annual scholarship night inside this issue thursday ... · co-op welding students, summer interns...
TRANSCRIPT
1 SEPTEMBER MEETING:SCHOLARSHIP NIGHT
1 MAP2 COMMITTEE CHAIRS2 CHAIR’S MESSAGE3 SCHOLARSHIP WINNERS4 SEPTEMBER HOTLINE5 HIGH SCHOOL WELDING
COMPETITION6 CWI CORNER: I NEED
HELP...PLEASE?7 EDITOR’S NOTE8 ASK THE WELDING
ENGINEER10 EDUCATION NIGHT
RE-CAP12 2018/19 PATRONS15 GOLF OUTING RESULTS!16 SAVE THE DATE:
SMWC XVIII 2018
September 2018Inside This Issue
Follow Us: awsdetroit.org
AWS Technical Nights are open toeveryone! We encourage thatmembers bring students and non-members to learn more about ourorganization and industry.
Affiliated With
For AdvertisingOpportunities
Contact Brian Peterson810-844-2800
The AWS Detroit Section promotes the welding industry by investing instudents who are attending various universities, community colleges, andtrade schools. This year, AWS Detroit Section was able to award scholarshipsover $60,000.00 to help students succeed and promote tomorrow’s weldingindustry. Student Night is a celebration honoring students, parents and teachers.We are very proud of these students. (See page 3)
Come out and celebrate Scholarship Night withus. We hope to see as many students as possible.Make note that we are at a new venue this year:the OCC Auburn Hills campus.
It will be a great event and we are expecting asold out crowd. So please RSVP as soon as possible!
Please RSVP by Sept. 10with Amanda [email protected]
Annual Scholarship NightThursday, September 13, 2018
Location: Oakland Community College – Auburn HillsABC Building – Room G240
2900 Featherstone Rd, Auburn Hills, MI 48326Enter at south doors at south-west corner of the ABC Buildings
Click here for Google Maps
AGENDA
5:30 - 6:00 pmWelcome Reception &
Networking
6:00 - 7:00 pmDinner
7:00 - 9:00 pmAwarding of Scholarships
9:00 pmAdjourn
The summer of 2018 is coming to its end. Even thoughmany of us are focused on squeezing in one last vacation, thenew work year is at our doorstep. We have a full year planned
– including technical meetings, our world-class Sheet Metal Welding Conference,welding educational series events, and the high school welding competition.
I would be remiss if I didn’t acknowledge all the volunteer hours that weregenerously given by the members of our committees. Donnie Crist and hisgolf outing committee prepared a very successful event a few weeks ago.Although a few golfers may have lost track of a stroke or two, we didn’t let itstand in our way from having a great outing. John Pippin, Jr. prepared a listof subjects and venues for our upcoming technical meetings. Warren Petersonand his entire Sheet Metal Welding Conference committee worked endlesshours to prepare for this October’s conference. With so many great technicaltalks available, I will personally find it difficult choosing among the presentations.The list of behind the scenes volunteer hours needed to keep our section vibrantgoes on and on – whether it be preparations for the Christmas Party, schedulingwelding educational series speakers, preparing budgets, balancing the books,preparing for the ladies night gala, working on SENSE and with schools,preparing the bulletin, reviewing scholarship and endowment applications,etc. – it takes a busy team to pull it all together. Thank you to my entirecommittee for starting your work in June (and sooner for some of you).
We officially start the year off on September 13 with our Student Night atOakland Community College – Auburn Hills. The scholarship program is oneof our proudest achievements. The investment in the matching funds programhas yielded a program that will allow us to contribute over $60,000 towardsstudents each year. Together with our new grant program, the scholarshipprogram helps us reach out to students, schools, and fabricators, to helpensure the steady supply of skilled trades and engineers that are needed tosupport our country’s needs. All this helps us achieve our mission of advancingthe science, technology and application of welding and allied processesincluding joining, brazing, soldering, cutting and thermal spray.
Finally, I would like to acknowledge the support from all our patrons andemployers who support us financially as well as allowing their employees tospend time volunteering in our society. Without all your support, we could notserve the welding industry and arts as effectively as we do. Thank you!
If you wish to be personally involved with the AWS-Detroit Section, pleasedon’t hesitate to contact me at (810) 602-9735 or [email protected].
Mark D. Gugel, P.E., Ph.D.Chairman’s MessageSeptember 2018
This Issue of the Bulletincan be viewed on the web at
awsdetroit.org�
ChairmanMARK GUGEL
TreasurerANDRE YOUNG
SecretaryDAN WELLMAN
1st Vice ChairJOHN SUTTER
2nd Vice ChairJOHN PIPPIN, JR.
1st Assistant to ChairERIC LICHTFUSZ
2nd Assistant to ChairNATHAN MILLER
3rd Assistant to ChairWEIJIE ZHANG
Bulletin EditorROBIN MICHON
WebmasterRODNEY BEREZNICKI
AdvertisingBRIAN PETERSON
Hotline CoordinatorCODY NICHOLS
Meeting ReservationsAMANDA E. DAVIS
Co-op Welding Students,Summer Interns andPart-time Welders
Contact Pat Bell:[email protected] (313) 282-8171 in Detroit
New Products!Fronius USA
The newest member of the new Fronius TIGgeneration is here! Smart TIG welding with thenew MagicWave 230i. It is connectible withother devices via Bluetooth, Wireless LAN andNFC such as welding helmets, remote controlsand also mobile phones. For details visit theFronius website at www.fronius.us or by usingthis link http://bit.ly/2LHmUw3
Weld Mold Company
New WMC SafetyRobot with Safety ValidationProvides Totally Remote Floodwelding
With the new WMC SafetyRobot™ teleroboticwelding system, operators can perform remoteflood welding in a temperature-controlledenvironment, maintaining total control usinglong established best welding procedures.Operators are protected from heat, smoke,fumes, and radiation, as well as many healthissues that often result. There is also a completesystem package available that comes completein a 20-foot container. Everything is preinstalledand interconnected, ready to connect to primaryelectrical and shop air.
The complete WMC SafetyRobot system packageincludes robot and controls with proprietarysoftware; welding power source with associatedequipment for running .035”-3/16” diameterwires; an operator station and office complete
with AC and heat and lighting; dual monitors,PC, cameras and video capabilities; allinterconnecting cables; safety caging, andmuch more. Weld Mold also offers two weeksof on-site training. The WMC SafetyRobotwelding process is patent pending.
It’s important to note that the WMC SafetyRobotrecently passed an extensive safety validationprocess.
AwardsASM International Recognizes WeldMold in Historical Landmark AwardPresentation
Brighton, Michigan… On Thursday May 17th,ASM International presented Weld MoldCompany its prestigious ASM Historical Land -mark Award for 2017. Attending the eventwere ASM International dignitaries, distin -guished representatives from the city of Brightonand state of Michigan, members of the press,Weld Mold officials and employees, and otherinvited guests. Weld Mold Company wasrecognized for developing and innovating theflood welding process for weld die repair. MattKiilunen (1905-1990), Weld Mold Companyfounder (1945), was personally responsible forinnovating the process, which took die repairto the next level–increasing die life whilereducing customer costs. From the Iron Bridgeto the Statue of Liberty to the Eifel Tower inParis, the ASM Historical Landmarks Designationrecognizes sites and events that have played aprominent role in the discovery, developmentand growth of metals, metalworking and allengineered metals. Familiar company recipientshave included AT&T, Republic Steel and GeneralMotors ASM International is the preeminentassociation to engage and connect materialsprofessionals and their organizations to theresources necessary for solving problems,
improving outcomes and advancing society.It is the largest and most established materialsinformation society in the world, providingreference content and data, education courses,international events, and research.
Weld Mold Company is an internationallyrecognized manufacturer that delivers high-quality custom solutions for general weldingapplications and forge welding. That includesa full line of specialty high-alloy weldingelectrodes, cored wire and solid wire productsolutions for welding and flood welding, withspecially designed machinery to facilitate theflood welding process. Weld Mold has officesin Brighton, Michigan, as well as in China andKorea.
Assistance Needed:ATTENTION RESISTANCE WELDING COMPANIESAND EXPERTS: The AWS and RWMA are inthe final stages of launching the new CRWT(Certified Resistance Welding Technician)certification. They are in need of people totake the beta CRWT test to help them sortout questions and make sure all is good tolaunch the official certification process by endof 2018.
Below is a link to help anyone willing to takethe test sign up. This CRWT certification onresistance welding is well overdue for ourindustry and it will help educate and also allowpeople working in the resistance welding fieldadd a world recognized credential to theirresume showing their ability to operate in theresistance welding field with the highest levelof competency.
It will also allow companies seeking individualwith RW experience to hire someone with theCRWT credential knowing they have passedan excellent technically based RW exam andachieved CRWT status.
PLEASE SIGN UP AND TAKE THE BETA TEST.There is no charge for this, the test will be givenlocally and you will receive free resistancewelding publications for volunteering yourtime. https://www.aws.org/library/doclib/BETA-CRWT-20180710-2.pdf
Please contact Don DeCorte or Donnie Cristat Roman Mfg. if you have any questions orissues signing up. 1-616-530-8641
September Hotline
45th Annual High School Welding CompetitionWashtenaw Community College • Ann Arbor, Michigan • May 11, 2018
This year marked the 45th year the AWS Detroit Sectionheld its annual High School Welding Competition whichover 30 high school seniors competed to showcase theirwelding skills and knowledge for a chance to win somereally amazing welding equipment and scholarshipfunding. If you’re not familiar with the HSWC, thecompetition is specifically designed for high school weldingprogram seniors in an attempt to help prepare them forwherever their journey takes them beyond high school;higher learning and the beginning of a successful careerin the welding industry! The competition is an all-day
event where students are pushed to use the skills andknowledge they learned in class and apply it to a seriesof timed welding projects and a fundamentals writtentest. The welded projects consist of an aluminum and acarbon steel project where the students must make theprojects conform to a set of blueprints where safety workpractices, dimensional tolerances, weld size, weld processand weld location are specified and scored. They are alsoscored on overall craftsmanship of their work and thejudges use a very rigorous scoring rubric to place theseprojects. Continued on page 16
I discussed in a previous article(March 2018) how important it is tohave a mentor, especially when you’rea brand-new CWI. I also discussedthe importance of building a solidsupport network. And, as importantas those things are, you don’t foreverwant to be the CWI that is alwaysasking everyone else for their opinion.Especially when you can never providea direct answer to questions that areasked of you. It’s important tounderstand when your research isbringing you to the right conclusionsand feel confident about them, butstill there are times when you need toreach out for help from your supportnetwork. At some point in time youneed to be able to recognize thesesituations and react accordingly. Thatcan be a bit scary, but rest assured
there are resources that can help youmake some of the critical decisionsyou might face as an inspector. Hereare some questions you may be askingyourself from time to time. Am I usingthe right tool for the type of inspectionthat I’m doing? Is this even the rightinspection method? What otheroptions are there? Am I looking forthe right things to make my deter -mination on acceptability? These canbe tough questions to answer but AWSpublishes several guides for this verypurpose. The order in which I presentthese resources does not represent theorder of importance. How you usethese guides, and the importanceplaced on them, will be somethingyou establish during your use andunderstanding of them.
The first guide that I would recom -
mend is the Guide for the VisualExamination of Welds, AWS B1.11M/B1.11. As the title implies, this guideprovides you with an introduction tovisual examination of weldments. Itbreaks the examination process downinto three categories, (1) prior towelding, (2) during welding and (3)after welding. It offers insight intowhat things you should be lookingfor before the welding begins, suchas review of contract documents andstandards. What to look for oncewelding has begun, such as review ofwelder qualifications, verification ofproperly functioning equipment,verification of proper consumables,etc. Also, what to look for after weldingis completed, including weld surfacequality and conditions, besides thecode requirements. There are illustra -tions and photos showing variousdiscontinuities that you would com -monly find in welding. Some of thesecan help you to determine wherecertain types of discontinuities aremore likely to be present. There is alsoa section dedicated to examination
CWICORNER
I Need Help...Please!By Eric [email protected]/CWI 09070281
Continued on page 7
equipment. In this section you willfind descriptions and methods forthe use of temperature measuringdevices, weld gauges, ferrite gauges,borescopes, electrical meters, etc.Below is a link to the AWS Bookstorefor information on this guide.https://pubs.aws.org/p/1547/b111mb1112015-guide-for-the-visual-examination-of-welds
Second is the Guide for the Non -destructive Examination of Welds,AWS B1.10M/B1.10. As the title forthis guide implies, its purpose is togive you an overview of some of themore common examinationmethods. It is not intended to givedetailed, in depth instruction intoeach method, rather general informa -tion that may help you decide whatthe best method for a given weldingproject may be. Topics covered in thisguide include, Visual (VT), LiquidPenetrant (PT), Magnetic Particle(MT), Radiographic (RT), Ultrasonic(UT), Electromagnetic (Eddy Currentor ET) and Leak (LT). This guide willfamiliarize you with common termsand definitions, various discon -tinuities and an informative selectionguide for the various methods. Belowis a link to the AWS Bookstore forinformation on this guide. https://pubs.aws.org/p/1680/b110mb1102016-guide-for-the-nondestructive-examination-of-welds
Finally, the last publication I’lldiscuss here is the AWS WeldingInspection Handbook (WIH). TheWIH covers topics that include testingand examination methods, and thegeneral duties and responsibilities ofwelding inspectors. Subjects such ascommunication of design weldingintent with the proper use of weldingsymbols, welding inspection opera -tions, quality assurance, weldingmetallurgy, preheating and postweldheat treating, weld and weld relateddiscontinuities, qualification of weld -ing procedures, welders and weldingoperators, destructive weld tests, prooftests, and more can be found in theWIH. This handbook is a must have
for the new and experienced CWIand welding inspec tion personnelalike. Not only can this handbookprovide you with valuable in form -ation on where and how to start yourreview of materials, drawings andspecifications before you even beginwelding, but it can also help walkyou through the entire inspectionprocess including prep aration of yourfinal reports. Below is a link to theAWS Bookstore for information onthis handbook. https://pubs.aws.org/p/1542/wi2015-welding-inspection-handbook There aremany other resources to considerwhen researching infor mation. Whenmaking a deter mination related towelding and welding inspection, Ihave found that these guides andhandbook are vital. These, alongwith a solid network of people thatyou trust and have proven themselvesreliable are absolutely critical inmaking decisions on your weldmentproject.
If you’re not already an AWS CWIand the idea of becoming a CWI is acareer that you would like to pursue,the AWS-Detroit Section is hostinganother AWS CWI Seminar/Examthis year. The seminar/exam dateand location are as follows:
CWI Seminar:September 30-October 5, 2018Exam: October 6, 2018
Washtenaw Community College4800 E. Huron River Dr.Ann Arbor, MI., 48105-4800
Check the AWS-Detroit e-Bulletinoften for other helpful information,at www.awsdetroit.org. For moreinformation on how to becomeproperly trained and certified by theAmerican Welding Society and toregister, you can visitwww.aws.org/certification.
By Eric [email protected]/CWI 09070281
I need help...please!continued from page 6 Editor’s Notes
Welcome to the first edition ofthe 2018/2019 AWS DetroitSection E-bulletin! It’s September!Kids are back in school, the roadsare a little more crowded on yourway in, and the AWS DetroitSection is back in full gear! Westart out this season with ourannual Scholarship Awards! Wehope you can come out andcelebrate the gifting of 30scholarships totaling $60,000 atour Scholarship and Tech Nightin September.The Sheet Metal Welding
Conference XVII is quickly comingup on us next month, October 17and 18 at the beautiful LaurelManor in Livonia, MI. The lastSMWC XVI (in 2016) was a hugesuccess and we hope to be evenmore successful this year withinteresting speakers, and asalways, the free Vendor night! Just a quick reminder that
although you don’t have to be amember to attend events that theAWS Detroit section provides,membership does have itsadvantages! Hope to see you during the new
2018/2019 season and until nextmonth…
Keep on Welding!
Robin
“My company is in the process of quoting several newassemblies that require resistance spot welding and I
am concerned that the specified widths of the flanges aretoo small for the required electrodes. Are there sources forflange width design recommendations that I can referenceso as to determine whether or not the proposed concept iscapable of supporting the required resistance spot weld?”
“As discussed in our previous column (May-18 ATWE), thesubject of a required minimum flange width is a source ofcontinual debate within the resistance welding community.
We also previewed some of the dimensional tolerances that mustbe considered as part of any analysis. With that as background,this column will illustrate the dimensional tolerances that effectthe placement of a resistance spot weld (RSW) on a flange.
The representation inFigure-1 details a genericelectrode cap/welding flangeinterface and the identifiedelements that can affect therequired minimum width.These elements are furtherdiscussed below. A note ofclarification; the assumption we are making for this column isthat we are dealing with a single side of a weld flange, as shownin Figure-1. If one assumes we add an identical mating flange(mirror image, etc.) the analysis still holds true, unless one flangeshifts along the mating surface of the other. Some designers saythat this shifting means the parts are no longer ‘line-to-line.’Also, we are not accounting for the effects of either the wall angleor bend radius. However, both are important considerations withregards to the selection of the electrode adapter and cap geometry.
Maximum Electrode Face Diameter (MFD): It is a giventhat the electrodes associated with RSW will wear over time. Thisphenomenon, also known as mushrooming, results in an increaseof the electrode contact face diameter. The exact amount of wearper weld is very difficult to predict as there are many factors thatcan affect the rate of degradation. Nevertheless, this wear mustbe accounted for by determining the maximum acceptable facediameter that the process can tolerate. Also, the degree thatelectrode face growth has on the location of the weld will varywith the process and the electrode maintenance philosophy. Asan example, the effect of electrode maintenance on altering theamount of wear can be tied directly to the periodicity of electroderedressing/changing. Also, the amount of variability associatedwith MFD, as a percentage of the total variability, tends to increaseas the ratio of body diameter / contact face diameter decreases.
Assembly Positional Tolerance (APT): The definition forAPT is the variation of the assembly from its desired locationwith respect to an established reference point. This critical elementapplies whether the assembly is located by means of manualpositioning, hard automation (ie. a dump or a slide), a robot, orany combination thereof, and is needed to account for the inherentpositioning variations associated the positioning of any part tobe welded.
Electrode Positional Tolerance (EPT): The definition for EPTis along the same lines as APT and is the variation of the electrode
position from its desired location, with respect to an establishedreference point. This variation may also be the result of manualpositioning, hard automation, or a robot. To further understandthis source of variability two different aspects must be considered.These are the physical condition of the tooling that is locatingthe electrode (ie. the robot itself) and the process utilized toactually position the electrode (ie. the robot program). As in allmechanical systems, EPT will be at its lowest value when thetooling is in its most mechanically robust condition. Please notethat one must be careful not to assume that new tooling is at itsmost robust condition and therefore contributing its lowest valuefor EPT. Why? This assumption would discount any potentialimprovements made by the hard working folks on the plant flooras they continuously strive to improve the assembly and weldingprocess. It almost goes without saying that the process utilized toposition the electrode caps has an effect on the EPT. One onlyneeds to visualize how unrepeatable a person is pounding in anail, let alone attempting to position a manual welding gun. Itshould be noted that some modern assembly lines employ separaterobots to independently position both the assembly to be weldedand the welding gun simultaneously, with the resultant potentialto significantly increase overall variation as both EPT and APTcome into play.
Expulsion Dam (ED): The act of creating a proper resistancespot weld is, by its very nature, a quick and violent physicaltransformation. To help constrain this process, a certain amountof unaffected base material must be present to surround thenewly forming weld nugget. For our purposes, this required basematerial is called the Expulsion Dam (ED). The minimum requiredamount of material needed to act as an effective ED can vary bymaterial, stack-up (total, ratio, 2T, 3T, etc.) and electrode capconfiguration. Figure-2 illustrates a generic stack-up/electrodecap combination and serves to illustrate how weld nugget growthcan relate to the contact area of the electrode faying surface.From a design perspective, values for ED of approximately 1.5 xGoverning Metal Thickness (GMT) should be sufficient.
Cut Flange Tolerance (CFT): This element of variability isperhaps the easiest for anyoneassociated with manufacturingto grasp, most likely due to thefact that ‘short metal’ is theinitial default answer for almostany edge welding condition,whether the flange is actuallydimensionally within specification or not. That being said, evenif the plant welding engineer is fortunate enough to have partsdesigned with sufficient flange width, vigilance is still needed.The steady accumulation of hits will take their toll on the stampingdies, and despite the best efforts of the maintenance staff,dimensions will subtlety change due to wear. This wear will oftenmanifest itself in many ways, with a common issue being flangebend radii ‘wash out’, or an increase in radii diameter. If it isassumed the overall dimension of the stamped part blank hasn’tchanged, an increase in the bend radius has the effect of reducingthe width of the flange’s weldable flat area, with the resultantcomplications associated therein and if, because of the apparentlength increase, the blank is trimmed to
s
Ask the Welding EngineerBy Donald F. Maatz, Jr.
A:
Q:
Figure-1
This article is a continuation of the May-2018‘Ask the Welding Engineer’
Continued on page 14
Figure-2
The Detroit Section’s [2nd of 2 yearly]Educational PDH Night was held on April 19thand attended by some twenty energetic and full-of-questions welding folks. The Tool & Die weldingexposition consisted of Eureka Welding Alloys’three presenters: Tom Web, Bob Addington, andChris Kerchkof. Their combined 95 years ofexperience with Eurekawent hand-in-hand withthe company’s rich andpioneered 92-year-old nichehistory. Tool & Die past vs.present, applications andprocesses, and finallyautomation solutions fortoday were explained.
For more informationon the event and EurekaWelding Alloys, pleasevisit: awsdetroit.org/events.
Recap of EducationalPDH Night
Presenters: Tom Web, Bob Addington, andChris Kerchkof
2019-2020 Patron’s Fund DonationsOur goal at the AWS Detroit Section is “to advance the science, technology
and application of welding.” We accomplish this by promoting education andSection participation.
It is time again this year to ask you for your generosity in contributing to thePatron’s Fund. We will, as always, contribute 100% of these funds directly towardsscholarships for students who are pursuing careers in Welding Engineering andWelding Technology. Each year the American Welding Society Detroit Sectionsponsors many students with these funds, and because this is such an importantpart of giving back to the industry that supports us, we hope you can help us bybeing a proud supporter in this effort. I have included the announcement letterwhich shows the many 2018-19 scholarship recipients that were helped in partby contributions from our Patrons in past years.
To be a Patron, simply send a check made out to the American Welding SocietyDetroit Section for a minimum of $100 or visit our website at www.awsdetroit.org,click on “Scholarships” in the blue banner then scroll down to the “Pay Now”button. I encourage you to please consider a contribution of more than the$100.00 minimum, and here’s why.
This year my plea for your support is with more intensity than ever before. Thelast four years were remarkable years for Patron contributions. Through you, ourPatrons, we were able to raise $9000 last year. Over the last four years the Patronshave helped us raise nearly $40,000. This year again my goal is $15,000. Thatmay sound ambitious, but I’m sure that many, if not all of you, have had anopportunity to interview applicants for welding related positions within yourcompany. If so, you’ve probably noticed that although the ambition may bethere with these potential new hires, the skill sets may not. That’s where thefunding comes in. The cost of education is high, and with your help we canprovide students that are seeking careers in welding related positions withfinancial assistance to improve those skills. This creates a stronger, better educated,workforce and a more efficient and profitable company for you. Additionally,you’ll be recognized in the industry for your contributions. Patrons are madeknown to the membership in the monthly technical bulletin, to the industry onthe AWS website, and are further acknowledged with a listing in the annualLadies Night Program.
If you are a Patron, we thank you for your support, and ask you to pleaseconsider increasing your contribution.Whether a longtime Patron or a first-timePatron, your help will assist us to bringabout an educated future workforce.
I thank you in advance for yourcontribution, and await your rapid responsefor the 2019/2020 season.Please make contributions payable
to AWS – DETROIT SECTION and mailto:
Steve GucciardoFCA US LLCCIMS: 481-00-35800 Chrysler Dr. Auburn Hills, MI 48326
Warmest regards,Steve Gucciardo, ChairAWS Detroit Section-Patron’s [email protected]
AET Integration Inc.ATI IndustrialAutomation
Aro Welding TechnologiesDengensha America
LuvataRoMan Manufacturing
MathesonCenterline Windsor
LeoniCAEtsObaraStaubli
Genesis SystemsGrossel Tool
United TechnologiesAirgas
Fusion WeldingFroniusICR
Ashley JonesMatuschek
Ohio State UniversityWelding Alumni
2018/19 Patrons
compensate, therewill be a too-short
flange condition when the die is repaired and returns the bendradius to design intent.
All of the above elements are present each and every time aweld is made. But, as stated above, the effect that each has onthe total variability of weld location on a given flange is verydifficult to quantify. There is an argument put forth by someengineering groups that maintains it is statistically unusual forall of the tolerances to stack up in a purely additive mannerand therefore do not advocate the use of a worst case, linearcondition sum of the tolerances. Instead, the square-root of allsquared and summed tolerances is used as a more reasonableapproach for determining the required minimum flange width.This is called an RMS tolerance and is used as a more realisticapproach to make tolerance calculations more reasonable.
While the above items focused on welding there can be otherconsiderations that directly affect the required minimum flangethat may have nothing to do with welding at all. Examples ofthis include the addition of sealer and adhesives into the weldjoint. These essential items require sufficient surface contactarea in the joint to be fully effective and sometimes mandatethe selection of a welding flange that is wider than would be thecase without their presence. Also, the higher strength materialsmuch more common in today’s designs may drive the need fora wider flange as they present a challenge to the stampingfacilities that are asked to form them. These are but two quickexamples that come to mind and I am sure there are others.
The above points, taken as a whole, attempt to illustrate afew of the many considerations that must be taken into accountwhen designing just the welding flange of a part to be spot
welded. However, the maturity of the RSW process has resultedin product designs, and designers, that have a great deal ofintrinsic inertia associated with them, resulting in many veryweldable joints. This maturity can be both a blessing, and acurse, as it is possible for those tied to the product design andreview process to become complacent. The addition of newermaterials to the system that do not conform with ‘the norm’and/or product designers attempts to reduce flange widths toomuch because they were never taught why they were that wideto begin with, are but two examples of why the design standardswere created and need to be adhered to, lest a less than robustprocess be given to the manufacturing facility. In other words,just because you have a voice activated dialing system in yourcar; it does not relieve you of memorizing your home phonenumber as you might find yourself in the situation where youmust perform the task of dialing manually.”
Acknowledgement: I would like to thank Tom Morrissett, former AWS D8chairman, for his invaluable perspective on minimum flange width requirements.Figure-1: Representation of a generic electrode cap/weld flange interface andpossible location dimensional variables. Figure-2: Metallographic representation of a generic stack-up/electrode capcombinationReferences:1) Resistance Welding Manual, revised 4th Edition2) AWS C1.1M/C1.1:2012, Recommended Practices for Resistance Welding
If you have more questions about this topiccontact Don Maatz at:R&E Engineering ServicesA subsidiary of R&E Automated Systems, LLC70701 Powell Road, Bruce Township, MI 48065(586) 228-1900 – Office; (734) 793-2304 – [email protected]
ATWE continued from page 8
2018 AWS Detroit Section Golf OutingThe American Welding Society - Detroit Section Annual Golf
Outing was held on Thursday, July 19th, 2018 at Cherry Creek GolfCourse. The outing was a success as 104 golfers turned out for a dayof golf on a beautifully conditioned golf course. The weathercooperated as we had an extremely comfortable outing with abreeze and temperatures in upper 70’s. As one of our sections fundraising events this year’s outing raised over $8000.00 with all theproceeds contributing to grants and scholarships.
As with many of our events our sponsors play a huge role in thesuccess of the event. The AWS Detroit Section would like to extenda huge thank you to our sponsors, participants and to the manyvolunteers that make the outing possible.
2018 AmericanWelding Society-Detroit SectionOuting Winnersfrom Left to RightChris Walker, RonMersman, JeffButerakos, andRob Adamek
Thank you sponsors!- RAM Solutions- SDK Engineering - Fronius- Centerline- Dengensha America- Obara- Milco Manufacturing- Parker- ARO Welding Technologies- T.J. Snow Co.- Changer & Dresser Corp- RoMan Manufacturing- Tarpon Automation- Applied Robotics- Rain Soft of Northern Michigan- ATI Industrial Automation- Gugel Photography
Please welcome me incongratulating the following contestwinners and their respective schoolfor all their hard work!
1st place: Kurtis Blumenauer (Southand West Washtenaw Consortium)
2nd place: Jacob Hausch (WilliamD. Ford Career Technical Center)
3rd place: Jacob Towle (Flat RockCommunity High School)
4th place: Tim Benninger (OaklandTechnical Campus Northeast)
5th place: Cameron Harnden(Oakland Technical Campus Southeast)
The success of the High School Welding Competition is only madepossible by the support we receive from our welding suppliers, ourcolleagues, patrons, section members, etc. To those that havecontributed this year and in years past, this competition supportsthe very lifeblood of our community and serves as an inspiration toour young welders to further their education, develop one’s skillsand continue to pursue a career in the welding industry. Your supporthas been truly invaluable.
Best regards, Glenn Kay, AWS HSWC Chair
Inspection
HSWC continued from page 5