Table of Contents

Technical Sessions

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Session 1: Aluminum Welding

Chair: Carl Cross, Montana Technical University

A.10:00 a.m.Variable Polarity Arc Welding Studies on 6061/A1203/10w

by T. Lienert, Los Alamos National Laboratory

B.10:35 a.m.Aluminum Flux Cored Wire Development

by G. J. Atkins and D. L. Olson, Colorado School of Mines

C.11:10 a.m.Electrical Resistance Hot Upset Welding of Aluminum Alloy 5454

by Frank Feng, Alcan International Limited

Session 2: Forensics and Weld Performance

Chair: Stephen Liu, Colorado School of Mines

A.10:00 a.m.Forensic Study of the Steel in the World Trade Center

by T. Siewert, F. Gayle, R. Fields, D. McColskey and C. McCowan, National Institute of Standards and Technology

B.10:35 a.m.Fitness-for-Service Evaluation of Bulkheads

by C. Tsai, The Ohio State University; G. Jung, Edison Welding Institute; and P. W. Sauser, U. S. Army Corps of Engineers

C.11:10 a.m.A Thermal Method to Reduce Buckling Distortion

by Randall Dull, Edison Welding Institute

D.11:45 a.m.Weld Repair of the U. S. Capital Dome

by T. Siewert, C. McCowan, NIST; K. Hildebrand, AoC; R. Bushey, ESAB Welding & Cutting Products; and D. Kotecki, The Lincoln Electric Co

Session 3: GMAW Ferrous 1

Chair: Dennis Harwig, Edison Welding Institute

Co-Chair: U.D. Mallya, IIT, Bombay, India

A.10:00 a.m.In Situ Weld Pool Measurement Using Stereovision

by C. Debrunner, T. Vincent, J. P. Steele, and F. Al-Baiya, Colorado School of Mines

B.10:35 a.m.Characterizing Adaptive Arc Length Control Methods for Pulsed Gas Metal Arc Welding

by B. Baughman and D. Harwig, Edison Welding Institute; and R. Richardson, The Ohio State University

C.11:10 a.m.Influence of Procedure Variables on C-Mn-Ni-Mo Metal Cored Wire Ferritic All-Weld Metal

by M. R. de Rissone, Facultad Regional San Nicolas; H. Svoboda, Facultad de Ingenieria UBA; E. S. Surian, Universidad Nacional de Lomas de Zamora; and L. de Vedia, UNSAM, CIC, Argentina

Session 4: FCAW/SMAW

Chair: Marie Quintana, The Lincoln Electric Company

A.2:00 p.m.Hydrogen Reduction in FCAW Steel Weld: Metal Spectroscopic Monitoring of Arc During Deposition

by J. Chandler, C. Clasper, S. Liu and G. Edwards, Colorado School of Mines

B.2:35 p.m.Fluoride and Yttrium Additions in Steel Welds: Effects on Hydrogen and Weld Metal Properties

by C. Clasper, J. Chandeler, G. Edwards and S. Liu, Colorado School of Mines

C.3:10 p.m.Characterization of Microconstituents in Welds Using FCAW-S Consumables

by J. Major and S. Liu, Colorado School of Mines; and M. Quintana, C. Dallam, The Lincoln Electric Co

D.3:45 p.m.Modeling of Fe-C-Al-Mn Steel Weld Microstructure

by S. S. Babu, S. A. David and J. M. Vitek, Oak Ridge National Laboratory; J. W. Elmer, Lawrence Livermore National Laboratory; and M. Quintana, The Lincoln Electric Co

E.4:20 p.m.Optimization of SMA Weld Metal Composition

by M. Marimuthu, S. S. Babu and S. A. David, Oak Ridge National Laboratory

Session 5: GMAW Ferrous 2

Chair: Zhili Feng, Oak Ridge National Laboratory

A.2:00 p.m.Heat Transfer Fluid Flow and Solidified Surface Profile During Gas Metal Arc Fillet Welding

by W. Zhang, C. H. Kim and T. DebRoy, Pennsylvania State University

B.2:35 p.m.Determination of Unknown Welding Parameters for GMA Fillet Welding Using a Smart Model

by A. Kumar and T. DebRoy, Pennsylvania State University

C.3:10 p.m.The Humping Phenomenon in High Speed GMA Welds

by T. C. Nguyen, D. C. Weckman, D. A. Johnson and H. W. Kerr, University of Waterloo

D.3:45 p.m.Robotic Out-of-Position GMAW Welding Downhill: A Study of Performance and Parameters

by J. P. Steele, T. Vincent and C. Debrunner, Colorado School of Mines

Session 6: Materials

Chair: Suresh S. Babu, Oak Ridge National Laboratory

A.2:00 p.m.Stray Grain Formation During Welding of Single Crystals

by J. M. Vitek, S. S. Babu, S. A. David, J. W. Park, Oak Ridge National Laboratory

B.2:35 p.m.Deformation Strains in Single Crystal Alloy Welds

by O. M. Barabash, J. A. Horton, Jr., S. S. Babu, R. I. Barabash and S. A. David, Oak Ridge National Laboratory

C.3:10 p.m.Topological Features of Grains in the HAZ

by S. Mishra and T. DebRoy, Pennsylvania State University

D.3:45 p.m.Direct Metal Deposition of Copper onto Steel Using a Nickel Interlayer

by F. F. Noecker II and J. N. DuPont, Lehigh University

E.4:20 p.m.Fluxless Plasma Soldering of Lead-Free Solders

by J. P. Jung and Y. N. Zhou, University of Waterloo; J. K. Moon, LG Electronics Institute; and K. I. Kang and J. S. Lee, University of Seoul

F.4:55 p.m.The Microstructure Characterization of Synchronous Vibratory Welding

by C. W. Kuo and W. Wu, National Chung Hsing University

Session 7: GMAW Non-Ferrous

Chair: Brian Damkroger, Sandia National Laboratories

A.9:00 a.m.Distortion Control in Welding Aluminum GIS Vessel

by C. Tsai, The Ohio State University; and D. S. Chou, IWTRL; and S. S. Lin, Chung-Hsing E&M Ltd.; and G. Jung, Edison Welding Institute

B.9:35 a.m.Fundamental Studies on the Relationship Between Plastic Strains and Distortion in Fillet Welded T-Joints

by G. Jung, Edison Welding Institute; and C. Tsai, The Ohio State University

C.10:10 a.m.Liquation, Cracking and Backfilling in Partial-Penetration Welds of Aluminum Alloys Comparing Alloys 2024, 6061 and 7075

by S. Kou, C. Huang and G. Cao, University of Wisconsin

D.10:45 a.m.The Effect of Flux Ingredients on Flux-Cored Arc Welding of Titanium

by G. M. Chirieleison, S. Liu, Colorado School of Mines; and M. Wells, Naval Surface Warfare Center; and S. Luckowski, US Army ARDEC

E.11:20 a.m.Contact Models of GMAW Wire Liner Friction: An Inverse Photoelastic Solution

by T. Padilla, J. R. Berger and D. R. Munoz, Colorado School of Mines; and T. P. Quinn, NIST; and R. A. L. Rorrer, University of Colorado

Session 8: Laser Beam Welding I

Chair: Pat Hochanadel, Los Alamos National Laboratories

A.9:00 a.m.A Novel Approach to Laser Weld-Bonding Al Autos

by R. W. Messler, Jr., E. A. Johnson and J. Y. Levene, Rensselaer Polytechnic Institute; and L. Chen, University of Rochester; and S. Bohnenstiehl, Montana Technical University. (Paper Withdrawn)

B.9:35 a.m.Effect of Temporal Pulse Shaping on Cracking Susceptibility of AA 6061-T6 Aluminum Alloy

by J. Zhang, D. C. Weckman and Y. N. Zhou, University of Waterloo

C.10:10 a.m.Radial Alignment of Photonic Packages with Sequential Laser Spot Welds

by P. W. Fuerschbach, J. T. Norris and J. E. Bernal, Sandia National Laboratories

D.10:45 a.m.Analysis of Welding Induced Submicron Movements in Laser Micro-Welding of Optoelectronic Packages

by Z. Feng, Oak Ridge National Laboratory; and J. Lu, Luxtera, Inc

E.11:10 a.m.A Coupled Thermal and Microstructure Model for Laser Processing of Ti-6Al-4V

by S. M. Kelly, S. S. Babu, S. A. David and T. Zacharia, Oak Ridge National Laboratory; and S. L. Kampe, Virginia Tech

Session 9: Weldability

Chair: Wangen Lin, Edison Welding Institute

A.9:00 a.m.Repair Weldability of Heat-Resistant Alloys

by S. Shi, J. C. Lippold, The Ohio State University; and J. Ramirez, Edison Welding Institute

B.9:35 a.m.Development of a Modified Cast-Pin Tear Test

by D. Ryan and J. C. Lippold, The Ohio State University

C.10:10 a.m.The Effect of C, Nb and Ti Additions on Ductility-Dip Cracking in Austenitic Stainless Steels

by A. J. Ramirez, J. W. Sowards and J. C. Lippold, The Ohio State University

D.10:45 a.m.Ranking the Resistance of Wrought Superalloys to Strain Age Cracking

by M. Rowe, Haynes International Inc

E.11:20 a.m.The Effect of Chromium on the Weldability and Corrosion Behavior of Fe-Al Weld

by J. R. Regina, J. N. DuPont and A. R. Marder, Lehigh University

F.11:55 a.m.Analysis of Crack Formation in the Longitudinal Varestraint Test

by C. V. Robino, G. A. Knorovsky and M. Reece, Sandia National Laboratories; J. N. DuPont, Lehigh University; and Z. Feng, Oak Ridge National Laboratory

*This paper sponsored by the Department of Energy/Interagency Manufacturing Operations Group – Subgroup on Joining.

Session 10: Electron Beam Welding

Chair: John W. Elmer, Lawrence Livermore National Laboratory

A.2:00 p.m.Electron Beam Diagnostics and Weld Transfer

by T. Palmer, J. W. Elmer, P. Terrill, Lawrence Livermore National Laboratory; and K. Nicklas and T. M. Mustaleski, BWXT Y-12 Plant

*This paper sponsored by the Department of Energy/Interagency Manufacturing Operations Group – Subgroup on Joining.

B.2:35 p.m.Effect of HED Welding on the Microstructural Development of Superaustenitic Stainless Steels

by M. J. Perricone and J. N. DuPont, Lehigh University

C.3:10 p.m.The Role of Pressure in Welding (And Cutting) Processes: Comparing Pressure Effects of Heat Sources for Various Weld Processes

by G. A. Knorovsky and D. O. MacCallum, Sandia National Laboratories

*This paper sponsored by the Department of Energy/Interagency Manufacturing Operations Group – Subgroup on Joining.

D.3:45 p.m.Controlled Scanning Electron Beam Micro-to-Nano Welding: Micro-to-Nano Electron Beam Welding via Adapted Scanning Electron Microscopy

by B. M. Nowak-Neely, D. O. MacCallum and G. A. Knorovsky, Sandia National Laboratories

*This paper sponsored by the Department of Energy/Interagency Manufacturing Operations Group – Subgroup on Joining.

Session 11: Laser Beam Welding 2

Chair: Todd A. Palmer, Lawrence Livermore National Laboratory

A.2:00 p.m.Beam Profiling of a 3.3kw CW Cd:YAG Laser

by T. Lienert and R. W. Carpenter, Los Alamos National Laboratory

*This paper sponsored by the Department of Energy/Interagency Manufacturing Operations Group – Subgroup on Joining.

B.2:35 p.m.Alloying Element Vaporization during Laser Spot Welding of 304 Stainless Steel

by X. He and T. DebRoy, Pennsylvania State University; and P. W. Fuerschbach, Sandia National Laboratories

C.3:10 p.m.Identifying Uncertain Material Parameters in Weld Pool by Integrated Modeling

by A. De, IIT Bombay; and T. DebRoy, Pennsylvania State University

D.3:45 p.m.Laser and E-Beam Joining Unusual Fe-Base, Ni-Base and Refractory Alloys

by D. O. MacCallum, B. M. Nowak-Neely, G. A. Knorovsky F. M. Hooper, Sandia National Laboratories

*This paper sponsored by the Department of Energy/Interagency Manufacturing Operations Group – Subgroup on Joining.

E.4:20 p.m.Optimization of an Laser+ GMAW Hybrid Welding Process

by P. Kinney, Robert W. Hunt Co.; and D. Farson, The Ohio State University

Session 12: Solid State Joining

Chair: C. H. Cadden, Sandia National Laboratories

A.2:00 p.m.Inertia Welding for High-Pressure Hydrogen Storage

by M. C. Balmforth, G. K. Hicken and J. D. Puskar, Sandia National Laboratories

B.2:35 p.m.Microstructural Characterization of Inertia Welded 2l-6-9 Stainless Steel

by J. D. Puskar, B. P. Somerday, D. K. Balch, C. H. Cadden and M. C. Balmforth, Sandia National Laboratories

*This paper sponsored by the Department of Energy/Interagency Manufacturing Operations Group – Subgroup on Joining.

C.3:10 p.m.Prediction of Residual Stresses and Property Distributions in Friction Stir Welds of Aluminum Alloy 6061-T6

by Z. Feng, X. Li Wang and S. A. David, Oak Ridge National Laboratory

D.3:45 p.m.Effects of Ti-C Coating on Electrode Degradation: Tip Life Improvement for RSW With HDG Steel

by K. R. Chan, S. J. Dong, Y. N. Zhou and Y. Ding, University of Waterloo

E.4:20 p.m.Modeling Resistance Spot Welding Electrode Life

by S. S. Babu and M. L. Santella, Oak Ridge National Laboratory; and W. Petterson and J. E. Gould, Edison Welding Institute

Session SP1: Current Research Topics in the U.S. Navy

This session is sponsored by the United States Navy

Chair: Michael E. Wells, Naval Surface Warfare Center, Carderock Division

A.9:00 a.m.Shielding Gas Dewpoint Study for Titanium Welding

by K. N. Tran, M. E. Wells, D. R. Forrest, Naval Surface Warfare Center

B.9:35 a.m.Friction Stir Processing of Nickel Aluminum Bronze

by J. P. Nguyen, M. Posada, J. J. DeLoach, R. S. Fielder and W. A. Palko, Naval Surface Warfare Center

C.10:10 a.m.The Effects of Tandem Submerged Arc Welding Process Parameters on HAZ Toughness in HSLA-65: Numerical and Experimental Simulations

by D. R. Forrest, J. J. DeLoach and R. J. Wong, Naval Surface Warfare Center

D.10:45 a.m.Weldability of Dissimilar High Strength Steel Weldments

by J. Kalp and J. P. Nguyen, Naval Surface Warfare Center

E.11:20 a.m.A Neural Network Analysis of HSLA Weld Wire: A New Weld Metal Composition for 100 ksi Weld Wire

by E. A. Metzbower, US Naval Research Laboratory; and J. J. DeLoach, Naval Surface Warfare Center

International Brazing and Soldering Symposium

Session BS1 - Advances in Brazing Equipment and Technology (talks A-C); Advances in Brazing and Soldering Processes (talks D, E)

A.9:00 a.m.Brazing Copper Tube Faster and Better

by W. Sperko, Sperko Engineering Services, Inc., Greensboro, NC, USA

B.9:30 a.m.Stainless Steel Brazing

by S.L. Feldbauer, Abbott Furnace Company, St. Marys, PA, USA

C.10:00 a.m.The Science (and Art) of Making Brazing and Soldering Powders

by D. Fortuna, Sulzer Metco (US) Inc., Troy MI, USA

D.11:00 a.m.Challenging Solders for Microjoints: Developments in the Field of Active solders and Transient Liquid Phase Systems

by E. Lugscheider and S. Ferrara, Aachen University, Aachen, Germany

E.11:30 a.m.Experimental Technique for the Investigation of Liquid Filler Metal Flow Process Through a Braze Gap and Fillet Formation

by J. C. Madeni and S. Liu, Colorado School of Mines, Golden, CO, USA; F. M. Hosking, Sandia National Laboratories, Albuquerque, NM, USA; C. H. Cadden, Sandia National Laboratories, Livermore, CA, USA

Session BS3 - Advances in Brazing and Soldering Processes (Talks A,B); Advances in Inspection, Applications and Properties of Braze and Solder Joints (Talks C-F)

A.9:00 a.m.Hermetic Joints Between Alumina and Kovar™ by Active Brazing Process

by T. Oyama and A. Demmons, WESGO Metals, Div. Of Morgan Advanced Ceramics, Hayward, CA USA

B.9:30 a.m.Orientation Effects in Metal/Ceramic Brazing Using Active Filler Metals

by C. Cadden, N. Yang and N. R. Moody, Sandia National Laboratories, Livermore, CA, USA; F. M. Hosking, Sandia National Laboratories, Albuquerque, NM, USA; M. Kennedy, Washington State University, Pullman, WA, USA

C.10:00 a.m.Effect of Brazing on Formation of Non-Equilibrium Phases During Diffusion Brazing of Inconel 738 Superalloy

by M. C. Chaturvedi, O. A. Ojo, S. M. Crouch and N. L. Richard, University of Manitoba, Winnipeg, Canada

D.10:45 a.m.Flexure Testing of Alumina Ceramic and Silver-Based Active Filler Metal Braze Joints

by F. M. Hosking, J. J. Stephens, T. Headley, and R. E. Loehman, Sandia National Laboratories, Albuquerque, NM USA

E.11:15 a.m.Elevated Temperature Mechanical Properties of the 62Cu-35Au-2Ti-1Ni (Nicoro+2%Ti) Braze Alloy

by J. J. Stephens, D. T. Schmale, J. B. Caris, F. M. Hosking and P. F. Hlava, Sandia National Laboratories, Albuquerque, NM, USA

F.11:45 a.m.Optimization and Characterization of Tool Steel Assemblies Obtained by Ag-Cu Brazing

by A. Nafi, O. Mercier and P. Revirand, Ecole Des Mines D'Albi, Albi, France

Poster Session

Student Category A: 2-year degree or certificate student level

SPA1.Sulfide Stress Cracking

Timothy Bridges, North Harris Montgomery Community College

SPA2.Smart Pigging Pipeline Inspection

Barbara Cupial, North Harris Community College

SPA3.Prediction And Measurement Of Ferrite Content In Stainless Steel Weldments

Robert Lee Hall, North Harris College

SPA4.Stress - It Can Happen To You

Garry Kaiser, North Harris Montgomery Community College

SPA5.Box Girder Welding Sequence: Longitudinal Welds

Michael J LaDeau, North Harris Montgomery Community College System

SPA6.Stress Corrosion Cracking Of Aluminum Alloys

Larry Mcgriff, North Harris Community College

SPA7.Steel Crack Origin Investigation

Rozena Turner, North Harris College

SPA8.Comparing Weld Fatigue Behavior Of Stainless Steels: Duplex Vs Austinetic

Kenneth L. Welch, North Harris Community College

Student Category B: 4-year degree student level

SPB1.Pulsing Parameter Effects on Weld Nugget Size and Apperance

Robert Huddleston, Darci Toussant and Mitchell Matheny, The Ohio State University

SPB2.Benchmark Testing Trends Of GMAW-CV And Pulsed Power Sources

Jeremy Rice, Monique Bland and Jeremy Westerheide, The Ohio State University

SPB3.Comparison Of GTAW & PAW On Titanium 6Al-4V & Inconel 718

Steve Busovicki, Scott Cunningham, Michael Monastra and Doug Proehl, Ohio State University </p>

SPB4.Weldability Evaluation Of Several Solid Solution Strengthened Nickel-Based Filler Metals

Jeffrey Sowards, Jeffrey Bernath and Matthew Slate, The Ohio State University

SPB5.Effect Of Torch Weave Parameters On Weld Bead Characteristics

Joseph Dierksheide, Aaron Lindsey and Chris Rodgers, The Ohio State University

SPB6.Pulse Parameter Development For GMAW Of Aluminum

Kevin Clear, Nathan Carter and A.J. Wagner, Ohio State University

SPB7.Feasibility Study Of FSW Penetration Control VIS Eddy Current Sensing

James Reynholds, Ryan Gneiting and Benjamind Schaefer, Ohio State University

SPB8.WISC Inspection Of Fillet Welds

Zachary Berg, Brandon Shinn and Shane Slack, Ohio State University

SPB9.The Simulation Of Heat Transport Phenomena In Fusion Welding

T.D. Gonzales, D.A. Hartman and V.R. Dave, University of New Mexico - Los Alamos (UNM-LA) (Poster Withdrawn)

SPB10. Development Of A 1080 To 316 Functionally Graded Joint

Jeff Farren, Lehigh University

Student Category C: Graduate degree student level

SPC1.Prevention of Fatigue Cracking in Structural Steel Welds

Fernando Martinez, Colorado School of Mines

SPC2.High Strength Steel Welding

Craig Clasper and Justin Chandler, Colorado School of Mines

SPC3.High Temperature Corrosion Behavior Of Nickel Based Weld Overlays

Ryan M. Deacon, Lehigh University

SPC4.Alloy Development Of A Robust Filler Metal For Sass Alloys

Timothy Anderson, Lehigh University

SPC5.Friction-Stir Welding Al-6xn: A Microstructural Characterization

Suzanna M. Klingensmith and Masashi Watanabe, Lehigh University

SPC6.Effect Of Weld Zone Chemical Composition On Structural Properties Of A97075 Weldments

Kevin Orme, Utah State University

SPC7.Diffusible Hydrogen Reduction in Steel Weldments

Justin Chandler, Center for Welding, Joining, and Coatings Research - Colorado School of Mines

Professional/Commercial Division

P1.Modeling of Single Crystal Growth in a Melt Pool: Effects of Melt Pool Geometrical Parameters

Weiping Liu and J. N. DuPont, Lehigh University, Center for Advanced Materials & Nanotechnology

P2.High-Speed GMA Welding Of Aluminum: Comparison Of Power Supply Performance On Droplet Transfer And Heat Input Characteristics

M.J. Cola, J.E. Talkington, D.A. Hartman, R.W. Carpenter and A. Joseph, Edison Welding Institute

P3.The Effect Of Strain Rate On Ferrite Formation In Type 21-6-9 And 304l Stainless Steels

V.R. Davé, P.W. Hochanadel, M.J. Cola, M.B. Lyons, and D.A. Hartman, Los Alamos National Laboratory (Poster Withdrawn)

P4.In-Process Monitoring Of Pinch Welding: An Investigation Of A Bond Quality Indicator

D.A. Hartman, M.G. Smith, V.R. Dave, M.J. Cola and T.G. Abeln, Los Alamos National Laboratory

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