may technical night thursday, may 9, 2019 - awsdetroit.org · coming events may 3 aws detroit...
TRANSCRIPT
We welcome members and non-members alike. Students are alwayswelcome and encouraged to join us!
1 MAY TECHNICAL MEETING 2 COMMITTEE CHAIRS2 CHAIR’S MESSAGE2 GOLF OUTING
SPONSORSHIP INFO3 GOLF REGISTRATION4 EDITOR’S NOTE5 MAY HOTLINE6 UPCOMING EVENTS6 STUDENT SECTION:
GOLIGHTLY7 REMINDER! H.S. WELDING
COMPETITION MAY 3RD9 CWI CORNER, “LET’S TALK
PQR”10 PATRONS11 LADIES NIGHT RECAP12 ASK THE WELDING
ENGINEER14 MEET OUR MEMBERS15 APRIL TECH NIGHT AT
CENTERLINE 18 DISTRICT 11 DIRECTOR
NEWS
May 2019
Inside This Issue
May Technical NightThursday, May 9, 2019
Aluminum Welding: What’s the Fuss?Speaker: Ge (Jason) Song, WTC Applications Engineer
Location: Welding Technology Corp (WTC)24775 Crestview Ct. • Farmington Hills, MI 48335
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Jason Song, Applications Engineer, will cover the main presentation materialfor the evening. Song received a Master’s degree in Mechanical Engineeringfrom Syracuse University in 2014, joining WTC’s product managementteam in 2015. Jason has focused on the research and development ofWTC’s aluminum welding technology. The presentation will address thechallenges associated with aluminum spot welding, the types of equipment
necessary for the process, and a new approach to achieving weld quality. Welding Technology Corp is a global manufacturer & supplier of technology in the
resistance welding industry. Their headquarters in Farmington Hills, MI is home toall core departments, including the engineering, manufacturing, and technical supportteams. With a multitude ofpatented welding productsincluding Medium FrequencyDC welding controls, network -ing, data collection and pre -dictive maintenance tools,Welding Technology Corp hasreached global customers in theaerospace, automotive andconsumer goods industries.
CONSTRUCTION NOTE: TheGrand River Bridge over M-5 iscurrently closed for construction. PerMDOT, the construction is expectedto continue into July 2019.
Westbound Grand River traffic willbe detoured to northbound HalstedRoad, then westbound Hills TechDrive to southbound HaggertyRoad. Intermittent lane closures canbe expected throughout the project.
AGENDA5:00 - 6:30 pm Network Manufacturing Tour
and Welding Lab Demos5:30 - 7:00 pm Light Dinner7:00 - 7:10 pm AWS Meeting & Award
Presentations7:10 - 8:00 pm Presentation by Jason Song
8:00 pm Adjourn
Please RSVP no later than Wed., May 1stto Ellis Mayton ([email protected])or Amanda Davis ([email protected])
There is no charge for this event.
Mark D. Gugel, P.E., Ph.D.Chairman’s Message
May 2019This Issue of the Bulletin
can be viewed on the web at
awsdetroit.org�
Chairman: MARK GUGELTreasurer: ANDRE YOUNGSecretary: DAN WELLMAN
1st Vice ChairJOHN MACKENZIE
2nd Vice ChairJOHN PIPPIN, JR.1st Assistant to ChairERIC LICHTFUSZ2nd Assistant to Chair
TBD3rd Assistant to ChairWEIJIE ZHANG
Bulletin EditorROBIN MICHON
WebmasterRODNEY BEREZNICKI
AdvertisingBRIAN PETERSON
Hotline CoordinatorCODY NICHOLSMeeting Reservations
AMANDA E. DAVIS
AWS Technical Nights are open to everyone! Weencourage that members bring students and non-members to learn more about our organizationand industry.
For Advertising OpportunitiesContact Brian Peterson
[email protected] AWS Detroit Section Sets Charity Golf
Outing for July 25thSubmitted by Donnie Crist
The AWS Detroit Section will hold its annual golf outing on July 25, 2019at Cherry Creek golf course located at 52000 Cherry Creek Drive, ShelbyTownship, MI. The cost is $150 per golfer or $600 per foursome and includesdriving range balls, hot dog on the turn, dinner, and all contests. Greatprizes will be raffled away during the dinner.
Please come join us for day of fun and golf for a great cause as all proceedsare to benefit grant and educational initiatives. Registration and sponsor -ship opportunities are available on the AWS Detroit Section websitehttps://awsdetroit11.wufoo.com/forms/x1ckswia12xkgyr/ If you haveany questions or hole sponsorship inquiries please contact Donnie [email protected] .
On behalf of our current chair, Mark D. Gugel..…
Thank you for another great year of serving the AWS Detroit Section and its members. I encourage all of you to get involved, invite a friend, invite a student, come out to a tech meeting or one of our successful fundraising scholarship events.
To all of the incoming executive committee and board members, I welcome you and wish you a very successful 2019-2020 Season.
We wish all the students participating in our Annual High School Welding contest the best experience! And, thank you to all of the volunteers and student educators who make this a great event every year.
Please remember to RSVP for our last Technical Night of the year which will be held at WTC in Farmington Hills, on Thursday, May 9, 2019.
I'd like to congratulate all the graduates of the high schools, colleges, and technical schools that will be entering the work force for the first time or beginning their career preparation and selection. For those of you who are undecided or know someone who is undecided, please encourage them to look into the many opportunties there are within the welding community.
Enjoy your summer and see you at the golf outing !
REGISTER ONLINECLICK HERE
EMAIL DONNIE CRISTCLICK HERE
www.awsdetroit.org
www.CherryCreekGolf.com
www.awsdetroit.org
Editor’s NotesIt’s May, and we have come to the end of the 2018-2019
AWS Detroit Section season. There are still several eventsgoing on through the summer, and plenty of events toremain active in your support of our future welders. One ofthe favored events of the summer is our annual golf outingin July which raises funds for our students and thescholarships that are awarded to them. You still have timeto get a spot in whether it’s to play, donate, or join us fordinner and prizes.
Our next technical night is approaching quickly–May 9,at WTC. Be sure to get your RSVP in early!
Thank you to all our members, column contributors, ourpublisher, DIMAC Graphics, the AWS Detroit Executivecommittee and all our advertisers and patrons for committingto our e-bulletin and making it one of the best in the country.It has truly been an honor and pleasure to be your editorfor the last 6 years.
As I pass the pen on to Forrest Lissner, your new e-bulletineditor, I wish him success and enjoyment in creating thismonthly ray of welding sunshine!
Have a wonderful summer! God Bless in All YourEndeavors!
And don’t forget to …Keep on Welding!
~ Robin
Check out the April 2019 Issue of Popular Mechanics,pages 73–75. “How To Be A Tradesperson,” writtenby Roy Berendsohn says the “demand for mosttrades is strong and getting stronger...” and“...industrial occupations like welding are in-demand trades that could mean either a stablecareer or a launching pad.”
The RWMA Resistance Welding Schoolis Coming to Michigan!!!!The RWMA Resistance Welding School will be hosted atRoMan Manufacturing on May 15-16, 2019 in Grand RapidsMI. The school is a comprehensive two-day course coveringall aspects of resistance welding. The RWMA instructorshave been working hard on updating material and somenew instructors have been recruited to bring YOU the bestof resistance welding technology! There will also be anopportunity to see RoMan’s updated world class transformermanufacturing facilities. For more information and a stream -lined process to sign up please check out: www.rwma.organd click on Resistance Welding School. Don’t miss thisopportunity to get excellent resistance welding educationright in your backyard!! Detroit’s own Don Maatz is oneif the instructors for the school! NEED WE SAY MORE!!!!
Fronius USA will be at EASTEC – will you? The East Coast premier manufacturing event is back May 14th – 16th.Will you be attending? If so make sure to stop by the Fronius booth#1737. We will have live welding with our Professional Welding Tools.And of course our knowledgeable staff from our NE Region will beavailable to talk to. Have a welding challenge? Come talk to us! Registerfor the event online https://www.xpressreg.net/register/east0519/landing.asp?sc=&aban=&hkey=&iq=&vip=&tm=&_ga=2.265563279.1845028348.1554129880-1304561047.1539024832
May Hotline
Coming EventsMay 3AWS Detroit Section High School Welding Contest
May 5-10AWS CWI SeminarPresented by AWS National
May 11AWS CWI ExamPresented by AWS National
May 7 – 9FABtech MexicoPresented by AWS, FMA, SME, PMA, and CCAI
May 9AWS Detroit Section Technical Night at WTC
May 15-16Emmett A Craig Resistance Welding SchoolPresented by AWS National
June 25-2824th Beijing Essen Welding & Cutting FairPresented by CMES, CWA, DVS and Messe Essen GmbH
July 21-26Instructors InstitutePresented by AWS National
July 25Annual AWS Detroit Golf Outing – Cherry CreekGolf CoursePresented by AWS Detroit
July 30Last day to nominate someone for theExcellence in Welding Awards.For more information or to nominate, go tohttps://webportalapp.com/sp/excellenceinweldingawards
Golightly CTC Vocational SchoolSubmitted by Jeff Hill
Over the past few years, AWS Detroit has been workingwith Golightly CTC in Detroit to assist in any way to betteror enhance the welding program at the school.
Jeffery Samuels, the instructor for the welding program,has been doing an outstanding job training our youngfuture welders. Many have chosen to move on to otherthings but many have been accepted to Ferris State andalso many attend Washtenaw Community College andtake advantage of the great welding program there.
Continued on page 12
Submitted by Glenn Kay, HSWC Contest Chair
Just a friendly reminder that the 2019 AWS HSWC will be held Friday, May 3rdat Washtenaw Community College. We are still accepting donations for welding
equipment, welding related tools and safety gear. If you have any items you can donate, please contact Glenn Kay at [email protected] or
Glen Knight at [email protected]. Thanks in advance to those that have already made donations
and we look forward to another successful event!
2019 AWS Detroit Section Annual High School Welding ContestEVENT REMINDER
Back in the April 2018 issue of theAWS Detroit Section e-Bulletin Idiscussed what WPS’s are and whythey’re important. What I did notdiscuss in detail is how they arequalified. For more information onwhat a WPS is, I invite you to go backand read the article from April 2018.For now, let’s get into how you wouldgo about qualifying your own WPSby PQR. I want to mention early onthat this is not a “how to” article onPQR development. How you qualifya PQR is a matter of following therequirements of your establishedstandard or code. I am simply tryingto give you some backgroundinformation on the subject.
First, let’s define what a PQR is. Forthat we’ll go to AWS A3.0M/A3.0:2010, Standard Welding Terms andDefinitions. According to A3.0, thereare basically two different kinds ofPQR’s that they identify. One is aBrazing Procedure QualificationRecord (BPQR) and the other is aWelding Procedure QualificationRecord (WPQR). They are ‘a recordof the welding variables used toproduce an acceptable test weldmentand the results of tests conducted onthe weldment to qualify a weldingprocedure specification.’ Tounderstand that definition I think weneed a more basic explanation. Wecan then explore a little deeper intohow a PQR is developed. For this articleI will not be discussing brazing andmore specifically I will be focusing onarc welding. Going forward I will bereferring to this “procedure” as a PQR.
I’m going to make several assump -tions before we start. I’m going toassume that you cannot write aprequalified procedure or purchase aStandard Welding ProcedureSpecification (SWPS) from AWS, whichI will discuss those options in a laterarticle. Let’s assume you are required
to qualify because you will be weldingbase materials that are unlisted inthe specified standard. I will alsoassume that you are required toqualify your procedure in accordancewith AWS D1.1/D1.1M:2015. Lastly,the PQR base metal(s) will be plate,not tube.
Let’s break this down into the twomain parts of the A3.0 definition, thevariables and the tests. In the A3.0definition they said a PQR is a recordof the ‘welding variables.’ Well whatare those? A3.0 doesn’t really tell uswhat variables are, but as the nameimplies, they are the things that couldchange, may not be consistent or areliable to change. You can establishyour own list of variables when you’requalifying a welding procedure andrecord everything you do and howyou did it. What I mean is, your recordof the event can include the time ofday, the ambient air temperature, thesize of the base metal coupon, thetemperature of the coupon at the startof welding, the brand/make andmodel of the machine you will use,the brand and filler metal type andsize, the shielding gas manufacturerand type, etc. The list can be as longas you like, and you could literallyrecord every detail. But as we look atAWS D1.1 we learn that whenpreparing a WPS the variables theylist are called “essential variables.”Essential variables are discussedthroughout clause 4 and whenreferring to table 4.5 we can see thatchanges beyond established limits fora given process to any of the essentialvariables require requalification. Withthat information, we see that whatwe consider to be a variable may notbe considered “essential” to the code.However, that does not mean we can’trecord them. Personally, I learnedmany procedures ago that recordingmore details than are required may
be helpful in the future. You only haveone chance to accurately record whatyou did, and that’s at the time of doingit. As an example, let’s say at somepoint after you’ve qualified asuccessful PQR for GMAW, you’vewritten your WPS and are now usingit in production. Unexpectedly youbegin to have issues with silicatestrapped underbead and yourweldments are failing radiography.What has changed since qualifyingyour procedure? By going back to yournotes that you made during PQRdevelopment, you discover youqualified using a different brand offiller wire from that which you’re usingnow. The brand is a variable, andsilica management is clearly betterfrom one brand to the next, as you’vediscovered, yet brand is not anessential variable according to D1.1.Had you only recorded “essentialvariable” information during testing,this issue may not have been as easilyresolved. There are other reasons youmay want to record “non-essential”variables, but for now let’s get backto the basics of a PQR.
To help you organize all the stepsneeded for PQR development it maybe helpful to turn to Annex M in D1.1.There you will find sample weldingforms, three of which are sample PQRforms. They show one for GTAW &SMAW, one for GMAW & FCAW andanother for SAW. There is also anexample of a completed PQR forFCAW. You may find these beneficialin determining what you need torecord and how it needs to be recordedduring your testing. You’ll need torecord the information for the basemetal(s), joint details, pre-heat,process, joint position, filler metal,shielding gas, the technique e.g.,weave or stringer, single or multiplepass, contact tip to work distance(CTWD), pre-cleaning and interpasscleaning, post weld heat treatment(PWHT), etc. Some or all of these mayapply to your particular PQR, andthere may be additional informationyou’ll need to record. You will need todetermine what you need to recordso that you have all the information
CWICORNER
Let’s Talk PQRBy Eric [email protected]/CWI 09070281
Continued on page 16
Co-op Welding Students,Summer Interns andPart-time Welders
Contact Pat Bell:[email protected] (313) 282-8171 in Detroit
AET Integration, Inc.ARO Welding Technologies, Inc.
ATI Industrial AutomationCAE Tooling Services
Centerline (Windsor) LimitedChanger & Dresser Corp.Dengensha America Corp.
Forrest Lissner
Fronius USA, LLCFUSION Welding Solutions
JEC Distributors Inc.LUVATA
MatuschekModels and Tools, IncObara Corp. USA
RAM Solutions IncRoMan Manufacturing, Inc.
Scott ProngerStäubli North America(formerly Multi Contact)
The Ohio State UniversityWelding Engineering Alumni
United Technical LLC
Patrons
AWS Detroit Section Ladies Night RecapThe AWS-Detroit section’s annual Ladies Night party was April 6, 2019 at the
Detroit Motor City Casino. This annual event has been an important activity for theAWS Detroit Section for 78 years and affords a unique opportunity for the weldingcommunity to come together and celebrate the achievements of our industry. Mostimportantly, funds raised from the evening gala are used to support the AWS-DetroitSection Scholarship program. Since its inception, the Detroit Section of the AWS hascontributed over $900,000 to scholarships for students pursuing a career in welding.
Past section Chairman of the AWS-Detroit Section Dan Wellman acted as Host,and Detroit section Past-Chair Don Maatz was MC. They were joined by AWS NationalPresident-Elect Bob Roth, AWS Foundation Director Monica Pfarr (David) AWS
Foundation Director, and over 400 other likeminded welding professionalsthat allowed the section to add over $6,000 to its scholarship fund.
The event also highlighted the other educational and support aspects ofthe section, including the section’s annual High School Welding Contest,
our student section atGoLightly, and Women WhoWeld, a unique program thatuses welding to help womenin need.
“My company is relatively new toresistance spot welding and we
are looking at efficiency improvementsthat would require running multiplepart combinations on a single tool.With an eye towards minimizingpotential changeover miscues we wouldlike to utilize a single welding electrodefor all of our spot welds, if possible.Unfortunately, after a review of themany electrode combinations thatmight work, we came away slightlyconcerned about the wide varietyavailable. Are there any rules orguidelines that you could pass alongto assist us?”
“In a previous column (ATWE Nov-18) we introduced the concept that
resistance welding electrodes werespecialized consumables with the dualrole of transmitting both the requiredforce and needed secondary current tothe parts being joined. We then put forththe idea (ATWE Jan-19) that it is notrealistic for one size electrode to workunder all conditions, and in fact, theyneeded to be sized in order to accom -modate the welding they were being askedto do. The next task was to determine thebest material from which to make ourelectrodes (ATWE Mar-19). We now needto determine the geometry of our elec -trodes, keeping in mind the goal of makingan acceptable resistance spot weld (RSW).Electrode Geometry: The selection ofthe contact face geometry is, to my mind,the most critical aspect of electrodeselection that must be considered. To helpfacilitate this selection several aspects ofthe weld must be considered. These includethe required weld size, substrate gauge,and surface quality requirements. Forcontext, the electrode’s contact facegeometry and the weld’s minimumrequired size all trend in the same directionas the substrate gauge. In other words,as the material you are joining gets thicker,almost everything else that supports thisendeavor increases in some form orfashion.But, how does this relationship impactthe RSW process? Well, from a practicalperspective, it should be noted that awelding process attempting to utilize alarger contact face to weld both a thick
and a thin section will often struggle onthe thin stack-up. This is due to amismatch between the contact face andthe material gauge (and hence therequired weld size). And this differencecan be a real problem. One hint that thismismatch exists: The weld will appear,or disappear, with a small change incurrent, and is accompanied by a narrowcurrent range. An electrode properly sizedto a gauge will have a weld that cansmoothly transition from a smaller tolarger size as the current is increased fora given force and weld time methodology.Other items such as substrate type andcoating, while important for determiningthe actual weld schedule (force, etc.) andinfluencing the potential life of theelectrode, do not have the impact onachieving the initial weld that therelationship between the contact facegeometry to substrate gauge does.Figure-1 illustrates six of many standardelectrode nose geometries. Each of thesegeometries has their own benefits andlimitations, supporters and detractors.The type A, B and E geometries are mostcommonly used for general weldingapplications. The type C and F geometriesare typically used where minimal surfacemarking is required. The type D geometrypermits for access in limited spaces. Thefollowing should also help with theselection process.• Type A: Good general design. The
selection of the contact face diameter isimportant so it is compatible with thedesired weld size and the substrategauge. The design is able to supportweld sizes larger than 4√GMT when aproperly sized contact face is utilizedfor a particular substrate gauge.
• Type B: Also, a good general design.The type B will typically result in moreindentation than the types A or E, andis not able to support very large weldsizes. Variants of this electrode havebeen fashioned with small (~4.8 mm)contact faces. This reduces indentationand improves the weld size capability,to a degree. As a rule of thumb, do notexpect to support weld sizes much largerthan 4√GMT, especially on strongermaterials. A good candidate for roboticdressing.
• Type C:Utilized for improved weld sur -face quality. This type of electrode hasthe potential to wear quickly whenwelded on coated materials and reallymust be dressed off-line in order to renewproperly.
• Type D:Utilized when a weld has to bemade close to an upturned flange orcorner. As an aside, the offset loadingassociated with the type D design ishard on the electrode taper. The basicrules regarding the type A and type Econtact face diameters also apply to thetype D electrode. Care should also betaken as these electrodes can be installedincorrectly due to the asymmetric natureof their face, and really must be dressedoff-line if they are to be renewed properly.
• Type E: Another good general designavailable in different rake angles. The30º and 45º designs are the mostpopular. This design is also a goodcandidate for robotic dressing. As withthe type A electrode, the selection of thecontact face diameter is important sothat it is compatible with the desiredweld size and the substrate gauge.
• Type F: Utilized for improved weldsurface quality. This elec trode also be
used when weld ingvery thick stack-ups,or aluminum, de pen -dent on the faceradius speci fied (any -where from 1”-3”). Aproperly sized type Fcan sup port verylarge weld sizes(>5.5√GMT) whenused with robustschedules and
s
Ask the Welding EngineerBy Donald F. Maatz, Jr.
A:
Q:
This article is a continuation of the Mar–2019‘Ask the Welding Engineer’
Figure-1: Resistance spot welding electrode face geometries
Continued on page 17
Hello Tony,
Thank you for being our featuredmember this month. Please tell us alittle bit about yourself.My name is Tony Rubio. I am a JoiningEngineer for Tower Automotive. I ammarried to my lovely wife Emily and wehave six children, Noah, Dominic, Jaxson,Lucas, Bennett & Georgia.
What do you like about your position?I grew up in this business on the OEMside, and now I am transitioning to theend user side. In my opinion, it has beencompletely different for me. The exposurehas been unique and completely different,being involved and taking the lead onupcoming projects that involve newmaterials and new technologies. It’s beeninteresting and I’m filling in a lot of gaps.
Why did you join AWS?I joined AWS in the late 90’S. I joinedbecause it was an avenue to learn andmeet people in the business. I look backnow and I am really glad I did. I’ve metso many people. I have a lot of friendsand, In the end, in my opinion, it’s anhonor to have worked with and knowsome of the true legends in our business.
What kind of things do you like to dooutside of work?I love to spend time with my family. Thisis the most important thing to me! Inaddition, I love golfing and just relaxingat home.
What would you say is your mostmemorable moment when it comes toAWS and/or welding?The most memorable moment for mewas in the late 90s, I was working withTeresa Brusadin of Ford Motor Company,on the WIN126 launch, OakvilleAssembly Plant with hydraulic presswelders and AC weld controls. I rememberthis moment because it was the momentRSW made sense to me, I was standingin the plant all alone and I remembersaying to myself “I get it, I get it now.” Ihad the basic understanding down butmuch more to learn.
Another question I like to ask ourfeatured members is there anything
that’s near/dear to your heart?Daniel Ravary. I worked for a companysome of you may know, Weldmation, Inc.The first true boss I have ever had was afella named Daniel Ravary. If you knewDan, he was a wonderful man and hewill always be a friend of mine, but hewas tough, and in the end, it made metough! I would not be where I am at todayif it wasn’t for him. I didn’t realize at thetime, but Dan was filling me up with somuch data and so much Information sofast. It was impossible for me to under -stand in such a short period of time, butmy mind was absorbing it. Dan knewwithin my first six months, I would beon my own, and launching major bodyshops without him. So, I had to surviveand I had no options. Twenty-four yearslater I am still here, and it has been awonderful ride…
Mentoring is a great advantage in anycareer. Have you ever been a mentor?Or, is there someone who has mentoredyou? Daniel Ravary was my mentor and yes,I have mentored a lot of people in thisindustry. If you look at the landscape ofour industry over the next 20 years, I willhave worked side-by-side with a goodpercentage of them.
How did you get your start in welding?I was working at a metal racking com -pany In Mt. Clemens, MI, called CateMetal Products. I was dating the presidentof the company’s daughter, making goodmoney as an Assembly Leader. I wascomfortable, no travel. I received a callone night on the house phone at myparents, it was my best friend Rob, andhe says to me “Hey, there’s a guy thatworks with me, his name is Dan, he’slooking for someone to do welddestructs≤…” I said, “Okay, I do not knowwhat that is, but I will come to talk tohim.” The next day my Dad drives me toMadison Heights, and I meet Dan.Remember, this is back in the 90s, I didn’tknow much was going on outside ofRoseville, Michigan, where I grew up.Going to Mt. Clemens, Fraser or SCS wasa big deal for me, Madison Heights…In the end, I met Dan, we hit it off,
he liked meand made mean offer and Iac cepted.
What do you seeas the biggest challenge for the weldingcommunity in the future? Materials! If you do know have a fullunderstanding of materials, it will behard to make an impact.
What would you tell someone who maybe “on the fence” about getting intowelding as a career? It’s a great industry and great career.Each person is their own brand, they havetheir own style. It’s ultimately yourreputation at the end of the day! It’s niceto be part of a team, to learn from otherpeople and grow with them. I’ve alwaysbeen relentless in my efforts to make animpact. If you try to do the right thingseach-and-every day, you will be successful!
Would you encourage more schools(both high school and junior high) toencourage more young people to lookinto technical schools and jobs andnot just degreed positions? Yes, I think the Industry is starting to seea ton of skilled trades retire. Some of theplant guys and gals I’ve worked with onlaunch, old school trades will go awayknowing things some of the youngerplayers will never have the opportunityto learn. Technologies have become souser-friendly.
Finally, if you weren’t involved in thewelding industry, what would be yourdream job?If I wasn’t in this field, I would’ve been aprofessional boxer. I had to make thedecision as I started working atWeldmation.
Thank you, Tony, for taking time outof your day to share a bit about yourexperience and life in the industry.
If you’d like to be a featured member inour e-bulletin, please contact MarkRotary, our membership chair [email protected].
MEET OURMembers Tony Rubio
The AWS-Detroit Section, the only Section that crosses an international border, held a technicalmeeting on April 11, 2019 at the Mechatronics Division of CenterLine (Windsor) Limited in Windsor Ontario, Canada.
The Section heard from Dan Cabanaw, Senior Account Manager from CenterLine (Windsor) Limited. The topic wasReducing Costs, Complexity and Quality Concerns Practical Strategies for Large Scale Fastener Welding Programs. This talkhighlighted the common project management and integration issues faced by machinery builders and providedsuggested improvements to the overall integration process aimed at improving final equipment design, integrationand operation.
April Tech Night Recap, Held at CenterLine Limited
We have been working to help theschool install new welding machinesfor the lab that the Detroit schooldistrict has purchased. Myself (alongwith the help of two of my coworkershere at ARO Welding Technologies)Joe Pfeifer and Rodger Popke arevolunteering to install the equipmentat the school at the end of the schoolyear.
Neil Morrison, the superintendentat Golightly, has also done a greatjob of supporting the welding program
and understanding the great careersin the trades that are available andneeded in the job market today morethan any other time in recent history.Golightly has been associated withAWS Detroit for over 6 years and isone of the premier CTC facilities inthe tri-county area.
Juan Whiting, retired instructorfrom Golightly, is one of those teacherswe all hope to have sometimethroughout our school years. He caresand has shown his support to the
school as on any given day he can befound helping out the best he canand staying involved in the weldingprogram.
AWS Detroit wanted to show ourappreciation for their dedication tothe students and welding in general,we had a table at Ladies Night justfor Golightly. They had a great timeand I was lucky enough to sit withthem, as over the years they all havebecome not only the people I workwith at Golightly but truly my friends.
Golightly CTC Vocational School continued from page 6
needed to write a viable WPS whenyour testing is complete, and you havepassed all the requirementssuccessfully.
So now the welding is complete,and your coupon has cooled so thatyou can handle it safely. What’s next?Well, you’ve recorded all the weldingparameters and essential (and non-essential as you’ve determinednecessary) variables, but your PQR isonly partially complete. Now comesthe second part of the A3.0 definition,the tests.
You will need to examine your testcoupon visually to make sure it meetsthe visual acceptance criteria for aPQR test. If it does, then you’ll needto do either UT or RT, mechanicaltesting, and possibly macroetch testingfor fillet welds and PJP groove welds.When all those results are in andyou’ve determined they meet therequirements of the code, you’ll addthat information to your PQR. It wouldbe wise to look everything over a fewtimes to make sure that you’verecorded the essential variableinformation, as well as the test datainformation correctly. You will bewriting your WPS from this record, soany information that has beenrecorded incorrectly, or not recordedwill have a direct impact on yourWPS. Remember, the PQR in NOTwhat your welders will be using onthe shop floor, the WPS is. The morethorough you are with your recordingduring testing, the better your WPSwill be. Always keep in mind thatyour PQR is the supporting documentto your WPS. If, for example, yourPQR states that your test coupon didnot have PWHT and your WPS lists aspecific temperature and time attemperature for PWHT, then your WPSis not supported by your PQR. This isan essential variable that wouldrequire requalification. Here’s anotherexample of how inaccurate recordingcould affect your WPS. Let’s say duringyour GMAW PQR testing your welderdeposited a root pass, five fill passesand four cover passes on your CJPgroove weld, welded from one side.
If your welder adjusted the wire feedspeed (WFS) for every pass, but youonly recorded a value for the rootpass, and an average for the fill passesand cover passes, then your WPS maynot have the WFS range needed forall the production welders (remembera welder is a person, not a machine).That’s because D1.1 states an increaseor decrease greater than 10% in theWFS for each electrode diameterrequires requalification. You arepermitted to be within that range, butif you did not record your high andlow range properly you will limit yourWPS unnecessarily. That’s why it isimportant that you record exactlywhat you did and how you did it. Noteverything will end up on your PQRas an “essential variable,” but it’s veryvaluable non the less. Some welderslike to travel fast with higher WFS,and others travel slower with lowerWFS. You’re WPS should be able toaccommodate more than one welderso a useable range is needed.
Lastly, keep in mind that a PQR isa record of events. The format andthe information contained in thatrecord are yours to record and control.What your code book tells you are“essential variables” are mandatoryelements as well as the rules regardingthose variables. The other informationcan be included at your discretionas well as the format for the record.The company you work for or yourcustomer may have input as to thedocument format, but the formsin Annex M are not mandatory.If you are limited in theinformation you can recordbecause of the format of adocument, then create your ownto keep as a back-up version. Itdoes not have to become the“official” PQR, it could simply bethe PQR details. At the end of theday you are the one signing thePQR and WPS so make sure youcan defend its validity if challenged.
If this type of subject is interestingto you and you’re not already anAWS CWI, why aren’t you? Ifbecoming a CWI is a career path
that you would like to pursue, theAWS-Detroit Section is hosting twoAWS CWI Seminar/Exams this year.The seminar/exam dates and locationare as follows:
CWI Seminar May 5 – May 10, 2019Exam May 11, 2019
Detroit Metro Airport Marriott30559 Flynn Dr, Romulus, MI 48174
Phone: (734) 729-7555
~ and ~
CWI Seminar Oct. 13 – Oct. 18, 2019Exam October 19, 2019
Detroit Metro Airport Marriott30559 Flynn Dr, Romulus, MI 48174
Phone: (734) 729-7555
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 andto register, you can visitwww.aws.org/certification
CWI Corner continued from page 9
capable equipment. Also, while possible, this geometry is nota great candidate for robotic dressing.The aforementioned types of electrode geometries have beencodified in various standards. Those listed above arefrom theRWMA (Resistance Welding Manufacturing Alliance). Othercommon sources are the ISO-5821 2009 (R2014) and the JIS C9304 1999 (R2015). Please be aware that there are many other‘standard’ electrodes that can fall broadly intoone of the above categories. Still others are acombination of two – a hybrid. One of themore common is a combination of the type E& type F. Specifi cally, it combines a truncatedshape, but the face has a radius.
Taken as a whole, the points brought outin these past four columns are really meantto raise awareness with the resistive weldingprocesses, specifically the electrodes. Theseprocesses can be very robust. However, inorder to achieve that robustness, there aremany variables that must be consideredand addressed.”
Many thanks to Greg Chambers, a Welding Specialist fromLuvata Special Products, for his assistance with electrodegeometries, and the standards that govern them.
If you have more questions about this topic, contact DonMaatz at: R&E Engineering Services A subsidiary of R&E Automated Systems, LLC 70701 Powell Road, Bruce Township, MI 48065 (586) 228-1900 – Office / (734) 793-2304 – Direct [email protected]
Ask The Welding Engineer continued from page 12
References:1) Resistance Welding Manual, revised 4th Edition3) ISO-5821 2009 (R2014)4) JIS C 9304 1999 (R2015)
AWS District #11 Annual Conference Date: May 20, 2019Location: Lansing Community College West CampusTime: 8:30 am to approximately 3:00 pmContinental breakfast and lunch providedAll Section and Student Section officers are encouraged
to attend; AWS members are welcome. It is a great timeto meet and exchange ideas with other Section officers.Put this on your calendar and plan to attend. Please sendme an email that you will attend: [email protected]
District AwardsCan you nominate someone for a District Award? We
have several awards that can be awarded each year andmany years no names are submitted. One of these is theDistrict Educator Award. Other national awards areavailable and it only takes a few minutes to nominate adeserving individual in our District. Please let me know ifyou have a nominee! Also, if you would be willing toassist on a small committee to seek nominations pleasenotify me. [email protected]
District Director AwardsEach Section has members that go above and beyond
in serving our Sections. As your District Director I wouldlike to know who these people are and recognize them fortheir service to your Section, on a National Committee, orto our industry. All it takes is an email or phone call anda brief explanation of why this person deserves thisrecognition.
AWS Welding Instructor Institute Applications should be submitted early for this and one
instructor from our District will be selected to attend withair, hotel, meals, and transportation expenses paid. Applyat: www.aws.org/events/detail/instructors-institute.
AWS Section Solutions ConversationsThis is an opportunity to participate in a teleconference
to listen to other Section leaders share successes and toolsfor use by Section Leaders. This is a great opportunity forall Section leaders to learn how to make our Sectionsbetter. The next teleconference is April 24th at 11amand generally lasts for 30 minutes.
RWMA Resistance Welding School 2019 When: May 15-16, 2019 Where: RoMan Mfg. in Grand Rapids, MIAWS\RWMA will hold its Resistance Welding School
with presentations by industry experts, this intensive two-day course dives deep into resistance welding theory,
application requirements, equipment and process setups.The focused learning environment better prepares thosenew to Resistance Welding, and further educates theexperienced. Day One discusses Resistance Weldingprocesses and the associated machines, materials, electrodesand power systems. Day Two explores resistance weldingcontrols, quality standards, machine set-up and mainten -ance. The course concludes on Day Two with a Q&A panelwhere students can get feedback from the instructors ontheir specific applications. The course is designed forwelding production managers, supervisors, engineers,setup and senior operators, trainers and educators. Classsize is limited to 40 people, so register now!
Membership and VolunteersI will be facilitating a District Director Workshop during
Board Week in Miami focusing on District Directorcommunication, membership, volunteers, and gettingSections active that are dormant. Any input from District#11 members is appreciated. Three questions I would likeanswered by you are:
• Why did you decide to join AWS? Why did you decideto remain a member?
• Why are you involved in AWS as an active volunteer? • What benefits do you believe would encourage
someone to join AWS? Please send an email or feel to call to provide your feedback.
NEW --- WELDING COMPETITIONS --- NEWAs I have often stated I wish to visit schools and attendwelding competitions in our District. Well, now you havea big reason to make sure I am invited. New for 2019 isfive $1000 scholarships are available to be awarded toPARTICIPATES in welding competitions. Your AWS Boardof Directors approved this in November and this is nowready to be implemented. PLEASE invite me to your competi -tions so I can award these new scholarships in our District.
CWI Certification Detroit Area 2019 Seminars & Exams are scheduled: Seminars: May 5-10 and Oct. 13-18Exams: May 11 and Oct. 19
District Directors RequestPlease let me know dates for events, welder competitions,
technical meetings, training sessions, golf outings, or justa Section Executive Committee meeting. If you have anopportunity for me to visit a school or a Section meeting,I am available and will travel on a mutually agreeabledate [email protected]
s s
Director News Phillip Temple, Director, District #11 Mobile: 734-546-4298Email: [email protected]
THE FOLLOWING ARE A FEW ITEMS OF INTEREST FOR THIS MONTH
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