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THE WORLD OF ENERGY CONFERENCE – WELDING'S GREATEST CHALLENGE
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August
31 - September 1, 2010
San Diego, Calif.
Facility: Doubletree Golf Resort, San Diego
Chair: Robert Irving
Welding plays a vital role in all of these industrial activities, and there does not seem to be one process that is not playing a critical role in this scene, from submerged arc welding to lasers to ultrasonic welding. Information on many of these topics will be discussed at the next AWS conference, The World of Energy - Welding's Greatest Challenge. It will be held on August 31-September 1, 2010, in San Diego, Calif. It will be a must both for fabricators and manufacturers who are already participating in the energy fields and for companies interested in entering the fields for the first time.
On-hand to welcome the members of the audience will be AWS President John C. Bruskotter, a heavy player in the offshore welding industry himself.
To keep pace with all the activity in energy, the National Science Foundation has established a new center aimed at improving the quality and productivity of welding technology. The keynote speaker will be Professor Sudarsanam Babu from Ohio State, who is the director of the new Center for Integrative Materials Joining. The center’s main aim will be to close the gap between material development and weldability.
Among the green industries are the wind power generators, the 21st Century's answer to Dutch windmills. The heart of these operations is the wind tower itself, the component that supports the blades or rotors. These tall, thick-walled steel towers are welded by submerged arc welding. Describing this effort in San Diego will be Teresa Melfi from The Lincoln Electric Co. Lincoln is heavily involved in this type of work. From the research side, Ian Harris of Edison Welding Institute will discuss narrow-groove GMAW and hybrid laser arc welding, and how those processes can not only be considered for use on wind power towers but also in nuclear fabrication.
There will be two presentations on the situation regarding nuclear construction. Lance Harbison of Westinghouse Electric Corp. will be discussing the roles that various welding processes will be playing. Westinghouse's new AP1000 power plant is attracting considerable attention. Four of these reactors are under construction in China. Also on the agenda is Nathan Ames from Edison Welding Institute. Ames is the technical director of EWI's Nuclear Fabrication Council.
Quite apart from the world of arc welding, the audience will hear Benjamin Christian discuss the use of ultrasonic welding in the manufacture of the new lithium-ion automobile batteries. Christian is with General Motors Research & Development in Warren, Mich. One of his main concerns is in the joining of dissimilar metals. The topic of welding dissimilar metals will be discussed by Donald J. Tillack of Tillack Metallurgical Consultants. Tillack works closely with The Nickel Institute.
Kevin Beardsley of Lincoln Electric will be on hand to discuss the recent advances in pipeline welding technology. According to Beardsley, some 190,000 miles of pipeline is planned for the near future. Richard Marslender of Kiewit Offshore Services will speak about the application of various processes in offshore construction. And Michael Blakely of Dynamic Materials will discuss the role of explosive welding in providing claddings of corrosion-resistant alloys onto steel plate for pressure vessels and heat exchangers in downstream oil refineries. Cheryl Botti from ATI Allegheny Ludlum will provide a run-through of some of the corrosion-resistant alloys used in the energy industries.
Switching to gas, Ben Pletcher of Chicago Bridge & Iron will talk about the selection of the right welding process in fabrication involving LNG facilities, especially when the job is being performed in some remote location. The creep-strength-enhanced ferric (CSEF) steels, Grade 91 in particular, will be the topic for Jeff Henry of Structural Integrity Associates. Specifically, Henry will talk about the use of a tempering parameter for the control of PWHT of these steels. Jim Byrne from Miller Electric will follow up with his discussion of two technologies - induction heating and the new controlled short circuit GMAW process - both of which can be beneficial in the welding of CSEF steels.
Ed Hansen of ESAB Welding & Cutting Products will give a thorough evaluation of the applications for hybrid laser welding throughout the energy industries. Todd Palmer of Penn State's Applied Research Laboratory will talk about laser-based additive processes with the emphasis on advances in laser cladding and additive manufacturing.
Conference Registration Fees
CONFERENCE CODE: CF37410AWS Member – $550
Nonmember – $680
ONLINE REGISTRATION
- Each nonmember attendee will receive a two-year complimentary membership in AWS. Your conference registration fee includes all conference sessions, two continental breakfasts, two lunches, and refreshment breaks.
- The registration fee does not include hotel accommodations. Hotel accommodations are subject to hotel regulations and are the responsibility of the attendee.
- You will receive a CD containing copies of all presentations.
- Each participant will also earn 14 Professional Development Hours (PDHs) for attending the conference. These PDH’s can be applied toward AWS recertifications and renewals.
Location and Accommodations
Doubletree Golf Resort – San Diego14455 Penasquitos Drive
San Diego, CA 92129
(858) 672-9100
http://doubletree.hilton.com/en/dt/groups/personalized/SANCMDT-AWS-20100830/index.jhtml?WT.mc_id=POG
Take advantage of the specially negotiated rate of $125 with booking code "AWS" by Aug. 5.
Program Schedule
WELCOME
8:45 AM - 9:00 AM
Robert R. Irving, Conference Chairman
9:00 AM - 9:35 AM
Sudarsanam (Suresh) Babu, Associate Professor Integrated Engineering Systems Engineering, Professor, Materials Science Engineering, and Director of the NSF Center for Integrative Materials Joining Science for Energy Applications, Columbus, Ohio
This new center is striving to close the
gap between material development and weldability. Scientifically based
methodologies for assessing material weldability/joinability will be
developed to address extending the life of material joints within the
aging energy infrastructure, and reduction of the time and cost of
deploying advanced/hybrid materials for the new energy
infrastructure. In addition to Ohio State, Lehigh University,
Colorado School of Mines, and the University of Wisconsin will also be
involved in this effort.
Westinghouse's
Position
in
the
Nuclear
Renaissance
9:35 AM - 10:10 AM
Lance S. Harbison, Principal Engineer, Materials Center of Excellence,
Westinghouse
Electric Company, Pittsburgh, Pa.
Although the nuclear renaissance is quickly coming, Westinghouse has
been active in the design and supply of replacement reactor vessel
heads and steam generators. From the experience currently being
gained in China, Westinghouse is positioned to hit the ground running
in rebuilding U.S. nuclear capacity. This presentation focuses on
the materials and welding nuclear components.
MORNING BREAK - 10:10 AM - 10:25 AM
Advances in Submerged Arc Welding of
Wind Towers
10:25 AM - 11:00 AM
Teresa Melfi, R&D Manager, Submerged Arc Consumables, Cleveland,
Ohio
The desire for green energy is driving a rapid increase in wind tower
investment in the U.S. and Canada. Tower sections are fabricated
using submerged arc welding for longitudinal and circumferential seams,
as well as for attachment of flanges and door openings. This talk
will explore advancements in submerged arc welding technology that
address the unique requirements of the wind tower industry. These
include high-productivity welding solutions, development of robust
mechanical properties for offshore towers, and weld processes that meet
the industry's specific requirements regarding weld bead profile.
In the spirit of renewable resources, we will also consider ways to
make the welding process itself more “green.”
Teresa Melfi has worked as an
engineer in the welding industry for over 25 years, with extensive
global experience in the design, manufacture and application of welding
consumables. She currently holds a management position in
research and development at Lincoln Electric headquarters. Ms. Melfi is
chair of the AWS A5B committee responsible for submerged arc welding
specifications, and is a member of the AWS A5 Committee on Filler
Metals. She is a member of ASME Section IX, including the
materials subgroup and the Section IX working group on advanced
waveform welding. She currently serves as the U.S. delegate to
IIW Working Group CXI, which covers pressure vessels, boilers, and
pipelines, and XI-E, which covers pipelines. Ms. Mefli holds
numerous patents for welding consumables and welding processes.
She has a BD degree (physics) from Heidelberg College, with graduate
coursework in metallurgy and an MBS from Case Western Reserve
University.
Capabilities in Offshore Welding at
Kiewit Offshore Services
11:00 AM - 11:35 AM
Richard Marslender, Senior Welding Engineer, Kiewit Offshore Services,
Ltd., Ingleside, Tex.
The following types of offshore structures have been built by Kiewit
Offshore Structures: topsides, fixed, jackets, towers, floaters, and
sub-sea structures. The company's fabrication facility includes yard
facilities, equipment, and personnel - both staff and craft. When it
comes to welding, the specifics are codes and specifications, material
types and sizes, structural and process piping, and the welding
processes themselves. In addition to the descriptions of the
above points of interest, the presentation will also present an outlook
for future projects.
LUNCH (PROVIDED) & EXHIBIT DISPLAY
- 11:35 AM - 1:35 PM
The Use of a Tempering Parameter for
the Control of PWHT of Grade P91 and Other CESF Steels
1:35 PM - 2:10 PM
Jeff Henry - Associate, Structural Integrity Associates, Chattanooga,
Tenn.
The final condition of the various constituents of a weld made in any
of the CSEF (creep-strength-enhanced ferric) steels will be a function
of the total time at all temperatures to which the material has been
exposed during any thermal processing following austenitizing and
cooling. To ensure both satisfactory elevated temperature strength of
the base metal and sufficient softening of the weld metal following the
completion of all welding and PWHT, sufficient "margin" should be
provided in the as-purchased material to permit use of a PWHT
temperature high enough to satisfactorily soften the weld metal. The
use of a tempering parameter to control thermal processing steps and
achieve an acceptable final condition for welds made in these materials
will be discussed in detail.
Using the Latest Technology for
Heating and Welding Chrome-Moly Pipe
2:10 PM - 2:45 PM
James A. Byrne - Manager, Applications & Sales Support, Miller
Electric Manufacturing Co., Appleton, Wis.
With the increased use of chrome-moly pipe materials, especially P91
steel, for the construction of power plants, and the power industry
facing increased demand, tighter deadlines, and a shortage of skilled
welders, a new controlled short-circuit GMAW process promises lower
costs, higher productivity and the ability to provide code quality
welds with less training. Along with improved welding equipment
and processes, the latest technology used to satisfy the heating
requirements while welding chrome-moly pipe will be introduced.
An induction heating system can improve overall cycle time and quality
of finished product.
AFTERNOON BREAK - 2:45 PM - 3:00 PM
Welding Challenges of Liquefied
Natural Gas Facilities
3:00 PM - 3:35 PM
Ben Pletcher - Welding Engineer/Metallurgist, Chicago Bridge & Iron
Co., Plainfield, Ill.
Liquefied natural gas storage and processing facilities utilize a wide
range of structural materials. Turnkey construction, often in remote
locations, requires well-trained welders and supervisors knowledgeable
in multiple welding processes. Manual, semi-automatic and machine
processes are commonly used to join carbon and stainless steels,
aluminum, and nickel-based alloys. This talk will focus on how
decisions are made for process selection.
Narrow-Groove Tandem GMAW and HLAW for
Wind Tower and Nuclear Fabrication
3:35 PM - 4:10 PM
Ian Harris - Technology Leader, Arc Welding, Lasers, and Automation,
Edison Welding Institute, Columbus, Ohio
Wind tower fabrication uses a substantial amount of SAW for the
thicker, lower elements in the structural tower supporting the turbine.
For shop fabrication, newer technologies including narrow-groove tandem
GMAW and hybrid laser arc welding (HLAW) vie with naroow-groove SAW for
development of a lower fabrication cost. Nuclear fabrication standards
are presently locked into the 1970s. Through NFC, EWI is working
to introduce more productive technology resulting from the last 40
years of process and equipment development.
9:00 AM - 9:35 AM
Benjamin Christian - Associate Researcher, Advanced Propulsion in Manufacturing Systems, General Motors Research & Development, General Motors LLC, Warren, Mich., and Daniel Hutchinson, Technical Fellow and Principal Welding Engineer, General Motors Research & Development, General Motors LLC, Warren, Mich.
The electrification of the vehicle and the integration of high-energy batteries with numerous cells have brought forward the need for more robust joining methods of dissimilar metals. Ultrasonic welding is one method for joining thin film and dissimilar metals. However, advances in the cladding of thin materials along with innovative products designs could enable the implementation of other more robust joining methods that exhibit less variations or affinity to material variations. This presentation will cover the challenges set forth by the auto industry for battery weld applications with regard to process variation tolerances, resistance to corrosion, and minimal change in performance over the life of the vehicle.
Daniel Hutchinson is a Technical Fellow at General Motors and is the Principal Welding Engineer in the Manufacturing Assembly and Automation Center. Daniel has his bachelor of science degree in Mechanical Engineering from Kettering University and a master of science in Manufacturing Management from Kettering. Daniel has been involved with the implementation of new technologies for automotive body welding, and is now the Technology Lead for battery joining.
Benjamin Christian is an Associate Researcher at General Motors Research & Development in the Manufacturing Systems Research Advanced Propulsion Lab. Benjamin has his bachelor's degree in Manufacturing Engineering from Ferris State University and is working towards his master's in Energy Systems Engineering at the University of Michigan. Benjamin's expertise is in ultrasonic welding and battery technologies and he is working in conjunction with several universities, including the University of Michigan and Oxford Brookes University on reversible joining methods for battery applications.
Advancements in Pipeline Field Construction Welding
9:35 AM - 10:10 AM
Kevin A. Beardsley - Pipeline Welding Engineer, Lincoln Electric Co., Cleveland, Ohio
With global energy consumption on the rise, pipeline construction must keep pace to deliver fuels necessary to create energy. In the near future, over 190,000 miles of pipelines are planned for construction worldwide. Recent advancements in pipeline field construction welding address the technical challenges of welding for improved productivity, quality, and robustness required to meet higher standards for today and the future.
MORNING BREAK - 10:10 AM - 10:25 AM
Explosion Welding and Its Application in Downstream Oil Refineries
10:25 AM - 11:00 AM
Michael Blakely - Director of Market Development, Dynamic Materials Corporation, Sugar Land, Tex.
Explosion welding is used widely in the energy industry. One of the primary uses of the process is to clad relatively thin layers of corrosion resistant alloys to thicker carbon or alloy steel plates. These combined metals are then employed in pressure vessels and heat exchangers in a number of refinery processes. This paper will focus on the process of manufacturing explosion-welded plates for fabrication. It will also highlight a few key process units where explosion welding is used to clad surfaces within a refinery. In addition to refinery applications, explosion-welded plates have a wide range of applications within the rest of the energy sector. A brief overview of these other applications will be covered as well.
Duplex Stainless Steels and Nickel-Based Alloys: An Overview
11:00 AM - 11:35 AM
Cheryl Botti, Manager, Market and Product Development, ATI Allegheny Ludlum, Brackenridge, Pa.
Duplex stainless steels and nickel-based alloys are widely used due to their balance of engineering properties, purchase price, and availability. ATI produces a variety of alloys that are candidates for uses in many applications in various product forms. Selection of materials of construction is a balance between the features and benefits of a material versus its cost. Materials selection is rarely determined by a single property. This presentation will cover a number of important alloys in the range from duplex stainless steels to nickel-based alloys. Discussion of the important material properties, corrosion test results, fabrication comments, end uses, and raw material cost ranking will be presented to compare various alloys.
LUNCH (PROVIDED) & EXHIBIT DISPLAY - 11:35 AM - 1:35 PM
Michael Blakely, Co-Chair
Laser-Based Additive Processes for Energy-Related Applications
1:35 PM - 2:10 PM
Todd A. Palmer - Assistant Professor of Materials Science and Engineering, Research Associate, Applied Research Laboratory, Pennsylvania State University, State College, Pa.
Laser cladding and laser additive manufacturing allow unique material combinations to be created, and because they are low-heat input processes, distortion of existing parts is limited, thus mitigating the need for follow-on machining and rework. Recent advances in laser source technologies have allowed these processes to provide higher levels of quality, while at the same time becoming economically attractive as compared to more established processing routes. A review of the current state of the art in both processes will be provided in terms of their direct application to the energy industry
Energy Applications for Advanced Joining Processes
2:10 PM - 2:45 PM
Ed Hansen - New Products Manager, ESAB Welding & Cutting Products, Florence, S.C.
As we all know, the world is experiencing a rapid growth in energy development from new sources of oil and gas, a resurgence of nuclear energy, massive expansion of wind energy capture, and new large-scale solar projects. Simultaneously, there are new demands for mitigating the environmental effects of energy use, including carbon capture and sequestration, long-term nuclear storage, and improved low-impact oil, gas and utility infrastructures. This rapid innovation is, in turn, driving new design and manufacturing requirements for methods of harvesting, processing, distributing, and delivering energy. Advanced joining processes like hybrid laser welding and friction stir welding will play a critical role in addressing many of the engineering challenges that these new energy systems will present to owners, developers, and constructors. This presentation will review some areas in which these technologies are actively being applied. We will also present some areas that in hold potential for future applications.
AFTERNOON BREAK - 2:45 PM - 3:00 PM
The Nuclear Scene
3:00 PM - 3:35 PM
Nate Ames - Technical Director, Nuclear Fabrication Council, and Engineering Team Leader, Edison Welding Institute, Columbus, Ohio
The nuclear industry is fraught with fabrication issues, the most cumbersome of which, potentially, is the balance between old and new. Many of the nuclear reactors in operation around the world today were built using materials and welding technologies from three decades ago. Most, if not all, the reactors being built today are leveraging advancements in the fundamental understanding of how the power reactor environment affects the facility life, but few are well positioned to capitalize on recent materials and welding technologies. This presentation will cover the basic relationships between materials, welding, radiation, and water that dictate the fabrication practices used then and now for nuclear fabrication.
Dissimilar Welding Metals
3:35 PM - 4:10 PM
Donald J. Tillack - Tillack Metallurgical Consultants, Inc., Catlettsburg, Ky.
This talk primarily examines the austenitic-to-ferritic weld joint - by far the most commonly encountered dissimilar combination and one that is present in hundreds of pipe and tubing joints in a power plant. Techniques for determining dilution and the resulting composition of a dissimilar weld are explained. Constitutional (ferrite) diagrams are used to analyze typical dissimilar welds.
ADJOURNMENT
(800) 443-9353 x 264(U.S.) or
(305) 443-9353 x 264(Outside the U.S.)