Welding Journal - March 2023

WELDING JOURNAL IN THIS ISSUE: SAFETY AND HEALTH COMMITTEE 50TH ANNIVERSARY ■ THE AMERICAN WELDER MARCH 2023 WELDING JOURNAL ■ VOLUME 102 NUMBER 3 ■ MARCH 2023 Your Guide to Pipe and Tube Welding

CONTENTS DEPARTMENTS 6 Editorial 8 News of the Industry 12 Education 411 14 Letters to the Editor 16 RWMA Q&A 18 Welder Q&A 20 Product & Print Spotlight 36 Coming Events 38 Certification Schedule 39 Standards Action 41 Society News 42 Tech Topics 47 Guide to AWS Services 48 Section News 60 Personnel 66 Fact Sheet 69 Classifieds 69 Advertiser Index 70 WJRS Letters March 2023 | Volume 102 | Number 3 FEATURES Heat Treatment and Other Variables in Pipe and Tube Welding Learn about industry resources, the importance of heat treatment, and inspection for welding of piping and tubing G. Lewis 24 AWS Guide Publications for Welding of Piping and Tubing An overview of the AWS D10 Committee’s standards to support pipe and tube welding applications S. Findlan and W. F. Newell 28 Renewed Opportunities for Girth Welding in High-Strength Pipelines Pipeline operators and contractors should feel confident using self-shielded flux cored arc welding for high-strength girth welds on their construction projects R. R. Panday 32 A Primer for Automating Grinding This article explains how automation improves your weld grinding processes N. Jackson 62 THE AMERICAN WELDER 24 28 32 62

CONTENTS On the cover: GTA welder engaged in feedwater heater tube welding for a power plant project. (Credit: William C. LaPlante.) March 2023 | Volume 102 | Number 3 OFFICERS President Dennis K. Eck Diversified Services & Solutions LLC Vice President Michael A. Krupnicki Rochester Arc + Flame Center Vice President Richard L. Holdren Welding Consultants LLC/ARC Specialties Vice President D. Joshua Burgess Tennessee Valley Authority Treasurer Mary Bihrle Consultant Executive Director & CEO Gary Konarska II American Welding Society DIRECTORS R. Ashelford (Dist. 13), Rock Valley College T. Brosio (Dist. 14), Major Tool & Machine D. E. Clark (Dist. 20), DEClark Welding Engineering PLLC A. Classens (Dist. 4), A. E. Classens & Associates J. Davis (Dist. 21), Consultant R. Emery (Dist. 22), College of the Sequoias M. Hanson (Dist. 15), Compass Electronics Solutions R. E. Hilty (Dist. 7), Hilty Sign & Fabrication Co. T. S. Holt (Dist. 18) J. Jones (Dist. 16), Evergy Inc. J. Jones (Dist. 17), Harris Products Group T. Kinnaman (Dist. 1), T. C. Kinnaman Welding Solutions T. Kostreba (Dist. 10), Erie High School D. H. Lange (Dist. 12), Northeast Wisconsin Tech. College S. Moran (Dist. 3), General Dynamics Electric Boat W. F. Newell (At Large), Euroweld Ltd. C. E. Pepper (Dist. 9), C. E. Pepper & Associates D. Peterson (Dist. 5), Central Maintenance and Welding N. Peterson (At Large), Miller Electric Mfg. LLC W. R. Polanin (Past President), WRP Associates S. Raghunathan (At Large), Saudi Aramco R. W. Roth (Past President), RoMan Mfg. Inc. K. Shatell (At Large), Pacific Gas & Electric Co. L. E. Showalter (At Large), Newport News Shipbuilding M. M. Skiles (At Large), Consultant R. H. Stahura (Dist. 6), ESAB Welding & Cutting Products K. Temme (Dist. 2) P. I. Temple (Dist. 11), Welding Consultant J. Thompson (Dist. 8), Consultant B. Towell (Dist. 19), Industrial Inspection & Services LLC WELDING JOURNAL Publisher/Editor Annette Alonso Editorial Managing Editor Kristin Campbell Sr. Editor Cindy Weihl Associate Editor Katie Pacheco Associate Editor Alexandra Quiñones Education Editor Roline Pascal Peer Review Coord. Brenda Flores Publisher Emeritus Jeff Weber Peer Review Editor Thomas J. Lienert Design and Production Managing Editor, Digital and Design Carlos Guzman Production Manager Zaida Chavez Assistant Production Manager Brenda Flores Advertising Senior Sales Executive Scott Beller Manager, Sales Operations Lea Owen Subscriptions Subscriptions Representative Marandi Gills [email protected] aws.org 8669 NW 36 St., # 130, Miami, FL 33166-6672 (305) 443-9353 or (800) 443-9353 AWS Mission Statement The mission of the American Welding Society is to advance the science, technology, and application of welding and allied joining processes worldwide, including brazing, soldering, and thermal spraying. AWS Promotes Diversity AWS values diversity, advocates equitable and inclusive practices, and engages its members and stakeholders in establishing a culture in the welding community that welcomes, learns from, and celebrates differences among people. AWS recognizes that a commitment to diversity, equity, and inclusion is essential to achieving excellence for the Association, its members, and its employees. Welding Journal (ISSN 0043-2296 Print) (ISSN 2689- 0445 Online) is published monthly by the American Welding Society for $150.00 per year in the United States and possessions, $195.00 per year in foreign countries: $15.00 per single issue. Not available for resale in either print or electronic form. American Welding Society is located at 8669 NW 36 St., # 130, Miami, FL 33166-6672; telephone (305) 443-9353. Periodicals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 8669 NW 36 St., # 130, Miami, FL 33166- 6672. Canada Post: Publications Mail Agreement #40612608 Canada Returns to be sent to Bleuchip International, P.O. Box 25542, London, ON N6C 6B2, Canada. AWS Claims Policy: All hardcopy editions are shipped FOB Origin. Publisher reserves the right to investigate and make a determination on all claims submitted for missing editions not received by a subscribing member or institution. Any claim request determined to be valid will be fulfilled with a digital copy of the edition. Publisher will NOT send any hardcopy replacement issues for any reason. Readers of the Welding Journal may make copies of articles for personal, archival, educational, or research purposes, and which are not for sale or resale. Permission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright. Copyright © 2023 by American Welding Society in both printed and electronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users. WELDING RESEARCH SUPPLEMENT Application of Machine Learning to Regression Analysis of a Large SMA Weld Metal Database A new equation for Ar3 temperature in low-alloy steels containing several minor elements was derived using a novel approach R. Varadarajan and K. Sampath 31-s Effects of Filler Wire Intervention on the Gas Tungsten Arc: Part III — Process Stability Control of Wire-Filled GTAW This work utilized a practical arc sensing method to achieve real-time feedback control of weld surface height and metal transfer S. Zou et al. 53-s

EDITORIAL Supporting Semiconductor Tubing Applications Being involved in the high-purity and ultrahigh-purity industries for almost four decades, I’ve seen the boom in the 90s, what outsourcing has done, and how we’re now trying to reclaim the industry domestically. What ups the game for end users, contractors, and organizations like AWS is $52.7 billion being poured into the industry from the U.S. government to stimulate semiconductor plant growth and regain balance in our current supply chain. Also, in contrast to the 90s, semiconductors play a huge part in our everyday lives, much like welding, but often both get taken for granted. Tubing’s Role Semiconductor manufacturing is largely dependent on gases conveyed via high- and ultrahigh-purity stainless steel tubing, most of which requires autogenous orbital welding for joining. The materials are also a consideration because you are now dealing with electropolished interior finishes that require special end preparation, cleaning prior to welding, and workplace protocols. Our Challenge Who is going to do the work? We skipped a generation in this scope of work mainly due to outsourcing. Whether it be an open- or closed-shop posture, there simply are not enough skilled workers experienced in this scope. These days, we struggle with finding a traditional welding workforce, so where do we find one with specialized skill sets? It’s telling when you go to a semiconductor job site and there are both postures of labor involved. It indicates that we are in trouble labor-wise; basically, we are in an all-hands-on-deck mode for staff projects. The same concerns apply to management. How many business leaders are still around from the 90s boom? These experienced people are a vanishing breed in short supply. Solutions This is where AWS can find opportunity! Organizations such as SEMI have taken the lead in codes and practices to govern semiconductor-related work. It is now a perfect time for AWS to reach out to SEMI and collaborate on training and qualification of the welders who join the tubing industry and the fitters who prepare the fitups prior to welding. Also, an AWS Certified Welding Inspector (CWI) endorsement is much needed to cover this scope. In Closing Changing times call for changing ways. As companies race to well-subsidized work, we, as the welding industry, need to prepare. It is critical to balance the semiconductor supply chain in the United States, and welding will need to play a huge role. WJ “Changing times call for changing ways. As companies race to well-subsidized work, we, as the welding industry, need to prepare. It is critical to balance the semiconductor supply chain in the United States, and welding will need to play a huge role.” Mike Lang, AWS CWI, ASNT Level II VT/PT/ RTFI, quality manager, Houston Mechanical, Cajun Industries 6 | WELDING JOURNAL

NEWS OF THE INDUSTRY Hobart Presents Customer Experience Center Hobart Brothers LLC opened its new Customer Experience Center at its headquarters in Troy, Ohio. This approximately 9000-sq-ft space provides customers and distributors with technical, product, and customer service support. It will allow for both onsite and virtual demonstrations of Hobart® filler metals along with welding solutions from other Illinois Tool Works (ITW) Welding Group companies, including Miller Electric Mfg. LLC, Bernard, Tregaskiss, and Jetline. The center consists of several dedicated spaces, such as the Customer Applications Lab (CAL), a classroom, and a welding training lab. The CAL features two robotic welding systems, including the new Hercules™ automated gas metal arc welding system, along with semiautomatic welding stations and submerged arc welding equipment. It also contains pipe positioners, plasma cutting machines, and advanced process equipment. The company’s welding engineers use the CAL to develop and test procedures to help customers improve productivity and quality. “The CAL offers our customers a great opportunity to improve their businesses. It allows us to bring in their parts or mock them up and apply the preliminary work to advance their welding processes,” said Tre’ Heflin-King, applications engineering manager at Hobart. “Our customers are able to see the filler metal and welding equipment solutions in action before putting them into production. They can also try new technologies here.” In the center’s classroom, distributors and ITW welding sales team members receive training on filler metals, new welding technologies, welding best practices, and more. The welding training lab consists of smaller power sources plus gas tungsten arc and shielded metal arc welding machines. It offers the opportunity for hands-on training with new equipment and filler metals. For customers, distributors, and sales team members who are not able to visit the center in person, Hobart can pro8 | WELDING JOURNAL

vide support via a virtual training lab. This lab features fully equipped welding stations and multiple cameras. “Ultimately, this new space is designed to benefit everyone involved: customers, distributors, our sales team, and Hobart,” said Blake Heim, commercial director at Hobart. “It sets the foundation for mutually beneficial growth and learning so everyone reaps the rewards.” Hydrex Replaces Class-Approved Underwater Shell Plating Hydrex, Antwerp, Belgium, mobilized a team to Algeciras, Spain, to perform a permanent insert repair on a 135-m (443- ft) tanker that suffered cavitation damage to the inside shell plating of one of its ballast water tanks. The repair prevented an unscheduled drydock visit for the vessel. The team sailed with a workboat and all necessary equipment to the ship, which lay at anchor in Algeciras. The process started with an onboard and underwater inspection of the damaged area. This revealed that the crack was 150 mm (6 in.) long. In close communication with the superintendent of the vessel and the attending class surveyor, it was decided that a 300 × 300-mm (12 × 12-in.) insert would need to be installed. Repairs included removing a part of the bilge keel to install a customized cofferdam, removing a temporary cement box, cleaning and preparing the damaged plating, cutting away a 300 × 300-mm area, preparing the edges of the opening for the insert, positioning the new plate, and welding the insert following the Hydrex class-approved procedure for insert plates using complete joint penetration. An independent inspector carried out ultrasonic examination, and the repair was approved by the classification surveyor who was present during the operation. The team then removed the cofferdam. A member of the Hydrex team welds an insert repair to the inside shell plating of a tanker’s ballast water tank. MARCH 2023 | 9

By removing the cracked section of plating and installing a new insert, this area of the ship will not require further repairs during its next drydocking. Solar Atmospheres of Michigan Invests in Future Location Solar Atmospheres of Michigan Inc., formerly Vac-Met, purchased 18,000 sq ft of plant space on four-plus acres in Chesterfield, Mich. “We are working feverishly in 2023 to prepare and equip this new facility to make it our fifth state-of-the-art vacuum heat treating and brazing facility in the United States,” said Bob Hill, president of Solar Atmospheres of Michigan Inc. “Once all of the electrical, water cooling, and specialty gas utilities are installed, we will strategically relocate the nine existing vacuum furnaces to their new home. Additionally, two new vacuum furnaces were purchased from Solar Manufacturing. This investment of over $5 million dollars gives Solar Atmospheres of Michigan the space to locate our valuable employees and equipment under one roof while continuing to grow the Michigan vacuum thermal processing needs.” CPI Aero Receives Follow-On Order for Welded Fluid Tank Assemblies CPI Aerostructures Inc. (CPI Aero), a manufacturer of structural assemblies for fixed wing aircraft; helicopters; and airborne intelligence, surveillance, and reconnaissance pod systems, was awarded a $1.8 million contract for complex welded fluid tank assemblies by an undisclosed aerospace original equipment manufacturer. The Edgewood, N.Y.-based manufacturer will begin deliveries in 2023 and end them in 2024. “This follow-on order demonstrates our customer’s satisfaction with CPI Aero’s performance and continued commitment to excellence,” commented Dorith Hakim, president and CEO of CPI Aero. “This fluid tank assembly involves complex fusion and resistance welding and leverages strategic investments CPI Aero has made in welded product capabilities since 2019. These investments were key to Solar Atmospheres’ new Michigan plant. the successful transition of this program from development 10 | WELDING JOURNAL

to production, resulting in improved quality and increased throughput.” Tecoi USA Opens Texas Headquarters Tecoi, León, Spain, has established new U.S. headquarters in Longview, Tex., for its Tecoi USA division. This will allow the company to provide more-comprehensive service and support for its growing customer base of metal processors in North America. Tecoi designs, develops, manufactures, installs, and maintains customized metal cutting and processing equipment for laser cutting, plasma and oxyfuel cutting, plate machining, and edge preparation for welding. The U.S. division offers metal processing stations that include large format and dimension laser cutting stations. It also manufactures large format oxyfuel and plasma plate cutting stations that incorporate and combine machining functions such as beveling, milling, and drilling; equipment for automated plate storage; waste disposal equipment; fume extraction and noise reduction equipment; and cutting tables as well as manual and automatic tube lathes. Industry Notes ■ Hentec Industries/RPS Automation, Newman Lake, Wash., a manufacturer of selective soldering, lead tinning, and solderability test equipment, announced that Agility Manufacturing has finalized the purchase of its Vector 300 selective soldering system. ■ AAA Tool & Machine and C-F Fabricators, both based in Southern Illinois, will now operate under the name Velocity Metalworks after joining forces in the metal fabrication industry nearly two years ago. Locations, services, ownership, and employees will remain the same under the new name. The brand’s new logo and website can be seen at velocitymetalworks.com. WJ Tecoi now has new headquarters for its U.S. division in Longview, Tex. MARCH 2023 | 11

EDUCATION 411 NASCAR Legend Richard Petty and Northern Tool + Equipment Partner to Donate Tools to School NASCAR legend Richard Petty, nicknamed The King, has partnered with Northern Tool + Equipment (NTE), Burnsville, Minn., and its Tools for the Trades™ program to help students at his alma mater, Randleman High School, Randleman, N.C., with a large tool donation. On December 8, 2022, Petty and NTE CEO Suresh Krishna presented the school with tools and gift cards. “We started the Tools for the Trades program in 2021 to give instructors the proper tools to effectively teach the trades and ignite excitement and curiosity for the trades in students,” Krishna said. “We work with men and women in the trades every day. We know there is a skilled labor shortage. This program can help address the labor shortage.” The partnership is fueled by Petty’s enthusiasm for the trades, particularly welding. “Most people know about my NASCAR career, but welding has been a passion of mine since a young age,” Petty said. “Arming myself with a trade served me well in my postracing days and is still an important part of the work we do at Petty’s Garage. Through this partnership, I hope more students will find a passion for the trades.” Together with Petty, NTE’s Tools for the Trades program will be donating pallets full of tools that will help hundreds of students in the school’s career and technical education programs for years to come. Lincoln Electric Forms LEEPSTM Program and Announces First-Ever LEEPS Award Recipient The Lincoln Electric Co., Cleveland, Ohio, has joined forces with the National Coalition of Certification Centers (NC3) and formed the Lincoln Electric Education Partner Schools (LEEPS) program to provide schools with instructional materials and resources to help the next generation of welders. Additionally, Brett Camacho, a welding instructor at Fresno City College, Fresno, Calif., has won the first-ever LEEPS Instructor of the Year Award. “[Camacho] rose above the other award candidates because his program exemplifies everything the LEEPS welding certification program stands for, including train the trainer, advancing and using new welding technology, and advocating for welding certifications and industry-recognized credentials,” said Dan Klingman, manager of educational programming at Lincoln Electric. Along with a trophy, Camacho received the Lincoln Electric POWER MIG® 215 MPi™ multiprocess welding machine. He was also named a member of the LEEPS Advisory Committee. The committee provides input on the in-demand skills and certifications needed by industry and supports the development, improvement, and implementation of the LEEPS welding program curriculum, among other tasks. Committee members serve two-year terms. To find out more about the LEEPS welding certification program, contact [email protected]. WJ 12 | WELDING JOURNAL Former NASCAR driver Richard Petty (pictured in a red scarf, sunglasses, and trademark hat) has partnered with NTE to equip students at his alma mater with tools. A group photo was taken next to Petty’s #43 car. Brett Camacho (left), welding instructor at Fresno City College, was the winner of the inaugural LEEPS Instructor of the Year Award from Lincoln Electric.

LETTERS TO THE EDITOR Online Tables for November 2022 WJRS Letters In the November 2022 Welding Journal, I read the WJRS Letters research supplement titled “Deposition Rate in GMAW of ER1100 and ER5183 Aluminum Alloys” and felt this interesting paper would have been much better if it had been published with the missing tables instead of having the readers visit a website to retrieve copies. If such a practice was followed by the Welding Journal in years past, today’s researchers would not be able to recover missing data. Over the years, there have been many changes in computer hardware, programs, and storage means. Much data has been lost due to those changes. Please, in the future, publish complete papers. Incidentally, a variation in anode voltage (Va ) would “explain the higher deposition rate obser ved in the Mg-containing alloy.” By my calculation, the ER1100 Va for current range 190– 230 A averaged 4.97 V. For ER5183, Va averaged 5.46 V over the same current range. A. F. Manz AWS Fellow Union, N.J. In September 2022, the Welding Journal began running Welding Journal Research Supplement(WJRS) Letters in addition to traditional research supplements. WJRS Letters is aimed at quickly publishing new research results on hot topic areas of interest. Accepted manuscripts must be less than 2000 words and with three to four figures. All content must fit into five (previously four) pages when laid out. Because of spacing, the tables for the November WJRS Letters supplement were posted online with prior permission from the authors who wanted the paper to meet WJRS Letters guidelines. Welding Journal issues are available in hard copy and available for viewing on the AWS website via PDF document. Digital issues are saved internally to AWS computers and servers to provide different back-up methods and ensure no information is lost. WJ 14 | WELDING JOURNAL

RWMA Q&A BY MICHAEL J. KARAGOULIS Q: Our automotive supply firm has close to 200 robotic welding guns, making an estimated 100,000 spot welds per hour. How do I design and implement a maintenance program for my resistance spot welding operation? Where do I begin? A: First, identify and tame the key variables. Any manufacturing process will follow certain classical principles of statistics. Joseph Juran coined the Pareto Principle, which states that 80% of process problems are caused by about 20% of the process defects (Ref. 1). He advocated focusing on the “critical few” process variables and largely ignoring the “trivial many” process variables. However, understanding resistance welding in these terms goes well beyond a casual look at the process. Here is a how-to summary. Applying the Pareto Principle, the critical few (key) variables of resistance welding have been found to be the following (Ref. 2): 1) Integrity of the high-amperage circuitry. Since the heat source for resistance welding is Joule’s Law (Heat = I2 × R × t), precise application of the current during welding is important. Notice how the formula squares the current. The implication is that maintenance of weld cables, leaf shunts, and all high-amperage connections must be a key variable along with good, verifiable current regulation at the weld control. A micro-ohmmeter is very useful for troubleshooting the cables and electrical connections that comprise the high-amperage circuitry (known as the secondary loop). Some weld controls monitor the overall secondary loop automatically. However, in order to positively locate a bad cable or connection, you still need a micro-ohmmeter. 2) Thermal management. Part of resistance welding involves generating heat. Heating the weld is important. But what often escapes our notice is the invisible other part: heat flow. So, where does the heat flow? The physics of heat flow may be understood simply: Heat naturally flows from hot to cold objects. Heat flow regulates the penetration (relative thickness) of the spot weld nugget. Without heat flow, all the work metal directly between the spot weld tips would melt from top to bottom. Since liquid metal has no strength, it would all be squeezed out by the tip pressure and found lying on the floor (or stuck to the ceiling). But thanks to heat flow, the workpiece heat closest to the electrode tips migrates into the electrode, which is water cooled. This localized cooling throughout the weld cycle protects the outer skin of the spot weld from melting. By controlling tip cooling properly, you can gain control of the nugget penetration and prevent surface defects like whiskers. You can’t easily measure heat flow, but you can easily measure water flow rates, pressure drops, and weld water quality. So, maintenance of the cooling system is a key variable. This is how you manage it: a) Manage the chemistry and filtration of your weld water system. b) Design the water distribution system so that there are local distribution substations at each separate weld line. All water (coming and going) will pass through this substation. Install bag filters and gauges for supply and return pressure and temperature monitoring. c) Verify proper plumbing and flow rates in every water line. This protects both the welds and equipment. d) Audit the cooling of a running production line with a portable infrared viewer. 3) Mechanical management. a) Check wear of the welding equipment. The mechanical environment around the spot weld is primarily dictated by the electrode tip, including the specific size and shape of the tip face that touches the weld, the alignment of the two opposing faces, and the weld force (magnitude and timing) exerted on the workpieces by the electrodes. Anything that disturbs this delicate mechanical environment must be addressed and maintained. Therefore, include mechanical maintenance for the following: ■ The weld gun force mechanism, ■ Any slides or pivots, and ■ Tip dresser (if applicable). b) Use standard equipment. If you can standardize a single electrode tip design and supplier for your entire shop, you will be free from errors due to incorrect cap changes. The same goes for weld guns, tip dressers, and tip dresser cutter blades. 4) Parametric management. Simply put, weld parameters are the recipe used for cooking each weld. The paramThe secondary loop of a spot welding machine or welding gun. In a healthy spot weld process, the weld nugget stays away from touching the electrode tips. This is mainly due to good water cooling of the tips. 16 | WELDING JOURNAL

eters include force, squeeze time, weld time, weld current, pulsation parameters, and hold time. a) Do you have a recipe book documenting how each metal combination is welded? b) Are the recipes machine independent? In other words, are they always used for a given metal combination, regardless of which gun makes the weld? c) Do you have control over unauthorized parameter changes on your factory floor? d) Do you know the useful current range of each weld schedule? (A robust weld schedule will have at least a 2000-A useful range.) Learn how to conduct a simple weld range test. Identify the maximum/minimum amperage range that only results in acceptable welds. e) Obtain reliable meters for the weld current and force. Send them out for maintenance and calibration once per year. Have two or three spare meters available for internal meter comparisons. You never want to use a faulty meter on the shop floor. f) Industry standard weld schedules are a good place to start, but expect that you may need to smartly adjust parameters to achieve requirements. Standard industry setups and materials may or may not match what you are using. So don’t be surprised if the initial weld quality needs tuning-in. Get outside help with this if you need it. What does an in-control spot welding process look like? An in-control process will tolerate variations of the trivial many variables. The trivial many variables of spot welding may include the following: ■ Batch variation of material ■ Stamping variables ■ Part temperature ■ Coating damage ■ Modest tip misalignment An in-control spot welding process will produce good welds no matter what. The inspection process will not find bad welds for weeks or months at a time. The process is robust to the usual trivial variables. A friend once told me that getting a process in control is like using a funnel to put oil in your car’s engine. The wind might blow, and your hand might be unsteady, but the oil still goes where it should. WJ References 1. Juran, J. M., and Gryna, F. M. 1988. Juran’s Quality Control Handbook. Fourth Edition. New York: McGraw-Hill. 2. Karagoulis, M. J. 1991. Control of material processing variables in production resistance spot welding. PhD diss., Michigan State University. MICHAEL J. KARAGOULIS, PhD, is a retired General Motors welding engineer, AWS Fellow, and AWS Certified Resistance Welding Technician. He was responsible for resistance weld process development, productionization, and 42 U.S. patents. Questions may be sent to Michael J. Karagoulis c/o Welding Journal, 8669 NW 36 St., #130, Miami, FL 33166-6672, or via email at [email protected]. Every metal combination you weld needs a recipe. You are cooking metal. For a robust process design, protect the environment between the electrode tips. This is your weld “kitchen.” For robust manufacturing, at a given weld time, the expulsion current should be at least 20% greater than the minimum acceptable weld current. MARCH 2023 | 17

WELDER Q&A Q: How do I pass a weld test? A: In my journey as an instructor and inspector, I’ve monitored countless weld tests. More importantly, I’ve also taken many welding tests (known as welder performance qualification tests) over the years during my career as a welder. These tests ranged from horizontal fillet welds to 6G ASME pipe tests, and I delivered quality welds while being watched. These tests not only measured my knowledge, skill, and ability to produce sound welds but also determined if I could control my nerves. When the inspector certified my weld tests, I was qualified for production. My responsibility was to weld at a code-quality level in various production environments, on small and large weldments, and sometimes in awkward positions. I am often asked, “How do you pass a weld test?” Below is Part 1, containing some common questions my students have asked over the years, along with my answers. What is a certification, and why is it important? In a nutshell, certification is the process of an authorized person monitoring a welder completing a weld test to ensure the weld is in compliance with the codes and welding procedure specifications (WPSs). Qualification is the process of the welder proving their weld meets the applicable code/standard under the guidelines of the code/WPS. Several codes used today require certification. Codes are also designed to protect the public at large so as people walk across bridges, enter buildings, or fly across the country, there’s confidence the products are well built. Codes and standards require the testing of personnel, too. You scheduled your test — how should you approach it, and how is it going to be evaluated? First and foremost, do your research. What code are you going to be testing to? For example, AWS testing requirements are slightly different than ASME and API. Identify the hold points, the visual testing standards, and sample types and locations (e.g., face, root, or side bends). Find out if the test coupons will be evaluated using nondestructive examination. Knowing these details will help you strategize how you weld your test coupon(s). What should you bring to your test? Preparation is key to success in a weld test. Once your test is scheduled, plan ahead for what you will face. Will you be taking a shielded metal arc welding (SMAW), flux cored arc welding (FCAW), gas metal arc welding, or gas tungsten arc welding (GTAW) test? Will you need extra practice metal, more contact tips, or a GTAW kit? In my experience, having extra items will help you be ready for the test. Preparation goes a long way to calm nerves. BY MATT SCOTT Matt Scott (right), welding instructor and department chair at Portland Community College (PCC), discusses the finer points of fitup with PCC welding student Vanntha Mao. 18 | WELDING JOURNAL

What should you focus on at the test site? When arriving at the test site, introduce yourself to the inspector(s) and get a rundown of the equipment. Next, ask for the WPS. This will include base metal type, joint configuration, amperage and voltage ranges, allowed cleaning methods, and welding techniques (stringer or weave) for preheat/ interpass/postheat requirements. This document may be provided by the test lab or the contractor. Follow it. Once settled in your area, it’s time to concentrate on the details. Are metal preparation and joint fitup important? I cannot overemphasize that base metal preparation and fitup are important to passing a weld test (see lead photo). Time taken here will surely pay dividends in completing the weld. Be sure to grind/sand your test coupons. Preassemble your plates to ensure your fitup is correct. And finally, tack your plates securely with the fitup needed. How do you make the root pass? This section focuses on the AWS D1.1, Structural Welding Code — Steel, welder qualification test on a 1-in.-thick plate. These tips hold true for both SMAW and FCAW, which are common welding processes for this plate test. The first pass in a weld test, known as the root pass, is the most critical. The last thing a welder wants to do is leave a flaw here. When completing the root pass on a single-V-groove weld with a backing strip, apply the following procedures: 1. Ensure the fitup is tight to the backing strip and both bevels are ground to a knife edge. 2. Set amperage high enough to produce a fluid but controllable pool. Your practice plates will assist you in adjusting the machine. 3. When applying the root pass, the main objective is to consume both knife edges of the beveled plates while fusing into the backing strip. With E7018, keep the electrode on the leading edge of the pool, and watch the leading edge carve into the base metal. The old adage “emphasize the sides of the pool and the middle will take care of itself” holds true. I also focus on the lower sides of the pool (4 and 8 o’clock positions) to ensure the molten pool is filling that area without leaving undercut. 4. Another focus point is the arc length for E7018 or contact-tip-to-work distance (CTWD) for FCAW. With E7018, it is critical to monitor the arc length. Also, hold a tight arc. This translates into a 1/16-in. arc length for an 1/8-in. electrode. The key indicator is the globular transfer; if you see droplets start traveling across the arc, tighten up ever so slightly. This maximizes the shielding while still allowing you to work the pool to let it blend. For E71T-1 (dual shield), carefully monitor the CTWD. At Portland Community College, we train with a 1/16-in.-diameter electrode with 100% CO 2 shielding gas and utilize a ¾-in. CTWD. What’s important is that the ¾-in. CTWD is our starting point. While welding, optimize the arc to produce a smooth transfer while laying down a smooth bead by adjusting the CTWD ± 1/8 in. It is important to ensure the root pass is thoroughly cleaned before beginning the second pass. This holds true for all subsequent passes as well. The WPS will state if power tools are allowed or if this cleaning is restricted to hand tools. Be sure to pay attention to these details. What’s Next? Stay tuned for Part 2 of this column in the August 2023 issue, where more questions will be answered. WJ MATT SCOTT ([email protected]) is a welding instructor and department chair at Portland Community College, Portland, Ore. His welding career began in high school, when his shop teacher sent him to work at a local fab shop; this path led to bridge work, then the piping industry. He has been training and testing welders for more than 30 years. Readers may email their questions for this column to the author. They may also send mail to the author’s attention at Welding Journal, 8669 NW 36 St. #130, Miami, FL 33166. MARCH 2023 | 19

PRODUCT & PRINT SPOTLIGHT Attention on Pipe/Tube and Abrasives Saw and Track System Cuts through Wall Boiler Tubes The MILLHOG® boiler tube panel replacement system combines the APS-438 saw with the steel EscoTrackTM to provide fast cutting of water wall boiler tubes. It also eliminates the need for tube rework and grinding before beveling. The saw can horizontally cut 4-in. O.D. tubes straight with 1/16-in. accuracy and no heat-affected zone. It can also be fit with a vertical track attachment for fast and accurate boiler tube membrane removal. Equipped with a 3-hp pneumatic motor that runs on 90 lb/in.2 shop air at 80 ft3/min, the saw uses proprietary reinforced fiberglass abrasive blades for quick cutting and long life. The saw and track system easily attaches to a panel using weld tabs. ESCO Tool escotool.com (800) 343-6926 Line of Angle Grinders Designed for Demanding Applications The M-Brush line of WEP 19-150 Quick, WEPBA 19-125 Quick Drop Secure, and WEPBA 19-150 Quick Drop Secure angle grinder models suits end users in demanding production environments. The 6-in. WEP 19-150 provides a no-load speed of 9600 RPM and comes with a standard guard as well as a clip-on type 1 cutting wheel guard. The 5-in. WEPBA 19-125 offers a no-load speed of 11,000 RPM while the 6-in. WEPBA 19-150 delivers a no-load speed of 9600 RPM. These two angle grinders include autobalance technology to decrease tool vibration by 50% while increasing tool and wheel life. The WEPBA 19-125 and 19-150 models also showcase mechanical safety brakes, which stop the wheel in 2.5 seconds or less when releasing the paddle switch and reduce any risk for injury. Additionally, the two angle grinders feature a drop-secure attachment point for lanyards. This can be used when working at heights to prevent injury or property damage from a falling tool. Metabo metabo.com (800) 638-2264 Article Highlights Abrasive Products for Cleaning Pipeline Welds “Gaining the Best Performance When Cleaning Pipeline Welds” informs readers on how abrasives facilitate proper weld preparation and interpass cleaning in pipeline applications. The article begins by detailing common pipeline welding challenges, such as avoiding wheel chatter and vibration during root grinding; grinding hot welds that may reach up to 500°F, which can cause some grinding wheels to glaze over; and finding abrasives that are designed to fit deep into the bevel of a V-groove so there is no accidental grinding of the pipe sidewall. The article then lists five common mistakes and how to avoid them. These mistakes include improper cleaning, using the wrong product, applying too much pressure, storing the product incorrectly, and not using the tool guard. The article concludes by summarizing some of the abrasive products available for pipeline weld prep 20 | WELDING JOURNAL

and interpass cleaning. It recommends that readers consider the following factors when choosing a product for a job: speed and size, pressure, workpiece orientation, and grind/ dwell time. The free article can be found at weilerabrasives.com/articles-news. Weiler Abrasives weilerabrasives.com (800) 835-9999 Pipe Patching System Completes Repairs in Two Hours or Less The pipe patching system achieves trenchless pipe repair in two hours or less. The all-inclusive, start-to-finish solution comes with all the consumables and equipment needed for a one-time patch in a 2- to 6-in. broken pipe up to 6 ft in length. Featuring a durable fiberglass patch, it is ideal for repairing small sections of damaged pipes in residential, commercial, and industrial settings. It can also be used on all sections of pipes, including straights, bends transitions, and p-traps. Designed for drain cleaning and inspection professionals, the system allows workers to show up on a jobsite and complete all three steps of a pipe repair — clean, inspect, and patch — in a few hours. Emerson Electric Co.; RIDGID emerson.com; ridgid.com (314) 553-2000; (800) 474-3443 Cut-Off Wheel Lasts Longer and Increases Productivity The ZIP™ XX cut-off wheel claims to outlast other industry-leading ceramic wheels by at least 30%, thus reducing changeovers and downtime. Its formulation of 100% self-sharpening ceramic grain also cuts up to 10% faster than aluminum-oxide wheels. Made of ceramic microcrystals with preset fracture points, the 1/16-in. cut-off wheel enables smooth, clean cuts; minimizes the need for rework; and decreases the risk of metal overheat or discoloration. Additionally, it is engineered with SMART RESIN™ technology, which allows the wheel to expose fresh grains at the optimal moment to maximize longevity and sharpness. Its premium reinforcements also make it safer and more durable without compromising speed. The cut-off wheel is compatible with steel, stainless steel, and hard alloys. It is available in 4.5, 5, 6, and 7 in. diameters. WALTER Surface Technologies walter.com (800) 522-0321 MARCH 2023 | 21

Book Focuses on Piping Engineering Piping Engineering: Preventing Fugitive Emission in the Oil and Gas Industry offers practical and comprehensive strategies to reduce or avoid fugitive emissions. The 416-page, first-edition book covers key considerations and calculations for piping and fitting design and selection, maintenance, and troubleshooting to eliminate or reduce emissions. It also discusses the various components, such as piping flange joints, that can allow/cause emissions. It describes the various devices used to tighten the bolts for flanges and details tolerances for essential flange fabrication and installation. Other topics include leak detection and repair, a key technique for managing fugitive emissions; piping stresses like principal, displacement, sustained, occasional, and reaction loads; and calculation of loads and acceptable limits. Wiley wiley.com Report Analyzes the Stainless Steel Pipe and Tube Market Global Stainless Steel Pipes and Tubes Market Research Report 2022 projects this market will reach $44,770 million by 2028, exhibiting a compound annual growth rate of 4.6%. It was estimated to be at $32,680 million in 2021. The 242-page report credits this growth to global oil and gas production activities due to the rising demand for transportation. The report also states that favorable government policies for bolstering the automobile sector and an increase in the number of oil reserves in the United States and other nations are expected to lead to market expansion in the coming years. To provide an analysis of this market, the report assesses different industry subsegments, focusing on regional bifurcation, type, and application. To gather a sizable amount of data, it evaluates various new product developments, emerging technologies, advancements in related industries, historical data, governmental regulations, the application’s domain, present trends, and the competitive environment. Its discussion on the industry’s competitive landscape includes the tactics employed by the top competitors. Market Study Report marketstudyreport.com (866) 764-2150 Stringer Bead Brush Cleans Both Sides of a Weld Simultaneously The Honey Badger® double-stringer bead brush utilizes two brush sections to clean 22 | WELDING JOURNAL

both sides of a weld at the same time. It is built with two sets of wire knots on a face plate and nut. This construction allows the brush to hit both sides of the root or intermediate pass while cleaning out any weld slag or debris. It also enables a longer tool lifespan and a faster cut while reducing operator fatigue. The double-stringer bead brush is designed for the pipeline, welding, and metal fabrication markets. Osborn osborn.com (800) 5378449 Leak Recognition System Provides Early Warning of Leaks The SpillGuard® leak recognition system uses intelligent sensor technology to instantly alert users when a leak is detected. When placed within the sump of a spill containment device or near the equipment to be monitored, it will alert users with an audible and visual alarm for a minimum of 24 hours if contact is made with a liquid. The easy-touse system only needs to be switched on and placed into position. Additionally, it features an explosion-proof, highly resistant, electrically conductive housing. It also comes equipped with a battery that lasts up to five years and provides an audible signal when the battery needs to be replaced. The system is suited for use with containers and sumps of all sizes and types as well as along pipelines, next to heating or cooling systems, beside hydraulic equipment, or anywhere liquids are used or stored. It is ideal for use with temperatures from 32° (0°) to 104°F (40°C). DENIOS denios-us.com (877) 388-0187 MARCH 2023 | 23

BY GARY LEWIS Industry resources and NDE are discussed Pipe and tube welding products exist in service in a variety of forms, from simple, straight-forward strings of piping to large, complex systems with joined components. They are produced from a broad spectrum of materials, from fairly mundane carbon steel to very advanced alloy combinations, and serve as essential infrastructure for transporting, containing, and supporting products and materials in all kinds of environments and industries. The methods, materials, and choices made to join these components are equally diverse. Riley Power Group (RPG), a field welding, machining, and specialty staffing company, reminds us that “good fit-up and the proper end prep are often the most important keys to a successful weld.” Those priorities are certainly fundamental to quality, simplification, and repeatability; however, a longer list of other considerations can be just as important. It would be too lengthy to address every aspect of material supply, welding process optimization, and welder attributes in this article. Instead, what follows are a few considerations and places to go for help as resources and knowledge continue to diminish through shrinkage in the supply chain, retirement, and changes in our culture. Field Heat Treatment One principal consideration in many applications is the need for field heat treatment . It is essential, in many cases, to good weld quality, fitness for service, and, ultimately, return FEATURE HEAT TREATMENT and Other Variables in Pipe and Tube Welding 24 | WELDING JOURNAL

on investment. Prevention of solidification cracking, diffusion of hydrogen and other harmful constituents that are common failure mechanisms, phase transformation, curing, and annealing are some reasons to heat treat. AWS D10.10/ D10.10M:2021, Recommended Practices for Local Heating of Welds in Piping and Tubing, and D10.22/D10.22M:2021, Specification for Local Heating of Welds in Creep StrengthEnhanced Ferritic Steels in Piping and Tubing Using Electric Resistance Heating, provide guidance for properly heating a specimen, regardless of heat source (electrical resistance, induction, furnace, or combustion). For years, this area of specialization has been greatly underappreciated and overlooked in its contribution to successful welding and material processing. As advanced alloys become more prevalent, their dependency on uniform, controlled heat treatment is more important than ever. It has been estimated that 90% of weld failures and anomalies in these alloys can be traced to improper heat treatment rather than mistakes from the welder themselves. This has driven industry to invest heavily into research and studies that have led to many of the revisions and updates to codes and standards we see today. In most cases, these changes were helpful, but they also add complexity that requires higher levels of competence, integrity, and attention to detail in pricing, asset allocation, control, and monitoring practices. AWS Codes and Standards AWS is recognized around the world for developing standards and best practices for pipe and tube welding through its D10 Committee on Piping and Tubing, chaired by Shane Findlan. Many D10 standards include references to heat treatment. Committee members are subject matter experts who contribute to documents like AWS D10.10; AWS D10.22; and the still-in-progress, tentatively titled AWS D10.23, Specification for the Qualification of Personnel for Local Heat Treatment of Welds in Pipe and Tube Components. AWS standards are updated regularly, based on the latest research, and provide a rich source of information for anyone wanting to increase their knowledge of pipe and tube welding. Check out the D10 standards catalog for more information at aws.org/standards/committee/ d10-committee-on-piping-and-tubing. Industry Champions Friends like Chris Brown, CEO of Legacy Heat Treatment, are respected practitioners who have devoted a lifetime to improvements and advancements in field heat treatment practices, training, and technology. He speaks regularly at technical conferences about various aspects of heat treatment and often illustrates common shortcuts taken to produce a good chart and the implications of ignorance in the field. Induction bending on a tube with 28-in. O.D. and 1.5-in. wall thickness as part of research conducted for the Electric Power Research Institute, December 2022. (Photo courtesy of Legacy Heat Treatment and Tulsa Tube Bending.) Typical welding schedule with associated heat treatment processing based off Fig. 6.4 from AWS D10.10M:2021. MARCH 2023 | 25

Another champion and innovator in the industry is Gerry McWeeney, president and CEO of AxiomHT. He invested in the Energy Resource Institute (energyresourceinstitute.com), an online heat treatment training program for prospective technicians, supervisors, contractors, and owners, when no such certification existed. This initiative commenced a number of years ago as business owners in North America and Europe expressed concern that training for this influential craft had never been formalized like in welding and field inspection. Now it’s possible to ensure a level of competence, ethics, and performance records to improve the quality on your jobsite. McWeeney has also been instrumental in the development of the AWS D10.23 standard. Inspection and NDE Safety and quality are important factors in this industry. Lots of exciting new tools and improved techniques are being introduced into field inspection services, nondestructive examination (NDE), and quality assurance programs. They significantly enhance safety, performance, and record keeping and minimize risk as part of overall operations and life management strategies. For example, two effective NDE methods to verify proper heat treatment are surface hardness testing and taking replications. In many cases, heat treatment providers are contracted to provide hardness testing themselves to validate the effectiveness of the process. By its nature, heat treatment is virtually impossible to declare a success through a visual examination alone. Even hardness testing has its shortcomings depending on the technician training and what the inspector is most interested in validating. The tools themselves are subject to variability from factors such as surface prep and the location where the measurement is taken. Terry Haigler, general manager and researcher at Applied Inspection Systems’ Advanced Technology Center, explained that hardness readings are generally taken from multiple locations around the circumference of a pipe, noting results in the weld metal, heat-affected zone (HAZ), and base material. Surface replications, or cutaways, can be performed after postweld heat treatment (PWHT) to evaluate actual grain structure to ensure the proper material transformation has occurred. Replications provide more information about the actual condition of the HAZ when the desired microstructure is known. Other inspection techniques might also be effective, depending on what the inspector is looking for. Field heat treatment mock-up (left) and pipeline testing. (Photos courtesy of Legacy Heat Treatment and Republic Testing Labs.) Hardness indentations on a weld sample (top, photo courtesy of Legacy Heat Treatment and Applied Inspection Systems) and grain structures from a surface replication. 26 | WELDING JOURNAL

Magnetic particle inspection (MT) can provide confirmation that no surface cracks are present. Improper heat treatment could cause the material to crack if the heat treatment ramp rate was too fast or it was cooled too quickly. Phased array ultrasonic inspection is a more advanced technique than MT in the sense that it will tell the inspector if cracking has occurred due to incorrect heat treatment parameters or if any welding defects like slag or incomplete fusion caused cracking during proper or improper PWHT. The reader is encouraged to investigate advances in pulsed eddy current, advanced ultrasonics, and multifrequency microwave technology as well as emerging modeling tools utilizing powerful, simplified, affordable software for collecting data, simulations, predictive analytics, record keeping, and reporting from industry experts like Haigler. Conclusion Piping and tubing systems are critical components in so many of our industrial operations and processes. The complexity and variability compel conscientious industry professionals and companies to invest in continuing education and networking with experts in the field to ensure safe, efficient, reliable service and remain competitive in a rapidly changing marketplace. Readers are encouraged to attend local AWS Section meetings in their areas and, if possible, plan to attend the upcoming three-day Welding Summit 2023 (aws.org/weldingsummit) at The Woodlands Resort in The Woodlands, Tex., August 16–18. Feel free to reach out to the author for access to a vast network of subject matter experts and specialty service providers as we attempt to restore our resources and supply chains from the disruptions and challenges over the past couple of years. WJ GARY LEWIS ([email protected]) is a 1982 engineering graduate of Georgia Tech., Atlanta, Ga., and the president of Lewis Reliability Resources, Mooresville, N.C. He is also a member of several AWS D10 Committees. MARCH 2023 | 27

FEATURE AWS Guide Publications Fluids and gases are essential to the operation and productivity of nearly all industrial processes. This can include products, such as gasoline, beverages, or medicines. It can also include materials, such as lubricants, industrial gases, steam, or hydraulic fluids that are used to control and operate machinery for production of many products. Steam, for example, is essential to electric power generation. One of the earliest examples of pipe welding was the joining of discarded musket barrels by William Murdock in 1815 to transport coal gas throughout London for his lamp system. During World War II, welding had moved from a fabrication method that was gaining popularity to one that was essential to the war effort to meet production and performance requirements. The use of welding quickly replaced practices, such as riveting for the construction of many necessary products. Shipbuilding was one area where large movement was made toward the use of welding, and this led to advances in pipe and tube welding. Establishing the AWS D10 Committee More than 70 years ago, AWS recognized the importance of welding to the pipe and tube industry. The AWS D10 Committee was established in 1951 for the purpose of writing recommended practices relating to the welding of piping and tubing for various industries. Its mission statement is the following: “The D10 Committee on Piping and Tubing is responsible for the preparation of standards that formulate safe, sound, and progressive practices for the welding of piping and tubing for all applications. This committee promotes education in the latest welding techniques.” The original committee, which consisted of 47 members, was a cross section of American industry. The industries represented on that first committee included oil, gas, power, chemical, aluminum and steel pipe manufacturers, founders, pipe fabricators, engineering companies, welding equipment and consumable suppliers, valve and fitting manufacturers, boiler manufacturers, the American Petroleum Institute, and the U. S. Navy and Coast Guard. BY SHANE FINDLAN AND WILLIAM F. NEWELL Gas tungsten arc welding of 316L stainless steel pipe for power plant coolant water application. for Welding of Piping and Tubing 28 | WELDING JOURNAL

PUBLISHING OF SPECIFICATIONS AND STANDARDS The D10 Committee published its first document in 1953. Ironically, this document did not specifically cover the welding of piping or tubing. Instead, it was AWS D10.1, Recommended Practice for Postweld Heat Treatment of Austenitic Weldments. It was a tentative recommended practice, and it cost 50 cents. This publication served its purpose well but was withdrawn in 1955 because its contents were incorporated in other documents published by the committee. Alloy steels were becoming popular in the piping industry, so two new publications were written in 1955: D10.3, Recommended Practice for Interruption of Heat Treatment Cycles for Low Chromium-Molybdenum Steel Piping Materials, and D10.4, The Welding of Austenitic Chromium-Nickel Steel Piping and Tubing. D10.3 was later withdrawn because much of the information contained in this document was incorporated into other D10 documents. D10.4 is still in publication and has been continually updated. With the construction of nuclear power plants came a need for a document to cover the welding of piping for these plants. The D10 Committee took on this task and in 1959, D10.5, Welding Ferrous Materials for Nuclear Power Piping, was published. This document was later withdrawn after the welding of nuclear piping and tubing was included in ASME Sections III and XI publications. Other documents followed as industry needs developed. These included the following: 1959 — D10.6, Gas Tungsten Arc Welding of Titanium Piping and Tubing 1960 — D10.7, Recommended Practice for GasShielded Arc Welding of Aluminum and Aluminum Alloy Pipe 1961 — D10.8, Welding of Chromium-Molybdenum Steel Piping 1969 — D10.9, Standard for Qualification of Welding Procedures and Welders for Piping and Tubing. This document was withdrawn in 1992 as there was no longer a need because AWS had published B2.1, Specification for Welding Procedures and Performance Qualification 1975 — D10.10, Local Heat Treatment of Welds in Piping and Tubing (revised in 2021) 1979 — D10.12, Recommended Practices and Procedures for Welding Plain Carbon 1980 — D10.11, Recommended Practices for Root Pass Welding and Gas Purging 1995 — D10.13, Recommended Practices for Brazing of Copper Pipe and Tubing for Medical Gas Systems 2018 — D10.18, Guide for Welding Ferritic/Austenitic Duplex Stainless Steel Piping and Tubing 2021 — D10.22, Specification for Local Heating of Welds in Creep Strength-Enhanced Ferritic Steels in Piping and Tubing Using Electric Resistance Heating Publishing of Guides The D10 Committee has continued to produce and update recommended practices to meet the emerging needs for knowledge transfer to support pipe and tube welding applications. These documents are now referred to as “guides” and are not considered codes. They are more prescriptive than codes, providing practical information on welding processes and procedures compared to the rules and requirements found in codes. However, it is very noteworthy that many codes that address pipe welding requirements cite D10 guidelines as informative references. The D10 publications are beneficial as a resource for experienced engineers to provide emerging welding engineers with practical knowledge of welding processes and practices used for pipe and tube applications. The expansion of the D10 guides has been focused on keeping up with new materials and welding technology. Several publications are in development and provide excellent opportunities for individuals to share their knowledge and be involved in the development of new guides. The first of these is D10.21M/D10.21, Guide for Welding Creep Strength Enhanced Ferritic Steel Piping and Tubing, which addresses creep strength-enhanced ferritic steels (CSEFSs) to meet the need for a document that is specific to welding of these materials and how they obtain and maintain properties. Shielded metal arc welding on carbon steel pipeline. MARCH 2023 | 29

The use of the filler metals specific to these alloys will be addressed, including their influence on the final properties of the completed weld. The importance of preheat and postweld heat treatment when welding CSEF materials identified a need to formally address the qualification of personnel performing these operations. Another new document, AWS D10.23M/D10.23, Specification for the Qualification of Personnel for Local Heat Treatment of Piping, Tubing and Components Using Electric Resistance Heaters, is being prepared to address this need. Conclusion When faced with challenges in pipe or tube welding, the D10 publications can provide a practical, quick, and economical resource to solve many welding-related issues. To access any of the D10 publications, visit aws.org and click the “Bookstore” tab. This is your entryway to a vast amount of useful information that can help reduce cost and time for your welding applications. WJ SHANE FINDLAN ([email protected]), PE, IWE, is consulting engineer, welding and materials engineering, Stone & Webster LLC, Rock Hill, S.C., and chair of the AWS D10 Committee on Piping and Tubing. WILLIAM F. NEWELL, PE, PEng, IWE, is vice president, engineering, Euroweld Ltd., Mooresville, N.C., and past chair of the AWS D10 Committee. “The D10 publications can provide a practical, quick, and economical resource to solve many welding-related issues.” 30 | WELDING JOURNAL

FEATURE BY RADHIKA R. PANDAY Renewed Opportunities for GIRTH WELDING in High-Strength Pipelines FCAW-S is capable of robust mechanical properties at a fraction of the deployment cost of other wire-arc processes. 32 | WELDING JOURNAL

Self-shielded flux cored arc welding (FCAW-S) was invented in 1959 as an alternative to shielded metal arc welding (SMAW) to improve productivity and reduce cost. It was introduced as a semiautomatic tubular wire process with conventional equipment: a constant-voltage, directcurrent power supply; a wire welding gun; and a wire feeder. As shown in Fig. 1, the key difference between FCAW-S and other open-arc welding processes is the absence of shielding gas. FCAW-S employs an arc in air without the intended shielding, so protection comes from a welding wire that is filled with flux and metal powders. These consumables contain aluminum (Al) and magnesium (Mg), which react with the oxygen and nitrogen (N) to remove contamination from the molten weld metal through slag formation. In addition to being a strong oxide and nitride former, Al has high solubility in iron (Fe) and is a strong ferrite former. Other metal powders in the welding wire are alloyed with the weld metal to achieve the desired as-welded properties. Over the years, in North America, the FCAW-S process has gained popularity in shipbuilding and field erection of steel structures, where processes like SMAW, gas metal arc welding (GMAW), and gas shielded FCAW (FCAW-G) experience loss of shielding in high winds and are less productive. With FCAW-S, there is no shielding to disrupt. However, the adoption of semiautomatic FCAW-S for girth welding applications has been slow in North America due to limited operational stability over the wide operating range needed for 5G pipeline applications. Additionally, there are questions about the ability of FCAW-S to consistently deliver the weld performance, particularly Charpy toughness, demanded by the intended service conditions. Despite these concerns, when used appropriately, FCAW-S is a viable option for producing girth welds in high-strength pipelines. Operational Stability Operational stability and weld performance are not independent issues with FCAW-S. Although the widest operating range in self-shielded cored welding wires is achieved by increasing the Al to the extent allowed in filler metal specifications, ensuring consistent weld properties requires closer control of the total Al content and maintenance of the stable arc length, as shown in Fig. 2. A consumable delivers enough deoxidizer/denitrider to accommodate the atmospheric contamination that occurs under nominal welding conditions. At a shorter than nominal contact-tip-to-work distance (CTWD), which typically is what a welder controls in semiautomatic welding, the electrical stickout shortens, the arc length increases, and the base of the conical arc increases. There may be insufficient deoxidizer/denitrider to manage the actual level of atmospheric contamination that occurs with a corresponding increase in N porosity and a less-than-ideal weld metal deposit. At a longer than nominal CTWD, the electrical stickout lengthens, the arc length decreases, and the base of the conical arc decreases. In this case, there is a likelihood of more deoxidizer/denitrider being present for the actual level of atmospheric contamination. The Mg will slag off, but the excess Al will remain in the weld, often resulting in a lower toughness and an increase in crack sensitivity. Thus, any difficulty in maintaining a stable arc length with semiautomatic FCAW-S contributes to operational instability and increases Self-shielded flux cored arc welding has become a viable option for pipeline operators Fig. 1 — Schematic of the FCAW-S process. Fig. 2 — Contact-tip-to-work distance (CTWD) and arc voltage. MARCH 2023 | 33

spatter, thereby incentivizing contractors to consider new processes and techniques (e.g., mechanization of FCAW-S) for maintaining quality and production rates. Weld Properties Al Limits for Pipelines When it comes to Al limits for pipelines, how much is enough and how much is too much? As discussed previously, Al is a key component in self-shielded flux cored arc welds to achieve operational stability and a favorable microstructure without shielding gas. The best microstructure possible for achieving reasonable notch toughness in the self-shielded flux cored arc weld metal is bainitic ferrite. To achieve this, the final transformation must occur from austenite. In an Fe-Al-Carbon (C) system for FCAW-S, this is highly dependent on the Al level where any possibility of delta ferrite remaining in the as-deposited weld metal must be avoided. The equilibrium phase diagram in Fig. 3 illustrates the influence of Al addition on a simple mild steel (2% manganese [Mn], 0.4% C). There is a targeted range for FCAW-S in pipeline applications. The lower limit is driven by the need to produce a sound weld with an adequate level of operational stability and operating range. The upper limit is controlled by the need to form the most beneficial final weld microstructure. This approach delivers the most desirable and consistent microstructure possible without the shielding gas. How Welding Procedure Impacts Toughness Simulated pipe joints (SPJ) were welded using E81T8 FCAW-S electrodes to understand the influence of microstructure and welding practice on weld metal impact toughness. Welds were made at relatively high (60 kJ/in.) and low (30 kJ/in.) heat inputs with multiple Charpy V-notch tests conducted for each of the two different E81T8 electrodes. The results for the early-generation pipeline consumable are illustrated in Fig. 4, while Fig. 5 represents a similar study for one of the latest-generation pipeline consumables. Frequency plots were used to illustrate relative consistency or Fig. 3 — Schematic of an equilibrium phase diagram. Fig. 4 — Influence of welding procedure on Charpy toughness for an early-generation pipeline E81T8 electrode. (CVN: Charpy V-notch; HI: heat input.) Fig. 5 — Influence of welding procedure on Charpy toughness for a current-generation pipeline E81T8 electrode. (HHI: high-heat input; LHI: low-heat input.) 34 | WELDING JOURNAL

inconsistency of toughness measurements at a single test temperature. In Fig. 4, the gray area represents 60-kJ/in. welds completed in five total layers, with single-pass layers up to the final layer. The Charpy behavior was characterized by a bimodal distribution with a relatively high frequency at the low energy levels and a maximum achieved energy of ~ 90 ft-lbf. The red area represents 30-kJ/in. welds completed in six total layers, with split-pass layers above the root/hot passes. The frequency at low energy levels was significantly reduced, and the maximum energy achieved exceeded 140 ft-lbf. Clearly, more weld passes deposited at a lower heat input ensured reduction in the prior austenite grain size in both as-deposited and reheated regions of the weld metal and resulted in a higher Charpy toughness. This type of scatter in FCAW-S Charpy toughness was not uncommon with the early-generation consumables. Subsequent research found this is due to a combination of a coarse microstructure because of welding practice and the relatively large number and size of Al-oxide-based inclusions that remain in the weld metal after solidification. Figure 5 shows current-generation FCAW-S electrodes, which are designed to minimize the influence of inclusions on Charpy toughness. Again, the same multimodal characteristics are apparent, but the influence of welding conditions was significantly reduced (i.e., frequency at lower energy levels and average/peak performance). Summary and Concluding Remarks FCAW-S technology has evolved significantly since its inception in girth welding of pipelines. Welding manufacturers now have a better understanding of the slag system and chemical changes necessary for better inclusion control and microstructure stabilization to achieve improved mechanical properties. They also have a better understanding of the welding practices that influence the key outcomes. When applied appropriately, FCAW-S is capable of robust mechanical properties at a fraction of the deployment cost of other wire-arc processes. Pipeline operators should feel confident that this process is a viable option for high-strength girth welds on their construction projects, and contractors should be excited by the increased deposition without the added cost of protecting the arc. WJ RADHIKA R. PANDAY ([email protected]) is engineering manager, wire products consumable R&D, The Lincoln Electric Co., Cleveland, Ohio. This paper is based on presentations made at the AWS Pipe Welding Conference on September 12 and 13, 2022, in New Orleans, La., and the ASME International Pipeline Conference on September 26–30, 2022, in Calgary, Alberta, Canada. MARCH 2023 | 35

COMING EVENTS Visit aws.org/conferences for more information. Note: These events/opportunities are subject to change. AWS-Sponsored Events How to Use ASME Section IX Workshop March 7–9 This three-day workshop held at AWS Headquarters, Miami, Fla., is designed to train participants on how to comply with the requirements of ASME Section IX, Welding, Brazing, and Fusing Qualifications. Participants will gain a working knowledge of ASME Section IX. Attendees will receive copies of the notes covering workshop content. Upcoming events include June 6–8, Houston, Tex.; Oct. 3–5, Charlotte, N.C.; and Dec. 5–7, Denver, Colo. Women in Welding Virtual Conference: Automation in Manufacturing March 16 (1:00–3:00 p.m. Eastern) The panel will discuss the mystery of automation, how the implementation of welding automation constantly evolves, and how humans and robots can work together to create an adaptive welding process. Aluminum Conference April 11, 12 Held in Seattle, Wa., this conference will include expert-led panels to deliver the latest developments in the field of aluminum welding. FABTECH Mexico May 16–18 Join industry professionals at Centro Citibanamex in Mexico City. The event is colocated with AWS Weldmex and Metalform Mexico. Visit mexico.fabtechexpo.com. Welding Summit 2023: The Future of Welding Aug. 16–18 Industry experts will gather in The Woodlands Resor t, Houston, Tex., to discuss the importance of implementing new practices, studying industry trends, discovering emerging technologies, and considering new ways of implementing traditional practices. Attendees will get a chance to witness presentations and demonstrations, visit exhibits, and network. Attendees can also earn up to 21 professional development hours. FABTECH Sept. 11–14 Returning to the McCormick Place in Chicago, Ill., this event will provide a convenient one-stop shop venue for participants to meet with world-class suppliers, discover innovative solutions, find the tools to improve productivity, and increase profits. Visit fabtechexpo.com. Welding Automation Conference and Exposition Oct. 10–12 Held at The Blackwell Inn & Pfahl Conference Center in Columbus, Ohio, this conference will feature a variety of industry leaders presenting on topics such as collaborative robotic arc welding, automated weld inspection, Industry 4.0/ IoT, scan-to-path robotic programming, welding automation best practices for solar and wind power manufacturing, and more. Additionally, attendees can earn up to 20 professional development hours. Inspection Expo & Conference Nov. 8–10 Meet industry experts, attend expert panel presentations and breakout sessions, and make connections that can boost your career and keep your inspections business on the cutting edge at this event in Austin, Tex. FABTECH Canada June 11–13, 2024 Improve productivity, increase profits, and discover new solutions for all your metal forming, fabricating, welding, and finishing needs at the Toronto Congress Centre (South Building) in Toronto, Canada. Visit canada.fabtechexpo.com. U.S., Canada, Mexico Events Furnace and Brazing Symposiums May 10–12; May 23–25 These two-and-a-half-day symposiums will cover brazing fundamentals, filler metals, joint design, troubleshooting, and the new AIAG CQI-29 – Brazing Special Process Assessment. The first event (May 10–12) will be held at the Francis Marion Hotel in Charleston, S.C., and the second event (May 23–25) will be held at the Fiesta Americana Hotel in Aguascalientes, Mexico. Visit abbottfurnace.com. Great Designs in Steel (GDIS) 2023 May 24 Comprising more than 30 technical presentations and displays, this event provides insight on the latest trends and applications in new cars and trucks from engineering, design, technology, policy, and academic leaders. Held at the Suburban Collection Showplace in Novi, Mich., this all-day, multitrack program will feature industry topics on lightweighting, advanced high-strength steels, ultra-high-strength steels, welding, steel engineering, sustainability, and innovative use of steel in new vehicles. Visit greatdesignsinsteel.com. International Events The 76th IIW Annual Assembly & International Conference on Welding and Joining July 16–21 The conference will take place at Marina Bay Sands Hotel and Convention Centre, Marina Bay Sands, Singapore. With the theme of advances in welding, joining, and additive manufacturing, this event will provide a platform for knowledge exchange and networking among scientists, engineers, researchers, and industr y experts in the field of welding and joining. Visit iiw2023.com. Educational Opportunities AWS Professional Development Webinars Participants can learn about different welding topics and earn professional development hours or continuing education units by enrolling in these instructorled webinars taught by techni36 | WELDING JOURNAL

cal experts and industry leaders. Go to awo.aws.org/professionaldevelopment to view the schedule of upcoming webinars. AWS CRWT In-Person Seminar and Exam This seminar will arm attendees with the knowledge needed to take the AWS Certified Resistance Welding Technician (CRWT) exam with confidence. Upcoming training schedule: April 26, 27, Detroit, Mich., and Sept. 20, 21, Cleveland, Ohio. Visit awo.aws.org. AWS Two-Week CWI Exam Prep Seminar This seminar package includes instruction by AWS Certified Welding Inspectors and Educators; early receipt of the code book, tools, and study materials; and daily lunch. Visit aws.org/ cwi2week. Brazing 101 Offered April 18–20 and June 27–29, this intensive three-day production-brazing program will teach individuals how to effectively conduct brazing operations in a way that will reduce operating costs and improve brazing productivity. For information, contact Dan Kay at dan.kay@kaybrazing. com or (860) 651-5595 or visit kaybrazing.com. Business Electronics Soldering Technology (BEST) In-person certification and training classes are held in Rolling Meadows, Ill., and Auburn Hills, Mich. Online classes are also available. Visit solder.net for the training schedule. Contact BEST at (847) 797-9250. Canadian Welding Bureau (CWB) Online/ Classroom Courses CWB offers courses in nond e s t r u c t i v e e x a m i n a t i o n disciplines to meet certifications to the Canadian General Standards Board or Canadian Nuclear Safety Commission. cwbgroup.org; info@cwbgroup. org; (800) 844-6790. CWI/CWE Prep Courses; CWI Endorsement Seminars Courses are held at the Welder Training & Testing Institute in Allentown, Pa. For a complete list of seminars, workshops, and training schedules, go to ndtinstitute.com/upcomingclasses. To register, contact [email protected]. CWI Exam Prep Course The American Institute of Nondestructive Testing offers Certified Welding Inspector exam prep courses for Parts A and C. (855) 313-0325; trainingndt.com; instructor@ trainingndt.com. Gas Tungsten Arc Welding Aerospace Course Provided by the Hobart Institute of Welding Technology, this 70-hour course will help attendees develop the skills necessary for entrance into the aerospace industry. Visit welding.org or call (937) 332-9448. MARCH 2023 | 37

CERTIFICATION SCHEDULE Note: The 2023 schedule for all certifications is posted online at awo.aws.org/seminar-exam-schedule. IMPORTANT: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. to confirm your course status before making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications received after that time will be assessed a $395 Fast Track fee. Please verify application deadline dates by visiting our website at awo.aws.org/seminar-exam-schedule. For information on AWS seminars and certification programs, or to register online, visit aws.org/certification or call (800/305) 443-9353, ext. 273 for Certification or ext. 455 for Seminars. Certified Welding Inspector (CWI) Seminar covers Parts A, B, and C of the CWI exam. Only Part B of the exam is taken following the conclusion of the seminar. Parts A and C are given at Prometric testing centers. Location Seminar Dates Part B Exam Date Fresno, CA April 23–28 April 29 Baton Rouge, LA April 30–May 5 May 6 Sacramento, CA April 30–May 5 May 6 Detroit, MI May 7–12 May 13 Cleveland, OH May 7–12 May 13 Denver, CO May 21–26 May 27 Nashville, TN May 21–26 May 27 Birmingham, AL June 4–9 June 10 Pittsburgh, PA June 4–9 June 10 Hartford, CT June 11–16 June 17 Certified Welding Inspector (CWI) Two-Week The two-week in-person CWI seminar is designed to give candidates sufficient time to prepare for all three parts in a focused classroom environment. Location Seminar Dates Part B Exam Date Tampa, FL June 5–16 June 17 Denver, CO July 31–Aug. 11 Aug. 12 Certified Welding Inspector (CWI) Part B Course covers only Part B of the CWI exam. The Part B exam follows the conclusion of the three-day course. Location Seminar Dates Part B Exam Date Las Vegas, NV May 17–19 May 20 Apple Valley, MN July 19–21 July 22 9-Year Recertification Seminar for CWI/SCWI For current CWIs and SCWIs needing to meet education requirements without taking the exam. Location Seminar Dates Denver, CO April 30–May 5 Boston, MA May 7–12 Miami, FL May 7–12 Pittsburgh, PA June 25–30 Location Seminar Dates Charlotte, NC July 16–21 Houston, TX Aug. 6–11 Tampa, FL Aug. 27–Sept. 1 Sacramento, CA Sept. 24–29 Dallas, TX Oct. 8–13 Denver, CO Oct. 22–27 New Orleans, LA Nov. 12–17 Certified Welding Educator (CWE) Seminar and exam are given at all sites listed under Certified Welding Inspector. Seminar attendees will not attend the Code Clinic portion of the seminar (usually the first two days). Certified Welding Sales Representative (CWSR) More information at aws.org/certification/detail/ certified-welding-sales-representative. Certified Resistance Welding Technician (CRWT) More information at aws.org/certification/page/ certified-resistance-welding-technician. Certified Welding Supervisor (CWS) More information at aws.org/certification/detail/ certified-welding-supervisor. Certified Radiographic Interpreter (CRI) More information at aws.org/certification/detail/ certified-radiographic-interpreter. Certified Robotic Arc Welding (CRAW) The Lincoln Electric Co., Fort Collins, CO; (970) 829-7806 Milwaukee Area Technical College, Milwaukee, WI; (414) 456-5454 Santa Clarita Community College (College of the Canyons), Santa Clarita, CA; (661) 259-7800, ext. 3062 CERTIFICATION SEMINARS, CODE CLINICS, AND EXAMINATIONS 38 | WELDING JOURNAL

STANDARDS ACTION AWS has formed the new G2F Subcommittee on Tool Steel Alloys to develop AWS/NADCA G2.6M/G2.6, Guide for the Welding and DED Additive Manufacturing (AM) of Tool Steels Exposed to High Temperatures. The subcommittee is looking for four to six members. Professionals, along with students, are welcome to apply. Dennis Harwig, research associate professor of The Ohio State University Welding Engineering Laboratory, serves as chair of the AWS G2 Committee on Joining Metals and Alloys. Here, he details five reasons why interested individuals should apply to be part of the group. 1. The welding and repair of tool steels exposed to high temperatures have historically been considered within the artisan field due to the complex metallurgy and thermal processing requirements of these alloys. There is a lack of best-practice standard data for the welding and repair of tools and dies used in die casting, hot forming, forging, and other high-temperature processes. There is also a need for best-practice standard data to support directed energy deposition (DED) additive manufacturing (AM) of tools and dies as the availability of American supply chains for large format dies and tools has diminished. DED uses an automated or robotic arc, laser and electron beam fusion welding processes, and computer-aided manufacturing software to digitally build large format parts. These features make high-mix, lowvolume applications affordable. 2. The subcommittee seeks to prepare bestpractice data that informs users on materials used for dies and tools exposed to high temperatures; fusion welding, DED, and repair process characteristics and guidelines; typical properties of commercial-process consumable deposits; thermal management to avoid hydrogen cracking; postweld heat treatments for typical fitness for service property applications; case studies of common welding, DED, and repair applications; and more. Robotic DED path planning for hardfacing die sections. (Credit: Kovacich, J. L. 2020. Anviloy wire – H13 cladding development. Master’s thesis, The Ohio State University.) Join the AWS G2F Subcommittee on Tool Steel Alloys Five reasons to participate in this new subcommittee Y X Z Z Z Y Y X MARCH 2023 | 39

3. The best-practice standard will be prepared in collaboration with the North American Die Casting Association (NADCA), Die Materials Committee, which plays an essential role in driving research and developing technology to support original equipment manufacturers, steel suppliers, and die manufacturing and repair companies that are core to the automotive and consumer products industries. Die casting is used to manufacture tens of thousands of parts per machine and millions of parts annually. As an example, advanced welding and DED offer tremendous opportunities to improve diecasting die life by improving die thermal management, thermal fatigue cracking resistance, and molten material soldering resistance. 4. Volunteers are sought who have expertise in and/or support the welding, repair, and DED of tool steels exposed to high temperatures. Volunteers will have an opportunity to network with leaders in the automotive and consumers product die casting and other related industries, tool steel suppliers, welding and consumable suppliers, and DED AM technology suppliers. Volunteers are also sought from the hot forming and forging industries who have expertise on materials, welding, repair, and DED applications. 5. Finally, this subcommittee will work closely with the AWS D20 Committee on Additive Manufacturing and the A5 Committee on Filler Metals and Allied Materials to help coordinate standards that serve the rapid growth in the welding, repair, and DED of tool steels exposed to high temperatures. Additional Details To apply for membership, visit aws.org/committeeapp. You may also direct questions to AWS Staff Secretary Stephen Borrero at [email protected] or (800) 443-9353, ext. 334. For more information, go to aws.org/g2committee. “Together, AWS and NADCA have the potential to significantly improve the affordability and performance of dies and tools used in the automotive, consumer products, and other industries that produce parts using high-temperature processes (casting, forming, forging, etc.),” Harwig added. “With the growth in additive manufacturing and advanced welding methods, American supply chain competitiveness can significantly be improved by preparing a best-practice standard to transition the know-how needed to process these steels, which have very complex alloy, welding, DED automation, and thermal management requirements to ensure performance.” WJ Have you ever thought about writing a feature article for consideration in the Welding Journal? If so, our staff stays on the lookout for original, noncommercial, practical, and hands-on stories. Take a look at our editorial calendar — available as part of the American Welding Society’s Media Kit at aws.org/wj — to see what topics will be highlighted in future issues as well as the editorial deadlines. Potential ideas to focus on could include a case study, a recent company project, and tips for handling a particular process. Here’s an easy breakdown of our guidelines: ■ The text of the articles should be about 1000 words and provided in a Word document. ■ Line drawings, graphs, and photos should be high-resolution JPG or TIFF files with a resolution of 300 or more dots per inch. ■ Plan on about one figure for every 500 words and provide captions for every image. Also, if a nice lead photo is available, please include it for review. ■ The authors’ names, along with the companies they work for and their positions, should be listed. If you’d like to discuss a particular idea or email a submission for evaluation, please contact Managing Editor Kristin Campbell at [email protected]. Guidelines for Submitting a Welding Journal Feature Article 40 | WELDING JOURNAL

SOCIETY NEWS Safety and Health Committee: 50 Years Young and Going Strong This year marks the 50th year of activities by the AWS Safety and Health Committee. In celebration of this milestone, the following highlights the past, present, and future of this influential committee. The Past In January 1973, AWS Past President Dr. Robert D. Stout appointed F. Carl Saacke as chair of a newly formed AWS committee for safety and health activities. At the time, Saacke was the chair of what is now the American National Standards Institute (ANSI) Z49.1 Committee. This action by Stout brought all safety and health activities of the AWS under the control of one committee. AWS has always been involved in safety and health, but this was the first time a separate committee was established for that purpose. Until this period in time, the former AWS A5 Committee on Safety Recommendations reported to the AWS Technical Activities Committee (TAC). The new AWS Safety and Health Committee reported directly to the AWS Board of Directors, just like TAC. This elevation in status for the Safety and Health Committee was a major step for AWS. Early on, one of the important activities of the AWS Safety and Health Committee was to provide the secretariat function for the ANSI Z49.1 Committee. This role continues today. To further define the committee’s role, on April 3, 1973, during the AWS Show in Chicago, Ill., an action plan titled “What Should AWS Do in Safety and Health?” was presented. During the meeting, Gerard Scannell, former director of the Occupational Safety and Health Administration (OSHA) Office of Standards, and Charles E. Powell, former director of the National Institute for Occupational Safety and Health (NIOSH) Office of Research and Standards Development, discussed the topic of government involvement in safety and health. Also in attendance were AWS Past President Roy C. Becker and past board of directors member Joe Caprarola. The Present Today, the AWS Safety and Health Committee actively promotes knowledge concerning the occupational and environmental effects of welding, cutting, and applied processes. This knowledge is freely distributed to the public via the AWS website (aws.org/safety). Through liaison with other organizations and committees, the Safety and Health Committee also helps ensure the coordination of efforts to improve safety and health practices. To find out more about this committee, visit aws.org/standards and click on “Technical Committees” then “Safety and Health.” You Can Help with the Future Currently, the Safety and Health Committee is very active. If you have any interest in joining and/or assisting in its continuing activities, contact Steve Hedrick, AWS program manager, Standards Development, at [email protected]. WJ This article was written by AUGUST F. MANZ, AWS Fellow and chair of the ANSI Z49.1 Committee. August F. Manz Duties of the AWS Safety and Health Committee ■ Promote knowledge concerning occupational environmental effects on the health and safety of personnel involved in welding, brazing, thermal cutting, and allied processes, including the storage and handling of welding and thermal cutting equipment and materials. ■ Promote standardization of methods for sampling and analysis of substances and radiations emitted in welding and thermal cutting processes. ■ Develop safe practices and standards for such processes to ensure a safe working environment for welders and associated personnel. ■ Make recommendations concerning projects to be funded by the Safety and Health Research Fund. ■ Establish liaison with other AWS committees and organizations to ensure coordination for improved efficiency and avoid duplication of effort. ■ Nominate and administer the activities of official safety and health representatives of the Society on committees of other societies in accordance with the “Rules for the Appointment and Functioning of Representatives of AWS on Technical Committees of Other Societies,” as approved by the board of directors. MARCH 2023 | 41

SOCIETY NEWS Tech Topics Opportunities to Contribute to AWS Committees The following committees and their subcommittees welcome new members. Some committees are recruiting members with specific interests in regard to the committee’s scope, as marked below: Producers (P), General Interest (G), Educators (E), and Users (U). F o r a d d i t i o n a l i n f o r m a t i o n , c o n t a c t t h e s t a f f m e m b e r listed at aws.org/standards/ committeesandstandardsprogram. Also visit this website for the complete list of AWS subcommittees. A — Fundamentals ■ A1 Metric Practice (E) ■ A2 Definitions and Symbols (E) ■ A5 Filler Metals and Allied Materials (E) ■ A9 Computerization of Welding Information B — Inspection and Qualification ■ B1 Methods of Inspection (E) ■ B2 Procedure and Performance Qualification (E, G) ■ B4 Mechanical Testing of Welds (E, G, P) C — Processes ■ C1 Resistance Welding (E, G, U) ■ C2 Thermal Spraying (E, G, U) ■ C3 Brazing and Soldering (E, G) ■ C4 Oxyfuel Gas Welding and Cutting (E, G) ■ C6 Friction Welding (E) ■ C7 High Energy Beam Welding and Cutting (E, G) D — Industrial Applications ■ D1 Structural Welding (E, G, P, U) ■ D3 Welding in Marine Construction (E, G, U) ■ D8 Automotive Welding (E, G, U) ■ D9 Sheet Metal Welding (G, P) ■ D10 Piping and Tubing (E, U) ■ D11 Welding Iron Castings (E, G, P, U) ■ D14 Machinery and Equipment (E, G, U) ■ D15 Railroad Welding (E, G, U) ■ D16 Robotic and Automatic Welding (E) ■ D17 Welding in the Aircraft and Aerospace Industry (E, G) ■ D18 Welding in Sanitary Applications ■ D20 Additive Manufacturing (E, G) F — Safety and Health (SHC) ■ SHC Safety and Health (E, G) G — Materials ■ G1 Joining of Plastics and Composites (E, G) ■ G2 Joining Metals and Alloys (E, G, U) J — Welding Equipment ■ J1 Resistance Welding Equipment (E, G, U) Technical Committee Meetings All AWS technical committee meetings are open to the public. Contact the staff members listed or call (800) 443- 9353 for information. March 28–31. D1 Committee and Subcommittees on Structural Welding. Miami, Fla. Contact: J. Molin, jmolin@ aws.org, ext. 304. New Standards Projects Development work has begun on the following new or revised standards. Affected individuals are invited to contribute to their development. Participation in AWS technical committees is open to all persons. B2.1-1-027, Standard Welding Procedure Specification (SWPS) for Self-Shielded Flux Cored Arc Welding of Carbon Steel (M-1 or P-1, Groups 1 and 2), 1/8 inch [3 mm] through 1/2 inch [13 mm] Thick, E71T-11, in the As-Welded Condition, Primarily Plate and Structural Applications. This standard cites the base metals and operating conditions necessary to make the weldment, the filler metal specifications, and the allowable joint designs for groove and fillet welds. It was developed primarily for plate and structural applications. Stakeholders: manufacturers, 42 | WELDING JOURNAL

SOCIETY NEWS welders, engineers, AWS Certified Welding Inspectors (CWIs), and accredited training facilities. Revised Standard. Contact: J. Rosario, jrosario@ aws.org, ext. 308. Standards for Public Review AWS was approved as an accredited standards-preparing organization by the American National Standards Institute (ANSI) in 1979. AWS rules, as approved by ANSI, require that all standards be open to public review for comment during the approval process. Standards open for public review can be found at aws.org/standards/page/standardsnotices. This column also advises of ANSI approval of documents. A5.25/A5.25M, Specification for Carbon and Low-Alloy Steel Electrodes and Fluxes for Electroslag Welding. New Standard. $37.00. Contact: K. Bulger, [email protected], ext. 307. C3.11M/C3.11, Specification for Torch Soldering. New Standard. $38.00. Contact: K. Bulger, [email protected], ext. 307. C4.9/C4.9M, Recommended Practices for Oxyacetylene Cutting of Steel. New Standard. $25.00. Contact: J. Rosario, [email protected], ext. 308. AWS Holds CWI Nine-Year Recertification Seminar at World Headquarters From January 15 to 20, AWS hosted attendees of the CWI Nine-Year Recertification Seminar at its World Headquarters in Miami, Fla. Attendees included seminar instructor Rick Suria, Anthony L. Thompson, Anthony W. Culbreth, Edward R. Arambula Jr., Gary S. Heinly, Greg S. Rowe, John C. Urton, Joseph G. Spahn, Joseph M. Murray, Kyle L. Jones-Anderson, Nicolas W. Broussard, Payton H. Owen, Rene Villalobos, and William E. Penland. MARCH 2023 | 43

SOCIETY NEWS Membership Activities New AWS Supporters Sustaining Corporate Members Dashing Sheet Metal Co. Ltd. No. 155, Gongye 2 Rd., Annan Dist., Tainan City 709 Taiwan Fought & Co. Inc. 14255 SW 72 Ave. Tigard, OR 97224 General Air Service & Supply 1105 Zuni St. Denver, CO 80204 Wilco Equipment Co. Inc. 101 Bluebird Pkwy. Wills Point, TX 75169 Educational Institution Members Agencia de Examinación en Tecnología de Soldadura (AETS) Av. Saracho #1317 La Paz, Murillo Bolivia Cedar Bluffs Public School 110 E. Main St. P.O. Box 66 Cedar Bluffs, NE 68015 Eastern Gateway Community College 4000 Sunset Blvd. Steubenville, OH 43952 Erie County Community College 2403 W. 8 St. Erie, PA 16505 Hutchinson Community College 1300 N. Plum St. Hutchinson, KS 67501 Ivy Tech Community College 815 E. 60 St. Anderson, IN 46013 John Stark Regional High School 258 Western Ave. Henniker, NH 03242 Latinas Welding Guild Inc. 1417 Commerce Ave. Indianapolis, IN 46201 Local Union 296 – SW Idaho Plumbers & Pipe Fitters Joint Apprenticeship and Training Committee (JATC) 575 N. Ralstin St. Meridian, ID 83642 Mars Ultor Calle Teniente Enrique, Deluchi 240, Barranco Peru New Caney Independent School District – Porter High School 21580 Loop 494 New Caney, TX 77357 North Central Kansas Technical College – Beloit Campus 3033 U.S. Hwy. 24 Beloit, KS 67420 Nueces Canyon High School 200 Taylor St. P.O. Box 118 Barksdale, TX 78828 Skybridge Restoration Inc. 32-62 Steinway St. Astoria, NY 11103 Wylie High School – Wylie Independent School District 2550 W. Farm to Market Rd. 544 Wylie, TX 75098 Supporting Corporate Members A-Z Process Solutions 5365 W. Clairemont Dr. Appleton, WI 54913 Barnum Mechanical Inc. 3260 Penryn Rd. Loomis, CA 95650 Better Header Inc. 355 Marcus Blvd. Deer Park, NY 11729 Praxair Surface Technologies 1500 Polco St. Indianapolis, IN 46222 Spotwelding Consultants Inc. 4209 Industrial St. Rowlett, TX 75088 Thermach LLC P.O. Box 1995 Appleton, WI 54912 Williams Patent Crusher and Pulverizer Co. Inc. 333 Grove Ave. Bonne Terre, MO 63628 Affiliate Corporate Members Bernard Contracting LLC 14058 N. Division Rd. Collins, NY 14034 Blackhorse Industrial Solutions 12796 Atomic Rd. Beech Island, SC 29842 BW Structural Services 5630 Flatrock Rd. Hoagland, IN 46745 AWS Member Counts January 1, 2023 Sustaining 533 Supporting 310 Educational 868 Affiliate 636 Welding Distributor 46 Total Corporate 2393 Individual 49,786 Student + Transitional 9060 Early Career 435 Total Members 59,281 44 | WELDING JOURNAL

SOCIETY NEWS EGW Utilities Inc. 1406 Hutton Dr. Carrollton, TX 75006 First State Fabrication LLC 26546 Seaford Rd. Seaford, DE 19973 Martini Construction Inc. P.O. Box 102 Fort Davis, TX 79734 NDT Lanka Pvt. Ltd. No. 87/B, Thotupola Rd. Mahabalana, Alubomula Pandura 12500 Sri Lanka Nipunatha Sanwardhana Piyasa Negombo Rd., Narangamuwa Giriulla 60140 Sri Lanka Ranburne Steel Fabrication Inc. 4108 County Rd. 63 Ranburne, AL 36273 Sedron Technologies 133 W. State St. Ste. 101 Sedro-Woolley, WA 98284 Final Tally — 2022 Sparking Connections Campaign Congratulations to the top recruiter of the 2022 Sparking Connections campaign, Kevin J. Campbell of the Santa Clara Valley Section. He earned 26 points. As the first-place winner, he has the choice of receiving a three-year AWS membership or a gift card. The second top recruiter was Robert L. Dricken, who earned 11 points, of the Milwaukee Section. He has the choice of receiving a two-year AWS membership or a gift card. 2023 Sparking Connections Listed here are the members participating in the 2023 Sparking C onnec tions progr am — p oint standings as of January 18. The campaign runs from January 1 to December 31, 2023. Members receive five points for each Individual Member and one point for every Student Member they recruit. For more information, visit aws.org/sparkingconnections. R. Bowie, Connecticut — 10 W. Burns, Iowa — 10 L. D. Dominguez Castan, Monterrey — 10 M. Cade, Puget Sound Olympic — 10 M. R. Tryon, Utah — 10 D. Merchant, Columbia — 10 D. W. Hardin, North Florida — 10 H. T. Kroll, Philadelphia — 10 J. E. Foster, York-Lancaster — 10 J. J. Holmes, Puget Sound Olympic — 10 Get to Know Your Member Benefits AWS hosts regular webinars to welcome new members as well as remind all members of their AWS benefits and how to take advantage of them. The webinar schedule is available at aws.org/memberwebinar. The January 4th “Weld Wednesdays with AWS” episode of the Arc Junkies podcast showcased guest speaker Gary Konarska II, AWS executive director and CEO. During the nearly 50-minute episode, Konarska discussed the current state of the welding industry, shared insights on recent activities held by AWS in 2022, previewed what’s in store for the Society in 2023, and detailed the resources and support available through AWS. The full podcast can be listened to at arcjunkies.com as well as Spotify, iTunes, and other music streaming platforms. Gary Konarska II AWS’s Gary Konarska II Makes Guest Appearance on the Arc Junkies Podcast MARCH 2023 | 45

SOCIETY NEWS Miguel Gonzalez decided to go after a career in the welding field when he discovered that his high school courses had only given him a small glimpse into the world of welding. At the age of 15, he began learning about the craft at Jersey Village High School, Houston, Tex. During his time there, he picked up the basics of welding; learned how to use different metalworking tools; became qualified in various welding processes, including gas metal arc welding, shielded metal arc welding (SMAW), and flux cored arc welding (FCAW); and challenged himself in the Texas Technology Student Association regional and state competitions. However, he wasn’t ready to hang up his welding torch upon graduation. “I ended up taking welding classes all four years of high school, and I learned that our shop class had only scratched the surface of all of the different areas of the welding industry, which led me to make the decision to pursue a bachelor’s degree in welding engineering,” he said. Laying the Building Blocks for Success Gonzalez continued his welding education at LeTourneau University, Longview, Tex., where he is currently majoring in materials joining engineering technology. The program has allowed him to learn more about metallurgy through numerous enlightening projects. His favorite project so far involved underwater wet SMAW and FCAW. “In my sophomore year of college, I helped my professor build two concepts for mechanized underwater wet welding applications for SMAW and FCAW processes,” he recalled. “The highlight of this project was having to modify and braze an extension to the welding torch that we used for the FCAW process concept.” Gonzalez has further bolstered his education through internships. During his sophomore year, he worked at Schulte Building Systems, Hockley, Tex., a manufacturer of pre-engineered metal buildings, steel framing systems, and building components. “At Schulte Building Systems, I was given the opportunity to shadow welding inspectors and get a better understanding of what NDE [nondestructive examination] is like in a production shop,” he said. Last year, he interned at AGT Robotics, Houston, Tex., a manufacturer of robotic welding cells for the structural and heavy fabrication industry. “AGT Robotics allowed me to use skills I’ve learned in college, such as producing a welding procedure, preparing a macroetch sample, reviewing codes, and performing economic calculations,” he stated. Gonzalez has also sharpened his welding knowledge and skills through his job as LeTourneau University’s course lab technician. In this role, he teaches students in the school’s manufacturing processes course how to safely perform oxyacetylene and arc welding processes. “Being able to teach others about something I’m passionate about has been the main highlight of my job, and it also has the added benefit of making me spend more time in the welding lab,” he affirmed. “I’m able to practice my welding skills in a variety of processes on a wide range of power supplies from various manufacturers.” Giving Back through Volunteer Work In addition to school and work, Gonzalez makes time to support LeTourneau University’s welding student body. He is currently the vice president of the LeTourneau University AWS Student Chapter and previously served as secretary. “My main motivation for volunteering with our chapter is to make people aware of the opportunities that come with being an AWS member and the mentoring I can give to the underclassmen in the welding engineering major,” he explained. Gonzalez also uses his role as student chapter vice president to benefit those outside the college. “One of the major goals our chapter has this year is to improve our community outreach by doing things such as hosting a toy drive for kids in East Texas and hosting welding competitions for high school students in the region,” he said. Looking Ahead to a Bright Future Gonzalez is slated to graduate with a bachelor’s degree this year. He hopes to one day work alongside NASA. In the distant future, he would like to positively influence younger generations as a welding instructor. “My dream job would be to work for a company that works on projects with NASA to support future space exploration,” he said. “I would like to spend the sunset years of my career as a welding instructor because of the profound impact my welding instructor and welding engineering professors have had on my life.” AWS Member Profile Student pursues his passion for welding engineering Miguel Gonzalez 46 | WELDING JOURNAL

GUIDE TO AWS SERVICES American Welding Society® 8669 NW 36 St., #130 Miami, FL 33166-6672 (800/305) 443-9353 Phone extensions are in parentheses. AWS PRESIDENT Dennis K. Eck / [email protected] President, Diversified Services Solutions LLC EXECUTIVE LEADERSHIP TEAM Executive Director / Chief Executive Officer Gary Konarska II / [email protected] / (210) Chief Financial Officer/ Chief Administrative Officer Gesana Villegas / [email protected] / (252) Senior Vice Presidents Cassie Burrell / [email protected] / (253) Marketing & Membership Development John Gayler / [email protected] / (472) Welding & Technology EXECUTIVE OFFICE Associate Director Jessenia Martinez / [email protected] / (215) Program Manager Malisa Mercado / [email protected] / (293) HUMAN RESOURCES Sr. Director Tatiana Milan / [email protected] / (209) GOVERNMENT LIAISON SERVICES Hugh Webster / [email protected] Webster, Chamberlain & Bean, Washington, D.C. (202) 785-9500; Fax: (202) 835-0243 Monitors federal issues of importance to the industry. CERTIFICATION SERVICES Dept. information / (273) Managing Director Denny Smith / [email protected] / (281) ACCREDITATION [email protected] CONFERENCES & EVENTS Director, Conferences Margaret Jamborsky / [email protected] / (213) CUSTOMER SERVICE & SUPPORT Dept. information / [email protected] / (280) EXPOSITIONS & SALES Director of Expositions and Sales Matthew Rubin / [email protected] / (239) Senior Sales Executive, Expositions Sarah Dickson / [email protected] / (297) Senior Sales Executive, Education Efram Abrams / [email protected] / (333) Manager, Advertising Sales Operations Lea Owen / [email protected] / (220) Senior Sales Executive, Advertising Sales Scott Beller / [email protected] / (319) EDUCATION & TRAINING Director Alicia Garcia / [email protected] / (229) INFORMATION SYSTEMS Managing Director John Perry / [email protected] / (247) RWMA, WEMCO, and ITSA Program Manager Adrian Bustillo / [email protected] / (295) MEMBER SERVICES Dept. information / (480) Director, Membership Nici Banks / [email protected] / (270) Serves as a liaison between members and AWS headquarters. Senior Manager, Sections and Student Chapters Darrill Gaschler / [email protected] / (260) PUBLISHING & EDITORIAL Dept. information / (275) Welding Journal Publisher/Editor Annette Alonso / [email protected] / (299) Managing Editor Kristin Campbell / [email protected] / (257) Section News Editor Cindy Weihl / [email protected] / (256) Society News Editor Katie Pacheco / [email protected] / (275) Education Editor Roline Pascal / [email protected] / (303) News of the Industry Editor Alexandra Quiñones / [email protected] / (465) Inspection Trends & Welding Journal en Español Editor Carlos Guzman / [email protected] / (348) STANDARDS DEVELOPMENT Dept. information / (340) Director — Standards Development Peter Portela / [email protected] / (311) Technical Committee Activities Program Managers Stephen Borrero / [email protected] / (334) Definitions and Symbols, Structural Subcommittees on Bridge Welding, Reinforcing Steel and Stainless Steel, Joining of Metals and Alloys, Piping and Tubing Kevin Bulger / [email protected] / (307) Filler Metals and Allied Materials, International Filler Metals, UNS Numbers Assignment, Brazing and Soldering, Welding of Machinery and Equipment Mario Diaz / [email protected] / (310) Automotive, Resistance Welding, Resistance Welding Equipment, Welding and Brazing in Aerospace, Additive Manufacturing Marandi Gills / [email protected] / (353) Computational Weld Mechanics, Methods of Weld Inspection, Welding in Marine Construction, Oxyfuel Gas Welding and Cutting, Friction Welding Stephen Hedrick / [email protected] / (305) Metric Practice, Safety and Health, Joining of Plastics and Composites, Personnel and Facilities Qualification, Mechanical Testing of Welds, Welding in Sanitary Applications Jennifer Molin / [email protected] / (304) Structural Welding, Sheet Metal Welding Jennifer Padron / [email protected] / (306) High Energy Beam Welding, Robotics Welding Jennifer Rosario / [email protected] / (308) Railroad Welding, Thermal Spraying, Welding Iron Castings, Welding Qualification, Structural Subcommittee on Titanium Welding Handbook Editor Stephen Borrero / [email protected] / (334) TECHNICAL SERVICES Staff Welding Specialist Steven Snyder / [email protected] / (298) Staff Welding Engineer Nathan Carter / [email protected] / (302) Director — International Activities Andrew Davis / [email protected] / (466) International Standards Activities, American Council of the International Institute of Welding AWS FOUNDATION INC. aws.org/foundation General Information (800/305) 443-9353 (212), [email protected] Chair, Board of Trustees William A. Rice / [email protected] Executive Director, Foundation Monica Pfarr / [email protected] / (461) Associate Director, Foundation John Douglass / [email protected] / (212) The AWS Foundation is a not-for-profit 501(c)(3) charitable organization established to provide support for the educational and scientific endeavors of the American Welding Society. You can support the AWS Foundation by visiting aws.org/donate. MARCH 2023 | 47

SECTION NEWS To find an AWS Section near you, visit: aws.org/membership/sectionsmap District Directory District 1 Timothy Kinnaman, director (401) 323-0535 [email protected] District 2 Kenneth Temme, director (856) 264-8377 [email protected] District 3 Sean Moran, director (717) 885-5039 [email protected] District 4 Anver Classens, director (704) 443-1223 [email protected] District 5 Daryl Peterson, director (813) 523-5436 [email protected] District 6 Ronald Stahura, director (716) 207-7869 [email protected] District 7 Roger E. Hilty, director (740) 317-9073 [email protected] District 8 James Thompson, director (256) 347-6481 [email protected] District 9 Calvin E. Pepper, director (225) 400-8159 [email protected] District 10 Tom Kostreba, director (814) 881-0632 [email protected] District 11 Phillip Temple, director (734) 546-4298 [email protected] District 12 Dale Lange, director (715) 732-3645 [email protected] District 13 Ronald Ashelford, director (815) 218-8766 [email protected] District 14 Tony Brosio, director (765) 215-7506 [email protected] District 15 Michael Hanson, director (763) 221-5951 [email protected] District 16 Jeffrey Jones, director (918) 638-2787 [email protected] District 17 J Jones, director (832) 506-5986 [email protected] District 18 Thomas Holt, director (409) 721-5777 [email protected] District 19 Boyce Towell, director (609) 284-7449 [email protected] District 20 Denis Clark, director (208) 357-6626 [email protected] District 21 Jeff Davis, director (858) 735-4506 [email protected] District 22 Randy Emery, director (559) 285-1803 [email protected] 48 | WELDING JOURNAL