APRIL, 1959

Welding

Journal

IN THIS ISSUE | yee j

FICIAL PUBLICATION
 SPEED YOUR PRODUCTION

with these Victor Cost-Cutters

DUPLICUTTER MODEL DC-2000 i. '

For cutting shapes —>

FLAME CUTTER VU-120

For straight and circle
cutting |

Victor Duplicutter, Model DC-2000 Victor Filame Cutter, Model VU-120

@ Duplicates shapes up to 1914" diameter e Cuts straight lines, square or bevel kerfs, circles
circles, 12" x 35” rectangles to 96” diameter
Holds tolerances of plus or minus | 64 Adaptable to submerged or inert arc automatic welding
in 2”) steel
Travels 0 to 180” per minute forward or reverse;
Templates easily changed, making practical both variable speed transmission provides full power over
long runs or a single copy entire range
Weight, 36 Ibs easily carried Free-wheeling neutral for easy positioning
Magnetized feet set on stock being cut Accommodates both 2 and 3-hose torches, with or
levelling needed without gear rack.
Uses Victor cutting tips thru size 5 Second torch holder available for parallel cutting

To see how Victor Cutting Machines can speed your production, ask your Victor
dealer for a demonstration or write us for descriptive Bulletin 353

Profitab/e dealerships open in a few areas; inguire now

ViIcIOR EQUIPMENI COMPANY

Mfrs. of welding & cutting equipment; high pressure and large volume gas regulators; hardfac-
ing rods, blasting nozzles; cobalt & tungsten castings; straightline and shape cutting machines

844 Folsom St., San Francisco 7 - 3821 Santa Fe Avenue, Los Angeles 58
1145 E. 76th St., Chicago 19
J. C. Menzies & Co., Wholly-Owned Subsidiary
For details, circle No. 1 on Reader Information Card
 a

Journal

Technical, Papers Welding of Equipment for the Dresden Nuclear Power Station, by William R. Smith .
Hampton Road All-Welded Steel Arch Bridge, by Wm — Powell Douglas A. A Nettleton ‘Milton F
Items and Elict and JoeC. Bridgefarmer. Soh ieeteuee
Maintenance Welding of High-Test Line Pipe, by A. M. Hill and F Ww Zilm
Reports Progress Report on the Flux-Cored CO. Welding Process, by A. F. Chouinard and J. A. Howery
Development of Welded-Steel Lathes, by Gordon M. Sommer.
The Welding of Inconel for Nuclear-Power Applications, by W. A Fragetta and G R Pease

Eight Miles of Welding on Cantilevered Plate Girders for Service Hangar, by Joseph Strauss
Practical Welder All-Welded Aluminum Boat Gives High-Speed Performance.....
and Designer Welded-Steel Flasks Prove Highly Successful, by R. P. Wolgast
Through Snow, Sleet or Swamp, by Web Purcell.
Tool Joints Surfaced with Tungsten-Carbide Particles......

Press-Time News... New Members. :

Society Welding Zones... News of the Industry.....
World-Wide Welding Nows.. Personnel.....
and Related Editorial—Everybody Can Win by Sidney Wade... Employment Service Bulletin.
Society News Abstracts of Current Patents
Events
Technical Papers Sessions—1959 AWS 40th Current Welding Literature
Annual Meeting and AIEE Electric Welding New Literature
Conference New Products.
Highlights of Exhibits at 1959 Welding Show.. Index to Advertisers
Section News and Events. Reader Information Card.

Welding Internal-Stress Distribution of Single Spot Welds in Relation to Their Fatigue Life, by G. Welter and A
Choquet _ 145-s
Research Effect of Residual Stress on Brittle Fracture, by Hiroshi Kihara and Koichi Masubuchi. . 159-s
Brittle-Fracture Tests of Stee! Plates Containing Residual Compressive Strain, by S. T. Rolfe, W. J. Hall
Supplement and N. M. Newmark....... 169-s
Cast-Pin Tear Test for Susceptibility to Hot Cracking, by F. C. Hull 176-s
Effect of Heat Treatment and Fabrication on Heavy-Section Pressure-Vessel Steels, by A. |. Rubin, J. H
Gross and R. D. Stout 182-s
Corrosion of Stainless-Steel Welds Formed with Carbon-Dioxide Shielding, by B E Hopkinson and D w
McDowell 188-s
Effects of Hydrogen Brazing on Properties of High-Temperature Alloys, by G. S. Hoppin 1 and E. N Son.
194-s
Quartz-Lamp Radiant Brazing of Titaaiom Alloy Honeycomb Sandwich Panels, by John F. Rudy, Robert M
Necheles and Harry Schwartzbart................ fs Be , .. 202-s

e American Welding Society. Publication ¢ e th and Northampton Streets, Easton

Published for the advancement 33 West 39th St., New York 1 ‘ Ss $8.00 per year in the
foreign countries $10.00. Single pies members $1.00
the science and art of welding privileges authorized at Easton, Penna. This publicatior l be 1 ed at the special
postage prescribed by Section 132 122. Copyright 1959, by tt merican plding Society. The Society
nsible for any statement made or opinion expressed in put ations Permission iS given to reprint
the American Welding Society jate of pub ation provided credit is given
 U. S. Steel Introduces Weldable
PRESS-TIME Vinyl-Coated Steel Sheet
From the research facilities of
U. S. Steel Corp. comes a new prod-
uct, vinyl-coated steel sheet. Pro-
duction of the material involves
curing and bonding of liquid viny]
plastisols to sheet steel in a continu-
ous coating process.
NEWSos

Products made of this material

... People can be fabricated in much the same
manner as cold-rolled sheet without
... Welding damage to the coating or effecting a
color change.
Liquid vinyl is applied in coatings
... Products
ranging from 0.008 to 0.020 in
thick. The coating thickness may
be specified in increments of 0.001
in. within this range.
Steel sheets are available in gages
from 18 through 28. Widths range
National Welded Products Month Proclamation
from 24 to 52 in., lengths from 30 to
Awaiting President’s Approval 144 in. It also can be supplied in
coils.
Vinyl-coated steel can be welded.
House Joint Resolution 179 ask- the month of April 1959 as ‘National Since vinyl itself is an insulator,
ing President Eisenhower to declare Welded Products Month,’ and in so current flow must be controlled
April “National Welded Product; doing I congratulate the more than from the back side. Four basic
Month” was introduced in Congress one million men and women who are welding techniques have been suc-
on January 2lst by the Honorable engaged in the art and science of cessfully applied to vinyl-coated
Frank Osmers, Representative from welding. I further urge all of our steel sheets. They are: stud weld-
New Jersey. citizens to join in observing this ing; capacitator-discharge; projec-
As the April JoURNAL went to tribute in appreciation of the con- tion welding; spring-loaded electrode
press, this proclamation had not yet tributions welding has made in welding; and magnetic-force weld-
been signed by the President, but modern industrial practice and to ing.
indications were that it would be the American way of life.” * Fields of application for vinyl-
signed within a few weeks. The coated steel sheets include the fol-
proclamation will probably read as lowing: automobile interiors, ap-
follows when signed: It is anticipated that the final text pliance cabinets, architectural prod-
of the proclamation will be available ucts, railroad car and bus interiors,
in time for the Chicago welding con- office and institutional fixtures, and
@ “Whereas our daily life and vention, April 6-10. furniture.
standard of living are improved by
the efficiency and reliability of
welded land, air and sea transport
equipment which carries us and our
needs swiftly and safely; and CHICAGO BECKONS VISITORS TO APRIL WELDING SHOW
“Whereas the household _ tasks
of the American family are speeded
and lightened by the welded stoves,
refrigerators and many other house-
hold appliances; and
**Whereas American industry
depends upon welded machinery
and equipment, and is powered by
the giant boilers and generators that
could not be built except by weld-
ing; and
‘Whereas our freedom and _ that
of the free world is guarded by air-
craft, tanks, missiles and men-of-
war in whose construction welding
makes a vital contribution; and
“Whereas welding technology and
welding inventiveness have ably
demonstrated their vital importance The waters of Lake Michigan add to the glitter of Chicago’s downtown skyline by night.
as the only means of fabricating This is but one of the sights in store for individuals planning to attend the AWS 40th An-
nuclear and space age components: nual Meeting and 7th Welding Show on April 6-10. Expected to be the largest welding
“‘Now, therefore, I, Dwight D. convention ever held, both in attendance and exhibit space, the 5-day program will in-
Eisenhower, President of the ciude many events of interest to everyone in the welding industry. Complete details
United States, do hereby designate on the entire program are published on Pages 365-379, 427 in this issue

296 | APRIL 1959

 HOBART

offers new

designs-greater

welding speeds
MODEL GO-2245-P
... bigger Savings aircooled combination
welder and power unit

CHOOSE from the finest, most

complete line of arc welding
equipment on the market today

DC ELECTRIC DRIVE DC RECTIFIER for

WELDERS for shop type welding,
production and production,
shop med maintenance. 7 §AY N F W/ - an d it

WELDS, RUNS TOOLS

LIGHTS, MOTORS
**CONTRACTOR'S AC/DC TRANS- :
4) 72 eve /
SPECIAL'* 250 omp. FORMER-RECTIFIER i a) .
gos drive model. combination for both
AC and DC welding.
@ It's powerful: sup @ It’s versatile: provides simulta @ It’s low in cost
300 AMP. GAS “a"% plies 200 D¢ amps neous lt 4 , rey at eveleli acm dalTametarl
DRIVE
purpose forwelding.
general
: : for welding
c on a welding, or 5 K full time / have made Hob
100% duty cycle ower when not welding tamous the

INCREASE PRODUCTION AND PROFITS WITH this new low cost “Power/Weld.” It
is the most versatile unit of its type on the market. Check these outstanding
NEW AUTOMATIC ARC WELDING features:
HEADS AND CONTROLS e DC WELDING RANGES from 30 to 225 amperes.
Inert Gas, CO,, and Sub- e 100% DUTY CYCLE: 200 amperes at 25 volts.
merged Arc welding heads
te set new standards for @ SIMULTANEOUS AC POWER: 1 to 2 KW while welding. Visit us at
fast, low cost—eoasily
accomplished automatic @5KW FULL TIME 110/220 VOLT AC POWER: when not BOOTH 601
oO { /, welds. welding, can permanently run shop and farm equipment, or National
*“*HANDOMATIC"’ an supply emergency power when you need it. Welding Show
easy-to-use semi-auto- a_i» /
matic submerged arc @ 5 RANGE SWITCH and rheostat for close control of welding April 7, 8, 9
welding unit. heat. Intl. Amphitheater
oo, ; =)
@ SHOP AND ROAD TYPE portable mountings available. Chicago, II.
©
Be sure to see and try this new Hobart “Power/Weld.”
**MIGARC"’ lightweight
<<
unit for semi-automatic HOBART BROTHERS COMPANY, BOX WJ-.49, TROY, OHIO * Phone FE 2-1223
Inert Gas Shielded arc “Manufacturers of the world's most complete line of arc welding equipment
welding.
SSSSSSSSSSSSSSHSSSSSSSSSSSSHSSSSSSEHS SHSHSHSSSHSHSSSHSSSHSSHSHSHSHSESHESSSSSSSSSSSSSESSESHESSSSESHESSEESESSEHESHEESESESCEOOOOSE

HOBART HOBART BROTHERS COMPANY, BOX W4J-49, TROY, OHIO * Phone FE 2-1223
LECTRODES Please send me complete details on the Hobart units I've checked:
mparison proves a
Power/Weld’’ [] Electric Drives [[] RC.Rectifier [] ‘‘Contractor's Special'’ [] AC/DC Combination
their superiority. ] Gas Drives Automatic: [] Submerged Arc [_] Inert Gas [] CO, Semi-Automatic: ] Migarc [_] Handomatic
Try them. There } Send complete cetalog on Hobart electrodes
ire new types of Name
rodes that help
0 speed welding Address
operations. City Zone State
For details, circle No. 3 on Reader Information Card
 WELDING ZONES

The 8700- to 8800-Ib Air Force Atlas ICBM now in orbit is

made entirely of light and thin stainless steel, except for the
satellite's large single rocket engine. The thin protective
skin of the 85-ft long missile also serves as the walls of
the propellant tanks, thus achieving an ultra-lightweight
structure. Convair recently disclosed the submittal to the
Government of an integrated space development plan which
Colorful blue gas flames painted on 95-ft high Horton utilizes the Atlas. The plan is based on the use of the power-
‘‘water-sphere”’ easily identify the new headquarters of ful Atlas booster to place satellites considerably heavier
Northern Illinois Gas Co.'s Joliet district. This welded tank, than the Soviet Sputniks in orbit. The Army’s ‘‘Explorer’’
which has a 40,000-gal capacity, was fabricated and erected satellites mount 13-0z blunt nose cones of thin-gage
by Chicago Bridge & Iron Co., Chicago Type 430 stainless steel. Another milestone in welding!

298 | APRIL 1959

 For Three Hose Cutting

Tor ches » » s SEPARATE REGULATION

oad
onPP

THE NEW TRIPLEX OXYGEN REGULATOR for three-hose

flame cutting torches.
Here is a brand new regulator combining into a single unitary body one high
pressure stage and two individually adjustable low pressure stages: one low pres-
sure stage to control the preheating flame oxygen and the other one for the high
pressure stream of cutting oxygen. The regulator is provided with two outlets,
three self-reseating relief valves to protect each individual stage and one inlet.
Three 214,” diameter gauges indicate respectively, the low pressure oxygen stream,
the high pressure oxygen stream and, the center gauge, the cylinder or cylinder
bank pressure. The regulator body and caps are machined of dense brass bar
stock, and all internal working parts are interchangeable with all other standard
regulators of comparable diameters made by our company. This new Model 5-121,
National Triplex Safety Regulator will be of interest to all companies operating
three-hose machine cutting torches — write for catalog FORM #16.

NAIIUNA welding eqUIpMENT COMPONY... 212 tremont street san francisco 5 caine

For details, circle No. 5 on Reader Information Card

WELDING JOURNAL | 299
 WORLD-WIDE WELDING NEWS

By Gerard E. Claussen

Bureau in the October 1958 WESTERN GERMANY

FRANCE
issue of Lastechniek. The bridge
Pressure Vessels Welded consisted of two welded main girders New Test Introduced to
for Atomic-Energy Plants 345 ft long, a welded box-section
arch, and a welded floor */s in. Analyze Residual Stress
An engineer in the French Navy thick, all made of ST 52 high-tensile A reliable indicator of residual
reports in the December 1958 issue steel. To hold the distortion of stresses in plain carbon steels was
of Soudage et Techniques Connexes the floor to a minimum, each section reported in the October 1958 issue
that consumable-electrode welding was welded as rapidly as possible of Schweissen und Schneiden. This
with argon containing 1% oxygen by 8 to 10 welders, each one starting new test for stress-corrosion crack-
produced welds and _ heat-affected in the middle and working toward ing is made in boiling 60% calcium-
zones in steel pressure vessels for the edges. ammonium-nitrate solution with a
atomic-energy plants having low circular-groove specimen 4-in. square
impact transition temperature. The and */, in. thick. The groove itself
electrode contained 0.12% C, 1.10% SOVIET UNION was */,, in. deep, '/» in. wide and 2
Mn and 0.50% Si and was used in. in diam. The length of cracks
on base metal containing 0.18% C, Improved Notch Impact with
on the front and back of the speci-
0.60% Mn, 0.19% Si and 0.60% Cr. Vacuum-Treated Bessemer Steel men was measured. Preheating up
Constant potential rectifiers were Vacuum-treated Bessemer steel to 480° F did not prevent cracking;
the preferred power supply, es- was found to exhibit higher notch however, of the two specimens
pecially for */.-in. diam wire. impact value than untreated Bes- tested at preheats of 660 and 840° F
semer stock in the heat-affected only one cracked. Cracking tests
Piping Welded at Natural-Gas zone close to the weld bead. This were investigated on welds produced
Purifying Plant same article in the October 1958 by oxyacetylene welding, bare and
issue of Svarachnoe Proizvodstvo fur- covered-electrode arc welding. No
The welding of piping and equip- ther states that vacuum treatment
ment up to 3 in. thick in steel lowered the oxygen content of the
containing 0.32% C and 0.75% Mn steel to 0.005%, compared with
at a natural-gas purifying plant is 0.027% in untreated steel. Nitrogen UNITED KINGDOM
described in the December 1958 and hydrogen contents were also
issue of the French magazine. Low- lowered, although not so extensively
hydrogen electrodes were used for as oxygen. Satisfactory notch
the root passes on the piping, while toughness in the heat-affected zone
rutile electrodes were used for the of submerged-arc welds was also
remaining passes. For heavy-wall maintained in oxygen-blown Bes-
pressure vessels, low-hydrogen elec- semer steel.
trodes were also used with 350° F
preheat. Columbium-stabilized 20
Cr 10Ni-3 Mo electrodes were used Boron Causes Hot Cracking
to weld the sheet lining of titanium- in Submerged-Arc Welds
stabilized Type 316 steel for scrub-
bers. Cracking tendencies were Hot cracking of submerged-arc
detected by fillet tests, while leak welds, exhibited in an alloy con-
tightness was examined by air- taining 19% Ni, 14° Cr, 2.5% W,
pressure tests. 0.9% Cb and the balance iron,
was caused by the presence, in
quantities as low as 0.005%, of
HOLLAND boron. As reported in the October
1958 issue of Svarachnoe Proi-
Description Given of Welding zvodstvo, the temperature of appear-
on Bridge Near Amsterdam ance of hot cracks in the heat-
affected zone in a bend test during
Some of the welding involved
welding fell from 2100 to 1850° F
in the Schellingwoude Bridge near as the boron content of the base
Amsterdam was revealed by a metal was raised from zero to
member of the Netherlands Bridge 0.015%. Low are energy tended
Dr. GERARD E. CLAUSSEN is associated with to prevent cracking in the presence Drag-line with tubular boom. (Courtesy
Arcrods Corporation, Sparrows Point, Md. of boron. of IIW)

300 | APRIL 1959

Try Linpe’s New “SIGMETTE” Torch!

-PORTABLE, COMPACT

WELDING CURRENT GUIDE TUBE

LOCKING KNOB
Guide tube locking knob releases guide
A R G 0 N G A Ss. tube for quick and easy replacement.

FEED ROLL

TRIGGER
Pull the trigger, and the flow of shielding gas
starts. Strike the wire to the work to establish
the arc and start wire feed. Release the trig-
er, and the entire operation stops
y ee WIRE SPOOL
Wire spool positioned for balance and
WIRE FEED MOTOR visibility. Holds .030, 3/64, or 1/16
in. aluminum wire, and .030 in. car-
bon steel wire
INCHING SWITCH

Here's the torch that goes to the job—lets you work in any
position ...1n confined spaces... at distance remote from
the power source!
Designed for Sigma welding of light metals, the “Sigmette”
torch is compact and sturdy. Notice the thin silhouette and
position of the spool for complete visibility. Torch and con-
trol are completely insulated and grounded —the operator is
protected from electrically “hot” parts. And the only main-
tenance tool needed is a screwdriver!
Find out how Linde’s new “Sigmette” torch can speed your
operations, bring new economies through its advanced de-
sign features. For a free demonstration and detailed informa-
tion, mail the coupon today or call the nearest Linde Office.
Complete unit —torch weighs 3 pounds, 1 oz.; control
Dept. WJ-4, Linde Company weighs 19 pounds, 2 0z.; Current rating, 125 to 200 amp.;
Division of Union Carbide Corporation Welding power, direct current reverse polarity
30 East 42nd Street, New York 17, N.Y.
Please send complete facts on the new “Sigmette™ torch
Please arrange to let me try it.
Name

ets ——_$_———— eK ——_—__— 5 UN Te). |

a tne FFRT Ate) =

For details, circle No. 7 on Reader information Card

WELDING JOURNAL | 301
NORWAY due to globular transfer were briefer
and more frequent with E6010 than
with E6015 electrodes. There were
still fewer and smaller short circuits
with the E6020 electrodes. The
spatter loss with E6010 electrodes
was almost the same from three
rotating generators of different
characteristics. Oscillograms with
the four types of dry rectifiers
were, in general, similar to those
obtained with the generators, except
that recovery from short circuits
was more rapid in the case of the
rectifiers.

AUSTRIA
Water Spray Behind the
Stainless-Steel Electrode
The range of conditions over
which it is possible to suppress sensi-
tization of unstabilized austenitic
0.28-in. thick stainless steel by
Building up a stainless-steel-layer for the Halden H. W. B. Reactor (Courtesy of 11W)
means of a water spray behind the
welding electrode has been sketched
in the December 1958 issue of
cracking was observed in the oxy- Lead Screens Used for Optimum Schweisstechnik. Steels of 18-8
acetylene-welded sample. The bare type, containing 0.08 to 0.10°; car-
X-ray Definition bon, were benefited to some extent
electrodes produced 10 in. of crack-
ing on both sides, while covered The use of lead screens to secure by the water spray. Lower or
electrodes produced 10-in. cracks on optimum definition with Indium higher carbon water cooling was
the weld side and cracks of 5 in. on 192 and Cesium 137 is discussed in ineffective.
the reverse side, with E6020, E6013 the December 1958 issue of Schweis-
and low-hydrogen electrodes. Aus- sen und Schneiden. Increasing the
tenitic electrodes also produced 10- thickness of the lead foil from 20 to
in. cracking on the weld side, but 150u increased the contrast and re- BELGIUM
cracks of only 1' . in. appeared on duced the exposure time with fine-
the reverse side. Cracking was grained film for pipe joints. Six Articles Describe Present
equally prevalent with low as well Welding Status in Belgium
as with high amperages. Postheat- Piping Backed by Forming Gas
ing at 930° F and higher tempera- A series of six articles, reviewing
tures prevented cracks, while heat- An article in the December 1958 the present status of welding in
ing at and below 660° F had no issue of Schweissen und Schneiden Belgium, appeared in the October
effect on cracking with either low- or recommends forming gas to back 1958 issue of Revue Universelle des
high-tensile steels. In addition, a joints in stainless and other alloy- Mines. L. Adam’s article on sub-
gradual decrease in cracking was ob- steel piping. Forming gas is a low- merged-are welding describes condi-
served between 660 and 930° F; cost mixture of 80°; nitrogen and tions for welding with one or two
time at temperature (15 min to 16 20% hydrogen and, although com- electrodes. Inert-gas welding is
hr) having little influence. bustible, is not dangerously explo- covered by A. Moreau, while the use
sive. A reducing gas, it promotes of cored electrodes in CO, welding is
wetting of the inside surface of the treated by F. G. Danhier. Mag-
German Welding Society Confirms netic-flux welding with and without
pipe near the root bead.
Russian Claims in Electro-Slag shielding gas is discussed by G.
Welding Doneux. E. Sellier presents a com-
prehensive review of ferrous and
The German Welding Society has ITALY nonferrous cutting of metals. This
supported the claims of Russian article illustrates several automatic
scientists for their unusually high Research Conducted cutting machines and describes the
rates of welding with the electro- on Arc-Welding Power Supplies characteristics of powder cutting
slag process in the October 1958 with limestone or iron, and of gas-
issue of Schweissen und Schneiden. Continuing his oscillographic re- shielded tungsten-arc cutting. In
The society’s Duisberg welding search on power supplies for arc the final article by W. Bonhomme
laboratory published results of data welding, Carrer compared, in the and G. Jasmin, the advantages and
which included radiographic studies October 1958 issue of Rivista Ita- disadvantages of deep-penetration
of the position of the electrode in the liana Della Saldatura, the behavior and high deposition-rate electrodes
pool of slag, as well as metallo- of E6010, E6020 and E6015 elec- are enumerated. Particular empha-
graphic and impact studies of the trodes on three rotating generators sis is given to the economics of the
weld metal and heat-affected zone. and four rectifiers. Short circuits electrodes.

302 | APRIL 1959

 ; Apri ‘

Visit The
AWS WELDING SHOW
Booth 530

Photo courtesy Chicago Bridge & Iron Co.

FOR WELDING

Low Alloy or High Strength Steels tesy Baldwin-Lima-Hamilton Corp.

With continually increasing fabrication costs, you can’t afford a margin Atom Arc 7018 Mo
for error. Successful fabricators specify the inherent qualities of all posi- AWS-E7018-Al
tion iron powder low hydrogen Atom Arc electrodes to reduce the un- Atom Arc 8018 N
AWS-E8018-C2
necessary rework that chews up profits and delays jobs.
Atom Arc 8018 CM
Inspection by X-ray is a requirement for most fabrications involving low AWS-E8018-B2
alloy or high tensile steels. There is an Atom Arc alloy with the right Atom Arc 9018 CM
physical properties and chemistry for welding most low alloy or high AWS-E9018-B3
tensile steels. An electrode that deposits X-ray sound weld metal, in- Atom Arc 10018 MM
AWS-E10018-D2
creases the efficiency of your welding operation and lowers your costs.
Atom Arc 12018 NMV
For complete details write for the “Handbook for Welding Low Alloy AWS-E12018-G
High Tensile Steels,” Alloy Rods Company, Dept. 03. P. O. Box 1828, Atom Arc T
York, Pennsylvania. AWS-E11018-G

QUALITY WELDING ELECTRODES FOR

Stainless Steel
Low Alloy Steels
Alloy Rods Company

Cast Iron
Tool Steel
YORK, PENNSYLVANIA bd EL SEGUNDO, CALIFORNIA Bronzes & Dissimilar Metals
Hard Surfacing Electrodes & Wires

NO FINER ELECTRODES MADE ANYWHERE

For details, circle No. 9 on Reader Information Card
WELDING JOURNAL | 303
How Ni-Rod “55”

builds up worn

cast iron...

keeps repair

cost down

When the owners of the M V Sun- Using Ni-Rod “55” Electrodes, they fraction of what replacement would
princess heard it would cost them welded cast iron inserts into posi- cost. What’s more, with Ni-Rod
over $7,200 to replace all six worn tion on the pistons to offset the worn “55”, the repair is done quickly and
ship pistons, they quickly called in areas. The pistons were pre-heated easily. Welds are strong, sound,
J & R Weir Ltd., Marine Engineers, to 500 F and each of the 6 inserts highly machinable.
Montreal. welded into position with two passes
These engineers in turn recom- by manual arc-welding. After weld- Keep Ni-Rod “55” in mind for
mended a Ni-Rod “55”* repair job ing, the pistons were covered with building up worn areas on cast iron
welding to be done by Welding asbestos to cool. Ni-Rod “55” elimi- parts. Even better, have a supply of
Engineers Ltd., Montreal. nated the need for post-heating. these electrodes on hand. Look in
Then the pistons were machined your classified directory under
Wear ran as high as ¥% inch on
and returned to the engine. “Nickel” for your local supplier.
some of the piston ring grooves. But
And write for “Repair Cast Iron
with Ni-Rod “55” Electrodes, weld- For your jobs Parts Quickly and Easily” for the
ors soon had all six pistons back in
Ni-Rod “55” can be used to build complete Ni-Rod “55” story.
the ship at a total cost of $2,450 —a
up worn areas in almost all cast iron
saving of over $4,750.
parts. Auto, truck, or ship pistons...
How they did the job valve seats ... cylinder walls... are THE INTERNATIONAL NICKEL COMPANY, INC.
with Ni-Rod “55” just a few. And the cost is just a

INCO WELDING PRODUCTS

electrodes «+ wires « fluxes
For details, circle No. 11 on Reader Information Card
304 | APRIL 1959
 Editorial

Everybody Can Win

All too frequently, we hear the resigned ex- attend the Welding Show should make every
pression: ‘‘Well, we can’t all win.” This is a effort to see understandingly the exhibits that
comforting philosophy to justify an easy way out. affect and concern them. The exhibitors are
In most cases, it need not be. spending a great deal of time and money to
For example, both buyer and seller benefit present their stories in three dimensions. Con-
equally in any good business deal. Neither does versely, those who exhibit should do their level
the other a favor and neither is imposed upon. best to enhance the effectiveness of their displays
The same truth is outstandingly illustrated in by manning them with people who know their
the annual AWS Welding Show. The visitor business, and by keeping them well organized
who attentively observes what is offered can’t and serviced right down to the final session.
help but be repaid many times over for the cost Exhibitors owe the man who comes to look and
of being there; the exhibitor who skillfully shows learn a good run for his money.
his products, processes or services can’t fail to In this kind of cooperative effort lies continued
regain his costs again and again in sales, prospects success and growth for the Welding Show. As
and prestige. visitor and exhibitor alike take out benefits com-
Unless both parties do their share, however, mensurate with what they put in, who can deny
these good results cannot be assured. Those who that ‘everybody can win” at the Welding Show?

Sidney Wade

CHAIRMAN, MANUFACTURERS COMMITTEE

AMERICAN WELDING SOCIETY

Welding

Journal
 CHINO SUREP

a el

LET

*
anything to which
attention is strongly
turned; a center
of attraction.

INDEED the center of attraction — The best and long-

est lasting rectifier ever placed in a welding machine

The mighty heart of the entire line of MILLER GOLD STAR similar devices? SIMPLE — MILLER research directed only to
WELDERS is the rectifier stack illustrated above. A MILLER a better and better rectifier FOR WELDING ONLY — MILLER
designed, MILLER built and MILLER guaranteed component — quality production control directed toward a uniformly high
one that has proven itself by establishing unprecedented per- standard product — MILLER production techniques involving
formance records in the only service in which you are interested extensive automation and electronic process regulation — and
arc welding MILLER “know how” gained as the largest producer of rectifier
We, too, are interested in no other service. For that reason type welders.
we have built, tested and retested welders utilizing every avail- For a more detailed treatment of this subject, you are
able rectifier — and every time the answer is still the stack invited to ask for a free copy of “‘A New Performance
illustrated above Record in Rectifiers,’ written by our director of research,
And the “secret” why this rectifier stack is superior to other G. K. Willecke.

*
| a Electric Manufacturing Company, Inc. arecer ON, WISCONSIN
EXPORT OFFICE 250 West S7th St New York 19, N.Y. © Distributed in Canada by Canadian Liquid Air Co., ltd , Montreal
For details, circle No. 13 on Reader Information Card
306 | APRIL 1959
New welding developments made possible the construction of the Dresden Nuclear Power Station

Welding of Equipment for the Dresden

Nuclear Power Station

Materials, processes, and quality-control methods employed in the fabrication

of the equipment in the nuclear portion of the plant are described

BY WILLIAM R. SMITH

ABSTRACT. The Dresden Nuclear Power Station is wealth Edison Co. Associated with the Common-
being constructed about 50 miles southwest of Chicago. wealth Edison Co. is the Nuclear Power Group, Inc.,
The service requirements of this plant necessitate the
employment of a variety of materials and, in turn, many consisting of : American Electric Power Service
welding processes and methods. Several new and Corp., Central Illinois Light Co., Illinois Power Co.,
unusual—as well as conventional welding techniques Kansas City Power and Light Co., Pacific Gas and
and applications are employed to produce the maximum Electric Co., Union Electric Co. of Missouri, and the
integrity and reliability in the nuclear system. This Bechtel Corp.
paper describes the materials of construction, welding
materials, welding processes, and quality-control meth- The Dresden Station, which is located approxi-
ods employed in the fabrication of the equipment in the mately 50 miles southwest of Chicago on the Illinois
nuclear portion of the plant. Schematic drawings and River at the confluence of the Des Plaines and Kan-
photographs are employed to help describe the fabrica- kakee Rivers, is rated at 180,000-kw net electrical
tion and welding of the equipment.
capacity. This dual-cycle “boiling-water reactor”
Introduction produces primary steam at 1000 psi and secondary
The Dresden Nuclear Power Station—the largest steam at 500 psi.
all-nuclear power plant in this country and entirely This important milestone in our technological his-
financed by private industry——is being designed and tory is only made possible by the rapid progress
constructed by General Electric Co. for the Common- made by the welding industry in the development
of new welding materials, new welding processes,
WILLIAM R. SMITH is associated with the General Electric C« and application of new welding techniques to meet
Atomic Power Equipment Department, San Jose, Calif
the requirements of new industries.
Paper to be presented at AWS 40th Annual Meeting in Chicago, Ill
April 6-10, 1959 A nuclear-power plant requires a system having a

WELDING JOURNAL | 307

 EMERGENCY PRIMARY STEAM PIPING
CONDENSER PRIMARY UNLOADING
STEAM LINES SYSTEM TURBINE -CONVENTIONAL MATERIALS WITH
CERTAIN EXCEPTIONS
PRIMARY
STEAM ORUM

SECONDARY — CONDENSER - ruse PHOSPHORIZED ADMIRALTY

STEAM LINES UBE SHEETS-MUNTZMETAL
SHELLS”~CARBON STEEL
+ HOTWELL
STAINLESSTRAYS
STEEL & BAFFLES—
FROM
- SECONDARY
FEEOWATER
HEATERS MATERIAL SPECIFICATIONS
UNLOADING = | {@%=*F5F3 CARBON STEEL-ASTM A106
SYSTEM GENERATORS a PIPE A2i2 PLATE
PuMPS = 3S LOW ALLOY-ASTM A302
FROM PLATE Ai55 OR A335 PIPE
PRIMARY ——— low ALLOY CLAD-ASTM A302
FEEOWATER gap worn A304(006 C
REACTOR HEATERS
CLEAN-UP 3 STAMNESS STEEL-ASTM Ai67
SYSTEM LATEASTM A3i2 OR
A3se°
TUBES PIPE ASTM A249
“NOT CODE APPROVED
TO WASTE ‘. » -DEMINERALIZER
> DISPOSAL
SYSTEM FEEDWATER SYSTEM (INCL PIPING, FLASH
SHELLS, & DRAIN LINES) CARBON STEEL TANKS, PUMPS-P-|,P-2,P-3,-CONVENTIONAL MATERIALS
Fig. 1—Schematic flow diagram shows Fig. 2—Schematic drawing shows the materials employed
the major reactor-plant equipment in the construction of the steam-supply system
which is contained in the reactor
containment sphere

high degree of integrity free of maintenance prob-

lems. An all-welded system is necessary in order to
Fig. 3—Schematic drawing of
satisfy this requirement. the reactor vessel and core
The major reactor-plant equipment is contained assembly. The cut-away
in a 190-ft diam carbon-steel sphere. The nuclear shows the reactor core and
equipment consists of such major items as: the reac- the vessel internals
tor pressure vessel, the primary steam drum, four
secondary steam generators, four reactor recirculat-
ing pumps, the emergency condenser, the reactor
coolant cleanup heat exchangers, and the nuclear
steam-supply-system valves. This equipment is all-
welded construction fabricated in accordance with
the ASME Boiler and Pressure Vessel Code and
applicable cases. The reactor-core assembly also
employs welding in its construction.
The fabrication and erection of piping and the decay heat of the fuel elements is dissipated by a
welding of the containment sphere for the Dresden separate cooling system.
Nuclear Power Station are subjects for other papers. A reactor cleanup system is provided to maintain
the desired water purity in the primary recirculating
Nuclear System loop. A reactor “‘poison system”’ is provided as a
The steam-supply system (Figure 1) is contained backup safety system to poison the reactor in the
in the reactor containment sphere. The steam-water unlikely event that the control rods fail to scram.
mixture produced in the reactor core flows from the
reactor vessel to the primary steam drum where the System Materials
steam and water are separated. The steam flows to In general, stainless-steel materials are employed
the turbine through the primary steam lines and the for all surfaces in contact with the primary water and
water flows from the primary steam drum to the reac- steam during operation. Chrome-molybdenum steel
tor recirculating pumps, which force the water is used for the primary steam piping from the steam
through the tubes of the secondary steam generators drum to the turbine, and carbon steel is used in the
and then back into the reactor vessel. Secondary secondary system. The unloading cooling system,
steam is produced by extracting heat from the re- which is used only when the plant is out of service,
circulating water, and flows into the turbine through employs stainless-steel materials on the reactor side
the secondary steam lines. The primary steam is of the shut-off valves, and carbon steel in the re-
produced at 1000 psi and the secondary steam at 500 mainder of the system. Carbon steel is used through-
psi. An emergency condenser is provided to remove out the main steam and condensate system with a
the decay heat from the reactor in the event that the few exceptions. The turbine metals are conven-
main condenser of the plant is not available to re- tional materials for the rated steam temperature and
ceive steam. During the refueling operation, the pressure except, in general, alloys of higher chromium

308 | APRIL 1959

 Fig. 5—Welding the first six 16-in. outlet nozzles to the 6'/;-
in. thick course. This section was stress relieved when the
welds were about 50% complete. The alternate six nozzles
were attached after completion of welding the first six
nozzles

Fig. 4—The 16-in. outlet nozzle course with the special nozzle
preparation shown in the foreground and a partially welded
nozzle in the background. The stainless-steel transition
piece can be seen at the end of the nozzle

content are used in areas most susceptible to erosion

and corrosion. The condenser materials are essen-
tially conventional, being carbon-steel shell, Muntz-
metal tube sheets, and Admiralty-bronze tubes. The
feedwater heaters are carbon steel with copper-nickel
tubes being used in the bottom feedwater heaters,
and Monel tubes in the three top feedwater heaters to
provide adequate corrosion resistance. The stain-
less steel of the primary system begins at the shut-off
valve following the last feedwater heater in the pri-
mary stream. Figure 2 provides a brief summary of
the materials employed in the system.
Nuclear Equipment
Reactor Vessel
The reactor vessel is 12 ft-2 in. 1D, approximately
42 ft high, and weighs approximately 350 tons.
Fig. 6—The last girth weld is being made by the automatic
Figure 3 is a schematic drawing showing the general submerged-arc process to join the top course and vessel
design of the unit including the core assembly. flange to the 16-in. nozzle course. The 10- and 16-in. outlet
The vessel is fabricated of manganese-molyb- nozzles are capped in preparation for hydrostatic-pressure
denum steel which is internally clad with */;-in. testing
thick austenitic stainless steel. The shell consists of
eight courses or ring sections. Seven courses were
fabricated from two hemi-cylinders which were hot 5'/, in. thick, except the bottom-head cap piece,
formed from 5',;-in. thick SA302B plate. The which contains the control-rod penetrations. The
course in which the twelve 16-in. outlet nozzles were 9-in. thick bottom-head cap piece, the top-head
installed was made in four sections of 6'/.-in. thick flange, the vessel flange, and the nozzles are SA336
SA302B plate. Three nozzles were attached to each Grade F1 forgings.
quadrant and the nozzle opening and reinforcement The vessel internal structure for supporting the
were formed in the plate by a special forging operation reactor core was fabricated from Type 405 ferritic
to enable the nozzle to be butt welded to the rein- stainless steel. A ferritic stainless steel was em-
forced penetration. This unusual method of attach- ployed for the internal structure because the thermal-
ment was necessary due to the close spacing of the expansion characteristics are similar to those of the
nozzles. The nature of the 16-in. nozzle penetra- SA302B vessel material.
tions is shown in Fig. 4. The seven shell courses were clad with Type 304
The top and bottom hemispherical heads were austenitic stainless-steel plate by a hot-rolling proc-
fabricated from spherical segments of SA302B plate ess. The course containing the 16-in. nozzles (Fig.

WELDING JOURNAL | 309

 5), the top and bottom heads, and the nozzles were
clad by manual metal-arc welding employing E312
electrodes for the first pass layer, and E308 ELC
electrodes for the subsequent layers. The flanges
and weld seams were weld clad using the automatic
a-c series submerged-arc process employing Type
ER312, 29 Cr-9 Ni, wire for the first layer, and
ER308 L wire for the subsequent layers.
The flange faces were clad with special wire by
the inert-gas-shielded metal-arc process to provide
a hardenable surface in the grooves and on surfaces
in contact with the stainless-steel ‘“‘O”’ ring seals.
The longitudinal and girth seams were made by
the automatic submerged-arc welding process (Fig.
6) employing wire and flux which provided welds
having mechanical properties equivalent to those of
the base metal. The head segments (Fig. 7) were
welded by the shielded metal-are process.
Fig. 7—Welding
the top head to the head-flange forging. The nozzles were welded to the vessel by the
The insulation is necessary to maintain the metal at the shielded metal-arc process. All shielded metal-arc
required preheat temperature welding of the-manganese-molybdenum steel was
performed with Type E8016 electrodes, because the
mechanical properties of weld deposits with these
electrodes are similar to those of the base metal.
A Type 304 stainless-steel transition piece (Fig. 4
was welded to each nozzle thus eliminating the neces-
sity of making dissimilar-metal joints in the field.
These welds were made by weld cladding the ends of
the nozzles and then welding the transition piece to
the nozzle by the shielded metal-arc process using
Type E308 electrodes. The vessel internal struc-
tures fabricated of Type 405 stainless steel which
were heat treated with the vessel were welded by
the shielded metal-are process using Type E430 elec-
trodes; those parts not requiring heat treatment
with the vessel were welded using Type E312 elec-
trodes.
Preheat temperatures ranging from 250 to 400° F,
depending upon size and location of the weld, were
employed during all welding of the manganese-
molybdenum steel. Intermediate stress-relief heat
treatments at 1150° F were performed on some joints
after the welding was partially completed. The
preheat temperatures were maintained from the start
of welding until the weldment entered the stress-
relieving furnace. These preheat and _ postheat
treatment procedures were found to be necessary to
insure the prevention of fusion-zone cracking of the
manganese-molybdenum steel.
All welds were inspected in accordance with ASME
Boiler and Pressure Vessel Code, Section I, and Code
Cases 1224 and 1234. All pressure-holding welds
were 100% radiographed, all ferritic welds were
magnetic-particle inspected, and all austenitic welds
were liquid-penetrant inspected. All clad surfaces
were ultrasonically tested to insure bonding, and all
clad surfaces were fluid-penetrant inspected to insure
freedom from cracks and other defects.
Fig. 8—The primary steam drum being rigged for raising Primary Steam Drum
to its permanent position near the top of the reactor
containment sphere The primary steam drum is 7 ft 10 in. ID, 67 ft long,

310 | APRIL 1959

 a:A F > fey"e.
4 *? Mi
PidCAL, >
° i
oe alee
Fig. 9—The longitudinal and girth seams of the steam drum were welded by the submerged-arc process. This
view shows the joining of two halves of the drum. Most of the nozzles had been attached

Fig. 10—The steam drum being withdrawn from the heat- Fig. 11—The steam-water separating apparatus was installed
treating furnace after the final stress-relief treatment. The in the primary steam drum before the vessel head was
steam-separating apparatus and one head was installed welded. The final girth-seam weld attaching the head was
subsequent to this heat treatment stress relieved by a local heat treatment

and weighs approximately 185 tons. Figure 8 shows photograph of a circumferential weld being made
the steam drum being erected in the reactor contain- joining two halves of the drum. Preheat and post-
ment sphere. It was fabricated of manganese- heat stress relieving were essentially the same as
molybdenum steel. The shell was fabricated from those used for the reactor vessel. Figure 10 shows
3°/,-in. thick SA302B plate, internally weld clad by the drum being removed from the heat-treating fur-
the a-c series submerged-arc welding process, nace.
employing essentially the same material as those All of the steam separating apparatus (Fig. 11)
used for weld cladding the reactor vessel. The longi- was fabricated from Type 304 stainless steel. The
tudinal and girth seams were made by the automatic welds and cladding were inspected in the same man-
submerged-arc welding process. Figure 9 is a ner as those in the reactor vessel.

WELDING JOURNAL
| 311
 Fig. 13—The bottom head of one steam generator being weld
clad by the a-c series submerged-arc welding process. The
primary steam drum and portions of the reactor vessel were
clad by the same welding process

Fig. 12—A cut-away of one of the four steam generators

shows the primary steam circulating water inlet and outlet
at the bottom. The inverted tube bundle is shown by the Fig. 14—The tubes are welded to the primary or weld-clad
cut-out of the outer shell on the secondary side of the side of the steam-generator tube plate by a special semi-
generator automatic inert-gas-shielded tungsten-arc apparatus em-
ploying a special joint preparation without the addition of
Secondary Steam Generators filler metal
The four secondary steam generators were fabri-
cated of carbon-silicon steel SA212 Grade B. The The tubes are welded to the weld cladding of the
primary side, bottom head, and tube plate were weld tube plate by a specially designed joint and a special
clad by the same method as the primary steam drum. torch employing the inert-gas-shielded tungsten-arc
The heat-exchanger tubes are '/, in. diam 0.050-in. process. The tube protrudes above the tube sheet
wall, Type 304 stainless-steel welded tubes produced and a filler lip is machined into the tube sheet sur-
in accordance with specification SA249. face. This lip is fused to produce the desired weld
Figure 12 is an artist’s conception of a steam contour without the addition of filler metal. Figure
generator with cut-away section showing the primary 14 is a photograph of a tube sheet being welded, and
steam circulating water inlet and outlet at the bot- Fig. 15 is a cross section through a welded tube-to-
tom, and the inverted tube bundle is shown by the tube-sheet joint demonstrating the weld penetration
cutout of the outershell. The weld cladding of the and uniformity obtained by this welding method.
primary, bottom head is shown in Fig. 13. All welds and cladding were inspected in essentially

312 | APRIL 1959

Fig. 15—This enlarged cross section shows the weld
penetration and uniformity of welds joining the tubes
to the tube sheets of the steam generator

Fig. 17—An assembled 18-in. gate valve. The body is cast

Type 304 stainless steel. The internal guides and seats
were welded employing shielded metal-arc and inert-gas-
shielded tungsten-arc processes

E7018 electrodes. The shop welding was performed

by the submerged-are and shielded metal-are proc-
esses employing E7016 electrodes.
Reactor-Coolant Cleanup Heat Exchangers
The reactor-coolant cleanup system consists of two
Fig. 16—The pump volute, a stainless-steel cast weldment, primary systems, each consisting of two heat ex-
of one of the four recirculating pumps is mounted on a weld- changers. These horizontal heat exchangers were
ing positioner. The root pass of the weld joining two halves fabricated of essentially the same materials as the
has been completed vertical steam generators and in a similar manner.
The shells and secondary sides are carbon steel, the
the same manner as those in the reactor vessel and primary sides are clad with stainless steel, and the
the steam drum. The tubing was inspected by eddy- tubes are Type 304 stainless steel.
current testing. Recirculating Pumps
Emergency Condenser The four recirculating pumps are of the canned
The emergency condenser referred to in the main rotor type. The design is such that by breaking a
flow diagram (Fig. 1) is fabricated of SA212 Grade B bolted flange, the entire motor and internal pump
carbon-silicon steel prefabricated in sections and assembly may be removed for maintenance without
erected in the field. The primary side consists of disturbing the welded connections to the pump
two tube bundles fabricated of Type 304 stainless- volute in the pipe line.
steel pipe and tubing in accordance with specifica- The pump volute (Fig. 16) is a cast weldment of
tions A358 and A213. The field welding was per- Type 316 stainless steel conforming to SA351 grade
formed by the shielded metal-arc process employing CF8M. The volutes were cast in two halves and

WELDING JOURNAL | 313

< RN
a> Pa eeal eat me =
 Fig. 20—A horizontal section of the core showing the relation
of the fuel assemblies and control rods

Fig. 18—Hard-surfacing metal being applied by the inert-

gas-shielded tungsten-arc welding process to the face of
a seat ring for an 18-in. gate valve

HELIUM FILLED VOID ( ae

Fig. 21—A Zircaloy-2 fuel channel which was formed

in two ‘‘U"’ shaped halves joined together by
two longitudinal butt welds
a
forming to SA351 Grade CF8. Figure 17 is a photo-
graph of a typical 18-in. valve, and Fig. 18 is a photo-
eo CLADDING TUBE graph showing a valve seat being hard surfaced by
the inert-gas-shielded tungsten-arc welding process.
The castings and welds were radiographed 100°,
Fig. 19—A fuel rod segment showing a uranium oxide pellet, and inspected by the fluid-penetrant method on all
Zircaloy-2 tube and end plugs surfaces.
Reactor-Core Assembly
welded together. The root pass was welded by the Fuel Assembly
inert-gas-shielded tungsten-arc process, and the The basic fuel ‘‘building block”’ is slightly enriched
welds were completed by the shielded metal-arc uranium dioxide fabricated as a sintered, solid, cylin-
process employing special electrodes which deposited drical pellet ('/, in. long by '/2 in. in diam). A
welds having ferrite content of about 12°. The series of these pellets is encased in a tubular Zircaloy-
castings had a ferrite content of about 15%. 2 jacket (Fig. 19) with 0.030-in. wall thickness, to
The castings and welds were radiographed 100°; form a 28-in. long rod. The end plugs are welded to
and all surfaces were checked by fluid-penetrant the tube and consist of a male threaded connector at
inspection. one end and a female threaded connector at the
Nuclear Steam-Supply System Valves other. Welding is performed by the _ inert-gas-
About 40 valves were installed in the recirculating shielded tungsten-arc process, without the addition of
and primary steam-supply system. These valve filler metal, in a closed welding box filled with helium.
bodies are Type 304 stainless-steel castings con- Four such fuel-rod segments are joined by Zirca-

314 | APRIL 1959

 \\

wi GRAPPLING
FIXTURE rue clus

_ZIRCONIUM
~~" CHANNEL

~~... UO.
PELLETS BOTTOM SUPPORT PLATE
Fig. 23—Reactor-core assembly
FUEL showing the fuel assemblies b>
RODS arranged in the core being
supported by the bottom
4 core support plate
Fig. 24—A poison section of one of 80 control
rods fabricated of austenitic stainless-steel
Fig. 22—One of 488 fuel assemblies plate containing 2% boron
which provide the energy
for the nuclear reactor

loy-2 screw connectors to make up the basic 9-ft-9-

in. rod. The adjoining shoulders formed by abut-
ting rod segments provide seating surfaces for spacer
plates which hold each rod in proper alignment.
Each fuel assembly (Fig. 22) consists of 36 of these
cylindrical fuel rods (Fig. 20) in a square array (ar-
ranged in 6 rows of 6 fuel rods each) encased in a
square Zircaloy-2 channel. All fuel rods terminate
in a common support or transition piece located at
the lower end of the assembly. The resulting fuel
bundle fits into a channel unit (Fig. 21) which is
formed of ') ;,-in. thick Zircaloy-2 strip in two “U”’
shaped halves joined by two longitudinal butt welds
by the inert-gas-shielded tungsten-arc process, with-
out the addition of filler metal, in a welding fixture.
The core consists of 488 fuel assemblies. The bot-
tom transition piece at the bottom of the fuel bundle
fits into a mating hole (Fig. 23) in the core support
plate.
Reactor Control Rods
The position of the control rods relative to the
fuel-assembly arrangement in the core is shown in
Fig. 20.
The control rods, 80 in number, are austenitic
stainless steel, nominally 18° chromium and 12%
nickel, containing 2.0°% natural boron as the nuclear
poison material. The rods have a 6.5-in. cross-
shaped cross section (Figs. 20 and 24), and they enter Fig. 25—A control-rod guide tube which was formed in two
halves joined together by two longitudinal butt welds. The
the core from the bottom and travel between fuel guide tube provides a channel for the control rod below the
channels. Their withdrawn position is below the core support plate
core; their upward movement decreases reactivity,
their downward movement increases it. The control rods are fabricated of three */,-in.
The control rods are spaced 9.96 in. apart within thick flat plates joined by chain intermittent welds
an 8-ft-3-in. diam cylindrical space in the central (Fig. 24) performed by the shielded metal-arc proc-
region of the core. The rods have an 8-ft-6-in. ess employing E312 stainless-steel electrodes. The
poison-section length and an 8-ft-10-in. travel. The guide tubes are fabricated from s-in. thick Type
rods are guided by the four adjacent fuel assemblies 304 stainless-steel plate. Two halves are formed and
in the reactor core and are guided below the core sup- subsequently joined by the inert-gas-shielded tung-
port plate by special cross-shaped tubes (Fig. 25 sten-are process, without the addition of filler metal,
termed guide tubes. in a welding fixture.

WELDING JOURNAL | 315

Pe
 Fig. 26—The circular holes in the core support plate provide Fig. 28—The core guide grid was fabricated to close
water passage through the fuel assembly and cross-shaped dimensional tolerances requiring special joint design,
holes provide entry for the control rods. The plate is 3 in. weld programming, and fixturing
thick and 11 ft in diam. All machining dimensions were
critical, with close tolerances being maintained
an upper core-guide assembly. Fuel assemblies rest
on the core bottom support plate and are held in
transverse alignment at the top by the upper core
guide (Fig. 26).
The core support structure is fabricated of Type
405 ferritic stainless steel welded by the shielded
metal-are process with E312 electrodes. The bottom
core support plate (Fig. 27) is 11 ft in diam and 3 in.
thick. The grid support is fabricated of one-inch-
thick plate joined by fillet welds, whereas the upper
core guide (Fig. 28) is fabricated of */;-in. thick plate.
Quality Control
All pressure vessels in the nuclear system were
fabricated and tested in conformance with the ASME
Boiler and Pressure Vessel Code, Section I or Section
VIII, and Code cases 1224 and 1234. All pressure-
holding welds were radiographed, ferritic welds were
magnetic-particle inspected, and austenitic welds
were fluid-penetrant inspected. The tube bundles of
the steam generators and heat exchangers were
checked for leakage with a helium mass spectrometer
and all vessels were hydrostatically tested.
The fuel rods are tested for leaks, the welds are
radiographed and the segments are autoclaved in
steam at 750° F and 1500 psi for 72 hr to check the
corrosion resistance of the Zircaloy-2 jackets
Fig. 27—The core support plate rests on the support grid Acknowledgment
which was fabricated of 1-in. thick Type 405 stainless-steel
plate The author wishes to express his appreciation to
the following industrial firms for permission to
present the information contained in this paper:
Core Support Plate and Grid Assembly New York Shipbuilding Corp.; Foster Wheeler
The bottom support plate rests on a ring girder, Corp.; Yuba Industries; Electric Steel Foundry
which in turn is supported through columns attached Co.; Byron Jackson Division of Borg-Warner Corp.:;
to the reactor-vessel bottom. A cylindrical core- Chapman Valve Manufacturing Co.; Willam mette
guide support, which also acts as a thermal shield, Iron and Steel Co.; Multitek Co.; Atomic Power
rests on the ring girder at the bottom and supports Equipment Department, General Electric Co.

316 | APRIL 1959

The Hampton Road all-welded steel arch bridge, as seen from the Dallas-Fort Worth Turnpike

Use of welding permits the rapid and economical fabrication and erection of the

Hampton Road All-Welded Steel Arch Bridge

and produces a structure of especially pleasing aesthetic appearance

BY WM. LLEWELLYN POWELL, DOUGLAS A. NETTLETON,

MILTON E. ELIOT AND JOE C BRIDGEFARMER

SyNopsis. The Hampton Road crossing over the Construction. A description of the erection procedures,
Dallas-Fort Worth Turnpike is a four-rib, 2-hinged, all- from initial layout to the completed structure, includes
welded steel structure. The ribs are box-girder sections. special emphasis on correlation of shop and field measure-
The decision to use all-welded construction on this ments and on radiographic examination of all major
bridge, as on the other steel bridges of the Turnpike, stress-carrying welds, both shop and field.
introduced an original challenge in design, fabrication
and erection, as welded construction had not, to the Introduction
designers’ knowledge, been previously used in this coun- The Dallas-Forth Worth Turnpike is a _ limited-
try on this type of structure. access, six-lane, median-separated thoroughfare
Use of welding produced a structure of especially
pleasing aesthetic appearance which was also economical providing a direct link between the downtown areas
and permitted rapid fabrication and erection on a proj- of the neighboring cities of Dallas and Forth Worth,
ect for which time was an important factor. which form adjoining metropolitan areas. In addi-
The four authors of this paper were responsible for its tion to providing direct access to each downtown
design, fabrication and supervision of construction, and area, the Turnpike is also integrated with compre-
discuss the problems involved in each phase.
Design. The arch-rib section is described; a general hensive freeway systems in both cities, considerable
discussion of the problems of arch-rib design is presented portions of which are already completed and in use.
and the advantages and economy realized from welding The Turnpike is owned and operated by the Texas
are discussed. Turnpike Authority, which is an agency of the State
Fabrication. The welding procedures for preventing
distortion in the box-girder assembly are described, as of Texas, having been created by the legislature on
are shop techniques for assuring dimensional accuracy Aug. 26, 1953, for the specific purpose of construct-
in the completed structure. ing a Dallas-Fort Worth Turnpike. Following
WM. LLEWELLYN POWELL is a Partner in the firm of Powell & preliminary feasibility and engineering studies,
Powell, Engineers, Dallas, Tex DOUGLAS A. NETTLETON is detailed engineering design was begun in December
District Bridge Engineer, Texas State Highway Department. MIL’TON
E. ELIOT is Vice President and Works Manager at Mosher Steel Co 1954; first construction contracts were awarded in
Dallas, Tex., and JOE C. BRIDGEFARMER isa Construction Engineer September 1955, and the Turnpike was opened to
Harry Newton, Inc., Graham, Tex.
traffic on Aug. 27, 1957.
Paper to be presented at the AWS 40th Annual Meeting to be held in
Chicago, Ill., April 6-10, 1959 Uncertainties due to right-of-way difficulties de-

WELDING JOURNAL | 317

 layed the start of detailed design until December West on the Turnpike. This interchange construc-
1955 for the Hampton Road structure, which is the tion necessitated a seventh lane on the Hampton
subject of this paper. Contract for this structure Road structure. Acceleration and exit lanes on the
was, nevertheless, awarded on Feb. 22, 1956, and, Turnpike pass under the structure, increasing the
despite delays in steel deliveries which did not permit required horizontal clearance over that required for
the fabricator to begin his work before Feb. 19, a structure crossing the Turnpike roadways alone.
1957, first steel was delivered to the site on March Considerable thought was given to the aesthetics
23, 1957, and the bridge was completed and opened of the Hampton Road bridge and to the creation of a
to traffic on May 23, 1957—three months and four structure that would blend with the deep cuts re-
days after the start of fabrication. quired for construction of the roadway at this point.
The Turnpike is financed by revenue bonds paid Selection of the arch structure was confirmed follow-
entirely from the tolls, and without recourse to tax ing preliminary design studies and was based pri-
revenues. When paid for, in an anticipated 17 marily on considerations of appearance, although the
years from date of opening, it will become a part of cost was little, if any, greater than would have been
the free State highway system. Final cost of the that of a girder-and-pier structure of the spans
Turnpike project, including right-of-way and all required.
other costs, except interest and financing, was The decision to use all-welded construction on this,
approximately $53,500,000. Cost of the Hampton as well as on all other steel bridges on the project,
Road structure was $325,832.76, representing a cost made at the inception of the project, was partly
per square foot of $12.90. from aesthetic considerations and partly from ex-
Over-all length of the Turnpike is slightly over pected economy over the use of riveted construction.
30 miles and, in that length and excluding a crossing The simplicity of the welded construction not only
over the Trinity River and the terminal interchanges, resulted in considerable economy of materials and
there are a total of 50 stream crossing and grade improved appearance over riveted construction,
separation structures. On some of the 2-lane struc- it also permitted rapid fabrication and erection on a
tures crossing over the Turnpike, continuous con- project for which time was an important factor.
crete girder structures were used. Generally, how-
Description of Structure
ever, the structures were steel girder bridges, rolled
beams, or welded girder sections shop fabricated The Hampton bridge, as designed and built, is a
from plates. These beams and girders were butt two-hinged arch span, with four arch ribs spanning
welded in the field to form continuous units of three 192 ft. The structure is skewed, with the roadway
or more spans. intersection angle of 18 deg. The roadway and
approaches are rolled-beam stringer spans, supported
Site Conditions Influencing Structure-Type Selection from the arch ribs and abutments by a system of
| At the Hampton Road crossing, special site condi- spandrel columns and floor beams. Over-all length
tions permitted and encouraged the use of an arch of the bridge is 267 ft 10'/, in. between abutment
structure. Here the Turnpike is constructed over the expansion joints; out-to-out width is 94 ft 4 in.
floor of an existing quarry, from which rock is taken The walls of the roadway excavation through the
for the manufacture of cement. Hampton Road bridge were cut on a 1-to-1 slope down to the level
crosses over the quarry at an elevation of some 43 ft of the arch-rib abutments. At this level, a berm was
above the quarry floo, at the Turnpike location, provided with its inner edge approximately five feet
and conditions on either side of the location pre- in from the arch abutment, and continuing from there
cluded any change in the Hampton Road grade, thus a 1-to-1 slope to the roadway drainage ditch. Width
fixing a rather severe grade differential between the of the cut, at the Turnpike level, is approximately
two roadways. With this difference in grade, 180 ft. toe-to-toe of slope. The rugged, natural rock
it was feasible to use the arch structure; in fact, an slopes of the roadway cut were left unsurfaced, as
arch could not have been used here with much less they provided a suitable frame for the arch struc-
difference in grade, as the final structure dimensions ture.
required a relatively flat arch. On the other hand, With the 1-to-1 slope which could be used in the
if a four-span continuous-girder bridge had been rock cut, it was possible to hold the approach spans
used here, as for other crossings over the Turnpike, to a length which, while longer than the interior spans,
very tall supporting piers would have resulted, with a could be bridged with a stringer of heavier section
low ratio of span to height, and unpleasing appearance. but of the same depth as that used for the interior
The arch structure was a logical selection struc- spans. It was thus possible to avoid the use of an
turally, because the necessary unyielding foundation intermediate supporting bent between the arch rib
was provided by the good, firm limestone rock. This and the deck abutments. Elimination of intermedi-
rock requires blasting where unexposed, and has ate supports here was desired because, had they been
irregular horizontal and vertical seams. used, they would have increased the structure cost,
Hampton Road is a major urban thoroughfare of and would have cluttered the clean open appear-
the City of Dallas, with six traffic lanes separated by ance which was desired at the bridge ends.
a four foot median. Interchange with Hampton The box-girder rib type was selected, rather than a
Road is provided for traffic traveling to or from the spandrel-braced arch or a trussed-rib arch, because

318 | APRIL 1959

of its architectural simplicity. Transverse and and proper fitting of all parts of the structure which
longitudinal bracing between the spandrel columns greatly facilitated the final erection.
was avoided, to maintain the clean-cut lines of the Design of this structure required no original tech-
structure. niques for analysis of stresses, and none were de-
The simple, slender lines of the welded arch ribs veloped. The multiplicity of arches and the skew
and spandrel columns gave the aesthetic effect which of the structure, however, did introduce complica-
the designers sought. Longitudinal stiffeners and tions in design and in fabrication and erection.
projecting flanges were used on the rib to emphasize Special attention was given to the detailing of con-
the lines and enhance the beauty of the arch, as well nections which would take full advantage of the
as for structural reasons. simplicity of welded work, as well as to provide the
The paint color selected for the steel work is a necessary accessibility for welding.
pleasing green, and serves the dual purpose of pro- All welds which were subjected to major stresses,
viding a pleasing harmony of the structure in its both shop and field, were examined by radiographic
setting and of reducing the glare of reflected sunlight techniques, to assure sound, top-quality welds in the
for Turnpike travelers during morning and evening completed structure, on this and all other Turnpike
hours. bridges.
The Hampton Road structure is believed to be
Design
unique in that, so far as the designers have knowl-
edge, it is the first use in the United States of an all- Arch-Rib Section
welded box-girder arch rib. The main supporting members of the Hampton
Some hesitation confronted the designers, in un- Road structure are the arch ribs which span 192 ft
dertaking the all-welded design of a box-girder arch, between the end pins, and have a rise of 27 ft. There
because of the fear of difficulty in controlling distor- are four of these arch ribs, side by side, and they sup-
tion during fabrication. No difficulty occurred. Ex- port columns which carry the bridge deck, as shown
perience on this structure has shown that, by careful in Fig. 1. Each arch rib is a box section made up of
attention to sound welding techniques, a competent plates which are joined together by welding. Figure
shop can fabricate this type of structure without 2 shows a cross section of the arch rib.
undue difficulty. The vertical web plates are 56 in. wide by '/» in.
The careful attention to detail which was followed thick except at the end shoes, where they are in-
throughout, in design, fabrication and erection, and creased to 1'/, in. The depth of 56 in. was required
the close correlation observed in these three major for proper stiffness of the rib, and the ' /, in. thickness
work phases, resulted in an accuracy of workmanship is the minimum permitted for the 56 in. depth by the

192-0" CENTER TO CENTER OF PINS

LONGITUDINAL SECTION
Dim. ALONG € Ris

(N)(S)
&D2°A MAT
37
(ns)
BBC

/
Le LACED
[“~strut
/@ ARCH RIB A
“ stat z— #4 = 2)
so'-eView | 29-4 Vier a30’-9Yie* - + @", ALONG ¢ OF RIS
29 ie to 29'-6"
192'-0" ALONG ¢ OF RIB
DEVELOPED PLAN IN PLANE OF RIBS
. 1—Longitudinal section of structure and developed plan in plane of ribs

WELDING JOURNAL | 319

 INTERIOR veg" | _'-g
EXTERIOR c '-3%2" -
~ Toe ee war

c DETAIL "A"
“STOP FLANGES 9%" To I%6" THK.Z

Ler SPEER 4" x Ye"

a 4e" THK. =

_— BOTTOM FLANGE %o" THK.

os Cc Q ]

SECTION AT DIAPHRAGM SECTION AT STIFFENERS

Fig. 2—Typical sections of arch rib

minimum thickness that can be used either in rela-

tion to the distance between the webs, or in relation
to the overhang outside the webs. The web plates
are joined to the flange plates by groove welds made
from the outside only. One-half inch square backup
bars were first fillet welded to the flange plates, and
the backup bars also served to position the web
plates which had their edges bevelled at 45 deg.
The box cross section is prevented from skewing
out of shape by internal diaphragms, */, in. thick,
spaced at about 14 ft 6 in., and 4- x */;-in. vertical
stiffener plates are used on the inside of the web,
midway between diaphragms. Holes 16- x 30-in. are
provided in the diaphragms to permit a man to crawl
through the arch rib, access being provided by
several manholes in the web. Two field splices
divided the length of the rib into three sections, with
a maximum length of about 67 ft, to permit ship-
Fig. 3—Photograph of arch shoe ment. These field splices were designed as double-
vee groove welds to develop the full section.
The ends of the arch ribs bear against 9-in. diam
pins which are supported by shoes consisting of three
AASHO Design Specification. With this depth-to-
2-in. thick web plates and a base plate, also 2 in.
thickness ratio, the specifications require that longi-
thick. These plates are joined by */s-in. fillet welds
tudinal stiffeners be used to prevent web buckling.
( Fig. 3).
Four longitudinal plates, 4 in. wide by */; in. thick,
are fillet welded to the outside of the webs to serve as Arch-Rib Analysis
web stiffeners, and also provide part of the re- The arch rib is designed to carry bending moments
quired arch cross section. The two webs are con- as well as axial compression. Symmetrical, uniform
nected by the top and bottom flange plates. The loading results almost entirely in axial compression
webs are 23 in. apart, and the flange plates are 36 in. of the arch rib, but unsymmetrical loading from
wide for the two inner arch ribs and 31 in. wide for traffic on the deck results in large bending moments.
the two outer arch ribs. The top plates vary in The section may be thought of, then, as part column
thickness from */, to 1*/,;, in., and the bottom plates and part beam. It must be investigated for buckling
have a constant thickness of °/,, in., which is the stability as a column,and it must have sufficient depth

320 | APRIL 1959

 134% 2is* 3 jos * mse 10a*
(ioa*) (w*) (vos*”) (yos*) (ui*) (104 *)
DEAD LOAD
DEFLECTION AT _-¢ ARCH RIB UNDER
CENTER= 0.7” Fo DEAD LOAD + LIVE
LOAD + /MBACT.
|Jd95” |T
¢ ARCH RIB UNDER 93.6% 1.38"
DEAD LOAD—

THRUST LINE
OA fib. Fa

FIGURES SHOWN THUS 1.75" ARE DEFLECTIONS

FIGURES SHOWN THUS (704") ARE DEAD LOAD ONLY
192'-0* C TOC OF PINS

DEAD LOAD + LIVE LOAD + IMPACT ON ARCH

Fig. 4—Arch thrust lines and deflection diagram

267*= 9:5"
7O OUT OF STEEL

24W 0
24W /00
T 7
DO A
vi DO RP
. [DO a THRUST
A- Do ~
NS>
/ “ DO A ‘© 9S
DO ; FO =N
\SUPPORT
, 4 g (BEAMS)
STRINGERS
{24W 100 wy
7
[24W 110

42'-0"” JL SPLICE POINT SPACING

NOTE « INTERMEDIATE DIAPHRAGMS NOT SHOWN.

Fig. 5—Deck framing and lateral-bracing plan

in the vertical plane for economy of material and for thrust line adjusts itself to this new parabola. But,
minimizing deflection. In any beam, deflection must under half-span loading, the thrust line must de-
be limited to avoid movements which are perceptible part from the parabolic shape. As shown in Fig. 4,
and unpleasant to people using the structure, and to the thrust line rises above the arch axis in the loaded
avoid cracking or damage to other structural ele- half of the span and drops below the arch axis in the
ments supported by the beam. However, in an arch unloaded half of the span. Thus we have a positive
rib, deflection is of even more importance, because bending moment, or tension in the bottom, in the
the bending moments, first calculated under the as- loaded half of the span, and the reverse in the un-
sumption of a fixed position of the arch centerline, loaded half of the span. However, a positive bend-
are intensified by the displacement of this center- ing moment results in a downward deflection, and
line. a negative bending moment in an upward deflection,
As is well known, an arch rib in the form of a pa- as shown in Fig. 4. These bending deflections tend
rabola, supporting a uniform load, will have axial com- to be rather large and increase the eccentricity of
pression only in the arch rib. For dead load, the the thrust line with respect to the arch centerline
thrust line or equilibrium polygon would coincide and thus amplify the bending moments. This
with the rib centerline except for the fact that most amplification of moment results in a 4% increase in
of the load is applied as concentration instead of stress in the Hampton Road arch. This action has
being distributed. There is a very small downward been gone into at some length to explain the selection
deflection under this load, as shown in Fig. 4, but the of a cross section which involves the use of com-
arch shape remains practically parabolic and the paratively thin wide plates. A more compact sec-

WELDING JOURNAL | 321

 tion composed of narrower, thicker plates would tween the arch ribs act as continuous members on
probably have less welding distortions, but it would four yielding supports, and were so designed. This
be too flexible for an arch rib. combination of continuity of cross members and
Deck Structure yielding of the supporting ribs has the effect of dis-
tributing concentrations of live load across the four
The deck framing, which directly supports the
ribs, and an analysis of this action resulted in de-
concrete roadway slab, is shown in plan by Fig. 5.
signing the outside ribs for 1.2 lanes oflive load and
This framing consists of ten lines of 24-in., wide-
the inside ribs for 1.6 lanes of live load. The design
flange beams which run continuously from end to
of the continuous longitudinal stringers also took
end of the bridge over the tops of the transverse
into account the deflection of the arch ribs. Con-
floor beams. The floor beams are three-span, con-
sideration was given to the use of transverse joints in
tinuous, all-welded girders. The two floor beams
the deck, but comparative studies proved the su-
immediately adjacent to the arch centerline are of
perior economy and stiffness of stringers continuous
box section and frame between the arch ribs with
from end to end of the bridge.
welded gusset-plate connections, which provide for
continuity. The remaining floor beams are single- Weight of Steel Used
web plate girders which pass over the tops of the The weight of steel in the arch ribs and their brac-
inner column lines and frame into the outside column ing struts is 440,000 lb, and the total weight of struc-
lines. The columns are 12 in., wide-flange sections tural steel in the bridge is 955,000 lb, which amounts
which are milled on their lower ends to the slope of to 38 lb per sq ft of deck area. This figure is indica-
the arch ribs, and are fillet welded thereto. A hori- tive of the economy resulting from the simplicity of
zontal bracing system is located in the plane of the welded splices and connections and from the con-
floor-beam top flanges. The T section diagonals to- tinuity of the members which can be most easily
gether with the floor-beam flanges form a _ truss achieved by welding, and also from the efficiency
which spans between the end abutments of the that can be obtained in a welded, built-up cross
bridge to carry horizontal forces, such as wind pres- section.
sure against the deck and the arch ribs. The arch
Fabrication of Arch Ribs
ribs are supported laterally near their crowns by this
Each of the four arch ribs consists of three ship-
bracing system, and have additional bracing con-
ping pieces approximately 67 ft O in. in length. The
sisting of laced box-struts framing between them at
the panel points. These laced struts act with the two end sections have a shop splice for flange and
arch ribs to form a Vierendeel Truss system to take web material about 21 ft 0 in. from the pin. The
lateral loads, and brace the arch ribs against lateral center section has a shop splice for web material only
buckling. This bracing system results in a safety at the centerline (Fig. 6).
For the full length of arch, the inside-to-inside
factor against lateral buckling of four, which is the
dimension of flange plates is 4 ft 8 in.; and the out-
same safety factor as is provided by the rib stiffness
against buckling in the vertical plane. side-to-outside dimension of web plates is 23 in.
Plate diaphragms occur at each panel point and
Interaction Between Deck and Arch Ribs midway between panel points. On each web, 4- x
Welded connections and splices make for ease in ‘/.-in. inside plate stiffeners alternate with the
obtaining of continuity in all members, and this con- diaphragms. Two 4- x */s-in. outside horizontal
tinuity results in economy of steel and in greater stiffeners run the full length of each web (Fig. 2).
stiffness. With continuity, the stresses in the arch Web plates for the entire length of all ribs, except
ribs and the deck structure are interdependent. adjacent to pins, are '/, in. thick. Flange plates
The deck floor beams and the transverse struts be- differ in width for interior and exterior ribs. Thick-

SPLICE
SHOP
WEB

|9g 2 ‘ oh as

Fig. 6—Arch-rib assembly

322 | APRIL 1959

 tion of fit-up and welding procedure on the center
section will apply to all parts.
Fit-Up and Welding Procedure
One web plate with prepared edges was placed on
the fit-up skids. Diaphragms and stiffeners were
located and tack welded to the web plate. The top
and bottom flange plates, with '! »-in. square backup
plates attached were tack welded to web. The
flange plates were made 2 to 3 in. longer than the
calculated dimension to allow for welding shrinkage.
The flange plates were fitted 4 ft 8's in. inside to in-
side to allow for shrinkage to 4 ft 8 in. after welding.
The other web plate was inserted and tack welded to
flange plates, diaphragms and stiffeners. The rib
section was now ready for welding.
Four welders were used on the joints connecting
flanges to webs. With the rib section on its side
(flanges vertical), one welder on the top flange and
one on the bottom flange started at the left end of the
member welding toward the center. At the same
time, one welder on the top flange and one welder on
the bottom flange started at the centerline of the
member welding toward the right end.
At each flange-to-web joint on the top surface, a
stringer bead was first placed, using a */\,-in. E6011
electrode. The rib section was turned over and a
similar bead placed on the other side. Without
turning, the next pass was made with a '/,-in. E6020
electrode. The member was turned and the other
side given one pass with a -in. E6020 electrode.
The welds on this side were then completed with a
sin. E6020 electrode. The member was again
turned and the welds on the other side completed
with a */\s-in. E6020 electrode. While the main
joints were being made, welders inside the box section
fillet welded the diaphragms and stiffeners to web
Fig. 7—Arch-rib shop and field splice with a E6013 electrode. After the flange-to-web
joints were completed, ends of diaphragms were
welded to flange plates with an E6013 electrode.
ness of flange plates varies along the length of ribs. Horizontal web stiffeners were added to the section
Minimum flange thickness is " \, in.; maximum is on each side with an E6013 electrode before the final
13/\, in. turn was made. This procedure produced uniformly
Fabrication was started by laying out the center- satisfactory sections without twist or undue distor-
line of arch ribs to full size. A base line was estab- tion in any direction.
lished, offsets calculated at one-foot intervals along On completion of welding of main rib material and
this line and the resulting location of centerline de- before any detail material was added, pin holes were
termined. The centerline was transferred to a web bored in end pieces. The length of each section was
plate for each section of the arch and the edges lo- marked and each end milled to exact length and
cated from this centerline. These web plates served bevel. Ends were then prepared for shop and field
as templets for the other seven webs required. Each splice welds (Fig. 7
section of web was made 2 to 3 in. longer than the
calculated dimension to allow for welding shrinkage Shop Assembly and Splicing
and minor irregularities in fit-up. To check the accuracy of fabrication, the five rib
The shop splice in web of center sections was made sections were shop assembled on level skids. A
before fit-up was started. To facilitate handling, the heavy H-section was first placed on the skids for the
shop splice in end pieces was not made until all full length of arch from pin to pin. This section,
other welding was completed. As a result, each rib representing the base line, was straightened and
was fabricated in five pieces with two final shop welded to the skids. Nine-inch round vertical mem-
splices producing the three shipping pieces noted bers representing the pins were next placed in proper
above. location and welded. ‘The end-rib sections were
Since all sections of the rib are similar, a descrip- placed on the pins and the interior sections placed in

WELDING JOURNAL | 323

 BEADS 1,7, //, 15,3, 9, 13, 6
SHOULD BE IN THE OVERHEAD POSITION.

BEADS 2,8,/2,4, 10,14

SHOULD BE MADE IN THE FLAT POSITION.

18
6
5 - =
17 pe

SECTION A-A SECTION 8-8 SECTION C-C

BOTTOM FLG. TOP FLANGE WEB WEB WELDS

Fig. 8—Double-V butt-splice welding procedure

FALSEWORK TOWERS
RE-ERECTED FOR RIBS REMOVED
A AND OD ANDAFTER
FIELD BUTT SPLICES X-RATED AND
proper location. The '/;-in. root openings for shop ~ ACCEPTED FOR R/8S B AND J,
and field splices were established. The distance \7 400 B08 On, oo a y
7] Tee 77 ToT
from centerline of arch rib to base line was checked ARCH RIB C
at all panel points and at other random locations.
Maximum deviation observed was '/, in.
While the sections of the rib were in the assembly bf
ARCH RIB» A \
jig, the shop splice for the two end sections was Ss
-
tacked and one half of each web-plate splice com- PLAN
pleted. After removal from the jig, the end section
was turned over and the web splice completed; then FIELO
S" SPLICES=—
I 4
the flange plates were welded, using sequence similar
_ “FALSE WORK~
TOWERS ~
to that shown in Fig. 8, with all downhand welding.
While all sections were in the jig, temporary field
splice material was added. This consisted of four ELEVATION
angles bolted on the outside corners of the box sec- Fig. 9—Arch-rib erection diagram
tion at the joint. These were removed after field
splices were welded, and all holes plugged.
Detail material, consisting mainly of outside verti- Because of difficulties in right-of-way negotiations,
cal stiffeners and plates for attaching lateral and steel deliveries being what they were at this time,
struts, was added after rib sections were removed work on the bridge started in the middle of Decem-
from the assembly jig. ber 1956, and was carried on under extremely un-
Construction favorable working conditions. In spite of this, work
progressed steadily without any serious delays. The
In the construction operations of the Hampton
work was completed within the allotted time and the
Road Arch Bridge it was required that the erection
bridge opened to traffic on May 23, 1957.
and welding procedures be the responsibility of the
Contractor with the approval of the Engineer. Substructure Location Control
Prior to the arrival of structural steel at the fabrica- Upon completion of the cut section for the Turn-
tor’s plant, conferences were held to determine the pike roadway, the Contractor proceeded to con-
method of welding, correlation of field and shop struct the deck abutments and the arch-rib abut-
measurements, and erection of the arch ribs. ments. Extreme care was taken in the alignment
The entire responsibility for the exact position and and slope of the arch-rib abutments. Prior to the
elevation of the arch ribs was that of the Contractor. fabrication and shipment of the rib sections, the rib
He was required to check all control lines and grades, bearing shoes were set, aligned and the distance be-
including the measurement of the distance between tween the pins was measured accurately and these
the pins, as well as the exact angle of the concrete measurements compared with measurements made at
arch abutments. the fabricator’s shop. Since the rib sections form the

324 | APRIL 1959

sole supporting members for the span, it was logical rib section to completed steel structure required 240
to erect them only, together with the lateral box and man days.
laced struts between, as the first operation. Several The structure required 954,911 lb of structural
methods of erection were discussed but it was decided steel and 2997 lb of deposited weld metal of which
that falsework towers at the points of splice, with 2185 lb was for shop welds and 812 lb for field welds.
blocking to adjust for line and grade, would enable The total lineal length of welds applied on this struc-
better control of the sections. ture was about four and one-half miles.
Erection Procedure The cost for the structure was $325,832.76. This
The first phase of erection consisted of erecting the comprised $26,246.80 for substructure, $250,642.44
end sections of the interior ribs from the pins to the for the 954,911 lb of structural steel, and $48,943.52
falsework towers (Fig. 9). This operation was ac- for roadway deck slab.
complished by using two cranes, one to lift the load The cost of $12.90 per sq ft and unit price of $0.26
and the other to position the sections. Prior to set- lb for the fabrication, erection and painting of the
ting the center sections, the end sections were structural steel was felt to be a very economical price
aligned and set to their correct elevation, allowing when compared with prices of other welded-girder
for deflection that would occur on releasing the structures used on the project. The radiographic in-
load from the towers. It was found that it was neces- spection for the total project averaged about $2.49
sary to set the center sections early in the morning, per ton, reflecting a cost of $1,188.85 for this struc-
when the temperature was low, to take advantage of ture.
the contraction in the rib sections. After the ribs The time required for field construction was ap-
were set and splice points tack welded, the struts proximately 940 man days, of which 300 were used on
were erected and bolted to the ribs. No welding was the substructure, 240 on steel erection, and 400 on
allowed between struts and ribs until the concrete forming and placing the deck. Due to the procedure
deck had been poured so as not to lock in the ribs of placing of concrete in the deck slab, additional man-
any stresses due to the additional dead load imposed. power was required. Compared with construction
It was required by specification that the butt field- time required for other structures within the project,
weld splices (Fig. 8) would be inspected radiographi- the time required in construction of the arch bridge
cally prior to removing the falsework and before was not abnormal, nor did it exceed that required
proceeding with other erection which would affect the for comparable bridges of other structural types.
splices. The Contractor used three certified welders Radiographic Inspection
in performing all the field weld work and at no time The radiographic inspection was performed by
was he delayed, waiting on the field welds to be com- the use of a mobile unit with all necessary equip-
pleted. After completion of the erection of the ribs ment to perform all operations at the job site. The
and struts, erection of the columns, floor beams, and film was exposed using a gamma-ray camera with
stringers between the deck and rib abutments began, Iridium 192 as source of ray. This type of operation
proceeding from each end of the bridge. Prior to enables a fast and accurate inspection of the welds,
placing columns on the ribs, accurate elevation and and was applied on all highly stressed groove welds
slope of rib at the panel points were determined, to subject to tension. The radiographic procedure first
check the length of columns and bevel of the bearing used was that as specified in the 1947 AWS Welded
at the rib and column junction. This information Highway and Railway Bridge Standard Specifica-
was forwarded to the fabricator and the columns tion. Extreme difficulty on the part of the Fabrica-
were milled to the required length and slope. tor and Contractor was experienced in meeting this
Concrete Placement Procedure specification. After considerable discussion, the
procedure and standard of acceptance adopted was
The forming for the concrete deck proceeded from
that as specified by the ASME Boiler Code Section
the deck abutments to first column before the closure
VIII, Paragraph UW51. Based on the latter specifi-
of the stringers was completed, and, as the last field
cation, approximately 10° of the shop welds and
butt splice was complete and approved, forming for
5% of the field welds were rejected on first inspection,
the deck was 90° complete.
due primarily to lack of penetration in the weld.
The procedure for placing the concrete was to be-
This is based on the total project. For the arch
gin at the center of the bridge for pour No. 1 and
bridge, all welds were accepted on first inspection.
progress transversely in each direction simultane-
The use of X-ray equipment for examination of
ously. The procedure for the remaining pours was
the welds in a structure of this type, or in any welded
to place the concrete simultaneously on each side of
structure, is endorsed without qualification. The
the center pour, proceeding toward the ends of the
assurance of adequate welds which this procedure
bridge, so as to load the structure as uniformly as
provided on this project at nominal cost and with
possible.
little, ifany, delay to fabrication or erection progress,
On completion of the concrete deck, the welds be-
gave the designers a freedom from concern and a
tween the struts and ribs were completed.
satisfaction with the completed structure which
Construction Time and Cost Data could not have been obtained with any other inspec-
The time required from the erection of the first tion procedure.

WELDING JOURNAL | 325

 JUAN)

\!
Uy

ale ee Oe ee ee

6 evens eGR
gage et
tn LAA ee

Fig. 1 Liquid leaking from crack in fusion zone of weld and patch

Test program undertaken to establish a welding procedure that would be dependable

for making repairs to corroded pipe, installing new connections, and performing general

Maintenance Welding

of High-Test Line Pipe

BY A. M. HILL AND F. W. ZILM

apsrrRAcT. 5LX Grades X46 and X52 line pipe have carried out at our company’s Tulsa Shops to find a
come into wide use throughout the pipe-line industry solution to the problem of underbead cracking of arc
since this specification was adopted by the API in 1948. welds where branch connections and reinforcing
Chemical and physical properties of the high-test line
pipe have presented a rather difficult problem in main- sleeves are attached to the pipe line by welding. In
tenance welding of oil pipe lines, due to the quenching these tests, the welding was performed under condi-
effect of the fluid contained in the pipe. tions simulating, as nearly as possible, those encount-
Established practices for maintenance welding on ered in the field. The tests consisted of making
Grade “‘B”’ pipe were unsatisfactory when applied to the
high-test pipe due to frequent underbead cracking. short welds and welding various-size patches and
Through a series of tests, a procedure described herein full encirclement sleeves on chambers fabricated
has been adopted by the authors’ company. from 24-in. OD pipe manufactured in accordance
Introduction with API Specifications 5L and 5LX. All welding
was done on test chambers cooled with a mixture of
During the early part of 1955, a testing program was
water, antifreeze, ice and salt. The brine was cir-
A. M. HILL is Superintendent of Line Maintenance and F. W. ZILM culated by a pump during the welding operation.
is Welding Technician at Service Pipe Line Co., Tulsa, Okla
Paper to be presented at the AWS 40th Annual Meeting in Chicago After welding was completed on the various cham-
Ill., April 6-10, 1959 bers, the welds were inspected for underbead cracks

326 | APRIL 1959

either with magnetic particles, or by sectioning 100% electrodes. These are the types of electrodes used
of the weld into coupons which were broken in the for field welding pipe joints and normal maintenance
weld zone to expose the root bead. Several cham- welding on lines laid with Grade “B”’ pipe. There
bers were subjected to destructive tests by hydro- was also a pronounced increase in the hardness of
static pressure. To simulate field conditions, an the pipe material in the heat-affected zone.
internal pressure of 500 psi was maintained in the Tests 1, 2, 3 and 4 revealed that underbead crack-
larger chambers during the time the patches and ing occurred in the fusion zone between the weld
sleeves were welded. The chambers which were beads and the base metal on welds made with E6010,
tested to destruction with hydrostatic pressure were E7010 and E9010 electrodes. These types of elec-
constructed so that the pressure in the chamber was trodes are unsatisfactory for use when welding is re-
exerted in the space between the sleeve or patch and quired on a pipe line (full of liquid under pressure)
the chamber wall. The destruction test on some of laid of pipe manufactured in accordance with API
the chambers was conducted while the assembly was Specification 5LX Grades X46 and X52.
cooled to approximately 32° F. Tests 5 and 10 revealed that welds consistently
free of underbead cracks can be obtained with
Materials Used in Tests
£7016 low-hydrogen electrodes, both conventional
Carrier Pipe (Test Chambers) and iron-powder type.
API 5LX Grade X52 pipe 24 in. OD, 0.312 in. wall Tests 6 and 7 revealed that a repair patch or a
thickness branch connection saddle welded onto high-test pipe
Chemical Analysis of Carrier Pipe (Percent) tends to reduce the ultimate strength of the pipe due
to concentrations of stresses in the fusion line of the
Ladle Check 1 Check 2
weld that is parallel to the axis of the pipe.
Carbon 0.270 0.300 0.290 Tests 8 and 9 revealed that high-test pipe is not
Manganese 1.210 1.250 1.110 suitable for fabricated piping systems such as mani-
Phosphorus 0.020 0.018 0.018 folds, pump headers, etc., unless close control of pre-
Sulfur 0.030 0.035 0.036 heating and interpass temperature is maintained.
Carbon equivalent 0.573 0.613 0.568 Test 11 revealed that E6010 and E7010 electrodes
Physical Properties of Carrier Pipe are not satisfactory for welding on pipe lines full of
Yield strength 60 ,620 psi liquid which are laid of pipe manufactured in accord-
Tensile strength 89 ,890 psi ance with API Specification 5L Grade “‘B”’ at tempera-
Percent elongation in 2 in. 27.5 tures as low as 25° F.
Tests 12 and 13 revealed that dye-penetrant ma-
Patches and Sleeves*
terial would be a satisfactory method for inspecting
API Grade “‘B”’ pipe 24 in. OD 0.500 in. wall thick- welds made on pipe lines full of liquid under pressure.
ness Although satisfactory results were obtained using
API Grade “B” pipe 24 in. OD 0.312 in. wall thick- both the conventional E7016 low-hydrogen elec-
ness trodes and the E7016 low-hydrogen iron-powder
API 5LX Grade X52 pipe 24 in. OD 0.500 in. wall electrodes, it was found that the latter kind had
thickness many advantages over the conventional low-hydro-
API 5LX Grade X52 pipe 24 in. OD 0.312 in. wall gen electrodes. The advantages are:
thickness
1. Deposition Rate. Using '/;-in. diameter iron-
Welding Electrodes
powder electrodes, the deposition rate per linear
AWS E6010 °/;. in. diameter inch of weld is equal to that of the size °/;.-in. diam
AWS E7010 °/;. in. diameter conventional low-hydrogen electrodes.
AWS E9010 °*/;, in. diameter 2. Less Operator Fatigue. The iron-powder elec-
AWS E7016 °*,;. in. diameter (low-hydrogen conven- trodes can be used in all positions without oscillating.
tional) This gives the operator better control of the weld
AWS E7016 '/, in. and °® in. diameter (low-hydrogen puddle and results in a deposit of weld metal having
iron-powder ) a smooth surface and contour. The fluidness of the
Cooling Medium molten metal of the conventional low-hydrogen elec-
Crushed ice, water, alcohol-base antifreeze, and trodes requires close observance and controlled
rock salt. (It was necessary to add antifreeze to the manipulation of the electrode by the welder when
brine to keep the circulating system from freezing. welding in the overhead and vertical positions. The
fluidness of the weld puddle and the necessity of
Conclusion manipulating the electrode results in a weld bead
The results of the tests outlined below show that having a very uneven surface. Undercutting of the
the high-yield-strength pipe is very sensitive to the base material adjacent to the weld bead is also a
quenching effect of the liquid contained in the test problem.
chambers. Underbead cracking occurred in all ex- 3. Ease of Cleaning. The beads of weld metal
cept one test specimen made with E6010 and E7010 deposited with the iron-powder electrodes have a
* The corners of all patches were cut on a radius. smooth contour that facilitates slag removal. With

WELDING JOURNAL | 327

 au ; Hr mnt 24 wv

- os > ~ _

Fig. 2—Patches welded to a chamber preparatory to testing Fig. 4—Hydrostatic pressure applied to patch on
test chamber. (Light areas on chamber are where
welds were ground down for inspection)

Fig. 3—Test chamber ruptured beneath patch. Note Fig. 5—Underbead crack revealed in hydrostatic test
liquid escaping near top of section cut from chamber of patch welded with E9010 electrodes

conventional low-hydrogen electrodes, it was meces- water at a temperature of approximately 50° F.

sary to use hammers and chisels to remove slag trom One patch each was welded with E6010, E7010,
the rough surface of the weld beads, especially where E9010 and E7016 electrodes. Upon completion of
undercutting occurred. Slag remaining on or adja- welding, hydrostatic pressure was applied to the area
cent to a weld increased the difficulty of handling the between the patch and the test chamber. Figure |
molten metal when depositing additional beads. shows this test and testing equipment. In all cases
4. Inspection. The tendency of the slag to the failure occurred in the fusion zone between the
adhere tightly to the weld metal deposited with the weld metal and the patch.
conventional electrodes can hide porosity and under- Test No. 2
cutting in or adjacent to the welding bead. Test No. 2 was identical to Test No. 1, except that
5. Elimination of Porosity. Porosity in the weld Grade X52 material was used for the patches (Fig. 2).
metal was a problem with the conventional low- In this test, failure occurred at the fusion zone be-
hydrogen electrodes, particularly when restarting the
tween the weld and the pipe on all patches with the
are after changing electrodes. Depositing more weld exception of those welded with E7016 electrodes. In
metal over such areas tends to increase porosity this case, the test chambers ruptured underneath the
rather than remove it. This trouble did not occur
patch (Fig. 3).
when the iron-powder electrodes were used.
Test No. 3
Description of Tests In this test, a chamber having various size holes
Test No. 1 drilled partially through the wall of the pipe was
Patches made from Grade “B” 0.312-in. wall pipe filled with water and temperature was reduced to
were welded on a Grade X52 pipe chamber filled with 50° F. The drilled holes were filled in by welding to

328 | APRIL 1959

Fig. 6—Frost on test chamber prior to installing Fig. 8—Test chamber with one 12- x 24-in. and one 16- x
full-encirclement sleeve 48-in. patch welded in place ready for testing (patches
are on lower side of chamber)

—s

Fig. 7—Installing bottom half of sleeve on test chamber Fig. 9—Failure in fusion zone between weld and 16- x
shown in Fig. 6 48-in. patch on test chamber shown in Fig. 8

simulate the repair of corrosion pits on a pipe line. that underbead cracking occurred where weld metal
Several patches were welded to the chamber to was deposited with E9010 electrodes. No under-
simulate conventional repair work, using various bead cracking occurred where weld metal was de-
types of electrodes. In addition, several weld beads posited with E7016 electrodes.
were deposited on the surface of the test chamber. Test No. 5
The beads were of both single and multiple-pass Full-encirclement sleeves made of Grade “‘B”’ pipe
layers. The weld beads were ground flush with the were welded to a test chamber cooled to 32° F.
surface of the pipe and examined for cracks by mag- E7016 electrodes were used for all welding in this
netic-particle inspection. The patches were tested test. Figure 6 shows frost on the surface of the test
with hydrostatic pressure applied to the area between chamber prior to installing sleeve. Figure 7 shows
the patch and the test chamber (Fig. 4). This bottom half of sleeve being welded. The entire
inspection revealed underbead cracking of all beads length of both the circumferential and longitudinal
deposited with E6010 and E7010 electrodes. No welds were sectioned and examined by making a
underbead cracking occurred in the weld metal de- reverse bend of the sleeve sections in relation to the
posited with E7016 and E9010 electrodes. surface of the test chamber. With the exception of
Test No. 4 some minor cracks at the area where tack welds were
deposited, no other evidence of underbead cracking
This test chamber was cooled to approximately
was found.
30° F. Patches and pit holes similar to those in
Test No. 3 were welded, using E9010 and E7016 Test No. 6
electrodes (Fig. 5). Hydrostatic tests, physical and One 24- x 12-in., and one 48- x 16-in. patch made
magnetic-particle inspection of the welds revealed from Grade “‘B”’ pipe, were welded to a Grade X52

WELDING JOURNAL | 329

 pipe chamber which was cooled to 32° F and pres-
sured to 500 psi (Fig. 8). Upon completion of weld-
ing, pressure in the chamber was increased to 1450
psi when failure occurred in the fusion zone between
the 48- x 16-in. patch and the weld (Fig. 9). The
hole in the test chamber which allowed the pressure
to equalize between the chamber and the patch, was
plugged by welding, and the chamber was again pres-
surized. During the second pressure test, failure
occurred at 1500 psi in the test chamber adjacent to
the weld at the edge of the 48-in. patch. In this
failure, the pipe ruptured parallel to the long side of
the patch. The rupture was approximately 39-in.
in length, and tore circumferentially around the
test chamber for 6 in. at each end (Figs. 10 and 11).
Test No. 7
The section of pipe which ruptured in Test No. 6
was removed, and a new section of pipe was inserted
in its place to maintain the original length of the test
chamber. Hydrostatic pressure was again applied.
Pressure of 2000 psi was obtained when a failure
occurred in the fusion zone between the weld and the
edge of the 24- x 12-in. patch (Fig. 12).
Test No. 8
A full-encirclement sleeve made from Grade ‘‘B’’
pipe, 0.500-in. wall, 24 in. in length, was installed and
welded with E7016 electrodes onto a 20-ft Grade
X52 pipe chamber cooled to 32° F (Fig. 13). A pres-
sure of 500 psi was maintained in the chamber during
the welding operation. Upon completion of weld-
ing, and while the chamber was still cool, the pres-
sure was increased to determine the maximum
amount of pressure which a repair sleeve of this type
would withstand. When a pressure of 1500 psi was
Fig. 11—Another view of failure shown in Fig. 10 reached, failure occurred in the weld adjoining one of
the weld caps to the pipe. The sudden release of
water pressure blew the weld cap a distance of
approximately 75 ft (Fig. 14). Simultaneously, the
shock wave of the water and ice contained in the
chamber caused failure in the weld adjoining the
other weld cap to the opposite end of the pipe (Fig.
15). Procedure used in making these welds was as
follows: the root beads were deposited with -in.
diam E6010 electrodes. The second bead (hot pass
was applied immediately using */;.-in. diam E7010
electrodes. The remaining beads were deposited by
the submerged-arc process. No preheating was used
as the ambient temperature was about 80° F. In
determining the cause of these failures, the order in
which the welds were made was reconstructed. The
second weld that failed was completed first. By
close inspection of the cross section of the weld metal,
it was found that the root and second beads in an
18-in. segment of weld had cracked. The remainder
of the weld was of good quality. It is evident that
the heat input to the base material, after deposition
of the root and second beads, had not dissipated be-
yond the critical range (for the greater portion of
the weld length) before the submerged arc was
Fig. 12—Failure that occurred in fusion zone of weld applied to deposit the third bead. By close examina-
and 12- x 24-in. patch tion of the other weld, it was found that the root and

330 | APRIL 1959

Fig. 13—Welding sleeve on chamber cooled to 25° F and Fig. 15—Portion of cracked weld between weld cap
pressured to 500 psi (note frost accumulation) and pipe which failed in Test No. 8

i
BY
ahoe
Fig. 14—Weld cap blown from test chamber resulting Fig. 16—Weld which failed in Test No. 8. First two beads
from cracked weld in Test No. 8 which cracked as weld was completed are the dark area
adjacent to inner wall of cap

second beads had cracked throughout their entire Test No. 9

length (Fig. 16). This weld was the last to be com- The weld metal which remained on the weld caps
pleted on the test chamber. It is logical to assume and pipe in Test No. 8 was machined off and new
that the heat input of the submerged arc would in- bevels made. The weld caps were then replaced on
duce an expanding force sufficient to crack the root the pipe and welded by preheating the weld areas to
and second beads after the base material had cooled approximately 350° F. The weld caps were then
to the critical point. This is substantiated by simi- welded to the pipe using E6010 electrodes for the
lar welding difficulties which have been encountered root pass and E7010 electrodes for the remaining
in constructing lines laid with X52 pipe. In many passes. These welds were inspected by radiog-
instances (after the pipe had cooled to ambient raphy and no defects were located. The chamber
temperatures) the root and second beads have was refilled with liquid and hydrostatic pressure was
cracked soon after the welder starts the third bead. again applied (Fig. 17). When a pressure of 2200
This trouble is more likely to occur when the welding psi was reached, a failure occurred in the longitudinal
crew begins welding at the start of the day, with weld of the encirclement sleeve (Fig. 18). Higher
atmospheric temperatures below 50° F. pressure could have been attained had the assembly

WELDING JOURNAL | 331

 been so designed to permit 100% penetration of the pipe chamber cooled to 25° F. Size '/s-in. low-
weld metal at this point. The lack of penetration hydrogen iron-powder electrodes were used for weld-
was deliberate, in that it was not deemed advisable ing in this test. The welds were inspected by dye-
to fuse or penetrate the chamber with a welded seam penetrant material. This inspection revealed that
parallel to the axis of the pipe. no cracking had occurred. The entire length of the
weld was then sectioned and examined by making
Test No. 10 reverse bends of the section. No cracks were found
This test was conducted to determine the handling in the test.
characteristics, and whether or not it was possible to
obtain welds free of underbead cracks using E7016 Summary and Recommendations
low-hydrogen iron-powder electrodes. (These elec- The tests described in the preceding pages were
trodes were not available when this testing program made to establish a welding procedure that would
was started.) Various-size patches and full-encircle- be dependable for making repairs to corroded pipe,
ment sleeves made of Grade X52 0.312-in. wall pipe installing new connections, and performing genera]
were welded, using these electrodes, to test chambers maintenance work on pipe lines laid of high-test line
made of the same material, which were cooled to 25° pipe.
F. Figures 19 and 20 show these tests. Physical The tests revealed that welding materials and
tests conducted on the entire length of the we!d metal procedures currently used by our company are not
deposited revealed that no underbead cracking had satisfactory for the repair and maintenance of pipe
occurred. lines laid with pipe manufactured in accordance with
Test No. 11 API Specifications 5L and 5LX in Grades “B,”
X42, X46 and X52, where the surface temperature
To determine the effects of maintenance welding
of the pipe is below 50° F.
on pipe lines laid of pipe conforming to API 5L Grade
Hydrostatic tests conducted on chambers proved
“B,”’ carrying liquid at temperatures below freezing,
that fittings constructed to encircle the pipe com-
various size patches cut from this grade material
pletely will consistently withstand higher internal
were welded to chambers of the same material.
pressures than the reinforced saddle type fittings.
These chambers were cooled to a temperature of 25°
F and this temperature was maintained during
welding. Both E6010 and E7010 electrodes were Fig. 17—2000-psi pressure on test chamber on which fuil-
encirclement sleeve was welded
used. These welds were examined for underbead
cracking by sectioning the entire length of the weld
and making reverse bends in the weld area of each
section. Underbead cracking was found at two
locations under the weld on a 16- x 33-in. patch.
One crack was about 1° /, in. in length, and the other
was °/, in. in length.
Test No. 12
This test was conducted to determine the most
practical nondestructive method of inspecting welds
(for underbead cracking) made on pipe lines full of
liquid under pressure. Patches cut from Grade X52
pipe were welded to a Grade X52 pipe chamber
cooled to 25° F. Welding was done with E6010 and
E7010 electrodes. Experience gained in our first
tests revealed that cracking would definitely occur
under these conditions. On some of these patches,
cracking occurred in the fusion zone between the
weld metal and the patch before the welds were Fig. 18—Failure which occurred at 2200 psi in longitudinal
completed (Fig. 21). These cracks were visible to seam of sleeve in Test No. 9
the naked eye. On completed welds where cracks
were not visible to the naked eye, dye-penetrant
material was used as an inspection medium. This
inspection exposed several cracks in the fusion zone
between the weld metal and the patch, also between
the weld metal and the chamber (Fig. 22).
Test No. 13
To determine whether dye-penetrant material, if
used for weld inspection, would consistently expose
underbead cracks, two size 16- x 33-in. patches cut
from Grade “B’”’ pipe were welded to a Grade X52

332 | APRIL 1959

ee)
= ge 2Bexr aea?
Pe 5 EELS
 By comparing the results of the various tests, API 5L Grade ‘“‘B”’ and 5LX Grade X42
new welding procedure was established. Also, a. Use fittings that completely encircle the
materials and equipment that were considered satis- pipe when welding is required for making
factory for making repairs and installing connections repairs, or for installing new connections on
on any pipe of the grades currently in use throughout pipe 12°/, in. OD and above.
our company’s system were selected. . Use E7016 low-hydrogen iron-powder elec-
It is common practice throughout the pipe-line trodes for all welds which are fused to the
industry to repair corrosion pits on common grades pipe wall, if the surface temperature of the
of 5L pipe by filling the pits with weld metal fused pipe is below 50° F. (E6010 electrodes may
to the surface of the pipe, or by welding patches over be used for welds which are fused to the
the pits. However, this method should be re- pipe wall, providing the surface tempera-
stricted to the low- and medium-carbon grades of ture of the pipe is above 50° F.
pipe.
As a result of these findings, it has been recom- General
mended that our company adopt the following proce- a. The longitudinal seams of fittings designed
dure for repair ard maintenance welding on pipe lines to encircle the pipe shall be equipped with a
that contain oil or petroleum products: steel backup strip to prevent the weld metal
deposited in these seams from fusing to the
API 5LX pipe, Grades X46 and X52 wall of the carrier pipe.
a. Use fittings that completely encircle the . Carefully check all completed welds for
pipe. This holds true regardless of pipe underbead cracks with dye-penetrant ma-
size, when welding is required for making terial.
repairs, or for installing new connections The operating pressure in a pipe line at the
onto a line. location of welding shall be reduced to 200
. Use E7016 low-hydrogen iron-powder elec- psi before any welding is started. This
trodes for all welds which are fused to the pressure shall not be increased until all
wall of the pipe. welding on a line is completed.

Fig. 19—Installing and welding sleeve with iron-powder Fig. 21—Underbead crack between weld and patch
electrodes on test chamber cooled to 25° F which occurred before weld was completed
» —_
‘
.
°

es
Fig. 20—Installing and welding sleeve with iron Fig. 22—Underbead cracks located with dye-penetrant
electrodes on test chamber cooled to 25° F inspection
 | SP PE
ee _# og Re <*>7 > ~ ee
ie

Progress Report

on the

Flux-Cored CO.

Welding Process

indicates that it has found many and flux-cored electrode provides a stable arc. This is
apparently due to the reaction between the oxygen
diversified applications in industry supplied by the CO., and the flux compounds.

since its introduction about two years ago Use in Industry

Since the introduction of the flux-cored CO
welding process about two years ago, it has found
many and diversified applications in industry.
BY A. F. CHOUINARD AND J. A. HOWERY
The different types of weldments to which this
process» has been applied are numbered in the
hundreds. They include all types of joints on rail-
road hopper cars, bearing supports, box girders,
the main frames for heavy-duty hydraulic presses,
storage tanks and pressure vessels (some made ac-
Introduction cording to code work), and roof trusses almost
150 ftinlength. This list, as long as it is, has covered
In April 1957, a paper entitled “‘A New CO, Welding
but a few of the uses to which this versatile process
Process,” was presented at the AWS National
has been successfully applied.
Spring Meeting. As a follow-up to this paper, this
This paper will discuss some of the actual case
second report has been prepared.
histories of the flux-cored CO. welding process, as
A few words reviewing the basic principles of the
recorded at users’ plants, but it is necessary to
process are necessary. This flux-cored CO, welding
first discuss the electrodes which have made pos-
process employs carbon-dioxide gas as a shield to
sible this wide range of uses.
exclude air from the arc and the molten metal.
The flux compounds in the electrode have the Electrodes Used with this Process
following functions: Even though the construction of the flux-cored
1. Some of them are deoxidizers which, by re- electrode is rather well known by now, a quick re-
ducing mill scale, help to purify the weld view of the method of manufacture should be of
metal. interest.
2. Some of them are scavengers which eliminate The electrode is made by forming steel strip into
impurities. a U-shape, and filling the interior with especially
3. Some of them are slag formers which, by form- prepared core material containing the degasifiers,
ing slag, prevent contamination of the weld scavengers and slag formers. The method of manu-
metal during and after solidification. facture of this electrode is shown in Fig. 1. This
The action of all of these flux compounds plus the schematic drawing shows how the steel strip is fed
CO, shield prevents porosity in the weld. into the forming rolls. When the strip has been
With the flux-cored process, there is none of the formed into the U-shaped section, the proper amount
excessive spatter associated with CO, welding. of flux is placed in the groove. Succeeding roll
Furthermore, the combination of CO, and the stations complete the forming and closing operations
in the production of this electrode.
A. F. CHOUINARD is Director of The Research and Development This flux-cored electrode is made in a */;, in. diam.
Department and J. A.HOWERY is Technical Service Supervisor for the and in succeeding operations is reduced to four other
National Cylinder Gas Division of Chemetron Corp., Chicago, Ill.
sizes. 'The smallest of these is the */,,-in. size.
Paper to be presented at AWS 40th Annual Meeting to be held in
Chicago, Ill., April 6-10, 1959. The flux-cored electrode is usable in a manually

334 | APRIL 1959

held welding gun for semiautomatic welding oper-
ations. A machine welding torch can also be used
with this process.
The type of electrode used is the key to the success
of the flux-cored process, as this electrode controls
the chemistry of the weld metal, in addition to
providing arc stability, slag formation, and protection
against contamination. Prior to the development of
the first commercially used electrode, many years of
research were spent on hundreds of composite
formulas. A commercial electrode, released in 1957,
was made for one- or two-pass welding on mill-
run stock of plain-carbon steel.
Single-Pass Electrode for Mild Steel
This electrode, hereafter designated as Electrode
No. 110, was designed for the welding of plain-
carbon steel having a maximum carbon content of
0.35%. It is considered a single-pass electrode even
though it can be used quite successfully up to a maxi- ELECTRODE
mum of 3 passes or '/, in. thickness, and still obtain mie) iA 130 451
good physical properties. AT WF ae 60 39 30
This electrode can be used to weld steel plate AT OF <4 45 32 2
covered with mill scale. It can also be used to weld AT -29F 12 30 26 10
rusty plate. This feature of the 110 electrode is due AT SOF 9 5 is 9
to its chemical composition. However, this compo-
sition limits the number of passes that can be made 60 ——llA
with the electrode to three. 50 —— 10
40 —— 150
Multipass Electrode for Mild Steel » -—— Bi
20
The flux-cored electrode hereafter designated as
111A is a multiple-pass electrode used to weld
plain-carbon steel having a maximum carbon TEMPERATURE IN °F
content of 0.35% A tensile strength of 70 to 75,000 Fig. 2—Impact-strength values in ft-lb (Charpy V-notch)
psi can be obtained in the as-welded condition on
A285 plate. An elongation of 28% in 2 in. is normal
with this electrode and good impact values are ob- Experience also indicated the necessity of develop-
tained at reduced temperatures. ing a multipass electrode that can weld other types
This electrode, in tests supervised by the American of low-alloy high-tensile steels used in code work.
Bureau of Shipping, was certified to meet ASME This electrode was developed and it will be referred
Boiler Code Specification A-233. to hereafter as No. 151.
This multipass electrode can be used to weld low-
Multipass Electrodes for Low-Alloy Steels
alloy high-tensile steels conforming to metals
It was true that the 110 electrode referred to
specified under ASTM A316-54 AWS 5.5-54 and
previously could be used, under certain conditions, MIL-E-16589 (Bureau of Ships).
for the welding of T-1 and A285 steels. However,
The weld deposit obtained has a nominal compo-
continued experience pointed out the need for an
sition of 1.25% chromium and 0.5°%% molybdenum.
electrode which could provide better physical
properties. To meet this need, Electrode 150 was Physical Properties
released. Tables 1 through 5 and Figs. 2 and 3 give the
The 150 flux-cored electrode is a multiple-pass type physical properties of all four of these electrodes.
electrode. The weld deposit obtained has a nomi- These data were obtained from tests conducted in
nal composition of 1.0% manganese and 0.5% accordance with specifications of the AMERICAN
molybdenum. WELDING Society, with the exception that the
This electrode may be used to weld T-1 steel, 110 electrode was run on '/,-in. plate in order to
AISI 4130 steel, and other high-tensile steels that study physical properties of the electrode at the
fall into this general category. maximum 3 passes for which the electrode is recom-
In both the as-welded and stressed-relieved con- mended.
ditions, tensile strengths slightly over 100,000 psi Tables 1 through 4 show the yield points, tensile
are readily obtained on T-1 steel. A strength of strengths, elongations, reductions of area, and
88,000 psi is easily obtained on A285 plate stock. Brinell hardnesses for all four flux-cored electrodes.
Elongations of 25% on T-1 steel and 22% on A285 Figure 2 shows the impact strength, using the
may be obtained. Charpy impact specimens, and Table 5 shows the

WELDING JOURNAL | 335

38 |; APRIL La09

Table 1—110 Electrode—Single-Pass Plain-Carbon Steel Table 5—Chemical Composition of Weld Deposits
A-285, '/2-in. A-285, */,-in. 1/, in. ———A-285, */, in. plate———.
plate as- plate as Element 110 110 111A 150 151
Physical properties welded welded Carbon, % 0.10 0.12 0.08 0.05 0.14
Tensile strength, psi 86 ,000 97 ,000 Manganese, % 0.90 1.30 0.80 1.24 0.68
Yield strength, psi 78 ,000 87,000 Silicon, % 0.45 0.75 0.40 0.27 0.90
Elongation in 2in., % 27 13 Chromium, % + a + ~ 1.50
Reduction of area, % 57 15 Molybdenum, % a x * 0.49 0.58
Brinell hardness, 3000-kg load 215 222
Table 6—Steels Weldable by the Flux-Cored
Table 2—111A Electrode—Multiple-Pass Plain-Carbon Stee! CO, Welding Process
A-285, */,-in. A-285, °/,-in. AISI classification Use electrode:
plate as- plate stress
Physical properties welded relieved Carbon steels
1005-1029, 1030-1040 (( 110 and/or 111A
Tensile strength, psi 70,000 68 ,000
Yield strength, psi 60,000 58 ,000
Elongation in 2 in., % 28 32 Ni-Cr steels )
Reduction of area, % 50 60 3115-3130, 3135-3150
Brineli hardness, 3000-kg load 162 160 Mo steels
4017-4028,"4032-4068
Table 3—150 Electrode—Multiple-Pass Low-Alloy Cr-Mo steels
High-Tensile Steel 4130-4132, 4135-4150
A-285, Chromium steels
‘/,-in. 5120-5130, 5132-5152 |
150 and/or 151
plate T-1, */,-in. plate Cr-V steels
stress As- Stress 6120
Physical properties relieved welded relieved
Ni-Cr-Mo steels
Tensile strength, psi 88,000 101,000 100 ,500 8615-8627, 8630-8660
Yield strength, psi 76,000 86,000 88,000 8720-8735-8750
Elongation in 2 in., % 22.5 25 26 9747-9763
Reduction of area, % 55 47 54
Brinell hardness, 3000-kg load 228 228 228 Mn-Ni-Cr-Mo steels
9437-9445 J
Table 4—151 Electrode—Multiple-Pass Low-Alloy
(1'/, Cr-'/, Moly) High-Tensile Steel
A-285, */,-in. plate
Physical properties stress relieved
Tensile strength, psi 145,000
Yield strength, psi 122,000 chemical compositions of the weld deposit obtained
Elongation in 2in., % 16 with each electrode.
Reduction of Area, % 40 Figure 3 is a graphic representation of tensile and
Brinell hardness, 3000-kg load 283 yield-strength values and Table 6 lists the metals
that can be welded with the flux-cored CO, welding
process.
Figures 4 through 8 show a few of the many test
samples that were made in evaluating the experimen-
tal electrodes. Many tests of these types were
made to determine accurately the physical values of
the weldments made with the flux-cored electrode.
Mentioning these five figures individually, Fig. 4
shows 0.505 tensile specimens from the tensile
tests; Fig. 5 shows 180-deg face and root-bend
specimens from the bend tests; Figs. 6, 7 and 8
show etched cross sections from butt, fillet and lap
weld tests.
Metals Weldable with Flux-Cored Process
The physical properties shown in Tables 1 through
5 and Figs. 2 and 3 indicate the suitability of all
four of these electrodes for welding plain-carbon and
some of the low-alloy steels. These low-alloy steels
THE 10 AM@ 1A ELECTRODES ARE USED TO WELD PLAIN~CARBON STEELS
have specific trade names; however, all of them are
THE GO © Gi ELECTRODES ARE USED TO WELD LOW ALLOY HGH TENSEE STEELS similar in chemical and physical properties. In most
Fig. 3—Tensile strengths of weld deposits cases, they can be welded by one or another of the

336 | APRIL 1959

Fig. 4—0.505 tensile specimens Fig. 6—Etched cross sections of butt welds

e
o

Fig. 5—180-deg face and root-bend specimens Fig. 7—Etched cross sections of fillet welds

~ we

flux-cored electrodes available at the present time.

The 150 and 151 flux-cored electrodes may be con-
sidered to be low-alloy high-tensile types.
Case Histories
The flux-cored CO, welding process has found in-
creasing and diverse uses in the last two years.
Visits were made to various plants using this process
in order to
1. determine the useiulness of the process, and
2. obtain welding and other operating data.
Information on these two points was obtained and
has been used to prepare this progress report on the
flux-cored CO, welding process.
Among many others, 6 plants were visited and were
chosen as having interesting case histories. They
will be referred to in this report as Plants A
through F.
Plant A
This plant makes track-laying vehicles for the
U. S. Army. The vehicles are equipped with guns
and can be dropped on an area by parachute. Fig. 8—Etched cross sections of lap welds

WELDING JOURNAL | 337

 Fig. 9—Steel suspension arms made of 4130 steel for
U. S. Army track vehicles

The vehicle body itself is made of aluminum. The

parts welded by the flux-cored CO, welding process
Fig. 10—Fabricated sections of skid shovel
are the suspension arms, which hold the wheels,
the gun support and the gas tank. The suspension
arms are AISI 4130 steel and the gun support and are welded. Currents of 350-400 amp and voltages
gas tank are AISI 8620 steel. of 28-30 are used.
These parts were formerly welded using stick Welding speeds of 20-25 ipm are obtained, as
electrodes, at a welding speed of 6ipm. CO, welding compared to 6 ipm with stick electrodes.
using conventional solid-core wires was tried next The result is an ultimate strength, in the as-
with adverse effects on performance, appearance, welded condition of 101,000 psi, and a yield strength
and quality. Considerable repair work had to be of 83,000 psi. Elongation averages 24°; and reduc-
done because of (a) undercutting adjacent to the
tion in area averages 47%.
weld area; (6) inability to maintain proper fillet Figure 9 shows the welded suspension arms used
size in the horizontal plane; and (c) abnormal on track vehicles.
amounts of weld spatter having to be removed.
Because of these problems, repair charges increased Plant B
the cost of the CO, welding using the solid-core This company makes front-end loaders, skid
wires over that of the stick-electrode method used shovels, buckets and lift arms for use with tractor
previously. equipment. Practically all the welding done on
Plant A then decided to experiment with the these loaders and buckets is done using the flux-
flux-cored CO, welding process. It was found that, cored CO, welding process.
by using this process, all of the problems experienced Man-Ten, T-1, and mild-steel thicknesses of
with the solid-core wires were eliminated. Also ‘'/s to 1 in. are welded with this process, using the
obtained with the flux-cored CO, welding process 150 electrode. It is reported by plant B that not
were: (a) proper physicals; (6) good weld ap- only has weld quality been improved by using the
pearance; and (c) savings in weld time and costs flux-cored CO, welding process, but that a savings in
all items with which Plant A is very much concerned. weld time of as much as 40% for some parts, has
With the flux-cored CO, welding process, Plant been realized. They have found that the flux-
A is using the 150 electrode to weld '/,, °/, and 1'/, cored CO, welding process is much faster than stick-
in. thicknesses. Ninety-deg, Tee and groove joints electrode processes, welding at a speed of about 18

338 | APRIL 1959

Fig. 1l—New-type covered hopper car

git RALPay ia
BLUE ISLAND. ILL

Fig. 12—Side view of welded hopper section Fig. 13—Fabricated gear blank showing the butt-weld area
before welding

ipm, compared to about 5-6 ipm for stick electrodes.

4. Penetration is better than with iron-powder
Penetration has been very good, with good weld
electrodes and better than with conventional
appearance. Weld quality is an important point
stick electrodes.
with Plant B and they have been able to get the
5. There is less time spent on metal preparation,
quality they want with the flux-cored CO, welding
such as champfering of plate edges. The champ-
process.
fered edge can be considerably less because of the
Figure 10 shows fabricated sections of a skid shovel
penetration qualities of the electrode.
made at Plant B.
Figure 11 is a picture of a new type covered hop-
PlantC per car made at Plant C, and Fig. 12 is a picture of
Plant C makes covered hopper cars for a number a welded hopper section on this car.
of railroads. Currently, all new covered hopper Plant D
cars being made at this plant are welded almost
Plant D makes gear blanks, using AISI 1035 steel
entirely with the flux-cored CO. welding process.
for the ring. The flux-cored CO, welding process,
This includes the side assemblies, the hoppers and
employing the 111A multipass electrode, is used to
the roof.
butt weld vee joints on gear rings, as shown in
These hopper cars are 47 ft long, with side as-
Fig. 13. The thickness of the ring material ranges
semblies that are 9 ft high.
from 1'/, to 3'', in. The width of it ranges from
The 110 electrode, -in. size, is used to do this
3'/,to 12 in.
welding. When Plant C used stick electrodes to
Plant D provided a cost comparison for this gear-
do this work, weld speed was only about 6 ipm.
gap welding, as shown in table on next page.
Now, with the flux-cored electrode, the weld speed
is 19 ipm. Use of Flux-Cored CO. Welding Process for Spot Welding
The use of the flux-cored CO welding process Before discussing the next case history, it is neces-
has been found justifiable by them because: sary to talk about the use of the flux-cored CO,
1. The welding speed possible with this process welding process for a very useful and economical
has resulted in an obvious increase in production application—-spot welding.
and savings in weld time. Flux-cored CO, spot welding can be used for those
2. A greater percentage of distortion has been steels that are ordinarily resistance welded. This
eliminated. includes metal fabrication for the automotive in-
3. There is less time spent on surface preparation, dustry. The process requires an arc spot-welding
such as removal of mill scale or rust. gun through which the fiux-cored wire is fed.

WELDING JOURNAL | 339

 to spot weld the stop bars on the jail and prison
COST STUDY OF GEAR-GAP WELDING door frames. These stop bars, found on both door
This study was made on six (6) gears, size 22'/, OD (rough) jambs and headers for the full length of the door,
and 2-in. ring x 4'/,-in. face are usually '/, xX 1'/. in. A simple jig is used to
locate those parts, and then the spot welding is
Using Flux-Cored CO, Welding Process
(111A Electrode) performed from the door frame side, which is usually
'/i¢ in. thick.
Procedure Time, minutes
Other applications of the flux-cored CO, spot-
Oxygen-cutting gap 10
welding process include the bunks and shelves men-
Total time required for butt-weiding gap,
includes welding gap and sides and tioned previously. Many other items which were
finishing up with fillet welds 33 formerly riveted or arc-welded are now welded with
Total time for cutting and welding 43 the flux-cored CO, welding process.
Remarks: welding was done on floor (no positioner). Furthermore, it is reported by Plant E that when
the cell bunks were welded with resistance welding,
Hand-Welding Process
two men were required. With the flux-cored CO
Procedure Time, minutes welding process, only one man is required to do the
Oxygen-cutting gap 10 job.
Butt-welding gap 75
Torch-trimming sides and rewelding 18 Also, it is indicated that considerable time and
Finishing up with fillet welds 7 labor savings had been realized on the bunks, book
Total time for cutting, trimming, and shelves and door frames.
welding 110
Remarks: welding done by experienced
operator on positioner.
Results
Total time, using hand-welding process 110 Minutes
Total time, using flux-cored CO, welding process 43 Minutes
Difference 67 Minutes
A 60% time savings was realized, using the flux-cored CO
welding process.

CO, is, of course, used as the shielding gas for the

weld area.
The process offers these advantages:
.
Very fast spot-welding speeds. Fig. 14—Mild-steel book shelf spot welded using
2. Full penetration. flux-cored process
3. Savings in weld material costs.
4. It is possible to spot weld through material as
thick as '/, in., without using a hole in the
upper piece. The arc penetrates through this
upper piece to make the necessary bond. For
thicknesses over '/, in., a hole is preferred.
5. Where it is difficult to resistance weld because of
location and inaccessibility, this flux-cored CO,
spot-welding process can be used with ease.
Plant E
This company is one of the oldest manufacturers
of prison equipment in the United States. The
parts welded with the flux-cored process include
prison bunks, door frames, and book shelves. These
products are made of mild steel, and are spot welded
with the 110 electrode, */;. in. diam. These bunks
consist of */\,-in. framing and '/;-in. plates.
Formerly, resistance welding, riveting and arc
welding were used to weld this equipment. The
flux-cored CO, spot-welding process saves the time
formerly required for layout, punching, fitting,
riveting and chipping. Fig. 15—Mild-steel prison bunk ready for spot welding
The spot-welding equipment, in one case, is used using flux-cored process

340 | APRIL 1959

 A
Fig. 16—Repaired steel castings

Figures 14 and 15 show two of the weldments process, many plants have used the process suc-
produced using the flux-cored CQO. spot-welding cessfully. The scope of its application, ranging from
process at Plant E. plain-carbon to low-alloy high-tensile steels, has
increased appreciably.
Plant F
The process is also being used in spot welding and
Another good example of the diversification of the in foundry repair welding, with good savings in
flux-cored process is its use for repair welding in the weld time and costs.
foundry. In this application the flux-cored wire is It has also been found that a relatively small
used as a filler metal for casting voids and cavities amount of time is required to train operators to use
caused by sand erosion and other casting problems. the process and that, once they have been trained,
Savings run from 40 to 65“. they have little difficulty using the process to its
Since repair work can be such a critical cost in best advantage.
foundries, the savings are very significant. The four flux-cored electrodes which are used with
Plant F is a foundry, that like many other found- this process are:
ries, is interested in cutting repair costs. This
was the primary reason for selecting the flux- No. 110—A single-pass electrode for plain-carbon
cored CO, welding process to repair defective castings steels with a maximum carbon content of 35
or castings having sand erosions. points.
The type 110 wire, in., is used as a filler metal No. 111A—-A multipass electrode for the same
to fill large voids and cavities in the castings. These steels welded by 110.
castings are used as parts of machinery frames and No. 150 and 151—-Multipass electrodes for high-
air cylinder trunnions. They vary in thickness tensile low-alloy steels.
from 1 to 2!/»in.
With the flux-cored CO, welding process, a very All of the multipass electrodes produce weld de-
clean flat weld requiring very little grinding, is posits that can meet code specifications.
obtained. Plant F reports that savings of 50 to The oxidizing, scavenging and slag-forming flux
60% are realized over the stick-electrode method. compounds, the greater amount of weld metal de-
Figure 16 shows some of this repair welding at posited with better penetration, the higher welding
Plant F. speeds, the combination of inexpensive CO, and the
flux compounds to provide arc stability, and the
Summary better weld quality obtained, are all factors which
In the two years following the release of the first have increased the scope of application for the
commercial electrode for the flux-cored CO, welding flux-cored CO. welding process.

WELDING JOURNAL | 34)

 — ’

AKELEON 2s |

eo

er
"O'=

Fig. 1—The 20-in. heavy-duty lathe of the new line

Original engineering thinking and willingness to depart from

convention are found to be essential factors in

Development of Welded- Steel Lathes

BY GORDON M. SOMMER

SYNOPsIS. ‘This paper discusses the basic objectives of a increase in weight, to meet more fully the de-
new lathe development and the reasons a welded-steel mands of carbide and ceramic cutting tools.
design is used. It also demonstrates the type of original
engineering thinking and willingness to depart from con- To provide a greater range of spindle speeds
vention that is essential to take full advantage of the with more closely spaced steps.
freedom of design possible with welded steel. The use of To increase horsepower.
models and the welding of the lathe structures are also To develop one basic design that provides for
discussed. either manual shifting or pre-selected power
Product Inception shifting for the different spindle speeds.
Clearing Machine Corp. started to manufacture and To evolve a basic design that could be modified
market the Axelson lathe in early 1958, when this easily from both the design and fabricating
lathe line was transferred to its plant from another standpoint to meet a broad range of customers’
division of U. S. Industries, Inc. It was decided, at special requirements.
that time, that the company would develop a new 6. Cost reduction.
line of lathes that would be totally different in con-
cept, appearance and operation from anything on It was decided that the lathe would be of welded-
the market. The 20-in. heavy-duty lathe is shown steel construction in the early stages of product
in Fig. 1. The basic objectives were as follows: inception, because it was the only practical way to
achieve the degree of rigidity that was sought.
1. To build a lathe at least several times more This decision was bolstered by extensive welding
rigid than competitive equipment, with no experience in the building of hydraulic and mechan-
ical presses. It was further determined, after
GORDON M. SOMMER is Vice President —Engineering, Clearing preliminary design studies, that welded fabrication
Machine Corp., Chicago, Ill
would provide manufacturing economy over cast-iron
Paper to be presented at AWS 40th Annual Meeting in Chicago, IIl.,
April 6-10, 1959 construction. The company’s well-equipped weld-

342 | APRIL 1959

 ing facility vs. its lack of a foundry was also factored bed still extends through this basic driving assembly.
into the final decision. Just as important was the Since clean, streamlined appearance of a machine
inherent flexibility which welded construction offered tool is essential, and because these driving mech-
in providing almost any type of “‘special” that could anisms are run in an oil bath which must be kept
be sold in the future. Once it was established that from leaking, the conventional approach to lathe
the lathe would be fabricated, the design was no design has created difficult sealing and appearance
longer dictated by the pattern maker. It was, also, problems. Their solution requires what may be
known from past experience that the potential of called “‘busy”’ design.
welded-steel construction is not fully exploited if it Welded-steel construction of the headstock made
simply copies cast construction. Further, in the it possible to extend the headstock to the floor and,
case of a complex machine tool, it does little good to thus, create a separate integral unit that contained
provide flexibility in the design and construction of all the basic driving mechanisms of the lathe. This
the structures, if the basic concept of the machine made it very easy and straightforward to obtain
and the design of the driving mechanism are not also good styling of the machine and good control of the
flexible. oil. This type of design would be very difficult and
expensive with cast construction because of the large
Design Concepts cubic volume of the unit and the relatively thin sec-
A critical analysis was made of the historical de- tions employed. The welded construction allowed
velopment of engine lathes to help evolve the basic the designers to place the material where required
design concept of the new lathes. This is shown by machine rigidity without concern of casting limi-
pictorially in Fig. 2. These sketches show how the
lathe, in its most rudimentary form, consisted of a
bed, tailstock and headstock. The headstock was
simply a housing which mounted the spindle. Sev-
eral step pulleys were attached to the spindle so it
could be driven at several different speeds from an
overhead lineshaft. This made mounting the head-
stock on top of the bed a very straightforward and
logical approach. The lathe has increased in com-
plexity ever since. First, a back-gear drive in the
headstock and a gear drive down to the lead screw
and feed rods were added. A quick-change gear
box, self-contained gears in the headstock for a
large number of spindle speeds, self-contained electric
motor drive, etc. were added later. These units Fig. 3—Sketch of headstock showing the use of a unitized
combine to become the complete driving assembly 20-speed drive unit. This sketch also shows how the bed
for the lathe. Yet, in conventional lathe design, the is flange mounted to the headstock

Fig. 2—Pictorial representation of the historical development of engine lathes which

was Studied to help evolve the basic design concept of the new lathes

WELDING JOURNAL | 343

 Fig. 4—This illustration shows how the bed, chip pan and pedestals of a conventional engine lathe are combined into an
integral unit in the new welded-steel lathe which almost doubles the depth of the bed structure

tations and technology. The rigidity of the spindle cipally because of the limitations of casting |tech-
mounting and the surface that flange mounts the bed nology. Since welding did not present these limita-
are of primary concern in the headstock. The bed is tions, it was a very obvious decision to incorporate
flange mounted to the headstock as shown in Fig. 3. these three elements into the single structure.
This configuration provides the utmost in design The “old school’”’ designers and mechanics often
flexibility. For instance, the front-to-back distance claim that welded-steel construction is no good for
| between the bed ways can be increased to meet the major machine elements because steel does not dam-
special requirements of the missile and aircraft in- pen vibration as well as cast iron, and that welded-
) dustries, without changing the headstock. In fact, steel ‘“‘creeps’”’ and distorts with use and age. This
almost any conceivable type of bed can be applied first claim is easily verified by comparing published
to a standard headstock. vibration dampening curves. What this argument
Further flexibility was obtained by developing a fails to consider is that it is so easy and economical!
self-contained drive unit which provides twenty to increase rigidity with welded-steel. This in-
speeds in 13.6% steps and includes the main clutch crease of rigidity reduces vibrations by the same
and brake. This unit mounts to the headstock with magnitude. Thus, the relative vibration dampening
4 bolts. A high-low gear set is incorporated as an characteristics are no longer important. The second
integral part of the headstock structure. Manual argument is simply erroneous and is not verified by
shifting of the drive unit is standard. The manual the facts if the structure is carefully and properly
shifting panel can be replaced in about 4 hours with stress relieved. This argument once to prevail in
another panel for pre-selected power shifting. This the power-press industry.
can be done when the lathe is built or retrofitted at Today, all large presses are made of welded steel.
any time in the field. More and more of the very small presses are now
Figure 4 shows how the bed, chip pan and pedes- even being welded for economy. Besides this,
tals of a conventional engine lathe are combined into grinders, broaches, transfer machines, and all types
an integral unit in this new welded-steel lathe. Con- of special-purpose machines have used this type of
ventional engine lathes are built, as shown, prin- fabrication with good results. Many jigs and fixtures

344 | APRIL 1959

 that require close accuracy have also been welded haustive testing has proved that the vibration dam-
with success. pening problem has been solved by this high degree
of rigidity.
Use of Models The accuracy of a conventional lathe is deter-
Different types of models are used by the author’s mined, to a large degree, by how accurately the
company to study design concepts and as an im- machine is leveled. Leveling is not nearly as critical
portant design tool when a new development pro- with this lathe because of its rigidity.
gresses. A well-equipped model shop is maintained The conventional cast-lathe bed incorporates cast
for this purpose. Very rudimentary scale models, ratchet-shaped teeth that act as a backup for the
which are made of cardboard and masking tape, are tailstock, under heavy loads. This is a most natural
often used in the early stages of a program. In the and economic method because these teeth are ob-
case of the lathe bed, many of these small models tained for ‘‘free’”’ in the casting. To provide such
were made to evaluate quickly the bending and tor- teeth in the welded bed would have been quite ex-
sional rigidity of different plate configurations. pensive. Instead, a totally new method of providing
Several of the more promising approaches were then tailstock backup was developed, utilizing the traverse
analyzed analytically. rack and a mating rack segment on the tailstock.
Scale clay models are also used to aid in these early This not only provides for close spacing of the tail-
parametic studies. These are often supplemented stock but, since the clamp is in front, also simplifies
by stylists’ drawings. Full-scale wooden models of tailstock clamping.
the headstock and bed were made to check assembly,
weldability and final appearance. These models are Welding of the Lathe Bed
also invaluable to the methods and tool design de- The major steps of a well planned welding opera-
partments to aid them in planning production weld- tion are as follows:
ing and machining fixtures, and general production 1. Preparation of cutting templates.
planning. Figure 5 shows the headstock model dur- 2. Preparation of details.
ing process of construction. This model was com- 3. Welding setup.
pleted in detail for styling studies and looked ex- 4. Welding.
actly like the finished headstock. An independent 5. Stress relieving.
styling firm was employed on this lathe program to 6. Shot blasting.
help determine final styling. 7. Testing and priming.
Design of the Lathe Bed Careful control of each step is essential for any
The design of the welded-steel bed for the lathe is
an interesting example of the type of engineering
thinking and the willingness to depart from conven-
tion that, the author believes, is so essential if the de-
sign potential of welded-steel is to be fully exploited.
As mentioned earlier, it was very obvious to com-
bine the bed, chip pans and pedestals into an integral
unit because of the willingness to depart from what
has been done for so long. Figure 4 shows how this
almost doubles the depth of the bed structure.
Since the front wall must resist most of the force of
the cutting loads, it has been extended down to the
floor and kept solid. The chip pan on the lathe must
extend considerably to the front and rear of the bed
to perform its function adequately. This member
contributes significantly to the horizontal rigidity of
the bed when combined as an integral unit.
The torsional rigidity of a lathe bed is also ex-
tremely important. Preliminary model studies and
final analysis showed that pyramid-shaped reinforc-
ing ribs would result in high torsional stiffness.
These ribs also form the walls of the chip disposal
chutes in the bed as shown in Fig. 4 and effectively
tie the heavy rails which form the bed ways to the
front and rear walls. The original objective was to
have several more times rigidity. This triple bar-
relled approach, when combined with the increased
modulus of elasticity of steel over cast iron, netted
an eighteen-fold increase in the rigidity of the bed Fig. 5—Photo of full-scale wooden model of headstock
without increasing the weight of the machine. Ex- during process of construction

WELDING JOURNAL | 345

 344 |; APRIL 1959

weldment if quality and costs are to be under con- element must be analyzed for function, appearance
trol. This control is of utmost importance on the and cost to determine the best material to be used.
lathe bed. Welded-steel construction is ideal for the headstock
Accuracy of the details that form the interlocking and bed of the lathe for the many reasons which
triangle sections is very important because of the have been mentioned. On the other hand, cast
compound joint lines; thus, all oxygen cutting is construction is used for the quick-change gear
done using metal templates. The ways are rough box, tailstock, apron and cross-slide for economy and
machined from rectangular bars and stress relieved appearance. All of these machine members are
before welding. A */,-in. stock is allowed for final relatively small in size and would require a multi-
machining of the bed. plicity of small details to form the walls, ribs and
The welding fixture used for the bed is shown in bosses. It is not economical to fabricate these
Fig. 6. It provides ease of setup and good accessi- components in the company’s weld shop which is
bility for welding. Underside welds are made after principally equipped to handle heavier and larger
removal from the fixture. Steel with a 0.22-0.29% weldments.
carbon content is used for all weld details. E6020 The importance of using castings to obtain econom-
welding electrodes are used. ical styling effects should not be minimized either.
For stress relieving, the furnace temperature is They can dramatically embellish weldments that
raised at a maximum rate of 125° F per hr. The are kept straight and clean for ease and cost of
structures are soaked at 1175° F for 4 hr. The fabrication. If production volume is high enough
furnace temperature is then lowered at a maximum to warrant the cost of forming dies, these same effects
125° F per hr rate to 400° F at which time the parts can, of course, be obtained with the use of weld-
are removed. The temperature is increased and de- ments combining stampings.
creased by cam control and is recorded at 8 positions
Conclusion
by automatic charts. Structures are shot blasted
after stress relieving to remove furnace scale and to Weldments on lathes are not new. Several com-
provide a good base for painting. Testing for leaks panies have used welded items on their lathes for
(the chip pan also contains the cutting coolant shipboard use with success to offset the detrimental
sump) and prime coating complete the welding effects of a weaving deck. As far back as 1939, the
operation. Germans built and tested several welded-steel lathes.
These were satisfactory in all respects except cost
When to Use Weldments and were not marketed. The new lathe just de-
Many engineers make a very common error when scribed is economical and in production because it was
designing a welded-steel machine. They seem to designed to use weldments and was not just a copy
feel that all elements must be welded design once it conversion from castings to welded steel, but rather
has been decided that the machine will be principally a totally new design. It takes full advantage of the
welded-steel construction. On the contrary, each freedom of design possible with welded steel.

Fig. 6—Drawing of welding fixture that is used for welding of the bed. The bed, which is shown in dark lines, is set up and
welded in the fixture in the inverted position. Underside welds are made after removal from fixture
Artist’s concept of the 100,000-kilowatt Enrico Fermi Atomic Power Plant as it will look when completed in 1960.
The plant is now under construction at a site on the western shore of Lake Erie about 30 miles south of Detroit, Mich.
(Designed and developed by Atomic Power Development Associates, Inc., Detroit, Mich.)

The Welding of Inconel

for Nuclear-Power Applications

ABSTRACT. It is becoming generally accepted that

Inconel-tubed steam generators weldments used in nuclear-power reactor systems must
meet more rigid quality standards than are required by
can be welded to conform to the desired most present-day codes and specifications. A demonstra-
tion that weldments can be produced to these standards
quality levels through the use of suitably has become an important part of the qualification pro-
cedure leading to the acceptance of any material used in
the construction of nuclear components. In the present
controlled inert-gas processes and a work, it has been demonstrated that, by the use of suita-
bly controlled inert-gas processes and a titanium-manga-
titanium-manganese modified filler wire nese modified Inconel filler-wire composition, Inconel-
tubed steam generators can be welded to conform to the
desired quality levels
BY W. A. FRAGETTA AND G. R. PEASE Introduction
Inconel has been known and used in high-tempera-
ture applications for many years. More recently,
there has been considerable interest in the use of
Inconel for the construction of certain nuclear-power-
W. A. FRAGETTA and G. R. PEASE are associated with the Research plant components, particularly in systems of the
Laboratory of the International Nickel Co., Inc., Bayonne, N. J
pressurized-water reactor type.
Paper to be presented at the AWS 40th Annual meeting tofbe held in
Chicago, Ill., Apr. 6-10, 1959 Weldments used in nuclear-power reactor systems
 must meet more rigid quality standards than those
required in conventional power-plant applications.
The investigation reported herein was undertaken to TY 308 ss.
demonstrate the feasibility of producing Inconel TRANSITION WELD
weldments to the quality requirements stipulated in u
OVERLAY
specifications for nuclear service.
Inconel will be used as a material of construction
in pressurized-water systems primarily in the form @ TUBE - TO- TUBE
SWEET WELO
of heat-exchanger tubing and tube-sheet overlays.
Therefore, the major emphasis in this program has Fig. 1—Three types of welds encountered in
been on the production of three types of weldments steam-generator construction
used in heat-exchanger construction, namely: (1)
overlaying of carbon-steel tube sheets with Inconel-
type weld metal; (2) welding heavy-section transi- PENDULUM STRAIGHT - LINE
tion butt joints between Inconel and 308 stainless TRAVEL
steel overlaid steels; (3) demonstration of soundness
and reproducibility in Inconel tube-to-Inconel over-
laid tube-sheet joints. These types of construction "|wecome HEAD -=
are shown diagrammatically in Fig. 1.
The primary objective of this investigation was
to qualify a welding method and one welding-wire y, SAAS AAAS
composition for each of these three weld types.
Available information indicated that the desired weld
quality could be obtained with a titanium-manganese OSCILLATION
modified Inconel composition recently developed in
the authors’ laboratory for use in the inert-gas-
shielded welding processes. The high-titanium con-
tent of this relatively new welding wire provides a
built-in and dependable safeguard against porosity
difficulties. From the start, the major problem
shaped up as that of defining the conditions under
which satisfactory, crack-free overlay welds could
be made. Earlier work* had demonstrated that
high-nickel overlay deposits were crack sensitive if
dilution by ferritic base metals was not adequately
controlled. Fig. 2—Automatic welding-head characteristics
Throughout these studies, the intent was to
demonstrate metallurgical feasibility and to provide
helpful suggestions rather than to set up inflexible Fig. 3—Pendulum-type equipment and test block used
welding procedures and specifications. The latter for preparation of overlay specimens. xX '/;
are more properly the function of the fabricator who
has to take into account, in addition to feasibility,
the capabilities and limitations of his own operations.

Materials
Steel Base Metal
For the overlay test welds, a single lot of 4-in.
thick, ASTM A-302, Grade B, pressure-vessel steel
was used as the base metal. It was supplied and
used in the normalized (1650-1700° F) and stress-
relieved (1200-1250° F) condition. The following
mill analysis was provided:
ect wkicoenntcensnsetenssnaecadeaweeemee ween 0.19
IL ils «5 5.¢.ca ansddaweseids hueaees oueneeee 1.17
i ee... isn vacbankenaddeeabue cabana 0.48
I orth 5 cm aucknncaducedaNdnayeedusanedantiue 0.21
I We. <seuunad savesou cs teedaenscaaeeeaenine 0.015
Ra tn rec idhd nha ones ucunskasoksawa>mecsa daa 0.027
To prevent underbead cracking with this steel, in
* Pease, G. R., Bott, H. B., and Waugh, H. C., “High Nickel Over-
lays on Ferrous Metals,” THe Wetpoinc JourNnaL, 34 (1), 40-48
(1955).

348 | APRIL 1959

 WELDING JOURNAL ! 347

Table 1—Composition, %, of Titanium-Manganese Modified Inconel Welding Wire (Five Heats)“

Cc Mn Cr Ni Si Fe Ti S Cu
0.03 2.23 16.41 71.25 0.08 6.83 3.04 0.007 0.04
0.03 2.13 16.54 71.23 0.09 6.75 3.10 0.007 0.03
0.03 2.28 16.31 71.49 0.10 6.53 3.14 0.007 0.03
0.03 2.21 16.47 70.94 0.10 6.97 3.18 0.007 0.02
0.03 2.21 16.63 71.24 0.11 6.74 2.92 0.007 0.03

@ Wire conforms to Specifications AMS-5675 and MIL-E-21562, Types EN6A and RN6A

pressure-vessel fabrication, it has been found desir-

able to use a preheat, the temperature of which has
been variously specified at levels from 250 to 400°
F, and an interber emperature of 300 to 500° F.
In all of the over’ and transition-weld tests, these
requirements we: incorporated as a part of the test
procedure. As a further precaution and in accord-
ance with some shop practices, the welded test speci-
men was charged directly, while still hot, into a
stress-relieving furnace at 450° F, and the tempera-
ture raised gradually to 1150° F. The holding time
at temperature was 1 hr per inch of section and the
cooling was done in still air.
In no case was a preheat or postheat incorporated
into the test program with the intent of improving
the properties or behavior of the deposited weld Fig. 4—Overlay test specimen, as-welded and stress
metal. relieved. Approx. x '/,
To provide material for the transition weld, a matic welding head with pendulum-type oscillation.
small quantity of carbon steel was obtained which The second was a modification of the first that was
had been weld-overlaid with AISI Type 308 stain- provided with straight-line oscillation and no-end-
less steel. Its thermal history is not known. dwell features.
Welding Wire The conventional, or pendulum-type, automatic
In all, five different commercially produced heats welding head and a test block after deposition of the
of the special titanium-manganese modified Inconel first weld bead are shown in Fig. 3. A typical test
filler wire were used in completing the various over- specimen consisted of a */s- to '/:-in. thick overlay
lay and transition test welds. Their compositions on a 5- x 10-in. surface of a 4-in. thick steel block
(Fig. 4). This buildup was generally obtained with
are shown in Table 1. Unless otherwise indicated,
the wire diameter was 0.062 in. either three or four weld layers. All beads were
deposited longitudinally to the 10-in. dimension.
Tubing The bead width was approximately 1'/, in. Over-
One lot of '/, in. OD xX 0.049-in. wall thickness, lap was '/, in. or 20% of the bead width. No re-
Inconel tubing was used throughout the tests, partly straint was superimposed on the block, the 4-in.
in the annealed (1850-1950° F) condition and partly thickness being sufficient to prevent distortion.
in the stabilized condition (1625° F). As far as The surface of the steel to be welded was cleaned,
could be determined, the heat treatment had no preparatory to welding, by either sand- or abrasive
effect on the welding response. blasting. Individual beads were cleaned by vigorous
power wire brushing. The forward travel speed of
Experimental Procedure the welding gun was 5 to6ipm. MHigh-purity weld-
Overlays ing-grade argon shielding gas was used at a rate of
All of the overlay test specimens were produced by 50 cfh.
the inert-gas-shielded consumable-electrode process. After heat treatment, the top surface of the overlay
The relative merits of several variations of this weld- was dressed with a fine-grit abrasive wheel and in-
ing process were investigated, which, in the text, will spected for defects by macroexamination or dye-
be referred to as (1) manual, (2) semiautomatic and penetrant inspection. ‘The maximum possible num-
(3) automatic. Supplementary cold-wire feed tech- ber of */s-in. thick, side-bend sections were then cut
niques were also examined briefly. The semiauto- from the test specimen and examined for defects,
matic method involved a temporary setup and after polishing and etching. Examples of side-bend
consisted of a manual welding gun mounted on a specimens taken from overlays deposited by various
motor-drive travel carriage, with oscillation provided methods are shown in Fig. 5. These specimens
manually. Two types of automatic equipment were were bent through 180 deg and re-examined at x 15
employed (Fig. 2). One was a conventional auto- to reveal any defects that may not have been

WELDING JOURNAL | 349

>...
S46 | APRIL 19909

Manual, X ‘*/s

Automatic pendulum-type oscillation, X 1

Automatic straight-line oscillation, X 1

Fig. 5—Transverse cross sections of Inconel overlays deposited by various inert-gas welding methods

observed on the unbent specimens (Fig. 6). ’/.s-in. thick overlay was removed for a distance of
Representative specimens of top, transverse and ‘/, in. from the lip of the edge preparation, on both
longitudinal sections were then examined at x 100 halves of the joint. A 45-deg beveled edge was
for the presence of defects not detected at the lower provided for the _ stripped-back overlays. The
magnification. steel side of the joint was V-grooved to a 45-deg
Transition Butt Weld included angle.
For the steel side of the joint, the plates were
Only one transition butt weld was made. This
tightly clamped to a 4-in. thick welding platen and
9- x 10-in. joint (Fig. 7) was 2*/, in. thick. The
preheated to 300° F. The steel weld was stress re-
lieved at 1150° F and the root pass ground clean in
Fig. 6—Series of defect-free transverse side-bend specimens,
Approx. X !/2 preparation for the Inconel deposit. No restraint
was superimposed on the work for this portion of the
weld. The joint was preheated to 250° F and the
overlay transition was made using the pendulum-
type automatic setup under conditions similar
to those previously outlined for overlay welding.
Postwelding heat treatment was the same as that
given the overlays. Likewise, the evaluation pro-
cedure, which was limited to the alloy side of the
joint, was the same as described earlier for the over-
lay specimens.
Tube-to-Tube Sheet Welds
All tube-to-tube sheet joints were welded by the
manual inert-gas-shielded tungsten-arc process. No
filler wire was used, nor was there any special or
particularly favorable edge preparation.
The top surface of 5- x 10-in. Inconel-overlaid test
specimens was machined flat, then drilled and
reamed to provide '/.-in. diam holes spaced */;-in.
center-to-center, in a triangular pattern. One
inch of mass was allowed around the outer welds in
 WeeUViNnNuUu JUURNAL | O92

Fig. 7—Transition butt weld. Approx. < 1/,

any given cluster of holes. The tubing and the

tube sheet were thoroughly degreased before assem-
bly. The tubes were either press-fitted, drift-
fitted or rolled into the tube sheet and, generally, Fig. 8—Tube-to-tube sheet welds. Approx. X '/;
positioned flush with the tube-sheet surface. All upon reproduction)
rolled-in tubes were mechanically expanded 0.004
to 0.005 in. on the diameter beyond the point of
contact with tube holes, to a depth of approxi-
mately 3'/. in. The drift-fitted tubes were manu-
ally expanded with tapered drift pins to make con-
tact with the top surface. A copper plug was in-
serted into the tube slightly below the top surface to
prevent rundown. Welding currents of 100 amp
DCSP, a '/,,-in. diam electrode, and argon shielding
gas were used to make the majority of welds. The
welding arc was directed toward the interface be-
tween the tube and tube sheet and rotated 1!'
to 1'/, revolutions to complete each weld. No
postwelding heat treatment was employed.
Upon completion of the welds they were wire
brushed and macroexamined for any sign of defects,
then examined microscopically at < 100, on a trans-
verse cross section. A typical cluster of test welds
is shown in Fig. 8, and a representative weld cross
section is shown in Fig. 9.
Test Results, Overlays
hi y : Fig. 9—Tube-to-tube sheet weld,
As mentioned previously, the quality of weld- Etchant: 3 Glycerine + 2 HCI + 1 HNO).
ments specified for nuclear applications is unusually x 50. (Reduced by 20% upon reproduction)

Table 2—Macroexamination and Bend-Test Results of Inconel Overlays on Steel

No. of Examination U-Bend-Test Results
overlays of top No. of
produced surface” specimens Total No. of No. of
(using Avg. no. of Total no. of containing no. of defect- **nuclear-
preferred _indications/ specimens defects’ pores, all free quality’’*
Welding method method) overlay Trans. Long. A B C specimens specimens = specimens
Automatic 4 1 31 22 0 0 6 0 47 §2¢
(pendulum-type
oscillation)
Automatic 3 a 36 ia 0 0 6° l 30 36
(straight-line
oscillation)
Manual 2 1.5 18 17 0 0 3 0 32 344
Totals 124 0 0 15 l 109 122
* Total surface area per overlay was approximately 32 sq in., all defect indications observed were <'/\¢ in. in length
» A, hot cracks located in first weld layer; B, splits or fissures in upper weld layers due to lack of fusion; C, weld-bead interface defects located at
the weld metal-base metal interface.
© “Nuclear quality’’—-based on one tentative specification that allows one linear defect (<'/is in. in length )per bend specimen
4 One specimen contained a single defect >!/i¢ in. in length
* Each of 6 consecutive specimens contained a single defect all in the same location. Inadequate overlap between adjacent beads failed to provide
good fusion

WELDING JOURNAL | 351

 high and entails substantially defect-free joints. In . Gas cup—1-in. diam.
the case of Inconel weld overlays, practical attain- . Gas cup-to-work distance—’/;, in.
ment of this goal was accomplished by both auto- . Electrode extension beyond contact tube
matic and manual welding methods. As shown in 1 to 1 '/2 in.
Table 2, more than 98% of the bend specimens met . Welding-head position—perpendicular to
the requirements of a particularly rigid proposed work.
specification and more than 95% were defect-free. . Welding-head oscillation rate—-100 osc.
In no case did further examination at X 100 reveal min.
defects that were not visible at the lower magnifica- . Bead width—1 '/, in.
tion. 2. Bead-edge contour 30- to 45-deg angle
The essential or, in some cases, preferred condi- with base metal.
tions and procedures for meeting the proposed 3. Overlap—20% of previous bead.
quality level are enumerated as follows: . Cleaning—sandblast or abrasive-blast sur-
Welding Wire: Special, titanium-manganese modi- face of the steel; wire brush individual
fied Inconel. beads.
Welding Equipment: Inert-gas-shielded consum- In the course of setting up these welding condi-
able-electrode equipment, preferably automated tions, a number of observations were made which are
and equipped with an oscillating head. pertinent to the production of satisfactory overlays.
Temperature Control and Heat Treatment: If re- Control of Dilution by Iron
quired, for the benefit of the steel, the following
Before the dilution of weld metal by the base
conditions have been found to yield satisfactory
metal was brought under control, it was not uncom-
results:
mon to observe rather large hot cracks in the first
1. 400° Fpreheat.
(bottom) layer of weld metal (Fig. 10). The most
2. 400-500° F interbead temperature.
important factors in reducing the dilution rate were
3. Direct postwelding heat treatment; weld-
the use of the lowest possible welding current (240
ment charged directly into a furnace at
250 amp) and techniques which served to insure
450° F, heated to 1150° F, held 1 hr per inch
arcing on the weld puddle, rather than directly on
of thickness and cooled in still air.
the base metal. Full automation, particularly when
Welding Conditions: it incorporated the straight-line oscillation and no-
. Forward travel speed of welding head—5 to end-dwell features, was additionally helpful (Table
6 ipm. 3 and Fig. 11).
2. Welding current—first layer, 240-250 amp, In the upper layers, where iron pickup was not a
DCRP; upper layers, 275-295 amp, DCRP. factor, a somewhat higher welding current (275-295
3. Gas coverage —50 cfh, high-purity, welding- amp) was helpful in obtaining freedom from cold
grade argon. shuts and other defects which lead to failures in the
. Wire feed—200 ipm. side-bend test (Fig. 10). Faster deposition was, of
5. Are length—'/, in. course, also possible.

Fig. 10—Types of
defects encountered
in development of
high-quality overlays.
(Reduced by 15% upon
reproduction)

Hot cracking in first weld layer. Note deep penetration, X 1!/;

ge MB us
ay

tie a u
Upper weld-layer defect-—inadequate fusion to adjacent bead. X 1'/, Weld-bead interface defects at base-metal fusion line. X 1!/,

352 | APRIL 1959

Table 3—Iron Dilution of Inconel Overlays on Steel”
Welding lron dilution-percent
current, - Location of sample area, inches above base-metal surface —
layer 0.020- 0.050- 0.080- 0.110- 0.140- 0.170- 0.200- 0.230- 0.260- 0.290-
Welding method no.1,amp 0.050 0.080 0.110 0.140 0.170 0.200 0.230 0.260 0.290 0.320
Semiautomatic 250 17.56 16.86 11.22 6.52 6.15 Ae
Automatic, straight-line oscillation 250 8.68 8.58 6.48 1.76 1.64 1.31
Automatic, pendulum-type 245 9.78 7.89 7.45 4.10 3.83 3.41
Semiautomatic’ 200 7.21 5.24 4.06 3.94 2.19
Semiautomatic + cold-wire feed‘ 220 7.61 6.92 6.97 3.15 3.9 a
Manual 250 20.26 15.02 10.61 6.02 4.43 3.45
Automatic, pendulum-type + cold- 310 6.75 6.61 6.41 S47 1.19 .20
wire feed@
' All of the overlays represented in‘ this; table were free of hot cracking. Add 6.8 (the average iron content of the filler wire) for total iron content.
® Combination overlay. Layer 1, 0.045-in. diam wire; upper layers, 0.062-in. diam wire
© Combination overlay. Layer 1, 0.045-in. diam wire + cold-wire feed; upper layers, 0.062 in. diam
4 Overlay produced by a cooperating laboratory

Weld Metal-Base Metal Interface Defects of defect, a uniform bead edge is desired with a
In some of the preliminary overlays, side-bend test contour such that a 30- to 45-deg angle is obtained
failures occurred because of interface defects at the between weld deposit and base metal.
bottom of the first weld layer (Fig. 10). These de-
Automatic Welding Methods
fects were always located at the weld metal-base
metal interface at points between successive beads. Automatic welding equipment, provided with an
They usually took the form of voids or folds, which, oscillating head, seems to be the most effective means
after bending, appeared as short cracks. Their of providing the kind of bead contour and bead edge
origin seemed to be associated with a lack of fusion or which best assures freedom from buried defects. A
‘‘bridging’”’ at these locations. To prevent this type type of equipment was described earlier which in-
corporates straight-line oscillation and no-end-dwell
features. This equipment was designed specifically
for overlaying applications, with the objective of
insuring shallow penetration and good bead contour.
The present test results seem to reflect the merits
of these features. An integral part of this equip-
ment is a provision for tilting the workpiece on an
inclined plane of about 5 deg which provided a posi-
tive down-hill flow of the weld metal and insured
AOD 68 PER CENT
FOR TOTAL IRON arcing in the weld puddle.
Several overlays were made with the straight-line
oscillation apparatus equipped with dual heads to
determine the potential of such equipment in the
overlay application. In the dual-head welding
assembly, the welding heads are positioned side-by-
side, the oscillation of each being greater than the
DILUTION
PER
CENT
- center-to-center distance between their respective
heads, to provide overlap. In effect, the two weld-
4uTomatT- TYPE
PENDULUM ing heads working in unison lay down a single de-
AUTOMATIC OSCILLATION posit approximately 3'/,; in. wide. A transverse
STRAIGHT-LINE cross section illustrating the low penetration and
1 i 1 i 1 1 high quality of overlays made with this equipment is
080 20 6c 200 24 280 shown in Fig. 12. The rate of metal deposition is,
DISTANCE ABOVE BASE METAL SURFACE-—in of course, doubled and, in addition, the number of
11—Dilution of Inconel overlays by steel base metal potentially troublesome weld-bead interfaces is

Fig. 12—Inconel overlay deposited by the dual-head straight-line oscillation method. x ?

WELDING JOURNAL | 353

 carefully fed ‘‘cold’”’ wire should not be overlooked
Table 4—Effect of Cold-Wire Feed in setting up a production job.
on Iron-Dilution Control
Cleaning
Wire feed, It is well known that cleaning of individual weld
Welding ipm
current, Hot Cold beads, between passes, decreases the chance of trap-
Welding method amp wire wire Dilution, %* ping troublesome nonmetallic inclusions. On the
Semiautomatic with 270 160 40 19.37 other hand, unnecessary cleaning is time consuming
cold-wire feed 275 160 50 17.07 and costly. To evaluate the criticality of interpass
280 160 80 16.57 cleaning, a single, 3-layer overlay was made without
290 160 160 9.32 cleaning between passes. In 16 side-bend speci-
“Sample removed from a location 0.020 to 0.060 in. above original mens, taken from this overlay, only three contained
base-metal surface. Add 6.83% for total iron. defects of any sort and, in each case, the defect oc-
curred at the weld metal-base metal interface. On
the basis of these results, a certain amount of unre-
halved. It is expected that this dual-head procedure
moved oxide residue appears to be tolerable but,
will be applicable for use with three or more heads
looking at the over-all picture, it is almost certain
to obtain correspondingly higher deposition rates.
that trouble will be experienced if the situation is
Manual Welding Method allowed to get out of hand.
Although it is clear that the use of automatic Submerged-Arc Process
welding equipment offers the best means of control A limited exploration with the submerged-arc
over the important welding variables, the possibility process indicated that it is not suitable for depositing
of qualifying experienced operators to make manual the titanium-manganese modified Inconel composi-
welds is by no means excluded. Test overlays of tion. Severe cracking of the weld deposit was ex-
good quality were produced using a manually oper- perienced, which was believed to be associated with
ated gun (Table 2). This was accomplished, how- excessive dilution of the weld metal with silicon from
ever, only by simulating, as closely as possible, most the flux. Chemical analyses of the submerged-arc
of the conditions of automatic welding and trans- deposits revealed a five- or sixfold increase in the sili-
lating them to manual welding. The position of the con level, which is known to be difficult to cope with
welding arc was perpendicular to the work and a in Inconel welds (Table 5). At the same time, the
slow rate of forward travel was maintained to allow titanium content was found to be reduced approxi-
arcing in the weld puddle. A welding speed of mately 75%, resulting in loss of much of its bene-
approximately 8 to 9 ipm was found to give the ficial effects. Test results suggested that, at best,
desired result. Bead width was 1 in. and oscillation an extensive research program would be necessary to
was such that a semicircular arc path, rather than a develop satisfactory submerged-arc procedures for
saw-tooth-shaped path, was followed. The first weld making Inconel overlays. The greatest burden of
bead of an overlay merits particular care, especially such a program probably would lie in the develop-
when deposited manually, since it undergoes maxi- ment of a suitable flux.
mum dilution from the base metal.
Postwelding Heat Treatment
“Cold-Wire”’ Additions A postwelding stress-relieving treatment of 9 to
Limited data indicate that it may be advantageous 65 hr at 1150° F was not detrimental to the U-bend
to introduce a second or “‘cold’’ wire into the arc, properties of overlay weld metal. Except as noted,
under the “‘hot”’ or electrode wire, in the consumable- all of the specimens included in Tables 2 and 6
electrode process. As the ratio of ‘‘cold”’ wire to passed the U-bend test. At 1300° F, however, the
“‘hot”’ wire is increased, the iron content of the de- titanium-manganese modified Inconel weld metal un-
posit is lowered (Table 4) and, although quantitative dergoes age-hardening and suffers some loss in ductil-
data are not yet available, an improvement in the ity. After holding at 1300° F for 10 hr (Fig. 14), bend
deposition rate can also be expected. specimens attained elongations of 18-20%. The
The authors had an opportunity to examine the corresponding increase in hardness is shown in Fig.
cross sections of an overlay produced by this method 15.
in another laboratory. Its appearance (Fig. 13) On the basis of these test results, postwelding heat
provides further evidence that the benefits of a treatment of the overlays should be limited to tem-

Fig. 13—Overlay deposited by the pendulum-type automatic method with supplementary cold-wire feed. x 1

354 | APRIL 1959

Table 5—Composition of Inconel Overlays Deposited on Steel
Location of Weight, %
sample, in.
Welding process above base metal Cr
Automatic, pendulum-type 0.020-0.050 14.87
0.140-0.170 15.70
0.290-0.320 16.03
Automatic, straight-line oscillation 0.020-0.050 14.90
0.140-0.170 16.26
0.290-0 .320 16.41
Automatic, pendulum-type with cold-wire feed 0.020-0.050
0.140-0.170
0.260-0.290
Submerged-arc 0.035-0.065
0.095-0.125

Table 6—Effect of Postwelding Heat Treatment on the

Ductility of Inconel Overlays on Steel
Average
elongation, %,° in
Condition '/, in. lin.
As-welded 27.3 NF 24.5 NF
AW + 1150° F/9 hr 25 NF 23 NF
AW + 1150° F/65 hr 23 NF 20.5 NF
AW+ 1150° F/9 hr+ 1300° F/10 hr’? 19 18.5
* NF—No failure, the reported values do not represent the maximum
elongation attainable.
> All-weld-metal specimens, failed after 40-deg bend.

Table 7—Room-Temperature Tensile Tests of Titanium-

Manganese Modified Inconel (All-Weld-Metal Specimen)
Yield
strength,
0.2% Tensile Elongation Reduc-
offset, strength, in lin., tion in
Condition psi psi G area, %
As-welded 51,100 90 , 850 46.5 51.3
Heat treated® 92,950 135,000 24 26.2
Heat treated’ 93,570 133,170 24.4 40.7
* Equalized at 1625° F/2 hr + Age hardened at 1300° F/10 hr + Fig. 14—Overlay bend specimens after aging at 1300° F/10 hr.
Cc Approx. X '/5
>» Age-hardened at 1300° F/10 hr + AC.
| Rockwell 8 " Rockwell C
1 i Loyer No
peratures of the order of 1150° F, if maximum duc-
tility levels are to be maintained. The deposited
weld metal can be expected to exhibit a rather vigor-
ous age-hardening response in the temperature
range 1200 to 1400° F (Table 7). [4sWelded || AW: | Awe || Awe
§\SO°F/ Sines '11 50°F /65nr! 11ISO°F/
Srv +
Chemical Analyses
Complete analyses of two Inconel overlays are Fig. 15—Effect of postweiding heat treatment on the
hardness of Inconel overlays on steel
given in Table 5. The cobalt level of overlays made
with two different wires was 0.08 to 0.09%, which is
This defect consisted of a small void at the weld
within the currently desired limit (0.10% max) for
metal-base metal interface at the edge of the
radioactive system service.
stripped-back Inconel overlay and appeared to be
Test Results, Transition Butt Weld associated with an inadequate fillet at that edge.
The same welding procedures and conditions A generous beveled-edge preparation for the stripped-
developed for overlaying were found to be applicable back overlay, insuring accessibility of the arc for
to the clad side of the transition butt weld. proper fusion, should be helpful in eliminating such
Fifteen bend specimens obtained from the clad defects.
side of a single test joint contained only one defect. With respect to welding sequence, the steel side

WELDING JOURNAL | 355

 Table 8—Tube-to-Tube Sheet Welds
Argon- Macro- Micro-
Method of Welding Electrode gas examination, examination,
tube current, diameter, flow, Total no. total no. types of defects
insertion amp in. cfh of welds of defects Porosity Others Comments
Press-fit 75-100 Vier */a 20 60 0 2 0 5 welds made with He gas
Drift-fit 100 "Vie 15 24 0 0 0
Rolled-in 100 /\6 10 48 9’ 0 0 9 welds contained a gas hole
at or near weld closure
point
Totals 132
* Figures represent number of welds containing defects.
» Porosity believed to be associated with moisture introduced inadvertently before welding rather than the rolling operation.

of the joint should be and, in the case of the test joint, Welding Procedure and Conditions
was welded first. Reversing this sequence and 1. Cleaning—tube sections and tube sheet thor-
welding into the Inconel deposit with steel filler oughly degreased.
metal would result in formation of a nickel- and 2. Tubes press-fitted, rolled-in or drift-fitted into
chromium-containing hardenable-steel weld deposit. hole.
If it becomes necessary to weld the Inconel side 3. Tube condition—annealed or stabilized.
first, Inconel wire must be used for the entire joint. . Welding electrode—'/,, in. diam, 1° thoriated
Use of manual welding for joining the alloy transi- tungsten.
tion is assumed to be feasible, judging from results 5. Gas flow—10 to 15 cfh.
obtained in the production of overlays by that . Gas cup—'/s; in. minimum diameter.
method. 7. Welding current—100 amp DCSP.
Test Results, Tube-to-Tube Sheet Welds Current Taper: Equipment utilizing this feature
The metallurgical feasibility of making welds of is desirable for the elimination of crater defects.
adequate quality was demonstrated, using the inert- Repair Welding: The procedure and conditions
gas-shielded tungsten-arc process. Excluding some outlined above are applicable also to repair welds,
slight crater cracking, there was no fissuring in over with or without filler wire.
100 test welds, whether the tube was rolled-in, Conclusions
drifted-in or press-fitted (Table 8). In the case of a 1. A titanium-manganese modified Inconel wire,
number of the rolled-in test welds, some porosity was deposited by the inert-gas-shielded consumable-elec-
encountered at the weld-closure point which, in trode process, is capable of producing high-quality
retrospect, appeared to be traceable to moisture overlays on steel, as well as transition welds be-
inadvertently trapped in the joint before welding. tween Inconel and stainless steel.
All but one of the defects were easily repaired in the 2. Metallurgically sound, tube-to-tube sheet
first attempt. welds can be obtained by the inert-gas-shielded
Although the success of the tube welding operation tungsten-are welding method.
does not appear to be directly related to the method 3. The submerged-arc process is not, at present,
of tube insertion, this experience pointed up the suitable for overlaying with Inconel filler wire.
importance of cleanliness, if the tubes are rolled-in 4. If high ductility levels are to be maintained
prior to welding. Where the tube is not rolled-in, in the overlay deposit, postwelding heat treatment
the entrapment of a small amount of moisture can be should be limited to temperatures below 1200° F.
expected to be much less damaging. The small 5. Control of iron dilution, which is important
amount of crater cracking which was experienced to the quality of overlay deposits, is closely associ-
was of the type which is readily overcome by the use ated with the welding current and the type of equip-
of a current-taper device such as that customarily ment which is used.
used in tube welding, but which was not available
for use in these studies. Acknowledgment
In none of these test welds was a filler wire used, The present effort could not have been completed
nor was it necessary for purposes of metallurgical without the help of others. The contributions of
reinforcement of the weld deposit. If, in order to L. C. Minard and W. T. VanKirk, test welders, and
increase the length of the “leak path” through the of C. E. Witherell were particularly important. In
joint, it is necessary to increase the throat or leg the final stages, supporting data were also made
dimensions of the weld, fortified filler wire of the possible through the cooperation of the Air Reduc-
same type as that used in the preparation of the over- tion Co., the Linde Co., and the Foster-Wheeler Co.
lay would be the proper choice. The authors also wish to express their thanks to the
High-quality tube-to-tube sheet welds were pro- management of the International Nickel Co., Inc,
duced under the following conditions: for making this publication possible

356 | APRIL 1959

 Practical Welder

and Designer

a
Fig. 1—Last 142-ft cantilever section goes up to be connected to the center section of the 365-ft welded-steel
plate girder. Each of the seven girders weighs 125 tons and requires 6000 lineal feet of welding. Large jet aircraft
are wheeled into cantilevered area, nosed into inner ‘‘core”’ for servicing

Eight Miles of Welding on

Cantilevered Plate Girders for Service Hangar

BY JOSEPH STRAUSS ment, electrical substations, shops, offices, class-

rooms and storerooms.
The massive girders are tied together by a net-
Seven double-cantilevered tapered girders 342 ft work of lightweight, triangular inclined trusses
long and weighing 125 tons each, all of arc-welded which provide both lateral bracing and support
steel-plate construction, frame the 365- x 309-ft for the purlins carrying the flat roof covering of
roof of a new United Air Lines service and mainte- metal deck and insulation.
nance hangar at San Francisco International Air- The structure has over-all floor area of 154,000
port (Fig. 1). The girders are supported on cast- sq ft, and can accommodate four DC-8 jet planes
steel rocker seats atop seven pairs of 42-ft torpedo- and two DC-7 propeller-driven planes at the same
shaped columns of reinforced concrete (Fig. 2). time. The planes are wheeled into position on
They are spaced 81 ft apart and on 51'/.-ft centers, each side of, and facing toward, the central core,
forming a central six-bay ‘‘core’’ which houses with “‘nose pockets’’ permitting the forward portion
mechanical systems, heating and ventilating equip- of each plane to project into the core. Douglas
JOSEPH STRAUSS is a welding engineer at The Lincoln Electric DC-8’s, of which United has a fleet of 40 on order
Co., Los Angeles, Calif for delivery starting in the spring, have wingspread

WELDING JOURNAL | 357

of 139 ft 9 in., length of 148 ft 10 in. and height of Fillet welds between webs and flanges were set
42 ft 4 in. The double-cantilever welded construc- up on fully automatic equipment, with standard
tion provides unobstructed area 142 ft deep on welding heads traveling on suitable rails. Vertical
either side of the core and extending the full length stiffeners and a longitudinal stiffener just above
of the building. lower flanges were welded manually.
Extreme weight and length of the girders—said Upon completion, all welds were inspected by the
to be the largest ever fabricated for building con- gamma-ray method, with Iridium 192. A total
struction—-precluded shipping them as complete of 240 gamma-ray exposures were made, with near-
units. So each one was broken up into six sections perfect welds indicated—one minor defect being
for field assembly as follows: two lengths on either readily corrected.
cantilevered end and two comprising the center Field welds joining each of the two outer sections
span between support columns. Taper of the of each girder were made by three certified operators,
cantilevers is from 14 ft at the bearing points to one on each flange and one on the web. With the
5 ft at the ends. back-step technique, and with all operators working
The two outer end sections have web plates free simultaneously, distortion and secondary stresses
from horizontal splices; the other four have spliced were avoided.
webs, butt welded in the shops of the steel fabri- On each of the two end girders the two center
cator, Pacific Lron and Steel Corp., Los Angeles sections were field assembled by welding. Center
(Fig. 3). The following sequence was developed sections on the other five girders were connected by
for shop welding each section: splice plates and 54 high-tensile steel bolts of 1!
1. Butt weld flange splices. in. diam.
2. Butt weld web splices. E6010 electrodes were employed on all vertical,
overhead and root passes in the field, while E6012
Fillet weld flanges to web.
electrodes were used on all flat-position welds.
Butt weld web-to-web sections.
Gamma-ray inspection was also specified on all field
Fillet weld stiffeners and other detail. welds. Each girder, incidentally, required approxi-
In so far as possible, all shop welding was done mately 6000 lineal feet of field and shop welding.
by fully automatic or semiautomatic submerged-arc Outer cantilever sections were connected to the
techniques. Semiautomatic welding was adapted center sections by splice plates and high-tensile
to all shop butt welds, with a degree of mechaniza- bolts. After the bolts were properly torqued, the
tion achieved by mounting welding guns on small dead load was applied evenly and secondary trusses
carriages for accurate traversing of all flange and were bolted to the girders to complete the novel
web splices. framing.
Flange splices vary from °*/,; x 16 in. to 2 x 36 in. An interesting feature of the structure is the use
Web plates vary in thickness from */, in. in the center of separate grids of welded steel pipe, buried in the
sections to '/, in. for outer sections. concrete floor of each of the six bays, for radiant
Since web and flange steel was of either ASTM-A7 heating by circulation of hot water through the
or A373 types, with edges double-beveled and back- grids, with thermostatic control for each bay.
gouged to insure 100% penetration, a mild-steel The entire installation was designed by Skidmore,
wire and a neutral flux were determined as best Owings and Merrill, San Francisco. Dinwiddie
for all submerged-arc welds. The flux is well Construction Co. was general contractor. Pacific
suited to multiple passes on deep bevels since it Iron and Steel Corp. of Los Angeles were fabricators
sets rapidly and is easily brushed off. and erectors of all structural steel members.

Fig. 2—Arc-welded triangular trusses of angles and tees are Fig. 3—Half of one of the girder center sections after shop
bolted to the girders to support roof purlins and provide welding and ready for shipment to the airport site. Hori-
lateral bracing. Girders rest on 42-ft concrete columns. zontal web splice is made by automatic submerged-arc
They taper from 14 ft at the support point to 5 ft at the ends. welding as are fillet welds between web and flanges.
Entire structure required 2000 tons of steel Stiffeners are welded manually in flat position
( SX

|
ry SS
All-Welded

Aluminum Boat
Fig. 1—The unusual hull form of the 52-ft, all-welded alumi-
num boat makes possible riding qualities and maneuver-
Gives High-Speed ability previously unobtainable in high-speed vessels in
other than calm water

Performance

A uniquely designed, all-welded aluminum personnel

boat whose high-speed performance could rev-
olutionize water transportation has been unveiled
by Higgins, Inc., New Orleans, La.
Termed a major advance in marine design, the
new boat was fabricated of aluminum alloy 5456.
The unusual hull form of the 52-ft craft makes
possible riding qualities and maneuverability pre-
viously unobtainable in high-speed vessels in other
than calm water.
Described as having a ‘polyhedral’ bottom,
the new boat was developed for such uses as trans-
porting personnel and performing patrol, rescue
and other services where speed and good sea per-
formance are vital. 'Two 500-hp gas turbine engines
power the light-metal vessel in the 40-mph range.
With the new design, high speeds easily can be Fig. 2—Aluminum sheet and plate in alloy 5456 were welded
maintained even in 3'/.-ft waves. by the inert-gas consumable-electrode method to form the
Alloy 5456 was supplied in accordance with Grade unusual polyhedral bottom design. The material ranged
B of the Code of Wrought Alloys for Ships’ Struc- from */.:, in. to 1 in. in thickness
tures proposed recently by the Society of Naval
Architects and Marine Engineers. The highest
strength alloy available in the aluminum-magnesium
series, 5456 has good welding qualities and excellent
resistance to sea-water corrosion.
Approximately 10 tons of aluminum sheet and
plate, ranging from */,, to 1 in. in thickness, were
used in the prototype vessel. Frames were formed
in the conventional curved shape, and a series of
steps then was cut into the outside edge of each
frame, giving a sawtoothed appearance. Cold-
formed 5456 plate, extending aft from the bow, was
fitted in the corresponding notches of each frame
and welded by the inert-gas metal-arc method.
The result was a bottom with multiple length-
wise steps that greatly reduce wave impact. The
new form deflects water away from the hull and
provides progressive cushioning for the downward Fig. 3—Termed a major advance in marine design, the
movement of the bow. polyhedral bottom extends aft for about 50% of the length
Based on a story by the Aluminum Company of America, Pittsburgh, of the new craft. The unique form enabies the vessel to
Pa. maintain speeds in the 40 mph range, even in rough water

WELDING JOURNAL | 359

 Fig. 1—A typical fabricated foundry flask used in casting iron bathtubs. Welded design permits
the manufacturer to put rigidity and strength in the sections where it is needed, while retaining
flexibility required to meet the dimensional requirements of individual foundries

Arc-welded foundry flasks made from fabricated-

Welded-Steel Flasks steel components have been gaining favor with the
foundry industry. Proper arc-welding methods, to-
gether with engineered sectional design, have re-
Prove Highly Successful sulted in equipment of maximum strength, longer
life and reduced weight of materials. Accompany-
ing these improvements is reduced cost.
BY R.P.WOLGAST In properly designed and welded flasks, materials
are placed where they are needed to provide the
strength and rigidity desired. At the same time,
they provide flexibility in meeting the dimensional
requirements of individual foundries.
High speed and high penetration are the key fac-
tors in the control of weldment distortion and warp-
age. The Foundry Flask and Equipment Co. of
Northville, Mich., achieved this by the use of the
semiautomatic submerged-arc process. This con-
trol is particularly important when dimensional
accuracy of close tolerances is required. The result
is the reduction of costly machining time.

R. P. WOLGAST is District Engineer for The Lincoln Electric Co

Detroit, Mich

360 | APRIL 1959

 Fig. 4—Welds made by the semiautomatic submerged-arc
process fill the joint flush. In the unusual case where it is
necessary to fill a small area of the joint missed with the
submerged-arc welding machine, manual welding is used.
Manual welding with iron-powder electrodes is also used on
joints which are inaccessible for semiautomatic welding

Fig. 2—Semiautomatic submerged-arc welding is extensively

used on the flasks. On this application, the operator is
welding the side wall of the flask to the 3-in. thick sand rail.
The edge of the */,-in. thick wall is beveled and butts the
sand rail. One pass on the beveled butt side of the joint,
plus one pass on the fillet side of the joint are all that is re-
quired to give 100% penetration. Welding procedure is
about 425 amp on -in. electrode with a travel speed of
10-12 ipm

Fig. 3—The thickness of the sand rail changes at different

locations around the flask, with the heavier material used
only where it is required. The joint below is between a
3-in. section and a 2-in. section, both 9 in. wide. The 2-in
plate has a 45-deg bevel. Seal beads in the bottom of the
joint are made with */,,-in. E-7018 electrode. The remainder
of the joint is welded in a single pass of the semiautomatic
welding machine. As compared with manual welding which
required seven passes, the semiautomatic weld is made in
about 55 sec. This is about one-fourth the time required
for manual welding

is,
Fig. 5—Semiautomatic submerged-arc welds have deep
penetration and good bead shape. The plate in the above
joint is '/.in, thick. The weld was made at 14 ipm using #/,-
in. electrode 425 amp, Dc, reverse polarity. The upper leg
size is about '/, in. and the lower leg size is about 5/;, in.
Throat thickness is in
 -
Fig. 1—This ‘‘Teracruzer"’ transports a Matador guided missile. Rugged gas-shielded metal-arc and
tungsten-arc welded construction insures joints that ‘‘stay welded”’ under combat conditions

components are gas-shielded metal-arc and tungsten-

Through Snow, Sleet arc welded. Although weighing only 15,000 lb,
it carries a 16,000-lb load at 40 mph on paved roads,
or at speeds up to 24 mph overland. It carries its
or Swamp 8-ton load over rough hills, or through snow, sand,
mud or swamps with no fear of failure.
BY WEB PURCELL Powered by a 250-hp engine, the truck was
designed to haul the ‘“Translauncher,’”’ Goodyear
Mobility is a prime requisite of any military weapon. Aircraft Corp.’s launching trailer for Martin Co.’s
And the epitome of mobility—a unique, new vehicle Matador guided missile. In extremely remote
called the ‘““Teracruzer’’—has made it possible to areas, the unit can transport a fuel train of 10 giant
transport entire self-contained guided-missile squad- tire-like carriers which have a capacity of 5000
rons at high speeds over all kinds of terrain. gal of fuel, water or other liquids. As fuel is removed
Developed and built by Four Wheel Drive Auto from the tires it is replaced by air pressure which in
Co., Clintonville, Wis., the ‘“Teracruzer’’ is con- turn inflates the tires.
structed mostly of aluminum and is especially Principal aluminum extrusions and formed shapes
designed to take rough-combat treatment—many used in the bantamweight ‘“Teracruzer”’ are of Type
6061 T6 aluminum. Gas-shielded metal-arc process
WEB PURCELL is Welding Sales Engineer at the Linde Co., Mil
vaukee, Wis is used for welding the outriggers for the load-

Fig. 2-This shot of the ‘‘Teracruzer"’ illustrates the comparative size of the huge vehicle.
it is hauling a giant fuel train with a liquid capacity of 5000 gal in its ‘‘balloon” tires

im alt
 i * .
Fig. 3—The skeleton takes shape as structural members are joined by tungsten-arc welding to form the four-man cab.
The ‘‘Teracruzer" is of cab-over-engine design and features eight-wheel drive

bearing bed. Argon, 99.995°%% pure, is used to shield ment is required for any of the welded joints.
the welds which are made with ' /,;,-in. diam ER 5356 In addition to its military uses, the ‘““Teracruzer’’
wire at a current of 200 amp, 18 v, DCRP. is being considered for off-highway commercial
Structural members of the cab are joined by applications as a vehicle for prospectors, geologists
argon-shielded tungsten-arc welding. A _ current and survey crews, whose work takes them to remote
of 110 amp, ACHF, is used. No postweld treat- and rugged areas.

Fig. 4—The load-bearing bed of the ‘‘Teracruzer’’ is gas-shielded metal-arc welded in this holding fixture.
The 7'/.-ton vehicle easily carries weights much heavier than its own

WELDING JOURNAL | 363

 Tool Joints Surfaced with

Tungsten-Carbide Particles

Hard surfacing with tungsten-carbide particles has

been made a production-line process in the Toledo,
Ohio plant of the National Supply Co., Pittsburgh,
following developments resulting from difficulties
with earlier methods.
The need for a production-scale process arose from
the high rate of wear on drill pipe couplings during
the drilling of deep oil wells. A rotating drill string Fig. 1—Production-line hard surfacing was developed for
may penetrate thousands of feet of sand and rock, tool joints used in oil-well drill strings. After passing through
the induction heater on a conveyor, tool joints are positioned
and the couplings, called “tool joints,” will wear by one of two operators for either of two identical automatic
most from the abrasion because of their larger di- hard-surfacing operations
ameter.
National Supply solved its production problems
in hard surfacing tool joints by using an automatic,
gas-shielded, surface-melting arc and a metered flow
of tungsten-carbide particles into the molten pool
behind the arc on the rotating tool joint. A non-
consumable electrode melts the surface of the tool
joint to a depth of about '/; in.
The present process has three major advantages
over the original process, which was a metal-arc
operation using coiled tubular rod containing tung-
sten-carbide particles. First, the carbide in the over-
lay is now uniformly distributed for most effective
wear resistance, and spalling and cracking have been
practically eliminated. The reason is that, by keep-
ing the carbide particles out of the arc, there is now
little tungsten-carbide dilution with the base metal
of the tool joint. Formerly, when the carbide par-
ticles passed through the open arc, part of them
melted and some settled to the bottom of the de-
posit. The melted particles alloyed with the steel, Fig. 2—In the automatic hard-surfacing process for tool
thus producing a hard matrix which is susceptible joints, tungsten-carbide particles are metered into a molten
to cracking and spalling. Particles that sink to the pool of metal behind the arc that melts the surface metal
of a rotating joint
bottom of the deposit are of little value until the sur-
face wears down to them. trical circuit to strike an arc (Fig. 1). Helium shield-
Only tungsten carbide is deposited by the inert- ing gas then starts flowing at 40 cfh. As soon as the
gas tungsten-arc process because there is no steel surface metal melts, the operator starts rotation of
filler metal to melt into the surface of the AISI 4142 the tool joint and flow of tungsten-carbide particles
alloy-steel tool joints. The deposit is 100% tung- (20/30 mesh) from overhead vibrators down through
sten carbide instead of only 60% as in the former a tube behind the arc (Fig. 2).
metal-arc process. After a single revolution of slightly more than 360
Finally, the tungsten-arc process eliminated a deg, the welding head indexes lengthwise two-thirds of
complex grooving operation which was necessary in a bead width to make another pass. The slight over-
preparing for the metal-are process. lap gives an interlocking effect which eliminates
In the tungsten-are process, tool joints move on a washout between the beads. Welding and indexing
conveyor through an induction heater which raises continue automatically until the deposit has the
their temperature to 750-800° F. This maintains required width. This is about 3 in. on a typical
the original physical properties of the steel through 5*/,-in. OD tool joint.
the welding operations. One of two operators of two Stress relief is a two-step process starting in an
identical automatic aic-welding machines thenclamps induction furnace into which the tool joints move
a preheated tool joint in a three-jaw lathe chuck, on a conveyor for a 3'/.-min postheat to ensure a
aligns the '/;-in. nonconsumable thoriated-tungsten stress-relief temperature of 1000° F. Tool joints
electrode, and presses a button that closes the elec- then pass into a vertical gas furnace where they are
held at 1000° F for 90 min. Cooling takes place on
Based on « story by the National Supply Co., Pittsburgh, Pa racks in still air.

364 | APRIL 1959

 Society News

cation and research. Categories

treated in this year’s AWS-spon-
Varied Program at Chicago Convention sored program include two sessions
each on _ nuclear-power equip-
ment and welded structures, while
Expected to Draw Thousands single sessions will include stainless
steel, processes and _ procedures,
cutting, heat effects on steel weld-
Features Will Include Welding Exhibits, ments, pipe lines, design considera-
tions, resistance and ultrasonic weld-
Adams Lecture, Technical Papers, President's ing, titanium and zirconium, weld-
ability of steel and cast iron, alu-
Reception, Annual Banquet, Plant Tours, minum alloys, gas-shielded welding
and brazing. The AIEE sessions
Ladies Program and Social Activities will concern arc-welding power sup-
plies, welding-arc fundamentals and
From Monday through Friday, will be sponsored by AWS, three by resistance welding. Brittle fracture
April 6th to 10th, Chicago will be the AIEE Committee on Electric and welding in ship structures will
the site for the AWS 40th Annual Welding and two by the Ship Struc- be covered in the SSC program.
Meeting and the 7th Welding Show. ture Committee. The AWS Techni- On Monday evening at 6 P.M.
Headquarters for the meeting will be cal Papers Committee, faced with the the President’s Reception will take
the Hotel Sherman where 63 papers task of selecting 48 papers from the place in the Sherman’s Bernard
are expected to be presented through hundred or more submitted, has Shaw Room, to be followed at 8
the joint sponsorship of the AMERI- drawn up a balanced program of o’clock by the Annual Banquet in
CAN WELDING Society, the Electric interest to industry, covering the the hotel’s Bal Tabarin. One of the
Welding Committee of the American wide range between practical appli- highlights at the banquet will fea-
Institute of Electrical Engineers
and the Ship Structure Committee.
Simultaneously, the largest welding
exhibit ever staged in the United
States will take place in Chicago’s AWS DIRECTORS-AT-LARGE
Donovan Hall, a section of the In-
ternational Amphitheatre. Term Expires 1959 1960 1961
The program will be unveiled at
10:00 A.M. on Monday morning at J. H. Blankenbuehler J. F. Deffenbaugh A. A. Holzbaur
the Opening Session, at which time
President G. O. Hoglund will address G. E. Linnert A. E. Pearson D. B. Howard
those in attendance. After his ad- P. G. Parks C. M. Styer C. E. Jackson
dress, he will present this year’s
national awards and will also intro- F. H. Stevenson R. M. Wilson, Jr. J. L. York
duce President-elect C. I. Mac-
Guffie to the membership. This AWS DISTRICT DIRECTORS
session will be brought to a close by District No. leNew England Sidney Low District No. 6*Central J. N. Alcock
the presentation of the Adams
Lecture. This’ year’s lecturer, District No. 2*Middle Eastern E. E. Goehringer District No. 7+West Central A. F. Chouinard
Clarence E. Jackson, will discuss ead. stones 1. i District No. 8¢Midwest F.G. Singleton
“The Science of Arc Welding.” ne ee District No. 9*Southwest P. V. Pennybacker
Throughout the remainder of the District No. 4*Southeast E. C. Miller District No. 10¢Western F. V. McGinley
week, 21 technical sessions, compris- District No. 5*East Central H. E. Schultz District No. 1l*Northwest C. B. Robinson
ing 63 papers, will be offered at the
Hotel Sherman. Morning sessions OTHER DIRECTORS
will be held from Tuesday through Junior Past-President J. H. Humberstone Junior Past-President C. P. Sander
Friday, while afternoon programs
will be featured on Monday, Tuesday Junior Past-President J.J. Chyle
and Wednesday. Sixteen sessions

WELDING JOURNAL | 365

 364 | APRIL 1959

Plant tours will be among the other

activities scheduled during the
week-long convention. ‘The Super-
heater Division of Combustion En- EMPLOYMENT
gineering and the electrode plant of
|
Champion Rivet Co. will be visited | OPPORTUNITY
on Wednesday, and the Dresden
Nuclear Power Plant on Thursday.
The Dresden visitation will journey FOR ENGINEER
to the Station’s 950-acre tract in
es 10° 2
nearby Grundy County where such
welded structures as a 190-ft diam
containment vessel will be seen. AWS is seeking an engi-
Over 17,000 ft of welds were com-
ture Kurt Stehling who will speak pleted in the fabrication of this neer to join Headquarters’
on “Rocketry and Space Travel.’ particular vessel.
Mr. Stehling, head of the Vanguard An active ladies’ program has been Technical Staff as Assistant
Rocket Propulsion Group, will pro- planned which will include a Euro-
ject into the future and describe the pean travelogue, the theater and a to the Technical Secretary.
problems in landing men on planets sight-seeing tour through Chicago’s
and in operating space stations. Chinatown.
President-elect C. I. MacGuffie Here are the duties—
will sever the chain at the entrance
of Donovan Hall with an oxygen Working with AWS technical com-
cutting torch at noon on Tuesday, mittees in gathering and correlating
symbolizing the official opening of technical data; preparing minutes, re-
the 7th Welding Show. This year’s ports and other records of committee
show will encompass more display Welcome activities; editing standards for publica-
area than any other exhibit in AWS tion as completed.
history. The doors will be open to Disseminating technical information in
registrants from noon until 10:00 e Supporting Companies
answer to inquiries from industry.
P.M. on Tuesday, from 10:00 A.M.
Effective Feb. 1, 1959: Related duties as assigned.
until 10:00 P.M. on Wednesday,
and from 10:00 A.M. until 6:00
P.M. on Thursday. Estimated at- Jersey Welding Supply, Inc. Here are the qualifications—
tendance at the show is expected to 234 East Third Street ‘
reach 15,000, a sharp increase over Ability to work with technical men at
the previous record high of 11,000 at Plainfield, N. J. all levels in a cooperative manner. This
Philadelphia in 1957. In addition is necessary to deal successfully with
to the exhibits, the hall will also be committee personnel, AWS members and
Effective Mar. 1, 1959: the general public.
the site for a panel discussion on
Wednesday afternoon on mainten- Efficient Engineering Co., Inc. A degree in engineering, any branch.
ance welding.
21680 Coolidge Highway At least three years’ experience in
This year’s Educational Lecture
Detroit 37, Mich. engineering work, preferably in welding
Series will be presented on Monday
or allied fields.
and Tuesday afternoons at 4:30.
Hiram Brown will discuss ‘‘Weld- Weber Welding Supply Co.
ing for High-Temperature Aircraft 5108 Liberty Ave.
Here is an opportunity—
Service.” Pittsburgh, Pa.
The man we are seeking has initiative
and imagination and is interested in
becoming familiar with welding in all its
INTERNATIONAL AMPHITHEATRE—SITE OF THE WELDING SHOW aspects and for every type of application.
Salary will be commensurate with quali-
fications and experience.
If interested in being interviewed for
this position, send a resume* of your
education, experience and _ personal
background to

Technical Secretary
American Welding Society
33 West 39th Street
New York 18, N. Y.

Chicago’s home for the 7th AWS Welding Show will be this huge 585,000-sq ft structure, * Will be held confidential.
International Amphitheatre, the largest building of its kind in the United States. All
welding exhibits will be housed in one of the main sections of the structure, Donovan
Hall, on April 7-9. The adjoining parking lot can hold as many as 4000 automobiles

366 | APRIL 1959

 7v & & 8 FF Ne sw wn ivev > | eww

WHOS KIDDIN’ WHO, MISTER’

A photocell tracer that automatically adjusts for kerf width?
A cutting machine that can handle any cutting area? No matter how wide or how long?
I'll believe it when | see it.

All right, don’t believe it. Stop at the Linde Company Booth (No. 300) at the AWS
Show, Chicago Stockyard Auditorium, April 7-9, 1959. You'll see ‘em both . . . in action!
Remember, that’s Booth No. 300.

LINDE COMPANY, Division of Union Carbide orporation

30 East 42nd Street, New York 17, N. Y. °
In Canada: Linde Company, Division of tne
L nion Carbide Canada Limited, Toronto Trode-Mork
The terms “Linde” and “Union Carbide" are registered trade marks of Union Carb‘de Corporation
For details, circle No. 31 on Reader Information Card
WELDING JOURNAL | 367
 366 | APRIL 1959

TECHNICAL PAPERS SESSIONS

1959

REGISTRATION
AWS AIEE
MEZZANINE FLOOR
HOTEL SHERMAN
40TH ELECTRIC
Sunday April 5 e 3:00 P.M. to 6:00 P.M.
ANNUAL *" WELDING Monday, April 6 e 8:00 A.M. to 4:00 P.M.
Tuesday, April 7 e 8:00 A.M. to 4:00 P.M.
MEETING CONFERENCE Wednesday, April 8¢8:30 A.M. to 4:00 P.M.
APRIL 6-10 « HOTEL SHERMAN, CHICAGO, ILL. Thursday, April 9 e 8:30 A.M. to 1:00 P.M.
Friday, April 10 e 8:30 A.M. to 11:00 A.M.

APRIL 6, MONDAY MORNING

ASSEMBLY ROOM
10:00 A.M.—Official Opening and Business Session
CHAIRMAN
J. E. Dato, Linde Company
ADDRESS
G. O. Hoglund, President, AWS
NATIONAL AWARDS
ADAMS LECTURE
The Science of Arc Welding
by Clarence E. Jackson, Linde Development Laboratory

Papers “A” Start at 2: 00 P.M.

APRIL 6, MONDAY AFTERNOON THREE SIMULTANEOUS SESSIONS, 2:00 P.M. Papers ‘‘B’’ Start at 2: 50 P.M.
Papers “C’”’ Start a t 3: 40 P.M.
.M

1. Nuclear-Power Equipment 2. Stainless Steels 3. Processes and Procedures

ASSEMBLY ROOM BERNARD SHAW ROOM LOUIS XVI ROOM
Chairman Chairman
Chairman
C. R. Sutton, International Nickel Co., Inc. G. E. Linnert, Armco Steel Corp. J. H. Carlson, Crane Co.
Co-Chairman Co-Chairman
Co-Chairman
R. Kohibry, Machinery & Welder Corp. J. E. Fitzwater, International Harvester Co.
R. E. Oller, Commonwealth Edison Co.
A. Elevated-Temperature Properties of A. Practical Welding Procedures
A. Welding of Equipment for Dresden
Modified Type 347 Weld Metals by Stanley |. Roberts and Clarence E.
Nuclear Power Station
by W. R. Smith, General Electric Co. by Thomas J. Moore, Arcos Corp. Cole, Portsmouth Naval Shipyard
B. Fabrication and Construction of Piping B. Welding Properties of Cr-Ni-Mo B. Control of Process Variables—Key to
System for Dresden} Nuclear Power Hardenable Stainless Steels Successful Welding of Foil
Station by Robert H. Kaltenhauser, Allegheny by John Campbell, Air Reduction Re-
by G. B. Grable and A. M. Croswell, search Laboratory
Ludium Steel Corp.
Bechtel Corp. C. Oxyacetylene Pressure Welding of
C. Corrosion of Stainless-Steel Welds
C. Welding of Containment Sphere for High-Speed Rocket Test Track
Dresden Nuclear Power Station Formed with Carbon-Dioxide Shielding by E. S. McKittrick, E. S. McKittrick,
by Perry C. Arnold, Chicago Bridge & by B. E. Hopkinson and D. W. Mc- Co., Inc., and W. E. Donalds, Linde
Iron Co. Dowell, Jr., International Nickel Co. Company.

368 | APRIL 1959

 WELDING JOURNAL | 367

APRIL 6, MONDAY AFTERNOON

4:30 to 6:00 P.M.—CRYSTAL ROOM—FIRST FLOOR
CHAIRMAN
Clarence E. Jackson, Linde Company
CO-CHAIRMAN
T. Embury Jones, Precision Welder & Flexopress
Corp.
Educational Lecture Series (Part !)
Welding for High-Temperature Aircraft Service
by Hiram Brown, Solar Aircraft Co.

| Papers “A” Start at 9 :30 A.M.

APRIL 7, TUESDAY MORNING THREE SIMULTANEOUS SESSIONS, 9:30 A.M. | Papers “B” Start at 10:20 A.M.
Papers “C’’ Start at 11:10 A.M.

4. Arc-Welding Power Supplies 5. Nuclear-Power Equipment 6. Cutting

BERNARD SHAW ROOM ASSEMBLY ROOM LOUIS XVI ROOM
(Sponsored by the AIEE Committee on Chairman Chairman
Electric Welding) F. W. Davis, Atomic Energy Commission E. H. Roper, Air Reduction Sales Co.
Chairman Co-Chairman Co-Chairman
J. H. Blankenbuehler, Hobart Bros. Co. Jay Bland, Knolls Atomic Power Lab. R. G. Kerber, Linde Company
Co-Chairman A. Cybernetics of Oxygen Cutting
A. Welding of Inconel for Nuclear-Power
G. W. Garman, General Electric Co.
Applications by R. L. Deily, Messer Cutting Ma-
A. Characteristics of Rectifier-Type High- by William F. Fragetta and George R. chines, Inc.
Current DC Supplies for New Welding
Pease, International Nickel Co., Inc. B. Recent Metal Removal Developments
and Arc Processes
by Robert Stuefen, A. 0. Smith Corp. B. Braze Bonding Stainless-Steel Fuel with Compressed-Air Carbon-Arc Proc-
B. Design Precautions for Proper Appli- Elements for Nuclear Reactors ess
cation of Silicon Rectifiers to Arc and by Peter P. King and Robert K. Mc- by Myron D. Stepath, Wm. J. Coughlin
Similar High-Transient Voltage and Geary, Westinghouse Atomic Power and Homer B. Nelson, Arcair Co.
Current Loads Department C. Tungsten-Arc Cutting of Stainless-Steel
by Dennis Pierce, A. 0. Smith Corp.
C. Welding of Nickel-Molybdenum Alloys Shapes in Steel-Warehousing Opera-
C. A Report on the Revitalization of the
by G. M. Slaughter, Peter Patriarca and tions
Multiple-Operator Power Source Weld-
ing System R. E. Clausing, Oak Ridge National Lab- by John D. Wait and Stephen H. Resh,
by William A. Faust, A. 0. Smith Corp. oratory Morrison Steel Co.

APRIL 7, TUESDAY AFTERNOON

4:30 to 6:00 P.M.—CRYSTAL ROOM—FIRST FLOOR
CHAIRMAN
Clarence E. Jackson, Linde Company
CO-CHAIRMAN
T. Embury Jones, Precision Welder & Flexopress
Corp.

Educational Lecture Series (Part |!)

Welding for High-Temperature Aircraft Service
by Hiram Brown, Solar Aircraft Co.

WELDING JOURNAL | 369

368 | APRIL 1959

| Papers “A” Start at 2:00 P.M.

APRIL 7, TUESDAY AFTERNOON THREE SIMULTANEOUS SESSIONS, 2:00 P.M. Papers “B”’ Start at 2:50 P.M.
Papers “‘C’’ Start at 3:40 P.M

7. Welding-Arc Fundamentals 8. Heat Effects on Steel Weldments 9. Pipe Lines

BERNARD SHAW ROOM ASSEMBLY ROOM LOUIS XVI ROOM
(Sponsored by the AIEE Committee on Chairman Chairman
Electric Welding) Clarence E. Jackson, Linde Company A. G. Barkow, Natural Gas Pipeline Com-
Co-Chairman pany of America
Chairman
L. P. Winsor, Rensselaer Polytechnic In- John L. Cahill, New York Naval Shipyard Co-Chairman
stitute A. Effect of Residual Stress on Brittle F. J. Pilia, Linde Company
Co-Chairman Fracture A. Submerged-Arc Welding on the Pipe
Morris Thomas, General Motors Institute by Koichi Masubuchi, Transportation Line
A. AnAnalysis of Transfer in Gas-Shielded Technical Research Institute, and Hiro- by William B. Handwerk, M. J. Crose
shi Kihara, University of Tokyo Manufacturing Co., Inc.
Welding Arcs
B. Effect of Heat Treatment and Fabrica-
by W. J. Greene, Air Reduction Co., Inc. B. Maintenance Welding of High-Test
tion on Heavy-Section Pressure-Vessel
B. The Measurement and Significance of Steels Line Pipe
Temperature in Welding Arcs by A. |. Rubin, Pratt and Whitney Air- by F. W. Zilm and A. M. Hill, Service
by Howard C. Ludwig, Westinghouse craft, R. D. Stout, Lehigh University, Pipe Co
Electric Corp. and J. H. Gross, United States Steel
C. Welder Qualification Requirements for
Corp.
C. A New Magnetic Arc Method for the Pipe-Line Welders
C. Cast-Pin Tear Test for Susceptibility
Electric Welding of Glasses and by Robert S. Ryan and Robert R.
to Hot Cracking
Ceramics by Frederick C. Hull, Westinghouse Re- Wright, Columbia Gas System Service
by E. M. Guyer, Corning Glass Works search Laboratories Corp.

Papers “A” Start at 9:30 A.M.

APRIL 8, WEDNESDAY MORNING THREE SIMULTANEOUS SESSIONS, 9:30 A.M. Papers ‘B’’ Start at 10:20 A.M.
Papers “C’’ Start at 11:10 A.M.

10. Resistance Welding ll. Brittle Fracture 12. Design Considerations

BERNARD SHAW ROOM ASSEMBLY ROOM
LOUIS XVI ROOM
(Sponsored by the AIEE Committee on (Sponsored by the Ship Structure Com-
Electric Welding) mittee) Chairman
Chairman J. R. Stitt, R. C. Mahon Co.
Chairman
Austin Dixon, Westinghouse Electric Corp. N. J. Hoff, Stanford University Co-Chairman
Co-Chairman John Mikulak, Worthington Corp.
Co-Chairman
Alex Paalu, A. 0. Smith Corp.
D. K. Felbeck, National Academy of
A. The Effect of Elevated Temperatures Sciences A. Development of Welded-Steel Lathes
on Flash-Welded Aluminum-Copper by Gordon M. Sommer, Clearing Ma-
A. Micromechanism of Brittle Fracture in
Joints chine Corp.
Low-Carbon Steel
by C. R. Dixon and F. G. Nelson, Alumi-
by G. T. Hahn, B. L. Averbach, M. B. Some Consideration on Design for
num Company of America
Cohen, Massachusetts Institute of Fatigue in Welded Aircraft Structures
B. Discussion of Direct-Writing Instru- Technology and W. S. Owen, Univer- by J. Koziarski, The Martin Company
mentation for Certain Applications in sity of Liverpool
the Field of Resistance Welding C. Practical Approach to Determine Weld
by W. K. Whittemore, Brush Instru- B. Prestrain, Size, and Residual Stresses
Size
ments, Div. of Clevite Corporation in Static Brittle-Fracture Initiation
by Omer W. Blodgett, The Lincoln
C. A Direct-Reading RMS Meter for by C. Mylonas, Brown University
Electric Company
Measuring Secondary Resistance- C. Brittle-Fracture Tests of Steel Plates
Welding Current Containing Residual Compressive
by E. F. Nippes, Hugo S. Ferguson, Strain
and Warren F. Savage, Rensselaer by S. T. Rolfe, W. J. Hall, and N. M.
Polytechnic Institute Newmark, University of Illinois

370 | APRIL 1959

 WELDING JOURNAL | 369

WELDING SHOW EXHIBITS AND DEMONSTRATIONS

INTERNATIONAL AMPHITHEATRE
Tuesday, April 7 @ 12:00 Noon to 10:00 P.M.
Hours of the Exposition { Wednesday, April e 10:00 A.M.to 10:00 P.M.
Thursday, April 9 @ 10:00 A.M. to 6:00 P.M.
Admission by Registration

Papers “‘A’’ Start at 2 00 P.M.

APRIL 8, WEDNESDAY AFTERNOON THREE SIMULTANEOUS SESSIONS, 2:00 P.M. Papers “B”’ Start at 2 50 P.M.
Papers “C”’ Start at 3 40 P.M

13. Welding in Ship Structures 14. Resistance and 15. Titanium and Zirconium
Ultrasonic Welding
ASSEMBLY ROOM
BERNARD SHAW ROOM ae a ae
(Sponsored by the Ship Structure Com- Chairman Chairman
mittee) T. Embury Jones, Precision Welder & R. J. Landrum, E. |. du Pont de Nemours
Flexopress Corp.
Chairman Co-Chairman
Co-Chairman
Captain Nathan Sonenshein, U. S. Navy A. F. Busto, Fansteel Metallurgical Corp.
J. Welch, Cutler-Hammer Inc.
Co-Chairman A. Roll-Spot Welding for Ballistic Missiles . Vacuum Diffusion Joining of Titanium
Cdr. F. C. Munchmeyer, USCG by James K. Dawson, A. B. M. A. Red- by Earl J. Clark, General Electric Co.
A. An Investigation of Welded Crack stone Arsenal
Arrestors - Internal Stress Distribution of Single- ®: oe — — :
by Robert J. Mosborg, University of Spot Welds in Relation to their Fatigue anium-Alloy honeycomb sandwic
Illinois Panels
Life
. Isotope Techniques for Inspection and by - res prscaiye _
by Georges Welter and Andre Choquet, Armour Researc
Evaluation of Ship Welds Ecole Polytechnique : a echeles,
by E. L. Criscuolo, U.S. Naval Ordnance
Laboratory . Fundamental Studies of Ultrasonic eeeonens
Welding C. An Evaluation of the Diffusion-Bonding
. Instantaneous Inspection of Ship Welds
by R. E. Monroe, N. E. Weare and J. N. Characteristics of Zircaloy-2
with Scattered Gamma Radiation
by J. |. Bujes, U. S. Naval Ordnance Antonevich, Battelle Memorial Insti- by William Feduska, Westinghouse
Test Station tute Electric Corp.

Informal Panel Discussion

DONOVAN HALL, INTERNATIONAL AMPHITHEATRE

WEDNESDAY, APRIL 8 2:00 P.M.

Panel Session on Maintenance Welding

Chairman: T. B. Jefferson, Welding Engineer

PANEL MEMBERS
R. M. Kolb, Standard Oil Co. of Indiana
J. J. Matusek, Inland Steel Co.
L. D. Richardson, Eutectic Welding Alloys Corp.
A. A. Wald, Caterpillar Tractor Co.
B. G. Wallard, Chicago & Northwestern Railroad

WELDING JOURNAL | 371

 370 | APRIL 1959

| Papers “A” Start at 9:30 A.M.

APRIL 9, THURSDAY MORNING THREE SIMULTANEOUS SESSIONS, 9:30 A.M. | Papers “‘B” Start at 10:20 A.M.
| Papers “C’’ Start at 11:10 A.M.

16. Welded Structures 17. Weldability of Steel and 18. Aluminum Alloys
Cast Iron
BERNARD SHAW ROOM CRYSTAL ROOM
LOUIS XVI ROOM
Chairman
Van Rensselaer P. Saxe, Consulting En- Chairman Chairman
gineer Sidney Low, The Chapman Valve Manu- M. J. Waite, Aluminium Laboratories
facturing Co. Limited
Co-Chairman
C. D. Jensen, Pennsylvania Department Co-Chairman
Co-Chairman
of Highways G. E. Claussen, Arcrods Corp.
H. E. Adkins, Kaiser Aluminum & Chemi-
A. Welding of Reinforcing Bars for Con- A. Development of Techniques for Sub- cal Sales, Inc.
crete Construction merged-Arc Welding HY-80 Steel
by John F. Rudy, Frank Suyama and by Wallace J. Lewis, G. E. Faulkner A. New Developments in the Welding of
Harry Schwartzbart, Armour Research and P. J. Rieppel, Battelle Memorial Aluminum
Foundation Institute by R. L. Hackman, Linde Company.
B. Welded Cantilever Wedge Beams B. Welding of Medium-Alloy Chrome-
B. Techniques for Welding Al-Mg Alloys
by W. J. Krefeld, D. J. Butler and Moly Steels
by Daniel M. Daley, Jr., Army Ballistic
G. B. Anderson, Columbia University by Kenneth R. Notvest, The Flori Pipe
Missile Agency
C. An Experimental Investigation of Co.
Welded Open-Web Beams C. Process Welding of Nodular and Gray- C. Certain Structural Properties of Ultra-
by A. A. Toprac, University of Texas, Iron Castings sonic Welds in Aluminum Alloys
and B. R. Cooke, Texas Highway De- by Ellis 0. Porter and Benjamin by J. Byron Jones and W. C. Potthoff,
partment Townshend, General Electric Co. Aeroprojects Inc.

Papers “A” Start at 9:30 A.M.

APRIL 10, FRIDAY MORNING THREE SIMULTANEOUS SESSIONS, 9:30 A.M. Papers “B” Start at 10:20 A.M.
Papers “C” Start at 11:10 A.M

19. Welded Structures 20. Gas-Shielded Welding 21. Brazing

BERNARD SHAW ROOM CRYSTAL ROOM
LOUIS XVI ROOM
Chairman Chairman
J. P. Quigg, Bethlehem Steel Co. Chairman A. N. Kugler, Air Reduction Sales Co.
Co-Chairman R. C. Becker, International Harvester Co.
Co-Chairman
LaMotte Grover, Air Reduction Sales Co.
Co-Chairman R. L. Peaslee, Wall Colmonoy Corp.
A. The Buffalo Bayou Bridge and Future
G. Williams, Hobart Bros Co. A. Heat-Extractive Brazed Bimetals Show
Long-Span Possibilities
by Charles S. Matlock and Farland C. Promise for Missile and Industrial Ap-
A. Progress Report on the Flux-Cored plications
Bundy, Texas Highway Department
Electrode Welding Process by Robert C. Bertossa, Pyromet Com-
B. The Hampton Road All-Welded Steel
by A. F. Chouinard and J. A. Howery, pany, and Steven Rau, Stanford Re-
Arch Bridge
National Cylinder Gas Div. of Cheme- search Institute
by Wm. Llewellyn Powell, Powell &
Powell, Milton E. Eliot, Mosher Steel tron Corp. B. Effects of Hydrogen Brazing on Proper-
Co., Douglas A. Nettleton, Texas High- ties of High-Temperature Alloys
way Dept., and Joe C. Bridgefarmer, B. Dip Transfer CO. Welding by G. S. Hoppin, Ill, and E. N. Bam-
Civil Engineer by Roger W. Tuthill, Air Reduction berger, General Electric Co.
C. Design Details for Welded Highway Sales Company C. Metallurgy of Bonding in Brazed
and Railway Bridges Joints, Part II
by Marcello H. Soto, Gannett C. Principles of Plasma Torches by Nikolajs Bredzs and Harry Schwartz-
Fleming Corddry and Carpenter, Inc. by R. M. Gage, Linde Company bart, Armour Research Foundation

372 | APRIL 1959

 WELDING JOURNAL | 371

Other Activities

APRIL 6, MONDAY

2:00 P.M.—Reserve Funds Committee Meeting in Time Room, Hotel Sherman

6:00 P.M.—President’s Reception in Bernard Shaw Room, Hotel Sherman
8:00 P.M.—Annual Banquet in Bal Tabarin, Hotel Sherman

APRIL 7, TUESDAY

9:00 A.M.—Exposition Committee Meeting in Time Room, Hotel Sherman

12:30 P.M.—Exhibitors’ Luncheon at Saddle and Sirloin Club, Stock Yard Inn
7:00 P.M.—Ohio State University Student Alumni Dinner in Gold Room

APRIL 8, WEDNESDAY

10:00 A.M. —Manufacturers Committee Meeting in Room 107

12:00 Noon—RWMA Luncheon Meeting in Orchid Room
2:00 P.M. —Open Meeting of National Nominating Committee in Room 107
6:30 P.M. —WRC Dinner in Ruby Room
8:00 P.M. —WRC Meeting in Gold Room

APRIL 9, THURSDAY

10:00 A.M.—Board of Directors Meeting in Life Room

APRIL 9, THURSDAY EVENING

7:00 P.M.—WESTERN SOCIETY OF ENGINEERS BUILDING,
84 E. Randolph St., 7th Floor Auditorium
Special Program on Control Systems
(Sponsored by the Industrial Group of the Chicago
Section, A.I.E.E., and Recommended by the
Committee on Electric Welding)
The Logic Approach to Welding Control Systems
by R. C. Mierendorf and C. R. Whitney, Square D
Co.

WELDING JOURNAL | 373

 372 | APRIL 1959

PLANT TOURS LADIES PROGRAM

e Wednesday, April 8— SUNDAY, APRIL 5

Tour of the Superheater 6:00-8:00 P.M. Get acquainted social in Crystal Room.
Division of Combustion En-
gineering, Inc., in combina- MONDAY, APRIL 6
tion with a tour of the elec-
9:30-10:30 A.M. Continental breakfast in Emerald Room.
trode plant of Champion 12:30 P.M. Ladies’ luncheon in Crystal Room, followed by a travelogue, ‘‘From the Moun-
Rivet Co. tains of Southern Austria to the Fjords of Norway,’’ by Mrs. Fred L.
Plummer.
e Thursday, April 9—

Tour of the Dresden Nu- TUESDAY, APRIL 7

clear Power Station on the 9:30-10:30 A.M. Continental breakfast in Emerald Room.
950-acre site in Grundy 12:00 Noon Lunch and card party at Illinois Athletic Club.
County, Ill. Many types of
welding used to fabricate WEDNESDAY, APRIL 8

this nuclear-power station 9:30-10:30 A.M. Continental breakfast in Emerald Room.

for the Commonwealth Ed- 2:00 P.M. Theater party at Goodman Theater.
ison Co. will be seen. In-
cluded will be a 190-ft diam THURSDAY, APRIL 9
containment vessel which
9:30-10:30 A.M. Continental! breakfast in Emerald Room.
required 17,000 ft of weld- 12:00 Noon Chinese luncheon at Chiam Restaurant.
ing. 1:00 P.M. Greyline sight-seeing bus tour of Chinatown.

@ AWS members and their guests are invited to attend the traditional President’s Reception
which will be held in the Bernard Shaw Room of the Hotel Sherman at 6:00 P.M. on Monday
evening, April 6th. Those who attend will have the opportunity to meet President ‘‘Gus”’
Hoglund and President-Elect ‘‘Charlie’’ MacGuffie, as well as other national officers.

@ At 8:00 P.M., on the same evening, the Annual Banquet will take place in the Hotel Sherman’s
Bal Tabarin. Tickets for this affair will be on sale at the hotel. $10 per person.

@ The SOCIETY has arranged to have Kurt Stehling speak to the banquet gathering on a timely
subject, ‘Rocketry and Space Travel.’’ Not only an authority on the important topic, but an
excellent speaker as well, Mr. Stehling is head of the Vanguard Rocket Propulsion Group of
the National Aeronautics and Space Administration, Vanguard Division, Washington, D. C.

374 | APRIL 1959

 WELDING JOURNAL | 373

wheels, holders and accessories.

Current welding literature will be
HIGHLIGHTS available.
Arcair Company Booth No. 906
Feature: Display designed to in-
OF EXHIBITS terest fabricators using automatic
welding processes, featuring Q-3 au-
tomatic Arcair torch with floating
head for plate-edge preparation,
AT 1959 WELDING SHOW deseaming, back gouging. This
torch, preceding a welding device,
eliminates prebeveling of weldment.
INTERNATIONAL AMPHITHEATRE Arcos Corporation Booth No. 523
CHICAGO, ILLINOIS Feature: Demonstration of new
cross section of “‘“EB Consumable
Weld Insert”’ for root passes in butt
APRIL 7-9 welding of pipe; ‘“‘Arcosarc”’ proc-
ess for semiautomatic CO, welding
of low-alloy steels, pipe and repair
of castings.
Aro Spot Welder Div. Booth No. 525
Feature: Air-operated model 410,
Acetogen Gas Company _ Booth No. 701 Amalgamated Industrial Corp. double-spot gun DP45, as well as
Feature: Display of equipment for Booth No. 625 new line of Spring Balancers. Also,
““Acetogen”” gas-oxygen cutting. Feature: Electro-slag welding proc- display and live demonstration of all
Comparison of cutting cost?, speeds ess with the automatic ‘‘Verto- other Aro models.
and oxygen consumption with nat- matic’” machine for extra-heavy
ural gas, propane and ‘‘Acetogen’”’ vertical butt joints. Single-pass Aronson Machine Co. Booth No. 221
processes welding contained between the plate Feature: Display of ‘‘Geared Ele-
Air Reduction Sales Co., a Division of ends and water-cooled sliding cop- vation Positioner” designed for
Air Reduction Co. Inc. Booth No. 521 per shoes, Multiple Swingable con- welding techniques in missile and
sumable electrodes. aircraft industries. Also, ‘Uni-
Feature: Demonstration of dip versal Balance’’ welding positioner
transfer CO, welding process. Also, American Manganese Steel Div. to handle loads up to 4000 Ib;
display of new line of inert-gas-flow Booth No. 412 turning rolls and bench positioners.
control equipment; tungsten inert- Feature: New semiautomatic
gas holders; natural gas hand and hard-surfacing and manganese weld- Balteau Electric Corp. Booth No. 226
machine cutting torches; and gas- ing machine along with new tube Feature: Baltograph 180 X-ray
shielded metal-arc heads. and solid-wire hard-surfacing al- unit for 360 deg coverage as well as
Alloy Rods Co. Booth No. 530 loys; also, precision-ground cast conventional radiography. Rated
hard-surfacing alloys. 180 kv-5-ma end grounded. For
Feature: Display of company’s portable or stationary use. Also,
complete line of welding and hard- American Platinum and Silver Div. portable and dual-purpose indus-
surfacing alloys. Emphasis and Engelhard Industries, Inc. Booth No. 322 trial X-ray units.
demonstrations will be on “Atom
Arc”’ alloys for welding low-alloy Feature: Complete line of silver,
“‘Nicrobraz” and other high-tem- Banner Welder, Inc. Booth No. 309
high-tensile steels and trade-name
steels such as T-1. perature brazing filler metal, includ- Feature: New combination spot and
ing alloys for honeycomb applica- projection-welding machine; rocker-
All-State Welding Alloys Co., Inc. tion; new methods of packaging arm spot-welding machine and
Booth No. 610 and forms of silver-brazing alloys, press-type spot-welding machine.
Feature: Demonstration of No. 430 Also, demonstration of production
silver brazing. Berkeley Company Booth No. 723
stainless solder for forming most
metals; color match to stainless American Pullmax Co., Inc. Booth No. 200 Feature: Demonstration of con-
steel. Also, thin-coated bronze and tinuous welding for increased pro-
HS-4 nickel-manganese electrode. Feature: Pullmax Models P-5 and duction in both the “‘Angle Seam
“Galvabar.”” New aluminum al- P-7 universal shearing and forming Welder’”’ for straight-line weldments,
loys. Bright-finish ‘“‘Spoolarc.”’ machine in operation. Also, new and the ‘‘Planatable’’ for circum-
Model X-8 beveling machine for ferential welding; an engineered ap-
Aluminum Company of America use in beveling heavy plate prior proach to fixturing.
Booth No. 421 to welding.
Feature: Demonstration of tung- Bernard Welding Equipment Co.
Ampco Metal, Inc. Booth No. 904 Booth No. 600
sten-arc cutting and welding, con-
sumable-electrode welding, torch Feature: Display of bronze elec- Feature: Live demonstrations of
brazing and_ soldering, pressure trodes, bare filler rod and wire; new-concept electrode holders and
welding and use of zinc-clad alumi- nickel-brass and manganese-bronze high-speed “‘LC’”’ welding system.
num soldering sheet. Also, discus- brazing rods and flux; welded Also, display of line of coolant
sion of aluminum-joining problems. specimens; resistance-welding tips, sources for welding, ‘“‘Shortstub”

WELDING JOURNAL | 375

 374 | APRIL 1959

electrode holders and ‘“‘Multi-Pic”’ Dockson Corporation Booth No. 908 General Electric Company Booth No. 802
chipping hammers. Feature: Exhibit of entire line of Feature: Manufacturing facilities
Brennen, Bucci & Weber, Inc. gas welding and cutting equip- and specific instruction features of
Booth No. 700 ment, as well as eye-protective General Electric welding ignitions
equipment. Also, display of new will be displayed to point out greater
Feature: Display of portable arc Levermatic torch, Dubl-check regu- dependability and longer life.
spot-welding gun for spot welding lator, and Econolite welding goggle.
sheet metal from one side without Glendale Optical Co., Inc. Booth No. 812
backup electrode; also, regular line Emerson Electric Mfg. Co. Booth No. 121
of portable arc-welding machines Feature: Display of welding mag-
and sand-blast equipment. Feature: Carbon-arc torch for braz- nifier; S-7 safety spectacle; chemi-
ing, soldering, heat bending. Re- cal goggle; two-tone spectacle; and
Cambridge Corporation Booth No. 408 designed 180-amp electric a-c port- full line of face and eye protection.
able welding machine. Also, 90-
Feature: The “liquid concept.” amp and 295-amp d-c gas-engine
Display will depict manner by which Goss Gas Inc. Booth No. 117
driven, portable welding machines.
liquefied oxygen, nitrogen or argon Feature: Complete line of replace-
is produced, delivered and con- Eutectic Welding Alloys Corp. ment cutting and welding tips along
verted. Booth No. 500 with line of LP torch equipment.
Also, new pilot flame LP torch in
Cam-Lok Division Feature: Live metal-arc and oxy- addition to Goss refillable hand
Empire Products, Inc. Booth No. 217 acetylene demonstrations of ‘“‘Eutec- torch.
Feature: New line of insulated re- Trodes” and “‘EutecRods’”’ for low-
ceptacles and mating plugs for heat-input welding of high-tensile Handy & Harman Booth No. 204
panel mounting. Neoprene insu- steels, alloy cast irons, aluminum
and magnesium. Liquid solder-type Feature: Live demonstration of
lated water-proof, shock-proof cable
alloy in squeeze-bottle will be shown. “Easy-Flo” and “Sil-Fos” low-
connectors for 750 MCM cable to
temperature silver-alloy brazing.
No. 18 wire. Cable repair and cable Exomet, Inc. Booth No. 715 Handy “Hi-Temp” and Handy
splicing kits, electrode holders, etc.
Feature: Presentation of ‘‘Exo- “‘Alumibraze”’ will also be shown.
Cayuga Machine and Fabricating Co., Inc. Anneal’”’ method of postheat treat- Technical specialists on hand to dis-
Booth No. 436 ing weldments by means of exo- cuss problems and render assistance.
Main attractions: New standard thermic materials. Display of
**Exo-Anneal’”’ assemblies for an- Harnischfeger Corp. Booth No. 425
line of Cayuga positioners; ex-
panded line of Cayuga-tron drives nealing several types of chrome- Feature: Demonstration showing
for welding and machine-tool trade; moly weld joints used in refinery and tape-controlled weld programming
and new developments in auto- chemical plant construction. and controlled-slope current build-
mated tank line installations in- up and decay in systems of sequence
F & N Metal Products, Inc. Booth No. 504
cluding complete handling and fab- timing. Also, ac, de and ac, de
rication. Principal attraction: Display of welding machines; WP-3 (3000-
new “‘Handy-Arc”’ electrode holder lb capacity) welding positioner in
Champion Rivet Co. Booth No. 910 featuring pistol-grip design, trig- operation.
Feature: Display of improved per- ger control and parallel gripping
forming iron-powder electrodes and jaws. Harris Calorific Co. Booth No. 120
newly developed low-alloy and stain- Fenway Machine Co., Inc. Booth No. 326 Feature: Multi-stage metering
less-steel types. Emphasis placed regulators; large-volume and light-
on mechanical properties of these Feature: Portable electric and pneu-
volume gaugeless regulators; com-
electrodes. matic metal-cutting tools, called
pletely ‘“O” ring-sealed torch as-
Fenway nibblers; models that will
Contour Marker Corp. Booth No. 234 sembly. Also, complete line of oxy-
cut 16- to 10-gage stainless steels oxy-nat-
acetylene, oxy-propane,
Feature: ““Co-Ma-Co”’ Allen and 18- to 8-gage mild steels. Also,
ural gas welding, cutting and heat-
wrench holder. Also, Contour new model with '/,-in. metal-cutting
capacity. ing equipment.
Marker Boyce centering head, pipe-
flange aligner. 24-in. radius marker. Fibre-Metal Products Co. Booth No. 434 Hobart Brothers Co. Booth No. 601
Coyne Cylinder Company Booth No. 912 Feature: *“‘Supergrip”’ ground Feature: Display of new model
Feature: Display of “Coyne 92” clamps and electrode holders, new “‘Powerweld”” d-c welding ma-
acetylene cylinder, newest of their lightweight Fiberglas welding hel- chine—a-c power conbination, a
line. The “92” features a new mets and combinations. ‘‘Super- “Tigpsk” unit that can be used
formula 92° porosity filler and a glas,”” ‘“‘Superlite’”’ and ‘Superlec- anywhere for tungsten-arc weld-
stronger steel shell. Also, field- tric” safety hats and caps. ‘‘Mon- ing. Also, new 180-amp a-c trans-
test data will be available. arch”’ face shields. ‘‘Fiberglas,”’ former called the “‘Hustler.”’
vulcanized fiber and ‘‘Wide Vision”
Curtiss-Wright Corp. Booth No. 330 welding helmets. Robt. W. Hoffman Co., Inc. Booth No. 633
Feature: Display of complete prod- Frommelt Industries Inc. Booth No. 805 Feature: Display of Hoffman-Chi-
uct line of Gamma radiography cago a-c and d-c welding machine
equipment from small hand port- Feature: ‘Porto’ welding screen, power supplies, special tools for re-
able units to large Cobalt units. portable sectional floor screen, room sistance-welding machines, and
Also, portable X-ray units and ac- divider, partition, windbreak. “Ruf Nek” reinforced wheels. Also,
cessory equipment, including film *‘Weld-Tex”’ vinyl-coated glass-cloth “Acme” air-operated butt-welding
viewer and radiation detector alarm fabric resistant to fire, oils and most machine and “Fox” swing-frame
system. acids. Also, other products. grinders.

376 | APRIL 1959

 WELDING JOURNAL | 375

Robert Holmes & Bros., Inc. Booth No. 609 Lenco, Inc. Booth No. 903 steel welding electrodes and wires;
Feature: Standard, stock equip- and mild-steel welding electrodes.
Feature: Display of threaded power
ment to salvage fused flux (slag) connections for electric arc-weld- Messer Cutting Machines, Inc.
from submerged-arc welding proc- ing accessories that have been Booth No. 336
esses. Feeders, elevators, con- added to the HI-AMP line of prod-
tinuous magnetic cleaners, ham- Feature: ‘‘Sicomet’ cutting ma-
ucts. chine demonstrates accurate, multi-
mer-mill crushers, air cleaners, ther-
mal dryers, and proportional blend- Lewis Welding & Engineering Corp. ple-torch oxygen cutting uging 1:10
ers. Booth No. 431 scale template drawings. Two 12-ft
wide plates, 40-ft long, can be cut
Independent Engineering Co., Inc. Feature: Demonstration of latest simultaneously using pilot machine
Booth No. 332 “Universal’’ welding head man- with a drawing 15 in. x 60 in.
ipulators equipped with LADC for
Feature: Introduction of new, automatic seam tracing. It will in- Metal & Thermit Corp. Booth No. 614
small, package-type generator that clude live automatic welding, auto-
produces high-purity liquid or high- Feature: New wire-feed unit for
matic seam tracing and automatic semi- and full automatic welding.
pressure oxygen and nitrogen. torch-tip height control. Also, ‘“‘Hardex”’ automatic wires for
Industry & Welding Booth No. 503 “‘open-are”’ automatic hard surfac-
Lincoln Electric Co. Booth No. 411
Feature: Free copies of new large- ing. Display of engine- and motor-
Feature: Multiple-arc automatic driven generators; ‘‘Murex’’ elec-
size “Industry & Welding’ maga- submerged-arc welding. New ‘In-
zine and ‘Welding Illustrated’’ trodes and 1300-amp ‘‘Gouger-
nershield’’ open-arc automatic proc- Welder.”
magazine. Display of 700-page
ess. New iron-powder electrodes for
1958 /1959 “‘Welding Directory.”’ Metal Removal Co. Booth No. 317
steel and new stainless-steel elec-
International Nickel Co., Inc. Booth No. 323 trodes. New line of ‘“Idealarc”’ Feature: Display and operation of
welding machines, transformer and ‘*Fastex’’ depressed-center disks for
Feature: Live demonstrations show-
transformer-rectifier types. grinding and preparation of welds.
ing welding of copper to stainless
steel, along with other dissimilar- Linde Company, Division ‘“‘Safetex”’ disks for heavier duty
alloy combinations as ductile iron, Union Carbide Corp. Booth Nos. 300-305 work. Also, ‘Master’ carbide
and high-nickel alloys to steel; also, burs, a technique for weld prepara-
High point: Live demonstrations tion. ‘‘Metal Removal” air grind-
new “Inco-Hard 1” electrode for
using ““Oxweld CM-60”’ new shape- ers.
hard surfacing.
cutting machine with photo-cell
tracer, new ‘“Sigmette’’ spool-on- Metallizing Company of America
Jackson Products, Air Reduction Sales Co.
gun “‘Sigma”’ torch, and new “‘Short- Booth No. 804
Booth No. 516
arc’’ technique for ‘“‘Sigma’”’ welding Feature: New ‘Mogul Powder
Feature: Complete line of Jack- with “‘ST-2” torch. Jet.”” Models for powdered metals,
son welding accessories and safety
Liquid Carbonic Div. ceramics, etc. Also, Type R-1
equipment, including new ‘“‘cable-
General Dynamics Corp. _—_Booth No. 621 ‘“‘“Rokide.”’ Larger rod capacity for
hitch’’ for overhead cable suspen-
spraying Norton ‘“Rokide”’ and
sion and new “‘Alumicap,” a safety Feature: Expanded ‘‘Do-It-Your- chrome oxide. ‘““Turbo-Jet” */6-
cap, also available combined with self’ kits for easy repairability of en- in. capacity, magnetic-governor
welding helmets, goggles and face tire line of ‘‘Liquidweld”’ torches for metallizing unit; automatic push-
shields. cutting, welding, brazing and heat- button control panels.
ing. Also, ‘“Liquidox 3M” unit for
Kaiser Aluminum & Chemical Corp. Mid-States Welder Mfg. Co. Booth No. 629
liquid oxygen. Also, applications
Booth No. 733
showing use of nitrogen. Feature: ‘‘Magna-Tran” line of
Feature: ‘‘King’’ welding wire, in- electrically controlled a-c, d-c and
cluding spooled electrode for gas- Magnaflux Corporation Booth No. 103
inert-arec welding machines; ‘Dot’
shielded metal-arc welding and Feature: Operating demonstrations welding process for die repairing.
straight rod for tungsten-arc weld- showing magnetic-particle testing Also, complete line of a-c, d-c and
ing, and three new aluminum weld- units for ferrous welds; fluorescent- inert-arc welding machines, high-
ing processes developed by Kaiser: penetrant and dye-penetrant tests frequency arc starters, and ac-
“Qualiweld,” ‘Econoweld,’’ and for nonferrous weldments, and con- cessories.
*‘Chlorecon.”’ ductivity measurement units for
determining heat-affected zones ad- Miller Electric Mfg. Co. Inc
Kedman Co Booth No. 803 jacent to aluminum welds Booth No. 623
Principal attraction: ‘‘Fibreglass Feature: Live demonstrations. Pa-
welding helmets, plastic face shields Marquette Manufacturing Co.
Booth No. 914 per-thin pieces of stainless-steel foil
and other products. ‘“‘Huntsman”’ will be joined using a Miller SR-15
welding helmets and quality weld- Feature: ‘Instant-Arc’’ welding welding machine powering an Air-
ing lenses. machines, ‘“‘Jet-Series’’ oxyacety- line automatic fixture. Display of
lene equipment, new welding elec- complete line of Miller arc-welding
KSM Products, Inc. Booth No. 320 trodes and gas welding rods; plus, machines.
Feature: Live demonstrations. new dispenser-type packaging of
Capacitor-discharge stud-welding low-temperature rods and fluxes, all Milwaukee Electric Tool Corp.
displayed in ‘‘Welderama’”’ trailer. Booth No. 900
units for welding aluminum fas-
teners, mild- and stainless-steel studs Feature: Display and demonstra-
to thin-gage metals. Mark XI McKay Company Booth No. 321 tion of complete line of heavy-
stud-welding units for heavy in- Feature: Low-hydrogen iron-pow- duty electric tools; ‘“‘Sander-grind-
dustrial application and ‘‘Power der electrodes; tube-alloy hard- ers’ built especially for welders,
Pack Rectifier.”’ surfacing welding wires; stainless- and “‘Sawzall”’ electric hacksaw, plus

WELDING JOURNAL | 377

a complete line of heavy-duty drills. ing steels of AISI 11XX series; also, metal welding rod, welders’ caps,
used as submerged-arc wire for chipping hammers.
Modern Engineering Co., Inc. critical weldments.
Booth No. 334 Reid Avery Company Booth No. 507
Principal attraction: Exhibition of Pandjiris Weldment Co. Booth No. 400 Feature: New “Dynaweld”’ process
the 50 most important design fea- Feature: External longitudinal for semiautomatic and automatic
tures used in construction of Meco seamer for thin-gage fusion welding; welding. ‘“‘Raco’”’ automatic heads
oxyacetylene welding and cutting a manipulator with remotely con- and controls. ‘‘Raco’”’ electrodes
equipment and industrial regulators. trolled movements; 3000-lb posi- and automatic wires.
National Cylinder Gas Division tioner with electronic controls; and Robotron Corporation Booth No. 520
of Chemetron Corporation Booth No. 730 a portable manipulator with remote-
control electronic devices. Feature: New NEMA Type 3B re-
Feature: Live demonstrations with sistance-welding control employing
“Dual Shield” flux-cored CO, weld- Cecil C. Peck Co. Booth No. 920 single-decatron circuit electroni-
ing process and the NCG electronic Feature: Live display showing Peck cally switched to multiple functions
line tracer. Also-display of ‘“‘Rego”’ spud-welding machine in operation. in sequence, providing 1 to 1000-
and ‘“Torchweld”’ welding and cut- Samples welded using Morrell * /,-in. cycle timing range, with accuracy of
ting apparatus, ‘““ComboKit’’ port- spud on 12-gage metal. Machine plus or minus zero cycles on all func-
able outfit and type SGW200P weld- shown will weld spuds or couplings, tions.
ing machine. ‘/, to 5 in. diam, to either heads or Robvon Backing Ring Co. Booth No. 901
National Torch Tip Co. Booth No. 617 shells.
Feature: Display of backing rings,
Feature: Display of new regulators; Philips Electronics, Inc. Booth No. 208 including commercial split rings,
gas-air appliances; natural-gas tips offset rings for joining differing pipe
Principal attraction: X-ray for in- schedules and machined rings for
and equipment; heavy-duty cutting dustry featuring constant-potential
and welding outfits; replacement pressure piping, in many ma-
fractional-focus industrial X-ray terials —carbon steel, chrome-
cutting and welding tips for all equipment, and extremely low-
equipment and gases; standard tip moly alloys, stainless steel, alumi-
temperature equipment consisting of num and cupro-nickel.
cleaners. an operating ‘“‘Norelco’’ recondenser
Nelson Stud Welding Division and cold chamber will be high- Sellstrom Manufacturing Co.
Gregory Industries, Inc. Booth No. 211 lighted. Booth No. 301
Feature: New stud-welding power C. E. Philips & Company Booth No. 605 Feature: Display of new eye and
source. Demonstrations of im- face protective equipment, including
Principal Activities: Live demon- No. 500 cup-type welding goggles,
proved equipment and techniques stration of welding cast iron with
for stud welding to aluminum; welding magnifier helmet plate, ny-
shielded metal-arc process—using lon welding-plate holder for curved
also, steel stud welding. two different electrode types for that front helmets, and “‘Show Case” car-
North American Aviation, purpose. rying kit.
Missile Division Booth No. 705 Picker X-Ray Corp. Booth No. 233
Sight Feed Generator Co. Booth No. 433
Feature: Display of ‘“‘“Spacemetal,”’ Feature: Display of Picker Iridium
a machine-produced, lightweight, Feature: Introduction of ‘“‘Rexarc”’
camera, portable, designed pri- automatic flux circulating system
high-strength stainless steel of sand- marily for welds on pipes; Andrex
wich construction, withstanding that provides a continuous flux sup-
140-kv portable X-ray; 100 Curie ply to automatic welding machines.
high-temperature requirements in mobile Iridium 192 unit; 10 Curie
fabrication of missiles and super- Live demonstrations with “‘Rexarc”’
Iridium 192 unit; and Andrex twin-head multiple-spindle roller re-
sonic aircraft.
160-kv diagonal 360-deg unit.
builder.
Ohio Nut And Bolt Co. Booth No. 700-A
Precision Welder & Flexopress Corp. Simonds Abrasive Co. Booth No. 311
Feature: Welding machine will be Booth No. 807
in operation to weld new “XN Spot- Feature: New “Double XX” de-
weld Nut’ with recessed target Feature: New ‘“Peco’’ resistance pressed-center wheel for weld grind-
electrode area. Complete line of butt welding machine for longitu- ing in operation. Also, “Fibrex”
products will be shown with many dinal sheet-metal joining. Other wheels, slightly flexible and for
typical welded assemblies using products: magnetic-force bench stainless steel; ‘“‘Simex’’ wheels for
“Ohio” weld fasteners. welding machine; complete line of heavy-duty use.
standard and special equipment.
Oxo Welding Equipment Co. Booth No. 216 Singer Glove Mfg. Co. Booth No. 126
Pure Carbonic Company _ Booth No. 511
Feature: New line of regulator and Principal attraction: Exhibit of re-
cylinder fittings and gas-cutting tips. Feature: Display of 150-lb CO, versible welders’ glove, complete
Pipe-turning rollers. Plastic cover ‘“‘Liquidor’’-CO, regulators, flow- line of welders’ clothing and gloves,
lenses for helmets and_ goggles. meters, electric heaters and other asbestos gloves, portable welding
Pipefitters’ layout guide books. carbon-dioxide ‘“Carboflex’’ equip- screens and welding curtain ma-
Carrying cases. ment. terials.
Page Steel And Wire Division J. M. Ragle Industries, Inc. Booth No. 911 A. 0. Smith Corporation Booth No. 122
Booth No. 533 Feature: Display of aluminum Feature: Full scale models of what
Principal attraction: A-S-18 “‘won- round soapstone holder, double case welding machines might look like 25
der welding wire’ designed for CO, for torch-tip cleaners, regular line of years from now. Also, live dem-
welding of medium-carbon steels drill kits, lighters, flints, soapstone onstration of button welding with
and the resulphurized free-machin- holders, measuring machine, white the “C-OMANUAL” hand gun.

378 | APRIL 1959

Smith Welding Equipment Corp. trodes and the Tec machine torch medium-duty turning rolls. ‘Steel
Booth No. 712 for automatic tungsten-arc seam Worker’ combination punch and
welding. Also, display of other im- shear machine. Also, double-act-
Feature: Smith gas-control unit, a
proved equipment. ing longitudinal seam-welding ma-
push-button device which regulates
flow of oxygen and fuel gas in weld- chine and offset forming machine
Tempil° Corporation Booth No. 613
ing and cutting operations. Also, for joggle jointing; punch-type
display of full line of oxyacetylene Feature: Demonstration of tem- bending roll.
equipment. perature indication by means of
““‘Tempilstiks®,” ‘“Tempilaq®,”’ and Welding Alloys Mfg. Co. Booth No. 903-A
Sperry Products, Inc. Booth No. 225 “Tempil®”’ pellets. Techniques for
determining temperatures in con- Feature: One and 10-lb aluminum
Feature: Demonstration of ultra- nection with metal-working opera- spooled welding wires. Also, dis-
sonic testing of welds, including an tions will be shown. Indicators for play of ‘“‘Walco” aluminum welding
automatic test of welded tubing. 306° and 319° F will be presented. and brazing alloys, bronze cable,
New ultrasonic test instruments and lenses and cover glass, electrode
search units exhibited for first time. Tweco Products, Inc. Booth No. 622 holders, atmospheric air-acetylene
Qualified inspection engineers on Feature: New line of electrode and propane torches, rubber hose
duty. holderg, ground clamps, _ cable and equipment.
splicers and lugs with ball-point
Square D Company Booth No. 232 type cable connection. Light- Welding Engineer Publications, Inc.
Feature: Display of new plug-in weight ‘“Tweco-Life’” aluminum Booth No. 915
panel design electronic resistance- welding cable will also be demon- Feature: Newly revised edition of
welding machine controls—N2, N3, strated. ‘‘Welding Engineer’? Data Sheets;
timers, contactors, heat controls. Uniflex Cable Division “The Welding Distributor,” the
Plug-in slope, forge, duals, current Gar Wood Industries, Inc. Booth No. 634 industry’s first merchandising pub-
regulator. Weld-time—one cycle lication; “Welding Engineer,”
steps, tap switch adjustment. Tube Feature: New Model “B”’ Superlife monthly magazine; ‘““The Welding
firing and tube valve ‘““Kickless’”” cable for portable gun Encyclopedia”; Jefferson’s “Gas
welding machines. Also, improved Welding Manual’; and ‘““The Oxy-
Steffan Mfg. Corp. Booth No. 130 standard cable will be on display. acetylene Weldor’s Handbook.”
Feature: Regular line of pipe-con- Unique Equipment, Inc. Booth No. 604
touring and _ hole-cutting equip- Martin Wells, Inc. Booth No. 333
ment. Also, “‘Heliarc”’ cutting of Feature: Display of turning rolls,
manipulators and positioners for au- Feature: ‘“Tong-Grip’’ electrode
aluminum and stainless-steel pipe; holder designed to burn stubs short
automatic welding of T joints; new tomatic welding; electronic controls
for speed regulation and ranges; without overheating. ‘“Slip-On’’ in-
structural shape-cutting machine. sulation provides lower maintenance
turning rolls with built-in self-
timers. costs.
Stoody Company Booth No. 316
Feature: New automatic electric- United Wire & Supply Corp. Booth No. 526 Weltronic Company Booth No. 721
welding head adapted to rebuilding Feature: Exhibit of complete line Feature: New all-electronic NEMA
and hard surfacing of many kinds of of silver-brazing alloys and fluxes, N2 welding-machine control de-
equipment. Demonstration of semi- as well as precision preformed rings signed for the general user. Also,
automatic welding with Stoody and shapes. Also, demonstrations of other welding-machine controls;
wires. Display of components for actual brazing showing advantages d-c arc-welding machines; and d-c
application of Bulk Borium; also, of modern brazing techniques. motor control, variable-speed drive
hard-surfaced parts. and press control.
Vacuum Tube Products Co., Inc.
Storch Products Co., Inc. Booth No. 800 Booth No. 325
Westinghouse Electric Corp. Booth No. 100
Principal attraction: Ceramic-mag- Feature: Specialized resistance-
net holding assemblies for spot- and welding machine for light-gage ma- Principal attraction: Exhibit of
arc-welding machines, as well as terials, including VTW-20—2.5-kva complete welding line of apparatus
magnetic rollers and other magnets spot and seam welding unit pro- and electrodes plus 2 new X-ray in-
used in automatic handling of sheet viding 4 secondary outputs for multi- spection tools.
steel. head welding; VTW-15 magnet-
ic-storage flux welding machine Worthingtcn Corp., Positioning
Sylvania Electric Products, Inc. and VTA-17 portable hydraulic Equip. Div Booth No. 235
Booth No. 907 welding head. One 6 X 6 and one 12 12 manipu-
Feature: Exhibit of complete line of lator. Two sets of power and idler
tungsten electrodes for shielded-arc Victor Equipment Co. Booth No. 620
rolls: Model ‘“‘O’”’ and Model “‘D.”’
welding, including 2% thoriated, Feature: Complete line of Victor Also two positioners: Model 10-P
1% thoriated, ‘“‘Puretung’”’ and flame-cutting and welding equip- and 60-P.
“Zirtung.”” Display will empha- ment; high-pressure and large-vol-
size that partially used rods need ume gas regulators; hard-surfacing
not be scrapped for lack of identifi- alloy rods, both manual semiauto-
cation. matic and automatic; blasting noz-
Soon before the April JOURNAL went to
zles; and straight-line and shape- press, several additional contracts for space
Tec Torch Company, Inc. Booth No. 220 cutting machines. were received for the 1959 Welding Show.
Feature: New air-cooled tungsten- Highlights of the exhibits of these com
arc torch, 300-amp off-set torch Webb Corporation Booth No. 917 panies are published on Page 427.
small enough to use 1-in. long elec- Feature: “Economy” series of

WELDING JOURNAL | 379

 KEEPING YOU POSTED

by Fred L Plummer

@ Soon after this message reaches Chairman Brewer in conducting a cancel and your Secretary spoke
you as part of the April issue of the well attended session at which Niels briefly. The programs are organ-
Journal, hundreds of AWS members Miller and your Secretary were the ‘ized by Harry Schwartzbart.
will gather in Chicago to greet old principal speakers. Mr. Miller dis- @ On February 2nd WRC Direc-
friends; to meet and talk with out- cussed recent developments in arc- tor W. Spraragen, your Secretary
standing scientists, educators, en- welding equipment in the United and Staff Member Frank Mooney
gineers and production leaders; to States and abroad, and outlined the attended the funeral of Past Presi-
view demonstrations of the newest unique incentive plan he has used in dent D. Arnott who died suddenly
welding equipment and processes in his rapidly expanding manufa tur- while returning to his home in New
the world’s greatest exclusively weld- ing activities. Jersey following a luncheon with
ing exposition; to listen to reports e@ The following day Mr. Miller and former associates at the American
of research, unique designs, new your Secretary flew together to New Bureau of Shipping in New York on
production techniques, simple and York, changing planes in Cleveland. January 29th. Mr. Arnott served
practical methods of welding diffi- Have you recently offered a friend as president of the Socirery during
cult-to-assemble fabrications; to or associate the opportunity of the 1943-44 term and was almost 81
participate in unusual plant tours; joining AWS? Mr. Miller suggests years old at the time of his death.
to relax at informal social events; the following appropriate slogan:
and to enjoy the good fellowship “If you join the AMERICAN WELD- e Important conferences held early
which is always an outstanding ING SocrETy you will help us in February included one with EAC
feature of such national conven- help you--help others—-help them- Chairman C. E. Jackson and Secre-
tions. Don’t miss this great event! selves.” tary A. L. Phillips in preparation for
@ Much of your enjoyment and a meeting of this committee in
e@ On January 26th your Secretary Columbus on February 11th, several
that of your lady will be the result was the guest of Rochester Section
of the fine cooperation and hard with Exposition Manager Ken-
Chairman D. Masterson and en- worthy, Convention Manager
work of a group of men from our joyed a visit at Pfaudler Co. where
Chicago Section who are serving on Mooney and Publicity Manager
glass-lined metal tanks are fabri- Phillips concerning plans for the
the many convention committees. cated and many of the “wonder”
Section Chairman R. Mueller and Annual Meeting and Welding Ex-
metals are welded. The largest position to be held in Chicago, April
General Chairman Les McPhee vessel constructed of tantalum was
have organized outstanding groups 6-10, others with Society Attorney
assembled and welded at this plant Holloway about bylaws and certain
with excellent leaders including the in a special welding chamber. Staff
following: H. Comstock on ladies Brazilian trademark applications in-
Members B. Payne and R. Haslip, volving questionable use of welding
entertainment, A. Meyer on techni- both active in AWS, were hosts dur-
cal sessions, R. Mueller on presi- terms, one with Philadelphia hotel
ing this most informative inspection managers concerning headquarters
dent’s reception, L. Monroe on trip.
hospitality, T. Jefferson on exposi- tor our 1963 April convention, and
tion panel discussion, P. McKinney e@ That evening Mr. Miller and many with staff members concern-
on publicity, E. Bailey on plant your Secretary were again principal ing Journal, Technical and Mem-
tours, W. Eyth on signs, E. Gruca speakers at the dinner meeting of bership activities.
on welded products exhibit, and A. the Rochester Section held in the @ On February 17th your Secre-
Craske on banquet. Liederkrantz Club. Chairman tary visited our Toledo Section for
Masterson and Secretary R. Wald- the first time and presented a tech-
@ On January 23rd your Secretary vogel were in charge of activities.
was met at the Fort Wayne airport nical talk describing the fabrication
by Section Chairman L. B. Brewer e The Midwest Welding Confer- of heavy welded structures at the
and transported to a local hotel for ence, a joint activity of Armour Re- dinner meeting held at the Toledo
lunch with Niels Miller who had search Foundation and our Chicago Yacht Club. Program Chairman M.
spent much of the preceding night Section, has become one of the out- J. Baughman and Section Chairman
on a train which had arrived at standing annual welding meetings R. Hoefler were gracious hosts.
Chicago several hours late. The with four technical sessions each, District Director J. N. Alcock also
afternoon provided time for an in- including three important papers attended this meeting.
teresting tour of the local Dana Corp. with adequate time for pertinent e@ The following afternoon Treas-
plant where rear axles are manufac- discussion. The fifth such con- urer H. E. Rockefeller held a meet-
tured for several of the major auto- ference was held January 28th ing of the Group Insurance Com-
mobile makers. The evening social and 29th. Vice-president R. D. mittee in the Pittsburgh airport
period, dinner and meeting of the Thomas, Jr., Director C. E. Jackson terminal with Vice-president
Anthony Wayne Section were held and other prominent AWS mem- Thomas, Director Alcock, Tom
at Halls Guest House (a remodeled bers presented technical papers, Dempsey and staff members in
and attractively decorated gas Past President J. J. Chyle partici- attendance. That evening President
plant) with officers McClain, Terry, pated in discussions, O. T. Barnett Hoglund, Directors Alcock, Blank-
Jacobs and Zimmerman assisting substituted for a speaker forced to enbuehler, Chouinard, Chyle, Jack-

380 | APRIL 1959

son, MacGuffie, E. Miller, H. Miller,
Rockefeller, Schultz, Stevenson,
Thomas, Wilson, Membership For Top Quality Welding
Chairman Dempsey, your Secre-
On Chrome-Alloy Steels
tary and Ass’t. Sec’y. Mooney
were guests of the Pittsburgh Sec-
tion for dinner at Webster Hall Use CHAMPION
Hotel and their technical meeting at
the Mellon Institute, where C. W. CROLOY®
Lytton and L. A. Colarossi dis-
cussed submerged-arc welding. Sec- ELECTRODES
tion officers H. E. Cable, P. E.
Masters and J. F. Minnotte were
hosts at this very successful and
well attended meeting.
e@ Your Board of Directors held
their third meeting of the fiscal year
on February 19th in the Pittsburgh
airport terminal with President
Hoglund presiding throughout the
all-day meeting which was devoted
to discussions leading in some cases
to important decisions concerning:
new sections; committee appoint-
ments (G. O. Hoglund will be chair- IT’S CROLOY
man; C. P. Sanders, J. J. Chyle and
J. H. Blankenbuehler will be mem- Only if it
bers-at-large of your National
Nominating Committee for next Bears the Imprint—
year); honorary members (James F.
Lincoln was elected to this special Your Assurance Of
membership); fall meeting sites
(Pittsburgh selected for 1960); a MAXIMUM
memorial for Founder Comfort A.
Adams; bylaw simplification; pol- QUALITY
icy on labor organization ques-
tions; group insurance plan for
members; a mid-Pacific conference
in Hawaii to follow April 25-29, —
1960 Los Angeles convention; sup- wfJ
port of the members fund drive for OT“. O23Ne
the new United Engineering Center
(have you contributed to this im- 4 sl
portant project?); and a number of A \\
matters of a more routine nature.
e@ The following morning was de-
voted to conferences with hotel man-
agers in Pittsburgh.
e An attractive new brochure list-
ing Sustaining Members and out-
lining their activities was printed For top drawer welding of Chrome Moly Steels, Cham-
February 16th. pion Croloy Electrodes have excellent handling char-
FRED L. PLUMMER acteristics in all positions, and produce radiographically
clean welds of unsurpassed mechanical properties. Cham-
pion Croloy Electrodes are available in all of the popu-
lar grades from 14% Chrome, }2% Moly to 9% Chrome
1% Moly in 3%” through %%’’ diameter. Only Croloy
Electrodes are identified with the Croloy imprint on each
APRIL IS Electrode and are manufactured under U.S. patent license.
NATIONAL Champion also offers a full line of Stainless Stee VISIT OUR BOOTH 1G =APRN 768 S08
WELDED Electrodes in all analyses with either lime or AC-D¢ *TLRRA ONAL AMOPWITHEATEL Coscage
PRODUCTS coatings. Champion is the leading manufacturer of WELDING SHOW
the increasingly popular 16-8-2 composition, which 4
MONTH gives unparalleled freedom from cracking in type 347 Sosesnr, AMERICAN WELDING SOCHTY, OHS
and 316 weldments APRIL RATIONAL WLLDED PRODUCTS mgertH
For further information on any of these electrodes, write today.

THE CHAMPION RIVET CO.

Cleveland 5, Ohio East Chicago, Ind.
For details, circle No. 15 on Reader information Card

WELDING JOURNAL | 381

 TECHNICAL PROGRESS

Help Wanted contains all the articles that ap- A few months ago, an Inter-
peared in the WELDING JOURNAL national Metal Spraying Conference
For the past few months, the last year and lists them under one or was held in England. The number
Technical Department has _ been more of the appropriate 28 welding and variety of papers presented, the
without an Assistant to the Tech- subjects. Copies of this supple- number of delegates attending and
nical Secretary. As a consequence, ment will be available very soon. the liveliness of the discussions left
a number of projects have been de- no doubt of the growing importance
ferred. We have tried various of metallizing. Papers were pre-
Publications Prepared
methods of obtaining a suitable man sented by delegates from England.
but our efforts to date have been un- on Fire Prevention France and Spain as well as from
successful. We would appreciate it In New York, the National Fire more distant countries such as
if you would “spread the word”’ re- Protection Assn. held the second South Africa and Australia.
garding the availability of this po- meeting of their Committee on Cut-
sition. Anyone interested should ting and Welding. Progress was Technical Translations Available
send a résumé of his education and made in the preparation of a publi-
experience to the Technical Sec- cation to cover safe practices in the For years, many requests have
retary at AWS Headquarters. All usage of oxyacetylene and arc weld- been received by the Technical De-
inquiries will be held confidential. ing equipment. Also, work was partment for information concerning
completed on the first educational English translations of foreign litera-
Second Printing for Mild Steel brochure, “Sparks Astray,” di- ture. At last, such a service is now
Electrode Specification rected at welders and oxygen cut- being rendered.
ters. Widespread distribution of The Department of Commerce
Six months ago, the new edition of this pamphlet by many organiza- has been designated as the collection
the Mild Steel Electrode Specifica- tions will take place shortly. Ar- and distribution center for a wealth
tion (AWS A5.1; ASTM A233) was rangements have been made of foreign scientific and technical in-
issued. In this short period our in- whereby each AWS member will re- formation. In order to make the
itial supply was exhausted. A sec- ceive a free copy. In addition, a data acquired readily comprehensi-
ond printing has just been com- limited supply of these brochures ble to American science and _ in-
pleted and copies are now available will be available from AWS Head- dustry, the Department of Com-
quarters at a very nominal cost (a merce, through the Office of Tech-
Filler Metals Approved for Section few cents each). nical Services, is concentrating its
attention upon English translations
IX—ASME Boiler Code and abstracts of significant ma-
Standard Brazing Specimen
Ever since AWS published the re- terials.
Discussed Volume I, No. 1, of Technical
vised Mild Steel and Low Alloy
Steel (AWS A5.5; ASTM A316) The second meeting of the AWS Translations, the first issue of the
filler metal specifications, many in- Subcommittee working on the de- new summary of the OTS transla-
quiries have been received regarding velopment of a standard brazing test tion program, is now available. It
their use under the provisions of Sec- specimen was held recently at Ar- lists and abstracts translated ma-
tion LX of the ASME Boiler and mour Research Foundation. Under terial available from U. S. Govern-
Pressure Vessel Code. For the in- discussion was a proposed program ment sources, cooperating foreign
formation of all concerned, the new built around two tests, the Miller- governments, educational institu-
electrodes in these specifications are Peaslee test and the single-lap shear tions, etc. Technical Translations
now permitted under Section IX. test. Also considered was the de- will be issued twice a month, with
F-Numbers for these electrodes have velopment of a new test that would annual subscriptions of $12 and
been added to Table Q11.2 as fol- approximate the actual shear single copies 60¢. Subscriptions
lows: strength of the brazing alloy-base should be addressed to the Office of
metal combination. The tests are Technical Services, U. S. Depart-
EXX24 EXX14 EXX18 being designed from a statistical ment of Commerce, Washington 25,
EX X27 point of view in order to get maxi- D. C., or to a Department of Com-
EX X28 mum information from a minimum merce field office.
Fl F2 F4 of tests.
Brazing Manual Enters
1958 Supplement Added to AWS Metallizing Included Second Printing
Bibliographies on SAE Program
In 1955, the AWS Brazing Man-
Just one year ago, the first edition The Society of Automotive En- ual was published with a first print-
of the AWS Bibliographies ap- gineers is holding a national meeting ing of 7500 copies. This was a joint
peared. Containing 20 years of ar- in Detroit next month with one of enterprise of AWS and Reinhold
ticles from the WELDING JOURNAL their sessions devoted exclusively to Publishing Co. with Reinhold bear-
on 28 welding subjects, it was an in- metallizing. It is interesting to note ing all the printing costs. We have
stant success. In order to keep the that two of the three speakers are just learned that the first printing is
Bibliographies up to date, a 1958 members of the AWS Committee on exhausted; a second printing is now
Supplement is being prepared. It Metallizing. under way.

382 | APRIL 1959

 -DUCATIONAL ACTIVITIES

Course Outline Prepared for In-Plant Training 4. Cast Iron

Nonferrous
Aluminum and Its Alloys
In January, 1959, the EAC’s 5. Nickel Magnesium and Its Alloys
Subcommittee B, In-Plant Train- 6. Titanium Copper and Its Alloys
ing, prepared a welding training The Structure and States of Nickel and Its Alloys
program for the education of per- Aggregation of Metals Titanium and Its Alloys
sonnel concerned with designing, in- ) The Atom 6. Other Metals and Alloys
r States of Aggregation C. Welding of Dissimilar Metals
spection and supervision. a Crystal Structure D. Filler Metals
The framework of the course has 4 Nucleation and Grain Welding Design
been developed with due consider- Growth A. Design Considerations for
ation to the outline and lesson 7 he Properties of Metals Welding
format. This outline has been gen- is Physical Properties 1. Welding Processes as Ap-
erally accepted by the committee A Mechanical Properties plied to Design
as a working document for the Alloying of Metals Types of Welded Joints
preparation of lessons. The general Solubility in Metals Service Requirements
outline as it stands revised is given Equilibrium Diagrams Position and Accessibility
Alloying of Iron of Joint
below. Joint Preparation
Alloying of Aluminum
Alloying of Magnesium Expansion, Contraction
Outline, Section No. & Title Alloying of Copper and Residual Stresses in
Orientation, Welding Terms, Posi- Alloying of Nickel Welded Structures
tions, Joints and Definitions hermal Treatment of Metals 7. Welded Jigs and Fixtures
Safe Practices in Welding Ferrous 8. Welding-Cost Estimating
Welding and Allied Processes Nonferrous B. Welding Symbols and Blue
A. ae Print Orientation
An Introduction to Welding orrosion Specifications: Their Construction
Processes Galvanic Corrosion and Use
Gas Welding, Cutting and Stress Corrosion A. Purpose of Specifications
Gouging etallurgy of Welds B. Basic Segments of Specifica-
3. Arc Welding, Cutting and Structure of the Weld tions
Gouging Penetration and Dilution C. Codes and Standards
4. Resistance Welding The Heat-Affected Zone Qualification
5. Ultrasonic Welding Expansion, Contraction A. Purpose of Qualification
Brazing and Residual Stresses 1. Welding Processes and
Surfacing and Metallizing Preheat and Postheat Procedures
Soldering (including Ultra- Treatment 2. Welding Equipment
sonic Soldering) Peening 3. Welding Operator
7/ Fluxes and Slags General Qualification and Re-
E. Selection of Welding Processes
Basic Metallurgy V. Weldability of Metals qualification Practices
A. An Introductioa to the Manu- A. Ferrous 1. Welding Processes and
facture of Important Weldable 1 Ingot Iron and Wrought Procedures
Metals lron 2. Welding Equipment
y Plain-Carbon & Low-Alloy 3. Welding Operator
1. lron and Steel
2. Aluminum Steels Inspection Testing and Quality
3. Magnesium 3. Stainless & Heat-Resisting Control
4. Copper Steels A. Inspection
1. Importance of Inspection
2. Types of Weld Defects
IN-PLANT Ldietscestehte wintnesasbllinae CONVENES IN PHILADELPHIA 3. Status of the Welding In-
spector
Testing Method
1. Nondestructive
2. Destructive
C. Quality Control
Production Methods and Eco-
nomics
Review and Examination

The complete course, as it is pres-

ently envisioned, will run approxi-
mately 70 hours. Each session
and demonstration tentatively rep-
At a meeting of the AWS Educational Activities Committee concerning “in-plant resent two hours.
training’ held at Philadelphia's Frankford Arsenal on November 5th are, left to right, The Committee, therefore, will be
W. F. Brown, S. T. Walter, J. M. Payne, E. K. Long, W. D. Taylor, Chairman Irving G. Betz, grateful for any comments or ideas
N. A. Chapin, EAC Coordinator Orville T. Barnett, W. M. Norton, T. E. Jones, W. L. Palmer that will contribute to the effective-
and P. L. Hemmes ness of the course.

WELDING JOURNAL | 383

 SECTION NEWS AND EVENTS

As Reported to Catherine M. O'Leary

senting the welding industry and panel with questions which were
two ASTE members representing fairly equally divided on subjects
the tooling industry. Moderator relative to both methods of fab-
DISSIMILAR METALS was Dave O’Connor, past chairman rication, and processes involved,
of the Section. Panel members rarely stumping the panel.
Birmingham The Birming-
representing the welding industry Interest in this type of program
ham Section met on January 13th
were Al Fenalson, welding engineer was such that a vote was taken to
at Salem’s Restaurant with an
for Consolidated Western Steel and repeat it on an annual basis.
attendance of 45 members and
past Section chairman, and Chet Upon conclusion of the program,
guests. Technical speaker was K.
Shira, senior research engineer, Pro- Ray Journeay, secretary of the
M. Spicer, head of a group con-
duction Development Lab, Roc- ASTE Santa Ana Section, presented
cerned with field service on Hunting-
ketdyne Division of North American the AWS Section Chairman and
ton Mill Products of The Inter- Vice Chairman with ASTE mono-
Aviation. All of the members and
national Nickel Co., Inc.
guests in attendance eagerly par- grammed pocket lighters in ap-
Mr. Spicer reviewed the past
ticipated in trying to stump the preciation of the coordinated efforts
history of dissimilar-metal joining,
factors involved and steps that
have been taken in the form of
recent developments to provide
electrodes and filler wires having a
high degree of predictability in the SECTION MEETING CALENDAR
welding of many diverse composi-
tions of dissimilar metals.
MAY 1 MAY 15
CLEVELAND Section. 20th Annual Symposium. CHICAGO Section. Vogel’s Restaurant, Ham-
WELDING POSITIONERS MAY 3 mond, Ind. Annual Dinner Meeting. ‘‘Weld-
ing of Dissimilar Alloys,’ Ken M. Spicer, Inter
Birmingham The February SAN ANTONIO Section. San Antonio, Tex. national Nickel Co.
meeting of the Birmingham Section “Welding and Metallurgy,” B. D. Rowland, Earl M. FOX VALLEY Section. Appleton Elks Club
was held at Salem’s Restaurant No. Jorgenson Co. Appleton, Wis. Dinner6:00 P.M. Installation of
2 on Tuesday, February 10th, MAY 4 Officers, Dinner Dance.
starting with a social hour at 6:30, LEHIGH VALLEY Section. Ladies’ Night MAY 16
followed by dinner and a technical MAY 9 MILWAUKEE Section. May Party.
session. MARYLAND Section. Southern Hotel, Balti- MAY 19
Speaker at the meeting was more, Md. Fourth Annual Dinner and Dance. NEW JERSEY Section. Essex House, Newark,
Anthony K. Pandjiris, president of STARK CENTRAL Section. Ladies’ Night. N. J. Dinner 6:30 P.M., Meeting 8:00. “Your
Pandjiris Weldment Co., St. Louis, MAY 11 Magazine—How It Is Published,”’ B. E. Rossi,
Mo. Hissubject was “All’s Well That Editor, WELDING JOURNAL.
NORTHWEST Section. Minneapolis, Minn. NEW ORLEANS Section. New Orleans, La
Ends Welded.”” The talk covered Annual Meeting, Election of Officers
an explanation of the various types “General Welding and Fabrication of Stainless
MAY 12 Steel,” J. A. Goodford, Crucible Stee! Co
of fixtures available, and the num- OLEAN-BRADFORD Section. Jade Room, Emery
ber of special applications such as DAYTON Section. Kuntz Cafe, Dayton, Ohio.
Social 6:30 P.M., Dinner 7:00, Meeting 8:00. Hotel, Bradford, Pa. Dinner 7:00 P.M. Plant
“electro-molding” (vertical weld- Annual Quiz Program. Tour—AWS-ASME Jointly—Corning Glass Works,
ing) used in production. Mr. Pand- NORTH TEXAS Section. 6:30 P.M. Family Components Plant, Bradford, Pa.
jiris discussed the practical methods Night. Western Hills Inn. MAY 21
of making weldments. WESTERN MASSACHUSETTS Section. Trase’s MAHONING VALLEY Section. E! Rio Restau
Restaurant, Springfield, Mass. Dinner 6:30 P.M. rant, Warren, Ohio. Dinner 7:00 P.M., Meeting
Coffee films: The Corporal Story and Ausable 8:00. “Power Sources for Arc Welding,” J.
Chasm. “Magnetic Particles and Penetrant In- Blankenbuehler, Hobart Bros. Co.
spection,” Robert G. Strother, Magnaflux Corp. MAY 22
MAY 14 INDIANA Section. Technical meeting and an-
STUMP THE PANEL IOWA-ILLINOIS Section. “Large Weldments nouncement of new officers. 6:30 P.M. “Welding
Fabrication,” J. L. Lang, Lukens Steel Co. Applications and Safety,’ A. N. Kugler, Air Re
Los Angeles—A joint meeting duction Sales Co.
of the AWS Los Angeles Section IOWA Section. Annual business meeting plus
entertainment and refreshments. NORTHWESTERN PENNSYLVANIA _ Section.
and the ASTE Santa Ana Section NASHVILLE Section. ‘Automatic Welding Annual Business Meeting and Ladies’ Nite.
was held Thursday evening, Jan- Alloys,” H. F. Reid, The McKay Co. MAY 23
uary 15th, at the Rodger Young SAGINAW VALLEY Section. Plant tour of PHILADELPHIA Section. Philadelphia, Pa,
Auditorium with approximately 150 Saginaw Steering Gear Div., GMC Annual Dinner Dance. Germantown Cricket Club.
members and guests in attendance.
The program titled “Stump the Editor's Note: Notices for July 1959 meetings must reach JOURNAL office prior to April 20 so that they may
Panel’ featured four panel members, be published in June Calendar. Give full information concerning time, place, topic and speaker
for each meeting.
with two AWS members repre-

384 | APRIL 1959

“STUMP THE PANEL” PROGRAM HELD IN LOS ANGELES

The four panel members who represented the AWS Los Angeles Section and the The moderator for the evening was
ASTE Santa Ana Section at the January 15th joint meeting were (left to right) Dave O’Connor, past chairman
J. Rust, ASTE; Dale Sewart, ASTE; Chet Shira, AWS; and Al Fenalson, AWS of the Los Angeles Section

Approximately 150 members and guests were present at the meeting to attempt ASTE Santa Ana Section Secretary Ray
to ‘‘stump the panel.”’ A few of those in attendance are shown above Journeay speaks at meeting. Los
Angeles Section Vice-chairman Dick
Hayes is shown at right

put forth by them in formulating taurant on January 20th. Approx-

the program. imately 45 members and guests
ASTE National President Wayne braved a snowstorm and freezing
Ewing, president, Arrow Smith Tool ALUMINUM ALLOYS rain to hear a talk by P. B. Dicker-
and Die Co., was one of the prom- Glastonbury ~The Hartford son, welding engineer, Process De-
inent members in attendance. Section held its fourth regular velopment Laboratory, Aluminum
During the dinner, entertainment meeting at the Villa Maria Res- Company of America, as well as
was furnished by the “‘Mad Hat-
ters’’, an old-style barber-shop quar-
tet.

SPEAK BEFORE HARTFORD SECTION

SAFETY IN WELDING oa
Sunnyvale—The Santa Clara
Valley Section met on January 27th
for dinner and meeting at Sabella’s
in Sunnyvale.
Technical speaker was Lee Reay,
merchandising specialist, Pacific Re-
gion, Linde Co. His subject was
“Safety in the Welding Industry.”
Mr. Reay described in detail the
hazards possible with every common
gas that is used in the welding
field. He demonstrated in detail
the proper use of oxygen-gas cyl-
inders, and also acetylene, and
conditions to be avoided. Mr.
Reay is a very fluent speaker and Among the speakers at the January 20th meeting of the Hartford Section were AWS
was well received. His talk was President G. O. Hoglund (left) and P. B. Dickerson (right) President Hoglund spoke
very educational in the _ general on the advantages of AWS membership, while Mr. Dickerson discussed the welding of
field of safety. aluminum alloys

WELDING JOURNAL | 385

 talks on the Socrery by honor
guests President G. O. Hoglund and
National Secretary Fred L. Plum-
mer.
J.A.K. SECTION Messrs. Hoglund and Plummer
filled the role of coffee speakers
MEMBERS HEAR quite well. They spoke of the
TALK ON progress and activities of the So-
CIETY for the past year, and its
OXYGEN CUTTING future. Mr. Hoglund also spoke
eloquently on the advantages of
membership in the Socrery.
Mr. Dickerson’s talk dealt with
George R. Spies addressed the J.A.K. improvements in the performance of
Section on the subject of oxygen aluminum welds as a result of the
cutting at the February 12th meeting development of the inert-gas-
shielded welding processes. The
talk covered the strength and ductil-
ity of butt welds in various alu-
minum alloys, the longitudinal and
transverse-shear strength of fillet
welds, and the effect of tempera-
ture over the range of —320 to
700° F.
Also included in Mr. Dickerson’s
talk were the most recent develop-
ments in the allied field of alu-
minum cutting by consumable elec-
trodes and tungsten-are inert gas.
The effects of these methods upon
A group of the Section officers are pictured at the meeting. Left to right, are: the metallurgy and weldability of
Me! Sumter, director; E. Egan, technical advisor; John Wolf, 1st vice chairman; aluminum alloys were discussed.
R. Barnet, secretary; and Tony Gerl, chairman Mr. Dickerson’s talk was il-
lustrated by slides, and followed
by an excellent film on ‘Welding
of Aluminum.” The meeting closed
The Pe rfect with a lively question-and-answer
: - period.
Welding Mates IES
TEC SPOT GUN
This TIG spot welding tool perfectly bridges the se? between LOCATORS OF ANY
resistance welding and TIG arc welding. The TEC Spot Gun
Cxpensite
! spot eldweldingoperatane . the iahtestweignmost_
, DESIGN AVAILABLE
compact apet gun on meds, it comfortably fits the opera- WELDED DESIGN
tor's hand. Weld up to, and ———, ¥” thickness to any
size stock and in any joint design. There are -
no movable parts to wear or replace, permitting att, Miami—The January dinner
maintenance free operation. - meeting of the South Florida Section
Touch starting is replaced —
by high frequency arc start- was held on the 21st at Edith &
ing, reducing
electrode waste —w7s Fritz. Attendance was small, due
and work con- to a number of conflicting events
tamination. .
in the area.
A most interesting talk on
— N “‘Weldesign,”” was given by N.
5
— Howard Dye, district manager,
Lincoln Electric Co. The talk was
followed by a film and a question-
TEC SPOT and-answer period.
CONTROL
This perfect welding mate for the
TEC Spot Gun, converts any DC
power source into a new TIG spot
welding machine. A choice of pre-
set weiding times can be selected
at the gun itself. The TEC spot
control unit is light and compact,
with easy to read controls. It is OXYGEN CUTTING
the only control unit of its kind.
This portable TEC spot control
unit can easily be connected to Joliet—The J.A.K. Section met
any DC power source. on February 12th at D’Amicos
Restaurant in Joliet for dinner and
Write NOW for full information on the TEC Spot Gun and other Superior Visuweld Equipment meeting. Coffee talk was given by
0 RSON AVENUE E. Egan, technical advisor, who
TEC TORCH CO., INC. fikasrao : : .
: —— spoke on the new AWS Welding
For details, circle No. 43 on Reader Information Card Symbols.

386 | APRIL 1959

 Guest speaker was George R.
Spies of the Air Reduction Co.,
New York. Mr. Spies spoke on
“Oxygen Cutting”’ with oxygen and
acetylene, as well as oxygen and
natural gas.

702-
3-C
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extra ventilation. Has all the famous Fibre-
HONEYCOMB PANELS Fibre-Metal’s Metal comfort features. Offers variety of
fixed and lift-front glassholders.
Martinsville——The January 23rd
meeting of the Indiana Section was
held at the Elks Club Dining Room
at Martinsville, Ind.
R. P. Roberts, division manager IBERGLAS

of Twigg Honeycomb Plant, spoke

on his company’s newly developed
brazing process of stainless-steel
honeycomb for the aircraft industry.
~
He went into detail in describing WELDING

a typical honeycomb-panel brazing 708-

stackup. Twigg Industries supplies 3-C
honeycomb panels for the aircraft
industry. The use of honeycomb Over 120% increased vision with its 44%” x
5%” lens...more vision both vertically and
sections is anticipated to increase HELMETS
horizontally. Reduces eyestrain and fatigue.
due to its light weight, high strength Excellent for welders who must wear bifo-
and heat resistance. After Mr. cals, or trifocals, while welding.
Roberts’ talk, a guided tour was Undeniable comfort, clearest wide vision
conducted through the Twigg Hon- and assured safety are basic quality fea-
eycomb Plant. tures of these Fiberglas welding helmets.
The meeting was attended by
68 members and guests, with H. E. FIBRE-METAL compression-molded,
Schultz, District No. 5 Director, as Fiberglas-reinforced polyester resin shells
a special guest. offer the very finest in durable face protec-
tion. Proper glass fiber distribution and a
MACHINE WELDING “beaded edge for strength” insure long-
South Bend—Thirty-four mem- lasting, trouble-free helmet life. Shells are
bers and guests braved adverse self-extinguishing, are unaffected by heat
weather to attend Michiana’s Na- The popular narrow-front shell for compact,
and moisture, will not warp or lose shape, lightweight protection. Best for welding in
tional Officers Night held on Jan- tight spots...eliminates flat, spatter-collect-
uary 15th at Russ Restaurant. The may be easily and quickly cleaned and ing surfaces. Less pitting, lasts longer.
sterilized. Welders TELL US these helmets 674-3-C has lift-front glassholder.
Section was honored to have not
only National First Vice-presi- help produce more and better welding!
dent Charles I. MacGuffie as a
speaker, but also National Sec- All helmets have Ratchet Adjustment
retary Fred L. Plummer and
District No. 7 Director A. F. “free floating’ Headgear, impact resistant
Chouinard to describe the various adjustable friction joints and adjustable
phases of the Society. chin rest. Glassholders are available in
Mr. MacGuffie spoke on the
subject of ‘““‘The Economics of plastic, steel or Dowmetal, in either fixed
Machine Welding.”’ This had to or lift-front styles. All types of helmets are
do with the decisions that many described in Catalog No. 26.
persons have to make when welding
jobs appear for scheduling, such Features extended neck and chest protection
Ask your Welding & Safety Distributor! with greater ventilation. Standard-size shell.
s “Is this a hand job or should we Also available with an Inner Bib (See our
put it on a machine?” The first *OWENS-CORNING TRADE MARK Catalog No. 26) for extra fume and light seal.
item to examine is the quantity of
assemblies involved. The cost of
establishing a machine-welding op-
eration—perhaps purchasing the CHESTER
machine itself—must be weighed ETAL Products Company PENNA
against the labor saving on each
individual weld. While this factor In CANADA: Fibre- Metal (Canada) Limited, Toronto
is extremely important, another is
coming more and more to the fore.
For details, circle No. 18 on Reader Information Card — See us at the WELDING SHOW—Booth 434—Chicago
WELDING JOURNAL | 387
 386 | APRIL 1959

A large crowd was on hand at the January 8th meeting of the Kansas City Section. Technical Speaker of the evening was
Here some of the members and guests are shown during the Social Hour R. W. Tuthill. His talk covered the car-
bon-dioxide-shielded metal-arc process

This one is: “‘Can it be welded as the job can be done satisfactorily. beam process. Performed in a
well by hand, or even at all?” Mr. MacGuffie also noted some vacuum, a stream of electrons is
Modern designs and metals some- of the newer welding methods, focused on the spot to be welded.
times preclude the use of hand mentioning especially one that, Very small areas and very shallow
welding from a quality standpoint. while it has not yet reached the depths can be welded in most any
In fact, the control required on production stage, holds great prom- material now available.
some joints is so close that machine ise for doing jobs that no other
welding is the only way in which unit can do. This is the electron-

RESISTANCE WELDING
Des Moines—The regular
monthly meeting of the Jowa Sec-
BRIGHT FINISH tion was held on January 15th at the
ALUMINUM Kirkwood Hotel. Forty-five mem-
bers and guests were present for the
WELDING WIRE annual ‘“‘Resistance-Welding Lec-
() deposits uniformly ture’? by J. Paul Thorne, chief elec-
[) eliminates trical engineer for the National
interruptions Electric Welding Machine Co. of
[] makes x-ray Bay City, Mich.
quality welds Since the Section is made up of
very few engineers and mostly non-
All-State Bright Wire technical people, Mr. Thorne re-
Spoolarc, extruded viewed the basic fundamentals of
and precision spooled, resistance welding before showing
is uniformly round, slides and a movie on special resist-
ance-welding equipment. The re-
microscopically clean... view of the basic theory of resistance
meets aviation, tank- welding and a discussion of the lat-
age, and shipbuilding est automatic resistance-welding
standards. equipment available were very well
received by the 45 members and
Send for booklet and chart
guests present.
on all types and forms
of aluminum in BRIGHT
FINISH including Massachusetts
1 lb. and 10 Ib. spools.
Stock maintained at HARD SURFACING
St. Louis, South Gate, Springfield—The February 10th
Calif., Toronto, Canada, meeting of the Western Massa-
and White Plains, N. Y. y chusetts Section was held as a joint
VISIT OURSBOOTH 610 AT THE WELDING SHOW meeting with the ASM Springfield
WHITE PLAINS Chapter at the Oaks Inn. Despite
ALL-STATE WELDING ALLOYS CO. INC. NEW YORK inclement weather, there was an
For details, circle No. 21 on Reader Information Card excellent turnout.

388 | APRIL 1959

 WELDING JOURNAL | 387

Following a fine dinner, a coffee

film, entitled ‘‘Deep Sea Fishing”
featuring Ted Williams, was shown. New Hi-Impact Plastic Insulated
Arnold Arnaut, district manager,
Wall Colmonoy, Inc., presented an
informative talk on ‘“‘Hard-Surfacing Panel Receptacles and Mating Plugs
Materials and Techniques.’”’ His
talk was accompanied by slides
which showed various materials
that are used for hard surfacing.
The response given to this talk was Mount directly
indicative of the excellent presen-
tation. on any

Electrical

Panel

SUMMARY OF MEETINGS
Pascagoula—The first meeting
of the year of the Pascagoula
Section was held on Oct. 8, 1958,
after a get-together and dinner at
the American Legion Post. Guest
Speaker Gordon E. Cossaboom,
supervisor, product planning, for
Westinghouse Electric, gave a talk
on new uses for CO, welding,
illustrated with projection slides.
On November 12th, a meeting
was held at Cotita’s Restaurant.
Guest Speaker Louis K. Keay, Now, you can make fast, positive power connections to any
manager, technical service, Lukens metal panel or housing without special insulating materials.
Steel Co., gave a talk on the process Simply punch outa hole and insert a Cam-Lok self-insulated
of cladding steel plates with stain- Receptacle! Uses standard electrical lock-nuts, affords
less steel and Monel. The talk was
illustrated with projection slides. ‘“‘dead-front”’ protection. Push in and twist Cam-Lok
On December 10th, a meeting mating Plug and you've made a locked connection, which
was held at Cotita’s Restaurant. can be released quickly.
Guest Speaker J. W. Clark, Linde
Co. Engineering Service representa- New Cam-Lok Receptacles eliminate costs of special
tive, Southern Region, gave an
insulating panels and reduce assembly time. Patented,
illustrated talk on “‘Magnetic-Flux
Gas-Shielded Arc-Welding Process.” high-pressure contact assures minimum resistance and
heating.

Cam-Lok has a complete line of Receptacles and Plugs in

Missouri many sizes and designs. Standard and special purpose
Power Distribution Connections are available. Write today
INFLUENCE OF WELDING
for new Bulletin No. 301.
St. Louis—The regular technical
meeting of the St. Louis Section
was held at Ruggeri’s Restaurant “Dead Front” design for fast
on Friday evening, January 9th.
A fellowship hour was followed by direct mounting on...
a buffet-style dinner.
The speaker for the meeting was © ELECTRICAL DISTRIBUTION PANELS «© SWITCHGEAR
L. A. “Dick” Butler, contracting * BUS DUCT «© JUNCTION BOXES
engineer in charge of estimating © WIREWAY or any electrical cubicle
costs on special field-erected pres-
sure vessels, Chicago Bridge &
Iron Co., Chicago, III. See the Cam-Lok line, Booth #217, AWS Welding Show,
Mr. Butler’s talk pointed out Chicago International Amphitheatre, April 7-9
the importance and influence of
welding in pressure-vessel design
and fabrication. The effect of EMPIRE PRODUCTS, INC,
welding on fabrication and erection P.O. BOX J-98
procedures and equipment was il- ee@nomollealkx
lustrated in a color movie showing DIVISION CINCINNATI 36, OHIO
the erection of a 190-ft diam nuclear
reactor. For details, circle No. 23 on Reader information Card

WELDING JOURNAL | 389

 First Order for All-Weilded
Aluminum Hulls Convinces Boat Builder: “ALUMINUM IS EASY TO WELD"

“Only four months for designing and **Prior to building these test boats, and joining methods can help you
building 72 all-welded aluminum- three of our welders had received all the way from design to produc-
hulled boats for the purse seining training at Alcoa’s New Kensington tion. For more information, contact
fishing fleet left us no time for weld- job shop. Now this really paid off. your Alcoa sales office. For welding
ing mistakes,’ says Mr. Donald C. We found that aluminum could actu- materials, call your local Alcoa Dis-
Hankin of RTC Shipbuilding Corp., ally be welded at a faster rate than tributor listed at the right. And for
Camden, N. J. ““These boats take steel, and with relative freedom from booklets and films that show how
tremendous punishment from pound- warping and distortion. Alummum’s easy it is to weld, braze and solder
ing seas, rugged weather and from lighter weight eased handling prob- aluminum, write Aluminum Com-
the drag of tons of menhaden fish lems and speeded assembly. As a pany of America, 1762-D Alcoa
against the hulls. This means that result, the order was completed on Bldg., Pittsburgh 19, Pa.
every weld has to be perfect. schedule and the customer reports Your Guide to the Best
“Our only previous experience no trouble with the aluminum hulls.” in Aluminum Value
with aluminum welding had been a This is only one example of the
trial order for two boats of the same many exciting possibilities in weld- Watch
ALCOA 5 ‘Alcoa Theatre
type. Our customer was so impressed ing, brazing and soldering Alcoa* ALUMINUAA Alternate Monc
with their performance that he im- Aluminum and its alloys. Alcoa’s NBC-TV
“Alcoa Presents
mediately ordered a whole fleet. research in alloys, welding techniques Every Tuesday
ABC-TV
For details, circle No. 25 on Reader Information Card
390 | APRIL 1959
Want technical help in welding, brazing or sol- | ST. LOUIS SECTION ADDRESSED BY BUTLER
dering aluminum? Contact your Alcoa sales
office, listed under “Aluminum” in the Yellow |
Pages of your phone book. |
For immediate delivery of Alcoa welding |
products, call your Alcoa outlet listed below. He |
carries a complete range of alloys and sizes.
|
ALABAMA New York |
Birmingham Whitehead Metals |
Hinkle Supply Co. Inc |
Syracuse |
CALIFORNIA Brace-Mueller-
Los Angeles Huntley, Inc. |
Ducommun Metals Whitehead Metals |
& Supply Co. Inc
Pacific Metals |
Company, Ltd. NORTH CAROLINA |
San Francisco Greensboro |
Pacific Metals Southern Oxygen Co |
Company, Ltd.
|
COLORADO OHIO |
Denver Cincinnati |
Metal Goods Corp. Williams and Co., inc
CONNECTICUT Cleveland | The effect of welding on design, fabrication and erection procedures was discussed
A. M. Castle & Co. |
Milford Williams and Co., inc by L. A. Butler at the January 9th meeting of the St. Louis Section. Left to right,
Edgcomb Steel of Columbus | above, are: H. W. Castle, F. Tohill, Section Chairman E. G. Mathae and Mr. Butler
New England, Inc. Williams and Co., Inc |
Windsor Toledo |
Whitehead Metals Williams and Co., Inc
Inc |
FLORIDA |
Jacksonville OKLAHOMA |
The J. M. Tull Metal Tulsa |
& Supply Co., Inc. Meta! Goods Corp.
|
Miami |
The J. M. Tull Metal OREGON
& Supply Co., Inc. Portland |
Tampa Pacific Metal Co. |
The J. M. Tull Metal J. E. Haseltine & Co. |
& Supply Co., Inc.
GEORGIA PENNSYLVANIA |
Atlanta Philadelphia |
The J. M. Tull Metal Edgcomb Steel Co. |
& Supply Co., Inc. Southern Oxygen Co |
Southern Oxygen Co. Whitehead Metals
Inc |
ILLINOIS Pittsburgh |
Chicago Williams and Co., Inc |
Machinery & Welder York
Corp. Southern Oxygen Co |
Steel Sales Corp. |
KANSAS | The members and guests enjoying the dinner that preceded the formal meeting
TENNESSEE
Wichita Kingsport
Metal Goods Corp. Southern Oxygen Co |
KENTUCKY |
Louisville TEXAS | facilities to control metallurgical
Williams and Co., Inc Beaumont | properties must be at hand.
Big Three The diversity of welding tech-
LOUISIANA Welding Equip. Co. |
New Orleans Corpus Christi | JOB-SHOP WELDING nique, equipment and materials
Meta! Goods Corp. Big Three has made it possible for the job
Welding Equip. Co | Newark—Some of the problems
MARYLAND Dallas | shop to attain quality welding,
Balt.more Meta! Goods Corp. of the job shop were described by
Southern Oxygen Co. Texas Welding | Harold C. Schanck, Jr., of the provided the problems that con-
Whitehead Metals Supply Co. | front the shop are recognized and
Inc | Swepco Tube Corp. of Clifton,
Bladensburg Houston appropriate procedures are _ insti-
Metal Goods Corp. | N. J., before an audience of about
Southern Oxygen Co. Big Three 75 members of the New Jersey tuted.
Welding Equip. Co. |
MASSACHUSETTS San Antonio | Section at the Essex House on
Cambridge Big Three | January 20th. He pointed out
Whitehead Metals Welding Equip. Co.
Inc. | that, by nature, the job shop must
MICHIGAN UTAH | tailor its operations to many in- PRESSURE-VESSEL
Detroit Salt Lake City | dividuals and different jobs rather
Stee! Sales Corp. Pacific Metals | FABRICATION
Company, Ltd. than repeated production. Yet,
MISSOURI | a profit must be realized. New York—On January 13th,
Kansas City VIRGINIA | He noted that a serious problem the New York Section held its
Meta! Goods Corp. Norfolk |
St. Louis Southern Oxygen Co ' arises from the acquisition in small regular monthly meeting. The
Meta! Goods Corp quantity of materials from local speaker of the evening was Wil-
Stee! Sales Corp. Richmond
Southern Oxygen Co | warehouses, accompanied by the liam R. Apblett, chief metallurgist
NEW HAMPSHIRE |
Nashua WASHINGTON | need for short-term delivery which for the Foster Wheeler Corp., New
Edgcomb Steel of Seattle | makes it necessary to accept ma- York, and the subject was “‘Nuclear
New England, inc Pacific Metal Co. Pressure-Vessel Fabrication.”
NEW JERSEY J. E. Haseltine & Co | terials that sometimes do not have
Spokane | the best welding characteristics. During the meeting Mr. Apblett
Harrison J. E. Haseltine & Co | showed three short movies covering
Whitehead Metals Judicious adjustments in welding
Inc | procedures are required. He also the processes and procedures used
WISCONSIN | to fabricate nuclear parts. One
NEW YORK Milwaukee noted that to control the properties
Buffalo Machinery & Welder | required to meet special require- of these showed the method of
Whitehead Metals Corp. | heat treating and quenching ex-
Inc Stee! Sales Corp. | ments, such as the ASME Code,

WELDING JOURNAL | 391

 THEIR TOPIC IS IRON-POWDER ELECTRODES completely passed.
Over all, it was a very successful
meeting and an audience in excess
of 60 persons attended.
The meeting, as usual, was held
at Victor’s Restaurant, 1 E. 35th
St., where an excellent dinner was
served prior to the meeting.

WELDING ELECTRODES
Menands—D. C. Smith, chief
metallurgist for the Electrode Di-
vision of Harnischfeger Corp., was
guest speaker at the February 5th
meeting of the Northern New York
Section. Following dinner at
Panetta’s Restaurant, Dr. Smith
spoke on “Iron-Powder Manual
Arc-Welding Electrodes”’ to an au-
dience of 70 members and guests.
D. C. Smith spoke on iron-powder arc-welding electrodes at the February
5th Starting with the bare welding
meeting of the Northern New York Section. Dr. Smith is shown above, during electrode, Dr. Smith traced the
the dinner which preceded the meeting, ready to pour another cup of coffee stages in the development of manual
metal - arc welding electrodes
tremely thick plates for nuclear out that extremely high quality is through the light sulcoated rods,
reactors. required for all welds connected the cellulose and mineral coated
Also shown were newly developed with atomic reactors, even those ones, to the low-hydrogen type and
techniques for automatically that are usually considered to be finally to the iron-powder covered
welding tubes to tube sheets, using relatively unimportant, such as electrodes. Today there are iron-
the tungsten-arc process. welds joining the clips that hold powder electrodes available which
Between movies, Mr. Apblett insulation on the exterior of the are the counterparts to about all
showed slides and presented a vessel. Even these welds had to of the commonly used conventional!
very interesting talk detailing some be ground smooth and completely metal-are welding electrodes. Gen-
of the procedures used. He pointed inspected before the vessels were erally, the iron-powder content of

Revolutionary Zexare Enables High Speed

Production in Tractor Roller Rebuilding

Here is the new Rexare MS-8 Automatic Twin Head Roller and Idler
Welder and Positioner that mounts 8 rollers at a time. Hydraulic
indexing enables virtually a continuous automatic welding operation.
Twin heads build up both sides of roller simultaneously.

Factory engineer trains your operator, assuring excellent results from

the very beginning of welding operations, at no additional cost.

SEE LIVE DEMONSTRATIONS OF THIS ezaze MS-8 AND THE

Rexare AUTOMATIC FLUX CIRCULATING UNIT AT CHICAGO
AWS SHOW, APRIL 7, 8, 9, BOOTH 433.

Phone, Wire or write today for complete information about this revo-
lutionary profit-maker.
Manufactured by

THE SIGHT FEED GENERATOR COMPANY

(Pictured Above) A complete Rexarc installation
at Michigan Tractor & Machinery Co., Detroit, SALES OFFICES AND FACTORY, WEST ALEXANORIA, OHIO, U.S.A.
Michigan.
For details, circle No. 27 on Reader Information Card

392 | APRIL 1959

 hh
?
4)

Lincoln

WELDYNAMICS

NEWS ABOUT ARC WELDING AT WORK CUTTING COSTS

ATLAS SOLVES HIGH COST PROBLEMS

High welding costs were eating away

at profits and making it tougher to
bid competitively on heavy fabri-
cating jobs at the Atlas Machine
and Iron Works in Arlington, Va.
Werner Quasebarth, production
manager and his brother, Bill
Quasebarth, pliant engineer, decided
immediate action had to be taken.
Since most of the work coming out
of their shop is welded, it was nat-
ural that their welding operations
come under scrutiny first.
To help them analyze all their
welding procedures and processes
they asked Jim Clauson, a welding
engineer from Lincoln, to conduct a
survey of their shop in an effort to
pinpoint inefficiencies.
Bill Quasebarth and Jim Clauson
checked every welding operation in Bridge bearings are welded manually with
iron-powder Jetweld electrodes.
the shop. They compared electrodes
expected to pay off in cost reduc- 51,’ fillet welds per manhour. By
tions of 's or more. utilizing two Lincoln Mechanized
The most dramatic improvement “Squirt”’ welders which are capable
was made on the process for welding of welding 50 feet of °,,’’ fillet per
cover plates on girders. Welding machine hour, Atlas was able to in-
manually, Atlas welders have been crease overall production 50% on
able to complete 12 actual feet of this operation.
For short welds, not accessible to
the semi-automatic or automatic
machines, iron-powder Jetweld elec-
trodes were found to offer greater
speed, higher operating factor and
better welds.
Werner Quasebarth says, ‘‘We’re
grateful to Lincoin for helping us
with our cost problems. We’ve
learned from experience that the ad-
vice of Lincoln engineers is sound.
We've been skeptical in the past,
but we’ve found the Lincoln man is
usually right.”

Bill Quasebarth, Plant Engineer, found the

way to cut costs and improve the product. THE LINCOLN ELECTRIC

and processes for operating factor, COMPANY

speed, weld quality and appearance. Dept. 1952 . Cleveland 17, Ohio
As a result of the survey several im- Welding cover plates on bridge girders. A
switch to semi-automatic has upped produc- The World's Largest Manufacturer of
provements were made which are tion 50%, improved weld quality. Arc Welding Equipment
For details, circle No. 29 on Reader Information Card
WELDING JOURNAL | 393
 3922 | APRIL 1959

these electrodes amounts to 30% ultra-high tensile strength iron- the Reynolds Metals Co., Rich-
of the coating for all-position powder, low-hydrogen type elec- mond, Va. Mr. Wilcox’s subject
electrodes and 50% for flat and hori- trodes that have been developed. “Welding, Cutting and General
zontal electrodes. However, a few Electrodes of this type have been Fabrication of Aluminum,” was
of the electrodes have as little as developed to deposit welds having accompanied by slides. Mr. Wilcox
5-10% iron powder in the coating. tensile strengths well over 200,000 brought out in his talk the new
In addition to improved weld qual- psi. These electrodes have also fields that have been opened for
ity which results principally from been designed so that the weld aluminum, such as oil drilling plat-
improved arcing characteristics, per- metal, heat-affected zone and base forms, under-water piping, alu-
haps the greatest attribute of these metal can all be simultaneously minum used in construction of
electrodes is their significantly postweld tempered to the same buildings and also uses found in
higher deposition rates rather than hardness. the mining industry. In each of
their conventional counterparts. these fields, the methods and ap-
Dr. Smith showed a number ofslides plication of construction and the
illustrating the higher deposition ela @elaeliite new techniques that have been
rates to be obtained with these developed were explained. This
electrodes with both low-hydrogen talk showed the importance of
ALUMINUM WELDING keeping abreast of the develop-
and nonlow-hydrogen coatings. An-
other important virtue of the low- Raleigh—-The regular meeting ments in this field of welding.
hydrogen iron-powder electrodes, of the Carolina Section was held
which Dr. Smith discussed and in the Colonial Room of the S & W
illustrated with slides, was their Cafeteria on January 19th. There
excellent Charpy vee-notch impact were 35 members and guests pres- ANNUAL EXECUTIVES NIGHT
strength at temperatures down to ent.
—40 to —60° F. Speaker for the evening was Cleveland—The January 14th
Dr. Smith concluded his talk Dana Wilcox, welding engineer, meeting of the Cleveland Section
with a discussion of several of the Engineering Service Department of was the annual Executives Night
Dinner. Over 300 members and
their executive guests gathered at
CLEVELAND MAYOR GUEST OF SECTION the Cleveland Engineering and Sci-
entific Center for the social hour,
dinner and meeting.
Cleveland’s Mayor, the Honor-
able Anthony J. Celebrezze, ad-
dressed the meeting on the subject of
Cleveland’s future growth and de-
velopment. He pointed out the
challenge to business and industry
to carry out with private capital
the many opportunities for growth
represented by the new St. Law-
rence Seaway. the new highways and
the lakefront and downtown de-
velopment projects. The audience,
men from a large segment of the
northern Ohio business community,
signified their interest with serious
Mayor Anthony J. Celebrezze addressed the Executives Night event held by the Cleve- attention and pointed questions
land Section on January 14th. His topic dealt with Cleveland's future growth and from the floor.
development. Here, as Section Chairman Harry E. McBride watches, George Staiger Section Chairman Harry McBride
presents to Mayor Celebrezze a certificate of appreciation presented a certificate of recognition
to William Mayor, the immediate
past chairman of the Cleveland Sec-
tion. George Staiger was chair-
man of the committee that planned
this outstanding meeting.
WELDED ALUMINUM
STRUCTURES
Cleveland—The technical ses-
sion of the regular February meeting
of the Cleveland Section was de-
voted to the welding of aluminum
structures. The meeting, which
started off with a social hour and
dinner, was held in the Cleveland
Engineering and Scientific Center on
February 11th.
Chairman McBride presents certificate “Darby”’ Darbyshire, who does most of There were two speakers sched-
of recognition to Junior Past-chairman Cleveland Section’s secretarial work, uled for this meeting. R. C. Kas-
William Mayor (right) shown with Director Mike Shane (left) ser, a Purdue civil engineer, who has
and Vice-chairman Irv Schreck spent most of his career with the

394 | APRIL 1959

 WELDING JOURNAL | 393

Today, surrounded as we are by dangers which threaten to

destroy our precious Freedom to Worship, it behooves us to
Kreedom seek guidance and spiritual strength in the manner of our
forefathers...through “instruction in the scriptures.” Attend
Sunday School regularly...make every week Sunday School
Week.

BYatstatatet

Holy Bible

A
+

NATIONAL SUNDAY SCHOOL WEEK, APRIL 1383-19

sponsored by the Laymen’s National Committee, an All Faiths organization

/ tok
This advertisement is presented as a public service by: \EUTECTIC
7 SWEDINGC ¢ AUOTS,
y
Rene D. Wasserman, President

WELDING JOURNAL | 395

 394 | APRIL 1959

DISCUSS WELDING OF ALUMINUM STRUCTURES relatively new field of welded alu-

minum structures.
Loren Miller, technical chairman
for this meeting, has been appointed
to the Board of Directors of the
Cleveland Section. He is general
superintendent of the Austin Co.’s
fabricating plant in Cleveland.

WELDING COST CLINIC

Cleveland—On February 19th,
the Cleveland Section Educational
Committee wound up its program
that has been running for the past
six weeks. Wasil Romance and his
committee planned a series of six
sessions on welding costs. Speak-
The welding of aluminum structures was covered by R. C. Kasser and P. B. Dickerson ers were invited to discuss their ex-
at the February 11th technical meeting of the Cleveland Section. Shown above are, periences telling how they have
left to right, Mr. Kasser, Chairman H. McBride, L. Miller and Mr. Dickerson made significant cost reductions
through and with welding. Equip-
Aluminum Company of America minum Company of America spe- ment manufacturers were invited
developing structural uses for alu- cialist in inert-gas welding, pressure to explain new developments that
minum, described examples of struc- welding and ultrasonic welding, also promise new possibilities for re-
tures of welded aluminum such as spoke to the meeting on various ducing the cost of welding. Pur-
cranes, bridges, sub-stations, etc. aspects of welding aluminum. The chasing agents spoke on the prob-
He described in detail the first large attendance at the meeting and lems of obtaining equipment. The
aluminum girder-type bridge re- the close attention it drew would February 19th dinner meeting fea-
cently erected near Des Moines, indicate that there is considerable tured L. T. Kenney, general man-
lowa. P. B. Dickerson, an Alu- interest in the Cleveland area in this ager, The United Welding Co., Di-
vision of Baldwin-Lima-Hamilton
Corp., who explained what his
RESISTANCE-WELDING COURSE COMPLETED organization does to achieve efficient
management in the welding indus-
try. The Welding Cost Clinic, as
the meetings were called, was limited
to 50 men who enrolled for the series.
The series was pronounced highly
successful by those who participated.

RESISTANCE- WELDING
COURSE
Dayton—One hundred and
twenty-three men from the Miami
Valley area completed the twelve-
week “‘Resistance-Welding Lecture
Course”? sponsored by the Dayton
Section at the Frigidaire Audi-
torium.
The last three speakers at the resistance-welding course recently sponsored by the Day- The last three classes were von-
ton Section were E. F. Holt, J. J. Riley and S. Rockafellow. Mr. Holt (above, left) spoke ducted by specialists in their field:
on resistance-welding electrode alloys. Mr. Riley (above, right) discussed resistance- E. F. Holt, P. R. Mallory and Co.,
welding transformers. Mr. Rockafellow (below, left) covered electronic controls. S. spoke on resistance-welding elec-
Schneider (below, right) awarded certificates to the graduates trode alloys and their applications;
J. J. Riley, Taylor-Winfield Corp.,
on resistance-welding transformers;
and Stuart Rockafellow, Robotron
Corp., on electronic control equip-
ment for resistance-welding ma-
chines.
Siebert Schneider, chairman of the
Educational Committee, presented
certificates to the graduates at a
social held at the Inland Activities
Center. Officers of the Dayton
Section and members of the Educa-
tional Committee were introduced
to the group and plans were re-
vealed for future courses in different
processes of metal joining.

396 | APRIL 1959

 WELDING JOURNAL | 395

Failure of any part of a missile—be it the mighty a flame test in order to meet specifications.
Atlas, Jupiter or Thor—can mean failure of the The silver-brazed connections are used on
mission. That’s why the complex connections in the hydraulic and pneumatic systems, fueldrain lines and
ducting systems of these and other missiles are sil- vent tubes. Some of these applications involve rigor-
ver brazed. These connections must stand up under ous service with extreme pressure shocks accompa-
6,000 psi; they are tested to 12,000 psi. nied by sudden elevations of temperature, which may
In lines made to specifications by Flexonics Cor- go from —60° to 400-600° F in a matter of seconds.
poration, Maywood, Illinois, silver brazing joins a A more “high level’? endorsement of Handy &
corrugated flexible pressure carrier, a braid sleeve Harman silver alloy brazing is not available. On the
and a coupling nipple—all of stainless steel; it per- ground or in the air, the qualities of this remarkable
mits joining all of these elements of the assembly metal joining method apply; strength, ease of pro-
without danger of annealing the pressure-carrying duction, cost, gas and liquid joint tightness to name
flex or the restraining braid as welding might do. a few. The entire brazing story is yours merely for
Assemblies designed for 6,000 psi operating pres- the asking. Inquiries and metals-joining ‘‘problem
sure are required to withstand a 12,000 psi test and exposure’’ may be addressed to Handy & Harman,
take four times their normal operating pressure 82 Fulton Street, New York 38, N. Y. We welcome
before failure. They may also be required to pass the opportunity to work with you.

Source of Supply and Authority on Brazing Alloys

HANDY & HARMAN

General Offices: 82 Fulton $1., Mew York 38, M.Y.
DISTRIBUTORS iM PRINCIPAL CITIES

No Margin Here

for joint failure!

Assemblies in

ATLAS Missile

HANDY & HARMAN

Silver Brazed

Close-ups of missile section, showing silver alloy

brazed ducting assembly.

Intercontinental Atlas missile being

made ready for launching.

FOR A GOOD START:

BULLETIN 20.
This informative booklet gives
a good picture of silver braz-
ing and its benefits...includes
details on alloys, heating
3 methods, joint design and pro-
i duction techniques. Write for
Best) | your copy.
For details, circle No. 33 on Reader Information Card
WELDING JOURNAL | 397
 How to produce low alloy welds
to resist tons of torture WELDING INSTRUCTION
Warren—An arc-welding school,
* | presented as an educational project
by the Mahoning Valley Section, in
order to better acquaint the area
manufacturers and their employees
of the fundamental applications
and processes of arc welding, held
its first session on Tuesday, March
10th at the Warren G. Harding High
School. This series of educational
lectures on “Fundamentals of Arc
Welding” has been held on each
succeeding Tuesday; the final two
sessions will be held on Tuesday,
April 4th and April 21st.
The first session covered the basic
arc-welding process including the
equipment required, type of metals
that can be joined and the mechan-
ical and physical properties of met-
als. The remaining sessions cover
Welding Metallurgy, Hand Welding
Electrodes, Submerged-Arc Welding,
Inert-Gas Welding and Miscella-
neous Applications such as hard sur-
facing, stud welding and carbon-arc
cutting and brazing.
The program is being conducted
under the chairmanship of Fritz
Forsthoefel, Educational Com-
mittee chairman and district sales
et ents Gentine of manager of The Lincoln Electric Co.
Food Machinery and Chemical Co. He is assisted by Robert H. Foxall
Ordhanse Givisien, Sun Secs, Coll. of The Federal Machine and Welder
Co. and Forrest Johnson of Ameri-
can Welding and Manufacturing
WELD WITH pcos Co., who is also chairman of the

LOW ALLOY ELECTRODES AUTOMATIC] WELDING

This 22% ton armored personnel carrier proves an important Warren—The scheduled speaker
point. When working with hard-to-weld low-alloy plate, and welds for the January 22nd meeting of the
must be extra strong and tough in the “as welded” condition, it Mahoning Valley Section was un-
pays to use the highest quality weld metal available. In this case, able to attend due to very bad
Arcos Tensilend 100, a low hydrogen coated electrode produced weather. Fritz Forsthoefel of the
weld metal that matched the physical and chemical properties of Lincoln Electric Co., Cleveland,
the base metal. In addition, it did the job with less nickel than the was contacted and graciously con-
19-9 modified electrode formerly used. There was no preheat, no sented to present a substitute talk
postheat .. . and complete freedom from cracking. ARCOS COR- on “New Developments in Auto-
PORATION, 1500 S. 50th St., Philadelphia 43, Pa. matic Arc Welding.’ Considering
the fact that Mr. Forsthoefel had
only two hours’ notice for this pro-
gram, his presentation was very
good and quite interesting to the
large majority of those in attend-
ance.
A social hour was sponsored by 13
local companies. This idea was
very well received and the attend-
ance was the highest this year.
This large turnout was very pleasing
to the officers since the area was in
the middle of the worst flood dis-
aster ever to hit Mahoning Valley.

SUBMERGED-ARC WELDING
Marion—Harold E. Baldwin of
For details, circle No. 35 on Reader Information Card LeTourneau-Westinghouse Co. was

398 | APRIL 1959

the speaker at the February 6th
meeting of the North Central Ohio
Section held at Lee’s Steak House.
Mr. Baldwin gave a very construc-
tive talk on the application of man-
ual submerged-arc welding. He
told of his company’s experience
with this application in their own
plant. He also showed a number of
interesting slides. It was the con-
census of opinion that everyone
present gained from Mr. Baldwin’s
talk.

LOW-HYDROGEN ELECTRODES
Perry Heights—The Jan. 14,
1959, meeting of the Stark Central
Section was held at the Town and
Country Restaurant. The speaker
was Donald C. Helton, contact
metallurgist for the Harnischfeger
Corp., and an active member of the
Milwaukee Section.
Mr. Helton discussed the early
development of the low-hydrogen
electrode, and how it has developed
from a stopgap stage in the early
part of World War II to one of the
more important tools of the welding Job report courtesy of
industry today. His comments on Superior Welding Co., Decatur, Ill
heat-treatable electrodes as a late
development in the history of low-
hydrogen electrodes were high- When welded stainless must protect
lighted by the use of slides.
Mr. Helton’s presentation was the PURITY of the products handled
well received and the knowledge of
low-hydrogen electrodes was in-
creased by his intelligent discussion.
WELD WITH =r RCOS Ls
MISSILE FABRICATION
—_ 3
Toledo—Very poor weather in
Toledo greeted Daniel M. Daley, Jr.,
of the Army Ballistic Missile Agency, STAINLESS ELECTRODES
Huntsville, Ala., who was the
This highly polished kettle is fabricated from type 304 ELC stain-
speaker at the January 20th meeting less steel. In use, it must process chemicals without a trace of
of the Toledo Section. Mr. Daley contamination. Arcos CHROMEND 19-9 Cb Electrodes were se-
spoke on ‘‘Missile Fabrication Using lected by the fabricator to assure a weld metal of high uniformity
Aluminum Alloys.”” The speaker one whose chemical composition would not break down under
covered material, gas selection, filler- corrosive attack and contaminate the product. Welding was done
metal selection and the elaborate by manual arc. When you, too, must safeguard product quality,
precautions taken to safeguard qual- specify Arcos Electrodes for the job. ARCOS CORPORATION,
ity. Slides were shown depicting 1500 South 50th Street, Philadelphia 43, Pa.
fixtures in production. Asa climax,
a film entitled “Countdown for
Space”’ was shown which depicted
many of the Army’s rockets, and
ended a very educational meeting.

@)alelatelite!

WELDING ALLOY STEELS

Tulsa—The Tulsa Section held
a dinner meeting at the Alvin Hotel
on January 7th with 33 members
and guests present.
The speaker, Bob Wilson, direc-
tor of application engineering for
the Lincoln Electric Co., began his For details, circle No. 37 on Reader Information Card

WELDING JOURNAL | 399

 presentation with the showing of SUBMERGED-ARC WELDING
slides on the application of auto- allie Sanaelilic
matic welding of alloy steels. He Allentown—The Lehigh Valley
described the possible pitfalls en- Section’s February meeting was
countered in the welding of these DEMONSTRATIONS held in Walps Restaurant on Febru-
special steels. He also showed how ary 2nd. The technical meeting
Bethlehem—tThe Lehigh Valley speaker was Allen G. Hogaboom,
it is often more economical and Section held a Demonstration Night
desirable to have the alloying ele- welding engineer, Central Technical
at the Fritz Laboratory of Lehigh Department, Shipbuilding Division
ments included as part of the flux University on January 5th. About
rather than to add them to the wire of the Bethlehem Steel Co. at
200 persons viewed the demonstra- Quincy, Mass.
itself. tions of cutting and various types of Mr. Hogaboom in his talk on
welding. There were also exhibits “‘Submerged-Arc Welding” gave a
PIPE WELDING of power sources, electrodes, con- brief history on submerged-arc weld-
Tulsa—The February 4th meet- verters, hard surfacing and inspec- ing equipment and fluxes. Slides
ing of the Tulsa Section was held at tion methods. showing early equipment and ma-
the Alvin Plaza Hotel. Members Twelve companies cooperated chine setups used in ship-welding
gathered for a social hour at 6:30 with the Section in arranging to operations were shown.
P.M., a chicken dinner at 7:00 have their latest equipment on The speaker also gave an outline
and a technical meeting at 8:00. exhibit. of the development of submerged-
A semitechnical talk, with the aid After the demonstrations, a butt- arc welding equipment and showed
of slides and a film pertaining to the welded plate was subjected to a slides of equipment in foreign coun-
techniques of welding pipe with tension test on Lehigh’s big tensile tries. He also told of the work that
the inert-gas tungsten-arc process, testing machine. The specimen Russia is doing in this field.
was given by Ralph Minga of the used broke in the plate above the W. M. Post, manager of the
Linde Co., Kansas City. weld. Allentown - Bethlehem - Easton Air-
port, was the coffee speaker. Mr.
Post told how aviation has grown
in the Lehigh Valley and of the
PHILADELPHIA SECTION HEARS BOYAJIAN increase of airport facilities by
private and _ corporation plane
owners.

CODE-WELDING
PROCEDURES
Erie—Raymond H._ Hoefier,
chief welding engineer for Kaighin
& Hughes, Inc., Toledo, Ohio, out-
lined the steps necessary to weld
according to code _ specifications,
at the January 20th dinner meeting
of the Northwestern Pennsylvania
Section, held at Nissen’s Grill.
He also discussed the duties of the
inspector and the evaluation of
B. D. Boyajian was the principal speaker This same meeting was marked by the code problems, as well as welder
at the January 19th meeting of the Phila- presence of many of the veteran mem- qualifications.
delphia Section. He discussed some of bers of the Section. AWS charter mem-
the design and welding problems at the bers Fred Judelshon (left) and Charley
Eddystone Power Station Cooper exchange greetings PAST CHAIRMEN’S NIGHT
Philadelphia—The annual Past
Chairmen’s Night, an event held by
the Philadelphia Section to honor
all past chairmen, was held on
January 19th at the Engineers
Club.
Section Chairman Carl Schaub
personally acknowledged the pres-
ence of past chairmen C. I. Mac-
Guffie, L. H. Christensen, T. M.
Jackson, A. J. Raymo, H. W. Pierce,
R. A. Guenzel, R. D. Bradway,
R. D. Thomas, Jr., E. E. Goeh-
ringer, B. D. Gates, H. J. Irrgang,
L. D. T. Berg and O. C. Frederick
thirteen in all. He also gave men-
tion to C. D. Cooper and Fred
Thirteen past chairmen of the Philadelphia Section were also in attendance. Front row Judelsohn, two charter members, in
(left to right): H. W. Pierce, E. E. Goehringer, H. J. Irrgang, L. H. Christensen, T. M. attendance.
Jackson and L. D. T. Berg. Back row (same order): R. A. Guenzel, B. D. Gates, C. |. The featured speaker was R. D.
MacGuffie, O. C. Frederick, A. J. Raymo, R. D. Thomas, Jr., and R. D. Bradway Boyajian, who is on the staff of the

400 | APRIL 1959

 SPEAK AT WELDING METALLURGY RESISTANCE WELDING
SEMINAR IS TOPIC

io
PWESTERN HILLS INN

John H. Gross and E. F. Davis were two of the lecturers at the recent seminar on Guest Speaker W. Farrell is greeted by
welding metallurgy sponsored by the Pittsburgh Section. Dr. Gross (left) spoke Chairman Al Bernson at February 10th
on steelmaking processes; Mr. Davis (right) spoke on welding processes meeting of the North Texas Section.
Mr. Farrell spoke on resistance welding

chief mechanical engineer of the grinding of header welds to prevent cracking problem introduced by
Philadelphia Electric Co. His sub- crack propagation into the base the higher speeds of automation
ject was on “Some of the Design metal. and the use of higher-strength
and Welding Problems at the Eddy- carbon steels.
stone Power Station Project.” Walter Mehl, superintendent of
Mr. Boyajian demonstrated very PANEL DISCUSSION experiment, Heintz Division, Kelsey
clearly what can be done in econ- Philadelphia. The well-at- Hayes Corp., was the moderator for
omy by an objective investigation tended Panel Discussion of the the evening.
of alloys. Since the final choice Philadelphia Section held on Febru-
was Type 316 piping, and there was ary 6th covered the subject ‘‘Factors
no previous experience using this Affecting Weld Failures.” ASPECTS OF WELDING
type at such extremes as 5000 psi The popularity and experience of Pittsburgh—The Pittsburgh Sec-
pressure and 1200° F temperature, the panel members and of the tion is in the midst of one of its most
considerable testing was necessary. moderator were, without a doubt, active years. In addition to regular
He acknowledged the work of M. W. responsible for the turnout. monthly meetings at the Mellon
Kellogg for gathering the necessary C. Dooley, welding engineer for Institute, three additional meetings
data on procedure, shrinkage, physi- Sun Ship & Dry Dock Co., dis- have been scheduled at Johnstown,
cal properties, etc. Also acknowl- cussed failures with respect to Pa. This latter action has been
edged was the work of Westing- metallurgy and heat treatment in taken to serve a group of people,
house, Combustion Engineering and low alloys. who, because of various reasons,
United Engineers. T. Moore, assistant director of such as distance and weather, are
Interesting were some of the research, Arcos Corp., discussed not always able to reach Pittsburgh.
problems encountered, such as the failures with respect to metallurgy The first of a series of three dis-
pipe hanger problem, due to a and electrodes in the stainless group. cussions to be presented by experts
shrinkage of 14 in. per 100 ft of pipe E. Goehringer, district manager, in their respective fields covering
during operations and the contour Lincoln Electric Co., dealt with the the most commonly used methods

CAMPBELL TALKS ON WELDING OF STAINLESS STEELS

s*

Pe ae
The guest speaker at the January 20th meeting of the Northeast Tennessee Section Dr. Campbell addressed the members
was Hallock C. Campbell. Seated at speaker’s table are (left to right) G. M. Slaughter, and guests present on the submerged-
C. H. Wodtke, Dr. Campbell, District Chairman E. C. Miller and Section Chairman T. C. arc welding of stainless steels
Swindell

WELDING JOURNAL | 401

The outstanding Type RCP Constant A complete 200-amp, Type RCC Con
Potential Power Sour e for gas-shielded stant Current Welding Power Source
fully automati and sem: automat« te) package’ for use with the popular
welding Available n 500-, 600- and WEST-ING-ARC®* SA-110 and SA 111
1000-amp ratings to suit every need ry-Janter-1 0h colaar-Lalommar-lale me 40 lala lalemroelslege),
May be used wit separate Oar taal) monitor. Converts to manual welding
Reactor use at the flick of a switch

a, |
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UR
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ing—specifically designed as the most important duced welding wire costs . . . improved “wash”
“companion” for the WEST-ING-ARC SA-120 and penetration over a broad range of applica-
and 121 hand gun and control monitor. tions and material thicknesses.
The RCV Power Source, with its built-in con- Contact your nearest Westinghouse welding
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thermal protection e Single phase—230 volts. May be used where higher primary voltage is not available;
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For details, circle No. 39 on Reader Information Card
 of joining metals took place at the stainless steel to stainless steel, and
January 21st meeting in the Audi- Tennessee in overlaying stainless steel on
torium of the Mellon Institute of carbon steel. He used the non-
Industrial Research. The speakers STAINLESS STEELS magnetic mine sweeper program, a
were D. H. Marlin, research engi- Knoxville—The Northeast Ten- typical nuclear-reactor containment
neer, Dravo Corp., and William H. nessee Section met on January 20th vessel, and an 8-ft sphere for liquid
Kauffman, manager of welding, for dinner and meeting at Regas oxygen storage, to illustrate the
Williams and Co. Both are Bros. Restaurant. Over fifty application of covered electrode
prominent and active members of the members and guests were present. “know-how” to submerged-arc weld-
Pittsburgh Section. Hallock C. Campbell, director of ing, using bonded fluxes.
A splendid discussion was pre- research of Arcos Corp., Philadel-
sented on the practical and metal- phia, Pa., was the featured speaker.
lurgical aspects of welding metals. Dr. Campbell discussed the early
Mr. Kauffman presented a thorough difficulties in welding stainless steel
discussion on welding electrodes automatically, illustrating his points
and Mr. Marlin followed with a by recalling a research contract for AIR-CARBON ARC
complete coverage of welding many the Hanford project which his com- CUTTING
types of welded joints. A _ 30- pany undertook a dozen years ago. Houston— Ninety-nine mem-
minute discussion, with many ques- The newly developed bonded fluxes, bers and guests attended the Janu-
tions from the large attendance of 95, which incorporate many of the ary 28th meeting of the Houston
followed. qualities of stainless-steel electrode Section held in the Houston Engi-
A get-together dinner at the coatings, have largely overcome neering and Scientific Society Build-
Hotel Webster Hall, at which Dis- those difficulties, according to Dr. ing.
trict No. 3 Director Harry E. Campbell. Typical weld composi- Myron D. Stepath, president of
Miller was present, preceded the tions were given, showing the control the Arcair Co. of Lancaster, Ohio,
meeting which can be achieved in welding was the guest speaker and he was
ably assisted by Durward B. Vaught,
the Aircair Co. representative in the
south. The subject covered was
‘ the air-carbon arc cutting process.
AIR-CARBON ARC CUTTING DISCUSSED BY STEPATH The principles involved in this proc-
4 . P >| ess for metal removal were de-
; ee scribed, including equipment used,
operating conditions and _ results
obtained.
RESISTANCE WELDING
Dallas—Fifty-five members and
guests of the North Texas Section
met at the Western Hills Inn on
Tuesday, February 10th, for the
regular monthly meeting. Guest
speaker for the evening was William
J. Farrell, chief application engineer
for Sciaky Bros., Inc., Chicago, Il.
Mr. Farrell started with a dis-
cussion, illustrated by slides, of
At the January 28th meeting of the Houston Section, the members and guests present resistance welding and a number of
heard a talk by Myron D. Stepath. Shown before the meeting are (left to right) Vice- its applications. Then, using a
chairman M. Avis, D. B. Vaught who assisted the speaker, Mr. Stepath and Chairman blackboard, Mr. Farrell pointed out
H. F. Crick some of the problems involved in
building the “‘all-steel” airplane
of the future.
Everyone present enjoyed the
evening immensely.

LOW-HYDROGEN
ELECTRODES
San Antonio—David S.
Gerould, Texas district manager of
the Harnischfeger Corp., Dallas,
Tex., gave a very informative talk
on AWS Types 7016, 7018 and 7028
and their uses, at the February 2nd
meeting of the San Antonio Section
held at Captain Jim’s Cafe. Some
of the highlights were the develop-
ment in early 1942 for use on aus-
Guest speaker Stepath discusses the Past-chairman W. H. Greer speaks on tenitic steels; a ferritic-type steel
compressed-air carbon-arc cutting current activities of Houston used as a substitute for moly-steel
process Engineers Council electrodes; the effect of moisture

404 | APRIL 1959

 ~~ Py nh

is
WEL
DYN
AMI
ES

NEWS ABOUT ARC WELDING AT WORK CUTTING COSTS

CLARK CUTS DOWNTIME, REDUCES

MATERIAL COSTS 25%

The Clark Machine and Welding

Company, Inc., of Baltimore, Mary-
land, has a department which
specializes in rebuilding industrial
and construction equipment.
They’ve grown in 25 years from a
4-man shop to the largest mainte-
nance shop in Maryland—employing
about 75 people. During that time
they’ve tried just about every auto-
matic hardsurfacing wire and flux
available, and have had troubles
ranging from high material costs to
excessive downtime in the shop.

Rebuilding tractor rollers in the Clark

shop. The fixture was designed and fab- HARDSURFACING
ricated by Clark.
INFORMATION

MADE AVAILABLE
A series of How-to-do-it bulletins
on Automatic Submerged Arc hard-
surfacing are being published by
The Lincoln Electric Company.
A basic bulletin, number 3200.1 on
Automatic Submerged Arc _ hard-
surfacing starts the series.
Specific information on hardsur-
A. L. Ballard, Clark's welding foreman, facing and rebuilding is presently
“We've eliminated many production available on the following items:
problems, cut costs and improved the Al Ballard, the company’s auto- tractor rollers, tractor idlers, mine
quality of our work.” car wheels, scraper blades, steel mill
matic welding foreman, has found
Work stoppages were caused when that Lincoln agglomerated fluxes rolls, crusher rolls (with automatic),
some welding wire would jam in the give him the most reliable perform- crusher rolls (with semi-automatic),
feed rolls of the automatic welder or ance. The fluxes not only cost 25°; Raymond bow! rolls, Raymond bow!
the wire would stick. This, of course, less than the most similar competing rings, tractor treads and cement mill
not only caused the machine to be product, but they contain the alloy- equipment.
stopped, but affected the quality of ing elements making it possible to use Copies of these bulletins may be
the deposit as well. less expensive mild steel wire. obtained by writing on company
Other granular fluxes with alloy Mr. Killen states that the use of letterhead to:
wire were tried. Performance was agglomerated fluxes and Lincoln
better, but the alloy wire proved too automatic welding equipment have The LINCOLN ELECTRIC CO.
expensive, according to Phillip given his shop a definite advantage Dept. 1953, Cleveland 17, Ohio
Killen, Vice President and General with consistently top quality work The World's Largest Manufacturer
Manager of the firm. at a substantial saving. of Arc Welding Equipment
For details, circle No. 41 on Reader Information Card
WELDING JOURNAL | 405
 GEROULD TALKS ON LOW-HYDROGEN ELECTRODES

PLAST-IRON

GRADE B-171

POWDER

This is the large group that attended the February 2nd meeting of the San Antonio
FOR Section to hear David S. Gerould speak on late developments of low-hydrogen electrodes
MILD STEEL, LOW

HYDROGEN AND

HARD-FACING

ELECTRODES

Also pictured at the same meeting are the current officers and directors of the Section.
Reading (left to right), seated, are F. Engels, R. B. Gordon, H. F Burkhart andF.W. Smith
Standing, in the same order, are J. E.Bowman, W. H. Woods, E. E. Wagner, J. E. Ber-
geron, C. E. Hosier and W. B. Hamilton, Jr., Chairman

@ IMPROVED QUALITY
@ HIGHER DEPOSITION RATE in the casting of low-hydrogen iron- To make the presentation was coffee
powder electrodes and their proper- speaker Prof. Clifford Liddle of the
@ FASTER OPERATION
ties and applications. University of Wisconsin. Prof.
Send for Technical Data The following committeemen ap- Liddle spent two years in India and
pointed to serve this year were in- plans to return in June of this year.
and Working Sample
troduced: Membership—C. E. Technical speaker for the evening
Hosier, C. R. Brownrigg and H. F. was Richard Ort of Handy and
Burkhart; Investigating—Frank Harman, New York. His topic was
DeLeon, H. R. Weir and Leonard “Brazing.”” Mr. Ort presented
Heimer; Educational—W. H. color films on applications and pro-
Woods; Program—Royce A. Pat-
cedures for silver brazing. A ster-
rick; Entertainment—John Petty;
Publicity—-C. G. Dyer; Attend- ling-silver-brazed sandwich panel,
ance—Edward R. Lang, W. H. the type being used on the B-58
Bentley and Robert E. Moylan; Hustler, was passed around for in-
and Hospitality——R. B. Gordon. spection. After explaining the
PLASTIC characteristics and applications of
the various brazing materials, Mr.
METALS Ort answered questions of the 50
Wisconsin members and guests present.

National-U.S BRAZING
Radiator Corporation * USE
Madison—aA regular meeting of
the Madison Section was held at the ¢ READER
Eagle’s Club on February 12th. e INFORMATION
Dinner wasserved at 6:30 P.M. and
JOHNSTOWN, PA was followed by a showing of slides e CARD
dealing with ‘““The Modern India.”
For details, circle No. 17 on Reader Information Card
406 | APRIL 1959
 IT’S
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Leveling and parallelism adjustments
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LEWIS “Universal” manipulators make automatic
~onoomnm $ A ete weldirg profitable for both production and job shops.
ee ad Developed by a production fabricator, they have ex-
— =a Ss —_-— - : oad
tates rr ¢ clusive advantages that assure maximum versatility,
_aan 7 dependability and cost savings. You can do more
... for less... with these truly “Universal” machines!
*Lewis Automatic
Directional Controls LEWIS also can furnish lightweight, portable “Ban-
tam” manipulators for diversified small jobs and
. “Heavy Duty” car-type machines for the king-size jobs.

THE LEWIS WELDING

See the “‘Universal”’ i & ENGINEERING CORP.
in operation... : <8 109 Northfield Road © Bedford, Ohio
BOOTH 431
AWS Show — April 7-8-9 DESIGNERS + ENGINEERS «+ FABRICATORS « MACHINISTS
For details, circle No. 45 on Reader Information Card
WELDING JOURNAL | 407
 For details, circle No. 17 on Reader Information Card
406 | APRIL 1959

EFFECTIVE FEBRUARY 1, 1959

New Members
MEMBERSHIP CLASSIFICATION
A—Sustaining Member D—Student Member
B-—Member E—Honorary Member
C—Associate Member F—Life Member

TOTAL NATIONAL MEMBERSHIP

Sustaining Members 198
Members ...... 6,015
Associate Members 5,665
Students .. . 201
Honorary Members g
Life Members. . ae
Total... 12,103

ANTHONY WAYNE Cromwell, Robert (B) Support Your Society—Be Active!

Lautzenheiser, Robert D. (C) Deoke, Herb W. (B)
Ullman, Howard M., Jr. (B) Detournay, Rene (B)
Galloway, J. W. (B)
BATON ROUGE Gondry, Louis (B)
Spann, Louis G. B) Holycross, Harold Lee (B) MARYLAND Denny, Lawrence B. (D)
Klaman, Edward L. (B) Palmer, Marshall F., Jr. (D)
BIRMINGHAM Lawrence, Edward W. (B) Neubert, James W. (C)
Parker, Milton (C) Poole, Charles S. (B)
McClune, C. U. (C) Linn, Wayne E. (B) Seal, Larry K. (D)
Temple, Paul C. (C) Livingston, James M. (B) MILWAUKEE Stapp, Richard G. (D)
Macdonald, Alan, Jr. (B) Sutton, Douglas (D)
BOSTON Mariage, James J. (B) Koneeny, Joseph P. (C)
D’Andrea, Mark M., Jr. (C) Morrow, Hiram E. (B) Schutz, H. H. (B) PROVIDENCE
De Mello, John, Jr. (B) Rowley, W. C. (B) NEW JERSEY Boulet, Joseph Albert (C)
Foley, Martin L. (C) Smith, Albert Sidney (B) Champagne, Rene P. (B)
Helmund, Joseph C. (B) Strebing, Henry L. (C) Anton, August C., Jr. (C) Walz, George (C)
Martin, Joseph E., Jr. (C) Umbanhowar, F. Harold (B) Ballard, J. L. (B)
Mosher, W. Fred (C) Weidenburner, Kenneth Collins, William F. (B) PUGET SOUND
Peffers, William F. (C) Wayne (B) Gage, Robert M. (B) Markey, George E. (B)
Qualey, Thomas R. (C) Welch, Theodore A. (B) Helmbrecht, Wilbur H. (B)
Reynolds, William L. (C) Young, Chester L. (B) Lakacauskis, Charles (B) RICHMOND
Tognarelli, Mario (C) Scanlon, Martin J., Jr. (B) Des Champs, Lawrence F., Jr.
FOX VALLEY Sibley, Craig R. (C)
CANADA (C)
Odom, Guy T. (C) Jennings, W. R., Jr. (B
NEW ORLEANS
Tarlton, Derek Luther (B) Morris, W. W. (B)
Turner, Everett Robert (B) HOLSTON VALLEY Brake, Obert L. (B)
Kitzmiller, Homer (B) Hensley, Emory Walker, Jr. SAGINAW VALLEY
CHICAGO (B)
HOUSTON Eckert, Clarence Edward (D
Bell, Richard S. (D) Miller, William O. (D)
Betters, R. J. (B) Robinson, Herbert A. (B) NEW YORK
Pettit, Paul H. (D)
Borkoski, Frank C., Jr. (B) INDIANA Goldsmith, Robert H. (B) Ramsey, Phillip L. (D
Lyons, Dean B. (C) Kujala, W. H. (C) Sanders, Charles E. (D
Savel, Allen F. (D) De Looff, Peter (C) Rogers, Royden H. (B)
Fritson, Ben D. (C) ST. LOUIS
CINCINNATI Stableton, Luther (C) NORTH TEXAS
Jarzenbeck, Julius (C
Crawford, Sam T., Jr. (C) J. A. K. Jones, J. A. (C) Zollman, William J. (C
Hamrock, Robert E. (C) Nordquist, Fred C. (B)
Baucher, Louis, Jr. (C) SALT LAKE CITY
CLEVELAND NORTHWESTERN PA.
KANSAS CITY Watts, Richard E. H. (C
Dalzell, Robert F. (C) Smith, George W. (B) Williams, Kenneth L. (C
Huddleston, Charles E. (C) Everhart, E. Wayne (C)
Kaminski, Edward W., Jr. (B) Greer, James P. (B) PEORIA SAN ANTONIO
Jenkins, Robert B. (C) Erwin, Leonard G. (C) Barrera, Roger J. (C
COLORADO
Hindricks, Don R. (C) LEHIGH VALLEY PHILADELPHIA SAN FRANCISCO
Horrocks, Richard J. (C) McClintock, Larson H. (B) Curry, Thomas P. (B) Clark, Byron L. (C)
DAYTON LOS ANGELES Dawson, Harry C. (B)
McCombs, Paul (C) SANGAMON VALLEY
Carlton, Cory R. (C) Axtell, H. B. (B) Fathauer, Herbert (C)
Herzman, Robert E. (D) PITTSBURGH Sykes, Jarratt C. (B)
DETROIT La Fontaine, Raymond H. (C) Bialosky, Jerome M. (B) Vinson, Lawrence (C)
Blasutta, Pio (B) Lauzon, Richard F. (D) Doorley, Richard B. (B)
Few, Alfred C. (C) Saperstein, Zalman P. (C) Fagan, Robert C. (C) SANTA CLARA VALLEY
Kozlowski, Edward L. (B) Sheets, Byron L. (D) Gaab, William J. (C) Carmicheal, Guy (C)
Machinchick, John (B) Ward, Charles Ray (B) Marks, Norman G. (B) Darcey, Thomas R. (C)
Peitz, Casper (B) McGeary, R. K. (B) Gates, Raymond L. (B)
Thompson, Lyeld F. (B) MADISON Seybold, Raymond Christian Norton, Albert C. (B)
EASTERN ILLINOIS Mitchell, Paul D. (B) (B) Sinnott, James M. (C)
Schuler, William P. (B) Weber, John E. (C) York, Harold P. (B)
Albert, Lloyd O., Jr. (B)
Bernardi, Edward P. (B) MAHONING VALLEY PORTLAND SHREVEPORT
Cowles, Fred (B) Stull, Donald J. (B) Demke, Richard W. (D) De Ryss, Emil B. (B

408 | APRIL 1959

~- i“ :
 For details, circle No. 45 on Reader Information Card
WELDING JOURNAL | 407

STARK CENTRAL
Beach, George T. (C)
Fisher, Jacque D. (C)

SUSQUEHANNA VALLEY
Tuttle, Harry E. (C)
TRI-CITIES
Painter, W. Don (B)

WORCESTER
Grenier, Otis J. (C)
YORK-CENTRAL PA.
Himes, Glenn E. (C)

MEMBERS NOT IN SECTIONS

Doshi, Nalinkant Motichand
(C)

Members Reclassified During

February

COLUMBUS
Balthasar, Howard A. (C to
B)
Barta, Irvin M. (C to B)

ST. LOUIS
Willers, Henry W. (C to B)
Ampco Metal grade 8 fabrication designed to handle steam
and corrosives field-welded with Ampco-Trode 10.

MEMBERSHIP IN THE No stress-corrosion cracking with

AMERICAN WELDING
SOCIETY improved Ampco Metal 8 alloy!

helps you improve your Unique Ampco Metal 8 Ampco-Trode 10 spooled wire and
product, increase your pro- properties equaled by filler rod using the inert-gas proc-
duction and lower your Ampco-Trode 10 weid esses to provide a deposit of match-
welding costs. You'll have deposit ing composition and properties.
for your own use latest Ampco-Trode 10 electrodes and
available welding ‘‘know- After nine months’ service — no filler rod are very versatile. They
how,”’ including the Soci- evidence of stress-corrosion crack- are used to join a wide variety of
ing in above field-welded installa- copper-, iron- and nickel-base
ety’s Welding Journal and
tion which required no subsequent alloys, dissimilar metals, as well
Welding Handbook. How
heat-treatment. as for the overlay of bearing, wear-
you can join the Society
REASON — because all weld- and corrosion-resistant surfaces.
and take advantage of its ments were fabricated from im- Ask your Ampco field engineer
many benefits is explained proved, “patented” Ampco Metal about new, “‘patented’”’ Ampco
in descriptive literature 8 alloy containing a new “additive” Metal grade 8 and Ampco-Trode
available. to provide extra protection against 10. Or write for details. Ampco
corrosion and erosion. Metal, Inc., Dept. 196D, Milwau-
For further details write to:
Also, all welds were made with kee 46, Wisconsin.

AMERICAN WELDING
SOCIETY AMPCO-TRODE*
33 West 39 Street PHOS-TRODE’
New York 18, N. Y. <a |
AMPCO-BRaZ
World’s largest producer of bronze electrodes
For details, circle No. 47 on Reader Information Card
WELDING JOURNAL | 409
408 | APRIL 1959

of the industry

1AA Honors Stanley B. Kirk Co. from 1944 to 1952, Mr. Kirk tion show will comprise 300 exhibits
was elected a vice president of the of tools and various production lines.
Stanley B. Kirk, former president Union Carbide Corp. in 1945 and Fifty of these exhibits will pertain
of Linde Co., was awarded the James was appointed a member of the to welding.
Turner Morehead Medal by the Appropriations Committee in 1952. Additional information on the
International Acetylene Association At present, he is a director of Union convention can be obtained by
at its 6lst Anniversary Convention Carbide Canada Ltd., and chairman
in New Orleans on March 9th and of the Pyrofax Gas Corp.
10th. The award is given annually The 1959 Convention of the Inter-
to the individual who, in the judg- national Acetylene Association at
ment of IAA officers and directors, New Orleans was the first meeting of COMING
has done the most to advance the the group held in that city. High-
industry or the art of producing or lights of the convention were techni-
utilizing calcium carbide or acety- cal sessions on acetylene-based EVENTS
lene. chemicals and safety with major
Presentation of the Morehead emphasis on safe practices in the use
Medal was made to Mr. Kirk at a of oxyacetylene processes and equip-
dinner held in the Grand Ballroom ment. A Calendar of Welding Activity
of the Hotel Roosevelt in New Or- The IAA is one of the oldest tech-
leans on March 9th. Principal nical associations in the country,
speakers at the award dinner, in having been founded in 1898. AWS National Meetings
addition to Mr. Kirk, were Charles
Haines, president of the Chemetron 40th Annual Meeting:
Corp., and Dr. A. B. Kinzel, vice Canadian Welding Show April 6-10, 1959. Hotel Sherman,
president, Research, Union Carbide Planned in Toronto Chicago, Ill.
Corp. H.S. Sutherland, president,
Shawinigan Chemicals Ltd., Mon- The Canadian Welding Society Seventh Welding Show:
treal, Canada, and president of the will sponsor a welding show during April 7-9, 1959. International
LAA, presided. the week of May 4th in Toronto. Amphitheatre, Chicago, Ill.
In the citation accompanying the As part of the National Industrial 1959 National Fall Meeting:
award, Mr. Kirk was honored for Production Show of Canada, CWS September 28-October 1. Shera-
his contributions to the use of cal- will hold a general convention on ton Cadillac Hotel, Detroit, Mich.
cium carbide, acetylene, oxygen and May 5th and 6th at which time six-
other industrial gases. In addition teen speakers will present papers in 4ist Annual Meeting and Eighth
to serving as president of the Linde the Coliseum Building. Among the Welding Show:
subjects to be discussed are welding April 25-29, 1960. Biltmore Ho-
costs and efficiency; function and tel, Los Angeles, Calif.
organization of a welding depart-
ment; preparation and application
of a welding shop standard; auto- NWSA
mation; processes, automatic vs. May 4-7, 1959. Annual Meeting.
manual; new developments in auto- Fairmount Hotel, San Francisco,
matic oxygen cutting; automation Calif.
and welding; welding in nuclear
reactors; productivity through proc- SESA
ess development; ultrasonic weld- May 20, 21, 22. 1959 Spring
ing and soldering; high-tempera- Meeting and Exhibition. Sheraton
ture furnace brazing; stainless-steel Park Hotel, Washington, D.C.
overlay welding; and welding of
thick aluminum calandria. The NEMA
speakers on the program will come
from Canada, the United States and June 4-5, 1959. Arc Welding Sec-
Great Britain. tion Quarterly Meeting, Hot
Stanley B. Kirk The National Industrial Produc- Springs, Va.

410 | APRIL 1959

 WELDING JOURNAL | 409

writing to the Secretary, William quarters for the meeting will be the The new facilities enable the com-
J. Cherry, 73 Adelaide Street West, Hotel Sheraton-Ten Eyck. pany to offer expanded technical
Toronto, Canada. Papers scheduled for presentation and sales service and increase the
will concern such general categories display and storage space for the
Linde’s West Coast Plant as brittle fracture, fracture preven- complete line of Airco industrial
tion, nonmetallic structural ma- gases, welding and cutting equip-
Nears Completion terials, creep behavior of metals, ment, supplies and accessories they
Linde Company has announced fatigue, high-temperature behavior carry.
that the major construction phase of and a workshop on the application A major feature of the new facility
its multi-million dollar oxygen-ni- of metals in heavy sections. is a large demonstration room where
trogen producing plant in Pittsburg, A reception and dinner on the new welding and cutting equipment,
Calif., has been completed three opening night of the conference will as well as modern developments in
feature an address by Glenn B. welding processes, can be shown con-
Warren, president of ASME, en- veniently to customers.
titled, ‘“The Challenges of the Me- In addition to Mr. Rowland,
chanical Engineer to the Metallur- other officials of the firm include
gical Engineer.” Gilbert F. Rowland, vice president;
Everett B. Harvey, treasurer; Jos-
New Location for New England eph E. Barker, technical represen-
tative; and Edward F. Husson,
Distributor store manager.
Announcement has been made by
Russell E. Rowland, president of
the New England Welding Supply American Bureau of Shipping
Co., Inc., of the opening of a new Holds Annual Meeting
sales and distribution office at 445
State St., North Haven, Conn. New At the 97th annual meeting of
England Welding Supply Co., an the American Bureau of Shipping
weeks ahead of schedule. Pictured authorized dealer of Air Reduction on January 27th, Walter L. Green
are the main processing components Sales Co., has been doing business and David P. Brown were re-elected
which have reached the final assem- in the New Haven area since 1938 chairman of the board and president,
bly stage. The plant, upon com- and was formerly located at 405 respectively. In other moves, Lewis
pletion in early 1960, will produce Chapel St. C. Host was elected senior vice
300 tons of liquid oxygen and nitro-
gen per day.
.... COMPLETE
NCG Opens New
Cleveland Office WELDING
The National Cylinder Gas Divi-
sion of Chemetron Corp. has es- SATISFACTION
tablished new offices for its north
central region at 2191 S. Green Rd.., Give Your Welding Problems to Cayuga
Cleveland, Ohio. In addition to a complete line
The regional headquarters, for- of standard Cayugamatics see
below) Cayuga designs and builds
merly located at 524 Terminal Tower special equipment, either single
Building, supervises sales and serv- units or complete assembly lines
ice of industrial gases and equip- for a high speed precision weld-
ing. This includes process de- TURNING @
ment for the metal working and al- velopment to fit your particular ROLLS
lied industries, and of medical in- requirements. Let us solve your to 100 ton, 6” and up dian
halation therapy gases and equip- welding problems. tank range theostat
not peed control OTHER
ment for hospitals and other users CAYUGAMATICS
throughout Ohio and parts of Penn- Turn Tables
sylvania and New York state. Turning Rolls
F. E. Cain is regional manager. Positioners
Chemetron’s NCG Division also Travel Carriages
and Beams
maintains district sales offices and Contour Welders
facilities for the manufacture of Horn Jigs
oxygen, nitrogen and acetylene at Sheet Splicers
1151 E. 22nd Street, Euclid, Ohio. Motor Stator
& Transformer
Core Welders
Metals Engineering Division Tank Welders
Head & Tail
to Meet in Albany 100 lb. to 50 ton capacities. 135 Stocks
tilt, vertical adjustment, rheostat Wire Reels
The ASME’s Metals Engineering remote speed control, ground col-
lectors Send for complete
Division, the same group which co- MANIPULATORS }§ information
sponsored sessions at the 1958 3’ x 3’ to 25’ x 30’, 360° rotation
Both vertical and horizontal pro-
AWS Annual Spring Meeting in St. tection by limit switches. Rapid
traverse standard all mode! s. CAYUGA MACHINE & FABRICATING
Leuis, will hold a three-day con- Safety devices prevent ram falling
ference in Albany, N. Y., from accidentally Rheostat remote CO., INC. DEPEW, N. Y.
speed control
April 29th through May Ist. Head- For details, circle No. 49 on Reader Information Card

WELDING JOURNAL | 411

 president; Arthur R. Gatewood was $3.47 per common share, a decline announced by Superweld president
re-elected vice president—engineer- from the record of $4.35 earned in Robert E. Jones.
ing; and Alfred Blum was named 1957, which included non-recurring Western Carbide has specialized
vice president—finance. income equal to 15¢ per share. in a line of hard-surfacing alloys
Elected to membership of the In the fourth quarter of 1958, and has been granted several pat-
American Bureau of Shipping were sales were $46,536,009 and net in- ents in the metallurgical processing
A. P. Jobson, R. O’Brien, W. F. come was $3,593,814, as compared field. Hoyt Todd, former vice pres-
Rapprich, H. G. Steinbrenner and with fourth quarter 1957 sales of ident and chief metallurgist of
J. C. Woelfel. $49,086,643 and net income of Western Carbide, will continue to
$4,085,455. be associated with Superweld.
P & H Names Two New Distributors Sales in 1958 were $175,307,384 Superweld Corp. is one of South-
and net income was $13,349,885. ern California’s leading firms in the
A-D Machinery Co., Inc., of In 1957 sales were $189,987,698 and fields of heat- and corrosion-resis-
Elko and Las Vegas, Nev., and net income was $16,476,180. tant metal finishing.
Grand Rapids Welding Gas & Sup-
ply Co., Grand Rapids, Mich., have Balaam Brothers Named by Kaiser
been appointed distributors for the Film on Mining Released
P & H line of welding equipment by Balaam Brothers, 1350 Powell
A 16-mm movie in color, entitled
Harnischfeger Corp., Milwaukee, Ave., Emeryville, Calif., have been
“From Sea Sands to Better Weld-
Wis. The former firm, owned by appointed a distributor of “‘King”’
ing,” is available without charge
Harold Anderson, will represent the aluminum welding wire in the Oak-
from Hobart Brothers Co., Troy,
Milwaukee manufacturer for the land-East Bay area by Kaiser Alu-
Ohio. The 8-min sound film fea-
state of Nevada. The Michigan minum & Chemical Sales, Inc.
tures the many steps involved in min-
distributor is directed by H. D. Balaam Brothers, which carry a
ing minerals for electrode coverings
Hoffmyer. complete line of welding gases, equip-
from the sea sands of Florida.
ment and supplies, will supply
Airco Reports Gain in 4th Quarter Kaiser’s aluminum welding wire in
Superweld Acquires Stock spools and straight lengths in all
Fourth quarter 1958 earnings of of Western Carbide commercially used aluminum alloys
Air Reduction Co., Inc., were 93¢, a including the new 5183 alloy.
12% increase over the third quarter Acquisition by Superweld Corp.,
of 1958. Fourth quarter earnings North Hollywood metal-treating Westinghouse Reports
in 1957 were $1.07. firm, of all the outstanding stock of Net Income Gain
Earnings for the year 1958 were Western Carbide Corp., has been
Chairman of the Board Gwilym
A. Price and President Mark W.
Cresap, Jr. announced that the net
VISIT BOOTH 903 income of the Westinghouse Elec-
tric Corp. in 1958 was equal to
AWS Show April 7,8,9 $4.25 a common share, compared
with $4.18 a year ago, although net
Chicago, Illinois sales billed declined 5.6% from the
1957 record.
Ask For Free Ash Tray Directors declared a dividend of
50 cents a share on the common
stock and 95 cents a share on the
THE WELDERS’ 3.80% preferred stock, both payable
HI-AMP. March 2nd to stockholders of record
ELECTRODE HOLDERS February 9th.
CHOICE
The net income in 1958 was $74,-
/- Wrap cround Gloss Fibre Tip In- 772,000 compared to $72,652,000
sulation—30% more heat resistant
than any other make. in 1957.
2- Brilliant Red Tips ond Trigger-
Bright Yellow Handle—all Glass Electronic Tracing
Fibre, an outstanding Safety Fea-
ture. Unit for Shipyard
3 Body completely insulated—no bare
spots. National Cylinder Gas has an-
nounced the construction of a fully
automatic oxygen plate-cutting ma-
chine designed primarily for ship-
yard use.
The new unit is expected to pro-
Just ask your Welding Sup- vide substantial savings in the cost
ply Dealer for PROOF of of preparing patterns and cutting
the above statements. huge steel plates used in ship con-
struction. All electronic compo-
nents have reportedly been proved
Usk
LENCO. Inc. and final design was jointly accom-
uth plished by NCG and Canadian
JACKSON, MISSOURI HI-AMP Westinghouse, Ltd.
Completion of the first unit is
For details, circle No. 51 on Reader information Card scheduled for June.

4i2 | APRIL 1959

 Rods
Welding
Bronze
ds are de-
Titan bronzein wel vice - + *
pendable strser eng th, excel-
have hig h
lent wear resist ance .-- cany
ily, quickl
be applied deas low carbon
to high an t iron, copper,
ough and
i

Titan proc trength.

tile, high-s
porous welds.

s Shapes uminum
Special Bras Brass & Al
ss ed Pa rts
Titan special bra Machin
,
es give highes!m
shapucti to meet ex-
prod on, maximu a- Sreduete preston :
workability - elimin Zé ;
: of excessive scrap
tion ween
ing 's to© ¢Tita
Machin
parts,and uns Comed-
urp ass tole ranc es
machinabi lity. specialty. Fast delivery
positions and odd assured.
shapes made t0 inten :

Hot-pressed from extr uded stock

m density,
to provide maximulife,
high strength, long superior
finished surface. Have thinner
ranc es and
sections, closer tolentages over
free machining adva
sand castings.

me Write for folder

describing Titar
welding rod com
positions and us¢
It free

METAL MANUFACTURING COMPANY

Bellefonte, Pa. Newark
_
RODS © FORGINGS ° DIE CASTINGS ° WELDING RODS © WIRE Serving te Welding
Industry for 40 Years

For details, circle No. 53 on Reader information Card

WELDING JOURNAL | 413
 Nuclear Congress Meets PARTICIPATE IN 5TH ANNUAL MIDWEST WELDING CONFERENCE

The 1959 Nuclear Congress will

be held from April 5th to 10th at the
Public Auditorium in Cleveland.
The meeting will feature papers deal-
ing with advances in reactor tech-
nology and the use of radioactive
materials, problems of industrial
management in the nuclear field and
laboratory problems in radioactive
materials. In addition, a_ trade
show, the ‘“‘Atomfair,’’ will be staged
currently with the meeting. The
AMERICAN WELDING SOCIETY is one
of the sponsoring bodies.

Wall Colmonoy Appoints

Milwaukee Firm
Pictured at January 28th luncheon at Midwest Welding Conference in Chicago were
Industrial Products Engineering (left to right): L. C. Monroe, publisher, ‘‘Welder's Digest,’’; John D. Eyestone, welding
Co. of Milwaukee, Wis., will rep- development engineer, Western Electric Co.; Fred Plummer, national secretary, Ameri-
resent the Stainless Processing and can Welding Society; J. R. Wirt, welding engineer, Delco Remy Division; John Cantalin,
Wallco Manufacturing Divisions of Fisher Body Division, General Motors Corp.; Harry Schwartzbart, supervisor, welding
Wall Colmonoy Corp., Detroit, research, Armour Research Foundation of Illinois Institute of Technology; Clarence
Mich. Industrial Products will rep- Jackson, staff engineer, Linde Co.; R. David Thomas, Jr., president, Arcos Corp.;
resent Wall Colmonoy in Wiscon- O. T. Barnett, assistant manager, Metals Research, Armour Research Foundation:
sin, Minnesota and Upper Michigan. and R. C. Becker, assistant general supervisor, Welding Research, International Har-
The Wallco Manufacturing Divi- vester Co.
sion specializes. in the manufacture
of tubular, stamped and machined specializes in the brazing and proces- NCG Opens Charleston Branch
components which utilize silver and sing of stainless steels, superalloys
copper brazing. and in the fabrication of brazed Establishment of a new sales
The Stainless Processing Division sheet metal assembly. office and warehouse at 2045 Meet-
ing St., Charleston Heights, S. C.., is
announced by the National Cylinder
Gas Division of Chemetron Corp.
NATIONAL CARBIDE « D. McGuinn, division vice
president, said the new facility will
handle the sale and service of indus-
trial gases, cutting and welding
IN THE RED DRUM
equipment and other NCG products
to customers in the Charleston area
and will provide warehouse facilities
firm’s office in Savannah, Ga.
HIGHEST
Electrode Pricing Format Changed

QUALITY The A. O. Smith Corp’s Welding

Products Division, Milwaukee 1,
Wis., on March 9th announced the
first major change in the pricing
format of welding electrodes to be
DUST FREE made in many years in the arc
welding industry.
G. E. Kemper, Division Manager,
said the new format will enable
DEPENDABLE distributors to obtain maximum
pricing benefits in 20,000-lb lots,
instead of 40,000-lb lots as has been
SUPPLY the industry’s past practice, and to
enjoy substantially greater per-
centage of profit margins in the
| ranges where they sell 95% of their
Write for the name and address | electrode products.
of the NATIONAL CARBIDE supplier nearest you. a eg The A. O. Smith announcement,
—S
National Carbide Company | Mr. Kemper pointed out, comes at
A DIVISION OF AIR REDUCTION COMPANY, INCORPORATED | a time when many large users of
GENERAL OFFICES: 150 EAST 42ND STREET, NEW YORK 17, N. Y. welding products and distributors
are beginning to stockpile against
AT THE FRONTIERS OF PROGRESS YOU'LL FIND AN AIR REDUCTION PRODUCT a possible strike in the steel industry.
For details, circle No. 55 on Reader information Card

4144 | APRIL 1959

 NUB diameter automati-
‘cally sets welding gap
for root pass.

Robvon Backing Rings

Form perfect welded-
joints eliminating slag
and icicles.

Robvon Backing Rings

Allow complete penetra-
tion and fusion.

Robvon Backing Rings

Eliminate the necessity
of tack welding.

Robvon Backing Rings

Radiograph perfect cer-
tified welds.

ROBVON BACKING RINGS

APPROVED FOR WELDED PIPE, VALVES,

AND FITTING JOINTS

Available in carbon steel, wrought iron, chrome alloys

stainless steel, aluminum and copper

TYPE ccc Designed for quics easy alignment of pipe where the variation in inside
Giameters is rel atively great _Ch ymfered NI IB WlOW lose tolerance
fit-up and CLEAN STRIKE OFF. The ROB N’ NUB automaticall
ets >} root gap. ROBVON rings are bev ele ? . ré r nt tr + Zo!
fluid flow
TYPE CC De igned to allow quick easy alignment of pipe where the 12 dian
eters are slightly out of round. The welder has tt hoice of IRIKING
FF’’ the NUBS or leaving them intact to b«
the first root pa
= ' T if
TYPE C Designed for precise close tolerance fit-up. Type “C’’ NUBS auto-
mati ally ets root gap Tt 2 NI IBS melt witn tne etal tO give Cc plete
penetration ana fusior

Robvon also manufactures machined rings to customer's specifications

All fabricated solid machined rings x-rayed. Write for full information

ROBVON
7 Vet @i, lcm ai, fcemietey
FT 7.Y. bd

675 GARDEN STREET ELIZABETH, NEW JERSEY

For details, circle No. 57 on Reader information Card
WELDING JOURNAL | 415
 president, the moves are part of a Dr. Castor joined Linde in 1953
broadening of engineering responsi- as a research chemist at the Tona-
bility in which Walter P. Schmitter, wanda, N. Y. Research Laboratory.
formerly vice president-chief engi- Since January 1957, he has been
neer, assumes the position of vice research supervisor at the company’s
president—engineering. Mr. Schm- Speedway, Ind. laboratories.
itter will be responsible for over-all Co-inventor of metal-loaded mo-
engineering planning and policy. lecular sieves for use as catalysts, Dr.
Mr. Wellauer, an electrical engi- Castor has more recently been en-
neering graduate of Marquette Uni- gaged in research work on crystals,
PERSONNEL versity, earned his master of.science welding, combustion and high cur-
degree in metallurgical engineering rent arcs.
from the University of Wisconsin in
1938. Anengineering co-op student
at Falk in 1933, he became an engi- Cox Named Technical Manager
neer at the company after gradua- of Whitehead Metals
tion. In 1942 he was named metal-
lurgical and research engineer and Gilbert L. Cox @§ has joined the
appointed assistant chief engineer— staff of Whitehead Metals, Inc. as
materials and research in 1950. Technical Manager, according to an
announcement by Clayton D. Gro-
ver, president of Whitehead. He
Wills Promoted by Blaw-Knox Brickett to Head Sales at Arcos will make his headquarters at the
Rochester office of Whitehead
J. G. Wills WS has been named James A. Brickett @S has been Metals. Prior to joining Whitehead,
manager—manufacturing of Blaw- appointed sales manager of Arcos a subsidiary of International Nickel,
Knox Co.’s Equipment Division in Corp., according to an announce- Mr. Cox was a member of Inco’s
Blawnox, Pa., near Pittsburgh. ment by R. David Thomas Jr., Development and Research Divi-
An employee of Blaw-Knox Co. WS, president of the firm. sion and was located in Rochester,
for 16 years until 1951, Mr. Wills The appointment was effective N. Y.
was employed in manufacturing January 1st. All district managers Mr. Cox came to International
management positions by U. S. will report directly to Mr. Brickett, Nickel in June 1931 from the Re-
Hoffman Machinery Co. and Crown who is now responsible for all sales, search Staff of the Massachusetts
Cork and Seal Co. before rejoining including distributor, export, and
B-K as assistant works manager in all direct sales efforts. He was
1957. formerly assistant sales manager.
He graduated as a mechanical en-
gineer from Cornell University,
majoring in metallurgy, and also Castor Transferred by Linde
attended Carnegie Institute of Tech-
nology and Syracuse University. Dr. C. R. Castor WS has been
named western sales engineer for
Crystal Products and Rare Gases
Wellauer Promoted by the Linde Co., Division of Union
Carbide Corp. This territory in-
The Falk Corp., Milwaukee, Wis.,
cludes the area west of the Rocky
announces several promotions in the
Mountains, with headquarters in
company’s engineering division.
Los Angeles, Calif.
George P. Maurer becomes direc-
A native of Parrottsville, Tenn.,
tor—gear engineering; W. Stephen
Dr. Castor received his B.S. degree
Richardson, chief engineer; and in Chemistry from Baylor Univer-
Edward J. Wellauer 3, director—
sity and his M.S. and Ph.D. degrees E. J. Wellauer
research and development. Accord-
from Duke University.
ing to Louis W. Falk, executive vice

J. G. Wills C. R. Castor J. A. Brickett

416 | APRIL 1959

 RUGGED ..DAMAGE PROOF!

HARRIS IMPROVED MULTI-STAGE 77

REGULATOR

Easily read working pres- —_———

sure indicator replaces Adjusting screw can
low pressure gauge. be leftin any position
without damage to
seats or diaphragms.

Nilemilcimslilictailli mie
duces breakage, readily
removed forreplacement. Thimble protects ad-
justing screw threads
and shows pressure
adjustments.

Approved by
underwriters
laboratories.

Nut supported
over inlet stem
to prevent
damage to’ High pressure MODEL TYPE
stem seat. cylinder content NO.
indicator, indi-
cates 4, 2, % First and second 77 = Oxygen
and full. Re- stage safety
77-A Oxygen
places high valves.
pressure gauge.
77-P P.O.L. Acetylene 0 to

X-77-P P.O.1. Propane 0 to

77-D Coml. Acetylene 0 to

X-77-D Coml. Propane 0 te

For more details,
see your nearest
Harris distributor HARRIS CALORIFIC Co.
or write to us.

S501 CASS AVE.*® CLEVELAND 2, OHIO

For details, circle No. 59 on Reader information Card

WELDING JOURNAL | 417
 New plans for the expansion of
r--- When You Weld Cast Iron
the company’s operations will be
7 announced shortly. Select the Correct
I
I Holcin Promoted by Rankin
_PORTABLE
I INGER |}! Rankin Manufacturing Co., Al-
(Sisees ) hambra, Calif., announces the pro-
I
motion of J. H. Holcin to regional CAST IRON WELDING RODS
I manager of Eastern operations in OR ELECTRODES
i NOW IN charge of sales for the company.
I 3 CURTAIN MATERIALS: During Mr. Holcin’s seven years
with the company he has served as
1 av 12 oz. DUCK — fire resistant. field representative in the Midwest FUSE-WELL No. 11, Square—Gray Cast
i df NEO-WELD — yellow neoprene-coated and district manager in the Eastern Iron Welding Rod for Acetylene use in
fiber glass. Gives greater protection and filling or building up new or worn
United States and Canada. castings producing machineable welds.
! longer service.
1 ¥ ALUMINIZED ASBESTOS CLOTH. Protects FUSE-WELL NO, 12
j by reflection against radiant heat and Barris Promoted
flame — up to 1400° F. FUSE-WELL No. 12, Round—Has the
Appointment of G. A. Barris as same uses and analytical ingredients
Light in weight, yet sturdy general manager of the Stainless as Fuse-Well No. 11.
and rust-proof. Assembles in Processing Division has been an-
! 5 minutes — no threads. Folds nounced by R. L. Peaslee WS, vice
I flat. Dozens of uses — weld- president of Wall Colmonoy Corp., FUSE-WELL No. 14, Moly—An Iron
I ing curtain, machine screen, Detroit. Base Rod with alloys added for finer
Mr. Barris, who studied mechani- grain structure and greater strength.
I grinding shield, wall curtain,
cal engineering at Lawrence In-
etc. Available in all sizes. Ask stitute of Technology, joined Wall | a= a=
your dealer or write us. Colmonoy seven years ago. Prior FUSE-WELL No. 22, Electrode — Light |
Special Products Division to his new appointment, he has been coated Rod to be used for AC or DC
16 PAGE welding in the fabricating and repair-
I CATALOG ing of cast iron castings.
I Complete line of
work gloves,
welding gloves GLOVE MFG. CO. THE CHICAGO HARDWARE FOUNDRY CO.
SINGER

I
and safety 860 W. Weed St., Weld Rod Division
I clothing. CHICAGO 22, ILL. NORTH CHICAGO, ILLINOIS
[se OUR AD IN WELDING DIRECTORY For details, circle No. 63 on Reader Information Card
For details, circle No. 61 on Reader information Card
plant manager for the Division.
Mr. Barris is a member of ASM.
Institute of Technology, joining the
staff of the Research Laboratory at Paxton Promoted by Weltronic
Bayonne, N. J. During his three
years at Bayonne, he was engaged in Charles F. Paxton 3 has been
research on the chemical, metallur- promoted to assistant general man-
gical and physical characteristics ager of Weltronic Co., Detroit,
and corrosion of nickel alloys and Mich. He joined the firm in 1955
steels. He was transferred to the J. H. Holcin
New York office of the Development
and Research Division in 1934 as
chemical and metallurgical engineer
on corrosion engineering problems.
A reserve officer since 1928, Mr.
Cox entered active service as a
major, United States Army Ord-
nance Corps, in 1941.
Upon his release from the Army
in September 1945, he returned to
Inco as manager of the Empire
State Section, Rochester, of Inco’s
Development and Research Divi-
sion.

Contour Marker Elects Holder

The Board of Directors of Con-
tour Marker Corp., Compton, Calif.,
have elected John H. Holder 5
president to succeed the late K. D.
Bryant. Mr. Holder, a_ welding
engineer, has been associated with
the company since its inception. John H. Holder Charles F. Paxton

ais | APRIL 1959

WHICH ONE OF THESE POSITIONERS

DOESN'T WORTHINGTON MAKE?

Of course, Worthington doesn’t make sitioning equipment—especially in these Worthington distributor or District Sales
barber chairs. We really don’t know days of steadily rising labor costs and Office for more information on profit-
anything about cutting hair . but, tight work scheduling. You get faster able positioning equipment. Worthing-
when it comes to positioning for weld- production, better and smoother welds, ton Corporation, Section 55-7, Plain-
ing, that’s where we're right at home. fewer accident hazards and less need for field, N. J. In Canada, Worthington
crane service. Every piece of Worthing- (Canada) Ltd., Brantford, Ontario.
Whether you're talking about a small
ton positioning equipment is job-rated WORTHINGTON... FIRST
positioner for automatic welding of a
for extra capacity, easy installation, IN POSITIONING FOR WELDING
sub-assembly, a 400-ton turning roll for
greater parts interchangeability and eco-
a nuclear reactor, or a completely inte-
nomical operation. And you can count
grated push button package, Worthing-
on equally complete Worthington engi-
ton is ready and able to serve you.
neering service . .. before you buy, dur-
You owe it to yourself to investigate ing installation, right through regular
the profit-producing possibilities of po- maintenance. Why not ask your nearest WORTHINGTON
See “Tomorrow's Welding Methods Today” in the 1959 Welding Show. Worthington Booth #235-238
For details, circle No. 65 on Reader information Card
 as a sales application engineer. bide in 1935 as an engineer in the Holscher Joins Tec Torch
The co-author of the book, ‘The development laboratory of Linde
Control and Resistance Welding,” Co. at Newark. After serving in Edward Andriola, president of
Mr. Paxton attended Wayne Uni- various posts throughout the Linde Tec Torch Co., Inc. of Carlstadt,
versity. organization he was transferred to N. J. has announced the appoint-
New York in 1954 as assistant man- ment of Robert Holscher as design
ager of development and engineer- engineer in charge of research and
Doherty Named to Management Post development at the company. Mr.
ing service for the company, be-
C. D. Grover, president of White- coming manager of development in Holscher was formerly associated
head Metals, Inc., has announced 1956. He was made vice president with the Engineering Department
the appointment of Joseph I. Do- gas products of Linde Co. in 1957. of the Bendix Aviation Corp. He
herty to the post of manager of Mr. Flood also became associated attended the Newark College of
Whitehead’s Windsor, Conn. office with the corporation in 1935 as an Engineering.
and warehouse. Mr. Doherty suc- engineer at the development lab-
ceeds Joseph C. Simmons who now oratory of Linde in Newark. He
will become associate manager. then served as a sales engineer Goldston New Direcior
Mr. Doherty joined the Boston throughout various cities, returning
at Champion Rivet
office of Whitehead in 1927. In to New York in 1953 as assistant
1957, after twelve years as a field sales manager—apparatus. He At a special meeting of the board
engineer, he was appointed assis- moved up to the position of general of directors of the Champion Rivet
tant manager of the then, newly manager—Flame-Plating depart- Co., Cleveland, Ohio, Eli Goldston,
opened Windsor facility. ment in 1955, and became general partner in the law firm of Hahn,
manager—new products in 1958. Loeser, Keough, Freedheim and
Nicholson and Flood Mr. Nicholson was graduated Dean, Cleveland, was elected a di-
Named by Linde from Baltimore Polytechnic Insti- rector. The board now consists of
tute and received the degree of B.S. T. Pierre Champion MS, president;
William B. Nicholson has been in mechanical engineering from C. P. Diemer, vice president; Chas.
appointed a vice president of Linde Georgia Tech in 1934. The follow- F. Silva, secretary and treasurer;
Co., division of Union Carbide Corp. ing year he received his M.S. degree David J. Champion 5, general
In another appointment Robert F. from University of Michigan. sales manager; and Eli Goldston.
Flood was named vice president—gas Mr. Flood attended Georgetown Mr. Goldston was born in Warren,
products. University in Washington and Mas- Ohio, and is a graduate of Harvard
Mr. Nicholson joined Union Car- sachusetts Institute of Technology. Law School.

NEW DEVELOPMENTS

i WELDING

VERTOMATIC
Electroslag vertical welding ENGINEER

machine for extra-heavy

steel plates. 3 electrodes
1 pass. Welding section of Manufacturing
Research and Process Department
See booth No. 625 AWS has excellent opportunity for college
graduate with BS in engineering or
Exposition—Chicago science plus 3 years experience in
April 7-8-9, 1959 welding. The applicant selected will
conduct research and development
programs in welding. Also act as
consultant to engineering and apply
welding processes for production
Experience in aircraft manufactur-
ing preferred. Salary commensurate
with experience and ability to work
Girth seam welding with high degree of independence
machine for storage
In addition to other advantages
tanks, using improved Republic offers a comprehensive
benefit program among the finest in
arc welding process. ii
iii industry.

Send resume to:

Mr. William Walsh
Write or phone Employment Office

AMALGAMATED INDUSTRIAL CORPORATION PIEPUMEME AVIAVIOy

421 MEMPHIS ST.—PHILADELPHIA 25—PA.—RE9-8893
)
For details, circle No. 67 on Reader Information Card

420 | APRIL 1959

 Smith Named to Rankin Sales Post McKenzie Appointed
Rankin Manufacturing Co., Al- by Smith Welding
hambra, Calif., announces the ap- WELDING Gerald C. McKenzie has joined
pointment of Edward C. Smith to Smith Welding Equipment Corp.
the position of district manager in ENGINEER of Minneapolis as general sales
charge of sales in the Midwestern manager.
The Armour Research Foundation
section of the United States. Mr. A native of Winnipeg, Manitoba,
has an opening for an experienced
Smith will make his headquarters in McKenzie served the past two years
welding engineer. Applicants
Kansas City, Mo., in order to pro- as sales engineer for Warner Electric
should have several years of ex-
vide the most efficient service to all Brake Co., Beloit, Wis. He pre-
perience in welding and brazing
Ranite distributors. He _ success- viously spent five years as a division
research with at least a B.S. degree
fully conducted his own business in manager for the Frigidaire Division
in Welding or Metallurgy.
Kansas City for eleven years and of General Motors in Milwaukee,
has since served in a sales capacity The Foundation is located on the and three years in market research
in related lines. campus of the Illinois Institute of with Frigidaire in Dayton, Ohio.
Technology and encourages gradu- Mr. McKenzie attended the Uni-
Tune Promoted by Atlas ate engineering study through its versity of Manitoba and Drake
educational program providing University.
Jack C. Honhart WS, president of tuition free graduate study, in
Atlas Welding Accessories, Inc., addition to offering competitive
Detroit, has named Raymond H. salaries and liberal benefits including
Tune as sales manager of the firm. generous relocation allowance and OBITUARY
He will head sales of the company’s vacation program.
manufacturing division as well as its David Arnott
wholesale jobber sales division. Mr. Please send complete résumé to:
A. J. Paneral David Arnott, former vice presi-
Tune has been with Atlas since 1946.
dent and chief surveyor of the
American Bureau of Shipping and a
ARMOUR RESEARCH FOUNDATION past president of the AMERICAN
EMPLOYMENT of Illinois Institute of Technology WELDING Society died on Jan. 29,
10 West 35th Street 1959. Hehad been retired since July
SERVICE Chicago 16, Ilinois 31,1947, when he terminated almost
30 years of continuous service. In
BULLETIN the interim he had been retained on
the Bureau’s staff in a consulting ca-
ing manufacturing methods. pacity.
Services Available Mr. Arnott was born at Glasgow,
A-716. Corrosion Engineer—Met- Scotland, on April 1, 1878, and be-
A-715. Welding Engineer. Age 35. allurgist. Broad experience in metal- came a citizen of the United States
Married, college graduate. Desires lurgy and corrosion control in steel and in May 1924. Graduating in 1894
position as superintendent of welding. chemical industry. Fourteen years from the Royal Technical College,
Extensive metallurgical laboratory ex- experience in sales, production, fabri-
perience. Thoroughly familiar with Glasgow, he served an apprentice-
cation, corrosion mitigation, and con-
all welding processes. Ferrous and sultation with major companies. De- ship at the Fairfield Shipbuilding
nonferrous alloy experience. Back- sires responsible position in corrosion and Engineering Co., Glasgow. In
ground also includes design, estimating, engineering or sales development. Will 1901 he became a surveyor for the
preparing specifications, and develop- consider any location. British Corporation for the Survey

GENERAL ELECTRIC HAS UNUSUAL OPPORTUNITY

Whatever the particular job FOR WELDING METALLURGICAL ENGINEER
you have to do—we have the You will be one of 4 or 5 engineers who have responsibility for all welding
right FLUXINE you need. Be- engineering programs for the entire Development and Production opera-
sides our 25 FLUXINES we tions of G-E’s Flight Propulsion Division. Work includes development
; carry a complete line of ‘‘“KOP- programs on the famous J-79, X-211 and J-93 jet engines. Your head-
62 R-ARC" coated rods for weld- quarters will be in a completely equipped laboratory. Applicants must
years of be degree engineers, American citizens, with background in physical
experience ing copper and all copper metallurgy and in welding or brazing of high temperature precipitation
in scientific alloys. hardening alloys such as René 41 or A-286. We prefer 3-5 years’ ex-
development perience, but applicants with no industrial experience will be considered,
in welding
if otherwise qualified. Starting salary range, $7,500-$10,000. Send
Write on company letterhead for chart and generous sample resumé to MARK PETERS, Flight Propulsion Division, Dept. WJ-31
stating which FLUXINE desired Bldg. 100.
KREMBS & COMPANY
(Est. 1875) GENERAL GD ELECTRIC
Dept. W, 669 W. Ohio St., Chicago 10, Ill. Flight Propulsion Div. Cincinnati 15, Ohio
For details, circle No. 69 on Reader Information Card

WELDING JOURNAL | 421

 International Safety of Life at Sea Dodge Division of Chrysler Corp.
Convention, London, 1929, as Tech- Later he spent over 20 years as su-
nical Advisor; International Load pervisor in the resistance-welding
Line Convention, London, 1930, as field for Murray Corporation of
United States Delegate; Institute America. From 1954 until 1958
of Naval Architects, England; and Mr. Johnston served the Detroit
the British Institute of Welding. firm of Weltronic Co. as general
Mr. Arnott edited the textbook sales manager. He had also been
“Design and Construction of Steel the firm’s AWS Sustaining Member
Merchant Ships,”’ published by the representative.
Society of Naval Architects and He is survived by his wife.
Marine Engineers. He was the
author of many technical articles on
ship construction, including a sec-
tion on “The Strength of Ships” in John E. Taylerson
the book ‘‘Principles of Naval Archi- John E. Taylerson, 43, manager of
David Arnott tecture,”” also published by the Engineering Service, Linde Co.,
SNAME. Division of Union Carbide Corp.,
and Registry of Shipping, Glasgow. was killed in an airliner crash at La-
In 1917 the British Corporation ap- Guardia Field at 10:35 A.M. Feb. 4,
pointed him as principal surveyor Wirt Buchanan 1959. Mr. Taylorson resided at
in Canada, where he took charge of Wirt Buchanan died on January 221 Glen Road, Woodcliff Lake,
the survey of the large shipbuilding 17th. He was 64. N. J. Since becoming associated
program undertaken there during An active member of the AWS with Linde, Mr. Taylerson worked
World War I. Mahoning Valley Section, Mr. Buch- first as service engineer and then
In 1918 he joined the American anan had served terms as its chair- was promoted to manager of Engi-
Bureau of Shipping, New York, as man, secretary and treasurer. He neering Service. His work was
deputy chief surveyor, becoming joined the Socrety in 1924 and, at largely in the New York area.
chief surveyor in 1925 and vice the time of his death, was only He was active in the AMERICAN
president in 1938. months away from obtaining life WELDING Society and spoke be-
The Miller Memorial Medal, membership in the AMERICAN fore meetings of the New York and
awarded for conspicuous contribu- WELDING Society, emblematic of New Jersey Sections also presented
tions to the art and science of weld- 35 years of standing. papers before the national annual
ing, was presented to Mr. Arnott by Mr. Buchanan, an ex-Marine with meetings of the Socrery.
the AMERICAN WELDING SOCIETY at pre-World War I service in the Far He attended Carnegie Institute of
its annual meeting in Philadelphia East, attended Slippery Rock State Technology and was graduated from
on Oct. 20, 1941. Teachers and began his career at the University of Michigan with the
At the 55th Annual Meeting, in Bessemer-Cooper Corp. in 1916. degree of B.S. in metallurgical en-
1947, of the Society of Naval Archi- Promoted to foreman in 1922, he gineering in 1938.
tects and Marine Engineers ‘““The had later been elevated to general After graduation, Mr. Taylerson
David W. Taylor Medal’’ was pre- foreman of the firm’s welding facili- worked for Federal Shipbuilding and
sented to David Arnott “‘for notable ties. Drydock Co. in Port Newark, N. J.
achievement in Naval Architecture.”’ He is survived by his wife and two as welding engineer from 1938 to
His knowledge of all the technical children. May 1945 when he came to work
phases of ship design and construc- for Linde Co.
tion led to participation in the work His wife, Mrs. Florence Taylerson
of numerous bodies engaged in J. M. Johnston was killed with him in the crash.
scientific and technical development, They were returning from Chicago
among which are the Society of J. M. Johnston died on Nov. 11, where they had attended the funeral
Naval Architects and Marine En- 1958. He was 65. of Mr. Taylerson’s sister. Mr. and
gineers, of which he was Honorary Born in Glasgow, Scotland, Mr. Mrs. Taylerson are survived by four
Vice President; Welding Research Johnston was in charge of mainten- children, John 16, Robert 14, Lynn
Council; United States Delegation, ance of electric welders with the 12 and Joanne 9.

Wirt Buchanan J. M. Johnston John E. Taylerson

422 | APRIL 1959

NOW! Liqua-Guard System Saves Money,

Increases Efficiency

Cambridge Corporation, working with e@ Eliminates need for high pressure

your gas supplier, offers a greatly simplified regulators
method for storing and handling atmos- e Reduces accidents to personnel and
pheric gases. A single outside reservoir property damage from cylinder handling
stores oxygen, nitrogen and argon in liquid
form. The Liqua-Guard System features a
This is truly the modern concept for gas complete line of vacuum jacketed vessels,
handling and gives you important cost and vaporizers and associated equipment. Ask
handling advantages: your gas supplier for a site survey.
@ Delivers 100% product volume, no
sidual gas loss Send for Bulletin CS19 on Cambridge Liqua-Guard
POUR Eas 108 System for Liquefied Atmospheric Gases
@ Eliminates large numbers of high pres-
sure cylinders €. Cc A
re 8 a é D G E
@ Reduces handling, labor, cuts storage
space c oR PP OF R A Tt GO WN
SUBSIDIARY OF CARRIER CORPORATION
10 Industrial Ave., Lowell, Mass.
— = = }

See us at the Welding Show

Booth 408
and Vaporizers
For details, circle No. 71 on Reader Information Card
WELDING JOURNAL | 423
 2,824,950—-ULTRASONIC COUPLING FOR lished to provide a continuous gap between the tube and around the circumference of the tube.
Wetpinc Rop—Howard R. Johnson, rails, and part of the body portions are welded to- The assembly is moved or progressed with rela-
N. J., and Jesse Eugene gether by the electrode without interruption of the tion to the electrodes while weld current flows
assignors to welding operation so as to remove the slag formed. Thereafter the tube is indexed and similarly an-
iain, Steel Sen Co., * Coatesville, Pa., a other pair of fin members are resistance welded to
the tube.
poet of Pennsylvania. 2,825,004—-Arc-WELDING APPARATUS
This patented — rod holder includes a —Martin Rebuffoni, Williamsville, and 2,826,673—-Rinc SEAM WELDERS— Karl
d shaft projecting Lewis F. Pettit, Jr., Kenmore, N. Y., W. Matthes, Golf Manor, Ohio, as-
pane te Ren a a fn: elie fe assignors to Westinghouse Electric signor to Precision Welder and Machine
ee nh < Se Cee ae. Corp., East Pittsburgh, Pa., a corpora-
This shaft is adapted to tr it ult Co., Cincinnati, Ohio, a corporation of
tions to a welding rod carried by the holder. ae tion of Pennsylvania. Ohio.
means are provided to secure a welding rod to the This new arc welding apparatus includes a pair Matthes’ patent is on a resistance welder
said member. of load duct to be a electrode assembly to form an annular or ring
electrode, a plurality of single-phase alternating seam weld. The apparatus includes a driven
current power supply conductors, and a rectifier spindle, a head on the spindle, and means for
2,824,951—WeELDING PrRocEss—Har- means connected to the supply conductors and effecting relative rotation of the spindle with
Strohmeier, Kapfenberg, Steier- having output terminals from which direct current respect to the head which is secured against ro-
mark, Austria, assignor to Gebr. is provided. Other means including a reactor are tation. An electrode is provided on the head and
Bohler& Co. Aktiegesellschaft, Vienna, connected to the output terminals of the load con- has an annular lip, concentric with the relative
ductors and which reactor is of such small! dimen- axis of the rotation of the head so that on rotation
Austria. sions that it begins to saturate at a current of of the spindle, the lip of the electrode engages a
This patented welding process is on a continu- between 10 to 30 amp. workpiece at a point that travels in a circle.
ous welding method including the steps of form-
ing two circular welding wires of substantial 2,826,674—-WELDING METHODS AND
length, each having a conductive core and an annu- 2,825,793—-WELDING Rop AND
MeTHop oF WELDING—lLeland M. APPARATUS— Lucien Peras, Billancourt,
Kee, Baltimore, Md., 7 - ignor, by France, assignor to Regie Nationale des
mesne nts, to uction Usines Renault, Billancourt, France,
Co., Inc., _ York, N. Y., a corpo- French works under the control and the
ration of New York. authority of the French Government.
Kee’s patent is for a method of producing a This patent is on the resistance spot welding of
titanium stabilized chrome-nickel stainless-steel metallic parts and includes the steps of subjecting
arc weld deposit. His new method includes the the parts to a selected welding pressure by elec-
step of forming an arc between a chrome-nickel trodes during a selected period of time. A
stainless-steel core wire and a workpiece and add- periodically interrupted flow of welding current is
ing titanium and aluminum to the weld in the provided in the welding cycle in a predetermined
form of an ingredient in the coating on the core time pattern. The spaced impulses of welding
wire. This coating contains specified amounts of current and the interruption periods vary in time
silicates, titanium, aluminum and other special in a selected sequence determined as a function of
materials. the welding characteristics of the parts being
welded.
Abstracts of Current PATENTS 2,825,809—ELECTRONIC WELDER 2,826,675—-METHOD FOR INSTALLING
PuLsE CONTROLLING Crircurir—David Firtincs IN METAL CELLULAR CORE
S. Ferguson, Huntington, W. Va., as- PaNELs—John R. Fullerton, Lawrence
signor to Sylvania Electric Products, E. Leech, and Donald L. Heyser, San
Inc., a corporation of Massachusetts. Diego, Calif., ignors to the Ryan
Ferguson's patent related to a welding unit Aeronautical Co., San Diego, Calif., a
comprising a two-wire, alternating current supply. corporation of California.
At least three grid controlled ionizable tubes are In the present patent, fittings are welded in
connected to the power supply and to the welding metal cellular core panels. First an opening in
circuit in specified relationship for pulse con- the cellular core is cut corresponding closely to the
trolling actien. shape of the fitting which is then inserted in the
opening and the cut end portions of the core are
2,826,671—-METHOD OF WELDING— welded to the fitting. The outer metal skins on
prepared by Vern L. Oldham Charles T. Gayley, Lansdowne, Pa., both sides of the core are welded to the fitting
The welding is accomplished by short pulses of
Printed copies of patents assignor to the United States of welding current each having a duration of the
may be obtained for 25¢ from the America as represented by the Secre- order of a few milliseconds
Commissioner of Patents, Washington, D. C. tary of the Navy.
In this new patented welding method, a welding 2,826,676—BrusH Type ELECTRODE
torch is provided that has a hollow handle for FOR RESISTANCE WELDING—John R
receiving insulated electrical conductors, inert
lar coating thereon. This coating lacks a seg- shielding gas and water coolant tubes, all to be Fullerton, Lawrence E. Leech, and
ment the radial height of which is equal to the used in the welding process. Hollow electrode Donald L. Heyser, San Diego, Calif.,
radial thickness of the coating and the cores of the holders are provided and are carried by the tubu- a? to the Ryan Aeronautical
wires are brought into contact where they are ex- lar handle and have the lower ends converging at Co., San Diego, Calif., a corporation of
posed due to the absence of a segment shaped part an angle of substantially 60 deg towards each other. California.
of the coatings. These cores are joined at the Each electrode holder has an electrode positioned
exposed portions thereof to form a single elongate therein so that the electrodes can be closely The patent covers the use of a plurality of
totally coated electrode immediately in advance spaced at their ends for formation of an arc be- thin, flexible, electrically conductive bristle
of the point of welding. tween their tip ends. The angle of disposition of elements secured at one end in a bundle and con
the electrodes and their holders prevents the stituting a brush. This brush has a rigid end
formed arc from moving upwardly of the holders portion for securement to an electrode holder and
to maintain the arc at the tip ends of the elec- means operatively connect the brush to the ele«
2,824,952—-MeTHOD OF WELDING trodes. tric circuit of a resistance-welding machine
Raits—Gerrit Zoethout, Eindhoven,
Netherlands, assignor, by mesne as-
signments, to North American Philips 2,826,672--M ETHOD OF WELDING FINS 2,827,544—TuBE WELDING By HIGH
Co., Inc., New York, N. Y., a corpora- To TusBes—John W. Brown, Jr., Lake- FREQUENCY RESISTANCE HEATING
tion of Delaware. wood, and Arvid C. K. Nihlen, Oberlin, Joseph Wesley Cable, Monroe, Conn.,
Ohio, assignors to Brown Fintube Co., and, Wallace C. Rudd, Larchmont,
The present patent relates to a method of arc Elyria, Ohio, a corporation of Ohio. N. Y., assignor to Magnetic Heating
welding end surfaces of two rails positioned in end- Corp., New Rochelle, N. Y., a corpo-
to-end relationship and it comprises the steps of The new method of making finned tubes in- ration of New York.
placing a relatively flat plate under the adjacent cludes the step of positioning a special member in-
rail ends and arranging a first pair of auxiliary side a tube for support of the tube from the inner This patent discloses the method of use of
pieces on the flat plate on either side of the junc- surface thereof, and assembling a pair of fin Patent No. 2,827,543.
ture of the rails at the foot portion thereof members, each having a base portion and a fin
‘These auxiliary pieces are no higher than the foot portion on the tube with the base of the fin 2,827,545—CoNTROL APPARATUS
portions to form a partially enclosed space and member engaging the tube wall and extending John P. Conner, Brighton Township,
the foot portions of the rails are welded together longitudinally thereof in diametrically opposite Adamsburg, Pa., assignors to Westing-
by means of a low-hydrogen welding electrode relationship to the other fin member. The base house Electric Corp., East Pittsburgh,
being melted down in the space. Next, a second portions of such members are then resistance
pair of auxiliary pieces, are placed on the first pair welded to the tube by exerting welding pressure Pa., a corporation of Pennsylvania.
of auxiliary pieces, and they are positioned adja- upon the base portions extending towards the The present patent is on apparatus for con
cent part of the body portions of the rails. This axis of the tube by welding electrodes. A weld- trolling the operation of a welding system in the
second pair of auxiliary pieces is placed in position ing current is caused to flow between the elec- joining of work with a series of welds as the work
immediately after the foot joint has been estab- trodes, through the base portions and wall of the is advanced through the system

424 | APRIL 1959

This New PLUG-IN Welder Control

Lets You

ADD CONTROL

FUNCTIONS |

AS YOU

NEED THEM

A Wide Range of Plug-in

Units Enables You to Add
Components as Your
Welding Jobs Change

HERE’S HOW YOU CHANGE

YOUR BASIC CONTROL wr ly feature you ve
—for every welding jo
SIMPLY BY ADDING PLUG-IN UNITS . ’
@ 22 standard units provide
FOR WELDING FOR WELDING “custom” control for every
MILD STEEL— ALUMINUM— welding sequinemiegy
BASIC CONTROL YOU ALREADY HAVE: ® all units are plug-in type
INCLUDES THESE 3B Timer for quick change
PLUG-IN UNITS: Relay Valve Control ®@ available in“all electronic”
3B Timer Tube Firing Panel or “relay firing” versions
Relay Valve
~ ge Control YOU ADD THESE e auxiliaries
aston £tor allm conven m
Tube Firing Panel PLUG-IN teers tional welding functions
Heat Control ® circuits include the latest
Up-down Slope safety features
Forge Delay

Write tor Bulletin SM-277 to Square D Company, 4041 N. Richards St., Milwaukee 12, Wisconsin

ECaM HEAVY INDUSTRY ELECTRICAL EQUIPMENT. ..NOW A PART OF THE SQUARE D LINE

SQUARE J) COMPANY

For details, circle No. 73 on Reader Information Card

WELDING JOURNAL | 425
 Hydraulic Turbines Refrigerators
Reduction in Turbine Costs as T-1 Making Refrigerator Cabinets on Auto-
Steel Proved at Brownlee, F. R. mated Welding Line, V. C. Rice.
McCormick. Elec. West., vol. 121, no. Automation, vol. 5, no. 11 (Nov. 1958),
5 (Nov. 1958), pp. 64-66. pp. 47-51.
Iron and Steel Plants Resistance-Welding Control
Submerged Arc Welding Helps Steel Electronic Control Times High-Speed
Plant Maintenance, J. Angus. Jron & Welding Cycle, S. C. Rockafellow.
Steel Engr., vol. 35, no. 11 (Nov. 1958), Electronics, vol. 31, no. 33 (Aug. 15,
pp. 132, 135, 137. 1958), pp. 70-72.
Iron Castings Resistance-Welding Machines
Salvage of Iron Castings by Welding, Factors Influencing Specification of Re-
J. C. Pellegrino. Foundry Trade Jnl., sistance Welding Plant, I. Jones.
vol. 105, no. 2195 (Nov. 6, 1958), pp. Welding & Metal Fabrication, vol. 26,
573-574. no. 11 (Nov. 1958), pp. 412-415.
Metals Cutting Resistance Welding
Spark Machine Tool Has Servo Con- Projection Welding of Mild Steel, G. A.
trol, E. M. Williams and C. P. Porter- Phipps. Brit. Welding Jnl., vol. 5, no.
For copies of articles, write directly to field. Electronics, vol. 31, no. 43 (Oct. 12 (Dec. 1958), pp. 549-552.
publications in which they appear. AA list of 24, 1958), pp. 90-92.
addresses is available on request. Nuclear-Power Plants Shipbuilding
Stress Relief By-passed on Ship, G. A.
Welding Cast Components for Nuclear Hughes. Welding Engr., vol. 43, no.
Power Application, W. H. Rice. 11 (Nov. 1958), pp. 41-42.
Aircraft Materials ASME —Paper no. 58-MET-10 (for
Fabricating Superalloys, H. E. Haley. meeting Apr. 15-17, 1958), 8 pp.; Ships
Tool Engr., vol. 41, no. 5 (Nov. 1958), see also Welding Jnil., vol. 37, no. 10 Welded Ship Construction—-Records
pp. 96-101. (Oct. 1958), pp. 971-978. of Common Fractures and Their
Aluminum Alloys Nuclear Reactors Causes, H. R. Gibbs and G. M. Boyd.
Extruded Aluminum Alloys for Low Aluminum Fabrication for Nuclear Instn. Engrs. & Shipbidrs. in Scotland
Temperature Service, R. J. Durham. Work, D. Slater. Nuclear Eng., vol. 3, Trans., vol. 101, pt. 5 (1957-58), pp.
Brit. Welding Jnl., vol. 5, no. 11 (Nov. no. 27 (June 1958), pp. 247-250. 282-301; (discussion) 301-302; (fur-
1958), pp. 510-516. ther discussion) pt. 6, pp. 303-316.
Vacuum Welding by Electron Beam,
Low Temperature Properties of Alu- J. A. Stohr. Nuclear Power, vol. 3, no. Stainless Steel
minum-Magnesium Alloys, R. E. Lis- 26 (June 1958), pp. 272-274. Cooperative Investigation of New
mer. Brit. Welding Jnl., vol. 5, no. 11 Welding Electrode for Stainless Steel,
(Nov. 1958), pp. 523-538. Welding Symposium. Nuclear Power,
vol. 3, no. 25 (May 1958), pp. 206-226. R. D. Wylie. ASME— Paper no. 58-
Low Temperature Properties of Welded MET-6 (for meeting Apr. 15—17, 1958),
and Unwelded Al-5% Mg Alloy Plates, Oil-Well Drilling 8 pp.
J. E. Tomlinson and D. R. Jackson. Production-Line Surfacing with
Tungsten Carbide Particles, R. Priest. Welding Metallurgy of Cr-Mo-V Steels
Brit. Welding -Jnl., vol. 5, no. 11 (Nov. for High-Temperature Steam-Turbine
1958), pp. 499-510. Industry & Welding, vol. 31, no. 11
(Nov. 1958), pp. 32-33, 52. Components, R. J. Christoffel, R. M.
Arc Welding Curran, F. H. Domina and C. H. Sol-
New Method of “Rivet Welding,” Oxygen-Cutting Machines dan. ASME—Paper no. 58-MET-7
Using Coated Electrodes, A. Ya. Powder-Cutting of Stainless Steel, (for meeting Apr. 15-17, 1958), 13 pp.
Brodskyi. Engrs.’ Digest, vol. 19, no. A.L. Chappell. Welding & Metal Fabri- Steel Castings
11 (Nov. 1958), pp. 482-483. cation, vol. 26, no. 11 (Nov. 1958), pp.
403-404. Welding Low-Alloy Steel Castings for
Welding Processes: Some Thoughts on High-Pressure and High-Temperature
Present Stage of Development Petroleum Gas, Liquefied Service, N. A. Chapin, C. H. Soldan
Presidential Address, J. Strong. Brit. Construction of Spherical Pressurised and L. W. Songer. ASME-— Paper no.
Welding Jnl., vol. 5, no. 12 (Dec. 1958), Tanks, C. J. Verzijlbergh. Acier 58-MET-4 (for meeting Apr. 15~17,
pp. 545-548. Stahl Steel, vol. 23, no. 5 (May 1958), 1958), 11 pp.
Automobile Manufacture pp. 221-223. Sugar Factories
Use of CO, Are Welding Expanding in Petroleum Refineries
Construction of Gear Rings for Rotary
Automotive Plants, A. W. Shearer. Casting-Weldments in Petroleum Re- Drums for Sugar Refineries, R. de
Automotive Industries, vol. 119, no. 9 finer, J. Bland, C. B. Parrish, and R. C. Vogelaere and M. Slegten. Acier Stahl
(Nov. 1, 1958), pp. 64-65. Wheeler. ASME— Paper no. 58- Steel, vol. 23, no. 4 (Apr. 1958), pp.
Brazing MET-5 (for meeting Apr. 15-17, 1958), 173-176.
12 pp.
Wide-Gap Brazing Alloy Assembles Testing
Engine Rings, R. C. Kellner. Am. Pressure Vessels
Mach., vol. 102, no. 23 (Nov. 3, 1958), Effect of Arsenic on Mechanical Prop-
New Tooling Concept for Welding Mis- erties of Welds in Mild Steel, D. Ca-
pp. 98-99. sile Pressure Vessels, G. Garfield. nonico and H. Schwartzbart. Welding
Bridges Western Metalworking, vol. 16, no. 11 Engr., vol. 43, no. 11 (Nov. 1958), pp.
(Nov. 1958), pp. 58-60. 32-35.
Current Structural Bridge Steels: Sur-
veys of Usage and Economy, N. W. Recommendations for X-Ray Exam-
Morgan. Pub. Roads, vol. 30, no. 4 Automation Takes Over in Rail Butt- ination of Fusion Welded Joints in
(Oct. 1958), pp. 100-104. Welding. Ry. Track & Structures, vol. Light Alloys. Brit. Welding Jnl., vol.
Car Building 54, no. 12 (Dec. 1958), pp. 23-27. 5, no. 11 (Nov. 1958), pp. 489-491.
Multiple Arcs and Powdered Iron Elec- Long-Welded Rails Laid in Continuous Welded Joints and Residual Stresses,
trodes. Industry & Welding, vol. 31, Operation. Ry. Gaz., vol. 109, no. 21 V. I. Trufyakov. Brit. Welding Jnl.,
no. 11 (Nov. 1958), pp. 38-39, 53. (Nov. 21, 1958), pp. 625. vol. 5, no. 11 (Nov. 1958), pp. 491—498.

426 | APRIL 1959

Tubes
Automatic Oxy-Acetylene Welding
Makes Quality Tubing, M. R. Gavin.
Industry & Welding, vol. 31, no. 11
(Nov. 1958), pp. 40-43.

Weld Defects
Calculating Hot Cracking Resistance of
High Tensile Alloy Steel During Argon-
Arc Welding, F. J. Wilkinson, C. L. M.
Cottrell and H. V. Huxley. Brit.
Welding Jnl., vol. 5, no. 12 (Dec. 1958),
pp. 557-562.

Welding-Machine Controls
Heat Program Timer Improves Re-
sistance Welds, B. B. Stuart. Metal
Progress, vol. 74, no. 5 (Nov. 1958) pp.
109-110.

(Continued from Page 379)

HIGHLIGHTS

OF EXHIBITS

Cosa Corporation Booth No. 101

Feature: Display of copy-nibbling
machine and Universal cross-cut-
ting and nibbling machines. Also,
a display of photographs depicting
other weld preparations obtained
with Schulze and Naumann roller
shears. Use Pureco CO,

Graham Mfg. Corp Booth No. 733 for LOW COST gas shielded
Feature: Portable percussive stud-
welding machine which welds alu- metal arc welding
minum or steel studs up to '/, in.
diam without marking thin metals.
Lightweight machine welds pat- Pureco carbon dioxide, used as a gas shield by fabri-
ented Graham Weld Studs from cators of miid steel, will provide quality welds with
115 v, 15 amp supply without inert unusual economy.
gas, flux or ceramic ferrules. Carbon dioxide is ideal for both single and mullti-
pass applications, manual or automatic, with large
or small diameter wires. And now—you can also use
MacLean-Fogg Lock CO: for position manual welding.
Nut Co. Booth No. 115 Your Pure Carbonic representative can give you
Feature: Long and short pilot and the technical assistance you need and recommend a
recessed projection-type weld nuts, CO, supply system best suited for your particular
both with and without a locking operation. There are more than 100 Pureco locations
feature. Also, free-spinning and from coast to coast for your convenience. Call or
prevailing torque-type lock nuts. write today.

APRIL IS
NATIONAL Cuneco
ey
WELDED
rnopucTs wisi Pure Carbonic Company
THE A.W.S. A Division of Air Reduction Company, Incorporated
WELDING 150 EAST 42ND STREET, NEW YORK 17, N. Y.
SHOW
AT THE FRONTIERS OF PROGRESS YOU'LL FIND AN AIR REDUCTION PRODUCT
For details, circle No. 75 on Reader Information Card
WELDING JOURNAL | 427

= 2
 New Literature Section 2 of Welding
Handbook Still Available
Copies of the Welding
Handbook, Fourth Edition,
Section 2, are still available.
This particular section is de-
voted to gas, arc and resist-
ance-welding processes. Over
500 pages in length, the vol-
ume is illustrated with photo-
Coated Abrasives Silver-Brazing Alloys graphs, graphs and symbols.
Copies may be obtained
A new information kit is now New silver-brazing paste alloys from the AMERICAN
available from the Carborundum (containing silver-braze alloy, special WELDING Society, 33 W.
Co., Niagara Falls, N. Y. In the silver braze flux, and special binders 39th St., New York 18, N. Y..,
kit is a buyer’s guide, Form A 1506, in homogenous suspension) are de- at a list price of $9.00 per
with reference tables and forms for scribed in a new single-page engi- volume.
the listing of requirements; a selec- neering data sheet, No. 88-1, just
tor chart for metalworking opera- issued by Fusion Engineering, 17921
tions, Form A 1507; and a brochure, Roseland Ave., Cleveland 12, Ohio.
“Basics in Coated Abrasives for the The new silver-braze pastes are de- equipment and structures.
Metalworking Trades,” Form A signed particularly for use with auto- For your free copy, circle No. 12
1509. matic dispensing equipment. on Reader Information Card.
For your free copy, circle No. 2 The three types of silver-brazing
on Reader Information Card. pastes outlined in the data sheet,
Oxyacetylene Welding
S-4, ST and S-5, are said to cover all
Nickel Alloy applications in the silver-brazing Modern Engineering Co., 3411
field. Each basic type is available Pine Blvd., St. Louis 3, Mo., has
“Engineering Properties of Ni- with any standard or special silver- issued a 24-page brochure, illus-
Resist Ductile Lrons,” a 28-page braze alloy. trated with cross-section drawings,
booklet containing the story of this For your free copy, circle No. 8 which evaluates 50 important de-
new cast metal has been published on Reader Information Card. sign features found in oxyacetylene
by the International Nickel Co., welding and cutting equipment and
Inc., 67 Wall St., New York 5, N. Y. High-Temperature Brazing industrial regulators produced by 19
The metal is said to combine high leading manufacturers.
strength and toughness with out- Selas Corporation of America, For your free copy, circle No. 14
standing resistance to heat, wear Dresher, Pa., describes an im- on Reader Information Card.
and corrosion. Tables and graphs proved and enlarged line of Multi-
explain mechanical and _ physical port P-R Gas-Air Burners in 4-page
Oxygen-Cutting Machines
properties, erosion and corrosion Bulletin PR-1.
resistance, and high-temperature The wide operating ranges of the Booklet N-102, published by the
strength. A special section points precision-built burners with any National Cylinder Gas Division of
out numerous industrial applica- commercial fuel gas permit their Chemetron Corp., 840 N. Michigan
tions of Ni-Resist ductile irons. use for a number of applications, Ave., Chicago 11, Ill, describes
For your free copy, circle No. 4 such as high-temperature alloy braz- NCG’s Type R oxygen shape-
on Reader Information Card. ing, glass fire-polishing and form- cutting machine, including a sec-
ing, heat-treating materials, heating tion on the new NCG electronic line
Copper Alloys solder pots, silver soldering, liquid tracer.
heating, food baking and textile Featured in the new booklet are
A detailed listing of the proper- singeing. views and descriptions of typical
ties, forms and composition of For your free copy, circle No. 10 installations. They include fabrica-
wrought copper and copper-base on Reader Information Card. tion of hydraulic presses at the
alloys is now being made available by Clearing Machine Corp., Chicago;
Western Brass in its new products Metallizing manufacture of parts for Caterpillar
brochure. The 14-page booklet has scrapers and other equipment at the
been issued by Western Brass sales, Bulletin 93XG, published by company’s Joliet and Peoria plants;
Metals Division, Olin Mathieson Metallizing Engineering Co., Inc., and uses in numerous other indus-
Chemical Corp., East Alton, Ill. Westbury, Long Island, N. Y., trial plants.
Reference sheets list the nominal describes the Metco metallizing sys- For your free copy, circle No. 16
composition, available forms and tems, a series of techniques devel- on Reader Information Card.
physical properties of the alloys. oped through the use of properly
Tensile, yield and shear strength, treated pure metals which are firmly Inert-Gas Welding
and elongation of the alloys, both bonded to a steel base by metal-
hard and soft, are also included. lizing. These metal coatings re- This 48-page instruction booklet,
Ratings for the corrosion resist- portedly assure low-cost positive entitled ‘How To Do Sigma Weld-
ance, as well as the hot working and protection against oxidation for 25 ing,” is available from Linde Co.,
annealing range, and fabricating to 50 or even 100 years. In addi- Division of Union Carbide Corp.,
properties are also featured. tion to describing the systems, the 30 E. 42nd St., New York 17, N. Y.
For your free copy, circle No. 6 new bulletin depicts some typical Revised to include latest recom-
on Reader Information Card. applications on a broad range of mendations for inert-gas-shielded

428 | APRIL 1959

For details, circle No. 77 on Reader Information Card ——>
 |

for critical /
welding

/ PsH Combination

ANOrs DL Oma
'/2)
le(2)us
with ON-OFF automatic
high frequency
aMal-1-\-meler-lbesol0lgelel-1-m 1-1 (el-1a-m- ta -Mleoler-l
ico] au-10] o]-1gexelahdior-1l1-1ell
ale i ol-ler- tert)
they offer you:
* pre-set gas and water timing
* foot-operated remote heat adjustment and
primary contactor control
¢ high-frequency intensity and phase-shift rheostats
* ON-OFF soft start
* specially built sequence timing for any
requirement

Get the complete work- and money -

saving story. Write to:

HARNISCHFEGER
WELDERS « ELECTRODES - POSITIONERS
Milwaukee 46, Wisconsin
 428 | APRIL 1959
For details, circle No. 77 on Reader Information Card ——>

metal-arc welding on all commer- Joining,” by Orville T. Barnett of ing of a 3000-lb board drop-hammer
cially available metals, the booklet, the Armour Research Foundation of ram; the fabricating of bearing
F-7825, also includes current, gas Illinois Institute of Technology will liners and the welding of those liners
flow, joint design and filler metal be distributed through the AMERI- to 26-ft propeller shafts; and the
recommended for various materials. CAN WELDING SOCIETY. overlaying of drawing dies used in
The section on filler metal has been The book is designed as a refer- forming automobile bumper guards.
completely revised to include new ence for all concerned with welding, For your free copy, circle No. 20
wires now available. brazing and soldering, and sum- on Reader Information Card.
For your free copy, circle No. 18 marizes the industrial practices in
on Reader Information Card. the selection of filler metals for any
metal joining problem. It also High-Temperature Brazing Sheet
places special emphasis on prod- A new single-page, 8'/, x 11-in.
Spot Welding of Inconel X ucts for manual and automatic arc two-color engineering data sheet,
welding. Price of book is $7.00 and Number 4-A, discussing a 0.005-in.
The Resistance Welder Manufac-
copies may be ordered through thick flexible Nicrobraz brazing
turers’ Association has published its
AMERICAN WELDING SOCIETY, 33 sheet for high-temperature service
latest Bulletin—-Number 26-—‘‘Spot
West 39th St., New York 18, N. Y. honeycomb applications is now avail-
Welding of Inconel “X”’ in Thick-
ness Range of 0.032 to 0.188 in.” able from Stainless Processing Divi-
The bulletin covers properties of sion, Wall Colmonoy Corp., 19345
Bronze Welding John R. St., Detroit 3, Mich.
Inconel X; welding with tri-phase
d-c machines; welding with single- The fourth quarter 1958 issue of Sizes and weights as well as
phase a-c machines; postweld heat ““Ampco Welding News,”’ published wetting and flow properties of the
and forging pressure; X-ray exam- by Ampco Metal, Inc., 1745 S. 38th sheet are discussed. Advantages,
ination; and spot weld macro- St., Milwaukee 46, Wis., is available application recommendations and
graphic examination. for immediate distribution. recommended brazing atmospheres
Copies are available from the Featured in this issue is informa- are included.
Association’s headquarters, 1900 tion regarding the overlaying of For your free copy, circle No. 22
Arch St., Philadelphia 3, Pa., at a steel pipe expander rings with on Reader Information Card.
cost of 20¢ each. Ampco-Trode 250 electrodes to
eliminate excessive wear and to pre- High-Tensile Electrodes
vent scratching and galling of the
Filler Metals A 2-page data sheet from the
pipes.
A new book, “Filler Metals for Other articles describe the repair- Lincoln Electric Co., Cleveland 17,
Ohio, describes two new high-tensile
arc-welding electrodes for welding
HY-80, T-1 and other 90- to 110,000-
psi tensile strength steels. Both
electrodes are of the low-hydrogen,
iron-powder type. Jetweld LH-90
is said to meet AWS requirements
for E9018-G and E8018-B2 elec-
trodes, while Jetweld LH-110 con-
forms to the E11018-G specifica-
tions. The literature includes such
information as operating charac-
teristics, physical properties, mark-
ings and current ranges, and welding
procedure.
For your free copy, circle No. 24
on Reader Information Card.

Arc-Welding Machines
The December-January, 1958-59
issue of ‘“‘Memco News’’ is available
from Miller Electric Mfg. Co., Inc.,
Appleton, Wis. Included in the 16-
page booklet are illustrated news
sections on export operations, dis-
f YOU haven't yet read the interesting facts tributor training schools and distri-
about the newest advancements in acetylene butor shows. A product review of
cylinder manufacture -- let us mail you this en- the company’s 1958 activities de-
lightening folder on the Coyne 92. And, when scribes and depicts the new Miller
you visit the AWS show, let us tell you more. models introduced during the past
We'll be in booth 912. year.
For your free copy, circle No. 26
For your foider, NOW, write to jCOYNE on Reader Information Card.
cylinder company
224 Ryan Way, So. San Francisco, Calif. © 155 W. Bodley Ave., Memphis, Tenn
Spot-Welding Machines
3800 Springdale Ave. Glenview, Ii! © 24 Commerce Street, Newark, NJ.
For details, circle No. 79 on Reader Information Card Arc spot-welding machines, dis-

430 | APRIL 1959

BUS ID NEERING

Aronson

In a board walk the largest item of expense is the

lumber; in a splendid violin the

A
A least item of expense is the lumber.

In a plain wall the stone is the chief cost; in a

S
piece of classic statuary the cost of
Sf
“a ‘ the stone is hardly reckoned.

LZ y\
This principle, in a certain degree, applies to the

making of a good positioner. We do not pretend

that we put more or less material into each

Aronson Positioner; but we do put in the best

materials, the scientific knowledge and expert

skill and the long-continued care which no

ordinary positioner contains.

If you want to get rich music or a treasure of the

sculptor’s art or a job of positioning that will

be satisfactory and increase your profits, you

must pay for something other than raw material.

UNIVERSAL BALANCE® POSITIONERS

BENCH TURNTABLE POSITIONERS
GEAR DRIVEN POSITIONERS
HEADSTOCK - TAILSTOCK POSITIONERS
TRACTRED’ TURNING ROLLS
TURNTABLES
FULLY AUTOMATIC POSITIONERS
MAGNETIC WELDING CLAMPS

= ARCADE, NEW YORK

For details, circle No. 81 on Reader Information Card
NG JOURNAL | 431
tributed by Guthery Machine Tool Cleaning Processes For your free copy, circle No. 34
Corp., 38-31 Crescent St., Long on Reader Information Card.
Island City 1, N. Y., are described To coincide with its 50th anniver-
in a catalog containing literature of sary, Oakite Products, Inc., 19 Rec-
all units. All models featured in tor St., New York 6, N. Y., has
the catalog are portable, thereby re- published a special 28-page issue of
portedly providing ease of manipula- “Oakite News Service.”’ The at-
tion and elimination of difficult tractive booklet traces the early
approaches to welding positions. history of cleaning processes, the !
history of the Oakite firm and pre- 7
Small built-in transformers and con-
tactors make the units self-con- sents an account of the current prod-
ucts manufactured by the firm. A =
tained, yet retaining light weight. ™\
Uf USS
They are recommended principally glimpse into the future reveals the
on sheet-metal applications. possibility of removing moon dust
from returning space transports. OF NEW BOOKS
For your free copy, circle No. 28
on Reader Information Card. For your free copy, circle No. 32
on Reader Information Card.
Radiography Aluminum ASTM Releases
A new 16-page illustrated booklet Design information on architec- Nonferrous Standards
in color is now available from the tural applications of aluminum is The first of 10 parts of the 1958
Curtiss-Wright Corp., Princeton available in a new brochure offered Book of ASTM Standards has re-
Division, Princeton, N. J. En- by the Metals Division, Olin Mathie- cently been published by the So-
titled ‘Industrial Radiography,” son Chemical Corp., 400 Park Ave., ciety. This will be followed by
the literature presents a_ basic New York 22, N. Y. other parts as rapidly as editorial,
explanation of the use of radiog- The 12-page booklet contains a press work and binding can be com-
raphy and also discusses isotope detailed listing of the properties of pleted. The first part off the pres-
radiography, selection of a radia- architectural aluminum alloys and ses was Part 2, Non-Ferrous Metals.
tion source, exposure calculations their use in both standard and basic The Book of ASTM Standards is
and training. Pipe line, all-purpose, mill products. unquestionably the American So-
shop and “puff” camera equipment A special section describes the ciety for Testing Materials’ largest
are also described. varieties of special finishes available publication venture. It represents
For your free copy, circle No. 30 with aluminum, their appearance
on Reader Information Card. and how they are obtained. (Continued on Page 436)

A Complete Sheet Metal Shop in One Machine

PULLMAX
DOES ALL OF THESE OPERATIONS
CIRCLE DISHING BEADING METALLIZING COMPANY OF
CUTTING AMERICA

(nessa Presents
STRAIGHT CUTTING
(014) e Anew “POWDER JET” Metallizing unit for the spraying of pow-
der or fragmented materials in both metals and ceramics
INSIDE SQUARE CUTTING LOUVER CUTTING
The R-1 ““TURBO-JET” Metallizing unit for the spraying of
ROKIDE* rods of Aluminum Oxide (A), Zirconium Oxide (Z),
JOGGLING IRREGULAR Zirconium Silicate (ZS) and other new experiment materials.
OR OFFSETTING OR FREEHAND Rods are available in larger diameters for faster and more economical
application.
The ‘““TURBO-JET” Metallizing unit for the spraying of all metals
except tungsten, obtainable in wire or rod form in diameters from
20 B&S to */:«” inclusive.
The “MOGULECTRIC” Metallizing unit for the fastest, most
economical and best in production spraying
The “F-12” Metallizing unit for light and medium duty spraying,
featuring low initial and operating cost.
SLOT CUTTING FLANGING NIBBLING
See and investigate these units at the A.W.S. Show in Chicago Booth 804
* CUTS MILD STEEL UP TO ''/,,”
The one machine that’s sure to save Executive Offices
time, labor and material when you Factory and Warehouse
work sheet or plate. Eliminates ex- 3520 West Carroll Avenue
Chicago 24, Illinois
pensive die costs—easy to operate. 7 Write for a demonstra-
sizes to choose from. tion right in your plant. Divisional Offices and Warehouses
16 MM SOUND FILM AVAILABLE 431 East 75th Street 849 East 6th Street
New York 21, New York Los Angeles 21, California
Write for free catalog on Metalworking Ideas.
* Trade-Mark-——Norton Company, Worcester, Mass.
AMERICAN PULLMAX CO., INC. U.S. Patents 2707691 & 2677627.
2467 N. Sheffield Ave., Chicago 14, Illinois
Visit us in Booth 5, Int. Petroleum Exposition, Tulsa, Okla., May 14-23. For details, circle
No. 85 on Reader Information Card
For details, circle No. 83 on Reader \nformation Card !
432 | APRIL 1959
aaa ICKERS.
METALLIC
ARC
WELDER

| | welding machines
CONSTANT
POTENTIAL
WELDER

in still maintaining

the top welding performance

In this versatile welder, Vickers has combined:

1. Standard Arc Welding
2. Constant Potential Welding
3. Tungsten Inert Gas Welding
in ONE Outstanding Machine
The price is less than half of separate mac hines!
And this combination has been achieved with no loss of complete
performance. Standard or CP operation is superior to operation of competitive
individual machines. Now you can do almost any welding job from this single
source, without an expensive investment in multiple machines
ES: =
NEW —Fr om Vi ;...500 Amp. Constant Potential Welder
Can be paralleled to give any current for any semi-automatic or auto
matic job requiring direct current constant potential power
e Built in remote control receptacle
e Voltage adjustable (stepless) from approx. 13 to 36 volts
e Slightly falling output slope—may be adjusted internally to flat o1
slightly rising for special conditions
e Hot start adjustable. May be internally adjusted to any desirable degre:
e High speed of response
e No moving parts
e Quickly paralleled for high output requirements

@ Contact our nearest welder dealer for prices or call factory!

@ Write for special descriptive bulletins 7136-1 and 7146-1,

VICKERS INCORPORATED
DIVISION OF SPERRY RAND CORPORATION
ELECTRIC PRODUCTS DIVISION
2933 LOCUST STREET « SAINT EGOUIS 3, MIssovxere

For details, circle No. 87 on Reader information Card

WELDING JOURNAL | 433
 Now— CYBERNETICS in Oxygen Cutting

Cybernetics? A strange word, we admit. But it is becoming a

BIG word in many phases of American industry where the
science of automation in production is growing in importance.

Ask us about Messer Cutting Machines—how they cut costs

and improve efficiency by making possible automatic control in
any oxygen cutting operation.

Miesser Cutting Machines,

CHRYSLER BUILDING ¢ 405 LEXINGTON AVENUE @e NEW YORK, N. Y.

For details, circle No. 89 on Reader Information Card
434 | APRIL 1959
Incorporated

For details, circle No. 89 on Reader Information Card

WELDING JOURNAL | 435
one of the main reasons for the 1957. 88 pages. (Order PB 131- Rieppel, Battelle Memorial Insti-
Society’s existence. Distributed 680 from OTS, U. S. Department of tute for U.S. Army. March 1956.
throughout the world, ASTM stand- Commerce, Washington 25, D. C., 30 pages. (Order PB 131689 from
ards are used to cover the produc- $2.25.) Continuous-seam_ _—type OTS, U. S. Department of Com-
tion, purchase and evaluation of ultrasonic welding of structural merce, Washington 25, D. C., $1.
millions of dollars worth of materials aluminum alloys was shown to be The development of Mn-Ni-Mo-V
annually. The size of the book has feasible. Ultrasonic welding also and Mn-Mo-V ferritic steel filler
increased steadily and rapidly and produced spot-type solid-state junc- wires with improved cracking resist-
will continue to grow because as the tions in 1100-H14, 2024-Ts and ance is reported. Additions of
Society’s technical committees’ work 7075-T6 Alclad, and 2024-Ts bare 0.30% misch metal to the experi-
increases many more specifications aluminum alloys, meeting the shear mental filler wires improved the
and tests will be issued. strength requirements of military cracking resistance and notch tough-
The increase from 7 to 10 parts in specifications for resistance spot ness of the weld deposits. Titan-
1958 was necessitated by a growth welds in 0.081-in., 0.064-in., and ium additions, when controlled very
in size of individual parts to the 0.051-in. sheet thicknesses. Metal- closely, had significant effects on
point where they could no longer be lographic studies indicated good notch toughness of the deposited
bound economically and were be- quality solid-state bonding with all weld metals. It was concluded that
coming unwieldy in size. materials studied. The joining proc- filler wires for use with the inert-
The statistics alone on this refer- ess was shown to be effectively gas-shielded consumable-electrode
ence work upon which American supplemented with heat at tempera- process may be produced to deposit
industry is so dependent for its tures below the critical levels for air- weld metals with strength and
materials requirements are impres- craft structural aluminum alloys. toughness properties comparable to
sive. Within the 10 parts will be Surface cleaning preparatory to those of weld metal deposited with
contained 2450 standard specifica- welding was indicated to be less low-hydrogen ferritic coated elec-
tions, methods of test, definitions of critical than for aircraft-quality re- trodes.
terms, and recommended practices. sistance spot welding.
These will occupy 13,600 pages.
Anode X-Ray Tubes
Armor Welding
Ultrasonic Welding The January 1959 issue of “‘Cath-
Development of Filler Wire for ode Press,” a 32-page standard-size
Ultrasonic Welding of Structural Welding Army Ordnance Armor by booklet in color is available from
Aluminum Alloys. J. B. Jones and the Inert-Gas-Shielded Consumable- Machlett Laboratories, Inc., Spring-
E. E. Weismantel, Aeroprojects Electrode Process. S. M. Silver- dale, Conn. Included is a 7-page
Inc. for the U. S. Navy. January stein, R. P. Sopher, and P. J. article, entitled ‘‘Extending the Life
of Rotating Anode X-Ray Tubes.”
Copies are available from the
manufacturer at the above address
for 75¢ in the USA and Canada or
What will they $1.00 from foreign countries.

* p* oP ®q ee
Mathematics
Mathematics for Industry, by S.
E. Rusinoff, Illinois Institute of
Technology. Revised second edi-
tion, 565 pages, 5'/, x 8'/,-in. hard-
bound book. Price, $6.25. Pub-
lished by the American Technical
Society, 848 E. 58th St., Chicago
37, Ill.
Included in this edition are basic
reviews, complete with problems, of
such studies as arithmetic, algebra,
geometry and trigonometry. In ad-
dition, separate chapters are also in-
cluded on logarithms, the slide rule
and engineering computations.
Preview some startling Practical chapters on screw threads
new ideas on display and gears are covered, while three
in Booth No. 122-— new chapters, viz., use of graphs in
Chicago international the solution of engineering prob-
Amphitheatre, April 7-9. lems, computation of automatic con-
trols for automation, and problems
in inspection and quality control,
Through research E&Y a better way round out the remainder of the
third edition. The text contains
an appendix of useful tables and an
AO.Smith index.
Concentration is given to actual
WELDING PRODUCTS DIVISION
Milwaukee 1, Wisconsin problems of engineering, shop and
For details, circie No. 91 on Reader Information Card drafting room.

436 | APRIL 1959

New caustic evaporator demonstrates how well one filler wire

_..Inco-Weld “‘A” wire...joins most dissimilar alloys°

This new 3-cycle evaporator produces

high-purity caustic—maintains purity
with all-Nickel surfaces. It is fabri-
cated of Nickel, Nickel-clad steel, and
carbon steel. All welds joining dis-
similar alloys are made with Inco-
Weld* “A” Wire.
NICKEL-CLAD Finished welds are sound, strong,
STEEL jee ductile, and resistant to caustic cor-
rosion. These superior welds are ob-
tained with exceptionally high weld-
ing speed by using Inco-Weld “A”
Wire and the inert-gas welding
CARBON process.
STEEL tees Add these extras: (1) easily joins most
combinations of dissimilar alloys, (2)
no preheat necessary in most cases,
(3) X-ray quality welds between 97
per cent of all weldable dissimilar
alloy combinations (examples listed in
table below), (4) good impact proper-
ties at sub-zero temperatures, (5)
Nia aimee) high stress-rupture properties at ele-
STEEL ange vated temperatures, (6) Inco-Weld“A”’
Wire deposits can be age-hardened;
important where super alloys are to
be age-hardened after welding.
Whether you specify Inco-Weld “A”
Wire or Inco-Weld “A” Electrode (for
field welding and hard-to-get-at
joints) you can expect sound welds.
Corrosion resistance in most cases
equals or betters that of the joined
metals.
Illustrated folder — “Now You Can
Weld Dissimilar Alloys,” shows where
and how Inco-Weld “A” Wire and
Electrode cut costs, join most weld-
VAPOR BODY | able dissimilar alloys. Just write us
vaporat weld for your copy.
*Trademark, The International Nickel Company, Ine.

FLOW THROUGH UNIT

Inco-Weld “A” Electrode was formerly

sold as Inco-Rod “A’”* — this electrode
10% Ni-Clad Steel to has been improved so that it gives still
10% Ni-Clad Steel greater hot ductility — particularly in
heavy sections.
Inconel Alloy to itself
THE INTERNATIONAL NICKEL COMPANY, INC.
67 Wall Street dikeo, New York 5, N. Y.

INCO WELDING PRODUCTS

electrodes * wires ® fluxes
For details, circle No. 93 on Reader Information Card
WELDING JOURNAL | 437
 New Products

A. 0. Smith Announces Welding contained welding gun. According

Machines of the Future to A. O. Smith’s welding engineers,
the gun could be built to handle back tilt from the table flat position
A welding machine that theoreti- liquid electrodes. is said to afford the greatest amount
cally draws its electrical operating For details, circle No. 36 on of accessibility of the weldment for
power from a thermonuclear source Reader Information Card. manual or automatic welding proc-
has been announced by A. O. Smith esses. Four selective variable-speed
Corp., Milwaukee, Wis. Stud Welding ranges are standard for rotating
The machine is identified as a small diameter workpieces at 0.40
“Stellarweld.”” Although practical Graham Mfg. Corp., 152 Second rpm as well as large diameters with
working models are still several Ave., Needham Heights 94, Mass., speeds as low as 0.006 rpm. Only
years away, the unit will embody has developed the Graham ‘‘Super- 93.6 sq ft of floor space is required
principles that are entirely plausible, Six’’ portable percussive stud-weld- for this positioner.
according to the manufacturer. ing unit for welding ferrous and non- For details, circle No. 38 on
ferrous metals. The unit is said to Reader Information Card.
be advantageous for such applica-
tions as architectural products, fab-
rication of stainless-steel kitchen High-Temperature Brazing Alloy
equipment, sheet-metal fabrication A new high-nickel brazing alloy
and shipyard construction. The for high-temperature service is now
manufacturer reports that distor- available from Stainless Processing
tion and discoloration are elimina- Division of Wall Colmonoy Corp.,
ted when studs up to '/, in. in diam 19345 John R St., Detroit 3, Mich.
Designated Nicrobraz No. 160,
the new alloy is similar to Standard
Nicrobraz (AMS 4775) but has
lower initial hardness. It is said to
produce joints with lower hardness
that are more easily machined.
Hardness before brazing is 35 to 40
Rockwell C, softest of all nickel-
It is pointed out that the device base brazing alloys.
could become a self-contained weld- Nicrobraz No. 160 has the lowest
ing machine operating on a perpetual boron content of the Nicrobraz line
power supply similar to those now of alloys. It has a wide melting
being developed to utilize the energy range (higher than Standard Nicro-
produced by nuclear fusion. High braz) and is recommended for use
welding amperages could be pro- with larger brazing clearances.
vided to offer power to a large num- The new alloy is recommended for
ber of welding operations. applications where high-strength
Another model that A. O. Smith’s machinable joints are desired in
welding engineers are planning will are welded to light-gage metals, in- assemblies intended for high-tem-
be the ‘‘Vega,”’ a portable anti- asmuch as sufficient heat is genera- perature operation. It is available
gravitational welding machine that ted and localized for such a short as powder, impregnated plastic
floats at a predetermined level off period of time that the weld is ef- wire, powder-flux paste or prefabri-
the plant floor and can be pulled to fected before these changes occur. cated rings for furnace brazing in
the welding site with little effort. Operation can be obtained from any
The unit also would draw its power 110-v a-c electric outlet.
from a self-contained atomic source. For details, circle No. 42 on
Cosmic rays from outer space con- Reader Information Card.
verted into electrical energy will
power still another model, the Welding Positioner
““Cosmos.’” Company engineers feel
that this is based on a highly com- Aronson Machine Co., Arcade,
plicated theory and would be par- N. Y., has developed Model G850, a
ticularly adaptable to field welding gear-driven welding positioner to
applications. handle weldments of up to 85,000 Ib
Two gases compressed to a solid at 12-in. center of gravity location
state unite to create the high heat from the workplate. Provision for
necessary for welding with a self- 90 deg of forward tilt and 45 deg of

438 | APRIL 1959

pure dry hydrogen, or vacuum FOR ANY STAINLESS WELDING JOB
atmospheres.
For details, circle No. 40 on
Reader Information Card.

Welding and Cutting Outfit

*‘Super-Range,’’ a complete weld-
ing and cutting outfit, packaged as
a single unit and capable of handling
a full range of shop work, including
welding, cutting, heating, brazing
and soldering, has been announced
by Victor Equipment Co., 840
Folsom St., San Francisco 7, Calif.

a
WELDING AND CUTTING UNIT

This Super-Range outfit, the

maker reports, is assembled from
standard, top-quality apparatus and
includes: two single-stage regula-
tors, welding torch, cutting attach-
ment, three welding torch nozzles
and a cutting tip, 12'/. ft of dual
welding hose, */,, in. in diam, spark
lighter, goggles and wrench.
As packaged, the Super-Range
unit can weld metal '/, in. thick and
cut up to 1 in.
For details, circle No. 44 on
Reader Information Card.

Gas-Shielded Welding Torch

The Wilson Equipment Corp.,
1806 Madison Ave., Paterson 3,
N. J., has introduced a lightweight, Specify Drawalloy “quality controlled” stainless steel welding wire for
air-cooled gas-shielded arc-welding your next “quality weldments.” Your greatest advantage is experience...
torch for use with currents from‘5 to our experience in producing wires for welding exclusively. Because we are
150 amp. Weighing 2°, oz, the specialists, Drawalloy stainless steel welding wire is produced to strictly
over-all length of the torch meas- controlled specifications to provide the right chemistry, finish and temper
ures 1*/, in. and is available in both
straight and angle head models. for the finest quality weld metal and smoother operation in your automatic
Recommended particularly for work or semi-automatic equipment. Drawalloy stainless wires are available in all
in confined areas, three electrode popular grades as well as 214 Cr, 1 Mo; 1!4 Cr, 4% Mo.
sizes and eight gas cup styles in-
crease the torch’s versatility. Dur- Why not discuss your stainless welding wire needs with your Drawalloy
ability is reportedly achieved by Distributor or Representative . . . a man with the products and knowledge
the use of laminated glass cloth and to help you. Bulletin 355 DC provides complete information on every grade
silicone resin to insulate the head,
of Drawalloy wire. Write to: Drawalloy Corporation, Lincoln Highway
West at Alloy Street, York 13, Penna.

—DRAWALLOY-——
CORPORATION
STAINLESS STEEL & TOOL STEEL WELDING WIRE

THE WIRE MILL FOR THE WELDING INDUSTRY

For details, circle No. 95 on Reader information Card
WELDING JOURNAL | 439
 along the pipe’s length after weld-
‘BMABB-AHIBT’ ing.
(see translation below) Alcoa ‘“‘Unistrength”’ Pipe, in 40-ft
lengths, currently is available in
@ Precision alloys 6063-T6 and 6061-T6 with
Schedule 40 wall thickness at the
e Ruggedness ends. This permits the use of
standard aluminum fittings and
© Flexibility
flanges. Additional combinations
e Long Life of wall thicknesses can be produced
for other joining methods.
Electronic Drive For details, circle No. 46 on
Minimum Deflection Reader Information Card.
Flame Hardened Silver-Brazing Pastes
V-Ways
An experimental kit of silver-
Double Chain Lift brazing pastes is now being offered
Dynamic Braking by Fusion Engineering, 17921 Rose-
land Ave., Cleveland, Ohio. The
e Complete Automation kit consists of three separate silver-
brazing pastes for use in testing
Welding Head Manipulator, CB 15 x 20 (above) provides motorized vertical production applications.
adjustment of 15’ (3’ to 18’), 20’ variable speed ram travel and motorized
360° rotation. Heavy duty carriage carries Manipulator, Generators and
Flux Recovery Equipment. All Manipulator and Welding Controls in
light weight pendant. Operator sits at working end of ram.
*Beller Manipulators Are Being Buill and Herrick Is Building Them*
LOW IN COST. (WRITE FOR NEW PORTFO!'O) HIGH IN QUALITY.

C. B. HERRICK MFG. CORP.

2000 CENTER STREET e@ CLEVELAND 13, OHIO
For details, circle No. 97 on Reader information Card

which materials will neither char Transmission parts are reportedly In production Fusion silver-braz-
nor soften. The attached light- produced on this machine at a rate ing pastes can reportedly be auto-
weight cable is said to remain flexi- of 120 assemblies per hour. matically applied as rapidly as three
ble in all working temperatures. For details, circle No. 50 on parts per second.
For details, circle No. 48 on Reader Information Card. The kit includes three basically
Reader Information Card. different types of brazing pastes
with the same standard 45% silver
Aluminum Pipe
Automated Welding Machine alloy, although any standard silver-
Aluminum Co. of America, Pitts- brazing alloy can be incorporated in
A new Expert 5-station in-line the paste.
burgh 19, Pa., has introduced a
transfer, automated welding ma- For details, circle No. 52 on
chine that combines assembly and seamless, one-piece ‘‘Unistrength’’
pipe combining thin walls with a Reader Intormation Card.
welding operations in the production
of disk and hub assemblies is now standard wall thickness at pipe ends.
The resulting weight reduction Spot-Welding Gun
available from Expert Welding Ma-
has reportedly lowered costs. At Brennen, Bucci & Weber, Inc.,
chine Division, 17144 Mt. Elliott
the same time, the variable wall 262 Mott St., New York 12, N. Y.,
Ave., Detroit 12, Mich.
The machine press assembles principle strengthens joints, usually announce the “‘Bren Weld”’ arc-spot
two steel transmission parts (disk the weakest link in a piping system, welding gun. Weighing less than
by concentrating metal at pipe ends. 2 lb, the Model G spot weld gun is
and hub) and welds the assembled
Increased use of light metal pipe said to weld sheet metal from one
parts in one continuous operation.
now is anticipated in petroleum, side, requiring no backup electrode
farming, mining, chemical and other It has no triggers or levers to operate
industries. during the spot-welding operation
Alcoa ‘“Unistrength Pipe’ is
adaptable to all joining methods,
but its advantages are well demon-
strated by welded joints. By de-
creasing wall thickness of weldable,
heat-treated alloys, except at the
joints where the heat of welding
lowers strength, a 40% weight sav-
ings is reportedly achieved. The
ratio of thick to thin walls is
selected to provide uniform burst-
ing, tension and bending strength

440 | APRIL 1959

in ULTRASONIC TESTING.

only SPERRY. offers,you

such awide range of Services,

Instruments ‘andAccessories

When youconsider Ultrasoni¢ Testing be sure to

consider the services. Sperry’s 14 years of proven
performance to industry has produced a complete
range of services for you:
SPERRY RESEARCH AND DEVELOPMENT SERVICE diversified in-
vestigations into testing problems for government and industry.
SPERRY APPLICATION RESEARCH SERVICE ready to help solve
your specific testing problems with the most advanced techniques.
SPERRY SPECIAL SEARCH UNIT DEVELOPMENT SERVICE the de-
sign of special search units and auxiliary equipment to meet
your testing requirements
SPERRY CUSTOM INSTALLATION SERVICE design and manufac-
ture of tailor-made inspection installations . . . from simple,
manually-operated to automatic systems
SPERRY COMMERICAL TESTING SERVICE Sperry’s engineers will
do the testing for you on a day-to-day basis at your plant or in
one of our laboratories
30 years specializing in
nondestructive flaw detection SPERRY SCHOOLS OF ULTRASONIC TESTING held
at convenient locations throughout the country
for industrial and government personnel.
VISIT BOOTH 225, APRIL 7-8-9, '59
G W
|WELDINSHO
COPE
eas FLECTOS
ULTRASONIC TESTING EQUIPMENT

SPERRY PRODUCTS, INC., 2404 Shelter Rock Rd., Danbury, Conn.

For details, circle No. 99 on Reader Information Card
WELDING JOURNAL | 441
and will weld galvanized as well as ten metal and slag, and provide the
mild steels. temperature-sensing probes which
It is recommended for duct work, actuate, through newly designed
auto body repair, signs and all other electronic controls, the automatic
types of sheet metal work. upward travel of the welding proc-
For details, circle No. 54 on ess.
Reader Information Card. The process reportedly permits
deposition rates of 0.055 to 0.065 Ib
per amp perhr. In 2-in. thicknesses,
Electro-Slag Welding Machine the complete weld is made in one
pass at the rate of 4 to 6 ft per hr.
Amalgamated Industrial Corp., Excellent mechanical properties, in-
421 Memphis St., Philadelphia 25, cluding impact properties, are said Infinite speed range is available
Pa., is now marketing an electro- to be obtained using special filler from '/, to 5 rpm. A heavy-duty
slag welding machine in the United metals and fluxes. The process is 110-v d-c shunt-type motor is used
States. Constructed in Europe, the also suitable for the welding of heavy in conjunction with a two-speed re-
machine, known as the ‘“Verto- thicknesses of alloy steel. duction gear box. The table speed
matic,’’ is designed for this new proc- For details, circle No. 68 on is constant, while direction of rota-
ess, and permits the butt welding of Reader Information Card. tion is reversible.
plates from 1 in. in thickness upward The sheet steel control panel is
in a single pass:in the vertical posi- mounted rigidly to the frame of the
tion. The machine comprises one or positioner or it can be removed for
more electrodes which supply the Turntable Positioner remote mounting on a pedestal.
welding heat under a molten slag. The table top can be tilted up to
The plates are mounted vertically, Miami Specialties Co., Trade 135 deg while loaded.
allowing a spacing between the oxy- Rd., Troy, Ohio, reports that the Dimensions are 27',, in. from
gen-cut butt edges and permitting load capacity of their turntable floor to table top. Base is 32'/, in.
an access for the electrodes. Water- welding positioner is 500 |b at center long and 22'/, in. wide. The
cooled shoes are placed against both of gravity 6 in. above the table sur- slotted turntable top is 26 in. diam.
plate edges, which contain the mol- face and 3 in. off center of rotation. Weight is 490 lb.
For details, circle No. 56 on
Reader Information Card.

Bus Distribution Plates

Resistance-welding contro! bus
distribution plates are now being
made to recognized dimensional and
performance standards. Manufac-
tured by Synthetics Development
Co., 27400 Red Leaf, Royal Oak,
Mich., these blocks are molded of
polyester plastic reinforced with
glass fiber. High impact and dielec-
tric strength, and good corrosion
resistance are claimed. Plates are
1'/, in. thick, 6'/. in. wide (to
jailable in 23 sizes. carry 4'/.-in. bars, for 400- and 800-
amp service) and are made in three
less than new teeth.
lengths, to hold one, two or four bus
bars. The bus bar mounting holes
are molded to accept and hold * /,-in.
diam hex head cap screws. Four
7/-in. mounting holes are _pro-
11%-14% MANGANESE vided ,in each plate.
For details, circle No. 60 on
Reader Information Card.
INDIVIDUAL SLIP-O¥
Available
Eliminate Steels Developed
for Nuclear Service
A new series of steels, now being
used in the fabrication of compo-
nents of nuclear-power plants, is be-
ing produced and marketed by
WRITE FOR
Jones & Laughlin Steel Corp., 3
OIsTRiBUTOR Gateway Center, Pittsburgh 30, Pa.
These steels, which have a chem-
istry considered to be a radical
For details, circle No. 101 on Reader Information Card departure from that of standard

442 | APRIL 1959

Produce ‘“Proof-Test’’ Weldments

Lower Cost

Increase Welding Markets -

Simple 4-Point Prograth

The designer, buyer or user.of welded fabrications

usually asks for just two things: dependable,
consistent quality, delivered at a fair price.

Our Magnaflux 4-point Program helps you to give

him both—at a substantially increased operating
profit! It has proved that it can increase the
number and types of welded components used in
all manner of products. Specifically, here is
what it can d o for you:

1. Improve welding design finding defects at the first pass saves need-
Use Stresscoat Brittle Coatings as a stress less waste of money, saves time spent in
analysis shortcut, to help design easier-to- completing welds certain to be rejected later.
produce, more economical welded parts This increases productivity!
You'll eliminate guesswork and wasted ef
fort save money and assure a fabrication 4. Promote the reputation and
right for its job. acceptance of your weidments
“Tested by Magnafiux’”’ certifies that your
2. Establish consistent standards welded fabrications are fully reliable for the
Know the service requirements you are service for which intended. This recognition
“shooting” for. Then set the standard of helps to create new uses and markets for
quality that will meet them. This does not welded fabrications. It also helps your own
mean an abstract, costly goal of perfection engineers to design functionally better prod-
Magnaflux Test Methods find all defects in ucts at lower cost
welds that need to be found easily and
quickly in both ferrous and nonferrous Why not decide now to get the whole story
metals . . . at any level of sensitivity you of the Magnaflux 4-Point Test Program
require. and how it can help you to tap new markets,
reduce waste and increase profits. Ask to
3. Gain better control of operators have your Magnaflux Field Engineer give
With Magnaflux Test Systems you have a you the facts, as they apply to your own
continuous check from stringer bead to fin- operation. Write or call for a meeting. No
ished product. You can spot trouble fast and obligation, of course but a strong likeli-
correct its cause. On multiple pass welds, hoéd of better earnings for your company.

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For details, circle No 103 on Reader Information Card
WELDING JOURNAL | 443
 announces development of a new
line of portable pneumatic grinders.
Both lightweight horizontal grind-
ers and high-speed die grinders are
included in the new line. The new
“ACRO WELDER MFG. CO, horizontal grinders are applicable
to a wide range of industrial opera-
MILWAUKEE
tions such as grinding, buffing and
wire wheel work. Various sizes and
WELDING MACHINERY
ENGINEERS BUILDERS

ESTABLISHED 18936

For details, circle No. 105 on Reader Information Card

steels, were developed over the past are made in grit sizes 16 through 180. <<
four years by the Nuclear Tech- Diameters include 6, 7, 8 and 9'/; in.
nology Unit of J&L’s Research and with '/, and ’/;-in. arbor holes. models are available, with speeds
Development Department. For details, circle No. 62 on ranging from 3100 to 12,000 rpm.
Reported to be superior to stand- Reader Information Card. Wheel sizes range from 3 to 8 in. in
ard grades of steel for use in nuclear diam. Lever, straight or grip-type
environments, these new steels have handles may be specified.
formability, weldability and Pipe Cutting and Beveling The die grinders have been de-
strength characteristics which make signed to increase speed wherever
them desirable in many nonnuclear The H&M Pipe Cutting and filing, grinding, cutting and polish-
commercial fields. Beveling Machine Co. of Tulsa, ing operations are involved. The
J&L’s nuclear steels can be pro- Okla., has announced improvements new tools are available in two sizes,
duced in the form of plate, sheet, in the design of two of the attach- with rated speeds of either 40,000 or
strip, bars, tubing, rods, wire and 60,000 rpm. They are _ suitable
extruded shapes, and can be welded for a wide range of wheel sizes.
and fabricated by conventional For details, circle No. 66 on
methods. Reader Information Card.
For details, circle No. 64 on
Reader Information Card.

Grinding Disks WE'VE

A new type of aluminum-oxide

grinding disk is now offered by
Abrasive Products, Inc., South
Braintree 85, Mass.
Called ‘Spitfires,’ the new sol- GOT

vent and waterproof disks feature

fully reinforced edges and a special
built-in shape control which elimi- |
ments for their standard pipe-cut-
nate limpness and disintegration ting and beveling machines.
due to excessive grit loss. The “Shape Cutter’ attachment,
NEWS :.....

“Spitfire” grinding disks are avail- as illustrated, has been completely

able in special, standard and heavy- remodeled. The new model is light-
duty models for a wide range of weight and features easy, fast
grinding and finishing applications. mounting, and is designed to cut see
Their uses include light-gage metal various shapes of pipe intersections
sanding and polishing, light and automatically.
heavy weld and braze removal, and The H&M “Out-of-Round”’ at-
high speed finishing. The disks US
tachment has been improved with
the addition of a new, free-wheeling
roller assembly that turns a full 360
deg. This roller rides the surface of |at booth 621
the pipe and automatically makes
corrections for imperfections. at the
For details, circle No. 58 on
Reader Information Card. AWS convention

Pneumatic Grinders GENERAL DYNAMICS CORPORATION

Liquid Carbonic Division
Thomas C. Wilson, Inc., 21-11
135 South LaSalle Street * Chicago 3, Illinois
44th Ave., Long Island City, N. Y.., Circle No. 107 on Readers’ Service Card

444 | APRIL 1959

 Index to ADVERTISERS Tempilstik’

PAGE 444 Acro Welder Mfg. Co.

Outside Back Cover Air Reduction Sales Co.
303 Alloy Rods Company
388 All-State Welding Alloys Co., Inc.
390, 391 Aluminum Company of America
420 Amalgamated Industrial Corp.
Inside Back Cover American Brass Co.
432 American Pullmax Company, Inc.
409 Ampco Metal, Inc.
398, 399 Arcos Corporation
421 Armour Research Foundation
431 Aronson Machine Company
423 Cambridge Corporation
389 Cam-Lok Division, Empire Products, Inc.
411 Cayuga Machine & Fabricating Co., Inc.
381 Champion Rivet Company
418 Chicago Hardware Foundry Company
430 Coyne Cylinder Company
439 Drawalloy Corporation
395 Eutectic Welding Alloys Corporation
387 Fibre Metal Products Co.
421 General Electric Company
Aircraft Gas Turbine Division
397 Handy & Harman
Harnischfeger Corporation
Harris Calorific Company
440 C. B. Herrick Manufacturing Corp.
297 Hobart Brothers Company
International Nickel Co.
421 Krembs & Company
412 Lenco, Inc.
407 Lewis Welding & Engineering Corp.
393, 405 The Lincoln Electric Co.
301, 367 Linde Company, Division of
Union Carbide Corporation
444 Liquid Carbonic, Division of
General Dynamics Corp. * Also Tempil® Pellets
443 Magnaflux Corporation and Tempilaq® (liquid form)
434, 435 Messer Cutting Machines, Inc.
446 Metal and Thermit Corporation
432 Metallizing Company of America Tempilstike °—« simple and
306 Miller Electric Manufacturing Co. accurate means of determining preheating
National Carbide Company and stress relieving temperatures in
406 National-U. S. Radiator Corporation welding operations. Widely used in all
Plastic Metals Division heat treating—as well as in hundreds
299 National Welding Equipment Co. of other heat-dependent processes
in industry. Available in 80 different
Pure Carbonic Company temperature ratings from 113°F
420 Republic Aviation to 2500°F... $2.00 each.
Robvon Backing Ring Company
The Sight Feed Generator Co. Send for free sample Tempil® Pellets.
392 State temperature desired ... Sorry,
Singer Glove Manufacturing Co. no sample Tempilstiks®.
436 A. O. Smith Corporation
441 Sperry Products, Inc. Most industrial and welding supply
houses carry Tempilstiks® ...If yours
Square D Company does not, write for information to:
442 Stulz-Sickles Company
Tec Torch Company, Inc.
445 Tempil® Corporation ACCESSORIES DIVISION
413 Titan Metal Manufacturing Co.
301, 367 Union Carbide Corporation
Linde Company Tempil® corporation
433 Vickers Inc. Electric Products Division 132 West 22nd St., New York 11, N. Y
Inside Front Cover Victor Equipment Co.
402, 403 Westinghouse Electric Corp. For details, circle No. 109 on Reader information Card
419 Worthington Corporation

WELDING JOURNAL | 445

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New Murex DRI-SEAL containers guarantee you A revised edition of up-to-date stainless
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METAL & THERMIT

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RAHWAY, NEW JERSEY
PARTNER IN WELDING PROGRESS SINCE 1904
For details, circle No. 111 on Reader Informacion Card

eee ee a ar e , aes © ee eg aes R SS ——<“— |

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 Welding

Research Sponsored by the Welding Research Council

of the Engineering Foundation Wee

SUPPLEMENT TO THE WELDING JOURNAL, APRIL 1959

Internal-Stress Distribution of Single Spot Welds

in Relation to Their Fatigue Life

Main objective of WRC investigation is to determine the reasons

why an outstanding improvement in the fatigue resistance of spot welds

can be brought about by a specific hydrodynamic treatment

BY G. WELTER AND A. CHOQUET

SUMMARY. Different new test meth- dynamic treatment of the spot. Other of about 7% of the same static tension
ods have been developed and tried methods such as electrical strain gages pullingload. Furthermore, other tests,
out in order to continue the funda- having a '/;, in. gage length, cemented such as shear tests, tension tests per-
mental research work on spot-welded in the interface, on the spot and the pendicular to the plane of the spot, tor-
joints. Our particular concern was to immediate vicinity, Huggenberger ex- sion tests, were carried out on hydro-
find out the ‘‘reason why”’ the improve tensometers, also revealed results of dynamically treated and as-received
ment of several hundred percent of the the same nature and approximately of specimens. ‘The load-deformation dia-
pull-pull fatigue limit of stainless steel the same values. Consequently, these grams were compared particularly in
Type 301 can be brought about by a results supported the deducted view- the elastic and semiplastic ranges in
specific hydrodynamic treatment. By point that the recorded improvement order to find some characteristic dif-
these tests it has been found out that of the spot weld by hydrodynamic ferences in the behavior of these two
such an outstanding improvement is treatment is due to a setup of favorable types of spot welds.
mainly due to a most advantageous internal-stress pattern. It is not excluded that, by other
arrangement of internal stresses set up The advanced explanation for this arrangements of tip and ring compres-
in the weld and around the spot, which quite-exceptional improvement of the sion, still-higher fatigue resistance can
results in a favorable interaction of the fatigue resistance of these treated spot be achieved as characterized by a 500%
applied external load. By using a welds has been verified by a very great improvement on spots as they are
mechanical hand strain gage indicating number of fatigue-test specimens presently fabricated in electrical resist-
strain of the order of one ten thou stressed at various levels to a cycling ance-welding machines.
sandth of an inch over a gage length of ranging from several hundred thou- The whole development outlined
about '/, in., internal stresses in and sands to the 10 million cycles endurance above has been worked out at Ecole
around the spot ranging from 30,000 to limit. Six zones can be readily dis- Polytechnique. An illustrated pamph-
35,000 psi could be clearly detected tinguished from these results: a 300-lb let summarizing our current work and
Two types of stresses were measured, limit for specimen in the ‘“‘as-received”’ theories, as they were expressed during
i.e., tension stresses of several 10,000 condition; a 600-lb limit for spots an- a subcommittee meeting held in our
psi due to thermal contraction of the nealed after fabrication; an 800-lb laboratories on September 20, 1957,
spot during the fabrication process, limit for hydrostatically compressed was prepared and diffused throughout
and compression stresses of about the samples; a 1000-lb limit for hydro- industry. This same pamphlet has
same value acting in the opposite direc- dynamic ring compression from one been fully reproduced in the July 1958
tion which are set up by the hydro- side only; a 1200-lb limit for a hydro- issue of the WELDING JOURNAL.
dynamic ring and tip compression and
G. WELTER is Professor of Applied Mechanics a maximum of 1400-lb limit for Introduction
and A. CHOQUET is Associate Professor in specially shaped compression tip and
Strength of Materials, both at Ecole Polytech One of the most important points
nique, Montreal. Canada ring with various contours producing a
still more favorable setup of internal concerning the low fatigue resist-
This investigation has been sponsored by the Sub ance of spot welds and their improve-
committee on Fatigue of Spot welds of the Weld stresses. This 1400-lb load represents
ing Research Council, New York about 30% of the static tension pulling ment by hydrodynamic or hydro-
Paper to be presented at the AWS 40th Annual load while the 300-lb load for “as- static treatments, is the fundamen-
Meeting to be held in Chicago, Il., April 6-10
1959 received” specimens is the equivalent tal question of residual stresses set

WELDING RESEARCH SUPPLEMENT | 145-s

 ea \

in this particular case to make an

Table 1—Fabrication Data of Stainless-Steel Spot Welds evaluation possible of the residual
~—- —Mechanical properties— — stresses being active in or around a
Tensile Yield Elonga- spot weld subjected to cyclic load-
Chemical strength, strength, tion in 2 Rockwell, ing. The following ones have been
Material analysis, % psi psi in., % C scale made use of:
Stainless steel Type 301, C: 0.12 159, 480 126,940 26 32-35 1 A mechanical hand strain gage
1/, hard, heat no. 69583, Mn: 1.54 (Whittemore type) with a dial grad-
thickness 0.064 in. P; 0.025 uation of one ten thousandth of an
S: 0.014 inch measuring over a gage length
Si: 0.60 of about °/,, in. before and after
Ni: 7.10 stress relief of the weld.
Cr: 17.55
Mo: 0.24 2 Electric strain gages of a !/\-
Cu: 0.15 in. gage length, cemented on and
around the spots, followed by a
Welding Procedures relief of the internal stresses.
Machine settings: 1700lb weld pressure, 5 cycles heat, 2cycles cool, 28% weld phase shift, 3 A Huggenberger extensometer
4 impulses measuring strains around the hole
Diameter of spot weld: °/,. in. resulting from the drilling out of
Results: Tension shear: 4250 Ib spot welds.
Number of specimens: 267
Remarks: All welds were sound and showed no signs of porosity or cracking The above three methods for
measuring residual strains were used
in this particular case and a com-
parison was made on results ob-
tained.
In addition, axial pulling tests,
beam-type torsion tests and nor-
mal pulling of the spot welds along
an axis perpendicular to the sheet
material have been carried out in
relation to micro-strain deforma-
tions.
Description of Mechanical
Whittemore Hand Strain Gage
With a special ° ,,-in. gage punch
which has been fabricated for this
purpose, four marks were provided
on diametrically opposite points
situated outside of each spot. The
distances between four points were
measured with the highest possible
accuracy, that is, within one ten
thousandth of an inch on stainless-
Fig. 1—As-received (left) and hydrodynamically treated specimen (right) showing steel ‘‘as-received”’ specimens. The
drilled-out spot weld and bi-directional punch marks to measure residual strains fabrication data of these specimens
mechanically are reproduced in Table 1. They
are self explanatory and represent
the main characteristics noted dur-
up in the sheets of the welds which ing the welding procedure. Due to
is the subject being dealt with in the very high temperatures reached
i this research work. The reason during the spot-welding process,
‘“‘why”’ these stresses bring about up to the melting point of the metal
such an outstanding improvement to be welded, it is evident that the
(

of the fatigue resistance of spot sheet material being at room tem-

welds, as described in previous perature, the spot is in a plastic
publications (see attached _ bibli- state at that moment and is cooled
ography), is the main objective of down extremely rapidly. This may
this investigation. After serious be compared to a kind of quenching
consideration of previous work and process, the surrounding material
several verifications, a search for the absorbing the heat of the electrodes
‘ residual stresses and the stress dis- in a fraction of a second, at least
tribution in and around spots of for the spot welds of 0.065-in. gage
resistance-welded joints was under- material used for these experiments.
taken. As far as possible, all ad- Furthermore, being under very high
vanced hypotheses were supported temperatures, the volume of the
by fatigue-test results of spot- spot itself is rather small compared
Lo welded specimens put under cyclic to the rest of the sheet material.
loads in steps of one million cycles It is generally accepted that due to
for each load applied and up to a this rapid cooling, residual stresses
Fig. 2—Assumed stresses due to thermal maximum of 10 million cycles. of fairly high values are developed
contraction of the spot material Very few methods can be used which put the spot and the sur-

146-s | APRIL 1959

 Table 2—Measurements of Internal Strains in Spot Weld—‘‘As-Received’’ Condition
Specimen No. 45/11
Direction of Difference, in
measure- Test As Boring out ten thousandth Deformation,
ments No. received of spot of an inch in./in.
Longitudinal
l-la 1 125 130 in tension +5 to +6 0.0016 to0.0019
2 125 130
3 125 130
4 124 130
5 124 131
Average 124 130
Transverse
2-2a 6 142 150 in tension +8 0.0025
7 141 149
8 142 150
9 141 149
10 141 149

Average 141 149

Fig. 3—Full view (top) and close-up
(bottom) of Whittemore strain gage
ured with sufficient accuracy. The and should not exceed about one
rounding materials in radial tension error is not greater than 0.0001 in. pound. Furthermore, it is neces-
stresses in analogy to the skin of a This accuracy reveals itself sufficient sary to keep the instrument sup-
drum. Stresses due to the thermal in this case to detect residual stresses ported by a spiral spring during the
contraction of the spot material in a stainless-steel spot weld. These measurement and, as much as pos-
during cooling can be assumed to residual strains are in most cases sible, vertically to the welded sheet
be directed from the circumferen- of the order of five to twenty ten so that the conical legs of the instru-
tial zones of the spot weld toward thousandth of an inch in welded ment accurately fit in the punch
its central part, as shown schemat- 0.062- to 0.065-in. thick stainless- marks near the spot welds. It was
ically in Fig. 2. This reasoning steel specimens. The distance over also deemed necessary to make pre-
seems logical and these residual which the measured changes oc- liminary series of trial tests on the
stresses could be the main cause for curred on the spot weld before and sheet and different other sheet
the generally accepted low resistance after stress relieving was in most materials to study and become ac-
of spot welds under cyclic loads cases about °/;, in. Furthermore, quainted with the conditions to be
which are only a small fraction of the gage punch used for this pur- fulfilled before obtaining reliable
their axial-shear strength (about pose is adjustable with screws over results. This instrument has the
16°, for aluminum-alloy sheets and a gage length of about '/, in. advantage that it can be put into
less than 10°; for stainless-steel This permits punch marking as place and removed as often as
Type 301 spot welds’). This should near as possible to the circumferen- desirable without any detrimental
be proved by experimentally repro- tial zone of the spot. The distance influence on the readings. This
ducible facts. measured between punch marks is indeed of special interest, if, as in
To prove or reject this working may change in length not only with the case of these tests, the speci-
hypothesis, the first method men- varying sheet-thickness material but men has to be machined and the
tioned above, namely a mechani- also due to the fabrication process spot weld bored out between two
cal hand strain gage, has been used. and the size of the electrodes used. measurements in order to find out
Despite a certain pessimistic ap- So far, to be able to put the conical the influence of internal stresses
proach to this method, having pre- points of the instrument on the released by the machining of the
viously tried out several other similar punch marks with a maximum of spot weld.
methods to detect residual stresses accuracy, i.e. exactly at the same
such as optical observation of sur- locations, these conical marks have Results of Measurements
face marks with a microscope, etc., an angle which is somewhat greater on Specimen in the
it may be said that the mechan- than that of the points of the instru- As-Received Condition
ical strain gage yielded, beyond ment. The fact that this instrument gives
expectation, very reproducible and It is evident that, in order to reliable results can be seen by the
reliable numerical data. obtain comparable results, the spec- measured values of one test series, as
The measuring instrument (a), imen must be handled with the shown in Table 2. Similar test re-
(Fig. 3), is mounted by means of a greatest care. A certain routine sults have been observed in numerous
helicoidal spring (b) and a support has to be acquired before obtaining other experiments. Each time, five
arm (c) fixed on a base plate (d). reproducible and accurate results. measurements have been taken in
It has two gage points (e) and For each measurement, the instru- longitudinal 1—1a direction as well as
(f) with « in. gage length, one ment must be applied vertically on in transverse direction 2—2a of the
of which (f) is fixed while point the spot weld in such a way that the spot weld. Afterwards, the spot
(e) is traveling over a maximum movable point (e) is put into the weld was drilled out in five steps,
distance of about 0.1 in. The dis- punch mark first, while the second starting with a °/,,-in. drill and
tances between the gage points can fixed point (f) is then entered in the finishing the operation with a !/,-
be increased to a length of about one diametrically opposite punch mark in. diam drill. The second drilled
inch. One ten thousandth of an near the spot weld. The pressure hole was of a °/;. in. diam while the
inch, as represented by one division applied by the hand gage to the spot following ones were each '/39 in.
of the calibrated dial, can be meas- weld should be more or less constant greater in diameter than the pre-

WELDING RESEARCH SUPPLEMENT | 14?-s

 146-s | APRIL 1959

residual stresses of hydrodynami- tion for treatment. The process

cally treated spot welds and to find is similar to the hydrostatic treat-
an acceptable explanation for the ment except that the compression
outstanding improvement of the is applied dynamically instead of
+ 30000+ fatigue resistance of spot welds. statically.
Surprisingly, it is now possible to In Tables 3, 4, 5 and 6 are repre-
obtain a value which is about 400% sented some results of measurements
# 20000+ higher compared to spot welds in carried out on specimens treated
: <>
TENSION
psi
the as-received condition. hydrodynamically either through a
#'Q000+ heat-affected-zone compression by
STRAIN injine / Results of Measurements on means of a ring (Table 3), through a
x 0006 0004 oooevk
0 bi i,
0002 0004 0006 Hydrodynamically Treated spot-weld compression by means
- STRAIN Jin Specimen of a tip (Table 4), or through
+10000 The first stage in a hydrody- a ring-and-tip compression (Tables
namic treatment consists in clamping 5 and 6).
pti20000 the sheet material around the spot Table 3 shows, firstly, results of
“Zz weld in a bolted steel jig in order to specimen No. 57/11 dynamically
x + 30000 prevent, as far as possible, lateral compressed by means of a */,-in.
plastic flow of both the sheet mate- outside, */;-in. inside diameter ring
_. 5
COMPRESSION rial and the spot weld. Then, very through a 30-lb weight falling
< high stresses in the neighborhood of freely from a four-foot height on one
Fig. 4—Strain measurements mechan- 200,000 psi are applied dynami- side of the specimen only. Strain
ically detected plotted on the stress- cally on one side of the spot weld measurements have been taken both
strain diagram of the material in the an- through a hole in the jig by way ofa longitudinally and transversally in
nealed condition hardened-steel tip, either alone or the vicinity of the spot weld, before
surrounded by a ring covering the and after stress relieving it by bor-
ceding one. The chips were ob- heat-affected zone. The process ing out the spot weld. The results
tained by a very slow rotation of may involve the compression of the in Table 3 indicate that the speci-
the drill in order not to heat the spot weld alone or the heat-affected men after this treatment showed,
material unduly. After this opera- zone or both. Figure 5 shows the between the punch marks, a short-
tion, the specimen No. 45/11, for drop hammer used in the process ening and, consequently, a com-
instance, was again measured. together with a specimen in posi- pression value of —6 to —7 ten
Table 2 indicates that the results
are very constant as measured in
longitudinal 1—1a as well as in trans- Table 3—Measurements of Internal Strains in Spot Welds—
verse 2-2a direction of the spot Hydrodynamic Treatment by Ring-Compression Only
weld. We can see further from
this Table 2 the important facts Specimens No. 57/11 and 58/11
that, by remeasuring the spot weld, Distances between punch marks, in
the distance between punch marks Dead ten thousandth of an inch
in longitudinal direction has in- weight, Height, Longitudinal Transverse
Ib ft Treatment Test No. l-la 2-2a
creased by +5 to +6 ten thou- No. 57/11 1 146 112
sandths of an inch over a °*/\,-in. gage 2 146 112
length and in transverse direction 30 4 After 3 147 112
by +8 ten thousandths of an inch. compression 4 147 111
The deformation being positive, 5 147 112
the spot weld was then in this case
under fairly high tension stresses Average 147 112
in this as-received condition. This 6 138 107
calculated unit deformation becomes 7 141 106
fourteen to twenty-three ten thou- After boring 8 139 108
sandths of an inch per inch. When out of spot 9 140 107
plotted on the X-axis of the stress- 10 141 108
strain diagram of the same material, Average 140 107
as tested in the annealed condition Difference in compression —6 to —7 (0.0019 to —5 (0.0016 in./in.)
and shown by oacd of Figure 4, 0.0022 in./in.)
this corresponds to internal tension No. 58/11 ll 161 181
stresses of between 32,000 to 35,000 12 160 181
psi. This experimentally measured 20 6 After 13 161 182
tension strain, indicating such high compression 14 161 182
stress values, is the most outstand- 15 162 181
ing fact disclosed so far by this
method. Average 161 181
These results seemed very prom- 16 153 176
ising and gave the necessary stimu- 17 154 175
lus to carry on this work further in After boring 18 153 175
out of spot 19 153 176
order to disclose other equally im- 20 154 174
portant facts about the most diffi-
cult search for residual stresses in Average 154 175
spot welds. From this point on, Difference in compression —7 to —8 (0.0022 to —6 to —7 (0.0019 to
it was only a matter of time to make 0.0025 in./in.) 0.0022 in./in.)
further disclosures concerning the

148-s | APRIL 1959

 WELDING RESEARCH SUPPLEMENT | 14)-s

thousandths of an inch in longi-

Table 4—Measurements of Internal Strains in Spot Welds—Hydrodynamic Treatment
by Tip Compression on Spot Only tudinal direction 1—-la and about —5
ten thousandths of an inch in trans-
Specimen No. 55/11 and 56/11 verse direction. Under higher en-
Dead . Distances between punch marks, in ergy loads through a drop-hammer
weight, Height, ten thousandth of an inch fall on the ring, from a height of6 ft
Ib ft Treatment Test No. Longitudinal l-la Transverse 2-2a instead of 4 ft, the results of speci-
No. 55/11 1 115 103 men 58/11 were as follows: —7 to
2 115 103 —8 ten thousandths of an inch of
30 1 After 3 116 102'/¢ compression in longitudinal direc-
compression 4 116 102'/; tion of —6 to —7 in transverse
5 116 102 direction.
On the other hand, as shown on
Average 116 103 Table 4, specimens 55/11 and 56/11
6 110 98 were treated with tips having sev-
7 109 99 eral concentric rings on their con-
After boring 8 110 100 tact area between the spot weld and
out of spot 9 110 99
10 109 100 the tip. The same 30-lb weight
falling from a height of 1 ft, due to
Average 110 99 the much smaller area involved, only
Difference in compression —5 to —6 (0.0016 to —3 to —5 (0.0009 to resulted in shortening the distance
0.0019 in./in.) 0.0016 in./in.) between the punch marks by —5
No. 56/11 11 83 104 to —6 ten thousandths of an inch
12 83 104 in longitudinal 1—la, and of 3-to-5
30 2 After 13 83 104 units or dial divisions in the trans-
compression 14 83 103'/ verse direction 2-2a for specimen
15 83 103'/. No. 55/11.
Similar results were obtained with
Average 83 104
specimen 56 /11, the tip being dynam-
16 77 98 ically compressed with a 60 ft-lb
17 78 98
After boring 18 77 99 energy, the same weight dropping
out of spot 19 77 98 from a 2-ft height. In longitudinal
20 77 98 1—la direction, —6 units were meas-
ured and the same number of units,
Average 77 98 or dial divisions, were noticed in
Difference in compression —6 (0.0019 —6 (0.0019 in./in.) the transverse 2—2a direction.
in./in.) The results on No. 56/11 speci-
men are in good accordance with
those of No. 55/11 specimen con-
sidering the fact that the former had
been treated with about half the
energy applied to the latter.
Table 5—Measurements of Internal Table 6—Measurements of Internal Furthermore, tests of the same
Strains in Spot Weld, Hydrodynamic Strains in Spot Welds, Hydrodynamic nature, carried out dynamically by
Treatment by Ring-and-Tip Compression Treatment by Ring-and-Tip Compression compressing both the spot weld and
heat-affected zone through a ring
Hydrodynamic compression on ring:- Hydrodynamic compression on ring:- and a tip in succession, showed still
weight:30 Ib; height 7 ft weight: 30 lb; height 7 ft more drastic differences in their
Hydrodynamic compression on spot:- Hydrodynamic compression on _ spot:- behavior before and after boring out
weight:30 Ib; height 4 ft 6 in. weight: 30!b; height 4 ft 6 in.
Specimen No. 72/11 Specimen No. 73/11 the central part of the spot weld in
five different steps. Tables 5 and 6
Distances between Distances between
punch marks, in ten punch marks, in ten represent results of spot welds
thousandth of an inch thousandth of an inch treated hydrodynamically both by
Longi- Trans- Longi- Trans- ring and tip compression under
Test tudinal verse Test tudinal verse fairly high energy loads of 30 lb
Treatment No. l-la 2-2a Treatment No l-la 2-2a falling from a 7-ft height on the
1 290 322 heat-affected zone and 30 lb drop-
1 281 370 ping 4 ft 6 in. on the spot weld.
2 281 370 2 291 322
After 3 281 370 After 3 290 322 They show compression stresses
compression 4 281 370 compression 4 291 322 in longitudinal direction of —13
5 281 370 5 290 322 and in transverse direction of —15
Average 281 370 Average 290 322 ten thousandths of an inch in weld
6 268 355 6 271 302 No. 72/11 as shown on Table 5.
7 268 355 7 271 302 Specimen No. 73/11, as reported on
After boring 8 268 355 After boring 8 271 303 Table 6, also indicates compression
out of spot 9 268 354 out of spot 9 271 302 strains of —20 ten thousandths of
10 267 355 10 270 303 an inch in both longitudinal and
Average 270 302 transverse directions. Each result
Average 268 355 reported is the mean value of five
Difference in —13 (0.0041 —15 (0.0048 Difference in —20 (0.0048 —20 (0.0048 readings of each kind taken in both
compression in./in.) in./in.) compression in./in.) in./in.) directions and recorded before and
after stress relieving. These last

WELDING RESEARCH SUPPLEMENT | 149s

 148-s | APRIL 1959

Fig. 6—Close-up view showing the three '/,,-in. resistance strain gages Nos. 1, 2 and 3,
cemented on spot weld (gage No. 2) and on each side of a longitudinal axis (gages No.
1 and 3) on the heat-affected zone, far enough from the spot to allow for a cross saw cut

Table 7—Strain-Gage Measurements on Specimen After Saw Cut

Between Gages No.1 and 2 (Fig. 6)
Fig. 5—Partial view of the free-falling- Specimen No. 104/11
weight impact machine showing a spot- Specimen No. 87/11 hydrodynamically
welded specimen inserted in compres- as-received treated
sion block, in place for hydrodynamic Strain Micro- Micro- Micro- Micro-
treatment gage No. Location of saw cut inch inch/in. inch inch/in.
compression strains measured on Tension Compression
a °/,-in. gage length correspond to 1 At right of saw cut +480 +0.00768 —750 —0.012
a value approximating 48 ten thou- 2 On spot +420 +0.00672 —1350 —0.022
sandths of an inch per inch. When 3 Away from saw cut at left of spot +280 +0.00448 —1450 —0.023
plotted, as in Fig. 4, this value repre-
sents a stress of about 35,000 psi.
The results are surprisingly stable sible maximum may be only about provement in the fatigue life of
and readings can be repeated a great 500° for this type of specimen and specimen. Only a more favorable
number of times without variations material. However, by considering stress pattern, set up by these com-
of more than one ten thousandth a stress-strain curve of higher values pression treatments, can be con-
ofaninch. The differences between of elastic limit and maximum load, sidered as the main factor involved
the measurements on the last two as shown in Fig. 4 by the line oa’ee’ in this improvement of the fatigue
spot welds which reach 5 to 7 ten representing a less ductile and more limit.
thousandths of an inch might pos- resistant material, the fatigue load The stresses can, from now on,
sibly be partly due to the initial can be expected to reach still-higher be qualitatively and quantitatively
stresses set up in the spot weld while percentages of improvement. measured by the described method
cooling during fabrication (see sec- It has, therefore, been noticed with a simple but precise mechan-
tion on “Description of Mechanical that the hydrodynamic compression ical strain gage. A series of fur-
Whittemore Hand Strain Gage’’). treatment has “‘shortened”’ the spec- ther tests carried out along similar
It is easy to assume that, in order imen after drilling out the spot weld lines, as presented above, may bring
to obtain a maximum in fatigue which was under high compression a still clearer picture of this improve-
resistance, the compression stresses strains up to —20 dial divisions. ment and express the final reason
set up in the spot welds should be Expressed in unit lengths, this means why this unique influence in fatigue
as high as possible. However, the 48 ten thousandths of an inch per life of spot welds is achieved.
stress-strain curve (Fig. 4) flattens inch. According to the diagram of
out very rapidly once an initial Fig. 4, this represents internal Results of Measurements
total deformation of the material stresses of about 35,000 lb/sq in. With Resistance Strain Gages
of only a few thousandths of an (oa’c’d). In order to confirm the results
inch per inch has been reached. In However, the most fundamental of internal strain measured on and
this region, an increase in deforma- and noteworthy difference is that around the spot weld, another test-
tion of a few thousandths of an inch these stresses are now acting in com- ing method was used. Instead of a
per inch brings about only a rather pression and not in tension, as was mechanical Whittemore strain gage,
small increase in the tension stresses the case for the specimen in the as- very small electrical strain gages
in the Y-axis. Consequently, high received condition. This artificial were cemented on the spot weld as
compression stresses set up in the setup of compression stresses by the well as on the sheet material near
spot weld by the hydrodynamic hydrodynamic treatment of the spot the spot weld. The deformations
treatment will bring up the ultimate weld and its environment in the plas- were measured after stresses, act-
fatigue load only by a small propor- tic range accounts for an important ing between the spot weld and the
tion. In other words, it will be part in the extraordinary effective rest of the sheet, had been relieved
rather difficult, having obtained an improvement of spot welds. In by means of a saw cut. As shown
improvement of about 400 to 450% fact, this seems to be a unique case in Fig. 6, three resistance strain
in fatigue resistance of spot welds, where such high internal stresses gages, Nos. 1, 2 and 3, of a '/j,-in.
to increase this percentage to still can be set up artificially, thus pro- gage length were cemented on the
much higher values where the pos- ducing such an outstanding im- specimen; No. 2 on the central

150-s | APRIL 1959

 WELDING RESEARCH SUPPLEMENT | 14-s

part of the spot weld, Nos. 1 and 3 2 a ee ee oe .vw..ve wee ww CT! CS Pe es ee eee eo fh. hh ee
LBs ~ pP-lO Cycles HYDROD YNAMICALLY ; 4HYDRODYNAMICALLY |SAME BUT WITH
on the sheet material on each side 1400} COMPRESSED AS |COMPRESSED ON CIRCULAR GROOVED |
of the spot weld and in longitudinal SHOWN AND AROUND SPOT TP
CONVEX TIP
direction. According to Table 7, 1300}- rr 4
the results of these tests are in good 1200}- 4
agreement with the measurements
and values obtained by the pre- Lele) TT ‘| Bi 6 i)
vious mechanical] method, namely, a 1000; 1} } :
Whittemore strain gage, considering |
that the gage length was, in this 900} 1] ; | :
case, very short when compared to a
800r- | | m
the distance between punch marks | | } |]
in the mechanical method. The 700}- }-ANNEALED SPOT—> |
z2000° 1| H
values of the central strain gage, im FURWACE |
after having separated the spot weld soor- with Torcn [*/? | '
|
from the rest of the sheet by a trans- soor As RECEIVED»,
verse saw cut (d-e Fig. 6), become |
shorter and, so, negative or tension 400 r | | 4
|
stresses set up during the welding wt | 33M al >10M
el | : | t
process of the spot weld were re- | | | } | I |
duced to zero. An average of zoo}|| || | || 1| |HH | :
about +280 to +480 micro-inches 100+ a | | Hy 1|]
due to contraction of the material | ' | | I|
° rf saa =SO ae=ssss
A eeez= ==Se ee ee ee ae ==es J === henhedinnintnh 4
under the strain gage were measured SPECIMEN Zs : s; =: FFF i+ 7 os s=--
Sat F774 ss = &
e* :—s
[= 5
with these three gages. This gives eo. —-22 2 o 4 25gt es , 4 oe pete tyv pr] nat z s
for the gage length basis of '/;, in. Fig. 7--Diagram showing the effects of various methods of spot-weld treatments
a total deformation of 0.0044 in. to compared to specimens in the as-received condition
0.0064 in. per in. If this negative
deformation in compression is re-
ported on the X-axis of the diagram Table 8—Strain-Gage Measurements on Specimen After Saw Cut
according to Fig. 4, an internal Between Gages No. 1 and 2 (Fig. 6)
stress of about 35,000 lb psi is
revealed, which is in fairly good Specimen No. 113/11 Specimen No. 114/11
hydrodynamically hydrodynamically
accordance with the stresses ob- treated treated
tained with the mechanical strain Strain Micro- Micro- Micro- Micro-
gage. On the other hand, hydro- gage No. Location of saw cut inch inch/in inch inch/in.
dynamically treated specimen re- Compression Compression
vealed, after cutting the specimen
1 At right of saw cut —673 —0.011 —166 —0.0027
between the gages No. 1 and 2, 2 On spot —1353 —0.021
micro-deformations directed in op- 3 Away from saw cut at left of spot —1461 —0.023 —1365 —0.022
posite sense compared to the speci-
men as-received. This means that
compression stresses were relieved
which were much greater than the sion setting up compression stresses in the welds of these specimens in
tension stresses in the as-received in and around the spot weld. the as-received condition. It is of
specimen. They were of the order interest to note that a first improve-
Pull-Pull Fatigue Tests to ment of the fatigue limit of these
of 750 to 1450 micro-inches, or
0.012 to 0.023 in. per in. More- Prove the Effect of Thermal spot welds can be brought about
over, they were greater in gage No. Tension Stresses on the by a simple annealing of the spot
3 and smaller in gage No. 1, while Endurance Limit weld at about 2000° F. This can
the sequence in the as-received For this purpose, pull-pull fatigue also be achieved by a slower cooling
specimen, showing tension stresses, ‘‘as-received”’ spot-welded specimens of the spot weld during fabrication
were greater in gage No. 1 near the were tested up to the 10 million or by an appropriate regulation of
saw cut somewhat smaller on the cycles limit in comparison with the welding cycles as well as a
spot weld, gage No. 2, and the specimens in the annealed condition. double-torch heating of the spot
smallest in location of gage No. 3, This could be brought about by weld after welding.
farthest from the saw cut. Other either heating the _ stainless-steel A fairly high scatter of the ulti-
test results obtained on specimen specimens up to about 2000° F mate load at the 10-million-cycle
113/11 and 114/11 are shown in followed by air cooling or treating limit could be observed during these
Table 8. the spot weld from both sides tests series, as the locked-in stresses
Before going on further with the simultaneously with two torches, of these specimens in the as-received
second part of this work, concern- in order to bring the temperature of condition are not of a constant value
ing an explanation of this improve- the spot only to bright-red heat and may vary in wide limits with
ment by internal stresses which is which, in this case, could be done in different settings of the welding
unparallelled in any other field of a matter of seconds. In fact, as machine.
fatigue failure, it was decided to represented on left side of Fig. 7,
support by experimental endurance it can be noticed that the annealed Fatigue-Test Results of
tests, first, the existence of thermal specimens had at 1 million cycles a Hydrodynamically Treated
tension stresses set up in the spot fatigue limit of 50 to 80% higher Specimen
weld due to rapidly cooling condi- than that of specimens in the as-
tions of fabrication and, second, the welded condition. This proves that In order to check if these internal
effect of hydrodynamic compres- harmful tension stresses are present compression stresses as produced by

WELDING RESEARCH SUPPLEMENT | 151-s

 150-s | APRIL 1959

ryVirvinn Fr euner * il Bd bd | -e eC PVeUTORD © OY Yee Pane 1400 lb was reached in one case
+ —— -~ +— resulting from a compression with a
| circular grooved tip. Further fa-
STAINLESS STEEL COMPRESSION
17-7 Ye HARD ON THE SPOT tigue results of tests carried out
11400 THICKNESS : 065" _| under somewhat different loading
‘ “ZONE 5 conditions are shown in Fig. 7.
he 3) RO 7'-27" In Fig. 8 are represented a great
1200 1or$ URS —troncompuec _comneseron FH BBE= number of fatigue-test results in
of + AROUND THE SPOT ONLY. relation to the total number of
a R 2 ng 20 OF 9 cycles for fracture of the spot weld
~ ‘aie 23 or|9
3on9 ZONE 4 occurring in most cases between
a} 009 2ior7
a 100,000 and up to 10 million cycles.
° HYDROSTATIC COMPRESSION These tests have been carried out in
- LEGEND
AROUND THE SPOT ONLY the normal way, i.e., the specimen
|800 4 — 4 —tentil "a was loaded in the neighborhood of
ROUND HEAD: R Y |
FLAT HEAD F ial ZONE 3 the fatigue limit and cycled up to rup-
HYDROSTATIC COMPR.: S ture or up to 10 million cycles with-
HYOROOYM. COMPRESSION :0 t-—~ ANNEALED) SPOT 2000°F
| 600 specimen BROKEN, S| —_—______-+ out developing any fatigue crack.
SPECIMEN NOT BROKEN: eo FURNACE (COOLED
25 24 ZONE2 It can be seen that, according to the
mechanical treatment of the spot
400 » nee
SPECIMEN
aon |AS RECEIVED
sentipaiainh welds, the endurance limit has been
T
increased from a load of about 300
} 4 ZONE | Ib (zone No. 1) of the material in
| a2 a | ?
200 Let fae neei
pet f a e eeeerseeee the as-received condition to about
10 4 10° 6
10 CYCLES 10
7
1400 lb for mechanically treated
Fig. 8—S-N curves showing the relative merits of various spot-weld treatment methods specimens. In zone No. 1 alone, 16
specimens have been submitted to
repeated loadings, 6 of which have
reached the 10-million-cycles limit.
residual Altogether, about 18 million load
stress cycles had to be applied to get the
p.s.i
results as presented in this zone.
40000 The scatter of the test results may
be related partly to the amount of
internal stresses set up during fabri-
cation of the spot weld.
30000; A second group of experimental-
test results is shown in zone No. 2,
representing the results of annealed
and stress-relieved specimens. By
20000 + this thermal treatment alone, the
fatigue limit of these spot welds can
be increased by about 50 to 100°.
10000 Furthermore, by a_ hydrostatic-
| compression treatment of the stain-
less-steel specimens in the as-re-
ceived condition and from one side
Precompression stress only, a still higher fatigue limit can
° 50000 100000 +——» P.$.!
150000 200000 25000 be reached as shown in zone No. 3.
Fig. 3—Residual stresses in relation to various precompression stresses on According to the compression treat-
Alclad 24-ST, */,-in. diam spot welds ment chosen, as for instance the
compression ring acting around the
spot weld, and depending on the tips
the hydrodynamic improving proc- represented on the right-hand side used, the fatigue limit was at 100,000
ess are in some way related with of Fig. 7 for specimens treated cycles of the order of 1200 lb and at
the fatigue resistance of these welds, dynamically by a ring compression 10 million cycles about 700 to 800
several series of pull-pull cyclic tests around the spot weld only, as well lb.
were carried out with treated and as on the spot weld with a cylindri- If this treatment is carried out
untreated specimens. For this pur- cal tip. A maximum repeated load dynamically instead of statically,
pose, the Krouse twin pulsator was of about 1200 Ib has been reached as seen in zone No. 4, the 10-million-
used. in this way, as can be seen by speci- cycle fatigue limit is about 1000 lb.
These fatigue tests were carried men Nos. 36/11 to 39/11 reported Another group of specimens
out in the following manner. The on the middle of Fig. 7, while, on treated dynamically with a flat and
specimens were loaded at about ?/; the right-hand side, results of about rounded tip on the spot weld, also
of their ultimate fatigue resistance 18 other specimens are shown which from one side only, reached, at a load
and cycled under pull-pull loading were dynamically treated in various of 1200 lb, the 10-million-cycle limit
one million times. The load was ways. Worthy of notice is a hy- without cracking, which is_ indi-
then increased by about 100 Ib and drodynamic compression treatment cated in this diagram by a horizon-
again one million cycles were run on and around the spot weld with a tal arrow.
on the specimen and so on until a convex tip which brought the fa- Still higher fatigue loads were
fracture of the specimen occurred tigue limit under the same test con- reached after having treated the
under a maximum load. This is ditions up to about 1300 lb, while specimens dynamically first with the

152-s | APRIL 1959

 WELDING RESEARCH SUPPLEMENT | 151-s

outside ring, compressing the mate-

rial plastically towards the center of
the spot weld, followed by a com-
pression on the spot weld with a tip 2200
having a flat or a rounded head
pushing the material from the cen-
tral part towards the outside ring, _ 2000 2000 LBS
thus setting up a very high amount
of internal stresses in and around
the spot. In this way, and accord- I 1800
ing to the energy load delivered by
a 30-lb hammer falling on the ring
and tip with flat and convex heads i 1600 "79-1
wo ‘HYDRODYN. COMPR.
from a height of up to 7 ft for the ring Pea] RUPTURE : 4050LBS.
and 4'/, ft maximum for the tip, ad
fatigue loads of 1500 lb at one million -—-i400
cycles and 1400 lb at 10 million oO a 78-li
cycles have been recorded (zone No. < HYDRODYN. COMPR
5). I 1200 be RUPTURE : 4240 LBS.
This last figure represents an AS RECEIVED
increase of about 450% in regards ‘ 66-1! "
to the fatigue resistance of the as- 1000
RUPTURE: 3950 /LB
received specimen. It is not ex- -
cluded that, by a still better arrange-
ment of the internal stress pattern, H- 800
an increase of the fatigue limit at
10 million cycles up to 500% can « ‘2
be reached in the near future. i 600 “
From these test results, it can be
seen very clearly by which means the
improvement of 400 to 450% of | 400 .
the fatigue resistance at 10 million
cycles can be achieved, a fact which ¥
is unparallelled in any other field of 20
fatigue failure. The reason “why” /
this achievement has been brought Ley 4 7 ‘Te »| |
about has been given a satisfactory DEFORMATION 9.001 in/in
answer by showing that, in Type 301 Fig. 10—Results of axial static pull tests on as-received and hydrodynam-
stainless-steel specimen, internal ically treated specimens
stresses of the order of 30,000 to
35,000 psi are set up in the welds
by the described mechanical treat-
ment acting in tension gnd also in
compression in and around the
spot weld, thus counteracting the
stresses set up by the application
4
of external loads. The governing —_—o2>—
factor in this type of fatigue-resist-
ance improvement seems to be the - 1600 }
more advantageous arrangement of
internal <-tresses in the spot weld - 1400 *959-11 AS RECEIVED +
as well as in its immediate environ- RUPTURE 2274!>%
ment. “—# 88-11
Z HYDRODYN. COMPRESSED
Test Results Obtained with RUPTURE: 20/18 ibs
Huggenberger Extensometer =
During a previous investigation’ LBS
on this subject carried out with
spot-welded aluminum-alloy speci-
mens Alclad 24-ST, 0.064 in. thick- LOAD
ness, it has been found that by using
a Huggenberger extensometer meas-
uring with satisfactory precision
of 0.00005 in. per in., interesting
changes in the gage length of about 1
in. could be observed by boring out
the spot weld while the instrument
remains fixed on the specimen. DEFORMATION: 722 '*-in
Those are very delicate experiments, howd 1 Lt j 1
since the extensometer has very Fig. 11—Results of static tension pulling in a normal direction to the plane
often the tendency to displace its of the specimen (see Fig. 12) on as-received and hydrodynamically treated
knife on the specimen due to uncon- specimens

WELDING RESEARCH SUPPLEMENT | 153-s

trollable vibrations of the cutting earlier test results, the fatigue limit However, by recording tension-
tool. These tests have to be re- of aluminum alloys can be, simi- shear diagrams with the sensitive
peated a great number of times be- larly to Type 301 stainless steel, Templin extensometer over a re-
fore reliable and reproducible re- increased by about 300% by an duced section of the specimen, as
sults can be secured. In Fig. 9 adequate hydrodynamic compres- represented schematically in Fig.
are shown the calculated stresses in sion process. 10, some indication can be obtained
function of the micro-deformations concerning the higher fatigue limit
measured in the axis of the spot Other Test Methods of hydrodynamically compressed
after application of various hydro- It is generally known that, up to specimen. As may be seen in this
dynamic compression loads in five now, no practical test method has Fig. 10, the proportional limit of
steps of about 50,000 Ib psi each. evolved which might reveal the dynamically compressed specimen
There again can be seen that rather fundamental difference in behavior is about 50% higher than that of
small compression loads set up under repeated loads of hydro- untreated samples, namely 1200 to
fairly high residual stresses. On the dynamically treated and untreated 1300 lb as compared to 1800 and
other hand, much larger deforma- spot welds. The usual tension- 2000 Ib. Neither the ultimate load
tions are less effective so that from shear test does not reveal any nor the modulus show, however,
100,000 lb precompression stresses, marked difference between test dia- any serious difference. Rupture
an additional 50,000 psi on the X- grams of treated and untreated occurred in all cases by shearing of
axis increases the residual stresses specimen which might indicate such the spot weld in treated as well as in
on the Y-axis only from about an important improvement in fa- untreated specimen.
25,000 to 29,000 psi. As proved by tigue life. Load-deformation diagrams re-

Fig. 13—View showing the cavities and cones resulting from a static pull
test to rupture in a normal direction to the plane of the specimen (see Fig.
12) for an untreated (top) and a hydrodynamically treated (bottom) spot-
welded specimens

TORSION TESTS
AS RECEIVED HYDRODYNAMICALLY
Fig. 12—Testing installation (top) and SPECIMEN COMPRESSED SPECIMEN
close-up view of a spot-welded specimen
in testing position (bottom) for a static
pull test in a normal direction to the plane
of the specimen
LOADS
Les

FIGURES AT END OF
CURVES REFER TO
RUPTURE LOADS (LBS)

0.001 in /in
DEFORMATION ==
Fig. 14—View showing the installation for Fig. 15—Results of torsion tests as shown in Fig. 14 on as-received and hydrodynamically
a torsion test on a spot-welded specimen treated specimens

154-s | APRIL 1959

corded on specimens tested in a increase somewhat faster than for low loads (at 50 lb, about 0.0015
perpendicular direction to the plane those of the untreated ones. At in. per in.), while, for all other spec-
of the spot weld, as shown in Fig. 12, higher loads, both diagrams are imens, far less than 0.001 in. per
brought only a slight distinction substantially parallel. The com- in. deformation was shown (Fig.
between treated and untreated spec- pressed specimen had an ultimate 15). This early deformation may
imens. load of 2018 lb while the as-received be in some relation to the locked-in
The deformation in 0.001 in. per specimen broke at a maximum load thermal stresses of the specimens in
in. in relation to the applied load up of 2274 lb. the as-received condition. In all
to 1600 lb as recorded with the Figure 13 shows a photograph of cases, early plastic deformations
Templin extensometer (Fig. 11) both specimens after rupture. The under higher loads were recorded
showed a slight difference between formation of a small crater (a) with ultimate loads of 474 lb to 682
untreated (No. 89-11) and dynami- in one leg and a cone (b) with a flat lb. Most of the specimens were not
cally compressed (No. 88-11) speci- surface in the other leg can be ob- broken by shearing after a total
men. Due to the locked-in stresses served. No remarkable difference deformation corresponding to an
of the compressed specimen, from between both types of specimens for angle bend of 15 to 18 deg.
the beginning up to about 600 Ib, rupture deformation of the spot weld On the other hand, the dynami-
it appears that the deformations could be found. cally compressed specimens showed,
In the same order of ideas, com- in general, higher maximum loads
parison tests of specimens under (700 to 744 lb). Two specimens
rt BASE METAL torsion loads were conducted as (91-11 and 106-11) indicated a
NUGGET shown in Fig. 14. The first perma- rather stiff behavior under loads up
nent deformation of treated and un- to 400 lb, while two others showed a
treated spot welds was recorded, similar stiffness; however, only after
which revealed some differences be- having fairly pronounced deforma-
tween the two kinds of specimens, tion under very low loads, which
particularly in the elastic and semi- may be also an indication of the
plastic range of these diagrams. hydrodynamic setup of locked-in
“HEAT-AFFECTED ZONE The as-received specimens showed stresses at the circumferential zones
Fig. 16a—Schematic presentation of a in one case only (No. 105-11) a of the spot weld supporting the
typical spot-weld failure in fatigue pronounced deformation under very highest local stresses.

Fig. 16b—Macrostructure of longitudinal cut of

tested spot weld at x 12 magnification (below)
and X 30 (center and right). Details: Around
the spot weld only—12-ft drop—30-lb weight—
specimen No. 72/10—fatigue testing: 1400-Ib
load—rupture at 225,600 cycles. (Reduced by
2/; upon reproduction)

Fig. 17—Macrostructure of longitudinal cut of

tested spot weld at X 12 magnification (below)
and X 30 (center and right). Details: On and
around the spot weld: on spot 4 ft 6 in.—around
spot 7 ft height—30 Ib weight—concave tip,
rounded ring—specimen No. 20/11—fatigue test-
ing: 1 million cycles at 1200 Ib rupture after 1.5
million at 1300 Ib. (Reduced by upon
reproduction)

WELDING RESEARCH SUPPLEMENT | 155-s

Development of Fatigue At both ends of the weld, a number the permanent deformation after
Cracks and Strain Detection of fatigue cracks a, b, c, directed the stresses have been removed,
under an angle of about 45 deg cut are in good agreement. The high-
in the Region of Failure
the nugget in small parts. They est values have been obtained al-
Another phase of the improve- are visible on the outside surface of ways with strain gage No. 3 placed
ment of spot-weld resistance has the spot weld only after a great nearest the spot weld, thus indicat-
been studied in parallel with the number of cycles and after increas- ing highest bending and tension
present investigation. For this pur- ing fatigue loads. It is of interest stresses in the zone of the fatigue
pose, the origin of the fatigue crack to note that several of these cracks crack initiation. The hydrodynam-
in spot welds was thoroughly an- start right in the corner of the nug- ically treated specimen (Fig. 20
alyzed by metallographical methods get between the two welded sheets showed the highest total deforma-
and it was found that the failure of and follow at the beginning the con- tion of about 2500 microinches per
Type 301 stainless-steel specimen tour of the nugget, change direction in. near the spot weld (gage No. 3
due to pull-pull loading does not, and break through the sheet nearer which is, for all practical purposes,
in most cases, occur in the spot weld to the center of the spot at a later totally elastic. The two others,
itself. As shown in Fig. 16a, the phase of the fatigue test. Nos. 1 and 2, showed also purely
crack a-b starts generally in the However, in order to explore elastic deformations which are in
sheet material at the interface about somewhat closer the zone a where some proportion to the distance of
'/s5 to '/ 9, in. outside of the weld and the crack starts, comparison tests their location from the spot weld.
at the circumference of the heat- with hydrodynamically treated and On ‘the contrary, for specimens
affected zone, one crack developing as-received specimens were carried tested in the as-received condition,
in opposite direction to the other out as follows: the deformation values under ten-
one, both being perpendicular to the Three '/\-in. gage length strain sion loads were distinctly smaller.
plane of the sheet. They spread gages, Nos. 1, 2 and 3, were glued At the load of 1400 lb strain, gage
simultaneously around the spot on the interface at this zone, i.e., No. 3 showed a total plastic defor-
weld in three directions, i.e., on one in the axis of the sheet as near as mation of about 1800 microinches
both sides of the axis x-y and in possible to the spot weld, i.e., less per in. while the treated specimen
perpendicular direction to the plane than '/;, in. (No. 3, Fig. 19), and showed a much greater elasticity
of the sheet until it becomes visible two others at a distance of about ' /i with practically no permanent de-
on the outside surface, first in the in. from each other (Nos. 2 and 1). formation (i.e., 2500 microinches
central part and further spreading About twelve of these tests were per in. total and 50 microinches per
with increasing number of cycles on carried out. For some of these in. permanent deformation). In
both sides of the x-y axis. In tests, the covering flap was cut off both cases the results of all three
general, it can be said that there is near the circumference of the spot gages were very consistent and
no exact load or number of cycles weld, while for other tests the flap showed, according to their location,
limit to indicate when one or the was slightly bent up and down again, deformations due mainly to bend-
other of these two types of cracks in the form of a flat “‘S,”’ so as to ing and tension stresses, in some
starts as it cannot be observed create a small interstice of about proportion of the most active gage
directly, being hidden away by the 1/, in. between these two sheets, No. 3 nearest to the spot weld.
covering sheet of the second leg of thereby introducing strain gage No. Gage No. 2 showed, in both in-
the weld. 3 securely near the circumference stances, intermediate values _be-
In Figs. 16 and 17 are shown char- of the spot weld, followed succes- tween gage No. 3 and No. 1.
acteristic cracks of this kind as sively by gages No. 2 and No. 1.
they have been observed in Type One of these specimens (Fig. 19) Outlook and Future Tests
301 stainless steel under a magni- was in the as-received condition,
fication of x 12 and x 30. Details while the other one was hydrody- Future work with the described
regarding treatment and fatigue namically treated (Fig. 20). new test methods will make it pos-
test conditions are also given in For both specimens, the total sible to obtain a clearer picture of
these figures. A still more typical deformation under tension loads what is going on in hydrodynami-
crack development from both sides at 1400 lb, which corresponds to the cally treated spot welds. The amaz-
of the spot weld is shown in Fig. 18. maximum fatigue load, as well as ing and up-to-now unexplainable

Fig. 18—Macrostructure of longitudinal cut of

tested spot weld at X 12 magnification (below)
and X 30 (center and right). Details: around
the spot weld only—/-ft drop—30 Ib weight—
specimen No. 31/1l—fatigue testing: in 100
Ib loads from 700 to 1200 Ib, inclusive, with
rupture at 600,000 cycles. (Reduced by 2/; upon
reproduction)

156-s | APRIL 1959

 T U T T i cre cee oe 2 ye
}
SPEC. No. Il-ll / SPECIMEN
AS RECEIVED / No. 33-1
y,

A No.2
8 1400/4
7 PERMANENT p Tt
DEFORMATIONS Cut off her
OMPRESSION VALUE '}er-No.! /No. 3
jorv
1200+
r=:
Mi—Nos. 2¢3 /
Lf DEFORMATION ra
P=4
LOAD
LBS ,
No.! TOTAL DEFORMATION
: 000+ +;| | PERMANENT
DEFORMATIONS (TENSION VALUES) —
Faas No. 3 4
| ||(TENSION VALUES) f
800} + |
| \
STRAIN GAGES +_s 23
T
Fiap cut off here S<

'

3 GAGES A-I9

fe) 1 1 1 L L i 4 1 1 1 1
o 200 1000 DEFORMATION
P infin —€ 2600 1000 DEFORMATION 2000 2800
iN/ in
Fig. 19—Strain measurements detected by '/,.-in. gage length Fig. 20—Corresponding results to Fig. 19 on hydrodynamically
SR-4 gages cemented on the interface of as-received spot- treated specimens
welded specimens

improvement of the fatigue resist- ultimate load, does not give the method used up to now should also
ance of treated spot welds becomes same high percentage of improve- be investigated.
readily understandable if internal ment than other ductile materials. °
stresses are recognized as principal Structural materials such as tita- General Considerations
factors involved. Due to external nium alloys and Inconel-X which By three different testing methods,
compression loads applied on and could likely give valuable results adapted to the detection of inter-
around the spot weld, a most ad- should be explored. Very little nal stresses in treated and untreated
vantageous arrangement of nega- is known in this respect, for instance, spot welds, it has been shown that
tively directed internal stresses in of various carbon steels, nickel steels the improvement of the fatigue
the spot itself and in its immediate and alloys, or other structural resistance of hydrodynamically
environment can be set up. materials used in the aircraft indus- treated welds is directly connected
It is evident that the described try. with the setting up of internal
tests represent only a first step in The influence of annealing the stresses in the spot and its environ-
this direction, and much more work specimen before the hydrodynamic ment. By external loads applied
still has to be carried out before the treatment in order to eliminate on the compression tools, the fatigue
complete mechanism, as well as the detrimental internal stresses also limit under pull-pull loading goes up
distribution of these internal stresses, deserves to be investigated. With drastically, resulting in an improve-
is fully known. Furthermore, it regard to the maximum of residual ment of 400 to 450% over untreated
remains to be ascertained that struc- stresses set up around the spot weld, samples. This is due to a more
tural materials, other than Type 301 it would be of interest to use an advantageous arrangement of inter-
stainless steel and aluminum alloy exterior concentric retaining ring nal stresses directed, first, inwardly
24-ST, also react favorably upon clamped on the specimen during the in the area between the compres-
hydrodynamic compression treat- hydrodynamic treatment. sion ring and the spot weld and,
ment. In order that this treat- Not having found, as yet, the secondly, outwardly from the com-
ment may be effective in a wide ultimately possible improvement of pression tip toward the external-
measure, it would seem that mate- the fatigue limit of stainless steel, it ring zone.
rial with high ductility and plastic is further desirable to determine the These facts have been checked by
properties should prevailingly be influence of sheet thickness, the a large number of time-consuming
used. It is already known that best possible compression tools, pull-pull fatigue tests with a 10-
more-or-less brittle material will as well as the optimum load to be million-cycle limit. As previously
not give any interesting improve- applied in order to obtain, by com- discussed, a high fatigue life is
ment of this kind. For instance, bination of these factors, the best closely related to the setting up of
mild steel, due to its pronounced possible results. Whether or not internal stresses which should act
yield limit which interrupts the this improvement can be brought as far as possible in opposite direc-
stress-strain curve by a horizontal about by some other treatment tion to the externally applied load.
portion about half-way from its which may be simpler than the It is evident that, under these con-

WELDING RESEARCH SUPPLEMENT

| 157-8
 introduced compression _ stresses
should be as low as possible. The
external load can surpass 3 to 4
times the load between O’ and the
Y fatigue limit of untreated welds
zFatigue Limit having high internal tension stresses.
4 It is an interaction of a most advan-
in Tension
Tension+ tageous arrangement of internal
' stresses set up in the weld through
9) rs hy the applied external loads which
! brings about this unbelievably high
improvement of the fatigue limit in
|
hydrodynamically treated spot welds.
) Acknowledgment
| The samples in this investigation
| have been spot welded by Sciaky
Compression /- Brothers and the sheet material
has been supplied by the Interna-
tional Nickel Co. to whom the au-
thors express their best thanks.
Bibliography
i — py 1. Forrest, G., “Some Experiments on the
Effects of Residual Stresses on the Fatigue of
Aluminum Alloys,” J. Inst. Metals, 72, 1-17
(1946).
2. Welter, Georges, “Fatigue Tests of Spot-
welds: Improvement of their Endurance Limit
by Hydrostatic Pressure,” THe WeLpinc Jour-
Fig. 21—Schematic interpretation of the improvement of the fatigue limit NAL, 27 (6), Research Suppl., 285-s to 298-s
due to the hydrodynamic treatment (1948)
3. Welter, Georges, ‘Fatigue Tests of Spot
welded Steel Sheets,” /bid., 28 (9), Research
Suppl., 414-s to 438-s (1949).
4. Welter, Georges, “Stresses Around a Spot
ditions, a major part of the applied by a rapid cooling of the weld dur- weld Under Static and Cyclic Loads,’ [bid., 29
(11) Research Suppl., 565-s to 576-s (1950).
external load is absorbed by the ing fabrication, the origin O of the 5. Welter, Georges and Choquet, Andre,
internal stresses acting in opposite diagram is shifted to O’ so that the “Stress Distribution and Fatigue Resistance of
or negative direction. This can applied external and repeated pull- Alclad 24ST Multiple Spotwelds,” Jdid., 33 (2
Research Suppl., 91-s to 98-s (1954)
roughly be illustrated by Fig. 21, pull load acting between O’ and the 6. Welter, Georges and Choquet, Andre,
showing schematically the pull-pull fatigue limit brings about the crack “Fatigue Tests of Spotwelds in Cor-Ten and Mild
Steel,” Ibid., 33 (3), Research Suppl., 134-s to
fatigue limit in the stress-strain di- in the weld at a fairly low load. In 140-8 (1954).
agram x-o-y. It is understandable a similar way, if instead of tension 7. Welter, Georges, Krivobok, V. N., and
stresses, compression stresses are Choquet, Andre, “Effects of Prestressing on
that if internal tension stresses of a Fatigue Strength of Spotwelded Stainless Steels,’
certain amount already exist in the set up by hydrodynamic treatment Ibid., 33 (10), Research Suppl., 509-s to 523-s
spot weld, as represented by the acting in the opposite direction, (1954).
8. Welter, Georges, “‘Fatigue of Spotwelds,”
line o-a, only a small overload of a then the origin of the diagram is Ibid., 34 (3), Research Suppl., (1955)
few hundred pounds is necessary lowered from O to O” in the com- 9. Welter, Georges, “Study of Improvement
of Fatigue Resistance of Spotwelds by Hydro
to bring about a fatigue crack in pression sector of the stress-strain static Treatment,’’ Dated Sept. 25, 1956, unpub
the spot weld a represented by diagram. The external load to be lished Progress Report.
applied to produce a fatigue crack 10. “Improving the Fatigue Life of Spot
the new stress-strain diagram hav- welds,” THE WELDING JOURNAL, 37 (7), Research
ing its origin in O’. Due to in- will now be starting from O” through Suppl., 315-s (1958)
ternal tension stresses in the weld, O and O’ up to the fatigue limit. 11. Hartman, E. C., “Mechanical Tests of
Spotwelds,”” Jbid., 37 (11), Research Suppl
for instance, thermal stresses set up The negative load in O” due to the (1958).

An Experimental Investigation of Open-Web Beams

by A. A. Toprac and B. R. Cooke - 16 pages - Price $1.00.

WRC BULLETIN NO. 47.

This report presents the results of an investigation of nine open-web expanded
beams fabricated from an 8B10 rolled shape. The beams tested to destruction
had depths varying from 1.33 to 1.78 of the original 8B10 shape.
Copies may be purchased from the American Welding Society, 33 West 39th
Street, New York 18, N.Y.

158-s | APRIL 1959

Effect of Residual Stress on Brittle Fracture

Japanese authors report the results of their studies

on the brittle fracture of welded structures at low stress level

BY HIROSHI KIHARA AND KOICHI MASUBUCHI

ABSTRACT. The authors made an ex- is as high as the yield stress, even in normal state. Because of the ex-
perimental investigation of the effect the specimens containing very sharp istence of the notch, the nominal
of residual welding stress on brittle cracks. Therefore, it is a very im- fracture stress will be decreased;
fracture. For this purpose, the speci- portant problem in this field of study however, the fracture stress in this
mens having sharp transverse notch in
the region of high-tensile residual to investigate the mechanism of case is still considerably high, and
stress were pulled by testing machine how brittle fracture occurs at such the fracture occurs after the yielding
under various temperatures. Through a low stress level in welded struc- of the material.! Even when the
the experiment it was found that re- tures. sharpness of the notch is extremely
sidual welding stress having no effect on It is also very important to clarify severe, the stress necessary to initi-
the ductile fracture of welded structure the effect of residual stress on the ate a brittle fracture from a pre-
may play an essential role in the case of strength of welded structure, as high existing sharp notch is very high.
brittle fracture. The complete frac- residual stress is produced due to For instance, Felbeck and Orowan?
ture of a welded joint may be produced welding. The effect of residual once investigated the fracture stress
by merely applying low stress in a
static manner when such unfavorable stress is almost negligible in the case from a sharp notch made by hammer-
conditions as the use of materials of of ductile fracture; however, residual ing the specimen cooled by liquid
low notch toughness, existence of sharp stress may play an essential role in nitrogen. Even in this case the stress
notch and high-tensile residual stress the case of brittle fracture. High- required to initiate a brittle fracture
are accumulated. The above-men- tensile residual stress originating in was higher than the values at which
tioned fracture at low stress level is one the region near the weld may act as the actual damage occurred. An
of the realization of brittle fracture a trigger to initiate a brittle fracture experimental investigation was car-
which occurred in the actual damages. if sharp notches such as weld flaws ried out by Martin and his collab-
The effect of preloading at high are present, and may cause the com- orators’ on the performance of
temperature on the behavior of a joint weld-joint flaws as reinitiation points
was also investigated and it was found plete fracture of a structure even
that the preloading produces favorable when the value of the external stress of brittle fracture, as the fractures
effect on the fracture strength at low is not high. have initiated at various types of
temperature. The possibility of this sort of weld-joint flaws in the actual fail-
In addition, the authors’ personal fracture was ascertained through an ures. Their experiment was con-
opinions on the application of stress- experiment recently performed in ducted on a large spherical pressure
relieving heat treatment and _ non- England. Wells successfully real- vessel with notches artificially made
destructive testing for the prevention ized a complete fracture of a welded by welding, and it was found that
of brittle fracture are also presented. joint having a sharp notch under the limiting length of crack which
Introduction considerably low stress. However, initiated fractures at nominal stress
in Wells’s paper, the occurrence of below the yield stress of the test
It is a particular nature of brittle
fracture at low stress level was lim- plate is 4 in. However, brittle
fracture that the actual damage us-
ited to only one case, and its repro- fractures have initiated from smaller
ually occurs at a considerably low
ducibility must be checked carefully. flaws at low stress level in actual
stress. The evidence obtained from
At the same time the mechanism of failures. Hence, as previously men-
actual failures in ships and other
this phenomenon needs to be inves- tioned, there must be other reasons
welded structures has_ indicated
tigated. for the initiation of a brittle frac-
that, in numerous cases, these tail-
The authors are now making a ture from small flaws at a low stress.
ures occur at the stress far below the
series of investigations concerning On the other hand, a brittle crack
yield stress of the material, i.e., 7 to
this problem, and some results ob- may propagate under a consider-
10 kg/mm?*. On the other hand, it
tained thus far are treated in this ably low stress if it once begins to
has been noticed that the nominal
report. extend. In order to maintain the
fracture stress of anotched specimen
propagation of brittle crack the
HIROSHI KIHARA is a Professor, Department Stress Necessary to following two conditions must be
of Naval Architecture, Tokyo University, Bun- Initiate and Propagate
kyoku Tokyo, Japan; KOICHI MASUBUCHL is satisfied:
Chief, Design and Method of Fabrication Section, Brittle Fracture—A Brief 1. The value of stress must be
Welding Division at Transportation Technical Review of Recent Studies higher than a certain value—critical
Research Institute, Tokyo, Japan, and is a Visit-
ing Research Fellow at Battelle Memorial Insti- The presence of a sharp notch is stress.
tute, Columbus, Ohio. indispensable in order to produce a 2. Temperature should be below
Paper to be presented at the AWS 40th Annual brittle fracture in a material such a certain value—arresting tempera-
Meeting to be held in Chicago, Ill, Apr. 6-10,
1959 as a steel which is ductile enough in ture.

WELDING RESEARCH SUPPLEMENT | 159-s

 A - TEST SPECIMEN
B- NOTCH DETAILS

DEPOSITED METAL
NOTCH
ye
Po eawes ¥Tteaecaseaseas
<— SUBMERGED
ARC WELD
reer
rrr
SECC
irreROLL DIRECTION
1*-
T 1000

PIDPYY
>>>»)
>>>
>>>>>>?>>>>
ee
>>>» C - SHAPE OF NOTCH AND JOINT PREPARATION
Sa
Fig. 1—Typical residual-stress
distrisution in butt-welded plate

A-—A’ SECTION
In this connection, studies made
by Robertson‘ are well known. Feely Fig. 2(a}—Specimen used in first series of tests.
and his collaborators’ also made a (All dimensions in mm)
wide experiment, using so-called
ESSO (SOD) test. In Japan, the
double tension test was originated
A - TEST SPECIMEN
by Yoshiki and Kanazawa,’ who
are also making a theoretical analy-
sis of the mechanism of crack prop- H og B -JOINT PREPARATION
agation.
As mentioned above, brittle frac- NOTCH F
ata
ture may propagate under low stress 6
4 ha(4040 44 144604444)“ 640 EREO
level after it has once initiated; ”
however, stress as high as yield stress 4 SUBMERGED
ARC WELD
must be applied in order to initiate
a brittle fracture. Consequently, ROLL DIRECTION 28
fracture occurs after yielding in a Ree os
tensile test of an ordinary notched -—— 1000
specimen. In the test of crack-
propagation characteristics of steel,
therefore, some special treatments C -NOTCH DETAILS ( PLAN)
such as impact (in Robertson and
SOD test) or high-tensile stress BASE vy /WELD METAL ~. BASE
applied at the auxiliary part of a METAL eA ABOUT 25)< METAL
+
specimen (in a double tension test)
are also applied in order to initiate
a brittle crack under a low stress
level in the test part.
Now, a question arises concerning
the kind of mechanism in which the
brittle fracture was initiated and
propagated at a low stress level in
the actual failures. The additional Fig. 2(b)—Specimen used in second series of tests.
shock or high stress previously men- (All dimensions in mm)
tioned cannot always be accom-
panied by actual failure. Residual
stress caused by welding may be
one of the main factors which in- the highly stressed zone, a brittle of catastrophic failure of welded
duced the initiation of brittle frac- crack may be initiated from this structure which has occurred at a
ture at a low stress level. notch even when the value of applied low stress level.
In an ordinary welded joint, high- stress is not too high. In this case, The possibility of the occurrence
tensile residual stress is usually pro- the crack may be arrested after run- of this sort of fracture was first as-
duced in the region near the weld. ning a certain length when the level certained by Wells’ who success-
The value of stress in the direction of applied stress is not very high; fully obtained a complete fracture
of welding usually is as high as the however, the brittle crack may prop- of welded joint under a considerably
yield stress of the base metal (Fig. 1), agate through the whole width of low stress by using a welded joint
and this high stress may act as a the plate when the value of applied having pre-existing sharp notches.
trigger to initiate a brittle fracture stress at crack initiation is higher When the test temperature was
at low applied stress. than the critical stress necessary to low enough, brittle crack was initia-
If there exists a sharp notch, such maintain the propagation of a brittle ted at a low applied stress, but it was
as a weld crack or lack of fusion, in crack. This may be a typical mode arrested after running a certain dis-

160-s | APRIL 1959

 w oO
CRACK INITIATION STRESS
WITHOUT RESIDUAL STRESS
CRACK INITIATION STRESS TENSILE e. RESIDUAL STRE
WITHOUT RESIDUAL STRESS KO/nm? | YIELD i Sa”
nN uw
we ital Oo 7 Meashilslnate
a
woo, fe) y /“BRIT TLE! DUCTILE
Oo /
TENSILE “| —|—>
YIELD v *BRITTLE | DUCTILE ~ Oo » f
o
/
| Dosis LOWER LIMIT
| LOWER LIMIT STRESS + OF ARRESTING TEMP.
4 OF ARRESTING TEMP a
AA e( ar
a
+
APPLIED
STRESS APPLIED &+
ESTIMATED VALUE OF ——---~~®
CRITICAL STRESS @ ESTIMATED VALUE OF
CRITICAL STRESS
* : e
| TIPPER TRANS. TEMP a"
-— j ng TIPPER TRANS.
i
/ TEMPERATURE
AiB 4 il = l Pi2 i j
OL | oa |ome |
-80 -60 -40 20 40 60 -8C -60 -40 -20 0 2 40 60
° TEMPERATURE ‘
TEMPERATURE C
(a) Materials A& B (b) Material C
--@--O- -stress at partial fracture (@) and complete
fracture of specimen without crack after welding (
--A--A-- stress at partial fracture (a) and complete
fracture of specimen which contains spontaneous crack
after welding (A)
Asingle-stage fracture (including multiple-stage
fracture prior to general yielding)
0 fracture in ductile manner
Data connected by broken lines in Fig. 3(b)
belong to the preliminary experiment
CRACK INITIATION STRESS Fig. 3—Fracture strength of welded plate
WITHOUT RESIDUAL STRESS

tance as the value of stress was not

ee
/BRITTLE DUCTILE too high. Reinitiation of the crack
/ from that once arrested did not oc-
/ cur until the applied stress reached a
ESTIMATED LOWER LIMIT value as high as the yield stress of
OF ARRESTING TEMP. the base metal. When the temper-
» ature was high enough, crack initia-
tion under low stress did not occur
and the specimen failed after yield-
ing. On the other hand, the speci-
APPLIED
STRESS men tested at 4° C failed completely
and suddenly at the stress of 9.4
® tons/sq in. (approx. 15 kg/mm’).
ESTIMATED VALUE OF Wells emphasized the complete frac-
CRITICAL STRESS ture of the specimen tested at 4° C,
__, @ aot and concluded that there is a dan-
TIPPER TRANS. gerous temperature range somewhat
EMPERATURE below the transition temperature
1 4 j 1 J
-20 O 20 40 60 it was called “‘calamity temperature”’
TEMPERATURE C by Wells. He also explained that,
in that temperature range, fracture
(c) Material D occurs at a low stress level; how-

WELDING RESEARCH SUPPLEMENT | 16l-s

ever, fracture stress was consider- First series tests on wide-plate to welding, as it was rather difficult
ably high in a temperature outside specimens (1000 mm wide). to make a sharp notch in the middle
this range, either higher or lower. * Second series tests on wide- part of a large plate. This type of
The results obtained by Wells are plate specimens (1000 mm notch is shown in Fig. 2(a). Weld-
of a significant nature in observing wide). ing was performed by the sub-
the brittle fracture of a welded joint In the first series of tests, the em- merged-arc method, with the follow-
at a low stress level by merely apply- phasis was placed on surveying the ing factors prevailing:
ing a static load, thereby success- occurrence of complete fracture at Welding flux: Granulated com-
fully realizing a typical form of low stress level. The very same position, Grade 20, 12 x D,
actual failure in the laboratory procedures as those used in Wells’ Welding wire: High-grade low-
test. However, the occurrence of experiment were used. carbon steel, '/, in. diam,
complete fracture at low stress level In the second series, however, the Conditions of welding: 750 amp,
is limited to only one case, and the type of notch was changed to pre- 33 v, 12 ipm, same condition in
reproducibility of results needs to vent the dynamic effect caused by both sides.
be checked in further studies. More- breaking the welded bead at a por-
over, the conclusion that a fracture In order to embrittle the deposited
tion of the notch which might act as metal at the location of the notch, a
at low stress level occurs in a limited a dynamic trigger to initiate brittle
temperature range just below the mixture of carbon powder and so-
fracture. dium silicate was inserted in the
transition temperature seems to be In these experiments, the speci-
doubtful as the general principle first-step notch prior to welding.
mens were pulled by a testing ma- The conditions of welding were so
governing the brittle fracture of a chine under various temperatures
welded joint made in steel. The selected that the weld penetrated
ranging between —70 and 50° C. just to the root of the first-step
authors of this paper have made an The majority of the specimens were
experimental investigation to sur- notch.
tested in the as-welded condition. In the second series of tests, the
vey the above mentioned points. In the second series of tests, studies type of notch was changed, with the
of the effect of mechanical stress- notch being cut by machining after
Method of Testing relieving treatment were also made. the completion of welding as shown
General Description and For this purpose, stress cycles to in Fig. 2(b). The length of the
Conditions of Testing certain values were adopted at 20 notch was designed to be longer than
C; afterward, the specimens were the width of the weld bead but short
The experimental work was carried
out on butt joints about 25 mm tested at low temperature (about enough to be laid in the region of
thick, having a short transverse —30° C). The preloading was ap- high-tensile residual stress. The
notch at the middle part of the joint. plied after the sharp notch had been conditions of welding for the speci-
These specimens were pulled in a machined. * mens in the second series of tests
tensile-testing machine under vari- were as follows:
ous temperatures. Specimens
For backing pass: 800 amp, 36 v,
The testing program was con- The specimen used in each series 11 ipm.
ducted in the following steps: of tests is shown in Figs. 2(a) and For finishing pass: 1100 amp, 36
2(b). v, 13 ipm.
1. Preliminary tests on smaller- Two types of notches were used.
scale specimens (400 mm In the preliminary tests and in the
wide). first series of tests, the notches were Material
* Regarding the experimental results of Wells made on the edge of the bevel prior Mild-steel plates of low notch
a discussion worth noticing was given by Benson.* toughness were chosen for the test.
In this discussion, characteristic natureof steel * Testing of specimens in which a sharp notch is Four types (A, B, C and D) were
concerning initiation and propagation of brittle machined after the application of preloading is
crack is taken into consideration also under way. used in the experiment. Two of

Table 1—Properties of Materials Tested

Chemical composition
Character of steel making
Steel Roll finish
designa- Chemical composition, % (check analysis) temperature, Ferrite Austenite
tion ; Si Mn P S Kind of steel “Cc grain size grain size
A" 2 Trace 0.49 0.022 0.022 Rimmed 1120 6~6.5 1
B 28 Trace 0.50 0.023 0.034 Rimmed 1140 6 ~ 6.5 5
Cc 0.04 0.42 0.016 0.020 Semikilled 1030 6.5 5
D .16 0.10 0.45 0.035 0.021 Semikilled oe 7
Mechanical properties and notch toughness
Notch toughness
V-Charpy test Tipper test
15 ft-Ib Shear Shear
Mechanical properties - Energy transition transition transition
Steel Yield strength, Ultimate Elongation, % absorbed at temperature, temperature, temperature,
designation kg/mm? strength, kg/mm? (GL = 50 mm) 0° C, kg-m/cm? “> *¢c *“¢
22.4 46.2 33 1.0 22 50 39
23.9 46.3 36 1.1 24 55 46
23.5 41.1 34 1.5 8 32 15
24.4 43.9 32 3.4 3 33 38

* Steels A and B are made from the same charge.

162-s | APRIL 1959

 Table 2—Summary of Test Results
Length Mean stress,
of kg/mm?
partial Temperature, C Com
Spec. Value of Length of frac- Com- Partial plete
Test Material code preloading, crack after ture, Partial plete frac- frac- Mode of
condition designation No. kg/mm? welding, mm mm Set fract. fract. ture ture fracture, etc.‘
As- Material A AB2° Tested in er 81 42.4 39.8 38.0 2 >31.2° Shear fracture
welded and B A] as-welded \155/ 15.1 \15.2/
conditions si / 258 \ ; 415.3) w
B8 ee .-. —6.0 aps!
B12 net 372 —16.6 —15.0
Bll bia ... —24.2
B9 a sce «waa? Pa
B14 ee 303 —45.6 —42.7
A3 \181/
13121 33.3 31.8‘ H
A4 198 12.1 12.7 ,7 e
H
A6 .-. —23.1 H
A2 ee —25.2 H
Al ... —53.1 S
B13 ... —61. 1 CO
oO=>O™NM
&Pp
©DM H
ABl 367 ~—71. 2 Fracture at low
stress level in
multiple stage
Material C na aa . oe 26.7 _— .3° Shear fracture
—7.5 —6.2 2 M
See! —20.( i 2c S
—23.4 —21.8 2 ==
—38.0 —36.5
—45
3 «6 =%”=E
Material C
(preliminary
experi-
ment) ede
119
110 YATANAMOOT
Material D Notch is made ( 98 red 26 2
after welding J)138 46 og 6
— po Shear fracture
700 46
85 24.5
Joris Jon's
pe ‘ 24.5
691 24.5

NOW
Mechanical Material D
stress
relieving

TANMNW
=A

Spec. AB2 Partial crack of 81 mm long occurred in brittle manner at 525.0 ton load, and after then the specimen
ner Fracture stress in the table (>31.2) was calculated from max load considering that the length of crack is 81 mm fractured in a completely ductile man-
he actual! value of fracture stress
may be much higher than the value listed, because the length of crack gradually increased in shear fracture
*In case of preliminary test, the temperature measurement was conducted only at the beginning of loading.
© Mode of fracture: S, single-stage fracture at low stress level: M. multiple-stage fracture; H, fracture at high stress level
‘Spec. C6 Specimen fractured in a completely ductile manner. The value of fracture stress in the table is cal ulated from max load
* Tensile test was stopped before complete fracture, as the fourth stage partial fracture occurred in ductile manner Iherefore, the value of stress at com
plete fracture is higher than 37.0 kg/mm
‘ Mechanical stress relieving was conducted at a temperature of 20 + 2°¢
9 Fracture occurred prior to the general yielding of the specimen
h Specimen indicated the general yielding at the preloading 23.0 kg/mm? stress level.

WELDING RESEARCH SUPPLEMENT

| 163s
these four plates, Types A and B, by welding. Also most of the elas- low stress in statical manner. More-
were plates rolled at different times tic strain energy caused by the re- over, it was found that the single-
but made from the same heat; these sidual stress may be released by the stage fracture at low stress level
plates were treated as steel having occurrence of spontaneous cracking, occurred in a wide range of tem-
the same properties. Type C was extending to about 140 mm. perature, quite different from the
mainly used in the preliminary tests. results obtained by Wells.
The properties of these steel plates Stress at Fracture in The remarkable difference in test
are listed in Table 1. As-Welded Condition results was observed between the
specimens with and without a spon-
Testing Machine and Other Equipment Main results obtained in the test taneous crack. The presence of a
Three different types of testing program, such as the temperature spontaneous crack did not produce
machines were used in the experi- of the specimen and the stress at any serious effect on the behavior of
mental program: which fracture occurred, are listed the welded plate under tensile load
in Table 2. Relations between so long as the temperature was high
Preliminary tests: Simplified test
rig of 200-ton capacity. testing temperature and fracture enough to produce a ductile fracture.
First series of tests: 1500-ton stress are shown in Fig. 3. The re- However, the existence of a spon-
testing machine, located at sults obtained in preliminary test on taneous crack produced an essential
Kure Steel Structure Labora- Type-C plate are plotted in Fig. change in the test results when the
tory of Railway Technical Re- 3(b). Type of fracture changed in temperature was low and brittle
search Institute. accordance with the change in test- fracture occurred.
Second series of tests: Test rig of ing temperature and stress at frac- All three types of fracture men-
1200-ton capacity newly con- ture. A discussion of this follows. tioned previously appeared in the
structed by Japan Shipbuilding When the temperature is high specimens having no spontaneous
Research Assn. enough to cause a ductile fracture, crack, while the fracture at high
the stress at fracture is much higher stress level only appeared in the
In brittle fracture, elastic strain than the yield stress (near breaking specimens having spontaneous crack
energy stored in the specimen plays strength) of the base metal. Below after welding. This appears to be
an essential role in the propagation a certain temperature, fracture oc- caused by the release of residual
of brittle cracks, as the speed of curs in a brittle manner and, in this stress, due to the spontaneous crack
crack propagation is extremely high. case, three different types of frac- reducing the welded joint to merely
Consequently, test specimens were ture are prevalent: an ordinary notched specimen free
welded to chuck-plates large enough 1. Single-stage fracture at low from residual stress. However,
to store sufficient strain energy in stress level: an instantaneous frac- when the temperature was ex-
the test plate. ture, through the whole width of the tremely low, brittle fracture at low
Specimens were cooled by means specimen, at a stress level below the stress level appeared even in the
of a mixed solution of carbon dioxide yield stress. A fracture of this specimen with a spontaneous crack.
and methanol contained in flat type occurs when the stress at crack As shown in Fig. 3, a variation in
boxes attached to both faces of initiation is higher than a certain the type of notch does not cause
the specimen. A methanol solution critical value determined by the any difference in test results. This
cooled by carbon dioxide was also property of the material. fact indicates that the dynamic force
poured over the specimen, when the 2. Multiple-stage fracture: par- which might be caused by breaking
test temperature was below —40° tial fracture of plate starts from the the welded metal in the preliminary
C. Infrared ray lamps were used pre-existing sharp notch, at a very tests and in the first series of tests
when it was necessary to heat the low stress level, extending to a cer- has no substantial effect on the test
specimens. ‘Temperature of speci- tain length; the reinitiation of the results, and the results obtained in
mens was measured by Fe-Constan- brittle crack from that once ar- this study may be considered to in-
tan thermocouples (0.3 mm diam). rested occurs after the yielding of the dicate the effect of residual stress
plate. In this case, the stress at on brittle fracture.
Test Results crack initiation is very low (3 to 6
kg/mm‘), but the stress at the com- Effect of Preloading at High
Spontaneous Crack after Welding plete fracture of the plate is con- Temperature on Test Results
In some specimens, cracking oc- siderably high. Loading at high temperature may
curred spontaneously after welding, 3. Fracture at high stress level: have remarkable effects on the be-
inasmuch as some procedure to fracture occurs at a high stress after havior of the test plate as the dis-
embrittle the material, such as the the yielding of the test plate. More tribution of residual stress may be
use of a base metal of low notch precisely: changed by the preloading. The
toughness or the embrittlement of (a) Fracture occurs in a single results obtained in the test program
the deposited metal by inserting a stage after the yielding of the ma- conducted for this purpose are shown
carbon-powder mixture in the terial. in Table 2 and Fig. 4. As shown in
notches, was adopted. The cracks (6) Fracture occurs in multiple Fig. 4, preloading produced a defi-
seemed to occur sometime after the stages. However, in this case, the nite effect on the test results, and
completion of welding, but no ac- stress at partial fracture is quite high it can be concluded that the speci-
curate information indicating the and its length is very short com- men loaded to a certain value at
time of cracking was obtained. The pared with the multiple-stage frac- high temperature cannot be failed
cracks extended almost perpendicu- ture. at a stress lower than the preloaded
lar to the direction of welding, start- As stated previously, the primary value. This result shows the bene-
ing from the root of the notch pre- purpose of this research was to ficial effect of mechanical stress-re-
viously made. The length of these achieve the brittle fracture of welded lieving treatment.
cracks was about 140 mm. plate at a low stress level in the
Above-mentioned facts show that laboratory test. The results indicate Fracture Appearance
the main cause of cracking is the that welded structures may possibly In all specimens, the" fracture ex-
high-tensile residual stress produced be failed completely by applying a tended in a direction almost perpen-

164-s | APRIL 1959

 dicular to the axis of loading, start- crack was arrested in the case of the gram can be explained, without any
ing from the notch or crack due to spontaneous crack after welding as contradiction, by the conclusions
welding; however, various types of well as in the case of the partial attained.
fracture appearance were obtained crack after the application of exter- If the specimen does not contain
by a change in testing temperature nal force. No visible sign of local a sharp notch, the fracture will oc-
and stress at fracture. plastic flow was observed at the cur at the ultimate strength of the
In a specimen failed in a ductile root of the pre-existing notch when material at the temperature con-
manner at a high temperature, the the fracture occurred at a low stress cerned as shown by Curve PQR in
fracture surface is inclined to the level. In both the case of second- Fig. 5.
plate surface at an angle of about 45 ary fracture in multiple-stage frac- The existence of a sharp crack
deg, and remarkable reductions in ture and in the case of fracture at causes a sudden decrease in the frac-
thickness and breadth are produced. high stress level, a reduction in ture stress at the fracture transition
In a specimen tested below the tran- thickness at the root of the notch or temperature. The schematic rep-
sition temperature and failed in once-arrested crack was observed; resentation of the crack initiation
brittle manner, the fracture surface at the same time, a system of Lu- stress or fracture stress regarding the
is almost perpendicular to the plate ders’ lines running in a direction in- notched specimen free from residual
surface, without any sign of thick- clined at 45 deg to the axis of load- stress are estimated as indicated by
ness reduction. In this case, a ing was clearly observed upon the Curve PQST in Fig. 5. When the
shear lip of some amount appeared surface of the specimen, indicating temperature is higher than T,, a
at the plate edge when the testing the occurrence of general yielding shear-type fracture occurs at a very
temperature was not much below prior to the fracture. high stress level, as high as the ulti-
the room temperature; however, mate strength of the material.
an almost-perfect brittle appear- When the temperature is below T,,,
Discussion
ance was obtained in the low tem- the fracture appearance changes to
perature region below O° C. General a cleavage type and the stress at
Type of fracture appearance was fracture decreases to the value near
also remarkably affected by the As stated previously, it was found the yield stress. In this case, the
stress state. The fracture surface that the testing temperature and value of fracture stress will increase
was very smooth and the so-called the presence of a spontaneous crack slightly in accordance with the de-
chevron pattern cannot be noticed after welding had remarkable effects crease in temperature.
clearly in the fracture at low stress on the value of stress at fracture. Next, the relation between the
level. On the other hand, a rough Although there remain some points temperature and the value of stress
fracture surface with a clear chevron to be investigated in the future, the necessary to maintain the propaga-
pattern was obtained in the fracture opinions formulated thus far are tion of a brittle crack may be shown
at high stress. Local plastic flow discussed below. The results ob- by Curve UVWinFig.5. A brittle
was observed in the part where the tained in this experimental pro- crack can propagate at a consider-

40 ~

FRACTURE STRESS WITHOUT SHARP NOTCH

ULTIMATE
¥ STRENGTH

FRACTURE STRESS WITH SHARP NOTCH

BUT FREE FROM RESIDUAL STRESS

\
} CLEAVAGE | SHEAR
—_— | —>
,
TIELO STRESS

== wr
APPLIED
STRESS i
PROP, | ARREST
PRE—-LOADING ee
|
UPPER LIMITOF WORKING STRESS
STRESS
APPLIED = PARTI 4
{
{COMPLETE FRACTURE)|
LEVEL
OF L PARTE!
Aes
wee
sa
oS
OS

! = a4 iA
“60 -60 -40 -20 0
TEMPERATURE °C TEMPERATURE
Fig. 4—Effect of preloading on fracture strength Fig. 5—Schematic figure on fracture strength of welded plate
and effect of residual stress on it

WELDING RESEARCH SUPPLEMENT | 165-8

 ably low stress when the tempera- effect of residual stress is eliminated necessity in obtaining a complete
ture is below T,,.* by the redistribution of stress en- solution to the problem of the effect
The strength of a welded joint countered at the arresting of the of residual stress on brittle fracture.
having a sharp notch is considered partial crack. The authors are now conducting
next. When the temperature is When the value of applied stress such a study, and some partial re-
higher than T',, the value of stress at is higher than that shown by Curve sults have been given in previous
which the fracture occurs is very UVW in Fig. 5, the crack once reports.’
high, and the existence of residual initiated may propagate endlessly
stress induces little effect on the test through the whole width of the Crack Initiation and Propagation
results, as the distribution of stress joint, thus originating a single-stage Characteristics of Test Plate
at such a high level is far different fracture at a low stress level.
from that of initial state, and the dis- As mentioned before, two different The test program covered in this
tribution of residual stress has a cases may occur in accordance with report may be considered a kind of
negligible effect on the stress dis- the relation between the value of realization of actual damage of
tribution at that stage. applied stress and critical stress of brittle fracture in a laboratory test.
When the temperature is between brittle fracture. In one case, the Therefore, it is also possible to ob-
T,and T,, a partial crack may occur final fracture stress is not affected tain some knowledge of crack initia-
at a low stress level in the specimen by the existence of residual stress; tion and propagation characteris-
having residual stress, as the value of however, in the other case, the frac- tics of the material from the results
stress near the pre-existing notch ture stress is decreased considerably obtained in the experimental pro-
where high-tensile residual stress is by residual stress. gram on the welded joint.
originated reaches the level of frac- It was noted, also, that there was The curve of stress necessary to
ture stress, even when the value of a tendency for the length of a partial initiate brittle fracture can easily
the externally applied stress is not crack to increase in accordance with be obtained either from the value of
very high. However, the crack an increase in the value of stress at fracture stress observed in the speci-
started from the notch will be ar- the crack initiation. mens having spontaneous crack or
rested after running a short distance When the testing temperature from the value of stress at which
as the stress necessary to maintain was extremely low, fracture at low secondary fracture initiates from the
the propagation of a brittle crack is stress level was observed together once-arrested partial crack.
sufficiently high. When the propa- with fracture at high stress level in Regarding the crack-propagation
gation of crack is once arrested, the specimen which had a sponta- characteristics of the material, the
redistribution of stress may take neous crack after welding and which value of stress at the boundary be-
place and the effect of residual stress was expected to be free from residual tween single-stage fracture and par-
is eliminated. Therefore, the load- stress. The occurrence of fracture tial fracture may be regarded as
carrying capacity at complete frac- at low stress level in this case may the critical stress of crack propaga-
ture of welded joint is not affected be explained as follows, although tion. The upper limit of tempera-
by the existence of residual stress. some points remain to be investi- ture range in which single-stage frac-
Namely, existence of residual stress gated in further studies. ture occurs may be considered as the
may cause a partial fracture of This phenomenon may possibly arresting temperature of a brittle
welded structure at low stress level, be called a kind of “ductility tran- crack.
but the load-carrying capacity of sition’”” in which brittle fracture Some estimates of the above-
the structure is not affected by re- may be initiated without any visible mentioned values are also made in
sidual stress. sign of local plastic flow, and it may this study, as shown in Fig. 3, but
When the temperature is below occur at extremely low tempera- the number of specimens is not
T.,, on the other hand, the existence ture. In this case, the energy neces- sufficient to make an accurate esti-
of residual stress may have an es- sary to initiate the brittle fracture mation.
sential effect on the strength of seems to be very low, and only such The critical values of stress neces-
welded structure. In the specimen small disturbances as a very small sary to initiate and to propagate
free from residual stress, the frac- amount of strain energy remaining brittle fracture seem to be estimated
ture occurs when the external stress after the occurrence of spontaneous fairly accurately. The critical value
reaches the value indicated by crack may be sufficient to trigger a of stress necessary to initiate a
Curve PQST. However, in the brittle fracture at a low stress level. brittle crack is as high as the yield
case of a specimen having residual On the other hand, fracture will stress of the material; on the other
stress, the initiation of a crack may occur at a high stress level when hand, the critical stress for crack
be encountered at a low stress level. there are no such disturbances. propagation is extremely low.
In this connection, two different It is a definite problem to predict With regard to the values of
cases will determine whether the the detailed behavior of the phenom- transition temperature, 7, and T’,,
level of externally applied stress is ena observed in the test program only a simple estimate was made,
higher or lower than the value of without performing an experimental since the number of specimens was
stress necessary to maintain the investigation. Crack initiation and limited. As for the values of ar-
propagation of a brittle crack. When propagation characteristics of steel, resting temperature, the lower limit
the value of applied stress is lower distribution of residual stress and is shown in Fig. 3. The approxi-
than that indicated by Curve UVW, its change under application of ex- mate values of T', are also shown in
the crack will be arrested after run- ternal force are the main factors the same figure.
ning a certain distance, and the com- governing the phenomena covered Moreover, it is necessary to com-
plete fracture of the specimen re- in this study, and the natures of pare these values to those obtained
sults after the applied stress reaches these properties can be obtained in- in other tests. For instance, the
the value shown by Curve ST’, as the dividually through proper experi- value of T, obtained through this
ments. Theoretically, experimen- program may have some correlation
* Although the relative state of temperature tal results can be deduced from the with those obtained by Robertson,
Ty and Tg is not well understood, these values are available knowledge regarding the by ESSO and by double tension
estimated as shown in the figure assuming that 7’,
is higher than T'y. above factors; this is an utmost tests. On the other hand, the

166-s | APRIL 1959

 values of T', obtained in this experi- the level of externally applied stress the welding industry to ‘determine
ment showed good agreement with is higher or lower than the value of whether a stress-relieving heat treat-
the value of the transition tempera- stress necessary to maintain the ment and nondestructive testing
ture obtained by the Tipper test, as propagation of brittle crack: should be applied during the fabrica-
shown in Fig. 3, so far as the results (a) When the value of applied tion of welded structures. The
achieved in this experiment are con- stress is lower than the critical stress, most important purpose of using a
cerned. A further investigation is the crack initiated at low stress will stress-relieving heat treatment is, in
needed of these points. be arrested after running a certain general, the prevention of brittle
Effect of Preloading at High distance, and a high stress equiva- fracture, although such a treat-
Temperature on Fracture Strength lent to yielding is required to produce ment may also be adopted for other
reinitiation of brittle fracture from purposes such as:
It was found that preloading to a the crack once arrested. In this
certain stress level, at a temperature 1. Softening of heat-affected zone.
case, the presence of residual stress 2. Prevention of stress corrosion.
high enough not to produce fracture did not produce any substantial ef-
at that stress, increases the value of 3. Improvement of fatigue
fect on the value of stress at com- strength.
fracture stress at low temperature. plete fracture.
The fracture does not occur at the 4. Prevention of deformation
(6) Conversely, if the value of which might occur during
stress lower than the value of the applied stress is higher than the
preloaded one. This result shows service.
critical stress, the brittle crack once
the beneficial effect of mechanical initiated may propagate endlessly Although many points remain to
stress-relieving treatment, and is and the complete fracture of joint be investigated in further studies,
very useful in actual application. in a single stage may occur at a the outline of the phenomenon re-
low stress level. In other words, a re- garding the effect of residual stress
Conclusions on brittle fracture may well be said
The following conclusions may markable decrease in strength may
be brought about by the existence of to have been clarified by the re-
be drawn concerning the results ob- search described herein. The per-
tained in this test program: residual stress.
As mentioned above, it has been sonal opinions of the authors con-
1. In a temperature range high cerning the selection of material,
enough to produce ductile fracture, ascertained through this test pro-
gram that the complete fracture of a application of stress-relieving heat
the value of stress at fracture is very treatment and nondestructive test-
high and the existence of residual welded joint may be produced by
merely applying a low stress in a ing for the prevention of brittle
stress has an almost negligible effect fracture are also presented in this
on the test result. static manner, when such unfavor-
able conditions as the use of mate- report.
2. When the temperature is be- Referring to the results obtained
low the fracture transition tempera- rials of low notch toughness, exist-
in this test program, the behavior of
ture, but above the arresting tem- ence of sharp notch and high-tensile
residual stress are accumulated. a welded structure with and without
perature of brittle crack propaga- residual stress and sharp notch un-
tion, the existence of residual stress In addition, it was found that
preloading at high temperature pro- der service temperature is summa-
has no effect on the fracture stress of rized in Table 3. The contents of
the joint at the final stage, although duces a beneficial effect on the frac-
ture strength of a welded joint hav- this table are self explanatory. As
a partial fracture starting from a shown clearly in the table, a welded
sharp notch in the region of high- ing a sharp notch at low tempera-
ture, as the distribution of residual structure may be caused to fail com-
tensile residual stress may occur at a pletely by applying only a static load
low stress level. stress is changed due to preloading.
The fracture does not occur at the of low magnitude, ifall of the follow-
3. Residual stress may have an ing unfavorable conditions are super-
essential effect on the fracture stress lower than the value of the
preloaded one. imposed:
strength when the testing tempera-
ture is below the arresting tempera- 1. Use of material of low notch
Recommendations for the toughness.
ture of the material. Brittle crack
may be initiated at low stress level Prevention of Brittle Fracture 2. Low temperature.
if the joint has a sharp notch in the 3. Existence of sharp notches.
Recommendations on the Application
region of high-tensile residual stress of Stress-Relieving Heat Treatment 4. High residual stress.
and, in this connection, the two fol- and Nondestructive Testing Based on the considerations men-
lowing cases will be true whether It is a very important problem in tioned here, the authors would like

Table 3—Behavior of a Welded Structure, With and Without Residual Stress and Sharp Notch, under Service Temperature
Existence of residual
Existence of notch stress (application
(application of of stress-relieved Condition of Condition of Fracture stress and occurrence of fracture Mode of
nondest. test) heat treatment) temperature stress in service state fracture
Eliminated \ Exist /
/ Stress relieved\ Any temp. Curve PQR in Fracture does not Shear
Fig. 5 occur in service state
Exist Stress relieved PQ Shear
ST Cleavage
Exist PQ Shear
Part Ill in Fig. 5 Partial fracture Cleavage
Part Il Cieavage
Part | Complete fracture Cleavage
(brittle fracture)
® T;, Expected lowest limit of service temperature. 7’ Fracture transition temperature of the material Ta, Arresting temperature of the material. cr,
Critical stress of crack propagation ow, Expected upper limit of working stress.

WELDING RESEARCH SUPPLEMENT | 167-5

 to present a recommendation on the when these factors are expected to 2. Impact stress: The perform-
application of nondestructive testing take place in service. ance of impact stress as a trigger
and stress-relieving heat treatment to initiate brittle fracture is well
Comments on the Determination of understood through such experi-
for the prevention of brittle fracture Transition Temperature as Criteria
as follows: for the Prevention of Brittle ments as the Robertson test or the
1. Both nondestructive testing Fracture in Welded Structure ESSO test.
and a stress-relieving heat treatment The personal opinions of the 3. Repeated stress and aging:
may be omitted for the purpose of authors regarding the determination When the length of crack produced
preventing brittle fracture, when of transition temperature as criteria by repeated stress reaches a certain
the expected lowest limit of service for the prevention of brittle fracture critical value, it might start to
temperature (7', in Table 3) is above in a welded structure are also stated propagate under a considerably low
the values of transition temperature in the following, although there are stress. Embrittlement of the ma-
of the steels from which the struc- many points to be investigated fur- terial due to aging may also cause
ture is constructed. ther by authorities in the fields con- the initiation of brittle crack under
However, the above omission does cerned. low applied stress.
not apply to the case where the If the occurrence of partial crack The authors consider that the ex-
stress relieving is required by some is admissible, the arresting tempera- perimental verification of the phe-
other reason such as stated at the ture of brittle crack, T,, which is nomena mentioned above needs to
beginning of this section. expected to be somewhat lower than be performed in further studies at
2. When the expected lowest the fracture transition tempera- the earliest opportunity.
limit of service temperature is below ture, may be adopted.
the transition temperature of the However, the transition tem- Acknowledgment
material from which the structure is perature for fracture appearance, The authors wish to thank the
constructed, it is desirable to apply T,, should be adopted if the occur- following people for their assistances
both nondestructive testing, thereby rence of partial crack cannot be per- throughout the investigation:
assuring the complete elimination mitted. T. Yoshida, W. Matsunaga and
of defects which may act as stress 1. Transition temperature for H. Oba of the Shipbuilding De-
raisers, and the stress-relieving heat fracture appearance, 7',: Theoret- partment, Kawasaki Dock Yard
treatment. If the application of ically a test on wide-plate notched Co.; S. Ichikawa, Y. Ogura and K.
these two treatments is prohibited specimens, such as adopted in the lida of the Welding Division, Trans-
by some reasons, it is necessary to authors’ experiments, is most suit- portation Technical Research In-
apply the following procedures, de- able to determine the value of T',, al- stitute.
pending on the circumstances: though such a test is not available The staffs of the Railway Techni-
(a) If the complete elimination for commercial applications. The cal Research Institute of Japan Na-
of defects by the application of non- values obtained by fracture appear- tional Railway, Kure Shipyard of
destructive testing is not expected, ance conducted on specimens having National Bulk Carriers, Inc., and
apply a stress-relieving heat treat- relatively large sectional area, such Ishii Steel Works, also gave their
ment. as used in the Tipper test or in the kind assistance.
Van der Veen test, may have good The experiment was conducted
(6) If the stress-relieving heat under the sponsorship of the Japan
treatment is not applicable, per- correlations with those obtained
from wide-plate test. Shipbuilding Research Assn., and
form a thorough application of non- the authors are grateful to Dr. T.
destructive testing, ensuring the 2. For the arresting temperature
of crack propagation, T,, and the Izubuchi, Managing Director, for
complete elimination of defects his kind treatments.
which may act as stress raisers. value of critical stress <c.,, the fol-
However, it must be noted that the lowing tests are available: Robert-
complete elimination of stress rais- son test,‘ ESSO test,’ and double- References
tension test." 1. Wells, A. A., “The Mechanism of Notch
ers in the actual structure is ex- Brittle Fracture,” Welding Research, 7 (No. 2
tremely difficult. Possibility of Experiencing Brittle 34r to 56r (April 1953).
Fracture at Low Stress Level in an 2. Felbeck, D. K., and Orowan, E., “Experi
(c) If neither the nondestruc- ments on Brittle Fracture of Steel Plates,”’ THE
tive test nor the stress-relieving heat Actual Failure WeLpING JoURNAL, 34 (11), Research Suppl
treatment is applicable, select the The authors ascertained that the 570-8 to 575-8 (1955).
3. Martin, D. C., Ryan, R. S., and Rieppel,
value of expected upper limit of complete fracture of a welded struc- P. J., “Evaluation of Weld-Joint Flaws as Reini
working stress lower than the critical ture may occur if a sharp notch is tiating Points of Brittle Fracture,’ /bid., 36 (5)
Research Suppl., 244-s to 251-s (1957)
stress of crack propagation of the located in the region of high-tensile 4. Robertson, T. S., “Propagation of Brittle
material concerned. However, it residual stress. There is also a Fracture in Steel,” Jnl. Iron & Steel Inst
361 to 374 (December 1953).
must be noticed that there is a pos- possibility of suffering brittle frac- 5. Feely, F. J., Jr.. Northup, M. S.. Kleppe,
sibility of suffering partial fracture in ture if the following factors are S. R., and Gensamer, M.., “Studies on the Brittle
service. Consequently, this proce- Fracture of Tankage Steel Plates,’ THE WeLDING
present, although the occurrence of JOURNAL, 34 (12), Research Suppl., 596-s to 607-s
dure cannot be applied when the some of these factors is not yet as- (1955).
occurrence of partial crack may cause certained in the laboratory test: 6. Yoshiki, M., and Kanazawa, T., “On the
Mechanism of Propagation of Brittle Fracture in
serious damage or disaster. 1. Structural discontinuities: Mild Steel,” Jnl. Soc. Nav. Arch. Japan, No. 102
Moreover, it must be noted that When a structure involves severe 39-44 (1957).
7. Wells, A. A., “The Brittle Fracture
factors such as (1) structural dis- structural discontinuities, there Strength of Welded Steel Plates,” Quart. TINA,
continuity which may cause stress might occur a condition like that 48 (3), 296-326 (July 1956).
8. Benson, L. E., ““Memorandum on Inter-
concentration, (2) repeated stress satisfied in the double-tension test. pretation of Wide Plate Tests,"” Document sub-
and (3) impact stress, may have ef- That is, a brittle crack originated mitted to Com. X of IIW, Doc. No. X-133-56
fects which are as harmful as the at the point of high stress may prop- 9. Kihara, H., and Masubuchi, K., “Effect of
Residual Stress on Brittle Fracture,’ Rept. Trans
existence of residual stress. There- agate through the main structure, Tech. Res. Inst., No. 30 (1958).
fore, the treatments mentioned in 2 where the value of stress is not too 10. Masubuchi, K., “Dislocation and Strain
Energy Release during Crack Propagation in
(a), (b) and (c), cannot be applied high. Residual Stress Field,”’ Jbid., No. 29 (1958)

168-s | APRIL 1959

Brittle-Fracture Tests of Steel Plates

Containing Residual Compressive Strain

Investigation undertaken to produce a residual

compressive-strain field in the central portion of a two-foot wide steel plate,

and to study the propagation of brittle fractures in such plates

SY &. fF. ROLFE, W.. S HALL AND N. M. NEWMARK

ABSTRACT. This investigation was compressive strain field, as well as strain response and crack speed
undertaken in an attempt to deter- the nature of the adjacent strain while the fracture was propagating.
mine some of the effects a residual com- field, affect the propagation of the
pressive-strain field may have on a fracture. In spite of these com-
propagating brittle fracture. Brittle- Preparation of Specimens
fracture tests were conducted on */,-in. plications, it still is of interest and
thick by 2-ft wide by 5-ft long steel importance to ascertain whether a Residual Strain Measurements
plates in which there was a longitudinal compressive strain field, in which The residual strains resulting
residual compressive strain in the cen- the major compression is perpendicu- from the flame heating or welding
tral portion of each plate, and a region lar to the expected crack path, can were measured by means of Type
of high longitudinal tensile strain at arrest a brittle fracture. To in- A-7 SR-4 strain gages and a 6-in.
each edge. This strain field was vestigate this problem, several frac- Berry mechanical gage. Berry gage
developed by welding tapered slots ture tests were made of 2-ft wide
cut perpendicular to the edges of the holes (6-in. gage length and oriented
plates in which there existed a longi- vertically) were placed every 1 in.
plates.
The tests show clearly that the resid- tudinal residual compressive strain across the central portion of the
ual strain field affects the initiation in the central portion of the plate. flame-heated specimens and every
and propagation of a brittle fracture. The initial phases of this study 1 in. across the entire width of the
In all these tests the residual tensile consisted of investigating two meth- welded specimens. SR-4 strain
strain at the edge of the plate was ods of producing a compressive gages used to measure residual
effective in reducing the applied stress strain field in the central portion of strains were located only in the cen-
at the notch required for fracture in. thick by 2-ft wide by 5-ft tral region of the plates. In general,
initiation. In one test in which the long steel plates. The first method for any particular specimen there was
fracture propagated completely across
the plate, the residual compressive consisted of flame heating and water good agreement between the strains
strain field decreased the crack speed quenching wedge-shaped areas along recorded by the SR-4 gages and the
and the associated strain response. both edges of a plate; the second Berry gage.
In two other tests, in which the residual method consisted of welding tapered After a specimen was placed in
compressive strains were much greater, slots cut perpendicular to the edges position for either heating or weld-
the brittle fractures arrested in the of a plate. It was believed that if ing, the initial Berry gage and SR-4
compressive strain fields. the nature of the strain field were gage readings were taken. At this
The results suggest the possibility of satisfactory, it would be possible to time, the plates were unstrained
prestressing elements of ships or struc- initiate and propagate a brittle with respect to the as-rolled condi-
tures, or perhaps entire structures, as a
means of arresting brittle fractures or fracture from one edge of the plate; tion; all succeeding strain measure-
providing a barrier for fracture initia- this in turn would permit a study of ments were referred to this zero
tion. the behavior of the specimen as the strain level. The specimen was
fracture entered the compressive subjected to the flame heating or
Introduction region. welding process and allowed to cool
In the past there has been con- Brittle-fracture tests were con- to room temperature before the final
siderable discussion as to what effect ducted on three specimens prepared strain measurements used to deter-
a compressive strain field may have by the method of welding tapered mine the residual strains were made.
on the propagation of a brittle slots. The specimens, tested at rel-
fracture in a steel plate. The prob- atively low average applied stresses Flame-Heated Specimens
lem is complicated by the fact that of 12,000 and 2000 psi, were cooled Three procedures were followed
the extent and magnitude of the prior to testing. The fractures were in preparing the flame-heated speci-
initiated at an edge notch by the mens and are illustrated in Fig. 1.
S. T. ROLFE, W. J. HALL and N. M. NEW- notch-wedge-impact method of frac- a) Specimen 1. The first
MARK are associated with the Civil Engineering ture initiation, from a nominal im- method investigated to produce a
Department, University of Illinois, Urbana, Ill pact energy of 1200 ft-lb. The residual compressive strain in the
Paper to be presented at the AWS 40th Annual plates were instrumented with SR-4 central portion of a plate consisted
Meeting to be held in Chicago, Ill., Apr. 6-10,
1959 strain gages to provide a record of of flame heating an are along both

WELDING RESEARCH SUPPLEMENT | 169s

 .

4"

——
eft d __JINITIATION
60"

H
ho
igen
t

SPECIMEN | SPECIMEN 2 SPECIMEN 3 SPECIMENS 4,5,6,and 7

Fig. 1—-General layout of specimens

edges of a killed and normalized The resulting residual compressive from back-to-back gages; very little
steel plate while cooling the central strain is shown in Fig. 2. bending was evident.
portion of the specimen with dry (c) Specimen 3. Four deep From Specimens 1 through 3 it
ice. Strain measurements recorded ‘*‘wedges”’ were heated to 1650° F on was concluded that high compressive
with the Berry gage showed an er- the same plate used as Specimen 2; strains could be produced in the
ratic residual-strain distribution. the wedges were water quenched central portion of the plate by heat-
(6) Specimen 2. Wedge-shaped immediately after heating. Resid- ing wedge-shaped areas and water
areas were flame heated to about ual strains at the center of the quenching them immediately.
1650° F along both edges of this specimen, as determined by Berry However, the resulting longitudinal
killed and normalized steel plate gage readings, reached a maximum strain distribution exhibited a steep
while the central portion was cooled of about —0.0025 in./in. in a longi- gradient along the horizontal as well
with dry ice. The wedge-shaped tudinal direction. However, the as the vertical axis which was not
areas were heated successively, with strain gradient was quite steep as considered to be desirable in this
each individual “‘wedge”’ being water may be noted in Fig. 2. The plotted series of tests. The steep strain
quenched immediately after heating. strains are the average of readings gradients and also the possible effect
of heating and quenching on the
brittle-fracture initiation and prop-
agation characteristics of the ma-
re) terial made an investigation of
welded-plate specimens desirable.
SPECIMEN 2 Welded Plates
—~ 0
Four specimens were prepared by
-0005 the method of welding tapered slots,
cut perpendicular to the edges of a
plate. Figure 1 shows the general
layout of the specimens. Speci-
£ -0010 mens 4 and 5 were prepared from a
© killed and normalized steel plate
| and Specimens 6 and 7 were pre-
za pared from a rimmed steel plate.
— -o015 The vertical distance between slots
” was 8 in. for all specimens, but
z \socomen 3
the slot lengths varied for each
3
”w Pe specimen; Specimens 4, 5, 6 and 7
= -0020 had slot lengths of 4, 5, 6 and 7 in.,
respectively. The four slots in
each plate were tapered from */;, in.
at the edge of the plate to '/; in. at
the tip of the slots. A photograph
-0025
of the slots for Specimen 6 is pre-
sented in Fig. 3.
¢ The welding sequence was similar
for Specimens 4 through 7 and will
-.0030 be described briefly with reference
f) 4 “ l2 16 20 24
DISTANCE FROM EDGE — in. to Fig. 3. For each slot, welding
began at a point two-thirds of the
Fig. 2—Average longitudinal strain distribution across plate at notch line way toward the tip of the slot and
after flame heating and water quenching—Specimens 2 and 3 proceeded to the tip. For example,

170-s | APRIL 1959

 which the residual compressive cause of the high longitudinal re-
strain was produced by welding sidual tensile strains that existed
tapered slots (Specimens 5, 6 and at both edges of the plate. The
7). The welded specimens were yielded tensile region extended in
ideally suited for fracture tests be- from the edges of the plate for a dis-

0016 . ‘ , ,
| |
|APPROXIMATE|
SPECIMEN NO Lenten
001 2)—S67__§ P

0008}
Fig. 3—Tapered slots before welding
—Specimen 6

in Fig. 3, welding began at a point ¢

S 0004+
4 in. from the edge of the plate and e
proceeded to the tip of the slot. |
The same number of passes was =a
made on each side of the plate and iecoad
they were placed alternately until a 0
the end one-third of all four slots <q||
was filled. All four slots were then oO
welded in the same manner again, WwxB
this time beginning at a point one- -0004 }——
third of the way toward the tip of
the slots and working to the pre-
viously completed welds; the last
one-third of each slot was welded in - 0008 K—
the same manner. It was felt this ] 7
welding sequence would keep the
bending to a minimum, and produce
a high uniform residual compressive -0012 ; .
strain in the central portion of the 0 4 8 12 16 20 24
plate. DISTANCE FROM INITIATION EDGE — in
Welding of the four different slot
lengths produced different amounts Fig. 4—Average longitudinal strain distribution across
of residual compressive strain across plate at notch line after welding—Specimens 4, 5, 6, and 7
the central portion of each plate as
may be seen in Fig. 4. In general,
the deeper slots produced a greater
residual compressive strain. The
strains on both faces were measured
every 1 in. across the plate width
with the Berry gage and, as are all
the other strains reported herein, are
plotted with respect to the as-rolled
prewelded condition. It will be
noted in Fig. 4 that, for any test, the
tension and compression areas ap-
proximately balance, thus serving as
a partial check on the recorded
strains.
After the residual strains were
recorded, the regular 1'/;-in. deep
notch, used in the notch-wedge-
impact method of fracture initia-
tion, was sawed in both edges mid-
way between the tapered slots; re-
laxation in strain in the central
portion of the plate resulting from
the notching was only 0.00001 to
0.00002 in. /in.
Brittle-Fracture Tests
General
Brittle-fracture tests were made
with three of the plate specimens in Fig. 5—Fracture path—Specimen 5

WELDING RESEARCH SUPPLEMENT | 1)l-s

 net stress of 12,000 psi, a tempera-
ture of —32° F and an impact of
1200 ft-lb for fracture initiation.
After applying the test load, the
compressive strain over the central
10-in. portion of the plate averaged
INITIATION about —0.00015 in. /in. During the
test, a brittle fracture propagated
across the entire specimen as is
shown in Fig. 5; the black string
denotes the notch line, i.e., an im-
aginary line connecting the edge
notches.
The dynamic - instrumentation
layout, strain-time traces of the
strain gages recorded during the
| fracture process and the breaking
0015+——— } times of the crack detectors are
2
presented in Fig.6. The zero strain
i\ level on the strain-time curve cor-
1\ a responds to the as-rolled prewelded
I| A
Oo010Fr 3 T + t strain condition. In other words,
\ the initial strain values in Fig. 6
A ] | i) 5
I\ ! fi correspond to the residual strain
. ~~ u plus the strain associated with the
| | \* VY fi applied test load.
€ 0005}+— t = $
« | H\ mee.” : : With several exceptions, the re-
/ ae sulting records were similar to those
! I} \j j RD of nonprestrained plates. The
F 0 LA a = te : strain trace of Gage 3, which was
=- . - +] ’ 1 ae = . } mounted at the edge of the ecompres-
sive-strain field, was similar to that
avamee onus \ al
% 5] found in tests of nonprestrained
plates in that it peaked sharply in
-0005 \
tension and relaxed immediately.
‘ ™ — i = i > mon os The traces of Gages 1, 2 and 4 which
CRACK . ° c o : were in the center of the compres-
DETECTORS H ! } sive-strain region, peaked sharply,
Rea 0.5 1.0 5 2.0 2.5 3.0 relaxed rapidly to a strain value ap-
TIME — milliseconds proximately one-half of the peak
value, and then took about one
Fig. 6—Instrumentation layout and strain-time record—Specimen 5 millisecond to return to their re-
spective final strain levels.
The trace of Gage 5 at the far edge
of the compressive-strain region
tance of several inches as may be tensile strength values for material behaved in a different manner; the
noted in Fig. 4. Since high-tensile from Specimen 5 were 34.8 and 59.8 trace took 1 millisecond to reach
strains existed at the edges even ksi, and for material from Specimens one-half of the maximum peak
before any test load was applied, it 6 and 7 were 34.9 and 68.4 ksi, re- strain, peaked sharply to the maxi-
was possible to initiate the fracture spectively. The Charpy V-notch mum strain value and then relaxed
at a low applied stress; in fact, as 10 ft-lb value for the killed and to its final strain fairly rapidly.
described later, in two of the tests normalized steel used in the test of Possibly, as the speed of the frac-
the applied net stress was only 2000 Specimen 5 was about —30° F. ture decreased, redistribution of
psi. The Charpy V-notch 10 ft-lb value load began; then, as the fracture
Eight channels of high-speed cath- for the rimmed steel used in the propagated past Gage 5, the strain
ode-ray oscilloscope and associated tests of Specimens 6 and 7 was about trace showed the customary tension
photographic equipment were used a2° 7. peak.
to record the strain and crack sig- The test procedure consisted of The fracture speed as determined
nals from SR-4 strain gages as the cooling the plate, loading it to the by crack detectors and strain gage
crack propagated across the plate. desired stress level and initiating peaks was quite low. Between de-
Details of the _ instrumentation the fracture by means of an impact tectors A and B, and B and C, the
equipment, calibration, measuring that drives a wedge into a notch in fracture speed was 950 and 1600 fps,
procedure and data reduction were the edge of the plate. A more com- respectively; the fracture speed de-
essentially the same as those de- plete description of the testing pro- creased to 450 and 350 fps be-
scribed in an earlier paper. ' cedure may be found in other reports tween detectors C and D, and D and
The specimens to be tested had and papers.'~* E, respectively, which were located
dimensions of */, x 24 x 60 in., and in the center of the compressive
were welded to pull plates having Test of Specimen 5 strain region. Fracture speeds
dimensions of 9 ft between the pull This welded plate was the first of based on the time interval between
heads mounted in the 600,000-lb three specimens on which brittle- the strain peaks of the dynamic
screw-type testing machine. fracture tests were conducted. The strain gages were 400, 1100 and 450
The yield strength and maximum test was made at an average applied fps between Strain Gages 3 and 4,

172s | APRIL 1959

1 and 2, and 4 and 5, respectively.
All of these fracture speeds (with
the exception of the 1600 fps value) Test 6
were well below any of those pre- Wevoto Specimen
NObs 65790
viously recorded as a part of this 20s! -9'F
program. It is of interest to note 1200 Fr-is
that both the fracture speed and Tested 26 July57
the magnitude of each successive
strain peak decreased as the frac-
ture traversed through the compres-
sive-strain field.
The fracture surface appearance
was not noticeably different than
that observed in other plain-plate
tests. In general, the fracture tex-
ture was fairly smooth for the first
3 in., rough for the next 7 in. and
then became smooth again for the
remainder of the fracture. Thus,
the slower fracture speeds were re-
corded in a region of slightly finer
crack texture. Fig. 7 Fracture path—-Specimen 6

Test of Specimen 6
The welding of the slots for this
plate resulted in an average residual 5 4«" 3
compressive strain of —0.00065 in.
in. across the central 10-in. portion ~<— FRACTUR
of the specimen (Fig. 4). The
specimen was tested at an average
applied net stress of 2000 psi, at a
temperature of —9° F, and with an
impact of 1200 ft-lb for fracture ini-
tiation. In this test, only enough
load was applied (32,000 Ib) to keep
the specimen taut in the testing
machine. This was done for two
reasons, namely: (a) to retain the
high longitudinal compressive strain
in the central region of the plate, WetoeD Specimen
and (6) to verify that a brittle frac-
ture could be initiated with a low NObs 65790
applied net stress and a region of
high residual tensile strain. Earlier 2.0 KSI -9°F
2-ft wide plain-plate tests? indi-
cated that an applied net stress of 1200 Fr-LB
15,000 psi was necessary for frac-
ture initiation.
The brittle fracture propagated Testen 26 July ‘57
about 10 in. and stopped in the
central compressive region; the Fig. 8—Fracture region—Specimen 6
last 4 in. of the fracture had the ap-
pearance of a submerged crack.
Photographs of the fracture are pre-
sented as Figs. 7 and 8. The of the plate, exhibited the usual the final strain distribution across
change in direction of the fracture as response of vertically oriented gages the plate after the brittle fracture
it neared the compressive strain with the exception that the peak- had arrested and the final test load
field may be seen in the figures. strain magnitude was low (approxi- was removed, are shown in Fig. 10.
On one face of the specimen a sur- mately 0.0005 in./in.). The traces The initial and final strain distribu-
face fracture */, in. long is clearly of dynamic strain gages mounted on tions were determined from the
visible in the submerged-crack re- the specimen exhibited behavior average of back-to-back static SR-4
gion; the location of this surface similar to that noted in crack-ar- and Berry gage readings taken at
fracture is noted in Fig. 8 by the two rester tests.‘ As the fracture speed room temperature. It will be noted
small arrows about 9'/, in. from the decreased and the fracture was ar- that the areas under the strain plot
edge of the plate. The arrow at rested (at approximately 0.5 milli- along the notch line measured after
6'/,in. marks the point at which the seconds), there was a redistribution fracture do not balance; this results
visible surface fracture ended. of strain as evidenced by the shift of in part from the fact that the crack
The instrumentation layout and the strain traces toward the zero- did not follow the notch line. The
the strain-time traces are presented strain level. final strain levels of the dynamic
in Fig. 9. The traces of Gages 1 and The initial strain distribution gages (minus the strains correspond-
6, which were mounted in the region across the plate resulting from ing to the final test load of 19,700 Ib)
of high-tensile strain near the edge welding of the tapered slots, and are also plotted in Fig. 10 and agree

WELDING RESEARCH SUPPLEMENT | 173-s

 quite well with the strain distribu-
tion as determined by the static
gages.
Because only one crack detector
broke and only one set of back-to-
back strain gages peaked in the usual
sense, no fracture speeds could be
computed for this test. A portion
of the fracture (resembling a sub-
merged crack) passed beneath the
second crack detector but did not
break it.
The reduction in plate thickness
along the surface fracture was on
the order of 1 to 2%; in the region
of the submerged crack the reduc-
tion in plate thickness was about 2
to 4%. The surface texture in the
fractured region was similar to that
found in complete fracture tests.
Test of Specimen 7
The test of Specimen 7 was es-
sentially a duplicate of the test of
Specimen 6 with the exception that
the length of the slots was increased
from 6 to 7 in. The strain records
were quite similar to those of Speci-
men 6, and are not presented.
The specimen was tested at an
average applied net stress of 2000
STRAIN
in./in
— psi, at a temperature of —5° F, and
with an impact of 1200 ft-lb for
fracture initiation. After applying
the test load, the compressive strain
over the central 8-in. portion of the
—— a : plate averaged —0.00075 in. /in.
i 43 | A brittle fracture propagated
ite fl | | | about 10 in. and arrested in the com-
0 o5 1.0 5 2.0 pressive strain region. The length
TIME —~ milliseconds and appearance of the fracture were
similar to that of the fracture oc-
Fig. 9—Instrumentation layout and strain-time record—Specimen 6
curring in the test of Specimen 6.
A photograph of the fracture region
is shown in Fig. 11. The small ar-
rows on the photographs, 9 and 10
in. from the initiation edge, show
where the fracture changed direc-
tion after it entered the compres-
sive-strain field. The visible sur-
<— STRAIN DISTRIBUTION face fracture ended at a point be-
ai Be tween the second and third crack
detectors.
The average fracture speed be-
in/
im tween the first and third detectors
(located 1!/. and 7'/, in. from the
initiation edge) was 550 fps. The
fracture passed beneath the second
STRAIN FRACTURE
AFTER. DISTRIBUTION ¥
detector i not break
but did sak it.
j
STRAIN
(NO APPLIED LOAD) Summary
\ GAGES 3 AND7GKQ wd The objects of the tests reported
or \ in this paper were to investigate
RESIDUAL X methods for producing a residual
\ compressive-strain field in the cen-
\ tral portion ofa 2-ft wide steel plate,
\ v / and to study the propagation of brit-
tle fractures in such plates.

eee Fig. 10—Average longitudinal strain

distribution across plate at notch line
8 '2 16 20 —Specimen 6
DISTANCE FROM INITIATION EDGE — in

174-s | APRIL 1959

 Two methods of obtaining the
desired residual compressive-strain
field in the central portion of the
plate were investigated. The first
method consisted of flame heating
and water quenching wedge-shaped
areas along both edges of a plate,
and the second method consisted of
welding tapered slots cut perpen-
dicular to the edges of a plate. The
welding of these slots produced a
fairly uniform longitudinal compres-
sive strain in the central region of
the specimens, as well as a region of
high longitudinal tensile strain at
each edge of the plates.
Brittle-fracture tests were con-
ducted on three specimens prepared LPs 22 2) 20 19 ee 7 6 ie a is ae) 1o- se7 ee ee
by the method of welding tapered Fig. 1l—Fracture path—Specimen 7
slots, and the results of these tests
may be summarized as follows. strain peak as the fracture propa- Acknowledgment
In all three tests, and particularly gated by the gage; this behavior is
in the last two tests, a low applied similar to that observed in tensile- The work described in this paper
net stress was used. Thus, it ap- strain regions of plain plates. The was conducted in the Structural
pears that a high-tensile residual strain traces of gages located in the Research Laboratory of the Depart-
strain of yield magnitude at the compressive-strain region on plates ment of Civil Engineering, Univer-
edge of a 2-ft wide plate, and little in which the fracture arrested ex- sity of Illinois, under sponsorship of
or no applied stress, is sufficient for hibited a behavior similar to that the Ship Structure Committee
fracture initiation and _ propaga- observed in crack-arrester tests, in through the Bureau of Ships, U. S.
tion with the notch-wedge-impact that as the fracture arrested, the Navy, Contract NObs 65790. The
method of fracture initiation. It redistribution of strain on the re- opinions expressed in this paper are
should be noted that the other test maining section was evident. those of the authors and do not
conditions, namely temperature and This investigation has demon- necessarily represent those of the
impact, were similar to those used strated that, under certain condi- Ship Structure Committee or its
for previous tests of 2-ft wide plain tions, a residual compressive strain member agencies. ‘The members of
plates, in which an applied net stress field may constitute an effective the Brittle Fracture Mechanics Ad-
of about 15,000 psi was necessary crack arrester; similarly, such a visory Committee to the Committee
for fracture initiation. strain field also could constitute an on Ship Structural Design have
The residual-strain distribution effective barrier for crack initiation. acted in an advisory capacity for this
obtained in the welded-slot type of In the opposite sense, these tests also program.
specimen decreased the speed of a demonstrated that a residual tensile
brittle fracture to the range of 400 strain at the edge of a plate was ef- Bibliography
to 1600 fps as the fracture propa- fective in reducing the applied stress 1. Hall, W. J., Mosborg, R. J., and Mc-
gated through a longitudinal comp- at the notch required for fracture Donald, V. J., “Brittle Fracture Propagation in
Wide Steel Plates l'uHeE WELDING JOURNAL, 36
ressive-strain field of low magnitude initiation. 1), Research Suppl., 1-s to 8-s (1957).
(—0.00015 in./in.); in the other Although this study was of an ex- 2. Hall, W. J., Godden, W.G., and Fettahlio-
two tests, the brittle fracture was ploratory nature and of very limited glu, O. A “Brittle Fracture Propagation in
Structural Steel,”’ Ship Structure Committee Re-
arrested as it entered the compres- extent, these tests suggest that, un- port SSC-111 (May 1958
sive-strain field of higher magnitude der certain circumstances, it may be 3. Rolfe, S. T., and Hall, W. J., “Brittle Frac-
ture Tests of Two Foot Wide Steel Plates with a
(average longitudinal compressive desirable to consider prestressing Residual Compressive Strain in the Central Por-
strain of —0.00060 and —0.00075 elements of ships or structures, or tion,’ Civil Engineering Studies, Structural
Research Series No. 150, University of Illinois
in. /in., respectively ). perhaps entire structures, as a means April 1958
The strain traces of gages located of arresting brittle fractures or pro- 4. Mosborg, R. J., Hall, W. J., and Munse,
in the tensile-strain region of all viding a barrier for fracture initia- W. M., “Arrest of Brittle Fractures in Wide
Steel Plates THe WELDING JOURNAL, 36 (9)
three plates exhibited a sharp tensile tion. Research Suppl., 393-s to 400-8 (1957).

WRC Bulletin No. 44 The Influence of Residual Stress on the Strength of Structural Members
by Robert L. Ketter. 11 pages. Price $1.00.

Concerned primarily with the stability of ‘“‘as-delivered,”’ rolled, structural

steel shapes of the I or WF type, this discussion considers the influence of
residual stresses on the load carrying capacity of compressed members.
Both the pure axial load case and that of combined thrust and bending due
to end moments, eccentric or lateral loads, etc. have been included.

Copies may be purchased from the American Welding Society

33 West 39th Street, New York 18, N. Y.

WELDING RESEARCH SUPPLEMENT | 175-s

 Cast-Pin Tear Test for Susceptibility to Hot Cracking

Susceptibility of alloys to hot cracking, such as

might occur during freezing of a weld bead, is evaluated

by means of a recently developed test

BY F. C. HULL

ABSTRACT. A new test has been electrode wire. Machining of spec- contamination of the melt by the
developed to evaluate the susceptibility imens is usually required. Some crucible or by the skull from pre-
of alloys to hot cracking, such as might require elaborate equipment for vious melts is avoided. Zirco-
occur during freezing of a weld bead or operation, and most are subject to nium, titanium, niobium and alloys
solidification of a casting. Samples the variables associated with hand of these and similar metals can be
weighing 19 g are levitation-melted in
an inert atmosphere and cast in the welding. To overcome these limi- levitation-melted, whereas ceramic-
shape of tapered pins in a series of tations, an attempt was undertaken crucible melting is impracticable.
copper molds. Restraints at the ends to develop a simpler test for hot Finally, pouring for casting is greatly
of the pin impose tensile stresses on the cracking. simplified in levitation melting, for
sample as the mold expands and as the A weld deposit freezing in a groove the coil acts like a magnetic funnel
casting solidifies and contracts. The in a heavy plate is subjected to rapid with an adjustable pouring rate.
geometry of the mold that will produce cooling and high-tensile stresses at The power source for melting is a
a certain extent of hot cracking pro- a temperature within or slightly 450-ke, 10-kw industrial R. F.
vides a means of classifying alloys in below the liquid-plus-solid range. generator. The levitation coil is
order of merit. The test is quick and made of '/;-in. diam copper tubing.
inexpensive, and is applicable both to These conditions, which lead to hot
the evaluation of existing materials and cracking in welds, are very similar It is conical, °/,, in. in ID at the
to studies of the effects of alloying addi- to those responsible for hot tearing bottom and 1',, in. at the top. It
tions and impurities on hot cracking. of castings in the foundry, as has has nine turns, the top two with 1 in.
been pointed out by Apblett and ID opposite in direction to the bot-
Introduction Pellini.’ It was therefore decided tom seven. The coil is coated with
Hot cracking during welding has to see if a small restrained test-bar Sauereisen cement and is water
received much attention because of casting, similar in principle to the cooled. With 650 v applied to the
the need for avoiding defects in large one used by Bishop, Acker- leads, the coil readily lifts and
critical applications, such as in lind and Pellini,* could be used for melts 19-g samples of stainless
heavy-walled austenitic stainless- weldability studies. Levitation steels and other materials. The
steel piping for steam turbines and melting of small charges of alloys had charge can have any shape, such as
in components of nuclear power recently been developed by Comen- a cube or cylinder, whose dimensions
plants. Since attempts to predict etz and Salatka’ into a simple, are roughly equal.
weldability from chemical analysis routine operation. This seemed to The alloys are readily made from
have been singularly unsuccessful, offer a unique opportunity for the powders or chips and do not require
to find out how an alloy will behave quick and inexpensive preparation thorough premixing because of the
one must weld it under conditions of a large number of alloys to study electromagnetic stirring that occurs
closely approximating those en- the effects of major additions as well during melting. Composition effects
countered in the field. Many types as impurities. It had also been are easily studied in samples of a
of tests have been developed in an noticed that small chill-cast pins base composition by placement of
attempt to simplify the problem of sometimes cracked if there was a one or more alloying additions or
predicting shop performance from heavy flash at the bottom of the impurities in a covered hole. Com-
laboratory experiments. Some of the mold. The levitation-melting tech- mercial alloys and other existing
most common of these are the Lehigh nique combined with the above materials can be evaluated by merely
restraint test,':? various types of observation inspired the new hot- cutting off samples of appropriate
circular-groove specimens, *~* Murex ductility test. Because casting a size for testing.
test® and the finger test of Apblett pin under conditions of restraint led The coil and mold are contained
and Pellini.’ to hot tearing, the procedure was within a vacuum-tight glass cylin-
All of the known tests for hot named the Cast-Pin Tear (or CPT) der which is evacuated and then
cracking are slow and expensive. Test. filled with one-atmosphere pres-
They require relatively large sure of helium or argon for melting.
amounts of metal for a welding base Details of the CPT Test R. T. Begley has described a levita-
and the processing of material into tion-melting unit, with a specimen
F. C. HULL is an advisory metallurgist at the Levitation Melting storage rack, manipulator and rota-
Westinghouse Research Laboratories, Pittsburgh There are several advantages of ting mold-table, in which up to 18
35, Pa. levitation melting over crucible melts can be made in succession. A
Paper to be presented at the AWS 40th Annual melting: there is no expense for schematic view of the CPT test
Meeting to be held in Chicago, Ill., Apr. 6-10,
1959. crucibles, and the possibility of apparatus is shown in Fig. 1.

176-s | APRIL 1959

 Mold Design
Manipulator Rod Blowout Plug
Hot cracking is readily produced and Plunger
in a mold made of a */,-in. diam cop-
Aluminum
per bar, 2 in. long, with a tapered Top Plate
hole about '/, in. in diameter along
its axis. Cracking is decreased if Tie Rods (6 rods
the pin length is shortened or if the equally spaced)— |
outside mold-diameter is increased.
Different diameters and sizes of Glass Cylinder Rubber Gasket
molds were tried until a series had Manipulator
been selected that seemed to pro- Molds
Fingers
duce comparable changes in each Levitation Coil
interval. Although the numbers of
the molds, whose dimensions are Water Cooled Specimen Rack
given in Fig. 2 and Table 1, are Coaxial Lead for
purely arbitrary, they serve as a High Frequency
means of qualitatively rating hot- Power
Button Molds or
cracking susceptibility of alloys. Pedestal Rack
Figure 3 shows how pin length and Pedestal
outside mold-diameter vary with
mold number. Pin volume is kept Rotating Table Rubber Gasket
constant at 2.4 cc, or the equivalent
of 19 g of stainless steel. Screened
The restraining lock at the bot- Pumping Port
tom of the pin is formed by two Stainless Steel
separable pieces (Fig. 2). The bot- Bottom Plate
tom plate has a small hole to permit
escape of trapped gas as the metal
enters the mold. Occasionally a
gas pocket will be trapped after the Fig. 1—Levitation melter
bottom vent has been blocked.
This may cause expulsion of molten
metal from the mold and loss of
the test. For the longer pins, a
split mold was found to yield better
castings and to have a longer life
than a solid mold.
The pedestals are mounted on the
turntable and hold each mold, re-
straining-lock plate and bottom plate
in position. By the use of the indi-
cated heights with different mold Break Sharp
sizes, all molds can be kept */, in.
Corner ~_-*
below the levitation coil for con-
stancy of pouring conditions. 45
-I¢
Cracking Index
After being removed from the Split Mold —J
mold, the cast pin is examined for
surface cracks, such as are illus- Restraining
trated in Figs. 4-7. This simple
procedure is permissible because the
interdendritic cracks usually ex-
tend to the surface. Examples of .750 Dia. ~
sections of pins are shown in Figs. 748
8-12. Cracking may vary from an
extreme of the pin being separated
into two pieces (Fig. 4) to such a Break Sharp
short, narrow crack (Fig. 5) that A. Corner
++ a
it can only be observed at a high ‘ 60°
>
magnification. rol GO a Cun.
The standard procedure is to ex- 752
amine the surface of the pin for ete
cracks with a stereo-binocular micro- .. Dia -
scope at a magnification of about 30
times. Hot tears are most readily
y °° Drill
observed under diffuse, oblique illu- t
mination of medium intensity, such Bottomf Hlih
as the reflected light from a small Plate =
750 Dia.
fluorescent tube. 748 ~~~™ olf
A mounted Jacobs chuck serves
as a specimen holder to provide for Fig. 2—Cast-pin tear-test molds

WELDING RESEARCH SUPPLEMENT | 17?-s

 inches

ia Pa
——-_4
Outside Mold
Diameter Fig. 4—Wide, deep crack extends all the
way around and through pin. Vacuum-
lSBy melted stainless steel: 16.5% Cr, 19.5%
Ni, 0.08% Zr. Mold 11, cracking index =
seEee 177. X 2.5
—-

Pin
Length
Mold
Diameter
or
10 12 14
Mold No.
Fig. 3—Bottom-to-shoulder length and diameter of CPT test molds

Table 1—Dimensions of Cast-Pin Tear-Test Molds Fig. 5—Example of very fine crack. Stain-
Standard Mold
Reamer Pedestal less steel: 16% Cr, 20% Ni, 1.3% Mn, 0.4%
Mold Pilot taper pin length,
extension, length, Si, 0.25% V. Mold 8, cracking index = 100
No. drill, in. reamer A, in.
in. B, in. x< 10
4 + ll
23 ‘ 1'/;
2°/ 16
—/ 23/5
+'/e 23/16
2
+"*/s2 1'3/16 . xo
+23/50 15/s
15/5
15/s
1'/, Si,
hen
13/;
l'/,
S&S
LS
NSNNNODOMAAMANN
1!/s YM
Mr
MM
PYDYee
HR~~ e«o’

Fig. 6—Typical cracking around rim of

support, rotation and translation index’”’ has been given to it to avoid “hot spot.'’’ Stainless steel: 16% Cr,
20% Ni, 1.25% Mn, 0.4% Si, 0.1% C, 0.5%
of the pin and measurement of confusion. Cb. Mold 9, cracking index = 189. x10
crack length. The axis of the chuck The cracking index plotted vs.
is inclined from horizontal by '/, mold number establishes the suscep-
in. in 12 in. to compensate for the tibility of the alloy to hot tearing.
taper of the pin and thus keep the Different alloys exhibit wide varia-
surface in better focus. The pin is tions in cracking behavior both as to
rotated by a handle on the chuck. shape of these curves as well as their
A graduated dial permits angular position, as illustrated in Figs. 13
measurement of crack size. Cracks to 15.
are usually circumferential. If there At the present time there are
is a component along the axis, this insufficient data to tell which of one
is ignored in measuring the percent or more characteristics of these
cracking. The entire surface of the curves will correlate best with field
pin is inspected systematically and experience in hot tearing, weld
crack lengths measured. The sum cracking and base-metal cracking.
of these values is the cumulative From the standpoints of simplic- Fig. 7—Example of filled crack. Stainless
percent circumferential cracking of ity and reproducibility, the mold steel: 16% Cr, 20% Ni, 1.25% Mn, 0.4%
the specimen. Since this often number corresponding to a crack- Si, 0.2% B. Mold 11, cracking index = 5
exceeds 100°%%, the term ‘“‘cracking ing index of 40 is used for compari- x< 10

178s | APRIL 1959

sons. This number is called the quantitative effects of these vari- upon the type of vacuum pumps,
CPT Test Susceptibility Number. ables have not been determined. pumping time, leak rate and purity
For the many variations of stainless When a factor is recognized as of the inert gas. For the work on
steel tested so far, for example, the important, an attempt is made to stainless steels, the chamber is
values have ranged from about 5 to keep it constant in all tests. evacuated to a pressure of 10~‘
17, with the higher numbers indi- mm of Hg before refilling with one
cating greater propensity for hot Original Material
atmosphere pressure of tank argon.
cracking. Large ingots and wrought prod- Helium would be satisfactory, but
ucts made from them invariably only if used exclusively, since the
Variables in the CPT Test show some systematic variation of cooling effects of the gases are
In Figs. 13 to 15, it is apparent composition from surface to center different and could affect the pour-
that there is a certain amount of and from top to bottom as the result ing temperature for a given power
scatter in the data when cracking of segregation of impurities. Spec- setting and holding time.
index is determined as a function of imens for the CPT test should there- For materials that are more sen-
mold number. This is not unex- fore be cut from comparable adja- sitive to contamination from oxy-
pected, however, for hot cracking is cent positions. The extreme sur- gen and nitrogen, such as niobium
a highly structure-sensitive prop- face or the hot-top should not be or zirconium, one should pump to
erty. Cracking is a localized phe- used because of the variable amounts a higher vacuum, and refill with pur-
nomenon that involves the simulta- of entrapped nonmetallic inclu- ified gases. As an additional pre-
neous interaction of chemical, me- sions as well as the greater segrega- caution, the atmosphere could be
chanical, thermal and geometric ef- tion. gettered by heating of a titanium
fects that are not necessarily all un- When the CPT-test charge is strip or melting of an expendable
der control. A sufficient number of prepared from powder, chips or button of a Ti-Zr alloy.
tests must be run, therefore, to get other finely divided materials, it is
a good evaluation. Some of the essential that each component be of Melting
possible sources of variation are dis- a uniform known composition. It If an existing alloy is being re-
cussed below. In most cases, the is also not safe to assume that lots melted for a CPT test, the only
purchased to the same specification requirement is that the melt reach
would be necessarily equivalent. a suitable temperature before cast-
Compacts should be pressed in a ing. This takes about four seconds
clean die. after the last solid melts. On the
Preparation of Sample other hand, when mixed powders
are melted or a master alloy is
Cutting of samples to an approxi-
doped with an impurity, additional
mately equiaxed shape with a vol-
time is needed for solution and
ume of 2.4 cc, can be done by ma-
homogenization. This was appar-
chining, sawing or using an abrasive
ent when particles of undissolved
wheel. If the surface is oxidized
chromium were found in castings of
from prior casting, rolling or heat
Fe-Ni-Cr alloys made from pow-
treatment, sufficient material must ders. Eight seconds holding elim-
Fig. 8—Longitudinal section of cast pin be removed to eliminate contamina- inated the difficulty. Excessive
of stainless steel: 16% Cr, 20% Ni, 1.5% tion. Machining, filing or grinding
Mn, 0.6% Si, 0.5% Ti. Mold 10, cracking holding times are undesirable be-
are preferred over pickling or sand- cause of loss of volatile elements by
index = 150. x 4 blasting. Abrasive wheels should
vaporization.
not be loaded with foreign materials
Because temperature measure-
that could be transferred to the ment during levitation melting is
sample surface. Finally, the speci-
difficult, temperature is controlled
men should be free of oil, grease
indirectly by regulating the power
and loose dirt. input and holding time after melting
Atmosphere is complete. For this reason, the
The purity of the atmosphere in type of inert gas, coil shape and
the melting chamber will depend charge weight are critical because

Fig. 9—Longitudinal section of cast pin of

stainless steel: 20% Cr, 6% Ni, 0.3% Si. x 4

Fig. 1l—Longitudinal section of cast pin Fig. 12—Longitudinal section of cast pin
of stainless steel showing interdendritic of AIS! 304 stainless steel showing
Fig. 10O—Longitudinal section of cast pin cracking. 12% Cr, 24% Ni, 0.3% Si. Mold interdendritic cracking. Austenite plus
of stainless steel: 16% Cr, 20% Ni, 1.4% 9, cracking index = 100. «35. (Reduced delta ferrite (dark). 200. (Reduced by
Mn, 0.5% Si, 0.9% Ti. «4 by '/. upon reproduction) 1/, upon reproduction)

WELDING RESEARCH SUPPLEMENT | 179s

these factors influence the tempera-
tures attained.
Casting — ' om
Commercial
The molten charge can be smoothly SAE 1020
poured into the mold by lowering
the power to the coil. A _ rapid,
reproducible rate of pouring is
obtained by a motor drive of the
power-control knob to avoid er-
ratic results caused by variations
in manual control. Cracking
Index
Factors, such as accidents of
casting or freezing, how the metal
enters the mold, trapping of air, VM 345
surface condition of the mold or (0.01 iy
amount or distribution of slag, can Vacuum
affect the surface roughness of the Melted Iron
cast pin, as shown in Figs. 4 to 7.
The amount of cracking is not par- , 4
ticularly sensitive to these factors, 10 12
except when the cross-sectional area Mold No.
of the pin is reduced appreciably,
as in Fig. 10. Fig. 13—CPT tests on vacuum-melted iron and low-carbon steel
When pins are cast in succession,
only the first melt is cast into a mold
at room temperature. Heat from
the first mold, after the melt is cast Vacuum
in it, warms the second mold. The Melted
remaining melts are cast under con- VM265 ~——
ditions comparable to the second Vocuum 6% Cr, 20% Ni
Melted 4
melt. This amount of preheat- +—— VM 300
ing does not affect the results. 16% Cr, 20% Ni |
0.01 %&C |
Discussion of the Nature and }_—_ et me
Cause of Hot Cracking
in the CPT Test
index
The CPT test reproduces, in cap-
sule form, the conditions and events
that are responsible for hot tearing
in industrial practice. After the @° 2
Cracking
melt is cast, dendrites are nucleated 20%Cr,
at the surface and begin growing to- _ 12% Ni, .3% Si
ward the center of the pin and also | Powder Charge |
in the perpendicular direction to-
ward each other. As these grains ba (2)
grow, the percentage of solid on the
surface increases and the amount ln
of liquid decreases. Soon the grains
start to impinge until only a few
scattered films of liquid remain. 10
No matter how uniform the mate- Mold No.
rial or the cooling by the mold, this
will always happen. If there are Fig. 14—CPT tests on stainless steels
any inhomogeneities in the melt or
variable thermal contacts with the tively uniform. During freezing, complete chain of contact is made
mold, it becomes possible for most the solid is only slightly below the from the top shoulder to the restrain-
of the surface to be nearly all solid temperature of the liquid and the ing lock, expansion of the mold
while a few other regions have con- rate of freezing is being controlled will extend the pin. Several things
siderable liquid. If impurities of by the transfer of the latent heat can happen at this state. If the
small ‘‘k”’ values are present, segre- of freezing across the gap to the cop- contacts between dendrites are
gation of these to the dendrite per mold. As long as liquid is strong and well distributed, the
boundaries can produce low-melting present, the temperature of the pin strain merely deforms the grains plas-
eutectic films and accentuate the is constant, whereas the heat trans- tically without opening up cracks,
condition. ferred to the mold causes it fo ex- even though liquid may still be
Because the diameter of the pin pand. Until the freezing surface present. If some of the grain con-
and thickness of the copper mold grains have impinged enough to tacts are weak or not well distrib-
are small, and since the gap between form a connecting network, ex- uted, the deformation will sepa-
the pin and the mold has a high re- pansion of the mold causes no prob- rate those grains joined only by a
sistance to the transfer of heat, the lems, for liquid from the hot-top film of liquid and produce a hot
temperature in the pin and the merely feeds down to fill the added tear. If the film extends back to a
temperature in the mold are rela- volume. However, once a fairly reservoir of liquid from the hot-

180-s | APRIL 1959

 equally successfully to vacuum-
melted iron and low-carbon steel
(Fig. 13), and to heat-resistant alloys.
Modified 316 Commercial There is no reason why a CPT test
Casting could not be used to evaluate hot-
16%Cr, IS%Ni, 2% Mo, cracking susceptibility of most
Index 1.5% Mn, 0.4%Si alloys.
Neither is the CPT test limited
T to welding problems. It is even
more directly related to studying hot
Cracking tearing of castings in the foundry.
The possibilities for development of
new alloys and investigation of
72997 impurity effects are obvious.
16% Cr, 20% Ni, Manufacturers of stainless-steel
° °
4% py ie--mn, welding electrodes occasionally proc-
natdege ess a heat into wire before discover-
t t t | | ing that the alloy is unsuitable for
critical welding applications be-
cause of its high susceptibility to
net Rd hot cracking. This happens be-
cause the present state of knowl-
Fig. 15—CPT tests on stainless steels edge and current analytical tech-
niques do not allow one to predict
crack sensitivity. CPT tests on
top, which is molten for 2 or 3 sec, have been obtained in a relatively the ingots before they are converted
feeding can refill and heal a thin short time on over one hundred to wire could detect the heats of
crack. An example of this is shown different stainless steels, including poor welding quality.
in Fig. 7, and supports the view that commercial alloys, and laboratory An application of greater poten-
hot tears occur while some liquid air and vacuum melts. Widely tial value than the above would be
is still present and not at some tem- different compositions are repre- a quality-control check on a heat of
perature below the liquidus. In sented in this group. The amount steel while it is still in the furnace.
these same specimens, at a later and cost of conventional testing in If a crack-sensitive steel can be
stage of freezing, cracks may open future alloy development programs spotted while there is an opportu-
up that are not refilled. Filled can be greatly reduced and limited nity for further refining or other cor-
cracks are not counted in establish- to compositions shown to be prom- rective treatment, the number of
ing the cracking index. ising by the CPT test. poor heats could be minimized.
When all the liquid in a partic- Another application has been a Eventually this control may be pos-
ular region of the pin has solidi- study of the iron corner of the Fe- sible from chemical! analysis, but in
fied, that portion of the pin will Ni-Cr system and evaluation of the the meantime a CPT-type test
start to contract as the tempera- effects of composition on sensitivity might profitably find an application
ture drops. The continued expan- to hot cracking. The microstruc- in the steel mills.
sion of the mold plus this contrac- ture and amount of ferrite can be
tion from the pin then combine to related to the phase diagram and cor-
related with the amount of crack- Bibliography
place a very large strain on any
local “hot spots’? that may remain. ing. The results of the CPT test 1. Stout, R. D., Tor, 8. S., McGeady, L. J
Figures 6, 8 and 10 illustrate crack- are in agreement with general weld- and Doan, G. E., “Quantitative Measurement of
the Cracking Tendency in Welds,” ‘THe WELDING
ing at obvious hot spots, but crack- ing experience that a small percent JOURNAL, 25 (9), Research Suppl., 522-8 to 531-s
ing may also occur in any location of delta ferrite is beneficial. 1946
2. Sopher, R. P., Jacobs, A. J., and Rieppel,
that is late in freezing, even in the A study of the effect of impurities P. J., “Investigation of Weld-Metal Cracking in
absence of a surface discontinuity. on hot cracking has been initiated High Strength Steel,” /bid., 34 (11), Research
Suppl., 544-s to 552-8 (1955
It is because the total strain can in order to gain an understanding of 3. Lang, J. L., and Wright,C., ‘‘Permeability
be concentrated at one weak link the fundamental cause of cracking. and Crack Sensitivity of Stainless Welds,” Jbid.,
A high-purity vacuum-melted stain- 35 (3), 225-228 (1956
that severity of cracking increases 4. Hoerl, A., and Moore, J. T., ‘“The Weld-
with pin length. In molds where less steel will be used as a base. ing of Type 347 Steels,"’ Jbid., 36 (10), Research
the length is constant but the di- To this, small additions will be made Suppl., 442-s to 448-s (1957
5. Linnert, G. E., “Welding Precipitation-
ameter or mass of the copper is by doping the charge button with Hardening Stainless Steels,’’ Jbid., 36 (1), 9-27
increased, the decreased severity elements such as As, B, Bi, Cd, P, 1957
6. Jones, P. W., “A Summary of Recent
of the larger mold is a result of Pb, S, Sb, Sn and Zn. Some of Work on the Murex Hot-Cracking Test,’’ Brit
reduced expansion of the mold dur- the usual alloying additions, as Welding Jnl., 4 (4), 189-197 (1957)
Apblett, W. R., and Pellini, W. S., “*Fac
ing the crucial stage of freezing. well as the common impurities, tors which Influence Weld Hot Cracking,” ‘THE
have been found to be extremely WELDING JouRNAL, 33 (2), Research Suppl.,
Applications of the CPT Test damaging. The advantage of being 83-8 to 90-s (1954
8. Bishop, H. F., Ackerlind, C. G., and
The conclusion that the CPT able to study this problem with 19-g Pellini, W. S., “Investigation of Metallurgical
test is a valuable experimental tool melts is obvious when one considers and Mechanical Effects in the Development of
Hot Tearing,” American Foundrymen’s Soc.,
is best illustrated by citing exam- the number of melts and tests that Preprint No. 57-1
ples of its present and potential would be required to evaluate the 9. Comenetz, G., and Salatka, J. W., ‘““Ten
Gram Levitation Melted Ingots,” Jnl. Electro-
applications. It has contributed effects of a large number of ele- chemical Soc., 105 (11), 673-676 (1958).
substantially to a research program ments and their combinations on hot 10. Begley, R. T. “Development of Niobium
dealing with weldability of stainless cracking by any other technique. Base Alloys,”’ Report No. A-2428Z, Sixth Quar-
terly Progress Report Contract AF33(616)-3316
steels. Crack-susceptibility ratings The technique has been applied Task No. 73022, September 1957

WELDING RESEARCH SUPPLEMENT | 181-s

 Effect of Heat Treatment and Fabrication

on Heavy-Section Pressure-Vessel Steels

Earlier PVRC study extended to determine what

alterations in the properties obtained by accelerated cooling

may be incurred by fabrication operations, such as cold working

and extended stress-relief treatments

BY A. |. RUBIN, J. H. GROSS AND R. D. STOUT

Introduction
In a previous paper,* the effects of Spray-Quenched Normalized
accelerated cooling from the aus-
tenitizing temperature on the tensile
properties and notch toughness were
reported for a group of carbon and
low-alloy steels used or being con-
sidered for heavy-wall pressure ves-
sels. It was shown that improve-
ment in both strength and toughness
can be obtained by accelerated cool-
ing followed by reheating to the
recommended stress-relief tempera-
tures.
This study has been extended to
A. 1. RUBIN is associated with the Pratt and
Whitney Co., Hartford, Conn.; J. H. GROSS, Tensile
Strength
KS|
in
formerly with Lehigh University, now with the
Applied Research Laboratories of the U. S. Steel aooO
Corp., Monroeville, Pa.; R. D. STOUT is Head,
Department of Metallurgy, Lehigh University,
Bethlehem, Pa
Paper to be presented at AWS 40th Annual Meet
ing to be held in Chicago, Ill., Apr. 6-10, 1959.
* J. H. Gross, E. H. Kottcamp and R. D. Stout, 100 |
“Effect of Heat Treatment on Microstructure
and Low-Temperature Properties of Pressure Tempering Time in Hours
Vessel Steels,” THe Weipinc JourNnAL, 37 (4),
Research Suppl., 160-s to 168-s (1958) Fig. 1—Effect of extended thermal stress relief on the strength of pressure-vessel steels

Table 1—Chemical Analysis, %, and Heat-Treating Temperatures

Stress-
Austen- relief or
itic tem- temper-
perature, ingtemp.,
Steel Grade" P YL B ad ve
ASTM A-285 0.53 0.020 vr 7 er ssa cae re awe 1650 1150
48s5 1.09 0.033 mae 1650 1150
ASTM A-212 0.70 0.010 1650 1150
ASTM A-203 0.64 0.010 1650 1150
HY-65 0.48 0.013 1750 1200
ASTM A-302 1.32 0.022 1650 1150
ASTM A-387 0.44 0.013 1700 1350
T-l 0.93 0.015 1700 1200
HY-80 High Anwoonawono
0.28 0.016 ooococooc.;oc
MHhe
NY
MR
mMwon
Mm&CO
onr 1650 1150
* All steels were firebox quality where applicable.

182-s | APRIL 1959

determine what alterations in the asMANNER OO ar ea ———60
properties obtained by accelerated Spray Quenched Spray Quenched
cooling may be incurred by fabri- ee }
cation operations, such as cold work- —I-1
I20
ing and extended stress-relief treat-
ments. The same group of steels aaa
has been used for this extension of
the work. 100 HY-80 (NORMALIZED) N.
KSI
IN
Experimental Program seg
=
PERCENT
IN
Two basic conditions of heat
treatment were imposed on each of
the steels to reproduce the micro-
structures characteristic of (1) a
normalized 4-in. thick plate and (2 20
a point near the surface of a spray- HY-80 (Normalized) ELONGATION
quenched 4-in. plate. The analyses STRENGTH
YIELD
and heat-treatment temperatures
for the steels are shown in Table 1
Specimens were obtained by split-
ting 1l-in. thick plates and cutting
20
them to 9 by 4 in. by the split |
thickness, 0.47 in. These blanks
were then austenitized at the rec- TEMPERING TIME IN HOURS
ommended temperature (see Table Fig. 2—Effect of extended stress relief on yield strength and ductility
1) and either still-oil quenched or of pressure-vessel steels
air cooled in a box lined with alu-
minum foil, in order to match the
spray-quenched and _ normalized
plates, respectively. Thermal stress
Spray - Quenched
relief for 1 hr at the temperatures
listed in Table 1 followed.
Because of the multiple stress-
relief treatments commonly applied
to heavy pressure vessels during
their manufacture, the effects of
extended stress relief up to 100 hr
were investigated by means of ten-
sion tests, and V-notch Charpy
tests. At the temperature of ther-
mal stress relief, tempering may
lower the strength level and it may
reduce notch toughness if the steel
is susceptible to embrittlement.
Table 2 contains the data obtained
in this study.
The strain-aging characteristics
of the steels were determined in both
heat-treated conditions. Tensile
prestrain of 5°% was used to simulate
deformation during cold forming. Stress-Relief Time (Hr)
Heating after prestrain was con- Normalized
ducted in the temperature range at
which aging is most severe; and, in _—_—-as
addition, specimens were exposed to
stress-relief temperatures to deter-
mine the extent to which the aging
effects could be eliminated by stand-
ard thermal stress relief. Complete
results are reported in Table 2. °F
Temperature
Transition
Expansion
|5-mil
V-Notch
Charpy
-

Discussion of Results
Extended stress-relief treatment
had a softening effect on some of
the steels, particularly if they were
previously given an _ accelerated
cooling after austenitizing. The
strength of the steels as a function
of time at stress-relief temperature
is shown in Fig. 1. Steels A 387, Stress-Relief Time (Hr)
T-1 and HY-80 lost over 20% of
their strength after 100 hr exposure. Fig. 3—Effect of extended stress relief on notch toughness

WELDING RESEARCH SUPPLEMENT | 183-s

 Table 2—Data on Extended Stress Relief and Strain-Aging Tests
Transition
Elongation, % Charpy 15-ft-ib temp., 15 mils

Oil quench, and SR 1150° F

lhr 30.5 —14
10 hr +16
100 hr owr 34.5 +10 —4
SR + 5% prestr. + SR at:
RT 24 +24 +24
500° F 23 +46 +36
700 25.5 +28
900 28.2 +10
1150 SIBSR
WONDio wi
OUD 30 —22 —26
Foil cool, and SR 1150° F
lhr 31 +34 +16
10 hr 35.5 +34 +12
100 hr its
oO
or >©
Mm
QER
SRESE
Bx 38 +50 +26
SR + 5% prestr. + SR at:
RT 24. +52 +46
500° F aa. +84 +68
700 24 +88 +68
900 28. ownwn +62 +42
1150 SRLWRD
FOwnwo +44 +24

Oil quench, and SR 1150° F

lhr 28 —16 —18
10 —18 —30
100 34 +2 —8
SR + 5% prestr. + SR at:
RT 21.5 +10 +6
500° F 20.5 +20 +12
700 21 +18 +6
900 24.5 —2 —12
1150 Ssssss
SNM
~ NyNonauwn 30 —30 —26
Foil cool, and SR 1150° F
lhr 29.5 +22 +12
10 ~wMm
> 31. uo +12 —4
100 ~s ™~ 32 anow +50 +24
SR + 5°;, prestr. + SR at:
RT 22 +52 +36
500° F 21 +92 +80
700 21 +78 +52
900 23.5 +26 +18
1150 BERR
ore
oS 29. or BoM
saoau
wo ro
onan +26 +10

Oil quench, and SR 1150° F

lhr 26 —56 —50
10 28.5 —26 —26
100 29 —24 —28
SR + 5% prestr. + SR at:
RT 22. —62 —46
500° F 19. +6
700 21 —2 +1
900 26. iPO
woo —12 —18
1150 LEK
Awow 26 —32 —28
Foil cooled, and SR 1150° F:
lhr 33 —% —36
10 33.5 —10 —20
100 ~~
aDoO
- oro 33 +30 +6
SR + 5% prestr. + SR at:
RT 28. —8 —4
500° F 25. +40 +40
700 26. +31 +27
900 28. +46 +24
1150 SSSSs
Kf
SO
ON +8 +8

184-s APRIL 1959

 Yield strength, Tensile Reduction of Transition
ksi (0.2%) strength, ksi Elongation, % area, % Charpy 15-ft-lb temp., 15 mils
A 203 Grade D
Oil quench, and SR 1150° F
lhr 74.6 90.9 27.5 75.0 —205 —180
10 76.3 92.4 28 75.2 —204 —178
100 74.0 88.0 30 74.8 —160 —160
SR + 5% prestr. + SR at:
RT 93.6 98 .6 23.5 73.0 —198 —172
500° F 103 103 19.5 70.8 —186 —164
700 96.8 100 23.5 72.4 —188 —172
900 89.4 100 26 73.0 —184 —164
1150 77.4 92.0 29 74.0 —202 —188
Foil cooled, and SR 1150° F
lhr 62.4 78.5 31.8 70.5 —130 —130
10 aoe sod sais tee —140 —136
100 63.3 79.6 32.5 71.6 —100 —106
SR + 5% prestr. and SR at:
RT 76.7 85.0 26.5 69.8 —106 —98
500° F 83.2 86.7 26 69.4 —106 —94
700 81.1 87.8 24.5 68.2 —120 —106
900 72.8 85.2 28.5 69.8 —110 —106
1150 66.8 82.0 29 70.8 —122 —130

A 302 Grade B
Oil quench, and SR 1150° F
lhr 87.8 106 21 63.6 —85 —79
10 2.2 108 22.5 62.8 —80 —68
100 82.3 97.8 24 74.7 —100 —%
SR + 5% prestr. + SR at:
RT 105 108 17.7 61.5 —44 —40
500° F 136 136 13 56.1 +4 +4
700 125 125 16.3 58.1 —6 +5
900 - ~ ee ; oF
1150 89.0 105 23.1 63.4 —100 —9%6
Foil cool, and SR 1150° F
lhr 66.4 85.7 27 63.0 —60 —60
10 71.2 88.6 27 63.0 —48 —58
100 60.6 81.4 29 64.1 20 —34
SR + 5% prestr. + SR at:
500° F 84.9 84.6 21.7 60.3 —6 —6
700 94.0 94.1 21.5 58.1 +5 0
900 93.0 96.3 19.3 57.3 —2 —2
1150 3.2 88.0 26 62.6 ~32 —42

HY-65
Oil quench, and SR 1200° F
lhr 104 114 23.5 71.4 —100 —56
10 116 124 23 71.4 —104 —80
100 93.0 104 24.5 73.8 140 —118
SR + 5% prestr. + SR at:
RT 129 129 ed 68.3 34 —18
500° F 136 136 17.2 68.8 —55 +12
700 128 128 20.8 68.8 —65 —10
900 129 130 18 69.0 —80 —48
1200 128 126 22 69.5 84 —36
Foil cooled, and SR 1200° F
lhr 90.1 104 25 70.1 —88 —64
10 94.0 107 25.5 70.8 58 —40
100 81.0 94 26.5 74.3 76 —68
SR + 5% prestr. + SR at:
RT 110 110 19.3 69.0 42 —12
500° F 120 120 17.2 68.5 0 0
700 116 116 18.5 69.4 6 0
900 112 112 22 68.9 —78 —50
1200 106 110 22.5 69.9 —28 —16

WELDING RESEARCH SUPPLEMENT | 185-5

Table 2—Data on Extended Stress Relief and Strain-Aging Tests (Continued)
Yield strength, Tensile Reduction of Transition
ksi (0.2%) strength, ksi Elongation, % area, % Charpy 15-ft-lb temp., 15 mils
T-1 Steel
Oil quench, and SR 1200° F
lhr 126 131 19.5 67.1 —225 —185
10 117 124 21.5 69.4 —190 —148
100 94.4 103 23.5 68.3 —90 —80
SR + 5% prestr. + SR at:
RT 135 136 17.6 66.1 —170 —100
500° F 150 150 14.2 62.8 —148 —98
700 147 147 15.3 65.0 —170 —86
900 138 139 17.0 59.0 —164 —64
1200 119 124 21.0 68.0 —180 —156
HY-80 Steel
Foil cooled, and SR 1100° F
lhr 100 128 21.0 65.2 —140 —76
10 92.8 111 21.5 68.2 —132 —102
100 77.0 95.8 25.5 75.2 —130 —122
SR + 5% prestr. + SR at:
RT 131 131 16.0 64.2 —110 —22
500° F 144 147 14.5 64.4 —30 +10
700 160 160 15 59.0 +24 +96
900 149 149 15.5 59.6 +16 +60
1150 94 151 17.0 3.5 —118 —92
A 387 Grade D
Oil quench, and SR 1350° F
lhr 87.7 102 25 79.7 —168 —142
10 68.2 84.3 30.5 79.0 —102 —98
100 58.3 75.4 35.5 77.2 —38 —46
SR + 5% prestr. + SR at:
RT 94.4 96.6 23.5 79.6 —176 —174
500° F 91.8 91.8 24.5 79.7 —144 —128
700 93.5 93.5 23.5 79.4 —132 —116
900 94.9 98.1 25 77.1 —128 —112
1350 72.0 89.3 31 79.4 —172 —154
Foil cooled, and SR 1350° F
lhr 59.2 89.4 28 77.4 —20 —18
10 53.2 75.3 33.5 79.1 —26 —34
100 50.4 68.5 34 75.6 +18 0
SR + 5% prestr. + SR at:
RT 89.2 93.8 3.5 76.8 —46 —42
500° F 89.7 90.4 22 75.8 —10 —4
700 92.6 93.4 22 75.7 —8 0
900 86.8 93.7 76.0 —4 0
1350 68.2 87.4 30 | —62 —56

: : : i ; ' The other steels decreased 5 to 10%

Spray-Quenched Normalized if spray-quenched, but were little
160 4 ie J affected if normalized. HY-65 steel
™~\ showed age-hardening at 10 hr but
Li o ol . overaging at 100 hr. As shown in
ri = BP Fig. 2, a similar trend is shown in
140 + ° 40 . yield strength for the spray-
* —_ ee ? it - ba quenc shed test s. The 1e elong
elongation of
o s \ - all of the steels improved after
3 ie o—r__ . . \ | 100-hr stress relief.
. — ’ wre a \ According to Fig. 3, the Charpy
> ° o~_s tests revealed that, for the most
= od . '. part, the softening induced by ex-
® 100 fa #2 ea ae » 4 tended stress relief was not ac-
2 t= A387, ae ; wes i — bg ae ;—
2 ° 4835 ¥ uenc an - steels
i _— a —— := + ile ‘— 2 Fo 100° Fembrittlement. Only
sor ° 4 = a io | HY-80 and spray-quenched HY-
rs - sie at 65 were improved, roughly 50

60 i i i i i 1
300 600 900 1200 300 600 900 1200 Fig. 4—Effect of prestraining and reheat-
Aging Temperature -°F ing on the tensile strength

186-s | APRIL 1959

F. The other steels showed very -200 T T T t T T
little change. Spray- Quenched Normalized
s -
All of the steels demonstrated
some sensitivity to strain aging. aE-150 a
Maximum effect is usually observed P-4
at about 600° F. The tensile woc 7
strength rose moderately, as indi- =s la
cated in Fig. 4, to a maximum around F -100 a —__A203 si hae =
600° F and dropped back to un- 8
strained levels when heated to stress- S |
relieving temperatures. Figure 5 Q |
WwW+ 50 HY6S
shows that the Charpy notch tough- E
ness dipped to a minimum around 2 r 39,
600° F and rose again noticeably at
temperatures of stress relieving. :S ae 02 ~
; 0 SHY65 up
This recovery after stress relief is =
important, because it indicates that ntl <.o
strain aging due to cold forming = " anne)
Oo ose
can largely be eliminated by the 50r vary \s 7
usual stress-relief treatments. a
It should be noted that the gains ot ~ 8
in strength and toughness obtained \,
100 i i i i 4. i
by accelerated cooling were not 300 600 900 1200 300 200° 900 1200
wiped out by these simulated fabri-
Aging Temperature- °F.
cation treatments. Also the alloy
steels maintained their superiority Fig. 5—Effect of prestraining and reheating on notch toughness
in strength and notch toughness to
the carbon steels after these treat-
ments. most of steels. A 387 and T-1 steels oratory tests suggest that the im-
showed a 100° F rise in transition provements in strength and in
Summary after 100-hr treatment. notch toughness obtainable from ac-
The following summary can be 3. All of the steels were sus- celerated cooling and from low-alloy
made from the results of this in- ceptible to strain aging. It is im- steels are not jeopardized by these
vestigation. portant to note that the standard fabrication operations.
1. Extended times of stress re- stress-relief temperatures obliter-
lief produced loss of strength and ated practically all of the embrittle- Acknowledgment
increase in ductility in both car- ment induced by prestraining. This investigation was supported
bon and alloy steels. Most spray- 4. An encouraging observation by the Fabrication Division of the
quenched steels decreased 5 to 10% from these results is that accelerated Pressure Vessel Research Com-
in strength, but the highest-strength cooling did not introduce a greater mittee. The aid and advice of the
steels lost as much as 25%. sensitivity to fabrication operations Division members was most valu-
2. Little change in notch tough- such as extended stress relief or able, and the authors are grateful to
ness resulted from long stress relief cold working. Generally, these lab- them.

WRC Bulletin No. 45 Ten Years of Progress in Pressure Vessel Research (1948-1958)
16 pages. Price $1.00.

This bulletin depicts in concise brief form the results of ten years of progress
by the Pressure Vessel Research Committee. It includes five reports as
follows:
A Decade of Progress, by F. L. Plummer
Materials Division Report, by R. D. Stout
Design Division Report, by E. Wenk, -Jr.
Fabrication Division Report, by J. E. Boberg
A Decade of Progress (Conclusion ), by F. L. Plummer
Copies may be purchased from the American Welding Society,
33 West 39th St., New York 18, N. Y.

WELDING RESEARCH SUPPLEMENT 187-s

Corrosion of Stainless-Steel Welds

Formed with Carbon-Dioxide Shielding

Authors compare the effect on weld chemistry

and corrosion resistance of stainless-steel weldments

made under carbon-dioxide shielding with similar welds

made under argon plus one percent oxygen

BY B. E. HOPKINSON AND D. W. McDOWELL

SYNoPsis. It was found that al- percent oxygen. Both single-pass arc. The detailed conditions are
though the carbon content of chromium- and multipass type welds were given in Table 1.
nickel stainless-steel weld metal in- fabricated and examined. The
creases when the welding is carried out Carbon Content of As-Deposited
multipass welds were made to deter- Weld Metal
under an atmosphere of carbon dioxide,
the corrosion resistance is impaired mine if the initial passes in a weld-
ment are sensitized by the heating The Type 308 electrode wire be-
only in multipass weldments. The fore deposition analyzed 0.04% C
resistance to corrosion was evaluated from subsequent deposits. The cor-
rosion resistance of the weld metal and the 308ELC 0.03% C. After
by testing in boiling 65% nitric acid,
and ferric sulfate-sulfuric acid solu- was determined by the boiling 65% welding, the carbon content in-
tions. In multipass welds the earlier nitric acid and the ferric sulfate- creased to the levels shown in Table
passes are presumably sensitized by sulfuric acid tests. 2. The carbon content of the car-
the subsequent heating during later bon-dioxide-shielded weld metal in-
welding operations. Single-Pass Cross Welds creased by about 100° compared
The changes in chemical composition to the original value, with a tend-
caused by welding under carbon dioxide Material and Welding Procedure
ency for the short arc to pick up
are related to the weld structure. All welds were made on Types slightly more carbon than the long
304 and 304ELC stainless-steel are.
Introduction '/,in. plates by the consumable-
The use of carbon dioxide as a are technique, the electrodes used Corrosion Tests of Welded Plates
shielding gas in consumable-arc being either Type 308 and 308ELC, The cross-weld plates were tested
welding has generally been confined and the shielding gas, carbon di- as-welded (after scrubbing with
to carbon steel. Its use in welding oxide or argon plus one percent pumice) in boiling 65% nitric acid,
stainless steels has been retarded by oxygen. To investigate the effect following the standard ASTM A-
the possibility of carbon pickup of arc length, deposits were laid 262-55T specification. The results
from the gas, followed by chrom- down with either a long or short of the test are given in Table 3.
ium-carbide precipitation and sensi-
tization of the weld metal. Some
experimental work on the welding
of stainless steel with the carbon- Table 1—Welding Conditions for Carbon-Dioxide and Argon-Shielded Cross Welds
dioxide-shielded consumable - arc
technique has been reported pre- Amp,
reverse Welding Wire
viously.'~* These reports consid- polarity speed, feed
ered changes in the weld chemistry Shielding gas dc Voltage Arc length ipm speed, ipm
caused by carbon-dioxide shielding Carbon dioxide
but no detailed corrosion data (a) Long arc 300 37.5 '/s 20 205
were given. This paper compares (b) Short arc 300 30.0 Electrode tip 20 205
the effect on weld chemistry and at plate surface
corrosion resistance of stainless- Argon + 1% oxygen 300 47.5 9/16 20 205
steel weldments made under car-
bon-dioxide shielding, with similar
welds made under argon plus one Table 2—Carbon Content of Weld Metal As-Deposited on 304 or 304ELC Plate
B. E. HOPKINSON is a Research Chemist, Re- Type 304ELC plate
search Laboratory, the International Nickel Co., Type 304 plate carbon, wt % carbon, wt %
Inc., Bayonne, N. J., and D. W. McDOWELL is Shielding gas 308 308ELC 308 308ELC
with the Development and Research Division of
the International Nickel Co., Inc., 67 Wall St., Argon + 1% oxygen 0.04 0.04 0.05 0.05
New York City. Carbon dioxide (short arc) 0.09 0.08 0.07 0.07
Paper to be presented at the AWS 40th Annual Carbon dioxide (long arc) 0.08 0.08 0.05 0.06
Meeting to be held in Chicago, Ill., April 6-10,
1959.

188-s | APRIL 1959

Table 3—Corrosion Rate of Cross-Welded Specimens in the Boiling 65% Nitric-Acid Test (Huey Test)
Corrosion rate, mils per month
Type 304 plate Type 304ELC plate ;
Type 308 electrode Type 308ELC electrode Type 308 electrode Type 308ELC electrode—
Carbon Carbon Carbon Carbon Carbon Carbon Carbon Carbon
Exposure Argon + dioxide dioxide Argon+ dioxide dioxide Argon+ dioxide dioxide Argon+ dioxide dioxide
time, 48-hr 1% (short (long 1% (short (long 1% (short (long 1% (short (long
periods oxygen arc) arc) oxygen arc) arc) oxygen arc) arc) oxygen arc) arc)
First 1.01 1.40 1.24 ‘a3 1.44 1.31 1.03 1.07 1.03 0.99 1.30 3.33
Second 0.68 0.75 0.89 0.73 0.83 0.70 0.73 0.80 0.74 0.59 0.85 0.89
Third 0.64 0.77 0.71 0.66 0.79 0.76 0.58 0.74 0.86 0.72 0.88 0.92
Fourth 0.65 0.76 0.77 0.66 0.77 0.85 0.62 0.78 1.05 0.71 0.98 1.03

Penetration rates obtained in specimens tended to show an in- JOINT DESIGN

this way are not too meaningful for crease of calculated penetration rate bo",
the detection of sensitization. with time, but all specimens aver- Nes “ ™
However, the actual values ob- aged less than 0.001 in. per month. ( Peer
tained are within the normal ac- However, no significant differences ¢ ; ee tS oe
ceptable limits of this test and no ) 11
in weight losses between the argon 4 —— ae \
significant difference was noted be- and the _ carbon-dioxide-shielded i/ieiv! RO
tween welds made under carbon specimens were seen.
dioxide or argon plus one percent In the ferric sulfate-sulfuric acid WELDING SEQUENCE
~
oxygen. A microexamination con- test, again no large difference in { —--——_—_————— 4
firmed that the difference in cor- corrosion rate between specimens * re {
rosion behavior between single-pass was observed but, as shown in pst Af\
welds made under a shielding atmos- Table 7, the argon-shielded weld- 2 _<~+ Re
phere of carbon dioxide or argon ments, and the specimen made
plus one percent oxygen is negli- by a Type 310 electrode with carbon- Fig. 1\—Joint design and welding sequence
gible.
Multipass Welds
Table 4—Composition of Electrode Wire and Base Plate in Weight Percent
Materials and Welding Procedure for Multipass Welds
With the consumable-arc tech-
nique, double-vee butt joint welds Man- Chrom- Molyb- Phos-
were made on Type 347 one- Type of wire Carbon ganese Silicon Nickel ium denum Sulfur phorus
inch plates. The carbon-dioxide- 308ELC 0.024 1.66 0.52 9.91 20.41 0.10 0.020 0.022
shielded deposits were laid down 308 0.067 1.83 0.36 9.90 20.16 0.13 0.023 0.019
310 0.102 1.80 0.40 21.88 27.05 0.02 0.009 0.011
from Types 312, 308, 308-ELC, 312 0.100 1.83 0.43 9.49 29.25 0.08 0.014 0.021
310 and 347 electrodes. Also, 347 0.045 1.87 0.57 10.07 21.24 0.011 0.023
similar welds were made _ by Base plate of
Types 347 and 308-EL Celectrodes Type 347 steel 0.062 1.86 0.70 11.41 19.03 00.12 0.025
with argon as a shield gas. A Note: The 347 electrode contained 0.75 Cb + Ta and the 347 plate 0.71 Cb + 0.05 Ta
Type 310 joint was not satisfac-
tory under argon shielding because
of cracking. Six passes were laid
down in the sequence shown in Table 5—Welding Conditions for Carbon-Dioxide and Argon-Shielded Multipass Welds
Fig. 1. The underside of pass No.
Welding speed, Wire feed
1 was ground out before pass No. 3 Pass no. Amp Volt ipm speed, ipm
was deposited. An analysis of the
electrodes before welding, the weld- Carbon dioxide
1 260 31 16 160
ing conditions and X-ray examina- 2-6 320 31 14 225
tion of the completed welds are Argon + 1% oxygen
given in Tables 4, 5 and 6 respec- 1 320 28 13 180
tively. 2-6 350 29 ll 210
The gas flow was 40 cfh for both gases
Corrosion Tests
Specimens two inches by one inch
were machined from the welded
plates as in Fig. 2. They were Table 6—Electrode Wires Used in Making the Multipass Weldments
tested in duplicate, as-welded (after on Base Material Type 347
scrubbing with pumice) in both the
standard boiling 65% _nitric-acid Specimen
plate-code Wire used X-ray examination of weld Shielding gas
test, and the ferric sulfate-sulfuric
1104-57 312 Clear poor wetting Carbon dioxide
acid test developed by M. A. Strei- 1104-58 308 Clear poor wetting Carbon dioxide
cher. The weight-loss data are 1104-59 308ELC Clear Carbon dioxide
again not very meaningful and only 1104-60 310 Clear poor wetting Carbon dioxide
the ferric sulfate-sulfuric acid re- 1104-61 347 Clear Carbon dioxide
sults are included. 1104-62 347 Scattered light porosity Argon + 1% oxygen
In the nitric-acid test, both the 1104-64 308ELC Three small holes Argon + 1% oxygen
argon and carbon-dioxide-shielded

WELDING RESEARCH SUPPLEMENT | 189-s

Fig. 2—Appearance of specimens after Huey and Streicher test. A, 1104-57, Type 310, CO.; B, 1104-58, Type 308, CO.; C, 1104-59,
308ELC, CO.; D, 1104-60 Type 310, CO,; E, 1104-61, Type 347, CO.; F, 1104-62, Type 347, argon + 1% oxygen; G, 1104-64: 308-ELC,
argon + 1% oxygen

Table 7—Corrosion Rate of Multipass-Welded Specimens in the

Boiling Ferric Sulfate-Sulfuric Acid Test (Streicher Test)
Corrosion rate after 120 hr,
Specimen Electrode mils per month
plate-code wire used Shielding gas Average
1104-57 312 Carbon dioxide (A) 2.38 2.64
(B) 2.90
1104-58 308 Carbon dioxide (A) 3.76 3.12
(B) 2.49
1104-59 308ELC Carbon dioxide (A) 2.42 3.03
(B) 3.64
1104-60 310 Carbon dioxide (A) 2.46 2.23
(B) 2.01
1104-61 347 Carbon dioxide (A) 2.49 2.80
* os ; ‘ (B) 3.11
Ain»~! %, t Uy ttn fae y 1104-62 347 Argon + 1% oxygen (A) 2.72 2.64
(B) 2.56
Fig. 3—Section through corroded weld 1104-64 308ELC Argon + 1% oxygen (A) 2.31 re
metal of weldment No. 1104-59, showing
the attack tending to follow ferrite areas.
Etched: Glyceregia. xX 500. (Reduced
by '/; upon reproduction)
dioxide shielding, tended to be lower and 1104-61, but extending up to
than the others. ten mils on specimen 1104-59.
After the tests had been carried Microexamination
out, general inspection of the speci-
A transverse section across all the
mens indicated that in both the
passes was prepared for each speci-
Huey and Streicher tests the initial
men. Also a section showing the
passes of the carbon-dioxide shielded
interface between the weld metal in
weldments had been attacked more
the area of passes three and four
severely than the later passes, and
and the base metal was prepared for
that the argon-shielded welds did
each of the carbon-dioxide-welded
not exhibit this attack. Figure 2
specimens.
shows the specimens after exposure
The results of the microexamina-
to the boiling 65% nitric acid test.
tion showed no indication of knife-
It is seen that specimens A(1104
line attack, or any heat-affected
57), B(1104—-58), C(1104-59), and
zone in the base 347 plate. On
E(1104-61) have been heavily
etching with glyceregia, a duplex
etched. There wassome slight etch-
structure of ferrite in austenite was
ing on the number D(1104-60)
brought out in the weld metal on all
specimen, but none on F(1104-62)
the specimens except 1104-60, which
and G(1104-64). The etched areas
is fully austenitic.
appear to correspond to passes three,
In Fig. 2 the attacked areas are
four and the part of one remaining
clearly seen in the welded specimens
after “‘grinding out.’’ The depth of
when carbon dioxide is used as a
attack in the earlier passes was meas-
shielded gas. A cross section of an
ured with a vernier microscope.
area denoting this corrosion is shown
Specimens exposed to the Huey test
in Fig. 3. It appears that the at-
were not heavily attacked, and pene-
tack taking place is associated with
tration was less than one mil on all
specimens. In the ferric sulfate- the ferrite areas.
Fig. 4—Electron photomicrograph of Chemical Analysis of Weld Metal
specimen 1104-57—outer passes of weld, sulfuric acid test, however, deeper
showing ferrite in austenite matrix. penetration in the inner passes was Samples for analysis were re-
Etched: picric/HCl. x 4500. (Reduced observed, viz., approximately two moved from as-welded material at
by '/; upon reproduction) mils on specimens 1104-57, 1104-58 two areas. One sample was taken

190-s | APRIL 1959

Table 8—Analysis of Weld Metal
, Carbon, % —_ - —Silicon, %— Manganese, %—-—.
Specimen Electrode Area not’ Sensi- Area not Sensi- Area not Sensi-
plate- wire sensi- tized sensi- tized sensi- tized
code used Shielding gas tized area Mean tized area Mean tized area Mean
1104-57 312 Carbon dioxide 0.15 0.13 0.14 0.37 0.45 0.41 1.62 1.64 1.62
0.36 0.46 1.66 1.76
1104-58 308 Carbon dioxide 0.12 0.12 0.12 0.34 0.40 0.37 1.76 1.52 1.67
0.34 0.41 1.76 1.52
1104-59 308ELC Carbon dioxide 0.11 0.10 0.10 0.44 0.49 0.46 1.42 1.46 1.48
0.44 0.48 1.48 1.56
1104-60 310 Carbon dioxide 0.15 0.12 0.13 0.43 0.46 0.44 1.56 1.56 1.59
0.43 0.46 1.64 1.60
1104-61 347 Carbon dioxide 0.11 0.11 0.11 0.45 0.50 0.48 0.42 1.52 1.50
0.47 0.51 1.48 1.58
1104-62 347 Argon + 1% oxygen 0.05 0.54 sn 0.55 1.62 ore 1.67
0.57 1.72
1104-64 308ELC §=Argon + 1% oxygen 0.026 0.51 0.51 1.56 ae 1.61
0.51 1.66

from the area corresponding to that from 4 to 22%. The results show outer resistant passes. The result-
which had been most heavily at- some difference between the sensi- ing micrographs are shown in Figs.
tacked in the Huey and Streicher tized and unsensitized areas but it 4, 5, 6, 7 and 8.
tests and the other from the less is not possible to determine if this is
severely corroded region. An anal- significant data or an artifact. Determination of Ferrite
ysis was made for carbon, silicon Table 9 indicates the ferrite con-
Electron-Microscope Examination tent of the as-welded metal, deter-
and manganese; the results are of the Weld Metal
given in Table 8. In this table, the mined by three different methods.
two areas are designated sensitized Since no obvious difference in the The Schaeffler diagram values have
and unsensitized, respectively. The chemical composition, structure or been obtained from Fig. 9, and the
carbon pickup varied according to carbide precipitation could be de- values of carbon, silicon and man-
the amount initially present in the termined by the usual chemical and ganese were averages from the sensi-
wire and, for instance, shows a analytical techniques, selected speci- tized and unsensitized areas.
variation from a 12% gain with mens were examined by the electron Magna-gage readings were taken on
Type 347 wire to 360° for Type microscope. The technique used the inner and outer passes with
308ELC wire. The total amount consisted of etching with hydro- magnet Number 3. The closer
of carbon increased to between 0.10 chlorie acid-picric acid solution and proximity of the base metal may
d 0.15%. stripping
, a negative replica
, of interfere with the accuracy of the
“ Manganese: and silicon were de- parlodion. After germanium shad-
pleted by the welding process in owing, areas were examined from
some cases. The silicon loss varied the inner passes that had suffered
from zero to 20%, the manganese corrosion in the tests, and from the

Fig. 5—Electron photomicrograph of Fig. 6—Electron photomicrograph of spec- Fig. 7—Electron photomicrograph of spec-
specimen 1104-61—outer passes of weld, imen 1104-57—inner passes of weld, imen 1104-6l1—inner passes of weld,
ferrite in austenite matrix. Etched: precipitate forming along the ferrite precipitate forming along the ferrite
picric/HCl. x 4000. (Reduced by '/; periphery. Etched: picric/HCl. x 7500. periphery. Etched: picric/HCl. > 5000.
upon reproduction) (Reduced by 45% upon reproduction) (Reduced by '/, upon reproduction)

WELDING RESEARCH SUPPLEMENT | 191-5

 P*co out under carbon dioxide but, even
RT In = —40,800 + 41.7T
Peo: x a(c) so, in some cases the loss is very
to calculate the equilibrium carbon- small. Also, van der Willigen and
monoxide content of carbon mon- Defize’ found that increasing the
oxide-carbon dioxide mixtures over arc length increased the oxidation of
iron of different carbon levels. silicon and manganese. These
They obtained typical values of changes in weld composition during
97% carbon monoxide over iron fabrication are probably responsible
containing 0.05% carbon at a tem- for the ability to weld stainless steel
perature of 1600° C, increasing to Type 310 under carbon dioxide but
99.2% carbon monoxide over iron not under argon shielding. Varia-
containing 0.05% carbon at 2000° C. tions in the carbon-silicon ratio to a
Therefore, the tendency to carbur- more favorable value are no doubt
ize will be higher; if the dissociation responsible for this.
of carbon dioxide to carbon mon- The increase in carbon and de-
oxide in the arc is large, if the orig- crease of silicon and manganese con-
inal carbon content of the electrode tent affect the resultant structure of
is small and if the temperature at all ferrite-containing weld metal,
which this dissociated gas comes into and ultimately its physical proper-
contact with the iron is low. They ties. Therefore, an estimation of
Fig. 8—Electron photomicrograph of concluded that in the conditions set the ferrite content before and after
specimen 1104-60, precipitate in the up during welding under carbon welding, and the effect of the carbon-
grain boundaries. Etched: picric/HCl. dioxide, a tendency for decarburiza- dioxide shielding gas is required.
<x 7500. (Reduced by '/; upon repro- tion will occur if the electrode wire A Schaeffler diagram was con-
duction) is over 0.07% carbon. When it is structed as in Fig. 9, and Table 10
below 0.07% carbon, carburization shows that welding under carbon
results. dioxide does cause a reduction in
readings on the inner passes, and no In this work, the single-pass welds ferrite content of the weld metal
readings were taken in this area for increased to a carbon level of about compared with no change using
the argon-welded specimens. 0.07%, whereas the multipass weld- argon. To confirm the Schaeffler
Discussion ments increased to 0.10—-0.15%. diagram values, ferrite determina-
Tables 2 and 8 shows that the This level of 0.10—0.15 could be an tions were also made with a Magna-
carbon content of the deposited equilibrium value and welds made gage and by X-ray diffraction. The
weld metal increased when the weld- with high-carbon stainless-steel elec- X-ray results are of little value as
ing had been carried out under car- trodes may be decarburized by weld- can be seen in Table 9. The
bon dioxide. The mechanism of ing under carbon dioxide. Further Magna-gage values agree fairly well
carbon pickup by the weld metal work would be needed to elucidate with the Schaeffler diagram except
has been considered by Rothschild! this point, but Medovar, et al.,‘ in specimen Number 1104-57.
and van der Willigen.’ At arc found austenitic steel electrodes The corrosion tests in boiling 65%
temperatures of 6500° K, the carbon containing 0.1% carbon did not in- nitric acid and ferric sulfate-sulfuric
dioxide must be dissociated to car- crease in carbon content during acid revealed some difference be-
welding under carbon dioxide. tween single-pass cross welds, and
bon monoxide and oxygen, but at
lower temperatures around the arc, The decrease in manganese and the multipass double-vee joints.
mixtures of carbon monoxide and silicon content when making carbon- The single passes appeared satis-
carbon dioxide will exist. dioxide-shielded stainless-steel welds factory, but earlier passes of the
* Since carbon monoxide is a weakly has been observed by various work- multipass weldments were prefer-
carburizing gas and carbon dioxide ers.'~* In most cases, the loss was entially corroded as seen in Fig. 2.
is decarburizing, then the carbon small, but Rothschild' and Eskin, The ferric sulfate-sulfuric acid solu-
increase in the weld metal must be et al.,? report losses of about 10— tion produced deeper attack than
brought about by changes in the 20% of both silicon and manganese. the boiling 65% nitric acid. There-
equilibrium The magnitude of silicon and man- fore, if these tests are to be taken
ganese depletion in these experi- as the sole criterion, the sensitiza-
2CO = (C) + CO, ments is shown in Tables 4 and 8. tion is due to carbide precipitation
where (C) is the carbon dissolved in It will be seen that the tendency to since the ferric sulfate-sulfuric acid
the austenite. van der Willigen lose both these elements is greater solution does not respond to sigma
and Defize used the equation when the welding has been carried sensitization.®

Table 9—Ferrite Content of Weld Metal

X-ray
Magna-gage Schaeffler ——% ferrite -
Specimen Electrode —- ——& ferrite-— ——_—_~ diagram (Inner- (Outer-
plate-code wire used Shielding gas (Innerpasses) (Outerpasses) % ferrite passes) passes)
1104-57 312 Carbon dioxide 13 18 32 3 56.0
1104-58 308 Carbon dioxide 1 2 3 5.5 <1.0
1104-59 308ELC Carbon dioxide 3 4 5 21.0 3.5
1104-60 310 Carbon dioxide None None None None None
1104-61 347 Carbon dioxide 4 6 7 6.5 6.0
1104-62 347 Argon + 1% oxygen Not taken 13 14 41.0 5.0
1104-64 308ELC Argon + 1% oxygen Not taken 12 12 11.0 5.5

192-s | APRIL 1959

 LEGEND
Plate 1104-57 312
AUSTENITE O -Before Welding
@ -After Welding
Plate 1|04-58 308
C - Before Welding
@ -After Welding
Plate \104+-59 308 ELC
© -Before Welding
@ -After Welding
Plate 1104-60 310
A - Before Welding
& - After Welding
Plate 1104-61 347
-Before Welding
-After
ter Wintding

|a e ae Plate 1104-62 347

| FEARITE Before + After
= n-
Ni
+O.5@
Nickel
Equivalent
+30*%C
»%Mn ~T os Welding
2 a » 8 1o 2 1+ 16 18 20 22 2e¢ 2 30 32 3+ 3e 3 40 Plate |104-63 ZBO8ELC
Chromum Equivalent =%Cr + % Mo +1.5*%5i +0.5 *% Cb ©- Gefore + After
Welding’
Fig. 9—Schaeffler diagram showing the changes in ferrite content caused by welding under carbon dioxide

A photomicrograph of the attack It is difficult to assess the impor- Triadis, L. S. Lemanski and Mrs. L.
shown in Fig. 3 indicates that the tance of these laboratory corrosion Pellier. We also wish to thank
attack is following ferrite areas and tests in relation to actual use in the H. R. Copson for helpful discussion.
no network of carbides can be seen. field. In the first instance, the Finally for permission to publish
The effect of delta ferrite on cor- inner passes will usually be covered the paper we thank the manage-
rosion resistance has been sum- by unsensitized material and, fur- ment of the International Nickel
marized by LaQue* and some ex- ther, the actual environments may Co., Inc.
perimental data have been pre- be much less aggressive than the :
sented by Bloom and Carruthers’ testing solution. To sum up, there- References ae
on the corrosion of ferrite /austenite fore,“ these results indicate that- N ..)),
2ide Hothechild, able-GR. lec de yng 2 ry .
welds. The presence of delta fer- stainless steel may be welded in THE WELDING JOURNAL, 35 (1), 19-29 (1956).
rite per se does . not often lead to carbon dioxide ‘ . without impairing 2. Eskin, E. M., Pogozhkin,
Novoshilov, N. M., “Properties of Welds Made E. P., and
enhanced corrosion, but transfor- the corrosion resistance. However, Under Argon and Carbon Dioxide,” Svarochnoe
mation to a sigma phase can cause if multipass welds are made, some Proizvodstvo, 1 (1), 15-17 (1957)
t bl bo h fi I f l nai iti ti f tl . li & t 3. Zaruba,I. 1. and Potapevskii, A. G. ““Auto-
rouble t rom ap nysica prop- sens za ion o 3 ne ear ler Passes : O matic Welding of Thin Steel in Carbon Dioxide
erty and corrosion point of view. boiling 65% nitric acid and ferric- Gas Medium,” Avtomat. Svarka, 10 (3), 22-27
ic
Streicher" 10has shown that ferrite : in: ‘ate.
sulfate-sulfuric [7 acid
ac .
can _
occur. In 1957Stes Oo. Se te ee
an austenite casting does not cause practice, this possible danger would Rublevskii, I. N., “Oxidation of Austenitic Elec-
enhanced attack in the . ferric . sul- _ have
. to be balanced . against . the de- _ ‘rede,as, Rods a., During 3), ©Welding
ps 957).in Carbon Dioxide
fate test; therefore, in these inner sirable feature associated with weld- 5. Medover, B. I. and Rublovekil, L N.
passes some more factors must be ing under an atmosphere of carbon “Problems of Welding in Carbon Dioxide of
*
involved than the presence of ferrite. . - :
dioxide. Austenitic
ant Alloys,”Chrome-Nickel
Ibid., 10 (3), Steels
70-84 and(1957).
Heat-Resist-
Since normal metallographic tech- pe led 6. Streicher, M. A ee Se
niques had not produced any con- , ee ASTM Bulletin No. 229, 77-86 (April 1968).
clusive results, the electron micro- The authors wish to thank A. 7. van der Willigen, P. C. and Defize, L. F.,
scope was used to study- the ferrite Lesnewich ° and G. °R. Rothschild
. of “CO: (Mz
69-77 oo956 van Staal,” Lastechniek, 22,
pools. Negative replicas of the the Welding Section, Air Reduc- 8 LaQue, F. L., “Introductory Summary,”
sensitized and unsensitized passes tion Ce. Inc. for making the welds. Symposium on Evaluation Tests for Stainless
were taken and examined. ° +:
Figures :
For the chemical analysis, .
: assistance Sed aAm.ER Socthe Testing
Steels, OF Mats., 1-39 (1949)
4 through 7 illustrate the results. with the experimental work and 9. Bloom, F. K. and Carruthers, M. E.,
‘ oe ° rlar Pe . ‘ n- “Accelerated Corrosion Testing of Chromium-
The outer passes, especially in electron mic tee sy ad: they are im Nickel Stainless Steel Weldments,” [bid., 87-100.
Fig. 4 show clean-ferrite deposits, debted to C. M. Davis, D. N. 10. Streicher, M. A., Private Communication
whereas the inner passes, i.e., Fig. 6,
have a precipitate forming along the
periphery. In the fully austenitic Table 10—Change in Ferrite Content by Welding in a CO. Atmosphere (from Fig. 9)
1104-60, a precipitate is present in Percentage
the grain boundaries as shown in Ferrite content Ferrite content decrease of
Fig. 8 and no apparent difference Specimen Electrode before weld- after weld- initial ferrite
was observed between the outer and plate-code wire used ing, % ing, % content
inner passes. One would expect the 1104-57 312 45 32 29
precipitate to be carbide from the 1104-58 308 7 3 57
data available, since sigma forma- 1104-59 308ELC 12 5 58
tion is not usually associated with 1104-60 310 No ferrite No ferrite a
welding temperatures and _ times sore “ = Rs a
other than in high-molybdenum 1104-64 308ELC 12 12
steels, such as Type 316.

WELDING RESEARCH SUPPLEMENT | 193-s

 Effects of Hydrogen Brazing

on Properties of High-Temperature Alloys

Eight alloys used for fabricated jet-engine components

are subjected to brazing thermal cycles and subsequently tested

for tensile and stress-rupture properties

BY G. S. HOPPIN IIl1 AND E. N. BAMBERGER

SUMMARY. The necessity for light- weakest high-temperature alloys in- the nickel-base brazing filler mate-
weight, high-strength components for curred the greatest strength losses, rials are being used. These mate-
aircraft power plants has resulted in which in most cases were irrecoverable. rials possess the high strength and
the use of brazing with nickel filler Conversely, the strongest alloys ex- oxidation resistance that the silver
metals as a means of joining high- hibited the least loss of properties and, alloys lack, but in turn present
temperature sheet-metal parts. An in most instances, responded to post-
inherent problem in this method is the brazing heat treatments. several problems of their own.
harmful effect on base metals of the Many of the problems inherent
high temperatures (usually above Introduction in brazing with the nickel-base
2000° F) needed to perform the braz- The advent of highly supersonic brazing filler metals relate to the
ing operation in hydrogen atmos- airplanes and aircraft power plants properties of the filler metals them-
pheres. These temperatures, as a have forced metallurgists and selves. These filler metals are all
rule, are significantly in excess of those welding engineers to provide ultra- relatively brittle and tend to
prescribed for the normal heat treat- light weight, high-strength, high- “erode” (or dissolve) thin-sheet
ments of heat-resistant alloys. base metal at their relatively high
To define quantitatively the extent temperature components. Brazed
of changes in base-metal strength re- fabrications of thin sheet metal are brazing temperatures (generally
sulting from brazing temperatures, being used increasingly to attain above 2000° F). Careful pro-
eight alloys currently used for fabri- this difficult combination of char- cedures, however, have been de-
cated high-temperature jet-engine com- acteristics. For components oper- veloped to minimize these problems
ponents were subjected to brazing ther- ating at 800° F or less, silver brazing inherent in the brazing materials.
mal cycles, and subsequently tested for is satisfactory for these fabrications. Another problem encountered in
tensile and stress-rupture properties. Above 800° F, silver brazing be- using the nickel-base brazing filler
In these cycles, the subject materials comes unsatisfactory, due to the metals is completely independent
were exposed for 1 hr at temperatures of the properties of the filler metal.
above 2000° F with a maximum tem- low strength and poor oxidation
perature of 2240° F. resistance of silver-brazing filler This is the effect on base-metal
Materials investigated in this study materials above this temperature. properties of exposure to the high
were: nonheat-treatable austenitic For parts operating above 800° F, brazing temperatures needed. To
stainless steel Type 310, heat-treat-
able martensitic stainless steel Type 2400 ——— r
410, age-hardenable stainless steel 17-7 2200 } cues wee
PH, iron-base, age-hardenable super-
alloy A-286, nickel-base, age-harden- 2000 |- | ANNEALING
CYCLE — i a a
able superalloy Inconel 702, nickel-base,
age-hardenable superalloy René 41, 1800 } — ‘ :
cobalt-base age-hardenable superalloy Temp (°F) | —_f-
J-1570, cobalt-base, nonage-hardenable
superalloy L-605.
The alloys investigated exhibited
strength losses and microstructural
changes to varying degrees. Several of
the alloys suffered irrecoverable
strength losses, whereas several others
responded to postbrazing cycle heat
treatments which fully or partially re-
stored their original strength levels.
It was noted that, generally, the
G. 8. HOPPIN III and E. N. BAMBERGER
are associated with the Metallurgical Engineering,
Flight Propulsion Laboratory Department, 4 5
General Electric Co., Evendale, Ohio. TIME (HRS.)
Paper to be presented at the AWS 40th Annual Fig. 1—Comparison of high-temperature brazing thermal cycle
Meeting to be held in Chicago, Ill., Apr. 6-10,
1959. with normal annealing cycle for Inconel

194-s | APRIL 1959

 minimize distortion, virtually all high temperatures were not highly
brazing of aircraft-engine sheet- loaded in subsequent service, little Table 3—Normal Heat Treatments of
metal assemblies is done in hy- attention was paid to the effect of Alloys Studied
drogen-atmosphere furnaces. As high brazing temperatures on base- Alloy Heat treatment
heating to and cooling from the metal properties. This effect first Type 310 None
brazing temperature is nearly uni- became a serious problem for the L-605 Anneal at 2200° F, air cool
form over the entire assembly, Aircraft Gas Turbine Division of Type 410 1750° F, 30 min, air cool;
very little distortion occurs. The the General Electric Co. in 1955. 1050° F, 2 hr, air cool
entire assembly is, however, sub- A relatively large experimental ro- 17-7 PH 1750° F, 10 min, air cool;
jected to considerable times at tating part of Inconel had been refrigerate at —100° F, 8
temperatures above normal heat- brazed with a _nickel-base filler hr; 950° F, 1 hr, air cool
treatment temperatures. The metal in a brazing cycle with a A-286 1800° F, 1 hr, water quench;
larger the part in a given furnace, maximum temperature of 2150° F. 1350° F, 16 hr, air cool
Inconel 702 1975° F, 1 hr, water quench;
the slower are the heating and After fabrication, the part was cold 1450° F, 5 hr, air cool
cooling rates, and the longer is the spin tested. At 80% of rated speed, J-1570 2150° F, 30 min, water
time above normal heat-treatment severe yielding of the Inconel oc- quench; 1650° F, 4 hr, air
temperatures. curred, and the part had to be cool
As long as parts being brazed at scrapped. (It was then necessary René 41 2150° F, 30 min, water
quench; 1650° F, 4 hr, air
cool
I-BRAZE PLUS AGE

TEMPERATURE

TimE
I-BRAZE PLUS NORMAL SOLUTION ¢ AGE

TEMPERATURE

——>

Fig. 2—Two thermal treatments for brazed age-hardenable alloys

Table 1—Tensile Properties of Inconel as Influenced by a High-Temperature

Brazing Thermal Cycle
0.02% 0.2%
offset offset
Test Ultimate yield yield Fig. 3—Sixty-inch retort diameter
tempera- strength, strength, strength, hydrogen bell-brazing furnace
Condition ture, °F psi psi psi
Mill annealed 2150° F cycle” Room 105,000 37 ,000 47 ,000 to redesign the part at a weight
Room 84,800 15,700 22,500 penalty to eliminate brazing.) Some
Mill annealed 2150° F cycle” 800 97 ,500 30,000 36 ,500 tensile tests were then performed
800 76 ,600 13,300 16,700 on normally heat-treated Inconel,
Mill annealed 2150° F cycle* 1000 92,400 32,000 37,400 and on material which had gone
1000 72,000 12,500 15,400 through the 2150° F brazing cycle.
* See Fig. 1 Results of these tests (Table 1)
conclusively showed that the brazing
treatment had more than halved
the yield strength of the Inconel.
Table 2—Nominal Chemical Compositions of Alloys Studied A comparison of the normal an-
- Element, % nealing cycle for Inconel with the
Alloy Cc Ni Cr Mo Co W Ti Al Fe Other treatment received by the brazed
Type 410 0.15 m 0.50 m 12.5 Bal. Mn—1.00 m part (Fig. 1) gave a good clue to the
1 Si—1.00 m cause of the strength loss. The
Type 310 0.10 20 25 Bal. part had spent over an hour and a
17-7 PH 0.07 7 17 aa .. 1.10 Bal half at temperatures up to 350° F
A-286 0.05 26 15 l 2.0 0 Bal V—0.3 over its normal annealing tempera-
Inconel 702 0.02 Bal. 15 3 0.5 3.0 0.35 ture. Photomicrographs showed
J-1570 0.20 30 20 > We Ge 42 9a: oh
Ren’ 41 0.16 Bal. es oe” Be ce ae Le oe that this had resulted in excessive
L-605 0.10 10 19.5 Bal. 14.5 2.5 B—0.04 grain growth, which correlated with
the strength loss.

WELDING RESEARCH. SUPPLEMENT | 195-s

 Immediately following the ex- B, heat-treatable martensitic stain- and stress-rupture testing were pre-
perience with this brazed part, a less steel, Type 410; C, age-harden- pared from all the heat-treatable
series of investigations was initiated able stainless steel, 17-7 PH; D, alloys save Type 410 and 17-7 PH
to determine how the mechanical age-hardenable superalloys, A286 stainless steels. Of the three sets,
properties of a number of other (iron base), Inconel 702 (nickel one was given the normal heat
high-temperature alloys were af- base), René 41 (nickel base), J1570 treatment for the particular alloy,
fected by high-temperature hydro- (cobalt base) and E, non age-harden- while the remaining two were run
gen-furnace brazing cycles. This able superalloy, L605 (cobalt base). through a hydrogen-atmosphere fur-
paper describes the bulk of these nace brazing cycle with a maximum
investigations and reports the sig- Processing of Test Samples temperature of 2240° F. Following
nificant results obtained. Three sets of samples for tensile this cycle, one set of samples was
Materials Investigated
Alloys selected for this study were
chosen on the basis of current or Table 4—Effects of a Brazing Cycle on Mechanical Properties
foreseeable application in brazed of Type 310 Stainless Steel
jet-engine components. Two of the
alloys chosen have excellent oxi- Tensile-test results
dation resistance in the 1800-—2000° 0.2% offset
Test Ultimate strength, yield strength,
F temperature range, while the Condition temperature, ° F psi psi Elongation, %
balance are representative high 39,400 43.0
Mill anneal Room 85,500
strength materials for application at After brazing cycle Room 80,000 28 , 800 45.0
temperatures in the range 800—2000° Mill anneal 1500 26 , 700 19,400 36.0
F. All alloys were tested in 0.063- After brazing cycle 1500 28,500 15,900 25.0
in. thick sheet form. Nominal com- Mill anneal 2000 2400 7200 43.0
positions of the alloys are listed After brazing cycle 2000 2250 7200 37.0
in Table 2, while Table 3 lists
Stress-rupture test results
normal heat treatments for these
alloys. Condition Test temperature, ° F Stress, psi Hours to rupture
The alloys’ investigated can Mill anneal 1200 19,000 578
roughly be divided into five groups. After brazing cycle 1200 19,000 573
These are: A, nonheat-treatable Mill anneal 1500 5700 506
austenitic stainless steel, Type 310; After brazing cycle 1500 5700 262
Mill anneal 1800 1700 464
After brazing cycle 1800 1700 227

1
TEMPERATURE
bs ,

5 4 5 >
TIME (hrs)
Fig. 4—Brazing thermal cycle for 2240° F
maximum temperature in bell-brazing
furnace

40

20
A]
MONE =. B min 30min = 60min
TIME AT 2240"IN HYDROGEN PRIOR TO
NORMAL HEAT TREATMENT
Fig. 6—Microstructures of Types 310 and 410 stainless steels. Before and after exposure
Fig. 5—Effect of time at brazing tempera- to 2240° F maximum temperature brazing cycle. Top left: 310 S. S., before. Top right:
ture on room-temperature strengths of 310 S. S., after. Bottom left: 410 S. S., before. Bottom right: 410 S. S., after. x 250.
Type 410 stainless steel (Reduced by '/; upon reproduction)

196-s | APRIL 1959

 Table 6—Effects of Brazing Cycle on Mechanical Properties of 17-7 PH
Table 5—Effects of Time at Brazing Precipitation-Hardening Stainless Steel
Temperature on Room-Temperature
Tensile Properties of Type 410 Tensile-test results
Stainless Steel Test Ultimate 0.2% offset
(All samples normally heat treated after temperature, strength, yield strength, Elongation,
exposure to brazing cycle in hydrogen) Condition ne psi psi %
Time at Normal H. T. Room 217,000 183,000
2240° F 0.2% Brazing cycle + normal H. T. Room 194 ,000 162,000
in offset Normal H. T. 600 173,300 154,500
hydrogen Ultimate yield Elon- Brazing cycle + normal H. T. 600 166 ,500 118,000
brazing strength, strength, gation, Normal H. T. 900 141,800 119,600
cycle, min psi psi % Brazing cycle + normal H. T. 900 127,200 109,500
None 115,000 99,200 10 Stress-rupture test results
(control Condition Test temperature,°F Stress, psi Hours to rupture
samples)
Normal H. T. 800 120 , 000 90
15 105,000 88 ,000 Brazing cycle + normal H. T. 800 120 , 000 75
30 90 ,000 72,000 Normal H. T. 900 52,000 85
60 53,200 33,700 Brazing cycle + normal H. T. 900 52,000 72

given the appropriate aging treat- heat treated, while the other was while the other was tested directly
ment, while the last set was given a fully heat treated after the brazing after the 2240° F brazing cycle.
complete heat treatment. The two cycle. Only tensile testing was performed
treatments given the samples run Processing of the nonhardenable on the Type 410 stainless-steel sam-
through the brazing cycle are shown alloys (Type 310 stainless steel and ples. Here four sets of samples were
schematically in Fig. 2. L605) was done on only two sets of used. The first set was normally
Only two sets of samples were run samples. One of these sets was heat treated, while the remaining
on 17-7 PH. One was normally tested in the mill-annealed condition, sets were fully heat treated following
exposures of 15 min (set 2), 30
min (set 3) and 60 min (set 4) to
200
2240° F in the hydrogen-brazing
160 |——* { furnace thermal cycle.
160 . MORMAL HT. 0 - 17-7PH All test samples were processed in
-310SS a large production brazing furnace.
STRENGTH (10°psi) The furnace used (see Fig. 3) con-
~~ sisted of a large bell wound with
120 AFTER BRAZING
CYCLE ~—__. molybdenum heating elements. A
100 ots 60-in. diam retort fits within the
bell. Separate hydrogen supplies
80 are circulated through the bell and
60 the retort.
It was desirable to use the large
40 oo _L MILL ANNEALED production furnace for this testing,
20 | (a Eo as it produced the same heating and
AFTER GRAZING CYCLE ib newedmes cooling cycles that actual compo-
0 —/ nents would experience in brazing.
” ag -— 2000 The actual brazing cycle used was
measured by thermocouples at-
Fig. 7—Effect of brazing cycle on 0.2% offset yield strengths of Type 310 tached to the test samples. This
and 17-7 PH stainless steels at various temperatures cycle is shown in Fig. 4. The maxi-

BRAZING
CYCLE ¢AGE ONLY’
mmm NORMAL HEAT TREATMENT
ime BRAZING ONLY
Wim GRATING PLUS NORMAL WEAT TREAT,
Av
\00
Temperature, CF) RUPTURE LIFE - Hours
Fig. 8—Effects of brazing cycle and heat treatment on ulti- Fig. 9—Effects of brazing cycle and heat treatment on stress-
mate strengths of A-286 superalloy at various temperatures rupture life of A-286 superalloy at various temperatures

WELDING RESEARCH SUPPLEMENT

| 197-s
 BRAI/NG CYCLE, PLUSNORMAL NEAT TREATMENT

BRAZING CYCLE ¢AGE OWLY

, _— See ree rae

aT = 1200 0 0 0 0 0 © 80 90 WO No
TEMPERATURE (°F) RUPTURE LIFE - Hours
Fig. 10—Effects of brazing cycle and heat treatment Fig. 1l—Effects of brazing cycles and heat treatments on stress-
on 0.2% offset yield strengths of René 41 superalloy at rupture life of Rene 41 superalloy at three temperatures
various temperatures

RT 1000 1200 400 1600 (600

TEMPERATURE (F)
Fig 13—Effect of brazing cycle on ultimate
strengths of L-605 superalloy at various
temperatures

conducted in air.
Metallographic specimens of all
materials in the various heat-treated
conditions were examined for grain-
size determinations and any other
structural changes.

Fig. 12—Microstructures of A-286 and René 41 superalloys showing normal heat-treated Test Results
Structure and effect of 2240° F maximum temperature brazing cycle. Top: René 41. Test results on each of the metals
Bottom: A-286. » 250. (Reduced by '/; upon reproduction) studied will be listed separately.
Average results on each pair of speci-
mens tested are reported. The
mum temperature of the cycle, 2-in. long gage length were machined closing discussion will point out some
2240° F, was dictated by the re- for testing. generalizations arising from these
quirements of a proprietary brazing Tensile tests were run in duplicate results.
filler metal being used. This tem- at room and elevated temperatures
perature is higher than those used with a 0.005 in. /in. /min strain rate. Type 310 Stainless Steel
for most of the nickel-base brazing A separable averaging-microformer Results of tensile and rupture
filler metals, and would be expected type extensometer was used to meas- tests on this material are shown in
to produce more’ mechanical ure strain. Yield strengths re- Table 4. Ultimate tensile strengths
property impairment of the base ported in the data were determined at all test temperatures, and stress-
metals tested than would lower from stress-strain curves. All ele- rupture life at 1200° F were vir-
temperatures. vated-temperature tests were run in tually unaffected by the brazing
air. cycle. Loss in yield strengths at
Testing of Materials Stress-rupture tests were run in room temperature and 1500° F
Following processing, sheet ten- duplicate in multistation rupture and rupture lives at 1500° F and
sile specimens with a 0.500-in. wide, furnaces. These tests were also 1800° F did result, however.

198-s | APRIL 1959

Type 410 Stainless Steel ASTM. GRAIN SIZE
Tests on this material were con- - ——EE
fined to studying the effect of time
at brazing temperature on room GEE NORMAL UT.
temperature tensile properties. Re- AFTER BRAZE CYCLE
sults listed in Table 5 and plotted in
Fig. 5 show that considerable time-
dependent losses in both tensile and
yield strengths occurred. Figure 6, tes
photomicrographs of Types 310 and ie
410 before and after brazing cycles,
helps explain the mechanical prop-
erty effects on both materials. Se-
vere decarburization of the Type
410 occurred, while Type 310 ex- gq %
perienced excessive grain growth as P 5%
a result of the brazing cycle. m.. A-286 —— J-1570 ==REWE41 L605

17-7 PH Fig. 14—Effect of brazing cycle on grain sizes of various

Test results on this alloy (Table 6) high-temperature alloys
show that tensile and _ rupture
strengths degenerated appreciably
at all test temperatures as a result
of the brazing cycle, while only
slight impairment of stress-rupture
strength occurred. Figure 7 graph-
ically presents yield strengths versus
temperature for 17-7 PH and Type
310 for normally heat-treated and STRENGTH 100
braze cycled material. (10? Psi)
80
A286
Test results on this alloy are 60
shown in Table 7 and Figs. 8 and 9. ° “oO WORMAL HEAT
40 a TREATMENT
It can be seen that both tensile and ;o7 © BRAZE CYCLE¢
rupture properties are badly im- 20 ||eat© INCONEL-702 AGEONLY =
paired when this material is braze
cycled and directly aged. Complete 0 4h.
reheat treatment fully restores rup- 1200 1300
ture strength and materially de- TEMPERATURE - °F
creases the _ tensile-strength loss. Fig. 15—Ultimate strength vs. temperature for four superalloys. Strengths
This is substantially in agreement obtained by aging following brazing cycle compared with those obtained
with the work of Aggen, Long and by normal heat treatments
Reynolds.* Their work on 2100
F brazing cycle effects on A-286
bar stock showed similar results on Table 7—Effects of Brazing Cycle on Mechanical Properties of A-286 Superalloy
tensile and V-notch rupture speci- Tensile-test results
mens.
Test Ultimate 0.2% offset
Inconel 702 temperature, strength, yield strength, Elongation,
Condition F psi psi %
Results on this alloy (Table 8
show an irreversible loss in tensile Normal H. T Room 52,000 64,000 23.5
, . Brazing cycle and age Room 18,500 86 ,000 15.0
and
henainerupture
coche properties
Very little after
iz the
a B razing : cycle + normalalH. H.T T. R oom ee> 000 8989, 000 20.0‘
razing Cycie. ery improve- Normal H. T 1000 6 650 82,400 21.0
ment in properties resulted from Brazing cycle and age 1000 000 72.500
complete reheat treatment instead Brazing cycle+ normal H. T 1000 200 ,650 1
of merely aging following the braz- Normal H. T 1200 400 81,100 1
ing cycle. Brazing cycle and age 1200 37 ,500 ,000
Brazing cycle + normal H. T 1200 93,850 75,450
J-1570 Brazing cycle and age 1350 8,050 8,800
Results on this alloy (Table 9 Brazing cycle + normal H. T. 1350 72,500 800
were surprising in that virtually no Stress-rupture test results
loss in properties occurred as a
.
result of the brazing cycle. The1 |
Condition T est temperature,
rat °F Stress,
tress, psi Hoursurs to rupture
p
only significant drop in any prop- Normal H.T 1100 80,000 81
. . ; Brazing cycle and age 1100 80 ,000 57
erty
4 ny meewas Jthe bre’
decline, from
} 11.0
00° toF Brazing cycle + normal H. T. 1100 -
80,000 94
0% in € ongation in the 14 Normal H. T 1200 62.000 92
tensile test results. Brazing cycle and age 1200 62,000 42
Brazing cycle + normal H. T. 1200 62 ,000 103
” : ai i Sal tl Normal H. T. 1350 35 ,000 42
* Aggen, Long anc eynolds, ““Ni-Cr raz
ing of a High Temperature Alloy,” THE WELDING Brazing cycle and age 1350 35000 15
JOURNAL, 36 (8), Research Suppl., 366-s to 373-s Brazing cycle + normal H. T. 1350 35 ,000 39
(1957)

WELDING RESEARCH SUPPLEMENT | 199s

 in the authors’ laboratory have sug-
Table 8—Effects of Brazing Cycle on Mechanical Properties of Inconel 702 Superalloy gested that this is due to hydrogen
embrittlement of this particular
Tensile test results alloy.
Test Ultimate 0.2% offset
temperature, strength, yield strength, Elongation,
Condition “7 psi psi % Discussion
Normal H. T. Room 141,000 81,500 30 In reviewing all of the results, it
Brazing cycle and age Room 128,500 62,500 28
Brazing cycle + normal H. T. Room 124,000 NS becomes apparent that the alloys
Normal H. T. 1200 87,200 strongest at high temperature (René
Brazing cycle and age 1200 70,500 41, L-605 and J-1570) were those
Brazing cycle + normal H. T. 1200 72,400 whose properties were least affected
Normal H. T. 1350 74,000 by the severe brazing cycle used.
Brazing cycle and age 1350 67,100 The cobalt-base alloys L-605 and
Brazing cycle + normal H. T. 1350 67,300 J-1570 were little harmed (save for
Normal H. T. 1500 55,600 a room-temperature embrittlement
Brazing cycle and age 1500 51,000 wo oumowmouwoow
Pwwoann
On of L-605) by the brazing cycle, while
Stress-rupture test results losses suffered by René 41 (nickel
Condition Test temperature, ° F Stress, psi Hours to rupture base) could largely be recovered
by complete reheat treatment.
Normal H. T. 1350 30,000 109
Brazing cycle and age 1350 30,000 48 On the other hand, the weakest
Brazing cycle + normal H. T. 1350 30,000 57 high-temperature materials (Type
Normal H. T. 1800 3000 120 310 and Inconel 702) suffered the
Brazing cycle and age 1800 3000 76 greatest strength losses. As these
Brazing cycle + normal H. T. 1800 3000 83 are not heat-treatable materials,
Normal H. T. 2000 1500 283 these losses were irrecoverable.
Brazing cycle and age 2000 1500 137 The remaining two materials suit-
Brazing cycle + normal H. T. 2000 232 able for use above 1200° F, A-286
and Inconel 702, suffered moderate
strength drops after the brazing
cycle. Reheat treatment recovered
Table 9—Effects of Brazing Cycle on the Mechanical Properties of J-1570 Superalloy most of the A-286 strength loss, but
did not markedly improve Inconel
Tensile-test results 702.
Test Ultimate 0.2% offset Some rationalization of the effects
temperature, strength, yield strength, Elongation, of brazing cycles may be made on
Condition “? psi psi % the basis of strengthening mech-
Normal H. T. Room 145,900 86 , 900 17.5 anisms for the various alloys.
Brazing cycle and age Room 144,200 87,850 17.5 The strength levels of the weakest
Brazing cycle + normal H. T. Room 143,100 85,700 17.0 alloys are dependent primarily on
Normal H. T. 1200 128 ,500 81,500 13.0 fine grain size as a result of mechani-
Brazing cycle and age 1200 122,400 80,700 12.0 cal working in the mill for their
Brazing cycle + normal H. T. 1200 125 ,000 80,200 cm
Normal H. T. 1400 120,600 97 ,200 1. strength. On the other hand, the
Brazing cycle and age 1400 113,500 89,600 4. strongest alloys derive most of their
Normal H. T. 1500 81,700 72,200 3. strength from complex, finely
Brazing cycle and age 1500 84 ,000 73,000 3. divided precipitate particles. The
Brazing cycle + normal H. T. 1500 76,000 68 , 800 3. grain size changes resulting from
Stress-rupture test results the brazing cycle (Fig. 14) thus
affect the strengths of the weakest
Condition Test temperature, ° F Stress, psi Hours to rupture alloys to the greatest degree. The
Normal H. T. 1250 90 ,000 256 strongly age-hardenable materials
Brazing cycle and age 1250 90 ,000 358 are only affected to the degree that
Brazing cycle + normal H. T. 1250 287 their strength is affected by fine
Normal H. T. 1350 66
Brazing cycle and age 1350 120 grain size and optimum precipitate
Normal H. T. 1500 76.5 dispersion resulting from a given
Brazing cycle and age 1500 58 solution temperature. The latter
Brazing cycle + normal H. T. 1500 49.7 portion of the strength lost due to
the brazing cycle can be regained
by complete reheat treatment.
In many cases it may not be
René 41 growth occurred on A-286 than on possible to reheat treat completely
Table 10 and Figs. 10 and 11 René 41. an age-hardenable material after
show the data obtained on this very brazing. When this occurs, only
high-strength material. Both ten- L-605 strength available by aging after
sile and rupture strengths were im- Results of this alloy are listed in brazing is available. Figure 15
paired by the brazing cycle, but Table 11 and graphically shown compares these tensile strengths for
were almost completely restored by in Fig. 13. Yield and rupture four alloys (René 41, J-1570, A-286
full reheat treatment. strengths were virtually unaffected and Inconel 702) with their normally
Microstructures of René 41 and by the brazing cycle, while room- heat-treated strengths. Curves of
A-286 showing brazing cycle effects temperature tensile strength and this type are needed to make
are depicted in Fig. 12. It is note- ductility dropped precipitously. proper selection of materials for
worthy that considerably more grain Some other experiments performed high-temperature brazed parts.

200s | APRIL 1959

 Alloys 17-7 PH and Type 410 ;
have not been discussed previously Table 10—Effects of Brazing Cycle on Mechanical Properties of Rene 41 Superalloy
as their strengthening mechanisms Tensile test results
differ from the all austenitic high-
temperature alloys. The loss of Test Ultimate =—_0.2% offset
strength in Type 410 by methane temperature, strength, yield strength, Elongation,
- ; hare ~ Condition =F psi psi %
reaction decarburization (C (alloy)
+ 2H. (brazing atmosph aa Normal H. T. Room 151,800 122,800
CH ;) appears toS account eauak eet for its Brazing
Brazi cycle and age Room 144,000 116,500
ime-d. dent st . 3 . razing cycle + normal H. T. Room 152,500 125,100
time-dependent strength loss in — jormal H. T. 1200 150,100 108, 200
brazing. The strength loss for 17-7 Brazing cycle and age 1200 140,500 101,500
PH cannot be so well-explained. Brazing cycle + normal H. T. 1200 149 ,000 109, 200
This complex alloy depends on both Normal H. T. 1400 114,700 102,200
the martensite reaction and pre- Brazing cycle and age 1400 102, 100 91,000
cipitation hardening for its strength. Brazing cycle + normal H. T. 1400 113,400 103,000
Either decarburization or nonopti- ae H. is i = way ae
ni SPR Se razing cycle and age ;
a ees cee 2 = Brazing cycle + normal H. T. 1500 102,200 91.750 rPPrPPwwwwowwouwo
oooococoowmoo
cause its strength loss. Stress-rupture test results
The remarks presented - this Condition Test temperature, ° F Stress, psi Hours to rupture
section represent the authors’ best N
‘ : ormal H. T. 1200 95 ,000 86
conjectures on the results obtained Brazing cycle and age 1200 95 ,000 57
in the test program, and should not Brazing cycle + normal H. T. 1200 95 ,000 102
be considered ‘‘pat’’ explanations Normal H. T. 1350 63,000 110
of all the effects of hydrogen brazing Brazing cycle and age 1350 63,000 62
on high-temperature alloys. The Brazing cycle + normal H. T. 1350 63,000 98
application of the generalizations Normal H. T. 1500 32,000 92
made to other base metals or braz- Brazing cycle and age 1500 32,000 73
ing cycles should be done with Brazing cycle + normal H. T. 1500 32,000 88
extreme caution. For any critical
application of a high-strength brazed
fabrication, performing tests similar
to those made in this work is Table 11—Effects of Brazing Cycle on Mechanical Properties of L-605 Superalloy
strongly recommended.
The greatest significance of the Tensile-test results
work done is that some data have Test Ultimate 0.2% offset
been collected conclusively proving temperature, strength, yield strength, Elongation,
that hydrogen brazing at very high Condition “F psi psi
temperatures does detrimentally Mill anneal Room 147,900 69,200
affect the strength of high-tempera- After braze cycle Room 108, 300 69,200
ture alloys to quite varying degrees. Mill anneal 1500 57,400 30,500
After braze cycle 1500 57,000 33,200
Acknowledgment Mill anneal 1800 21,000 18,100
Most of the data presented in After braze cycle 1800 21,500 18,800
this paper was originally obtained Stress-rupture test results
by Paul Miskulin, formerly of the
FPLD laboratory. The authors are Condition Test temperature, ° F Stress, psi Hours to rupture
indebted to him + for setting up the Mill anneal 1500
z 24,500 82
original test program, organizing rece cycle oo eo —
the data and providing valuable After braze cycle 1650 15 000 36
insights into the metallurgical Mill anneal 1800 6500 110
mechanisms affecting the strengths After braze cycle 1800 6500 120
of the alloys tested.

WRC Bulletin No. 46 Observations of Strains Near Reinforced and Non-Reinforced

Cone Cylinder Intersections, by C. Kientzler and S. F. Borg
Discussion, Design Formulas for a Thin Cylinder with Cone Shaped Ends
by CyrilO. Rhys. 10 pages. Price $1.00.

To test theory a full-size vessel having both a reinforced and nonreinforced

cone to cylinder intersection was subjected to internal pressures and the
resulting strains at various points were measured.
Copies may be purchased from the American Welding Society,
33 West 39th Street, New York 18, N. Y.

WELDING RESEARCH SUPPLEMENT | 201-s

 Quartz-Lamp Radiant Brazing of Titanium-Alloy

Honeycomb Sandwich Panels

Process is described and a discussion of

its possible application to full-sized production

panels is presented by the authors

BY JOHN F. RUDY, ROBERT M. NECHELES AND HARRY SCHWARTZBART

SUMMARY. The object of this Initially, these sandwich-panel type bonds between core and face
experimental program was_ twofold. members were fabricated by glue- sheet. However, higher operating
Critical consideration was given to temperatures have brought on the
processing for brazing fabrication of requirement for a_ metallurgical
honeycomb sandwich, leading to the bond, usually a brazement. Brazed
development of a new process-——quartz-
lamp radiant brazing. This process honeycomb panels are _ presently
shows promise of providing a more fabricated for military aircraft by a
economical brazing method. Secondly, furnace-retort method which has
titanium alloys were fabricated into been described in the _ technical
honeycomb sandwich panels, with literature. However, this process
consideration given to the metallurgical is very costly and an improved
problems characteristic of the substitu- method would lead to wider ac-
tion of titanium for the more popular ceptance. This paper presents the
stainless steels. preliminary development of a braz-
The quartz-lamp _radiant-brazing
process is described, and a discussion of ing process which shows promise for
the expansion of the process to full- improving production efficiency.
sized production panels is presented. This process is quartz-lamp radiant
Recommendations are given for the brazing.
selection of titanium alloys for panel All production honeycomb panels
cover sheets. Brazing temperatures to date have been fabricated of
are given for both commercially pure stainless steels. Titanium alloys
titanium and 17-7 PH stainless-steel were used for this experimental pro-
honeycomb cores. Of the 17 brazing Fig. 1—Radiant-heat brazing apparatus.
alloys included in preliminary screen- Shown are the reflectors, quartz lamps gram. Brazing alloy and brazing-
ing, several are recommended for and supporting members surrounding temperature requirements were de-
titanium-alloy honeycomb-sandwich the sandwich assembly. The whole ap- veloped for this new alloy class,
brazing. paratus is under a bell jar and the commercial-titanium sheet
Introduction
With materials requirements of
the aircraft industry becoming more
and more exacting as performance
demands progress, it has become
necessary to fabricate composites of
unlike materials in order to obtain
improved hardware properties. The
aircraft industry has recently be- 4),

come interested in a composite eT

sandwich of honeycomb core be- WK
TO a
tween two face sheets. This com- rrerrrevyr
bination provides an efficient struc-
tural part with a minimum of
weight.
JOHN F. RUDY and HARRY SCHWARTZ-
BART are associated with the Metals Department
of Armour Research Foundation of Illinois Insti-
tute of Technology, Chicago, Ill ROBERT M.
NECHELES is associated with North American
Aviation, Los Angeles, Calif
Paper to be presented at the AWS 40th Annual
Meeting to be held in Chicago, Ul., April 6-10,
1959 Fig. 2—Radiant-heat brazing apparatus. A second view

202-s | APRIL 1959

 alloys were reviewed for applicabil- Component Parts used at power levels of approxi-
ity to face sheet requirements. mately 100 w per linear in. Brazing
A discussion of the applicability
of this process to production panels experiments, however, have shown
Quartz-Lamp Radiant Brazing
can best be presented in terms of the the lamps to become inoperative
The ‘“‘quartz lamps’’ used as the requirements and failings of each by a reaction which clouds the
heat source for this brazing process component part of the system as quartz surface before any electrical
are tungsten wire, resistance heat- presently developed. failure occurs. Since most of the
ing elements which are encapsulated alloys contained lithium, it may
in long */;-in. diam tubes of clear Quartz Lamps. —The quartz lamps have been lithium vapor which
quartz. According to their manu- themselves are fairly rugged and caused this clouding. However,
facturer, they are the ‘smallest can be reused an undetermined this degradation is not prohibitive
hottest electrical-heat sources avail- number of times. The manufac- since over 40 panels were brazed
able.”” These properties combine turer’s life rating is 5000 hr when with the same set of lamps. Fur-
to provide an ideal heat source for
brazing honeycomb sandwich
panels. REFLECTOR
The apparatus for quartz-lamp QUARTZ LAMPS
radiant brazing of 5- x 7-in. panels is
shown in Figs. 1 and 2. The [|Co00000
brazing procedure can be more EGG-CRATE STRONGBACK
conveniently explained with the aid OOOO veo ovare
of the schematic diagram of Fig. 3. =
The components were placed in TOP ViEW
order from bottom to top as follows: EGG CRATE
SANOWICH
COTTA) COMPOSITE
1. The bottom reflector and |-————-
quartz-lamp unit which rests
on the base plate of the bell eee
jar.
. The bottom egg-crate support
network which rests on the re-
flector. loocc00000]
. The Vycor plate glass sepa-
rator. Fig. 3—Schematic of a method for utilizing radiant heat to braze sandwich. The egg-
crate strongbacksand the Vycor plates are transparent to radiation and apply flattening
. The sandwich composite—-i.e., pressure. The whole apparatus is in an inert-atmosphere chamber (exploded view)
face sheet, brazing-alloy foil,
honeycomb core, brazing-alloy
foil and top face sheet. All
components were precleaned
by acid etching not more than
8 hr prior to brazing.
. The top Vycor, egg-crate and
heating unit.
6. Weights on the top reflector
framework.
Electrical connections were made
to the lamps and to the control ther-
mocouples which were welded to the
top cover sheet of the sandwich.
The bell jar was then lowered into Fig. 4—Longitudinal center section of a quartz-lamp radiant-heat brazed panel.
place; the chamber was evacuated Materials are: RS 140 face sheet, commercially pure Ti core and Ag + 3% Li
and back-filled with helium, after brazing alloy
which electrical power was switched
to the lamps, and the brazement
was accomplished. A typical longi-
tudinal section of a quartz-lamp
brazed panel is shown in Fig. 4.
A wide range of time-temperature
plots was obtained by various
power cycles. Figure 5 shows an
optimum plot obtained by manually
switching the power as indicated.
A plateau of +10° F was obtained
at the target brazing temperature of
COOLING RATE 6O*F/miN.
1500° F. The time for heating was $8
8
cover
sweet
TEMPERATURE,°F
approximately 110 sec, and the
brazing temperature was main- Fi 1 4 okt.
tained for 180 sec. The cooling a 5 2 ®
rate is more rapid than that ob- THE FROM POWER INITIATION MINUTES
tained with systems which require Fig. 5—Typical time-temperature plot for quartz-lamp radiant-heating method.
massive strongbacks for support. Ag-28Cu-0.2Li brazing alloy at 1500° F

WELDING RESEARCH SUPPLEMENT | 203s

 thermore, the amount of lithium sure to insure brazing-surface con-
used in the brazing alloy can be tact, a retort envelope could be made
greatly reduced. a part of the support system of the
Reflectors. Two types of re- process by peripherally joining the
flectors were used. The first was a top and bottom mild-steel separa-
gold-surfaced stainless-steel reflector tors mentioned above, and partially
which had a subsurface ceramic dif- evacuating the envelope so formed.
fusion barrier. The second was an However, flat mechanical pressure
aluminum reflector surfaced with has been satisfactory to date.
high-purity reflector-grade alumi- Temperature Control.—Tempera-
num. No difference was observed ture was controlled by cycling the
in the specimen heating character- power input according to thermo-
istics with the two designs. Both couple temperature indications of
reflectors tended to develop cloudy the panel itselfas indicated in Fig. 5.
surfaces similar to the quartz-lamp This manual control means was sat-
surface clouding mentioned above. isfactory for maintaining a given
On first consideration the alumi- panel area to within close tolerances.
num might be expected to be lim- Automatic power control could be
ited to lower temperature braze- obtained with standard furnace
ments than the gold-surfaced reflec- limit switching equipment. Sev-
tors. However, the plots of Fig. 6 eral sub-areas of a large panel could
show that this is not necessarily so. Fig. 6—Time-temperature relationship be controlled separately if this were
It can be seen that the aluminum- during a quartz-lamp radiant-heat desirable. Such may be the case
reflector temperature is only ~770° brazement with the setup of Fig. 2 with massive edge connections, at-
F when the specimen has reached tachments, or with panels of vary-
2000° F. The higher conductivity ing depth where brazing-alloy flow
of aluminum offsets the higher melt- must be controlled.
ing point of gold. Therefore, with drawbacks become evident. First, Temperature uniformity was not
water or fin cooling, its operating Vycor is expensive and fragile; obtained over the whole 5- x 7-in.
temperature should be adequate to second, it is not available commer- panel area investigated because the
perform any conceivable sandwich- cially in sizes greater than 1 by 1 ft; heating-unit plane area (lamps and
pane! brazement. and third, it would be very difficult reflector rectangles) was too small
Since aluminum is cheaper (by a to adapt to curved surfaces. There- in relation to the size of the panels.
factor of 7) and more easily worked fore, several experiments were per- Some heater overhang is evidently
to special curved-surface shapes, formed with no Vycor in the appara- necessary to obtain uniform heating
production adaptation should be tus. A brazement with the egg- out to the edges of the panels. The
made with the assumption that alu- crate network in direct ccntact with plots of Fig. 7 show time-tempera-
minum will be satisfactory. The the face sheets resulted in intercellu- ture relationships of seven thermo-
life-time limit of reflectors experi- lar buckling of the face sheets couples placed as shown on an ex-
enced during brazing experiments away from the braze bond surface. perimental panel. Plots number 1,
was approximately 30 brazements Smaller egg-crate cells (<'/, X '/: 2 and 5 are within approximately
before clouding became prohibitive. in.) may give better support at the 30° F of each other; but the others,
It seems likely that this life could be sacrifice of radiation efficiency. which were closer to the edge of the
extended appreciably, possibly by A second experiment substituted heating unit, were appreciably
lowering the lithium content of the 0.048-in. mild steel for the Vycor cooler. These data indicate a re-
brazing alloys. separators with satisfactory results. quirement for 2 to 3 in. overhang for
Jigging.-The egg-crate network Heating time was comparable to the suitable uniformity.
(Fig. 3) is transparent to radiant Vycor separator brazements, and no With production panels, which
heat and provides flat support. The difficulty was experienced with in- have edge-attachment members
egg crates used for these experi- sufficient brazing-surface contact. more massive than the panel proper,
ments were made from 0.020- by This support system appears most it will be more difficult to maintain
/,-in. Inconel strips slotted and in- promising for future development. temperature uniformity, and some
terlocked every '.in. This system Chamber.—The inert-atmosphere means of supplying additional heat
was satisfactory for the 5- by 7-in. chamber of the process as developed to the edges must be developed.
panels brazed; however, larger pan- is a complete design departure from Several possibilities exist, including
els would require interspan support presently employed sandwich-panel reflector design for heat concentra-
to prevent deflection. One of the brazement techniques. With this tion, closer lamp spacing, less lamp-
problems for scaling the process up heating process the chamber sur- to-panel distance, separate lamp
to larger sizes is the means for pro- rounds the heating unit as well as power control for the edge areas, or
viding this interspan support which the panel, allowing the use of a per- auxiliary lamps around the edges.
must come from columns connecting manent gas-tight container instead Power Requirement.—The elec-
the reflectors (weights) to the egg of the conventional ‘‘one-shot”’ re- trical-power requirement for quartz-
crates. Quartz or Vycor has the tort envelopes. The chamber used lamp brazing was as follows:
best likelihood of operating success- was a bell jar, but any vacuum-
fully very close to the quartz tight box could be substituted. The Velie. ..... ' 240 v
lamps. Perhaps composite quartz- chamber remains at essentially am- Current (16 bulbs). 72 amp
metal columns would prove most bient temperature throughout the Panel area.
satisfactory. brazing cycle since the heat is con- approximately 45 in.’
The Vycor separators are very centrated by the reflectors on the “On” time... 150 sec
satisfactory for the small flat panels panel itself.
brazed to date. However, in scal- In the event that larger produc- These figures give a power de-
ing up to production, several serious tion panels require pneumatic pres- mand on the order of 55 kva per

204-s | APRIL 1959

 400
800
1400} \
~, y
«200 -—
#1200} \
~. ‘?
> 1100}-
o7
=3 1000}-
.s &
~= s00- «
z* s00}
~
=2 TOOR
600}

Hs zr |_— nerwocouere ©7 ums morERatve

iP hee
.

4 hn rt 4 n at.
« id ® © i]
Tim FROM POWER SaTIATION tenUTES
Fig. 7—Time-temperature plots showing thermal gradients during brazing. The thermocouples were placed as
indicated on the sketch

square foot of panel, or 2.3 kwhr of LLLLLLELLALLIL LALLA AAA L LALA AAALALL I LL
electrical energy per square foot of
panel. VACUUM INERT
PUMP GAS IN
Advantages.—In order to appre- , Satine
ciate the potential advantages of /
quartz-lamp radiant brazing, a brief | _— STRONGBACK
description of the commercial fur- i — COVER SHEET
nace-retort system is_ presented. + ——J
FACE SHEET
Figure 8 shows a schematic of the re- —- BRAZE ALLOY
tort envelope with sandwich-panel SuR =| vE Ma CORE
— BRAZE ALLOY
composite. The two sheets com- ie —FACE SHEET
prising the envelope are thin and PERIPHERA ' ONGBACK
can transmit pneumatic pressure SEAL WELD \\ mane
¢ BOTTOM SHEET
when the retort cavity is partially
evacuated. The notable difference FURNACE WALi
between the two processes centers TITVTTTTTTTTTTTTT ITTV TTT TT TTTTTTTTTTTTTTT TTT TTT TTT TTT TTT TTT TTT
around the necessity for fabrication
Fig. 8—Retort for furnace brazing (exploded cross section)
of the ‘‘one-shot,” gas-tight envel-
ope and the necessity for the two
massive strongbacks above and be-
low the sandwich. The retort in-
creases handling time, and the mas- e00r
sive strongbacks make heating and 1800} ’ a atialiibonn v
cooling rates dependent on their
1.00}
thermal conduction. The resulting :.
time-temperature cycle for the proc- oe. '300}-
>
ess is shown in Fig. 9. Thus, braz- i&: 200}
ing time is decreased appreciably by .a toor 20°F
/
the quartz-lamp process. § 1000}
$H soor i
Titanium-Alloy Honeycomb . L
Sandwich Panels roo}
Face-Sheet Alloy Selection._-To soo
adapt titanium alloys to honeycomb 300!
sandwich panels, decisions must be i,° w1 ss1 adi as4 soi osrm «0i —4 ve- "=4 eo1
reached concerning the choice of Tuae FRoe mTRoovc™Om TO Fummace aT 600°, muuTES
face-sheet alloy and the choice of Fig. 9—Time-temperature plot for the furnace-retort method
brazing parameters, i.e., alloy, time
and temperature.
A summary of the pertinent fac- Producibility is an important con- cannot be heat treated to a soft,
tors of the titanium alloys which sideration since, generally, high- malleable condition. In this regard
were more promising at the time of strength titanium alloys are difficult B 120 VCA, a relatively new experi-
the survey appears in Table 1. to reduce to thin sheets because they mental alloy, is reported to be a no-

WELDING RESEARCH SUPPLEMENT | 205-s

 leads to selection of the range 1400
Table 1—Summary of Pertinent Factors for Face-Sheet Alloy Selection to 1600° F as being the most prom-
Heat treat ising brazing temperature. The
Producibility, Solution heat- yield strength 1400° F minimum was arrived at
0.010-in. treat tempera- (0.2% offset), 800° F because difficulty
, / had. been experi-
Alloy sheet ture, ° F min ksi stability enced wetting titanium at lower
3Al - 6Mo Fair 1525 160 Good temperatures. This is evidently due
4'/,Al -3Mo -1V Fair 1575 (or higher) 160 Good to the inability of titanium to dis-
6Al - 4V Poor 1700 150 Good solve its own oxide (self-flux) at
16V - 2'/,Al Good 1370* 165 Good lower temperatures. The 1600° F
RS 140 Fair 1450 (or higher)* 160 Questionable maximum arises from the increasing
rs 1108 aad 1380° _ reese died tendency of brazing alloys to dis-
00 r e
Rem-Cru-Beta (B 120 VCA) Excellent 1400 . 170-200 Poor (500 max) solve the thinis honeycomb
temperature increased. core as
Exces-
* Least critical in cooling rate from brazing temperature. sive core solution results in erosion.
Actual brazing results indicated
that 1600° F was too high with ti-
tanium core, 1500° F being more
table exception. MST 16V — 2.5Al tion of the possibilities for accom- satisfactory.
and RS 110 B are more producible plishing both brazing and heat On this basis 17 alloys were chosen
than the others, with Ti — 6Al — 4V treating leads to a cycle wherein for preliminary screening, the de-
being the most difficult to roll to solution treating is accomplished tails of which have been reported
0.010 in. The heat-treated strengths during brazing, followed by an at- previously.* On the basis of cur-
are all in the same range except B mosphere cool ‘“‘quench”’ and _ post- sory wettability, joint strength and
120 VCA, which is stronger, and RS braze age for optimum strength. ductility indications, coupled with
110 B, which is considerably weaker. Therefore, the face sheet must have brazing temperature and metallo-
Since a general-purpose alloy was acceptable heat-treated properties graphic observation, the seven al-
desired, stability at 800° F was con- after solution treatment at the tem- loys shown in Table 2 were chosen
sidered, which eliminated the other- perature which is chosen for brazing. for final evaluation on panel con-
wise promising B 120 VCA. Thus, Choosing the most desirable solu- figurations. This evaluation in-
considering producibility, strength tion-treatment temperature de- cluded recommended brazing tem-
and stability, the four alloys of the pended on the choice of brazing al- perature for panel, flow comments,
Department of Defense sheet rolling loy and brazing temperature. For joint strength and environmental ef-
program (the first four listed) ap- reasons discussed below, Ag-3% Li fects in 750° F air and salt spray.
peared to offer the most promise, was originally considered the best The behavior of each alloy in these
with RS 140 also being attractive be- alloy, with 1400° F being the opti- respects was observed with both
cause of its availability. In choos- mum temperature for its applica- stainless-steel and titanium-cored
ing among these five alloys, the tion to titanium-alloy honeycomb panels. With titanium core there
solution-treatment temperature was panels. Largely on this basis RS were three alloys which could be
an important consideration for sec- 140 and MST 16V-2.5Al, with solu- brazed at 1400° F (Ag-19Cd-2Li,
ondary reasons which are discussed tion temperatures of 1450 and 1370 Ag-15Cu-16Zn-24Cd, and Ag-3Li)
below. F, respectively, were selected for while 1600° F was required to ob-
Since the titanium alloy in its use in this program. Later consid- tain satisfactory wetting with stain-
final sandwich cover sheet form is erations have shown 1500° F to be less-steel core. Of the 1400° F
desired in its high-strength heat- superior to 1400° F as the optimum alloys, however, the two containing
treatment condition, a brazing ther- brazing temperature, indicating that lithium were very poor with regard
mal cycle must be employed which is Ti-3Al-6Mo may have been a desir- to oxidation resistance, and the
compatible with the thermal-cycle able alloy.
requirements of the alloy. Thus Brazing Alloy. Prior knowledge
heat treatment and brazing thermal on brazing of titanium alloys with * Rudy, J. F., Necheles, R. M., and Schwartz-
bart, H.,. WADC TR 58-467, “Brazing Titanium
cycles are interrelated. Considera- thin cross sections (honeycomb foil) Sandwich Construction,” (July 1958

Table 2—Summary of Brazing-Alloy Panel-Specimen Data

Recommended brazing Flow comment,*— Edgewise comp.” Hours to marked”
temperature, ° F % of nodes filled strength, ksi strength reduction
Brazing alloy Ti core S.S. core Ti core S.S. core Ticore S$.S.core 750° F air Salt spray
Ag - 19Cd - 2Li 1400 1600 80 100 144 pe 24 >50
Ag - 28Cu - 0.2Li 1500 1600 100 100 150 149 >192 8-50"
Ag - 7Cu -0.2Li Attacks core 1600 100 100 85 147 >192 >50
(1600)
Ag - 30Cu - 10Sn Attacks core 1600 100 wet 70 85 104 >192 50
(1600) cell walls
Ag - 15Cu - 16Zn - 24Cd 1400 1600 100 wet 100 wet 53 >192 8
cell walls cell walls
Ag - 3Li 1400 1600 100 wet 100 130 152 4 8
cell walls
Ag - 0.25Mg - 0.2Ni-1Li 1500 1600 100 wet 100 105 126 96-192” 24-32”
cell walls

“Data from panels brazed at recommended temperatures.

®* 8 hr with Ti core, 50 hr with S.S. core.

206-s | APRIL 1959

 =
wwws=
nn
ueVv
aa CORE FACE
SHEET

(A) BRAZE TENSION (8) CORE COMPRESSION (C) SIDEWISE BUCKLE

(USUALLY FRACTURES (USUALLY OCCURS NEAR (MISALIGNMENT)
IM CENTER OF SPECIMEN) ONE END OF SPECIMEN)

Fig. 1l—Typical edgewise-compression failures

Fig. 10—Edgewise-compression testing the brazed joints, to provide the wise compression results taken from
fixture. The strain gages record eccen- lateral restraint necessary to prevent the detailed coverage given previ-
tricity which is corrected for by the mova- face-sheet buckling during com- ously.j Figure 11 illustrates the
ble support
pression column loading. The test three failure types noted in the table.
simulates an actual structural func- The Ag-28Cu-0.2Li and Ag-7Cu-
tion assumed by many panel parts 0.2Li alloys are generally higher
third gave low joint strengths.
in service. The alignment fixture strength with stainless-steel core.
Therefore, 1500° F brazes were at-
shown in Fig. 10 is for the purpose of The Ag-30Cu-10Sn specimen is typ-
tempted with two other higher-melt-
correcting for eccentricity of loading. ical of lower strength values caused
ing alloys (Ag-28Cu-0.2Li and Ag-
Eccentricity is indicated by a differ- by a tensile failure of the braze
0.25Mg-0.2Ni-1Li) on titanium-core
ential reading between the two joint. The specimens tested at
panels. Of these, Ag-28Cu 0.2Li
appears better with greater joint strain gages. Testing procedure is 700° F were approximately 70%
important with edgewise compres- of room-temperature values. Some
strength, good oxidation resistance,
sion, as small degrees of eccentricity aging response is evident even
but only marginal salt-spray corro-
lead to low indicated strengths.
sion resistance (8 hr). Two higher-
Table 3 gives some typical edge- + See footnote on page 206-8
melting alloys (Ag-7Cu-0.2Li and
Ag-30Cu-10Sn) were applied to ti-
tanium-cored panels at 1600° F with
unsatisfactory results due to ex-
cessive core erosion. Table 3—Edgewise Compression Data
With stainless-steel cores, 1600
Brazing
F was a satisfactory brazing tem- tempera- Brazing Post-braze Face sheet Failure’
perature and behavior in oxidation Panel no. Brazing alloy ture,°F process® age,°F-hr UCS, ksi type
and salt-spray environments was
improved. Thus, regarding strength, RS 140 face sheet, S.S. core
oxidation and salt-spray corrosion, F-33 Ag - 28Cu - 0.2Li 1600 FR None 168 b
Ag-28Cu-0.2Li and Ag-7Cu-0.2Li F-33 1600 FR None 134 b
F-33 1600 FR None 109° b
were best with stainless-steel cored F-33 1600 FR None 25° b
panels. F-33 1600 FR 925-8 177 b
To summarize, with titanium F-33 1600 FR 925-8 174 a
core, Ag-28Cu-0.2Li at 1500° F is R-34 Ag - 30Cu - 10Sn 1600 QL None 103 a
satisfactory in all respects except F-19 Ag -7Cu-0.2Li 1600 FR None 136 b
salt-spray corrosion; and, with F-19 1600 FR None 104‘ b
stainless-steel core, Ag-28Cu-0.2Li F-19 1600 FR 925-8 157 b
and Ag-7Cu-0.2Li at 1600° F are R-35 Ag-7Cu-0.2Li 1600 QL None 142 b
satisfactory. Ti - 16V- 2'/.Al, C.P. Ti core
Mechanical Evaluation.—The me- F-21 Ag - 28Cu -0.2Li 1500 FR None 150 a
chanical evaluation performed was F-21 1500 FR 925-8 187 c
primarily for the purpose of ob- R-25 Ag - 28Cu -0.2Li 1500 QL None 120 a
taining a measure of brazed-joint R-25 1500 QL 925-8 180 a
properties rather than supplying di- R-26 1500 QL 925-8 230 b
rectly applicable design information. R-27 Ag - 30Cu - 10Sn 1600 QL None 77 a
R-29 Ag -7Cu -0.2Li 1600 QL None 91 a
However, since this joint-loading F-20 Ag - 3Li 1400 FR None 130 a
system is difficult to simulate with F-20 1400 FR None 89 a
other configurations, small panel R-31 Ag - 0.25Mg- 1500 QL None 123 a
specimens were used for test speci- 0.2Ni-1Li
mens. The loading system chosen R-31 1500 QL 925-8 140 a
was edgewise compression as shown
in Fig. 10. This system tests the * FR—Furnace Retort, QL-—-Quartz Lamp
» See Fig. 11 for schematic of failure types
ability of the honeycomb core, via Tested at 700° F All others tested at room temperature

WELDING RESEARCH SUPPLEMENT | 207-s

 avers | APRIL L079

with the slow cooling from brazing promise to warrant additional ap- which are less susceptible to oxida-
temperature which is experienced plication effort for larger production- tion and salt-spray corrosion dam-
with the furnace-retort method. sized honeycomb panels. The ad- age.
With commercially pure titanium vantages have to do with (a) rapid 3. The best brazing alloys, of the
core, post-braze aging of Ag-28Cu- and closely controlled (uniform) 17 studied, were Ag-28Cu-0.2Li at
0.2Li specimens gave the highest heating, (b) low-heated mass which 1500° F on titanium core to tita-
strength values obtained. The contributes to process efficiency as nium-alloy face-sheet joints, which
quartz-lamp process, which gives well as high cooling rates, and (c) a were satisfactory in all respects ex-
faster cooling from the brazing clean heat source which allows at- cept susceptibility to salt-spray cor-
temperature, gave higher aged mosphere control design latitude, rosion, and Ag-28Cu-0.2Li and Ag-
strengths and lower ‘as-cooled” including permanent chambers as 7Cu-0.2Li at 1600° F on stainless-
strengths. The two alloys which opposed to presently used “‘single- steel core to titanium-alloy face-
required 1600° F for brazing (Ag- shot”’ chambers. sheet joints.
30Cu-10Sn and Ag-7Cu-0.2Li) ex- 2. Brazed titanium-alloy honey- Acknowledgment
hibited poor strengths due to core comb panels present no unusual The authors are grateful to the
erosion and subsequent weak brazed problems as concerns wettability or Materials Laboratory, Wright Air
joints. joint strength. However, further Development Center, Lts. R. Walk-
brazing-alloy development is sug- osak and G. Haley as project of-
Conclusions gested to (a) possibly reduce wetta- ficers, for sponsorship and permis-
1. The quartz-lamp __radiant- bility to obtain more uniform alloy sion to publish the results of this
brazing process offers sufficient distribution, and (b) obtain alloys work.

EXTERNAL LOADINGS ON PRESSURE VESSELS

BY P. P. BIJLAARD

Welding Research Council Bulletin No. 49 to be “Stresses in a Spherical Vessel from External Mo-
published in April 1959 contains three papers describ- ments Acting on a Pipe’—Summary—In addition to
ing theoretical work done on the calculations of stresses the case of a spherical vessel with an inserted pipe, sub-
resulting from external radial and bending moment jected to a radial load, treated in an earlier paper, the
loadings on pressure vessels. These papers describe case of an external moment, acting on an inserted pipe,
research investigations carried out at Cornell Univer- is investigated. After deriving the general solution for
sity under the sponsorship of the Pressure Vessel Re- the displacements of the pipe, considered as a cylindri-
search Committee of the Welding Research Council. cal shell, the continuity conditions between vessel and
The Subcommittee on External Loadings on Pressure pipe are established, in order to determine the con-
Vessels assisted Prof. Bijlaard in guiding this work. stants in the general solutions for the deflection and
Single copies may be purchased through the AMERICAN stress function of the spherical vessel.
WELDING Society, 33 W. 39th St., New York 18, N.Y. The deviations from the case of a rigid insert follow
Quantity lots may be purchased through the Welding the same lines as for an applied radial load. The maxi-
Research Council, 29 W. 39th St., New York 18, N. Y. mum bending moments M, and M, in the vessel de-
The titles and abstracts of the three papers compris- crease and increase, respectively, with increasing flexi-
ing Bulletin No. 49 are given below to inform design bility of the pipe wall; that is, with increasing ratio
engineers of the objectives and scope of these research t /h, but if this ratio is smaller than 3 or 4, the maximum
investigations. moment M, does not exceed the maximum moment
“Stresses in a Spherical Vessel from Radial Loads (M.) for the case ofa rigid insert. The maximum mem-
Acting on a Pipe’’—Summary—As a continuation of brane forces N, and N, may become higher than in the
the computation of the stresses from local loads in a case of a rigid insert.
spherical vessel with a rigid cylindrical insert, the more “Influence of a Reinforcing Pad on the Stresses in a
realistic case of a spherical vessel with an inserted tube Spherical Vessel Under Local Loading’’—Summary
is investigated for the case that the tube is subjected to The paper deals with a spherical vessel with reinforcing
a radial load. As shown by the graphs the maximum pad, subjected to a radial load or an external moment,
deflection is only slightly increased by the fact that the acting on an inserted rigid pipe. After deriving the
insert is now flexible, which flexibility is mainly deter- equations from which the deflections, bending moments
mined by the ratio = t/h. The maximum bending and membrane forces can be computed for any case,
moment M, is greatly decreased by the flexibility of the the special case is worked out where the diameter of the
pipe, whereas the bending moment M, increases to pad is two times the outer diameter of the pipe and
maximum values that may be somewhat higher than where the total thickness at the pad is two times that
the maximum value of M, for a rigid insert. However, of the plain vessel. The results are presented in graph
if t/h is smaller than about 3, as will be true in most form. Comparison of these graphs with those in refer-
practical cases, the maximum value of M, does not ence 5 shows the decrease of deflection, the increase of
become la: ger than the maximum moment (M,) for the the bending moments and the change in the membrane
case of a rigid insert. The maximum membrane forces forces due to the pad.
may become higher than those for a rigid insert.

208-s | APRIL 1959

 WELDING RESEARCH SUPPLEMENT |207-s

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

Braze Welding of Cast Iron

There are two major obstacles to Fuming) Bronze, and Nickel

successful repair welding of cast Silver-828, permit yielding while the
iron: 1. low-strength and poor repairs are being made and after
ductility of cast-iron weld metal, they are returned to service, and the
2. embrittlement and hardening danger of failure is practically elim-
produced by rapid cooling from inated.
fusion-welding temperatures. The braze-welding operation itself
is virtually foolproof because the
Oxyacetylene fusion welds with molten bronze automatically “tins
cast-iron rods have such very low out” or spreads over the joint sur-
strength and ductility that they faces when the correct temperature
often crack under the stresses im- is reached. Since the base metal is
posed during welding and cooling. not melted, control of the weld
If they survive these hazards, they metal is very easy and braze weld-
are likely to fail when subjected to ing is readily done in all positions.
the service stresses that caused the
original failures. ADVANTAGES OF BRAZE WELDING
Are welding, because of steep WITH ANACONDA WELDING RODS ARE:
temperature gradients between weld 1. Economy in welding time and
and base metal, is likely to em- gas consumption.
brittle and harden both weld and 2. Development of low residual
adjacent base metal. Here, too, fail- stresses with less distortion and less EXTENSIVE BRAZE-WELDING REPAIRS on the
ure may occur during welding and frame of this big steam hammer used 1850 lb.
tendency to crack. of Tobin Bronze Welding Rod — saved six
cooling, or later in service. It is usu- months’ production time, for one-fifth of replace-
ally necessary to resort to carefully 3. No embrittlement, and complete ment cost
controlled schedules of preheating, machinability of the weld areas.
peening, and _ post-heating, often 4. Minimum delay in returning the These are some of the subjects
with high-cost alloy filler metal, to repaired parts to service. covered; Copper-Alloy Welding
avoid the twin evils of embrittle- Rods in steel sheet metal work, braz-
ment and hardening. DETAILED INFORMATION AVAILABLE ing and soldering, resistance weld-
Oxyacetylene braze welding is an Detailed suggestions on the meth- ing, surfacing, welding copper
excellent solution to the problem for ods of chipping grooves, removing alloys to steel, arc welding of cop-
two reasons. With the low tem- oil, positioning the work, and pre- per and copper alloys.
peratures required, there is no rapid heating are given in Publication For information on special prob-
cooling from high temperatures and B-13, which gives full information lems—or for a copy of Publication
therefore no embrittlement. Excel- on Anaconda Welding Rods, dis- B-13—write: The American Brass
lent ductility and high strength of cusses procedures for welding with Company, Waterbury 20, Conn. In
the weld metal deposited by Tobin copper and copper alloys in a wide Canada: Anaconda American Brass
Bronze “-481, Anaconda-997 (Low variety of applications. Ltd., New Toronto, Ontario. 510

WELDING ROD APPROX. COMPOSITION, % APPROX. MELTING POINT

Deg. C Deg. F.
59 copper, 40.40 zinc, ANACONDA
Tobin Bronze-481 0.60 tin 885 1625 WELDING RODS
57.80 copoer, 40.27 zinc,
Anaconda-997 0.95 tin, 0.85 iron, 0.10 Made by
(Low Fuming) Bronze silicon and 0.03 manganese 870 1598
48.58 copper, 41 zinc, The American Brass Company
Nickel Silver-828 10.25 nickel, 0.15 silicon,
0.02 phosphorus 930 1706
For details, circle No. 113 on Reader Information Card
 use Airco’s new Dip Transfer' CO. Process”

for ALL-POSITION WELDING OF

STEEL IN ALL THICKNESSES

low costs-easy fit up+ high speed+ very low spatter+ no warpage

In welding mild sheet steel manually, there’s only e No flux needed.

one way to reduce costs and produce high quality e Penetrates deeply — critical for high quality.
welds at the same time. Airco Dip Transfer CO» e Welds much faster than flux-based processes.
Process Welding. Let’s be specific: e Uses money-saving Pureco COzas shielding gas.
e The complete Airco Dip Transfer CO» package e The basic equipment welds all weldable metals.
welds in all positions ... manually! The Airco Dip Transfer CO» Process gives you
e Welds are hydrogen-free. consistently high quality welds at lower costs
e Virtually ends warpage — only low average than any other process. For complete informa-
currents are used for burn off. tion, phone or write your nearest Air Reduction
¢ Creates little or no spatter. Representative. Ask for the new 24-page
e Handles typical steel joint fit ups. “ATRCOMATIC COs WELDING” Catalog.
-
Visit our booth §21—April 7-8-9 at the Welding Show—International Amphitheatre, Chicago, Ill.
Pureco CO, is supplied by the Pure Carbonic Company, a division of Air Reduction Company, Incorporated
tTrademark
**Patent Applied For On the west coast—
Air Reduction Pacific Company
internationally—
AiR REDUCTION SALES COMPANY Airco Company International
in Cuba—
A division of Air Reduction Company, Incorporated Cuban Air Products Corporation
150 East 42nd Street, New York 17,N.Y. in Canada—
Air Reduction Canada Limited
Offices and authorized dealers in most principal cities All divisions or subsidiaries
of Air Reduction Company, Inc

For details, circle No. 115 on Reader Information Card