Developers of new weld consumables are very active of late in their attempts to keep pace with the demands from industry. Deanna Murlin from Lincoln Electric will address the new filler metals targeted toward wind towers where impact toughnesses of 60-100 ft•lbs at -40°F are required. A new consumable developed mainly by researchers at the Electric Power Research Institute with help from Babcock and Wilcox and Euroweld will be introduced by Roger Swain of Euroweld. Intended for dissimilar metal welding, this nickel-base alloy is aptly called EPRI P87.

Russel Fuchs of Bohler Welding GroupUSA will provide an update on the welding of the creep-enhanced ferritic steels. The most important member of this group is P91 steel. Joe Zowadny will be on hand to describe Avesta Welding’s new consumable for welding the popularlean duplex LDX 2101 stainless steels.

Doug Krebs from Hobart Brothers Co.will talk about productivity enhancements in the metal core process, while Jerry Mathison of ESAB Welding & Cutting Products will describe some of the improvements in flux-cored welding filler metals, some made possible by lower diffusible hydrogen levels.

Stoody’s Ravi Menon will go into some detail concerning the recently developed composite alloy systems for hard facing and will even mention the new “crack-free” wires. Kevin Lyttle from Praxair, Inc. will discuss the favorable results in welding specialty stainless or aluminum alloys when minor additions of hydrogen and nitrogen are added to an argon based mixture.


REGISTER

Attendee Registration Rate
AWS/FMA/SME/NAM/CCAI members $345
Nonmembers $480

• Each nonmember attendee will receive a two-year complimentary membership in AWS.
• 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 7 Professional Development Hours (PDHs) for attending the conference. These PDH’s can be applied toward AWS recertifications and renewals.

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Program Schedule

WELCOME
8:50 AM - 9:00 AM

Robert R. Irving, Conference Chairman

9:00 AM - 9:35 AM
Deanna Murlin, Product Manager, Submerged Arc and Mig Welding Consumables, The Lincoln Electric Co., Cleveland, Ohio 

Filler Metals for the New Creep Strength Enhanced Ferritic Steels
9:35 AM - 10:10 AM
Russel Fuchs, Manager, Bohler Welding Group USA, Inc., Stafford, Tex. 

By increasing the operating temperatures and pressures of fossil fuel power generation plants the efficiency of the plant can be improved. In order to realize the increased operating parameters, new steels had to be developed with improved elevated temperature properties. These are the so-called Creep Strength Enhanced Ferritic (CSEF) steels.  The common names for these steels include P91, P92, T/P23, and T/P24.Welding, as an integral part of the fabrication and construction process must also be considered. Matching filler metals to the CSEF steels have been developed that exhibit sufficient properties to ensure safe and reliable operation of these plants under the more demanding operating conditions. The design considerations necessary in the development of these consumables, as well as the achieved properties, will be discussed. Various applications for these materials will also be highlighted.

MORNING BREAK - 10:10 AM - 10:25 AM

What’s Changing in the FCAW World?
10:25 AM - 11:00 AM
Jerry Mathison, Sr. Sales Application Engineer, ESAB Welding & Cutting Products, York, Pa.

This brief presentation will look at a few of the changes occurring with FCAW electrodes, namely, more welder friendly, how'd they do that? Why'd they do that? Lower diffusible hydrogen levels, and the overall evolution of the FCAW process.

EPRI P87, a New Filler Material for Dissimilar Metals Welds
11:00 AM - 11:35 AM
Roger Swain, President, Euroweld. Ltd., Mooresville, N.C.        

Dissimilar metal welds between ferritic and austenitic materials at elevated temperatures have concerned boiler manufacturers/operators because of the proven potential for premature failure. The industry has desired an improved filler metal that would minimize or eliminate DMW failures while retaining suitable creep strength for joining higher strength materials. After years of research, EPRI concluded the development and initial commercialization of a nickel-based, shielded metal arc welding electrode, EPRI P87.This work describes both the mechanical behavior and weld ability o of EPRI P87 for application in gas tungsten arc, gas metal arc and shielded metal arc welding processes. Mechanical evaluation of EPRI P87 included creep testing, elevated temperature tensile testing, and PQR evaluations of several tube-tube combinations. Weld ability evaluation of EPRI P87 included varestraint testing, microstructure evaluation, circular patch, and edge build-up - plates. This paper supports the acceptability of EPRI P87 for its intended use in high-temperature power generation applications. This alloy should also offer solutions for other industries, depending on operating conditions.
   
LUNCH (PROVIDED) & EXHIBIT DISPLAY - 11:35 AM - 1:35 PM

Metal Core - A Process with Potential for Productivity Improvement
1:35 PM - 2:10 PM
Doug Krebs, Business Unit Manager - Heavy Equipment, Hobart Brothers Co., an ITW Co., Troy, Ohio

Organizations are increasingly recognizing the advantages of the metal core process. These advantages cannot be recognized without a thorough examination of the fabrication process. A comprehensive look at the pre- and post-weld operations must be undertaken. An examination including only the welding cell will not reveal the full benefit of metal core. This discussion will examine several critical fabrication issues that can be mitigated, or eliminated, using the metal core process. Additionally, it will address potential productivity enhancements linked to adoption of the process. Finally, an examination of the latest tools to capture productivity information inside the welding cell will be discussed.

Welding the Lean Duplex LDX 2101 Stainless Steel
2:10 PM - 2:45 PM
Joe Zowadny, Technical Services Manager, Avesta Welding LLC, Fairview Park, Ohio     
 
Presentation will focus on the use of filler materials for welding LDX 2101, including GMAW, GTAW, SAW, and FCAW. Highlights include “How to Weld LDX 2101”, welding procedure do’s and don’ts, comparison to using other  filler materials, and status of AWS classification for LDX 2101.

AFTERNOON BREAK - 2:45 PM - 3:00 PM

Hardfacing Applications for Wear and Corrosion Resistance
3:00 PM - 3:35 PM
Ravi Menon, Ph D, Fellow AWS, Vice President Technology and Product Line Management, Stoody, a Thermadyne Co., Bowling Green, Ky.
 
Hard facing technology has progressed significantly in the past twenty years from the days where the primary applications were in the mining and construction areas. With the rapid advancements in cored wire manufacturing technology, composite alloy systems are being created that can combat wear and corrosion situations in a multitude of applications. Some of these include slurry transportation in the oil sands, steel mill rolling components, and severe erosive-corrosive conditions in oil and refinery process equipment. The presentation will cover ferrous and non-ferrous consumables developed for many of these applications as well as some novel consumable concepts such as “crack-free” wires for severe wear/impact applications..

New Applications for Shielding Gases
3:35 PM - 4:10 PM
Kevin Lyttle, Senior Development Associate, Praxair, Inc.,Tonawanda, N.Y.

Shielding gases are viewed by some as a necessary evil to accomplish the job at hand. In doing so, some fabricators miss the opportunity to improve weld quality and mechanical properties while achieving higher levels of productivity. Carbon steel welding operations at a single manufacturing site can be both simplified and optimized by identifying the best shielding gas composition to be used with the varying filler materials - solid, metal-cored and flux-cored wires - that may be used at that site. It is also possible, through the use of minor additions of gases such as hydrogen and nitrogen to an argon based mixture, to produce enhanced weld quality and improve welding productivity when joining specialty stainless or aluminum alloys. An understanding of how recent developments in shielding gases can impact welding operations will increase a fabricator's ability to reduce welding costs.

ADJOURNMENT

Questions, to register or need additional conference information? Call
(800) 443-9353 x 264 (U.S.) or
(305) 443-9353 x 264 (Outside the U.S.)