Practicalwelding20130708 DL

July/August 2013
THE REAL WORLD FOR WELDING PROFESSIONALS
2013
PWTeacher
of the Year
Scott Schreiber,
Green River Community College
An official publication of the Fabricators &

Manufacturers Association, International
www.practicalwelding.com
Winner of the 2010 ASBPE Silver Digital Azbee Award

in the Step-by-Step/How-To video category!
Join the Welding Revolution! With over 59,000 video plays, Practical
Welding Television brings you videos in the same practical and down-to-earth
approach that makes the printed version of Practical Welding Today the most useful
welding magazine by a 2-to-1 margin.*
But dont take our word for itcheck out some of the comments from PWTVs viewers:
"I just viewed the video on welding safety. It was very good and I will be a regular viewer."
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Associate Editor
Practical Welding Today
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The fact that it can be viewed over and over is excellent when stressing a point or
gaining understanding."
"This was a very informative video, especially to someone that is starting out.
You did a nice job and it was plainly spoken. I look forward to viewing more episodes."
We want more! Keep moving forward.
*Source: 2011 Harvey AdQ Study
www.thefabricator.com/pwtv
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The Real World for Welding Professionals
An Official Publication of the

Fabricators & Manufacturers Association, International
July/August 2013 / Vol. 17 No. 4

6 Editors Corner
8 Calendar of Events
8 Industry News
16

Accepting the torch,
carrying a legacy
PWTeacher of the Year winner
Scott Schreiber, head welding
instructor at Green River Community College, Auburn, Wash.,
possesses an innate ability to
connect with his students, a tenacious drive for excellence and
continuous improvement, ingenuity, and a commitment to improving the welding trade. (Cover photo
courtesy of Bruce Ikenberry Photography, Lacey, Wash.)
looking to aluminum to help lighten the load. Properly addressing

the troublesome attributes of aluminum and its alloys will help you
to avoid potential issues during
the laser welding process.
30

Previewing Schweissen
& Schneiden 2013
Planning on making the trip to Essen for the show? Weve got everything you need to know before
you go.
32 Aluminum Workshop
Frank Armao explains why 7075
and 2024 alloys shouldnt, under
most circumstances, be welded.
34 Consumables Corner
Nino Mascalco guides a reader
who is experiencing weld root
penetration issues in single- and
multipass welds.
22 Angle grinding 101

In fabrication shops across America and around the globe, power

toolsmore specifically, angle
grindersare often used in an
improper and unsafe manner.
Taking the time to learn the dos
and donts of cutting and grinding
can help prevent serious injury to
yourself or those around you.
26

Joining aluminum
with laser
36 Product News
44 Advertorial
Read about the latest products
offered by PWT advertisers.
53 Classified Ads
53 Advertisers Index
54 Arc Welding 101
A reader asks Paul Cameron
for clarification regarding what
is written about cosmetic weld
discontinuities in the AWS D1.1
Commentary section.
As the automotive industry takes

steps to increase fuel economy,
fabricators and suppliers will be
Coming next issue

Get a sneak peak at FABTECH 2013.
Learn about different types of
contact tips and where they are best
suited.
26
4
Find out how to choose the right

gas delivery systems.
PRACTICAL WELDING TODAY July/August 2013
16
practical welding today staff
President & CEO, FMA Edward Youdell
Group Publisher Dave Brambert
Editor-in-Chief Dan Davis
PWT Associate Editor Amanda Carlson
Associate Editor Sue Roberts
Senior Editor Tim Heston
TPJ Editor Eric Lundin
Green Manufacturer Editor Kate Bachman
Contributing Editor Amy Nickel
Senior Copy Editor Teresa Chartos
Graphic Designers Jennifer Paulson, Margaret Clark,
Mary Mincemoyer, Janell Drolsum
Publication Coordinator Kelly Palmer
Director of Circulation Kim Bottomley
Circulation Manager Brenda Wilson
Data Verification Specialist Rhonda Fletcher
Senior Fulfillment Specialist Anna Peacock
Web Content Manager Vicki Bell
Multimedia Specialist Sherry Young
Senior Web Developer Jason Bartholme
Web Developer Johanna Albee
practical welding today advertising sales

Associate Publisher Jim Gorzek, jimg@thefabricator.com
Senior Account Representatives
Michigan/Northeast Sean Smith, seans@thefabricator.com
Ohio/Southeast/International Mike Lacny, mikel@thefabricator.com
West/Arkansas/Louisiana/Mississippi Tony Arnone
tony@thefabricator.com
Minnesota/Iowa/Illinois/Indiana/Iowa/Minnesota/
Missouri/Wisconsin/Canada Amy Hudson, amyh@thefabricator.com
Alabama/Florida/Illinois/Tennessee Michael Scott
michaels@thefabricator.com
Classified Advertising Patricia DAmico, patriciad@thefabricator.com
Director of Accounting Bob Young
Accounts Receivable Mary Simons
how to contact practical welding today

833 Featherstone Rd., Rockford, IL 61107
Phone: 815-399-8700 Fax: 815-484-7700
E-mail: info@thefabricator.com Web site: www.practicalwelding.com
statement of policy
As a publication of the Fabricators & Manufacturers Association, International, Practical Welding Today recognizes the need and importance of disseminating information about modern metal welding and joining techniques,
machinery, tooling, and management concepts for the metalworking professional. The policy of the publisher and this journal is to be nonpartisan, favoring no one product or company. The representations of facts and opinions
expressed in the articles are those of the author and are not necessarily
endorsed by the publisher and this journal. By including information on new
products, new literature, news of the industry, articles, etc., this impartiality
is strived for and extends to the mention of trade names. Unless product
identification makes the reference unavoidable, the generic name is used.
We acknowledge that on occasion there may be oversights and errors; the
editors regret such oversights and re-emphasize their policy to be impartial at all times. The Publishers reserve the right to refuse advertising they
deem inappropriate for publication in Practical Welding Today, including ads
for classes of products and services not considered of significant interest to
the readership. Standard Rate & Data Service lists our advertising rates in
Section 156. Consult SRDS or our current rate card for full rates and data.
Publications of FMA Communications Inc. maintain a policy of keeping
editorial and advertising separate to ensure editorial integrity that most benefits our readership. Editorial content, including feature articles and press
releases, is determined solely by the publisher. Editorial content cannot be
purchased, nor can it be used as a benefit of advertising dollars spent. Editorial is free-of-charge, subject to space availability, and open to all interested
parties that submit items meeting our editorial style and format as determined by the publisher.
Note: Some photographs printed in this publication may be taken with safety
equipment removed for photographic purposes. However, in actual operation,
it is recommended that correct safety procedures and equipment be utilized.
Editors Corner | Amanda Carlson

FMA Officers & Directors
A family of welders
Last August Forbes published an article
titled 5 Ways Leaders Must Build a
Family Environment to Achieve Excellence. The title itself is a mouthful, but
the message is very simple: A leaders
ability to build relationships based on
trust and the promise that each individual persons efforts contribute to a higher cause is crucial. A leader does this by
creating an environment where group
members feel a sense of ownership, have
each others backs, know whats expected
of them, feel comfortable voicing concerns or asking questions, and have a
clear idea of how to attain their personal
goals.
Other than parenting, there is no
higher responsibility than that of a
teacher. Teachers are leaders and rarely
do they just teachtheir job requires
them to wear many different hats.
Whether they like it or not, teachers
play a part in developing the whole person, not just a particular skill set.
When I read the article I immediately thought of my visit to the Green River
Community College welding lab in Auburn, Wash., headed up by Scott Schreiber, this years PWTeacher of the Year.
As I spoke to students, instructors, administration staff, advisory board members, and others who know Schreiber, it
was very clear that he treats those around
him like family. Why is that important?
As the article stated, leaders who can
develop a family environment achieve
more in the short term and build a foundation of hard work, determination, and
perseverance for the long run.
This is something Schreiber is acutely
aware of and takes incredibly seriously.
As you read more about Schreiber,
youll find that communication, accountability, and trust are the founda-
tional elements of his teaching philosophy. It is through these elements that

younger students cut their teeth on reallife expectations, work ethic, and how to
conduct themselves as professionals.
The line of communication that we
have is healthy, very open, and that in
turn brings it back around to the students when they do have a problem. We
become the counselor. A lot of times on
a personal level were the only ones they
feel like they can talk to, Schreiber explained.
The instructors care about each
students individual goals and they are
service-minded. That example rubs off
on students, explained Devin Wheeler,
a 20-year-old Green River welding
student.If anyone ever needs help with
anything, theres no one here that would
say no. If someone needs help with
something, everyone jumps in.
Schreiber and his staff have created an environment where everyone is
learning together and supporting one
another. Its not a perfect environment
by any means, but what family is? As
the article summed up perfectly, In the
end, its about leadership and the ability
to manage the moving parts and sustain
momentum.
Send comments and technical

questions in writing to:
Amanda Carlson, Associate Editor
833 Featherstone Road
Rockford, IL 61107-6302
Fax: 815-484-7788
E-mail: amandac@thefabricator.com
Chairman of the Board

Burke Doar, TRUMPF Inc.
First Vice Chairman
Carlos Rodriguez-Borjas, Feralloy Corp.
Second Vice Chairman
Edwin Stanley, GH Metal Solutions
Secretary/Treasurer
Al Zelt, ASKO Inc.
Immediate Past Chairman of the Board
Dave Barber, The Wilmington Grill Co.
Directors
Teresa Beach-Shelow, Superior Joining Technologies Inc.
Robert Clark, Clark Metal Products
Vivek Gupta, Texas ProFab Corp.
Rick Hargrove, American Strip Steel/Marino\Ware
William Jeff Jeffery, IRMCO
Dan McLeod, Brenco Industries Ltd.
Lyle Menke, Peddinghaus Corp.
Carlos Mendizbal Prez, Industrias Selbor S.A. de C.V.
Ed Severson, SB Specialty Metals
Gregg Simpson, Ohio Laser LLC
Jerry Ward, METCAM Inc.
President & CEO
Edward Youdell, Fabricators & Manufacturers Association Intl.
Practical Welding Today Editorial Review Committee

Tony Anderson, ITW Global Welding Technology Center
David Bell, Witt Gas Controls LP
Paul Cameron, PWC Inspection Service
J. Gerard Doneski, Lors Machinery Inc.
James Feil, Energy Steel & Supply Co.
Michael Francoeur, Joining Technologies LLC
Kenneth Frye, Air Liquide America Corp.
Bennett B. Grimmett, AREVA NP Inc.
Steve Hidden, Miller Electric Mfg. Co.
Richard Holdren, Greenfield Professional Services LLC
Bob Hollingsworth, Consultant
Mike Jacobsen, Genesis Systems Group
Chuck Keibler, Genesis Systems Group
Ken Lee, The Lincoln Electric Co.
Greg Metko, Miller Electric Mfg. Co.
Andre Odermatt, Hobart Institute of Welding Technology
Mike Pankratz, Miller Electric Mfg. Co.
Dean Phillips, ITWHobart Bros.
Marty Rice, Dale Jackson Career Center
FMAs Certified Education Centers

Advanced Manufacturing Institute (AMI)
Manhattan, Kan., www.amisuccess.com
Anoka Technical College
Anoka, Minn., www.anokatech.edu
Austin Polytechnical Academy
Chicago, Ill., www.austinpolytech.com
British Columbia Institute of Technology
Burnaby, BC Canada, www.bcit.ca
College of the Canyons
Santa Clarita, Calif., www.coc.ca.us
(EWI) Edison Welding Institute,
Columbus, Ohio, www.ewi.org
Fresno City College
Fresno, Calif. www.fresnocitycollege.edu
Harper College
Paletine, Ill. www.harper.edu
Illinois Central College
East Peoria, Ill., www.icc.edu
Kalamazoo Valley Community College
Kalamazoo, Mich., www.kvcc.edu
Kirkwood Community College
Cedar Rapids, Iowa, www.kirwood.cc.ia.us
Kwantlen Polytechnic
Surrey, British Columbia, www.kwantlen.ca
Long Beach City College
Long Beach, Calif., www.lbcc.edu
Moraine Park Technical College
Fond du Lac,Wis., www.morainepark.edu
Northeast Alabama Community College
Rainsville, Ala. www.nacc.edu
Ogden-Weber Applied Technology College
Ogden, UT, www.owatc.edu
Ranken Technical College
St. Louis, Mo. www.ranken.edu
Rock Valley College
Rockford, Ill., www.rockvalleycollege.edu
Thomas Nelson Community College
Hampton, Va., www.tncc.edu
Triton College
River Grove, Ill., www.triton.edu
Waukesha County Technical College
Pewaukee, Wis., www.wctc.edu
For more information on FMAs Certified Education Centers,
visit our hotlink at www.fmanet.org/cecs
BUSINESS PUBLICATIONS
AUDIT OF CIRCULATION
PRACTICAL WELDING TODAY July/August 2013
A Tribute
to Service
3M Speedglas Welding Helmet Series 100 - Tribute
Designed to honor the servicemen and women who protect our freedom, and for the
American welders that build our country. Dedicated to those who have sacrificed all.
Wear it with respect.

facebook.com/speedglas
3M and Speedglas are trademarks and The Power to Protect Your World is a service mark
of 3M Company, used under license in Canada. 2013 3M. All rights reserved.
www.3M.com/Speedglas
Calendar of Events
Sept. 4-5Arteaga, Mexico

The FABRICATOR en Espanl
Leadership Summit
Sponsor: Fabricators & Manufacturers
Association International
Phone: 888-394-4362
Web: www.fmanet.org
Sept. 10-12Chicago
Design & Manufacturing Midwest
Sponsor: UBM Canon
Phone: 310-445-8535
Web: www.canontradeshows.com
Sept. 11-12Schaumburg, Ill.

Lasers for Manufacturing Event
Sponsor: Laser Institute of America
Phone: 800-345-2737
Web: www.laserevent.org
Sept. 16-21Essen, Germany

Schweissen & Schneiden
Sponsor: German Welding Society
Phone: 49-0201-72440
Web: www.schweissen-schneiden.
com/en/schweissen_
schneiden/index.html
Oct. 4North America

Manufacturing Day
Sponsor: Fabricators & Manufacturers
Association International
Phone: 888-394-4362
Web: www.mfgday.com
Nov. 18-21Chicago
FABTECH
Sponsor: FMA, SME, AWS, PMA,
CCAI
Phone: 888-394-4362
Web: www.fabtechexpo.com
Industry News
Hypertherm hosts Building America Conference at
New Hampshire headquarters
U.S. manufacturers productivity has

tripled, and products of value are still
made in the U.S. That was the message that Evan Smith, president of
Hypertherm Inc., Hanover, N.H., gave
to attendees at the companys Building
America Conference in early May.
Smith went on to point out that
American workers are increasing productivity throughput with fewer workers than their Chinese counterparts11
million compared to Chinas 110 million. And a lot of that has to do with
substituting capital for labor. The U.S.
is second only to Japan in the use of industrialized robots. Spending on equipment and software has increased by 31
percent, Smith added.
The two-day seminar provided attendees with tips to promote continuous improvement, operational excellence, and leadership and a peek at why
some businessesdespite being led by
smart individualsfail. Hypertherm
employees presented on topics such as
branding, lean manufacturing, strategic
planning, cutting efficiency, and the future of air plasma.
Kevin Duggan, president of Duggan
Associates, author of Design for Operational Excellence, and a consultant to
Hypertherm, spoke on the importance
of integrating a continuous improvement plan--a series of improvements and
sustaining measuresinto a business.
Companies that move forward are
the ones where its leaders have the same
answers to the tough questions. If you

want to achieve operational excellence,
you create flow only to know if flow is
stopping. Any good company can create
flow, but great companies know what to
do when flow stops, Duggan said.
He went on to say that operations
excellence isnt just about creating flow,
its about creating self-healing flow and
immune systems for flow to ensure that
your operations are able to start every
time.
Sydney Finkelstein, professor of
management at the Tuck School of
Business at Dartmouth College and author of Why Smart Executives Fail, cautioned attendees, saying even good leaders make bad decisions because they let
emotions overcome rational thinking.
Sometimes the same things that
have led to your success will eventually
lead to your demise, Finkelstein said.
He said that leadership capabilities
that differentiate winners from losers include intellectual honesty, adaptability,
self-awareness, and accountability.
Hypertherms Building America
message is one that it has taken to heart.
With 12 facilities in New Hampshires
Upper Valley Region, the company
manufactures 90 percent of its own
components stateside. Hypertherm
founder and CEO Dick Couch told
attendees about the companys meager
beginnings and how it developed over
time into one of the best places to
work in the U.S. Among an aggressive
Industry News
(continued from page 8)
strategy to incorporate continuous

improvement strategies in-house, the
company also has a no-layoff policy
one that garnered some attention when
the economy tumbled late last decade.
Watching companies hire workers
only to then lay them off during hard
times made me realize that it would be
tough to have positive moral. After all,
theyre people with families, not machine tools, Couch explained.
Hypertherm designs and manufactures hand-held and mechanized plasma
cutting systems and consumables used
in a variety of industries, including shipbuilding, automotive, and metal manufacturing.
Harris Products Group adds

video to YouTube channel
The Harris Products Group, a Mason,

Ohio-based wholly owned subsidiary
of the Lincoln Electric Co., has added
a 5-min. video to its YouTube channel
at www.youtube.com/user/harrisproductsgroup/featured that gives viewers a
glimpse of its century in product manufacturing, its quality, and its product
portfolio.
The channel also includes a variety
of industry-related resources, such as informational videos on new products and
instructional videos on brazing and cutting applications.
The Harris Products Group supplies
welding and cutting products for the
aerospace,
heavy fabriCSU-201305-PWT 3rd_CS Unitec PWT 3rd Ad 4/24/13
2:15offshore,
PM PageHVAC,
1
Amanda Carlson, Associate Editor cation, and automotive industries.
PTX Eco Smart
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Industry News
Hobart Institute adds online course, expands welding training area
Hobart Institute of Welding Technology, Troy, Ohio, has released a new online course called Discontinuities and
Defects, designed for people involved in
arc welding inspection, quality control,
engineering, and supervision.
The online course, found at www.
welding.org/c-54-e-courses.aspx, contains five video segments, totaling a run
time of 70 minutes. These segments
cover weld inspector responsibilities
related to discontinuities and defects,
as well as identification and definition
of weld discontinuities and defects.

They also present the common causes
of discontinuities related to shape, size,
contour, internal inconsistencies, weld
metal irregularities, and weld and base
metal properties.
The institute also has broken ground
on a 6,360-sq.-ft structure that will
house 50 to 60 additional arc welding
booths equipped for all processes and a
fume exhaust system.
Revenue from skill training at HIWT
has more than doubled in the past eight
years. To accommodate that capacity,
the organization has made more efficient use of existing space and added a
second shift. This new construction will
enable the Institute to accommodate up
to 60 additional students on each shift.
10 PRACTICAL WELDING TODAY July/August 2013
People news
Fronius USA LLC, Portage, Ind., a

manufacturer of welding equipment,
has hired Matt
Chynoweth as a
sales/system engineer and promoted
Vadim Nakonechnyy to area sales
manager for the
Chynoweth
southeast region.
Chynoweth did
part of his internship at the company
before graduating
from Ferris State
University.
He
holds an applied
science degree in
Nakonechnyy
welding technology
Industry News
(continued from page 8)
and a bachelors degree in welding technology. Nakonechnyy has worked as an

application engineer out of the Chattanooga, Tenn., office since April 2012.
His territory includes Georgia, Florida,
South Carolina, North Carolina, West
Virginia, and Virginia.
innovation exemplified by U.S. manufacturing. The event is co-produced by

the Fabricators & Manufacturers Association Intl. (FMA), the National Association of Manufacturers (NAM), The
MIG GUN
CenterLine (Windsor) Ltd., Windsor, Ont., has added

Greg Van Dyke to
its sales team as an
account manager
specializing in resistance welding consumables and automation component
Van Dyke
products. Van Dyke
has more than 10 years of resistance
welding experience in sales and service
with Resistance Welding Products Ltd.
and the Tuffaloy Group of companies.
He holds a marketing diploma, majoring in international marketing.
Science Channel named official
media partner for second annual
Manufacturing Day
Science
Channel, Silver Spring,
Md., has been
named the official
media sponsor for
the second annual Manufacturing Day, a broad-based
grassroots effort created to drive public
awareness of the U.S. manufacturing industry and manufacturing careers. The
networks How Its Made manufacturing series was named official program
partner for the event, which takes place
Oct. 4, 2013.
Manufacturing Day 2013 will feature several hundred manufacturers,
educational institutions, and other partners offering open houses, public tours,
career workshops, and other activities
to share the technology, ingenuity, and
Manufacturing Institute, the National

Institute of Standards and Technologys
(NIST) Hollings Manufacturing Extension Partnership (MEP), and Industrial
Strength Marketing (ISM).
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Industry News
Victor contests recognize users of oxyfuel, plasma cutting equipment
Victor Technologies, St. Louis, has

launched two contests as part of its celebration of the 100th anniversary of its
Victor brand of cutting and gas control
equipment.
The A Cut Above contest, open to
students in cutting, welding, and related
programs at secondary and postsecondary schools, will award more than
$30,000 in equipment and cash prizes.
Beginner students will write a 500-word

essay supporting the contest theme,
while advanced students will submit a
team metal fabrication project that incorporates an oxyfuel, air-fuel, or plasma cutting process.
The Show Us Your Innovations
2014 calendar contest will award 12
Medalist 250 cutting outfitsand a
Thermal Dynamics CUTMASTER
42 plasma cutter as the grand prizefor
the best photos and associated captions
of the entrant using any Victor or Victor
Thermal Dynamics cutting equipment.
Both contests run through September.
They are open to residents of the U.S.
and Canada (excluding Quebec). Contest
details and entry forms are available at
www.victortechnologies.com/victor100.
Miller Electric introduces robotic

welding cell rental program
Miller Electric Mfg. Co., Appleton, Wis.,

has introduced a new robotic welding cell
rental program for companies interested
in trying robotic welding technology.
The program also is suitable for companies that receive contract work for short
runs of parts that dont warrant the capital expenditure for a robotic welding cell.
Rental contracts are for a threemonth minimum. The company also
rents robotic welding cells on-site and
will oversee short runs of parts in its
own facility.
As part of the program, the company
offers a full assessment before rental to
determine that the parts to be welded
are repeatable and able to benefit from
automation.
Industry News
Handy & Harmans LucasMilhaupt Inc. acquires Wolverine
Joining Technologies
Global diversified manufacturer Handy

& Harman Ltd., White Plains, N.Y., has
announced that Lucas-Milhaupt Inc.,
Milwaukee, an indirect wholly owned
subsidiary, has acquired the assets of
Wolverine Joining Technologies, Warwick. R.I., a wholly owned subsidiary of
Wolverine Tube.
The acquired company, which will
operate as Lucas-Milhaupt Warwick
LLC, provides Lucas-Milhaupt with
both a primary domestic mill for brazing consumables and an expanded customer base in key market sectors.
Wolverine Joining Technologies
manufactures a variety of silver- and
copper-based brazing and soldering filler
metals and fluxes for the appliance, construction, and metalworking industries.
Lucas-Milhaupt supplies brazing
and soldering materials to the electrical/electronic, appliance, transportation, construction, and mining markets
worldwide.
AccuBilt celebrates 25 years in business
AccuBilt Inc. of Jackson, Mich., marks

25 years in business in 2013. Founded
in 1988, the company is a turnkey systems builder and integrator, providing
design, build, installation, and support
of robotic and dedicated automation
systems for welding, assembly, material

handling, and automation support.
In 2012 the company expanded its
facility by 15,000 sq. ft. and added several new employees.
Hypertherm facilities recognized

as OSHA VPP Star worksites
The U.S. Department of Labor has recognized four Hypertherm facilities as

OSHA Voluntary Protection Program
(VPP) Star worksites.
The program recognizes workplaces
for operating outstanding safety and
health management systems for employee protection. These worksites are selfsufficient in identifying and controlling
workplace hazards. To be recognized as
a VPP Star worksite, an employer must
operate a comprehensive safety and
health management system that is integrated into a worksites operations.
Hypertherm, Lebanon, N.H., designs and manufactures hand-held and
mechanized plasma systems and consumables, fiber laser and waterjet products, CNC motion and height controls,
and CAM cutting software.
13
Industry News
Flux-cored wire use expected to rise
The use of flux-cored wires across a variety of end user sectors is expected to
rise, according to Frost & Sullivan, with
adoption levels projected to be particularly strong in sectors such as energy and
construction.
New analysis from the San Antonio,
Texas-based firm, Global Flux Cored
Wires Market, finds that the market
earned revenues of $1,811.2 million
in 2012 and estimates this to reach
$2,560.7 million in 2017.
The ability to support higher productivity, enhanced versatility, and
properties such as corrosion resistance
are spurring demand for flux-cored
wires, noted Frost & Sullivan Industrial Automation & Process Control
Program Manager Archana Chauhan.
An increase in investments is expected
in the next two years, positively impacting on market prospects.
Market expansion will be largely
driven by infrastructure developments
in emerging economies such as India
and China and the growth of end user
sectors such as energy and construction, remarked Chauhan. Renewable
energy sectors in EMEA and North
America are also central to the longterm growth strategies of flux-cored wire
manufacturers.
Lincoln Electric Mexicana earns

TS-16949 certification
Lincoln Electric, Cleveland, has announced that the Torreon manufacturing operations of Lincoln Electric
Mexicana S.A. de C.V. has earned ISO/
TS-16949 certification, applicable to
the design and manufacture of welding
consumables.
In general, the technical specification applies to the design, development,
production, and installation/servicing of
automotive-related products. The certification enables Lincoln Electric Mexicana to mesh its quality systems with
those of its automotive customers and
suppliers.
The first choice

for finishing solutions.
Whether its decreasing downtime,

increasing parts per brush or training your people, the Osborn team
will provide the right solution to
your metal cleaning and prepping
challengeswith more than 10,000
standard products backed by expert
local support.
When you start with Osborn,
you finish first.
For more information,
visit: welding.osborn.com
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Industry News
AlcoTec offers aluminum welding
technology program
AlcoTecs School
of
Aluminum
Welding Technology: Theory
& Practice Program is designed
to
incorporate
both a theoretical and practical approach
to welding aluminum alloys. Designed
for welding engineers, product design
engineers, and sales personnel, the program includes comprehensive classroom
instruction combined with hands-on
laboratory applications.
In this three-day program, students
learn metal preparation, weld procedures, inspection procedures, processes
for joining aluminum, and much more.
Metallurgical, welding, and quality engineers and technicians with years of
aluminum manufacturing experience
educate participants in the theory and
general characteristics of various aluminum alloys and tempers.
AlcoTec, Traverse City, Mich., is a
subsidiary of ESAB Welding & Cutting
Products. For more information, visit
www.alcotec.com/weldschool.
Camfil APC opens U.K. manufacturing facility
Camfil Air Pollution Control (APC),

Jonesboro, Ark., a manufacturer of dust
and fume collection equipment, has
opened a 40,000-sq.-ft. facility in Heywood, Greater Manchester, U.K.
The facility has a current staff of 40,
with plans to grow to 100 employees in

engineering, manufacturing, and support positions. The plant includes a
four-bay welding area, fabrication area,
powder paint line, assembly area, and
storage space.
Sciaky enters partnership with

Evobeam GmbH
Sciaky Inc., a Chicago-based subsidiary

of Phillips Service Industries (PSI), has
entered into a business partnership with
Evobeam GmbH of Mainz, Germany,
to further expand its electron beam (EB)
welding product portfolio.
Sciaky provides large-vacuum-chamber EB welding systems with internal
moving guns. The systems, which use
low voltage and high power, are suitable
for large-scale parts. Evobeam supplies
high-throughput, small-vacuum-chamber EB welding systems with external
guns. Using low voltage and low power,
the systems are designed for rapid production of small-scale parts.
15
Cover Story
Scott Schreiber left his job doing weld repair to

take over as welding instructor at Green River
Community College for his mentor. He hasnt
looked back since. Photos courtesy of Bruce
Ikenberry Photography, Lacey, Wash.
Accepting
the torch carrying

,
a legacy
Welding, people, and a commitment to the trades

fuel 2013 PWTeacher of the Years success
By Amanda Carlson, Associate Editor
s Scott Schreiber sat in his officenicknamed the

fishbowl for its four walls of windows that open up to
every angle of the shopand reflected on his relatively short 12-year teaching career at Green River Community
College in Auburn, Wash., he was almost constantly interrupted by students who either needed keys to a storage closet,
had questions, wanted to share a joke or an observation, or
just wanted a chance to hear what their teacher had to say for
himself.
Yeah, youd better put that back, he said to a student returning a tool to its proper place. Almost always these students, who range in age from early 20s to early 50s, were met
with a fatherly, or in some cases brotherly, ribbing that was
friendly, not biting. The positive dynamic, the energy, and the
comradery between the four walls of the Green River welding
lab are palpable.
Schreiber, the 2013 PWTeacher of the Year, took over a
welding program that was good to begin with and made it better. For the last 12 years he has surrounded himself with a loyal
and passionate staff to help him expand an already good program built by his mentor into a bigger, more modern version.
Schreiber demands excellence, continuous improvement,
and is always in search of creative and meaningful learning
opportunities for his students. He is committed to the welding trade and asserts ownership over a program that has meant
so much to him throughout his entire adult life. But most
impressive is his ability to connect with each of his students
in the way that they require to be successful. They arent just

bodies taking up spacethey are people with goals, problems,
strengths, weaknesses, and personalities. Each individual is an
integral part of something bigger than themselves and even
bigger than Schreiber.
Making a Good Program Better

Schreiber always knew he wanted to be a welding instructor,
he just didnt know when or where the opportunity would
present itself. He finally got the call after spending 17 years as
a heavy equipment repair welder for an excavating company
in eastern Oregon.
It was 2001 and longtime Green River welding instructor
and Schreibers former teacher-turned-mentor, Al Croppi, was
experiencing health issues that threatened to force him into
retirement. Croppi called his protg and offered him the opportunity to take over the welding program. Despite the fact
that his family was in Oregon and that hed be taking a significant pay cut, Schreiber accepted the position in his hometown, not wanting to see the program that he cared deeply for
fall into the wrong hands.
Immediately Schreiber realized he was taking over a wellcared-for program with immense growth potential.
When I got there, we had 18 students in a class that ran
from 8 a.m. to noon, five days a week. Just one class. The shop
was shut down until the 5:30 p.m. to 10 p.m. class that ran
four nights a week. That class also had 18 students. That was
it. The lab was shut down more than it was open, Schreiber
explained.
17
In Their Words
Students, industry peers, and colleagues share their thoughts and
perceptions about Scott Schreiber as a friend, mentor, and instructor.
Its obvious that his program means a lot, if not everything, to him. The
success of it comes first for him, and when I say that I mean the students
and their success. David Ornsby, street and vegetation manager, city
of Auburn
At a community college we see a lot of people just starting out or pressing
the reset button. It takes a special type of person to shepherd them
through learning a valuable skill and at the same time getting them through
the program. He also ensures that the graduates are of the utmost quality,
so that when someone calls Green River and wants to talk about welding,
they know the candidates coming out of the program are going to be
outstanding employees. Josh Clearman, dean of instruction: trades
and technology divisions
Scotts a funny guy. Hes always there to help, but hes not afraid to
give you lip if youre slacking. Hell make sure to let you know that youre
wrong and tell you how you need to fix it. Hes just an awesome guy.
Devin Wheeler, 20, welding student
Hes tied to industry and is very conscientious to the needs of industry.
Since I first met Scott two years ago, Ive seen things that tell me hes
going above and beyond for the school and for his students. Tim Honn,
technical sales representative, Lincoln Electric Co.
I will never be able to touch his welding skill. I guess thats why hes
got the big office. Steve Harrison, 53, welding student, Green River
welding lab aide
I couldnt be prouder. Hes done it all on his own and he makes Green
River shine in his own way. The reputation of the welding department
really isnt falling on administrations roles, it really is shining because of
Scott and the other instructors who are working over there. Eileen Ely,
president, Green River
Its like welding is his second nature or an extension of who he is. We are
lucky to have him because he pretty much knows everything about getting
us to understand the process. Brian McCorkle, 47, welding student
He envisioned growing the program to the point where it was pushing

through as many welders as it could handle in an efficient manner. And growth
did take place, gradually, with the addition of a three-credit class from noon to
1 p.m. every weekday to fulfill the basic
welding requirements of degree-track
students not necessarily heading toward
a career in welding.
Things picked up in 2008 when the
economy took a nosedive, resulting in

mass layoffs in the region. Enrollment
in the welding program exploded to the
point that it developed a wait list upward of 100 people.
That triggered the idea to start up
an afternoon session. We had the space
and the facility to do it, and with that
time slot from 1 p.m. to 5 p.m. free, it
was the perfect scenario to start another
full-time, 13-credit section.
Schreiber brought onboard a former

boss, Ed Vesser, to teach the afternoon
session. Not long after implementing
the afternoon session, the program again
developed a wait list, so he hired Casper
Fox, a former student, to lead weekend
classes on Friday nights, Saturdays, and
Sundays.
Today, even with all four sessions at
or slightly over capacity, they still arent
able to keep up with demand. Approxiwww.practicalwelding.com
Top left: Cameron Nelson practices his overhead GMAW technique. Approximately 80 to
85 percent of Green River welding students find employment with local fab shops or are
placed with local unions after graduation.
Bottom left: Schreiber and weekend instructor Casper Fox (far right) pose with the welding students in the morning session. The program runs morning, afternoon, and evening
sessions Monday through Friday and weekend sessions Friday night through Sunday.
Below: Devin Wheeler (center) and two classmates perform a repair on a drift trike.
Schreiber bases half of their grade on attendance and punctuality in an effort to hammer
home the soft skills.
mately 115 people are on the wait list.

Plans for a new building to house welding, automotive, auto body, carpentry,
and manufacturing classesapproval is
due this summerwould allow the program to double in size.
The ever-expanding welding program is just one clue that Schreiber and
his staff have built a solid program that
gives people a skill. Approximately 80
to 85 percent of students are hired by
unions or fabrication shops. Much of

that is due to the programs reputation
for developing strong, independent,
competent, and responsible welders.
And that sentiment is echoed by local industry representatives like Rene
Johnsen, training coordinator for Helac
Corp., a fabricator of hydraulic helical
rotary actuators. Johnsen, a Green River
welding program graduate who now sits
on its advisory committee, calls Sch-
reiber first when she needs to fill a slot.

Eighty percent of our welding crew
came from Green River. For the most
part, we end up hiring and keeping a
majority of the people Scott sends us.
Theyve showed consistency and pride
in their work, and we see that immediately. I know a lot of that comes from
Scott, Johnsen asserted.
Schreibers philosophy is very simple:
Come to class, be on time, well do the
19
rest. Meaning, students who are committed, serious, and open-minded will
succeed. In fact, half of a persons grade
is based on attendance and his or her
ability to show up on time.
Their grade is something for them
to lose. Even though I still have to be
critical of their assignment and tell
them whats wrong, it always ends on a
positive note. I think they respect that.
I wouldnt ask them to do anything that
Im not willing to do.
Schreiber also knows the value of the
struggle. To become free-thinking, accountable, and confident welders, they
have to learn how to problem-solve and
communicate. He encourages the welders to help each other figure things out
through group think.
Weve found that as we pull away
from them as instructors and let them
struggle a little so that they have to start
to think, they start to work together as
a group, comparing notes. Then we can
go back in and talk to these guys about
what theyre doing, and they get the
concepts that much quicker.
If they can problem-solve, they can
be successful, Schreiber added.
Learning Through Service

You can tell a lot about a leader by his or
her ability to serve others. One project
in particular involved assisting the city
of Auburn in curbing rampant copper
wire theft from city street light junction
boxes. David Ornsby, street and vegetation manager for the city of Auburn,
said in one year these thefts have cost the
city about $170,000 in labor and material. After considering their options,
Ornsby inquired about the welding program at Green River. After a few phone
calls he and Schreiber met with other
city personnel to hatch a plan to put the
students to work welding shut the street
light boxes that contained the copper
wire. The plan meant valuable work experience for students and an economical
fix to the problem for the city. Schreiber
was thrilled.
I couldnt get back to the college
quick enough to tell my dean. I wasnt
going to ask I just told him what we

were going to do. Sometimes that gets
me in trouble, but if you wait and go
through the process, you risk losing it.
Theres not enough time for all of that,
Schreiber explained.
He, Vesser, and Fox assembled the
students, put them through a step-bystep training session, and got city employees up to speed on safety considerations. City trucks were outfitted with
a gas-driven welding power source, and
student welders were paired with city
employees. Fifteen business days later,
the Green River welding students successfully sealed 1,833 boxes. Ornsby was
amazed.
Schreiber demands
excellence, continuous
improvement, and is
always in search of
creative and meaningful
learning opportunities
for his students.
Once they started figuring out a
rhythm and how they were going to
go about it, it went very smoothly. Of
course, like with any project, the start
was a little slow, just getting the details
worked out, but once it started rolling,
it went incredibly smooth. I told Scott
that if any other cities approached him
to send them my way, because I will tell
them all about the program and I would
definitely recommend his students
again, Ornsby said.
The students efforts garnered the attention of local media outlets and was
the source of praise from Dr. Eileen Ely,
president of Green River, who said the
initiative was above and beyond anything shes ever witnessed in any professional technical program.
The project had nothing to do with
me, nothing to do with the dean; it was
all the instructors efforts of going out
and taking the extra step on behalf of

students. To me, he really is a master
teacher, Ely said.
And it gave students like 20-yearold Devin Wheeler an opportunity to
get real-world experience outside of the
typical controlled classroom setting.
We were outdoors where there was
water, wind, and people around. Being
able to weld on rust, galvanized, paint,
there were actually some boxes that I
welded that were submerged in water
and all I could do was push as much of
it away as I could with my hand. It was a
lot different. I knew how to do it right,
but with those other factors, it definitely
changes things and requires a whole new
set of skills, Wheeler said.
Championing the Trades

Schreibers service extends to other
technology programs beyond his own.
He feels that it is his responsibility as a
Green River employee to make sure the
college as a whole continues to adapt
and grow to meet industry demands.
Many of those industry demands revolve around aerospace, thanks to Boeing plants in nearby Renton and Everett
and their 330 supplier companies.
But over the last several years, explained Josh Clearman, dean of instruction: career and technical education at
Green River, Boeings workforce has
aged. The company expressed a desire
for area colleges to offer short-term certificate programs (lasting roughly two
quarters, or six months time) based on
specific knowledge, skills, and abilities
(KSAs) that it needed entry-level applicants to possess. In particular, Boeing was looking for workers with skills
training in precision machining, quality
assurance, and machine maintenance.
The Puget Sound area is the fourthlargest manufacturing sector in the
country. Our fortunes arent tied to Boeing, but it is important that they be able
to get what they need from the workforce here. The fear was if we couldnt
provide a good workforce, Boeing would
go somewhere else. It mobilized the colleges, the government, and businesses
into action, Clearman explained.

Even though the short-term certification was not welding-related, Schreiber
got involved anyway. Why?
I have an obligation to industry as
an instructor to provide qualified personnel to fill the slots that are in high
demand and that are being left vacant by
retirement. Its my way of giving back.
We have a pretty good reputation at the
college of providing qualified personnel, and its not just in my class; its in
all of the classes. We want to maintain
that level of excellence so that industry
and local shops we deal with, when they
need someone, were the go-to source,
Schreiber said.
He and several other college representatives met with Boeing and its
suppliers; he then helped write a grant,
secured the instructors, and assisted in
writing the curriculum.
The result was the creation and implementation of an aerospace manufacturing program at Green River in 2012
and three brand-new short-term certificate programs in 12 other colleges across
the state, and in record time.
They went from an idea to classes
in 100 days. At a college, thats light
speed, Clearman added.
That sense of obligation has led to
108 people walking away from Green
River with a short-term certificate, employable skills, and subsequently jobs
within aerospace manufacturing.
Hes got a great pulse on all parts of
metal fabrication. I dont encounter people too often with such a broad knowledge base who are enthusiastic, who are
giving freely of their time. Its hard to see
anything that hes not helping or being
successful with, Clearman said.
Forward Progress
Schreiber has a reputation among his
students and colleagues as having unparalleled welding skills. Hell be the
first to admit that his welding ability is
a product of repetition and a tenacious
drive to one-up himself, no matter how
good the weld looks or how structurally sound it is. It should be no surprise
that he applies the same approach to his wait list is a challenge in terms of rewelding program. No matter how well cruiting. After all, how do you convince
things are going or how much the pro- someone that a two-year wait is worth it?
gram is growing, hes never satisfied, and
Maybe the actions and direction set
he never wishes to remain stagnant.
forth by its leader are the reasons. n
Even though Schreiber is proud that Associate Editor Amanda Carlson can be
his program is in such high demand, the reached at amandac@thefabricator.com.
fact
that it is currently running at6/23/2013
112 Green2:48
PWTJulAug2013REVISED.qxp
Page 1College, 253-833River PM
Community
percent capacity with 115 people on the 9111, www.greenriver.edu
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21
Technology Overview
By Terry Tuerk
o do or not do to, that is the question. When it comes

to cutting and grinding with professional-grade electric power tools, the answer to that question could
mean the difference between a safe work environment and an
accident waiting to happen.
In fabrication shops across the U.S. and around the globe,
power toolsmore specifically, angle grindersare being
used in an improper and unsafe manner, especially by workers who are less experienced in metal fabricating. Taking the
time to learn the dos and donts of cutting and grinding can
help prevent serious injury to yourself or those around you.
The Background on Angle Grinders

Over the past several years, the small angle grinder has become the most versatile tool in a fabrication shop. The tool
used to be considered bulky, heavy, and hard to manipulate,
but a lot has changed. Power tool design engineers have
worked hard to make angle grinders lighter, safer, more ergonomic, and more powerful. This is particularly true for small
angle grinders now offered with 12 amps or more of power,
as well as for cordless versions that can deliver up to 100 amps
with an 18-volt lithium-ion battery.
The design advances of todays angle grinders have increased the number of applications you can use them for.
Quality angle grinders usually have industry-standard
safety features such as a toolless, easily positioned wheel guard
that allows you to quickly reposition the guard rather than
remove it entirely. Safety slip clutches also are available on
many industrial-grade angle grinders. The safety slip clutch
helps to protect you from kickback should the wheel bind
or snag.
All angle grinders are equipped with a side handle, which
helps you to better control the tool while it is in operation,
especially when performing heavy grinding or cutting. Antivibration side handles and side handles that are offset from 90
degrees are safe, ergonomic, and allow you to work for long
periods of time without fatigue. By keeping two hands on
the tool, not only will you work safer, but youll work more
efficiently too.
Safety First
All humans become complacent at one time or another, especially when we have done a job over and over and over
again. Im sure youve experienced a moment when youve
thought, Whats the worst that could happen? It will only
take a second.
This invariably translates into ignoring the written or
unwritten rules of whatever you are doingin this case,
ignoring basic safety by using a cutting

or grinding disc that is not meant for the
application you are performing, or simply deciding not to attach a wheel guard
or a side handle to a grinder. It seems benign, harmless even, but if done enough
over a period of time, sooner or later an
accident will happen. So, how do we
avoid complacency?
First, familiarize yourself with the
rules of operating your angle grinder,
and second, follow those rules. Underlying translation: Read the instruction
manual!
The owners manual not only offers
excellent information about the tool and
how to operate it safely, it also gives you
all the information you need, from how
to care and maintain your tool to how to
select the appropriate accessories.
It should be no surprise that because
angle grinders are being used in a wider
variety of applications than ever before
such as removing metal, deburring,
cleaning, brushing, sanding, finishing,
polishing, and cuttingthe number of
operator injuries has increased. By simply taking the time to read the manual
and becoming familiar with all of the
tools safety guidelines, you can avoid a
majority of these injuries.
Accessorizing Your
Angle Grinder
As a power tool user, you really need to
think about your application and properly match the accessory to the grinder
itself. Its important that whatever you
choose falls within the manufacturers
tool and accessory recommendations.
Accessories always should be rated at
or above the no-load speed of the angle
grinder. Start by choosing the correct
grinding wheel size for your angle grinder. By using wheels that are oversized,
you run the risk that they may shatter or
explode at very high speeds.
Depending on the type of accessory,
different safety guards may be required.
For example, thin cutting wheels require
Angle grinders can be used for a variety of applications including cutting, grinding, and polishing.
Being familiar with a tools safety guidelines keeps you safe.
a guard that encloses the wheel on two

sides by 180 degrees. Cup-type wheels
require a different guard than regular
grinding wheels.
The owners manual

not only offers excellent
information about the
tool and how to operate
it safely, it also gives
you all the information
you need, from how to
care and maintain your
tool to how to select the
appropriate accessories.
Some grinding wheel manufacturers have released a reinforced wheel that
can be used for both cutting and grind-
ing applications. This type of wheel not

only saves you time because you dont
have to switch wheels between applications, but also enhances safety because
you dont have to remember to switch
wheels when working on a job.
The Dos and Donts:

A Checklist
Before you operate your grinder, be sure
to go through this checklist before turning it on.
Do
Visually inspect the tool and all
wheels for possible damage before
mounting.
Check the mounting flanges for
equal and correct diameter. They should
be at least one-third the diameter of the
wheel and relieved around the hole.
Always use a safety guard that
covers at least one-half of the grinding
wheel.
Run a newly mounted wheel at
operating speed for at least one minute
before grinding.
23
Wear safety goggles or some sort of

eye protection during grinding.
Handle and store wheels carefully.
Avoid dropping or bumping them.
Store abrasive wheels in a dry area
not subject to extreme temperature
changes. Some bonds may be adversely
affected by excessive humidity and temperature differentials.
Dont
Use a cracked wheel or one that has
been dropped or damaged.
Force the wheel onto the tool or
alter the size of the mounting hole. If it
doesnt fit, dont use it.
Exceed the maximum operating
speed specified by the manufacturer.
Overtighten the mounting nut.

Stand in front of the grinding
wheel when the grinder is turned on.
Grind material that the wheel is
not intended to grind.
Expect the Unexpected

Always expect the unexpected. When
using a grinder, be aware of your environment and situation. Keep your mind
on the task and be prepared for the possibility of tool kickback. If you are alert,
the tool will be more easily controlled
and less dangerous.
Many power tool and abrasive manufacturers offer on-site safety training and
support programs to review proper tool
and accessory use. Training can last anywhere from 15 minutes to an hour and
a half, covering everything from safety
tips to hands-on demonstrations of safe
tool operation.
Making yourself familiar with a tools
safety requirements is a must. Knowing
safety guidelines and understanding
why, how, and how fast an accident can
happen is the first step toward a safe
work environment. n
Terry Tuerk is senior product manager at Metabo USA, 1231 Wilson Drive, West Chester, PA
19380, 800-638-2264, ttuerk@metabousa.
com, www.metabousa.com.
Photo courtesy of Metabo USA, West Chester,
PA.
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Years of Research and Development
Technology not old habits!

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E3 Electrodes run much cooler

therefore extending tip life! In tests,
the E3 electrode is shown to run
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and less erosion. The two electrodes shown
here were subjected to the same welding
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E3 Electrodes were tested

on a remote orbital welding
system against 2% thoriated
and were found to last
approximately 230% longer
in this particular application.
Both electrodes were run on
a 20 inch pipe with a 2" wall.
2% ran approx. 19 linear ft
E3 ran approx. 50 linear ft
A 360 VIEW OF THE MOST INNOVATIVE TECHNOLOGY AND PROCESSES. FABTECH 2013.
METAL FORMING | FABRICATING | WELDING | FINISHING

FABTECH represents every step of the metal manufacturing process
from start to finish. Its where new ideas, products and technology are
highlighted through interactive exhibits, education and networking.
Compare solutions from 1,500+ exhibitors, find machine tools to
improve quality and productivity, and learn ways to increase profit.
REGISTER NOW for the show with a degree of difference.
November 1821, 2013 | Chicago, IL | fabtechexpo.com
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Meeting the challenge head-on
Properly addressing the troublesome attributes of aluminum and its alloys will help prevent potential issues during the laser welding process.
By David Havrilla
Editors Note: This article is based on David Havrillas presentation at the Aluminum Laser Welding Symposium, co-sponsored by TRUMPF Inc. and Fraunhofer
USA in Plymouth Township, Mich.
luminum possesses many characteristics that make it an ideal

material in the world of manufacturing. It has excellent corrosion
resistance and is roughly one-third the
mass of steel. This bodes well for the automotive industry in particular, which
must increase fuel economy to a fleet
average of 54.5 miles per gallon by 2025.

Aluminums other positive attributes
include its high thermal conductivity
a very useful trait for heat exchangers
and similar componentsand its low
electrical resistivity, which makes the
metal a good current conductor and reinforces the versatility of the material.
But these unique and useful attributes
would be worthless if aluminum was
not also easily formed, machined, and
welded. Its manufacturability establishes
aluminum as a highly desirable material
for production.
The kicker, as many familiar with
aluminum already know, is the material
and its alloys have a few troublesome attributes that must be properly addressed
to avoid potential problems during the
welding process.
Problems and Solutions to

Laser Welding Aluminum
With eight wrought alloy groups, the
aluminum family can accommodate a
wide variety of manufacturing applications (see Figure 1). Regardless of the alloy or application, the question of weldability inevitably arises. Luckily, most
alloys can be successfully fusion welded,
either with or without filler material.
Joining with lasers can solve some of
the problems that plague conventional

welding techniques.
The wide range of temperatures in
alloy vaporization and solidification
can lead to keyhole instability, porosity,
blowholes, a loss of mechanical properties, and various defects in the weld metallurgy such as hot cracking. The high
rate of hydrogen solubility in molten
aluminum can lead to extensive weld
porosity and blowholes. The low viscosity of highly fluid molten aluminum can
result in dropping or sagging of the underbead.
Finally, aluminums high reflectivity
combined with its high thermal conductivity can lead to challenges with
coupling of the light energy into the
material. While this may sound dismal,
the history and success of laser welding
of aluminum is quite the opposite. Each
characteristic and its related issues have
a well-defined and production-proven
solution. Lets take a brief look at five of
the most common issues, mechanisms,
and control measures.
Hot Cracking, or Weld Solidification Cracking. This complication occurs because of solidification stresses on
the microstructure and is worsened by
aluminums high thermal expansion and
conductivity. Hot cracking sensitivity often can be avoided by adding the appropriate filler wire or inlaid filler foil material, thereby altering the weld chemistry
away from the crack-sensitive peak (see
Figure 2). For example, standard values
for good weldability are greater than 2 to
3 percent silicon and greater than 3 to 4
percent magnesium, yet the typical range
in the 2000 and 6000 series aluminum
alloys is between 0.4 and 1.6 percent.
Therefore, these alloys usually require
filler for crack-free welding.
The Presence of Hydrogen. Hydrogen is abundant, especially in manufacturing environments, and its solubility
in molten aluminum can lead to gross
porosity. Water, lubricants, and air all
contain the element, and although it
readily dissolves into molten aluminum,

it has virtually no solubility in solid
aluminum. As a result, hydrogen in the
molten weld pool is either trapped in
the weld as pores, or it outgases, which
causes blowholes upon solidification.
Fortunately, some simple preventive
measures can be taken to prevent hydrogen-related issues from occurring.
Alloy
Series
Alloy
ing elements such as zinc, magnesium,

and lithium. These elements vaporize,
escape through the keyhole, and pull
molten material along with them, leaving weld voids and spatter in their wake.
The solution is to simply provide a large
enough path (e.g., large focused spot size
or tandem focus spot) or enough time
(e.g., reduced weld speed) for the vapors
Applications
1xxx
Pure
Low strength, excellent thermal/electrical conduction and

corrosion resistance, highly reflective
Fuel filters, electrical conductors, radiator tubing, lighting reflectors,
decorative components
2xxx
Cu
High strength, relatively low corrosion resistance, good elevatedtemperature strength

Aircraft skin, aircraft fittings and wheels, ballistic armor, forged and
machined components
3xxx
Mn
Medium strength, good formability, good corrosion resistance

Storage tanks, beverage cans, home appliances, heat exchangers,
pressure vessels, siding, gutters
4xxx
Si
High castability, high machinability, high fluidity, low ductility

Variety of castings including large castings, filler metal (2xxx, 3xxx,
5xxx, and 7xxx used for castings)
5xxx
Mg
Medium strength, good formability, excellent marine corrosion

resistance
Interior automotive, appliance trim, pressure vessels, armor plate,
marine and cryogenic components
6xxx
Mg, Si
Medium strength, good corrosion resistance, easily extruded

Exterior automotive, automotive profiles, railcars, piping, marine,
screw stock, doors and windows
7xxx
Zn
Very high strength, prone to stress corrosion, poor corrosion

resistance
Aircraft construction, truck trailers, railcars, armor plate, ski poles,
tennis rackets
8xxx
Li
Very high strength, low density

Aircraft and aerospace structures, foil, heat exchanger fin stock
Figure 1
With eight wrought alloy groups, the aluminum family can accommodate a wide variety of manufacturing applications.
Keep materials clean and dry, including the filler wire or foil.

Avoid temperature differentials
(e.g., storage to production area) that
can cause condensation on the parts or
filler material.
Clean weld joints and remove porous oxides when needed.
Use a shielding gas.
Porosity and Blowholes. These issues also can be caused by volatile alloy-
to exhaust without causing damage.

Underbead Dropping. This issue
occurs in penetration welds of about 6
mm or more, though the exact thickness
threshold depends on variables such as
wavelength, alloy type, power, speed,
and spot diameter. The simplest way to
avoid it is to position the weld joint horizontally, but this is often impractical or
impossible. When a vertical weld joint
is necessary, there are several strategies
27
Figure 2
The graph shows the sensitivity to hot cracking versus the alloy content. The range of silicon and magnesium in 2000 and 3000 series
aluminum is shown in red. Standard values for good weldability are
greater than 2 to 3 percent silicon and greater than 3 to 4 percent
magnesium, yet the typical range in the 2000 and 6000 series aluminum alloys is between 0.4 and 1.6 percent.
Sensitivity to Hot Cracking
2XXX/6XXX
Magnesium
Silicon
Crack-free
Alloy Content (%)
that can be used to avoid underbead dropping in deeppenetration welding (see Figure 3):
Use a partial-penetration weld.
Redesign the component to avoid a through-penetration weld.
Use an underbead backing material (e.g., copper).
Reflectivity. In the past aluminums high reflectivity
was a problem for laser welding. However, with the evolution of high-power, good-beam-quality carbon dioxide
(CO2) lasers, and the advent of high-power, high-brightness solid-state, fiber-delivered lasers, coupling the energy
into aluminum is no longer an issue.
These developments have led to a common misconception: Since the shorter-wavelength solid-state lasers,
like disk and fiber, have a higher absorption into aluminum, they must be the best laser for all applications. This
is not the case. For thicknesses up to about 4 or 5 mm,
Aluminum: A History Lesson

Aluminum is a versatile metal with remarkable attributes. Its
low atomic mass, high corrosion resistance, and excellent
thermal and electrical conductivity make it a very unique
material. It is easily machined, cast, drawn, and extruded
all appealing traits for manufacturers. Plus, theres a lot of
it. Next to oxygen and silicon, aluminum is the third most
abundant element in the world and the most abundant
metal, comprising more than 8 percent of the earths crust.
Although plentiful, it is typically found in compounds, most
often as the ore bauxite, rather than in its pure form. This
has kept the resource largely untapped until the early 19th
century, when scientists began to isolate and extract the
metal.
Production of aluminum was still far from economically
viable until the end of the century. In 1888 American chem-
ist Charles Martin Hall formed the Aluminum Company

of America (ALCOA) and within a year patented an inexpensive process to obtain aluminum from aluminum oxide
using electrolysis. At the same time, French chemist Paul
Hroult independently invented the same process, which
became known as the Hall-Hroult method. In the same
year, Austrian chemist Karl Bayer developed an inexpensive process for obtaining aluminum oxide from bauxite ore.
After the Bayer and Hall-Hroult processes were introduced and refined, the price of aluminum decreased drastically so that it was no longer considered a precious metal.
Production of aluminum grew in popularity, and approximately 2 million metric tons were produced in 1943. In 2012,
46 million tons were produced, and it is estimated that by
2018 this number will grow to 71 million tons of aluminum.
the 1-micron wavelength of the solidstate laser is preferred; however, when

material thickness is 6 mm or more, the
CO2 laser (10.6-micron wavelength) is
the best choice. While the exact physics
may be debated, an easy way to think
about this is that due to the higher absorption of the 1-micron wavelength, a
greater amount of the power is absorbed
by the upper portion of the material.
A 10.6-micron wavelength, however, is
able to penetrate deeper into the material as it reflects down the keyhole.
Aluminums weight-to-strength ratio
and corrosion resistance are two of the
many reasons that manufacturers see it
as a desirable material for their applications. While most aluminum alloys can
be fusion welded, either with or without
filler, there are a few well-known and
Partial penetration
Component redesign
Underbead backing
material (e.g., Cu)
FIGURE 3
Employing these strategies will help eliminate

underbead dropping during laser welding.
-understood welding issues that can be

easily overcome by production-proven
methodologies.
To accentuate that reality, we need
only look at the numerous aluminum
and aluminum alloy components that
have been laser welded for various industries since the 1990s. With the fuel
economy mandates in automotive, lightweighting is a necessity, and aluminum
is sure to be a significant part of that
endeavor. With all its advantages and capabilities, laser joining these aluminum
components is just as certain.
David Havrilla is manager-products and applications at TRUMPF Inc. Laser Technology
Center, 47711 Clipper St., Plymouth Township, MI 48170, 734-454-7200, oeminfo@
us.trumpf.com, www.us.trumpf.com.
29
Previewing Schweissen & Schneiden 2013

By Amanda Carlson, Associate Editor
More than 55,000 attendees from more than 100 countries are expected to converge on Essen, Germany, for Schweissen & Schneiden, the International Trade Fair for Joining, Cutting, and Surfacing. Held every four
years, the show is one of Europes largest gatherings of welding, cutting, and finishing industry professionals from around the world. Since
its inception in 1952, the exhibition has established itself to be one of
the most significant platforms for the exchange of ideas. Representing
40 nations, 1,000 exhibitors will present the latest developments and innovations at Schweissen & Schneiden 2013 from all sectors, including:
Plants and equipment for joining, surfacing, and cutting processes
Plants and equipment for heat treating and other production
processes
General production plants, systems for computer-aided production,
data processing, instrumentation and control technology, and
automation
Production plants for filler metals, consumables, and auxiliary metals
Thermal spraying
Workshop and workplace equipment, safety devices, and
occupational safety and health equipment
Accessories
Filler metals
Bonding, sealing, and application products
Consumables and auxiliary materials
Quality assurance, measuring, and testing technology
Order execution services
Organizations that promote vocational training, research,
information, and specialized literature and regulations
Special Events
Competition Welding. A variety of special events highlight this years
show. The 10th DVS-sponsored National Young Welders Competition,
Sept. 16-18, pits welders under 23 years of age against one another in
one of the four welding disciplines. Following the national competition
is WeldCup 2013, a competition featuring young welders representing
European countries. On Sept. 20, an international competition including
Chinese participants will take place.
Young Innovative Companies. New German companies will have
the opportunity to showcase their new products and technology in their
own section in Hall 9. Exhibits include welding gap clips for root welding, special nozzles, and mobile lasers for ships and drilling rigs. It is
sponsored by the Federal Ministry of Economic Affairs and Technology.
Automation in Welding Conference. The International Institute
of Welding (IIW) will hold its 66th Annual Assembly and its international conference in Essen Sept. 11-17. At the Annual Assembly, industry experts from roughly 60 member countries will discuss current
technical topics, as well as the outlook for the world market. The IIWs
international conference, Automation in Welding Conference, Sept. 1617, combines the scientific work of the IIW with the global offerings of
joining technology provided at the trade fair. For more information, visit
iiw2013.com. Approximately 1,000 industry experts will gather for the
two-day conference.
Merging products, technology, networking, and education
At a Glance
What: Schweissen & Schneiden Essen
Welding Show 2013
Organizer: Messe Essen
Partner: German Welding Society (DVS)
When: Monday, Sept. 16 Saturday, Sept. 21, 2013
Hours: Monday Friday, 9 a.m. to 6 p.m.;
Saturday, 9 a.m. 4 p.m.
Website: Visit www.schweissen-schneiden.com
to register to attend the show.
Please visit these advertisers at Schweissen

& Schneiden.
Dont forget to visit the team who brings you
Practical Welding Today and The FABRICATOR
in Hall 7, Booth #G139.
American Torch Tip, www.attcusa.com
Cor-Met Inc., www.cor-met.com
ESAB, www.esabna.com
Foerster Welding Systems GmbH, www.foerster.de
Hypertherm, www.hypertherm.com
IGM Robotersysteme AG, www.igm-group.com
Lincoln Electric Co., www.lincolnelectric.com
Osborn, www.osborn.com
OTC Daihen Inc., www.daihen-usa.com
PFERD, www.pferd.com
Strong Hand Tools, www.stronghandtools.com
Trafimet, www.trafimetgroup.com
31
Aluminum Workshop | Frank Armao
Whats so bad about welding 7075, 2024?

You have discussed previously the
fact that some aluminum alloys,
such as 7075 and 2024, should not
be welded. But I know a fabricator
who occasionally welds 7075. Is
he engaging in a poor practice, or
is there something I dont understand?
I cant really answer your question definitively because I dont know the specific
application of the parts the fabricator is
making. In the vast majority of cases, it
is a very poor and possibly even dangerous practice to weld 7075 or 2024. The
problem is that these two and similar alloys are extremely prone to microcracking, which is not always easily detectable and can lead to catastrophic failure
while in service. For this reason, you will
never find a recommended filler metal
for welding 7075 or 2024 in any manufacturers literature.

However, there is one relatively common application in which 7075 is welded with no risk of dire consequences,
and that is the repair of molds for injection or blow molding of plastics. Most
of the thick plates that are used to make
injection molds are made from either
7075 or 2618 in thicknesses from 3 to
18 inches. Such mold plates are sold by
many manufacturers under proprietary
names. Some are wrought plate and
some are cast plate. Regardless of the
suppliers proprietary designation, they
are almost always 7075 or 2618 or similar alloys.
In making molds for injection or
blow molding, the negative portion of
the part is machined into the mold plate.
In doing so, the part is sometimes mismachined. To address this you must fill
in this area with weld and remachine it.
A similar technique is used to build up
worn areas on molds. Why is this acceptable when I just got through saying that
you shouldnt weld 7075? The reason is
that in this case, the weld isnt structural
and has very little stress. You can use gas
tungsten arc welding (GTAW) or gas
metal arc welding (GMAW) for the repair. You can use either 4043 or 5356 to
make the repair, although 5356 is usually used on molds for textured parts.
The reason is that 5356 is harder and
machines more like 7075, so the texture
looks more like the original mold plate.
Once youve completed the repair,
just make sure you dont get carried
away with enthusiasm and weld lifting
lugs onto the mold. That would be a
very bad idea.
Frank G. Armao is director of aluminum
technology at The Lincoln Electric Co., 22801
St. Clair Ave., Cleveland, OH 44117, 216481-8100, frank_armao@lincolnelectric.com,
www.lincolnelectric.com. He is a member of
the AWS D1 Committee, chairman of the AWS
D1 Aluminum Subcommittee, and member
of the Aluminum Association Committee on
Welding and Joining.
Do you have an aluminum

question for Frank?
Fax: 815-484-7788
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Consumables Corner | Nino Mascalco
Tackling root penetration problems

We are experiencing weld root penetration issues in our single- and
multipass welds. Our base metal is
A36, and we oxyfuel-cut it in thicknesses from to 3 in. Most of the
weld joints are standard T-joints
with a few groove joints. We are
using a 0.045-in.- dia. E71T-1C/M
flux-cored wire with 75 argon/25
CO2 shielding gas and a 0.045- in.dia. ER70-S6 with 90 argon/10 CO2.
Almost all of the welding is done in
the 2F or 1F position. How can we
fix this?
This is a common problem in many

shops and a main concern when considering new welding processes or filler
metal and shielding gas mixes. However,
many times there is a misunderstanding
of what is required for root penetration. Generally speaking, root penetration is considered successful if the root
of the weld intersects all of the individual components of the base material. For
example, a -in. fillet weld bead that
penetrates 116 to 18 in. past the individual
components of base material at the root
will provide a buffer for manufacturing
variations.
A couple things typically contribute
to the lack of penetration that you are
experiencing: weld joint preparation,
shielding gas, filler metal classification,
weld parameters, and welder technique.
You should make sure your weld
joints are free of heavy mill scale, rust,
dirt, or paint. If the weld joint involves a
beveled edge that was cut using oxyfuel,
be sure there are no gouges or heavy
dross that could interfere with welding.
Assuming a procedure qualification
record (PQR) or welding procedure
specification (WPS) was performed,

make sure the welders are staying within
the qualified parameters.
Shielding gas plays a key role in arc
characteristics, fume generation, weld
bead profile, and cleanliness. Argon-rich
gas mixes will produce a less penetrating
arc. If weld cleanliness and fume generation are not of high importance, simply
changing to 100 percent CO2 for the
flux-cored arc welding (FCAW) process
and 75 argon/25 CO2 for the solid wire
(GMAW) process will produce betterpenetrating arcs and may resolve your
issues.
A couple things typically

contribute to the lack of
penetration that you are
experiencing: weld joint
preparation, shielding gas,
filler metal classification,
weld parameters, and
welder technique.
The other area of concern is that if
a majority of the welding is performed
in the 1F/2F position, consider changing to a E70T-1C/M (flat and horizontal) filler metal. This is because the allposition flux-cored wire you currently
use can sometimes cause problems with
lack of penetration because of how the
wire/slagging system is designed to perform. Another option you may want to
consider is increasing the wire diameter to a 0.052-in. or 116-in. flux-cored
wire, which can increase your optimal
amperage range and produce a betterpenetrating arc because of the increase

in current.
Finally, your technique is critical
to ensuring a sound weld. For FCAW,
you should perform a drag technique
to keep the arc on the front edge of the
weld puddle. This torch drag angle can
range anywhere from 5 to 40 degrees,
although 5 to 15 degrees is typical. Also,
the work angle for a 2F weld should be
from 40 to 60 degrees when measured
from the horizontal member.
For GMAW, you can use either a
push or pull technique without fear of
trapping slag at the root. However, it is
essential for you to keep the weld arc on
the front edge of the puddle with either
technique. Typically, welders use a push
technique, allowing the welding arc to
ride on top of the weld puddle without
melt-through. The result of this action
is the puddle acts as an insulator, which
prevents the arc from penetrating down
to the edges of the base metal and causing lack of penetration.
Nino Mascalco is application engineering manager at ESAB Welding & Cutting Products,
411 S. Ebenezer Road, Florence, SC 29501,
636-485-2253, www.esabna.com.
Do you have a consumables

question for Nino?
Fax: 815-484-7788
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Product News
Needle scalers
Torch cleaning system
Welding training device
CS Unitec has introduced a line of lowvibration needle scalers with an optional

dust shroud. The Trelawny Vibro-Lo
VL series is designed to remove coatings
and corrosion and clean other accumulated materials from metal surfaces.
According to the company, the machines offer 7 times less vibration than
traditional needle scalers. The internal
air pressure is used to absorb the recoil
and impact from the anvil and needles.
The optional dust shroud helps maintain a clean working environment when
the tool is attached to a vacuum.
The lightweight, pneumatic needle
scalers provide up to 3,000 blows/min.
They are suitable for irregular surfaces, as
well as cleaning and stress-relieving weld
seams and steel joints. The tools can be
converted to chisel scalers for splitting,
chipping, and pointing applications.
Fronius
Intl.
GmbH has released the Robacta TC 2000
torch cleaning
system. Available for nearly
any torch geometry, the touchless system can
be integrated into any existing robotic
welding cell.
Spatter buildup is removed electromagnetically with its dual magnet coils.
The contact tip, front, and inner area of
the gas nozzle are cleaned in one cycle,
without damage to the surfaces of the
wearing parts, the company states. The
welding wire is precisely positioned to
have no influence on the tool-center
point.
RealWeld Systems Inc. has announced

that its patent-pending RealWeld
Trainer system will support welding of
18-in. joints, which meets or exceeds the
test requirements of the AWS B2 specification for plate welding.
The system, designed for a welding booth, can be used while under the
hood with the arc on or for practice
welding with the arc off. When users
configure their welding procedures in
the system, they also select plate length
of 6 or 18 in. for GMAW, SMAW, and
FCAW processes welding fillet, lap, and
groove joints in the flat, horizontal, and
vertical positions.
The training system is suitable for
screening welders before being hired,
assessing skill certification levels, and
cloning the techniques of master welders
into documented welding procedures.
CS Unitec Inc., 800-700-5919,

www.csunitec.com
Fronius Intl. GmbH, 877-376-6487,

www.fronius.com
RealWeld Systems, 614-688-5000,

www.realweldsystems.com
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Ideal for the set-up of 2D frames,

tacking jigs, welding fixtures, or
holding and clamping fixtures for
MRO, assembly, or inspection.
meltric.com
800.433.7642
Product News
Weld purge monitor
Dust collector TCO calculation
Camfil Air Pollution Control (APC)

has published a brochure that describes
how to calculate total cost of ownership
(TCO) for cartridge dust collectors.
TCO identifies and calculates the
main components of true filter cost: energy, consumables, and maintenance and
disposal. Similar to life-cycle costing, a

TCO evaluation determines what it really costs to own dust collector filters over
time. The brochure provides sample calculations and offers energy-saving tips.
Camfil APC, 800-479-6801,
www.camfilapc.com
The PurgEye 300 Nano Weld Purge

Monitor from Huntingdon Fusion
Techniques has been updated to read
down to 1 PPM using a new-style zirconia sensor. It is suitable for weld purging of stainless, duplex, and superduplex
steels, as well as titanium, zirconium,
and nickel alloys.
In addition to measuring the oxygen
levels when welding exotic alloys, the
monitor can be used for weld purging of
tube and pipe joints, either with manual
or orbital welding techniques, and for
ensuring the internal atmosphere in
welding chambers, boxes, and enclosures
is reduced to 10 PPM oxygen or less.
Huntingdon Fusion Techniques Ltd.,
44-1554-836836,
www.huntingdonfusion.com
Pleated bag filter
United Air Specialists Inc. offers a new

pleated bag filter with a one-piece construction that allows it to be used in new
systems or as a retrofit in existing bag
house equipment.
ProPulse expanded ePTFE surfaceloading technology resists moisture
and offers good release characteristics.
Increased filtration media efficiency
helps improve air quality and reduce
dust emissions. The filters are short and
compact to help reduce inlet abrasion
and provide a large drop-out area underneath. They are available in a variety
of configurations for top-load, bottomload, and oval styles with multiple filter
media options, including ePTFE and
spunbond polyester.
United Air Specialists Inc., 888-515-8800,
www.uasinc.com
37
Product News
Two-gas, adjustable mixer
Welding helmet
AC resistance welding control
SuperFlash Compressed Gas Equipments Mini-PGM

two-gas, adjustable
mixer now can be
configured for use
with hydrogen, so
users can customize their own hydrogen/argon or hydrogen/nitrogen mixes
for GTAW; GMAW; and plasma gouging, cutting, and welding.
The 7.5-lb. unit uses less than 1 cu.
ft. of space while providing enough gas
for eight welding machines at about 40
to 50 SCFH per machine. It comes standard with a mounting bracket for hanging on a wall, machine cage, or other
location.
Save Phace has introduced the Extreme

Face Protector (EFP) Gen Y series of
welding helmets, offering welding,
grinding, and splash protection.
The helmets offer an adjustable 4/913 auto-darkening filter with grind
mode integrated into a 180-degree viewing lens. The face-forming design helps
the user get into tight spaces. The rounded shape doesnt trap the welders breath,
making it 6 degrees cooler than other
helmets, according to the manufacturer.
Features include a replaceable, sweatabsorbent headband and flexible, heatresistant nylon helmet material. Three
graphic options are available: Black Ice,
Razor, and Twisted Soul. Each model is
ANSI- and CE-approved.
Entron Controls
LLC has released
its EN6021 singlephase AC resistance
welding control.
It comes standard
with a weld log that
stores 14 weld parameters for the last
57,600 welds made.
Other standard features include a
flash drive port, three valve outputs, 16
24-VDC inputs and 16 24-VDC outputs, a sequencer, and four analog inputs
and outputs. Optional communication
cards can be used to communicate via
Modbus or EtherNet/IP with AllenBradley PLCs to implement schedule
changes, data retrieval and remote I/O.
SuperFlash, 888-327-7306,
www.oxyfuelsafety.com
Save Phace, 866-783-3223,

www.savephace.com
Entron Controls LLC, 864-416-0190,

www.entroncontrols.com
Product News
Weld shaver
Arc welding reel
Flap wheels
Heck Industries has introduced a handoperated fillet weld shaver. The tool uses
indexable carbide inserts in a milling cutter to remove weld beads from flat butt
welds and inside 90-degree fillet welds.
The unit features adjustable depth
of cut and an adjustable fence, allowing
removal of the weld bead without affecting the surrounding primary materials.
The 2.3-HP tool weighs 12 lbs.
Hannay Reels SWCR

arc welding reel is
designed to handle
single-conductor
electrode cable or
grounding lead. Current passes through
a 400-amp-rated rotary electrical device
for use with any unwound cable length.
The unit features a heavy-duty spring
motor that allows self-contained rewind. A nonsparking ratchet assembly
locks the reel in place when the desired
amount of cable has been payed out,
while a declutching arbor is provided to
prevent damage from reverse winding.
Weiler Corp. offers flap wheels for

aggressive cutting
action in a variety
of industrial production environments. They are
designed for cleaning, edge blending,
deburring, blending, and finishing on
machined parts, metal surfaces, dies,
molds, tools, tubing, and channels.
Tiger flap wheels are designed for
medium- to high-production environments. They provide a high cut rate and
long life, according to the manufacturer.
Vortec flap wheels, also with a high cut
rate, are suitable for low- to mediumproduction environments.
Heck Industries, 810-632-5400,

www.heckind.net
Hannay Reels, 877-467-3357,

www.hannay.com
Weiler Corp., 800-835-9999,

www.weilercorp.com
39
Product News
Antispatter, cooling fluids
Thermacut has introduced three new

welding chemical products: a heavyduty antispatter and two glycol-based
cooling fluids.
The nonflammable, solvent-based
antispatter evaporates quickly to provide an effective surface coating. By
preventing spatter buildup in welding
applications, the antispatter eliminates
the need to grind or brush the surface
after welding.
The cooling fluids are designed
and recommended for use in plasma,
GTAW, GMAW, and resistance welding
systems, as well as general industrial applications. They help eliminate the internal buildup of mineral deposits during welding and cutting operations. The
Electric polishing system
coolants also lubricate the pump, the

liner, and the gasket and seal. Thermally
stable and featuring dielectric properties, the cooling liquids are suitable
for plasma and arc welding, as well as
GTAW systems.
CFPG cooling fluid, a nonhazardous
blend, is an inhibited blend of deionized
water and propylene glycol. Its corrosion inhibitors protect iron, steel, aluminum, brass, and copper components.
CF2 cooling fluid is an inhibited blend
of deionized water and ethylene glycol.
With a low viscosity, it doesnt require as
much power to pump.
Suhner Industrial Products LLC

has launched the
new UMC 6-R
L electric power
file/polishing system for difficult-toaccess polishing, graining, and brushing
applications on stainless and aluminum.
The unit offers low-vibration action
for close edge work. To impart a grained
finish on internal corners, it provides
file-type action that makes a brush effect in the same direction right up to the
weld or internal joint. The abrasive pads
and conditioning pieces use hook-andloop attachment for quick changeover.
Thermacut Inc., 800-932-8312,

www.thermacut.com
Suhner Industrial Products LLC,

706-235-8046, www.suhner.com
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USA_PWT_Practical_Welding_Today_177_8x123_952.indd 1
20.03.13 14:06
Product News
Chromium carbide materials
Kjellberg offers the Fidur line of products, which includes cladded standard
and special sheets, ready-to-install parts,
and flux-cored wires for surface welding.
Fidur 10/65, 10/65V, and 10/65W
are chromium carbide materials that
resist abrasive wear. Standard surfacewelded sheets can be supplied in sizes
up to 1,500 by 3,000 mm. The thin-
nest producible sheet has a base material

4 mm thick with a welded surface of 2
mm. On request, standard sheets can be
plasma-cut to size, deformed, welded,
and mechanically processed.
With robotic techniques, pipes, containers, and other construction elements
can be coated with the flux-cored wires,
and workpieces can be surface-welded
close to the final contour.
The companys coating service includes the regeneration of worn parts
such as grinding rolls and
grinding tables for coal and cement
mills. The manufacturer offers stationary gantries, mobile plants, and robotic
welding stations for surface welding.
Kjellberg, 49-3531-500-319,
www.kjellberg.de
Abrasives for welding, metal

fabrication
Norton Abrasives has updated its welding and metal fabrication market catalog. The 180-page literature reflects the
latest changes and additions to the companys Norton and Merit product lines.
New product and technology additions in the updated catalog include
a proprietary, next-generation zirconia
grain technology product portfolio for
BlueFire depressed-center wheels, portable cups, cutoff wheels, flap discs, fiber discs, belts, and quick-change cloth
discs. Patent-pending surface conditioning discs and belts for stripping (RapidStrip), blending (Rapid Blend), and
finishing (RapidPrep) have been added.
Norton Abrasives, 254-918-2313,
www.nortonindustrial.com
41
Product News
Reamer
Tregaskiss has introduced the

TOUGH GUN Reamer TT3
series. According to the company, the reamer helps extend the
life of robotic GMAW guns and
consumables.
The unit features a new
sprayer reservoir location on
the opposite side of the unit
(compared to previous models)
to safeguard against overfilling
and leakage onto internal electronics. An electronic check valve has been eliminated,
reducing the number of parts to be maintained in the
system. New plug-and-play internal replacement parts
feature smart-keyed connections to simplify assembly
and provide quick in-cell troubleshooting.
The reamer also includes simplified internal wiring
by way of a centralized terminal strip, and the AntiSpatter Sprayer comes standard with the new model.
Features include internally mounted pneumatic valves
and protected external setup switches, as well as seals
on all points of entry to the reamer.
Tregaskiss, 877-737-3111, www.tregaskiss.com
Micro resistance welding power supplies
MacGregor Welding Systems

has introduced its Smart line of
touch-panel DC resistance spot
welding power supplies. Combining PC-based technology
with real-time control, the power
supplies allow users to distribute
and update weld schedule-related quality control work instructions and visual checking methods to the shop floor.
The units provide stand-alone, self-contained,
closed-loop weld capability directly linked to weld
validation media in a single unit platform. The DC
power supplies combine SPC, monitoring, and graphing capabilities with the flexibility, connectivity, and
ease of use offered by multimedia formats and devices
such as cameras, keyboards, and USB data sticks, the
company reports.
A high-resolution, 7-in. color touch-panel interface presents the setup and monitoring information in
various languages and graphical formats.
MacGregor Welding Systems, 44-1638-510011,
www.macgregorsystems.com
Product News
Oxyfuel torch
Arc process monitoring system
Spark-Robo is a new arc process viewing and monitoring system produced

by Servo-Robot. It includes dual digital
color video technology for weld pool
and global process area viewing and
control combined with laser vision.
This system is applicable to arc pro-
Victor, a Victor Technologies brand,

has launched its new 400 series oxyfuel
torch in medium- and heavy-duty models. It also is sold as part of the Medalist
250 and Medalist 350 outfits. Outfits
include the torch handle, cutting attachment, welding tip, G series regulators,
and hoses.
The two-piece torch incorporates a
patented, contoured handle with a size
and shape to fit naturally in most operators hands. Employing an engineered
zinc-aluminum alloy called Zamak, the
handle resists deformation. It is lighter
than brass, yet it balances naturally when
hoses and attachments are connected.
Oxygen and fuel valves are colorcoded and labeled for identification
and to indicate directions for open and
closed valve positions.
The cutting attachment employs a
three-tube design (fuel gas, preheat oxygen, and cutting oxygen) to improve
cutting area visibility and support gas
flow rate requirements for tip sizes 000
through 6. The universal mixer design
mixes the gases in the head of the torch.
Operators can use one torch for all fuels
by selecting the correct tips and attachments.
When used as part of the Medalist
250 and 350 outfits, the torch includes
the new G series regulator. A combination of colors on the gauge face provide
clarity for reading needle position, while
a scale and red tick mark indicate the
regulators actual service pressure. Color-coded knobs indicate gas type.
Victor Technologies, 636-728-3000,
www.victortechnologies.com
cesses that require precise remote control of weld pool conditions, joint root
penetration, and weld wire positioning
to prevent fusion defects and ensure
very high quality on critical welds.
Servo-Robot Inc., 450-653-7868,
www.servorobot.com
929
After $ 100 Rebate
Come on, you know you want it.

When youre ready to start, were ready to help.
Whether youve been putting off purchasing your first welder or youre looking
to upgrade, theres never been a better time than now. The Power MIG 180 Dual
comes complete and ready to go with the clamp, cables, hose, regulator and
accessories you need to get started. We even throw in a couple spools of welding
wire. With Money Matters, you get to choose your reward a cash rebate,
a Traditional Welding Gear Ready-Pak or a 2-year Extended Warranty!
Visit www.lincolnelectric.com/moneymatters today to get info on all eligible
products and to find your local Money Matters distributor today!
*Traditional Welding Gear Ready-Pak Includes: Industrial Duffle Bag, VIkInG 1840 Series Auto-Darkening Helmet Black, FR Doo
Rag, Traditional FR Cloth Jacket, Full Leather Steel Worker Gloves, Traditional MIG/Stick Welding Gloves, Lincoln Starlite Clear
Safety Glasses, over $250 value. 2-Year Extended Warranty, over $80 value. Extended Warranty not available on
Torchmate product. Valid July 1, 2013 through March 31, 2014.
AR13-57 The Lincoln Electric Co. All Rights Reserved.
PRACTICAL WELDING TODAY 43
New Product
Special Advertising Section
3M www.3M.com/speedglas
Welding helmet that helps provide both head & respiratory protection
The new Speedglas Welding Helmet 9100 MP from 3M meets the
need for head and respiratory protection for weldersparticularly in
heavy industries such as mining, shipbuilding, marine repair, heavy
construction, offshore operations (oil, gas, and wind farm), and
heavy-duty maintenance welding.
Comfortable, well-balanced, and intuitive to don, adjust, and
maintain, the Speedglas welding helmet 9100 MP offers a premium
welding protection system for highly demanding environments.
The demand of head protection for welders has been a difficult
issue; until now, the options were limited. At our field trials, which
included mines, shipyards, construction and other heavy industries
worldwide, the comments from the welders included comfortable,
balanced, great vision and easy to use, says Staffan Johansson,
Global Marketing Manager for 3M OH&ES Welding Safety.
The Speedglas welding helmet 9100 MP may be used with the Adflo
Powered Air Purifying Respirator (PAPR) or the Speedglas Fresh-air III Supplied Air Regulator System from 3M. When used in an approved configuration, the Speedglas welding helmet 9100 MP has an Occupational Safety
and Health Administration (OSHA) assigned protection factor (APF) of 25.
The Adflo PAPR comes with a high efficiency (HE) filter for welding particles
with an optional organic vapor/acid gas (OV/AG) cartridge for removing
nuisance odors generated from some welding processes.
The key to the Speedglas welding helmet 9100 MP is its well-balanced,
low center of gravity, even when the welding helmet and the visor are in the
raised position. The welding helmets hard hat is made from heat resistant
polycarbonate. An optional aluminum fabric cover helps reflect radiant heat
from welding. In addition, the optional flame-resistant shroud can offer neck
and shoulder protection.
The Speedglas welding helmet 9100 MP comes with a wide (approx.
8in x 4.25in), curved, protective visor, with excellent vision up, down, and
peripherally. Passive shade 5 SideWindows add extra peripheral vision or
can be easily covered with reusable cover plates (provided). The protective
visor meets the requirements of the high mass impact test in accordance
with ANSI Z87.1-2010 standard. The Speedglas welding helmet 9100 MP is
100% compatible with all of the latest Speedglas Auto-Darkening Filter Series 9100 (ADFs) from 3M, including the 9100XX filter with an approximate
2.8 in x 4.2 in viewing area. The Speedglas welding helmet 9100 MP meets
the hard hat requirements of ANSI Z89.1-2009 standard for Type 1 Class G hard hats. Visit www.3m.com/9100MP for
more information.
About 3M Welding Safety

At US$29 billion in annual sales and 84,000+ employees worldwide, 3M is one of the largest innovation-driven companies in the world. 3Ms safety brands include: AOSafety Apparatus; Peltor Face, Head & Hearing Protection and
Industrial Communication Headsets; E-A-R Hearing Protection; SafeWaze Fall Protection Equipment; and Speedglas
Welding Equipment. Visit www.3M.com/speedglas for additional information on personal protective equipment for
welders, including welding and hardhats, powered and supplied air respirators, auto-darkening welding filters (lenses),
grinding visors, hearing protection, and related welding accessories.
3M, Speedglas, Adflo, AOSafety, E-A-R, and SafeWaze are trademarks of 3M, used under license in Canada. Peltor is
a trademark of 3M Svenska AB, used under license in Canada.
New Product
Arcos www.arcos.com
ARCOS INTRODUCES NICKEL ELECTRODE FOR CORROSION-RESISTANT WELDS
Arcos Industries, LLC has developed a
premium nickelchromium-iron electrode for the welding of alloy 690 in
nuclear reactor and steam generator components. Arcos 352 provides
corrosion-resistant welds on a broad
range of low alloy and stainless steels
in applications requiring resistance to
oxidizing acids.
Arcos 352 bare wire and covered
electrodes deliver the higher chromium levels needed for stress-corrosion
cracking resistance. These wires are
specifically designed for welding in
the critical pure water environments of
nuclear power generation plants. They
also weld NiCrFe alloys ASTM B163,
B166, B167 and B168 to themselves
and to dissimilar joint configurations.
Arcos 352 has earned ASME Nuclear
Certificate #QSC448.
Arcos 352 bare wire electrodes are
available in diameters from .035"
3/16", the covered electrodes from
3/32"3/16".
Arcos manufactures a comprehensive line of superior quality bare, covered and tubular welding electrode products
including high alloy, stainless steel and nickel alloy electrodes.
For more information on Arcos 352 or the companys other welding wires, contact Arcos at 800-233-8460 or visit
our website at www.arcos.us.
45
New Product
Camfil Air Pollution Control

www.farrapc.com/welding
Updated Gold Series Dust & Fume Collector Features Many Enhancements
Clean air is critically important to ensure worker safety
in welding applications. A well-designed and maintained
dust and fume collection system can prevent respiratory
problems and keep facilities in compliance with air quality
requirements. Also, robotic welding equipment and other
computerized systems are more sensitive than machinery
of 10 or 20 years ago. If dust is not collected properly
from welding stations, a million-dollar investment can be
ruined in no time.
Camfil APC has made major updates to its popular line
of Farr Gold Series cartridge dust and fume collectors
for welding applications. Weve made these changes to
uphold our mission statementto supply the best dust
collector from an end-user and maintenance standpoint,
says company president Lee Morgan. Combining rugged
modular construction with high performance and ease of
service, the collectors come with a 12-year warranty and
are guaranteed to meet applicable emission standards.
Features of the new-generation dust collector include:
A reinforced door has double-thick hinges, easier-tooperate hardware and a single flat inside panel to create a
smooth, air-tight gasketed seal.
A taller inlet collar accommodates larger fans with
adequate clearance, and fans are equipped with a damper
actuator handle that allows the user to see from ground
level whether the damper is open or closed.
Inside the collector, gaskets have been moved to the
edges of the pan so that no dust builds up on top of the
vertically-mounted filters during operation.
For enhanced aesthetics, the collector now has gold
valves and hardware and a Built Like a Safe logo featured prominently on each housing module.
An expanded list of accessories and options is available, many of which are also updated. These include redesigned long-life filter cartridges with new media choices, a wider selection of hopper configurations, new touch
screen controls for energy savings and enhanced filter
cleaning, integrated or remote safety monitoring filters,
New-generation Farr Gold Series dust and fume collector

a high performance spark diverter inlet, and a new diaphragm silencer that reduces the noise level by 8 decibels.
A wide selection of explosion protection devices are
also offered for inlet and outlet explosion protection and
explosion venting.
Camfil APC
Web: www.farrapc.com/welding
Email: filterman@farrapc.com
Phone: 800-479-6801 or 870-933-8048
New Product
ESAB Welding & Cutting www.esabna.com

WARRIOR - A BREAKTHROUGH WELDING MACHINE
Warrior by ESAB is the breakthrough welding machine designed with input
from real-world-welders to be reliable, rugged, energy efficient and easy to
use.
Built with ESABs leading-edge engineering, Warrior is a multi-process machine designed for GMAW (MIG), FCAW (Flux-Cored), SMAW (Stick), and
GTAW (TIG) welding, as well as ACAG (Arc Gouging).
This high productivity machine delivers up to 500 amps at 60% duty
cycle. It welds .030" 5/64" flux-cored and solid wires, has a full range of
SMAW (Stick) capabilities with outstanding 7018 and 6010 performance,
and carbon arc gouges with electrodes up to 3/8 diameter.
RUGGED, RELIABLE, EASY TO USE

Warrior provides superior starts and an extremely smooth and stable arc
transfer with excellent weld finishes.
State-of-the-art inverter technology delivers energy savings and exceptional functionality right from the start, and
for less than the cost of an old technology SCR machine.
Timesaving productivity features include an all-in-one intuitive front control
panel, read-anywhere display, and comprehensive cable connection.
Warriors durable external body withstands the elements. Its IP23 rating is designed to endure harsh outdoor environments. Ergonomically designed handles
are built to withstand mechanical hoisting, and double bend 14 gauge galvanized steel side panels protect against collisions and drops. It is also generator
compatible, making it perfect for remote job sites.
In addition to the power source, the Warrior Feed 304 is a rugged, userfriendly wire feeder. It features a high-torque 4-roll drive for superior feed even
with long GMAW (MIG) guns and better feedability than a 2-roll drive. The
feeder includes all the controls required for the job, including remote voltage,
gas purge, inch wire, and wire feed speed (WFS), trigger lock, and slow run-in.
Warrior delivers consistent, reliable performance for a wide range of applications in unlimited industries from ship building, rail cars and maintenance, to
energy generation, construction, pipeline, and general welding fabrication.
Warrior is backed by a 3-year warranty and ESABs industry-leading service
and support. Learn more at www.esabna.com/warrior.
GEAR UP FOR BATTLE

Now theres more reason to choose the all-new multi-process Warrior with ESABs Gear Up For Battle promotion. For a limited time, purchase any Warrior
ready-to-weld package and receive your choice of a $500 manufacturer rebate
or a $1,000 ESAB shopping spree. For details, visit www.esabna.com/gearup.
ESAB Welding & Cutting Products is a recognized leader in the welding and
cutting industry. From time-honored processes in welding and cutting to revolutionary technologies in mechanized cutting and automation, ESABs welding
consumables, equipment, and accessories bring solutions to customers around
the globe. For more information, visit www.esabna.com or call 1-800-ESAB123.
47
New Product
Pferd Inc. www.pferd.com

CC-GRIND-SOLID
The Next Generation of Grinding Wheels by PFERD
PFERD presents the tough new CC-GRIND-SOLID for rough grinding
applications. PFERD advances the innovative CC-GRIND by integrating
a fibreglass backer and a high-performance coated abrasive. Available
with a patented cooling and mounting system, or with quick-change
5/8-11 threaded hub. With it, PFERD is presenting the new generation of reinforced grinding wheels!
The innovative high-strength layer structure of the fibreglass backer guarantees the same tough and safe use as with a reinforced grinding wheel. CC-GRIND-SOLID fulfills all the safety requirements of a
reinforced grinding wheel according to DIN EN 12413 and ANSI B7.1
standards, particularly the lateral load test.
CC-GRIND-SOLID is a new grinding disc offering a large surface contact area. The quick-change hub version, and the
un-hubbed version combined with custom flange set, allow flat grinding.
CC-GRIND-SOLID is ideal for the following processing tasks:
Surface grinding
Weld removal
Chamfering
Deburring/edge grinding
User benefits:
Innovative high-strength disc design for especially

ergonomic, safe work.
CC-GRIND-SOLID grinding discs excel on rough
grinding applications.
CC-GRIND-SOLID may also be purchased with
5/8-11 threaded quick-change hub.
Very good cooling of tool and workpiece through
patented cooling system.
Unique mounting system allows for fast and easy disc
change.
Ergonomic grinding instead of just rough grinding

Noise, vibration and dust considerably reduced
The new CC-GRIND-SOLID grinding discs from PFERD produce significantly less noise, vibration and dust than conventional reinforced grinding wheels.
PFERDERGONOMICS recommends the CC-GRIND-SOLID grinding disc as an innovative tool solution for all rough
grinding applications.
For more information about CC-GRIND-SOLID please visit us

@ pferdusa.com or call customer service @ 800-342-9015.
New Product
Select - Arc www.select-arc.com

NEW SELECT-ARC METAL CORED ELECTRODE DESIGNED
FOR OIL FIELD APPLICATIONS
Select-Arc, Inc. has introduced a metal cored, nickelbased, low alloy steel electrode that is manufactured
to match the properties of certain quench and tempered steels following post-weld heat treatment.
Select 4130C is a nickel-chromium-molybdenum bearing wire that provides these weld metal properties.
This electrode contains less than 1% nickel in the weld
deposit and delivers smooth arc transfer with minimal
spatter.
Select 4130C is designed to weld 4130, 4140, 8630
and similar alloy steels that are to be post-weld heat
treated. The low nickel deposit makes this product well
suited for most oil field applications.
This premium electrode is available in .045" and 1/16"
diameters.
Select-Arc, Inc. manufactures a comprehensive line
of flux cored and metal cored carbon steel, low alloy,
stainless steel, nickel alloy and hardsurfacing welding
electrode products.
For more information on Select 4130C as well as the
entire range of exceptional Select-Arc electrode products, contact Select-Arc at 1-800-341-5215 or visit our
website at www.select-arc.com.
49
New Product
Weiler www.weilercorp.com
GET THE EDGE - with Weilers New Tiger Paw Flap Discs
Have you seen them yet? Now you can GET THE
EDGE with Weilers new Tiger Paw abrasive flap
discs! Tiger Paws are designed for aggressive performance on tough EDGE grinding applications.
These 100% zirconium flap discs last 30-40% longer than competitive standard zirconium flap discs
due to both a high performance grain and special
poly cotton backing that provides superior grain retention. This unique combination gets the job done
faster and more efficiently.
The Tiger Paws multiple layers of coated abrasive
material expose sharp, fresh grains as they slowly
wear away, and the 100% premium zirconium grain
prevents premature grain shedding on aggressive
applications, resulting in increased productivity and
reduced operating costs.
Weilers phenolic back Tiger Paw is available in
4-1/2", 5 and 7" sizes with or without a 5/8"-11
nut in both Type 29 & 27 standard and Type 27 super high density (4-1/2" & 7" Only) configurations.
The Type 29 configuration is made for the toughest,
most aggressive applications. The super high density Type 27 configuration contains 35-40% more
flaps for increased flexibility, extended life and lower operator fatigue. Popular uses for the Tiger Paw include pipe beveling, EDGE chamfering, weld blending, grinding,
deburring, stock removal, surface finishing and blending.
An informational video featuring the new Tiger Paw is available
as well. The video demonstrates how you can GET THE EDGE with
Tiger Paw and illustrates Tiger Paws superior grinding ability vs.
competition.
Weilers Tiger Paw video is available on Weilers website (www.
weilercorp.com), on YouTube or by contacting Weilers Customer Service Department: 800-835-9999.
For additional information on Tiger Paw flap discs or any Weiler
product, please contact: Weiler Corporation, One Weiler Drive, Cresco,
Pennsylvania 18326-0149 Toll free (888) 600-5857 FAX: 570-5952002.
New Product
Bluco www.bluco.com
How To Reduce Material Handling Time In Your Tack Welding Operations
Most fabricators experience a common problem with the amount of

time it takes to move parts through
their tack welding stations: material
handling time to reposition parts for
welding on both sides. As the parts
get heavier, this problem can get
worse as welders wait in line for crane
availability.
There are several options for modifying the welding fixture itself to help
alleviate this bottleneck. For simple
parts, simply raising the material "

off the welding table surface can provide enough space for the welder to
complete tacks on both sides of corners and other joints. Or setting up
the fixture to allow corners to hang
out in space away from the table provides 360 degree access for tacking.
With traditional welding tooling,
these simple fixture adjustments can
take more time than just flipping the
part over. Without a better option to
save time, fabricators continue with
their current methods.
A high precision modular welding system from Bluco Corporation
provides the solution that companies
need. Standard components are designed to work together and be interchangeable, including the height
of the components. Adding the "
height increase is easily achieved using any number of standard compo-
nents, so the fabricator can achieve a

significant time savings compared to
flipping the parts over.
For more complex parts, Bluco
has introduced a line of manual rollover positioners to complement its
existing modular fixturing system for
welding. With 360 degrees of rotation, the welder has full access to all
sides of the part. And because the rotation is clocked in 22.5 degree increments (custom increments available),
the part can always be located at the
ideal weld position of each joint.
There are several styles and
lengths of positioners available to
suit your application. Contact a Bluco
sales engineer to discuss your application and get a free design proposal.
Industrial Press www.industrialpress.com

THE ART OF WELDING
With Contributions by Ryan Friedlinghaus of West Coast Customs
By Ryan Friedlinghaus and William Galvery August 2013, 250 pages, illustrated, ISBN 978-0-8311-3475-4, $24.95
Ryan Friedlinghaus, the celebrated
guru of automotive customization
and host of West Coast Customs adds
practical knowledge to William Galverys acclaimed welding insight and
everyday tips and tricks developed
over his long professional career as
an educator.
This unique and original book
improves upon the shortcomings of
competitive titles by providing complete, in-depth coverage of the equipment and techniques used in the most
popular welding processes: oxyacetylene, stick welding,
MIG welding and TIG welding. Whats more, it presents
information in a lively, easy-to-follow design. Each chapter
contains the pros and cons of each process and information on equipment, setup, materials, safety and welding
techniques.
To provide a solid footing for the novice welder, there is
a chapter that provides an overview of welding and another on tools and materials. The bulk of the book is devoted
to the more popular welding techniques. The authors also
provide a chapter on soldering and brazing and another

on plasma cutting. The Art of Welding is perfect for anyone who wants to learn welding, to make repairs or as part
of a hobby. Even experienced welders will discover many
tips and procedures to improve their welding technique.
Table of Contents
An Overview of Welding. General Tools and Materials,
Safety Equipment. Oxyacetylene Welding. Shielded Metal
Arc Welding, Stick Welding, Arc Welding. Wire-Feed Welding Processes, MIG Welding and FCAW. Gas Tungsten Arc
Welding, TIG Welding. Thermal Cutting, Oxy-fuel and
Plasma Arc Cutting. Brazing and Soldering. Welding Tasks
and Tips.
To order, contact:
Industrial Press
32 Haviland Street, Unit 2C,
South Norwalk, CT 06854
212-889-6330 Fax: 212-545-8327
Toll-Free in the U.S.: 888-528-7852
Web: www.industrialpress.com
email: info@industrialpress.com
51
New Product
Lincoln Electric www.LincolnElectric.com

Burny Kaliburn Spirit II
The new Spirit II

Series plasma system from Burny
Kaliburn, a Lincoln
Electric
company,
features FineLine
high definition plasma cutting technology that delivers
excellent cut quality
over the entire consumable life at lower
costs. The system
does this by achieving the least part taper over the life of
an electrode. When paired with Burny Kaliburns proprietary UltraSharp Hole technology, the system also delivers exceptional hole quality.
This family of Spirit II plasma cutting and marking
systems features three amperage options: The 150-amp
Spirit II 150 has the ability to pierce most metals up to
1 inch (25 millimeters) thick, with a maximum capacity
of 1.5 inches (38 millimeters). The 275-amp Spirit II 275

can pierce most metals up to 1.25 inches (32 millimeters)
thick and has a maximum capacity of 2.5 inches (65 millimeters). The 400-amp Spirit II 400 is able to pierce most
metals up to 2 inches (50 millimeters) thick, with a maximum capacity of 3 inches (75 millimeters).
All Spirit II models deliver precise, square, dross-free
cuts with 2 or less cut-edge bevel, using up to 78 percent
less plasma gas than the competition. Operating costs are
also controlled by using the same consumables to cut and
mark.
For more information on the Spirit II Plasma Cutting
System, call (888) 355-3213 or visit www.lincolnelectric.
com to obtain Bulletins E15.14, E15.15 and E15.16.
Lincoln Electric
22801 St. Clair Ave.
Cleveland, OH 44117
1-888-355-3213
Wayne Trail www.waynetrail.com

Robotics, Welding, and Fixturing
Advanced robotic automation solutions are being used
in many industries to improve quality and increase productivitywhile reducing cost. Material handling, weld
processing, fixturing, inspection, and racking of finished
parts can be combined into a fully integrated system.
Wayne Trail is a supplier of such advanced robotic systems and tooling packages. These solutions can be fully
or semi-automated for MIG, TIG, or spot welding; material handling; machine tending; palletizing; and dispensing. In addition, these solutions can contain advanced
tooling and fixturing designs along with sophisticated
vision-based systems.
For those manufacturers working under tight deadlines, Wayne Trail utilizes 3-D design and simulation software to validate overall system concept, robot reach, and
cycle time projections. This enables off-line programming
of robots, which can reduce the time required for system
de-bug and completionresulting in quicker delivery to
customers.
Whether your plan is to use new or re-deployed robots, Wayne Trail can integrate the design, supply new
fixturing solutions, and bring your project to a successful
conclusionsafely, efficiently, and affordably.
Wayne Trail utilizes 3D design and simulation software to validate

overall system concept, robot reach and cycle time projections. This
enables off-line programming of robots, which can reduce the time
required for system de-bug and completionresulting in quicker
delivery to our customers.
Classified Advertising
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For classified advertising sales in

2013, contact:
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Ph: 815-227-8278 Fax: 815-484-7753
E-mail: patriciad@thefabricator.com
Advertisers Index
Please visit our advertisers showrooms by entering
their reader service codes at www.ffid.net
RS
Code
483328
131641
103579
PAGE
727-299-0888
855986
230031
138119
186451
179241
Bluco . . . . . . . . . . . . . . . . . . . .13,51
Camfil Air Pollution Control . . 3,46
108189
560657
www.fabtechexpo.com
887522
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CERBACO. . . . . . . . . . . . . . . . . . 10
RS
Code
FABTECH . . . . . . . . . . . . . . . . . 25
www.bluco.com
461901
keithmcclean@cerbaco.com
108173
Frster Welding Systems . . . . . 39
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G A L Gage . . . . . . . . . . . . . . . . . 41
www.galgage.com
Heck Industries . . . . . . . . . . . . . 10
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Hougen Mfg. . . . . . . . . . . . . . . . . 38
853049
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Cor - Met . . . . . . . . . . . . . . . . . . . . .9
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Hypertherm. . . . . . . . . . . . . . . . . 38
270093
CS Unitec . . . . . . . . . . . . . . . . . . . .9
1712945 IGM Robotersysteme . . . . . . . . 32
452273
Industrial Press . . . . . . . . . . .21,51
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Diamond Ground Products . . . 12
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1140904 Easy Abrasives. . . . . . . . . . . . . . 29

www.easyabrasives.com
128605
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American Torch Tip . . . . . . . . . . 11
www.americantorchtip.com
Arcos Industries. . . . . . . . . . .45,55
PAGE
Fabricators & Manufacturers
Assn., International . . . . . . .40,42
3M. . . . . . . . . . . . . . . . . . . . . . . . 7,44
www.speedglas.com
2091349 Astaras . . . . . . . . . . . . . . . . . . . . 24
200844
RS
Code
ESAB Welding & Cutting . . . 47,56
www.esab.com
Publications Mail Agreement No. 12345678 (41467014)

RETURN UNDELIVERABLE CANADIAN
ADDRESSES TO:
PITNEY BOWES INTL MAIL SVCS
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Scrape-N-Burr . . . . . . . . . . . . . 36
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Lincoln Electric. . . . . . . . . . . .43,52
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Meltric . . . . . . . . . . . . . . . . . . . . . 36
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Osborn. . . . . . . . . . . . . . . . . . . . . 14
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Oxylance . . . . . . . . . . . . . . . . . . . 54
www.oxylance.com
PFERD . . . . . . . . . . . . . . . . . . .33,48
800-342-9015
Saar Hartmetall USA . . . . . . . . . .8
www.shmusa.com
Select - Arc . . . . . . . . . . . . . . . . 2,49
1-800-341-5215
Strong Hand Tools. . . . . . . . . . . 36
www.stronghandtools.com
Trafimet USA . . . . . . . . . . . . . . . .37
www.trafimetusa.com
Wayne Trail - A Lincoln Electric

Company. . . . . . . . . . . . . . . .15,52
www.waynetrail.com
Weiler . . . . . . . . . . . . . . . . . . . .35,50
www.weilercorp.com
Practical Welding Today (ISSN 1092-3942) is published bimonthly by FMA Communications Inc., 833 Featherstone
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53
Arc Welding 101 | Paul Cameron
Finding clues in the commentary

The company that I work for makes
a single-pass circumferential weld
on which there is a minor tendency
for an open pore in the weld crater
at the tie-in. Our engineering department deems this weld discontinuity
as a cosmetic issue only and thereby
has authorized the use of a sealant.
In the 2010 version of the AWS
D1.1 code, the Commentary paragraph C-5.28 states that if all inspections of weld and base metal
have been completed and accepted
prior to application, a nonmetallic
filler or mastic may be used for cosmetic reasons.

Is our application consistent with
the intent of this paragraph in the
Commentary, or is it referring to
something different?
Anonymous
I cant tell you how good it makes me

feel that you would explore the Commentary to learn more about the codes
intent. Thats what the Commentaries
are there for.
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Your interpretation on the use of fillers in this situation is correct. If your engineers have deemed this discontinuity
to be acceptable, then the use of fillers is
a good way to enhance the look of this
surface. And, yes, you are still within the
guidelines of AWS D1.1.
I implemented this same repair recently for a local manufacturer. Their
old way of doing business was to take a
GMAW gun to these pinholes and zap
weld into them. This version of the repair turned a perfectly acceptable discontinuity into an arc strikea big nono in the wonderful world of welding.
There is risk with this practice. The
last thing you want to do is to use that
same filler on unacceptable defects. Using fillers to mask unacceptable undercut, overlap, or porosity (pinholes)
would be disastrous. So be sure to monitor this practice closely.
Im glad you opted for the Bondo
over the arc strike, and Im glad you
turned to the Commentary to understand the codes intent.
Paul W. Cameron, CWI, is quality control
manager for Thomas & Betts, Hager City,
Wis., 507-269-7142 or weldinspector@
charter.net. He also is a member of Practical
Welding Todays Editorial Review Committee.
Do you have a welding

question for Paul?
SURE CUT
EXOTHERMIC SYSTEM
[205] 322.9906 | oxylance.com | info@oxylance.com

Fax: 815-484-7788
The Electrode That Takes the

Stress Out of Stress-Corrosion
Resistant Welding
Arcos 352
Arcos Industries, LLC has

developed a premium nickelchromium-iron electrode for the welding of alloy 690 in
nuclear reactor and steam generator components. This
wire provides corrosion-resistant welds on a broad range
of low alloy and stainless steels in applications requiring
resistance to oxidizing acids.
Arcos 352 bare wire electrodes

are available in diameters from
.035" 3/16", the covered electrodes from 3/32" 3/16".
Arcos 352 bare wire and covered electrodes:

Deliver the higher chromium levels needed for
stress-corrosion cracking resistance.
Are specically designed for welding in the
critical pure water environments of nuclear
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Weld NiCrFe alloys ASTM B163, B166, B167
and B168 to themselves and to dissimilar
joint congurations.
Have earned ASME Nuclear Certicate # QSC448
Arcos Industries, LLC

394 Arcos Drive Mt. Carmel, PA 17851
Phone: (570) 339-5200 Fax: (570) 339-5206
Discover for yourself the vital advantages afforded

by specifying Arcos 352. Contact Arcos today at
800-233-8460 or visit our website at www.arcos.us.
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And with an offer like this, now is the time to get it.
Contact your ESAB sales rep or distributor or visit
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this offer wont be around as long as your Warrior will.
ESAB Welding & Cutting Products / esabna.com / 1.800.ESAB.123

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July/August 2013

THE REAL WORLD FOR WELDING PROFESSIONALS

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Editors Corner | Amanda Carlson

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(continued from page 8)

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