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PFFHCIAL PUBLICATION OF THE AMERICAN WELDING society. @&
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 Jackson ST Holders

“Theyre

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These copper alloy quality Jackson electrode holders have a @ Slide on the connection nut—
permanent-type cable connection device good for the life of
the cable. It grips the cable jacket as well as the cable, sealing
out moisture and dirt. The jacket can’t slip back, the strands
won't flex and break. The ‘stinger end’ of the holder can be
replaced repeatedly without remaking the connection.
These ST holders are attached to the cable in a simple mechani-
cal way, but the result is an almost fused connection having
excellent conductivity.
Get the utmost in conductivity, ease of connection, and long
life. Get lower holder costs when buying ST holder stinger
end replacements. Get a Jackson Sealed Tight holder in your
hands soon and you'll see why they’re better.
a
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Model ST-5 copper alloy

holder for electrodes
through %" dia. Rated HT Se
for 500 amps.

Sold Everywhere by Better Welding Supply Dealers.

— ae ”

Jackson Products :
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For details, circle No. 1 on Reader Information Card
 "Welding

Journal

Technical Papers CO.-Shielded Welding of Horizontal Joints in Oil Storage Tanks, by Paul W. Turner
Consumable Electrode Spot Welding, by J. A. Howery and G. F. Mack ;
Items and
Series Spot Welding of Missile Fins, by D. W. Herold
Reports Use of Inconel Deposited Weld Metal for Nuclear Component Parts, by R. W. Minga and H. Richardson

‘
Highway Tunnel Has Welded Tube, by J. F. Guiley
Practical Welder |
Self-Contained Mobile Rigs for Flux-Cored Welding Process Speed Fabrication at Naval Weapons Plant
SHG DOSIBMCL —cxares tox Peaduction wr Bf Menne and PT. Seaslems b
Snaking Rugged Piping Across Rugged Terrain
One-Piece Welded Machine Housing—Stronger, Lighter, Lower in Cost, Better Looking.
Arteries for a Stratofort, by G. R. Clay and J. C. Rodgers
Into the Winner's Circle, by R. M. Stuchell and J. R. Flynn....
Positioner Improves Welding of Shuttle Cars....

Society Press-Time News.. me News of the Industry

Welding Zones. .... Personnel
and Related World-Wide Welding News Employment Service Bulletin
Fvents Editeriel~Weldina Research nip . — =
Current Welding Literature
Council, by K. H. Koopman : New Literature
Society News. New Products.
Section News and Events . Reader Information Card
New Members..... Index to Advertisers

oi A
Welding Phenomenological Considerations in Ultrasonic Welding, by J. B. Jones, M. Maropis, J. G. Thomas and
D Bancroft... ; ; came : ;
Research Exhaustion of Ductility by Hot Straining—An Explanation of Fracture Initiation Close to Welds
by C. Mylonas and K. C. Rockey ORT AT a
Supplement Transition Temperature from Test Bars Using a Strain Aged Initiation Site, by Claes Pfeiffer
European Welding Research
Effectof an Irregular Notch on Subsize Impact Data, by A. L. Lowe, Jr
Experimental Determination of Dimensional Heat Flow in Weldments, by S. S. W ite
Weldability of a Modified Hot-Work Die Steel, by W. A. Sipes and E. J. Fogarty
Welding PH 15-7 Mo Precipitation Hardening Stainless Steel, by H.Smalien
Influence of Some Platinum Metals on the Wettability of Silver, by J. B.Adamec and R.N Rhoda

Published for the advancement Published monthly by the American Weld ) , 20th and Northampt Streets, Easton,
Pa. Editorial and general offices, 33 Sth S York 1 Y. Subscrig year the
.
of the science and art of welding - nited States and possessions: foreig
Secembclens oxiclinaee uikectand ax Ueaten, Ga,untri 10.00 opies,
Sita cenilentiin ts Gaitesael te Ge $1.50;calGa
nonmembers members
ok ee $1.00
eaneee
rates of postage prescribed by Section 132.122. Copyright 1961, by the American Weldi Societ The Society
s not responsible for any statement or opinion expressed in its pub ations Per sion is given to re
by the American Welding Society Sat aoe orticly eter WE Gas of mebiaaiten cleus Ged a ee
 important development in the field
of automatic arc welding machinery
Berkeley-Davis will continue to
build the Berkeley line of standard
fusion welders, in addition to its
own high production weld mills and
PRESS-TIME special transfer type welding ma-
chines.

11A Names Andrew

C. G. Andrew, vice president
production-distribution for Air Re-
NEWS about duction Sales Co., has been named
president of the International Acety-
lene Association at its 63rd anni-
People versary meeting recently held in
Boston, Mass.
Welding The IAA—one of the oldest
technical societies in the country
Products was organized in 1898 to develop
broader applications for calcium
carbide, acetylene gas and allied
products, and to disseminate tech-
nical information concerning such
New NWSA President Western Brass Renamed useful developments.
William P. McLendon, president By Olin A director for the IAA also, Mr.
of Keenan Welding Supplies Co., To achieve closer identification Andrew has been associated with
Albany, Ga., was elected president with its brass products, Olin Mathie-
of the National Welding Supply son Chemical Corp., has announced
Association at its Seventeenth that it is replacing the 45-year-old
Annual Convention of the Associa- Western Brass Mills Div. name
tion in New York City. with “Olin Brass.”” A change in
Mr. McLendon has been active graphic trademark is also being
in the Association’s affairs for a made.
number of years, having served in
the past year as executive vice
president and as national member- Bakken Heads Research
ship chairman. Previously, he was Association
vice president for two years of the Glenn P. Bakken was recently
Southeastern Zone and has served
re-elected president of the Copper &
on a number of Association com- Brass Research Association at its
mittees. 39th Annual Meeting in Hot
Active in the welding industry Springs, Va. Mr. Bakken is presi-
since 1930, Mr. McLendon became dent of Chase Brass & Copper Co.,
associated with Keenan Enterprises Inc.
in 1944 and helped organize the C. G. Andrew
present firm, Keenan Welding Sup-
plies Co., in 1946. Mr. McLendon Berkeley-Davis Merges Airco since 1923. He has directed
is also active in the Independent the company’s production and dis-
Oxygen Manufacturers Association, Berkeley-Davis, Inc., Danville, tribution system for many years.
and the International Acetylene Ill., recently announced purchase Mr. Andrew is a past president
Association. of the Berkeley Co., also of Dan- and executive committee member
ville. The combined operation will of the Compressed Gas Association,
be known as Berkeley-Davis, Inc., he is also a member of the Traffic
a wholly-owned subsidiary of the Club of New York National Defense
McKay Machine Co., Youngstown, Transportation Association.
Ohio.
Principal officers of the new com- Linde Installs New Onsite
bine are A. J. Wardle, chairman of
the board; J. R. Barefoot, presi- Oxygen Plant
dent; J. P. Berkeley W3, executive Latest addition to the steel in-
vice president; and C. H. Davis 3, dustry’s burgeoning supply of metal-
vice president. Mr. Wardle is presi- lurgical oxygen is a 280-tons-per-day
dent of the McKay Machine Co.., plant recently put into operation
and Mr. Barefoot, vice president by Linde Co., at Colorado Fuel
of McKay, is chief executive officer and Iron Corp., Pueblo, Colo.,
of the Federal-Warco Div. of the Div. of Union Carbide Corp. De-
McKay Machine Co. signed to meet the increased require-
Merging of Berkeley-Davis and ments of a $21 million expansion by
the Berkeley Co. is part of the ex- CF&I, a major portion of the two
pansion program of the McKay new plant’s output will be used in
W. P. McLendon Machine Co., and represents an basic oxygen steelmaking furnaces.

696 JULY 1961

 SEMI-AUTOMATIC Micro-wire SEMI-AUTOMATIC Migare FULLY AUTOMATIC— SUBMERGED ARC
Welding process Inert Gas Welding CO,— Inert Gas or Fabricated Wire Welding

SEMI-AUTOMATIC Mamumiatic DC WELDER/AC POWER COMBINATION AC OR DC METALLIC ARC WELDING

for submerged or open arc welding for Shop or Field Welding with Inert Gas Facilities

— |

BIGGEST

PACKAGE
IN THE
WELDING
BUSINESS

i
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AC TRANSFORMER ARC WELDING DC ROTARY TYPE ARC WELDING CHOOSE THE COMPLETE PACKAGE
that best suits your requirements

Whatever your welding requirements, there’s a complete Hobart package for

handling it—power sources, electrodes, wire, flux, auxiliary equipment and
accessories. HOBART BROTHERS COMPANY, BOX WJ-71, Troy, Ohio, Ph.
FE 2-1223. ‘‘Manufacturers of the world’s most complete line of arc welding
equipment”
For details, circle No. 2 on Reader information Card
 WELDING ZONES

Rocket engine identical to one that launched the first U. S. Interior view of a compartmented rotary dryer showing
astronaut into space is readied for shipment from Rocket- welded retaining dams and adjustable skimmer. This type
dyne, a division of North American Aviation, Inc. of dryer, developed by Standard Steel Corp., is used for
drying plastic material

Multiple-electrode submerged-arc welding for a 147-ton

turbogenerator steam drum at the Foster Wheeler
Corp., Mountaintop, Pa. (Courtesy Linde Co.)

Soma ai 2 m

Step-on fenders, fabricated from a checkered floor

plate supplied by Jones & Laughlin Steel Corp., are
used in boat trailers made by Riverdale Boat Trailers,
Riverdale, Mich
WELDED STAQILESS. INTERIOR

~e.,
“Sy, © (KEY TO VITAL
’

“HIGH-PURITY

43,000 pounds of stainless elec- SYSTEM rOrR

trodes and wire protect nuclear #9 RESDEN rdw
\ om ge),
system from corrosive impurities an —

Dresden Nuclear Power Station, near Chicago,

is one of the first installations to use nuclear
energy for commercial purposes Vital to its op-
eration is the maintenance of a high degree of
water purity. The extensive use of stainless steel
in the reactor keeps the unit as free as possible
from corrosive elements which would lower this
purity level
The weld-clad interior of the reactor vessel re-
quired in excess of 43,000 pounds of stainless
steel electrodes and welding wire. New York
Shipbuilding Corporation, Camden, New Jersey,
fabricators of the vessel, used ARCALOY Stain-
less Steel Electrodes for manual cladding and
welded joints. Alloy Rods Company Bare Stain-
less Steel Welding Wire was used for submerged
are cladding.
When job standards demand the ultimate in
stainless steel weld metal, discerning fabricators
rely on the high quality products of Alloy Rods
Company, the world’s largest producer of stain-
less steel electrodes and welding wires. Call in
your Alloy Rods’ Representative or Distributor
on your next stainless fabrication. He has knowl-
edge and products to improve the quality of your
welds . . . on any of the weldable grades of
stainless steel.
Distributors, warehouses and representatives are
located throughout the country for intelligent
and efficient servicing of all your stainless weld-
ing requirements. For information, write to Alloy
Rods Company, P. O. Box 1828, York 3, Penna.

ALLOY RODS COMPANY

YORK, PENNSYLVANIA
SALES OFFICES & WAREHOUSES; BOSTON, NEWARK, PHILA. PITTSBURGH, BIRMINGHAM, CLEVELAND, CHICAGO, SAN FRANCISCO & EL SEGUNDO, CAL.—DISTRIBUTORS IN ALL OTHER PRINCIPAL CITIES

TWENTY YEARS OF LEADERSHIP IN THE DEVELOPMENT OF QUALITY ALLOY ARC WELDING ELECTRODES
For details, circle Ne. 3 on Reader information Card
WORLD-WIDE WELDING NEWS

By Gerard E. Claussen

contains the following articles in its coating with Epoxy resin, 2,260,000
AUSTRIA
September 1960 issue: cycles withstood at the same stress.
An article on the electronic con- e The Central Welding Institute ¢ Application of low-alloy steel ST52
trol of resistance welders appears in analyzed the yearly welding record 74,000 psi min tensile strength
the August 1960 issue of Schweiss- of four plants fabricating machinery is lagging in East Germany because
technik Vienna. The application of from four viewpoints: (a) consump- it costs $5 a ton more than ST37
ignitrons is stressed, and several tion of electrodes and submerged-arc 52,500 psi min tensile strength).
instruments are illustrated including wire, (6) average pounds per hour of ¢ Ultrasonic and isotope methods of
a toroid meter for rms current, a deposited metal per operator, (c nondestructive testing are explained.
cycle counter, a contact resistance percentage of used metal in the ¢ The construction of a 5-t welding
meter and an oscillographic re- structures, (d) planned increase in manipulator is detailed.
corder production for 1961. The poor
The September 1960 issue con- showing of two plants was traced to
poor design that prevented the FRANCE
tains a description of the Schlatter
flash welder for rails. It is shown application of automatic welding. The manufacture of welded pipe
that platen speeds of 0.02 to 0.08 ips e The application of resistance for gas and oil pipe lines at the
are adequate for steel, but 0.4 ips is welding, flash, foil and spot welding, Société Lorraine-Escaut firm in
needed for aluminum and 1 ips for to railroad car building is illustrated. Longwy and Sedan, France, is
copper. For American rails 10 e An air-cooled tungsten - arc described in minute* detail. The
amp/mm? are needed, approxi- torch was used for welding stainless steel contains 0.10—-0.25 C, 0.70
mately 100,000 amp total, with an steel at currents up to 200 amp. 0.95 Mn, 0.05-0.11 Si. The rolling
impedance of 10~* ohm and 10 v. Schweisstechnik for October 1960 mill maintains accuracy of thickness
Oscillograms of Schlatter rail weld- contains the following articles: of the plates to the extent that plate
ing show a total welding time of 46 e The costs in marks per meter of weight is never more than 3°; above
sec and a push up time of 6.5 sec. weld for gouging out the back side of theoretical. The external weld is
Preheat time is 29 sec, flashing time butt welds preliminary to welding made before the internal. Both are
16 sec for a rail of 8.7 sq. in. Pre- the reverse side were found to be made by the submerged-arc process
heat is applied in six impulses 3 sec 3.96 for compressed air chisel, 2.34 with tandem electrodes, the leading
each, with pauses of |, to2 sec. A for oxyacetylene gouging torch, and electrode on dc, the trail on ac, 650
push up pressure of at least 2800 psi 1.11 for carbon-arc air device. to 850 amp for */,-in. wall. The
and up to 22,000 psi is required. « Complete details are given for the welds are inspected ultrasonically
Cooling curves and TTT diagram of design and fabrication of a 10-ton and radiographically. In 1961 a
0.55 C, 1 Cr, 1 Mn steel show that welded steel ore bridge with a 130-ft third line will be installed, boosting
martensite is avoided without post- span. The main girder is of tri- the production rate to 3'/; miles of
weld heat treatment. angular cross section with internal pipe per day.
ribs. Back step welding is em- The new French standard A81-
ployed to reduce residual stress. 309 for covered electrodes for mild
BELGIUM and low-alloy steels establishes a
e Low-cost reamers are made of mild
The Belgian monthly Acier Stahl steel hard surfaced in an automatic series of symbols for each electrode.
Steel for September 1960 has a machine by submerged-arc welding The symbols show the type of
number of articles on welded steel with bonded-alloy flux and mild- covering (acid or 6020; basic or low
structures. The Bessemer plant of steel wire. hydrogen; cellulosic; oxidizing;
the Cockerill plant in Belgium con- and rutile), position of welding,
tains a number of welded solid-web Official Journal type of current and open circuit
beams and thermit-welded crane ZIS' Mitteilungen of the East voltage, tensile strength, elongation
rails. Open web beams for the German Central Welding Institute and impact value. The welding of
Washington Building in Seattle, contains the following articles of tensile specimens is done at an
were made from rolled wide-flange general interest in the September interpass temperature of 480° F
beams flame cut in zigzag fashion 1960 issue: without boiling water or asbestos.
down the webs. The columns of a e A paper read by W. Gilde at the
large store in Locarno, Switzerland, Symposium on Fatigue of Welded
were provided with pairs of large SWITZERLAND
Structures held in England, Apr. 1,
plates at each floor level for beam 1960, showed that a plastic coating According to the October 1960
connections. The plates were shop raised the fatigue strength of issue of the Swiss Zeitschrift fiir
welded. notched mild-steel bars 130 to 200°. Schweisstechnik, The Swiss Welding
The coating increased the fatigue Society and Aluminum-Industri Co.
strength of butt welds by 75%. have organized a course in tungsten-
EAST GERMANY The manual single-vee weld had arc and metal-argon-arc welding of
The East German Schweisstechnik severe undercut and broke in the aluminum for atomic reactor con-
DR. GERARDE. CLAUSSEN is associated with weld after 200,000 cycles at +21,- struction. Welders are trained to
Arcrods Corp., Sparrows Point, Md 300 psi. After sandblasting and meet U. S. Navy Class 1 porosity

700
| JULY 1961
HUSKY to handle Petroleum Molecules
‘ re,
Welded Hortonclad spheri-
cal reactor for oil company
catalytic reforming unit
works under very high
pressures. Chicago Bridge
and Iron Company uses
radiography to prove every
seam sound.

TURDY STUFF, this husky refinery unit.

S Seventeen feet in diameter, made of
}.65-inch-thick Horton lad plate come
posed of '4-inch 405 stainless steel on car-
bon steel. Seams between segments and end
covers are welded —then radiographed to
check for complete, continuous fusion
Welding is steadily taking on bigger and
more important jobs and radiography 1s
providing the proof of quality If vou would
like to learn how radiography can save
you time and help build business, have a
talk with an x-ray dealer or write us fora
Hortonclad spherical reactor for a petroleut Kodak lechnical Rx I resentative to call.
catalytic reforming unit

lechnician positions Kodak In 2-million-volt x unit set to Roundabout s«

dustrial X-ray Filn Ivpe AA radiograph rte e sean with 90-curt

Now ... Ready Pack in ROLLS and SHEETS

Kodak Industrial X-ray Film, Types AA and M
in 200-ft. rolls (16mm, 35mm, 70mm) and
sheets (8 x 10, 10 x 12, 11 x 14, 14 x 17).
4 No darkroom loadin film sealec
tight envelope
Radiograph SHOW CG ster cat of reactor betore cladding B Just place Ready Pa
ind € x pose
Film protec ted trom «
light and moisture
EASTMAN KODAK COMPANY Sa Se
X-ray Sales Division Rochester 4, N.Y. ee
and process Oaleyk
TRADE MARK

For details, circle No. 4 on Reader Information Card

WELDING JOURNAL 701
 welding 6 fold. Three flux plants
are under construction.

WEST GERMANY
High-frequency, skin-effect weld-
ing of tubing may require a 30- to
560- kw transformer, according to
an article in the October 1960 issue
of the West German Schweissen und
Schneiden. The frequency of the
output is 450 ke at 1000 to 2000 amp
and 100 v. The copper contact
shoes are '/, x °,s; in. in cross section
and have a life of 8 hr on cold-rolled
steel and two weeks on aluminum.
A 280-kv outfit is used to weld hot-
rolled steel pipe, '/:-in. wall, at 500
to 700 ipm. Other applications are
welding helical fins to tubing, spiral
welded stainless steel tubing and
Monel and copper alloy tubing.
Another article in this resistance
welding issue illustrates a number
of mechanisms for automatic
forming and handling of parts for
~~ resistance welding. A third describes
Atomic reactor containment vessel—a steel Hortonsphere 160 ft in diam— equipment and applications of
in final stage of construction for a 150,000 kw nuclear power plant near Naples, Italy. induction brazing. Bicycle frames
(Courtesy Chicago Bridge & Iron Co.) are induction brazed in a single
standards. be made between a cast steel (0.24 automatic machine in 2 min, 30 kw,
The principles of the sine-cosine 0.30 C, 0.5-0.8 Si, 0.9-1.2 Mn, 0.7 5000 cycles.
coordinate oxygen-cutting machines 1.0 Ni) and similar wrought steels In the fourth article, research on
are explained in another article in '/ie- to °/-in. thick with an alloy- current distribution in indirect spot
this issue. Sketches show the an- steel electrode. welding with two electrodes is ex-
choring of guide rails, the damping of eA recording magnetic defecto- plained. The proportion of total
vibrations in the arms of the scope has been developed for control current flowing through the weld
machine, and the automatic adjust- of welded pipe. Operating at 46 instead of through the upper sheet
ment of tip height in the torch cycles, the instrument makes 1400 increased from 25 to 65% as the
carriage. traverses per min, resulting in a electrode spacing was_ increased
A third article shows on the basis stationary image on the screen. from */, to 3'/, in. in one series of
of statistical mathematics that ten Sensitivity is 5°, of thickness. tests on bare steel. The proportion
specimens of brazed or silver eA tank for producing CO, for was 10 to 25% with sealed sheet.
soldered joints must be tested in welding from dry ice is described.
order to reduce uncertainty in re- eA mixture of 93% nitrogen, 7% Forge Welding
sults to permissible limits of 20% hydrogen is recommended as a Stahl und Eisen for Oct. 27, 1960
uncertainty. Increasing the num- backing gas in welding austenitic contains a description of steel pipe
ber to 25 specimens lowered the stainless steel pipe. manufacturing processes in Ger-
uncertainty to 10%. The results e An aluminum electrode °*/.-in. in many. The Fretz-Moon process
are based on 1300 specimens of lap diam was used to weld zinc at 80 forge welding) is used for gas and
joints, joint spacing being 0.025 in 110 amp DCRP. The weld was water pipe up to 4°/, in. Small
ductile, but respirators were neces- pipe is made at a speed of 328 fpm.
USSR sary. Low-frequency resistance welding
e A review of calcium carbide pro- 50 to 400 cycles) is used for the
Svarachnoe Proizvodstvo, in No- duction statistics for 1958 showed thinner gages of tubing from 6
vember 1960, published the fol- that Russia and satellites produced to 20-in. diam. Speeds of 200 fpm
lowing articles of general interest: 2 million of the world total of 7 and more are attained with the
e Polyethylene film 60-u thick is million tons. While East Germany thinner walls. High - frequency
welded automatically at a speed of used 76% of its production for 400,000 cycles) skin-effect welding
10 fpm with gas-heated tools. organic purposes, Poland used 55° has not yet become established.
e Asystem for surfacing consists ofa for cyanimid. Japan and West Medium-frequency induction heat-
consumable electrode connected to Germany produced one million tons ing (2,000 to 10,000 cycles) is used
one terminal of the power supply, each, half being used for organics. for gas and water pipe up to 6'/, in.
and two nonconsumable electrodes e At the first Ural welding sym- Flash welding has been used since
connected to the other terminal. posium in Sverdlovsk, May 1960, it 1925 for large pipe—16 to 48 in. in
The consumable electrode is was estimated that the volume of diam. In this range, the sub-
centered between the nonconsum- welded construction in 1965 would merged-arc process is widely used.
able electrodes and is_ spaced be double that of 1958. Mechanized Alloy-steel pipe is welded by the
sufficiently above the work to welding is expected to increase 3.6 inert-gas-shielded arc process. Tub-
prevent appreciable penetration. fold; submerged-arc and resistance- ing * y.- to */s-in. diam is soldered in
e Transverse tensile tests showed spot welding 2.5 fold; electroslag a continuous furnace after it has
that satisfactory butt welds could welding 15 fold; and gas-shielded been rolled two-ply.

702 | JULY 1961

 This is a P&H engine-driven welder.
We make 10 different kinds.
All sizes. All good. All dependable.
Nothing fantastic about how they work.
They just weld good like they should.

Know why?

We build ’em as though we were going to buy’em ourselves!

Know a better guarantee of quality?

HARNISCHFEGER |
Milwaukee 46, Wisconsin —— op
id

WELDING JOURNAL 703

 Tempilstik’
“°"T“ JOINING

—Sompotaliure
ing
PROBLEM ?

Having trouble with corrosion? Dissimilar or

unusual metals? Successive joints on the same Ceay Orb-
work? We'll tackle it...at no cost to you.
Tough joining problems gave this company
its start. Every time we solved a problem we
had a new customer . . . and often a new prod-
uct to sell! That’s how we got into the special
alloys business in 1946. That’s how we grew.
FOR EXAMPLE
Automobile air conditioning
units called for a low-cost but
highly corrosion resistant heat
exchanger with freon-tight seals
in aluminum tubing. ALL-STATE
developed a cadmium-zinc alloy
that was low in cost, resistant to
all atmospheric conditions, and
leak-proof. Same alloy now
used for repair of automobile
radiators.

Our 430° non-acid flux was

developed for joining stainless
with minimum hazard to users.
A subsequently discovered
application was joining Hydro
T-metal without discoloration

It took months to figure out how

to braze the cathode wire to the
terminal inside radio vacuum
tubes without blackening the
inside of the tube. Our silver-
copper-indium alloy lowered * Also Tempil® Pellets
brazing temperature without and Tempilaq® (liquid form)
increasing vaporization rate,
solved the problem.
Tempilstik °—a simple and
Stainless steel kitchen sinks be- accurate means of determining preheating
came economically feasible only and stress relieving temperatures in
after we helped a manufacturer welding operations. Widely used in all
solve the problem of a perfect heat treating—as well as in hundreds
color match with a monel gas of other heat-dependent processes
welding rod. in industry. Available in 80 different
temperature ratings from 113°F
We still like tough joining problems. That’s why to 2500°F . . . $2.00 each.
we invite you to put your joining problem up to
: us. We may fail or succeed, but Send for free sample Tempil” Pellets.
we'll work on it with the best State temperature desired .. . Sorry,
research brains and equipment, no sample Tempilstiks .
and it won't cost you a penny. Most industrial and welding supply
Write and tell us what your houses carry Tempilstiks® ...If yours
does not, write for information to:
joining problem is, with the es-
sential details.
ACCESSORIES DIVISION
Send for a free copy of our 56-page Manual and Catalog.
Distributors everywhere
Tempil® corporation
GAS oe ALL-STATE WELDING ALLOYS CO., INC 32 West 22nd St.. New York 11, N. Y
All-3F White Plains, N.Y. Dial 914 WH 8-4646
ae QUALITY WITH SERVICE
For details, circle Ne. 6 on Reader information Card For details, circle No. 7 on Reader Information Card

704 | JULY 1961

 Welding Research Council

Many AWS members have asked: ‘‘What is industry of foreign research developments. One
the Welding Research Council? What does it outcome has been the ready acceptance of re-
do? How is it supported?” In answer, the search results by code-writing bodies. Another
Council was organized by the Engineering is a steady flow of university graduate students
Foundation some 25 years ago and its objectives already familiar with important welding problems
are: (1) to conduct needed cooperative research and available to industry and government
in welding and closely allied fields, (2) to dis- agencies.
seminate research information, (3) to promote What significance does the Council have for
welding research in universities, and (4) to AWS members? In reply, | do not think it im-
cooperate with similar agencies abroad. It is modest to say that research projects,as sponsored
supported by over 200 companies, several trade by the Council through its many committees,
associations and government agencies. ‘Their assist greatly in promoting the use of welded
cooperation enables the Council to utilize the components and structures. All users of welded
diversified talent of experts in many branches of products are thereby benefited —not just the
science and engineering, thereby greatly enhanc- welding industry. However, we hope to see
ing the chances of broadly applicable funda- more industrial and government support for
mental solutions. The cost to any one organ- research projects of a more basic rather than
ization is small, and unnecessary duplication is applied nature. Here, more basic research is
avoided. considered absolutely essential before major ad-
The results of research sponsored by the vancements can be made in the development of
Council are given the widest possible circulation. ; he
nee ; ar BREF new welding processes and their application
Thus Council publications describing the prog- ae
ress of research in this country are available to Welding in this country has unusual economic
subscribers and researchers; these are Welding potentials for the future. The realization of
Research, Reports of Progress, Welding Research these potentials will, however, depend in large
News and Bulletins. The Council also publishes part upon the successful outcome of present and
Welding Research Abroad to inform American contemplated basic research investigations

kK. H. Koopman
oe
DIRECTO!
MNG RESEARCH COUNCII
——
=

EDITOR OFFICERS OF THE SOCIETY WELDING JOURNAL COMMITTEE

T. P. Schoonmaker
A. F. Chouinard, President J. E. Norcross, Chairman
ASST. EDITOR ’ H. R. Clauser
Jay Bland, Vice-Pres'dent Vien Chaieaan
W |
(® R. H. Chamberlin
J. H. Blankenbuehler, Vice-Pres F. E. Abbott
Qe |t o ADVERTISING MANAGER C. E. Jackson, Vice-President J. J. Chyle
F. J. Talento H. E. Miller
H. E. Rockefeller, Treasurer F. X. Neary
| PRODUCTION MANAGER F. L. Plummer, Secretary A. G. Oehler
J Q U Nn d Catherine M. O'Leary A. W. Sawyer
F. J. Mooney, Asst. Secretary
A. V. Scherer
ART E. A. Fenton. Technica! Secretary R. D. Stout
Gil Miller A. L. Phillips, into -Ed. Sec. T. S. Watson, Jr.
 of foe
< oe

Ba &

Now—eritty contaminants of gases can no longer

interrupt service...not when you use a KG regula-

tor with the new stainless steel sintered filter.

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liberately, then opened the valve. Not a particle large diaphragm that greatly increases sensi-
of sand came through the filter. None reached tivity; the new filter that practically eliminates
the seat. And gas volume and pressure were seat failure; ball bearings in adjusting mecha-
undisturbed! nism to allow smooth, accurate control with
mechanism itself fully enclosed for complete
SHOWN: one of the new KG 1200 Series Single
protection against damage or loss
Stage Regulators that delivers Two Stage Per
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rior performance, longer life, faster and easier of our new brochure that spells out in detail the
maintenance. They feature bodies and bonnets working advantages of KG Regulators.

INCORPORATED

DISTRICT OFFICES: ISELIN, N. J, + EDGEWOOD, MD. + GRANITE CITY, ILL * PHILADELPHIA, PA. * LONG ISLAND CITY, N. Y. + SOUTH BEND, IND
CHICAGO, ILL. + PITTSBURGH, PA. + PARKERSBURG, W. VA. + CLEVELAND, OHIO +« LOS ANGELES, CALIF. * MINNEAPOLIS, MINN. » KANSAS CITY, MO
For details, circle No. 8 on Reader information Card
JULY 1961
 ra a

Helicopter view of a 144-ft diam tank showing an automatic girth welder running
on the 7th course and guy cables arranged to prevent plate buckling

CO.-Shielded Welding of Horizontal Joints

in Oil Storage Tanks

is carried out satisfactorily in the Middle East on - to 1'/.-in. thick courses

in accordance with requirements of latest specifications

for welded oil storage tanks

BY PAUL W. TURNER

Introduction tankers and to build loading terminals and facilities

The Suez Canal crisis in 1956 did a great deal to in water deep enough to berth them. One such
stimulate interest in Vasco da Gama’s old route terminal, which will accommodate supertankers of
around Africa for shipping crude oil to Europe from the 100,000-ton class, has been completed at Kharg
the Middle East. This route is about 5000 miles Island, 25 miles off the coast of [ran in the Persian
longer than the Suez short cut through the Medi- Gulf. Fifteen oil storage and fuel bunkering tanks
terranean and Red Seas. To make the route eco- of welded construction are included in the facilities
nomically feasible, it was necessary to use large of this terminal.
The carbon-dioxide-shielded metal-arc welding
PAUL W. TURNER is Welding Engineer, Unior Carbide Nuclear prot ‘ess was selected for welding the horizontal
Oak Ridge. Tenn He vas formerly Welding Engineer joints of these tanks. About three-fourths of the
Exploration & Producing Co Tehran Iran
welding on cylindrical tank shells is on horizontal
Paper presented at AWS 42nd Annual Meeting held in
N. Y., Apr. 17-21, 1961 seams To a large extent the speed and efficiency

WELDING JOURNAL 707

 The purpose of this paper is to describe experience
gained by the application of the carbon-dioxide-
shielded metal-arc process for welding horizontal
seams of storage tanks under field conditions in the
Middle East.

Specification, Material and Equipment

Tank Plate
The tanks were designed and built in accordance
with the requirements of API Standard 12C (15th
ed.), ““‘Welded Oil Storage Tanks." Shell plates
less than ' , in. thick conformed with requirements of
ASTM A283 grade D. Plates '. to *', in. thick
inclusive were manufactured from steel complying
with Lloyds Rules 1952, Class P403. The require-
ments of British Standard 2762-1956 grade ND1
Fig. 1—Diagram showing cross section of flux-cored wire applied to plates thicker than * , in.
for carbon-dioxide-shielded metal-arc welding Filler Wire
A composite welding wire was supplied in 16-in.
diam coils. In Fig. 1 a view of the cross section of
the wire shows that flux powder is enclosed in a
curled, steel strip. This shape imparts strength to
the wire and prevents it from crushing under pressure
exerted by the wire-feed rolls. The flux supple-
ments the CO, gas shield by deoxidizing and scaven-
ging the weld metal and by stabilizing the arc. It
also forms an easily removable slag which protects
the hot weld from the adverse effects of the air.
The typical mechanical properties and chemical
composition of weld metal in as-welded condition
were provided by the manufacturer and are listed in
Table 1.
Shielding Gas
Carbon-dioxide gas was manufactured in Iran.
The supplier agreed to ship up to 360 lb of gas per
day in cylinders containing 40 lb each. Purity was
specified at not less than 99.3°;, CO. by volume.
Initially there was some doubt about the ability of
the local manufacturer to produce gas of consistent
weld-grade quality. As a safeguard, a sampling
plan was devised to check the purity of gas in each
shipment. The outcome was that no welding prob-
lems during the course of the project could be at-
tributed to poor quality of shielding gas
Fig. 2—View of inside platform of a
girth welder in position for welding Girth Welding Machine
Figure 2 illustrates the type of automatic girth

of welding these seams determine the speed of tank

erection. Consequently, it is usually justifiable to
utilize automatic welding equipment as a means of Table 1
increasing the speed of welding horizontal seams.
For several years the submerged-arc process has been
applied extensively for this operation.' The re-
sult, when compared with manual welding methods,
has been marked reduction in welding time and
much improvement in weld quality. In this case,
however, the carbon-dioxide welding process was
chosen, mainly because it offered the advantages of
an open-arc process. This selection was a radical
departure from past practice

708 JULY 1961

welding machine employed on this project. Weigh- running on the upper course of the joint to be welded.
ing approximately 1!/, tons, it consists of a carriage Both welding heads can be adjusted at various
from which two welding heads with platforms and vertical angles and are retractable. The inside
control panels for two operators are suspended. head precedes the outside head, and the distance
The carriage straddles the tank plate to provide a between them is adjustable. The carriage speed is
welding unit on each side of the joint. It is power- regulated by the operator who controls the leading
driven by a variable speed system that drives rollers head. Otherwise, separate controls are manned by

Table 2 Data from Procedure and Operator Qualification Tests

ROOT
INSIDE
A

Ss

a2.

J OL TS; A DCRP
mor S-HATCHED D JOINT
CROS
BACKING
DIAM IS 1/8
DIAM IS 1 8

WELDING JOURNAL 709

 each operator. <A telephone system provides com-
munication between the operators and enables them
to coordinate their work.
Propane heaters, one preceding each welding head,
are employed to preheat and dry the joint when
necessary. An endless belt of copper pads shown in
Fig. 3 crawls just beneath the weld and supports
and cools hot slag to prevent it from flowing away
from the weld bead. A beryllium-copper welding
nozzle,‘ also shown in Fig. 3, surrounds the wire-
guide tube. The nozzle and tube are cooled by the
flow of carbon-dioxide gas and by the surrounding
atmosphere. A_ sliding gas shield covers each
welding nozzle. Canvas curtains, covering the en-
tire machine, are fitted positively against the tank
shell by a rubber seal as further protection for the
s weld zone and the operators against wind and in-
Fig. 3—CO, welding nozzle, sliding-gas
shield and slag supporting track clement weather.
Cylinders of carbon dioxide gas are stowed on the
carriage to shorten the length of supply hose and de-
crease the chance of leakage. Other hose and cables
extend from a pivot point in the center of the tank.
Welding power sources are positioned outside the
tank, and cables and remote control lines are brought
through a nozzle in the tank shell to the pivot in
the center of the tank.
Power Source
A pair of 400 amp, air-cooled, 3-phase rectifiers
having drooping volt-ampere characteristics was re-
quired for each welding head. These welders were
connected in parallel to supply reverse-polarity
direct current. Owing to the remote location of the
tank farm site, electrical power was not readily
available. Therefore, it was necessary to use a
diesel-driven, 3-phase alternator to run rectifiers
and auxiliary equipment on a girth welder. The
rating of the alternator for continuous duty was
156.3 kva at 237 amp.
Fig. 4—Arc time calculated from carriage speed
Welding Procedure
A welding procedure test was conducted at a
laboratory on three sets of 24- x 6-in. plates to deter-
mine the suitability of the carbon-dioxide welding
process for welding tanks. Three types of joints,
representing the basic ones to be welded in the field,
were welded in the horizontal position: (1) the
maximum thickness square-butt joint, (2) the maxi-
mum thickness double-bevel joint to be welded with
a single pass per side and (3) the maximum thickness
double-bevel joint to be welded with multiple passes.
The last joint also contained an intersecting vertical
weld to simulate field conditions.
Details and data describing results of this test
are shown in Table 2. Wire contact-to-work dis-
tances were *, and *’, in. for °/3.- and '/s-in. diam
wires respectively. Porosity and blowholes tended
to form whenever these distances were altered ap-
preciably. It was found that the vertical angle of
welding heads above the horizontal plane could be
Fig. 5—Girth welders in tandem operating in windy weather set at 35 deg to weld plates thicker than ‘/; in., 10
with curtains closed. Deslaggingis done from deg to weld square-butt joints and 20 to 25 deg to
the manually operated carriage weld plates of intermediate thicknesses. Space be-

710 JULY 1961

tween heads was maintained at 8 to 10 in. to weld
all plates except those thinner than '*/;. in. where
the space was 12 to 14 in.
The mechanical properties of these welds complied
with the requirements of API Standard 12C.* The
segment of the weld containing the intersecting
vertical weld was radiographed and then cross
sectioned and macroetched to assure that cracks and
internal faults did not exist at the junction of the
two welds.
Operator Qualifications
Operator qualification tests were conducted on
actual construction on ‘“‘the first 10 ft of horizontal
joint of each type and thickness (based on the thick-
ness of the thicker plate at the joint).”’ These
tests determined the ability of the operator to pro- .;
ee
duce sound welds with the girth welder in the field.
Each pass was inspected visually for correctness of Fig. 6 (a)—Top tee with face of vertical weld chipped flush
bead-shape, coloration and other surface defects. to assure free passage of girth welder
A portion of the completed weld was examined by
radiography.
These tests not only served to qualify operators but
also provided deposition data for joint thicknesses
not included in the welding procedure test. This
information is set forth in Table 2 along with pro-
cedure test data.
Field Welding
The method of tank assembly was planned to
assure a high operating factor with the girth welding
machine. Bevels of tank plates were cleaned with a
power-driven brush just before the plates were
erected. Plates were lifted into position with a
mobile crane. Then, the vertical joints were aligned
and prepared for welding. As soon as the welding
of the vertical joints in the course was substantially
completed, the horizontal joint was faired and tacked
along the inside at about 12-in. intervals with elec-
trodes of the E6010 classification. The root gap
Fig. 6(b)—View of lower
tee showing a suggested
was adjusted as specified in the welding procedure method of preparing tips of vertical welds to
specification. Local places with excessive gap were assure sound welds at tee junctions
filled with low-hydrogen-type filler metal. The
joint was then welded with the girth welding machine
Effect of Wind
while a course of an adjacent tank or of the same tank
Winds with velocities up to 26 knots sometimes
was being prepared for welding. Thus the sequence
of assembly was programed to keep the girth prevailed during welding operations. The weld
zone, however, was protected very effectively by the
welding machine busy.
sliding gas shields and canvas curtains. In fact,
Arc Time girth welding machines were operated at times when
The arc time for welding various joints was derived wind velocity was too great to permit manual welding
from carriage travel speed and is indicated graphi- operations.
cally in Fig. 4. There was a marked increase in arc
Spatter
time for welding joints thicker than ’ ; in., because
more than one pass per side was required to fill Sometimes very simple techniques that are de-
joints greater than this thickness. A constructional veloped in the field have great effects on welding
bottleneck tended to develop when thick plates were production. During the early stages of construction
welded. It was overcome, however, by utilizing two it was periodically necessary to stop the girth welding
welders in tandem as illustrated in Fig. 5. It will machine and open the gas shields so that spatter
also be observed in this illustration that the welders could be removed from the gas-cooled nozzles of the
were operating in windy weather. welding heads. Later, it was found that an operator
could remove the spatter with a rod which he manipu-
* Par. 7.1.4 and 6.2.3 of API Standard 12¢ lated through a small hole in the sliding gas shield

WELDING JOURNAL | 71il

 as welding progressed. Although this technique Even though complete penetration is not specified
appears to be a trivial one, its use resulted in the in the standard,’ it was required on the work de-
elimination of many stops and starts. Consequently, scribed herein because of the difficulty in controlling
weld appearance and weld quality as well as the and measuring the degree of minus root penetration.
operating factor were greatly improved. Radiographs disclosed that gas cavities and slag
inclusions were the most common types of defects in
Thin Plates welds at tee-junctions. In Fig. 7 radiographs indi-
There was some concern about the applicability cate the nature of these defects. It is believed that
of the girth welding machine for welding courses cavities were formed whenever the motion of the
consisting of thin plates. With the machine in carriage caused the welding nozzles to be slightly
position, a plate can be considered a column under raised or displaced away from the weld groove. The
the compressive load of the welder. Also wind and carriage sometimes tended to move erratically as it
the like tend to sway the machine and create eccentric passed over irregularities such as faces of vertical
loading conditions which further enhance the danger welds and slight peaks in vertical joints. This condi-
of plate buckling. Nevertheless, it was found that tion altered the burn-off characteristics of the wire
plates as thin as ' , in. could be welded successfully because of changes in wire extension and accompany-
without the occurrence of buckling and distortion. ing /°?R heating effects. It also introduced difficulties
The lead photograph shows welding in progress on in shielding and tracking the seam. Figure 6(a)
the 7th course ('/,-in. plate) of a 144-ft diam, 8-course shows how the faces of welds at top tees were chipped
tank. The only extra precaution taken was to flush to alleviate this problem.
assure that guy-cables were pitched at intervals close Welds at lower tees were likely to contain defects
enough to prevent the girth welder from swaying. unless lower extremities of vertical welds were clean
The swaying effect became more pronounced on large and built up to the contour of the horizontal joint
tanks (180 ft diam by 60 ft high) because these tanks with small diameter electrodes before the horizontal
were weaker than small tanks in the radial direc- weld was commenced. A lower tee, properly pre-
tion. pared for welding, can be seen in Fig. 6(b).
Aside from tee-junctions, consideration should be
Tee Junctions
directed to any segment of the horizontal joint which
A discussion of tank welding would not be com- might be subjected to restraint. For example, dur-
plete without mentioning problems associated with ing the experimental stage of testing the girth welder
welding tee-junctions. A tee-junction is the inter- it was discovered that, unless conditions were correct,
section of a vertical joint with a horizontal joint. welds at horizontal seams of plates containing API
Intersections of upper and lower extremities of verti- flush-type cleanout fittings might crack because
cal joints and horizontal joints form the two types of heavy reinforcements around the fittings tended to
junctions shown in Fig. 6. Hereafter these junctions constrain the horizontal weld. One case can be
will be referred to as top and lower tees respectively. cited in which this design feature coupled with a
It is generally known that special care should be heavy root face and zero root gap on 1-in. thick plate
exercised when welding at points where joints inter- caused a weld to crack at the root when high energy
sect. In tank welding it is established practice to input was employed to obtain penetration. It was
weld all vertical joints on each side of the horizontal partly from this experience that dimensions of root
joint before tacking or starting the horizontal weld. faces and gaps for various joints of the welding
Circumferential shrinkage resulting from vertical procedure specification were developed.
welding is taken care of in this way. Then, after
the horizontal joint is faired, the entire weld can be Inspection and Testing
completed without crossing unfinished vertical joints. Radiography
Welding across unfinished vertical joints is undesir- The results of field inspection and testing provide
able, because cracks at tee-junctions may be trig- engineering data which buttress the results obtained
gered by multiaxial stresses when vertical joints from the welding procedure test. Completed welds
are welded or perhaps later when the seam is hydro- were examined visually and then spot-checked by
statically tested. radiography. A spot included the length of weld
Writers of the API-12C specification were cogni- covered by 7'/, in. of film. The radiographic method
zant that tee-junctions are critical segments of the and definitions of defects used on this work can be
horizontal joint. They stipulated that at least 3 in. found in API Standard 12C.
of the horizontal weld on each side of vertical welds In Table 3, results of radiography on eight tanks
should have complete fusion and penetration but (180 ft diam by 60 ft high) show the number of radio-
permitted two-thirds fusion (one-third from each graphs and rejections for each of the two types of tee-
side of the joint) on other parts of the horizontal junctions and for the main horizontal seams. Most
seam, provided that the plate thickness was greater of the rejected spots were caused by porosity and
than */, in. This concession of partial penetration slag inclusions. It is particularly noticeable that
was granted, because it can be shown theoretically defects were found more often at lower tees than at
that the horizontal joints of open-top storage tanks the remainder of the horizontal joint. As previ-
are not subjected to transverse tensile stresses. ously mentioned. the frequent occurrence of defects

712 | JULY 1961

Table 3

at this location is attributed largely to imperfect

alignment of joints and to defects at the tip of the
vertical weld, itself. Consequently, one should
consider that some of these defects were probably
due to errors in the manual technique used to weld
vertical joints. Such defects tend to obscure the
ability of the automatic carbon-dioxide welding
process to produce acceptable welds.
The total shows that approximately 92°% of 483
Fig. 7—{a, left) Gas cavity and slag at a lower tee;
spots were radiographically sound. However, an (b, right) heavy slag inclusions at a top tee
examination of results for only the top tees and the
main horizontal seams reveals that about 95°% of
the inspected spots were acceptable.
Other Tests
Additional tests were conducted to assure that
tank shells were leaktight, structurally sound, and junctions are more susceptible to defects than the
dimensionally correct. Each tank was filled with remainder of the horizontal seam. The main cause
sea water for at least 24 hours, and seams were of defects occurring at these locations appears to be
examined for leakage. The degree of interference improper joint preparation at the junction itself.
between horizontal welds and the seal around the Resultsof hydrostatic tests and dimensional checks
periphery of floating roofs was checked as roofs confirmed the ability of tank shells to meet design
floated during the cycle of filling and emptying the requirements. It is reported that all tanks are per-
tanks. Diameters and circumferences of tanks were forming satisfactorily in crude oil service.
carefully measured at various levels to make sure
Acknowledgment
that capacities were within the limits of design
specifications. It was found that diameters did not Staff of Welding Supervision Ltd. of England,
vary more than 0.2% from the specified nominal Werkspoor N. V. of Holland, Arcos S. A. of Belgium
diameter. Results of all of these tests were satisfac- and the Iranian Oil Exploration and Producing Co.
tory and are further confirmed by the report that all participated in the work described herein.
of the tanks are currently performing satisfactorily Figure 1 and the data in Table 1 were supplied
in crude oil service. through the courtesy of the Arcos Corp., Phila-
delphia, Pa.
Summary Special thanks are due N. J. DeStefano of the
Sparling Tank and Mfg. Co. Ltd. of Canada for
Horizontal seams , to 1'/,in. thick) of oil storage reviewing the paper and for his valuable suggestions.
tanks were welded successfully with the carbon-diox-
ide-shielded metal-arc welding process. Figure 4 References
shows that a marked increase in arc time resulted l Arnold, P. C., “Automatic Field Welding of Girth Join of Large
Storage Tanks,” THE WELDING JOURNAL, 32 (5), 399-406 (19
when joints greater than ’7/; in. thick were welded. Meyer, A. R., ““Automatic Horizontal and Vertical Welding of Field
This increase was brought about by the need for Erected Structures,’ [bid., 33 (7), 651-659 (1954
3 API Specification for Welded Oil Storage Tanks,”’ APJ Standard
making more than one pass to fill the weld grooves 12C, 15th Edition (May 1958), American Petroleum Institute, New York
of plates thicker than */; in. It is quite possible N.Y
4. Bulletin, Arcosarc Welding Equipment Form A41660, Arcos Corp
that further experimentation with joint design may Philadelphia 43, Pa
>». Green, G. J., and Marlin, D. H., “Stress Concentration Problems
result in more favorable arc time for welds on thick in Welded Construction,” THe WELDING JOURNAL, 30 (7 607-61
joints. 1951
6. Anonymous, “Automatic Weldingof Large Storage Tanks,’’ Welding
Results of radiographic tests disclosed that tee- and Metal Fabrication,25 309-315, 1960

WELDING JOURNAL | 713

 4
Assembly line application of arc spot welding with the consumable electrode process to an automobile center post

Consumable Electrode Spot Welding

using solid wire and flux-cored electrodes is applied to a

variety of automotive components in production-line operations

A HOWERY AND G F MACK

Fig. 1—Consumable-electrode spot welding equipment Introduction

This paper deals with a process known as consumable
electrode spot welding. In this process, a consum-
able electrode is fed from a spool or reel through a
gun to the work. Gas shielding is provided by
either a mixture of argon and oxygen, argon and
carbon dioxide, or by carbon dioxide alone. The
consumable electrode spot-welding process, of course,
is a completely different spot-welding process and is
not to be confused with resistance-type spot welding
as commonly known
It is rather well known that consumable electrode
spot welding has been used in industry for some time.
However, application of this process had been rather
limited, up to about two years ago. This was due
basically to the inadequacies of the control equip-
ment, which often caused inconsistent results when
consumable electrode spot welding was used.
Now there is available new equipment which has
J. A. HOWERY and G. F. MACK are with the National Cylinder Gas
Div. of Chemetron Corp., Chicago, Ill Mr. HOWERY is Divisiona!
Service Representative, Research and Development Dept and M
Mack is Sales Representative, Automotive, Detroit, Mich
Paper presented at AWS 42nd Annual Meeting held in New Yor N.Y
Apr. 17-21, 1961
incorporated all of the improved features to provide welding speed. Second, it energizes the welding
accuracy and reliability in the control unit. This time control relay.
equipment will provide consistent results in produc- The arc is then maintained for the period of time
tion operations. In several automotive plants it is predetermined by the adjustment of the welding
now being used at rates of 1000 to 1500 spots per time control relay. During the arc time, metal is
hour. deposited in a localized area, resulting in a nugget-
type weld deposit.
Basic Equipment Used When the welding time control relay completes its
The equipment for this process is shown in Fig. 1. timing cycle, the welder contactor is opened, the arc
It consists of a constant-potential power source, an is extinguished, the weld current relay drops out,
electronic control and wire drive unit, a pistol-grip and the control and timing equipment returns to its
gun with special shielding nozzle, 15 ft of hose and pre-set condition.
cable assembly, spooled electrode wire and shielding
gas supply. Also, since the pistol-grip gun is water Welding Power Sources
cooled, it is necessary to have a water circulator. The welding machine recommended for this proc-
The equipment shown in this picture is mounted on a ess is of the constant potential type. This machine
three-wheel truck for portability. is available in the d-c rectifier and motor-generator
types, and should have at least a 400 to 500 amp
How the Process Works rating for the consumable electrode spot-welding
The process is used in the manner shown in Fig. 2 process.
The gun is placed against the metal joint to be The d-c rectifier-type machine or power source
welded. There it is held in proper position and the was designed for semiautomatic and automatik
trigger of the gun is depressed, initiating the entire operations. As a result, it has a welding contactor
sequence of operations necessary to make the weld as a standard part of the equipment. ‘Therefore,
The sequence of operation is as follows: an external contactor is not required This type-
power source is best suited for this operation
1. The shielding gas begins to flow. , motor generator type power source will also
2. The welder contactor is closed. perform satisfactorily with the process. However,
3. The electrode is automatically advanced to the when this type of power source is used, it is necessary
work at a preset rate. to install a contactor in series with the electrode
When the electrode comes in contact with the circuit A contactor having a 115-v, 60-cycle oper-
work, it effects a current flow which in turn closes a ating coil is required. A single-pole contactor or a
current relay. This current relay initiates the double pole contactor (with two poles connected in
following sequence: First, it changes the electrode parallel) will be suitable as long as the current capac-
feed rate from a slow or inching speed to a fast or ity is a 300-amp rating.

Fig. 2—Equipment in use

 Bene

Fig. 5 Consumable electrode spot welding gun and nozzles

x
8

Fig. 3—Welding power source (constant potential

d-c rectifier)

Fig. 6—Various sizes of nozzles available

for different gages of material

ter collects in the nozzle of the gun, causing a short-

ing condition and impairing the flow of shielding gas.
These conditions result in poor weld quality. When
used, the reactor should have a 150 to 300 amp rat-
ing.
The constant potential power source functions in
this manner: The control is set at a specific voltage,
this preset voltage determining the arc length and
the physical shape of the weld nugget, e.g.:
When a motor-generator type power source is 1. With a low voltage, a short arc length, a small-
used, it is desirable to connect an external reactor in diameter, high-crown nugget, and deeper penetration
series with the electrode circuit of the motor genera- are obtained.
tor. The advantages provided by this reactor, when 2. With a high voltage, a long arc length, large-
connected to the welder secondary, are improved arc diameter, flatter nugget and shallow penetration
stability, satisfactory metal transfer, current densi- are obtained.
ties about half of the densities required without As the electrode is fed to the work, the current out-
reactors, improved weld quality and appearance, put of the machine will vary to regulate the burn-off
and minimized spatter. Without the reactor, spat- rate so that an arc length will be maintained which is

716 JULY 1961

 consistent with the preset voltage of the welder. Purge Time
Figure 3 shows a picture of a welding machine or The purge time control potentiometer controls
power source. the welding electrode inch-down speed. ‘This device
Electronic Welding Control and is electrically removed from the circuit when the
welding electrode touches the work. It also con-
Wire Drive Unit
trols the flow of shielding gas prior to actual are
The control unit in Fig. 4 performs the following weld time.
functions:
1. It drives the electrode through the flexible Consumable Spot-welding Gun
conduit into the gun and to the work. Figure 5 illustrates the consumable spot-welding
2. It provides for current adjustment by means of gun and nozzles.
the potentiometer mounted on the cabinet door of This gun is ruggedly constructed for production
the control unit. This potentiometer current ad- operations. No tools are required for tightening the
justment regulates the electrode feed rate. contact tube. The gun has a collet-type chuck
3. It controls and regulates the time period of the provided to permit hand tightening from the back
shielding gas flow. of the gun.
4. It provides for adjustment of the welding time There are several types and sizes of nozzles
control relay. available for this gun, which consist of inside and
5. It provides for adjustment of the burnback outside corner nozzle, flat surface nozzle and all-
timer. purpose nozzle known as 135 deg. These nozzles
have indexing pins which permit alignment in the
Variable Adjustments gun.
With the constant potential power source as The trigger is spring-loaded. The water and
indicated above, current adjustment is obtained by gas-in hoses and the current-carrying water-out
means of the potentiometer which controls the wire cable, have nut and nipple union connections which
feed rate. The feed rate of the wire electrode must tie into the handle of the gun. These connections
be synchronized with the burn-off rate. Thus, as are covered with a rubber boot for insulating pur-
the feed rate is increased, the voltage must be in- poses.
creased to obtain faster burn-off of the electrode.
Increasing the current or wire feed rate results in Contact Tube
increased penetration and metal deposited. This For best results, the contact tube should be
adjustment must be correlated with the welding time maintained approximately in. from the end of the
control relay and arc voltage settings. nozzle. ‘Too close an adjustment will cause burn-
back of the wire electrode into the contact tube
Welding Time Control Relay This results in the wire electrode freezing to the
This device regulates the length of time that the contact tube, while too long an adjustment will
arc is maintained and is, accordingly, a means of cause erratic arc start, small high-crown weld
regulating the amount of heat input into the work nuggets, and inconsistent results
and also the amount of deposited metal. The ad- Figure 6 shows the different sizes of nozzles
justment of the welding time control relay is de- available for the consumable spot-welding gun
pendent on the shape of the joints and the metal The larger nozzles are used for heavier plates
thickness to be welded or both. Arc times may
vary from approximately 10 to 60 cycles, dependent
upon the conditions already mentioned. Arc times Fig. 7—Arc welding with covered electrodes
below 10 cycles should be avoided if at all possible.
The time base referred to here is the standard line
frequency of 60 cps.

Burnback Timer
Adjustment of the burnback timer allows the
welding wire to burnback to a_ predetermined
length, thus preventing the electrode from freezing
in the weld pool or burning back into the contact
tube. This timer measures out an increment of
time between the stoppage of the wire feed and the
opening of the welder contactor. The adjustment of
the burnback timer can be made by first visually
inspecting the position of the welding wire in the
gun nozzle after making a spot weld. The timer
should be adjusted so that the electrode is maintained
just within the end of the nozzle. This will prevent
freezing of the electrode in the weld pool.
 Fig. 8—Assembly line use of consumable Fig. 11—Close-up of consumable electrode spot
electrode spot welding welds on floor plan assembly

Shielding Gas
For economy and accuracy, a two-stage gas
regulator equipped with a flowmeter, calibrated in
cfh, should be used for the shielding gas flow control.
In those cases where the volume of shielding gas
required necessitates a manifold or bulk gas system
of supply, the supply line pressure is controlled by
the gas regulator mounted on the manifold or bulk
control unit. A flowmeter attached to the spot-
welding station will assure accurate delivery of the
shielding gas. Results of laboratory tests on
shielding gas mixtures of 95% argon— 5°, oxygen
provided the best results on straight polarity. It
is possible to obtain satisfactory weld quality on
different type joints of different metal thicknesses.
Welding can also be done with a carbon dioxide-
shielded atmosphere. However, the increased heat
transfer through an arc shielded with this gas
makes the process more critical insofar as adjust-
ment, joint tolerance and weldable metal combi-
nations are concerned.
When a 95% argon-—5% oxygen mixture is
Fig. 9—Bottom section of center post after used, the shielding gas flowmeter should be adjusted
consumable electrode spot welding
to give an approximate flow of 20 cfh. This can be
Fig. 10—Consumable electrode spot done by using the purge switch on the control
welding on floor plan assembly cabinet door. Experience has shown that in some
cases, depending upon the condition and length of
the gas-carrying hoses, as well as the condition of
the regulator, a flow somewhat lower than 20 cfh
may give satisfactory results. An insufficient flow
of shielding gas will result in weld porosity— and, of
course, poor weld quality. An excessive flow rate of
shielding gas may create a siphoning effect, drawing
in atmospheric air, which in turn will contaminate
the weld metal and also cause weld porosity.

Application in the Automotive Industry

The consumable electrode spot-welding process
is now being utilized in the automotive industry
with considerable success. Its present use caps
an evolutionary process wherein automobile pro-
duction initially had something in common with

718 JULY 1961

 Table 1—Consumable Electrode Spot Welding: Table 2—Tensile Specimen Data: Lap Joint-Solid
Cost Data Obtained from Its Use in the Wire Electrode—with 95-5 Argon-Oxygen or
Automotive Industry CO, Shield—DC Straight Polarity
Power Consumption Metal Elec- 95 -£
Cost per inch of arc weld... $ 0001248 thick trode gas Tensile
Cost per resistance spot weld ). 0001068 ness diam, Am >| flow strength,
in Volts peres ar cfh
Cost per consumable electrode spot weld
Materials Costs
Gas Welding
/ie-in. diam wire per inch of weld
Acetylene per inch of weld.
Oxygen per inch of weld.

Arc welding
Cost of in. diam electrode per inct
weld. center post on the assembly line. Figure 9 shows
the finished spot weld on the bottom section of
Consumable electrode spot weld
this center post.
Cost of in. diam wire for 1 spot weld.
Cost of 95.5 argon-oxygen mixture for 1 spot Illustrating another operation, Fig. 10 shows two
weld 00049 operators working on a floor pan assembly, and
Fig. 11 shows a close-up of the finished spot-weld
Total savings per body nuggets on the floor plan assembly
Material per body Table 1 gives some cost data and savings that are
Labor per body possible on automobile production It indicates
Sub Total that the material savings to be realized when using
Material and maintenance the consumable-electrode spot-welding process are
Grand Total relatively small and that the big savings are in time
and labor. In one plant, it was reported that
twelve consumable spot-welding operators are now
wagon manufacturing in that is the bodies of both producing the same number of units formerly
were joined to the frames with bolts. Eventually produced by twenty-one operators using oxy-
are welding (Fig. 7) came to be used on automobile acetylene and covered-electrode welding Even
production lines, and today —unitized-structural though it is necessary to have one maintenance man
members and the body of automobiles form a single per shift to service the equipment, the actual savings
compact unit. Here, the consumable-electrode in time and labor are sufficient to more than justify
spot-welding process is now playing its part. the process. It is obvious that, when so much more
As an example of its use, Fig. 8 shows consumable production can be obtained in the same period of
spot-welding units mounted on an overhead monorail time and with less labor, the unit cost much drop
for production operations on the assembly line, way down.
while the lead photograph shows a consumable Some cross sections of spot welds are shown in
electrode spot-welding operator welding on a Fig. 12 while the corresponding tensile strength

>

METAL
THICKNESS -O35 050 O72

Fig. 12—Lap joint tensile specimens prepared using DSCP, solid wire electrode and both
95-5 argon-oxygen and carbon dioxide for shielding (consult Table 2 for details)

WELDING JOURNAL
 data appear in Table 2. Furthermore, Fig. 13
COMPANY NO COMPANY NO. 3
shows the results of tests conducted on the electrode
CAST 2 wire, which is a copper-coated mild steel spooled
HELIX electrode having the following chemical analysis:
TENSILE Carbon, 0.13-0.19°,; Manganese, 0.95—1.30%; Sil-
icon, 0.15-0.30%; Sulfur, 0.034%; Phosphorus,
0.025%
The tests indicated that an electrode wire with a
cast of 18 to 22 in., a helix of0 to */, in. and a tensile
strength of slightly over 100,000 psi is desirable for
consistent results.
Figure 14 shows an operator making twelve
consumable spot welds while his helper unloads the
other fixture, and Fig. 15 shows a close-up of the
liam wire electrode spot weld nugget that holds the angle iron stiffener
in place.
Fig 16 shows a complete spot-welded assembly
being hot-spray painted before shipment. Pro-
duction is 50 or more louvers per hour, and the
Table 3—Tensile Specimen Data: Lap
Joint—Dual Shield Electrode—CO completed unit consists of some 600 spot welds.
Gas shield—D C Reverse Polarity The results of a cost analysis showed that each
louver panel required 1 oz of a flux-cored electrode
Elec
Metal trode Tensile and about 0.042 cu ft of carbon dioxide. This
thick diam, Am Weld strength, compares with : lb of °/3 in. Type E-6013
ness, in. f Volts peres timer Ib electrode for intermittent arc welding and results in
0.035 ] 31 900 a */; cost cut of welding materials, plus descaling
0.050 , 3 é 2300 and cleaning, as well as the time and labor savings
0.061 388 2600 realized on this operation.
0 125 2 Rae As 4A 5? nN Additional spot-weld test specimens and data
5600 are shown in Fig. 17 and Table 3, respectively, while
8900 Table 4 presents data pertaining to some of the
many process variables encountered for fillet, lap,

14—Operator making 12 spot welds on sheet metal panel while helper unloads other fixture
 Table 4—Process Variabies for Fillet, Lap, Through, and Butt Welds in
Mild Steel (Type 101 */, and '/,,-in. diam electrode)
Nominal Purge
Metal size of Electrode Voltage Voltage switct Burn-
Type thick- electrode diameter, range, rheostat, Weld 3 o’clock back
weld ness, in wire, in in \ Vv time Amps Volts é positio tin er
Fillet 0.040 i 0.045 25-31 52 1 195
- 050 , 0.045 25-31 44 14 200
pe 060 . 0.045 25-31 52 210
L222 072 0.063 30-37 13 320
).090 0.063 37 3 18 360
Lap 040 0.045 5-31 2 1] 180
” 0.050 * 045 5-3] 1] 200
“<QNs 060 045
072 063
090 063
Through 0.025 0.045
: 040 P 0.045
050 045
0.060 045
).072 063
090 é 0.053
040 a 0.045
050 , 045
.060 045
072 5 ).063
090 ‘ ).063
Note: Ali of these settings are approximate and may vary for

through, and butt welds. Samples of spot welds

in 0.040-in. thick material are shown in Fig. 18 Table 5—Data for Samples Tested with ‘“‘Peel Quick’’
after having been tested with the ‘‘Peel Quick”’ Quality Control Tool (See Fig. 18)
quality control tool; the corresponding data appear Sample — ih B
in Table 5. The ‘Peel Quick’’ quality contro! Amperes 200
tool is illustrated in Fig. 19. Volts 34
Vernier 20
Range 25-31
Fig. 15—Close-up of spot weld nugget P-2 20
holding angle iron stiffener in place Cycles 14
Burnback Timer 9

Fig. 16—Spot-welded assembly being

hot-spray painted before shipment

WELDING JOURNAL | 721

 METAL
THICKNESS
p joint tensile specimer re
ing (consult Table 3 for details)

A B Cc
Fig. 18—Samples tested with ‘‘Peel Quick"’ quality control tool (consult Table
5 for details)

Summary Fig. 19—Quality control Peel Quick”’

spot weld testing tool
The consumable spot-welding process is suitable
for welding materials in thicknesses from 0.035 to
, in. Solid wire and flux-cored electrodes in sizes
from , to in. in diam are being continually
used in production operations.
This process is suitable for spot welding low- to
medium-carbon steels and low-alloy to high-tensile
steels. Itis also being used to fabricate stainless and
aluminum alloys. Physical properties are equal to or
higher than for covered electrodes. One spot weld
nugget °/, in. in diam is equivalent to one lineal
inch of arc weld
Comparison tests with covered electrode tack
welding indicate that an operator using the con-
sumable electrode spot welding process can make
welds 3 to 20 times faster than an operator who is
arc welding. The process is used with semiauto-
matic equipment and can be made automatic. The
constant potential d-c type rectifier welding machine
is best suited for this process.

722 | JULY 1961

 Spot welding through tubing without internal support

Series Spot Welding of Missile Fins

involves a novel variation of resistance spot welding to meet aerodynamic weight

and dimensional requirements in the fabrication of missile dorsal fins

BY D. W. HEROLD

One of the many problems that plagues the missile produce a series spot and an indirect series spot.
welding engineer is how to join pieces of steel metal, This method is the subject of this paper.
forgings, castings and tubing into the configuration The dorsal fin for the Terrier missile consists of
of a control surface to meet the aerodynamic weight a skin, a tube, two stiffener channels and leading
and dimensional requirements of the design en- and _ trailing edges. The material used in these
gineer—and to do this at minimum cost. To ac- parts is low carbon steel (AISI 1018). The welding
complish this, it was necessary to develop two unique problem consists of joining the two parts shown in
methods and each has been used to weld dorsal Fig. 1~-that is, welding 0.042-in. thick skins to a
fins for the Terrier missile. The first involves the 0.090-in. tube and welding the 0.042 in. thick skins
use of an automatic tape-controlled, gas tungsten- to a 0.042-in. channel
arc spot welding unit with four torches. * The second
unique method calls for a roll-spot welding unit to Selection of Series Spot Welding
Roll spot welding of the skin to tube had been
discussed in the early design stage, but it was be-
lieved that a reliable weld could not be made when
*R.L Hackman Inert-Gas Spot Welding in the Aircraf nd Mi joining the skin to tube since there was no practical
Industry,” WELDING JOURNAL, 40 (1 > 33 (1961 way to place an electrode on the underside of the
D. W. HEROLD is Manufacturing Development Engineer Senior weld (inside the tube). Many types of electrodes or
Applied Manufacturing Research and Process Development Corvatir
Pomona, Convair Div of General Dynamics Corp., Pomona, Calif mandrels were considered. However, since the

WELDING JOURNAL 723

 CHANNEL .042 IN. SKIN .042 IN.

TUBE .090 IN.

Fig. 1—Dorsal fin assembly, showing parts welded by roll spot welding. The
over-all length of the dorsal fin is 61 in. The material is AISI 1018

width of the required mandrel would be about 1 in. wheel, the actual welding pressures were placed as
and the length would be over 54 in., no design could shown in Fig. 3.
be developed that would ensure the necessary con-
tact on the inside of the tube. Although the tubes Weld Requirements
were cold-drawn to close tolerances, variations in The weld had to meet the requirements of Spec-
wall thickness and contour made a solid bar im- ification Mil-W-6858A, including a nugget diameter
practical. Due to economic and reliability pressures, of 0.19-in. average and a tensile-shear strength of
a program was undertaken to weld the skin to tube 1100 lb average. About 500 tensile-shear tests and
without using a backup bar. 100 macrosections were required to develop the
Since the critical operation would be welding the optimum welding schedule. The major obstacle
skin to the tube, this was attempted first. As shown was achieving the required reliability while using the
in Fig. 2, the welds were to be made on an angle of least possible electrode pressure. It was determined
22° 45’. As previously discussed, there was no that 600 lb actual pressure was sufficient, while
practical way to support the inside of the tube. 500 lb gave erratic results and 700 to 800 lb col-
To make this operation competitive with automatic lapsed the tube and caused serious deformation.
gas tungsten-arc spot welding, it was necessary to Penetration in the skin averaged 0.025 in. and in the
weld both sides at one time. This required an in- tube 0.015 in.
direct series spot weld using the tube itself as the The design requires approximately 70 welds to
current carrying member. RWMA Class 3 wheels be made on each side with a spacing of 0.75 in. be-
of 10 in. diameter were selected and were profiled tween centers. The heat buildup in the tube had
as shown in Fig. 3. Because of the side thrust on the to be kept to the minimum to keep the tube from

G OF INDIRECT WELD

G OF DIRECT WELD

042 IN SKIN

iia
042 IN. CHANNEL

.090 IN. TUBE

Fig. 2—Cross section of dorsal fin The indirect series spot weld (with current path
shown) is on an angle of 22° 45’ The direct series spot weld is on a 2-in. radius bend

724 | JULY 1961

 losing strength and collapsing. This could be
achieved by external cooling with water or by using
sufficient hold time in the weld schedule and, de-
pending on the heat being withdrawn from the weld,
by the internal cooling of the electrode. The latter
method has been used in production, and the dis-
tortion due to excessive heat buildup is negligible.
The required 70 welds on each side, or a total of
140 welds are made in 3 min.
The second part of the problem that of welding
the skin to the channel—was much easier, because
the underside of the weld was accessible to a sup-
porting electrode. Figure 4 shows the details of the
parts to be welded and also details of the welding
electrodes. Although undesirable, the 1’ /; in. radius
on the wheel electrode was necessary because of the
contour of the skin in the area to be welded. Sev-
eral profiles were tried on the supporting electrode,
such as matching contour and an included angle of
13 deg, but the most successful profile is that shown
in Fig. 4. Both the wheel electrodes and the sup- G OF WELDING
porting electrode are made of RWMA Class 3.
Fig. 3—Profile of 10-in. diam wheel electrode used for in-
A material of higher conductivity was tried on the direct series spot welding. The welding pressure is exerted
support electrode, but this proved to be too soft as shown to give sufficient support during welding
to maintain proper contour (and nugget diameter
and also required frequent redressing.
The design requirement is 50 welds per side on a
spot spacing of one inch. These 100 welds are made an adjustment has been added to the fixture to con-
in 3 min again using sufficient hold time to prevent trol this. The lead photograph shows a dorsal fin in
heat buildup and distortion. The average shear position to be welded.
strength required is 1100 lb and the average nugget Conclusion
diameter is 0.19 in.
The use of series spot welding and indirect series
Operating Problems spot welding as production methods has been proved
There were several problems that were common reliable and economical, provided that close con-
to both operations that had to be overcome before trol is maintained on all factors affecting the weld-
this technique could be used in production. The ing operation.
first of those was to develop consistent strength
values on both top and bottom welds. Although
many factors influenced this, the prime considera-
tion was found to be the alignment and positioning
of the parts in relation to the welding electrodes.
The electrodes had to be on center and perpen-
dicular to the surface to be welded. The parts to
be welded then had to be mounted level and sup-
ported to maintain this. Proper care in maintain-
ing correct relationships gave consistent values on
both top and bottom welds. Another problem was
maintaining round nuggets. This was dependent
again on maintaining proper relationships and proper
support during the welding cycle. Cleanliness was
not considered a problem as normal methods for
cleaning low-carbon steel proved to be adequate.
Since spot spacing had to be held to close tolerances
> in.), the indexing was done using low motor
speeds. This afforded closer control on the braking
action and also lessened the possibility of overheat-
ing the brake.
Both welding operations are performed on the same } i electrodes and sup
Fig. 4 ross section of 10-in diam wheel
fixture merely by positioning the backup rolls as port electrode in position to series spot weld skin to chan-
required and changing the front support roller. nel. Both wheels and support electrode are made of RWMA
Since the parts must be level to assure reliable welds, Class 3 material The line of welding force is shown

WELDING JOURNAL 725

=* by

(a

Inconel component (5 , in. thick) butt welded with semiautomatic gas metal-arc process

Use of Inconel Deposited Weld Metal

for Nuclear Component Parts

calls for identification of given boundary constituents that cause fissuring and hot

cracking so as to reduce the cost of producing nuclear quality weldments

1GA AND W. H. RICHARDSON

Introduction austenitic stainless steel components cannot be

In reviewing the problems encountered over the ignored. This attack is known to be especially
past few years in the welding of Inconel for nuclear severe when stainless steel components are exposed
power applications, one might wonder why Inconel to halogen and oxygen ions, particularly if stresses
has gained preference over the more easily welded are present as they always are to varying degrees
austenitic stainless steel for certain applications in in any power system. Stress corrosion can be in-
the nuclear power field. hibited through rigid control of water chemistry,
For nuclear service where component integrity but in seaboard units a source of halogen ions is
is all important, the hazard of localized attack of always present and increases the importance of
built-in protection.
R. W. MINGA and W. H. RICHARDSON ith Chattanooga Div Because of the stress-corrosion problem with
Combustion Engineering, Inc., Chattanooga
Paper presented at the AWS 42nd Annu Meeting austenitic stainless steels, various governmental
N. ¥ Apr. 1 1, 1961 and industrial research organizations conducted
 test programs to evaluate alternate materials for Applicable Codes and Specifications
these critical applications. Inconel was a logical The primary basis of all nuclear specifications is
choice for consideration since this material had been the ASME Boiler and Pressure Vessel Code and
used for high temperature and corrosion resistant applicable cases. In the Naval Program, additional
applications for many years. Welding had been requirements have been imposed by NAVShips
used extensively in fabrication of Inconel for such 250-1500-1 which has recently superseded S9-1
critical parts as jet engine components as well as Ships and MIL-STD-278 as a general welding spec-
for chemical, food and drug processing equipment ification. Requirements in addition to these spec-
With this background, it appeared that the problems ifications have been imposed by prime contractors
associated with welding Inconel to nuclear quality in areas where adequate data were not available
requirements could be resolved. for operating conditions. Qualification of welding
The net result of these test programs was that procedures have followed the general pattern es-
Inconel was found to provide an acceptable bal- tablished by Section [X of the ASME Code.
ance between desired characteristics and _ basic Corrosion Resistance
economics. The problem then remaining was the
The main factors in the selection of Inconel over
refinement of existing processes and development
stainless steel for nuclear components was Inconel’s
of new procedures to provide Inconel weldments in
better resistance to corrosion and stress corrosion.
the thickness and shapes dictated by design re-
An example of stress corrosion in stainless steel
quirements.
weldments is shown in Fig. 1 Localized corrosion
Preliminary investigation established that con-
lowers the strength of nuclear vessels, and general
trol of the analysis of Inconel plate was a critical
corrosion may result in crude deposits which could
factor in the comparatively thick sections required
affect heat transfer surfaces as well as make de-
for nuclear components. Additional difficulties
contamination of nuclear vessels difficult Nuclear
were presented by the realization that Inconel welds
vessels must be decontaminated to safe levels fo
were prone to fissuring and hot cracking. Othe
repair, refueling and modifications Therefore
problems were encountered early in the program
it is desirable that products of corrosion with a long
For example, the oxides formed on Inconel weld
radioactive half life be kept outside th boundaries
deposits may result in oxide inclusion. They also
of the primary coolant
reduce the wetting action of the molten weld metal
Fo) corrosion resistance purposes carbon in
This can result in cold laps if careful procedure con-
Inconel welds has been limited to 0.08 and iron
trol is not exercised.
to 12 maximum values In order to maintain
Applications of Inconel to nuclear components now
carbon and iron contents below these levels, the
range from 0.050-in. wall tubing to reactor sections
relatively iron-free 80/20 Ni-Cr fille material has
in excess of 5 in thick. The largest single use of
been used as a buffer first layer in weld overlaying
Inconel welding is in the weld overlaying of carbon
ferritic material. Since the chemical analysis of an
and low alloy steels in contact with primary cool
Inconel weld bead made under controlled conditions
ants.
This paper is a summary of the problems en-
countered in welding Inconel to satisfy nuclear
quality requirements, principally with the gas tung-
sten-arc process and the gas metal-arec process. Con- Fig. 1—Early stagesof stress corrosion cracking
Type 321 stainless steel. X 500; 90% nitric etc
currently with the developments in welding In-
conel with the inert gas processes, extensive use
has been made of the covered electrode processes
and development work in submerged arc welding
has been conducted. The problems relating to
these two latte processes will be described only
briefly.
Nuclear Quality Requirements
Today, the metals fabricating industry is con
fronted with many levels of quality such as missile
quality, aircraft quality, nuclear quality, etc. In
essence, these levels of quality only denote the added
requirements above normal fabrication to produce
an end product consistent with service require-
ments. The problem of maintaining nuclear
quality, as associated with pressure vessels, deals
primarily with design and nondestructive testing.
The actual fabrication procedures used in most
instances closely parallel those of less critical pres-
sure vessel work.
 Longitudinal cross section of splintered nickel base wire. X 100; marble etch

Fig. 3—Surface appearance of splintered nickel base wire. X 50; unetched

has been found homogeneous throughout any given in structural failure at the junction with the fer-
cross section and since the analyses of filler wires ritic base materials.
are not difficult to control, it generally is not difficult In general, nuclear quality is the best quality
to control weld deposit analysis. obtainable with present fabrication techniques.
In many cases, scale mockups of weldments have
Weld Soundness Requirements been made to establish quality levels and inspec-
Weld soundness, in addition to affecting the phys- tion standards.
ical properties of Inconel welds, also determines the
effectiveness of overlays in eliminating corrosion. Problems in Maintaining Nuclear Quality
Overlays with surface defects or excessive porosity In discussing the problems of maintaining nu-
can result in excessive corrosion of nuclear com- clear quality in Inconel welds, one must first consider
ponents. the effects of the usual variables in fusion welding
Qualification testing of Inconel welding and such as (1) choice of welding process, (2) filler wire
weld overlaying procedures, as with other materials, surface condition and analysis, (3) line voltage varia-
are performed and evaluated by both destructive tion, (4) joint designs and other aspects of welding
and nondestructive inspection. The destructive procedures, (5) welding techniques, (6) skill of the
tests are those outlined in Section [IX of the ASME manual or machine operators, (7) welding fixtures,
Code 8) type and condition of welding torches and (9
Nondestructive Testing shielding gas. These and other variables are com-
mon to the are welding of all materials. However,
The most commonly used nondestructive in-
the control of these variables necessary to produce
spection methods for nuclear component welding
consistently sound welds is much more critical for
are radiography, liquid penetrant and ultrasonic
Inconel than for most other commonly used ma-
testing. Magnetic particle inspection is limited
terials—certainly more critical than for most stain-
to ferromagnetic materials. Radiographic inspection
less steels.
is mandatory for pressure boundary welds with
minor exceptions which are excluded from the re- Filler Wire Surface Condition
quirement by ASME Code cases. This require- The filler wire surface condition is one of the largest
ment is also applied to certain internal and support- problems in gas metal-arc welding of Inconel. In
ing structures. gas tungsten-arc welding, however, the wire surface
Liquid penetrant inspection is a straight forward is of little significance. It has been known for sev-
process that has been in general use for many years. eral years that nickel-base filler wires are prone to
This inspection method is used extensively in de- splintering during manufacture, as illustrated in
termining the soundness of Inconel overlays. The Fig. 2. When nickel-base filler wires’ are
acceptance standards set forth for all nuclear ves- splintered, areas of poor electrical conductivity
sels are basically the same and consist of a numerical beneath the splinters will result in are instability.
value of size and frequency of indications. In gas metal-arc welding, this is caused by the in-
Ultrasonic inspection is used in the evaluation ability to transfer high current densities uniformly
of the bond of weld overlays. Continuity of bond across the contact tip. The surface appearance
is required because thermal cycling could result of a splintered nickel-base filler wire is shown in

728 | JULY 1961

 Fig. 3. Splintering has been found in varying de- the case in weld overlaying small diameter reactor
grees in most all nickel-base filler wire. head penetrations in the vertical position.
Another problem with nickel-base gas metal-arc The arc plasma characteristics of helium were
welding filler wires is a scratched surface. Scratched utilized in welding the comparatively thin walled
wires may also result in instability of the arc due Inconel tubes to tube sheets. Because of the thin
primarily to a varying contact surface. Scratched tube wall, it would appear that argon would be the
wire is often dirty, because the rough surface best choice to eliminate burn-through. However,
serves as a trap for wire-drawing lubricants. the arc plasma produced by argon frequently
Splintered, scratched or dirty wire surfaces are melted down the top of the tubes. Helium, on the
not always apparent from visual inspection. Con- other hand, gave a more constricted arc plasma
ventional wipe tests will not reveal the splintered and a more concentrated heat source, thereby
or scratched condition. ‘The most useful visual alleviating the problem
inspection of filler wires is to compare the luster Physical Properties
of acceptable wires with wires that are not accept-
The propensity of some nickel-base alloys to
able. In most cases, the unacceptable wire will have
change physical properties as a result of strain aging
a dull luster compared to that of acceptable wires.
and as a result of precipitation hardening at opera-
Of course, this trial-and-error method is of limited
tion temperature or heat-treatment temperatures
value because part of a wire coil may be satisfactory
must be considered. No instances of precipitation
and another part unsatisfactory. As yet it has not
hardening or strain aging have been found in Inconel
been possible to develop a satisfactory test for de-
welds produced with gas metal-arc welding wires to
termining the quality of nickel-base wires for gas
Specification MIL-RN62 and MIL-RN6N or with
metal-arc welding other than by welding with the
MIL-3N12 and MIL-4N1A covered electrodes.
wires.
Welds produced with MIL-RN6A wire have been
Various methods have been tried by wire producers
found to be precipitation hardening during some
in overcoming the surface condition problems such
stress relief heat treatments applied to ferritic ma-
as increasing the stiffness of the wire and the use
terials. As a result, such filler materials are used
of ultrasonic cleaning or other cleaning methods.
only where the loss of ductility from precipitation
The producers must give increased recognition to
hardening would not be detrimental to the quality
the fact that the problems are different from those
of nuclear components. In som«s cases, changes in
of stainless steel. If gas metal-arc welding filler
physical properties may occur only after a combina-
wires could be obtained free of surface contaminants,
tion of straining, followed by aging over a range of
splinters and scratches, Inconel weld defects such
temperatures. There have been indications of
as cold laps, entrapped oxides and porosity would
this with MIL-4N85 electrode deposits. The possi-
be greatly reduced. This would improve the fabrica-
ble changes in the physical properties of welds
tion of nuclear components by reducing the frequency
deposited with this electrode as a result of fabricat-
of repairs which usually entail reinspection and other
ing techniques and service requirements are currently
high-cost operations.
under study by several investigators. Weld de-
Choice of Shielding Gas posit analysis, electrode characteristics and other
Since most Inconel welding is now being done variables in Inconel welding must be fully evaluated
with the inert-gas processes, some mention of the
effect of shielding gases should be made. The weld-
ing industry is quite conscious of CO., CO, mixtures
and argon-oxygen mixtures for shielding gases.
None of these mixtures have been found satis-
factory for welding Inconel, and the purest welding
grade argon and helium obtainable is used with the
tungsten and metal arc processes. The usual prac-
tice is to use argon for all gas metal-arc welding.
Both argon and helium are used for gas tungsten-
arc welding, depending upon the application and
arc characteristics required.
It is well known that argon produces a lower arc
voltage which results in a correspondingly lower
weld penetration. The lower weld penetration usu-
ally results in a flat, shallow deposit with both the
tungsten and metal-arc processes. The flat, shallow
deposit is less susceptible to fissuring and hot crack-
ing. In weld overlaying, the lower penetration ob-
tained with argon also results in less dilution. Fig. 4—Grain boundary constituent in cast Inconel.
Somewhat cleaner gas metal-arc welds and better X 2000; electrolytic HNO, etch (Reduced 50% on
shielding are usually obtained with argon as was reproduction)

WELDING JOURNAL 729

 Peet = he
ade Jalen a
Fig. 7—Solidification pattern of an Inconel fillet weld. Hot
cracking did not develop but a weak plane does exist where
the dendritic columns meet. X6; Lapiso’s etch

Fissuring and hot cracking appear to be intimately

associated with weld metal analysis, weld bead size
and shape and joint design.
In determining the effects of joint designs on
fissuring, it was found that even when the same
coil of filler wire was used, fissuring and hot cracking
occurred in certain weld joints and not in others.
The difference in the welds was principally in the
directional solidification pattern. As _ illustrated
in Fig. 5, when a weld is deposited in such a manner
as to allow weld solidification to progress normal to
Fig. 6—Inconel weld in narrow groove showing the weld surface, fissuring and hot cracking almost
hot cracking that resulted from solidification in never occur. This type of deposit has a relatively
more than one direction
uniform dilution pattern and stress levels are less
in each bead or layer than in butt or fillet welds.
The grain boundary constituent appears to be carried
in their effects on the physical properties of nuclear along with progressive solidification of the deposit
components. so that low-strength areas do not develop.
Weld Defects As illustrated in Fig. 6, an Inconel weld formed
from a comparatively large deposit in a relatively
The following weld defects are common to Inconel
narrow groove causes weld solidification to progress
welding if the previously listed welding variables
in more than one direction. It will be noted that
are not carefully controlled: (1 fissuring and hot
the dendritic columns meet in the center of the de-
cracking, (2 oxides and inclusions, (3 cold laps,
posit. Weld shrinkage stresses are high with this
1) porosity.
solidification pattern, and hot cracking usually
Fissuring and Hot Cracking results in the plane of concentration of the grain
Figure 4 shows an Inconel cast structure at boundary constituent. For these reasons, grooves
2000. It will be noted that there is a grain boundary for butt welding Inconel should be wider than for
constituent. This constituent has been segregated welding other materials. The wider grooves permit
by holding at a temperature just below the melting the production of comparatively flat deposits as in
point for several minutes. It is this grain boundary the case of weld overlays. The wider grooves,
constituent that appears to be the cause of fissuring together with proper welding techniques, virtually
and hot cracking by segregating as the weld freezes. eliminate the problems of fissuring and hot cracking

730 JULY 1961

Beare
4 Pa pei nN

Fig. 8—Effects of surface oxides on weld overlay Fig. 9—Lack of dye penetrant indication in
soundness. Dye penetrant indications in top photograph re top photograph shows improvement in weld overlay
sulted from surface oxides in previous layers soundness by removal of surface oxides

in Inconel butt welds, even in thick sections

Note the dye penetrant indications in the top photo-
Fillet welds in Inconel are very prone to fissuring
graph caused by the lack of wetting in the second
and hot cracking. Figure 7 shows a cross section of
layer. Cross sections of such welds usually show
a fillet weld. Even though hot cracking did not
subsurface cold laps and oxide inclusions. Figure 9
occur in this weld, this type of weld structure is to
shows a weld overlay on which the oxidized surface
be avoided. The tendency toward fissuring and hot
of the first layer was removed by grinding. Note
cracking can be reduced by producing fillet welds so
how the improved wetting has eliminated dye
that the dendritic columns do not meet in the center
penetrant indications in the top photograph. If
of the deposit.
excessive surface oxides are present, cold laps and
The problems of fissuring and hot cracking fall
oxide inclusions are almost certain to occur in sub-
into the same category, that is, they appear to be
sequent layers of Inconel weld overlays.
different degrees of the same problem. In most
Since gas tungsten-arc and gas metal-arc welding
cases, the problem can be overcome by the proper
are the main processes used for Inconel welding, the
welding procedures and welding techniques. For
causes of excessive surface oxides can be attributed
example, it was found to be difficult to produce
to improper gas shielding of the arc and the molten
sound butt welds in heavy sections with fully auto-
weld metal. Gas-shielding problems are controlled
matic gas metal-arc welding using stringer beads.
by eliminating excessive drafts, by using the cor-
On the other hand, sound deposits were readily
rect shielding nozzle size, by maintaining correct
produced with semiautomatic gas metal-arc welding
shielding gas flow rates and by preventing gas or
by using a weaving technique, thereby obtaining a
water leaks in lines and torches. Weld-puddle size,
more favorable bead shape and solidification pattern.
in both weld overlaying and in welding, should be
Oxides, Inclusions and Cold Laps kept small enough so that molten or excessively hot
The oxides that form on Inconel weld deposits areas are not exposed to the atmosphere.
have a higher melting temperature than Inconel, Oxide inclusions and cold laps can also be pre-
itself, and result in the comparatively poor wetting vented by proper welding techniques. For example,
of molten Inconel weld metal. This can result in the center portion of gas-shielded arcs are consider-
oxide inclusions and cold laps if welding procedures ably hotter than the outer arc plasma. If the hotter
are not carefully followed. Figures 8 and 9 show portion of the are is allowed to impinge on weld-
the effects of surface oxides on the wetting of an bead overlaps or against the sides of the weld joint,
Inconel overlay. Figure 8 shows an overlay on oxides usually are melted and floated out of the weld
which the oxidized surface of the first layer was deposit. For this reason, sounder butt welds can
not removed before depositing the second layer. usually be made with semiautomatic gas metal-

WELDING JOURNAL 731

 arc welding using a weaving technique than with
fully automatic stringer beads. In like manner,
sounder weld overlays are easier to produce with an
oscillating technique rather than with stringer beads.
Fissures may also initiate from oxide inclusions.
An example of this is shown in Fig. 10. The in-
clusions apparently act as stress risers at grain bound-
aries causing fissures to radiate from the edges of the
inclusions. Whether or not inclusions will result in
fissuring depends on the stress levels and location of
inclusions in the deposit.
Slag inclusions are quite common in covered elec-
Fig. 10—Effects of inclusions on fissuring in Inconel weld trode deposits. The causes of slag inclusions can
deposits. X 500; electrolytic nitric etch be traced to four major factors: (1) welding operator
skill, (2) welding position, (3) joint configuration and
(4) welding electrode characteristics. These factors
are closely related and generally are dependent upon
one another. With a satisfactory joint design, a
skilled welding operator can usually prevent in-
clusions from occurring in a deposit with most
Inconel electrodes by properly cleaning the slag
and by controlling electrode angle, arc length, weav-
ing and rate of travel.
Porosity
Porosity in Inconel welds deposited with the gas-
shielded-are processes can be attributed to two major
causes. The first is from the presence of foreign
matter such as water or oil on the metal surface,
and the second is from improper gas shielding.
Porosity caused by surface contaminants is easily
controlled if proper care is taken in preparation of
the surface to be welded. Improper shielding, in
most cases, is much more difficult to detect and us-
ually is the chief cause of porosity.
Porosity caused from air or moisture in the shield-
ing gas stream is quite common with the gas-
Fig. 1l—Porosity at the root of an Inconel weld shielded-are processes. This is especially true in the
resulting from improper gas shielding case of gas metal-arc welding. Figure 11 shows
porosity in a weld cross section resulting from im-
proper gas shielding. If the cast of gas metal-arc
welding filler wire is not closely controlled, the wire
Fig. 12—Automatic gas metal-arc overlay ona high will form a helix as it leaves the contact tip. If this
pressure head approximately 4 ft in diameter
effect is too great, the arc becomes eccentric within
the inert-gas stream and aspirates air into the shield-
ing gas. With only small amounts of air, the surface
of the deposit will not be noticeably altered since
the porosity which forms will be close to the root
of the deposit. However, with large amounts of
air, gross porosity will occur, together with a severely
oxidized surface.
Improper flow rates of inert-gas for the design of
the shielding gas cup can also cause weld porosity.
For example, if flow rates are too low for the cup and
torch being used, porosity will result because of in-
sufficient gas coverage. If flow rates are too high,
porosity can result from the aspiration of air into
the outer edges of the shielding gas stream.
Another cause of porosity is water vapor. Almost
all gas shielded-arc welding torches used in welding
and overlaying Inconel are of the water-cooled type
which used O-ring seals. The seals sometimes de-
velop smail leaks which permit the introduction of
water into the shielding gas stream. It is rare that pne® eerie:
visible water can be detected during welding, since
dine
een
the high heat of the arc rapidly vaporizes the water ~ wh
which enters the welding pool. Small amounts of
water vapor usually are not detected by weld sur-
face appearance, but they often result in fine po-
rosity near the root of the deposit as does improper
gas shielding.
Water can also enter the shielding gas from
condensation within the torch and gas lines on cold
days or the inert-gas, itself, can be contaminated
with water vapor. The latter is not a likely cause
but should not be overlooked, especially since some
of the manufacturers use statistical methods to de-
termine the frequency of bottled-gas testing.
-
Welding Equipment Dictated by Quality 2
Requirements and Component Design
As the quality of nuclear components becomes 13—Close-up view of automatic gas metal-arc
verlay on high pressure head shown in Fig. 12
more critical, the applications of the welding proc-
esses also become more critical. This means that
more precise and more automatic equipment must
be used in producing quality welds. A large por-
tion of the welding equipment on the market today
has been in existence for many years and was de-
signed and built prior to the advent of nuclear power.
Some of this equipment has done an acceptable job
on most commercial applications but is not suitable
in many instances for the production of welds to
nuclear requirements. New welding equipment de-
signs and refinements of existing processes required
to produce nuclear quality welds have lagged far
behind the needs. Because of this, most fabricators
of nuclear components have been forced to produce
much of their own new equipment. Of course, the
old problems of developing welding procedures,
techniques and operator training, even with auto-
matic equipment, also exist.
Four examples of new welding equipment designs
and refinements of existing processes necessary to
overcome the problems in weld overlaying and
welding Inconel components have been encountered
recently. The first example is the large area over-
lays of Inconel on low-alloy material in the flat
position; the second is the welding of heavy sections
of Inconel in excess of 5 in. thick to itself and to dis-
similar materials; the third is large area Inconel
overlays on head penetrations or nozzle bores which Joint design and illustration of weld t
ranged down to 5'/, in. in diameter and approx- yntour used in butt welding 5'/. in. thick Inc
imately 3 ft long; and the fourth is the welding of
Inconel tubes to tube sheets. laying to nuclear quality standards.
The basic parts of the gas metal-arc machine In the butt welding of Inconel in excess of 5 ft
used in weld overlaying with Inconel in the flat thick, a standard semiautomatic gas metal-arc
position was purchased from an equipment supplier. machine was used. The principal problem was the
The parts were adapted to existing fixtures and the development of suitable welding techniques and the
machine made fully automatic. Figure 12 shows a training of operators. The lead photograph shows a
high-pressure head weld overlayed with this machine. 5 in. thick Inconel component on which the
A straight line oscillator was used with a single arc longitudinal and cirumferential seams were welded
to produce a wide, flat deposit. Figure 13 shows a with the new techniques. All tests showed that
close-up view of this overlay. The process and ma- these 5!'/.-in. thick butt welds were as sound as
chine have met all the requirements for weld over- welds on thinner sections. Figure 14 illustrates the

WELDING JOURNAL 733

 joint design used and how thin, fiat layers were pro-
duced to overcome the problems of fissuring and
hot cracking. Fully automatic machines were
tried for these butt welds, but it was found that
stringer beads produced with them were much more
susceptible to the usual Inconel weld defects than
semiautomatic welds produced with a weaving
technique.
There was no equipment available for Inconel
weld overlaying the inside of reactor head and
nozzle penetrations of 5 in. inside diameter.
These approximately 3-ft long penetrations had to
be weld overlayed with the axis of the penetrations
in the vertical position because of the weight of the
reactor heads. The gas metal-arc process was chosen
for this application because of the good deposit
quality and high deposition rates obtainable with
this process. The machine took the form of a spe-
Fig. 15—Inconel weld overlay in 5 and 7'/,-in. diam re- cially designed torch that could be lowered into the
actor head penetrations The overlay was produced with penetrations and weld circumferentially around the
the penetrations in the fixed vertical position ID as the torch was moved vertically up to produce
a continuous deposit. Figure 15 shows one of the
reactor head penetrations before machining. It
will be noted that the diameter of the penetration
varied since ledges were required at the upper end.
This, of course, complicated control of the welding
equipment. Figure 16 is a close-up view of a test
sample weld overlayed with this machine. Figure
17 shows a test sample bored out on a taper so that
the soundness of both layers could be determined.
The dye penetrant test shown in the photograph
at the left shows that both layers are free of in-
dications.
Variations relatively unimportant in other gas
metal-arc welding applications had to be closely con-
trolled, and precise rotational and vertical travel
speeds had to be maintained. Arc voltage and cur-
rent control were simplified by the use of a constant
potential power supply. Since wire extension from
the contact tip results in /*R heating of the wire,
however, this variable also had to be closely con-
Fig 16 Close-up view of weld overlay produced with the trolled.
Same gas metal-arc machine as the overlay shown in Fig. 16 The fourth project, strength-welding Inconel
tubes to Inconel weld-overlayed tube sheets, was
the same as the inside weld overlaying project with

Fig Mockup of Inconel weld overlay taper bored to determine soundness

of th e tw o layers Dye penetration test is shown at the left

RY
s —Abe
 respect to the lack of commercially available equip-
ment that would produce welds to meet job spec-
ification requirements. The problem in this case was heey
ra
to weld ' ‘:- and °s-in. diam Inconel tubes to Inconel
weld-overlayed tube sheets. ty,sem
Petes
Figure 18 shows the appearance of these welds.
The escape path through the weld was specified
to be 1 times the thickness of the tube wall.
For the appt OD tubes shown, the tube-hole
ligament is 0.2 5 in. The welding machine had to be mn mn

reliable and rageed enough for production welding

The tungsten-arc process was chosen fot this job
since it had been found that it was very difficult ig. 19—Cross section on Inconel tubet
to maintain consistent weld quality with the gas tube-sheet welds shown in Fig 18
metal-arc process. A portable design was chosen
which could be positioned within the tube to be
welded with filler wire fed into the weld. Figure 19 of basi research in fabricating knowledge of this
shows a cross section of a row of welded tubes material. The basic metallurgical problems must
The machine was made fully automatic with none be overcome before any rapid progress can be ex-
of the welding variables left for control by the opera- pected in solving the remaining welding problems.
tor after positioning the welding gun. Although it The principal metallurgical problem is to identify
had been found that welds of 1 times the tube the grain boundary constituent or constituents which
wall thickness could be made on stainless steel with- is believed to cause fissuring and hot cracking.
out filler wire, filler wire additions were necessary If the tendency toward fissuring and hot cracking
for Inconel in order to meet the minimum weld could be reduced significantly by the identification
thickness requirements. The welding procedure of the grain boundary constituents, then rapid
was set up for a two-pass weld The mandrel that progress could be expected in the development of
served to center the gun in the tube also served as a Inconel submerged-arc fluxes, electrode coatings
weld chill. and in simplifying automatic welding equipment.
With these developments, the cost of producing
Conclusion nuclear quality weldments could be greatly reduced.
From the trial-and-error method used in over- In applying the welding processes, it is apparent
coming the problems in welding Inconel, it is ap- that fabricators of nuclear components must do
parent that engineering applications are far ahead most of their own welding equipment development.

Fig. 18—Appearance of Inc« nei tube

to tube-sheet welds produced with
automatic gas tungsten-arc welding
machine

Teiane
a \Ay\ Je Je\_4\ JB

EPPS
(Ox

> WELDING JOURNAL 735

OU
 Practical Welder

and Designer

Massive task of handling, shaping, welding and as-

Highway Tunnel sembling 6500 tons of steel plate for a new vehicular
river tunnel under the Elizabeth River between
Norfolk and Portsmouth, Va., for the Elizabeth
Has Welded Tube River Tunnel Commission called for some unusual
departures in practice on the part of Wiley Manu-
BY J. F. GULLEY facturing Co., Port Deposit, Md., steel fabricator.*
The tunnel is a tube of 33 ft inside diameter,
lined with 18 in. of reinforced concrete. Twelve
J GULLEY is Field Engineer t incoln o., Baltimore
Md * Subsidiary of Republic Industrial Corp., Newark, N. J

Fig. 1 Ends sealed tightly, a 300-ft tunnel section is side launched into the
Elizabeth River prior to towing down the river to Portsmouth, Va

4
 Fig. 3—Rolling jig of welded steel tubing wraps ur
the plate to cylindrical section and octagonal
diaphragm rings are welded in place

Fig. 2—Welded steel plate 30 ft wide and 102 ft long, with stif
feners attached, is transferred by crane to the rolling
platen in the background

sections make up the 3462 ft length, each about 300

ft long. Each of these comprises 10 segments of
tubes welded together and sheathed by octagonal
diaphragms spaced 14 ft, 10 in. apart. Form plates
are welded over the sides and bottom of the dia-
phragms to make a seaworthy unit, one of which
is shown being launched in Fig. 1.
The tube segments carry longitudinal stiffeners
on the outside of the shell plate, manually welded in
the flat position with iron powder electrode for fast
travel on the intermittent fillets. The shell plate
itself is made up of eight pieces which are square
butt welded together on both sides by semiautomatic
welding guns traversing the seams at 24 ipm.
Next, shown in Fig. 2, a gantry crane picks up the
flat plate and turns it over onto a rolling platen.
The stiffeners fit into slots in the platen. Then, Fig. 4—Completed sections were towed down the river to
the installation site where additional concrete ballast was
much as a sheet of dough would be wrapped up on a added to sink the tunnel tube into position in a previously
rolling pin, the plate is formed into a cylindrical excavated trench
shape over a rolling jig, Fig. 3, which turns on a
central shaft supported by heavy tripods at either
end. At this stage the octagonal diaphragms, to the inside surface of the shell to receive the re-
resembling girder sections with outer flanges and inforcing bars. About one-third of the concrete
radial reinforcing stiffeners, are fitted over the shell keel is poured on the ways prior to launching, the
and welded in place. remainder after launching and prior to towing to the
The 30-ft segments are welded together on the outfitting pier at Portsmouth, Va.
ways and rows of radial angle struts are welded to General contractor was the Diamond Construction
the shell to serve as attaching points for the outer Co., Savannah, Ga. Engineers on the project were
form plates. Parsons, Brinckerhoff, Quade and Douglas of New
Meanwhile, rows of short struts are being welded York.

WELDING JOURNAL 737

Self-Contained Mobile Rigs for Flux-Cored Welding Process

speed Fabrication at Naval Weapons Plant

Speed and versatility are high among the charac- flux deoxidizes the weld area and the outer gas
teristics required of production techniques at the shield completely protects the weld area from
U. S. Naval Weapons Plant, Washington, D. C. atmospheric air. Because of the deoxidizer in the
They enable the plant to act swiftly in order to meet flux, joints require little or no surface preparation.
deadline defense jobs considered too ‘‘rush’’ for The flux also contains a slag forming agent. Slag
time to let bids to private contractors. rises to the surface of the molten weld metal and
For example the Weapons Plant has attained literally pops off the weld as it cools. The fiux-
speed and flexibility in the fabrication of heavy steel cored electrode also minimizes the spatter associated
plate assemblies through the use of eight self- with conventional CO, welding processes. Thus the
contained, semiautomatic welding rigs. Employing finished welds require very little cleaning.
a fast semiautomatic welding process these mobile Weapons Plant production supervisors also report
welding stations are easily moved to work locations, that because of its operating simplicity, and because
yet are also adaptable for semipermanent positioning the weld area is visible at all times, very little
for production runs. operator training is required. After adjusting the
As shown in Fig. 1, each dolly mounts a welding voltage, current, wire feed rates and CO, flow, the
power supply, control unit and welding gun and operator merely pulls the welding gun trigger,
hoses. It also carries its own supply of shielding strikes his arc and welds. This operating simplicity
gas and a self-contained cooling system consisting and arc visibility have led to more consistent and
of a radiator containing 8 qt of coolant and a circula- repetitive weld quality than previously experienced
ting pump. Antifreeze added to the coolant permits with stick electrodes.
outdoor work in the wintertime when necessary. The Weapons Plant also reports that welding time
Thus semiautomatic welding can be performed at has been substantially reduced wherever the process
almost any plant location. Because its shielding has been employed. This is attributed to the
gas and coolant supply travels with it, only electrical system’s basic simplicity, coupled with the high
service is necessary near the point of operation. deposition rates characteristic of CO, welding
The Weapons Plant has attained additional speed processes. On one job, a 219-in. diam cylinder
and flexibility through the selection of the welding component, from '/, and ',,-in. mild steel plate with
process itself. All six units were either originally about 60 ft of welds, welding time was cut to '
designed for or have been converted to the CO, of that previously required with electrodes—Fig. 2.
flux-cored electrode process. The inner core of Weld quality is indicated by the fact that X-ray
inspection has been waived as unnecessary on
Based on a story from National Cylinder Gas, Division of Chemetron
Corp., Chicago, TU several jobs welded with the flux-cored process.

Fig. i—One of eight self-contained, mobile, semi

automatic welding rigs used at the Naval Weapons Fig. 2—Weldor is preparing to weld a '/,-in. bar which has
Plant. Dolly mounts power supply, control unit, been tacked to a '/,-in. thick end piece. Use of the CO, flux-
CO, supply and coolant system. Mounted atop cored electrode process has cut welding time on this job to
the radiator, the Sureweld electronic control unit '/, of that previously required with covered electrodes. After
governs wire feed, CO. and coolant flow. It also setting the voltage, current, electrode feed rates and shield
carries the spool of flux-cored electrode gas flow rates, the operator merely strikes his arc and welds
 Geared for Production

BY R. E. McLANE AND P. T. SESSIONS, JR.

To provide faster and more efficient operation of the

vital Ohio River Waterway, the Corps of Engineers
is building the Markland Locks and Dam, near
Warsaw, Ky. Important partsof this new structure
are the giant ‘“‘gate-hoist’’ gears, fabricated with
magnetic-flux shielded-arc welding by Goslin-Bir-
mingham Manufacturing Co., Inc., Birmingham, Ala.
The Markland Locks and Dam will consist of one
Fig. 1—Magnetic-flux shielded-arc welding torch is used to main lock, 110 ft wide by 1200 ft long; one auxiliary
cast steel half-gear to l-in. frame. Magnetizable flux in
CO, both shields and refines the weld lock, 110 ft wide by 600 ft long; and an all-gated,
nonnavigable dam consisting of twelve 42- x 100-ft
gates between 15-ft wide piers. The supporting
arms are designed to permit raising the gates above
all floods on record.
Goslin-Birmingham is supplying 12 Tainter gate
hoists for the dam: five for the submergible type
gates (each rated on 417 tons capacity) and seven for
the nonsubmergible type (each rated at 335 tons
capacity). Also included are two emergency gate
hoist units for the upstream and downstream gate
leaves.
Gate hoist gears are assembled by welding the
half gear section of cast steel to a frame of Type
A-7 steel plate, l-in. thick. Each 15'/.-ft diam half-
gear weighs 14,500 lb, and requires 200 ft of */;
in. fillets and 20 ft of 1-in. fillets. Fillet welds are
made using Oxweld 43 wire, in. diam, at an
average current of 440 arnp at 33 v.
Two magnetic-flux shielded-arc welding machines
equipped with pistol-grip torches, achieved an out-
Fig. 2—Magnetic-flux shielded-arc welding assemblies in use
for 15'/.-ft diam gate hoist gear weighing over 7 tons at R. E. McLane is Welding Supervisor, Goslin Birmingham Manufacturing
Goslin-Birmingham Manufacturing Co., Inc., Birmingham, Co., Inc Birmingham, Ala P. T. Sessions, Jr., is a Welding Sales
Enzines Linde Co., Division of Union Carbide Corp., Birmingham, Ala
Ala.

Fig. 3—U.S. Army Corps of Engineers

is supervising construction of 16 new
locks and dams on the Ohio River, to
replace 43 outmoded structures. This
is the Markland Locks and Dam, near
Warsaw, Ky
 1200° F for 6 hr, followed by final machining and
painting.
Stairway of Lakes
A profile of the Ohio River waterway appears as a
stairway of lakes, with a series of dams forming the
risers. Boats pass the dams by means of locks,
into which water is admitted and released to raise or
lower the vessels from one water level to the next.
Gravity feeds the water through passages around the
lock gates. Water is released downstream to lower a
vessel, or admitted from upstream to raise the vessel
The Ohio River waterway has been under the
auspices of Congress since 1824, when an act was
passed providing for removal of restrictive sand bars.
The first Ohio River navigation dam was con-
he structed in 1878. The present system of locks and
dams was authorized in 1909 and essentially com-
ie
-% pleted by 1929.
¢
The River and Harbor Act of 1909 provides for
replacement of navigation works as they become
Fig. 4—Aerial view of completed Markland Locks. Still to obsolete. The present program calls for replacing
be constructed is 1400-ft diam across river, which will create
deeper, wider pool extending 90 miles upstream 43 of the 46 existing works between Pittsburgh, Pa.,
and Cairo, Ill., by only 16 new or enlarged structures.
Markland Locks and Dam will replace five out-
standing operating factor on the job of 75°. Normal moded structures. The deeper, wider and more
manual welding with covered electrodes achieve at stable pool it creates will extend upstream for a dis-
most a 50% operating factor. The higher operating tance of 95.5 miles. Maintenance costs on the five
factor is due to the continuously fed wire electrode, old works will be eliminated. Less channel main-
which eliminates continual changing of electrodes tenance will be required, because of greater water
and resultant stub-end waste. depth in the lake.
The magnetic flux, carried in a carbon-dioxide gas Travel time will be sharply reduced, since only
stream, both shields and refines the weld, even one lockage will be required instead of five. In
tolerating normal rust and scale. Sound, nonporous addition, the 1200-ft lock chamber will pass long
welds result, with almost no spatter to remove prior tows in one operation, without breakup into two or
to painting. Completed gears are stress relieved at three sections as before.

Snaking Rugged Piping Across Rugged Terrain

Fig. 1—-The rugged mountains of eastern Kentucky Pipeliners, working a weld and drag pipelaying
were selected as an ideal testing ground for the first method never before attempted in rugged U. S.
permanent underground aluminum line installed in the
Appalachian gas fields mountains, have completed the Appalachian gas
fields’ first permanent aluminum line.
United Fuel Gas Co., Charleston, W. Va., now
operates the 4-in. pipe line as part of a gas-gathering
network, tying UFG wells to a cross-country trans-
mission system. Aluminum Company of America
supplied all pipe for the precedent-setting installa-
tion, which saw a welded pipe line dragged snakelike
over two mountains.
Eastern Kentucky was selected purposely to test
handling and laying procedures, and to evaluate
aluminum’s corrosion-resistance under a wide range
of operating conditions. The weld and pull pipe-
laying method, adapted for use in rough terrain,

Based on story from the Aluminum Company of America, Pittsburgh

Pa
Fig. 2—The H. B. Rainer Construction Co., Prestonburg, Ky.,
to lay the aluminum line in the rugged mountainous area

was employed by the H. B. Ranier Construction

Co., Prestonburg, Ky.
The aluminum line connects two UFG wells,
separated by a straight line distance of 4500 ft.
To bridge the distance, and cross two mountains
that rise between the wells, 5700 ft of schedule 40
pipe in alloy 6061-T6 were required.
Developed especially for pipe lines, the product is
seamless and one-piece, with regular wall thickness
at the ends and thin walls along the length. Ratio
of thick to thin walls is selected to provide uniform
bursting, tensile and bending strengths for an entire
pipe line, after welding. The product also achieves
a substantial weight reduction—up to 30% over
aluminum pipe with uniform, standard wall thick-
ness.
The right of way for the UFG line was sliced
across terrain varying from reasonable slopes of
from 10 to 20 deg, to swift drops as steep as 50 deg. o
Ordinarily, pipe would be strung along the ditch, -
and welding equipment would be moved up and down
Fig. 3—-Welding was performed by a gas-metal-arc automatic
the steep mountains to make the joints. pipe welding machine, which traveled the pipe circumference
Once the trench was dug, however, aluminum making multiple passes. A butt weld was completed in
pipe and a 65-lb Linde Co. gas metal-arc automatic approximately 50 sec. The welding machine weighs only 65
pipe-welding machine, were stationed at the top of Ibs., which greatly eased handling procedures, particularly
the first mountain. As each 40-ft section of pipe in rough terrain. A 0.035-in, diam alloy 5154 electrode was
used to weld the schedule 40 pipe ends (0.237-in. wall thick-
was joined, the entire line was pulled along the right ness) The welding machine can be adapted for use on 4-,
of way, until the next job was positioned. The 6- and 8-in. diam pipe

WELDING JOURNAL 741

welded pipe line eventually was pulled across the Welding equipment was then moved to UFG Well
mountain top and eased down to UFG Well 8918. 8888, on the far side of the second mountain. As
Aluminum’s favorable modulus of elasticity made it pipe was joined, the entire line was pulled up the
possible for the pipe line to bend and curve, following side, across the top and lowered to the valley floor,
the contour of the ditch. to meet the free end of the line coming off the first
In the same way, Ranier ran the line down the mountain. The last weld tied in the two sections
other side, into the valley between the two moun- to form the completed pipe line.
tains. A weld joined the two 1700-ft lengths at the Neither coated nor wrapped, the buried aluminum
welding station, and the first mountain was crossed. pipe line is protected by magnesium anodes.

One-Piece Welded Machine Housing—Stronger,

Lighter, Lower in Cost, Better Looking

In the redesign of its line of beverage filling machines, against 3415 lb for three castings used in the older
a change from castings to a one-piece weldment for design.
base and housing, by Crown Cork and Seal Co., The design story is essentially the ability to place
Baltimore, Md., achieved increased strength and the right amount of steel in the right place to meet
rigidity with better appearance. On top of these any given set of operating conditions. Beyond
advantages, weight of the housing was cut 25% and that, future possible alterations can be accommo-
costs nearly 15°), without figuring pattern costs for dated quickly, without the burden of additional
castings. pattern costs. A saving of $200 per housing in setup
When compared to the old design in Fig. 1, the and machining time also was possible with the
new design in Fig. 2 reflects the clean, unbroken welded design.
lines of the arc welded housing. It is an assembly of Over-all savings are further amplified when con-
plates ranging in thickness from '/, to */,-in. stand- sideration is given to annual production requirements
ard rolled bar, structural sections, and tubing. of about 20 such units.
Weight of the finished housing as welded is 2560 lb, Use of modern steel fabricating equipment and
techniques, including flame cutting, press brakes,
welding positioners and iron powder electrodes, was
Based on an award paper submitted by HANS C. HAFERKAMP, an important factor in the development of this
machine design for the Machinery Division, Crown Cork & Seal Co., to
The James F. Lincoln Arc Welding Foundation, Cleveland, Ohio successful weldment.

Fig. 1 (left}—Old design beverage filling machine. Fig. 2—New beverage filling machine, with housing
redesigned from cast iron to arc-welded steel. Appearance and strangth were improved, weight reduced 25%
and cost lowered by 15%, excluding pattern costs
Jetweld Mild Steel Electrodes are the fastest electrodes this side of
an automatic process. Their high travel speed—made possible by the
iron powder in the coating—is literally astonishing. No wonder they’re
popular. Where do you make best use of them? On jobs welded downhand
in flat or horizontal positions. Premium price? No indeed. In fact, their
low initial cost will amaze you. See inside how other fabricators have
upped their production and cut costs with Lincoln Jetweld electrodes.
 THESE ARE LINCOLN

JETWELD

MILD STEEL ELECTRODES

ON THE JOB

Jetweld 1, because of its extremely high deposition rate,

t selection for this 120-foot-long expressway
bridge plate girder. Finished weld looks as g as one made
arc process. Its soft arc gives slight penetra-
tion, virtually no spatter.
 There are three Lincoln Jetweld electrodes . . . Jetweld 1, of the higher speeds of iron-powder electrodes, but which
Jetweld 2 and Jetweld 2-HT. We call them “‘fast-fill’’ ele require some downhill or other out-of-position welding,
trodes because of their high deposition rates. Management you can take advantage of still another Lincoln electrode,
people like this since it means low production costs. But Improved Fleetweld 47. Here’s a truly versatile electrode
operators like Jetweld electrodes, too. Why? Because which compromises some of the high Jetweld 1 speed to
they’re easy to use even by inexperienced weldors and the gain some of the all-position capability of Fleetweld 7...
final weld is as good-looking as one produced by the sub particularly in the smaller sizes. Many plants save money
merged arc process. However, the Jetweld group is limited by standardizing on this electrode when faced with the
to operation in the downhand position. problem of getting highest speeds on
Jetweld 1 is the original fast-fill electrode. urregular-shaped parts
It delivers a soft, virtually spatter-free arc. We at Lincoln are dedicated to the princi-
Because of high deposition rates coupled ple of bringing the best electrode performance
with a slag that just curls up and flakes to you at lowest possible cost. We are proud
away without chipping, production runs ELECTRODES to offer the Jetweld electrode series to you at
with Jetweld 1 are extremely fast. And costs prices only slightly above ordinary electrodes
stay low. for mild steel. Are you taking advantage
Jetweld 2 is designed to give especially good physical of this superior performance on your jobs? Why not look
properties, X-ray quality, and exceptionally high deposi- into the feasibility of doing so, particularly since you
tion rates. Washes up well in deep groove, avoids under will be able to save money not just in the long run
cut. And slag crumbles for easy removal. Only difference but right now .. . in terms of higher production
between Jetweld 2 and Jetweld 2-HT is that 2-HT is a at lower costs. Why not get all the facts about these
moly electrode. With it you get X-ray quality at high and the full line of Lincoln electrodes from your Lincoln
speeds on low-alloy, high-tensile steels. field engineer. He’s a specialist in welding. No obligation,
On those jobs where you would like to take advantage of course

Improved Fleetweld 47 is an iron-powder electrode that

combines both high deposition rate and versatility. It is
an excellent electrode for production welding of irregular-
shaped products such as this engine mount which culls for
45° downhill as well as flat position welding.
 FOR mun STEEL

FOR LOW ALLOY NIGH TENSILE STEELS

~ ane we ~ FERROUS met

*#2gaeeee
2tee

LINCOLN
 Fig. 1—Wing-tip fuel tanks give added range to SAC intercontinental bombers

Arteries for a Stratofort

BY G. R. CLAY AND RODGERS

Boeing Airplane Company’s B-52G missile platform

Stratofortress is a long-range weapon capable of
striking any point on the globe (Fig. 1). The 244-
ton giant requires more than 2800 ft of stainless
steel and aluminum tubing, internal ‘“‘arteries’’ which
carry high-octane gasoline, hydraulic fluid, water,
hot and cold air, and oxygen to various parts of the
plane.
Boeing’s Wichita Division uses gas tungsten-ar«
welding for most of this tubing in production of the
B-52G bomber. Stainless-steel tubing varies in
thickness from 0.016 to 0.090 in., while aluminum
tubing, Type 5052, ranges above 0.035 in. in thick
ness.
Approximately 50 separate aluminum-tubing as-
semblies and 100 different stainless-steel-tubing
assemblies are tungsten-arc welded (Figs. 2-5
Two welding machines are used for tack welding
where required. Final welding is performed at
16 stations in the welding shop
Stainless-steel assemblies are welded at a current
of 10 amp, DCSP, using pure argon as shielding and
inert-gas backing (Fig. 2). A light-weight torch is
used to reduce operator fatigue.
Aluminum-tubing assemblies are gas tungsten Ps
G. R. CLAY is Welding Sales Engineer inde Co Tulsa. Okla Fig. 2—Gas tungsten-arc welding torch, weighing only
J. C. RODGERS is Manager. Contract Administration, Longren-( 3 oz for operator comfort, welds stainless steel tubing
fornia Div. of Aeronca Manufacturing Corp., Torrance, Calif assembly for Boeing B-52G Stratofort
< For details, circle No. 9 on Reader information Card
WELDING JOURNAL 747
 Fig. 3—Tungsten-arc welding a B-52G fuel vent
assembly, one of 150 different parts so assembled
Fig. 7—Tungsten-arc automatic welding of
circumferential butt weld on nose of 750-gal
fuel tank for Boeing B-52G Stratofortress

Fig. 4—Gas-tungsten-arc fusion welding follows

tack welding of aluminum fuel line
Fig. 8—Finished fuel tanks pass final
inspection at end of assembly line
gprs
arc welded, with the torch, operating at 45 amp,
ACHF. Tack-welded assemblies are supported
in a jig during finish welding (Fig. 4).
Alike as Peas in a Pod
External fuel tanks for the B-52G are highly-
streamlined, wing-mounted pods which must add
as little drag as possible to SAC’s 650-mph inter-
continental bomber. The Longren-California Div-
ision of Aeronca Manufacturing Corp., Torrance,
Calif., secured an Air Force contract to build these
fuel tanks and strut assemblies. It chose mech-
anized gas tungsten-arc welding equipment to
realize production-line performance within exact-
\Z “me ing specifications (Figs. 6-8). Result: tank as-
semblies come off the production line “‘alike as peas
hm catheal in a pod.”
Fig. 5—Tungsten-arc welding with filler-rod These 750-gal tanks : fabricated from 6061
addition completes joint on stainiess aluminum alloy. Highly-specialized welding fix-
steel hot air duct for Boeing B-52G bomber tures, combined with machine torches and cold-
wire feeder units, automatically perform a series
Fig. 6—Tungsten-arc machine torch with of butt welds on the tanks.
cold-wire feeder unit welds aluminum fuel tank in Metal thicknesses range from 0.050 to 0.100 in.
highly specialized welding fixture Gas tungsten-arc welding rapidly penetrates the
base metal, as 5% silicon-alloy filler wire, 3/32-in.
diam, feeds into the puddle. An argon shield,
supplied from a four cylinder manifold, insures a
shiny, smooth, oxide-free weld.
Failure-proof welds are a must in fabricating the
Boeing B-52G bomber. Tungsten-are argon-
shielded welds help make the B-52G a dependable
servant of freedom.
 courses, using two passes from each side per course.
Into the Winner's Circle Root passes were made at 280 amp and 33 v, d.c.r.p.
Cover passes required a current of 240 amp at
32 v, d.c.r.p., using the hooker welding wire, ;-in.
BY R. M. STUCHELL AND J. R. FLYNN diam, type CS magnetic flux, and 55 cfh of low-cost
CO, gas for shielding.
A square-butt joint—an ideal joint for COQ,-
Carbon-dioxide welding with the magnetic-flux shielded magnetic-flux welding was used between
consumable-electrode process, used in fabricating the fourth and fifth courses with a in. opening
a 5-million gallon water tank in a Pittsburgh, Pa., in the joint. This joint was welded with a single
suburb, has achieved speeds averaging 3 to 5 times pass from each side, at a welding current of 220 amp
faster than could be obtained with manual covered at 30 v, d.c.r.p. Reduction from double-pass to
electrode welding. These speeds were achieved in single-pass welding increased the previous time-
spite of a handicap due to vee-joint preparation. saving by about 100%.
The fabricator—The Pittsburgh-Des Moines Steel
Co.—reports that these remarkable welding speeds
would have been even higher, since plate edges had
been prepared in advance for covered electrode
welding. This company was employing the CO.-
shielded magnetic-flux consumable-electrode weld-
ing process for the first time in production welding
of tanks.
Horizontal tank seams were welded via four
traveling platforms, two inside and two outside the
tank. Vertical seams were completed with covered
electrode welding. Carbon steel plates, each 8 ft
wide by about 25 ft long, were set in place by a crane
and held by erection clips until tack welded.
Steel plates varied in thickness, the bottom plate
being 1 in. thick, followed by four consecutively
lighter courses of 11/16, } and °/\, in. thick-
nesses. The first three courses incorporated a 40-
deg double bevel in the upper plate edge, and a
square lower plate edge. This was the same joint
design as employed with covered electrode welding.
Steel spacers provided a in. opening between
plates.
Following tack welding, four portable Co,-shielded
magnetic-flux welding units joined the first three

R. M. STUCHELL is Chief Engineer, Pittsburgh-Des Moines Steel Co

Pittsburgh, Pa J. R. FLYNN is Welding Engineer, Linde Co., Pitts
burgh, Pa a ————
<j Ag [fy
- . * .
Fig. 1—Semiautomatic welding of giant water tank proved Fig. 2—Crane lifts 8 x 25-ft steel plate section into place; steel
from 3 to 5 time sfaster with the CO.-shielded magnetic Spacers provide a in. opening between plates
flux consumable-electrode process than with covered elec
trode welding
Fig. 3—One of four motorized welding platforms
which traveled around the 5-million gallon tank

<a
 Positioner makes it possible to rotate shuttle car to position to bring each seam
and weld location into flat or downhand position for welding with E-6014 and E-6024 electrodes

Positioner Improves Welding of Shuttle Cars

Welding at Joy, Franklin plant, has taken another position. With all welds now flat, the switch to a
step forward, with the addition of new and improved faster electrode was possible. The faster r and
welding methods. One of the outstanding improve- , in. E-6014 and E-6024 are now used on all inside
ments has been the addition of an Aronson Machine and outside seams using single pass downhand welds.
Co. 32,000-lb head and tailstock positioner to the With the use of iron powder type electrode and single
present line of positioning equipment now in use. pass, an average of 400 in. of vertical weld was
This equipment was placed in the shuttle car area eliminated.
for the welding of shuttle car bodies and frames, In addition to the above, use of the positioner has
plus any large weldments adaptable to this position- resulted in a superior quality of weld, using less
ing equipment. time and eliminating unnecessary build-up in all
Previously these car bodies were welded by tipping unpositioned welds. With the elimination of build-
the cars on a 45-deg angle, using an overhead crane up, the weld appearance and quality is superior to
and blocking in position. This method would previous unpositioned work.
position the car body with a major part of welds The average weight of the shuttle cars welded on
to be done downhand using , in. E-6012 type the positioner is approximately 15,000 lb, with a
electrode The outside seams were welded in the maximum length of 25 ft and width of 10 ft. To
same position using a vertical down-hand weld. accommodate the different size cars, the positioner
The majority of the outside seams would be of the head is mounted on an 18-in. box type base and
multipass type welds secured to the floor. The tailstock is also mounted
With installation of the positioners, universal on the same type base but is free to move on a steel
adapters were made to fit the ends of the shuttle cars. base plate for setting the over-all lengths. The
These are placed and bolted securely, then the whole guide rails which are mounted to the steel base plate
unit is placed in location on the head and tailstock to keep the location of the tailstock on center have
and secured by two caps and eight bolts. The car .-in. clearance on either side to compensate for any
is now ready to rotate in any position to bring each misalignment which might occur when mounting,
seam and weld location into a flat or downhand or welding of assemblies. This floating action thus
eliminates any strain on the fixtures, weldments and
Based on a story from the Aronson Machine Co., Inc., Arcade, N. Y positioner.

750 JULY 1961

 UNITED

ENGINEERING
: ¢ sat 4y,
a ; °~ F-
yee" B- , 44 a CENTER

Honor Sections
Wall sections
are installed bringing
the AWS
Headquarters
in the UEC Buildingnear completion Section Goal, % section
Oklahoma City 138 Long Island
New Jersey 133 Toledo
Louisville 130 lowa
Mahoning Valley 121 Niagara Frontier 107
Kansas City 120 Sangamon Valley
Worcester 120 Maryland
Baton Rouge 119 Bridgeport 105
Birmingham 118 San Antonio 105
Northwest 117 Syracuse 105
North Texas 115 Cincinnati 104
Hartford 114 Providence 104
Wichita 113 Northern N. Y. 103
Philadelphia 112 N. E. Tennessee = 102
Colorado 111 Puget Sound 102
Detroit 111 Tulsa 102
Albuquerque 110 San Diego 101
Dayton 110 Chattanooga 100
New Hampshire 110 Eastern Illinois 100
Pascagoula 110 Long Beach 100
Richmond 110 Madison-Beloit 100
Central heating- air-conditioning control operated byair Western Mass. 110 Michiana 100
pressure and electric power gets a final checkout Holston Valley 109 Nashville 100
New York 109 N. Central Ohio 100
Rochester 109 Olean-Bradford 100
St. Louis 109 Salt Lake City 100
Boston 108 Santa Clara Valley 100

Pledges Needed to Meet Goal

Finishing Touches ection Needed Sectior Needed

Pittsburgh Susquehanna
Carolina Valley 350
Mohawk Valley York-Central Pa 375
Tri-Cities Saginaw Valley 400
Anthony Wayne Lehigh Valley 415
Shreveport Fox Valley 450
lowa-Illinois Indiana 465
Pledges continue to move sections up the ladder
Washington Portland 485
to reach their goal. Many sections, on the Honor Arizona Stark Central 495
Roll, have attained 100% or more of their assigned Nebraska Columbus 770
goal. However, AMERICAN WELDING SOCIETY J. A. K. Houston (and
pledges stand at 81% of goal. Northwestern Pa. Sabine) 800
Mobile Milwaukee 877
South Florida Cleveland 900
Western San Francisco 988
Michigan Chicago 1460
Peoria Los Angeles 2805
New Orleans

WELDING JOURNAL 751

 Society News

Governors Lead Nation in Proclaiming

“National Welded Products Month”

Four governors—representing the similar proclamations included: C. dignitaries was in recognition of a

states of Massachusetts, Minnesota, L. Babcock, Canton, Ohio; W. H. fast-growing billion dollar industry.
Washington and Wisconsin- -led the Backrach, Cincinnati, Ohio; J. M. Their action was also in response to
way in hailing welding by calling on Barr, Pittsburgh, Pa.; J. W. the role which many AWS sections
their people to observe ‘‘National Cameron, Bossier City, La.; Louis are assuming in different parts of
Welded Products Month.” Cuterer, Houston, Tex.; P. W the country.
Their action was followed by Day, Alton, Ill.; J. M. Delaney,
similar proclamations on the part of City of Wood River, Ill.; C. E. Fant, Additional Activities
mayors of municipalities through- Shreveport, La.; J. T. Hanlon, Supplementing the actions of
out all parts of the United States. Scranton, Pa.; M. Jacobs, Over- state and local government officials
In the East, for example, Mayor land, Mo.; J. E. Kuyendall, San were numerous special meetings, din-
Robert Wagner of New York City Antonio, Tex.; D. Levine, Seattle, ners, speakers, plant tours and other
signed a proclamation acknowledg- Wash.; T. A. McCann, Fort Worth, events as reported with regular
ing the dependency of our national Tex.; J. D. O’Brien, Worcester, section news in previous issues of
economy on welding and extending Mass.; P. R. Olgiati; Chattanooga, the WELDING JOURNAL. Equally
congratulations to the more than Tenn.; F. Slattery, Wilkes-Barre, important were the many newspaper
one million men and women engaged Pa. series, radio and TV announcements
in welding. Other mayors signing The action of all state and city together with advertising copy and
feature articles appearing in differ-
ent publications.
The object of all activites was
a promotional effort to inform the
AWS DIRECTORS-AT-LARGE American public on the importance
of welding in many phases of caily
Term Expires 1962 1963 1964 living and to make the nation aware
W. H. Hobart R. B. McCauley J. E. Dato that welding and industrial progress
F.G. Singleton John Mikulak A. N. Kugler are bound together.
C. B. Smith E. F. Nippes T. E. Jones
J. R. Stitt R. D. Stout E. C. Miller
Technical Papers to Highlight
AWS DISTRICT DIRECTORS AWS Fall Meeting in Dallas
Work is now under way in prep-
District No. leNew England G. W. Kirkley District No. 6eCentral aration for the 1961 National Fall
District No. 2eMiddle Eastern C. L. Kreidler District No. 7eWest Central Meeting in Dallas, Tex. During
District No. 3eNorth Central J. W. Kehoe District No. 8eMidwest September 25-28, members and
District No. 4eSoutheast J. M. Shilstone District No. 9eSouthwest guests of the AMERICAN WELDING
District No. SeEast Central P. J. Rieppel District No. 10eWestern Society will meet at the Hotel
District No. 1leNorthwest . Ericksen Adolphus to attend a varied pro-
gram of technical sessions and social
AWS PAST-PRESIDENT DIRECTORS activities.
Main emphasis of the Fall Meeting
R. D. Thomas, Jr C. |. MacGuffie will be on the 16 sessions scheduled
for the technical program. Of these
sessions, one is being sponsored by

752 | JULY 1961

 procl mation

PROCLAMATIONS FROM FOUR STATES AND NUMEROUS MUNICIPALITIES

the AEC Welding Forum in conjunc- TREASURAMA FIRST PRIZE DRAWING

tion with another meeting in Hous-
ton during the prior week while a
second session is being sponsored
by the Society for Nondestructive
Testing. One unusual feature of
the technical papers sessions will be
the scheduling of two papers on basic
research wherein one session will in-
clude two papers to be followed by
seminar session which will be bas-
ically a continuation of the first.
In keeping with policy of previous
years, the National Fall Meeting
will not include a welding show. A
preliminary calendar of technical
sessions giving the title, author and
preliminary calendar of technical
sessions giving the title, author and
time of presentation was published A television set was the Treasurama first prize at the Coliseum during the AWS Exhibition
in New York City from April 18th to 20th. Here Walter Edstrom (center), president of the
in the June issue of the WELDING International Institute of Welding, gets an assist in determining the name of R. M.
JOURNAL. Further details will ap- Thatcher as winner after drawing for first prize. New York section Publicity Chairman
pear in August, and a final program John Roderick is helping Mr. Edstrom and to the left is National Information and Educa-
will be published in September. tion Secretary A. L. Phillips

WELDING JOURNAL 753

 KEEPING YOU POSTED

By Fred L, Plummer

e District Director R. H. Hoefler G. O. Hoglund and Past-chairman technical talk on ‘‘Factors Affecting
has reported that 310 individuals, of TAC, A. N. Kugler lunched with the Properties of Stainless Steel
including 90° of the Toledo Section your Secretary and discussed our Weld Metal.’” Chairman J. S. Mc-
members, attended the annual weld- national meeting and other activi- Keighan, Vice-chairman L. E.
ing clinic held at Toledo University ties. Bluhm, Past-president J. J. Chyle
on four consecutive Thursday eve- @On April 28th, President-elect and others welcomed President
nings during March and devoted and Mrs. Chouinard, together with Thomas to Milwaukee.
to ‘‘Joint Design for Welding.” Mrs. Plummer and your Secretary, e@ Your Secretary spent May 4th
@ Sponsored by the Wichita Section joined members of the Pittsburgh and 5th in Cleveland, conferring
of AWS, a Mid-western Welding Section at their Annual Ladies’ with industry leaders including J.
Show was held in the National Night Dinner. During the evening, F. Lincoln. Together with Vice-
Guard Armory in Wichita, Kan., Chairman D. H. Marlin announced president C. E. Jackson, he at-
March 24th and 25th. Reports in- a pledge of $1500 to the UEC Build- tended the 22nd Annual Welding
dicate that this event was an out- ing Fund and presented a check to Symposium of the Cleveland Sec-
standing success. your Secretary covering a major tion, listening to technical talks on
part of the pledge. He also an- ‘Semiautomatic Welding Proc-
e During the evening of March nounced a drive for additional
25th, your Secretary flew to Hunts- esses,” by AWS directors John
pledges which assures early success Mikulak and P. J. Rieppel at the
ville, Ala., so that he might officially in meeting the Section quota of
install the officers of the new AWS afternoon meeting session for which
$2400. Chairman-elect C. W. Charles Herbruck was chairman.
Greater Huntsville Section at a
Lytton, Secretary R. L. Nourie The Symposium was dedicated to
dinner-dance celebration at the Red-
and other section officers assisted J. F. Wagner, vice president of
stone Arsenal Officer’s Club the
in conducting this outstanding event Burdett Oxygen Co. and secretary
following night. Huntsville Mayor which included fabulous door prizes,
R. B. Searcy and your Secretary of the Cleveland Section during the
professional entertainment and a period 1944-53. Following the con-
spoke at the meeting at which R.
gay social period in addition to short tact booth technical conferences and
W. Scearce was master of ceremonies
talks by Mr. Chouinard, your a social period, more than 400 mem-
and Lt. E. J. Wilson, Dan Daley, Secretary, District-director J. W.
Bob Conner, E. Lindsay, S. Gold- bers and guests attended the banquet
Kehoe and various section officers. at which Sen. Stephen M. Young
stein, J. Dawson, C. Green and J.
Past-president G. O. Hoglund, H. was principal speaker and Chair-
Kubler were installed as officers.
E. Cable, Paul Masters and many man R. C. Pagenkopf turned over
@ On March 30th, your Secretary other important AWS leaders at- his gavel to 1961-62 Chairman Wasil
made a one-day trip to the Pitts- tended this meeting. Former Sec- Romance. Vice-chairman Charles
burgh Airport to join members of retary J. F. Minnotte, absent be- Berka was general chairman for
the Arc-Welding Section of NEMA cause of illness, was represented by the Symposium. Jerry Hinkel
in a discussion of economic prob- his daughter and secretary. served effectively as Toastmaster,
lems and a possible joint AWS- @ Following the banquet, Mrs. introducing Vice-president Jackson
NEMA program devoted to pro- and your Secretary for brief talks,
Plummer and your Secretary were
motion of welded fabrication including a tribute to E. T. Scott
guests of Leon Bibber, retired U. S.
through education of architects and who was unable to attend because
Steel executive, on a midnight visit
structural engineers, and the use to his home and workshop on a of illness, however reported by tele-
of codes and specifications prepared phone that he anticipated a full and
transformed barge anchored at 21st
to take full advantage of current St. on the Allegheny River, where rapid recovery. Secretary-treasurer
advances in design and construction Jenine Darbyshire and Vice-chair-
he is constructing a 79-ft steel
techniques. man-elect A. Graskey were also
boat which will be powered by twin
@ The joint IIW and AWS meeting diesel engines, have complete living seated at the speaker’s table.
activities, occupying the period from facilities, including garage, and will e@ The annual Convention of NWSA
April 9th to 22nd were reported become his floating home in ports was held in New York May 8-10.
in the June issue of the WELDING from Maine to the Carribean. Past-presidents A. C. Axtell, Ray
JOURNAL. Your Secretary has re- The skill and ingenuity with which Tarbell, Jim Alcock and many
ceived a large number of letters from he has designed and is completing others played prominent parts as
our European friends paying tribute this one-man project is most en- President V. B. Anderson presided
to the success of these meetings and viable. at this well-attended meeting
expressing thanks for the cordial @ On this same night, President planned by Executive-secretary R.
reception given them by our mem- R. D. Thomas, Jr., met with the C. Fernley and his associates. New
bers. AWS Milwaukee Section, discussing President of the NWSA is W. P.
@On April 26th, Past-president AWS activities and presenting a McLendon of Albany, Ga. AWS

754 | JULY 1961

Director Roy B. McCauley was one @e The AWS fund drive on behalf tablishment of an _ independent
of the several excellent speakers. of the new United Engineering AWS section in this area. Mr.
He discussed ‘‘Education in the NW- Center was given a major assist on Mooney then flew to Dallas, Tex.,
SA Future.’””’ The Contact Booth this same day when Past-president where he was met by Director
Program was again a feature J. H. Humberstone delivered to Cliff Moss and driven to Austin for a
of the convention with 93 manu- your Secretary a check for $5000 meeting of District 9 section officers.
facturers participating. The 1962 on behalf of the Air Reduction Co Returning to Dallas, he spent two
NWSA Convention will be held in It is now expected that AWS Na days with representatives of the
New Orleans May 15-17. There- tional Headquarters will be moved North Texas Section, local hotels
after, the NWSA conventions will to the new building. offici illy located and bureaus, completing arrange-
be held in September or October so at 3 15 E. 47th St.. New York 17. ments for our National Fall Meeting
as to avoid possible conflict with N. Y ibout August 19th which will be held in Dallas Sep-
the AWS Annual Meeting and Weld- e@ The Design, Materials and Fabri- tember 25-28
ing Exposition. cation Divisions and the Executive @ President Thomas ‘Treasurer
e Treasurer H. E. Rockefeller, Committee of the Pressure Vessel Rockefeller and President-elect
Special Course Chairman C. W. Research Committee of the Welding Chouinard spent considerable time
Witherell and your Secretary were Research Council held meetings at National Headquarters late in
speakers at the dinner held on May on May 17th and 18th at WRC May directing the preparation of
15th in the Sheraton-Atlantic Hotel Headquarters in New York. I. E. our 1961-62 budget, recruiting com-
in New York for attendees at the Boberg is chairman, L. F Kooistra mittee members and considering
five-day course devoted to ‘““Welding is vice chairman and C. F Larson future plans and projects. Our
Piping for Industrial Piping Sys- Jr., is executive secretary of the 1961-62 Executive and Finance
tems” and sponsored by the AWS PVRC, K Koopman being the Committee and Board of Directors
School of Welding Technology under director of the WRC Your Secre- held their first meetings on June
the direction of A. L. Phillips. tary is a member of the Executive 5th and 6th
Opening day technical speakers Committee and past chairman of the @ Vice-president C. E Jackson
were Gene Smith of the American PVRC met with the New Orleans Pasca-
lron and Steel Institute and AWS e@ Asst. Sec. Frank Mooney, to- goula and Baton Rouge Sections
Director Art Kugler. These ex- gether with H. E. Cable, met with on May 16th, 17th and 18th
perts were followed by C. E. With members of the Johnstown Div @ President R. D. Thomas, Jr.,
erell, H. Thielsch and other leaders of the Pittsburgh Section on May and his family left for an extended
from industry. 17th and 18th to consider the es- stay in Europe on May 29th

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sent promptly upon request Also available is a
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WELDING JOURNAL 755

 EDUCATIONAL ACTIVITIES

Industrial Piping Course been found most desirable because if encountered by the students.
the basic facts and terminology are The following instructors assisted
The first course on Welded Piping not clearly understood—the re- at the Piping course: Eugene Smith,
for Industrial Piping Systems, given mainder of the course is wasted American Iron & Steel Institute;
by the AWS School of Welding During the morning the ferrous Arthur N. Kugler, Air Reduction
Technology, was held in May in metals were covered. The various Sales Co.; Charles E. Witherell,
New York. It was a complete suc- methods of making steel were de- International Nickel Co.; Helmut
cess and once again emphasizes the scribed and the different types of Thielsch, Grinnel Co.; K. M. Spicer
need for courses on welding. steels produced by the _ various and C. W. Case, Huntington Alloy
There is virtually no school, col- methods were covered. The rea- Products Div., International Nickel
lege or institute in the U. S. where ons why certain types of steel were Co.; and Nino Pompilio and Robert
such specialized information can be better for some operations than for Snow, Electric Boat Div., General
obtained. Educational — establish- others were discussed and _ the Dynamics Corp.
ments are organized to teach a sources of available literature were
curriculum which has been de- given.
veloped over a period of years. Course Outline
In a crash program, where an
This curriculum is, of necessity, entire subject has to be covered in a Monday, Fundamentals and Gen-
basic knowledge upon which the few days, it is generally impossible eral Principles
student can build as his career op- to retain even one quarter of the Tuesday, Materials, Processes and
portunities open. information given. For this reason Nonferrous Metals
The speed of technological de- students were encouraged to take Wednesday, Ferrous Metals
velopment today, however, has re- notes. They were given the names Steels, Stainless Steels, and
vealed a need for instruction in of reference books, articles, man- Coated Piping
specialized fields-crash programs, uals and manufacturers’ literature, Thursday, Materials, Design,
to acquaint engineers and others where related information may be Nickel and Nickel Alloys
with the latest developments and obtained. These’ references, to- Friday, Inspection, Codes, Pro-
techniques in a given field. A point gether with notes, are exceedingly cedure and Welder Qualifica-
has been reached in our economic valuable when the student returns tion.
development where a knowledge of from the course.
the latest techniques, processes, During the first afternoon of the
equipment and materials is needed Results
course, safety was covered and a
for survival in this competitive age. complete run down of the AWS The results of this course, as with
The AWS School of Welding Chart of Welding Processes was the others presented, have been very
Technology is trying to fill this given. Their terminology and the gratifying. In a single class, as
need for specialized information type of joints used in pipe welding many as 35 different types of engi-
with courses which are slanted to was discussed, completing the first neers have registered. Demon-
the needs of the average engineer. day. strating that the very people who
A practical approach is combined need it most are obtaining the in-
with sufficient theory to show why a struction. Many of them return
AWS Dinner
material, process or technique is with an entirely new concept of
used. The student is given the A dinner was held the first even- welding and this is a very healthy
facts and shown how to analyze the ing and students were guests of the situation for the welding industry.
problem so that he can prevent AMERICAN WELDING SOCIETY. Stu- Another plus feature—and possi-
failures by using the proper pro- dents mingled over cocktails and bly the most far-reaching of all——is
cedures. He can also predict posi- were able to get to know each other the additional course material we
tive duplication of results because and their instructors An _ infor- can make available to our Sections.
he knows the metallurgical con- mal, friendly atmosphere was es- Each course given by the AWS
siderations and the other welding tablished which continued through- School of Welding Technology pro-
parameters. out the course. vides us with a complete course out-
line and a textbook. With the aid
Fundamentals Instructors of these, and an instructor who un-
All students enrolling in these It has become a practice to obtain derstands the subject, any Section
AWS courses are on the graduate instructors from industry in order can present a similar course. With
engineer level or are foremen, in- that first hand actual experience the aid of the outline the instructor
spectors and engineers who have can be drawn upon. These men can teach the course with the mini-
learned in the hard school of experi- are fully aware of the latest de- mum of preparation.
ence. As long as a man has the velopments in their field and know Course Presently Available, Gas
background necessary to understand the problems—and many of the Shielded-Arc Welding
the course, he will benefit tre- solutions. Such instructors’ can Courses in Preparation, Welding
mendously. draw upon their own experiences to Metallurgy, Inspection & Test-
The first day of each course is illustrate a point and have, in many ing, Welded Piping for Indus-
confined to fundamentals This has cases, solved many of the problems trial Piping Systems

756 | JULY 1961

 SECTION NEWS AND EVENTS

As reported to Catherine M. O'Leary

CRYOGENICS Tech-Ser, Inc., Los Angeles.

In his talk on “‘Resistance Weld-
ing of Minute Articles,’”’” Mr. Woods
CRYOGENICS explained the theory of capacitor
discharge d-c resistance welding,
Los Angeles—-Members of the
how weld schedules and machine
Los Angeles Section gathered at the
settings are determined, quality
Roger Young Auditorium on April
problems and their cure, and benefits
20th to hear, question and enjoy a
of this type of welding.
program presented by Frank E.
In the electronic field resistance
Maddocks of Arthur D. Little, Inc.,
welding has made possible extreme
Santa Monica, whose subject was
miniaturization of packaging. For
**An Introduction to Cryogenics’’-—a
instance, one unit was reduced from
subject on which he is well versed.
450 to slightly more than 100 cu in.
Mr. Maddocks covered the uses of
Thermal shock to components is
the various liquid gases, their
practically nil, and reliability is ex-
dangers and causes as well as pre-
tremely good.
cautionary measures required in
Guest speaker, F. Maddocks, makes Mr. Woods had many samples to
their use. ‘Two pictures were shown
mercury hammer with help of liquid ni demonstrate that this concept of
of the prolonged testing programs to
trogen at Los Angeles Section April 20 welding is not limited to the field of
determine the combustionable quali- meeting electronics. It has, in fact, opened
ties of the pure gases and those
the door to the micromanufacturing
mixed with hydrocarbons. During
of mechanical devices which pre-
his presentation, demonstrations
viously could not even be con-
were given with liquid nitrogen
spring and was capable of bouncing a sidered. Also, almost any combina-
showing the effects of low tempera-
fairly good sized claw hammer held tion of metals may be successfully
tures on materials. Mercury, a
joined with this method
liquid at room temperature, was in suspension
hard enough at 320° F to drive HONEYCOMB BRAZING
nail into wood. Rubber becomes WELDING MINUTE ARTICLES
like a metal and could penetrate Fullerton—The regular monthly San Diego A. J. Schlosser, fore-
wood when cooled to liquid nitrogen dinner meeting of the Orange County man of high temperature structure
temperature. A _ piece of solder Section was held at Hughes Recrea- brazing at Rohr Aircraft Co., Chula
developed sufficient tensile strength tion Club on April 25th. Speaker Vista, Calif., presented a very en-
and elasticity to make an effective for the evening was John Woods of lightening critique on honeycomb
structures from the _ production
man’s point of view, at the May 17th
meeting of the San Diego Section.
STUDENTS AND A SCHOLARSHIP He pointed out that the potential
and growth of honeycomb was
seriously being held up for general
lack of industry type standards of
acceptability that in essence left
honeycomb in the position of being
produced on a_ laboratory scale
rather than reasonable production.
It was felt that, because of this fact,
the additional cost of the product
has limited the applications of this
fine product.

BRAZED JOINT PROPERTIES

Sunnyvale—A. T. Cape, metal-
lurgical consultant and vice presi-
dent of Powder Melting Corp.,
Monterey, Calif., was the speaker at
the April 25th meeting of the
Santa Clara Valley Section Education Chairman R. H. Rhoades introduces visiting Santa Clara Valley Section.
students and their instructor from the Welding Department of California State Polytech During Mr. Cape’s presentation
nic College at the April 25th meeting. Left to right are: R. M. Laird, T. M.Andrews, Prof. on “Physical Properties of Brazed
R. C. Wiley, K. Hannah, A. L. Finney and Chairman Rhoades. Mr. Finney was awarded Joints,” he discussed the work of his
a Section $100 welding scholarship organization on the physical proper-

WELDING JOURNAL | 757

ties of brazed joints. One of the P. Saxe, consulting engineering from gradient systems. The uses, ad-
methods used during their study of Baltimore, addressed the Wash- vantages and disadvantages, ranges
the subject was to employ photo- ington Section meeting on the sub- and limitations of each system were
elastic stress technique, with the ject “‘Welded Structures.” In his explained. An _ interesting ques-
plastic applied directly to the part talk Mr. Saxe compared riveted and tion-and-answer period followed the
or test specimen under study. welded design of buildings. The talk.
The results of photoelastic stress different factors including codes, The standing ovation which Dr.
investigations of simple lap joint general design, simplicity, economy, McMaster received at the conclusion
specimens, butt joint test pieces, safety, practicability, and speed of of his presentation was evidence of
and the distribution and magnitude fabrication and erection were ex- the membership’s appreciation for
of stresses were included in the dis- plained. Numerous - slides were this outstanding talk.
cussion as was also the effect of the used to illustrate this talk. A
physical and chemical properties of lively question period followed and
the brazing alloys, themselves, on showed that a large number of civil
the distribution of stresses. Mr. and structural engineers were in
Cape offered a set of rules for select- attendance.
ing brazing alloys to meet a variety The dinner was held at the Hotel MICROWIRE WELDING
of conditions under various situa Ebbitt, and the meeting was at the Hialeah On April 19th the
tions including brazing for elevated Washington Gas Light Co. Audi- South Florida Section held its eighth
temperatures. Of interest to the torium. dinner meeting of the year. The
audience was a “TLV” torch he hac
NONDESTRUCTIVE TESTING meeting was held at the Park Lane
brought with him. This is : i gas-
Cafeteria in Hialeah.
brazing torch which is used to Washington —This season’s final Guest speaker for the evening was
introduce powdered brazing ma- technical session of the Wash-
Preston Scott, field engineer with
terial into the joint during the actual ington Section took place on Thurs-
the Hobart Brothers Co. of Troy,
brazing operation day, April 20th, at the Washington Ohio.
Gas Light Co. Auditorium. Guest
His lecture and slide presenta-
speaker was Dr. Robert C. Mc-
tion on ‘“‘Microwire Gas-shielded
District of Columbia Master, professor of welding engi-
Welding Process’ was very well
neering at Ohio State University.
received.
He spoke on nondestructive testing:
WELDED STRUCTURES
radiography, television fluoroscopy,
Washington —On Thursday magnetic particle, penetrant, ultra- NATIONAL DEFENSE
night, March 16th, Van Rensselaer sonic, eddy current, and thermal Hialeah On May 17th the
South Florida Section was host to 34
members and guests attending the
last regular dinner meeting of the
for best results in hard facing, use season at the Park Lane Cafeteria in
Hialeah.
The program for the evening was
CLECOLOY presented by the Southern Bell
Telephone Co., headquartered in
tubular tungsten carbide Hialeah. A colored motion picture
narrated by Raymond Massey of
Close Laboratory Control insures High Quality
motion picture fame, entitled “Our
Clean CLEC-ITE particles (granular Defense System,’ opened the even-
cast tungsten carbide) of controlled ing’s program. At the close of the
mesh sizes are used in CLECOLOY. film, a direct person-to-person tele-
Daily laboratory tests conducted by phone call was put in to Norad
experienced technicians check the headquarters at Colorado Springs,
CLEC-ITE for micro-structure, grain Colo. This call was amplified so
size, carbon contents and non-metallic that all present could hear firsthand
inclusions. Welding characteristics are just what the functions of Norad
checked daily. consist of. In closing the call, the
Prior to rolling the tubes, the flux Southern Bell Telephone technician
is thoroughly mixed with CLEC-ITE told the audience to ask any ques-
for uniform distribution of tungsten tion pertaining to our defense sys-
carbide. Accurate records are kept on tem that would be of interest to all.
each batch of fluxed material. Flux is Norad officials promptly answered
prepared specifically for oxy-acetylene all questions put to them.
or atomic hydrogen methods of This program was undoubtedly
application. the most interesting program pre-
For hard-surfacing applications sented by the section during the
specify CLECOLOY tubular tungsten entire year.
carbide.
For free literature and complete information,
contoc? ...
OF CLECO AUR TOOLS
A DIVISION OF REED ROLLER BIT COMPANY
WELDING T-1 STEEL
P. 0. Box 2541 © Houston, Texas
PRODUCTS ORchard 2-1761 Chicago—Perry C. Arnold, chief
For details, circle No. 11 on Reader information Card welding engineer of Chicago Bridge

758 | JULY 1961

CHICAGO GUEST operation, theory and manufacture
= of transistors and semiconductors
and their application. The mem-
bers then adjourned to the cafeteria McKAY Hardalloy
for a delicious dinner, which was
followed by the plant tour.
The production operations, com- 61Electrodes@>
ponents and assembly of various
types of automobile radios were ob- ; /
served from the strip stock forming
in the chassis to the completed
radio. Many specialized and auto-
mated resistance welding applica-
tions were observed as well as other
processes such as die casting and
plastic forming operations. This
meeting proved to be one of the
P. C. Arnold as he spoke to the Chicago highlights of the year for the
Section on April 13th Indiana Section

LADIES’ NIGHT
& Iron Co., was the guest speaker
at the April 13th dinner meeting of South Bend— The Michiana
the Chicago Section held at Vogel’s Section enjoyed a quite different
Restaurant in Whiting, Ind. type of speaker for their annual
Mr. Arnold _ discussed various Ladies’ Night program held on
problems encountered in the welding April 20th at Russ Restaurant.
of T-1 steels. He also reviewed The guest speaker was Nancy
their high-strength, chemical and Stouffer, the first woman to be
physical properties employed as a full time and regular
A very interesting discussion reporter by the South Bend Tribune.
period followed. Approximately Assigned to the Niles, Mich., office
180 members and guests were pres- of the paper, she covers all types of
ent. news stories developing in_ the
southern portion of those Michigan
WELDING DESIGN counties immediately adjoining
northwestern Indiana
Kankakee—The May meeting Miss Stouffer first gave a general
of the J. A. K. Section was held at description of what it takes to be a ... give steelmaker’s
Mantoan’s Restaurant, Kankakee reporter, such as a willingness to be
on May 18th. The new officers for on 24 hr call, to eat and sleep accord- billet mill guides 900%
the coming year were introduced ing to the whims of news stories, to
and details announced for’ the witness all sorts of situations such as longer service life
‘‘Gold Stag”’ to be held in August numerous queen contests to grisly
The Section was fortunate to have wrecks, society events to the machi- One montt good rvice life for new,
for its last technical meeting of the inprotected £ ¢ { cted to the
nations of politicians—all cover- ‘ gh tem
season LaMotte Grover, a former ing the whole spectrum of human said
Adams Lecturer. emotions. Afterwards, she showed ind Bil
Mr. Grover, a welding engineer for some of the pictures she has taken Com
Air Reduction Co. in New York, Guides
while covering her ‘beat’ the 61 weld
talked on ‘Properties of Welded pathos of a family whose son had
Joints and Details of Design.” to twelve
been imprisoned in another country
In his talk, he stressed the tech- and the jubilation when he re- McKay
nical and practical considerations turned, the desolation of the ruins nly hard
that should be evaluated in the 1 Mr. Gets
of a country home fire, the gory wear re
design of a _ welded fabrication. mess of an automobile wreck, a onger life
Properties and weldability of some prize winning sheep at the county w unpro
newer steels were also discussed. fair—all in a day’s work for a news- time and
ed sub
paper reporter. guides

WRITE FOR M
Hard > fa
PLANT TOUR mendat
METALLURGY
Kokomo— Seventy-one members
and guests of the /ndiana Section Wichita— The Wichita Section
participated in a plant tour of the held its May meeting at the Uni-
Delco Radio Div., General Motors versity of Wichita, Student Activi- ie THE
Corp., at Kokomo on April 28th. ties Center Building on May 8th.
The members assembled in the Following an excellent dinner served
auditorium where they were wel- by the student chefs, the group
comed by C. D. Moore of Delco. heard a talk on “‘Basic Concepts of COMPANY
A film was shown describing the Metallurgy”’ given by Thomas H. 401-A McKay Bidg. «© PITTSBURGHE22, PA.
For details, circle No. 12 on Reader information Card
WELDING JOURNAL | 759
 UNDER THE NORTH POLE... ject, is an excellent speaker and hit
informative talks have been of greas
AMERICAN Pog assistance to members of the Baton
Rouge Section.

ELECTION OF OFFICERS
Baton Rouge—The Baton Rouge
Section announces the election of the
following officers: Chairman, Har-
mon Cuttler; 1st Vice-chairman,
Craig Kennedy; 2nd _ Vice-chair-
man, Robert Daniel; Secretary,
Seth Kidman; ‘Treasurer, Louis
Mire. Harold Brou, Harold Mc-
Murtry, A. R. Patterson, and Her-
man Watson were selected for the
Executive Committee.
Guest speaker, N. Pompilio (left), is shown with Worcester Section
officers at the April 10th meeting. Mr. Pompilio described the voyage iteltitelealtht
tit
of the Nautilus under the North Pole with the aid of movies
IRON POWDER ELECTRODES
Nicholl, district sales manager, Lin- Ken Spicer of the International
coin Electric Co., Kansas City, Mo. Nickel Co., was featured at the Springfield—-The Western Mas-
Mr. Nicholl ably presented, in the April 27th meeting of the Baton sachusetts Section held its annual
common operator’s language, the Rouge Section held at the Sherwood meeting at the Oaks Inn on Tuesday
iron carbon diagram and its relation Forest Country Club. evening, May 9th. Thirty-two
to the welding processes. His discussion included slides members and guests listened to a
depicting nickel and nickel alloy very instructive talk on “Iron
welding situations and recommen- Powder Electrodes—Pro and Con’”’
Rel tielate by Wayne L. Wilcox of the Arcos
dations for joint design, welding
procedures and techniques. Mr. Co.
NICKEL ALLOYS The following officers were elected
Spicer, one of the foremost authori-
Baton Rouge A repeat speaker, ties in the United States on this sub- for 1961-62: Chairman, Leon W.
Jaeger, Jr. Vice-chairman and
Program Chairman, Thomas Ske-
han; Secretary, Harley B. Good-
rich; Treasurer, Leon W. Jaeger,
Sr.; Technical Advisor, Victor Bis-
sonnette; and Membership Com-
mittee Chairman, Raymond G.
Trombley.
Past General Chairman’s pins
were presented to Sidney Low,
Victor Bissonnette, Leon W. Jaeger,
Sr., and Raymond G. Trombley.
Student guests were present from
, AM you
the Springfield Trade High School
\ want — and from the Chicopee Vocational
when you High School.
want it.
/n the SUBMARINES
The
’ Wationay’ Corbidle's
Ce RED Worcester—The scheduled
|f calcium carbide- DRUM. speaker, Nino Pompilio of the
Electric Boat Div., General Dy-
"'Gpoten’... 7t'S Wire for namics Corp., was unable to present
hot-‘criished:/ supplier... his talk on ‘“‘Consumable Inert
Welding Developed for Submarine
Welding” at the April 10th meeting
of the Worcester Section due to its
confidential nature. However, he
did an excellent job with the two
motion pictures on nuclear sub-
marines traveling around the world.
Calcium Carbide

National Carbide is ao product of

TIME AND MOTION STUDIES
AIR REDUCTION CHEMICAL & CARBIDE CO.
A DIVISION OF AIR REDUCTION COMPANY, INCORPORATED © 150 EAST 42nd STREET, NEW YORK 17, NEW YORK © MURRAY HILL 26709 Grand Rapids—The Western
For details, circle No. 13 on Reader Information Card Michigan Section held its regular

760 | JULY 1961

 monthly meeting on Arpil 24th at welding is used in the fabrication of
Duck’s Restaurant. There were 39 their products. McKAY D. C. Titania
present for the dinner and technical
session. EXOTIC METALS
The technical session was STAINLESS STEEL
St. Louis—Jay Bland, manager,
addressed by Martin J. Geerlings, Welding Development at Knoll’s
chief industrial engineer for the Atomic Power Laboratory, General
American Seating Co. Mr. Geerl- ELECTRODES
Electric Co., Schenectady, N. Y.,
ing talked on ‘“‘Motion and Time was guest speaker at the May 11th
Study.” His talk was excellent and meeting of the St. Louis Section,
included several well prepared slides held at Ruggeri’s Restaurant, where
to illustrate how time and motion are 68 members and guests were present.
figured in preparing wages on the var- Mr. Bland’s topic, ‘Welding or
ious jobs in manufacturing plants. Joining of Exotic Metals,’ was
He gave several illustrations for the especially timely and _ interesting.
group to figure and many questions The talk was a review of the proper-
were asked pertaining to figuring ties of the exotic metals and their
time and motion. influence on the welding processes
This was one of the most interest- and procedures used to join these
ing meetings of the year. metals.
A short movie, showing the space
ELECTION OF OFFICERS capsule being manufactured, was
presented by McDonnell Aircraft
Grand Rapids—-The following Corp. after the talk. George Bowl-
officers and Executive Committee ing, welding engineer for McDonnell
of the Western Michigan Section was present and granted an informal
were elected at the April 24th interview to members and guests
meeting: Chairman, Ken Richards; who wished to ask questions con-
Ist Vice-chairman, Merrill Block; cerning the processes and procedures
2nd Vice-chairman, Frank Slack; used in its fabrication.
Secretary, Gordon Hill; and Treas-
urer, Art Hedges. ELECTION OF OFFICERS
Ed Stapleton, Mike Ignatoski,
John Pifer, Arnold Lankenau and St. Louis—-The annual election
Ed Leazenby were picked for the of officers of the St. Louis Section
Executive Committee. was held during April, and the
results were announced as follows:
Chairman, Carl Burrow; Ist Vice- ... ficiently weld
chairman, Russ Elfvin; 2nd Vice-
Missouri chairman, Art Houser: Secretary, critical pumping
Bob Morrison; and _ Treasurer,
Larry Winkeler. weldments
SUBMARINE VESSELS
McKay D.< Titania Stainless
St. Louis—E. H. Franks, chief trodes beca
because we ggetet fewer
welding engineer, Operations De- New Mexico weld deposit,” sai 1 Mr. Mike
Shop Supt., of V lean Manu
partment, Electric Boat Co., Div.
General Dynamics Corp., Groton, ROCKS tion of these primary and
Conn., was guest speaker at the ng units for a critical ap
April 13th meeting of the St. Louis Albuquerque—Installation of McKay Type 308
Section, held at MRuggeri’s Res- officers and ladies’ night of the Electrodes exclu
Albuquerque Section was held on to pass dye pene
taurant, with 99 members and guests welds also are :
present. Mr. Franks’ topic was, May 11th at the Desert Inn.
Guest speaker was Dean Wise of ubjected to a
“The Fabrication of High Strength, tical that it shows
Low-Alloy (HY-80) Steels as Ap- Sandia Corp., Albuquerque, and his
subject was “Rocks in Your Lives.”’ McKay lectrodes have reduced our
plied to the Construction of Sub- Mr. Wise has held all the offices in production costs substantially, said Mr.
marine Vessels.”” The talk was Und Woo ) 1 Welds save time-con-
designed to be of special interest to the ‘““Gem and Mineral Club” and sumin smooth flat beads
welding engineers and steel fabri- has been its president several times. req' if to blend weldments
cators. He brought along his collection of with parent ft tal
rocks, some of which were “blue Got a welding problem? Look into
Mr. Franks’ wide experience with McKay's complete line of Welding Elec-
the Naval Shipyards and with ribbon winners.”” Along with these
trodes and Automatic Welding Wires.
Electric Boat, working on welding he showed a 16 mm film on ‘“‘Earth- WRITE FOR new catalog on the
procedures for various materials quakes and Volcanos,”’ which was Welding of Stainless Steels
very interesting. Provides data on chemical
used in the hull structure of ships, analysis mechanical proper
made him well-qualified for his sub- ties, corros resistance and
NEW OFFICERS types of electrodes available
ject. Slides were shown to illus- for welding stainiess steels
trate the welding procedures and Albuquerque—The following
processes used. officers have been elected by the
In observance of April as ““Welded Albuquerque Section for the year
Products Month,” twenty-six local 1961-62: Chairman, Orrin Leach;
steel fabricators presented exhibits Ist Vice-chairman, Lowry Stewart; COMPANY
at the meeting to illustrate how 2nd_ Vice-chairman, Wilbert W. 401-B McKey Bids. © PITTSBURGH 22, PA.
For details, circle Ne. 14 om Reader Information Card
WELDING JOURNAL | 761
ST. LOUIS MEETING WELDED PRODUCTS EXHIBITS

ST LOUIS METALLIZIN
“
mon Mag

A partial view of the many St. Louis Section members who Another highlight of the St. Louis Section April 13th
gathered for dinner on April 13th and heard E. H. Franks speak meeting consisted of 26 local steel fabricator welded products
on the use of HY-80 steels in submarine construction exhibits in commemoration of National Welded Products Month

Wood; Secretary, E. C. Jones; and Development Div., Interna PLANT TOUR

Treasurer, Waiter S. Webb; and tional Nickel Co., explained the
Technical Secretary, Arthur P. principal parts of a reactor and how Olean The Olean-Bradford Sec-
Bailey. materials were selected on the basis tion met on April 18th at the Castle
of melting point, corrosion resist- Restaurant in Olean. The group
ance and neutron cross section. was addressed by Ear! Geiss, general
He said that, for the pressure superintendent of the Turbo Prod-
vessel and piping, Inconel X is ucts Division of Clark Bros., Co.
largely replacing stainless steel due He gave a brief summary of the
HIGH-SPEED WELDING work done at this company’s plant,
to troubles with stress corrosion
Bellmore Wallace C. Rudd, cracking and weld cracking of the with emphasis on the growth of the
vice-president in charge of engi- latter. Welding Department.
neering of the New Rochelle Ther- There is still too little data on the After dinner the members went on
matool Corp., was the guest speaker effect of radioactive exposure on a conducted tour through the Turbo
at the May 11th dinner meeting of properties of metals. Generally it Products plant of Clark Bros., where
the Long Island Section held at the raises the yield strength but im- they saw modern welding equipment
Sunrise Village Restaurant in Bell- pairs the ductility and transition used in the fabrication of this
more, L. I. temperature. A high service tem- company’s products.
Mr. Rudd’s talk covered the use perature tends to anneal out these
of 450,000 cycle current for the high effects.
speed welding of pipe, tube, spiral
tube, containers, spiral and longi- PANEL CONTEST
tudinal fins on tube, and structural Niagara Falls A lively ‘‘Battle NONFERROUS WELDING
shapes. of the Sections” was held on April
Cleveland— Over 125 members of
27th by the Niagara Frontier Sec- the Cleveland Section attended the
MATERIALS FOR tion at the LaSalle Yacht Club in regular monthly meeting held on
NUCLEAR REACTORS Niagara Falls. Guests of the Sec- March 8th to hear a panel discuss
Buffalo—At the March 23rd tion were the Rochester and Olean- the subject, “‘Non-Ferrous Weld-
meeting of the Niagara Frontier Bradford Sections. ing.” The meeting, chairmanned
Section, 55 members heard Marcel The plan of Program Chairman
A. Cordovi discuss ‘‘Materials for Sam Corica, in which questions were
Nuclear Reactors.’’ Mr. Cordovi, submitted by the audience prior to NUCLEAR MATERIAL
who is a supervisor in the Research the quiz, worked very well in en-
couraging participation by the
group of 85 members. The supply
of questions and of Moderator
ALBUQUERQUE OFFICERS Morrison’s stories (one per ques-
tion) outlasted the time available.
Of the Olean team only Harold
Thompson was able to come, so
three Niagara fill-ins were ap-
pointed: Ed Hebeler, Roger Stouffer
and Berl Dillman. The Rochester
participants were Mark Minkler,
Cince Cimino, Bob Haslip and Don
Masterson. The Niagara Frontier
team— Dick Raney, John Kaluzny,
Jerry Wright and Leo Rodgers
Recently elected Albuquerque Section was the winner with Rochester a
officers for 1961-62 are: Chairman, O
Leech; Ist Vice-chairman, L. Stewart; very close second. The Olean team, M. A. Cordovi was guest speaker at
2nd Vice-chairman, W. W. Wood; Secre handicapped by their missing ex- the Niagara Frontier Section March
tary, E. C. Jones; Treasurer, W. S. Webb; perts, came in an enthusiastic third. 23rd meeting and he discussed materials
and Technical Secretary, A. P. Bailey Ed. question: Who kept score? for nuclear reactors

762 | JULY 1961

 by Frank G. Flocke, followed a
dinner-business meeting at the
Cleveland Engineering and Scientific
Center. GOT A WELDING
Preliminary material presented by
the panel concerned aluminum,
stainless steel, and copper and PROBLEM ? as
brass, respectively. The panel con-
sisted of William M. Rogerson of
the Aluminum Co. of America,
William Kauffman of Williams &
Co. and L. H. Hawthorne of
Revere Copper and Brass, Inc.
Each panel member’s background
was particularly suited to his sub-
ject matter. After the formal pres- Technical Chairman F. G Flocke (stand
entation, the meeting was opened ing) chats informally with anel members
to the membership for an informal at the March meeting. Seated left to
question-and-answer session. Many right are W. Kauffman, W Rogerson
interesting questions were posed and L.H Hawthorne
covering all types of nonferrous
metals. previously made by the speaker
The enthusiastic attendance and Don Hinton of Hinton’s Sport
participation in the discussion dem- Shop in Marion.
onstrates a strong local interest in The slides and narration began
this subject matter. with a flight from Ohio via com-
mercial airlines to the final trans-
PROCESS SELECTION ferring to small aircraft in Alaska.
Dayton—-The seventh meeting Mr. Hinton was accompanied by
of the 1960-61 season of the Dayton an employee, Al Roach.
Section was held on April 11th at The slides were then followed by
Kuntz’s Cafe. There were twenty a 16 mm film taken by the speaker
members present to enjoy the social and Mr. Roach. All films were in
hour and a dinner of barbecued color
spare ribs.
Thomas J. Moore, the guest Pennsylvania
speaker representing the Arcos
Corp., gave an hour talk on “‘Se-
STEEL CASTING WELDMENTS on the following pages
lection of Best Arc Welding Method
for Welding Stainless Steel.’’ The Philadelphia—‘‘Design of Weld-
talk covered primarily the metal- ments Incorporated Steel Castings’”’
lurgical aspects of stainless steels was presented as the subject of the
and the methods used in obtaining March 29th technical meeting of the
READ...

good sound welds. The effects of Philadelphia Section held at the

the various elements such as carbon, Engineers Club. Samuel W. Gear-
sulfur, and phosphorus on the grain hart, chief metallurgist of the Birds-
structure and subsequent classifica- boro Corp. was the speaker ultr mh Stec | Com-
tion of the weld with respect to its Mr. Gearhart discussed modern
mechanical properties were covered. nded th service
design practices which utilize the
He also discussed filler materials, best features of castings and weld- f Blooming Mill Guides
their preparation and metallurgical ments incorporated in many fabri- DY ul Sing N IcKay
properties that should be used with cations resulting in economical high Electr odes.
the various stainless steels to pre- quality products.
vent conditions such as intergran- The discussion clearly emphasized
ular corrosion and hot cracking. the part castings can and should How N IcKay D.< Titania
play in the field of fabricated weld- Steel Elec trodes
HUNTING IN ALASKA ments. hel px Vulcan Manufactur-
Bucyrus-—A nontechnical meet- Slides were presented showing
examples of the use of welding in ing ¢ ompany in the f abrica-
ing of the North Central Ohio Section
making more economical castings. ion of primar y and second-
was held on Thursday, April 6th
at the American Legion Home in ary pun ping units for a crit-
PANEL MEETING IC al application
Bucyrus.
This was a highly entertaining Philadelphia—A wide variety of
program of hunting in Alaska for experience in stainless, aluminum
brown and black bear. Actually and copper base alloy welding was
the hunting was done with bow and represented at Chairman Bill
arrow as well as with gun. The Brooks’ final panel meeting in
presentation was very unique. The Philadelphia on Friday, April 7th.
first portion of the program con- Matt Waite, Arcos Corp., Tony
sisted of color slides accompanied Calzalaio, Pottstown Metal Prod- COMPANY
by a tape recorded commentary ucts Corp., and Sam Reynolds, 401 McKay Bids. « PITTSBURGH 22, PA.
For details, circle No 15 on Reader information Card
WELDING JOU RNAL 763
 FROM THE HIGHLY TECHNICAL TO THREE “BULL” ARTISTS

Panelists listen intently to a question from the floor Three members of the Philadelphia Section proudly display
at the Philadelphia Section Apri! 7th meeting. Left to Bull Throwers trophy which was presented to them at the April
right are: S. Reynolds, A. Calzalaio and M. J. Waite 24th meeting. Left to right are: S. Reynolds, W. Scattergood
and A. Young

Westinghouse Electric Corp., made meeting of the season held on April and motion—of these arcs. It was
up a very interesting panel creating 24th. His subject was “Natural shown that use of thorium in tung-
a lively interest in their respective Fuels for Welding and Cutting.” sten electrodes for inert-gas tung-
fields. Mr. Anthes discussed proper sten-arc welding had the effect
“Stainless and Nonferrous Weld- ratios of preheat oxygen to volume of increasing the emissivity of the
ing’’ was covered from the labora- of natural gas and propane gas for electrode. In the inert-gas-shielded
tory stage through the shop fabri- peak efficiency. Slides were used metal-arc, the addition of a very
cating problems. to give a more descriptive picture. light coating of a cesium-bearing
Preceding Mr. Anthes’ discussion, material had the effect of increasing
NATURAL GAS AND PROPANE Section Chairman Walter Wooding the emissivity of the electrode. As
Philadelphia Clifford Anthes announced the following newly- a result, the transition point from a
of the Development Laboratory, elected officers for the 1961-62 sea- droplet melt-off of the electrode to a
Linde Co., Newark, N. J., spoke son: Chairman, Frank Hussey; Ist spray type melt-off occurred at a
at the Philadelphia Section’s final Vice-chairman, Dave Buerkel; 2nd lower amperage. This resulted in
Vice-chairman, Albert Young; Sec- the increased stability of the arc
retary, William Brooks; and and decreased weld spatter.
Treasurer, K. William Ostrom. Mr. Rothschild maintains, that,
Chairman Wooding then pre- with the better understanding of
sented Messrs. Sam Reynolds, Wil- arcs through study, better controls
liam Scattergood, Al Young and of welding variables will enable us
INSIST ON Walter Shire with the Bull Throwers to tailor the arc to the needs of our
trophy. profession.
On April 21st the above-men-
tioned gentlemen journeyed to Bal-
timore to accept the Baltimore ELECTROSLAG WELDING
HI-AMP
Section’s challenge to a “Battle of Shickshinny—The regular
the Sections” wherein members and monthly dinner meeting of the
MANUAL ARC WELDING guests ask questions concerning weld- Susquehanna Valley Section was
ing problems and the respective held on May 3rd at the Foot Hills
teams attempt to answer the ques- Manor. Speaker at the meeting
tions or frustrate the audience to the was Walter H. Wooding of the
ELECTRODE HOLDERS point where they are sorry they asked Arcos Corp. in Philadelphia.
the question in the first place. Mr. Wooding discussed the elec-
The Philadelphia team did not troslag welding process which can be
GROUND ATTACHMENTS make it clear just how they won described as a process specifically
but they did. designed for welding in the vertical
Ed. question: Any comment, position moving from the bottom
Baltimore? of the joint toward the top. The
welding is accomplished in one pass
and is similar to, although not the
Buy from your local GAS-SHIELDED ARC
same as, the conventional sub-
Shickshinny—The Susquehanna merged-arc welding process. A
WELDING SUPPLY HOUSE Valley Section met on April 5th bare wire with flux addition or a
at the Foot Hills Manor. ‘Arc flux-cored wire can be used—with
Characteristics of Mig and Tig” the latter favored in the Western
was the subject of a talk by Gilbert World due to the greater capabilites
LENCO, INC. R. Rothschild of the Air Reduction toward better grain refinement of
Sales Co., Murray Hill, N. J. the weld metal. Retention of the
Mr. Rothschild discussed the weld metal in the root gap
350 W. ADAMS ST., JACKSON, MO. important characteristics of tung- approximately 1 in between plates
sten and consumable-inert metal is accomplished by the use of
For details, circle No. 16 on Reader information Card arcs and showed films—both still movable articulated water-cooled

764 | JULY 1961

 copper shoes incorporating probes ventional submerged-arc process. Orange, Tex. The tour took ap-
for proper determination of molten Many electroslag installations can proximately 2' » hr.
flux and molten weld metal heights. be found in Western Europe using
The molten flux cover has two the flux-cored filler wire to ad- ARC WELDING EQUIPMENT
purposes—namely, to protect the vantage. The applications are pri-
marily for joining large plates and Beaumont—The April 20th
molten weld metal from the at-
longitudinal seams in heavy cyl- meeting of the Sabine Section was
mosphere and to melt-off the filler
inders. held at the Flying Chief Restaurant.
wire as the arc is snuffed out shortly
Application of this process and Emil F. Steinert of the Westing-
after the weld is initiated.
the electrogas process—-using CO house Corp. was the main speaker.
A single filler wire of '/; in. diam
capable of depositing 35-45 Ib as shield instead of flux—are not at He gave a history of are welding
all widespread in this country. The and the development of welding
of weld metal per hour is suggested
machines. This covered’ the
for thicknesses up to 4'/, in. Two primary objection seems to be based
on previous undesirable experience development of both smaller and
wires are used for the range of
with one pass submarged-arc weld- larger machines.
4'/, to 10 in. and three wires for
thicknesses exceeding 10 in. The ing on heavy sections. By the use
process is economically sound for of the flux-cored wire with certain STEAM BOILERS
thicknesses over 2 in. and becomes additives, better grain refinement San Antonio—Two — speakers
increasingly competitive as_ the can be obtained which may be ex- were scheduled for the May Ist
thickness increases for the reason tremely helpful in winning confi- meeting of the San Antonio Section
that the root gap remains constant dence in the process. It is impera- held at Cap’t. Jims
at 1 in. max. Therefore, the cross- tive that those who are directly A. J. Bell, San Antonio Public
sectional area of a weld in 10-in. concerned with welding heavy sec- Service Board, presented a program
plate would be 10 sq in. vs. the tions familiarize themselves with the on the testing of welds on high pres-
conventional area of a submerged- capabilities of electroslag welding. sure steam boilers. One of the
arc weld of 20 to 30 sq in. Also, common testing procedures is the
the ratio of flux to filler wire is Texas use of Zyglo with the black light.
roughly 100 lb of filler wire to 5 lb of Mr. Bell demonstrated the use of
flux. In submerged-arc welding, Zyglo on a welded flange and some
the ratio is roughly 1:1. PLANT TOUR
sections of tubing. It was interest-
The Russians, who have de- Orange—A joint meeting of the ing to note how effective Zyglo is in
veloped control mechanisms for Houston and Sabine Sections was the finding of flaws, slag inclusions
this process, currently claim to held on March 16th. The meeting and cracks with a very small amount
have 200 of these units in use was in the nature of a plant tour of of the flourasine powder and a
using bare filler wire. They claim the American Bridge Div., United large volume of water.
remarkable savings over the con- States Steel Corp., located at The second portion of the pro-

ELEVEN FEET PER MINUTE PULLMAX X-8 BEVELER

AVAILABLE 30°, 374° and 45° BEVELS
FASTEST WAY TO BEVEL STEEL
PLATE FROM *%’ TO 2’ THICKNESS

LARGE PLATES OR SMALL SEGMENTS

Speeds up to 11 ft. per min. Large Cuts costs by 85%. Small pieces are
plates mounted on a table equipped usually very difficult and time con- No more slow grinding, burning or planing
with rollers, the Pullmax X-8 Beveler suming to bevel. Now, they are hand a bevel on steel plate before welding. Now
feeds the material automatically as it held and quickly run through the the Pullmax X-8 Beveler does the work faster
bevels the edge. Pullmax X-8 Beveler. and easier than any other method.
Write for literature—Have a FREE demonstration in your plant

For details, circle No. 17 on Reader information Card

WELDING JOURNAL | 765
 MERITORIOUS AWARD
ATTENTION: Wisconsin
MANUFACTURERS & DISTRIBUTORS
OF ACETYLENE GAS! GAS APPARATUS SAFETY
uh Appleton— At a meeting of the
Fox Valley Section held on April
19th at the Appleton Elks Club,
F. F. McKenzie, owner of McKenzie
Welding Equipment Repair Service,
St. Paul, Minn., enlightened the 76
members present in a manner seldom
seen before on a subject that is very
important to all shops. Mr. Mc-
Kenzie discussed, with the aid of
When your truck pulls away from the cartoon type charts, the proper
loading dock your trucking costs methods of operating and maintain-
ing gas apparatus so as to be both National President, R. D. Thomas, Jr
per cubic foot of gas depend on safe and efficient. Some of his (right), presents Meritorious Award to
how much GAS is in the load — not points were “old hat,’ but these F. E. Garriott at the Milwaukee Section
how many cylinders. If the gas YOU points are violated every day in so April 28th meeting. Mr. Thomas also dis
many shops that they cannot be cussed stainless steel weld metal proper
sell is in COYNE CYLINDERS with repeated too often, such as keeping ties
the higher porosity filler, then you grease and oil away from oxygen.
are selling and delivering up to 30% His discussion included the proper
method of lighting a torch, setting
MORE GAS ON EVERY TRUCK, regulators and obtaining proper National President R. D. Thomas,
and decreasing trucking cost by 30%. cutting and welding flames in the Jr.—also president of the Arcos
safest manner with the greatest Corp., Philadelphia—-was the guest
Get the facts speaker. His subject was ‘Factors
efficiency. Members solicited Mr.
direct from COYNE McKenzie for visits to their plants Affecting the Properties of Stainless
cylinder company to present the same talk to other Weld Metal.” It was well delivered
A ON OF AMER AN RYO shop employees and also meet with and greatly appreciated because of
safety clubs in various cities. Many the vast extent to which stainless
224 RYAN WAY, SOUTH SAN FRANCISCO, CALIFORNIA steel is being used in this area.
155 WEST BODLEY AVENUE, MEMPHIS, TENNESSEE of the members stated that it was
the most practical discussion of the Mr. Thomas, as president of the
3800 SPRINGDALE AVENUE, GLENVIEW, ILLINOIS
subject that they had ever heard SOCIETY, gave a meritorious award
For details, circle No. 18 on Reader information Card and highly entertaining. to F. Emery Garriott, vice president
and manager of Finished Products
gram was conducted by E. E. at Ampco, Inc., for his outstanding
Wagner, Alamo Iron Works, in a EXECUTIVE NIGHT
devotion and efforts toward
discussion of distortion due to weld- Milwaukee—An “Executive advancement of both the national
ing. One point brought out was the Night”’ dinner meeting was held by and local Society activities.
common practice of excessive weld- the Milwaukee Section on April 28th The Section invited the presidents
ing due to over design at the Ambassador Hotel. and vice presidents of its patron
members for “Executive Night.”
There were many in attendance. It
CHANGE OF RESIDENCE ADDRESS OR COMPANY AFFILIATION not only gave them an opportunity
to hear Mr. Thomas but also gave
A ARIAT SR A A HE them an opportunity to show their
employees that they were interested
in the efforts they were putting into
LAST related activities.
MIDDLE
Section Chairman John Mc-
RESIDENCE ADDRESS Keighan gave a detailed report on
STREET what some of the members have
been doing to promote welded con-
ZONE struction of bridges in Wisconsin.
This included a paper on welded
COMPANY NAME construction of bridges by Yost T.
COMPANY ADDRESS Smith as presented at the Wisconsin
STREET Road Builders annual convention
held on March 13th through 16th.
CITY [It also included the report of a
meeting in Madison with the High-
Title of position heid way Commission attended by Mr.
Mail should be sent to my residence company (check one) McKeighan; E. Charles Fenske,
chairman of Madison-Beloit Sec-
| wish to be affiliated with the AWS Section tion; Fred Theiler, coordinator and
welding instructor of the Madison
NOTE: To assure that your copy of the Welding Journal is mailed to your new address, this change of Adult Educational School; and
address notice must be received at American Welding Society, 33 West 39th Street, New York 18,
N. Y., no later than the 25th of the month previous to issue mailing. John Teigen, chairman of Fox Valley
Section.

76 | JULY 1961
 Members EFFECTIVE MAY 1, 1961
MEMBERSHIP CLASSIFICATION

A—Sustaining Member Student Member

Member Honorary Member
Associate Member Life Member
TAL NATIONAL MEMBERSHIP
Sustaining Members
Members.
Associate Members
Students...
Honorary Members
Life Members
ALBUQUERQUE EASTERN ILLINOIS Total
Baudoin, Louis P. (B Crawford, Everett (B
Hollingsworth, Marion D. (C
BIRMINGHAM
Saur Gail E. (B FOX VALLEY
Smith Arthur C., Jr. (B Clark, Ronald L. (¢ NEBRASKA ST. LOUIS
Wright Billy E. (C Ehernberger, John E. (B Barker, Fred Allen (B
HARTFORD
BOSTON Rudeen, Walter D. (C Meyer John J B
Kordys, Edward P. (C West, Lewis J B
Hildebrand, Charles W Palmer, Clarke A. (B NEW JERSEY
Juliano, James A. (C Smith, Harold E. (B Schultz John B. (C SALT LAKE CITY
Massa, Bernard A. (C Ske r he k Michael A. (B sramblett, John Deen (D
Rober, Thomas K. (B HOUSTON Walt« rs David D. (C
St. Aubin, Edward J. (C Bullard, Robert L. (C SAN DIEGO
Cornelius, Frank H., Jr. (B NEW ORLEANS Blackwell, R. D. (B
BRIDGEPORT Freeman, Harold B. (C Kitchen, Robert L B Plummer, Glenn F B
Schneider, Frank Robert, Jr Jennings, Maurice F. (C
( Jones, Lorenz B B NEW YORK SHREVEPORT
Nelson, K. R. (C Colligan, Vincent P. (B Durham, Joy Joseph
CAROLINA Preston, W. B Dick, Emmanuel Joseph (B Smith, Edgar E. ((
Poterala, Joseph F B Spencer y Be Seaman, Matthew (C
W ilkes, Woodrow W B STARK CENTRAL
INDIANA NIAGARA FRONTIER
CHICAGO McKinstry, W. B. (B
Redman, James E. (B Connelly, Thomas J. (C
Kasper, Walter (C Ruehman, Bill (D SUSQUEHANNA VALLEY
Kiwiet, John (B NORTH CENTRAL OHIO Atkinson, William R. (B
Meydrech, Ray F. (B IOWA
Jones, Joseph H. (C
Walsh, Anthony Joseph (B Vuper, Edward B. (B SYRACUSE
Wishart, William T. (C NORTH TEXAS Sleight, C. B. (B
IOWA-ILLINOIS
CINCINNATI Bettinghaus, James R. (C Blacketer, Robert A B
Callins, Melvin (B TOLEDO
Ashcraft, Harold Harding (C Sulewski, Edward J. (B Kerr, H. Herbert (B
Brooks. Flovd + Bs Pee Ke
Residori, John (C NORTHEAST TENNESSEE TULSA
CLEVELAND
KANSAS CITY Tackett, Joseph William (C Butts, ¢ alvin ¢ B
Fisher, Ervin (C Hall, Thomas Hou ston _6-
Matthews, Sidney (B Jahr Robert E NORTHWEST
Richards, Glenn Gordon (B WASHINGTON, D. C.
Rusnah, William A. (C LONG BEACH Herman, Erick C. (B
Cooper, G. R. (B Hopps, Richard (B Deuterman, Martin (B
Sanford, Richard F. (C
Degner, Harold H. (C Lindholm, Ralph V. (C
WESTERN MICHIGAN
COLORADO Dennen, Bill G. (B PHILADELPHIA Johnson, Norman H. (B
Huber, David J. (B Morey, Clinton S Jr B Shearer David (B
Brown, Donald (B
COLUMBUS LONG ISLAND Dowd, Thomas V. (C WORCESTER
Bain, Clifton (C Fedak, Paul (C
Dick, Hayward H. (C Martin, Norman H., Jr. (C
Wilson, Albert H. (B Mroz, Benjamin, J. (C PITTSBURGH
Nettuno, Louis (C YORK-CENTRAL PA.
DAYTON Fetzko, Russell (B
LOS ANGELES Tkatch, Richard S. (C Burg, Joseph R. (C
McNutt, Norman A B Wanderer, Edward T. (C
Young, Jack O. (C Green, Edwin F. (C MEMBERS NOT IN SECTIONS
Le Master, Ralph, Sr B PROVIDENCE Carson, J. E. (B
DETROIT Mc Bride, William H. (C Chung-A-On, Ronald Orlando
Bird, Karl J. (B Poliquin, L. F. (D Golembeski, Richard (C B
Burke, Chas. F. (C Walker, James (D Greene, Alfred W., Jr. (B Dumpelmann, R. (B
Campbell, Frederick C. Waters, S. E. (D Young, James L. (C Finlayson, A. W. (B
Hallenbeck, Richard E MARYLAND PUGET SOUND Harpring, John R. (¢
Marry, N. K. (B Jaxon, J. H. (B
Morrow, Bruce C. (B Hiser, Oscar Kermit, Jr. (B Gaither, W. W. (C Kamat, Giridhar Pundalik (C)
Shekell, Treman C. (B Mapps, G. H. (B
Siefferman, W. H. (B MILWAUKEE SAGINAW VALLEY Tullington, N. H. (B
Wishnow, Rudolph (B Hart, Willard H. (C Werschky, Jerald H. (D Ulrich, N. L. (B

WELDING JOURNAL 767

 Ward, Leonard James (B)
Waters, David (B)
Zeyen, Karl Ludwig (B)

Reclassifications During
May 1961
ALBUQUERQUE
Stewart, Lowry L. (C to B
DETROIT
King, Robert J. (C to B
MARYLAND
Parker, Milton (C to B
NORTHWESTERN PA.
Biltz, Jack C. (C to B
PHILADELPHIA
Kopf, George W. (D to C)
PUGET SOUND
Prebula, John D. (D to C)

FOR POSITIVE HOLDING OF COMPONENTS

IN JIGS AND FIXTURES...
Welcome

YOU CAN DEPEND ON

e Supporting Company

<i> TOGGLE CLAMPS Effective June 1, 1961:

General Dynamics Corp., Liquid
Carbonic Div. Belleville, N. J.

An Important Reminder

AUTHORS...

August 15, 1961, is the dead-

line when application forms
and abstracts must be post-
marked in order to receive con-
Simple drilling fixture made up of 5 toggle action clamps mounted sideration for presentation at
f on a plywood base holds drill bushing plate firmly in position
the AWS 43rd Annual Meeting
to be held in Cleveland, Ohio,
April 9-13, 1962.
phone, wire or write for NEW 36-PAGE CATALOG
The application form was
included as a detachable insert
pgeleic)@ aael) h-) STAMPINGS
in the May issue of the WELD-
SHIMS BLOWER ING JOURNAL.
AND SPACERS HOUSINGS

DETROIT STAMPING COMPANY

340 MIDLAND AVENUE - DETROIT 3, MICHIGAN
For details, circle No. 19 on Reader Information Card
768 | JULY 1961
 \ EWS of the industry

Marquette Breaks Ground 15, Pa. The course is intended to

For New Plant provide a basic knowledge of the
principles and important applica-
Marquette Corp. broke ground tions of ultrasonics for technicians, COMING
recently for a new $450,000 welding engineers and other people working
electrode plant. The 21,000 sq ft with ultrasonics.
plant is under construction at Bank
St. and Southeast University Ave., All-State Open House EVENTS
Minneapolis, and will be ready for
occupancy early this fall. All-State Welding Alloys Co.,
Inc., White Plains, N. Y., held its
The new plant will double the
15th Anniversary Open House and
firm’s capacity for producing weld- A Calendar of Welding Activity
Plant Tour recently, which coincided
ing electrodes, according to of-
with the final session of the National
ficials. It is the latest move in
Welding Supply Assn NWSA
Marquette’s expansion program.
Annual Convention held in New
Recently a second floor was added
York City. 5-28. 1961 National Fall
to the present electrode plant,
Thomas D. Nast, president, out- , Hotel Adolphus, Dallas,
located across the street from the
lined the past and present progress
new building.
of All-State Welding and announced
the future program of company
Hobart Appoints Distributors expansion which is already under-
Sept. 20-22. Welding Forum
Hobart Brothers Co., Troy, Ohio, Annual Meeting classified >
has appointed the following new DEMONSTRATION
IN Granada Hotel, San Antonio,
distributors: Industrial Service Co.,
HONOLULU Tex.
R. H. Fogarty, 2 Richmond St.,
Providence 3, R. I.; Georgia Supply
Co., W. B. Weeks, P. O. Box 28 ASME
821 East Bay St.), Jacksonville, Aug. 28-Sept. 1. International
Fla., Phone: EL 3-8467; Georgia Heat Transfer Conference, Uni-
Supply Co., John Howarth—Megr., versity of Colorado, Boulder,
P. O. Box 1229 (1302 West Bay Colo
St.), Savannah, Ga., Phone: AD
14-4442: Mansfield Oxygen Co.,
Attn.: Edward O. Delp, 217 Nortl ISA
Diamond St., Mansfield, Ohio; Irish Sept. 6-8. Joint Nuclear In-
Welding Supply Co., Robert R. strumentation Symposium, North
Irish—President, 1177 Sycamore Carolina State College, Raleigh,
St., Buffallo 11, N. Y.; Northern N. C.
Welding Supply Co. of San An- Sept. 11-15. Fall Instrument
tonio, 2812 Culebra Ave., San Automation Conference and Ex-
Antonio 1, Tex.; Coss Welding i
hibit and 16th Annual Meeting,
Supply, 890 Virginia Ave., Hagers- More than 100 men representing the
metal fabricating industry in Hawaii, The Biltmore Hotel and Memorial
town, Md.; Spina’s Welding, R.D. Sports Arena, Los Angeles, Calif.
No. 1, Vineland, N. J. some coming by air from as far away as
100 miles, attended demonstrations in
Honolulu recently of new welding and
Ultrasonics Course cutting methods. The demonstrations
were conducted by Lee Reay, sales pro- Western Plant Maintenance and
A new course on ultrasonics has motion manager for the Linde Co., Div Engineering Show and Confer-
been developed by International of Union Carbide Corp. in San Francisco ence, Pan Pacific Auditorium, Los
Correspondence Schools, Scranton and James F. Stacy of GasprO Angeles, Calif. July 18—20.

WELDING JOURNAL
| 769
way in White Plains with a second Houston, Tex.; Ohio Abrasive &
factory building being constructed Tool Co., 3195 Kersdale Rd., Cleve-
on Ferris Ave. land 24, Ohio; Quality Mill Supply
Co., Inc., 2345 Beam _ Rad.,
Plant, Equipment Columbus, Ind.; and Quality Mill
Lease Plan Supply Co., Inc., 150 S. Senate,
Indianapolis, Ind.
A new plan, by which welding
companies can sell their existing
plant and equipment and im- Corrugated-Core
mediately lease it back for terms of Sandwich Panels
from three to 12 years, was an- A method of producing corruga-
nounced recently by Nationwide ted-core sandwich panels that re- both covers, rolling also reduces
Leasing Co., 11 S. La Salle St., duces costs substantially has been the thickness of the panel up to
Chicago 3, Ill. developed in research sponsored by 60°; to provide desired corrugation
Robert Sheridan, president, said the Douglas Aircraft Co. at Battelle shapes.
the Nationwide Sale-Leaseback plan Memorial Institute. The method re- After rolling, the retaining frame
was designed specifically for firms quires no jigging, provides com- is sawed or sheared off and the metal
which have an over-large invest pletely sound core-to-cover bonds, covers which were welded to the
ment in fixed assets and whose and allows the panels to be exten- frame are peeled away. With the
growth, as a result was being ham sively formed after assembly support wedges still in place, the
pered by tight working capital The process—called roll-welding sandwich panel can now be formed
Welding firms will be able to sell, uses hot rolling to pressure-weld into a wide variety of shapes, in
for cash, fully or partially deprecia- the peaks of the corrugated metal cluding hemispheres, without buck
ted equipment to Nationwide at core to the cover sheets. ling the core. Standard tooling
greater-than-value and lease it back Size of the sandwich panels is can be used, and the panel can be
Sheridan stressed. This is the first limited only by rolling-mill capacity worked as though it were a solid
such plan ever developed for the metal plate of equal thickness.
One-fourth in.-thick panels as large
welding industry, he added. Also The V-shaped inserts are then
as 36 by 72 in. have already been
a first, Sheridan pointed out, is the leached out of the formed structure
produced. Roll-welded sandwich
inclusion of custom-built equipment panels have been made of 2014 with a chemical reagent, such as
and the availability of terms as long nitric acid Although the leaching
aluminum alloy, B-120 VCA ti-
as 12 years
tanium, unalloyed A-55 titanium, process requires several days for
steel, molybdenum and Inconel. very large panels, it is a straight
Elgin Names Eight Distributors To form the corrugated core, an forward operation and is relatively
The Abrasives Division of the accordion-pleated sheet of metal is inexpensive. If necessary, leaching
Elgin National Watch Co., Elgin, woven over and under V-shaped can be accelerated by mechanical
Ill., has announced the appoint- inserts of a chemically soluble, de- means.
ment of the following eight com- formation-resistant metal such as Roll-welding can also be used to
panies as distributors for the Divi- copper oriron. A rectangular metal produce sandwiches with vertically
sion’s Diamond Wheel Products: frame is placed around the core, and ribbed cores, since core design is
Adroit Tool & Supply, Inc., 603-B the face sheets of the sandwich are determined by the design of the
Alton St., Santa Ana, Calif.; A. S. added. The entire assembly is filler wedges. The only limitation
Childs Co., Inc., 55 Millbrook St., clamped in place by two additional is that the core has to be unidire«
Worcester 6, Mass.; H. D. Geisler metal cover sheets, which are welded tional.
Co., Ine., 1228 McCook Ave., to the rectangular frame. The Roll-welded corrugated sandwich
Dayton 4, Ohio.; Industrial Dia- whole package is then hot rolled in panels approach the all-round
mond Products, P.O. Box 11374, a direction parallel to the corruga- rigidity of honeycomb sandwiches,
Fort Worth, Tex.; Industrial Dia- tions. and are simpler and much less
mond Products, P.O. Box 12241, In addition to welding the core to costly to manufacture.

you do the job better

with Airco quality equipm mat...

PVatelta’

AiR REDUCTION
SALES COMPANY

For details, circle No. 20 on Reader Information Card

770 | JULY 1961

Nuclear Fuel Element Contract spokesmen for both organizations
said the Swedish firm will also act as No other
The Sylecor Division of Sylvania procurement representative for
Electric Products, Inc., New York, European manufactured compo-
N. Y., has received the largest nents of the MgO recovery units.
single contract for the production of tool saves
nuclear fuel elements for test re-
actors ever awarded to a private GE Realigns X-ray
industry, it was announced recently Sales Staff so much time,
by Dr. Lee L. Davenport, vice
president and general manager of The recent completion of a com-
prehensive industrial sales realign- material...
ment at General Electric’s X-ray
Dept. was announced recently by
J. D. Webster, industrial marketing
manager of the Milwaukee-head-
quartered operation. The present
sales organization is grouped in
part by product line and in part
by user industry to best serve the
Department’s wide variety of cus-
* ein alli 8 tomers, according to Webster.
A newly created chemical process
the division. Sylvania is a_ sub- sales function is managed by Dr.
sidiary of General Telephone & W. F. Loranger. The wide-spread
Electronics Corp. need for X-ray emission and dif-
The contract, which calls for pro- fraction equipment to control a
duction of more than 1000 elements mushrooming number of automatic
and control rods, was awarded to chemical processes led to formation
Sylvania by the Atomic Energy of this specialized sales group, ac-
Division of Phillips Petroleum Co., cording to Webster
which operates test reactors for the Prior to his appointment, Dr.
Atomic Energy Commission at the Loranger was associated with the
National Reactor Testing Station Department’s multi-industry X-ray
near Idaho Falls, Idaho. sales effort. He has also directed
General Electric’s annual X-Ray
Southern Oxygen Plans Merger Yiffraction and Emission School
The Southern Oxygen Co., for the past five years Arcair process cuts
Bladensburg, Md., recently con- Assuming responsibility for the
firmed reports that merger nego- sale of all X-Ray Department prod- rework time 93%
tiations have been under way with ucts to the federal government is zie cones
the Spencer Chemical Co. of Kansas D. F. Raymond. Raymond, who
City, Mo. Robert B. Swope, chair- has managed the sale of aerial
man of the board, said that, for reconnaissance cameras to the gov-
the last few months, Southern ernment since the product line was grinding
Oxygen has been discussing merger founded during the Korean War, saved
possibilities with Spencer. received the additional responsi- This vital job was performed by
According to Mr. Swope, the bility as part of aDepartment move the Carson Machine & Supply Com-
negotiations have progressed satis- to increase the efficiency of its multi- pany of Oklahoma City. The job was
factorily. However, no merger product government sales effort. completed iy ahead of schedule
will be consummated without the Rounding out the realigned head- ind be ~ \rcail i mechanical
approval of the boards of directors quarters sales management team are pend on
and security holders of both com- H. W. Pickett, in charge of instru- effective
panies and no request for such ap ment and sensor system sales, and 1ioving welds,
provals have been made by the S. T. Workman, responsible for but did not caus he slightest dam-
managements of the respective com- radiation generator, image presen- age to these vital gin ympo-
tation system, and X-ray supply nents
panies. You can save time and materials,
sales. The Department’s field sales too with .z al ‘all your local
Babcock & Wilcox Signs Agreement are directed by three zone sales Arcair dealer or write for further
with Swedish Firm managers, working in conjunction informatio! f ait -ompany
with General Electric’s Industrial Lancaster
The Babcock & Wilcox Co. has Sales operation.
signed an agency agreement with
Aktiebolag Nordstroms Linbanor of New Research Data Firm
Stockholm, Sweden, under which the
Swedish firm will represent B&W Technical Aid Service, Inc., 500
USA) in the sale, erection and serv- W. Third Ave., Columbus 12, Ohio,
icing of magnesium oxide (MgO is now offering a unique service
recovery equipment and in the especially tailored for management
licensing of magnesium base sulfite and research and development staffs
pulping processes for pulp mills in of electronics, petroleum processing,
Sweden. petrochemical, chemical, pharma- 4| ‘Vay MMhA\/ J J J IN nr
In announcing the agreement, ceutical and related firms. The
For details, circle No. 21 on Reader information Card
WELDING JOURNAL 771
 service entails the reduction of stitute in Technical and Industrial
technical literature to easily under- Communications scheduled for July
stood digests of basic principles. 10-14 at Colorado State University
These digests are integrated into in Fort Collins.
an intelligent retrieval system. Dr. Herman M. Weisman, direc-
These short summaries of tech- tor of the annual summer institute,
nical data, free from irrelevant said an intensive week-long course
terminology and redundant detail, and workshop have been arranged
can be scanned and understood in a for writers, editors, scientists, en-
few minutes by scientific personnel. gineers, administrators and _ infor-
Personnel are kept appraised of new mation specialists in government
developments as well as prior ac- research agencies.
complishments revealed in technical The course is designed for per-
literature. Thus, maximum useful sons engaged in the supervision or
information is obtained in minimum preparation of reports, manuals,
time. articles, house organs, brochures
When provided with these concise and other technical communica-
data, clients of this service can tions material.
reportedly assimilate 50 to 100 Further information may be ob-
articles a week in les@ time than is tained by writing to Dr. Weisman
required to review a single lengthy at Colorado State University, Fort
article. The analyses of conjunc- Collins, Colo.
tion with an easy retrieval process
Kellogg Opens Chicago Office END THIS COSTLY
are said to be time-saving research
tools which can realize significant The M. W. Kellogg Co., New AFFAIR BY KEEPING
cost savings. York, a subsidiary of Pullman Inc., YOUR RODS AT HOME
announces the opening of a new
sales office of its Power Piping Div. in
Faculty Members Announced
in Chicago, Ill. The office, at 200 PHOENIX
for Communications Institute
S. Michigan Ave., will service the
Fifteen top professionals from power piping needs of the steam-
such organizations as General Elec- electric utility industry in the DryRod:
tric, IBM, McGraw Hill Publishing Midwest. Robert G. Thompson
Co. and the Navy will comprise the will be Midwest Regional Manager, ELECTRODE OVENS
faculty for the Fourth Annual In- in charge of the new office.
Pioneer ond tender te the Field
7. * oa
Dry Rod is the Trademark of
measure weld Good welding everywhere

TEMPERATURES
7 TYPE 300
350 Ib size
“ accurately
+ 2% full scale
9:00
quickly 1100 Ib size
3- to 10-sec response

inexpensively
models from $77.50 . TYPE 10
= Portable
10 Ib size

with an instrument
of toolbox sturdiness

THE ROYCO PYROTEM Welding electrodes are a

perishable product. Reworks
are extremely costly. Insure
good welds with Dry Rod
Ovens. Write for folder “Dry
Rod as Standard Welding
Equipment”.
ROY
ODsnernamenss ne

PHOENIX PRODUCTS COMPANY

4753 N. 27th Street © Milwaukee 9, Wis.
440 OLIVE STREET + PALO ALTO 3, CALIFORNIA
For details, circle Ne. 22 on Reader Information Card For details, circle No. 23 om Reader Information Card

772 | JULY 1961

 and brazing equipment, and
customer processes employing Air
Reduction products is the function
of the new division.

J. D. Webster Named Industrial

Marketing Manager
J. D. Webster has been named
manager of industrial marketing at
General Electric’s X-Ray Depart-
ment, Milwaukee, Wis. Prior to
the appointment, Webster had been
manager of the Department’s in-
dustrial sales for seven years
In his new position, the 20-year
General Electric veteran is_ re-
sponsible for the sale and service J. D. Webster
of the Milwaukee plant’s entire
industrial X-ray and aerial recon-
naissance camera output. He thus
assumes section level responsibility
M&T Names Orden for one of the seven major areas of
David B. Orden W3 has been named X-Ray Department operation—the
manager of Latin American opera- others being finance, engineering,
tions for the International Div. of manufacturing, employee and com-
Metal & Thermit Corp. In his new munity relations, medical marketing
post, Mr. Orden will be responsible and legal.
for M&T’s over-all development in
the Latin American area. His Champion Appoints Three
headquarters will be in the com-
pany’s executive offices at 100 Park Champion Rivet Co., Cleveland,
Ave., New York City. Ohio, recently announced three
Mr. Orden joined M&T in 1956, executive appointments—E. J.
when he was appointed M&T’s Markert to vice president of manu-
special representative for Latin facturing, William F. Dempsey to
America. In 1959, he was made a forging division manager, and
director of M&T’s Mexican sub- Donald J. Schaefer to welding
sidiary, Industrias M&T de Mexico division manager.
S.A., a company in Monterrey, T. Pierre Champion, president of
manufacturing zirconium silicate the Cleveland company, explained
used in the opacifying field. that these appointments were made
as a result of the recent reorganiza-
Rothchild Heads tion of the company into distinct
operating divisions.
New Airco Division Mr. Markert joined Champion in
Gilbert R. Rothschild a has been 1923 as a billing clerk, and William
appointed assistant director-metal- Dempsey, a graduate of John Carroll
lurgical development, heading a new University of Cleveland-Marshall
division of the Central Research Law School, became manager of
Laboratories of Air Reduction Co.., the forging division after 12 years
Inc., in Murray Hill, N. J. De- in sales with The Champion Rivet
velopment and refining of welding Co. da Oberst

David B. Orden G. R. Rothschild W. J. Greene

WELDING JOURNAL 773

 Donald Schaefer will manage vice president, had been president of Airco Names Two
Champion’s welding electrode pro- the Federal Machine and Welder Assistant Sales Managers
duction, sales and research. A Corp., until that firm’s merger with
graduate metallurgical engineer, his McKay. Until his appointment, V. B. Cassilly and G. C. Wingate
affiliations include the American he had been a McKay vice president have been appointed assistant sales
Society for Testing Materials Com- and operating head of the newly- managers by Air Reduction Sales
mittee on filler metal codes and created Federal - Warco Div. A Co.
specifications. graduate of Pennsylvania State Cassilly will coordinate sales of
College, Mr. Barefoot started with Airco products in Florida and
Federal in 1941, and was elected Southern Georgia with headquarters
Two New Appointments president of that firm in 1957. In in Tampa.
Announced by Burdett addition, he has served on the Wingate replaces John T. Winn,
McKay Board of Directors since III, in the Charlotte, N. C., District
The addition of two new execu-
1958, and is president and a director covering North Carolina, South
tives was announced by William
of the firm’s subsidiary, Berkeley- Carolina, Virginia, Eastern Ten-
H. Loveman WS, president of the
Davis, Inc., of Danville, Il. nessee, Northeast Georgia and the
Burdett Oxygen Co. of Cleveland.
Robert B. May was appointed to Leitzell, who had been a director, Bluefield area of West Virginia.
the office of treasurer and controller, vice president, and treasurer of the
Federal Machine and Welder, was Coyle Named Eutectic
and Jack Oberst was promoted from
resident manager in Santa Fe elected a vice president of McKay Personnel Manager
Springs, Calif., to vice president in April of this year, with the merger Harold K. Coyle has_ joined
in charge of sales. of the two firms. He started with Eutectic Welding Alloys Corp.,
Federal in 1942. A native of Johns- Flushing, N. Y., as Manager of
town, N. Y., he had been a director, Personnel. He will report directly
Greene Appointed Associate vice president and treasurer of the to Leonard C. Barr @\3, president,
Director at Airco Utility Employees’ Securities Corp., and will be responsible for coordinat-
William J. Greene has been ap- of Wilmington, Del., prior to com- ing and directing the personnel ac-
pointed associate director-physical ing to the Warren firm. tivities of the company, including
In addition to his new position employment, wage and salary ad-
research, heading a new division of
with McKay, Mr. Leitzell also ministration, management develop-
the Central Research Laboratories
holds the positions of Director of ment, employee benefit programs;
of Air Reduction Co., Inc., in
Dolaveo, Inc., director and presi- and the development of personnel
Murray Hill, N. J. Primary func-
tion of the new division is the de- dent of Par 20, and is director and
velopment of new products through treasurer of McKay’s subsidiary,
experimental research involving Berkeley-Davis, Inc., of Danville,
physics of gases, liquids and solids. Ill.
D. M. Davis, a native of Youngs-
This includes study in practical
town, has been with McKay Ma-
flame problems, plasma research and
chine since 1926, when he started
electronic optics.
as an accountant and office manager
while attending Youngstown College.
Barefoot Appointed He was superintendent of the Heat
Treating Department from 1936
The Board of Directors of the
McKay Machine Co. has appointed to 1943, when he was elected a
J. Roy Barefoot to be the firm’s director of the company, and was
appointed auditor. In 1945, Mr.
executive vice president, and Ralph
N. Leitzell to fill the post of vice Davis was appointed assistant secre-
president and treasurer. D. M. tary of McKay, and in 1947, secre-
Davis, formerly vice president and tary of the company. In 1957, he
treasurer, was appointed to vice received appointment as vice presi-
president, in charge of special proj- dent and treasurer.
H. K. Coyle
ects.
Mr. Barefoot, the new executive

J. R. Barefoot V. B. Cassilly G. C. Wingate

774, JULY 1961

 electric welding, ferrous and nonferrous
WELDING metals. Age 40, married
EMPLOYMENT
A-750 Senior Welding Engineer
ENGINEERS SERVICE with 12 years’ experience in heavy
Unusually attractive opportuni- structural and alloy fabrication seeking
ties now exist with Foster BULLETIN similar position or that of Welding
Wheeler Corporation, a_ pro- Superintendent in charge of produc-
gressive organization of inter- tion. Prefer San Francisco Bay Area
national stature. or Pacific Northwest Also has con-
These openings require thor- Services Available siderable materials engineering and
ough knowledge of all types of specification experience on nuclear
code welding, including latest A-747 M.S. Welding Engineering, and code pressure components. Thinks
techniques. Applicants should Ohio State University, August 1961 creatively on development of cost-
have BSME degree or Bachelors B.S. Civil Engineering, three years
or Masters degree in Metallurgy; cutting production methods and under-
plus 3 to 5 years welding experi- high temperature metals research as stands business management tech-
ence in the heavy metal fabri- project officer in USAF Interest in niques At age 44 has 25 years’ ex-
cating industry. welding metallurgy, applied research, perience in welding
Attractive salaries and excellent bene welding process development Loca
tion preference Pacific Northwest or A-752 Welding Supervisor and
fits for those who qualify Openings are Gamma Ray ‘Technician Teaching,
available at our facilities in CARTERET Northern California Age 26, family
N. J. & MOUNTAIN TOP, PA Available October 1961 instructing, inspection and engineering.
Please send complete resume to Broad experience in manual, sub-
Personnel Manager A-748. Technical writer Experi- merged, semiautomatic ar« inert-gas
(at either address listed below) enced in all phases of communications tungsten-ar« manual and semiauto-
FOSTER WHEELER CORP. advertising, sales promotion, motion matic), oxyacetylen: welding and
377 Roosevelt Ave., Carteret, N. J. pictures, trade shows and _ exhibits, cutting, et« ASME-AWS 1Specifica-
or technical papers, publicity specifically tions. Gamma Ray processing and
Mountain Top, Pennsylvania in electric welding equipment and interpretation of film; magnetic par-
processes Looking for small to me ticle, dye penetrant, plugging and
dium size company willing to handle hydrostati Some metallurgy
policies and procedures. increased business through more effec
Coyle’s extensive experience tive communications Résume on re A-753. Welding Engineer. Educa-
quest tion in metallurgy, electronics and tech-
covers almost fifteen years in per- nical writing ['wenty years experience
sonnel work including such assign- A-749 Welding Engineer with wide in all welding processes including elec-
ments as Manager of Personnel with practical and formal education desires tron beam Past ten years in Research
the American and Foreign Power responsible position in either sales, and Development of welding methods
Corp., and Supervisor of Personnel engineering or production Mechani and equipment for materials intended
with the M. W. Kellogg Co. cal Engineering degree: 7 years’ prac for cryogenic and high temperature
tical experience; 5 years engineering application. Materials experience in-
and sales representative in process cludes special tool steels, stainless steels,
Texas Alloy Appointments development and manufacturing prob- alloy steels, cobalt and nickel base
J. P. Ekholm was appointed lems; 5 years in sales and engineering steels, refractory materials, beryllium,
Sales Representative, Weld Clad of automatic welding machinery. Well aluminum and magnesium alloys Ré-
acquainted with all inert arc processes sumé on request
Products, and R. A. Pennell
was made Shop Superintendent,
Weld Clad Dept. of the Texas
Alloy Products Co., Houston. Tex

Picker Appoints Guise

WELDING REPRESENTATIVES
Frank C. Guise has been pro-
moted to industrial sales manager National manufacturer has immediate openings for two representatives
of the New York Metropolitan area
by Picker X-Ray Corp., according SALES REPRESENTATIVE...
to a recent announcement by Fr
immediate opening for a welding electrode and machine salesman to cover
Harvey Picker, president. Welding sales experience des
New York State (outside of N. Y. C.) area
Guise was manager of accessory
but a good welding background or industrial sales experience will be consi
sales for Picker X-Ray, which he
joined in 1954. He has 29 years of
experience in X-ray sales, service TECH SERVICE REPRESENTATIVE...
and management fields. Guise will working out of Metal & Thermit’s General Offices at Rahway
be headquartered at Picker’s metro- service repesentative will cover Atlantic Coast States He must
politan offices at 75 Varick St., with automatic, semi-automatic, and manual welding processes ande
New York City. He will also be respon ble for conducting product knowledge and
sessions for company sales personnel and distributors A good
D. M. Beckett Named background including shor or plant experience is desirable
Fabriform Superintendent Regarding both positions, please send resume ands
Dennis M. Beckett has been A. D. Smitt Personne! Division
appointed plant superintendent of
Fabriform Metal Brazing, Inc., a Metal & Thermit Corporation
Los Angeles metal joining firm. Rahway Avenue
Beckett will be in charge of all Rahway, New Jersey
production and maintenance for
the company’s brazing operations.

WELDING JOURNAL 775

 2,938,993 H1GH-FREQUENCY ELECTRI- and electrode actuator so that when the piston has able stud arc welding tool of the one-hand
CAL WELDING--Wallace C. Rudd, moved to its limit of movement and engages the operated type. The tool includes a single hollow
Larchmont, N. Y., assignor to Mag work, the spring can cause the actuator to move elongated hand grip and housing unit and a stud
netic Heating Corp., New Rochelle, toward the work when the work has become gripping means movably mounted on the hand
plastic due to heating action thereon grip and housing unit solely for manual actuation
N. Y., a corporation of New York. thereof while a fixed workpiece engaging portion
Rudd's new process relates to welding a longi 2,938,997--WeELbING Device—Arthur is also provided on the hand grip and housing
tudinal edge of one metal portion to the longi W. Anderson, 423 Bedford St., La unit Electric circuit means for applying high
tudinal edge of another metal portion In the Habra, Calif. voltage electric power to the stud to initiate and
method, said portions are rapidly advanced and A specialized welding device is covered by An sustain an electric arc between the stud and
brought together for pressure contact at least derson’s patent. This apparatus is designed to vorkpiece before contact therebetween are pro
by the time they reach a predetermined weld deposit weld metal on the circumferential surfaces vided and a manually actuatable trigger member
point A final heating zone is maintained along of an object carried by a rotatable spindle in the is mounted on the hand grip and housing unit
the edges shortly in advance of the weld point by apparatus. Other means supply welding flux and a to control such circuit means. The trigger mem
a heating current of a frequency of the order of welding rod to the rotating object and other con ber closes the electric circuit means to render
100,000 eps or higher Such edges are preheated trol and positioning means are provided in the such circuit means operative and a second switch
in advance of the final heating zone to a tempeta apparatus of the invention is provided in the hand grip unit and actuated
ture lower than welding temperature by producing to make such circuit means inoperative upon
heating currents therein of a frequency of the 2,939,942—-METHOD OF WELDING first projection of the stud against the work
order of about 10,000 cycles or leas to provide piece when moved manually toward it
heat sumps along such regions and to check STAINLESS STeEL—-Merrill A. Scheil,
dissipation of heat from the edge surfaces in the Whitefish Bay, Wis., assignor to A. O 2,941,066—Mop!IFIED ARC WELDING
final heating zone Smith Corp., Milwaukee, Wis., a SystemM—Robert B. Hartman II,
corporation of New York. Bridgeport, Conn., assignor to Reming-
2,938,994 ELectTrRIc ARC-WELDING ton Arms Co., Inc., Bridgeport, Conn.,
AppARATUS-Paul Christiaan van der The present patent is on a method of ar
velding that includes establishing an arc between a corporation of Delaware.
Willigen, Leon Frits Defize and Jan 4 consumable stainless steel electrode and a stain
Anthonie van Bergen, all of Eindhoven, less steel workpiece and feeding a gaseous me By this patent, a unitary stud assembly is
Netherlands, assignors to North Amer- dium consisting essentially by volume of 10 to provided for use in arc welding two metallic
ican Philips Co., Inc., New York, N. Y., 50° nitrogen and the balance being substan vorkpieces together The assembly includes
tially an inert gas to the arc. ‘The electrode is 2 primary stud element, a distinct separate
a corporation of Delaware secondary fusible stud element and a _ solid
Chis new electric arc-welding apparatus com fed toward the workpiece at a rate determined fusible conductive slag-forming body for initiat
prises a nozzle forming a chamber for flow of by the consumption of the electrode so as to ing and timing the arc. The two separate stud
provide a generally constant arc length elements are in abutment and in axial alignment
2,939,944--METHOD OF FABRICATING with a passageway therethrough so as to position
HONEYCOMB GRID REINFORCED the separate secondary fusible stud element be
tween the primary stud element and the slag
SrTRUCTURE—Walter S. Eggert, Jr., forming element
Philadelphia, Pa., assignor to The
Budd Co., Philadelphia, Pa., a cor 2,941,067—-WELDING APPARATUS AND
poration of Pennsylvania. FLEXIBLE DAM FoR USE THEREWITH
Eggert’s patent is on a method of forming a R. L. Kitrell, 5100 E. 17th St., Tulsa,
honeycomb grid reinforced sandwich structure Okla.
and it includes securing together bent strips to Kitrell’s patent relates to apparatus for forming
form a small honeycomb grid unit and thin cover elding joints between contiguous members and
sheets are brazed to the end edges of the strips here a carriage is provided and means mount the
on the opposite sides of the grid unit. One of the irriage for movement along the joint to be welded
Abstracts of Current PATENTS sheets has electrode-receiving apertures coin between such contiguous members The ap
ciding with honeycomb spaces and the other paratus also includes a concavely grooved pres
sheet is generally imperforate A plurality of ser member mounted on the carriage and a spool
small grid units are secured together in side by rotatably mounted on the carriage. The ap
side relation, and a skin sheet is welded to the paratus is completed by a length of welding dam
other grid cover sheet using an electrode ex in the form of an elongated strip having an arcuate
tending through the perforations of the one grid cross-sectional configuration complementary to
cover sheet. Another skin sheet is welded to the the concavity of the presser member so that the
said perforated grid cover sheet by indirect or dam can be wound from one end of the spool in a
projection welding to complete the unit plurality of turns and extend between the presser
2,940,169--MeETHOD OF BRAZING Two member to the joint to be welded
Metat Heaps TO A METAL BARRE! 2,941,280—-SHEET METAL FABRICA-
ro PropucE A BOBBIN FOR YARN rion——Charles A. Heuer and Charles
prepared by Vern L. Oldham Harold S. Barnes, Allentown, Pa., O. Kunz, Alton, Ill., assignors to Olin
assignor to Allentown Bobbin Works, Mathieson Chemical Corp., East Alton,
Printed copies of patents Allentown, Pa., a_ corporation of Ill., a corporation of Virginia.
may be obtained for 25¢ from the Pennsylvania.
Commissioner of Patents, Washington, D.C The present patent relates to a new materia
Ihe present patent is on a specialized method of for use in forge welding actions. The material
producing a unitary metallic bobbin wherein omprises a hydrosol of particles of graphite and
protective gas therethrough and means to supply metallic heads are brazed onto a metallic barrel in use, such composition is interposed between
an electrode to the nozzle at the outlet opening by special brazing operations superimposed metal sheets for preventing weld
thereof. Other means are present to prevent the ction in that area Then the other areas of the
formation of welding material deposit upon the 2,941,063—-PLASMA-JET TORCH Ap- superimposed component sheets are velded
surface of the nozzle which means include a PARATUS AND METHOD RELATING TO together by forge welding action.
massive body and a driving mechanism to bring INCREASING THE LIFE OF THE BACK
the body into impact with the nozzle. ELEcCTRODE— Adriano C. Ducati, 2,.943,182—-FLuip STABILIZED ARC
Corona Del Mar and Vernon H. Black- MEcHANISM—John W. Prout, Bridge-
2,938,995-—-ADJUSTABLE MACHINE man, Laguna Beach, Calif., assignors
rooL FIXTURE FOR WELDING ELEC to Plasmadyne Corp., Santa Ana, port, and Noel J. Sheehan, Philadel-
TRODES AND THE Like-—John E. Calif., a corporation of California. phia, Pa., and James W. Reid, Jr.,
Tracey, Reisterstown, and Elwood Collingswood, N. J., assignors to
L. Wheeler, Owings Mills, Md., as- In this patent, a plasma-jet torch is covered General Electric Co., a corporation of
signors to Bendix Aviation Corp., and it includes a nozzle electrode having a nozzle New York.
Baltimore, Md., opening therein, and a back electrode having an
corporation of arcing region spaced from the nozzle opening so In this patent, a fluid stabilized are control
Delaware that an electric arc may be struck between the mechanism is disclosed. A fluid chamber forming
This patent covers a specialized machine tool arcing region and the nozzle electrode in the member is provided and a hollow cylindrical
fixture for supporting an electrode in a controllable vicinity of the nozzle opening. Other means are member is concentrically mounted within the
ind resettable manner with relation to a support present in the torch to cause the current density means forming the fluid chamber with the interior
ing frame means of the portion of the arc at the arcing region of the of such cylindrical member forming a _ swirl
back electrode to be substantially lower than that chamber. A nozzle electrode is mounted in the
2,938,996— DUAL-PISTON WELDING of a portion of the arc more remote from such end of the means forming the fluid chamber
Gun—James R. Carswell, Huntington arcing region. and a rod electrode is axially movable within the
Woods, Mich., assignor to Delta swirl chamber. Fluid is introduced under pres
2,941,065—Strup WELDING APPARA- sure into the fluid chamber and it flows into the
Welder Corp., Detroit, Mich., a corpo- rus—Robert B. Hartman II, Bridge- swirl chamber to form a vortex. Other means
ration of Michigan port, Conn., assignor to Remington connect a source of electrical power between the
Carewell’s construction relates to a hydraulix Arms Co., Inc., Bridgeport, Conn., rod and nozzle electrodes, and servo means are
welding gun wherein a piston and an electrode a corporation of Delaware. provided for axially actuating the rod electrode
actuator are provided for supporting the electrode in response to the voltage between the nozzle
Resilient means are provided between the piston Hartman's patent relates to a compact, port and rodelectrodes.

776 | JULY 1961

 Carbon Steel 1960), pp. 615-22.
Stress-to-rupture Strength of Welds of Oxygen Cutting
Low-Carbon Steel, L. G Achkasov.
Welding Production English transla- Automated Flame-Cutting Paying Off
tion of Svarochnoe Proizvodstvo). no. 1 at National Steel, B. L. LeBlanc.
Jan. 1960), pp. 58-68 Mar. Eng., vol. 65, no. 11 (Oct. 1960),
pp. 70-71
5 Columbium
Batch-Production Methods Employed
Welding of Columbium and Colum- at Works of British Oxygen Engineer-
bium Alloys, W. J. Lepkowski, R. E ing, A. W. Astrop Machy. (Lond.),
LITERATURE Monroe and P. J Rieppel Battelle vol. 97, no. 2500 (Oct. 12, 1960), pp.
Memorial Inst DMIC Memorandum 832-55
69 (Oct. 24, 1960), 28. p
Penstocks
Corrosion
Use of Welding in Sulzer Penstocks for
Preferential Corrosion of Stabilized Hydro-Electric Power Stations, J.
Stainless Steel Welds, C. L. Anger Bienz. Sulzer Tech. Rev., vol. 42, no. 1
man and P. M. Kranzlein Am. So 1960), pp. 23-31
Metals—Preprint no. 208 (for meeting
Oct. 17-21, 1960), 14. p Petroleum Refineries
For copies of articles, write directly to Earthmoving Machinery Design Factors and Comparative Costs
publications in which they appear. A list of Welded Wheel Excavator Moves Earth for Low Temper iture Piping Materials,
addresses is available on request Far and Fast, O. Young Welding H M Howarth Petroleum Er gr... vol.
Engr., vol. 45, no. 9 (Sept. 1960), pp 32 no. 7 July 1960 pp C33-36,
34-35 38-41

Electrodes Precoated Metals

Aircraft How to Join Precoated Metals Tron
Electrode Fusion and Parent Metal
X-Y Recorder Programs Tapered Penetration in Manual Arc Welding, Age, vol. 185, no. 26 (June 30 1960),
Sheet Welding on B-70, Space/Aero A G Mazel Welding Production pp. 148-51
nautics, vol. 34, no. 4 (Oct. 1960), pp English translation oO Svarochnoe
167, 170, 172, 175, 178 Pressure Vessels
Proizvodstvo), no. 1 (Jan. 1960), pp.
39-49 Design and Analysis of Welded Pres-
Aluminum sure-Vessel Skirt Supports, N. A. Weil
Design Changes Cut Downtime in Specification for Filler Rods and Wires and J. J. Murphy. ASME—Trans
Welding of Aluminum. /J/ron Age, vol for Inert-Gas Arc Welding—Pt 2. Jnl. Eng. for Industry, vol. 82, Ser. B,
185, no. 22 (June 2, 1960), pp. 66-67 Wires for Gas-Shielded Metal-Arc no. 1 (Feb. 1960), pp. 1-14
Welding Brit. Standards Instn
Design of Welded Aluminum Struc Brit. Standard no. 2901, pt. 2 (1960), Rails
tures, H. N. Hill, J. W. Clark and R. J 30 p
Brungraber. ASCE—Proc., vol. 86 (J New Units Speed Rail Welding. Jron
Structural Div.), no. ST6 (June 1960), Whither Electrode Design? I] Age, vol. 186, no. 16 (Oct. 20, 1960), p.
Paper no. 2528, pp. 101-24. Fitch. Brit Welding Jnl., vol. 7, 161
10 (Oct. 1960), pp. 600—4
Square-Butt Welding Costs Less. Jro: Refractory Metals
Age, vol. 186, no. 22 (Dec. 1, 1960), p Electron Beam Welding and Brazing Two Columbium
139 Electron Unit Solves Problem of Weld Alloys, C. F. Burrows, M. M. Schwartz
Automobile Transmissions ing Refractory Metals, A. Adelhardt, and L. J. Gagola Matls Design
R. H. Witt. Jron Age, vol. 185, no. 17 Eng., vol. 52, no. 4 (Oct. 1960), pp.
Automatic Induction Brazing and Test Apr. 28, 1960), pp. 108-10 13-15.
ing of Seven Joints in Automati
Transmission Part Indus. Heating, Heat Exchangers Riveting
vol. 27, no. 9 (Sept. 1960), pp. 1828, Fabricating Equipment with Zir-
1830, 1832 Russians Weld Rivets with Coated
conium, B. S. Payne. Indus. & Eng Electrodes. Steel, vol. 146, no. 15 (Apr.
Brazing Chem., vol. 52, no. 3 (Mar. 1960), pp 11, 1960), p. 100
15A—-46A
How-Frequency Induction Brazing of Sandwich Construction
Small Components in Argon Streams, Metallurgy
P. M. Bartle and J. G. Young. Brit Ceramic Platens Help Shape Stainless
Weld Metal Carburisation when Weld- Honeycombs. Jron Age, vol. 186, no.
Welding Jni., vol. 7, no. 10 (Oct. ing 1Kh1I8N9T Steel, I. A. Levin and
1960), pp. 638-42 10 (Sept. 8, 1960), pp. 98-99
V A. Nikiforov Welding Production
High to Design for Preform Brazing, English translation of Svarochnoe Shafts
H. Olson. Welding Engr., vol. 45. no Proizvodstvo), no. 1 (Jan. 1960), pp Welding Shafts by Electro-slag Proc-
9 (Sept. 1960), pp. 36-39 50-57. ess, P. Trippe Machy Lond.), vol.
Carbon Dioxide Welding Nickel Alloys 97, no. 2498 Sept 28, 1960 pp 725
26
CO, Welding 30KhGSA Steel in Hard Welding Metallurgy of Nimonic Alloys,
ened State, K. V. Lyubavskii, V. M J. Hinde and D. R. Thorneycroft. Stainless Steel
Nikitin and G. F. Murov Welding jrit. Welding Jni., vol. 8, no. 10 (Oct Welding of Precipitation-Hardening
Production English translation of 1960), pp. 605-14 Corrosion-Resisting Steels, J. I.Morley
Svarochnoe Proizvodstvo) no. 1 Jan and J. A. McWilliam. Brit. Welding
1960), pp. 11-17. Nuclear Reactors
Jnl., vol. 7, no. 10 (Oct. 1960), pp.
Certain Features of Welding with Car Nuclear Reactor Construction Depends 651-58
bon Dioxide Shielding on Alternating on Precision Welding, C. R. Allison,
Current, R. M. Gufan, N. G. Dyur Jr... J LaForce Machy N. Y . vol Steam Turbines
67, no. 2 (Oct. 1960), pp. 109-13
gerov, Yu. L. Ishchenko and L. M Automatic Machine Brazing of Stellite
Ronskii. Welding Production (English Welding Problems Associated with Nu- Inserts to Turbine Blades, J. van
translation of Svarochnoe Proizvodstvo), clear Fuel Elements, A. F. Taylor. Opynen. Indus. Heating, vol. 27, no. 7
no. 1 (Jan. 1960), pp. 69-74. Brit. Welding Jnl., vol. 7, no. 10 (Oct. July 1960), pp. 1368-70, 1372, 1378.

WELDING JOURNAL 777

 New Literature
New AWS Technical
Publications
AWS Definitions—
Welding and Cutting $2 each
Master Chart of
Welding Processes
Wall Size $1.50 each
Desk Size $0.50 each
Recommended Prac-
tices for Automotive
Welding Design $2.50 each
Recommended Prac-
tices for Gas-
Eye Protection Chart Available Shielded-Arc
Welding of Alumi-
The AMERICAN WELDING SOCIETY relatively low light intensity, is num and Alumi-
announces the publication of a chart listed first. "The shade numbers in- num Alloy Pipe $2 each
giving the correct shades of glass crease as the light intensity in- Recommended Prac-
to be used for proper eye protection creases until the highest shade num- tices for Metallizing
in all welding and cutting opera- ber is reached when carbon-arc weld- Shafts or Similar
tions. ing is used. Objects $1 each
The simple design of the chart These Lens Shade Selector Charts 1960 Supplement to
enables the answer to be obtained should be invaluable wherever weld- the AWS Bibliogra-
immediately to the question of what ing is done, and are intended for phies $1.50 each
shade of lens to use for a particular display in all welding shops in order Special Offer—AWS
operation. On the left of the chart that maximum eyesight protection Bibliographies and
are the various soldering, brazing, may be given by using the correct 1958, 1959 and 1960
cutting and welding operations. On Supplements $8 per set
lens shade for each operation.
the right are listed the correct
shade numbers to use for each Copies are available at 50¢ each, Send orders to Technical Dept.,
process. or 10 charts for $4.50, from the American Welding Society, 33 W.
The operations are arranged in AMERICAN WELDING Society, Tech- 39th St., New York 18, N. Y.
the order of increasing shade num- nical Dept., 33 W. 39th St., New
bers. Soldering, therefore, with a York 18, N. Y.

Welding Rocket Motor Cases Guide rocket motor cases is perfection, and mittee of experts drawn from all
the welding techniques recom- the major automobile manufacturers
Consistent quality and reliability mended for accomplishing such and related industries.
of welded rocket motor cases can welds are described in detail. Many Regarded as the most compre-
now be obtained, according to an useful tables are given on the hensive manual on _ automotive
announcement by the AMERICAN standards of acceptance for radio- welded design ever published, the
WELDING Soctetry, by means of a graphic inspection, mechanical test- subjects covered include: resistance
recently published, comprehensive ing, visual inspection and other welding, arc welding, oxyacetylene
guide to their fabrication. methods of assuring the highest welding, braze welding and torch
Prepared by the Missiles and possible results. brazing. A unique cartoon ap-
Rockets Welded Fabrication Com- This 72-page booklet, Fabrication proach has been used to emphasize
mittee, it is the first national pub- of Welded Motor Rocket Cases, is the need to design for the process
lication on the subject. The areas packed with information and is a specified.
covered are materials, design, ‘“‘must”’ for all in the missiles and The intent of this publication is
welding and quality assurance. rockets industry. Engineers in to provide a ready reference to each
Included in the Materials Section other fields will find it a valuable of the processes including: a de-
are detailed data on the ultra high addition to their libraries. Copies scriptive pictorial presentation of
strength steels which are capable may be obtained, price $2.50 post- the process; a definition of the
of developing yield strengths in paid, from the AMERICAN WELDING process; joint design recommenda-
excess ol 200,000 psi. Chemical Society, Technical Dept., 33 W. tions; AWS symbol designation;
compositions are given, their me- 39th St., New York 18, N. Y. limitations of the process; and ad-
chanical properties, heat treatment ditional references of any special
and fracture toughness. characteristics of the process and
In the Design Section, each type Automotive Welding Design resulting weldment.
of joint is analyzed and its ad- The manual is slanted to the
Recommended Practices for Auto- needs of welding engineers in the
vantages and limitations discussed.
motive Welding Design is the title of automotive industry but it contains
Illustrations give examples of good a new publication issued by the a wealth of design information
and poor joint design and indicate AMERICAN WELDING Society. The useful to all engineers. Copies may
the advantage of locating a weld manual contains 48 pages, innumer- be obtained from the AMERICAN
in one area as opposed to another able illustrations, and a chart of WELDING Soctety, Technical Dept.,
area. AWS Standard Welding Symbols. 33 W. 39th St., New York 18, N. Y.
The welding requirement for The material was compiled by a com- Price $2.50 postpaid.

778 | JULY 1961 For details, circle No. 24 on Reader Information Card ——>
For the man on the job...

THE VICIOR JOURNEYMAN UNIT

The most flexible, useful tools

in the metalworking industry cnn at i
Journeyman <-—
WELDING AND CUTTING UNIT iesCoreamad
For cutting, welding, melting, brazing, hardfacin
heating, heat treating, heat priming and descaling, TI l€
Journeyman Unit provides a complete outfit of ViéT6R
juality, standard industrial-type equipment, including
Regulators ...SR400 series single stage safety type
Welding Torch... Model 315 (9” long
Cutting Attachment Model CA2050
Welding Nozzles ...Type 4, sizes 1,3
Cutting Tip...Type3-101, size 1 cuts to 1
Accessories... 25 ft. 4” dual hose, goggles, spark lighter
wrench and instruction book (Form 1]

DI iat dk hd
The man on the job using the Journeyman unit will WELOING AND CUTTING unit
prove it costs less to own and operate ViéTOR
Nickel Brazing Data Known as Vacuum Tube Grade al- 100° F. The data contained in the
loys, they are composed of gold, sil- book was compiled from information
Two 8!5 x 11 in. Nicrobraz data ver, platinum or palladium in alloyed developed by the country’s leading
sheets, one (No. 2.2.1) describing or pure form. They are made in industrial corrosion testing labora-
Green Stop-off for brazing alloy various types and compositions to tories. Alphabetical listing of the
flow control, and the other (No. provide brazing properties for almost corrosive media provides ready ref-
2.2.2) on Nicrobraz Cement, a every requirement, and to permit erence and the booklet is a useful
binder for powdered brazing filler selection of the most economical tool for anyone who has an interest
metal, are now available from alloy without sacrifice of quality or in improving a product or a process
Processing Div., Wall Colmonoy performances. Brazing temperatures involving corrosion resistance.
Corp., 19345 John R St., Detroit 3 for VTG alloys range from 1435 to For your free copy, circle No. 57
Mich. 3216° F, with steps provided for on Reader Information Card.
For your free copies, circle No. 51 sequential brazing where required.
on Reader Information Card For your free copy, circle No. 53 Boiler Reference Manual
on Reader Information Card. A new, one-volume reference en-
Resistance Welding Manual titled Boiler: Types, Characteristics
Standards Catalog and Functions has been compiled by
The Third Edition of the Re-
Carl D. Shields, a consulting en-
sistance Welding Manual is now The 1961 Catalog of American gineer and has been published by
complete with the publication of Standards has been published by F. W. Dodge Corp., 119 W. 40th
Volume Il. This companion to the the American Standards Assn., 10 St., New York 18, N. Y.
previously-published Vol. I is fully- E. 40th St., New York 16, N. Y. Covering all practical aspects of
illustrated with photographs, charts The booklet contains a listing of boilers, the book contains 32 chap-
tables, etc. The two volumes (avail- special publications in the standardi- ters organized within 6 major sec-
able separately) now cover the zation field, pamphlets and stand-
entire field of resistance welding. tions: Boiler Classification, Boiler
ards recommendations of the In Design, Steam Generating Equip-
The two volumes containing 617 ternational Organization for Stand- ment, Boiler Construction, Industry
pages are available from the Resist- ardization and the _ International Regulation and Industry Status.
ance Welder Manufacturer’s Assn., Electrotechnical Commission. It also The broad scope encompasses all
1900 Arch St., Philadelphia 3, has an index to titles of American information necessary or helpful to
Pa., at a cost of $7 per set Standards and International rec- the person selecting, installing or
ommendations. operating boilers of all types.
For your free copy, circle No. 54 The book containing 559 pages
AMPCO Alloys, Facilities on Reader Information Card. 7', x 10 in.) has more than 500
A comprehensive description of illustrations, including many tables
its alloys, facilities and products is Cutting Tools and charts. It is available at $15
offered in a new bulletin published per clothbound copy.
by Ampco Metal, Inc., P.O. Box The Carborundum Co., Niagara
2004, Milwaukee 1, Wis. The 16- Falls, N. Y., offers a new catalog Air Filters
page, full color bulletin includes on Stupalox ceramic cutting tools,
chemical compositions, physical with, 28 pages, two colors, in a 3- Wilkerson Corp., 1231 W. Mans-
properties and typical applications hole punched folder, giving the field Ave., Englewood, Colo. has
of a series of special wear and cor- properties data on Stupalox and announced the publication of Cir-
rosion-resistant copper-base alloys specs and prices on throwaway cular 1040. This 8-page catalog
produced exclusively by the Mil- inserts, heavy duty button inserts, illustrates a complete line of filters
waukee firm under the AMPCO solid inserts, unground blanks, single for converting regular factory com-
trademark. The forms in which point tools and tool holders. pressed air to air so pure it is usable
each alloy is available are listed. For your free copy, circle No. 55 for operating pneumatic precision
The new bulletin also describes on Reader Information Card. instruments. Air regulators and
Ampco’s complete and modern pro- air accessories are also included.
duction facilities for sand, centrif- Welding Positioners For your free copy, circle No. 58
ugal and shell mold castings, ex- on Reader Information Card.
trusions, machined parts, fabrica- A 28-page printed article dis-
tions and finished products cussing welding positioners, written ASTM Supplements Availabie
The functions of the company’s by Charles N. Aronson, is avail-
The 1960 Supplements to the
metallurgical and chemical labora able from Aronson Machine Co.,
1958 Book of American Society for
tories are illustrated and its world- Arcade, N. Y. Many features of
positioners that are necessary and Testing Materials Standards are
wide marketing organization is de- now available in 10 parts. Each
scribed. how they work for the user’s benefit
are noted. part-supplement brings up-to-date
For your free copy, circle No. 52 the corresponding part of the 1958
on Reader Information Card. For your free copy, circle No. 56
on Reader Information Card. Book of Standards and 1959 Supple-
ment by including new standards
and revisions adopted in 1960.
Precious Metal Corrosion Resistance of Zirconium For a complete listing of parts
Brazing Alloys write to ASTM Headquarters, 1916
“The Corrosion Resistance of
Special high-purity grade precious Zirconium” is a new _ publication Race St., Philadelphia 3, Pa.
metal brazing alloys for electronic offered by the Zirconium Assn..,
tubes are described in a new data 2130 Keith Bldg., Cleveland 15, Specialty Products Catalog
file published by the American Ohio. This 14-page book contains A compact 4!5-page User’s Cata-
Platinum and Silver Division of detailed graphs for over 100 highly log Folder released by All-State
Engelhard Industries, Inc., 113 corrosive media in concentrations Welding Alloys Co., Inc., White
Astor St , Newark 2, N. J. up to 100° and temperatures up to Plains, N. Y., provides a handy

780 | JULY 1961

and authoritative reference to stand- damage and is designed to be hung are classified and illustrated accord-
ard and specialty products for on the wall for easy reference by ing to use—makes it convenient to
welding, soldering and brazing. welders. It is being made available find information in the booklet.
Helpful charts and tables sum- through Sylvania welding distrib- The wear protection provided on
marize alloy selection. Product utors for distribution to interested industrial and construction equip-
names and numbers are printed in customers. ment by Airco hardfacing alloys
bold-faced type for easy location. is discussed in detail. A description
Fluxes are featured in a _ special Automatic Precision Welding of each electrode is presented along
section. with application data. Over 100
For your free copy, circle No. 59 Developments in automatic pre- specific equipment parts that bene-
on Reader Information Card. cision welding equipment for such fit from hardfacing are listed in an
miniature electronic parts as transis- extensive section, together with the
Welding Automation tors and diodes—-including what is type of wear which each is subject
Acro Welder Manufacturing Co., believed to be the first application and the alloy needed to protect it.
Milwaukee, Wis., has released a new in this field of the new spike welding For your free copy, circle No. 63
bulletin (No. 261) entitled ‘‘Weld- method—are described in a new on Reader Information Card.
ing Automation.” The 16-page cata- publication issued by National Elec-
log illustrates 68 special welding tric Welding Machines Co., Trum-
units with brief captions where bull St., Bay City, Mich. Corrosion Resistance
necessary to describe the specific The 6-page illustrated issue of
Welding News, Vol. 12, No. 2, A new 8!4 x 11 Technical Data
function of the unit. Sheet No. T-1 which discusses
For your free copy, circle No. 60 describes precision capabilities as
well as versatility and application corrosion resistance of Colmonoy
on Reader Information Card. nickel alloys is now available from
range of eight standard and special
welders developed by the company Wall Colmonoy Corp., 19345 John
Pulp Digester Cladding Reprints R St.. Detroit 3, Mich.
for the expanding electronic com-
Reprints (ADR131) of two arti- ponent industry. The range of The literature lists the corrosive
cles on pulp digester cladding en- machines described covers equip- media in which Colmonoy nickel
titled, ‘‘Stainless Steel Weld Metal ment operating in a_ controlled alloys are generally resistant and
Overlay Linings for Pulp Digester atmosphere from single point console discusses corrosion resistance in
Vessels” and ‘‘Current Status al- units to dial feed design capable of general terms. A bar chart is also
kaline Digester Corrosion as Re- 2700 pieces per hr. included which plots corrosion re-
ported by Regional Digester Group,” For your free copy, circle No. 62 sistance of Colmonoy No. 6 vs.
have just been made available by on Reader Information Card. 18-8 stainless steel in sodium hy-
Air Reduction Sales Co., 150 E. droxide (50% at 150° F), sulfuric
42nd St., New York 17, N. Y. acid (10% at 220° F), nitric acid
Revised Alloy Specifications
These articles were presented as 65% at 70° F) and acetic acid
papers at the fifteenth Engineering A second revision of Compilation glacial, boiling).
Conference of the Technical Asso- of Chemical Compositions and Rup- For your free copy, circle No. 64
ciation of the Pulp and Paper ture Strengths of Super-Strength AIl- on Reader Information Card.
Industry (TAPPI) at Jacksonville, loys, containing 12 pages, is avail-
Fla., in October 1960. able from the American Society for
Liberally illustrated, these arti- Testing Materials, 1916 Race St., High-Strength Steels
cles represent the first comprehen- Philadelphia 3, Pa., at a cost of For Missiles
sive survey of digester cladding $1.50 per copy.
failures. Practical recommendations All known alloys are included, Problems in development and
on improving the quality of overlay and those no longer in commercial application of ultra-high-strength
linings are outlined. production, as well as experimental metals used in missiles are featured
For your free copy, circle No. 61 alloys, are so indicated in High-Strength Steels for the Mis-
on Reader Information Card. siles Industry, edited by H. T.
Sumsion and published by _ the
Welded Pipe Joint Design American Society for Metals, Met-
Gas Tungsten-Arc
A-36-page booklet (5!5 x 8!4¢ in. als Park (Novelty), Ohio
Welding Guide
covering many aspects of welded The book, comprised of papers
A new guide designed to assist pipe joint design, written by Stephan presented at the Golden Gate Met-
welders in the proper use of tungsten A. Grubish, president of Steffan als Conference in February, in-
electrodes is being made available Manufacturing Corp., discusses the cludes such subjects as “‘Materials
to the welding industry by the principals of transmission pipe joint and Fabrication Problems in Pres-
Chemical and Metallurgical Div. design. sure Vessels,” “Stress Corrosion of
of Sylvania Electric Products Inc., Copies of the booklet are avail- Aircraft and Missile Steels,”’ ‘‘Frac-
730 Third Ave., New York 17, able from Steffan Manufacturing ture Theory in Pressure Vessels,”
N. Y. Corp., P. O. Box 275, Salem, Ohio, ‘‘Pressure Vessel Reliability,”’ ‘‘New
The Tungsten Inert Gas Welding at a cost of $2 each. Ultra-High-Strength Steel for High-
Guide includes detailed information Performance Rocket Motor Cases,”
about welding procedures for five ‘Fabrication Techniques for Rocket
Hardfacing Electrodes, Wires
metals aluminum, magnesium, Motors” and ‘Future Applications
stainless steel, deoxidized copper and A new 44-page brochure (ADC of High Strength Steels.”’
titanium. Information is arranged 9551 has been issued by Air More than 200 illustrations,
in tabular form in the correct se- Reduction Sales Co., 150 E. 42nd tables, charts and graphs are in-
quence for proper welding pro- St., New York, 17, N. Y., on hard- cluded in the book’s 276 pages.
cedure. facing electrodes and wires. A cross- Price is $12 within the continental
The guide is printed on heavy referenced, pictorial layout in United States and Canada. Else-
coated paper to resist handling which all the hardfacing materials where, add $2 postage

WELDING JOURNAL 781

 Hard Metals Production contain complete information on Metals Course
size, grade, order number, heat
CleMet Products of Cleco Air American Society for Metals,
number and weight.
Tools, a Division of Reed Roller Metals Park (Novelty), Ohio, offers
In conjunction with the color code
Bit Co., P. O. Box 2541, Houston 1, program, a special pocket card is a 6-page folder describing new
Tex., has published brochures de- Metals Engineering Institute Ex-
available showing the complete color
tailing two new products in a line tension Diploma, granted for com-
code to aid the warehouse man in
of materials for the production of pleting sequence of five home study
selecting wire and checking wire
hard metals for general industry. courses in the following subject
inventory.
Bulletin No. CMP-1060 covers areas: Ferrous Metallurgy, Welding
For details, circle No. 67 on
CleMet’s granular tungsten carbide, Metallurgy, Nonferrous Metallurgy
Reader Information Card.
Clec-ite, a high-strength, abrasion- or Metallurgical Processes.
resistant material suitable for appli- For your free copy, circle No. 70
cation in petroleum, construction Ignitron Excitation Circuits on Reader Information Card.
and minging industries whose equip-
ment is subject to extremely rugged, Bulletin PT-50 with 16 pages and
abrasive duty. containing detailed information, of
The second bulletin, entitled Cle- particular interest to designers of Bus Duct Booklet
coloy, features CleMet’s new tubu- equipment for military application, Westinghouse 100-amp bus duct
lar tungsten carbide which is avail- on ignitron excitation circuits is now is described and illustrated in an
able in either oxyacetylene or atomic available from the General Electric 8-page bulletin now available from
hydrogen rods. Power Tube Dept., Schenectady 5, Westinghouse Electric Corp., Stand-
For your free copy, circle No. 65 N. Y. It explains the functions of ard Control Div., Beaver, Pa.
on Reader Information Card. the associated electrodes (anode, The booklet shows how and bene-
grid and ignitor). fits of conventional bus duct
The bulletin details typical cir- flexibility of application, re-use and
X-ray Microscope Problems cuits which assure accurate and re- frequent plug-in openings——-can be
liable firing, and contains schema- obtained for installations where
A new 8-page folder titled ‘‘Iso-
lation of Selected Elements with tics, graphs and charts to illustrate smaller blocks of power are used.
An X-ray Projection Microscope,”’ the technical data. Included are Drawings in the bulletin illus-
reprint of an article by a Pomona selection chart of General Electric trate the construction of the duct
College physicist, is available free ignitrons. and the complete line of standard
For your free copy, circle No. 68 fittings available with it. Typical
from Philips Electronic Instru-
on Reader Information Card. specifications are given.
ments, 750 S. Fulton Ave., Mount
Vernon, N. Y. For your free copy, circle No. 71
The author covers: Basic Idea, on Reader Information Card.
Abrasive Materials
Value of Absorption Coefficient
Ratio, Analyzing Pictures by Elec- The Carborundum Co., P.O. Box
tronics, Analyzing Pictures Photo- 337, Niagara Falls, N. Y., recently
graphically, Preliminary Results, announced the availability of its Silicon and Selenium Rectifiers
Instrument Requirements, and Con- “Catalog of National Standard A new illustrated catalog de-
clusions. Abrasive Belts, Rolls, Sheets and scribing its complete line of cer-
Included in the article are five Discs’’ which lists standard coated tified silicon and selenium rectifiers
drawings, six microradiographs and abrasive products used throughout has been published by the Semi-
a table giving absorption edge data industry. All items listed are main- conductor Div., Syntron Co., Homer
for twenty-one selected elements tained in warehouse stock by elec- City, Pa.
in the atomic scale from No. 6 tronic order processing and inven- Illustrated in color, the eight-
carbon) to No. 82 (lead). tory control. The catalog was said page condensed catalog No. 100
For your free copy, circle No. 66 to be a customer tool to help cut is featured by cutaway drawings
on Reader Information Card. costs and expedite service through revealing the unique construction
use of standard catalog items. features of Syntron’s silicon diodes
For your free copy, circle No. 69 and stacks, and its selenium rec-
Wire Coding on Reader Information Card. tifiers, stacks and cartridge rec-
The Page Steel & Wire Div., tifiers.
American Chain Cable Co., Ist A full list of more than 350
and River Sts., Monessen, Pa., X-ray Analysis Index JEDEC types of silicon rectifiers
recently expanded its color coding The first of a series of biblio- which are available from Syntron
to all forms of its welding wire graphical surveys, the Index to the is included.
packaging and it covers all grades Literature on X-ray Spectrographic Complete electrical and me-
of automatic welding wire. Analysis, Part I, 1913-57 STP chanical specifications are listed in
A specific color is used for each 292, has been published by the individual tables devoted to each
grade of wire (in some cases two American Society for Testing Ma- product line. Typical operating
colors are used for one grade). terials. characteristics of both silicon and
Color is on the cardboard coil liner The 48-page, paper cover, 6- x selenium rectifiers also are shown in
and is also used on the special 9-in. book covers 211 references curves displaying forward current
labels for all spools, reels, cartons, for the years 1913 through 1957, rating levels and derating curves
leverpaks and payoffpaks containing although it is admittedly not an for raised ambient temperatures.
the same grade. This is said to exhaustive compilation. Spelled out in the catalog is
do away with scrap loss due to lack Copies of this book may be ob- Syntron’s unique semiconductor cer-
of identification. tained from ASTM Headquarters, tification and guarantee policy.
Another feature of the color 1916 Race St., Philadelphia 3, Pa., For your free copy, circle No. 72
coding program is that all labels at $1.50 each. on Reader Information Card.

782 JULY 1961

 wanted to be able to move an X-ray
head 6 ft vertically and 6 ft hori-
New Products zontally, as well as to rotate it 90
deg from horizontal to vertical, and
90 deg from side to side—all by
remote control.
‘“‘We mounted a small motor-
operated positioning device on the
end of the ram of a_ standard
Ransome Model 66 Welding Head
Manipulator. The positioning de-
vice offered the required adjustment
of the X-ray beam from horizontal
to vertical and 45 deg on either side
Headshields of the manipulator boom, while the
manipulator itself provided the 6 ft
Lincoln Electric Co., Cleveland, vertical and 6 ft horizontal travel,”
Ohio, announces the addition of a Galton reported
new series of protective headshields For details, circle No. 103 on
to their line of welding supplies. Reader Information Card.
Protection, comfort, convenience
and durability are performance fea- Ball-Type Indicator
tures claimed for the Lincoln Cool-
shield welding helmets. A new “‘Ball-type indicator for
Four styles of the fiberglass and very low flows is available from
McIntosh Equipment Corp., 15
Park Row, New York 38, N. Y.
The indicator is for flows down to
0.075 gpm (water) and cfm (air
to prevent cutting or scoring of
wire, is assured by “‘V”’ notches on
the stripping blades. The upper
blade remains stationary, while
the lower one moves up and down
with piston like precision in a milled
slot. Stripping blades are re-
movable for sharpening and may be
replaced if necessary.
For details, circle No. 102 on
Reader Information Card

X-ray Head Positioner

A slightly modified Ransome
Model 66 Welding Head Manipu-
polyester resin molded Coolshield
lator is being used to position a or gas). Clearly visible from a
provide a wide range of helmet shapes Picker X-Ray head for the Union
to accommodate varying physical distance according to its manu-
Carbide Nuclear Research Div. in facturer, the flow makes the ball
proportions of welders and different
Oak Ridge, Tenn. dance in the toughened glass dome.
working conditions. Pliable ther- “The Picker Co. came to us,”
moplastic headgear easily adjusts to If the flow stops, the ball drops out
said Paul Galton, general manager of sight.
exact head size and forms itself to
of the Ransome Co., Scotch Plains, For details, circle No. 104 on
exact head shape assuring maximum
N. J., “‘because they had a most Reader Information Card
operator comfort.
unusual problem. Their customer
For details, circle No. 101 on
Reader Information Card. Welding Tough Plastics
Known as Sonoseal, a new device
Steel Wire Stripper
which resembles a household sewing
A new tool that ‘‘works like a machine, seals or welds the tough
pair of pliers’ and strips insulation plastic films of the polyester group
from both stranded and solid wire is through the use of ultrasonic energy
being introduced by Holub Indus- sound waves above the frequency
tries, Inc., Sycamore, Ill. of the audible range is available
A single squeeze on the handles is from Internationa! Ultrasonics, 331
said to strip wire clean, without arvedna
7sbghepsy
ead Centennial Ave., Cranford, N. J.
nicking. An arm _ automatically Previously, none of the commercial
drops down to hold jaws open and solutions to sealing these very
prevent crushing of stranded wire. tough plastics were practical.
After wire is removed, a second Technically known as oriented plas-
squeeze releases arm and stripper is tics, the new films achieve their
ready for the next wire. strength in a _ stretching process
According to the manufacturer, which aligns or orients the molecular
perfect alignment of stripping holes chains in such a fashion that the

WELDING JOURNAL | 783

 end product is exceedingly resistant
ARCOS STAINLESS OVERLAY CUTS COST to tearing or breaking.
For details, circle No. 105 on
Reader Information Card.

Multigun Welding Machine

A multigun, inclined-frame-type
welding machine manufactured by
Federal Machine and Welder Co.,
Warren, Ohio, welds oven front
brackets to oven fronts. Equip-
ment is designed with 6 weld-

ing guns and necessary inner die

units. Each welding gun and in-
ner die unit is mounted on a
sub-plate in a guided slide and is
fully adjustable for different sized
assemblies. Electrode holders are
Job Report Courtesy of Pottstown Metal Products Works water cooled and replaceable copper
Cochrane Div. of Crane Co., Pottstown, Pa.
alloy inserts are utilized.
Arcos stainless overlay cuts overall cost For details, circle No. 106 on
Reader Information Card.
of chemical reactor 10%. The application of
lron-free Electrode
a stainless overlay to the face of a carbon steel
A new iron-free aluminum bronze
flange, not available in clad material and too arc welding wire and filler rod have
been developed by Ampco Metal,
expensive in solid stainless, resulted in a 10% Inc., P. O. Box 2004, Milwaukee,
Wis., specifically for overlay appli-
overall saving in the construction costs of an cations.
AMPCO-trode 7 is suggested for
unusual epoxy resin reactor. The overlay was use where high hardness is not
required. It reportedly meets
applied by automatic submerged arc, using Arcos
AWS-ASTM Classification E Cu Al
Type 308 bare wire and Arcosite C7 flux. This is A-1. The material is available in
bare 36-in. lengths for use with the
another example of the economy and performance inert-gas, tungsten-arc welding
process in bare spooled wire for use
you get with Arcos stainless filler metal products. with the inert-gas, metal-arc process.
For details, circle No. 107 on
Reader Information Card.

Magnesium Cleaner
A new cold magnesium cleaner
and bright dip is available from
© #Areos

Bernard Chemical Products Co.,

98-21 Linden Blvd., Ozone Park 17,
Arcos Corporation - 1500 S. 50th St. + Philadelphia 43, Pa. N. Y. The dry-powdered cleaner,
Bernite BR4, used cold, is designed
to remove oxidation products,
For details, circle No. 25 on Reader Information Card
704 | JULY 1961
 Be
Pe St -— ——-
foreign matter and stains from the
surface of magnesium. A solution BETTER WELDING WITH ARCOS SERVICE
of Bernite BR4 may be used for
preparing magnesium for spot weld-
ing or other welding. The solu-
tion, according to the manufacturer,
will not cause a change of dimensions
nor are there any handling, fuming
or toxicity factors to deal with.
For details, circle No. 108 on
Reader Information Card.

Miniature Welds
Automatic Electric Co., North-
lake, Ill., in conjunction with Acro
Welder Mfg. Co., Milwaukee, Wis.,
has developed a special welding
machine to make seventeen minia-
ture welds at one time. The ma-
chine welds precious metal contacts
to their contact arms. The contact
assemblies, part of Automatic Elec-
tric’s new Type WQA Relay, have
a row of 34 contact arms molded into
a plastic mounting bar. 6,96"
3@
0%
@2¢
Seventeen spools of palladium- ©
silver ribbon are fed into the ma- o.2@eo

chine and projection-welded to the

nickel-silver contact arms. The
contacts are cut off in the welder
and the contact assembly indexes to
position for seventeen more welds.
The total of 34 welds per assembly Know what you’re getting—know what
is accomplished in 15 sec. The
welds will withstand over 10 lb of you’re going to get. The combination of Arcos
shear force before failure. quality filler metals and Arcos technical assistance
The miniature precious metal
contact is 0.032 x 0.010- x .002-in.; brings you predictable welding results you can de-
it has a projection, triangular in
cross-section, that is two-thou- pend on time after time—job after job. The skills
sandths inches high and runs the
length of the ribbon. The contact of the Arcos research and service team are avail-
arm is 0.022 diam wire.
For details, circle No. 109 on able to help solve your problems—to give you top
Reader Information Card. performance on every welding job. You can add
Welding, Cutting Outfits quality to your welding and save money by con-
Two new tungsten-inert gas weld
ing and cutting outfits have been sulting your Arcos representative.
introduced by Linde Co., Division
of Union Carbide Corp., 270 Park
Ave., New York 17, N. Y. The
new units, called Heliarc ‘‘Tig-
Twins” Kits., contain all the
standard line Heliarc apparatus and
accessories needed for most average TIRCOS

tungsten-inert gas welding and cut-

ting.
Featured in the HW-17 kit is the
air-cooled HW-17 torch which has a Arcos Corporation - 1500 S. 50th St. + Philadelphia 43, Pa.
continuous-duty welding capacity
of 130 amp, ac or de. It is ap-
plicable for light-gage metals cut- For details, circle No. 26 on Reader information Card

WELDING JOURNAL 785

 tists of International Nickel Co.,
Now you can check Inc.
WELD TIME with The discovery—made at the com-
pany’s Bayonne, N. J., Research
new PORTA-COUNT Laboratory—-paves the way for a
new family of high-strength ‘‘Mar-
cycle counter aged”’ steels with advanced engi-
neering design possibilities for
civilian and defense applications
involving exceptionally high pres-
sure and stress.
It is the only known material
which has the ability to achieve a
Counts actual weld time during firing.
PORTA-COUNT is light and small enough yield strength in excess of 250,000
to carry easily-—keep right on the job. psi while maintaining a nil ductility
Completely portable and self-contained temperature below -—80° F. An-
with long life (up to 2 years) batteries other outstanding characteristic of
Counts single phase
18° nickel steel is its excellent electrically controlled gas and water
No Plug In No Clips No Clamps notched tensile strength which ex- valves; high frequency intensity
PORTA-COUNT uses an inductive pick up ceeds 400,000 psi—-(measured under control; direct or remote operation;
to count, sensing magnetic field around the most severe test conditions with post flow control and pilot light.
power line, welding buss, transformer or
electrodes. a notch radius 0.0005 in.). Tests For details, circle No. 113 on
have shown that this new alloy Reader Information Card.
INSTRUMENT CONTROL CO. possesses a remarkable resistance
2309 Snelling Avenue
Minneapolis 4, Minnesota delayed cracking when exposed to
a severe corrosive atmosphere in a Cutting Machine
For details, circle No. 27 on Reader information Card highly stressed condition.
The new steel develops its high The Model TE-250 Lennox Tru-
strength while maintaining un- Edge MetlMastr manufactured by
matched ductility and toughness by the Lennox Tool and Machine
ting. Cutting speeds on ;-in. means of a remarkably easy heat Builders, Lima, Ohio, will cut in
aluminum range between 10 and 40 treatment involving age-hardening the center of ' ,-in. mild steel plate
ipm and 10 and 20 ipm on '/,-in. of martensite. This treatment has
stainless steel. been given the abbreviated descrip- ‘v
Included in the HW-20 kit is a tion of “‘mar-aging.”’
featherweight water-cooled HW-20 The 18% nickel steel can be
torch which is capable of welding at readily welded by either manual or
200 amp continuous duty, ac or automatic methods. Sound, crack-
de. Its higher-rated cutting ca- free welds are achieved, even on
pacity permits cutting of most light- material in the fully heat-treated
to medium-gage metals condition, without preheating.
For details, circle No. 110 on Post-weld mar-aging restores the
Reader Information Card. softened heat-affected zone of the
parent plate to full strength and
establishes in the weld metal proper-
Hard-Surfacing Electrode
ties closely approaching those of the
A new hard-surfacing electrode is base plate. without a starting hole. It also
available from McKay Co., 1005 A patent application covering has a variable stroke mechanism
Liberty Ave., Pittsburgh 22, Pa., this new nickel steel has been filed which is easily and accurately ad-
for use on equipment with surfaces with the U. S. Patent Office. justable for cutting various gages
that are subjected to metal-to- For details, circle No. 112 on of mild steel, stainless steel, alumi-
metal frictional wear or severe Reader Information Card. num or copper. It cuts at a rate
earth scouring under low stress of feed up to 36 ipm.
conditions. For details, circle No. 114 on
McKay Hardalloy 48 is an Gas Tungsten-arc Welding
Reader Information Card.
iron powder, low-hydrogen hard- Compact design, simplified opera-
surfacing electrode with deposition tion and low cost are features of a
rates said to be 50°; higher than new TIG-WELD 295 ac Tig Welder New Manual Gun
conventional electrodes. The sur- recently announced by the Emerson
for Thin Gage Metal
face of the weld bead is said to be Electric Mfg. Co., 8100 Florissant
extremely smooth, minimizing fric- Ave., St. Louis 6, Mo. A new, low-cost, air-cooled weld-
tional resistance. Designed for a welding range of ing gun, designed specifically for
For details, circle No. 111 on 13 to 295 amp, this new a-c welder the gas-shielded metal-arc welding
Reader Information Card provides economical operation in of thin gage ferrous metals, has
many applications such as truck, just been announced by Air Re-
bus and boat repairs, new con- duction Sales Co., 150 E. 42nd. St.,
New Nickel-alloy, Stee! New York 17, N. Y. This manual
struction, tool and die shops, custom
A new 18% nickel alloy steel alloy fabrication and window frame Model AH30-A gun has particular
with reported unmatched toughness construction. Its many deluxe fea- value on applications requiring rug-
at the highest strength levels of tures include fully rated duty cycles gedness, high duty cycles, and an
traditional alloy steels has been for gas tungsten-arc welding—40% absolute minimum of downtime,
discovered and developed by scien- at 200 amp, or 30° at 295 amp; qualities especially appropriate to

706 | JULY 1961

 W-4000-FSR is characteristic of all
Sonoweld® ultrasonic welding equip-
ment—that the power source can
be remotely located from the welder,
even on a different floor if desirable.
Only small interconnecting cables,
which can be a hundred feet or more
in length, are required between the
welder and power source, thus
making installation and portability
of the equipment a simple matter.
The welding machine fits easily
into closed-packed production areas
where a minimum of space is

the automotive industry and most

other fabricators of mild steel. It
is used for welding steel with the dip
transfer process. The Finest Available!
For details, circle No. 115 on
Reader Information Card. STULZ MANGANESE-XL
For high-strength joining of dissimilar car
Easy to Open Electrode Carton bon and alloy steels. Excellent shock resist
‘“‘Quick-Lid” is the name of new ance. Porosity free. Easily cut by oxy-acety-
mild steel electrode carton which lene. Good vertical welding. Low hydrogen
was recently announced by Hobart
Brothers Co., Troy, Ohio. Austenitic manganese-nickel analysis.
This new carton is not only easier AC-DC
available. ‘These welders are con-
to open than the conventional elec- veniently operated from remote lo- write for name of nearest distributor
cations and, of course, the power
source can be placed as far from the STULZ-SICKLES COMPANY
welder as necessary. 929 JULIA ST. © ELIZABETH, N. J.
The ultrasonic coupling system, producers of famous manganal steel products
which is the backbone of ill ultra-
sonic equipment, has been rede-
signed to permit greater accessibility For details, circle No. 28 on Reader information Card
of the welding tips into hard-to- handles enables them to sit much
reach locations. The ultrasonic closer to the torch body, providing a
coupling system incorporates water lower profile and making the valve
cooling to permit high welding handles considerably less vulnerable
repetition rates at higher powers to damage from blows or dropping.
than previously possible. The The new, husky, solid brass valve
greater welding throat depth of 36 handles are specially designed for
in. greatly increases the size of positive grip control. Handles are
trode carton but offers more pro- weldable components over earlier
tection to unused electrodes from permanently press-fitted to the
models. valve stems which are equipped
damage, dirt and moixture. For details, circle No. 117 on
Built in pull tabs when pulled in with oversized lifetime packing
Reader Information Card sleeves of antifriction Tefion
opposite directions expose the entire
length of the electrode box. The Valve bodies are of sturdy die-
New Torch Valve Design forged bronze with accurately drilled
electrodes are cradled in a strong
separate liner to keep them in Dockson Corp., 3839 Wabash, gas and air ports.
perfect condition when the ‘‘Quick- Detroit 8, Mich., has announced an For details, circle No. 118 on
Lid”’ is replaced improved design and stream-lining Reader Information Card.
For details, circle No. 116 on of the valve systems on all their
Reader Information Card. welding and cutting torches Redesigned Magnetic Force
According to Charles Piggott, Welding Machines
Ultrasonic Welding Machine vice-president of the Dockson Corp.,
the concave design of the new valve Clean lines, full visibility and
Sonobond Corp., West Chester easy access to magnetic system
Pa., subsidiary of Aeroprojects Inc., components mark new models of
has announced a new 4000-w capac- PVA-1 magnetic force resistance
ity ultrasonic spot-type welding welders recently announced by Pre-
machine. The new _ welder _in- cision Welder and Flexopress ( ‘ rp.,
corporates many advances in the Cincinnati, Ohio
development of ultrasonic welding PVA-1 standard welders are now
equipment, as well as_ features offered in 20, 30, 50 and 75 kva
found desirable from field experience models. These magnetic force ma-
with previous models. chines are primarily designed for
In addition to a throat depth production welding of critical mate-
which has been increased to 36 in., rials, heretofore difficult o1 im pos-
another feature of the new Model sible to weld Such combinations

WELDING
 anywhere on the cap... within
180 deg positioning . . . to be out of
the way and to give proper balance
on the worker’s head.
For details, circle No. 120 on
Reader Information Card.

Dual Spot-Welding Tip Holders

A new dual spot-welding electrode
holder device has been announced
by Air Reduction Sales Co., 150
E. 42nd St., New York 17, N. Y.
Called the Equa-Press Dual Holder,
it automatically exerts equal forging
pressures through its two tip-hold-
ing barrels regardless of ° minor
variations in work thickness or
electrode wear. The equalizing lb, one-fourth less than its prede-
include welding silver tungsten to
cessor.
brass, stainless to brass, and copper
The Mobile Ferroscope can re-
to copper. “ portedly find defects such as thermal
Magnetic force welders employ an
cracks, hot tears and shrinkage in
electromagnet, energized by the
castings, thermal and crater cracks
weld current, to coordinate’ weld
and lack of fusion or penetration
heat and forging pressure more pre-
in welds, and fatigue cracks, lamina-
cisely than can be done by pneu-
tion and forging flaws in a variety of
matic or hydraulic means.
applications.
The PVA-1 models are all based
For details, circle No. 122 on
in cabinets 20 x 36 x 64 in. A 20
Reader Information Card.
kva bench model (PVB-1) and larger
standard PVB-2 models of 100, 150,
200 and 250 are also available. Cadmium Sulphide Cell
For details, circle No. 119 on Amperex Electronic Corp., 230
Reader Information Card. Duffy Ave., Hicksville, L. I., N. Y.,
announces a miniature photo-con-
Safety Cap with Goggles mechanism is purely mechanical
ductive cadmium sulfide cell type
and provides maximum conduc-
Newly developed, lightweight side ORP90 with high sensitivity to
tivity through its working parts. A
arm attachments for combining visible light. It features a dark
water cooling system is_in-
safety caps with goggles are now in current of only 2.5 microamps, and
corporated.
production by The Fibre-Metal an average cell current of 10 ma
The use of offset tips gives a
Products Co., 5th & Tilghman Sts., with 5.0 foot candles illumination
range of distances between welds of
Chester, Pa. The side arm at- (color 2700° K).
from 0 to 4 in. Models are avail-
tachments enable quick connect- Because of this high sensitivity
able for mounting in a welder arm
disconnect through a minor adapta- (pictured) or for bolting to a press
tion of the standard QUICK-LOK® welder platen. Reduced welding
Attachment (a kind of universal time for a given number of welds
with good weld uniformity and
precise spacing between welds are
the claimed benefits of the new dual
holder.
For details, circle No. 121 on
Reader Information Card.

Small Mobile Magnetic Tester

A much lighter and smaller ver-
sion of a mobile 3000-amp magnetic
particle unit has been developed for
industrial inspection of a wide
variety of metal products according
joint that can interchange the to the Picker X-Ray Corp., White and its high dissipation rating of |
goggle or goggles with most other Plains, N. Y. w, the ORP90 can actuate relays
Fibre-Metal Welding Helmets, Face The unit, called the Mobile directly, without need for the con-
Shields or Face Masks). Ferroscope, operates on a-c or ventional amplification stage. ‘The
The combination illustrated (F- half-wave d-c current and is said to ORP90 is designed to be used in
1055-P-2Q), of SuperGlas Safety be especially effective in detecting relay and illumination stabilizer
Cap with Solo goggle, may be used surface and sub-surface flaws on applications. Its miniature size
by those workers who require full parts too large for inspection on makes it feasible for the ORP90 to
time head protection with inter- stationary wet horizontal units. be mounted directly in the probes of
mittent eye protection. The Solo The new Picker unit measures only flame control apparatus.
goggle, when not in use, is merely 23 x 37 x 37'/; in., rolls easily on For details, circle No. 123 on
extended over the Cap bead to rest solid rubber casters and weighs 600 Reader Information Card.

788 | JULY 1961

Two-Stage Regulators ing at a glance all ‘“‘on”’ and “off”
time recorded. The recording op-
A new series of two-stage reg- eration is said to be completely
ulators is produced by Kim Prod- automatic, the stylus being actuated
ucts, Lexington, Ky. The company by the welding current itself for
reports that output pressures are “on” tabulation. Access is provided
not affected by varying inlet pres- for operator to write directly on
sure, and flow capacity is not re- tape at relevant point any reason
for downtime.
Also furnished is a time totalizer
which accumulates the “‘on’’ read-
ings from the tape and shows total
productive time (to min) for
any given period.
For details, circle No. 125 on
Reader Information Card.

Hard Facing Increases The Finest Available!

Pump Screw Life
A change of the hard-facing mate- STULZ UNIVERSAL HARDFACE
rial used to rebuild the flights of Reduces need for inventory of a variety of
stricted by extra valving. These cement pump screws at the plant
regulators will not flutter or vibrate, hardfacing. All-purpose electrode used in
of Kennametal, Inc., Latrobe, Pa., heavy industry and mining where varying
even when full cylinder pressure is has increased the service life of the
suddenly applied with the pressure screws from an average of 2 months conditions of abrasion, impact and metal-to
adjustment turned to maximum. to 6 months. metal wear occur. Rapidly self-hardens up to
Compact, rugged, Kim gages are
said to be unaffected by over- 53 R.C. Low hydrogen type. Forgeable. AC-DC
pressure, even full tank pressure,
name of nearest distrit
and are not subject to easy breakage.
For details, circle No. 124 on STULZ-SICKLES COMPANY
Reader Information Card.
929 JULIA ST. © ELIZABETH, N. J
pr f manga
Time-Indexed Tape
Recording Instrument
For details, circle No. 29 on Reader information Card
Using a _ recording instrument whose only duty is to load parts,
available from the Weld-Record has been developed by National
Corp., 2105 Dawson Rd., Albany, Electric Welding Machines Co.,
Ga., job and production data may 1846 Trumbull St., Bay City, Mich.
reportedly be obtained directly from Automatic application of paste
welding machines or devices. Re- is a feature of the special machine,
sults show increased efficiency with designed to assemble an accelerator
substantial savings. linkage consisting of two levers and
Designed to provide data on any 2 rod. Company engineers report
type of job from large or small pro- the machine has wide application
duction work to maintenance and where a brazed joint is indicated but
repairs, instruments are equipped where an oven js economically im-
with time-printed chart rolls which practical. They cite carburetor
feed continuously while a_ ball- In addition, downtime for chang- parts and filler necks on portable
point stylus draws graph lines show- ing screws has been greatly reduced gasoline tanks as typical applica-
and the time of application of hard tions.
facing is less than half. This means Production of 300 units an hour
a saving of 2 to 4 hr of plant down- is reported on the brazer. In pro-
time each time a feed screw replace- duction, the operator loads the two
ment is eliminated, and a reported levers in self-aligning upper and
saving of a full day’s time for hard lower fixtures, slips the rod in posi-
facing the screws. Screw life was tion and then depresses a foot switch
lengthened with a tungsten carbide to begin the automatic sequence.
hard-facing material to further im- The Geneva actuated dial table
prove the carbide’s_ effectiveness first indexes to the paste station
over formerly used material where two pairs of applicators,
For details, circle No. 126 on positioned 180-deg apart, meter a
Reader Information Card combination flux and solder com-
pound to the upper and lower joints.
Eight-Station The air operated applicators are
rocked into the work. Each ap-
Brazing Machine plicator has its own reservoir. The
A new automatic eight-station work is then indexed to the first
dial feed brazer capable of high of two preheat stations where eight
hourly output with one operator gas jets--four on each joint—-bring

WELDING JOURNAL 789

 plate.
These nails serve to anchor the
trim plate in proper position on the
automobile.
For details, circle No. 128 on
Reader Information Card.

Helium Leak Detector

A new high sensitivity, dual-range
helium detector that permits quick
and precise location of helium leaks
in tanks, piping and other fittings,
has just been announced by In-
dustrial Instruments, Inc., Cedar
Grove, N. J. The two-range fea-
ture is said to permit high sensitivity
the work up to 400° F. Heat is pickup of small leaks while mini- make operation of the instrument
increased to 800° F at the second mizing overdrive of the meter on easier and more convenient.
preheat station. The Immerscope is used for ul-
Preheating is required because trasonic nondestructive testing of
of the thickness of the 1010 steel plates, ingots, pipe, tubing, forg-
used; in. for the levers, and ings, castings, welds and _ other
, in. for the rod. bonds, rolled shapes, honeycomb,
Final heat station where brazing extrusions, etc. Inspection is not
actually takes place, brings the limited to metal objects; other
work up to 1100° F with special reasonably elastic materials such
flame thrower type jets. Gas jets as glass, hard rubber and ceramics
at each of the heating stations are can also be inspected.
positioned for pinpoint heat control New features claimed include:
on the work. The jets revert to built-in facilities for high-sensitivity,
pilot between indexes to conserve high-resolution contact testing; var-
gas output. iable pulse repetition rate, high
For details, circle No. 127 speed flaw alarm circuit (for posi-
Reader Information Card.
tive automatic warning when flaws
are detected), built-in recorder out-
put circuits for direct connection to
Nail Welding Machine
Curtiss-Wright electrosensitive re-
The Taylor Winfield Corp., 1048 large leaks. The thermal conduc- corders, and built-in video delay
Mahoning Ave., Warren, Ohio, has tivity sensitivity detector is powered circuit.
a machine whereby standard round- with mercury cells, assuring long For details, circle No. 130 on
head nails are mechanically fed from battery life. The unit includes a Reader Information Card.
a hopper and into a rotary indexed “transport position’’ on the range
upper electrode to weld 45 nails selector switch to short out the
Decade Counter Tube
per min. meter movement during transporta-
Trim plates may be flat or have tion. The Type Z302C, a cold cathode,
return flanges. Various shapes and This detector is available in two gas-filled decade counter tube which
sizes of plates are manually indexed models: Model HDL incorporating is said to provide an output pulse
along the edge guides provided. a hand pumped rubber aspirator of such magnitude that the usual
Tooling permits either direct or bulb for use where no 115v ac power interstage coupling amplifier is not
indirect welding with no surface is available, and Model HDLP with needed, has been announced by
marking on the show side of the a small 115v ac operated vibrating Amperex Electronic Corp., 230
reed pump to draw the gas for Duffy Ave., Hicksville, L. I., N. Y.
scanning through the detector. The Indication is by an orange-red
unit can be calibrated for use in glow discharge which is viewed
detecting hydrogen and other gases. through the dome of the tube
For details, circle No. 129 on envelope at the end of the elec-
Reader Information Card. trodes.
The Z302C is designed for use in
sealers and industrial counting per-
Ultrasonic Testing
forming such functions as batching,
The Model 424-D Immerscope, frequency division, pulse selection,
produced by the Princeton Div., timing and the counting of random
Curtiss-Wright Corp., Princeton, pulses.
N. J., represents over five years of Being a cold cathode tube, it
continuous research, development, requires no heating power, nor is
production and field use for ul- there any warm-up time. It is
transonic nondestructive testing. inoperative during standby periods
The new model has new features and, therefore, is reportedly a very-
that are said to increase its flexi- long-life device. Another feature
bility and range of usefulness, and is freedom from photoelectric ef-
additional detail refinements to fects with the ignition character-
 clude joining gold leads to gold
plated semiconductor material, and
gold, silver and aluminum leads to SPRA y.
germanium, silicon and ferrite. We ER HARD
Other materials such as paladium, x Se i, ‘@)
copper, quartz and tellurides may
be ultrasonically joined by this
instrument
The spot welder is also useful in
joining polyester film materials in-
cluding those which have been
vacuum coated.
For details, circle No. 132 on
Reader Information Card.

Unit Welds Pails

High speed, fully-automatic pro-
jection welding of pail and drum
bail ears is made possible for the The Finest Available !
first time in the container industry
with a new machine developed by STULZ SPRAY-ROD
National Electric Welding Machines For “spray on’ layers of hardfacing. Goes
Co., 1846 Trumbull St., Bay City,
Mich. The unit welds both ears on fast! Hard, smooth skin to protect all
simultaneously and is said to achieve steels against abrasion. Fine for edge-fac-
istics remaining constant during production of up to 2400 con- ing where section is important. AC-DC
daylight and darkness. tainers an hour on drums and pails of
Also comprising this family of 3'/, to 8-gal capacity.
In operation, expanded, beaded write for name of nearest distributor
tubes are the Types Z303C, sim-
ilar to the GC1OB and 6802, and and flanged containers are auto-
matically fed into the unit and first STULZ-SICKLES COMPANY
the Z502S similar to the GS10C and 929 JULIA ST. e ELIZABETH, N. J.
6476. The Z3038C is a bidirectional pass through an orienting station
which positions the work for weld- producers of famous mangana
decade counter tube and the Type
Z502S is a _ bidirectional decade ing. A chain conveyor then indexes
selector tube. All three types oper-
ate at speeds up to 4 kc. ’ For ‘details, circle No. 30 on Reader information Card
For details, circle No. 131 on Automatic Sample Changer
Reader Information Card.
An automatic sample changer that
Ultrasonic Foil “efficiently handles up to 30 solid
radioactive samples and may be
Welding Machine used for automatic absorption curve
Commercial production of a new measurements” has been added to
10-w Glennite ultrasonic welder the nuclear instrument line of
has been announced by Gulton Picker X-Ray Corp., 25 S. Broad-
Industries, Inc., 212 Durham Ave., way, White Plains, N. Y.
Metuchen, N. J. The changer holds planchet sam-
The welder can spot weld foil ples up to 30 mm in diam and 3
in thicknesses ranging from 0.00025 the container to the weld station. or 8mm high. It can be used with
to 0.002 in. Using high frequency Ears are hopper fed into a pair a Picker proportional flow counter,
vibrations to weld without heat or of gate-type escapements, one on Geiger tubes or alpha, beta and
without materially deforming the each side of the weld station, from gamma scintillation detectors, the
metal, the new product produces where they are picked off and car- announcement said.
welds that are as strong or stronger ried to the pail by the outside weld- Two different data printing sys-
than the parent material. Her- ing rams as the rams move forward tems can be used—a count-and-
metic seals are also provided. on the work stroke. Inner weld time printer and a less expensive
Applications for the welder in- heads are synchronized to rock into printing timer. The count and
position opposite the oute heads time printer are said to record up
to complete the welding circuit. to 999,999 radioactivity counts and
After the ears are welded, the con- up to min, and print this
tainer is automatically ejected into information alongside the sample
the user’s take-away conveyor. number.
Two 75 kva transformers, one Printing is performed by an
for each set of rams, provide weld- electric typewrite! which can be
ing power. An automatic lubricat- hand operated to make margin
ing system and a common motor notes on the tape. The printing
drive off which all mechanical timer records the time required
motions are synchronized, are other to reach the preset amount of radio-
features of the machine. activity.
For details, circle No. 133 on For details, circle No. 134 on
Reader Information Card Reader Information Card

WELDING JOURNAL | 791

Welding Viewer junction with a wide variety of
compression loading equipment for
Airline Welding and Engineering, performing ball punch and cup-type
15899 S. San Pedro St., Gardena,
ductility tests.
Calif., has developed the Shield-all For details, circle No. 136 on
Weld Viewer. This weld shield
Reader Information Card.
takes the hood off the welding op-
erator. It may be used in any ap-
Oxyacetylene Hole Cutter
Model ST Hole Cutter, a greatly
simplified and reportedly much less
expensive machine for cutting 90
deg holes in pipe, tanks and flat
plate was recently announced by black figures and polished chrome
Steffan Manufacturing Corp., casings. The thermometers are
1585 S. Lincoln Ave., Salem, Ohio. graduated 2 deg divisions.
Three sizes permit cutting per- The thermometers come in two
pendicular holes up to 18 in. in temperature ranges: Model No.
diam without cams, patterns 01 APFT 460 for the range from +32
to 320° F and Model No. APFT
plication where the operator must 161 for the colder ranges of —14° to
have complete visibility of the weld, 134° F.
but requires frequent removal of For details, circle No. 138 on
the hood. Reader Information Card.
Model WH6B embodies a flip-
up front for natural viewing. A
6-power magnifier can be installed Motor Shell Manufacturing
to enable the operator to follow a Automated
joint when welding at low amperages
on thin material. A light may be A machine made by Precision
installed under the lens to aid op Welder and Flexopress Corp., Cin-
erator vision. Model WH11 pro cinnati, Ohio, takes a stack of slotted
vides a viewing area of 20 sq in. steel blanks, rolls them into cyl-
layouts. It is a lightweight machine inders, welds them to exact circum-
4x 5in.
For details, circle No. 135 on that may be used with electric drive ference, and ejects them at a rate
or may be completely hand operated of 420 per hr.
Reader Information Card
in the field. It forms and assembles a variety
Cutting is accomplished with an of shells which Westinghouse uses
Adapter Units for Ductility Tests oxyacetylene torch arrangement for fractional-horsepower appliance
which is reported to overcome many motors. Cut blanks are loaded
A self-contained adapter unit of the difficulties encountered with into a magazine which feeds them
is said to permit existing com- previous methods. Edges are clean, from the bottom of the stack into a
pression equipment to be used in burr-free and have excellent weld- roll forming mill. After the mill
making ductility tests on sheet ability according to the company. has formed the blank into a cylinder,
metal up to s-in. thickness. Grinding is not necessary as little an air-operated transfer mechanism
Named Sheet Metal Tester Cell slag is accumulated.
Model CTC), the new unit is the For details, circle No. 137 on
result of over a year of development Reader Information Card.
work by Detroit Testing Machine

Pipe Thermometer
The Abrax Instrument Corp.,
179-15 Jamaica Ave., Jamaica 32,
N. Y., has announced a new pipe
thermometer that simply, easily
and instantly clips to steam, water,
refrigeration, gas and other pipes
by means of twin spiral spring clips
supplied with each instrument. The shuttles the shell to the weld station.
instruments can be attached or Air-operated, wrap-around clamps
r-- removed from the pipes in seconds mold the shell firmly to the welding
and require no alteration of the arbor, and carry current as a rocker-
pipes. This factor is said to elim- type, antifriction head mash welds
9390 Grinnell Ave., Detroit inate any need for branching or the seam. Then the clamps relax
3, Mich. Tests by the company drilling. The thermometers are and the welded shell is automatically
reportedly show that this _inex- precalibrated to counteract the pos- ejected from the arbor into a dis-
pensive unit offers results as ac- sibility of error through heat losses charge chute.
curate as those of machines costing of radiation or convection. Clamps and arbor are adjustable
three times as much. The tester They can be used for all pipes for various lengths of motor shells
cell is a compact unit weighing up to 3'/, in. in diam. The dials For details, circle No. 139 on
22 lb. It may be used in con- are 2'/, in. in diam, silvered, with Reader Information Card.

792 | JULY 1961

Brazing Alloy Strip transmitters, has been developed
by General Electric’s Power Tube
A reportedly unique physical
Department.
form for brazing alloys has been
Scientists and engineers at the
developed by Western Gold and
department Traveling-Wave Tube
Platinum Co., 525 Harbor Boule-
Product Section, Palo Alto, Calif.,
vard, Belmont, Calif. The new
have announced a technique for
configuration, known as ‘“Wesgo
making wave guide power filters
Polyform,”’ is said to provide greater
which effectively eliminate RFI
brazing convenience and economies caused by harmonics.
in a wide range of applications,
Working on a principle analogous
particularly in laboratory and pro- to that of the common automobile
duction brazing of vacuum-tight muffler, General Electric’s new
seals for electronics. filters absorb the unwanted har-
Since the L-shaped strip is slotted
monic signals produced by all trans-
along its widest dimension, . the
mitting tubes, but still allow the
intended fundamental frequency to
pass through with its power un-
diminished The Finest Available !
For details, circle No.
Reader Information Card. STULZ PIERCING ELECTRODES
Cryogenic Pump CUT - GOUGE - CHANNEL - PIERCE. Removes
any metal: cast iron, stainless, copper, armor
Cosmodyne Corp., located at
plate, aluminum, brass, bronze, nickel, man-
12833 Simms Ave., Hawthorne,
Calif., has announced a single cyl- ganese steel, monel, etc. Use on DC ma-
inder, high-pressure, cryogenic chines without special attachments. Leaves
pump, designed for low and medium scale-free surface. DC
flow ranges.
This unit, available from produc- write for name of nearest distributor
company claims it can be _ bent
tion delivers liquefied gases, such
around virtually any contour to STULZ-SICKLES COMPANY
as oxygen, nitrogen and hydrogen,
form round, rectangular, oval or 929 JULIA ST. e ELIZABETH, N. J.
at pressures up to 10,000 psi and
any other shape of brazing alloy flows up to 4.65 gpm (26,000 scfh producers of famous manganal steel product
desired. Its principal economic
of N The pump, although com-
advantage over conventional pact and weighs only 42 lb, is
punched washers is stated to be the For details, circle No. 31 on Reader information Card
designed for commercial and _ in-
elimination of scrap, which is par-
ticularly beneficial in precious metal
Net positive suction heads as
alloys. It also eliminates the neces-
low as 10 psig are possible due to the
sity for special tooling to produce
hydrodynamic design of the inlet
unconventional shapes. port, and a vent port, which removes
The strip can be supplied in thick-
entrained gas from the inlet liquid
nesses down to 0.002 in. The width
and prevents cavitation
of the serrated or punched out For details, circle No. 142 on
section can be varied from ' , to Reader Information Card.
in. in '/g-in. increments. The
strip is available in all of the low Variable-Frequency Generator
vapor pressure brazing alloys of- dustrial applications, and features
fered by the company. for Ultrasonics Studies
low maintenance operation.
For details, circle No. 140 on The pump is designed with three A 2-kw variable-frequency ul-
Reader Information Card. separate thermal sections cryo- trasonic generator covering an ex-
genic, intermediate and ambient tremely wide range of output fre-
Solution Seen for temperatures—-separating the cryo- quencies, power levels and im-
RF Interference genic pumping end from the lubri- pedances, is available from Inter-
cated drive end. national Ultrasonics, Inc., 1697
A solution to the growing problem
Heat transfer from the warm Elizabeth Ave., Rahway, N. J.
of radiofrequency interference
drive end to the cold end is reduced Intended primarily for research and
RFI) from high-power microwave
by the intermediate temperature, development work in_ ultrasonic
dead-gas space of the interbody, cleaning, welding and _ soldering,
reducing heat absorption and cavita- the generator pre »vides flexibility
tion. for determination of optimum power,
The cold end has a low thermal frequency and impedance for spe-
mass, allowing for rapid cool down, cific applications; allows trial of
reduced start time and liquid losses. widely-differing transducers and
The cold end requires no lubrica- loading conditions; and permits
tion, except for the cyrogenic fluid general investigations unhampered
being pumped. The _ drive-end by the limited output values avail-
lubrication is circulated by the able from standardized ultrasonic
mechanical action, and is sealed by generators.
springloaded, self-adjusting chevron For details, circle No. 143 on
packings. Reader Information Card

WELDING JOURNAL 793

:
é

SUREWELD WELDING RODS hove

long been preferred by metal fabri-
cators. A leading automobile manvu-
facturer uses Redifluxed® No. 30, a
pre-fluxed, low cost, high quality
bronze rod for braze welding light
gauge steel.

a ea

Whe
n
wel
din
g is

wed ‘Electrodes, Welding

Rods and Wire meet the test

The critical jobs . . . those that demand un- your nearby NCG Sales Office, Distributor
usually high performance under exacting or Dealer for SUREWELD Data Sheets giv-
conditions, that require extra ability-to-per- ing complete and detailed information oneach
form . .. put fabricating methods, equip- SUREWELD product and its applications.
ment and materials to the real test. Also, write today for the new NCG Elec-
It’s on jobs like these that SUREWELD trode Data Book . . . an informative 20 page
electrodes, welding rods and wire prove they catalog to help you in choosing the correct
are built-better to do better-work. Each are electrode for any application. Ask for
manufactured under a program of exacting NH-504-E-1G. NATIONAL CYLINDER
quality control, beginning with testing of GAS DIVISION OF CHEMETRON COR-
raw materials and continuing through every PORATION, 840 N. Michigan Avenue,
step in production to final testing of the Chicago 11, Illinois.
finished product. NCG sales offices, distributors, and dealers
Find out what SUREWELD electrodes, in all principal cities. Consult the ‘‘Yellow’”’
welding rods and wire can do for you. Ask pages for the one nearest you.
NCG, SUREWELD, DUAL SHIELD, REDIFLUXED are Trademarks
©1961, CHEMETRON CORPORATION
 SUREWELD ELECTRODES are used
for all kinds of jobs. No. 6013, devel-
oped for welding light and heavy
gauge steel, provides equally good
results when welding vertically down,
overhead, horizontal or fiat fillet welds:

SUREWELD WELDING WIRE is rapidly

growing in use. A heavy equipment
manufacturer has cut production costs
with the Dual Shield, CO, automatic
and semi-automatic, welding process,
and No. 111A multiple-pass wire for
welding mild steel.

SUREWELD DATA SHEETS Complete, de-

tailed information; welding characteristics, welding
procedures, color identifications, physical proper-
ties of deposit metal, etc.

NEW ELECTRODE CARTON . Strong, moisture-

resistant carton for maximum protection. Also, a
new zipper opens carton easily, about one-third
comes away and the remainder provides excellent
temporary storage.

NATIONAL CYLINDER GA
Diviotor of- |CHEMETRON / (o1601alore i
¥ NEW ELECTRODE SOUND, COLOR STRIP FILM
— "How to Select an electrode” is available from
For details, circle No. 36 on Reader information Card your nearby NCG sales office. See it soon.
 J
Joining tubular members is easy for Howe Folding Furniture, Inc., of South Norwalk, Conn. Joints
are fluxed with Handy Flux, a half-circle preform of EASY-FLO brazing alloy is dropped down
the tube and a torch is applied. Result: A smooth, strong joint quickly and economically made.

How Handy & Harman Brazing Alloys

GIVE FOLDING FURNITURE 100% JOINT RELIABILITY

The experience of Howe Folding Furniture, Inc., with silver brazing merits close
attention if your operations involve metal-to-metal joining of any kind. Howe
manufactures folding metal tables and seats for commercial, industrial and insti-
tutional use. You can imagine the hard usage the furniture has to take—yet survive
indefinitely.
Some years ago, it was Howe’s practice to purchase prefabricated steel tubular
assemblies in which the joints were brass brazed on the outside surface. To im-
prove their product, Howe thoroughly tested all joining methods, and decided
~ g0 — te altves brazing . their own plant, using Handy & Harman EASY- ET SS Te OY PE A
O Alloys 45 and 35. Look at the results: conweed te Gn saditcciom
Complete Joint Reliability: Since adopting silver brazing, Howe has completely bench with backrest in a single
eliminated the problem of broken joints. motion. Silver brazed joints eas-
Economy: Silver brazing costs Howe less than other methods, requires less heat- Uy absorb strains.
ing time, simpler equipment, much less cleaning and grinding of joints.
Appearance: Silver brazing provides a smoother, more attractive joint, that can
be plated directly.
Isit any wonder Howe says: “We'd stay with silver brazing even if it cost more?”
There are few fields of industrial activity where the strength, high production
rates and economy afforded by the Handy & Harman family of silver brazing Rei | ae
alloys cannot improve the look of the balance sheet. Interested in complete dee juaNDY @ HARMAN
tails? Just write for a copy of our Bulletin 20— it’s packed with engineering 59 Third Avenue, New York 22, N.Y.
and application data. PLaza 2-3400
For details, circle No. 32 on Reader information Card
See the next page for details.
 nit at
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UNION
CARBIDE
 July 1961
Card valid until Sepiember 30, 1967
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49 74 99
50 75 i100

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706 Air Products Incorporated
760 Air Reduction Chemical & Carbide Co.

770, ,.
Outside Air Reduction Sales Company
Back Cover
704 All-State Welding Alloys Co., Inc.

699 Alloy Rods Company

American Pullmax Co., Inc.

Arcair

Arcos Corporation

758 Clement Products Div. of Cleco Air Tools

766 Coyne Cylinder Co.

33 New
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July 1961 703 Harnischfeger

Card valid until September 30, 1961 697
Hobart Brothers Company
Please send me, without cost or obligation, further
information and literature on items circled below: 786 Instrument Control! Co.

saat Jackson Products

764 Lenco, Inc.

743-46 The Lincoln Electric Company

797-98 *Linde Company, Division of

Union Carbide Corporation
759, 761
The McKay Company
103 763
104
10s 775 Metal & Thermit Corporation
107 755 Miller Electric Manufacturing Co.
108
a 794-95 National Cylinder Gas
112 772 Phoenix Products Co.
113 '
4 772 Royco Instruments, Inc.
116 787, 789 ,
oo 791,, 793 Stulz
tul Sickles
kles C ompany
mg
120 704 Tempil® Corporation
121
= 797-98 Union Carbide Corporation
124 Linde Company
125
—— 779 Victor Equipment Company
a list of AWSpublications *For details, circle We. 33 omReader Information Card
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 Welding

Research Sponsored by the Welding Research Council

of the Engineering Foundation

SUPPLEMENT TO THE WELDING JOURNAL, JULY

Phenomenological Considerations in Ultrasonic Welding

Equipment and techniques are developed for observing phenomena and

evaluating factors relevant to ultrasonic welding

BY B. JONES, N. MAROPIS, J. G. THOM D. BANCR'

ABSTRACT. Investigation resulted in to determining the oy passing duce a , ea in 0.001-in.

special instrumentation and techniques through and beyond the weld zone thick stainles eel. ¢ race a large
for observing phenomena and inter since this n t be deducted from the range } e ord yf { 00 }joules.
preting factors relevant to the ultra total delivered ultrasonic energy to The net ergy required for welding
sonk welding process It included determine the net energ required to copper sheet ot he same thickness
preliminary study of certain ultrasoni produce a weld. The energy passing falls betwee
weld phenomena and considered th through the weld zone can be measured 6. Interf i ' nce and
influence of material properties on by the standing-wave-ratio techniqu¢ Metallurg {xplorat were made
weldability. In particular, methods 1. Temperatures Developed in the into the characteristics the inter-
were developed to study Weld Zone Che need for reliable in faciai disturbance routinely observed in
1. Stress Distribution in the Weld formation on weld-zone heating and the ultrasonic welds in various materials.
Zone. Photoelastic techniques were necessity for correlation thereof with Various metallurgica mena were
considered and later developed to per the process variablesare obvious A noted [his facet of th vestigation
mit observing and photographing the cordingly 1 fine-single-wire-thermo served to orient n subsequent work
internal dynamic stress pattern asso couple technique was developed to which will be repo i 1 second
ciated with the applied statk ind accomplish temperature sensing The paper } itora graph tech
superposed oscillating shear forces technique was used to obtain prelimi nique i ng eta emission was
associated with producing a spot-type nary but significant information con utilized erin ally possible
weld between two sheets of metal cerning the effect on the weld tempera device fo udying interfacial dis
The work was carried far enough to ure of the process va bl powe! placements where d metallog
establish the usefulness of this tech clamping force and w ime —for raphy was inadequate sower energy
nique in studying the stress distribu copper, aluminum and iron Validity beta radiation was found to be essential
tion in the weld zone of the temperatures obtained was con to obtaining meaningful information
) Vibratory Energy Delivered to firmed by means of f a meltable-insert Metal displacement, recrystallization
the Weld Zone Possible techniques technique diffusion, phase transformation and
were investigated for determining total 5. Material Properti nd Their miscellaneous effects were noted in
delivered energy ind instantaneous Relationship to Ultrasonic Weldability various materials
values of power delivered during the A statistical approach to determine the
interval in which a weld is generated relationship of material pro] 3 to Introduction
No practical method for measuring ultrasonic weldability was considered Ultrasonic welding has become in-
transmitted ultrasonic power was avail at length, but the com; ind the creasingly practical throughout the
able. Thus a_ standing-elastic-wave effort required appeared to be exces
measurement technique was developed sive. Success in utilizingthe standing pa - See During this
its validity established in calorimetrix wave-ratio method for measuring the period, considerable research and
experiments, and its use reduced to net energy required to generate a weld development relating to the applica-
routine suggested a less complex method, i.e., tion of ultrasonic welding to various
3.? Energy Transmitted Through thi an “‘order of weldability”’ in terms of problems has been completed with
Weld Zone. Consideration was given energy and material thickness should gratifying results Furthermore,
yield correlation with certain material considerable progress can be re-
The authors are with Aeroprojects In« properties, whi h could be determined ported in isolating the effects of
ere > ste : f sis ot ater. . .
Chester, Pa by systematic analy material various fundamental! factors, in-
his paper reports on work accomplished un properties
; data, including variations
with temperaturs It was determined cluding material properties. The
Phase I of an extended study of the fundamentals basic bonding
of ultrasonic welding under Navy Contract No that the net energy involved in generat : : Teprocess associated
were ded wy
cam provider suines ef
ry :RO "GCrustatson de tan.t
of the ing a weld of unit area, for example,
> re two sheets 00 , thick*k
with
wor thisaa new OIning
ever,* has not been 7 . method,
completel . . how-
terials Branch, Airborne Division, Bureau of between sheets of 0.001-in. I y ex-
Naval Weapons aluminum, and that required to pro- plained.

WELDING RESEARCH SUPPLEMENT 289-s

 Efforts prior to this program were least, were known to be involved:
aimed largely at developing equip- 1
Stress distribution in the weld
ment for making reproducible welds, , zone.
investigating the weldability of
various materials, determining cer- Energy delivered to the weld
tain properties of ultrasonic welds, zone.
and investigating certain specific Energy transmitted through
applications. !~¢ In general, this the weld zone.
approach was successful in achieving Temperature developed in the
essential short-range objectives. weld zone.
However, prior to this program, no Properties of the materials
significant effort was applied to in- being used.
vestigating such important funda- Interface disturbance and
mental factors as the relation of metallurgy.
FORCE material properties to their weld- . .
ability or to the acquisition of basic A reasonably complete investiga-
Fig. 1—Ultrasonic welding transducer knowledge relating to the mecha- tion of these areas was accomplished,
coupler system nism by which ultrasonic welds are the initial phase of which is covered
generated. Hypotheses were ad- by this paper. This phase included
vanced to explain this new joining the establishment of reliable qualita-
process but systematic investigation tive and quantitative methods for
was not possible. evaluating and investigating each of
The research program described the six factors listed. Each area
in this paper was undertaken to was investigated separately, though
develop fundamental theories of it was evident that considerable
ultrasonic welding that will account interdependency of the factors
for the observed effects and that can existed. Present plans are to dis-
be used to improve the design of cuss the effects of these factors in a
ultrasonic welding equipment and second paper.
to extend the usefulness of the
process. Discussion of Investigation
and Procedure
Background
Ultrasonic welding is a nonfusion, Stress Distribution in the Weld Zone
solid-state process for joining metals Evidence exists that welding is
without the aid of solders, fluxes or accomplished, at least partly, as a
filler materials. The metals to be result of deformations at the weld
joined are clamped at low static interface. These act to disintegrate
pressures between a welding tip, or and to disperse surface film, both in
sonotrode tip, and a suitable oppos- a manner and in an end effect re-
ing tip or anvil. Vibratory energy markably unlike the phenomenon
is delivered to the sonotrode tip associated with pressure welding.
from a transducer acting through a These interfacial deformations result
resonant coupling system. The from the combination of oscillating
ultrasonic energy is applied for a shear forces and superposed static
brief interval, usually not exceeding clamping force applied through the
about 1.5 sec. A strong metallurgi- sonotrode tip and opposing anvil
cal bond is produced without the face. The process achieves con-
significant external deformation that siderable local deformation at the
characterizes pressure welding and interface being welded, with rela-
without the cast metal zones asso- tively little deformation at the sur-
ciated with resistance welding. faces where the static force and
Pioneered in the early 1950’s, elastic vibratory forces are applied.
development began with the success- Within the range of weldment thick-
ful welding of thin gages of alumi- nesses studied, measurements show
num. Since then, the process has that the external deformation is
been applied to many metals within nearly always less than 5% of the
the limits of power available in total thickness of the sheets being
existing equipment. Spot weld welded. Inspection of numerous
strengths have generally been in microsections of welds in foils and
excess of values considered satis- thin sheets reveals internal disturb-
factory for aircraft structural appli- ances affecting as much as 80% of
cation, and the success of the pro- the total thickness. In thicker sheet
gram has led to the consideration of materials, the actual internal distur-
ultrasonic welding for an ever-in- bances affect about the same volume
creasing number of applications. as in thin foils. This, of course,
ain frame with polariscope and represents a much smaller _per-
Scope centage of the total thickness.
close-up view of triaxially restrained-type
A (top), strain frame in Most of the fundamentals were Internal deformation can _ be
operating position; B (bottom), plastic previously defined but were not in- examined and measured in photo-
direct-observation vestigated until initiation of this micrographs of ultrasonic welds.
type model under sonotrode tip program. The following factors, at Such measurements are indicative of

290-s | JULY
 the stress distribution existent at calibrated spring resting upon the
completion of welding after a tem- central column. The _ transverse
perature rise of some magnitude; forces were originally applied by
they are not necessarily related to weights connected through a pulley
the stress distribution existent dur- system to a lateral member pinned
ing the initial and presumably to the central column, as shown in
critical part of the welding cycle. Fig. 2B. Later modification re-
To isolate the vectorially combined placed the weight-and-pulley system
static and oscillatory forces from with air cylinders, which permit
other variables that affect the weld, more convenient load adjustment.
photoelastic techniques of study Model Configurations. Originally
were developed. it appeared that a “‘frozen-stress’’
It had generally been considered model would be required to give
that the photoelastic analysis would meaningful results, since triaxial
be applicable only under stresses restraint on the vibratory stress
that would maintain the materials in zone might affect the stress distribu-
the elastic range. It was further tion. However, preparation of such
considered that photoelastic studies models is time consuming and
would not be feasible under condi- prohibitively expensive where a
tions of plastic flow. Hence, the wide range of conditions must be
initial experiments attempted to investigated. Thus, consideration
establish steady-state conditions was given to developing models that
just below the yield point as a would provide similar restraint with-
means of approximating force-flow out the tediousness of the stress-
conditions. As the investigation freezing technique. ‘Three types of
progressed, it became apparent that photoelastic models were investi-
the photoelastic analog was also gated: (a) plank, (6) frozen-stress
applicable into the plastic flow range and (c) direct-observation triaxially
and that direct observation of restrained models.
internal plastic deformation might Plank model: A thin slab or
have meaningful results. plank-type model permits detailed
study of the weld interface in which,
Equipment. For observing the
from a dimensional standpoint, the
photoelastic effects, a General Radio
interfacial detail is probably not
Type 1534 polariscope with 8-in.
greatly different from that of the D
polarizer and analyzer was obtained.
triaxially restrained model. The
Brief preliminary studies with a Fig. 3—Plank models with ltoading con-
model consisted of two pieces, 3 in. ditions specified: A, with 35 Ib nor-
crude model were made to establish long by 15 in. wide by '/, in. thick
criteria for the design of a strain mal and zero lateral load; B, with 55 Ib
cast resin. * normal and zero lateral load; C, with 55
frame suitable for appropriate load-
Frozen stress model: The stand- Ib normal and 14.5 Ib lateral load to the
ing of large-scale photoelastic models ard-type frozen-stress model pro- right; D, with 55 Ib normal and 14.5 lateral
of ultrasonic welds. load to the left
vides triaxial restraint of the model
This strain frame was designed to weld zone approximately as it exists
simulate the welding of two pieces in the sheets for a metal weldment.
of sheet metal, the top sheet of Any single frozen-stress model can
which is 0.050 in. thick, with a provide a pattern of the stress
typical ultrasonic welding array resulting only from the resultant of
shown in Fig. 1. Various dimen- the single value of clamping force
sions of this array (such as tip and the single associated value of
radius, position of drive on the reed shear force existent when the stress
and flexural wave length in the reed pattern is frozen. Freezing is ac-
that might affect the stress pattern complished by a laborious thermal
in a photoelastic model were con- cycle, and the model is later
sidered for photoelastic scale effects. sectioned and a thin portion re-
Provision was made for applying a moved for study. It is not feasible
controlled force normal to the weld- to use this technique to study the
ment and slowly oscillating a second broad range of tip geometries and of
force essentially parallel to the sur- normal and lateral load combina- Fig. 4—Transducer-coupler array for
face of the model weldment. tions essential to a _ systematic standing-wave-ratio measurements
To simulate ultrasonic welding investigation of the internal stresses
procedures more closely, a strain that lead to welding.
frame capable of applying normal However, a_ few frozen-stress
and “in-plane” forces to photo- models were developed and used to
elastic models was designed and ascertain the validity of the stress
fabricated. Figure 2A shows the patterns evident in the direct-
strain frame in operating position in observation triaxially restrained
the polariscope and the cylindrical models described below.
sonotrode tip in contact with one of Direct-observation triaxially-re-
the types of models being studied. strained model: A model was
Normal forces are applied by means
of the hand screw at the extreme top * Catalin cast resin, 61-893, from the Catalin
of. the frame, which acts on a Corp. of America, New York, N. Y Fig. 5—Standing wave ratio diagram

WELDING RESEARCH SUPPLEMENT | 29l-s

 developed which would simulate effected. with a commonly used commercial
weldment restraint on all three axes Independent Evaluation of Stress negative film. Still photographs
and still permit direct observation. Distribution Analysis. Since the enlarged from these frames are in-
This early model consisted of optical DOTRM was a somewhat novel adequate for two reasons: (a) Still
Plexiglas (which has an extremely concept in photoelastic model de- enlargements in the range above »
low photoelastic fringe value and an sign, it was deemed advisable to 10 are not adequately sharp, and (6
elastic modulus of 450,000 psi) with subject its validity to review. After the time period associated with
a photoelastically sensitive insert of examination of the program in con- stress reversal is not bracketed
,;- in. thick cast resin (elastic siderable detail with Professor M. tightly enough. Before undertaking
modulus of 610,000 psi). It was M. Frocht of the Illinois Institute of analysis of the dynamic stress sys-
considered that modification of the Technology, the use of this concept tems in photoelastic models, it will
true stress pattern in such a com- appeared to be justified. be necessary to overcome these
posite model would be within limits Improvements in Techniques. As inadequacies by means of other film
that would permit valid interpreta- work progressed, refinements were and equipment, e.g., still photo-
tion of the results. Residual made in the equipment and tech- graphs of 35-mm frames at about
stresses resulting from cementing niques. The strain frame was 4 enlargement to provide satis-
were relieved by heat treatment of altered to provide more sensitive factory sharpness, and 64 frames /sec
the model. control of the oscillatory lateral to bracket the time period of stress
Model Configuration Evaluation. forces on the model. It was noted reversal more sharply.
The fringe pattern existent in a that, as the lateral force reached the
Determination of Vibratory Energy
direct-observation triaxially __re- point of incipient slip at the tip- Delivered to the Weld Zone
strained model (DOTRM) is a work interface, rapid and significant
tunction of applied normal (clamp- changes took place in the stress The vibratory energy delivered to
ing) load: (a) Zero load, (6) 35-lb patterns. ‘To obtain more sensitive the weld zone is dissipated in a
load, (c) 55-lb load, (d) 75-lb load, control of the lateral force at this variety of ways. A trifling fraction
e) 108-lb load and (f) 125-lb load. point in the applied stress cycle, of it is always present as elastic
The plank-type models provided compressed-air cylinders with pro- energy stored in and adjacent to the
weld zone. A large part of it pro-
sharp and clear fringes. As ex- vision for precise control of force
pected, the Plexiglas blocks on the duces either plastic deformation in
build-up were utilized.
polarized-light-source side and the Interim refinement of the tip-work the weld zone or local slip at the
camera side of the photoelastic contact-zone condition was accom- weld interface and appears as heat,
plished by incorporating tips of which flows outward under the in-
insert of the triaxially restrained
models involved some refraction and Gafite* having an elastic modulus of fluence of the resulting temperature
gradient. Some of the energy is
reflection, reducing sharpness and 750,000 psi. This just exceeds the
clarity. Comparative scanning of radiated acoustically into the mate-
modulus of the sandwich inserts of
the stress patterns showed lace- the DOTRM and offers a more rial around the weld zone, and some
like, asperity-produced fringes along is transmitted to the anvil beneath
reasonable approximation of the
the interface of the plank models relative modulus and surface inter- the weldment and is lost to weld
appearing as a smudged band in the action existent in actual welding. generation.
triaxially-restrained models. The A complete photoelastic equip- Accurate determinations of the
effect of triaxial restraint was evi- acoustic energy delivered to the
ment array, including provisions for
dent. Fringes produced in the welding tip are fundamental to any
taking motion pictures, evolved
study of the ultrasonic welding
plank-type models had somewhat from these efforts. The white-light
different shape and pattern. process. In particular such meas-
source is directed through the re-
With allowance made for mis- urements, combined with a
flecting diffuser tube and through a
match between the restraining ma- knowledge of the tip velocity, permit
diffusing and filter screen to the
terial (Plexiglas) and the Catalin calculation of the transverse force
polarizer behind which the DOTRM
insert, the fringe patterns clearly exerted by the tip on the weldment
photoelastic models are loaded. At
delineated internal stress distribu- and of the acoustic resistance pre-
the opposite end of the essembly is
tion across the weld zone. Elastic sented by the weldment to the tip.
the motion-picture cumera, which
deformation was also indicated, al- Unfortunately, precise determina-
has been used to obtain several
though a detailed photoelastic analy- tion of this energy is not straightfor-
series of motion pictures to date.
sis will be required to deduce the ward.
The strain frame permits applica-
individual components of the stress Methods of Measurement. At
tion of axial force to the model by
tensor. least three methods might be used to
means of a screw which acts to
With a plank model, a normal- determine the vibratory power de-
compress a calibrated spring against
plus-lateral loading combination was livered to the weld zone as a function
the upper end of the reed element.
observed and photographed —Fig. of time during a welding cycle:
Lateral force is applied to the reed
3. Although photoelastic stress- in either direction by means of air a) Measurement of electrical
pattern symmetry of right and left cylinders located under the air power delivered to the trans-
normal-plus-lateral loading was not lines. The lateral force can be ducer with appropriate deter-
achieved in this exploratory study, built up slowly to and beyond the minations of transducer
it appeared that, in the loading point of slip, or it can be alternated characteristics.
range examined, the zone of inti- rapidly to simulate force application Determinations of the stand-
mate interfacial contact shifts from in welding. ing-wave ratio in an element
a central zone under normal force To date, 16-mm motion pictures of the coupler system.
only to zones displaced from the exposed at 32 frames sec have been Measurements at the weld-
axis of symmetry. The lace-like obtained with the camera loaded ment: (1) acoustical (fre-
fringes adjacent to the interface quency, oscillatory force,
indicate this to be the energy sink amplitude and shape of dis-
in the system, i.e., the zone where * Product of the General Aniline and Film placement curve); (2) calori-
maximum temperature rise might be Corp., New York, N. Y. metric.

292-s | JULY 1961

 Experimental Considerations. In- exponential taper, was wetted with and
dications were that standing-wave- a tin-lead solder flux and then cast A (ellipse
ratio (SWR) measurement promised into a cylindrical lead billet. Use of
to produce the greatest amount of the solder coating prior to casting in where
reliable information most economi- the lead billet ensured a metallurgi- P power, watts.
wy 2 xf, radians /sec where /
cally. Thus, this was the avenue cal bond between the tapering steel quency
thoroughly explored in the study. rod and the lead, ensuring that the area of rod, m
In addition, it has the distinct ad- lead billet would couple to the density, kg/m
vantage of eventually permitting tapered steel rod and thus constitute wave (longitudinal rod) veloc-
ity, m/sec
rapid response recording, enabling a sink for the elastic vibratory amplitude of wave traveling
the computation of instantaneous energy traveling down the bar from toward load.
values of impedance during weld the transducer. Isolation of the amplitude of reflected wave
formation. entire system from its mounting and traveling back toward trans-
ducer
When vibratory power is trans- supports was insured by the use of transverse particle acceler-
mitted along a coupling member by force-insensitive resonant mounts. ations which are proportional
means of longitudinal waves, appro- The entire array, with thermal to longitudinal displacements
priate measurement of these waves insulation removed, is shown in and to which mi rophone ele-
ments respond
can be used to compute values of the Fig. 4.
power transmitted. Theoretical The lead cylinder and the portion the power transmitted via a
proof of the validity of a proposed of the steel coupler between the vibratory coupler is proportional to
concept for such measurement was SWR sensing element and the the resulting elliptical area traced by
obtained, and suitable apparatus cylinder were equipped with thermo- the horizontal and vertical deflec-
was prepared and installed. couples to permit determination of tion of the beam of the cathode ray
Experimental Procedure. The temperature rise. This, in turn, tube, to which the signals from the
sensing elements used to detect permitted calculation of the energy sensing elements, after appro-
vibratory amplitude in the coupler delivered by the transducer-coupling priate amplification, are applied.
must be calibrated in some manner to the lead billet. The temperatures developed at
In order to achieve this, an experi- With the transducer and the various points along the coupler rod
ment was performed in which trans- instrumented coupler length dis- are shown in Fig. 6. Most of the
mitted power was determined calo- connected from the lead billet and heat is developed where the steel
rimetrically. Comparison of this its cast-in-place tapered coupler sec- enters the lead, so it seems that the
known magnitude with the uncali- tion, oscillograms associated with transition from steel to lead should
brated indications of the SW micro- the delivery of power into air were have involved a more gradual taper.
phones served to calibrate the obtained. Additional oscillograms One infers that energy delivered to
latter. Moreover, the validity of were obtained with the coupler de- remote parts of the lead results
the SW measurements was thus livering power to water. Traces primarily from thermal conduction.
verified over a wide range of ampli- were also taken with the lead billet Integration of the thermal energy
tudes. At the same time, it was in place at two power levels, 100 and distribution shown in Fig. 6 provides
relatively straightforward to meas- 100 w. Air loading gave the highest an immediate determination of total
ure the total electrical power de- SWR, which is to be expected. energy absorbed
livered and thus to determine the If the microphones, which are Figures 7 to 10 show calorimetric,
net acoustic efficiency of the entire acceleration sensitive, are properly electrical and ellipse area meas-
system. located, the SWR is equal to the urements made afte! ultrasonic
The SWR sensing elements ratio of the major to the minor axis energy had been applied for 20
microphones were cemented a of the ellipse—-Fig. 5. The power min to the associated insulated lead
quarter wave length apart along a being delivered at the instant the mass. Figure 7, shows that energy
coupler rod of 1',,-in. diam trace is photographed is_ propor- delivered to the lead is directly
wave length The input end of tional to the area within the ellipse proportional to the electrical power
the coupling rod was attached to a From input, within the precision of the
magnetostrictive nickel transducer, measurements. These data also
and the output end, machined to an suffice for a determination of the

Fig. 6—Temperatures achieved in lead billet after 20 min

of ultrasonic activation of transducer-coupling at 400-electrical Fig. 7—Energy transmitted to lead billet in 20 min as a function
watt input of electrical input power

WELDING RESEARCH SUPPLEMENT 293-s

 LEAC
T

TRANSMITTED
ENERGY

we wo PSE AREA SQUARE INCHES

Fig. 8—Oscillographic ellipse area as a function of Fig. 9—Energy transmitted to lead billet related to
electrical input power oscillographic ellipse area

over-all conversion efficiency from in. Armco iron. With a 3-in. radius
electrical to mechanical power, spherical tip, and a flat-faced anvil,
which is approximately 28 to 30% welds were produced in each mate-
and in good agreement with the rial at each of two power levels
accepted values for magnetostrictive 800 and 1600 electrical watts to the
nickel transducers. transducer as measured with a VAW
Figures 8 and 9 show the propor- meter*), at each of two clamping
tionality between ellipse area, elec- forces (250 and 750 lb), and with a
trical power and thermal energy. weld time of 1.5 sec. For each set
(Since these data were obtained, the of data, three welds were made, and
accuracy of this type of observa- Polaroid photographs of the oscillo-
tion has been greatly improved, scope traces were taken immediately
particularly at low power levels. after initiation of the first weld (0.2 Fig. 10—Experimental welding array with
Difficulty was encountered in ob- sec), at the middle of the second standing-wave-ratio-sensing elements
taining accurate values for the weld (0.75 sec), and near the com- attached to ultrasonic coupler
ellipse area at low power levels. It pletion of the third weld (1.4 sec).
is clear from a priori considerations Table 1 presents data calculated cycle. This variation may be
that zero power must correspond to from the oscillograms for each set of greatest at the lowest clamping-
zero ellipse area, and that, therefore, conditions: standing-wave ratio, force level. It appears that effi-
these values may be used only for area of the ellipse, acoustic power ciency is related to clamping force,
the purpose of discovering the slopes traversing the coupler as calculated the higher efficiencies appearing at
of the respective lines. The need from equations previously pre- the higher clamping force for alumi-
for somewhat improved technique is sented, and the efficiency, .e., num and at the lower clamping force
evident, but the validity of the acoustic power/electric power for ingot iron. Further investiga-
method was established. 100. tion is necessary to establish opti-
Further Experiments. In an effort As suspected, the acoustic power mum clamping force and power re-
to associate the electrical energy is not high; moreover, the values lationships. This topic is discussed
delivered to the transducer with the listed in Table 1 have not been more fully further in this paper.
acoustic energy traversing the corrected for the possible losses Except for two values, the effi-
coupler the SWR technique was mentioned. Variations in the SWR, ciencies noted in Table 1 range
applied to a 2-kw ultrasonic welding the acoustic power level, and the below about one-half that which can
system using the arrangement illus- efficiency may be partially ascribed be expected from nickel transducers.
trated in Fig. 10. The measure- to variations from weld to weld; In essentially all cases, the lower
ments on this system have two however, agreement is reasonable. i.e., better) standing-wave ratios
potential sources of error. First, These data indicate that the correlate with the higher clamping
some of the acoustic energy thus delivery of acoustical energy is in- forces. The voltage reversal ob-
measured may traverse the upper fluenced by clamping force. This is tained in the one set of values with
reed-support mass and not be de- expected, since the clamping force is ingot iron is yet to be explained, as
livered to the weld zone at all. one of the factors that dictates the is the differing efficiency and clamp-
Second, some portion of the energy acoustic impedance presented by the ing-force relationship for the same
traverses the weld zone itself and is weldment to the tip. The utility of material.
lost through the anvil. Measure- this type of instrumentation for
ments of energy losses in the two control of the entire welding process Energy Transmitted Through
zones should permit correction for is clearly demonstrated by these the Weld Zone
these errors. data. It has been pointed out that
Investigations were made with The data show considerable varia- determination of ultrasonic power
four different materials: 0.032-in. tion in acoustic power during a weld actually dissipated within a weld
1100-H14 aluminum, 0.032-in. 2024- zone during generation of a weld is
T3 Alclad aluminum alloy, 0.032-in. * Model 102 from the John Fluke Mfg. Co., not straightforward. The SWR
commercially pure copper and 0.028- Inc., Seattle, Wash. technique measures the energy de-

294-5 | JULY 1961

 livered to the weld zone, but these
data also include whatever fraction
Table 1—Results of Standing-Wave-Ratio Measurements
of the energy passes through the During Welding of Several Materials
weld zone to be dissipated elsewhere.
Determination of true energy loss
via the anvil was not carried out. Electric Time after
However, it was considered desirable power tc Clamping start of Standing pse Acoust!
transducer force weld, wave i power, Efficiency,
to explore the compliance of the sec ratio } Ww ofO
anvil during generation of welds in
several materials. This is one of
several promising approaches for
determining weld quality during
actual weld generation. Anvil com-
pliance was evaluated by means of
microphone sensing elements at-
tached to the anvil and connected to
suitable recording equipment.
Experimental Procedure. Initial
studies were made with anvils of
varying geometry and _ material,
since both characteristics were
known to play a role in preventing
transmission of energy beyond the
weld zone. Impedance mismatches
at the junction of materials with
different acoustical properties were
considered, with no clear-cut results
Anvils were then equipped with
barium-titanate microphonic ele-
ments, which in operation were con-
nected to suitable automatic record-
ing equipment. Both low-speed d-
recording equipment and high-speed
oscillography were used, the latter
proving more satisfactory.
Records of signal level as a func-
tion of time during the entire ultra-
sonic weld cycle indicated no sub
stantial changes after the first 0.2
to 0.3 sec. Therefore, a series of
welding operations was studied and
microphone signals recorded with
high-speed equipment during the
initial 0.2 sec of weld time.
Four sheet materials were used in
the studies: 2024-T3 Alclad, 0.040
in. thick; 1100-H14 aluminum,
0.050 in. thick; CP copper, 0.032 in.
thick; and Armco ingot iron, 0.028
in. thick. Each was welded at three
applied power levels (800, 1000 and
1400 electrical watts to the trans-
ducer), and at two clamping forces
340 and 1000 lb
Results and Discussion. It is
significant that every time the
clamping force was low, the signal
envelope was erratic in shape; in-
crease in applied power did not
appreciably alter the signal magni-
tude. It might be concluded that
the low clamping forces were inade-
quate for some of the power levels
utilized.
At the highest power-highest
clamping force condition, the enve-
lopes for all the materials studied
were of similar shape and magni-
tude. After the initial pulse, all
showed a decline in signal level that
could be associated with the lower
maximum temperature observed ates that maximum voltage from sensing

WELDING RESEARCH SUPPLEMENT 295-s

 with adequate clamping-force levels. The thermocouple junction con- oscillographic records are smooth,
It appears that, at a suitable sisted of the weldment itself, and a clean curves rising steadily until
clamping force for the power level single wire potted into the zone of well after the normal ultrasonic
used, the anvil response becomes the intended weld. The thermal welding time (less than 1.5 sec).
sensitive to some factor or factors electromotive force data were re- The clamping force was 400 lb, and
associated with weld generation, corded by moderate-speed oscil- the power values noted are electrical
possibly temperature and the result- lography. Three materials were watts delivered to the transducer.
ing transient material properties. selected on the basis of previous The highest initial rates of tempera-
experience and current interest: ture rise were achieved at the lower
Evaluation of Temperatures
Developed in the Weld Zone a) 0.032-in. 2024-T3 Alclad alumi- power levels, suggesting that 400-lb
num alloy sheet; (6) 0.032-in. CP clamping force was inadequate to
It has long been known’ that copper, hard; and (c) 0.028-in. ensure coupling between the sono-
ultrasonic welding produces a tem-
Armco ingot iron sheet. Each was trode and the weldment at the
perature rise at the interface be- welded to itself, effecting a mono- highest power.
tween the sheets being welded.
metal weld between the sheets and a The single-wire thermal electro-
Inasmuch as this increase in tem- bimetal thermocouple junction with motive force technique was also
perature transiently affects the prop-
the wire. utilized to explore the temperatures
erties of the materials during weld-
Appropriate properties of these developed at the two outer faces of
ing and possibly is related to the
metals and data for the thermo- the weldments, i.e., at the sono-
welding mechanism, the phenom- couple wire material used to form trode-weldment and anvil-weldment
enon required investigation. A
the junctions are shown in Table 2. interfaces, and to compare them
preliminary calculation, in which
Figure 11 shows typical weld- with the interface temperature
thermal losses to tip and anvil were
interface temperatures recorded simultaneously developed. It was
neglected, indicated that in a typical
with a Brush d-c amplifier and strip- repeatedly observed, in the cases of
case, a temperature rise of about
chart oscillograph. In general, the aluminum and copper, that the
600° F could be expected after 1 sec,
with an actual net power input to interfacial weld-zone temperature
the weld zone of 200 w."’ Subse- invariably exceeded the temperature
quent work showed that neglecting at the sonotrode and anvil contact-
ing faces by 75 to 200° F. No
the vertical losses was not justified,
but the general magnitude of the similar temperature difference was
expected temperature rise has been detected with iron.
confirmed. The second approach to determi-
Experimental Techniques. Two ' nation of temperature achieved
procedures for determining tempera- during formation of a_ vibratory
tures achieved during ultrasonic weld involved metallographic tech-
welding were explored: a) re- niques and study of weld cross sec-
cording thermal electromotive force tions. In particular the following
Fig. 1l—Temperatures developed at weld were considered:
data obtained from a thermocouple interface during welding of 0.032-in. 2024
in the weld zone, and (6) metallo- T3 Alclad aluminum alloy at various power a) The use of foil or fuse wire
graphic study of the materials levels inserts or of surface plating

Table 2—Material Data

Thermal —Thermal emf
Noted conductivity," Specific Material Tempera-
Density temperature cal/cm, heat," of opposing ture, Voltage,
Metal p, g/cc Cc F cm?/sec/° C cal/gm/° C junction F mv
Aluminum 7 0 3 7 0.2079 Monel ).009-in. wire 100 0.76
5 0.520 500 6.7
100 0.540 1000 15.6
600
Constantan, 0.013-in 100 52
0.948 wire 500 2.57
0.908 1000

lron Alumel, 0 025-in. wire 100

0.173 500
212 0.163 1000
392 0.147 1500
932
1400
1472 0.071
1832
« At ‘‘noted temperature."

296-s | JULY 1961

 aluminum, 0.032 in. thick, to itself; these temperatures were generally
Armco ingot iron, 0.028 in. thick, to associated with the lowest rate of
itself. Weld time and tip radius temperature rise.
were constant at 1.5 sec and 3 in., d) The highest temperatures
respectively. were achieved in the metal of lowest
Within the limits of the experi- thermal conductivity—iron; the
ment, the data (Figs. 13 and 14) are lowest temperatures were developed
generally consistent: in the material of highest thermal
a) Increased power, uniformly in conductivity copper.
all three materials, increases the The data for copper and iron are
maximum temperature achieved at generally consistent with data pre-
the interface, as would be expected. viously obtained’ when weld time
b) Increased clamping force, and the power and clamping force
within limits, reproducibly in all interaction are taken into considera-
three materials: 1) increases the tion. The data for 1100-H14 alumi-
initial rate of interface temperature num cannot be firmly rationalized
rise and (2) suppresses the maximum on the basis of time, power and force
temperature achieved. in the light of data obtained in the
4 t. c) The lowest clamping forces, preliminary experiments for the
Fig. 12—Photomicrographs of ultrasonic which were inadequate to make the 2024-T3 Alclad aluminum alloy,
weld, 99% copper to zinc-plated steel. strongest welds, produced _ uni- which show noticeably higher
X 1250 formly in all three materials the values. The difference suggests an
highest temperatures achieved, and effect of physical properties such as
consisting of a low-melting
metal (preferably a low-melt-
ing metal of very low diffu- S00 WATT
sivity in the metal of the weld- AMPING FORCE (LB!
A - 25¢
ment 8 550
Metallographic determination 400
750
of phase transformation.
Metallographic determina-
tion of recrystallization.
A selected example of (a), but
one in which the components welded
exhibit high diffusion appears in
Fig. 12, which shows a weld inter-
face between zinc-plated steel and a
99% copper alloy. It is probable
that the zinc layer did not reach its
melting point of 787° F. However,
the considerable extent of diffusion
in the short weld time of 1.5 sec is
interesting. The acceleration of
diffusion reactions resulting from ul-
trasonic agitation has been variously
reported.'!: ! Fig. 1 Time-temperature curves obtained during ultrasor
Dimensional Analysis. Prelimi- with parameters of power level and clamping force
nary experimental studies indicated
clearly that the temperature rise
during vibratory welding is related
to the properties of the metal being
welded. Accordingly, a preliminary
analysis was made to determine the
important variables that contribute RE-*F
to the temperature rise at a weld
interface if it is assumed that the
TEMPE
RAT
heat is primarily due to shear.
This analysis, which is essentially
dimensional in nature, indicates
that a maximum temperature rise
can be expected in a material that is
thin, has low heat capacity and low
thermal conductivity.
Thermocouple Temperature Meas- ~*F
JRE
urements. The single-wire-thermo-
couple technique was utilized at
four clamping-force levels and four TEMPERAT
power levels, to explore the tem-
perature rise associated with ultra-
sonically welding three monometal
junctions: Half-hard CP copper, Fig. 14—Time-temperature curves obtained during ultrasonic welding of iron, with
0.032 in. thick, to itself; 1100-H14 parameters of power level and clamping force

WELDING RESEARCH SUPPLEMENT 297-s

 modulus, hardness or yield strength.
Table 3—Maximum Interfacial Temperature Recorded During Weld Formation The harder 2024 core and the soft.
with Several Single-Wire Thermocouple Junctions low-yield-strength cladding might
Temperature recorded with be expected to localize the work
input Clamping ———noted thermocouple, ° F— done and thus to concentrate the
power, force, 0.010-in. 0.003-in. 0.003-in. temperature rise in the cladding
Weldment material Ww Ib Constantan Constantan Alumel layers at the weld interface.
0.032-in. 1100-H14 aluminum — 1400 700 400 420 400 Further data are needed to
200 590 590 600 rationalize the observation that
a00 700 240 210 250 increased clamping force suppresses
the maximum temperature. One
200 440 440 430 explanation might be that increased
0.032-in. CP copper 750 326 340 clamping force reduces the power
550 500 560 actually delivered into the weld
750 254 275 250 zone, although the instantaneous
372 350 380 power and time curve’ indicates no
: such condition. Another possibility
0.028-in. Armco iron 550 285 385 350 is that increased clamping force
results in increased contact area, so
that energy is delivered to a greater
volume, and vertical losses occur
over a larger surface area.
However, it appears most reason-
able that increased clamping force
Table 4—Commercial Silver Brazing Alloys improves coupling between sono-
trode and weldment, effecting a re-
ASTM ——Composition, 4—————— —Temperature, ° F- duction in external slip and im-
Designation Ag Cu Zn Cd Ni Solidus Liquidus
proved power delivery to the weld
BAg-1 45 16 24 én 1125 1145 zone. This reasoning is partially
BAg-3 50 - 15.5 16 1170 1270
BAg-5 45 26 ; ve 1250 1370 substantiated by observation on ofof a
BAg-10 70 2 10 i ra 1275 1360 greatly increased rate of initial
BAg-11 5 4 3 : 2 1365 1450 temperature rise associated with the
" 20 35 = - 1430 1500 higher clamping forces and
seemingly agrees with the idea pre-
® Handy and Harman AT special braze viously expressed that an approxi-
mate relationship should exist be-
tween power and clamping force,
Table 5—Temperature in Weld Zone as Determined by Meltable Wire Inserts* presumably for any combination of
Recorded sonotrode tip material and weld-
Published thermocouple ment material.
Insert melting Power, Clamping temperature, Weld strengths obtained in this
material' range, ° F W force, Ib “Ff experiment showed no correlation
DE(BAg-5) 1250-1370 2100 225 1900 with temperature. For example,
AT 1430-1500 2300 225 1600 very good welds in copper (500-lb
DE(BAg-5) 1250-1370 1800 225 1380 tensile-shear strength) were ob-
EF-3(BAg-3) 1170-1270 1900 225 1170 tained at 1500 w and 750-lb clamp-
EF-45(BAg-1) 1125-1145 1600 225 1160 ing force with maximum recorded
* All inserts meited temperature of 240° F; welds of
b 0.015-in. diameter 500-lb tensile-shear strength were
also obtained at 1500 w and 400-lb
clamping force with maximum re-
Table 6—Experiments to Determine Weld Interface Temperatures corded temperature of 570° F.
in 0.032-in. Armco tron Excellent welds in aluminum were
obtained at 1400 w power with
Electrical Temperature Metallurgical analysis of le . "es d 00. , 55DDO ¢ 4 00
power to Clamping recorded by —0.003-in. meltable inserts- clamping forces of 4 950 and 7
transducer, force, thermocouple, BAg-1 BAg-3 lb, where each coupon pulled nug-
Ww Ib oF (1125-1145 F) (1170-1270° F) gets above 400 lb and the corre-
1800 250 1120 ‘ sponding temperatures ranged from
1800 250 1170 a . 590 to 420° F. With iron at the
specific welding parameters selected
or = = _—_ es for the test, only a few of the weld
1650 x00 1170 aie es coupons exhibited the usual order of
1500 350 1125 Not melted Partial strength.
1300 350 1050 Not melted Not melted No clearly defined “‘spikes’”’ in-
1450 350 990 Melted Not melted dicative of high local temperature
1450 350 1170 oa bee were observed in the records of initial
1450 350 905 Not melted Not melted first '/, sec) temperature rise made
1450 350 1125 Not melted Not melted with fast-response (up to 10 mega-
1400 350 990 Melted Partial cycles /sec) equipment. It cannot
1400 350 1060 Not melted Not melted be concluded that such hot spots do
not exist, although the single-wire-
* Control specimens, no inserts. thermocouple technique reduces the

298-s | JULY 1961

 possibility of close-proximity short microscopically examined to deter- The data of Table 6 indicate that
circuiting. mine whether or not a _ solid-to- melting of the BAg-1 (mp 1125
In order to refine the technique, liquid phase change appeared to 1145° F) occurred at thermocouple
additional experiments were carried have taken place. electromotive force values ranging
out using finer gage thermocouple One limitation of this technique from 990 to 1215° F, and partial
wires. In the previous measure- involves thermal properties of the fusion of the BAg-3 occurred within
ments, the Constantan thermo- various materials. These may be this same range. In some instances
couple wires used were mostly of sufficiently different to yield ap- there was close agreement between
0.010-in. diam. These were re- parently conflicting values unless recorded temperatures and those
placed first with 0.003-in. diam time at temperature is sufficient to indicated by melting or nonmelting
Constantan wire and later with permit most of the wire-insert ma- of the inserts; in other cases there
0.003-in. Alumel. The original terial in the weld interface to re- was variation. Welds repeated
0.060-in. length of wire embedded spond to the temperature achieved. under the same conditions did not
was reduced to a few thousandths This limitation may be circum- always show identical results. With
of an inch. The extremes of the vented to some extent by reducing iron monometal welds, the meltable-
experiment were repeated for the the size of the inserts. insert approach showed apparent
various metals in the same gages Investigations were carried out temperature variations of approxi-
used in the earlier work. with 0.032-in. Armco iron sheet mately 200 deg in the vicinity of
The maximum recorded tempera- material and inserts of six commer- 1200° F. Thermocouple measure-
tures are presented in Table 3 along cial silver brazing alloys (Table 4 ments were more consistent but
with data obtained earlier under with melting points in the range of apparently indicated somewhat
identical conditions with 0.010-in. temperatures indicated by the ther- lower temperatures than the melt-
Constantan wire. In general, very mocouple technique. able inserts.
similar results were obtained in all The alloys were obtained as 0.015- In general, detection of local
three sets of measurements; varia- in. diam wire, short lengths of which melting is to be expected when the
tions are random and_ probably were force fitted into holes drilled in maximum temperature locally ex-
result from slight differences in the one of each pair of iron tabs. After ceeds that of the liquidus. The
location of the wire with respect to insertion, the wire ends were ground thermal electromotive force, how-
the weld spot. to the planes of the tab surfaces. ever, corresponds to some average
Metallographic Temperature Meas- The tabs were welded with the junction temperature, which is al-
urements. 'To verify the validity of piece containing the insert adjacent ways less than the maximum except
temperatures recorded by the single- to the sonotrode tip, and a Constan- at thermal equilibrium. Thus the
wire-thermocouple procedure, efforts tan thermocouple lead was inserted discrepancies noted are in the direc-
were made to bracket the recorded between the tabs with care to keep tion that would be expected.
maximum temperature with metal- the insert adjacent to the region cor- Review of all thermal-electro-
lographically detected melted vs. responding to the location of ther- motive force and meltable-insert
nonmelted fine-wire inserts. The mocouple lead. The first speci- data obtained to date indicates a
fine wires were embedded in the weld mens were welded at powers of variation of approximately 15%
zone prior to welding. The inserts, 1600-2300 w to determine whether from the average for all power levels
with known melting points, were melting of the wire inserts could investigated at constant clamping
actually be achieved; results are force, and in general a decrease in
given in Table 5. temperature occurs with decrease in
All inserts appeared to be melted. power under otherwise constant
In most instances, the fusion was conditions
restricted to a small zone imme-
diately adjacent to the wire inter- Effect of Properties of Materials on
Ultrasonic Weldability
face and was sometimes difficult to
detect. There was no doubt, how- Preliminary Analysis. The re-
ever, that the liquidus of the highest lationship between material proper-
temperature alloy AT Special ties and the vibratory weldability of
Braze) was reached. Intergranular a metal or alloy is complicated by a
penetration of the iron was usually numberof factors.
observed. The temperature rise associated
After it was shown that the inserts
could be melted, specimens were pre-
pared using two different indicator
wires (ASTM BAg-1 and BAg-2
and a thermocouple lead. A smaller
insert (0.003-in. diam) was used for
this test series to improve the
thermal response.
A few specimens were welded
without the alloy inserts and with
only the thermocouple leads. Weld-
ing parameters’ were _ initially
selected from average thermo-
couple data to produce temperatures
in the range of 1150 to 1200° F, and
the power was progressively reduced
Fig. 15—Restricted recrystallization zone until no fusion was evident metal- Fig. 16—Generalized recrystallization
in ultrasonic weld between 0.040-in. 2014 lographically. The conditions and zone in ultrasonic weld on 0.005-in.
T6 aluminum alloy results are summarized in Table 6. “A’’ nickel. X 150

WELDING RESEARCH SUPPLEMENT | 299s

 with joining: Although there is no However, the SWR technique pre- sonic welding is by no means estab-
evidence on any ordinary micro- viously described now makes such lished.
scopic scale that the temperature measurements possible with ade- Experimental Studies. Explora-
reaches the melting point in a mono- quate accuracy. tory experiments were initiated to
metal weld, it is recognized that It thus becomes feasible to relate determine the acoustic power neces-
properties such as yield strength, the net total acoustical energy, or sary to accomplish welds in several
hardness, modulus, etc., are tran- any specific instantaneous value materials as a function of sheet
siently and markedly affected. thereof delivered into a weld zone, thickness.
Thus, the actual room-temperature to the accomplishment of a weld of A small precision welding machine
properties of metals or alloys may unit area in a metal or alloy. The operating at 28 kc was assembled
have little relation to their weld- relationship of such data to sheet and suitably instrumented with
ability, since welding occurs at thickness provides direct informa- SWR microphone sensing elements.
various elevated temperatures. tion concerning the relative weld- This device was a standard “‘lateral”’
Material thickness: While mate- ability of materials. However, this drive unit, which does not involve a
rial thickness is known to affect the information must ultimately be reed-mass system. The possibility
power required to produce a weld, interpreted in terms of thermal of energy loss to the mass that
the role played in the process by this conductivity, the effect of which can supports the reed, as in Fig. 1, was,
factor is difficult to isolate from be calculated, and of other factors therefore, eliminated, so that the
those of certain other properties. not so readily interpreted. only evident source for error was
For example, increasing material For a given sheet thickness, it the energy transmitted through and
thickness augments the heat sink should be possible to arrange the beyond the weld zone via the anvil.
associated with lateral thermal materials into an “order of weld- With a view to ascertaining the
diffusivity in the weldment mate- ability,”’ which is expected to corre- minimum acoustic energy requisite
rials, just as it does in resistance or late the more familiar material to accomplish vibratory welds of
other types of fusion welding. On properties. As the sheet thickness unit area as a function of sheet
the other hand, the elastoplastic me- is decreased toward zero, the mate- thickness in several materials, it was
chanics associated with vibratory rials can be expected to fall into a necessary to approximately or*i-
welding involve not only thickness “limiting order of weldability.”’ mize the power-clamping fore 77
but also modulus, yield strength and Recrystallization: That recrystal- lationship for each thickness of each
other properties at the transiently lization may be achieved during material. This value was ascer-
altered values thereof corresponding ultrasonic welding is indicated in the tained by arbitrarily selecting a
to the elevated temperature at photomicrographs of Figs. 15 and single clamping force and a fixed
which the junction is effected. 16. Recrystallization takes place weld time on the basis of previous
Difficulties of energy measurement: over a restricted region when it experience, and by producing welds
Associating one or several significant occurs in the aluminum alloy, 2014- with progressively decreasing power
material properties with weldability T6, (Fig. 15) while the nickel has until the bond obtained no longer
on a quantitative basis requires recrystallized completely in the failed in peel by nugget tear out.
correlating vibratory energy with weld zone (Fig. 16). The nature The procedure was then repeated at
the accomplishment of a_ weld. and extent of these recrystallization other arbitrarily selected values of
Previous to this study there had effects are probably associated with clamping force but at the same
been no _ satisfactory method of the local working at the interface fixed weld time, until sufficient data
measuring either instantaneous or and the thermal properties of the were obtained to show a curve of
integrated values of vibratory bulk material. The role of cold clamping force vs. power which
energy delivered to a weld zone. work and recrystallization in ultra- would represent the threshold value

i i j
0.2 06 08
Fig. 17—Relationship between electrical power vs. TIME - SECONDS
clamping force for ultrasonically welding Fig. 18—Acoustic power delivered to the weld zone during weld formation
AISI 302 stainless steel between 0.009-in. 1100-H18 aluminum sheets

300-s | JULY 1961

 for welding, as defined by the nugget- were taken of the oscilloscope trace alloys as a function of sheet thick-
pullout peel test. during the formation of a single weld ness can be used to establish an
Preliminary data were obtained to provide a continuous record of order of weldability. The slope of
with a weld time of 1 sec. This the power ellipse and SWR during such curves is expected to be sig-
same procedure was reproduced for the period of weld formation. nificant.
several gages of aluminum with a Measurements of the oscillogram Table 7 summarizes various data
weld time of 0.5 sec. It was noted ellipse areas from consecutive frames relating material thickness to several
in the second series that the power of the motion picture film permitted measured and calculated factors
level required to accomplish a weld, plotting acoustic power delivered to associated with successful welds in
as defined by the nugget-pullout the weld zone as a function of time 1100-H19 aluminum. Figure 19 in-
peel test, was about twice as high as Fig. 18. cludes curves of clamping force and
in the first, indicating that, under Determination of the mean value electrical power for five thicknesses
the general conditions of the experi- of acoustic power during the time of this material. The curves havea
ment, weld time can be reduced as interval gave 67.2 w as the power characteristic shape and indicate
power is increased, within limits. requisite to accomplish a weld in a that the minimum power for ac-
It was, therefore, concluded that, at time interval of 1.0 sec. (As pre- complishing a weld occurs at a dis-
least for the purposes of this ex- viously noted, about the same total crete value of clamping force.
ploration, the weld time of 1 sec energy, 67.2 joules, will accomplish Moreover, the curves for the
produced representative results. the same weld in one-half the time. different thicknesses fall into more
The threshold curves obtained The value of power required was or less regular orders of power and
from the nugget-pullout peel tests then related to the weld area, which clamping force. It is to be noted
have acharacteristic shape. Figure was determined from an average of a that with somewhat greater power
17 shows data for AISI 302 stainless number of measurements from dif- than the minimum required for a
steel. Such a _ concave-upwards ferent welds. In this case, the mean given thickness, successful welding
threshold curve characterized all weld area was 2.2 mm?” The is accomplished over a very broad
materials and gages investigated. acoustic energy required to produce range of clamping force.
The acoustic power required to a weld in this material at this thick- Figure 20 shows the average
produce a weld, as defined by the ness was therefore 67.2/2.2 or 30.6 minimum electrical power to the
nugget-pullout peel test, was deter- joules /mm*. transducer for 1 sec (Curve A)
mined only at the minimum elec- Application of Experimental required to provide the elastic vi-
trical power value found on the Studies to 1100 Aluminum. Curves bratory power traversing the coupler
electrical-power vs. clamping-force of energy required to produce a weld Curve B) which accomplished
curve. Instead of obtaining several of unit area in various metals and welds in the several gages of un-
still photographs of the oscilloscope
trace at discrete intervals during for-
mation of several separate welds as
previously described, motion pictures

-POWER
WATTS
CAL
LU

ELECTRi(
wott-seconds,
|throughout)
second
weld
time
since
used
was

A(Also
energy

LAMPING F
Fig. 20—Comparison of minimum average electrical
Fig. 19—Curves of clamping force and electrical power to the power and acoustic power required to weld several
transducer for several thicknesses of 1100-H19 aluminum gages of 1100-H19 aluminum

WELDING RESEARCH SUPPLEMENT 301-s

 commercially pure half-hard copper
and AISI 302 stainless steel were
used to extend the experiment.
STEEL LECTRICAL STAINLESS STEEL
POWER r Table 8 is a summary of the
welding power requirements for
STAINLESS STEEL copper and stainless steel. As be-
= ACOUSTIC POWER fore, curves were plotted to establish
the minimum electrical power re-
quired to accomplish a good weld (as
revealed by the nugget-pullout peel
test) at discrete values of clamping
force; they confirm previous data
on the clamping force at which welds
are produced with minimum power.
Figure 21 shows the relationship
/ between sheet thickness and the
Yl / COPPER minimum electrical power (solid
oS/ 7 ELECTRICAL POWER
lines) required to produce welds in
, these materials, as well as_ the
elastic vibratory power (broken
9 A
lines) traversing the coupler as ob-
/ COPPER -ACOUSTIC POWER | tained by means of the SWR tech-
yasf VIBRATORY
JOULES/MM2
ENERGY
PER
UNIT
WELD
AREA
- nique from oscilloscope traces as
previously described. The varia-
tion in weld area with sheet thick-
:) . ) 1 ness for these materials when welded
0.000! 0.01 0.000! 0.00! under the optimum conditions
SHEET THICKNESS - INCH SHEET THICKNESS- INCH noted may be shown logarithmically
Fig. 21—Minimum average electrical and Fig. 22—Minimum vibratory energy as a straight line by using the data
acoustic power required to weld thin required to produce welds of 1-square in Table 8. Finally, the data thus
gages of CP copper and 302 stainless steel millimeter area in aluminum, copper and far obtained with aluminum, copper,
stainless steel and stainless steel are summarized in
alloyed aluminum. Curve A is the curves of Fig. 22. These curves
essentially a plot of the electrical ness of the SWR acoustic power represent the minimum vibratory
power values’ constituting the determinations. energy per unit weld area as a func-
minima from the curves of Fig. 19. As may be determined logarithmi- tion of sheet thickness. (It should
Curve B summarizes the acoustic cally from data in Table 7, the trend be noted that these energy values
power values (last column in Table of weld area is a function of sheet still contain the increment of energy
5), each of which was obtained by thickness for the production of good which traverses the weld zone and is
integrating a curve plotted through welds, as defined by the previously dissipated elsewhere.) ‘The curves
the several points obtained from described nugget-pullout peel test represent the most probable relation-
power ellipse areas as recorded on under conditions of minimum power ship as determined by logarithmic
motion-picture film from the chang- and concomitant optimum clamping transformation techniques and indi-
ing oscilloscope pattern. Actual force. cate correlations in so far as is
values of vibratory power are listed Exploratory Studies of Copper and possible in this preliminary testing.
in the last column of Table 5; Stainless Steel. The foregoing dis- Data of this type, when extended
the values in this table represent the cussion described a practical tech- to a broader range of materials and
most probable correlation of the nique for determining an order of sheet thicknesses, will provide a
actual values and foil thickness weldability for various gages of means for correlating the weld-
statistically determined. It will be 1100-H18 and 1100-H19 aluminum. ability of various materials with
noted that Curves A and B, plotted This rather complex and laborious their physical and mechanical prop-
separately from independent experi- procedure was repeated to obtain a erties. This approach was covered
mental data, differ by a constant series of curves of required acoustic under the second phase of this
factor. This result is gratifying power vs. sheet thickness for addi- research program.
confirmation of the inherent sound- tional materials. Several gages of
Interface disturbance and metal-
lurgy: The photomicrograph of the
Table 7—Vibratory Energy Data for Welding 1100-H19 Aluminum with Sonotrode Tip ultrasonic weld in 1100-H14 alumi-
of 2-in. Spherical Radius and Anvil Face of Infinite Radius num (Fig. 23) shows that this soft
Vibratory ductile material exhibits plastic
Sheet Normal Electrical Weld Vibratory energy per flow, large displacement of the
thickness, force power, area,' ——power,° w—— unit weld area, parent metal in the weld zone, and
in Ib Ww mm? Actual Correlated* watt-sec/mm apparent mixing of the surface films
0.0007 1.49 0.29 0.092 0.089 0.069 0.81 with the displaced parent metal.
0.0010 ?.10 0.51 0.144 0.144 0.181 1.03 In contrast, spring-temper brass
0.0017 3.50 Ba 0.279 0.640 0.748 2.20 Fig. 24) shows an apparent frag-
0.004 7.97 46.0 0.815 8.48 7.45 8.48 mentation of the grain structure and
0.009 17.41 170.0 2.24 65.4 0.8 29.70 little apparent metal displacement,
* Minimum average electrical power as obtained from a VAW meter. with virtual elimination of the
Each value represents an average of at least 4 specimens. interface. The ultrasonic weld be-
¢ The integral power curve over 1 sec, considered an average for a 1-sec period. tween two sheets of bare 2024-T3
i Values obtained by correlation with thickness, using regression technique with logarithmic
transformations. aluminum alloy (Fig. 25) exhibits

302-s | JULY 1961

both localized plastic flow at the
contact surface and strain markings Table 8—Vibratory Energy Data for Welding Fully-annealed CP Copper and AISI 302
adjacent to the interface. Between Stainless Steel
dissimilar metals, a variety of Vibratory
interface - displacement charac- Sheet Normal Electrical Weld Vibratory energy per
teristics have been noted. thickness, force, power," area, power,° w— unit weld area,
During welding of low-carbon to Material in Ib mm? Actual Correlated w-sec/mm?
high-carbon steel, the low-carbon Copper .0002 12 0.072 0.33 0.36 4.60
steel may increase its carbon con- 001 : 0.174 6.49 4.64 36.20
tent adjacent to the weld area at the .0014 0.264 7.63 7.91 28.90
expense of the high-carbon steel. .002 0.420 11.35 13.9 27.00
Accelerated diffusion of carbon ap- Stainiess 0.0003 0.0464 2.26 ep 48.75
steel 001 0.078 16.7 16.‘ 267.00
0015 0.145 33.6 33.3 232.00
* Minimum average electrical power as obtained from a VAW meter
Each value represents ar average of at least 4 specimens 1
The integral power curve over 1 sec, considered an average for a 1-sec weld interval
Values obtained by correlation with thickness using regression technique with logarithmic
transformations

pears to be the only explanation face in local areas. The dependence

that is tenable. of plastic flow on the transient tem-
Metallographic Studies. Displace- peratures achieved in the bond zone
ments brought about by me- must also be considered. Flow in
chanical action can usually be estab- directions both parallel and normal
lished metallographically. In addi- to the original interface is commonly
tion mechanical working may be observed. In some cases the plas-
accompanied by localized recrystal- ticity of material in the bond zone
lization and grain growth. When results in extrusion of thin layers of
bonding similar components, re- the plastic metal between the sur-
crystallization and grain growth can faces just outside the weld periphery.
Fig. 23—Photomicrograph of ultrasonic replace the worked structure and The bonding of dissimilar com-
weld in 0.012-in. tabs of 1100-H14 eliminate traces of the original inter- ponents, such as aluminum-copper
aluminum. X 500 alloys with a commerically pure
aluminum foil insert between the
sheets, very often exhibits the re-
crystallization and growth described
above. Figure 26 is a section of a
weld between two sheets of 0.032-in.
2014-T6 aluminum with a 0.001-in.
1100-0 aluminum foil insert. The
microstructure suggests that copper
has been brought to the area occu-
pied initially by the aluminum foil.
It cannot presently be determined
whether the copper is, in fact, dis-
tributed in this area, and if so,
Fig. 24—Photomicrograph of edge section Fig. 25—Photomicrograph of ultrasonic whether it was transported by me-
of ultrasonic weld in 0.006-in. spring weld in 0.032-in. 2024-T3 bare aluminum chanical action at the surfaces or by
temper cartridge brass. X 390 alloy. Keller’s etch. X 150 diffusion.

LL. Jere *

: » - re, e
Phu 7 .
. = — «san: < " Pe ah sts -
ae) .~ >,. i ed
- a
Fig. 26—Section of ultrasonic weld between two sheets of 0.032- Fig. 27—Interface of foil-insert weld between two sheets of
in. 2014-T6 aluminum alloy with foil insert of 0.001-in. 1100-0 2024-T3 aluminum alloy with superimposed autoradiograph
aluminum. X 1000 X 1000 (20% reduction on reproduction)

WELDING RESEARCH SUPPLEMENT 303-s

 The study of structure developed and autoradiograph can be com- ing nonradioactive foil inserts were
during welding of similar materials pared by focus adjustment from also fabricated.
is, in itself, not sufficient to deter- above. After bonding, the specimens
mine completely the material dis- Protective coating must be ap- were sectioned through the center
placements that occur. plied to the sample to eliminate cor- of the bond zone normal to the
Radioactive Tracers. The use of rosion or chemical reaction with the faying surfaces, filed to a thickness
radioactive tracers as a means of emulsion. A 2% solution of VYNS of approximately 0.030 in., mounted
investigating the problem of metallic Vinylite in methylethylketone was in Bakelite, and ground and pol-
migration is being investigated. used for both the wet and dry ex- ished. A radioactive specimen and
Autoradiographic methods have posures. This film did not provide a control specimen were included
been successfully applied to diffusion sufficient protection from the wet- in each mounting. Activity was
research and wear studies that in- process solutions during exposures measured with a mica-window coun-
volve interface displacements. '‘ exceeding 16 hr; whereas, it did ter, and trial exposures were calcu-
Two methods were selected as offer adequate protection during lated from the data of Wain-
promising. The first involved wet stripping-film processing. The wet wright, et al.”
processing of the sensitive emulsion process was therefore abandoned be- An example of the results ob-
and exposure in a silver nitrate solu- cause of the corrosive action, and all tained with the Kodak film is
tion, thus producing an autoradio- specimens were processed exclusively shown in Fig. 27. In this area
graph in situ on the surface of the by the stripping film method, using of the bond zone the aluminum-
specimen. The second method in- exposure periods of approximately copper foil has been completely
volved the use of Kodak Permeable 16 hr. recrystallized. It was noted that
Base Autoradiographic Stripping Specimens of 2024-T3 aluminum the autoradiographs displayed high
Film (experimental) secured from alloy 0.040 in. thick were ultra- densities adjacent to the surface
the Eastman Kodak Co. The sonically bonded together with a of the radioactive foil insert in
stripping film consists of a 5-micron 0.001-in. foil of an aluminum-4% several areas of the weld.
emulsion reinforced with a 5-micron copper alloy sandwiched between In order to explain this variation
gelatin layer on a temporary sup- the bond members. The foil had in density, a series of photographs
port, that may be transferred to the previously been irradiated for three of the interface areas were pre-
surface of the specimen mount for days in a neutron flux of 5 x 10"! pared at a magnification of 1600
exposure. The exposed film is de- n/em?*/sec at the Oak Ridge Na- diameters. At this magnification,
veloped while attached to the tional Laboratory. This radiation individual silver halide grains could
mount, allowing the autoradiograph resulted in a calculated saturation be resolved at a separation distance
to remain in register with the micro- of 94%, the active isotope being of 0.5 microns. The counts were
structure so that microstructure 2g9Cu"*. Control specimens contain- made in areas of both high and low
density adjacent to the bond inter-
face.
The results are presented in Fig.
28. This plot shows the distribu-
tion of silver grains as a function
of distance from the _ interface.
The density curve was determined
in areas of high initial density
Curve A) and low initial density
(Curve B). Both distributions are
exponential within the accuracy
of the measurements, and the high-
density areas adjacent to the bond
differ from other areas only in the
CURVE A initial concentration of tracer.
HIGH-DENSITY AREA These results indicate that sub-
surface radiation alone can account
for the observed density distribu-
tion of the autoradiographs. Thus
any details of material transport
are obscured by the long range of
the beta emission used for detec-
tion. The use of an isotope yield-
ing shorter range beta particles
should greatly improve the effective
resolving power of the method.

CURVE 8B i Conclusions
LOW-DENSITY AREA 1. Equipment and_ techniques
necessary for photoelastic study of
the internal dynamic stress patterns
© associated with initiation of an ultra-
sonic weld between two sheets of
1 ] 1 1 i metal were developed and applied
0.005 0.010 0.015 0.020 0.025 successfully.
DISTANCE FROM INTERFACE - CENTIMETERS
2. Laboratory investigation dem-
Fig. 28—Distribution of exposed silver halide grains in high- and low- onstrated that the acoustical energy
density areas adjacent to bond interface in autoradiographs traversing a coupling bar can be de-

304s | JULY 1961

 termined by measuring the standing quired with increasing sheet thick- Acknowledgment
elastic wave ratio therein. Thus, ness, among other factors, appears The authors acknowledge with
the energy considerations implicit to be associated with increased appreciation assistance with the
in studying the mechanism of ultra- thermal diffusivity and with vibra- original report by Dr. W. C. El-
sonic welding are determinate. tory energy absorption in the in- more, Chairman of Physics at
3. Observations of anvil compli- creased thickness of plastic metal Swarthmore College and of Dr.
ance during weld formation in sev- between the weld interface and the George S. Ansell of Rensselaer
eral materials indicate that in- outer faces of the weldment where Polytechnic Institute, in the prepa-
creased power delivery into the work the sonotrode tip and anvil make ration of this abridgment
requires increased clamping force, as contact. It is also to be expected
was also apparent in the tempera- Refere ces
that the thicker specimens would l. Jone I DePrisco, C. I Vhomas
ture studies. permit radiation of more acoustic J.G Ult sonic Welding of Met Contract
4. Transient temperatures devel- power into the material surrounding No DA-36-034-ORD-140 Aeroprojects Inc
oped during the formation of ultra- Research Re port N« Apri } Avail
the weld area. Transient tempera- able from OTS, Departmer: f mmerce $2.7 2.40,
sonic welds can be studied by means tures act to depress such material PB 131084
of a fine single-wire thermocouple, properties as hardness, yield Jone J. DePri C.] and Chomas,
J.G Ultrasonic Welding for Ordnance
which is a satisfactory device for strength, and modulus, so that Applications Contract No. |! 36-034-ORD
sensing such temperatures. Various straightforward relationships based 166 Aeropro ject I Report No
6-14 Mar« Available from Armed
metallurgical phenomena, includ- on room temperature properties Services ‘Techni m Ag y
ing heat-affected zones, recrystal- are not expected Jones I eis! l E., “Ultra
lization, diffusion and unusual metal- sonic Weldi: of ruct Aluminum Alloys
6. Areas of welding disturbance I ojects Inc
lurgical structures appear in ultra- in an ultrasonic weld between two ry 1957
sonic welds; cast structures offering 1 (ommerce
sheets appear to be maximum in an
evidence of melting have thus far annular locale just inside the weld Further
not been detected with an optical periphery of Struc
No. NOas
microscope. Nor have thermo- eport No
7. Good ultrasonic welds can be
couple measurements or tempera-
produced over a broad range of Ultrasonic
tures implied by meltable inserts 8), 761
both power and clamping force,
approached the melting point in any
provided that minimum threshold 6. Froch M n i 1, John
ultrasonic monometal weld thus far
values of power are exceeded. The Wiley & Sons, Inc., N < 5 41
studied. Love, A Tre ‘ he Mathe-
existence of a power minimum in the
Failure to detect ‘‘spikes’’ in- cal The f over Publications,
power-clamping force relationship York, 4th ed., p . 203-20 44
dicative of high temperatures on Mindlir R ison P Osmer,
is possibly of even greater impor-
fast-response oscillograph traces cer- r. F., and Deresi« » Oscillat
tance because it implies the possi- ing Tangential | Surfaces of
tainly does not establish that sharp
bility of some impedance-matching Elastic Spheres i tl. ¢ ar. Appl
high-temperature peaks do _ not Mech American Societ tical Engineers
control between the _ transducer- ) Bowden, F. P., and Tabor, D., The Friction
occur. The lack of cast structure
coupling system and the weld zone. nd Lut ut f 1 ord University Preas,
in ultrasonic welds characterizes London (1950
such junctions as solid-state bonds. Within the range of power, clamp- 10. Elmore. W. ¢ \ stin r of the Tem
In the preliminary studies reported ing force and time relationships that perature Rise Which ccur During Vibratory
characterize contemporary ultra- Welding Appendix A, Aeroprojects Inc. Re
here, there was no correlation be- search Report No I see reterence
tween weld strength and maximum sonic welding, the accomplishment 11. Fairbanks \ and Dewez, Jdr., F. J
of a good weld relates roughly to the Ultrasonics Effects on Ste l Heat ‘Treatment
temperature achieved in the weld Iron Age, 176, 139-142 (Dec. 8, 19
zone. energy utilized, e.g., twice the power 1 Pogodin-Alekseev, G Effect of Ultra
5. The SWR technique for meas- will produce a weld in about half the sonic Vibrations on Diffusion in Steels and Alloys
time, etc. at Elevated ‘Temperatures Metaliovedenie i
uring the energy required to gen- Obrabotka Meta 1958 (¢
erate welds in various materials The use of sufficiently powerful, 13. Conner, J. G., “Berylliun An Air Force
Metal,” Techni Memorar WCRT TM
and thicknesses, together with meas- frequency-stable, ultrasonic-welding Materials Laboratory, Wright Air De
urement of the transient tempera- equipment incorporating force-in- velopment Center, Wright-! erson Air Force
tures developed and metallurgical sensitive transducer-coupling sys- Base, Ohio (Febru ry 1955
14. Colding B an Kr “Wear
study, is expected to bring the re- tems produces sound, crack-free f ‘ ie ng ‘Tools
lationship between material proper- welds in a broad range of metals and ll, 46-49 b y Proceed
ng of Rad R r fere rd 2, 181
ties and ultrasonic weldability into alloys. Short weld time and in- 154
focus. creased power should act to extend 1 Bowden
Metalli lransfe Operations
On an energy per unit weld area the process to the efficient welding Radioactive mbridge
basis, the energy that is necessary of thicker materials. Moreover, the Engineer l
combination of higher power and 16. Simnad, } I iclear liation and
to produce the interfacial disturb- Radioisotope. terr Jn
ance that is associated with weld- shorter time also operates to reduce He
ing a given material should be the the number of stress cycles in the I {
Simplified
same in thick or thin pieces. The material being welded, and an ex-
value of energy per unit weld area cessive number of stress cycles
to produce such a welding disturb- probably accounted for the weld-
ance should approach a limiting zone cracking experienced 4 or 5
value for a metal or alloy at thick- years ago with elementary designs
ness zero. Increase in energy re- of low-power equipment

WELDING RESEARCH SUPPLEMENT

Exhaustion of Ductility by Hot Straining—

An Explanation of Fracture Initiation Close to Welds

The pronounced reduction of ductility at room temperature

resulting from straining at about 500° F appears to be the cause

of the frequent initiation of brittle fracture close to welds

BY C. MYLONAS AND K. C. ROCKEY

ABSTRACT. Plastic compression or ex- yielding occurs. Wells indicated nominal stress fractures in riveted
tension reduced the ductility of steel that only at such large strains can structures or in regions unaffected
far more when performed at a tempera- sufficient strain hardening and frac- by welding. In effect, Shank’ has
ture around 500° F than at room ture occur. He further suggested found that service fractures can be
temperature. In particular, plastic ex-
tension at 450° F drastically reduced one mechanism by which a localized usually traced back to a defect or
the ductility in subsequent tension at straining and work hardening could cold worked region. A number of
16° F and resulted in brittle fracture occur without general yielding and tests were made to duplicate such
after additional straining of only 0.02. high average stress. This happens damage and to obtain low net stress
This exhaustion of cold ductility by in the region close to a long weld. brittle fractures of unwelded steel
hot extension occurs during the cool- During cooling this zone is stretched in the laboratory. This was effec-
ing of welded plates and provides an by amounts up to 0.02, and any tively achieved’~'* by a _ precom-
explanation of fracture initiation close notch or defect in this region will pressing and aging which exhausted
to welds. locally multiply the strains by a the ductility in subsequent tension.
substantial factor. The resulting Notched precompressed plates, axi-
Introduction
strain hardening by stretching and ally compressed bars and bent bars
As is well known, brittle fracture the extensive residual stresses were fractured in tension at very small
cannot be initiated in undamaged proposed as causes of the fractures strains and in a typically brittle
structural steel subjected to static which had been obtained by Greene‘ manner. These results give an
central loading, even in the presence and Weck.‘ Similar results were explanation of the initiation of frac-
of the deepest notches or cracks obtained in numerous new tests ture at points which have suffered
and at a temperature below transi- of plates containing longitudinal some damage such as punching,
tion, as long as the average net welds over specially prepared de- shearing or cold forming.
stress level is below yield.' This is fects or notches. In the course of those studies,
in marked contrast with service However, some points had still notched plates were also subjected
fractures which, at least in a few to be answered. Drucker' gave to permanent extension and were
clear instances, are known to have an extensive discussion on the subsequently tested in tension at a
failed at low average stress level. theories and data on brittle fracture temperature below the toe of the
The explanation of the yield stress based on the concepts of plasticity transition range. All plates strained
failures, given by Wells,’ is one of and incorporating the observations by about 0.02 withstood average
the most fundamental for under- of Wells. He concluded that all net stresses larger than virgin yield
standing the phenomenon of brittle structural steels in their undamaged level but frequently broke below
fracture. Plastic strains develop or virgin state have sufficient duc- raised yield level. Numerous other
at the notch roots at very low tility to withstand the strains de- tests confirm that a small amount
loads, but they are relatively small veloping at a notch root up to of cold extension may not exhaust
as long as the average stress level general yielding. He also con- the ductility in tension to the same
is low. These strains can become cluded that low static stress level degree as a precompression. The
very large only when the average fractures are a certain indication of ductility of cold rolled steel in the
stress reaches yield level and general a reduction or exhaustion of the rolling direction is the most striking
original ductility, which must have example. Likewise, room tempera-
C. MYLONAS is Professor and K. C. ROCKEY is happened during fabrication, serv- ture stretching of the welded plates
Visiting Associate Professor, Div. of Engineering ice or repair. The cause of frac- of the Wells’ type seemed to pre-
Brown University, Providence, R. I
Results presented in this paper were obtained in ture initiation near a weld may vent the low stress fractures at
the course of research sponsored by the Ship well be the heating due to welding low temperature,'*: although its
Structure Committee under contract Nobs-78440 or the straining occurring during effect could only be a further ex-
with the Bureau of Ships, Department of the
Navy, but represent the authors’ personal opin- cooling, particularly when locally tension and strain hardening and a
ions. This paper was presented as documents intensified by a defect. However, stronger embrittlement of the notch
IX -302-61" and IX-303-61" at the annual meet- more general causes of damage are roots. This result led to some in-
ing of the Intern. Inst. of Welding, New York,
April 1961 needed in order to explain low completely demonstrated conclu-

306-s | JULY 1961

 sions on the importance of residual elevated temperatures can drasti- and of 84 tests at —16° F are shown
stresses. cally reduce ductility and lead to in Figs. 2 and 3; detailed tables are
Other tests! show that ex- extremely brittle fractures. at found in references (20) and (21).
haustion of ductility by precompres 16° F. The influence of the prestrain tem-
sion can cause fracture but local perature is quite marked. Al-
residual stresses do not. On the Reversed-bend Test ready at 200 to 250° F, the transi-
basis of this result and of the previ- The hot compression and subse- tion occurs at lower prestrains
ously given evidence of ductility quent cold extension were produced (the embrittlement is stronger) than
after extension, it is more likely by the reversed-bend method of at room temperature. The lowest
that the stretching of the welded testing used earlier. Steel bars transition limit occurs at the blue
plates restored to the embrittled of dimensions 0.75 x 1.00 X 8.00 brittleness range around 450
steel some of its lost ductility. in. were first bent lightly under four for reversed bending at 75° F,
How then did the notch region of point loading (Fig. la) and then and around 600° F for reversed
the Wells’ specimen get embrittled more severely by a compressive bending at 16° F. The transi-
by stretching in the first place? action Fig. lb During final test- tion prestrain for bending at 450
The answer is obvious. The ing they were pulled open in re- to 600° F is almost half as big as
stretching which results from cooling versed bending (Fig. Ic The in- at room temperature. As expected,
of the weld, occursat a high tempera- trados was subjected to compressive the transition prestrains are lower
ture. In fact, there is a continuous straining during initial bending and for 16° F than for 75° F. The
plastic extension of the weld zone then to extension during the subse- lowest transition prestrain is only
from red-heat down to room tem- quent reversal. The method was about 0.20. However, even at a
perature. Stretching at some in- developed for a rapid pre- temperature as low as 250° F the
termediate temperature must em- liminary investigation of the effects reduction of the transition range is
brittle steel, whereas limited stretch- of room temperature precompres-
ing at room temperature does not sion, and was followed by more
as much and may even restore some critical tests of bars subjected to
ductility to a highly embrittled axial compression. In spite of its
steel when performed at a tempera- simplicity, the reversed-bend test
ture above transition. The strain- was found to give very consistent
ing during cooling is further com- results of great interest. It was
plicated by a biaxial or triaxial found that prestraining in com-
stress field and by the change of pression (at intrados of the bent
mechanical properties with tem- bar) beyond a narrowly determined
perature. Nevertheless, it can be limiting strain (close to 0.50) pro-
stated that both compression and duced a sudden rapid decrease in
extension occur transversely to the the ductility in subsequent tension.
weld at various points and times Prestraining to values smaller than
during and after welding. Also this limit left the steel sufficiently
some permanent longitudinal com- ductile and permitted reversed
pression is likely to occur at a short strains of the order of 0.30 without
distance from the weld. It is fracture. Prestraining at or above
clear, however, that the predomi- this limit exhausted the original
nant effect close to the weld is a ductility strongly and resulted in
substantial longitudinal stretching, fracture at small strains during
which can be highly accentuated subsequent reversed bending. The
locally by the presence of a notch limiting or transition compressive
or defect. In this respect, it is prestrain was determined to within
interesting to note the appreciable 0.02 strain, or better.
difference in strain distribution of
cold and hot strained notched bars Effect of Hot Compression
as found by Soete.! In the present tests bars of
A wealth of results exists on the E-Steel* (0.75 x 1.00 8.00 in.
effect of high temperatures on
were used. They were cut from
steel, and some results have been a 0.75-in. thick plate in the direc-
given on the effect of a high tem- tion of rolling. They were heated
perature after room temperature at the required temperature, for
straining.'*: '* However, no. sys- a period between 45 and 90
tematic study seems to have been
min, then given the initial four-
made of the low temperature proper- point bending (Fig. la After
ties after high temperature strain-
reheating for about 15 to 30 min,
ing.* The present tests show that
they were bent (Fig. 1b) to various
plastic compression at tempera-
radii and left to cool. About one
tures up to about 700° F greatly day later they were finally tested
reduces the ductility in subsequent in reversed bending (Fig. 1c) at
extension at 75° F and at —16° F. to 6F, of al 16° F. The as-
Likewise, plastic extension at these rolled faces were at the intrados and
extrados of the bent bars, and were
* Simultaneously with the present paper, two
other reports on the phenomenon of exhaustion subjected to the highest strains.
of ductility by hot prestraining were presented The results of 122 tests at 75° F
in Commission IX of the Intern. Institute of
Welding at its annual meeting in New York, Fig. lc—Third stage: reversed bending
April 1961. They are given as References 23 * Composition and properties are given in
and 24. Reference 7 Fig. 1—Stages of bending

WELDING RESEARCH SUPPLEMENT | 307-s

 T
| E-STEEL UNAGED E-STEEL UNAGED
TESTED at 75°F TESTED at -i6°F
L

TEMPERATURE
°F

»
ITAL
GEWOING
TEMPERATURE
«Ff NITIAL
BENDING

COMPRESSIVE PRESTRAIN MPRE VE PRESTRAIN

Fig. 2—Reversed-bend tests of unaged bars of E-steel Fig. 3—Reversed-bend tests of unaged bars of E-steel
prestrained at various temperatures prestrained at various temperatures

substantial. The damage dimin- lower most embrittling tempera-

ished when the temperature of ture of precompression.
prestraining was raised above 500 An ASTM A-7 steel was used.
to 600° F as is obvious from the Its composition was found to be:
increasing transition prestrain. C—0.209; Mn—0.77%, P
Above 900° F the effect of pre- 0.011%, S—0.034%, and Si
straining was smaller than at room 0.05%; the yield and ultimate
temperature. Tests were made up strengths were 35,000 and 65,000
to 1250° F where no reduction of psi, respectively. Its transition pre-
ductility by prestraining could be strain by cold compression was
detected. found to be 0.52-0.55 (strain)
Fig. 4—Blue brittleness: cracks in the when unaged and 0.46-0.48 when
Effect of Hot Extension aged, both for final testing at
tension zone during the bending of
The hot and subsequent cold A-7 steel bars at 450° C 16° F. The dimensions of the
extensions were done with a modifi- bars used were 0.75 x 1.00
cation of the previous method, bars, because the estimated nominal 10.00 in.
which may be called the continued- strain is still a good measure of the
bend test. Test Results
damage done. Furthermore, when
The test was performed in three embrittlement is strong, the change As was expected, some bars
stages. In the first the bars were of radius and the additional strain fractured in the tension zone while
heated to 450° F and slightly bent Ae are small and, for similar bars, being bent at 450° F, which is in
in four point loading (Fig. la). are quite accurately determined. the range of blue brittleness. Two
In the second, they were heated The choice of temperature was such bars (Nos. 13 and 16) are
again and subjected to axial com- made on the basis of the results of shown in Fig. 4, and their thermal
pression till large bending occurred and mechanical treatments are given
the tests in hot bending—cold
(Fig. 1b). The strain «¢« at the reversed bending, when approxi- in the first two lines of Table 1.
extrados was estimated from the They fractured at strains of 0.36
mately 450° F was found to be the
radius of curvature Re and the
bar thickness d
€ d 2Re d l
The bars were slowly cooled to Table 1—Exhaustion of Ductility in Tension Following Hot Prestraining in Tension
-16° F and subjected to a con- Continued Bending Tests of 0.75 in. Thick Bars of A-7 Steel*
tinued bending (Fig. 1b), which Minutes at —Initial Bending— Continued Bending—
increased the extension of the ex- Bar at 450° F F R, in € F R, in. Ae Remarks
trados. The additional extensional 16 35 450 1.15 0. 4 Tension fracture
strain Ae was calculated from the 13 40 450 1.43 0.363 during initial
change of radius of curvature. As bending
shown by Frankland,** simple geo- 10 40 450 - 0.34 Tension fracture
metric relations may be used to 4 60 450 ; 0. during cold con-
find a good approximation of the tinued bending
strains due to severe bending. The 60, before 75 No fracture
initial 75
strains measured in the present bending
tests reach 0.40, and their calcula-
tion from the curvature will con- 60, after 75 0.34 No fracture
tain some error, particularly since initial 75 0.34
the trapezoidal deformation of the bending
cross section is not taken under
consideration. This, however, is * All radii of curvature and strains refer to extrados
not a serious drawback for identical After aging for 1'/: hr at 150° C

308-s | JULY 1961

 and 0.47, respectively. The crack- after bending at 450° F to nominal
ing along reversing directions at strains lower than about 0.30.
45 deg to the maximum tension is Hence, such defects, if at all pres-
characteristic of all the fractures ent, at most accentuate this phe-
which occurred at 450° F. nomenon of embrittlement by hot
Other bars were bent hot to straining at about 500° F. It should
slightly smaller strains. Thus, bars also be kept in mind that steel plate
Nos. 4 and 10 were bent to nominal with its original rolled faces is used
strains of 0.37 and 0.34, respectively. in all structures. If the quality of
When tested again in continued the faces affects fracture initiation,
bending at —16° F, these bars at Fig. 5—Exhaustion of ductility in tension it is important to know it.
first sustained the usual maximum following hot extension: cracks in the The causes of fracture in tension
load (about 4000 lb) but fractured tension zone during continued bending at at —16° F after hot extension or
in the tension zone at the very small —16° F after initial bending at 450° F compression at 450° F appear to be
additional strains of 0.03 and 0.02, quite distinct from the phenomenon
respectively. These bars are shown of blue brittleness. Blue brittle-
in Fig. 5. The fractures occurred ness exists only at the elevated
in rough surfaces approximately temperature and disappears upon
perpendicular to the maximum ten- cooling if no hot deformation has
sion, and the fracture appearance occurred. Exhaustion of ductility
(Fig. 6) was typical of the texture by stretching at 450° F appears
associated with low stress brittle after cooling. Furthermore, the
fractures but without chevron pat- direction and appearance of the
tern. Other bars, bent hot to an two fractures differ significantly.
initial maximum strain of 0.27, The blue brittle cracks follow zig-
did not fracture in continued bend- zag paths at 45 deg to the tension
ing. (Fig. 4), whereas the cracks at
Control tests were made with —16° F are roughly perpendicular
bars (Nos. 3 and 7) heated first Fig. 6—Fracture appearance of to the tension (Fig. 5). The cold
the bars shown in Fig. 3
to 450° F for 1 hr, then allowed to fracture appearance is much more
cool, and bent at 75° F to strains rugged than the hot fractures and
of 0.35 and 0.36, respectively similar to ordinary low stress brittle
Table 1. They were then aged for fractures. The change of grain
1'/, hr at 300° F (standard proce- structure due to hot straining is
dure of earlier tests)'*® and finally of some interest. Figure 8 shows
tested in continued bending at photomicrographs of a bar after
—16° F. They were ductile and hot bending at 450° F. The hot
were bent up to the point where the extension of the extrados and com-
two legs were flattened against pression at the intrados were nomi-
each other, when the additional nally +0.37 and 0.37, respec-
strains were about 0.37. Likewise, tively. However, the natural
bars bent at 75° F to about the logarithmic) strains were +0.32
same strain and then heated for 1 and -0.46, respectively. The
hr at 450°F were flattened out higher strain at the intrados results
without fracture as shown in Fig. Fig. 7—Extreme ductility of bars bent in a greater deformation and align-
7 with additional strains of 0.34 at 75° F, then heated to 450° F, and finally ment of the grains transversely
Table 1. Obviously the extreme subjected to continued bending at to the compression (Fig. 8c). The
brittleness of bars like Nos. 13 and —16° F grain deformation and alignment
16 is caused by the extension at parallel to the extension at the
450° F and not by preheating or by extrados is much smaller than at
accelerated aging at 450° F after However, the results of hot bend- the intrados, smaller even in com-
straining. ing and cold unbending tests were parison with their natural strains.
A limited number of tests with almost identical with both steels. This is in marked contrast with
prebending at 900° F were also It thus appears that small varia- cold bending, where the grain align-
done, but no fractures were ob- tions in composition or in methods of ment at extrados and intrados dif-
tained. fabrication may result in consider- fered little.'* However, it is in-
Two of the bars, which fractured able differences in the behavior of teresting that some alignment in
at —16° F after bending at 450° F, steel subjected to hot extension. the direction of extension clearly
showed small traces of a surface occurs at the extrados even in hot
defect at the region of fracture Discussion of Results straining. This is of some interest,
initiation. It seems that the de- The pronounced brittleness in because it is generally accepted
fect existed from the time of rolling. cold extension after hot straining that exhaustion of ductility in ten-
The other fractured bars, among is of particular interest, because it sion after precompression is due,
them those in Figs. 5 and 6, showed appears to be a phenomenon oc- at least in part, to the flattening and
no trace of any defect. curring near welds. Although two alignment of flaws or cavities in a
Similar tests were also made fractures seem to have been in- direction perpendicular to the final
with another A-7 steel very similar fluenced by surface defects, the rest tension. In the case of hot ex-
to the first (semikilled with C at of the fractured bars had no trace tension, the alignment is smaller
0.23 %, Mn at 0.70%, P at 0.006%, of any defect. Furthermore it is but in the direction of reduced
S at 0.033%, and Si at 0.05% clear that defects in the rolled faces ductility.
but no fractures were obtained in have not led to fractures after bend- The different behavior of two
continued bending at —16° F. ingat 75° F or above 800° F, or even nominally identical steels subjected

WELDING RESEARCH SUPPLEMENT 309-s

 to hot extension, contrasted with 6. Shank, M. E., ““The Control of Steel Con-
struction to Avoid Brittle Fracture,” Published
their almost identical behavior after by Welding Research Council, New York (1957).
hot compression, may be an indica- 7. Mylonas, C., Drucker, D. C., and Isberg,
tion that exhaustion of ductility L., “Brittle Fracture Initiation Tests,” Tue
WELDING JOURNAL, 36 (1), Research Suppl., 9-s
by hot straining may be a composite to 17-8 (1957)
effect very sensitive to small changes 8. Mylonas, C., Drucker, D. C., and Brun-
ton, J. D., “Static Brittle Fracture Initiation at
in composition or in the fabrication Net Stress 40% of Yield,” Jbid., 37 (10), Re-
of the steel. search Suppl., 473-8 to 479-s (1958).
9. Allen, N. P., “The Mechanical Properties
of the Ferrite Crystal,” Eleventh Hatfield
Conclusions Memorial Lecture, Jnl. Iron Steel Inst., 191, Part
I, 1-18 (January 1959)
Earlier tests have shown that 10. Mylonas, C., “Prestrain, Size, and Resid-
room temperature straining sig- ual Stress in Static Brittle Fracture Initiation,”
WELDING JOURNAL, 38 (10), Research Suppl.,
nificantly exhausts the ductility of 414-s to 424-s (1959
mild structural steel and provides Ll. Drucker, D. C., Mylonas, C., and Lianis,
G., “On the Exhaustion of Ductility of E-Steel
an explanation of the initiation of in Tension Following Compressive Prestrain,”’
brittle fractures at regions which Ibid., 39, (3), Research Suppl., 117-s to 120-s
l 1H)
have suffered some cold working. 12. Ludley, J. H., and Drucker, D. C., “A
The present tests show that ex- Reversed-Bend Test to Study Ductile to Brittle
haustion of ductility by hot strain- lransition,”’ Jbid., 39 (12), Research Suppl., 543-s
Fig. 8a—Extrados (top edge). Horizontal! to 546-28 (1960)
natural strain 0.32 (nominal—-strain ing may be the cause which is 13. Rockey, K. C., Ludley, J. H., and My-
responsible for fracture initiation lonas, ( “Exhaustion of Extensional Ductility
Determined by Reversed Bending of 5 Steels,’
at defects close to welds. Report NObs-78440/5 of the Division of En
The present tests, although of a gineering, Brown University (March 1961). Pre-
preliminary nature, show that strain- sented as Document IX-293-61 at the annual
meeting of the Inter. Inst. of Welding, New
ing in compression or tension at York (April 1961)
temperatures around 400 to 600° F 14. Kennedy, R., “The Influence of Stress
Relieving on the Initiation of Brittle Fracture in
reduces the original ductility much Welded Plate Specimens,” Brit. Welding Jni., 4
more than straining at room tem- 11 929-534 (1957).
15. Masubuchi, V., and Kihara, H., “Effect
perature. In particular, simple ex- of Residual Stress on Brittle Fracture,"’ WELDING
tension by bending at 400 to 600° F JOURNAL, 37 (4), Research Suppl., 157-s to
168-s (1959
exhausts the ductility so drastically 16. Mylonas, C “Static Brittle Fracture
as to result in fractures at —16° F Initiation Without Residual Stresses,’’ Report
at additional tension strains of a NObs-78440/4 of the Division of Engineering,
Brown University (February 1961
few hundredths. Such hot ex- 17. Soete, W., “The State of Stress and
tension certainly occurs during cool- Brittle Fracture,” Report to the British Welding
Institute (1948)
ing of the weld zone, and pre- 18. Osborn, C. J., Scotchbrook, A. F., Stout,
existing notches or flaws may raise R. D., and Johnston, B. G., “Effect of Plastic
the strain to the levels applied in Strain and Heat Treatment,” We_pinc Jour
NAL, 28 (8), Research Suppl., 337-s to 353-s
the present tests. Hence it is 1949
reasonable to consider the phe- 19. Lagasse, P. E., and Hofmans, M., “Effets
Chermiques sur la Fragilité des Profile en Acier
nomenon of exhaustion of cold duc- Doux,”’ Report RA 101 of the Centre National de
tility by hot extension as one of the Recherches Metallurgiques, Section de Liége
1959
important causes of fracture initia- 20. Rockey, K. C., and Mylonas, C., “Re
tion at defects close to welds. versed-Bend Tests for the Exhaustion of Duc-
Many questions must still be tility by Hot Compression,’’ Report of the Divi
sion of Engineering, Brown University (March
answered, but it is felt that the 1961 Presented as document IX-303-61 at the
tests described isolate one of the annual meeting of the Inter. Inst. of Welding,
New York (April 1961
causes of brittle fracture initiation 21. Mylonas, C., and Rockey, C., “Exhaustion
and may facilitate the search for the of Ductility by Hot Extension. An Explanation
specific mechanism which produces of Fracture Initiation Close to Welds,’ Report
NObs-78440/6 of the Division of Engineering,
it. Brown University (March 1961). Presented as
document IX-302-61 at the annual meeting of
References the Inter. Inst. of Welding, New York (April
1961
1. Drucker, D. C., “An Evaluation of Current 22. Frankland, J. M., and Roach, R. T., Jnl.
Knowledge of the Mechanics of Brittle Frac Aero. Sci., 21 (1954).
ture,’ Ship Structure Committee Report SSC-69 23. Terazawa, K., Otani, M., Yoshida, T., and
1954 Terai, K., “Effect of High Temperature Pre
2. Wells, A. A., “The Influence of Welding straining on Retained Ductility of Steel,” Re-
on Notch-Brittle Fracture,” Jni. West Scot. Iron port of Kawasaki Dockyard Co., Kobe, Japan
Steel Inst., 60, 313-325 (1953). January 1961). Presented as document IX-
3. Greene, T. W., “Evaluation of Effect of 285-61 at the annual meeting of the Intern. Inst
t - Residual Stresses,"” THe WELDING JOURNAL, 28 of Welding, New York (April 1961)
a”. ot 5), Research Suppl., 193-8 to 204-s (1949) 24. Terazawa, K., Otani, M., Yoshida, T.,
4. Weck, R., “Experiments on Brittle Frac- and Terai, K., “Effect of High Temperature
Fig. 8c Intrados (bottom edge). Horizontal! ture of Steel Resulting from Residual Welding Prestraining on Notch Toughness of Steel,” Re-
natural strain —0.46 (nominal—strain — 0.37) Stresses,"’ Welding Research, 6, 70-r to 82-r (1952) port of Kawasaki Dockyard Co., Kobe, Japan
Fig. 8 Photomicrographs of A-7 steel 5. Wells, A. A., “The Brittle Fracture January 1961). Presented as document IX-
Strength of Welded Steel Plates,” Trans. Inst 285-61, at the annual meeting of the Intern. Inst
prestrained hot Naval Arch., 60, 296 (1956). of Welding, New York (April 1961).

310s | JULY 1961

 Transition Temperature from Test Bars

Using a Strain Aged Initiation Site

Strain aged zones may be used as initiation point for brittle fracture

in test bars, both in drop-weight and notched tensile tests.

BY CLAES PFEIFFER

ABSTRACT. Investigations demon- source ofa brittle crack formed dur- same type of testing condition
strated that the transition temperature ing testing has been suggested in namely, a running brittle crack
could be determined either (1) by drop- several types of tests. The weld reaching the unaffected material.
weight test bars with the brittle weld has definite advantages and gives The embrittlement of a zone of the
metal substituted by a pressed notch,
which has been thermally aged after- an indication of the ability of the material to be tested was obtained
ward, or (2) by flat tensile test bars material tested to stop a running by the same technique in both types
with a pressed notch afterward ther- crack. If welding changes the of tests.
mally aged on both edges of the test properties of the material—for in-
bar. stance, by forming tougher struc- Part i—The Modified
Provided the material tested was tures in the heat affected zone—by Drop-weight Test
sensitive to strain aging, the pressing giving a tough martensitic zone in
of a sharp knife edge to a depth of at a low alloyed low carbon steel, or a Materials and Testing Procedure
least 0.02 in., followed by heating to tough grain-refined zone, or even
500° F for 1 hr, caused a local em- In the drop-weight tests, a 1-
brittlement in the cold worked ma- a tempering effect, the test will give in. long sharp knife edge with 45
terial, thus forming a zone with a a transition temperature lower deg edge angle was impressed in the
higher transition temperature than than that of the unwelded material. surface of the testpiece to a depth
the surrounding material. This zone The existence of toughened zones of at least 0.03 in.
showed brittle fracture at higher test- in welded drop-weight tests has The materials tested were all
ing temperatures than the transition been pointed out by Agnew, Mit- 1 in. thickness. The A285 and
temperature of the unworked ma- telman and Stout,' who compared A212 steels were tested as-received;
terial; testing conditions thus showed A212 steel specimens quenched and A203 was tested as-received and as-
the ability of the material to stop a then welded with others welded normalized from 1650° F. Two
running crack.
The drop-weight testing described and then quenched. In the welded different heats of A302 were tested
in Part I showed, with one exception, and quenched series with the heat one heat as-received; one heat
that the transition temperature was affected zone absent, the NDT was normalized from 1650° F. The
either the same or higher than the tem- 100° F, while the quenched and chemical compositions of the steels
perature obtained by normal drop- welded series showed an NDT of are given in Table 1, and their
weight testing. The pressed notch 60° F. These men also tested mechanical properties appear in
type of test bars showed higher transi- A203 and A302. {Both materials Table 2.
tion temperature for steels where the showed a shear riteg in the heat The drop-weight testing was made
welding on the test bar caused a affected zone, and the NDT of the
tougher heat-affected zone than the with test pieces which were 12 in.
unaffected material. In one case the A203 steel was observed to fall by 3 in. by 1 in. with an 11 in.
material tested was too insensitive to below the Charpy-V 15 ft-lb tem- span. The welding was performed
strain aging; in this particular heat perature, which was unusual for with sin. Hardex N. at 5 ipm at
the test failed. The notched tensile this type of low-alloy steel. 190 amp and 22 v.
test bars described in Part II indi- Norén? has suggested welding The stop distance was varied ac-
cated the temperature at which notch brittle weld metal orr the edges of a cording to the strength of the steel.
brittleness occurred in two different flat tensile test bar in the NC-test. A302 steel was tested with a stop
ways—-one, by measuring the lateral The brittle weld metal furnishes distance of 0.35 in. instead of the
contraction in the center between the fast-running brittle cracks during standard 0.30 in. The testing con-
notches of the test bar; the other, by the pulling of the bar in the tensile
registering the yield strength and the ditions were intended to be the
nominal tensile strength. The transi- testing machine. In this case, not same for all materials, and thus
tion temperature for a °/s-in. thick only the toughening of the heat the stop distance was adjusted in
plate tested in its full thickness was in affected zone but also the un- order to permit the same amount of
fair agreement with the Charpy transi- certainty of the measurement of the plastic deformation regardless of the
tion temperature. fracture area may interfere with the strength of the steel.
test results. The heat treatment of the A203
Introduction These investigations were made steel was performed on individual
The use of a brittle weld metal as a in order to find out if the brittle drop-weight test specimens. One
CLAES PFEIFFER is Research Metallurgist for weld metal could be replaced by series of ordinary drop-weight test-
the Atomic Energy Co., Stockholm, Sweden another type of notch to give the pieces of A285 was also heated

WELDING RESEARCH SUPPLEMENT | 3ll-s

 aged notch than the NDT obtained
Table 1—-Chemical Analysis of Steels (wt.-%) with the standard test procedure.
Steel Grade C Si Mn P As has already been pointed out by
A203 0.17 0.24 0.59 0.01 Agnew, Mittelman and Stout,' the
A285 ¥ 0.20 0.07 0.79 0.01 shear rings shown at the fracture
A302-1* 0.21 0.25 1.20 0.01 surface in these types of steel in-
A302-11° 0.0 CA 1.97 0.013 dicate an interruption of the cleav-
A212 0.32 0.24 0.71 0.02 age crack propagation, thus demand-
“ Tested as-received ing a reinitiation of the crack. This
® Tested normalized leads to a lower indicated NDT than
the true NDT.
The NDT for A302-I steel as-
Tabie 2—Mechanical Properties of Steels received with a strain-aged notch
was obviously at a far lower tem-
0.2% yield Ultimate
strength, tensile Elongation Reduction perature than the standard NDT.
Steel Condition ksi strength, ksi in 1 in., % area, % The only possible explanation for
A203 As-received 52.5 80.9 29.5 63.1 this behavior is that this heat was
A203 Normalized 60.6 81.5 29.0 66.6 extremely insensitive to strain aging.
A285 As-received 28.9 60.2 33.5 64.0 The increase in Charpy transi-
A302-1 As-received 81.4 120.0 22.5 59.2 tion temperature from strain-aging
A302-11 Normalized 91.6 121.0 19.0 51.3 of this heat was almost negligible
A212 As-received 41.8 83.7 28.0 55.8 compared to the other steels. This
series indicates a limitation of the
test method, namely, the need for a
to 500° F for 1 hr before welding. test bars were taken longitudinally certain sensitivity to strain aging.
The heat treatment of A302 from the material split into two The A212 showed a very faint
steel was performed on plates which '/,-in. thick plates and were notched increase in transition temperature
were 12 by 12 by 1 in. Each plate perpendicular to the plate surface. when tested with a strain aged
was cut along the rolling direction notch; the increase might be due to
to two drop-weight test specimens, Test Results
the influence of a slight toughening
which were 12 by 3'/, by 1 in., and The test results are given in of the heat affected zone. The in-
12 by 1 by 1 in. for the strain aged Tables 3 and 4. Table 3 shows that crease was, however, within the
impact test bars. The remaining the strain aged notch series gave the limits of error.
2 in. on each edge parallel to the same NDT as the welded test series The disagreement between the
rolling direction was discarded. for three of the steels tested. There NDT obtained with the strain aged
Charpy impact testing was also are three exceptions—namely, A203 notch test bars and the 15 ft-lb
made after strain aging. The ma- as-received, A302-I as-received and transition temperature criterion for
terial was strained 5% and heated A302-II normalized. A302B-II was due to the improve-
to 500° F for 2 hr before machining The NDT for the A203 as- ment in toughness of the steel
the test bars. The test bars were received was 30° F higher, and for caused by tempering at 500° F
taken out in the same way as those the A302-II normalized it was not after processing the notch.
for impact testing of unworked less than 70° F higher when the The impact test results from test-
material. The Charpy V-notch material was tested with a strain- ing the steel in the normalized and
tempered (lh. 500° F) condition
showed a transition temperature
Table 3—Test Results Obtained with Strain Aging of 65° F, in agreement with the
——NDT-——— strain aged notch test results.
Transition Temp., ° F, Strain The 500° F tempering treatment
Charpy V-notch aged is not necessary in order to produce
Steel Condition 15 ft-lb 20 ft-ib 15 mil Welded notch the aging effect at the root of the
A203D_ As-received —28 —10 —40 —60 —30 pressed notch. Lower’ tempera-
A203D Normalized —128 —110 —130 —100 —100 tures and longer times can be used
A285C_ As-received to develop aging.
+ th. 500° F 46 oe ed 50 50
A302B-| As-received 38 60 34 50 <0
A302-Bli Normalized 110 [65 130 (85)' 100 (60)’ —10 60 Part Il_—Notched Flat
A212B_sAs-received 80 98 68 50 60 Tensile Test Bars
Not tempered test bars. ° Bracketed values Material and Testing Procedure
represent A302-II Normalized + lh. 500° F
This part describes results of
testing a normalized constructional
Table 4—Change in Charpy 15 ft-lb of Table 5—Chemical Composition and steel SIS 14 14 11 used for hull
Normalized Steels through Strain Aging Mechanical Properties for SIS 14 14 11 constructions in shipbuilding. The
plate thickness was °/; in. The
Wt-% Wt-% chemical composition and mechan-
Un- Strained 5% In- av dendcedomeee poreFO ical properties for the steel are
strained, + 1h. 500°F, crease, ee 0.30 | err given in Table 5. The testing was
Steel al F eee _. See 0.16 made with LC-test bars previously
A203 —128 — 50 rE 0.017 Di ovevdvnaies 0.005 described by the author.* The
A285 + 46 +106 Yield strength, ksi flat test bars in full plate thicknesses
A302-1 — 12 + 2 Ultimate tensile strength, ksi were notched with a normal Charpy-
A302-1! +195 . Elongation, 10 xd 24%
A212 + 42 +100 : Grain size ASTM nr 6 V notch cutter at both edges. In
the root of each notch, a sharp

312-s | JULY 1961

 x fraCture strength
e yield ns
A lateral contraction,%

Fig. 2—Microstructure under the fracture

surface of a test bar tested at 100° F.
Microcracking and twinning has occurred.
x 800 Etchant nital

by Williams’ who found that source

30+ plates, or plates through which
brittle fractures had passed with-
ee eee ee ennaeae Or out being stopped, showed a lateral
-110 -I0O0 -90 -80 -70 -60 contraction usually less than 2 to
TEMP,°F 3%, while the stop plates showed
lateral contraction higher than 2 to
Fig. 1—Results from testing bars with strain aged notches to.
The test bars were in full plate thickness The microstructure from a test
bar tested at 100° F is shown in
Fig. 2. The structure showed both
knife edge of the same shape as the 2. By registration of the yield microcracks and deformation twins.
Schnadt K, knife was impressed strength and the nominal ten-
Conclusion
to a depth of 0.02 in. The test sile strength. These values
bars were then heated 1 hr at 500 plotted against testing tem- These investigations have shown
F. The width of the test bars perature gave curves which that a strain-aged zone can be used
measured between the roots of the coincided at the _ transition as the initiation point for a brittle
notches was equal to twice the plate temperature. fracture in test bars, both in drop-
thickness. weight tests and notched tensile
The material was also tested with
The testing was executed in a standard Charpy V-notch bars. tests. The method has the limita-
standard tensile testing machine. tion of requiring a certain sensitivity
Test Results to strain aging of the material. Its
With the use of friction grips, it
The impact testing showed a advantage, compared with test bars
was essential to limit the width of
15 ft-lb transition temperature at with brittle weld metal as the initia-
the test bar to twice the plate thick-
ness in order to avoid displace- -32° F for unworked material. tion site, is that in steels in which
Strain aging by 5% strain followed one or more of the heat affected
ment of the axis of loading from the
by heating to 500° F. for 1 hr zones are tougher than the un-
centerline of the test bar. A dis-
placement equal to '/,; of the width raised the transition temperature to affected steel These may in-
5° F. terrupt the propagation of the run-
of the test bar doubled the stress
The strain aged-notched series ning cleavage crack, and thereby
at the edge closest to the load axis.
gave the results shown in Fig. 1. cause a lower transition tempera-
This meant that a crack starting
The cleavage strength increased ture, which may be misleading.
from that notch might stop after
with falling testing temperature This was demonstrated for two
a short run and invalidate the test.
down to the temperature T, below steels by the drop-weight test.
The test bars were cooled in
which the cleavage fracture was For one steel, the NDT was not
liquid beforehand and _ insulated
preceded mostly by twinning. The less than 70° F higher with the
during the testing. The tem-
perature on the surface of the test formation of microcracks was at strain aged notch than with the
these low temperatures con- standard test bars.
bars was measured and registered
centrated to a very narrow zone The use of a strain aged notch
at the moment of the yielding and
adjacent to the cleavage surface. in tensile test bars gave a transi-
fracture. The coolant was nor-
The plastic deformation was also tion temperature in fair agreement
mally a mixture of dry ice and
restricted to very low values. This with the Charpy V-notch test when
methyl alcohol. For temperatures
behavior has been pointed out by a */, in. thick steel was tested in its
lower than —60° F liquid nitrogen
Wessel,‘ who found the same phe- full thickness.
was used as coolant.
nomenon in testing notched tensile
The transition temperature, or Acknou ledgme nt
test bars.
the temperature at which a running
The transition temperature was The author wishes to thank Dr.
cleavage crack could not be stopped
at --28° F where the curves for the R. D. Stout for permission to con-
by the steel, was determined in two
yield strength and the fracture duct the investigation described in
different ways:
strength coincide. The lateral con- Part I at Lehigh University, and
1. By measuring the lateral con- traction at that temperature was to Elektriska Svetsningsaktie-
traction in the center between about 2%, which is in good correla- bolaget, Gothenburg, for per-
the notches of the test bar as a tion to failures in welded ships. The mission to conduct the work de-
function of testing tempera- lateral contraction has been measured scribed in Part II. The author also
ture. in steel plates from fractured ships wishes to thank S. A. Agnew,

WELDING RESEARCH SUPPLEMENT 313-s

D. Canonico, and T. M. Norén for tion, and thus be able to conduct Engineers and Shipbuilders, New Castie upon
I'yne, 73, 87-112 (1957)
their interest in these investiga- part of these investigations. 3. Pfeiffer, C., “Bestimning av omslagstem-
tions. peraturen hos stal genom statisk dragprovning,”’
Finally the author wishes to thank Jernkont Annaler, 142 720-730 (1958)
References 4. Wessel, E. T., “A Tensile Study of the Brittle
Aktiebolaget Atomenergi for their 1. Agnew, S. A., Mittelman, M. D., and Stout, Behaviour of aRimmed Structural Steel,”” ASTM
help in making it possible for him to R. D., “Some Observations on the Kinzel and Proc. 56 (1956) p. 540-554
Drop Weight Tests,"” Wetpinc JOURNAL, 39, 5. Williams, M. L., “Correlation of Metallur-
study in the United States on an (5), Research Suppl., 205-8 to 211-8 (1960) gical Properties and Service Performance of
Honorary Fellowship from the 2. Norén, T. M., “The Nominal Cleavage Steel Plates from Welded Ships,” THe Wetpinc
Strength of Steel and Its Importance for Welded JouRNAL, 37 (10), Research Suppl., 445-s to
American-Scandinavian Founda- Structures,"" Trans. North East Coast Instn. of 454-s (1958).

EUROPEAN WELDING RESEARCH

By Gerard E. Claussen

FRANCE -49° F. For thicknesses over */, fill a 40 | cylinder was reduced from
in. preheating to 300-400° F is 8 to 3 hr.
The French magazine Soudage advisable. A wire containing 0.07 e Marble, granite and sand from
et Techniques Connexes for Sept.- C, 0.30 Si, 1.50 Mn and 0.35 Mo South Russian quarries were found
Oct. 1960 contains an article by is used for CO, welding, the weld to be suitable for electrode coatings.
Russian metallurgists describing an metal having a tensile strength of e A torch and iron powder dispenser
instrument for reproducing the 90,000 psi. for cutting stainless steel has been
thermal cycle of welding on tensile developed. Formulas exponential
specimens. The thermal cycle is in thickness are given for cutting
reproduced by a cam which actuates USSR travel speed, gas consumption and
the tap of a resistance welding trans- width of cut.
Svarachnoe Proizvodstvo for Au- ¢ Tabulated information is given on
former which heats the specimen by gust 1960 contains the following
resistance. Heating rates from 5 dimensions of oxygen cutting tips
articles: and on optimum cutting conditions.
to 2700° F per sec are feasible in ¢ Sodium-silicate-bounded sub-
the range 1300 to 1800° F. The in- merged-arc fluxes were made for
strument was used to study cold Svarachnoe Proizvodstvo contains
hard surfacing at the 200 and 450 the following articles in its October
cracking in five steels containing Brinell !Jevels. The Mn, Cr, and C
0.23--0.50 C, 0.14-1.16 Cr, 0.53-1.64 1960 issue:
contents of the deposits increased as e A condensed statement of the hot
Mn and 0.26-1.32 Si. With the in- the current was decreased and as
strument, it was found that low- cracking problem was made by a
the voltage was increased. Besides group of five prominent welding re-
austenitizing temperatures and alloying elements the fluxes con-
short times favored fine grain size searchers, including A. A. Bochvar
tained CaCO, and CaF, in the ratio and N. N. Rykalin. Hot cracks re-
and heterogeneity of austenite, and of 2'/,or4to1. A mild steel elec-
consequently absence of martensite sult from relative movement be-
trode was used. tween adjacent crystals that are
cracking. ‘TTT curves derived from
e A machine for CO, welding steel under strain. Heating depends on
customary heat treating conditions
pipe without backing rings was de- the hydrostatic pressure and capil-
required correction before they could
be applied to welding. veloped. The pipe rotates under lary energy of remaining liquid.
the welding head, which is 30 deg The term “effective crystallization
over center. The root pass was de- interval’ is used for the tempera-
SWEDEN posited with */,-in. wire, 200-260 ture range in which there is a sharp
amp, 20-24 v, 14-18 ipm, !/.—/\,-in. drop to zero in the ductility of the
The TTT diagram, Jominy curve oscillation of electrode. solid.
and microstructure of Bofors No. e After heat treatment, electroslag e High-frequency welding of spiral-
345 steel are applied to welding in welds in steel forging 4 in. thick had seam steel pipe, '/,-in. wall, was
the September 1960 issue of Svet- better tensile and impact properties investigated on experimental equip-
saren, the Swedish welding journal. than base metal. ment. An inner roller and an outer
The steel contains 0.16 C, 1.5 Mn, e Fewer slag inclusions occurred at roller squeeze the beveled edges
0.3 Si, 0.2 Cr and 0.3 Mo normalized the root of butts welds made by the together. The best bevel angle
and drawn at 1200° F; the steel submerged-arc process in steel with was 42 deg. The sliding contact
is 3 in. in thickness, has a 0.2% backing strip when welding in the was 0.12 x 0.59 in. and was made of
yield strength of 59,000 psi and flat position or up to 8 deg uphill, molybdenum. The frequency was
Charpy V 15 ft-lb transition at than in downhill welding or uphill 200 ke.
more than 8 deg. ¢ Several examples are given of local
e By removing the heat of solution heating to convert tensile residual
DR. GERARD E. CLAUSSEN is associated with of acetylene in acetone by means of stresses in welds in bridge girders
Arcrods Corp., Sparrows Point, Md cooling water, the time required to to compressive residual stresses.

314s | JULY 1961

 Effect of an Irregular Notch on Subsize Impact Data

SY A £. LOWE, JR.

ABSTRACT. ‘Two series of subsize im any given temperature increases. Heating and cooling of the speci-
pact specimens were evaluated to de- Accordingly, the sharp corners of mens were done in a_ special
termine the correlation, if any, of V- the irregular notch could be con- clamping device, which also held the
flat root notch and V-round root notch sidered as very small radii notches, specimen for testing. Heating was
impact data. The reproducibility of
the energy absorption values from the which could actually lower the accomplished by a heating coil set
V-flat root specimens permitted com energy absorption. Thus, it was in the jaws of the clamping mech-
parison with similar data, but not with pure conjecture as to the effect of anism, and cooling by circulating
the V-round root data. Excessive the notch, but it appeared feasible liquid nitrogen through passages in
scatter in the lateral expansion data to test both configurations and to the same clamps. ‘The temperature
made correlation impractical. The V compare the data. was measured by a thermocouple
flat root notch lowered the energy ab clamped against the specimen.
sorption brittle transition temperature; Test Specimens
however, the shear fracture brittle The specimen had been designed Evaluation of Results
transition temperature appeared to be
raised. for studying the effect of irradia- The impact properties of the steel
tion on the impact properties of were evaluated by the three com-
Introduction materials. The specimen, as shown monly used criteria—energy absorp-
In the course of investigating the in Fig. 1, is essentially a subsize tion, lateral expansion and fracture
effects of irradiation on the impact Izod specimen in that all dimensions appearance. ‘The results of the eval-
toughnessof a 1!/,% Cr — '/2% Mo except notch depth have been re- uation of each criterion are dis-
steel, a series of subsize Izod speci- duced by a factor of two. The cussed separately. No formal con-
mens were inadvertently machined specimens contained notches of two clusions have been made since the
with a flat root V-notch (V-flat different geometries—Fig. 2. The study does not represent a complete
instead of the standard notch with a correctly notched specimens had a evaluation.
radius at the root (V-radius). The notch which was 0.060 in. deep with Two factors are important in
immediate concern was what effect a 0.005 in. radius at the bottom. evaluating the results 1) The
the irregular notch would have on The second series of specimens con- range of values for the test data is
the impact data. tained a flat bottom notch which low because the specimens were sub-
A review of the literature indi- was 0.060 in. deep with a 0.012 in. size and, therefore, the energy level
cated that, as the notch radius is in- land at the bottom. Optical meas- for determining the transition tem-
creased, the energy absorption for urements proved all the square perature has to be defined. (2) The
notches to be identical. large amount of scatter observed in
the ductile region is not related to
A. L. LOWE, JR., is with the Atomic Energy Testing Procedure the geometry of the specimen;
Div., The Babcock & Wilcox Co., Lynchburg
Va All specimens were tested on an instead, it is a result of this partic-
Work performed on Atomic Energy Commission impact tester which had been modi- ular type of test. The specimens
Contract No. AT (30-1 1940 fied for operation in a hot cell. in the ductile range generally were
not completely fractured, but only
bent sufficient to permit the pen-
dulum to pass
5.950
Energy Absorption
5 SPACES @ 0850"= 4 250"
The data obtained fromthe
measurement of the energy absorbed

Notes
1. Unspecified tolerances are 0.005
\ . 0005 . 2. Notches milled with formed cutter
nonK"Rt?
3. ASA 32 finish unless otherwise
specified

»t0.001"
_ 0.200" NOTCH DETAIL
SECTION A-A Fig. 2—Comparison of the regular V-
notch (V-radius) profile with the irregular
Fig. 1—Details of subsize |zod impact specimen V-Notch (V-flat) profile

WELDING RESEARCH SUPPLEMENT | 315-s

 © ‘Vv RADIUS DATA
© ‘Vv FLAT OaTA
b + +

Expansion,
Lateral
percent

Temperature, F
Fig. 3—Effect of notch geometry on the transition
temperature as measured by the total energy absorbed
Temperature, F
a - Fig. 4—Effect of notch geometry on the transition temperature
OV RADIVS DATA as measured by the percent lateral expansion on the
b Ov F.at and
pata side of the specimen opposite the notch

Fig. 5—Effect of notch geometry on the transition temperature

measured by the percent shear on the fractured face

Temperature, F

are presented graphically in Fig. 3. be compared with data obtained line, the shift is appreciable and
The major difference observed from similarly notched specimens. indicates that they are not com-
between the V-radius and V-flat However, the data would not be parable to the V-radius data. Asa
notch data is a change in the slope of suitable for inclusion with regular result of this variation, these meas
the curve between the brittle and V-notch data. urements cannot be used for corre-
ductile regions. This was accom- lation of data.
panied by a shift of the ductile
region for the V-flat data from +50 Lateral Expansion
to 0° F without any change in the The lateral expansion of the Fracture Appearance
brittle region. The curves are iden- specimens measured on the side of
tical below the 1',, ft-lb level, and the specimen opposite the notched The fracture appearance plotted
even at the 2 ft-lb level the differ- side is presented in Fig. 4. The as the percent of shear observed on
ence between the curves is within data for the V-radius specimen the fractured surfaces is shown in
15 deg. Thus, it appears that the show good reproducibility, partic- Fig. 5. The data obtained from
V-flat geometry has little effect on ularly in the brittle range, and the the V-radius specimens are typical
the brittle transition temperature, only scatter is in the ductile range. of the type of transition curve
provided it is defined at a sufficiently The data for the V-flat specimens generally observed for this steel.
low energy level. Apparently, the show excessive scatter over the The data for the V-flat notch
energy level should be defined below entire test temperature range and transition curve are incomplete be-
the two foot-pound level, in which for that reason the points have been cause of insufficient data between
case, the data obtained from the two banded instead of averaged with a +50 and +100° F. The data from
different specimens are comparable line graph. The shift of the lateral the V-flat notch specimens show con-
for measuring the brittle transition deformation curve to a lower transi- siderable more scatter than the data
temperature. tion temperature indicates that the from the V-radius specimen and ap-
The degree of scatter observed in data was affected by the notch parently is a result of the notch
the data appears to be similar for geometry. The narrowness of the configuration. However, even from
both notches. If one considers the scatter band apparently is related the limited data, it appears that the
wide variation in the notch geom- to the fact that the data was ob- transition curve may have been
etries, a greater degree of scatter tained from an area which was suffi- shifted to a higher temperature and
could have been anticipated. The ciently removed from the notch as only the magnitude would require
fact that only the degree of scatter to be less affected by the notch further definition. The shift in the
characteristic of this type test geometry. If the V-flat data are curve as shown in Fig. 4 has been
occurred indicates that the data can averaged, as shown with a broken made primarily by deduction.

316-s | JULY 1961

 Experimental Determination of

Dimensional Heat Flow in Weldments

A new technique utilizing temperature-sensitive lacquers

is developed to determine

heat-flow transitional temperature

BY Ss. S. WHITE

Introduction plate without filler on various tita- initial temperature of the

nium alloy sheets of constant thick- plate
For a given bead-on-plate weldment, rate of heat flow from source.
it is to be expected that low peak ness (0.122 0.002 in.). To thermal conductivity of plate.
temperatures are associated with eliminate the effects of lacquer on thickness of the plate
the molten-weld puddle, the lacquer VR/2a
two-dimensional heat flow. As velocity of heat source
higher temperatures are encoun- was painted on the underside of the
weldment. The melting point of V 2re
tered nearer the fusion zone, heat distance to point of tempera-
flow tends to be more three-dimen- the lacquers used varied from 1000 ture measurement from
sional. The purpose of the current to 2000° F in increments of 100 weld centerline.
deg. The lacquer was applied by thermal diffusivity k/ pC
research was to determine experi- f density of plate.
mentally, for a constant energy in- painting strips, each corresponding Cc specific heat of plate
put, that temperature above which to a certain temperature sensitivity,
heat flow is more three- than two- transversely to the welding direc- For any given weld, gq, k, t, V,
dimensional (hereinafter referred to tion. Subsequent to welding, the C, are constant. Therefore
as the heat-flow transition tempera- width of the resultant molten and
ture). It was also desired to reduce resolidified band in each strip re-
a peak-temperature vs. distance vealed the area in which the metal
plot to linear coordinates, thereby had been heated to or above the
allowing accurate extrapolation to particular temperature in question.
all temperatures, and from heat-flow These bands were measured to the
measurements to recognize any nearest one-thousandth of an inch where:
geometrical changes in the fusion under a 12 X microscope.
W width of molten-and-re-
zones. Interpretation of Results solidified temperature-
The difficulties involved in using sensitive band
many thermocouples or of accu- Plotting this information directly constants
rately placing thermocouples at spe- as (width-of-band) /2 vs. peak tem-
cific locations on weldments to de- perature yielded smooth curves
termine peak temperatures led to Fig. 1) but did not reveal the heat-
the use of temperature-sensitive flow transition temperature. Also,
lacquers for such work.! These although these curves could be
lacquers, because of their composi- back-extrapolated to yield the peak
tion and low heat-of-fusion, melt temperatures along the weldment
within +1% of their rated tempera- centerlines, the nonlinearity of these ref
tures, thus providing accurate read- plots limited the accuracy of such
ings. Since complete temperature determinations. ‘The mathematical
information for all distances from relationships between peak tempera-
the fusion-zone edge is readily at- ture and distances from fusion lines
are known, and these were applied TEMPERAT
PEAK
tained with such lacquers, they were
used in this effort. to the present work. Adams! has
shown that, for two dimensional
heat flow from a vanishingly small
Experimental Procedure and infinitely intense heat source, \ |
A fully-automatic 500-w capacity the following relationship holds:
inert-gas-shielded tungsten-arc torch a uss J
T T. — l 25 30 35 40 45 5O 55 60
mounted on a radiograph carriage 2kink
ras used to produce a_ bead-on- MIDTH OFBAND INCHES x10"
where:
is peak temperature at a dis- Fig. 1—Peak temperature F vs. (width
S. S. WHITE is Supervisor of Materials Joining tance R from the heat of band/2), in. for run 71. (117.5 amp;
Alloyd Electronics Corp., Cambridge, Mass source. 15 v, 20 ipm travel rate

WELDING RESEARCH SUPPLEMENT | 3l?-s

 a= APPROXIMATE
WIDTH OF WIDEST
BANOS
b= APPROXIMATE
WIDTHOF FUSION
ZONES
c= ZONE OF
GENERAL TEMP
MEASURING
INTEREST

where K; constant. For three-

dimensional heat flow, half of the
+ ~ a - width of the molten-and-resolidified
6 8 10 i2 14 16
18 20 22 24 26 28 30 temperature-sensitive band may be
2 > e looked upon as one leg of a right
(mors & BAND ) x lO, INCHES triangle having R as hypotenuse.
Therefore,
Fig. 2—1/(T,, — T..) * 10 F vs. (W/2)? & 10°, in.? for run 64. l } WwW F
(117.5 amp; 15 v; 30 ipm travel rate) T T a TS
The same relationship obtains if one
ieee ‘ ' ; : : considers a real heat source.
Similiarly, taking cognizance of fi- ture is again related to width-of-
nite dimensions of the heat source band as follows Heat-flow Transition Temperature
and its latent heat effects in two- ; Thus, for two-dimensional heat
; . . : I » te ; : ; one
dimensional heat flow, the following , 1, Ke | 5 + Kp (E flow, the reciprocal of the difference
relationship holds:! . between peak temperature and room
l Vr'tpC,K where Ke, Kp constants. For temperature bears a linear relation-
a‘ three-dimensiona! infinitely intense ship to (width-of-band)/2. For
point source heat flow, three-dimensional heat flow, (width-
V ; of-band /2)? is a linear function of
ry ray ¢ > . . .
where: T 7 (5! Ne .) 6 this reciprocal temperature factor
.4 Th ae ar h* "eo 9 rw " rio
r distancea from edge of -¢ fusion pas : . Fig. fa 2). = The ; curve of W/2 vs.
sone hus, for any given weld, W /2 (Fig. 3), although par-
y, melting point ' abolic in shape, may be taken as
F , id kt = = linear except for small values of
or any Bgiven weld, i pea empera- W r r2.e In the present work, small
values of W/2 (nonlinearity) em-
braced distances equal to or less

a“
re
7
7
CENTERLINE
PEAK TEMPERATURE = 2560°F
[= ae eo ee = ae aS SS ae SS ee a ae oe Se |
10 12 4 16 18 20 22 24 26 28 30 0 4 6 (i2 16 20 24 28 32 36 40 44 48 52 56 60
¥, INCHESor(W.)*, CHES® x10° (¥) x 10°, INCHES?

Fig. 4—1/(T, — T.) X 10*, °F-' vs. W/2, in. or W?/4 in.? Fig. 5—1/(T, — T.) X 10*, ° F-' vs. (W/2)? X 10%, in.?
for run 140. (80 amp; 16 v; 36 ipm travel rate) for run 93. (117.5 amp; 15 v; 24 ipm travel rate)
318s | JULY 1961
than the width of the fusion zone. temperature-sensitive lacquer used. greater dependency of geometry on
Hence, from geometrical considera- Repeats of many runs have shown temperature since the material used
tion alone, distances corresponding that such determination are repro- was Ti-—6Al-4 V alloy having a
to small values of W/2 were defined ducible to within +30° F. very different diffusivity from Ti-—-
as being predominantly three-di- 5Al — 2!/; Sn.
Predication of Weldment Geometry
mensional in heat flow.
When the reciprocal of the tem- From eq 6 or from the relation-
ship for a real three-dimensional Conclusions
perature gradient was_ plotted
against (width-of-band)/2, devia- heat source, ! 1. An experimental technique,
tion from linearity appeared above l 2K ae| ) which utilizes temperature sensitive
a certain critical temperature which qVv L . lacquers, for the determination of
was taken to represent the transi- the heat-flow transitional tempera-
tion from predominately two- to ture has been developed
predominately three-dimensional 2. This simple research tool also
heat flow (Fig. 4). Since two- and it may be seen that, with voltage lends itself to the measurement of
three-dimensional width-of-band and amperage constant for a given other heat flow parameters such as
factors are directly related be- series of welds, peak-temperature locations and
low this temperature, (width-of- fusion-zone geometries.
band /2)? vs. the reciprocal of the ie L T K;V
temperature gradient bisects the Acknowledgment
two- dimensional line at the transi- if R or r’ is approximately constant.
Thus, any deviation from linearity The author wishes to thank the
tion temperature.
signifies a change in the depth of the Watertown Arsenal Laboratories for
Peak Temperature Extrapolation fusion zone and indicates a change granting technical assistance and
From the above, it is seen that, in cross-sectional area of the molten counsel.
despite measured peak temperature puddle. Figure 6 in which T', is the
being two- or three-dimensional in centerline peak-temperature on the Re jerences
heat flow, a plot of the results as weldment underside, shows relative 1. Adams, C. M., Jr Cooling Rates and Peak
three-dimensional will yield correct insensitivity of r’ to changes in Temperaturesin Fusic mn Wel ling HE WELDING
peak temperature locations and velocity over the range of centerline JOURNAL, 37 Research Suppl., 210-s to 215-8
1958
enable accurate extrapolation to peak-temperatures investigated for 2. White, S. S., D’Andrea, M. M., Jr and
specific temperatures. This is shown Ti — 5Al — 2'/,Snalloy. The weld- Hartbower, ( Air Contamination of Titanium
Weld-HAZ Surfaces lechni il Report No. WAL
in Fig. 5, where the centerline tem- ing speed which produces melting PR405.1 Waterto Arsenal Laboratories
perature is determined, although it of the weldment backside can be ac- October 1960
was several hundred degrees higher curately predicted from this curve 3. Udin, H., Funk, E. R., and Wulff, J Weld
for Engine John Wiley i Sons, Inc.,
than the sensitivity of the highest Figure 7 however, shows a much Ne Yor}

—%;

/INCHES
MINUTE
+ ’
/
10°,
—FINCHES
MINUTE x10
v Vy Tp-To
T-to

SS ee ee ee ae | 4
.e) 400 600 800 1000 1200 1400 7) oo a ig
v* (INCHES MIN.) ) 200 400 600 800 1000 1200 1400
v2 (INCHES/ MIN)*
Fig. 6—V/(T, — T.) X 10*, ipm ° F vs. V?, (ipm)* Fig. 7—V/(T, — T.) X 10%, ipm. F vs. V?, (ipm)? for
for Ti-5Al-2'/2 Sn alloy runs at 117.5 amp and 15 v Ti-6AI-4V runs at 117.5 amp and 15 v

WELDING RESEARCH SUPPLEMENT 319-s

Weldability of a Modified Hot-Work Die Steel

Using a low-hydrogen electrode, welded joints are made and achieve strength levels

in the 300,000 psi range with efficiencies approximating 100%

BY W. A. SIPES AND E. J. FOGARTY

ABSTRACT. A limited study of the tions. This electrode was one of

weldability of a typical modified hot Table 1—Chemical Composition
several developed under a Bureau of
work die steel (AISI H-11 type) was Naval Weapons contract De-
made. Satisfactory welded joints were Base posited
produced using an _ experimental, Procedure Element metal, % metal,» %
coated, low-hydrogen electrode. After Carbon 0.40 0.43
suitable heat treatment, the weld joints Results of preliminary tests indi-
achieved strength levels in the 300,000 cated that the experimental elec- Manganese b 0.80
psi range, with efficiencies approximat- trode had excellent operating char- Silicon b 0.53
ing 100%. acteristics and was capable of pro- Chromium 6.00
ducing sound weld beads free from Molybdenum 1.52
Introduction objectionable porosity. As shown Vanadium 0.42
New concepts in the application of in Table 1 the chemical composition Iron Bal. Bal.
hot-work die steels have led to their of the weld metal, as deposited,
consideration and use as structural closely approximated that of the * Manufacturer's analysis
materials for aeronautical compo- base material. Not determined.
nents. The modified hot-work die Four single-vee butt weld test
steels of the AISI H-11 type offer assemblies were prepared. The
the characteristics required for such weld schedule included a 700° F following designations indicate the
applications, being deep hardening preheat, with an interpass tempera- types of specimens removed from
air hardenable), with low residual ture maintained at a minimum of the weld assemblies:
stresses after heat treatment, with 700° F, and a post heat (anneal) of A Standard Vee notch Charpy
thermal stability up to 1000° F. 1550° F followed by controlled specimens
These attractive properties, along cooling, not exceeding 50° F per hr, Sub-size tensile speci-
with favorable strength to weight to 1000° F. Visual and radio- mens (0.357-in. gage diam)
ratios, permit the consideration of graphic examination established Bend specimens ('/»x 1 in.)
such steels for use in high speed that the welds were sound and free Tensile impact specimens (un-
thermal flight (to 1000° F). from injurious defects such as notched), Fig. 6
To apply these steels in structural cracks, inclusions and porosity. A Tensile impact specimens
components of aircraft required photographic reproduction of a ra- (notched), Fig. 6
information as to their fabricability diograph typical of the quality of The test specimens were rough
by fusion welding. Accordingly, the deposited metal is given in machined 0.020 in. oversize, then
the Aeronautical Materials Labora- Fig. 1. heat treated to a strength level in
tory initiated a limited research Figures 2 to 5, inclusive, illustrate the 300,000 psi range before finish
study of the fusion welding char- the method of sampling the test machining to specified dimensions.
acteristics of a typical hot-work die assemblies. As shown, the various The heat treatment included a
steel of the 5° chromium type. specimen samples were oriented with 1400° F preheat, austenitizing at
Weldability was studied in terms of reference to the test assembly in 1850° F in a controlled reducing
base weld metal compatibility, re- such a manner that the effects of atmosphere, followed by air cooling.
sponse to heat treatment, quality of directional properties in the base Double tempering at 1000° F (2
the weld deposit and mechanical metal could be determined. The hr + 2 hr) comp!eted the operation.
properties of the welded joints.
Cursory information was to be de-
veloped with regard to the suitabil-
ity of an experimental electrode
specifically tailored for such applica-

W. A. SIPES and E. J. FOGARTY are with the

Metallurgical Division, Aeronautical Materials
Laboratory, Naval Air Material Center, Philadel
phia, Pa
Nore: The opinions or assertions expressed are
the private ones of the authors and are not to be
construed as official or reflecting the views of
the Department of the Navy of Naval Service at
large. Fig. 1—Reproduction of radiograph typical of weld deposits in test assemblies

320-s | JULY 1961

 Lingeaieigeal
_ ~<
Test assembly #2 showing method of sampling

SCRAP|

oa
nl
mh
in | LILI
weis
tall
%|

9|

TTI. |
|
|
|J

=e Mm
wie

| | | 4}] |PLL
LLL
i
TO

tik =|

4
H-/1 TYPE t H-ll TYPE
DIE STEEL DIE STEEL E

Fig. 4— Test assembly #3 showing method of sampling Fig. 5—Test assembly #4 showing method of sampling

WELDING RESEARCH SUPPLEMENT | 321-s

 , weldability of the H-11 type steels
Table 2—Tension Test Results should be made. Since such steels
Ultimate are used in the heat-treated condi-
tensile Yield Elongation, tion, the primary concern of this
strength, strength, strength, Location of investigation was the availability
psi psi in 1.411, % failure of an electrode, with good operating
Longitudinal (L-1) 220, 000* ams eee characteristics, that could deposit
Longitudinal (L-2) 295 ,000 33, 300 8.5 filler metal having heat-treatment
ne sasetnty? fe Pye 23 <4 ae response compatibility with the
be ‘ ; andi base metal at the high strength
epeaaaperlntains eines eines oA levels desired. The study estab-
Weld metal tee lished that the electrode considered
Spec. 1 307 ,000 239,000 wee achieved these objectives. Other
Spec. 2 310, 000 241,000 : oee investigators! * have shown that
Transverse weld ve high strength levels may be achieved
Spec. 17 281,000" 235.000 ace with weld schedules different than
Spec. 2T 258 , 000" 235,000 Weld those used in this investigation,
Spec. 3T 297 ,000 237 ,800 ; Base metal i.e., lower preheat and post-heat
Spec. 4T 293,000 237 ,000 : Base metal temperatures.
5 Rated in tieeede. It should be recognized that the
Weld defect values obtained from mechanical
tests, particularly the somewhat
x E : : low impact and tensile impact test
rhe results of the mechanical prop- Discussion values, would be significantly im-
wees tests are tabulated in Tables Obviously, since only one steel proved if a higher tempering tem-
2 to 5, inclusive. was considered, it was not intended perature had been used. However,
Additionally, a weld cross section that an exhaustive evaluation of the since this work was directed toward
was removed from each test as-
sembly, heat treated to the 300,000
psi strength level, and examined — 3.5” APPROX.
metallographically. A photomacro-
graph of a typical weld cross section — |.75”% MIN.
is presented in Fig. 7. Photo- |
micrographs showing typical micro- :
angel g typu
structures of the weld and base wate THREADS—
metal are shown in Fig. 8. Xe —14 (CL.2A

0.25” R.MIN—— |+!.4"40.005"—

Table 3—Tensile Impact Results 45+"
Unnotched, Notched,
ft-lb ft-Ib
Base metal Z
(longitudinal) 168, 174 29, 27 -236"D. +0. on’ /
Base metal
(transverse) . 32, 39, 35,
34 +0.314"
0.001"
Transverse weld 32,142,°40> 15, 27, 294 0.010”R
t 0.001
7.5, 6.0, A
9.0
TENSILE IMPACT SPECIMEN -NOTCHED
Specimens failed in the threads
Failed in the fusion zone
Failed in the base metal
Specimens notched in the base meta!
pecimens notched in the weld metal NOTE: SPECIMENS SHOWN ARE TRANSVERSE WELDS.

Table 4—Bend Test Results’

Angle of — 3 5APPROX
bend to Location ——|.75"” MIN— ———}
failure, of
deg failure J 0.236"D t0.001”
Base metal (longi- 30 : r
tudinal) 32 ‘ 4
Transverse weld 13 Weld | "
(face in tension) 14 Weld \ Ih4 t 0.005”
Transverse weld g Weld 0.25" R.MIN. — | % MIN. —> |
(root in tension) 10 Weld
TENSILE IMPACT SPECIMEN-UNNOTCHED
Bend radius, 2T; plate thickness 1/2 in Fig. 6—Tensile impact specimens

322s | JULY 1961

Table 5—V-Notch Charpy Impact Test Results
Notch
location Av ft-ib
Base metal (longitudinal)
4
b
Cc
Base metal (transverse) Fig. 7—Typical cross section through weld
a
b
Cc
Weld metal-base metal
(transverse)
a Weld
b Weld
¢ Weld
Weld metal-base metal
a Fusion zone
b
Cc
Weld metal-base metal
a Heat-affected zone
b Heat-affected zone
Cc

the investigation of weldments at ture in the weld due to the position

the 300,000 psi strength levels, a of weld deposition or operator’s
tempering temperature of 1000° F technique with the impact test
was required. Thus, optimum values results. °
for Charpy impact and_ tensile
impact tests could not be expected. Acknowledgments
Thread failures were encountered The authors particularly wish to
during the testing of standard acknowledge the efforts of M. C.
specimens suggesting that the base Huff in experimentation with the
material is notch sensitive. Con- electrodes and preparation of the
sequently, the threaded ends of test weld assemblies.
specimens were modified to preclude
such failure. References
A comparison of the impact 1. “Metallic Arc Welding of High Strength
values for the deposited weld metal, Steel,’’ Final Engineering Report, Report No
MRP 58-74, Republic Aviation Corp., Farming-
as compared to those for the base dale, Long Island, N. Y
metal, show the normally expected 2. Ruff, P. E., “Fabricating and Finishing Tool
Steels for Aircraft Part, Metal Prog April
difference between cast and wrought 1959
properties of a material. No at- 3. Smith, D. C “Development, Properties Fig. 8—Typical microstructures with
tempt was made to correlate the and Usability of Low-Hydrogen Electrodes,” base metal shown at top and weld
WELDING JOURNAL, 38 (9), Research Suppl., 377-s
distribution of coarse-grained struc- to 392-s (1959 metal below. Etchant—nital. X500

An Important Reminder
AUTHORS...
August 15, 1961, is the deadline when application forms and abstracts must be postmarked in order to
receive consideration for presentation at the AWS 43rd Annual Meeting to be held in Cleveland, Ohio, April
9-13, 1962.
The application form was included as a detachable insert in the May issue of the WELDING JOURNAL.

WELDING RESEARCH SUPPLEMENT | 323-s

Welding PH 15-7 Mo Precipitation Hardening Stainless Steel

Using standard tungsten-arc and resistance-welding equipment

ultimate tensile values approximating 100% parent metal strengths are obtained

after post-weld austenite conditioning and transformation treatment

BY H. SMALLEN

ABSTRACT. This report is a summary mation to martensite enables both —100° F for a period of 8hr. Final
of a program to determine satisfactory 17-7PH and PH 15-7 Mo to be hardening is accomplished at 950° F
welding and heat-treating sequences for hardened to ultimate tensile values for 1 hr. The alternate TH1050
PH 15-7 Mo precipitation hardening in excess of 200 ksi. treatment incorporates austenite
stainless steel. Both fusion and resist- In the annealed condition both conditioning at 1400° F for 90 min.,
ance welding were included in this
study. Hardness curves, mechanical 17-7PH and PH 15-7 Mo possess the transformation at 60° F and final
property data, photomicrographs and soft ductile austenitic structure hardening at 1050° F for 90 min.
photomacrographs (of the welded struc- with the formability characteristics Lack of weld metal ductility has
ture) are included for each condition in- comparable to that of Type 301 been one of the major problems as-
vestigated. Ultimate tensile values ap- stainless steel. High speed weapon sociated with heat-treatable weld-
proximating 100% parent metal systems will undoubtably incorpo- ments. Ductility of the precipita-
strength are obtainable for fusion rate many assemblies which will be tion hardenable type stainless weld-
weldments when austenite conditioning joined by fusion and/or resistance ments may be improved by increas-
and transformation treatments are per-
formed after welding. Highest lap welding. ing the time andor temperature of
shear values for resistance weldments the final hardening treatment.
Material and Equipment Final TH hardening temperature
were obtained by welding after trans-
formation and before the final harden- The PH 15-7 Mo stainless steel used after welding was increased
ing treatment. fusion welded specimens and parent from 1050 to 1080° F, and the final
metal coupons were fabricated from RH hardening time was increased
Introduction 0.063-in. thick sheet material. Pre- from 60 to 90 min. throughout this
This paper presents the results of cleaned 0.045-in. bare PH 15-7 Mo program.
@ program to determine satisfactory (15.64 Cr, 6.5 Ni, 2.71 Mo and 0.91 A number of heat treatments and
welding and heat treatment re- Al) stainless steel wire was used as welding sequences were selected for
sponses for fusion and resistance the filler metal. The 48-in. longi- both types of welding. These re-
welded PH 15-7 Mo stainless steel tudinal weld positioner used in- presented methods for (1) obtaining
sheet required for specific design cluded a 300 amp direct current, optimum strengths, (2) obtaining
applications. straight polarity welder and asso- increased ductility with some sacri-
PH 15-7 Mo, a double treatment ciated automatic equipment for fice in strength and (3) compromis-
martensitic, high strength, corrosion controlling the wire feed, wire ing where shape and size of assembly
resistant steel possesses desirable speed, current, arc length, gas rate would prevent high temperature
elevated temperature properties for and other pertinent variables. Two heat treatment following welding.
high speed weapon aircraft and percent thoriated, '/,,-in. diam tung- The heat-treat designations and
guided missiles. This steel is a sten electrodes were used for satis- heat-treat weld sequences used are
modified 17 -7PH _ stainless steel factory arc stabilization. A _pro- outlined in Table 1.
where the chromium content is duction type spot welder was used SFA represents the assembly com-
lowered from 17 to 15% with a 2% to obtain the _ resistance-welded pletely heat treated to the RH950
molybdenum addition, which in- specimens. condition prior to fusion welding.
creases the tensile strength in the SFB represents the assembly com-
800 to 1000° F temperature range. Test Procedure
pletely heat treated to the TH1050
Chemically 17-7PH is similar to The two most widely accepted condition prior to fusion welding and
Type 301, an austenitic chromium- methods to accomplish transforma- then given an additional aging at
nickel stainless steel, the main dif- tion and final hardening of PH 15-7 1080° F. It was believed that suffi-
ference being a 1°; aluminum addi- Mo stainless steel are the RH950 cient strength could be obtained in
tion replacing a like amount of man- and TH1050 treatments.* The RH- the weld area without resorting to
ganese in Type 301. This alu- 950 treatment incorporates austenite the 1400° F transformation. SFC
minum addition and the transfor- conditioning at 1750° F for 5 min. represents the assembly fusion
and subzero cool transformation at welded prior to austenite condition-
H. SMALLEN is associated with Norair Division ing and transformation treatments.
of Northrop Corp., Hawthorne, Calif SFD represents the assembly fusion
Paper presented at the American Welding Society * Linnert, G. E., 1956 Adams Lecture—“‘Weld- welded and subsequently given the
Section of the ASM Western Metals Congress ing Precipitation-Hardening Stainless Steel,”
held in Los Angeles, Calif., Mar. 16-19, 1959 Tae Wetpinc Journat, 36 (1), 9-27 (1957 RH950 heat treatment. SFE rep-

324s | JULY 1961

 Table 1—Heat-treat Designations and Weld Sequences
Heat- Heat-
treat treat
desig- Heat-treat and fusion desig- Heat-treat and fusion
nation weld sequence nation weld sequence
Annealed Fusicn weld in the as-received Transform at —100 + 10° F for
(annealed) condition with 8 hr
no further heat treatment Harden at 950 10° F for 90
Condition austenite at 1750 + min
15° F for 10 min
Condition austenite at 1400 +
Air cool to room temperature 25° F for 90 min
Transform at —100 + 10° F for Air cool to room temperature
8 hr Transform at 60 + 0-10° F for Fig. 1—Annealed PH 15-7 Mo micro-
Harden at 950 + 10°F for 60 30 min structure (note stringers of delta ferrite
min Fusion weld in a matrix of austenite). 500. 10%
Fusion weld Harden at 1080 10° F for 90 oxalic acid electrolytic etch. (Reduced
min 50% on reproduction)
Condition austenite at 1400 +
25° F for 90 mi Condition austenite at 1750 +
Air cool to room temperature 15° F for 10 min
Transform at 60 + 0-10° F for Air cool to room temperature
30 min Transform at —100 + 10°F for
8 hr
Harden at 1050 + 10° F for 90
min Harden at 950 10° F, for 60
Fusion weld min
Harden at 1080 + 10° F for 90 Resistance weld
min Condition austenite at 1400 +
Fusion weld 25° F for 90 min
Condition austenite at 1400 + Air cool to room temperature
25° F for 90 min Transform at 60 + 0-10° F for
Air cool to room temperature 30 min
Transform at 60 + 0-10° F for Harden at 1050 + 10° F for 90 Fig. 2—Specimen SFF microstructure in
30 min min the TH 1050 condition (note stringers of
Harden at 1080 10° F for 90 Resistance weld delta ferrite in a matrix of precipitation
min hardened austenite) x500. 10% oxalic
Resistance weld acid electrolytic etch. (Reduced 50% on
Fusion weld Condition austenite at 1400 + reproduction)
Condition austenite at 1750 + 25° F for 90 min
15° F for 10 min
Air cool to room temperature
Air cool to room temperature
Transform at 60 + 0-10° F for
Transform at —100 + 10° F for 30 min
8 hr
Harden at 950 10° F for 90 Harden at 1080 10° F for 90
min min
Condition austenite at 1750 + Condition austenite at 1400 +
15° F for 10 min 25° F for 90 min
Air cool to room temperature Air cool to room temperature
Transform at —100 + 10°F for Transform at 60 + 0-10° F for
8hr 30 min
Harden at 950 10° F for 60 Resistance weld
min Harden at 1080 10° F for 90
Fusion weld min Fig. 3—PH 15-7 Mo weld metal as-
deposited microstructure (note delta
ferrite in a matrix of austenite) x 500.
10% oxalic acid electrolytic etch. (Re-
duced 50% on reproduction)
resents the assembly completely ance welding the assembly follow-
heat treated to the RH950 treat- ing TH1050 treatment. SRC rep- welded specimens were prepared in
ment prior to welding and followed resents the TH1080 treatment sub- accordance with established com-
by subzero cooling to —100° F and sequent to resistance welding and pany processes for welding and
aging at 950° F. Here it was be- SRD represents austenite condition- cleaning stainless steel. Welding
lieved possible to develop sufficient ing prior to welding and subsequent was comparable to that established
strength without resorting to the aging at 1080° F. by MIL-W-6858A. Three parent
1750° F austenite conditioning treat- One fusion weld specimen was metal coupons were prepared in
ment. SFF is a modification of prepared for each of the heat treat- accordance with ASTM Designa-
SFB. This method accomplishes ing and welding sequences men- tion E8-54T (except that the speci-
welding in the partially hardened tioned by butt welding sheets to- men ends were 1',» in. wide to allow
condition followed by aging at gether in the longitudinal positioner. the use of the pin method, rather
1080° F. All specimens were fabricated so than the wedge method for welding
SRA represents resistance welding that the tensile properties would be specimens) and identified with each
the assembly following the RH950 determined in the longitudinal di- fusion and resistance-weld specimen.
treatment. SRB represents resist- rection of the sheet. Resistance These coupons were cut from the

WELDING RESEARCH SUPPLEMENT 325-s

 properties are indicated in Table 11.
Table 2—Mechanical Properties for Annealed PH 15-7 Mo (As-welded) Photomicrographs and photomacro-
Yield graphs of representative fusion and
strength Uitimate Parent resistance-welded structures are
at 0.2% tensile Elongation material, shown in Figs. 1 through 11. Knoop
offset, strength in2in., hardness Location of hardness traverses for each of the
Coupon psi psi % Rp failure fusion welding and heat-treating
Parent metal Al 49,000 137, 000 40.5 96-97 sequences investigated are shown in
Parent metal A2 49 ,000 137, 000 42.5 96-97 Fig. 12.
Parent metal A3 48 ,500 135, 000 38.0 95-96
Average ,000 136, 500 40.3 Machine Settings
Bead removed A4 ,000 114, 23. Weld metal Generally, control of machine
Bead removed A5 ,900 116, 500 22. variables for gas tungsten-arc weld-
Bead removed A6 , 500 116, 22. ing PH 15-7 Mo with filler wire is
Average , 500 116, 22. more critical than for welding the
300 series stainless steels. Accept-
Bead intact A7 130, 28. Between weld able welds with 0.063-in. material
Bead intact A8 2.000 130, 28. metal and were obtained using carriage travel
Bead intact A9 132, 30. HAZ speeds for 12 to 18 ipm, argon flow
Average ,500 131, 29. rates of 16 cfh, and wire feeds of 20
to 40 ipm. Spot-weld machine
settings for 0.020-in. PH 15-7 Mo
Table 3—Mechanical Properties for Specimen SFA stainless steel are similar to those
settings used when welding the 300
Yield Elonga- series stainless steels. When weld-
strength Ultimate tion Parent ing transformed or hardened PH
at 0.2% tensile in material
offset, strength, 2 in., hardness Location of 15-7 Mo, slightly higher forge pres-
Coupon psi psi eas failure sures and heat inputs are required.
Parent metal Al 220 ,500 239, 000 5 Generally it was found that accept-
Parent metal A2 219,500 239, 500 5 able spot welds are obtainable within
Parent metal A3 217 ,500 238, 000 a relative wide range of machine
Average 219,000 239, 000 settings.

Bead removed 89,500 128 , 000 Weld metal Fusion Weldments

SFA-6 The sequence represented by
Bead removed 91, 000 129 ,000 specimen SFD, which incorporates
SFA-7
Bead removed 90, 000 RH transformation and hardening
SFA-8 treatments after welding, approxi-
Bead removed 129,§ mates 100% parent metal strength
SFA-9 and appears to be the optimum
Bead removed 153, treatment for fusion weldments in-
SFA-10 corporated in PH 15-7 Mo material.
Average 132, The sequence represented by SFC,
which incorporates TH transforma-
Bead intact SFA-1 149, Between weld tion treatment after welding, pro-
Bead intact SFA-2 97, 000 147, metal and duced satisfactory weldments which
Bead intact SFA-3 96, 500 147, HAZ
Bead intact SFA-4 96 ,500 approximate 100°, parent metal
146,
Bead intact SFA-5 98 ,000 148, tensile strengths.
Average 97 ,000 Note the low ductility of the
147,
coupons with weld bead removed.
This was probably due to the in-
same sheet and subjected to the weld bead intact, five tensile cou- complete refinement of weld struc-
same heat treatment as their related pons with the weld bead removed, ture at the lower temperatures used.
welded specimens. and one metallurgical examination If the configuration of the final as-
Austenite conditioning _ treat- specimen. Coupon preparation and sembly does not permit austenite
ments were performed in protective testing was done in accordance with conditioning after the welding treat-
atmosphere and hardening treat- ASTM Designation E8-54T and ment, the sequence represented by
ments were performed in an air the standards of the AMERICAN specimen SFF could be used with
atmosphere. WELDING SOCIETY. proper reinforcement at the weld to
Initial fusion weld machine set- The criteria for establishing ac- compensate for the reduced strength,
tings were obtained for 0.063-in. ceptable spot-weld machine settings if required.
thick Type 321 stainless steel speci- were spot geometry, visual quality Tensile values for specimen SFA
mens. After acceptable settings were and spot shear strengths as defined are representative of fusion welds
established, variations of these were in MIL-W-6858A. made on RH treated material. This
used as a basis for the annealed and sequence should be considered only
heat-treated PH 15-7 Mo specimens. when further thermal treatment of
After welding, the selected speci- Results and Discussion the final assembly is not possible.
mens were X-rayed and found free Tensile values for fusion weld Further treatment may be impracti-
from adverse discontinuities. Each specimens are presented in Table 2 cal when the size or configuration of
specimen was then heat treated to through 9. Spot shear strengths the finished assembly exceeds fur-
its final condition and machined for resistance-weld specimens are nace capabilities.
into five tensile coupons with the presented in Table 10; base metal Sequence represented by speci-

326-s | JULY 1961

Table 4—Mechanical Properties for Specimen SFB
Yield
strength Ultimate Elonga- Parent
at 0.2% tensile tion in material
offset, strength, 2 hardness Location of
Coupon psi psi in., % Re failure
Parent metal B1 190,500 198 ,000 9. 43
Parent metal B2 193,000 200 ,000 . 43
Parent metal B3 193 ,000 199 ,500 P 43
Average 192,000 199 ,000
Bead removed SFB-6 110,000 ,500 Weld metal
Bead removed SFB-7 110,000 155 ,500
Bead removed SFB-8 110,000 157 ,500
Bead removed SFB-9 109 ,000 153,000
Bead removed SFB-10 107 ,500 154, Fig. 4—PH 15-7 Mo weld metal micro-
Average 109 ,500 154,500 naownunwn
2 structure in the TH 1080 condition (nute
delta ferrite in a matrix of precipitation
Bead intact SFB-1 118 ,500 Weld metal hardened martensite). 500. 10% oxalic
Bead intact SFB-2 119,000 168 ,000 acid electrolytic etch. (Reduced 50%
Bead intact SFB-3 117 ,000 167 ,000 on reproduction)
Bead intact SFB-4 115 ,000 161,500
Bead intact SFB-5 115,000
Average 117 ,000 165 ,500 wococouw

Table 5—Mechanical Properties for Specimens SFC

Yield
strength Ultimate Elonga- Parent
at 0.2% tensile tion in material
offset, strength, 2 hardness Location of
Coupon psi psi in., % Ry failure
Parent metal Cl 193 ,500 200 , 500 } 43
Parent metal C2 192,000 199 ,000 : 43
Parent metal C3 190 ,500 198 ,000 43
Average 192,000 199 ,000
Fig. 5—PH 15-7 Mo as-deposited weld
Bead removed SFC-6 198 ,000 207 ,500 2.§ : Weld metal metal microstructure hardened at 1080° F
Bead removed SFC-7 195 ,000 204 ,500 : 3 and HAZ specimen SFF (note delta ferrite in a
Bead removed SFC-8 193 ,500 203 ,000 2.5 matrix of austenite) No martensite
Bead removed SFC-9 193,000 201 ,500 could be resolved at this magnification.
Bead removed SFC-10 190 ,500 198 ,500 <x 500. 10% oxalic acid electrolytic etch.
(Reduced 50% on reproduction)
Average 194 ,000 ,000
Bead intact SFC-1 203 ,000 211,000 ; Parent metal
Bead intact SFC-2 203 ,000 211,000
Bead intact SFC-3 202 ,500 ,000
Bead intact SFC-4 202 ,500 ,000
Bead intact SFC-5 203 ,000 ,500
Average 203 ,000 ,000

Table 6—Mechanical Properties for Specimen SFD

Yield
strength Ultimate Elonga- Parent Fig. 6—Resistance weld specimen SRA
at 0.2% tensile tionin material (also representative of specimen SRB).
offset, strength, hardness Location of Showing cast austenitic structure. X 20.
Coupon psi psi « % Ry failure Marbles etch
Parent metal D1 218 ,000 238 ,000 ; 48.5
Parent metal D2 217 ,000 237 ,500 : 48
Parent metal D3 218 ,000 237 ,000 : 48.
Average 217,500 237 ,500
Bead removed SFD-6 226 ,500 ,500 : Weld metal
Bead removed SFD-7 222 ,500 ,000 2. :
Bead removed SFD-8 222 ,500 ,500
Bead removed SFD-9 223,000 5 ,000
Bead removed SFD-10 222 ,500 ,000
Average 223 ,500 ,500
Bead intact SFD-1 ,000 ,500 ; 48 Parent metal
Bead intact SFD-2 ,000 ,500 é ¢
Bead intact SFD-3 ,500
Bead intact SFD-4 ,000 :' , :
Bead intact SFD-5 ,000 a Fig. 7—SRA weld metal microstructure.
Average ,500 < 500. Marbles etch. (Reduced
50% on reproduction)

WELDING RESEARCH SUPPLEMENT | 32)-s

 mens SFB and SFE, incorporating ent material is austenitic or marten- ing treatment for specimens SFF,
duplex hardening cycles have no sitic in nature. A comparison be- no visual difference appears to exist
particular advantages. tween the austenitic matrix of the at X500 when comparing Figs. 3
Ductility of welded specimen ap- annealed material (Fig. 1) and the and 5.
proached that of the parent material martensitic matrix of specimen SFF Knoop hardness traverses are in-
only when complete austenite con- (Fig. 2) reveals only the heavier dicative of the heat-treat responses
ditioning treatment followed the outlined ferrite stringers, which may and as Fig. 12 clearly indicates, the
welding operation. This was noted be attributed to preferential precip- weld deposits of specimens SFC and
only on welds with bead intact. itation at the ferrite boundaries SFD only are comparable to their
This ductility was actually that of during the hardening treatment. hardened parent material.
the parent metal. A contrast is observed when com-
It is difficult to determine from paring the austenitic weld deposit Resistance Weldments
photomicrographs whether the par- before transformation (Fig. 3) and Definite advantages are realized
the final martensitic matrix of the by the welding and heat-treating
weld deposit for specimen SFC (Fig. sequence represented by specimen
4). Although tensile values indi- SRD. The cast like structure
cate a response to the final harden- shown in Figs. 6 and 8 is basically

Table 7—Mechanical Properties for Specimen SFE

Yield
strength Ultimate Elonga- Parent
at 0.2% tensile tion in material
offset, strength, 2 hardness Location of
Fig. 8—Resistance weld specimen SRD Coupon psi psi in., % Ry failure
showing cast austenitic structure.
< 20. Marbles etch Parent metal El 220,000 236 ,000 8.0 48.5
Parent metal E2 220 ,500 236 ,000 7.5 48.5
Parent metal E3 221,000 238 ,000 8.5 48.5
Average 220 ,500 236 ,500 8.0
Bead removed SFE-6 122 ,000 159 ,000 Weld metal
Bead removed SFE-7 122 ,500 157 ,000
Bead removed SFE-8 123 ,000 157 ,000
Bead removed SFE-9 122 ,500 153,500
Bead removed SFE-10 123,000 155 ,000
Average 122,500 156 ,500
Bead intact SFE-1 132,000 176 ,000 Between weld
Bead intact SFE-2 133,500 178,000 metal and
Fig. 9—SRD weld metal microstructure. Bead intact SFE-3 133 ,500 175,500 HAZ
x 500. Marbles etch. (Reduced Bead intact SFE-4 135 ,000 179,000
50% on reproduction) Bead intact SFE-5 134,500 181,000
Average 133,500 178 ,000

Table 8—Mechanical Properties for Specimen SFF

Yield
strength Ultimate Elonga- Parent
at 0.2% tensile tion in material
offset, strength, 2 hardness Location of
Coupon psi psi in., % Ry failure
Fig. 10—Resistance weld specimen SRC Parent metai Fl 191 ,000 199 ,000 10.5 43
showing cast martensite structure Parent metal F2 193 ,000 200 ,000 10.5 43
<x 20. Marbles etch Parent metal F3 192,000 199 ,000 10.0 43
Average 192 ,000 199 ,500 10.3
Bead removed SFF-6 117 ,500 ,000 Weld metal
Bead removed SFF-7 120,000
Bead removed SFF-8 121,000 ,500
Bead removed SFF-9 118 ,500 ,000
Bead removed SFF-10 118 ,500
Average 119,000 ,000
Bead intact SFF-1 123,500 Between weid
Bead intact SFF-2 123,500 metal and
Bead intact SFF-3 125 ,000 HAZ
Bead intact SFF-4 126 ,500
Fig. 11—SRC weld metal microstructure. Bead intact SFF-5 128 ,500
<500. Marbles etch. (Reduced Average 125,500
50% on reproduction)

328s | JULY 1961

 austenitic in nature and is much strength of specimen SRD is slightly
more ductile than the transformed higher than the other sequences in- Table 11—Parent Metal Mechanical
structure represented by specimen vestigated. Properties for Resistance Welds
SRC (Fig. 10). The spot shear The heat-treating sequence rep- Vield
strength Ultimate Elon-
Table 9—Summary of Mechanical Properties for Fusion Welded Specimens at 0.2%, gation
Ultimate Yield offset h inéin.,
tensile strength Coupon psi %
strength, at 0.2% Elongation SRA-1 19,000
Designation psi Offset, psi t in., % SRA-2
Annealed Bead removed 116 ,000 54,500 é SRA-3
Bead intact 131,000 52,500 Average
Parent metal >, 500 49,000 + SRB-1
Bead removed 32 ,000 5 000 5.3 SRB )
Bead intact 147 ,500 97 ,000 SRB-3
Parent metal 239 ,000 19,000 8 Average
Bead removed 54,500 109 ,500 SRC-1
Bead intact 165 ,500 117 ,000 } SRC
Parent metal ,000 192 ,000 SRC-3
Bead removed 03 ,000 n00 : Average
Bead intact 211,000 03.000
000 199 QN0 SRD
Parent metal
Bead removed 3, 900 3,500 resented by specimen SRC should
Bead intact 41,500 22 ,000 3.0 only be considered when thermal
Parent metal 37 500 17 ,500 8.5 treatment is done in a protective
Bead removed 500 122.500 4 3 atmosphere, or where a ceramic
Bead intact 178,000 133,500 heat-treat coating is used to protect
Parent metal 236 ,000 20,500 the surface from oxidation. It
would be practically impossible to
Bead removed 168 , 000 119,000 9-1 rinse corrosive descaling solutions
Bead intact 181,500 125,500 3.9 from between the faying surfaces of
Parent metal 199,500 192,000 10.3 the spot-welded joints
Heat-treat sequences represented
Table 10—Spot Shear Results for PH 15-7 Mo Resistance Welds by specimens SRA and SRB are de-
Average sirable for many applications where
spot shear Number the higher strength of the parent
strength, metal is the important criteria.
Designatior Gage When resistance welding is ac-
SRA 0.020-0.021 complished after final heat treat-
SRB 0.020-0.021 5 ( ( Slug ment, warpage of the finished as-
SRC 0.020-0.021 17 17 Slug sembly would be minimized
SRD 0.020-0.021 ‘ ).143 ug Representative photomicrographs
Differenc e between large f ma ¢ hear tre value of
. the=e resistance
os welds are
rwr presented
.
? Variation ae Fa Sp Sa in Figs. 7, 9 and 11 lhe cast like
Nugget pulled out structures of specimens SRA, SRB
. and SRD are contrasted by the
~T i slightly refined structure of SRC,
which was transformed and hard-
ened after welding.
Conclusions
PH 15-7 Mo precipitation hard-
KHN enable stainless steel is readily weld-
able, utilizing standard fusion and
resistance-welding equipment. UlI-
NUMBER timate tensile values approximating
100% parent metal strengths are
obtainable for fusion weldments
PHARDNESS when austenite conditioning and
transformation treatments are per-
formed after welding. Highest lap
shear values for resistance weld-
ments were obtained by welding
after transformation and before the
final hardening treatment
Acknou ledgme net
100 200 300 400 500 The author wishes to acknowledge
MARDNESS TRAVERSE SUMMARY FOR FUSION WELDS the valuable assistance of H. Spa-
Fig. 12—Hardness traverse summary for fusion welds letta, A. Bondesen and K. Kuschell.

WELDING RESEARCH SUPPLEMENT 329-s

Influence of Some Platinum Metals on the

Wettability of Silver

Up to 20% palladium and platinum in silver brazing alloys

is found to improve wetting on Inconel and Inconel X

in both hydrogen and argon

BY J. B. ADAMEC AND R. N. RHODA

SYNOPSIS. An investigation of the Theory of Wetting solid metal system under conditions
relative influence of additions of the approaching their brazing applica-
platinum metals on the wettability of The degree to which a liquid
‘“‘wets’’ a solid surface is revealed tion.
molten alloys was undertaken as part
of a program for developing brazing by the angle of contact between Description of Wettability Tests
fillers for nickel base alloys. Wetting them. Figure 1 shows diagram-
tests on Inconel and Inconel X matically the appearance of wetting The present investigation in-
nickel chromium alloys were made drops for various values of the con- volved measurement of the angles
with silver alloys containing up to 20°; tact angle, @.°:’ established by silver-platinum metal
by weight of palladium, platinum and Wetting is greatly altered by alloys, in various furnace atmos-
ruthenium. The wetting of Inconel pheres, on Inconel nickel-chromium
alloy in both hydrogen and argon by factors such as oxide surface films,
alloying between components at alloy and Inconel X age-hardenable
the silver alloys was generally in- nickel-chromium alloy containing
creased by the presence of palladium liquid-solid contact surfaces and
contamination of the solid surface aluminum and titanium. The nomi-
and platinum. The enhanced wetta-
bility was accomplished by the forma- by vapors derived from the liquid nal compositions of the base metals
tion of a palladium or platinum rich metal.*.’ The ability of a molten are given in Table 1.
phase which was immiscible in the metal to wet a solid metal also The silver-platinum metal alloy
silver alloy. This noble phase wet and appears to be closely related to the fillers, which were tested, contained
flowed readily on the Inconel alloy alloying tendency of the two; if palladium, platinum and ruthenium
surface, forming a film which was in the pair do not form an alloy no as indicated in Table 2. Palladium
turn wet by the silver rich phase. On and platinum are completely soluble
Inconel X_ nickel-chromium alloy wetting occurs, but if they form a
solid solution or intermetallic com- in silver at the composition levels
which contains aluminum and _ tita- studied, while the solubility of ru-
nium, the same mechanism of wetting pound, wetting is good." The most
was encountered. In this case, how- convenient method for studying this thenium in silver is known to be
ever, the wetting was enhanced to a property is to measure the contact very low. These fillers were made
lesser degree because of the presence angle established by the liquid- by alloying together silver shot and
of oxide films on the base which inter- a platinum metal powder or sponge
fered with the formation and spread of in dry hydrogen. The alloys were
the noble phase. Under slightly oxi- allowed to solidify under the hy-
dizing conditions the platinum content drogen atmosphere; the resulting
of the silver alloys was a more im- bright buttons were cut into pieces
portant factor than the palladium con- of approximately 0.1 g for wetting
tent in improving the wetting charac-
teristics; this was due to the greater tests. Pure silver shot was also
oxidation resistance of the platinum subjected to the melting procedure.
alloys and to the ability of these alloys
to undermine and wet oxide films.
Introduction Table 1—Nominal Composition of Base
Metals in Weight Percent
Palladium is frequently used in
brazing alloys for high temperature Alloy
applications.'~* The present work Inconel Inconel X
describes a study of the effect of Ni 77 73
palladium and other platinum Fe 7 7
metals on the wetting properties of Cr 15 15
molten silver. Cb and Ta = 0.85
@=0 a Al ta 0.80
COMPLETE WETTIN Ti — 2.50
Cc d 0.04
J. B. ADAMEC and R. N. RHODA are asso Mn ; 0.70
ciated with the Research Laboratory of the Fig. 1—Equilibrium shape of wetting test Si . 0.30
International Nickel Co., Inc., Bayonne, N. J drops

330-s | JULY 1961

Table 2—Contact Angles in Wetting Studies
Filler
Filler components, Contact angles, deg, on Inconel alloy « Contact angles, deg, or
components, atomic in various atmospheres in various
wt % Percent ——Argon ——Hydrogen ——Argon-
Ag Pd Pt Pd Pt Dry Cyl Wet Dry Cyl Wet if Dry Cyl
12 NT¢@ 10 47
; 5.06 113
10 ed 10.1 132
20 20.2 125/56?
133
63-118
80-130
136
120
130
120
70-120
NT NT
Not tested Nonwetting bead on top of partial wetting button nge of angles on a single sr

The base material specimens for the cut perpendicular to the surface of
contact angle studies were made by the base.
cutting '/,-in. thick sheets of The effects of a number of fur
Inconel and Inconel X alloys into nace atmospheres were studied.
, in. squares. Dry argon and hydrogen were
The wetting tests were made by produced by passing these gases
placing several of the base metal through a train consisting of a
specimens on alumina grains in an palladium catalyst Deoxo unit, a
Inconel boat. Specimens of the calcium chloride drying tower, an
filter alloy were then positioned in activated alumina drying tower and
the center of the base metal squares finally a drying tower containing
and the whole assembly charged into molecular sieves. To produce the
the hot zone of a tube furnace which Fig. 2—Interface fi i | ilver on
wet atmospheres the cylinder gases Inconel! alloy at 1200° C in cylinder hydro-
had been preheated to 1200° C were bubbled through water at gen. Contact angle jeg. X 200.
and purged with the atmosphere room temperature before passing Etct Marble’s (Reduced
under study for at least 15 min be- them into the furnace. Wet- about 40%
fore making the wetting test. Melt- ting tests were also made with the
ing usually took place approximately specimens heated to 1200° C in
two minutes after charging. After air.
the fillers had been molten for 5 min,
the boat was drawn into the cooling Results and Discussion
zone and allowed to cool in the at-
mosphere of the furnace. The con The Nature of Oxide Films on Base
tact angles between the filler and Metal Specimens
base were measured directly from Several degrees of discoloration
their silhouette at 20 times magnifi of the surfaces of Inconel and
cationon anoptical comparator. At Inconel X alloys were noted on
least two readings with an accuracy making wetting tests in the various
of +3 deg were made at different furnace atmospheres. As these sur-
locations on each specimen before face films appeared to have a great
reporting the contact angle—Table influence on the wetting results, an Fig. 3—Interface alladium -
2. Metallographic studies were investigation of the composition of 95 silver on Inco I at 1200° C in
cylinder hydr yntact angle = 22
made on sections of the specimens the films by X-ray diffraction was deg . 0 ch: Marble’s reagent.
(Reduced about » on reproduction)

Table 3—Appearance and Probable Composition of Films Formed on Inconel and

inconel X Alloys as Determined by X-ray Diffraction
Furnace
atmosphere in Films formed on Inconel alloy Films formed on Inconel X alloy
which films Appear- Appear
were formed ance Composition ance Composition
Dry argon Very bright None detected Very bright None detected
Cylinder argon Bright None detected Bright None detected -] * ">
=
Wet argon Dark Hematite (a-Fe20;) Dark Hematite (a-Fe,0;)+ un- / (> S-
knowns i
Dry hydrogen Bright None detected Dark Iron Titnaium Oxide a % .=
(FeO-2TiO-)
Cylinder Bright None detected Dark Iron Titanium Oxide Fig. 4—Interface formed by 10 platinum -
hydrogen (FeO.2TiO2) 90 silver on Inconel alloy at 1200° C in
Wet hydrogen Dark Hematite (a-Fe:0;) Dark Hematite (a-Fe20;) + un- cylinder hydrogen. Contact angle = 12
knowns deg. X 200. Etch:n Marble’s reagent.
(Reduced about 40% on reproduction)

WELDING RESEARCH SUPPLEMENT | 33l-s

 made. The appearance and proba- between the base and the filler as Formation and Effects of the
ble compositions of these films are shown in Fig. 3; this alloy layer Noble Phase. One can now postu-
given in Table 3. Unfortunately was not developed by pure silver. late a possible mechanism for the
in some atmospheres the films were In specimens with 20 palladium — 80 formation of the noble phase and its
too thin to be analyzed. silver alloy the noble alloy layer ran contribution to the lowering of the
The Wetting of Inconel Nickel- over the edge and across the under contact angles follows. Nickel, iron
chromium Alloy surface of the Inconel alloy test and chromium from the base inter-
Silver. The limited solubility of pad. diffuse with the molten silver-
As shown in Fig. 4, the low contact platinum metal fillers. The dif-
nickel in molten silver (approxi-
angles obtained for the silver- fusing metals form a phase with
mately 1°%,) at the test temperature
platinum alloys on Inconel alloy the platinum metals in the filler
was apparently enough to enable
were also associated with the for- which is immiscible in the silver-
silver to wet readily and spread on
Inconel in dry argon (@ 0 deg). mation of a spreading noble alloy rich phase. Globules of the im-
Due to the low solubility no penetra- layer. By relating the contact miscible platinum metal-rich phase
angles measured with the atomic can be seen suspended in the sil-
tion of the base by the molten silver
was observed. In other atmos- percent of the platinum metals in ver-rich matrix in some of the wet-
pheres, such as cylinder argon and silver, the equivalency of the contri- ting specimens——-Figs. 3 and 4. The
dry and cylinder hydrogen, the butions of both palladium and formation of the noble phase appears
platinum to the wettability became to depend upon the concentration of
higher contact angles (4 12, 10
and 42 deg, respectively) were apparent; there were only slight both the platinum metal and the
probably due to the formation of differences between the effectiveness metals from the base. An increase
very thin oxide films on the Inconel of these metals. in concentration of either increases
alloy surface. The interface formed Silver-palladium-platinum Alloys. the amount of noble phase formed in
by silveron Inconel alloy in cylinder It can be seen in Fig. 5 that excellent a given period. Droplets of the
hydrogen is shown in Fig. 2. wetting of Inconel alloy’ was immiscible noble phase migrate to,
Silver-palladium and _ Silver-pla- achieved with a composition of wet and spread on the surface of
tinum in Nonoxidizing Atmospheres. about 12 atomic percent platinum the Inconel alloy. Apparently the
The addition of palladium to silver metal. Consequently the wetta- noble phase can spread readily, even
lowered the contact angles obtained bility of the alloys with a total of on the slightly oxidized surfaces of
on Inconel alloy in cylinder argon 12 atomic per cent of palladium and Inconel alloy which are not wetted
and dry and cylinder hydrogen. platinum in various proportions by pure silver.
The low contact angles were as- 1:0, 3:1, 1:1, 1:3, 0:1) was also The thickness of the noble phase
sociated with the formation of a studied—-Table 2. Under the clean appears to be rather constant for
noble alloy layer at the interface brazing condition of dry and cylin- all specimens, indicating that the
der argon and hydrogen, contact area covered by the spreading noble
angles of less than 10 deg were phase is directly dependent upon
obtained for these alloys on Inconel the volume formed. As the noble
alloy. In all cases the excellent phase spreads to its maximum extent
wettability was due to the forma- the remaining silver-rich phase
tion of a spreading noble phase at spreads almost to the edge of the
the interface between the filler and newly formed surface. Platinum
the base. metal is removed from the filler to
Nature of the Noble Phase. The form the noble phase and the remain-
interface alloy shown in Figs. 3 and ing silver-rich phase has, necessarily,
4 was found to be more noble a lower platinum metal content than
to Marble’s reagent than either the original filler composition. Since
the silver-platinum metal alloy filler the silver-rich phase can spread only
or the Inconel alloy base. This to the limits of the spreading noble
suggested that the interface ma- phase, the gross shape of the wetting
terial must be an alloy with a high button is determined solely by the
platinum metal content. An In- total volume of silver alloy which
conel alloy plate was brazed with has to position itselfon the limited
the 90 silver—10 palladium alloy area covered by the noble phase.
ANGLE and immersed in boiling 1:1 hydro- In this way the greater the amount
chloric acid. The entire Inconel of silver alloy on a given area of
alloy base was dissolved in several noble phase the steeper are the
hours. The residue was then washed sides of the molten bead, and the
CONTACT greater is the measured contact
and immersed in 1:1 nitric acid at
room temperature in order to com- angle. The contact angle measured
pletely dissolve the silver rich for a silver-platinum metal alloy
phase. Only a thin foil, in the order on Inconel alloy is, therefore, di-
of 0.001 in. thick, remained after rectly related to the amount of noble
the two acid treatments; this phase which can be formed by the
represented the original noble phase platinum metal in the filler.
interface which had formed between Silver-ruthenium. Tests with 5
the Inconel alloy and the silver- ruthenium — 95 silver alloy showed
ATOMIC PERCENT PLATINUM METAL palladium alloy. The interface al- the wetting properties to be similar
loy was found to contain approxi- to those of pure silver. This was
Fig. 5—Effect of platinum metal content
on the contact angles of silver alloys on mately 20 weight percent palladium, expected as there is no significant
Inconel alloy at 1200° C in various atmos- 12 chromium, 5 iron, balance nickel alloying between silver and _ ru-
pheres and a small amount of silver. thenium. Figure 6 shows the inter-

332-s | JULY 1961

 In contrast to the reaction of the
palladium alloys in the oxidizing
atmospheres, the silver-platinum
alloys remained bright and showed
some tendency to wet Inconel
alloy. In wet hydrogen and wet
argon the slight wetting was ac-
companied by the formation of
spreading noble phase as shown in
Fig. 8. The oxide film on the In-
conel alloy inhibitied the normal
rapid spreading of the platinum- Fig. 7—Interface forme 20 pal ladium —
Fig. 6—Interface formed by 5 ruthenium rich phase either by alteration of
95 silver alloy on Inconel alloy at 1200° C 80 silver alloy on Inc nel aio at lz 00° C in
in cylinder hydrogen. Contact angle = surface forces or by restricting the air x i Et reagent.
interdiffusion of the film and the (Reduced about 40% 4 repro duction)
40deg. x200. Etch: Marble’sreagent
(Reduced about 40% on reproduction) base. The presence of a dark line
in the noble phase layer, apparently
the remnants of the original oxide
face of such an alloy on Inconel. film on the Inconel alloy, indicated
Large clots of unalloyed ruthenium that the noble phase broke through
can be seen in the silver matrix; the film and spread both above and
the string of globules at the Inconel below it. The silver-rich phase
alloy surface indicated that there was oxidation resistant enough to
was some tendency for a noble phase resist scale formation and flowed
to form. to the edge of the spreading noble
Apparently the solubility of ru- phase resulting in a medium contact
thenium was much too low to allow angle.
sufficient noble phase to form. Except for a slight wetting tend-
Without the benefit of a ency of the alloys with the higher
readily flowing film of noble phase, platinum content the silver-pal-
the contact angle obtained for the ladium-platinum all exhibited poor
silver alloy was thus the same as wettability of Inconel alloy in the ) platinum -
at] 00° C in
for pure silver. oxidizing atmospheres. Marble’s
Silver-platinum Metal Alloys Un- ) repro-
der Oxidizing Conditions. The ac- Wetting of Inconel X Age-hardenable
tion of oxidizing atmospheres, such Nickel-chromium Alloy
as wet argon, wet hydrogen and air
Silver. Partial wetti g of In-
on Inconel, served to produce in-
conel X alloy by silver was ob-
terfering surface films which greatly
altered the wetting mechanism from served in dry and cylinder argon.
The films formed, however, were so
the idealized sequences previously
outlined. Complete nonwetting was thin that they could not be analyzed
obtained for the alloys of low palla- by X-ray diffraction.
dium content. The oxide films A slight halo of deep discolora-
may have reduced the diffusion of tion was formed around the silver
the nickel, chromium and iron from bead obtained on Inconel X alloy
the base into the fillers to such a in dry argon (0 90 deg This
low level that a noble phase could discoloration resembled the deposit
not form. of iron-titanium oxide (FeO: 2TiO
In the case of the 20 palladium which formed on Inconel X alloy in
80 silver alloy in air, the wetting dry hydrogen. It is possible that
test had the form of a scaled non- this halo may be due to the presence
wetting bead (@ 100 deg) resting of hydrogen which was absorbed
on a partially wetting button (é by the silver in preparing the
40 deg). A typical interface for filler and liberated in this test
this condition is shown in Fig. 7. In the cylinder argon atmosphere
A noble phase had formed and enough oxygen may have been
wet the Inconel alloy, but ap- present to nullify the effect of the
parently the oxide film prevented liberated hydrogen, for in _ this
its spreading over the surface. The case no halo was formed and a
palladium appears to have dif- contact angle of 47 deg was ob-
fused through the oxide film into tained. Films formed on Inconel
the Inconel alloy to form the noble X alloy in dry and cylinder hydro-
phase. The noble phase advanced gen prevented wetting by silver.
only by alloying with the base and Silver-platinum Metal Alloys in
forming a molten pool which pene- Nonoxidizing Atmospheres. In cyl-
trated quite deeply into the Inconel inder and dry argon the contact
alloy. Dark oxide films on the sur- angles obtained for silver-palladium
face of the noble phase and on the alloys on Inconel X alloy were Fig. 9—Effect of platinum metal content
surface of the silver-rich phase sepa- much lower than those obtained on the contact angles of silver alloys on
rated the two and caused the non- for pure silver. In these atmos- Inconel X alloy at 1200° C in dry and
wetting condition. pheres, were the base remained cylinder argon

WELDING RESEARCH SUPPLEMENT

 fairly bright, a condition of com- conel X alloy showed the properties the Inconel alloy under similar con-
plete wetting by the alloy was ap- to be similar to those of pure silver. ditions.
proached at about 10% palladium. The ineffectiveness of the ruthenium Silver-palladium and Silver-plat-
Silver-platinum alloys also _ exhi- alloy was due again to its inability inum in Dry and Cylinder Hydro-
bited lower contact angles than did to form a continuous noble phase. gen. In dry and cylinder hydrogen
pure silver but the decrease was The silver-palladium-platinum al- only a limited amount of wetting
not as great as was achieved with loys exhibited contact angles of was achieved with silver-palladium.
silver-palladium alloys. The rela- about 10 deg on Inconel X alloy Considerably lower contact angles
tive influence of atomic percent ad- in dry and cylinder argon. The were obtained for the silver-plat-
ditions of palladium and platinum palladium-rich alloy appeared to inum alloys in these tests. Fig-
on the contact angles established have slightly better wettability ure 12 illustrates the relative ef-
for silver alloys on Inconel X alloy than the platinum-rich alloys of the fectiveness of the palladium and the
is shown in Fig. 9. The lower con- series. These results were of about platinum additions on the contact
tact angles obtained on Inconel the same order as were obtained on angles obtained. Here the superior
X alloy in dry and cylinder argon wetting qualities of the platinum
were also associated with the for- alloys are markedly shown. The
mation of noble phases at the inter- silver-palladium-platinum alloys
faces; these are shown in Figs. also exhibited better wettability
10 and 11. The noble phase formed on Inconel X alloy than the silver-
by the platinum alloy appeared palladium alloys. In the hydrogen
to be similar to that formed on In- atmospheres, noble phases formed
conel alloy. The palladium alloy with both the palladium- and the
wetting specimens were charac- platinum-silver alloys on Inconel
terized by the formation of a large X alloy. The palladium noble
amount of the noble phase and by phase, however, did not spread as
some penetration of the Inconel well as did the platinum noble
X alloy by this phase. The phase on the iron titanium oxide
apparent superiority of palladium film. The palladium noble phase
over platinum in lowering the had built up to a considerable thick-
contact angles in this case was most ness, which increased with increas-
likely due to the slight aggressive- ing palladium content and pene-
ness of the palladium noble phase trated the Inconel X alloy to some ex-
on Inconel X alloy. waJ tent, but had not spread. Under
The tests made with the 5 ru- oz the same conditions the platinum
thenium-—95 silver alloy on In- < noble phase had spread to a uniform
- thickness regardless of the platinum
e content of the silver alloy.
z
oo A possible reason for the difference

eS
a
5 10 5
Fig. 10—Interface formed by 5 palladium -
% silver on Inconel X alloy at 1200° C in ATOMIC PERCENT PLATINUM METAL Fig. 14—Interface formed by 9 atomic
cylinder argon. Contact angle = 8 deg. percent palladium —-3 platinum-silver al-
x 200 Etch Marble’s reagent. Fig. 12—The effect of platinum metal loy on Inconel X alloy at 1200° C in
(Reduced about 40% on reproduction) content on the contact angles of silver cylinder hydrogen. Contact angle = 9
alloys on Inconel X alloy at 1200° C deg. X 500. Etch: Marble’s reagent
in dry and cylinder hydrogen (Reduced about 40% on reproduction)

Fig. 13—Interface formed by 12 atomic Fig. 15—Interface formed by 12 atomic

Fig. 1l—Interface formed by 5 platinum - percent palladium-silver alloy on Inconel percent platinum-silver alloy on Inconel
95 silver on Inconel X alloy at 1200° C in X alloy at 1200° C in cylinder hydrogen. X alloy at 1200° C in cylinder hydrogen.
cylinder argon. Contact angle = 20 Contact angle = 110 deg. X 500. Etch: Contact angle = 4 deg. xX 500. Etch:
deg. X 200. Etch: Marble’s reagent. Marble’s reagent. (Reduced about 40% Marble’s reagent. (Reduced about 40%
(Reduced about 40% on reproduction) on reproduction) on reproduction)

334s | JULY 1961

 in wettability of the alloys is given noble phase spread above and diffuse through the oxide films and
by the microstructures of the filler- beneath and disrupted the oxide form a wetting surface beneath
base interfaces shown in Figs. 13, film in a manner similar to that them.
14and 15. The noble phase formed shown in Figs. 14 and 15. The
by the palladium-silver alloy had remaining silver-rich phase was oxi- Conclusions
not spread on the surface but dif- dation-resistant enough in this case This investigation has shown that
fused through the oxide film and to flow to the limits of the spreading palladium, platinum and mixtures
penetrated the Inconel X alloy noble phase. In wet argon all the of both are equivalent on an atomic
to some extent. The oxide film silver-palladium-platinum alloys ex- percent basis in improving the
appeared to be more or less intact hibited poor wettability on Inconel wettability of silver on Inconel and
at the interface between the silver- X alloy, since the oxide films on Inconel X alloys under clean con-
rich phase and the noble phase. the base were thick enough to pre- ditions. The enhanced wettability
The noble phases formed by the vent the spread of the noble phases. is accomplished by the formation of
platinum-containing alloys spread There was a slight tendency to wet a palladium or platinum rich phase
both above and beneath the oxide the oxide film by the alloy containing which is immiscible in the silver
films. Remnants of the oxide film the greatest amount of platinum. alloy. This noble phase wets and
appeared in the noble phase layers In wet hydrogen, despite rather flows readily on the surface of the
and were progressively disrupted thick oxide films formed on the base, forming a film which in turn
as the platinum content of the alloy Inconel X alloy, a progressive im- is wet by the silver-rich phase. The
was increased. The oxide film had provement in contact angles was observed gross effects on the wetta-
been transformed to a series of observed with increased platinum bility of the silver alloys by the
particles in the noble phase layer content of the silver-palladium- various atmospheres studied were
of the platinum-silver alloy. platinum fillers. The wetting that determined to a great degree by the
Silver-platinum Metal Alloys Un- was achieved was due to a noble reaction of the noble phases with
der Oxidizing Conditions. In the phase which spread above and the surface films formed on the
oxidizing atmospheres of wet argon, beneath the oxide films. However, bases. The action of the palladium
wet hydrogen and air the results of the thick remnants of the dis- and platinum noble phase on the
the wetting tests with 20 palladium rupted oxide films which were incor- various surface films encountered are
80 silver on Inconel X alloy had porated in the noble phases acted as summarized in Table 4.
much the same form as obtained planes of weakness. The wetting Palladium additions were quite
with Inconel alloy in Fig. 7. The buttons could be stripped from the effective in lowering the contact
noble phases which formed tended base because of a fracture path angles under clean conditions. On
to flow under the oxide film and which formed through the oxide oxide films, however, instead of
penetrate into the Inconel X layer. The erratic wetting of In- spreading the palladium phase dif-
alloy. The remaining silver-rich conel X alloy by the 80 silver - 20 fused through the film into the
phases were all prevented from platinum binary alloy in the wet base and formed a molten pool.
wetting by thick films on their sur- hydrogen atmosphere (4 9 and The platinum noble phase wet and
faces and on the surface of the 120 deg) is rather hard to explain. spread on more types of surface
noble phase. Tests with lower Perhaps variations in the thickness films than did the palladium noble
palladium content alloys all pro- of the oxide films forming on the phase. A better over-all wetta-
duced nonwetting conditions. No Inconel X alloy duriig various bility was also obtained for the
wetting of Inconel X alloy was tests were the cause. The noble platinum alloys because of their
obtained with platinum-silver alloys phase would form and tend to dis- superior oxidation resistance.
in wet argon and air. In wet hy- rupt the oxide film but it did not From the contact angle measure-
drogen wetting was sometimes always spread to the edge of the ments made for the various silver-
achieved with the 20 platinum — 80 filler bead. It may be that the platinum metal alloy compositions
silver alloy. Apparently the oxide advance of a noble phase under it was found that a platinum metal
film was thin enough to allow a these conditions required the pres- content of about 10 atomic per-
noble phase to form. The platinum ence of palladium for its ability to cent was required for angles ap-

Table 4—Action of the Platinum Metal Noble Phases on the Various Surface Conditions Encountered in the Wetting Tests
—<Action of noble phase
Atmosphere forming Palladium-platinum
Nature of surfaces Base alloy surface Palladium phase phase Platinum phase
No film (or very thin) Inconel Cylinder argon, Spreads readily Spreads readily Spreads readily
dry hydrogen,
cylinder hydrogen
Hematite (a-Fe,0;) Inconel Wet argon, wet Restricted spreading, Tends to spread Tends to spread on
hydrogen penetration of base on top and top and beneath
beneath film film
No film (or very thin) Inconel X Dry argon, cylinder Moderate spreading, Spreads readily Spreads readily
argon penetration of base
Iron titanium oxide Inconel X Dry hydrogen, No spreading, deep Spreads readily Spreads readily
cylinder hydrogen penetration of base
Thin hematite (a- Inconel X Wet hydrogen No spreading, deep Some spreading on Erratic spreading on
Fe.0;) + unknowns penetration of base top and beneath top and beneath
film film
Thick hematite (a- Inconel X Wet argon, air No spreading, deep Not tested Forms droplets on top
Fe.0;) + unknowns penetration of base of film, no spread-
ing
@ As determined by X-ray diffraction.

WELDING RESEARCH SU PPLEMENT | 335s

proaching zero. This may be an the micrographs is also gratefully 5. Chalmers, B., and Wadie, R. H., “‘Factors
Influencing the Formation of a Smooth Coating
indication of the practical limit for acknowledged. of Tin on Copper by Hot Dipping,” Jnl. Inst
platinum metal additions to brazing Metals (London), 66, 241-253 (1940).
alloys where the wetting is ac- Bibliography 6. Humenik, M., Jr., and Kingery, W. D
1. Deuchler, P. G., “Evolution of Brazing ‘Surface Tension and Wettability of Metal
complished by a mechanism of noble Alloys for High-Temperature Applications,” Ceramic Systems,” Jni. Am. Ceram. Soc., 37 (1
phase formation. Western Machinery and Steel World, 50 (1), 59-62 18-23 (1954).
1959) Kingery, W. D., “Role of Surface Energies
2. Perry, E. R., “Palladium Containing Alloys and Wetting in Metal Ceramic Sealing,’”” Am
Acknowiedgments for High-Temperature Brazing,’ Australasian Ceram. Soc. Bull., 36, 108-112 (March 1956)
The authors are grateful to the Engr., 51, 53-56 (May 7, 1959). 8. Report, “Joining of Metals,” Metal Ind
3. Sistare, G. H., and McDonald, A. §&., 91, 495-497 (Dec. 13, 1957).
management of the International “Oxidation Resistant Brazing Alloys,"” WADC 9. Bailey, G. L. J., and Watkins, H. C.,
Nickel Co., Inc., for permission Tech. Rept. 55.22, Wright Air Development “Surface Tensions in the System Solid Copper
to publish the results of the investi- Center (April 1955) Molten Lead,” Proc. Phys. Soc., 3, B, LXITI, 350
4. Slaughter, G. M., Leitten, C. F., Patriarca, 358 (1950).
gation. The help rendered by B. P., Hoffman, E. E., and Manly, W. D., “Sodium 10. Bailey, G. L. J., and Watkins, H. C., ““The
Albert of the Bayonne Research Corrosion and Oxidation Resistance of High Flow of Liquid Metals on Solid Metal Surfaces
Laboratory of this company in Temperature Brazing Alloys,” THe WELDING and its Relation to Soldering, Brazing and Hot
JOURNAL, 22 (5), Research Suppl., 217-s to 225-s Dip Coating,” Jnl. Inst. Metals, 80 (2), 57-76
producing the test specimens and 1957) 1951

A Coated Electrode for Fusion Welding AISI 4340 Steel for Ultra
High Strength Applications, and Method for Determining the
Total Water in Welding Electrode Coatings
Welding Research Council Bulletin No. 68, published in April 1961, contains the
following reports”
A Coated Electrode for Fusion Welding AISI 4340 Steel for Ultra High Strength
Applications—Ultra high strength steels have come into contention as basic struc-
tural materials with the advent of aircraft and missiles destined for supersonic flight.
Fabrication of these steels demanded the concurrent development of welding elec-
WRC
trodes to provide efficient and compatible welded joints for service at the ultra
high strength levels. This report describes the development of a low-hydrogen
Bulletin
coated electrode for use with AISI 4340 steel heat treated to ultra high strength
levels. The electrode exhibited satisfactory welding characteristics and deposited
No. 68
weld metal compatible with AISI 4340 steel at the ultra high strength level.
Method for Determining the Total Water in Welding Electrode Coatings—A
modification of the method developed by Gayley and Wooding for determining the
total water in electrode coatings is presented. ‘This modified method requires less
time per determination and produces results which are accurate and reproducible.
The procedure is given in detail to avoid differences in interpretation of the method.
The price of this Bulletin is $1.00 and single copies may be purchased through
the AMERICAN WELDING SOCIETY, 33 W. 39th St., New York, 18, N. Y. Quantity
lots may be purchased through the Welding Research Council, 29 W. 39th St., New
York 18, N. Y.

The Effect of Internal Pressure on Thin-Shell Pressure Vessel

Heads; Wrinkling of a Large, Thin Code Head Under Internal
Pressure; and Biaxial Stress Criteria for Large Low-Pressure Tanks
Welding Research Council Bulletin No. 69, published in June 1961, was sponsored
by the Pressure Vessel Research Committee and contains the following papers:
The Effect of Internal Pressure on Thin-Shell Pressure Vessel Heads—-This is the
final report on a research project carried out at Auburn University for PVRC.
The objective of this work was to determine experimentally the shell-to-head junction
stresses for certain thin-shell steel pressure vessels. The types of heads which were
used during the study were a torispherical head, a two-to-one ellipsoidal head and
a 90-deg toriconical head.
WRC Wrinkling of a Large, Thin Code Head Under Internal Pressure—The purpose
of this paper is to report on a recent case of instability of a very large, thin semi-
Bulletin ellipsoidal head designed and fabricated according to the applicable rules of the
ASME Unfired Pressure Vessel Code; 1959 Edition.
No. 69 Biaxial Stress Criteria for Large Low-Pressure Tanks—In 1957 the Design Task
Force of the API Subcommittee on Unfired Pressure Vessels was asked to study
and submit a recommendation on the suggestion that where compressive stresses
exist only in one direction, the allowable compressive stress for an axially-loaded
tubular column be allowed with the stress reduced, in the region of failure by plastic
yielding, by deducting 0.3 times the actual tensile stress existing at the same point.
The design basis proposed by the Design Task Force was approved by the API Sud-
committee and an API report explaining the design procedure in greater detail was
prepared.
The price of this Bulletin is $1.00 and single copies may be purchased through
the AMERICAN WELDING Society, 33 W. 39th St., New York 18, N. Y. Quantity
lots may be purchased through the Welding Research Council, 29 W. 39th St., New
York 18, N. Y.

336-s | JULY 1961

Tops in the Industry!

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world’s most authoritative

welding and allied process

magazine; it has fully 2'/

times the editorial content

of any competing magazine;

if is unequalled in coverage

of welding engineering,

research and application.

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pages will reach your market!

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