This conference covers welding, examination, and post-weld heat treatment of dissimilar joints, including carbon-steel, nickel-base, stainless, chrome-moly and other alloys. Also covers topics such as explosive welding and how standards address the complicated nature of dissimilar welds.
Monday, November 18, 2013 |
Conference Chair: Ben Pletcher |
8:20 |
Welcome
Ben Pletcher |
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Welcome, introduction, and overview of the conference program. |
8:30 - 9:05 |
Dissimilar Joints Involving Stainless Steel (The Keynote Address)
Damian Kotecki, Damian Kotecki Welding Consultants
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Dissimilar joints involving stainless steel can include a stainless steel of one microstructural family to a stainless steel of another microstructural family (e.g., austenitic stainless steel to martensitic stainless steel), stainless steel to carbon steel or low alloy steel, and stainless steel to nickel base alloys. Cladding of carbon steel or low alloy steel is also a dissimilar metal joint. Since many of these joints are more easily produced without cracking when filler metal which deposits weld metal that is austenitic with a small amount of ferrite under the dilution conditions of the particular joint is used, the WRC-1992 Diagram is a very useful tool for selecting filler metal for all such joints. This presentation will highlight the use of the Diagram for such joints. It will also examine transition zones along the fusion boundary of such joints, where cracking sometimes occurs. |
9:05 - 9:40 |
Welding of Dissimilar Chromium-Molybdenum Alloys,
Critical Considerations for Assured Success
Russel Fuchs, Bohler Welding Group North America
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In fossil fuel fired power plants, different heat and creep resistant steels are used depending upon the different temperatures and oxidation behaviors found in the boiler and superheater area. This requires not only the welding of these materials to themselves, but also to each other. The right choice of filler metal depends upon which combination of base materials will be used, as well as the desires properties. Carbon diffusion is one phenomenon that is well known when welding steels with different carbon and chromium contents. This paper discusses the welding of dissimilar Chromium-Molybdenum steels, welded with matching consumables to both materials - one matching to the lower Chromium steel and one to the higher Chromium steel. Also included in the investigation are Cr-Mo filler metals with additions of carbide forming elements. The results show that there is a different behavior depending upon which filler metal is used, and how proper filler metal selection can eliminate or greatly reduce the problem of carbon diffusion. |
9:40 - 10:15 |
NDE Techniques for Dissimilar Weld Metal Structures
Brian D. Laite, CB&I
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In today's modern welding and fabrication industry, joining dissimilar metals together is required in order to maximize the beneficial properties of both metals. This discussion will focus on the requirements of NDE procedure qualifications using Computed Radiography (CR) & Ultrasonic Testing (UT). Also discussed will be some specific application of each technique. |
10:15 - 10:30 |
Coffee Break |
10:30 - 11:05 |
The Welding of Nickel Alloys to Stainless Steels
Brian D. Gaal, Wire Products Division
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Information will be available soon. |
11:05 - 11:40 |
Codes and Standards: Do they address Dissimilar Metal Welding?
Ben A. Pletcher, Select-Arc Inc.
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Codes and Standards provide a baseline for engineering design, fabrication, and final service life. They serve as a guiding metric for industries to follow. But do they adequately address the complicated nature of dissimilar metal welds? A survey of the ASME Codes, specifically: Section VIII, Section IX, and B31.3 will provide a basis for the discussion, while incorporating industry feedback. |
11:40 - 12:45 |
Lunch |
12:45 - 1:20 |
Challenges Encountered with Post Weld Heat Treatment of Dissimilar Weldments
William F. Newell, Jr., Euroweld Ltd.
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This presentation will cover a basic history and various deviations of the Gas Tungsten Arc Welding (GTAW) process used for fusion welding of aluminum base materials. As the technology evolved, so have the adjustable parameters. A section will be dedicated to discussing new technology and the benefits that it has to offer. |
1:20 - 1:55 |
Explosive Welding Dissimilar Metals
Don Butler, High Energy Metals, Inc.
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Explosive welding is an interesting, viable and vetted technique for welding dissimilar metals. This presentation will show how the explosive welding process works, its advantages and limitations. Pictures and illustrations of specific applications will be shown and discussed. |
1:55 - 2:30 |
Crack-Free Welding of Nickel-Base Alloys
Donald J. Tillack, Tillack Metallurgical Consulting, Inc.
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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 power plants, refineries, and chemical plants. Techniques for determining dilution and the resulting composition of a dissimilar weld are explained. Constitutional (ferrite) diagrams are used to analyze typical dissimilar welds. Both nickel-based and stainless alloys are covered. |
2:30 |
Adjournment |
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How to get “up to speed” quickly. How to ask the right questions. How to get the results you need, save money, and stay out of trouble! This two-day conference is for managers, engineers, designers, and others with welding responsibility but limited exposure to or background in welding. The conference focuses on arc welding applications, but the principles have universal applicability. Presentations and discussion are based on the “Application Analysis Worksheet,” which was developed to teach a senior college course to engineers about to enter industry, with the objective of helping them develop a path to understand and deal with the challenges they were about to face.
Tuesday, November 19, 2013 |
Conference Chair: Fritz Saenger |
8:00 - 8:30 |
Welcome and Introduction |
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Welcome, introduction, and overview of the conference program. |
8:30 - 10:00 |
The Application Analysis
Fritz Saenger, Manufacturing Consultant
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Introduction to the concept of application analysis, i.e., identifying the questions that need to be answered in order to identify the key factors affecting the quality, productivity, and cost of the welding portion of the total manufacturing process, and to recognize the interactions between welding and other operations. |
10:00 - 11:00 |
Key Background Information
Walt Sperko, Sperko Engineering
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What is steel? Why is it different from most other materials? What do alloying elements do? What happens when you make a weld? What is "weldability?" |
11:00 - 12:00 |
"Matching" the Base Material and the Weld
Kevin Beardsley, Lincoln Electric
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Common industrial steels and common welded joints. Selecting the proper filler metal. Weld performance requirements, such as strength, toughness, color match, corrosion resistance, and method of testing. Preparation and surface conditions, welding position, etc. |
12:00 - 1:00 |
Lunch |
1:00 - 2:00 |
Pre- and Post-Weld Operations
Blaine Stoesz, Weldco
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The effect of pre- and post-weld operations on productivity, quality and cost. |
2:00 - 3:30 |
Arc Welding Process Modes
Bob Bitzky, ESAB
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What are you using? What are "advanced" modes? Would you benefit from "advanced" equipment and techniques? How do you make the right purchasing decision? |
3:30 - 4:30 |
The Welding Procedure
Lee Kvidahl, Ingalls Shipbuilding
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Sources of welding procedure requirements. Testing and confirmation. |
4:30 - 5:00 |
Make Your Procedure Robust
Dennis Harwig, AWS
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Controlling the critical parameters – the wire feed speed and travel speed ratio. |
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Wednesday, November 20, 2013 |
8:00 - 9:00 |
Weld Quality
Dick Holdren, Arc Specialties
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Requirements of different types of applications: commercial, military, industry, etc. Specifications and how to be sure you understand what is required by the customer. |
9:00 - 10:00 |
Welding Costs
Pete Ullman, Techniweld
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"Standard" cost calculations and sources of cost overruns. |
10:00 - 11:00 |
The Automation Decision
Jeff Noruk, ServoRobot
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Would you benefit from automation? What robots can and can't do. How to make the right decision. |
11:00 - 12:00 |
What Is "Productivity"?
Fritz Saenger, Manufacturing Consultant
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How do you measure productivity? How do you find the best opportunities for improvement? Dealing with repairs. Operations management concepts. |
12:00 - 12:30 |
Lunch |
12:30 - 1:30 |
Welding Safety
Kevin Lyttle, Praxair
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A checklist to assure operator safety - and compliance with state and federal standards. |
1:30 - 2:30 |
Aluminum
Tony Anderson, Miller Electric
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Key differences in materials, process requirements, equipment, etc. for welding aluminum. |
2:30 - 3:30 |
Stainless and Heat-Resisting Steels
Bill Newell, W.F. Newell & Associates
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How stainless and heat-resisting steels differ from carbon and low alloy steels. Why filler metal selection is different. Joining dissimilar materials. |
3:30 - 4:30 |
Review of the Application Analysis - and a "TO DO" List
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How does your welding operation relate to other plant functions? How does it relate to principles discussed in this program? Summary, questions, one-on-one discussions. |
