shot. can dollars. Money cannot buy
twenty years. There are some out- There is historical precedent for brains or wisdom. But it can buy
standing cases in which the time lag this, too, so we cannot hide behind the environment, the equipment,
was less, the case of Salk vaccine the idea that it can never happen to the opportunity, and the help for
for polio, for example. But the us. In the past of not so long ago, those individuals who show promise
seven to ten year figure stands as a Italy ruled the Western World in in their youth of developing into
good average. learning, research, arts, crafts and mature men and women of out-
This means that we have to fill commerce. Slowly. supremacy trav- standing achievement.
a gap created by World War II eled West through Central Europe
Dr. John Turkevich, Eugene Hig-
during which time the major por- to France, to the British Isles and
gins Professor of Chemistry at
tion of our research went toward finally to the United States. We
Princeton University, summed it
the war effort, and to extend our made much of this happen by our
all up magnificently when he said:
research to bring it back to the energy, our drive, our pursuit of
normal curve which had been dis- things ever better, ever bigger, by “Science and education are nu-
turbed during the war years. the presence of the frontier of the trients essential for the industrial
This, in turn, means that we Golden West and the more im- growth of any modern state. For
must educate increasingly greater portant presence of a mental front- industrial processes are constantly
numbers of boys and girls, not only ier which was never satisfied, never changing, making continued de-
in the sciences and engineering but conquered. Some of it happened mands on technology. Technology,
in those technical skills which sup- because some European peoples for its part, rests heavily on a widely
portthem. Scientists and engineers grew complacent. We must vigi- developed scientific activity. All
cannot work effectively without the lantly guard against any such these in turn depend on education.
We must have a general education
to assure that people know how to
live in the modern world; we
must have specialized education
to produce operators of the mani-
“OXYGEN IS USED... IN ELECTRIC FURNACES...” fold technological services of modern
living; we must have engineering
education to develop new facilities
and processes; and then we must
have a scientific education leading
by a continued study of nature to
the discovery and systematization
of new findings. Finally, the
development of man’s destiny re-
quires a favorable political, social
and cultural milieu (environment)
and an education that produces the
individually creative man—the man
who will make the logically un-
predictable and the intuitively un-
expected discoveries of science.
- For these may radically change
weet bal the industrial development of a
The above sketch typifies how oxygen may be used in electric nation, alter its technology and in-
furnaces. Here oxygen is being used to enrich fuel gas as supplied fluence the very character of science
through an auxiliary scrap-melt down burner itself.”

§l6-s | DECEMBER 1960

Our Universities “THE BASIC OXYGEN PROCESS...”
It would appear that we have
adequately established the idea
that research is necessary to our 400-rla, +... ae
60-65% HOT META
survival and growth as a nation -\00 CFH 02/TON
and that in turn education is neces- “200 CFH O2/TON
sary to foster research. Actually, —400 CFH 02/TON
teaching is the major responsibility REGULAR ORE PRACTICE
of a university. But the faculty, (NO OXYGEN)
the teaching fellows, must increase BATH MELTED
their store of knowledge before they
can impart it to the students. They
must explore new fields, find new \
\
applications for knowledge, and \- OXYGEN LANCE
in order to do that they must ““"\, PRACTICE
200 CFH
engage personally in original re- O2/TON
search. It is easy to see that
shut off from research, teaching
and learning would revert to
the conditions which prevailed in
the Dark Ages when specific books,
and only those books, were per-
mitted to be read. BASIC OXYGEN FURNACE (L-D) 4450 CFH 02/ TON
A second responsibility of a uni- eis eee
Ke) 20 18) 40 50 60
versity is to teach by experiment. TIME AFTER HOT METAL- HOURS
In undergraduate work, classical
experiments are repeated to confirm
known facts, and to impress them
on the student, as well as to im- The broken curve at the far left above indicates one of the
potentials expected with the new basic oxygen process. On
part knowledge of available and the other hand, curves to the right show how basic open-heartt
proved research techniques. production can be increased through the use of oxygen
In graduate school, new fields
are explored by new methods, and
this sort of teaching must be in the
hands of a faculty that knows the An interesting but difficult set “What then is the American,
problems which are worthy of of legal problems is posed by the this new man, who has made the
effort and the methods by which successful launching of both deserts bloom, who has taken the
techniques may be devised to solve American and Russian satellites. peasantry out of farming, who has
them. It is only by research that The legal fraternity is now faced removed the drudgery from facto-
that such knowledge and experience with solving problems which may ries, whose productivity per worker
are gained. arise on i\ocal, national and inter- is by far the highest there is, who
In the normal course of events national fronts. is surrounded by the world’s best
it is to be expected that some of the In other areas, the peacetime existing systems of communications
men and women trained in our uses of nuclear energy, the indus- and transportation? Was this pro-
universities will remain to teach; trial and social promises held out gram made by a people with an
others will go on into industry and to us by jet and rocket power, are inferior educational system? If so,
the professions to transform their giving rise to new studies in such inferior to what? To their own
learning into action for the benefit fields as road building, airport lo- ideals perhaps but to little else.”
of the economy and for mankind. cations and construction, city plan- There is no question in any of
We cannot afford to have any ning, civic centers, industrial de- our minds as we look about us here
serious interruption to the flow of centralization and ocean-going traf- in Pittsburgh and elsewhere in the
trained men and women. We must fic, both surface and undersea. United States, that Dr. Hollinshead
make sure that it goes on through in- has fairly characterized our edu-
dustry which needs them most, Defends American Education cational system and the benefits
through our churches, through our We have seen much in the which have flowed from it. But,
service clubs and professional socie- public press the past few months back of it all has been a vast pool
ties, through our personal contribu- criticizing American educational of fundamental information which
tions, and by any other honorable methods and advocating a swing originated in Europe on which we
means at our command. We must to the European pattern. We all have drawn to make our achieve-
put a premium on ability coupled recognize, of course, that our ments possible—and we have not
with the desire to put it to use. methods are not ideal, that there contributed our proportionate share
In making those statements I is room for improvement, and that of replenishment to that pool.
am not thinking only of such areas the necessary improvements will These facts pose a problem to us.
as physics, chemistry and metal- be made. Dr. Byron S. Hollins- It is evident that we cannot continue
lurgy. I am thinking, too, of the head, former President of Coe to depend on Europe for our fun-
social sciences: economics, so- College and Director of the Tech- damental ideas. And if we could,
ciology and law. They must be nical Assistance Department of the we should not. The United States
quick to adjust to new discoveries United Nations Educational, should soon begin to assert itself
and new accomplishments and keep Scientific and Cultural Organiza- in a larger way in all areas of
pace with the front runners in the tion, has this to say about American science and fundamental research.
field. education: We should learn to spend money

WELDING RESEARCH SUPPLEMENT | 51?-s

effectively in these areas, and see much of it has been couched ir such know enough of a foreign language
to it that such research efforts are terms as to place scientists and the to be able to read correctly and
made. engineering and medical professions translate into English foreign writ-
But how shall we accomplish in an unenviable light. ings of any sort whether they be
this? There are many ways, but At a meeting in Boston in 1955, scientific papers or novels. And
I am not going to put forth any Dr. Detlev W. Bronk, President it is important to us to know what
plan. There are men far more of the National Academy of Sciences, other peoples are doing and what
able than Iam who willdothis. All said: “‘... these are days when the they are thinking about. This is a
that I can hope to accomplish is to ends and aims of our material civili- serious matter but one which we
create an awareness of the problem zation are being questioned and the can handle if we will discard some
and suggest some broad areas of spiritual qualities of our culture old prejudices and fetishes.
participation. doubted. It is well in times such as We should permit a student his
these, then, to be reminded that choice of the major foreign lan-
Communication with the Public engineers create the machines for guages; heor his parents may know
man to use as man desires.” more about his aptitudes and pre-
To start with, there is the problem
It may serve some useful pur- school learning than we do; we
of communicating to the public at
pose again to remind critics to con- should require a more complete
large the facts concerning the
sider carefully the last seven words mastery of one language rather than
work going forward on the many
of the foregoing paragraph. Pro- a smattering of two; and, we
fronts of science and engineering. should start our students on these
ponents of the humanities are in-
To do this we must have men who
sistent upon invading the curricula studies early in their school lives.
have respect for truth and reverence A secondary but important con-
of science and engineering while
for the Universe, who know some- sideration should be to make the
appearing to repel that which
thing of the subject matter with studies interesting and attractive.
science and engineering has to teach.
which they are dealing, and who
Is the history of science and When a mother teaches her child
are skilled in writing good English to talk, there is joy in the teaching
engineering less rewarding, less able
with proper respect for word mean-
to fit people for life than the his- and most mothers do an adequate
ings. There are too few such men job preparing the child for profes-
tory of political and military strife?
on the public scene today, and this sional teachers.
Which is more important to us
is the dual responsibility of our en- If these three things can be ac-
today, the story of the work of
tire educational and communication complished in the not too distant
Louis Pasteur or the story of the
systems. future we shall have gone a long
War of Jenkins’ Ear? In the year
Much excellent work is con- way forward.
1960 should we be more interested
cealed from the public, because all
in studying King Phillip’s War or
too often promise has been reported Research and the AISI
studying about Lister’s discovery of
as accomplished fact and able re- I should like to say just a few
antisepsis. I wonder if a person
search men grow shy under such words to tie all these ideas together.
faced with major brain surgery
conditions. Failure in research is American Iron and Steel Institute
cares more for the history of the
frequently caused by lack of sup- is pursuing extensive research in
Mississippi Bubble than he does
porting knowledge, a _ condition the physical chemistry of iron and
for the history of the life and works
beyond the responsibility or even steel making. Each project, while
of Dr. Harvey Cushing?
beyond the ability to help, of the re- paying relatively small immediate
Next, the public must be con-
search worker. Inept or inaccurate dividends, has potentials for the
ditioned to receive and appreciate
reporting reflects adversely on the future which are truly breathtaking.
these facts. And this is the second
researcher’s professional reputation These projects have brought the
area of responsibility which educa-
and upon that of the institution name of American Iron and Steel
tion must assume. This is a problem
under whose auspices he works. Institute in a favorable manner to
which involves time, but a major
The writer must know how to in- every steelmaking country in the
portion of it can be done in the rel-
terpret the facts of science with world, into many homes in Europe
atively short time of twelve years;
sympathy and with pinpoint accu- and the United States and into
from first grade elementary to
racy. many universities both at home and
senior high school graduation—
Writing in the October 1955 abroad.
a “school-days’” generation. 3y
issue of the American Scientist, using accelerated methods, con- Our work in the physical chemis-
Eugene Ayres, Sigma Chi National try of iron and steel making has
centrated in high school, the time
Lecturer for 1954-55, said: ‘Even been pursued over the years at
might be shortened to four years.
in relatively modern times im- Massachusetts Institute of Tech-
For those who do not intend to go
portant technical events have rarely nology, Carnegie Institute of Tech-
on in science these studies need not
made contemporary headlines. And nology, Pennsylvania State Uni-
be profound; they can be made
yet these events comprise the real versity, Ohio State University, Pur-
nonmathematical, interesting, even
bone and sinew of history—not due University, University of Penn-
exciting. For those who do intend
the civil and military adventures sylvania, University of California,
to gc on, more rigorous courses
that arouse our fleeting interest should be available. McMaster University, Armour Re-
and quicken our pulse—for these search Foundation and Battelle
things often seem rather trivial in Foreign Languages Memorial Institute. Much of this
retrospect.” work has been done by graduate
And then, there is the matter
of foreign languages. We are told, students, who have earned some or
Re-examines Materialism and we know it to be true, that all of their college expenses in doing
Within the past decade there has Americans do not approach the it. Many of these men were Euro-
been a great deal of criticism of the study of foreign languages seriously, peans who returned home, some to
materialism of our civilization. that too few of our people know even go into industry and some to go into
Much of that criticism has been one foreign language well enough to their universities, to continue the
leveled at the United States and use it in everyday living. Fewer still work they started here and to

518s | DECEMBER 1960

teach. Of the Americans who were of this work will be a continuous quarter drive for increased produc-
trained by way of our research proj- steelmaking process. It will not tion from all types of iron and steel
ects, there are many presently come soon, but it will come after melting furnaces. It is anticipated
employed in our industry and there we know the order of operations of that this information will increase
are some who are teaching in some of chemical reactions at high tempera- in value along with the increasing
our leading colleges and universities. tures in the steelmaking complex, tempo of steel production with its
It is a correct generalization to the rates at which they occur and greater emphasis on basic refrac-
say that these research projects the methods by which they can be tories and higher temperature reac-
are raising the art of iron and steel- altered, modified and controlled. tions.
making toascience. The experimen- We feel that the research work The second aspect of these re-
tal work has encompassed many com- being conducted on basic oxide sys- searches concerns education.
binations of slag-metal-gas systems tems involved in slag and refrac- The steel industry of the United
Studies of these systems have been tories technology at Pennsylvania States has a major interest in both
made under equilibrium conditions State University is a part of the education and research. It is a
to establish their thermodynamic foregoing and is one of the out- highly technical industry, which
properties. Kinetic studies have standing programs of its kind in the must have an ever increasing supply
also been conducted in an effort to world. In fact, the research per- of men and women educated in
determine factors controlling over- sonnel at the University are closely many fields of science and technol-
all reaction rates. This will lead to in touch with world affairs in their ogy, the social sciences and the
a better understanding of iron and field. humanities. On the other hand, it
steelmaking processes than would The research work on refractories must have the results of funda-
be possible by equilibrium studies was conducted at a most opportune mental research on which to build
alone. time, because the information ob- the iron and steelmaking processes
I am convinced that the end result tained has been put to use in the first of the future.

Welded Interior Beam-to-Column Connections; Transfer of Stresses in

Weldin Cover Piates; and A Survey of Literature on the Lateral
Instability of Beams

Welding Research Council Bulletin No. 63, published in August 1960, contains
the following reports and investigations sponsored by the Structural Steel Com-
mittee of the Welding Research Council:
Welded Interior Beam-to-Column Connections In this investigation,
studies are made of two- and four-way interior beam-to-column connections.
Transfer of Stresses in Welded Cover Plates Two series of tests are re-
ported. The first series was conducted to obtain data on the stress or strain
concentration factors produced by welded cover plates. The second series was
to determine the stress transfer at various stress levels, to evaluate the effect
WRC of transverse fillet welds at the end of cover plates and to determine the proper
location of the terminus of cover plates.
Bulletin Stresses in Cover Plates and Bearing Stiffeners—This paper presents
test data obtained in tests of large welded girders having partial length cover plates
No. 63 and bearing stiffeners.
Appendix—Application to Design—-This Appendix discusses generalizations
useful to design that can be drawn from the two previously listed reports of this
Bulletin.
A Summary of Literature on the Lateral Instability of Beams—The paper
contains an historical review of the lateral buckling problem, discussions of several
papers on inelastic solutions and a review of current and future research needs. A
list of references in a table showing existing solutions are included at the end of the
report.
The price of this Bulletin is $2.00 and single copies may be purchased through
the AMERICAN WELDING Society 33 W. 39th St., New York 18, N. Y. Quantity
lots may be purchased through the Welding Research Council, 29 W. 39th St.,
New York 18, N. Y.

WELDING RESEARCH SUPPLEMENT | 519s

Fusion-Zone Structures and Properties

in Aluminum Alloys

Laboratory investigation includes the effects of structure

and composition on the properties of arc deposits, as well

as the effect of welding procedure on structure

BY PAUL E. BROWN AND C. M. ADAMS, JR.

ABSTRACT. Microstructural details (alloys) has been treated theo- the composition of the first solid
of 2014 aluminum alloy arc deposits retically*® * ° and experimentally,*~® which forms is substantially dif-
have been quantitatively related to but attention has been directed ferent from that of the liquid.
solidification rate as determined by arc- almost exclusively to the relatively The detailed pattern in which the
energy input. The results conform to
the theory of dendritic solidification low solidification rates which obtain solute distributes itself relates to
based on mass transport in the liquid in castings and ingots. This work the dendritic character of solidifi-
phase. Because of their very high has included some assessment of cation which, in turn, results from
rates of solidification (far greater than the effects of solidification rate on the limited rate with which solute
in any casting process), arc deposits cast structures, but even the most can diffuse through the liquid during
exhibit very fine dendrite textures lead- severely chilled castings (e.g., per- freezing.
ing to unique mechanical properties manent mold or die castings) freeze To visualize the cause-and-effect
and rapid response to heat treatment. in order of magnitude more slowly development of the dendritic freez-
than do arc deposits. One purpose ing pattern, consider a_ binary
Introduction of the present work has been to alloy of 4% copper in aluminum.
One of the areas of major interest to determine whether the observations As the alloy starts to solidify, the
the modern materials engineer con- and structural analyses made at first solid which forms contains
cerns the response of metals and relatively low solidification rates can only 0.7% copper; part of the
alloys to the process of fusion weld- be extended in some logical way to copper is literally pushed aside by
ing. In particular, the metallurgical interpretation of fusion-zone struc- the growing solid, and tends to
reactions and properties which result tures. accumulate in the liquid imme-
from thermal cycles associated with As a mediun: for initial study, diately adjacent to the liquid
welding have received intensive alloy 2014 has been selected prima- solid interface. Since liquid dif-
study, and much progress has been rily because structures are easy to fusion is quite slow, a concen-
made toward understanding the observe and interpret, and the tration gradient is thereby es-
relevant heat-flow pat’erns' and alloy is a member of an important tablished with the liquid near the
solid-state reactions.’ class of high-strength aluminum interface being somewhat enriched
The fusion zone remains quite alloys and is responsive to heat in copper. In this circumstance,
mysterious. The effects of struc- treatment. Also, there is a wealth the liquid near the interface has the
ture and composition on the prop- of prior solidification studies on lowest freezing temperature, and
erties of arc deposits, and of weld- aluminum-copper alloys. further solidification takes place
ing procedure on structure, have by the growth of protrusions, which
The Mechanism of literally reach out for that liquid
not been studied systematically.
In the same sense that compre- Alloy Solidification which is most ready to solidify
hension of nonequilibrium, solid- When a liquid solution is allowed (i.e., is most dilute and has the
state reactions has been prerequisite to solidify, the solute is almost highest freezing temperature).
to understanding heat-affected zone invariably distributed in a non- These protrusions develop such a
behavior, so must the fundamental uniform way throughout the result- fine texture that the liquid pools
solidification mechanism be con- ing solid. This is true even in between them are very small] indeed,
sidered before fusion-zone structures systems which exhibit complete and the mass-transport problem is
and properties can be analyzed in solid solubility. The reasons for obviated, because in these tiny
any depth. The subject of non- the partial “unmixing’’ which is liquid zones the diffusion path is so
equilibrium solidification of solutions brought about by freezing are short. These peninsular solid pro-
basically simple and have received jections are commonly referred to as
PAUL E. BROWN is Research Associate and much attention in the literature. dendrites. Thus, in effect, the
Cc. M. ADAMS, JR. is Associate Professor of In cast structures, this phenomenon dendritic mechanism of solidification
Metallurgy, Massachusetts Institute of Tech-
nology, Cambridge, Mass. is often referred to as microsegrega- is the means by which nature solves
Paper presented at AWS National Fall Meeting tion and is caused by the fact that, the mass transport problem which
held in Pittsburgh, Pa., Sept. 26-29, 1960. when a solution starts to solidify, results in the liquid when aluminum-

§20-s | DECEMBER 1960

rich crystals precipitate from an solidification rates as high as those Cy, and the segregation coefficient
aluminum-copper melt. which are realized in are deposits. (l1 — &).} A one-dimensional
The interdendritic spacing, which There is no evidence of the side analysis of the fundamental mass-
can be observed metallographically, branching, or tree-like structures so transport problem yields:
is an important structural charac- often observed in castings. The
8DAT t
teristic of many cast alloys and is a structure perpendicular to the fiber ie «we 5y
measure of the dimensions of the direction is seen in Fig. 2, showing a
liquid zones which were prevalent section parallel to the plane of the where:
during solidification. Since mass plate, near the bottom of the L interdendritic spacing.
transport governs this characteristic deposit. t = solidification time.
dimension and is time dependent, No matter how fine the dendrite In a linear arc deposit on a thick
it would be expected that the more structure, the liquid-diffusion prob- plate, the solidification time for any
rapid solidification, the finer the lem is never completely “solved,” small volume of metal in that
dendrite structure. This is seen to and concentration gradients always deposit can be assessed from the
be the case for arc deposits produced exist in the interdendritic pools equation for centerline cooling rate:
at three different energy inputs, during solidification, with the result
shown in Figs. 1, 2 and 3. The that the liquid in the centers of the Hg 9)
Ta
sections shown are from inert-gas pools is slightly below its liquidus , 2 rKC,V
metal-arc (consumable) bead-on- temperature, the situation defined where:
plate deposits of 2014 alloy and by Chalmers as “constitutional heat of fusion.
are taken perpendicular to the supercooling.”’* The dendrite spac- = arc power.
plane of the plate, parallel to the ing depends, among other things thermal conductivity.
arc deposit. The white fibers are upon the amount of supercooling, specific heat of solid metal.
the aluminum-rich primary den- AT, which the liquid can sustain, = arc-travel speed.
liquidus temperature of alloy.
drites separated by dark-etching, and is also influenced by the liquid = initial temperature of plate.
copper-rich, interdendritic filling. diffusivity, D, the slope of the
The fibers parallel the direction of liquidus line, M, on the pertinent Equations 1 and 2 indicate den-
principal heat flow whenever the alloy-phase diagram, the over-all drite spacing should be proportional
gradients are as steep, and the concentration of solute in the alloy, to the square root of arc-energy

ee a

~< > - Pin “2% 4 ~

AX
pee i
i PAY NEHAI Le. , 2
ES REF SRLS Bayass at
Fig. 1—2014 arc deposit. Section parallel Fig. 2—2014 arc deposit, as-deposited. Fig. 3—2014 arc deposit. Section parallel
to arc travel and perpendicular to plate Power input 9300 joules/in. x 300 Keller to arc travel and perpendicular to plate
surface. Power input, 4400 joules/in. double etch surface. Power input, 37,900 joules/in.
< 300. Keller’s double etch Top: parallel to arc travel and < 300. Keller’s double etch
Top: as-deposited. Bottom: solu- perpendicular to plate surface. Top: as-deposited. Bottom: solu-
tionized 940° F 1 hr, quenched, Bottom: parallel to plate surface tionized 940° F 1 hr, quenched,
aged 340° F 10hr aged 340° F 10hr

WELDING RESEARCH SUPPLEMENT 521-s

 temperature gradients which pre-
Table 1—Compositions of Wire and Plate vailed during solidification. The
Cu, % Si, % reason arc deposits freeze so much
Plate 4.4 0.90 more rapidly than severely chilled
Wire 4.4 0.84 castings is that, with an arc deposit,
there is wetted contact between the
metal and its ““mold”’; the absence
of a heat barrier interface is of
input,\/q/V. Figure 4 shows this ple, in 2014, the 0.9% silicon is transcendent importance in a proc-
is indeed the case for a series of arc probably almost as influential as ess involving such steep tem-
deposits embracing a 15 fold vari- the 4.4% copper, and it is probable perature gradients and rapid cooling
ation in energy input, achieved by that these elements function addi- rates.
independent variation of arc power tively in controlling dendrite con- The only castings, which could be
and travel speed. Quantitative figuration. produced with solidification rates
interpretation of the slope of the It would be expected, of course, high enough to yield dendrite spac-
straight line in Fig. 4, using eqs that different alloys would, under ing of the same order as found in
1 and 2, indicates the degree of the same welding conditions, yield an arc deposit, were droplets 0.004
constitutional supercooling which different dendrite configurations, de- 0.020 in. in diam, quenched in a
actually obtains in interdendritic pending upon which element is stream of nitrogen. Droplets of
pools is the order of 0.04° F. Of controlling, the value of AT and
far greater importance is the fact the thermal conductivity of the
that this degree of supercooling is alloy; but the linear dependence
apparently quite independent of of dendrite spacing on arc energy
deposition conditions, and is, in input, as reflected in Fig. 4, should
fact, a characteristic of the alloy; prevail for all systems. A limited
otherwise the data in Fig. 4 could amount of work with 1100 alloy
not be correlated by a straight line. has exhibited finer dendrite spacing
Equation 1 is strictly valid for a than with 2014, probably because of
binary alloy. When several alloy the higher thermal conductivity
elements are present, the situation of this alloy, but linear conformance
is somewhat more complex. How- with eqs 1 and 2 wasstill observed.
ever, if the alloy is a dilute solution For comparison, photomicro-
of several elements in one major graphs of chill cast 2014 (in a steel
constituent, usually one of the mold) are shown in Figs. 5 and 6.
alloying elements will have a pre- Although this was a very small
dominating effect in establishing chill casting, having the approx-
the fineness of dendrite structure. imate dimensions of an arc deposit,
The element of controlling im- and froze quite rapidly, it may be
portance in this sense is always the seen that the structure is much
one which presents the greatest coarser than that developed in
mass-transport problem (i.e., which any of the arc deposits, reflecting
gives the lowest value of L in eq 1). a huge difference in solidification
Thus, the vital element may or rate. The fact that some dendrite
may not be the one present in branching occurs in the casting
greatest concentration. For exam- relates to the relatively shallow

Fig. 5—2014 alloy cast in stee! mold. x 300.

(Reduced by '/. upon reproduction.)
Keller’s double etch
Top: ascast. Bottom: solutionized
940° F 1 hr, quenched, aged 340° F 10 hr

(microns)
@3oO

@
ARC Deposits
oO) Sprayed Particles
Spacing
Dendrite
. Decreasing
Solidification
Rate
ine

6 8 10 2 14 16 18 y+ a
Solidification Parameter, (Vz )
Fig. 6—2014 alloy, as cast in steel mold.
Fig. 4—Dendrite spacing of 2014 deposits and sprayed particles x 16. (Reduced by 50% upon re-
vs. square root of energy input production.) Keller's double etch

522-s | DECEMBER 1960

various sizes were examined and
solidification times calculated on Table 2—Mechanical Properties of 2014 Arc Deposits
the basis of a convective heat- Solution
transfer coefficient at the droplet (940° F) 5 min. soln 14 min. soln
surface of 50 Btu/sq ft hr °F; As- and quench quench
the results conforni in magnitude deposited quench and age and age*
with the arc deposits (Fig. 4). Tensile strength, psi 45 ,000 63,000 63,000
The microstructure of such a droplet Elongation, % 10 6.5 9
is shown in Fig. 7; the fiber texture Hardness, Rp 50 77 85
is still pronounced but, since the * 340° F, 10 hr.
heat was radial, more than one
orientation can be cbserved.

Grain Size mechanical properties to dendrite the properties of the casting are
The structural characteristic of spacing, subsize test bars were measured transverse to columnar
weld fusion zones which is more machined from weld fusion zones. grains as has been done with the arc
discussed than any other is grain The heat-flow pattern is such that deposits, differences become even
size, and it is important to dis- the dendrite orientation in a fusion more pronounced
tinguish between grains and den- zone is always nearly perpendicular The effect of heat-treating time
drites in assessing the properties to the axis of the fusion zone, and on properties and structure in arc
of cast structures. dimensional limitations dictated deposits is directly related to solute
Two macrostructural views of that test bars be machined with distribution. It has been pointed
2014 are deposits are shown in their axes parallel to the deposits. out that the process of liquid
Fig. 8; these are low-magnification Thus, tensile properties could only diffusion was the controlling in-
views of the same deposit shown in be measured across rather than fluence in establishing dendrite spac-
Fig. 2. The grain size is 50 times parallel to the dendrites. ing. With more rapid solidification,
as great as the dendrite size, and it Earlier work on chill-cast alumi- the diffusion path is shortened and
is readily established by X-ray num-copper alloy indicated marked dendrite spacing reduced. In the
diffraction that all dendrite fibers mechanical anisotropy of columnar solid-state process of solution heat
in a single grain have a common structures; strength and ductility treatment, this same diffusion path
crystallographic orientation. In measured parallel to columnar prevails and homogenization obtains
other words, these arc deposits grains were substantially higher more rapidly, the finer the dendrite
consist. of relatively large columnar than those determined in the trans- spacing. Thus, arc deposits can be
grains, which are truly single crys- verse direction.’ The mechanical fully heat treated using solutionizing
tals of aluminum-rich solid solution, properties of 2014 arc deposits times measured in minutes, whereas
within which the alloying elements produced at relatively high-energy castings require hours; it has been
are heterogeneously distributed to input (42,000 joules per in.) are demonstrated that impracticably
form the much finer dendrite pat- shown in Table 2. long solutionizing times (more than
tern. This means that the den- The general level of properties one week nay be required to
drites are continuous to some extent, compares very favorably with those achieve optimum properties in a
even though secondary phases are which can be realized in cast sand casting, simply because inter-
precipitated along the _ interden- structures produced using foundry dendritic diffusion paths are so
dritic regions. It is not known procedures. Especially noteworthy great."
whether or not the secondary phases is the tensile strength after heat From this point of view, it has
also have a common crystallo- treatment and the ductility before been possible to detect differences
graphic orientation in a _ single and after heat treatment. In alloys in minimum solution time between
grain. of this type, it is very difficult, arc deposits made at high-energy
even in the laboratory, to realize input and the finer deposits pro-
Heat Treatment and Properties tensile strengths in excess of 50,000 duced at low-energy input. The
To study the relationship of psi or elongations greater than 5% time required to achieve a given
in chilled castings. Moreover. if degree of homogenization should

Fig. 7—Section of 2014 droplet, roughly

0.003 xX 0.010 in., cooled in nitrogen Fig. 8—Transverse (left) and longitudinal (right) views of arc deposit. Power
< 300. (Reduced by 70% upon reproduc- input 9300 joules/in. x 16 (Reduced by 50% upon reproduction.) Keller's
tion.) Keller's double etch double etch

WELDING RESEARCH SUPPLEMENT | 523-s

 drites are essentially ‘“‘one dimen-
sional,’’ exhibiting very little of the
side-branching characteristic of
usual cast structures.
Acknowledgment
SSThe authors gratefully acknowl-
oo—— edge the sponsorship of the Office of
Ordnance Research, Department of
the Army, which made this study
possible, and The Aluminum Co. of
@ As Deposited America who provided the fellow-
4 Solutionized Smin at 940°F ship which initiated the program,
Quenched, Aged Onhrs. at 340°F in addition to offering valuable
Solutionized 5min at 940°F suggestions and supplying some of
Quenched, Aged !Ohrs. at 340°F the necessary materials.
Bibliography
Solidificatio 1. Adams, C. M., Jdr., “Cooling Rates and
Peak Temperatures in Fusion Welding,” THe
Fig. 9—Effect of energy input on response to heat treatment of 2014 arc deposits WeLpInc JourNaL, 37, (5) Research Suppl.,
210-s to 215-8 (1958).
2. Nippes, E. F., ““The Weld-Affected Zone.”
Tbid., (1) 38, Research Suppl., 1-s to 18-s (1959).
3. Research work done on solidification by
B. Chalmers and associates
depend upon the square of the influence on ductility. This is (a) Chalmers, B., and Martius, U. M., ““The
Self-Perpetuating Step in Crystal Growth From
dendrite spacing or, in other words, probably a major reason why arc the Melt,”” Phil. Mag., Ser. 7, 43, 686-687, (June
be directly proportional to the arc- deposits compare so favorably to 1952).
castings, especially when ductility 6) Weinberg, F., and Chalmers, B., “‘Fur-
energy input. Since precipitation ther Observations on Dendritic Growth in
heat treatment depends upon the measurements transverse to co- Metals,”’ Can. Jrnl. Phys.,30, 488-502 (September
homogeneity resulting from the lumnar-grain structures are con- 1952).
c) Tiller, W. A., Jackson, K. A., Rutter J.,
solutionizing process, fully heat- sidered. W., and Chalmers, B., ““The Redistribution of
treated hardness is influenced by Solute Atoms During the Solidification of Metals,”’
Conclusions Acta Metallurgica, 1, no. 4, 428-437 (July 1953)
arc-energy input and solutionizing d) Winigard, W. C. and Chalmers, B.,
time as shown in Fig. 9. It may be 1. In are deposits, dendrite spac- “Supercooling and Dendritic Freezing in Alloys,”
ing decreases parabolically with Trans. ASM, XLVI, 1214-1224 (1954)
seen for low-energy arc deposits, e) Chalmers, B., ““Melting and Freezing,”
solutionizing is essentially complete energy input, in conformance with Trans. AIME, 200, 519-532 (1954).
after 5 min and longer solutionizing mass-transport theory. 4. Wagner, Carl, ‘“Theoretical Analysis of
Diffusion of Solutes During the Solidification of
times have little observable in- 2. Interdendritic constitutional Alloys,” Trans. AIME, 200, 154-160 (1954).
fluence, but high-energy arc deposits supercooling is the order of 0.04 °F 5. Michael, A. B., and Bever, M. B., “Solidifi-
cation of Aluminum Rich Aluminum-Copper Al-
required 15 min for fully effective for 2014 alloy, constant over a 15 loys,”’ Trans. AIME, 200, 47-56 (1954).
solutionizing. fold variation of arc energy input. 6. Jaffe, D., and Bever, M. B., “Solidification
3. Arc deposits freeze much faster of Aluminum-Zinc Alloys,” Trans. AIME, 206,
The effects of prior cast structure sec. 2, 972-975 (1956).
on solutionizing are shown in the than chill castings and _ exhibit 7. Walther, W. D., Adams, C. M., Jr., and
microstructures of two arc deposits finer dendrite structures than pro- Taylor, H. F., “Effect of Casting Fiber on Me-
chanical Properties of Aluminum—4 per cent Cop-
and one chill casting in Figs. 1, duced in any foundry process. per Alloys,”’ AFS Trans., 61, 664-673 (1953).
3 and 5. Alloy 2014, like most 4. Arc deposits exhibit mechan- 8. Hucke, E. E., Flemings, M. C., Adams, C
‘M., Jr., and Taylor, H. F., ““The Degeneration of
commercial aluminum alloys, has ical properties before and after Freezing Plane Interfaces in a Controlled Solidifi-
substantial concentrations of ele- heat treatment which are _ sub- cation System,”’ Proceedings, International Sym-
posium on Physical Chemistry of Process Metal-
ments such as iron, manganese stantially superior to those of labo- lurgy, AIME Pittsburgh, Pa., (Interscience Pub-
and silicon, which form interme- ratory castings, probably because lishers), (April 1959).
tallics much more reluctant to of fine dendrite texture. 9. ASM Seminar: Liquid Metals and Solid-
ification, American Society for Metals, Cleveland,
dissolve than CuAl,. The dispersion 5. The minimum time required Ohio (1957
of these relatively insoluble com- for effective solution heat treat- 10. Physical Chemistry of Steelmaking Com-
mittee, Iron and Steel Division, AIME, Basic
pounds is rather permanently es- ment of arc deposits, as reflected in Open Hearth Steelmaking, The American Insti
tablished during solidification and final properties, depends in simple tute of Mining and Metallurgical Engineers, New
fashion on dendrite spacing (energy York (1951).
substantially unalterable by solid- 11. Passmore, E. M., Flemings, M. C., and
state heat treatment. The more input). Taylor, H. F., “Fundamental Studies on Effects of
finely dispersed these intermetallics 6. In arc deposits, there are many Solution Treatment, Iron Content and Chilling
of Sand Cast Aluminum Copper Alloy,” AFS
are, the less deleterious is their dendrites per grain, and the den- Trans. 66, 75 104 (1958)

§24-s | DECEMBER 1960

Analytical Investigation of Residual Stresses

And Distortions Due to Welding

Investigation aimed at developing an analytical study

which can be applied to the determination of residual-stress distribution in

various types of joints and the influence of welding procedures

on residual stresses and distortions

BY KOICHI MASUBUCHI

SUMMARY. An attempt has been made formation produced in the base equivalent to reaction stress in
to develop an analytical method of plate in the region near the weld constrained weldment
studying residual stresses and distor- during welding. It is, therefore, 2. Stresses caused by a system
tions caused by welding. The analysis necessary to take the plastic be-
is based on an analogy between the of strains which do not satisfy the
theory of residual stresses in mechanics havior of the material into con- conditions of compatibility (equiva-
of a deformable body and the theory of sideration in order to trace the lent to residual welding stress in
vortex motion in fluid dynamics. A history of the occurrence of residual weldment).
method of analysis which is analogous stresses. Analytical studies of resid- When a body occupies a multiple
to Prandtl’s wing theory in aerody- ual stresses due to welding have connected region, such as a circular
namics has been developed to study been conducted by several research- cylinder or a body containing a
residual stresses in a welded plate. ers including Boulton and Lance cavity or cavities, residual stresses
The fundamental principles of the Martin,' Rodgers and _ Fetcher, can be produced even when strains
theory and a summary of the results Watanabe and Satoh.* However,
obtained in its experimental verifica- satisfy the condition of com-
tion are described in this paper. The because of the difficult mathematical patibility. For example, residual
following were investigated: analysis required, theoretical in- stresses are produced in a circular
vestigations have been limited to cylinder when a thin slice of ma-
1. Transverse shrinkage and residual simple models such as a long strip terial, bounded by two axial planes,
stress in a butt joint with a welded edge and a centrally is removed from the cylinder and
Distortion of a structure caused heated circular plate. new surfaces thus formed are
by angular change occurring in a Unfortunately, these models have brought together and joined.
butt joint. little relationship to important prac- In a more generalized residual-
Distortion of a structure caused tical problems. Many experimental stress field, where residual stresses
by angular change occurring in a investigations of practical problems are produced because of the exist-
fillet joint. have been conducted but few analyt- ence of a system of strains which do
Longitudinal distortion of ical investigations have been made. not satisfy the condition of compati-
welded beam.
For several years, investigations bility, the distribution of stress is
In order to conduct a quantitative of residual stresses and their in- rather complicated. Several at-
discussion, first, it is necessary to de- fluence on brittle fracture were tempts’: * have been made to analyze
velop a method of obtaining mathe- conducted at the Welding Division the stress distribution in a general-
matical expressions describing the dis of the Transportation Technical ized stress field. Moriguchi’ devel-
tribution of residual stresses and dis- Research Institute of Japan.‘ As oped a fundamental theory of dis-
tortions. The first step toward ob- a part of these investigations, an location in an elastic body. The
taining these expressions was to treat effort was made by the author to basic concept of his theory is that
the distribution of residual stresses and develop an analytical method of the condition of compatibility in
distortions as a boundary problem of studying residual stresses caused by
elasticity. Next, a study was made of the elasticity theory corresponds
the effects of various welding proce- welding.’ A method of analysis to the condition of irrotation in
dures on residual stress and distortion. similar to that applied in Prandtl’s the hydrodynamic theory. He de-
wing theory in aerodynamics was fined ‘“‘dislocation”’ and “‘incompati-
introduction developed. The fundamental bility” as similar to “circulation”
Residual stresses in a welded joint principles of the theory and a sum- and “vorticity,” respectively, and
are caused by the contraction of mary of the results obtained in its obtained the mathematical relation-
the weld metal and the plastic de- experimental verification are given ships between the distribution of
in this paper.
KOICHI MASUBUCHI is Chief of The Design
and Methods of Fabrication Section, Welding Basic Principle of This Research * The term “dislocation” used here is not the
Div. of the Transportation Technical Research same as the “dislocation” used in physical metal
Institute, Tokyo, Japan, and is a Visiting Re- Residual stresses can be classified lurgy, although their fundamental natures are
search Fellow at Battelle Memorial Institute closely related mathematically. As used here,
Columbus, Ohio as follows: dislocation means discontinuity in displacement
1. Stresses caused by disloca- such as opening of a crack in a residual-stress
Paper presented at AWS National Fall Meeting field. In this case, displacements are expressed in
held in Pittsburgh, Pa., Sept. 26-29, 1960. tion* in a multiple connected region multivalued functions.

WELDING RESEARCH SUPPLEMENT | 525-s

 incompatibility and residual copper
Table 1—Comparison Between stresses.
Theory of Residual Stress Wing Theory An attempt has been made by
{ { the author, under the guidance of
Moriguchi, to develop Moriguchi’s
fundamental work and to develop
a method of analytical investigation
of residual stresses and distortions
in a welded joint.'*: '' Similarities
in the mathematical description of
phenomena which occur in the
velocity distribution around the
wing of an airplane and in the resid-
ual-stress distribution in a welded
joint were investigated. In Table
1, a comparison is made between
some values related to the stress
problem caused by dislocation in
an infinite plate and some values
which appear in Prandtl’s three-
dimensional wing theory.'? Equa-
tion 1 in this table shows the re-
lationship between the dislocation
lv} which occurs along the part
Stress: or, cy, Ts Velocity: u,v of the x-axis between (—*“ », 0) and
Slit length (weld length): LZ Wing breadth: 6 ' 0) and the transverse stress
Transverse Stress on Slit: oy Down Wash: w produced at that part of the x-axis
1/2 designated as ow. The physical
E . 1 (<2 w = or) dx’ meaning of this stress problem can
‘ dx’ 1 dx
; 4x fz — x’ \ dx ). be interpreted as follows. When
where: where: transverse stress o,, aS given by
E Young’s modulus. r = circulation. eq 3 is applied along both sides of
[v] dislocation. a slit of length L located on the
r= 26V 2 A,, sin n9 x-axis, the relative displacement
{v)] = >» * sin née n 1 of the sides of the slit is given by
n=1 eq 2. The value U given by eq
. sin né 5 can indicate the elastic strain
w V nA, —;
E + sin née p> sin 6 energy stored in the plate (per
i e, ee, oe
ZL Be sin @ V = velocity at infinity unit plate thickness) when transverse
b stress co, is applied along the slit.
x
= 5 cos @ x = 5 cos @ In order to determine the distri-
Z
Mean Dislocation: [v] bution of residual stresses in a weld
» 4/2 joint and to investigate the influence
o) = J Sf lwidx pV S (x)dx of welding procedures on _ stress
L/2 6/2 distribution, it is not always neces-
sary to trace the history of non-
L (p> A,, sin no)sin @-dé@ 7pb?V2A, elastic deformations. The im-
n=l portant thing in these problems is
(4) where: p = density. to determine the distribution of
The magnitude of life is determined incompatibility. If the distribution
The magnitude of mean dislocation | only by the value A). of incompatibility is determined,
is determined only by the value A). residual stresses and distortions can
Strain Energy: Induced Resistance: D,; be calculated theoretically. Con-
b/2 sequently, in the first stage of the
D; = p S I(x)w(x)dx research, efforts were made to cor-
b/2
relate various problems related to
= ‘ obeve( nan) residual stresses and distortions with
n=1 certain boundary problems of elas-
ticity. In the second stage of the
= pb?V2(1 + 8)A,? research, efforts were made to in-
where: where: vestigate the influence of welding
procedures on residual-stress dis-
4 i( = n Ai) tribution and distortions. At this
aE") stage, for the most part, investiga-
The magnitude of strain energy be- ; The magnitude of induced resistance tions were conducted experimen-
comes minimum when 6 = 0 provided becomes minimum when 6 = 0, provided tally, since it is difficult to handle
that the length of L and mean disloca- that the wing breadth and lift L re- the problem fully from a theoretical
tion [v] remain constant. Whené = 0, main constant. When 6 = 0, the standpoint. However, the results
the form of dislocation [v] is elliptical distribution of circulation I is elliptical of theoretical consideration were
and the distribution of transverse and the distribution of down wash is
stress o, is uniform along the slit. uniform along the wing. used in various ways in the analysis
of experimental findings.

526-s | DECEMBER 1960

Estimation of Residual-stress ~<
Distribution and Distortion—
Physical Interpretation of the e
Problem
Residual Stresses in a Butt Joint
Strain Distribution in a Welded ®
Plate. An experimental investiga- ° °
° 2 )
tion was conducted by the author'®
on the slit-type specimen, shown in ° 9eoe00
e>oo
-—-@
Fig. 1, to determine the distribution > ®
)0 ° 7° >2
of strain produced by welding. The e
strain at various points on both sur- oe o@
e a
faces of the specimen was measured
with Gunnert’s strain indicator.'‘ 0¢
02
&©eo
Since strain produced by welding
may include both elastic and plastic
strain, particularly in the region ee
wg
near the weld, the elastic component
of the strain also was measured by
a relaxation method after the com-
pletion of the welding to determine
residual stress. The distribution
of strain produced by welding is Fig. 1—General view of slit-type specimen and measuring points (unit mm)
shown in Fig. 2. In this figure, the
values of J determined with strain
components (e€;, €,, y.) by the fol- I was relatively large in the region It appears that residual stress
lowing equation are plotted: near the weld. Curves of equal J acting in the direction transverse
value (equi-/ curve) also are shown to the weld (transverse stress, oy)
in Fig. 2c. The half breadth of is determined mainly by the first
the plastic region which corresponds factor, while residual stress acting
to oy = 21 kg/mm? (30,000 psi in the direction parallel to the weld
was about 55 mm (2 in.), and (longitudinal stress, c,) is deter-
the penetration of the plastic region mined mainly by the second factor.
beyond the end of the weld was It was found in previous experi-
about 50 mm (2 in. ments'*-*® that, in a constrained
The values of J due only to elastic- butt joint, transverse shrinkage is
strain recovery (/J,) were obtained mainly elastic except in a circular-
(broken lines in Fig. 2) and com- patch weld specimen with a high
pared with those determined with degree of constraint. After the
strain caused by welding. No dif- completion of the welding, a slit was
E Young’s modulus; » Pois- ference between the values of J and
son’s ratio. Equation 6’ shows that made by machining along the weld
I, was observed in the area outside line, and the elastic recovery of
the values of c,’, cy’, 7: indicate the above-mentioned plastic region;
the apparent values of stress com- shrinkage (or opening of the slit
however, the values of J, were much was measured and compared with
ponents, assuming that the meas- lower than those of J in the plastic
ured values of strain components the transverse shrinkage produced
region. The values of J, on the during welding. In the slit-type
€r, €y, Tz are elastic. The value t’ weld metal were about 35 kg/mm? specimen," the elastic recovery of
is an invariant which is usually 50,000 psi). Since the yield stress
referred to as octahedral shearing shrinkage when the slit was made on
of the weld metal is between 38 and the weld metal was about 80% of
stress in a plane stress field.'® Ac- 43 kg/mm? (54,000 and 61,000 psi),
cording to Mises, the yield condition the value of transverse shrinkage.
the state of residual stress in the The value of elastic recovery in-
in a plane-stress state is shown as weld metal was probably near the creased up to about 85% of the
follows: yield condition. value of transverse shrinkage when
The distribution of residual the slit was extended for 40 to 60
stresses is shown in Fig. 3. mm (1°/; to 2°/; in.) beyond the end
Analytical Investigation of Resid- of the weld. The shapes of the
ual Stresses. The results of previ- curves of elastic recovery of shrink-
(é ous investigations'*~'* and the stress age were quite similar to the shape
where o; yield stress of the ma- distribution shown in Fig. 3 suggest of the transverse shrinkage curve.
terial. Therefore, J is an invariant that residual stresses in a con- On the basis of the above experi-
indicating the residual-stress state strained butt joint are produced mental results, it was decided to
and can be used as a measure to mainly by the following two factors: draw the curve of elastic-disloca-
determine whether the material 1. Elastic dislocation caused by tion as 85% of the curve of trans-
at a specific position has undergone transverse shrinkage. verse shrinkage.
plastic strain or has deformed only 2. Incompatible’ strains pro- Since the determination of dis-
elastically during welding. It is duced in a region near the weld tribution of incompatibility is very
believed that the region has under- caused mainly by longitudinal complicated, an approximate theory
gone plastic strain when the value shrinkage of the weld metal and similar to the boundary-layer
ofJ is larger than the value of cy. plastic deformation produced in the theory’? in aerodynamics has been
Figure 2 shows that the value of base plate. developed for the residual stress

WELDING RESEARCH SUPPLEMENT 527-s

caused by incompatible strains pro- when the shearing stress 7) acting is much smaller than that in the
duced in the region near the weld. along the boundary of the plastic y-direction:
The welded joint is divided into and elastic region can be determined.
two regions: the plastic region and Regarding the stress distribution in 1. Transverse stress cy is uni-
the surrounding elastic region. The the plastic region, the following form in the y-direction.
plastic region is assumed to occupy simplified conditions are used based 2. The equilibrium condition be-
a slender rectangle of length L and on the assumptions that the width tween longitudinal stress and shear-
width 26(25 << L), as shown in of the plastic region is very small ing stress is:
Fig. 4. The stress distribution in compared to its length and that the dé
-dx+-i+ndx=0 (8
the elastic region can be calculated change of stress in the x-direction dx

where
@: = mean value of oc, over the
width of the plastic region. When
the distribution of 7, is known, the
distribution of 7 is determined;
thus, the stress distribution in the
elastic region also can be determined.
The above analysis suggests that
the distribution of residual stress
in a butt weld can be calculated
when the distribution of the follow-
ing two are known experimentally:
1. Transverse shrinkage.
2. Longitudinal residual stress in
the weld metal.
The distribution of dislocation
lv} is determined from transverse
shrinkage. The distribution of
shearing stress 7, is determined from
longitudinal residual stress in the
weld metal, assuming that experi-
mental results obtained in the weld
metal represent the stress values
in the plastic region.
The problem considered in the
numerical analysis of experimental
results was how to determine the
values of L and 6 to be used in the
analysis. It was decided that the
equivalent length L,,, which is 60
mm (2°/; in.) longer than the weld
length, be used. The value of 6
was fixed as 32 mm (1'/,in.). These
decisions are equivalent to the as-
sumption that the equi-J curve for
I = 40 kg/mm? (57,000 psi) cor-
responds to the boundary of the
plastic region (see Fig. 2c). The
curves of measured transverse
b Oristribution of I along y-direct shrinkage u and estimated dis-
location [v] are shown in Fig. 5.t
Theoretical residual-stress distribu-
tion is shown in Fig. 3, where it is
compared with experimental re-
sults. t§ Theoretical stress dis-

+ In estimating the distribution of dislocation

the experimental results were modified in the
following way: (1) to be symmetric in the direc-
tion of welding, and (2) to decrease to zero at the
end of the equivalent weld length.
tSome modifications of the theoretical curve
were made at particular points, such as the end of
weld and at the boundary between the plastic and
elastic regions, in order to obtain smooth curves
c. Equi-I curves $A further experiment’* was conducted to
investigate the residual-stress distribution more
thoroughly. It was found that relatively high
Fig. 2—Distribution of | as calculated from strain produced by welding. stress is produced at the ends of the slit where the
see eq (6) degree of constraint is relatively high.

§28-s | DECEMBER 1960

tribution is obtained as the sum- fillet joint is free from outer con- eners welded to a plate is prevented,
mation of two curves which cor- straint, the joint simply bends to wavy distortion of the plate, as
respond to the influence of trans- a polygonal form having a knuckle shown in Fig. 7b, results.
verse shrinkage and longitudinal at the weld, as shown in Fig. 7a. Investigations ! of the mech-
shrinkage, respectively. A good However, if the joint is constrained anism causing this wavy distortion
correlation was obtained between by some means, a different type of have been made. Some of the ex-
the theoretical stress distribution distortion is produced. For ex- perimental results obtained with
and the experimental results. Fig- ample, when the movement of stiff- a constrained framework are shown
ure 3 also shows that the term which
corresponds to dislocation plays
an important role in determining
transverse residual stresses, while
the term which corresponds to
longitudinal shrinkage plays an
important role in determining long-
itudinal residual stresses.
Distortion Due to Welding }
Distortion Caused by Angular
Change in a Butt Joint. Angular
change is often produced in a butt
joint at the weld line. If no con-
straint is present, the joint simply
bends, forming a knuckle at the
weld line. However, if the joint is
constrained by some means, dis-
tortion is produced over the whole
weldment.
An investigation’® was made of
distortion in a ring-type specimen
produced by angular change due to
butt welding. An example of dis-
tortion measured by a dial gage is
shown in Fig. 6. A single-vee-type
bevel was prepared in the ring-type
specimen (outer diameter, 600 mm;
inner diameter, 300 mm; plate
thickness, 19 mm). The results
shown in the figure were obtained
after one side of the bevel was com-
pletely welded (point P in Fig. 11
Mathematical analysis of the dis-
tortion also was made. It is sup-
posed that when the edges of a cir-
cular ring at 6 0 and @ 2x do not
fit and are inclined against each
other at an angle ¢, distortion 64
is produced when the edges are
forcibly joined together (Fig. 6):
of residual | stress in a slit-type specimer
H 9

where
H (0,9

a, b/a 9’
a outer diameter of ring and 6
inner diameter of ring. It is evident
that the distortion of a circular
ring can be calculated when the
angular change (¢) is known. As
shown in Fig. 6, excellent correla-
tion was obtained between cal-
culated and measured distortion.
Distortion Caused by Angular Fig. 4—Equilibrium of stress Fig. 5—Transverse shrinkage u
Change in a Fillet Joint. If a in plastic region and estimated dislocation [v

WELDING RESEARCH SUPPLEMENT | 529s

 in Fig. 8. Three vertical plates
(12 mm thick) were welded to a
horizontal test plate (19 mm thick,
200 mm wide), the vertical plates
having been previously welded to a
constraining girder. The specimen
simulated the double bottom struc-
ture of a welded ship in which wavy
distortion of the bottom plate may
become a serious problem.' When
only one side of each fillet joint
was welded, asymmetric distor-
tion was produced (Curve 1); how-
ever, when both sides of the fillet
joints were welded, symmetric dis-
tortion was produced (Curves 2
and 3). Tensile stresses were pro-
duced in the upper surfaces and
compressive stresses in the bottom
surfaces of the bottom plates. When
the constraining member was re-
moved from the specimen after the
completion of welding, wavy dis-
tortion and residual stresses in the
Fig. 6—Distortion of a ring-type specimen due to angular change at the weld. NOTE: bottom plate disappeared, and dis-
points plotted in the figure are the distortions measured at various locations, broken tortion became polygonal such as the
lines indicate the calculated distortion (angular change ¢ = 0.058 radian) distortion observed in a free joint. **

sidihy dlls dL a |oa

} i}
| | |
|
_ | |e J J
= af PO —
a. Free joint b. Constrained joint

Fig. 7—Distortion caused by angular change in two types of fillet welded structures (left view—free joint; right view—constrained joint)

It has been found that the problem

of analyzing wavy distortion and the
associated stresses can be handled
as a problem of stress in a rigid
SLIYIII, } frame. In the simplest case of a
A“ “ uniform distortion, the relationship
=. oO between angular change at the weld,
¢, and distortion, 6, is given as fol-
lows (see also Fig. 7):
2
; =} .o-(F-3)¢ 10

3° re) where / = length of span.

Distortion,
|O°mm Longitudinal Distortion in a Fillet
Joint. When the weld line does not
coincide with the neutral axis of a
weld structure, longitudinal shrink-
age of the weld metal induces bend-
ing moments and longitudinal dis-
4 It is believed that initial distortion and resid-
g ¢ ual stresses thus produced decrease the buckling
| pp -O= 0, f + strength of a bottom plate. The major reasons
“a % 4 fos for the corrugation damage of the bottom-shell
plating which occurred in a number of all-welded
Left span Right span transversely
. framed cargo, boats several : years ago
was attributed to excessive wavy distortion.**. %
; ** Distortion of the specimen after the con-
550 mm 550 mm straining member was removed was smaller than
that which was obtained in a free joint, since less
angular change was produced during welding be-
Fig. 8—Wavy distortion in constrained framework cause of the constraint.

§30-s | DECEMBER 1960

 4L*

o. General view b. Incompotibie strain €," c. Residual stress o,

Fig. 9—Analysis of longitudinal distortion in fillet joint

tortion of the structure results.

A theory similar to the bending-
beam theory has been developed
for the analysis of longitudinal dis-
tortion caused by welding of a long,
slender bar.*‘ Longitudinal re-
sidual stress (c, and curvature of
longitudinal distortion (1/R) are
given by the following equation (see
Fig. 9):
M,*_, P.*
Ee,” +
En ** at
1 M,* P,*|*
R EI Ei, |
11
where:
€ ” incompatible strain in the x-
direction. Fig. 10—Increase of transverse shrinkage in a butt joint during multipass welding.
sectional area of the joint. NOTE: w= weight of electrode consumed per weld length, u = mean value of trans-
moment of inertia of the verse shrinkage along weld line
joint around the neutral axis.
apparent shrinkage force,
P,* SS Ee,"dydz.
apparent shrinkage moment,
f,* SS Ee",
r,s.
distance between the neu-
tral axis and the acting axis
of apparent shrinkage force
Equation 11 shows that it is nec-
essary to know the distribution of
incompatible strain (« in order to
know the distribution of residual
stress (oc, however, information
about moment (M,*) only is suf-
ficient for determining the amount
of distortion (1/R). Moment (M,*
is determined when the magnitude
of apparent shrinkage force (P,*
and the location of its acting axis
are known. Through experiments,
it was found that the acting axis
of P,* is located somewhere in the
weld metal. It is considered that
the apparent shrinkage force (P.*
is the origin of residual stress and
that distortion is produced as the
result of the existence of P,*.
More information can be obtained
when the value of P,* is used
rather than when the value of dis-
tortion itself is used in the analysis
of experimental results. For ex- \( double
ample, in discussing the influence 20 25
of various factors on the magnitude
of distortion, it is possible to sep- w, gr/cm
arate the influence into those at-
tributable to the change in geom- Fig. 11—Increase of angular change in butt joint during multipass welding

WELDING RESEARCH SUPPLEMENT 53l-s

etry (A, J,, or /*) and/or those metal deposited. It is sometimes value of transverse shrinkage along
attributed to the change in the value necessary to modify the test results weld line u mm (see Fig. 14a for
of P,* itself. obtained by different welding pro- the definition) are shown. A rela-
cedures to eliminate the effects tively large amount of shrinkage
Effects of Various Factors on caused by the difference in the was produced by the earlier layers,
Residual Stresses and amount of weld metal deposited. and lesser amounts were produced
Distortions Since welding of a joint in a plate by later layers. This is because
of any thickness is commonly done the resistance against shrinkage
The amount and distribution of in several passes, a study of shrink- increases as the weld gets larger.
residual stress and distortion in a age and distortion during multi- A linear relation was found between
welded joint are affected by many pass welding was made. log w (common logarithm) and u
factors such as follows: Transverse Shrinkage in a Butt as shown in Fig. 106. The loga-
Joint. Figure 10 shows the increase rithmic relation between weight of
. Variations in welding tech-
of transverse shrinkage in a butt electrode consumed and transverse
niques, such as type of bevel,
joint during multipass welding. shrinkage was used in the an-
type and diameter of electrode,
The results shown in the figure were alysis of experimental results for
etc. evaluating the effects of various tech-
obtained in a ring-type specimen"
2. Degree of constraint.
(same dimension as that referred niques on the shrinkage.'® For ex-
3. Welding sequence.
to in Fig. 6). A double-V bevel ample, Fig. 10b shows that the re-
Many studies‘ 2° of the effects was prepared and welding was done duction in shrinkage which occurred
of these factors have been made. in the following way: when larger-diameter electrodes
Some basic principles and general were used was mainly a result of less
trends obtained in the experiments Specimen 11: with 3.2-mm ('/sin.) shrinkage in the first weld layers.
conducted at the Transportation diam electrodes, 10 layers.tt+ Angular Change in a Butt Joint.
Technical Research Institute are Specimen 13: with 6-mm ('/, in.) The increase of angular change ob-
described in the following sections. diam electrodes, 6 layers. tained in a ring-type specimen (same
dimension as that referred to in
increase of Shrinkage and Distortion in Welding was done on both surfaces Fig. 6) during multipass welding is
Multipass Welding and Effect of Amount alternately to minimize the angular as shown in Fig. 11.'° Five spec-
of Weld Metal change. imens with different types of bevel,
In Fig. 10a, the relation between from symmetrical double-V bevel
One most influential factor on weight of electrode consumed per to single-V bevel, were tested.
test results is the amount of weld weld length w gr/cm,tt and mean Welding was first completed on
one side, then the specimen was
tt In this paper, “layer” and “‘pass’’ are used
for the different meaning as shown in Sketches A
and B
|

Number
of
bpd
|+>
b td
py Pid pass
| | a.
‘ eS 'a
vara
HHH ! -wnr™
hun
Ye, xy
p*fon
Px, W,

oe
—__— ip ==
Sketch A_ Butt joint

Number of
/ pass
Shrinkage
Apparent
Force - P
6
3
| 2

1;2'3 Number of
layer
i ot
0.5 1.0 15 20 2.5 Sketch B Fillet joint
Weight of Electrode Consumed Per Unit Weld Length , gr /mm tt Although the amount of shrinkage is more
4 i d. i directly related to the amount of weld metal
0 6 8 12 14 rather than the weight of electrode consumed, the
weight of electrode consumed was commonly
Length of Leg , mm used in the analysis of experimental result be-
cause of the simplicity in measurement. From
the definition, the value w is proportional to the
Fig. 12—Increase of longitudinal distortion during multipass welding cross-sectional area of weld metal.

§32-s | DECEMBER 1960

 unit increase of weld metal de- In all cases, the specimens were 12C0
Welding Direction creases in the later stage of mul- mm (4 ft long). They were made
tipass welding.” Additional in- with mild-steel plates 12 to 13 mm
vestigations were conducted on (1/2 in.) thick. The values of
this subject by Hirai and P.,* increased proportionally to the
Nakamura.”!: * weight of electrode consumed per
Longitudinal Distortion in a Fillet weld length except for the first
Joint. The increase of longitudinal layer. A rather large amount of
distortion (apparent shrinkage force distortion obtained in the first layer
P,*) during multipass welding is was due to less-resisting area at
a | as shown in Fig. 12.% The results that stage of welding, as the fiange
Fig. 13—Rotationai distortion were obtained from the following plate was not yet fixed firmly to
of a butt joint weldments: the web plate.
1. Continuous welding of T-bars Practically no distortion was pro-
turned over and the other side was of different dimensions. duced by intermittent welding
back chipped and welded. Specimen I-4). This is probably
In regard to the increase of an- due to the fact that longitudinal
gular change during welding on the Flange- residual stress does not reach a
first side, a rather mild increase of plate Web-plate high value in a short intermittent
angular change was observed in breadth, height, weld. ?'§§
mm mm
the earliest stage of welding. The Distribution of Transverse Shrinkage
increase of angular change became Specimen T-1 100 100 and Its Change in Multipass Welding
Specimen T-2 100 150
greater in the intermediate stage, Specimen T-3 150 150 The amount of transverse shrink-
and it became mild again in the age is not always uniform along the
final stage. The back chipping did weld line, and the distribution of
not affect the angular change. 2. Welding of the web-to-bottom shrinkage also changes during mul-
Angular change of the reverse di- flange joint of /-beams (flange-plates tipass welding. Unevenness of de-
rection was produced by the welding breadths, 100 mm; _ web-plate gree of constraint along the weld
of the second side. The angular height, 150 mm) with different web- line and rotational distortion which
change remaining after completion to-top flange welds. is produced by the rotational mo-
of welding depends on the ratio tion of unwelded plate edges (Fig.
of weld metal deposited on the two 13) are major factors which de-
sides of the plate. Since the an- Web-to- termine the distribution of trans-
gular change increased more rapidly bottom verse shrinkage.
during welding of the second side, flange joint, Web-to-top The results of experimental meas-
the minimum angular change was test weld flange joint
urements of the change of the dis-
obtained in the specimen having a Specimen Continuous Tack weld tribution of transverse shrinkage
little larger groove in the first side weld
Specimer yntinuous intermittent during multipass welding in a
welded. ring-type specimen (outer diameter,
Angular Change in a Fillet Joint. weld weld
Specimen I-3 Continuous Continuous 1000 mm; inner diameter, 600
As in the case of butt-joint trans- mm; plate thickness, 19 mm) and
weld weld
verse shrinkage, a relatively large Specimen Intermittent Tack weld
amount of angular change is pro- weld $§ According to Hirai and Na
duced in the first and second passes reduction in angular change
mittent welding s not
and the rate of angular change per longitudinal distortior

u-afiract-n}
tan 8, Shrinkage,
u
n
a= tone

Shrinkage
mmr
u,

- 200 mm
Center of
ring Outer
circle

a. Explanation of U anda Examples of form of c. Relation between U anda

shrinkage

Fig. 14—Change of distribution of transverse shrinkage in multipass welding and influence of welding direction (ring-type specimen)

WELDING RESEARCH SUPPLEMENT 533-s

 B: Spec. I-2 respectively. As shown in Fig.
14c, during welding of the first
D: Spec. 4- O-O-O- layer there was a tendency for the
Multilayer—— unwelded plate edges to open dur-
C: Spec. |-3
ing welding. This was contrary
to the closing motion obtained in
A: Spec. I-! manual-arc welding. When the
second layer was welded, the open-
O-@-O-
°@ ing tendency became greater.
In a long butt joint, welding is
done in several steps with various
welding sequences. Welding se-
° fea)
quences can be classified into the
following two types:
1. Block-welding sequence, where
mm°o psy
Transverse
Shrinkage, a joint is divided into several
blocks and welding of the blocks
is completed one by one.
2. Multilayer-welding sequence,
where the welding of a layer is
done through the whole weld length
before the welding of succeeding
layers.
+100 mm-—
There are many variations in
Fig. 15—Distribution of transverse shrinkage obtained in slit-type both block and multilayer-welding
specimens with different welding sequences sequences. Examples of the effect
of welding sequence on the amount
and_ distribution of transverse
shrinkage obtained in a slit-type
the influence of direction of weld- where: specimen (19 by 800 by 1200 mm)
ing are shown in Fig. 14.'° When are shown in Fig. 15." Specimens
u = mean shrinkage.
welding was done from the inner a@ = parameter to express the rota- 1-1, 1-2, and 1-3 were welded with
circle (Specimen 21), the distribu- tional component in shrinkage, a_block-welding sequence. The
tion of shrinkage after the welding a = tan 6,/tan @. weld joint was about 500 mm (20
of the first layer was as shown by r = radius. in. long) and was divided into three
r = mean radius.
Line A; in Fig. 14b; however, when blocks. Welding of a block was
welding was done in the opposite The parameter a was used in the done in eight layers in different
direction (Specimen 22), the dis- analysis of experimental results. orders as follows:
tribution of shrinkage after the From the definition a = 0 when
welding of the first layer was as the shrinkage is uniform along the
shown by Line B;. More shrinkage weld line, a > O when larger FIRST SECOND THIRD
was produced in the region welded shrinkage is produced in the outer Specimen I- Left Middle Third
later. This is due to a tendency block block block
circle, and a < O when larger Specimen|-2 Left Right Middle
for rotational motion to occur in shrinkage is produced in the inner block block block
the direction which closes the un- circle. A_ theoretical study has Specimen |-3 Middle Right Left
welded plate edges. shown that the amount of elastic- block block block
The distribution of shrinkage strain energy stored in a ring-form
changed as A,, As, , during mul- specimen becomes minimum when
tipass welding when welding was the value of a is about 0.65 in the In Specimen 4-1, the joint was
done from the inner circle to the type of specimen used in the ex- divided into three parts and weld-
outer one; however, the distribution periment. Change of the value of ing was done with a multilayer
of shrinkage changed as B,, B:, a during multipass welding is shown sequence progressively from the left
..., When welding was done in in Fig. 14c. The value of a after to the right.
the opposite direction. In the final the welding of the first layer was Curves Au, Ar, Au and Ais in-
stages of welding, more shrinkage quite different when different weld- dicate the distribution of trans-
was obtained in the outer circle ing direction was used. However, verse shrinkage after the comple-
than in the inner circle regardless the value of a approached a stand- tion of 1, 2, 4 and 8 layers in the
of the welding direction. This is ard value during multipass welding first block Specimen 1-1. Curve
due to the difference in degree of regardless of the difference in weld- A», indicates the distribution of
constraint along the weld joint. ing direction. The fact that the transverse shrinkage when the weld-
The joint is more highly restrained experimental value of a is some- ing of the second block was com-
in the region near the inner circle what lower than the theoretically pleted, and Curve A (or A;) shows
than in the region near the outer most stable value can be attributed the distribution of transverse shrink-
circle. to the uniform shrinkage of the age after welding was completed.
An analytical investigation was metal during welding. Curves B and C show the distribu-
conducted of the above-mentioned The phenomena observed when tion of shrinkage after completion
phenomenon. Transverse shrinkage a joint was welded by submerged- of welding on Specimens 1-2 and
u was expressed in the following arc welding were quite different. 1-3, respectively. Curves Diu, Di
equation (see Fig. 14a): Specimens 23 and 23’ were welded and D,; show the distribution of
\ r from the inner circle to the outer shrinkage after welding the first
u l1+a ( layer of the first, the second, and
/ r circle and in the opposite direction,

534-s | DECEMBER 1960

 the third part of the joint of Spec- dislocation over the portion of the
imen 4-1. Curve D, and D in- slit where the load is applied |z| is
dicate the distribution of shrink- given by eq 14:
age after the welding of the second o = K- [i] 14
layer and when welding was com-
pleted, respectively. Quite un- Since transverse shrinkage obtained
even transverse-shrinkage distribu- in a slit-type specimen is mainly
tions were obtained with block- elastic, as stated before, it is ap-
weiding sequence whereas the shrink- proximately assumed that trans-
age distribution obtained with the verse residual stress of oa» is pro-
multilayer-welding sequence was duced at the welded part when
rather even and was similar to that the mean value of transverse shrink-
shown in Fig. 5 which was obtained age at the welded part is [7].
without intezruption of welding. Fig. 16—Definition of degree of con- Relations between degree of con-
straint in slit-type specimen straint K and transverse shrink-
An analytical investigation of the
transverse-shrinkage distribution age obtained in an experiment are
obtained in a slit-type specimen shown in Fig. 17. This experiment
also was conducted. A parameter was conducted on various com-
6 defined by eq 5’ (see Table 1 binations of slit length L (75 to
Residual stresses in a _ welded 500 mm) and weld length /(//L =
was used in the analysis. From plate are classified into “residual
the definition, the shrinkage dis- 0.3 to 1.0). Results obtained in a
welding stresses’’ which occur even specimen welded with a_ block-
tribution which corresponds to 6 in a free joint and “‘reaction stresses” —
0 induces the minimum amount of welding sequence also are plotted.
or locked-in stresses) which are in- Different symbols are used in the
strain energy in the plate at a given duced by an external constraint. In
value of mean shrinkage. In speci- figure to indicate the difference
the case of distortion due to welding, in the value of //Z and to indicate
men 4-1, the value of 6 was about also unique differences in character-
0.1 at the completion of the first whether the specific result was ob-
istics are induced by the existence tained during the first or later
layer (shrinkage curve, D,;), and it of constraint. Some examples have
decreased as low as 0.02 at the final welds in a specimen. The results
been discussed previously. Another obtained from the specimen welded
stage of welding. In Specimen I-1, example is that of fillet joints sub-
the value of 6 was 0.52 when the by a multilayer-welding sequence
jected to a postweld heat treat- is shown by X. Mean values of
welding of the first block was com- ment to eliminate distortion. Con-
pleted (shrinkage curve, Ais, and it transverse shrinkage over the weld
strained joints behaved quite dif- length u; for w, = 10 (u,;: weight
decreased as low as 0.09 at the final ferently than unconstrained joints.*'
stage of welding. of electrode consumed per unit
The results of experiments with weld length, gr/cm) are plotted
Investigations also were con- fillet joints showed that the dis-
ducted on the increase of the amount in the figure.
tortion in a constrained joint al- Angular Change Due to Fillet
of shrinkage in a slit-type specimen. ways decreased when the joint
A linear relation was found be- Welding. An _ investigation was
is given a postwelding heat treat- made of the influence of the degree
tween transverse shrinkage and ment. This was not so for free
the logarithm of weight of elec- of constraint on wavy distortions.”
joints. This was probably caused As shown in eq 10, distortion 6
trode consumed when a specimen by the reaction stresses which were
was welded with a _ multilayer- decreases when the length of span
present in the joint. l decreases, even if the amount of
welding sequence. When a spec- Some of the results obtained so
imen was welded with a_block- angular change @ remains un-
far regarding the influence of de- changed. However, the amount of
welding sequence, however, the gree of constraint on tLe magnitudes
logarithmic relation was valid only @ itself increases as the length of
of shrinkage and distortion are span decreases since the degree of
in the shrinkage and the electrode summarized as follows:
consumed obtained in each block. constraint increases.
These results suggest that the Butt Joint. In a slit-type spec- Equation 15 has been developed
mechanism of shrinkage obtained imen, the degree of constraint K analytically to express the in-
in the first layer when the separate when welding is done in a part of
plates are joined together is quite slit between x x, and x» (slit
different from that obtained in the length, LZ; weld length, 1 = x,
~ Xo) is defined by the following
succeeding layers in which shrink-
age occurs in the already joined equation (see Fig. 16):
plates. y l 1
K = 13
Nearly the same results were EY ae a
obtained with circular-patch weld where:
specimens welded with different
welding sequences.'* I = ,
F = bi if sin @ sin né-dé Shrinkage
,mm
et 6
Effects of Constraint
Mean
The state of constraint of a joint >- « Cos @
has a unique influence on residual
stresses and distortions due to |S
X2 = 2 cos y
welding. Not only are stress and
distortion magnitudes affected by The physical meaning of K is as 00
the degree of constraint but es- follows. When uniform stress a»
sential differences are produced in is applied along the part of the slit Fig. 17—Relation between degree of
their characteristics by external between x x, and x, the relation constraint and transverse shrinkage in
constraint. between o) and the mean value of slit-type specimens (We = 10gr/cm)

WELDING RESEARCH SUPPLEMENT 535-s

fluence of length of span / and tions on slit-type specimens and In addition, the author is in-
flexural rigidity of the plate D on circular-patch weld specimens, it debted to the staff of the Welding
the amount of angular change: was found that a smaller amount of Division of the Transportation
strain energy was produced with Technical Research Institute for
>= > " (15 the block-welding sequence than their assistance in conducting the
vial 2D 1 ,.
1 + with the multilayer sequence. work. Finally, the author is in-
e£&
These results suggest that the debted to the staff of the Battelle
where: influence of welding sequence on Memorial Institute, Columbus,
@ = angular change in a free joint. residual stresses might change with Ohio, especially D. C. Martin, for
® = angular change ina constrained the type of joint. In a free joint, their help in the preparation of
joint. — where high-residual stresses are the manuscript.
C = coefficient. produced in the region near the
The coefficient C can be considered weld but low stresses are pro- References
as of a joint against angular change. duced in the base-plate region, 1. Boulton, N. S., and Lance Martin, H. E.,
The value of C was 7.4 X 10kg-mm “Residual Stresses in Arc Welded Plates,’ Proc.
the influence of welding sequence Institution of Mechanical Engineers, 133, 295-339
mm for the following experimental on residual stresses is small. On (1936).
conditions: the other hand, in a constrained 2. Rodgers, O. E., and Fetcher, J. R., ““The
Determination of Internal Stresses from the
Thickness of bottom joint where fairly large reaction Temperature History of a Butt-Welded Plate,”
plate, 19 mm(*/, in.) stresses can be produced in a wide THe Wetpinc JourNaL, 17 (11), Welding Re-
Length of span, 350 to 950 mm search Suppl., 4-s to 7-8 (1938).
area of the joint, welding sequence 3. Watanabe, M., and Satoh, K., “Plastic
(14 to 37 in.) Study on Residual Stress Due to Welding,”
Weight of electrode may have a significant influence
Technol. Repts. Osaka Univ., 1 (13) (1951).
consumed per unit on residual stresses. 4. Kihara, H., Watanabe, M., Masubuchi,
weld length, 10 gr/cm(0.056 Ib/in.) K., and Satoh, K., Researches on Welding Stress
Conclusions and Shrinkage Distortion in Japan, 60th Anniver-
Further investigations of the value sary Series, 4, published by the Society of Naval
of coefficient C under various con- Architects of Japan (1959).
An attempt has been made to 5. Masubuchi, K., “New Approach to the
ditions were carried by Hirai and develop an analytical method of Problem on Residual Stress and Deformation Due
Nakamura.” studying residual stresses and dis- to Welding,’ Monthly Reports of Transportation
Technical Research Institute, 8 (12), 247-365
tortions caused by welding. The (1959).
Effects of Welding Sequence investigation has been particularly 6. Love, A. E. H., Mathematical Theory of
Elasticity, Fourth Edition, Cambridge at the
Investigations of the effect of aimed at developing an analytical University Press, 221-228 (1934).
study which can be applied to such 7. Reissner, H., “Eigenspannungen und
welding sequence on shrinkage and Eigenspannugsquellen,” Zeit. fur Ang. Math. u.
residual stresses were conducted problems of practical importance Mech., 11 (1), 1-8 (1931).
on slit-type specimens” and circular- as the determination of residual- 8. Neményi, P., ““Selbstspannungen elastischer
stress distribution in various types Gebilde,” Handbuch der Physikalischen und
patch welding specimens."* In the Technischen Mechanik, 4-1, 199-212 (1931).
case of a specimen where a whole of joints and the investigation of 9. Moriguchi, S., “Fundamental Theory of
the influence of welding procedures Dislocation in Elastic Body,’’ Oyo-sugaku Rikigaku
weld joint was welded without Applied Math. and Mech.) 1, 29-36 and 87-90
changing electrodes, a fairly regu- on residual stresses and distor- 1948)
tions. The concept is based on an 10. Kihara, H., and Masubuchi, K., ‘“Theo-
lar residual-stress distribution, such retical Studies on Residual Welding Stress,"’ Re-
as shown in Fig. 4, was obtained. analogy between the theory of re- port No. 6 of Transportation Technical Research
However, when the joint was welded sidual stresses in metals and the Institute, (June, 1953).
theory of the vortex motion of fluids. 11. Moriguchi, S., “Analogy Between the
in several steps, quite different Theory of Residual Welding Stress and the Wing
results were obtained. A fairly An analytical method similar to Theory,” presented at the 5th Japan National
Prandtl’s wing theory in aerody- Cong. for Appl. Mech. (1955).
regular stress distribution was ob- 12. Durand, W. F., Aerodynamic Theory, Vol. 3
tained in the base-plate region, but namics has been developed. and 4, Julius Springer Berlin (1934).
Experimental as well as theoret- 13. Masubuchi, K., “Distribution of Residual
the strain measurements obtained Stresses in Butt-Welded Joint,” Jnl. Soc. Naval
in the weld-metal region were quite ical studies were conducted. On Architects (Japan), 102, 99-109 (1957).
scattered. and could not be used the basis of the analytical in- 14. Gunnert, R., Residual Welding Stresses,
vestigation of experimental results, Method for Measuring Residual Stresses and Its
to determine the stress distribution. Application to a Study of Residual Welding
This scattering of strain measure- physical models suitable for various Stresses, Almqvist E. Wiksell, Stockholm (1955).
types of joints were established. 15. Hill, R., The Mathematical Theory of
ments was observed not only in a Plasticity, Oxford University Press, London
block-welded specimen but also The effects of various welding pro- 1950).
cedures on residual stresses and 16. Kihara, H., and Masubuchi, K., “Studies
in a multilayer welded specimen. on the Shrinkage and Residual Welding Streases
Summarizing the results obtained distortions also were studied. of Constrained Fundamental Joint,’’ Reports No.
7 and No. 20 of Transportation Technical Re-
in these experiments and _ those search Institute (August 1953 and April 1956)
obtained by DeGarmo, et al.,*? and Acknowledgments Jnl. Soc. Naval Architects (Japan), 97 (1955).
Weck,** it appears that the residual- The author wishes to thank H. 17. Kihara, H., Masubuchi, K., Ogura, Y.,
and Matsuyama, Y., “Effect of Welding Sequence
stress distribution in the weld- Kihara, professor at the University of on Transverse Shrinkage and Residual Stresses,”’
metal zone is quite uneven and that Tokyo for his general direction Report No. 24 of Transportation Technical Re-
search Institute (March 1957).
it is practically impossible to con- given to the author during the 18. Kihara, H., Masubuchi, K., and Ogura, Y.,
trol the distribution of residual whole period of this research. He “Radial Contraction and Residual Stresses in Cir-
cular Patch Weld,” Jnl. Soc. Naval Architects
stress in the weld-metal zone by the also wishes to thank M. Yoshiki, Japan), 99, 111-122 (1956), and 100, 163-170
use of a proper welding sequence. T. Naka and S. Moriguchi, pro- 1956).
However, a distinctive difference fessors at the University of Tokyo for 19. Kihara, H., and Kusuda, T., “‘Effect of
Root Gap on Residual Stress and Shrinkage in
in the distribution and the amount their guidance and suggestions. Restrained Butt Joint,” presented at the 1959
of transverse shrinkage was ob- The author would like to acknowl- Annual Meeting of Commission X of International
Institute of Welding, Document X-221-59 (1959).
served when the welding sequence edge T. Izubuchi, director of the 20. Masubuchi, K., Ogura, Y., Ishihara, Y.,
was changed. This indicates that Shipbuilding Research Association and Hoshino, J., “Studies on the Mechanism of
the Origin and the Method of Reducing the
welding sequence may have con- of Japan, and Y. Matsuyama, of Deformation of Shell Plating in Welded Ships,”
siderable influence on the amount Harima Shipbuilding and Engineer- International Shipbuilding Progress, 3 (19),
of strain energy produced in the ing Co., for their help in conducting 123-133 (1956).
21. “Investigation on the Corrugation Failure
base-plate region. In the investiga- some of the experiments. of Bottom Plating of Ship,”” Report of the 16th

536s | DECEMBER 1960

Research Committee, Report No. 19 of Shipbuild “Shrinkage Distortion in Welding,”’ THE WeELp- Effects of Welding Procedures on Initial Corruga-
ing Research Association of Japan (June 1957 ING JOURNAL, 16 (7), 29-39 (1937 tion of Ship-Bottom Plate,” Ishikawajima Engi-
22. Murray, J. M., “Corrugation of Bottom 26. Spraragen, W., and Claussen, G. E., neering Review, 12 (37), 59-68 (April 1955
Shell Plating,’”’ Trans. Inst. Naval Architects “Shrinkage Stresses in Welding,’ Jbid., 16 (11), 31. DeGarmo, E. P Meriam, J. L., and
London, Volume 94, 229-250 (1954). 2-62 (1937 Jonassen, F., ““The Effect of Weld Length Upon
23. Report of Ship’s Hull Failures Investiga 27. Spraragen, W., and Cordovi, M. A., the Residual Stresses of Unstrained Butt Welds,’
tion Committee, Nippon Kaiji Kyokai (Japanese “Shrinkage Stresses in Welding,’ /bid., 23 (5), THE WELDING JOURNAL, 25 (8), Research Suppl.,
Maritime Corp.) (1954). Research Suppl., 209-s to 246-s (1944 485-s to 486-s (1946
24. Masubuchi, K., Sasayama, T., and Mori 28. Spraragen, W and Cordovi, M. A., 32. Jonassen, F., Meriam, J. L., and DeGarmo,
guchi, S.; ‘Longitudinal Deformation of Long “Shrinkage Distortion in Welding,’ /Jbid., 23 E. P., “Effect of Certain Block and Other Special
Beam Due to Fillet Welding,’ presented at the 11), Research Suppl., 545-8 to 559-s (1944) Welding Procedures on Residual Welding
Annual Meeting of International Institute of 29. Spraragen, W., and Ettinger, W. G., Stresses,”’ Jbid., 25 (9), Research Suppl., 492-s to
Welding, Document X-88-55 (1955). Abstract was “Shrinkage Distortion in Welding,”’ /bid., 29 496-s (1946
published in THE WerLpInGc JouRNAL 34 (12), 6), Research Suppl., 292-s to 294-s (1950) and 33. Weck, R., ““Transverse Contractions and
Research Suppl. 581-s to 582-s (1955 29 (7), Research Suppl., 323-8 to 335-8 (1950 Reaction Stresses in Butt Welded Mild Steel
25. Spraragen, W., and Claussen, G. E 30. Hirai, S., and Nakamura, Y., “Studies on Plates,” Report No. R4, Admiralty Ship Welding
Committee (January 1947

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No. 53 Plastic Design of Pinned-Base “‘Lean-to’’ Type Frames, by Robert L. Ketter and Bung-Tseng Yen,
September 1959. $1.00.

No. Bending of 2:1 and 3:1 Open-Crown Ellipsoidal Shells, by G. D. Galletly, October 1959. $1.00.

No. Fourth Technical Progress Report of the Ship Structure Committee, November 1959. $1.00.

No. Interpretive Report on Welding Titanium and Titanium Alloys, by G. E. Faulkner and C. B. Vold-
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No. 57 Some Observations on the Brittle Fracture, by G. M. Boyd, January 1960. $1.00.

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No. 99 Factors Which Affect Low-Alloy Weld Metal Notch-Toughness, by S. S. Sagan and H. C. Campbell,
April 1960. $1.00.

No. 60 (1) Interpretive Commentary on the Application of Theory to Experimental Results for Stresses
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No. 63 Welded Interior Beam-to-Column Connections; Transfer of Stresses in Welded Cover Plates;
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No. 64 Web Buckling Tests on Welded Plate Girders, September 1960. $2.00.

WELDING RESEARCH SUPPLEMENT | 537-s

Design of Interior Columns in

Multi-Story Frames

The use of a special end connection between beams and

columns of steel building frames, intended to minimize the moments

transferred into the columns, is discussed by the author

SY JS ELLIS

ABSTRACT. This paper is concerned In this paper it will be assumed End Rotations of Columns
with the design of interior columns in that the beams are continuous and
steel-framed buildings of moderate are designed by the plastic theory. In this paper, the maximum axial
height. As such, their strength is not related load, P,, that a short column can
In this paper it will be assumed that carry is the cross-sectional area of
the beams are continuous and are to the stiffness of the columns.
Sidesway is considered to be re- the column multiplied by the lower
designed by the plastic theory. As yield stress of the steel.
such, their strength is not related to sisted by cross bracing or its equiva-
the stiffness of the columns. Side- lent and over-all frame instability The axial-load capacity of a pin-
sway is considered to be resisted by is assumed to be unimportant. ended column is less than P, if the
cross bracing or its equivalent and The columns will be subjected to slenderness ratio of the column is
over-all frame instability is assumed to both axial loads and end rotations. high. (The slenderness ratio is the
be unimportant. These end rotations are induced in length of the column divided by its
Because a column is stronger when the columns by the deflected shapes minimum radius of gyration.) For
pin-ended than when subject to end example, a pin-ended pipe column
rotations, a connection between the of the beams.
This paper attempts (1) to ex- with a slenderness ratio of 100 can
beams and columns has been invented take an axial load of about 0.87 P,
to minimize such rotation. This con- plain why it is desirable to minimize
nection is called a Stirling hinge after the end rotations of columns; (2) to according to Euler’s theory.
its inventor. show how it is possible to minimize Also, the end rotations of columns
This paper attempts to describe such rotations by using a special reduce the members’ ability to carry
why it is desirable to minimize the end connection between the beams and axialload. ‘Theoretical studies have
rotations of columns, to show how it is the columns; and (3) to record indicated that a pipe column with a
possible to minimize such rotations by experimental results which are re- slenderness ratio of 100, when
using a special connection between the subjected to end rotations which
beams and the columns, and to record lated to this problem.
relevant experimental results.
It is estimated that, by using the
Stirling hinge, a savings in the weight
of columns of about 25% could be
realized. The savings in cost would be
somewhat less because of the extra
fabrication required by the hinges.
Should the idea of the Stirling hinge
be favorably received by engineers,
then further experiments will be re-
quired. Only after much experi-
menting should the theory be elabo-
rated; at present, it would be prema-
ture to do so. Thus, the purpose of
this paper is not to present a theory
but rather to set forth the idea of the
Stirling hinge.

Introduction
This paper is concerned with the de-
sign of interior columns in steel-
framed buildings of moderate height
(see Fig. 1).

J._S. ELLIS is Professor of Civil Engineering at

The Royal Military College of Canada at King-
ston, Ont., Canada.
Paper presented at AWS National Fall Meeting
held in Pittsburgh, Pa., Sept. 26-29, 1960 Fig. 1—A steel frame with continuous beams over interior columns

§38-s | DECEMBER 1960

 (a)
Fig. 2—Comparison of column end rotations

can be expected to accompany But the axial load on column XY is of end rotation has a reduced load-
plastic failure in a beam, can carry almost 75% of the total axial load carrying capacity. This is a serious
an axial load of about 0.4 P, to 0.72 that would be expected on this handicap for multi-story frames and
P,. These values should be treated column, were all spans loaded to for frames where the loading se-
as estimates only because it is diffi- their maximum. Thus a condition quence is unknown. Thus it is
cult to ascertain the amount of end of partial loading is more serious desirable to eliminate the end rota-
rotation that a column will experi- due to the end rotations, than the tions of columns and thereby to
ence. These theoretical studies were condition of maximum load. design them as pin-ended.
based on some unpublished curves For Fig. 3 (b) let it be assumed This problem would be resolved
of the shapes of columns stressed that the uniform load is applied were it possible to use an end fitting
in the plastic range. first. ‘This causes the interior col- for columns that would exclude the
In Fig. 2 it is obvious that the umn to deflect to the right. The effect of end rotations and the
rotation at X will be greater in addition of load P might cause the bending moments which accompany
frame (b) than in frame (a). The column to fail because of its de- them.
end rotation is dependent on the flected shape due to the end rota-
fully plastic moment of the beam, tions. In contrast, however, the End Fittings for Columns
the length of the unloaded span, the addition of P might cause the The insertion of rollers between
moment of inertia of the unloaded column to straighten sufficiently so the beams and columns would
span, the loadings and lengths of that it is able to take a greater load. eliminate the effect of end rotations
distant spans and the moment re- A further complication arises if the on the columns. Such rollers would
sistance offered to the beam by the concentrated load is applied first, not transfer bending moments into
column. The calculation of the for in this case the column would the columns and thus would permit
end rotations of columns is a com- deflect to the left and the subsequent pin-ended design. However, rollers
plex problem. addition of the uniform load would present two difficulties: (1) Such
Figures 3 (a) and (b) illustrate straighten the column and thereby end fittings would make the columns
two frames for which it is important increase its strength. The relation- difficult to erect and would require
to eliminate end rotations of the ship between the strength of col- considerable attention during con-
interior columns. At X in Fig. 3 umns and the sequence in which struction; and (2) such end fittings
a), the end rotation would be con- loads are applied to structures is would require some downhaul at-
siderable and the lower column involved—-especially because the tachment to prevent the uplift of
would suffer a marked reduction in principle of superposition does not the beams under certain loading
its ability to carry axial load due hold for columns. conditions.
to its end rotation. Let it be To conclude this part of the dis- An end fitting which transfers
assumed that the axial-load capac- cussion, it may be said that a relatively little bending moment
ity of the column is about 0.56 P,. column subjected to a high degree into the column and which does not

SO@STSAASTEBRSERKTERTSERES!

i. s = ‘ pit |
- x

iN AY rR

(q)
Fig. 3—Comparison of end rotations under conditions of partial loading

WELDING RESEARCH SUPPLEMENT | 539-s

 when the stresses across the hinge because all stresses are in the plastic
are all in the plastic range; i.e., range. This means that, for a given
Maximum moment = (hadbc) (lower axial load, the transmission of
yield stress) (x) + (fgde) (lower yield moment does not increase past the
stress) (x) calculated value regardless of the
where x is given in Fig. 5 in the end rotation.
illustration of the stress pattern Figure 5 also illustrates a more
across line B-B. The end rotation compact design of a Stirling hinge
which accompanies this stress dis- which has received no experimental
tribution can be very considerable attention to date.

om
OF
B
'

cross hatched area

Fig. 4—The Stirling hinge multiplied by lower
% | yield stress =imposed
suffer from the two disadvantages
ee=O
ae ee4 axial load
ClCs72S
SS
listed above has been suggested by
L. Stirling.* Figure 4 illustrates
the Stirling hinge.
The hinge material is mild steel
lower yield stress between 35,000
and 40,000 psi). Its web and end
plates are welded together with A possible development of
E6012 d-c arc welding. The hinge the STIRLING HINGE.
is then welded to the column using a
jig to assure that the centerlines of
the web and column coincide. The lower yield stress
column with the Stirling hinges can
be either bolted to the beams or lower a.
attached to them by downhand yield stress
welding. t Li
In full-scale steel frames, the use STRESS PATTERN
of suitable rolled sections as Stirling across line B-B.
hinges might well be considered.
In designing the hinge, the area of Fig. 5—Stress pattern in web of Stirling hinge
the web which is presented to a
vertical load must be sufficient to
take the maximum axial load.
Two facters govern the thickness
of the web: (1) The L/r of the web
of the hinge must not be excessive.
So far, its value has been limited to “\X = 0.835 inches
40 taking L most conservatively as
the clear distance between the
flanges of the hinge. (2) The thick-
ness of the web must be a minimum
in order to reduce as much as
possible the transfer of moment
through the hinge to the column.
The amount of moment trans- IN
KIPS _ X= 2.125 inches
mitted by the hinge at any given
percentage of P, can be readily “pe
calculated by referring to Fig. 5.
Let it be assumed that for Section
A-A of Fig. 5, the distance cd is one
third of be. On this assumption, ae ‘
the axial load is 0.33 P, and the tie X = 8.5 inches
cross-hatched area resists this load. LX Ip
| ae
The maximum moment that can be AXIAL
LOAD
NOTE
transmitted by the hinge when sub- columns |-1/4" std. pipe 02 04 O06 O8 10
jected to this axial load occurs 50" long OD. 2 x 0835" DIAL GAUGE READING IN INCHES WHICH
with Stirling hinges MEASURED END ROTATION
* Senior Technician in the Civil Engineering slenderness ratio= 92.5
Department of the Royal Military College of
Canada Fig. 6—Axial load vs. end rotations for pipe columns with Stirling hinges

540-s | DECEMBER 1960

 Thus an end fitting has been in- minimizes the amount of moment
vented which poses no problems of that can enter the column for any
construction, which resists uplift range of end rotations that are
and which minimizes the moment liable to occur in building frames.
that can enter the column.
Next, the design of the column Experimental Results
between the Stirling hinges must be A set of three experiments was
considered. The following informa- conducted to determine qualita-
tion is known: the axial load on
the member, the maximum terminal
Fig. 7—Test frame
moment and the length. End rota-
tion is no longer important. The
plastic theory of columns has pro-

Fig. 8—Test frame in machine

Fig. 10—Buckled column without

Stirling hinges failed at 0.58 P,
vided ultimate loads for columns of
several cross sections when sub-
jected to axial loads and terminal
moments. For this work, the ter-
minal moments at each end of the
column are considered to be equal
in magnitude and to cause single-
curvature bending. The ultimate
loads for columns are given in two
papers by the writer. *
The following points summarize
the theoretical aspects of the prob-
lem of the design of columns in
multistory frames:
1) The design of multispan
beams by the plastic theory does
not depend on stiff columns.
(2) The end rotations of columns
reduce their strength; such end
rotations are difficult to calculate.
(3) To reduce the weakening
effect of the end rotations, the
Stirling hinge was invented. It

* “Plastic Behaviour of Compression Members,”

2, No. 2 of the Transactions of the Engineering
Institute of Canada, and “Plastic Design
Columns in Multi-Story Frames,” 4, No. 2 of the
Transactions of the Engineering Institute of Fig. 11—Buckled column with Stirling
Fig. 9—Measuring devices on column Canada hinges failed at 0.76 P,

WELDING RESEARCH SUPPLEMENT | 54i-s

tively the relationship between the occurred suddenly by the buckling of been called a “Stirling” hinge after
axial load and the end rotations for one of the columns. For the frame its inventor.
pipe columns equipped with Stirling with the Stirling hinges, the plastic The plastic theory of steel struc-
hinges. The columns were 1'/,-in. theory was used to predict a maxi- tures has been used to estimate the
standard pipe, 50 in. long with an mum column load of 0.78 P, and failure loads of pipe columns subject
OD of 1.67 in. and a slenderness failure occurred at 0.765 P, or 2.6% to single-curvature bending moment
ratio of 92.5. The experimental below the theoretical load. For the in a framework. Theoretically, the
arrangement and the test results are frame without Stirling hinges the ultimate strength of the columns is
given by Fig. 6; the flat-topped plastic theory was used to predict a increased by about 20% due to the
curves are to be noted. maximum column load of 0.58 P, Stirling hinge.
Two tests of pipe columns in a and failure occurred at 0.58 P,. The Stirling hinge might be used
framework have been conducted in Figure 8 shows the frame in the for compression members in trusses
which the loading caused single- testing machine. Figure 9 illus- and other frames as well as in build-
curvature bending in the columns trates the devices to measure the ings.
which is the most severe condition. end rotations of the columns and Obviously, further experiments
In one test frame, the columns were their mid-height deflection. Fig- are needed; these can be carried out
equipped with Stirling hinges and in ures 10 and 11 record the buckled and the theory can be elaborated
the other they were not. Figure 7 state of the columns which failed. providing the general idea appears
illustrates the test frame for which to warrant such work.
the beams were 5I 14.75 and con-
tinuous with two equal end spans of Conclusion
6.2 ft, and a larger central span of Acknowledgment
8.23 ft. The columns were 1'/;-in. A special end connection be- The writer wishes to express his
standard pipe with an _ over-all tween beams and columns of steel indebtedness to Professor J. W.
length of 54 in. and a slenderness building frames has been invented Dolphin, MEIC, and the members
ratio of 100. Tension rods with to minimize the moment transferred of his staff of the Civil Engineering
load cells were provided at the into the columns and, thereby, to Department of the Royal Military
ends of the beams. permit a more economical design of College of Canada for their generous
For both test frames, failure columns. This end connection has cooperation in this project.

weld zone, vibratory energy delivered discussion of theoretical considera-

to the zone, energy transmitted tions regarding altering of the ul-
through the zone, temperature de- trasonic beam diameter by collima-
RESEARCH NEWS veloped in the zone, material proper- tion; and (4) exploration of the
ties and their relationship to ul- possibilities of predicting static and
trasonic weldability, and interfacial fatigue properties of materials con-
disturbance and metallurgy. taining gross amounts of very
Research and Development Leading minute discontinuities. Among
Ultrasonic Welding and Testing to the Establishment of Ultrasonic other conclusions, it was determined
Test Standards for Aircraft Ma- that the most significant of the
Three reports of Armed Services- terials, G. L. Cross and others, material variables affecting com-
sponsored research on the use of Ultrasonic Testing & Research Lab- pressional wave energy are the
ultrasonics in welding and in non- oratory, for Wright Air Develop- amount of working to which the
destructive testing of materials have ment Division, U. S. Air Force. material is subjected the more im-
been released to science and industry Feb. 1960. 147 pages. (Order PB portant factors in determining the
through the Office of Technical 161753 from OTS, U.S. Department quantities of shear and surface wave
Services, Business and Defense Serv- of Commerce, Washington 25, D. C., energy are sheet thickness and ratio
ices Administration, U. S. Depart- $2.75). Results ofa four phase study of flaw size to sheet thickness,
ment of Commerce. evaluating materials and techniques and that ultrasonic and mechanical
Fundamentals of Ultrasonic Weld- for the detection and evaluation properties show good correlation
ing (Phase 1), J. B. Jones and others, of internal defects by ultrasonic as far as fatigue life and ductility
Aero-projects Inc., for Bureau of means are reported. The report are concerned. A report covering
Naval Weapons, U.S. Navy. May includes: (1) information regarding the first phase of this investigation
1959. 99 pages. (Order PB 161677 material variables in certain steel, also is available. It is PB 131564
from OTS, U. S. Department of aluminum and titanium alloys with Research and Development Leading
Commerce, Washington 25, D. C., particular emphasis on defect size to the Establishment of Ultrasonic
$2.50.) Special instrumentation and material production methods; Test Standards for Aircraft Ma-
and techniques were developed for (2) analysis of variables involved terials. Oct. 1957. 133 pages.
observing and interpreting the fac- in contact and immersed methods Price $3.50.
tors of stress distribution in the of inspecting sheet metal; (3)

542-s | DECEMBER 1960

 A Reversed-Bend Test to Study Ductile to Brittle Transition

The use of a sharply bent beam as a test specimen to explore the influence of

material and environment on the borderline between ductile and brittle behavior of structural

Steels is proposed by the authors

SY J. WH. LUDLEY AND BO. C DRUCKER

ABSTRACT. The proposal is made to plates with their very uneven stress perature of testing and the tempera-
use very sharply bent beams as test distribution and extremely high- ture of precompression, the effect of
specimens to explore the influence of strain concentrations were not really a machined surface as compared
material and environment on the bor-
derline between ductile and brittle be- suitable for a study of the properties with an as-rolled surface, mild
havior of structural steels. Although of the steel itself. Their function corrosion effects and many other
far removed from the homogeneous was to establish that deformations influences of possible practical and
cylindrical test specimens reported on produced during the fabrication of fundamental importance come to
previously, the reversed-bend test of- ships and pressure or storage vessels mind. So many tests are needed,
fers real hope of becoming a simple might well account for subsequent that a much simpler alternative to
shop- and field-inspection test of direct brittle behavior. the cylinder tests is essential for an
and understandable physical meaning. The notched-plate tests, there- exploration of the influence of
At the least, it provides a reproducible fore, were followed by a preliminary material and environment of the
laboratory test forthe preliminary study
of such factors as the amount of pre- series of standard-type unnotched borderline between ductile and
compression, aging, temperature of tensile tests’ on longitudinal speci- brittle behavior.
testing, machined vs. as-rolled surface, mens cut from uniformly precom-
etc. Some results are given for project pressed cylinders. During the large Bent-beam Specimens
E-steel, A-7 and T-1. All show brittle compression and the subsequent The proposal is made to use
behavior in tension following large pre- tension to the point of fracture or beams which are sharply bent,
compression and all are adversely af- necking, the state of stress through- without shear force in the region of
fected by aging. out the gage length was homo- interest, to delineate the border-
geneous and there were _ conse- line in an approximate manner. Cy]l-
Introduction
quently no residual stresses on a inder tests, far fewer in number,
Many environmental and material macroscopic scale. Large com- would then be employed to deter-
factors may combine to produce pression is required because an mine the influence of the significant
brittle fracture in a steel which is average strain of 2% in the notched variables with much greater pre-
ductile at room temperature in the plate would give a maximum strain cision. Figure 1 shows the means
as-received condition. Stress, strain at the root of the notch of the of producing the specimen, and
history, time and temperature all order of 40%. Fig. 2 the method of testing. Al-
are important and have attracted a The cylinder tests gave a clear though the method of making the
great amount of attention. It has indication that extremely brittle specimen is not as convenient as
been established, for example, that behavior, with a total plastic strain using point loading at midspan,° it
precompression of edge-notched prior to fracture of less than 2% in has the advantage of not disturbing
plate specimens of project E-steel at tension, was a real material property the surface of the beam at the
room temperature leads to reason- induced by precompression and critical point where the maximum
ably reproducible brittle fractures in aided by aging. Earlier work by tension will be induced in the test.
tension at below-zero temperatures. ' Baldwin and Ripling* gave indica- Also, a larger region of the bent
Average strains of the order of 2°; tions that this was so, and very beam is under nearly uniform pre-
across the net section were ample to recent work at the National Physical compression. Of course, the state
produce the effect. Laboratory‘ reports extreme brittle- of the specimen is far from uniform.
Clearly, in an experimental pro- ness induced in rather pure poly- Only the surface layer in the region
gram, the more homogeneous the crystalline iron by precompressions of high curvature is under the pre-
factors are throughout the specimen up to 75%. Although cylinder compression whose effect is being
or over its surface, the more reliable tests are essential if a definitive studied. Residual stresses are large
and meaningful the results will be. answer is to be obtained, they are because of the inhomogeneity of the
Therefore, the tests on the notched tedious and time consuming. Many deformation which goes from very
materials should be tested and high compression on the inside to
J. H. LUDLEY is Research Associate, and D. C many environmental factors should moderately high extension on the
DRUCKER is Professor, Division of Engineering, outside of the sharply curved beam.
Brown University, Providence, R. I be studied to obtain an adequate
The results presented in this paper were obtained understanding of the brittle-fracture Furthermore, the tensile-test load
in the course of research sponsored by the Ship problem. The amount of precom- produces a bending stress on the
Structure Committee under contract NObs-78440 pression, the time, the stress and cross section of the curved beam
with the Bureau of Ships, Department of the
Navy the temperature of aging, the tem- which is nonlinear from tension on

WELDING RESEARCH SUPPLEMENT 543-s

the inside to compression on the however, the possibility that the of greatest importance. When the
outside. Also, an elastic curved- bent beam can provide an absolute tensile loads are small, the response
beam stress distribution is far type of test. For example, it may of the bent beam is elastic. Stresses
different from the distribution of be found that a steel will be satis- caused by the bending moment can
stress in the plastic range. factory in construction if it un- be computed with reasonable ac-
Nevertheless, the bent-beam bends in a ductile manner at 32° F curacy from the formulas of elemen-
specimen is far more homogeneous after having been bent to a maximum tary curved-beam theory. The
than a notched specimen and far strain of 45% and aged. These maximum tensile stress due to bend-
more reproducible within one labo- numbers are illustrative only, there ing occurs at the inside radius and
ratory and from laboratory to is no evidence so far to fix them at all will be a large multiple of the
laboratory. Because a gross effect firmly. A very extensive series of straight-beam value Mc,/I because
is looked for—the transition from tests would have to be made by curvatures are extremely sharp for
ductile to brittle behavior—res‘dual many groups. the prestrains of interest. In the
stresses and nonuniform applied notation of Fig. 2, where R is the
stress are of secondary importance. Some Expe: imental Results inside radius, d is the depth or
Even size effects are likely to be thickness of the beam, and 6 is the
small because fracture starts at or A number of tests have been width
very close to the surface and the performed to examine some of the
important factors in brittle fracture. d
available surface area under high prestrain = (1
Results are reported in Tables 1-3 2R+d
precompression is appreciable.
There will, of course, be disturbing for three steels: project E, A-7 2R/d = (1/prestrain) — 1 (2
effects of residual stress on aging. and T-1. Figures 3 and 4 show
one of the brittle fractures that was A prestrain of 50% corresponds to a
Also, cracking may occur upon un- value of unity for 2R/d.
loading of the beam following the obtained in E-steel. This fracture
was accompanied by virtually no Small bending moments, there-
completion of the forming of the fore, cause large tensile stresses at
specimen and prior to the applica- visible plastic yielding. Figure 3
shows the cracking to start at the inside surface which add to the
tion of the tensile load. residual stress. However, if the
The bent-beam test offers real several points on the surface or,
perhaps, to start below the surface. steel behaves in a ductile manner
hope of being a simple shop- and and unbends plastically, the residual
field-inspection test of direct and Tests which have been repeated
under the same conditions show that stresses are, in effect, wiped out as
understandable physical meaning. the load increases and the stress
Of course, it cannot be used for fracturing or, conversely, the ab-
sence of brittle behavior, can be distribution on the cross section
this purpose until the record is approximates to a rectangle of
accumulated for the behavior of reproduced consistently. There is
far less scatter than was obtained uniform tension on the inside and a
many steels and this record is rectangle of uniform compression
correlated with cylinder tests and previously with the notched-plate
tests. on the outside. At this stage, the
with field experience. There is stress s, is given by
The first of the series of tests was
carried out on beam specimens with 8, = 4M/bd? 3
a width to thickness ratio of over
five. Plane strain conditions then This stress will, of course, be much
held very closely over much of the closer to the ultimate strength of
central region of the width of the the steel than to the original yield
beam. As shown in Table 1, tests point because the material of the
on beams of various widths demon-
strated that the ratio of width to
thickness could be reduced to ‘/;
without altering the fracture point
very much. The results of tests of
Fig. 1—Three stages during geometrically similar bars showed
the prestraining that the size could be reduced
substantially from the initial 4 x
'/-in beams. No “cut-off” size
effect was encountered as in the
notched plates; beams only '/,; in.
thick fractured at closely the same
stresses as the */,-in. thick bars. Fig. 3—Specimen No. 3, 4 x 3/, in.
Except for the '/;-in. beams, the Prestrain = 43%
inner surface of the beams was the
original as-rollecdl surface of the
plate.

Stresses Produced
by Unbending
The pair of tensile forces applied
to the bent beam, Fig. 2, add a
tensile force and a bending moment,
M, on the cross section to a state of
high-residual stress left by the
fabrication of the specimen. It is Fig. 4—Specimen No. 4, 4x ?/, in.
Fig. 2—Method of testing the added bending moment which is Prestrain = 43%

544-5 | DECEMBER 1960

Table 1—Unbending Tests on Bent Beams of E-steel
Compressive ____— —- Unbending test
prestrain, % 4M hd?, psi-—— $$$ —_$_—_ —__—
Bar Size: width 100d First No fracture,
no. x thick in. 2R+d crack Fracture highest stress omments
4x 33 ‘ 2 : , > 33,000 Unaged
4x 23 > 33,000 Jnaged
4 x 432 Aged
4 43 Aged
4 43 Aged
4 43 : Aged
l 5 >90 ,000 aged
1 >75 ,000 Unaged
1 82,000 Unaged
1 > 85,000 Unaged
1 > 100 ,000 Unaged
1 > 100 ,000 Unaged
1 > 100 ,009 Unaged
1 > 66 ,000 Unaged
l > 100 ,000 Unaged
1 Unaged. Frac
{ ture after large
]
f deformations
>60 ,000 Unaged
Unaged. Fracture
after large
deformations
Unaged
5.000 31,500 Aged
20.800 28,500 Aged
0,000 Aged
36 500 Aged
53,000 Aged
6,500 Aged
300 Aged
30, 700 Aged
41,000 Aged
33,000 Aged
Aged
Aged
Unaged
Jnaged
Unaged
Unaged
Unaged
Unaged
Unaged

31,20
Failed
at unknown stress

J64 80
K60 80
K61 80
K65 80 Aged
90 Aged
K66
K(60) 80 Unaged
K(64) 80 Aged
* All aging carried out at 150 C for 11/1 hrs. prior to testing.

WELDING RESEARCH SUPPLEMENT 545-s

Table 2—Unbending Tests on Bent Beams of A-7 Steel
Compressive Unbending test
prestrain, % 4M/bd?, psi —_—
Size: width x 1004 Temp., First No fracture,
thick., in. 2R+d F crack Fracture highest stress Comments2
1x 3/, <—16 94,000 Unaged
s/ <—16 90 ,000 Aged
<—16 87 ,000 Unaged
<—16 60,000 Aged
<—16 28500 35,000 Aged
<—16 30.200 38 ,000 Aged
<—16 46 ,000 Aged
<—16 9.600 40 ,300 Unaged
<—16 12,500 35 ,000 Unaged
<—16 <5,350 37,000 Unaged
<—16 3,550 39,500 Unaged
80 kes ius Unaged
80 wa oe Aged
K65A meKK
K~Ke
x
KKK
Ot 80 we ies Unaged

All aging carried out at 150° C for 1'/: hr. prior to testing

beam is so strongly work hardened 4M /bd? values only half as large are perature and 32 F tests with
by the process of forming the speci- very brittle indeed. prestrains of 60%.
men, Fig. 1.
Brittle fracture intervenes in the References
Preliminary Conclusions 1. Mylonas, C., ““Prestrain, Size, and Residual
tests which are of the greatest
Based on Test Results Stress in Static Brittle Fracture Initiation,”
significance. Although there may WELpING JouRNAL, 30 (10), Research Suppl.,
be no apparent plastic deformation The scatter of the results have 414-s to 424-s (1959). (Contains references to
at fracture, the stress at the surface been much less than was expected; earlier work as well.)
2. Drucker, D. C., Mylonas, C., Lianis, G., “On
certainly will have reached the so, it is possible to reach some the Exhaustion of Ductility of E-Steel in Tension
raised yield point, s,, long before tentative conclusions at this early Following Compressive Prestrain,”’ Jbid., 39 (3
Research Suppl., 117-s to 120-8 (1960)
fracture and prior to first cracking. stage. Rather remarkably, all three 3. Baldwin, W. M., Jr., and Ripling, E. J
However, until the limit moment steels tested as l-in. wide beams “Overcoming Rheotropic Brittleness: Precompres-
behave in a brittle manner at below- sion Versus Pretension,”” ASM Trans., 44, 1047
8,bd* /, is reached, the elastic core of 1952)
the beam limits the maximum strain zero temperatures when prestrained 4. Allen, N. P.. ‘““The Mechanical Properties of
to the order of elastic strains. by 50% or more and aged. The E- the Ferrite Crystal,”’ Eleventh Hatfield Memorial
Lecture, Jni. Iron Steel Inst., 191, Part I, 1-18
Therefore, the nominal plastic stress steel is the worst but not by much January 1959
4M ‘bd* serves as an excellent meas- of a margin. Aging is harmful for 5. Lagasse, P. E., and Hofmans, M., “Effets
thermique sur la fragilité de profils en acier doux,”
ure of the brittleness or ductility of all three, but all will fracture with- Report RA101 Centre National de Recherches
the fracture. For E-steel and for A- out aging if the prestrain is in- Metallurgique, Section de Liege (August 1959)
Also previous report “‘L’Aptitude des Acier’s A37
7, the borderline is in the neighbor- creased to about 60% and the au profilage a froid.”
hood of 70,000 psi; for T-1 about testing is done at below-zero tem- 6. Ludley, J. H. and Drucker, D. C., “Size Ef-
110,000 psi. The brittle fractures peratures. Brittle fractures of E- fect in Brittle Fracture of Notched Steel Plates
in Tension,’ Brown University Report NObs-
indicated in the table which have steel were obtained in room-tem- 78440/1 (June 1960).

Table 3—Unbending Tests on Bent Beams of T-1 Steel

Compressive Unbending test
prestrain, % —_—_———_——4M bd’, psi
Size: width x 100d Temp., First No fracture,
thick in. 2R+d ws crack Fracture highest stress Comments’
1 x 3/, 40 <—16 131,000 Unaged
_ - 3/, 40 <—16 114,000 Aged
48 <—16 130 ,000 Unaged
45 <—16 136 ,000 Aged
48 <—16 111,000 Aged
50 <—16 Aged
49 <—16 Aged
61.5 <—16 Unaged
61.5 <—16 Unaged
61.5 <—16 Unaged
61.5 <—16 Unaged
50 80 131,000 Unaged
50 80 121.000 Aged
etMh~*KeKKK
KK
ww x 58.5 80 Unaged. Fracture
after large defor-
mation.

* All aging carried out at 150° C for 1'/+ hr. prior to testing.

§46-s | DECEMBER 1960

Current Welding Research Problems

This list is published to inform Welding Research Council Project Committees

and University Research Workers of some of the more important research problems
facing the Industry. It is also hoped that this list will assist industry and government agencies
by pointing out to them the more urgent welding problems requiring solution.
These suggestions are important because they have come largely from engineers,
scientists and executives of American industry and government agencies.

General Comments problems require substantial in- important activities embraces ap-
vestment of equipment, time and pointment, if desired, of an advisory
Welding is of great importance now money, but many of them can be committee composed of eminent
because it has become firmly estab- subdivided or enlarged to conform men in the field. These committees
lished as an accepted method of to the limitations of time and equip- are of great value to the professor
fabrication with a very wide range ment of any research worker for in charge. Also, a conference of
of application. Welding is used to short or long periods of time. university research professors is
join hundreds of different commer- The Welding Research Council held each year during the annual
cial alloys in many different shapes. AWS Welding Show. The Welding
at 29 W. 39th St., New York 18,
Plain-carbon steels, low-alloy steels N. Y., welcomes offers of university Research Council makes funds avail-
and stainless steels, as well as a professors to carry out or participate able to help pay for transportation
great many nonferrous alloys such in an investigation of any of the expenses of professors who attend,
as aluminum, nickel, copper, ti- problems listed here. As a basis of with a limit of $50 to any one pro-
tanium and zirconium are welded discussion with the Welding Re- fessor or research worker. This
very widely. Many of the new search Council, it would be of helps to provide an opportunity
high-temperature metals and super great help if the professors would for the university research worker
alloys are fabricated into useful outline their proposed program and to discuss his problems with repre-
components by welding. Sheets of accompanying budget and submit sentatives of industry and with
all thicknesses ranging from a few it to the Council for preliminary other research workers in many
mils to over 20 in. thick are evaluation and comments. It is fields of activity.
joined. Actually, some products recommended that these proposals Through close association of the
could not even be made without be made well before the time at council with the AWS, opportunity
the use of welding—for example, which it is hoped to start the pro- is provided for the presentation of
guided missiles, nuclear power gram, because of the time required results of a research project before
plants, jet aircraft, chemical proc- for coordinating it with other pro- the SocrETy at Annual meetings.
essing equipment and thousands of grams, obtaining Council agreement An opportunity is provided for its
others. Welding is of great eco- and arranging for financial support publication in the Welding Research
nomic importance because it is one if needed. A comprehensive and Supplement of the WELDING JouR-
of the more important tools avail- thorough investigation of a problem NAL even though the paper may not
able to the engineer in his efforts to frequently requires a continuity of be presented at an annual meeting.
reduce production and fabrication effort, such as a series of studies and This ‘‘Supplement’”’ accounts for
costs. Welding also enhances free- investigations, properly coordinated about half of the technical pages of
dom in design. by the professor in charge. Prog- the WELDING JOURNAL and exerts
Approximately every two years, ress reports of each professor and great influence in the welding in-
the Welding Research Council asks his co-author are published. This dustry because, as a separate mailing
for suggestions and opinions on helps to develop the interest of item, it reaches scientific workers
problems which might be under- industry and government agencies throughout the world.
taken by the project committees and, also, to give recognition to the
of the Council and its University professor and his university. Suggested Programs
Research Committee. Some of The professors at those univer- In a similar compilation of sug-
these problems are so broad and sities which have been affiliated with gested research problems prepared
complex that their solution requires the University Research Committee two years ago and published in the
the coordinated effort and knowl- of the Welding Research Council August 1958 issue of the Welding
edge of experts in many branches for many years appreciate the use- Research Supplement, approximately
of science. Many welding problems fulness of such a list of suggested 100 suggestions were listed. This
are suitable for university research welding research problems and the year the list has been expanded to
projects. Some which are not suit- advantages of affiliation with this some 150 problems. If further
able for universities can be handled Committee of the Council. To elucidation of any suggestion is
by and would be of interest to those who are not familiar with the desired, it can be secured from the
industrial research institutes or advantages afforded to research Welding Research Council. These
foundations. workers by such affiliation, it might suggested welding research prob-
Some of these welding research be pointed out that one of the lems are presented as follows.

WELDING RESEARCH SUPPLEMENT | 547-s

Group |—Carbon and Low-Alloy Steels on cracking or reduced ductility of 18. A further study of the effect
1. Determine the effect of weld- weld metal. of chemical inhomogeneity on welded
ing at low ambient (subzero) tem- 10. A basic study of the relation- properties.
peratures on the weld properties ship between the amount and dis- 19. Investigation of the effect of
and weld cracking. tribution of inclusions such as surface condition on the properties
(a) Quantitative information is sulfides and silicates on hot crack- of thick steel plate. Correlate steel
needed on the value of preheating ing, general weldability and notch composition and tendency to form
on decreasing the hydrogen, nitro- toughness of welds. surface defects, e.g., the effect of
gen and oxygen contents and on (a) A study of weld metal, heat- alloying additions of Mo, Mn,
improving notch ductility. This is affected zone and base metal. Si, Ti, Al, V, Zr, S, P, Cr, Ni,
an effect separate from the “‘drying”’ 11. Further study of methods for C, ete. It would be particularly
effect of preheat. correlating the behavior of small- important to determine the effect
(6) Advantages of killed steel over scale weldability-test specimens with on strain concentration of surface
rimmed steel. the service performance of large defects on notch ductility and
2. Welding of phosphate-coated sections. performance of welded structures
steel—welding procedures should be 12. Investigation of composition in fatigue-type loading.
developed to eliminate weld porosity variables on the weldability of the 20. Explore the parameters for
using the inert-gas-shielded arc newer very high-strength steels. welding of 0.50-1.0% plain-carbon
welding process. 13. Further studies of theories to steels.
explain the origin of microscopic 21. Welding of steel reinforcing
(a) Other protective coatings
fractures that lead to low-tempera- bars. This is a problem because
should also be included.
ture brittleness, for example, the of the variety of miscellaneous
3. A study of the effects of weld- study of dislocation and other steels used.
ding on the corrosion resistance of theories in initiating and propagat-
structural steels in a marine en- ing cracks. Group |I—Pressure Vessels and Piping
vironment.
14. Investigate the effect of vari- 1. Continue further development
4. A study of the effect of prior ous degrees of restraint in thick of theory and data which will permit
cold working of base material on sections and the effect of fabricating the accurate calculation or deter-
over-all properties of weldments. processes other than welding. mination of stresses around rein-
5. Determine the mechanism and (a) Influence of prestrain on the forced openings.
causes of transverse weld cracking initiation of brittle fracture. 2. Creep buckling of steel plates
in high-strength steels. (6) Influence of residual stresses used in pressure vessel construc-
6. Further study of welding of on the initiation of brittle fracture. tion.
thick T-1, HY-80 and armor steel 15. Investigation of the factors 3. Analysis of transient thermal
using ferritic electrodes. which influence the properties of stresses and_ resulting residual
(a) With controlled interpass steels made to fine-grain practice stresses developed during and after
temperature. and determination of practical steps welding.
7. Determine the factors that other than spray quenching which 4. A study of the mechanical
limit ~the maximum possible yield can be used to improve mechanical properties of heavy weld deposits.
and tensile strength of as-deposited properties of commercially hot- 5. Further’ investigation and
multipass weld metal. This is a rolled material. evaluation of dissimilar metal welds
problem in welding all high-yield- (a) Influence of various deoxi- for high- and low-temperature
strength steels, e.g., 150,000 psi dizers on weldability. service.
yield, such as HY-150. 16. Determine if vacuum-melted 6. The study of stress concen-
8. Further studies of weld-metal bare welding rod and wire is essen- trations at the circumferential fil-
deposits with a high-hydrogen at- tial to produce high-quality welds let welds of girth joints between
mosphere welding process compared in vacuum-melted base material axially symmetric components of
with that deposited using low-hy- such as high-strength steels using pressure vessels, such as at head-to-
drogen welding processes such as the inert-gas-shielded arc welding shell junctures.
low-hydrogen covered electrodes, processes. 7. Techniques for induction pres-
inert-gas-shielded arc welding and (a) Study the effect of H, N and sure welding of carbon steel, stain-
the submerged-arc welding proc- O on thick steel sections, with par- less steel and high-alloy tubing
esses. ticular reference to flaking, cracking should be developed. Such pro-
(a) Determine the distribution of or reduction in ductility. The value cedures could be adapted to the
hydrogen in ferrite, bainite, mar- of vacuum - melting and vacuum- fabrication of heat exchangers.
tensite and austenite because no pouring in permitting deoxidation 8. A study of the effect of yield-
single theory has been universally with carbon rather than with silicon strength to tensile-strength ratio on
accepted. should be determined because of weldability, weld-affected zone, and
(6) Determine the relation of the important effect of reduction weldment properties in low-alloy,
diffusible versus nondiffusible hy- of silicate and sulfide inclusions high-strength steels. The opinion
drogen to cracking or reduced duc- on improving the notch toughness has been expressed that high-
tility. of the steels. This might be par- strength, low-alloy steels with yield
(ec) Are there any factors other ticularly important for welded pres- to tensile-strength ratios over 0.70
than pre- and postheat that can sure vessels and structures. necessitate higher safety factors
counteract the effect of hydrogen? (6) Determine if metallurgically because of reduced capacity for
(d) Determine the effect on crack- clean welding rod can be more con- plastic deformation. A systematic
ing of grain boundary alloy en- sistently and reliably produced by demonstration of the effect of vary-
richment of heat-affected zone of vacuum melting or by conventional ing yield-strength to tensile-strength
welds in high strength low-alloy melting practices. : ratios on the weldability of low-
steels. 17. Further studies to determine alloy, high-strength steels would
9. Determine the effect of dif- the reasons for delayed cracking in seem to be a worthwhile under-
fusible and nondiffusible nitrogen steel welds. taking.

§48-s | DECEMBER 1960

 9. Determine quantitatively the trodes having mechanical proper- strumentation for measuring three-
benefits of .overstressing, such as ties different from those of the base phase secondary current, voltage
hydraulic testing, in improving the metal. Under such circumstances, and power output more accurately.
notch toughness of pressure vessels. the yield strength of the base metal 8. A basic study of equipment and
Since the Japanese have done some and the electrodes differ. Influence procedures required for making wide
interesting work on this problem, it of these factors on the strength of seam welds so that seam welding
may be necessary to confirm or the connections needs further in- can be used for producing clad
supplement their findings. vestigation. metals.
6. Gusset design for tubular mem- (a) The study of welding pa-
Group I1l—Structural bers. The shape and proportions rameters, use of intermediate ma-
1. The study of intermittent of gusset plates for different loading terials and temperature pattern
welding of thin stiffening panels and conditions needs to be investigated. should be included.
plates is needed. The design cri- Strength and economy of joints for 9. Develop electrode alloys resist-
teria for such light steel structures tubular members have not received ant to alloying with Al- and Zn-
are not sufficiently developed. sufficient attention. A systematic coated steel.
2. The development of better experimental study of this problem 10. Develop “weld - through”
designs for transition sections in seems highly desirable. paints which have a minor inter-
structures. For example, structural 7. Effect of residual stresses on ference with welding.
members such as box beams that strength of welded connections.
are normally subjected to bending, This problem is particularly im- Group V—Study of Welding Arcs
column or torsion loads are also portant in proper selection of weld- 1. Investigation of arc stability
used to carry loads at some angle to ing sequence in such structures as and methods for stabilizing arcs.
the main load. The problem be- heavy plate girders, rigid frames, It would be worthwhile to study
comes one of not only designing as well as in stiffened plates. ionization potentials of the arc
for the extra load but also providing 8. Further studies to develop atmosphere, voltage gradients in
a suitable transition between the quantitative information on dis- the are column, the effects of current
bracket or pad and the main mem- tortion resulting when using various density, electrode materials and
ber. This problem is being en- welding processes and techniques. shielding atmosphere.
countered quite frequently as indi- For example, the cumulative effect 2. The possibility of arc heating,
cated by the fact that products are of numerous stringer beads, the when using a rapidly moving arc,
now being designed for welding that relative effect of large vs. small for example, up to several thousand
might be considered unrealistic if weld passes, the effect of high vs. inches per minute.
cast or forged because welding allows low welding speed, etc. 3. Investigate the influence of
such freedom in design. 9. Develop new types of rolled metal properties upon the welding
3. Performance of welded con- and formed sections that are es- arc, for example, the melting and
nections as a function of their pecially adapted to welded con- boiling points of the metal, the
rigidity. A number of variables struction. This will be of increasing thermal conductivity, the heat of
would have to be investigated such importance in the future in an effort vaporization, the ionization po-
as the number and type of welds and to reduce fabrication costs. tentials, etc.
the stiffness of the connection. 10. Determine the effect of tem- 4. An investigation of the ioniza-
This investigation is particularly perature and size of heated areas tion of the arc and of the nature of
significant for determining the be- used in localized removing of buckled the ions contributing to conduction
havior of the welds themselves in areas from plates and structural in various types of arcs would be
the elastic range, and for the com- shapes. valuable. Some of the problems
plete connection in the elastoplastic would be:
and plastic ranges. Group IV—Resistance Welding a) The source of the charge
4. Plates reinforced with stiffen- 1. Establish procedures and carriers, for example, electrode, base
ers of large torsional rigidity. When equipment for resistance cross-wire metal, covering or flux or gas shield.
hat or trough-type sections are welding of aluminum. b) Influence of the shield on the
attached to steel plates by welding, 2. A study of welding-current discharge. For example, include a
the composite stiffeners are very distribution in resistance butt welds study of arcs under inert gas and
rigid torsionally since a closed cross- in the area of the contacts used. in a vacuum chamber such as used
section is formed by this manner of 3. An investigation of the prob- for electron-beam welding.
fabrication. Further research on lem of stitching as influenced by the c) The nature of arcs using dif-
the effective stiffness of such or- design of the contact rolls and the ferent metal electrodes.
thotropic plates is needed to derive temperature relationships in con- 5. A study of the electrical con-
maximum benefit fron this type of tinuous tube welding. ductivity, surface tension and vis-
construction. Spacing of stiffeners 4. A study of time-temperature- cosity of welding slags up to arc
and the methods of welding them space-force relationship in the spot- temperatures, particularly slags used
to the plate are some of the im- weld area. for submerged-arc welding.
portant variables. a) Include a study of the effects 6. An investigation of the slag
(a) The orthotropic plates need of elevated and subzero tempera- metal reactions in submerged-arc
to be investigated for their behavior tures on the mechanical and metal- welding of stainless steel and high-
in compression, bending and shear. lurgical properties of spot welds. temperature alloys. This work
The problems of interaction of these 5. Development of information on would help to determine the ef +t
parameters is particularly important. the value of spring follow-up for of flux composition upon the effi-
(6) High-yield-strength steels and spot and projection welding. ciency of alloy transfer across the
aluminum should be included. 6. Development of information arc.
5. Strength of welded connections on ring-type projections of the 7. Fundamental study of arc
fabricated with different types of formed-ring, machined-ring and an- plasmas.
electrodes Occasionally it is neces- nular-ring types. 8. Further evaluation of the plas-
sary to weld members with elec- 7. Development of improved in- ma jet as a welding, cutting and

WELDING RESEARCH SUPPLEMENT 549-s

39073 | VEVCNWOOCN L1970N

heating tool. Group Vill—Nondestructive Testing materially reduced? Are they ini-
9. An investigation of the oxida- 1. Development of more rapid and tially damaging in ductile steel?
tion-reduction reactions in shielded economical nondestructive testing 5. Determine if preheating re-
arc welding atmospheres contain- methods. duces residual stresses in a simple
ing carbon dioxide and oxygen alone (a) Improvement in existing ra- welded structure in which reaction
or together with argon or helium. diographic methods and techniques stresses do not occur. This study
10. Fundamental investigation or new techniques such as_ back should determine what preheating
of the effect of magnetic fields and reflection using X-ray machines or temperature would be required and
causes of arc blow as a basis for radioactive isotopes. quantitative information on how
controlling it when welding with (6) A study of means for improv- much the stresses are reduced.
direct current. ing filmless radiographic techniques. An effort should also be made to
11. Investigation of causes of 2. Investigation of penetrant determine how much of the struc-
undercutting in high-speed welding. methods of nondestructive testing. ture must be preheated.
The basic phenomena, materials, 6. Determine if the improper use
Group Vi—Stainless Steel and High equipment, surface preparation, sen- of preheating would increase residual]
Alloys sitivity exposureand time parameters or reaction stresses in a welded
1. Further studies of the weld- should be investigated and stand- structure.
ability of heat- and corrosion-resist- ardized for the various penetrants 7. Investigate whether residual
ant castings to eliminate cracking. and types of defects. stresses influence the endurance
2. Basic research to determine the 3. A quantitative evaluation of limit of a welded structure subjected
causes of hot cracking in stainless the factors involved in magnetic to cyclic stresses, and if so, under
steel and nickel-base alloy welds. particle and ultrasonic testing pro- what conditions?
3. Development of quantitative cedures and equipment. 8. Determine if residual stresses
information on the value of stress Group |X—Residual Stresses can be properly placed in such a
relieving of welded stainless steels. manner as to increase the load-
4. Determine the relationship of 1. A study of possible uses of carrying capacity of columns.
vacancy and defect concentration in ultrasonic energy for the relief of
9. It is generally agreed that
the rapidly cooled weld-metal lat- residual stresses and for grain re-
residual stresses in a structure can
tice to porosity or microcracks. finement in the weld metal and heat-
be reduced by the application of
(a) Determine the effect of low affected zone.
loads on the structure. Under what
pressure of the shielding gas and 2. Determination of optimum
conditions is this true? Under what
the effect of the type or composi- stress-relieving procedures for welds
conditions do load stresses and
tion of the shielding gas or gas mix- and dissimilar metals or for weld
residual stresses add up? Is the
tures while welding in a vacuum overlays of austenitic stainless steel
reduction of residual stresses in-
chamber. on carbon steel. It would be worth
while to develop procedures for stantaneous? Can the relation be-
5. Determine effect of phosphorus tween residual stresses and applied
on the cold workability of welds in providing sufficient stress relief of
load be determined so as to permit
18-8 alloys. the carbon steel, if needed, with-
plotting a curve of residual stress
6. Type 316 weldments some- out damaging the properties of the
vs. applied load?
times suffer preferential attack at austenitic material.
3. Determine the role of residual 10. G. Welter of Ecole Poly-
the welds when subiected to hot technique has produced in the
acids. The cause of this attack stresses in delayed cracking of
welds. This would require an in- laboratory 400 or 500° improve-
should be investigated and methods ment in the fatigue life of a
devised for overcoming the problem. vestigation of when cracking occurs
and whether the cracks are in the spot-welded joint by hydrodynamic
7. Further development work is stresses. The Czechs have pro-
needed on the submerged-arc welding weld metal or base metal and if
they are parallel or transverse to duced improvement in the fa-
of high-nickel alloys and stainless tigue life of structural members by
steels. the weld.
(a) Distinguish between brittle introducing suitable compression
8. The welding of 25-12 and 25-20 stresses at points of stress concen-
chromium - nickel castings after and ductile material.
4. Develop the stress pattern for tration and British tests have veri-
prolonged exposure to tempera- fied the results of the Czech ‘in-
tures in the range of 1000 to 1500° F. a simple type of structure, such as a
flat plate 1 in. thick and 3 ft. vestigators. Can these improve-
9. Investigate the stress-corro- ments be counted upon to last
sion cracking tendencies of welded square having a longitudinal butt
weld in the center, in order to un- indefinitely under cyclic loads in
precipitation-hardening steels: 17—7 an actual structure or is the im-
to 15-7, AM350 to AM355, etc. derstand more about this problem.
The stress pattern would involve provement temporary? To what
the magnitude of the longitudinal extent can the designer rely on such
Group Vii—Fatigue stresses in the weld and base metals improvements?
1. Determine the effects of fluc- parallel to the weld and the magni- 11. In a structure such as a
tuating fatigue stresses on welded tude of the transverse stresses on pressure vessel, can residual stresses
joints and structures. the surface and within the material. be eliminated or reduced by hydro-
2. Fatigue strength of welded (a) In weldments of moderate static pressure or will the applica-
quenched and tempered steels. The thickness, 1 in. or more, it is known tion of pressure result in perhaps
effect of contoured weld-bead shape that residual stresses are of a complex even greater residual stresses around
should be included. nature and vary from tension to nozzles or other attachments?
3. Additional studies of fatigue be- compression throughout the thick- 12. Are residual stresses a con-
havior of large welded beams and ness and vary widely longitudinally tributory factor to strain-aging phe-
girders having thin webs. and transversely. Are these resid- nomena which occur in weld metal
4. Fatigue strength of dissimilar ual stresses affected by (a) time and in zones slightly beyond the
welds at low and high tempera- in service, (b) load applied? If so, heat-affected zone?
tures. what is the effect? Are they ever 13. Are residual stresses a factor

§50-s | DECEMBER 1960

in hydrogen embrittlement? means for measuring of distortion investigative attention is the un-
14. For structures in which during welding. predictable loss of strength and
neither dimensional stability nor (a) Development of procedures ductility in the thickness direction
stress corrosion is a factor, are to minimize or eliminate distortion in heavy plate. There is no stand-
residual stresses important when of components of thin-sheet ma- ard control test to reveal such a
no notch or stress concentrator is terial fabricated by welding. condition and to detect it until the
present (a) below transition tem- 12. Further studies of the appli- structure involved is close to com-
perature, (b) above transition tem- cation of ultrasonic welding for pletion. Biaxial anisotropy in thin-
perature? both spot and seam welding. sheet stock has been thoroughly
15. Determine if reaction and (a) The engineering design cri- investigated with reference to press-
local residual stresses are of the teria and _ limitations, manu- ing and deep-drawing operations.
same importance. If not, deter- facturing process specifications, and Perhaps such research work could
mine under what conditions one is quality control requirements should be extended to the third dimension
more important than the other and also be established for ultrasonic in heavy plate.
why. welding. Group Xi—Arc Cutting
Group X—General 13. Further exploration of the
1. An investigation of the gra-
use of electro-percussion welding.
1. A basic study of the nature of dient of hydrogen and nitrogen
This process should be particularly
weld-joint bonds and what the contents in arc-cut plate edges and
useful for joining small sections to
welding process basically consists their effect on quality of welds sub-
large sections but requires addi-
of. sequently made.
tional study.
a) The solid-liquid-atmosphere 2. Further studies of the inert-
14. Determine the relative ad- gas arc-cutting process to deter-
interface properties should be stud- vantages and disadvantages of
ied as well as the kinetics of weld- mine the effect of various types and
welded high-strength low-alloy mixtures of shielding gases and noz-
ability of liquid weld metal, surface steels, stainless steels. titanium al-
tension and the influence of impuri- zle shape on cutting rates and
loys and aluminum alloys for pres- economy.
ties and additions.
sure vessels subjected to high ex-
2. Basic research on _ solidifica
ternal pressures. Such information Group Xii—Aircraft and Missile
tion including a study of the mech-
is needed for use in design of deep- Problems*
anism of solidification in single-
diving submarines. 1. The joining of refractory
phase and poly-phase alloys under
welding conditions. 15. Further development of pro- metals using all joining processes
a) A study of the structure and cedures for joining zirconium alloys such as fusion, resistance, electron-
properties of very rapidly solidified to stainless steel. beam, solid-state welding and braz-
solid solutions and multiphase al- 16. Further development of pro- ing.
loys in fusion welds. cedures for joining titanium and 2. Establish optimum fusion-
3. An investigation of the effects aluminum alloys to carbon steels, welding methods and associated
of porosity and other weld defects low-alloy steels, and stainless steels. welding parameters for ““hot-work’”’
on the quality and performance of 17. Hard - surfacing alloys useful tool steels in both light and heavy
welds. for eliminating crevice corrosion in sections.
4. Hard-surfacing alloys fre- nuclear reactor cores should be de- 3. Welding of high-temperature
quently develop cracks when de- veloped. Alloys that have low alloys. A need exists for developing
posited. The effect of these cracks cobalt and boron contents are re- techniques and filler materials for
on the static and fatigue strength quired in order to minimize the welding precipitation and strain-
of the underlying base metal should neutron absorption and accessibility hardened alloys and still approach
be studied. problems. Many of the normal 100 percent joint efficiency.
5. A study of fusion-zone graphi- commercial hard-surfacing alloys 4. The development of pressure
tization of arc-welded cast iron as a cannot be used because they are bottles for use as high-strength
function of thermal variables in high in cobalt or boron. thin-walled rocket bottle cases.
chemistry. 18. Determine those characteris- 5. Nondestructive inspection
6. A study of shear failures in tics of a filler metal which would methods for evaluating brazed hon-
welded shear reinforcing for con- eliminate welding spatter. eycomb-sandwich structures.
crete beams. 19. A basic study of methods of
refining the weld-metal grain size Welding—General
7. The application of electron-
beam welding to joining skin to the during the welding operation would 6. Beryllium joining methods
butt of honeycomb and corrugated- be quite valuable. methods for welding and /or brazing
sandwich structures. 20. A study of the factors in- beryllium should be investigated.
8. A study of the possibility of fluencing stress-corrosion factors of 7. Investigate repair and removal
using an ultrasonic beam introduced various types of alloys. of parts from all-welded airframes.
into the weld puddle for preventing 21. Additional studies of diffusion A research program should be es-
columnar grain growth in austenitic bonding are needed. The basic tablished to study this problem
mechanism should be studied and with a view toward arriving at a
and nickel-base alloy welds, and
improving weldability and mechani- procedures should be developed. standard procedure for removal and
cal properties. a) Investigate and develop dif- replacement of sections to the air-
9. A study of weldability and fusion-bonding systems and _ tech- frame.
means of eliminating porosity in niques applicable to high-strength 8. Investigate the influence of
some welded copper-base alloys. high - temperature alloys for struc- surface films, oxides and coatings
tural applications at elevated tem- on spot, seam, flash, pressure and
10. Research in surface chemistry
as related to the wetting action and perature and at subzero tempera-
other physical and chemical phe- tures. * These aircraft and missile problems were also
nomena in brazing and soldering. 22. One fabrication problem published in the April 1960 Reports of Progress
of the Welding Research Council. The first five
11. Determination of accurate which has never received much vere considered the most urgent

WELDING RESEARCH SUPPLEMENT 551-s

ultrasonic welds in precipitation- construction—techniques for resist- 27. Develop the inert-gas-
hardening stainless steels, super ance-welded sandwich structures shielded consumable - electrode
alloys, die-tool steels, molybdenum, should be developed. As a second- spot-welding process to _ the
aluminum, magnesium and titan- ary structure, resistance - welded point where aircraft quality welds
ium. sandwich composites may be more can be consistently produced on
economical than brazed structures. high-strength steels and titanium
Fusion Welding 18. Investigation of the resist- alloys.
9. Study methods of making fu- ance welding of titanium alloys 28. Development of suitable
sion welds in the _ precipitation- and the establishment of shear- equipment that will furnish re-
hardening stainless steels, such as strength values for different gages of peatable settings for tungsten-arc
17-7PH, AM-350 and AM-355. alloys. spot welding ultra-thin gages for
Weld areas tend to change in metal- 19. Development of a spot-weld aircraft application.
lurgical structure to a degree that monitoring system which can be
frequently results in reduced duc- used on any type machine (a-c Brazing and Soldering
tility and reduced mechanical prop- single phase, 3-phase frequency 29. Brazing techniques and joint
erties. Many welds in these ma- converter or 3-phase direct energy) designs for use in elevated-tempera-
terials are planned for service in the and during welding any gage and ture hydraulic lines and _ hot-air
as-welded conditions. pile-up combination (up to at least ducting.
10. Investigation of exothermic six sheets). 30. Brazed sandwich structures
materials as heat source for pre- 20. Establish recommended sin- for application up to 2000° F
heating and postheating of weld- gle-spot shear strength for spot extensive research is required to
ments. welds in aluminum, magnesium, develop brazing techniques for the
11. Fusion welding of B120 V CA titanium, stainless steel and low- super alloys such as J-1650, R-235,
titanium alloy. alloy carbon steel for thickness Inconel X, etc., for application up
12. Weldability and _ operator combinations heavier than 0.125 in. to 2000° F.
qualification of new titanium alloys. 21. To develop and build spot- 31. Development of a method to
This would include weld-joint prep- welding equipment incorporating rework and repair brazed sandwich
aration, effect of multiple-pass hydrostatic pressure to be applied panels. This investigation should
welding, effect of joints having a during the process to increase fa- also include the joining of a sand-
self-chilling effect, establish if color tigue resistance of spot welds as wich-type structure to itself or to
may be used as a basis for indicating shown by work done at Ecole other conventional-type structures.
oxide contamination, criteria for Polytechnique. 32. Develop heat - treatable
certifying operators, etc. 22. Evaluation of electrode ma- brazed titanium honeycomb-sand-
13. Investigation of the effect terials for use in spot and seam weld- wich structures and base - metal
of weld-metal contamination by ing of high-nickel alloys. braze alloys for elevated - tempera-
brazing alloys on the mechanical Ultrasonic Spot and Seam Welding ture service.
and metallurgical properties of fu- 33. Investigate the brazing of
23. Ultrasonic spot and seam
sion welds in precipitation-harden- H-11-type hot-work die steels (in-
welding of refractory metals, in-
ing stainless steels and titanium. cluding sandwich structure).
cluding molybdenum, beryllium,
14. Establish techniques for fu- columbium, etc.
sion welding refractory metals such Flash and Pressure Welding
24. Investigation of ultrasonic
as molybdenum, tungsten and co- spot and seam welding of dissimilar 34. Development of a _ consist-
lumbium with methods easily adapt- base-metal combinations, such as ently reliable nondestructive method
able to production. molybdenum to stainless steel to for evaluation of flash welds.
15. Thorough investigation of titanium. 35. Evaluate the mechanical (in-
ultrasonic and pressure techniques 25. Investigation of ultrasonic cluding fatigue at subzero, room
for stress relief of large weldments and resistance spot and seam weld- and elevated temperatures) and
at room temperature. ing of super alloys, such as M-252 metallurgical properties of flash and
16. Development of a nondestruc- and Unitemp 500, etc. pressure welds in titanium alloys
tive test for fusion welds, other than such as 6AI-4V, 6Al-4Mo, etc.
radiographic, which is not influenced Arc-spot Welding 36. Evaluation of mechanical (in-
by changes in section thickness in 26. Fusion-spot welding—exten- cluding fatigue at subzero, room and
the weld or near the weld area. sive research is required in this area elevated temperatures) and metal-
to further the application of this lurgical properties of welds (fusion,
Resistance Spot and Seam Welding relatively new process in aircraft resistance, flash and pressure) in
17. Resistance-welded sandwich and missile fabrication. H-11-type hot-work die steels.

552-s | DECEMBER 1960

 WELDING CLINIC
J. Imperati and R. F. Pulver, Welding Engineers
The American Bross Company, Waterbury, Conn.

Spooled copper electrodes and Aircomatic Process

help simplify welding of heavy-duty connectors

Fabrication of copper cathode straps

and anode flexes for an aluminum pot-
line is simplified and expedited by
inert-gas consumable-electrode weld-
ing using spooled electrodes of Ana-
conda Copper-372. At the Reynolds
Metals reduction plant in Gregory,
Texas, one operator makes 12 welds
each about %” thick by 3” wide, in 12
to 15 minutes, using an Aircomatic
Model 21 torch, argon shield, and *”
diameter electrodes.

are subje ct to very high

temper itures The se are the Same ct nstruction as the cathode straps, shown at left below >
]
except that the flexible portion 1 longer

The connectors consist of solid cop has led to its widespread use, not only
pel bus bars joined by flexible pack for joining bus conductors, but for the
of 36 leavesof 24 B&S gage (0.0201” fabrication of pressure vessels and
3” wide copper strip. The joints are other equipment.. Anaconda Copper-
welded over carbon back-up plates 372 Welding Electrodes are available
Usually, welding of %” thick sections in sizes from .035” through %” on
requires the use ol single-, or double standard 25-lb spools.
vee grooves. Reynolds found that with
FOR MORE INFORMATION. Anaconda dis
inert-gas consumable-electrode weld-
ANACONDA COPPER-372 Welding Wire, ing, these butt joints can be made with- tributors will gladly help in the selec
layer-wound on standard 25-pound spools tion of the exact rod for your job. But
is carefully cleaned and shipped in a spe- out beveled-edge preparation by simply
spacing the edges 4” apart if vou have a special problem. Anaconda
cial carton. Supplied to Reynolds by Big spec ialists will be glad to he p vou. For
Three Welding & Equipment Co., Corpus The ease and speed of inert-gas con
sumable-electrode welding of copper this service, or a copy of Publication
Christi, Texas.
B-13, “Anaconda Welding Rods and
Procedures for Welding Copper and
Copper Allovs,” write Anaconda
American Brass Company, Waterbury
20, Connecticut. In Canada: Anaconda
American Brass Ltd., New Toronto,
Ontario. 6081I

ANACONDA
WELDING RODS
Made by
Anaconda American Brass Company
A SKID load of completed cathode straps ready for installation on the potline.
For details, circle No. 35 on Reader Information Card
AIRCOSPOT* TUFFSPOT AIRCOMATIC® SPOT .

as
If you want to spotweld from one side only, Aircospot is the number one gun for really precise light gauge work. For heavier
jobs, there’s the Aircomatic spot . . . and, for low-cost resistance spotwelding on light gauges, be sure to check Tuffspot.

SPOTWELDING, too, means AIRCO

...backed by the most experience

For spotwelding rail cars . . . or radar telescopes . . . or auto are produced by Airco. You can get them from your near-
frames—or anything in your operation—there’s Airco equip- est Airco office or Authorized Airco Distributor. Look in
ment to give you top results. your Classified Telephone Directory under “Welding Equip-
Spotwelders, shielded arc welding equipment, arc welders, ment and Supplies” for your nearest Airco representative.
gases, and a complete line of other welding equipment—all

On the west coast—

Air Reduction Pacific Company
AIR REDUCTION SALES COMPANY __ internationaiiy-
Airco Company International
A division of Air Reduction Company, incorporated In Cuba—
Cuban Alr Products Corporation
150 East 42nd Street, New York 17, N. Y. in Canada—
Air Reduction Canada Limited
More than 700 Authorized Airco Distributors Coast to Coast All divisions or subsidiaries
of Air Reduction Company, Inc.
For details, circle No. 36 on Reader information Card