Show Conferences

2008 Show Conferences

Four conferences on specific topics, with presentations from experts on state-of-the-art advances in welding science and practices.

 8:50 AM – 9:00 AM
Welcome and Introduction
Chairman: Robert R. Irving; Co-Chairman: John Dawson

9:00 AM – 9:35 AM
Quality Flame Cutting After 107 Years
John Dawson, Consultant, ESAB Cutting Systems

9:35 AM – 10:10 AM
State-of-the-Art of Mechanized Plasma Cutting Technology
James Colt, Strategic Accounts Manager, Hypertherm Inc.
James Colt, Strategic Accounts Manager, Hypertherm Inc. Mechanized plasma arc cutting has been commercially used since the early 1960s for a variety of applications. Plasma has always had a reputation as the “Productivity Process” due to its ability to cut a wide range of materials and thicknesses at high speeds. Advancements in the last ten years have further developed plasma into a more refined process that provides dramatically higher cut part accuracy, high cutting speeds, full automation capability…all at a lower cost per foot of cut.

10:10 AM – 10:45 AM
How Nesting Solutions Develop a Positive Impact on Thermal Cutting Processes
Scott Grindstaff - Applications Engineer, SigmaTEK Services, SigmaTEK,
This particular CAD/CAM software is designed to achieve the following: integration for scheduling, estimating, engineering and costing; improved part quality; improved utilization of materials; and improved cutting flow.

10:45 AM – 11:00 AM Refreshment Break

11:00 AM – 11:35 AM
Introduction to Industrial Lasers
Lou Derango, Icon Machine Tool
An introduction to basic laser workings and considerations with follow up in a few typical metal applications. This presentation is meant to be a primer for those interested in pursuing laser technologies. The follow-up of the presentation will include a few samples of laser processing quality with question-and-answer period.

11:35 AM – 12:10 PM
Computerized Pipe and Tube Cutting
Jim Blackburn, General Manager, Vernon Tool Co., a business of Lincoln Electric Co.
Using a Powerpoint presentation, the speaker will briefly discuss current pipe cutting methods with attendant efficiencies. Specific industries dictate different machine configurations, computer controls, and cutting methods. Recommendations for designing an efficient “burn rack” will be disclosed. The speaker will address improvements in mechanized cutting machines, material handling alternatives and CAD-CAM data flow from popular isometric and structural modeling software. Machine operations and features are a guide to effective, efficient shop production and labor saving opportunities. Thirty-five years of management provide historical perspective of machine evolution; from simple gear-driven machines to 6-axis CAD-CAM driven work cells.

12:10 PM – 1:30 PM Lunch

1:30 PM – 2:05 PM
Waterjet Systems Can Cut a Wide Variety of Materials
Wiktor Stepien, Vice President-Sales, and Bob Pedrazas, Marketing Manager, KMT Waterjet Systems
Waterjet cutting systems are able to cut virtually any material. Waterjet machining offers many advantages compared to other technologies, including colder cutting, increased precision and a greater variety of applications. This presentation will be centered on the use of waterjet cutting applications for flat stock metals (aluminum, stainless steel), ceramics, stone, plastics, and composites for the aerospace, automotive, job shop, electronic, stone, glass and metal industries. Video examples will be included within the presentation to demonstrate how waterjet technology can help improve the quality, speed and efficiency of these manufactured products.

2:05 - 2:40 PM
Innovative CNC Control on State-of-the-Art Plasma Shape Cutting Technology
Mark Osowski, Product Manager, Burny/AMC Business Unit, ITT Cleveland Motion Controls
Innovative features developed in Burny CNC controls are tightly coupled to Kaliburn plasma systems in order to create a fully automatic shape cutting motion control process. This talk will detail how ITT Cleveland Motion Controls is striving for new technology that takes the waste, both in time and material, out of the shape cutting process. Learn how you can save on labor and operating expenses in your plasma application.

2:40 PM – 2:55 PM Refreshment Break

2:55 PM – 3:30 PM
Fuel Gases, Piping, and a Little OSHA
John Dawson, President, Thermal Cutting Consulting Inc.
The decision as to which fuel gas to use in a specific cutting operation is not always an easy one. The choice is extensive. It includes acetylene, propane, natural gas, propylene, MAPP, LPG, etc. However, the appropriate choice can be made based on the best performance/cost ratio. In addition, users of fuel gases who have them piped into their plants are facing problems with certain OSHA regulations. This situation will be explained.

3:30 PM – 4:05 PM
The Use of CAD/CAM Software to Program Robts to Cut Structural Steel and Pipe
Chris Anderson, Technology Leader-Welding, Motoman
Typically, robots are programmed manually with teach pendants creating point-to-point programs. Offline programming is done in a similar fashion, just in a virtual environment. Cutting machines use CAD/CAM software to generate shapes and often automate programming tasks such as nesting multiple shapes in an optimized pattern on a sheet. Utilizing a conversion routine, these shapes patterns can be converted to robot programs without the use of traditional programming methods. This allows paths from CAD software such as AutoCad to be converted into cut paths. Cut paths can also be created from G-code generated out of CAM software. Robotics brings the advantage of 6 degrees of freedom for positioning so beveling and contours can be cut on 3D parts such as structural shapes and pipe.

4:05 PM  Adjournment

8:50 AM – 9:00 AM
Welcome and Introduction
Chairman: Robert R. Irving; Co-Chairman: Ron Kruzic

9:00 AM - 9:40 AM
Ultrasonic Technique for the Examination of 9% Nickel Inner Shells of Large-Diameter Liquid Natural Gas (LNG) Storage Tanks
Ronald W. Kruzic, Senior Welding Engineer/Corporate NDT Level III, CB&I
A semiautomatic, first-of-its-kind ultrasonic examination technique that is currently being utilized for the examination of the high-nickel alloy welds of 9% Ni LNG tanks will be described. It is currently being utilized to examine the world’s largest LNG tanks,190,000 m3, and will shortly be applied to a 200,000 m3 storage tank. This technique takes the volumetric examination of the shell welds off the critical path and places the welding operation in its place.

9:40 AM – 10:20 AM
Computed Radiography – Innovations for Film Quality Results in Industrial Applications
Terry Plasek, Western Regional Manager, Fujifilm NDT Systems
This paper addresses the evolution of Computed Radiography dedicated to Industrial use and applications. Discussion on the improvements in systems resulting in the ability to achieve results equal to or in some cases better than conventional wet film radiography. System specifications and example imaging are also included.

10:20 AM – 10:35 AM Refreshment Break

10:35 AM – 11:15 AM
Eddy Current Array and Ultrasonic Phased-Array Technologies as Reliable Tools for FSW Inspection
Michael Moles, Senior Technology Manager, and André Lamarre, Business Development Director, Aerospace and Defense, Olympus NDT
Ultrasonic phased-array technology has demonstrated over the years its capabilities to reliably inspect aluminum Friction Stir Welds (FSW) as many aerospace manufacturers have used it during their manufacturing process. Recent developments in Eddy Current Array technology added new perspectives to the FSW evaluation. It is now possible to characterize the tool penetration and minimize the presence of an oxide layer, so-called kissing bond. This article will summarize results of both technologies for the evaluation of FSW.

11:15 AM – 11:55 AM
Use of Acoustic Emission for Field Inspection of Welds for In-Service Bridges
Richard Gostautas, Infrastructure Group Leader, Physical Acoustics Corp.
This presentation includes a few case studies that describe and illustrate how acoustic emission (AE) monitoring was used as a NDE tool for condition assessment of defects and discontinuities (e.g. cracks) in welds on different types of in-service bridges.

11:55 AM – 1:00 PM Lunch

1:00 PM – 1:40 PM
Advancements in NDE at Edison Welding Institute
Kevin M. Clear, Project Engineer–NDE Technology, Edison Welding Institute
This presentation will discuss the advancements in nondestructive evaluation at Edison Welding Institute. It will provide a brief overview of linear and matrix phased array, digital computed radiography, phased array eddy current, and microwave inspection techniques.

1:40 PM – 2:20 PM
Practical Applications of the Time-of-Flight Diffraction (TOFD) Ultrasonic Technique
David Dechene, NDE Level III for US Operations, Sonomatic
Originally developed in the late 1970’s for the nuclear industry as a very accurate flaw sizing tool, the time-of-flight diffraction (TOFD) ultrasonic technique has also gained popularity over the years for its other unique abilities, such as one-scan weld inspections, corrosion mapping, hydrogen damage detection, and rapid screening of vessel shells, to name a few. This presentation is designed to explain what TOFD is, how it differs from pulse echo UT, its advantages/disadvantages and its applications for industry today.

2:20 PM – 2:35 PM Refreshment Break

2:35 PM – 3:15 PM
An Introduction to Alternating Current Field Measurement
Robert E. Cameron, Manager, Quality Assurance and Training, TWI North America, LCC
ACFM is an electromagnetic test technique used for the detection and sizing of surface breaking cracks. It was initially conceived for use underwater to detect flaws in offshore structures and proved to be very effective. Now ACFM is used to inspect structures both in and out of the water. ACFM has the advantage, over some other NDT methods, that the surface requires minimal cleaning. Also, ACFM can be applied to surfaces that are painted, or have other coatings up to about 5 mm in thickness. ACFM is used not only to detect and size surface-breaking cracks, but also to monitor crack growth.

3:15 PM – 3:55 PM
Emerging Ultrasonic Guided Wave Applications in NDT, Structural Health Monitoring (SHM), and Weld Inspection
Joseph L. Rose, Paul Morrow Professor, Engineering Science & Mechanics Department, Pennsylvania State University. Dr. Rose is also Senior Scientist, FBS Inc.. Dr. Rose’s paper will be presented by Michael Moles, Senior Technology Manager, Olympus NDT Canada
Ultrasonic guided waves have always been of interest for decades but little used in NDT and SHM. Today, however, with significant advancements in theoretical understanding and computational efficiency the road ahead for guided waves is clear. Phased array utilization has advanced guided wave applications even further. Sample problems in pipeline, aircraft, and rail will be covered along with special emphasis on newly developed phased array scanning of an entire plate from a single sensor position and weld inspection with simple single line scan at any arbitrary distance from the weld.

4:00 PM  Adjournment

8:25 AM – 8:30 AM
Welcome and Introduction
Chairman: Thomas J. Lienert, Ph.D

8:30 AM – 9:00 AM
Friction Stir Welding History and Licensing
Ian Smith, TWI Ltd.
This presentation will contain a brief review of the history of the early development of FSW and its rapid take-up by industry. It will also discuss the approach TWI uses for the control and exploitation of the intellectual property. Finally, it will briefly review the very large number of patents filed by FSW users.

9:00 AM – 9:30 AM
Friction Stir Welding Tool Designs
Iain Smith, TWI Ltd.
This presentation will describe the evolution of FSW tool designs from the simple forms used to establish the process through to the most popular types used today, and some indications of the future challenges for tools.

9:30 AM – 10:15 AM
Friction Stir Welding and Processing
Murray Mahoney, Consultant
General discussion of FSW including metal flow and defect avoidance, temperature gradient issues, lap vs. butt joints, some tool material and tool design considerations, current applications, FSW limitations, benefits such as properties and the solid state benefits of welding unweldable alloys and zero emissions, all as they apply to Al, Cu, and Fe based alloys. A description of Friction Stir Processing (FSP) and its benefits will also be discussed.

10:15 AM – 10:30 AM Refreshment Break

10:30 AM – 11:00 AM
Advances in Friction Stir Welding Tool Technology
Scott Packer, Advanced Metal Products
Limitations of FSW have included the feasibility of joining high melting temperature materials such as steels, stainless steels, and nickel base alloys. Tool materials able to withstand the high temperatures along with adequate wear resistance during the joining process are required. Generally, there have been two distinct material systems used including polycrystalline cubic boron nitride (PCBN) and tungsten based materials such as tungsten rhenium alloys. This paper will present the development of PCBN materials for FSW, and the development of composite tungsten rhenium alloys with PCBN and diamond reinforcement.

11:00 AM – 11:30 AM
Friction Stir Welding Machines and Configurations
Tim Haynie, Transformation Technologies, Inc.
Friction Stir Welding is performed on a variety of equipment types ranging from simple milling machine to highly sophisticated purpose-built FSW systems with specialized features and advanced control algorithms. In this presentation, the requirements of the FSW process and the implications on the equipment selection are discussed. The basics of force control and position control modes are presented and the advantages of each control mode are discussed. Commercially available machine configurations from several manufacturers are presented. These include simple two-axis seam welders through multi-axis complex contouring machines with advanced pin-control features.

11:30 AM – 12:00 PM
Eddy Current Array and Ultrasonic Phased-Array Technologies for FSW Inspection
Michael Moles, Olympus NDT
Ultrasonic phased-array technology has demonstrated over the years its capabilities to reliably inspect aluminum Friction Stir Welds (FSW) as many aerospace manufacturers have used it during their manufacturing process.  Recent developments in Eddy Current Array technology added new perspectives to the FSW evaluation. It is now possible to characterize the tool penetration and minimize the presence of an oxide layer, so-called kissing bond.

12:00 PM – 12:30 PM Lunch & Q&A/Panel Discussion

12:30 PM – 1:00 PM
Cost/Benefit Analysis for Friction Stir Welding
Jeff DeFalco, ESAB
A cost/benefit comparison is made between conventional fusion-type welding processes to FSW by evaluating their relative production output, production costs, and weldability attributes in various heavy industry applications. Applications will include joining both low and high melting point alloys while assigning numbers to each evaluation.

1:00 PM – 1:30 PM
Robotic Friction Stir Welding, Friction Stir Processing and Supporting Operations
John Hinrichs & Christopher Smith, Friction Stir Link
FSW and FSP are relatively new processes. Principles of the friction stir welding process and FSW and FSP with robots will be discussed. Several FSW robotic applications and an FSP robotic application will be discussed. In addition, robotics used to support manufacturing of FSW products will be described.

1:30 PM – 2:00 PM
Friction Stir Welding Standards and Specifications Used in Today’s U.S. Manufacturing and Fabrication
R. Jeffrey Ding, NASA Marshall Space Flight Center
Discussions will include the AWS FSW Specification for Aerospace Applications. The presentation will also cover standards used in private industry.

2:00 PM – 2:30 PM Q&A / Panel Discussion