Vol 14 2012 WeldED

Sponsors

Shindaiwa http://www.shindaiwa.com.au

South Pacific Welding Group http://www.spwgroup.com.au/home.asp

Smenco http://www.smenco.com.au

Cigweld www.cigweld.com.au

SafeTac http://www.safetac.com.au

Bureau Veritas http://www.bureauveritas.com.au

Southern Cross Industrial

Supplies http://www.scis.com.au

Technoweld http://www.technoweld.com.au

Hardface Technologys http://www.hardface.com.au

3834 Weld Management weldtraining@iinet.net.au

AWI operates this service for members. Information and comments in AWI publications are the opinions of specific individuals and companies, and may not reflect the position of AWI or its Directors. Information on procedures and processes herein, as well as any advice given, are not sanctioned by AWI, and AWI makes no representation or warranty as to their validity, nor is AWI liable for any injury or harm arising from such entries or from reliance on any entries. Participants should independently verify the validity of information prior to placing any reliance thereon.

Index Cigweld Consumable App Cigweld / Victor Technologies New ASME IX Requirements for Calculating Heat Input Manufacturing Skills Australia Inspection Equipment Kit CSWIP Training Course Progress Update

Cover Page CIGWELD's Welding Consumables Pocket Guide

App is now available on I-Phone & Android for

FREE

A 430 page welding guide with quick touch menus

allows you to access relevant welding information

such as product specifications, classification codes,

deposition data, welding positions, symbols,

defects, joints etc.

Page 3 4 5 9

10

11

12

Cigweld Consumable App 3

Vol 14 2012 WeldED

Press Release Subject

CIGWELD's Trusty Pocket Guide Has Gone

Mobile

CIGWELD's Welding Consumables Pocket Guide App

is now available on I-Phone & Android for FREE

A 430 page welding guide with quick touch menus

allows you to access relevant welding information

such as product specifications, classification

codes, deposition data, welding positions,

symbols, defects, joints

etc.

The CIGWELD Pocket Guide

has for a long time been

referred to as the bible of

the welding industry, and so

in keeping with the digital

age, CIGWELD have

condensed this 430 page

guide to an easy-to-use

phone and tablet

application.

All the information that welding engineers, boiler

makers, fabricators or general tradies have needed to

know about welding guides, defects, joints, positions,

symbols, classifications, gas, safety etc., have always

been available in the industry renowned CIGWELD

Welding Consumables Pocket Guide.

This guide outlines the relevant procedures,

applications, operating data and packaging data for

CIGWELD welding consumables and STOODY hard

facing

consumables, in addition to all the important

technical trade advice mentioned above.

CIGWELD have recognised

the need to have this

guide close at hand to

enable you to do your job

safely and efficiently, so it

seemed only a natural

progression that this 430

page book should join the

ever growing list of Apps

in the I-Phone & Android

market.

Now, with quick touch category menus and a simple

product or part number

search function, you can

ensure you have all the

relevant welding information

at hand no matter where you

are.

You can also make a

technical welding enquiry via

the App, and where

reasonable, receive a same-

day answer to your question.

Whether you are the home hobbyist who dabbles

with welding creativity in your home workshop, or

you are the heavy industrial welding enthusiast, this

App is a 'must have' and best of all it's FREE!!!’

Cigweld / Victor Technologies 4

Vol 14 2012 WeldED

CIGWELD’s

Parent

Company

name

change from

Thermadyne

to Victor Technologies - Innovation

to Shape the World

CIGWELD is one of the strongest and most respected

brands in welding and cutting throughout Australia.

Engrained in a proud heritage and distinguished

history that commenced back in 1922, the CIGWELD

brand continues to grow throughout the Asia Pacific

region, strengthening its attributes of authenticity,

reliability and innovation.

J.B Arnold & Sons and EMF Electric commenced

operations in Australia in 1922 and 1923 respectively

as leading manufacturers of gas welding equipment,

before establishing CIG in the 1930’s.

CIGWELD branched off as CIG’s equipment division in

1985 with a focus on welding and gas equipment, and

in 1996 CIGWELD was acquired by Thermadyne – one

of the world’s leading suppliers in cutting and welding

products.

Thermadyne, originally founded in 1987, brought with

it an impressive portfolio of other welding and cutting

brands:

• Stoody hard facing consumables,

• Thermal Dynamics plasma cutting equipment,

• Tweco MIG and ARC accessories,

• Arcair gouging products, and

• Victor

which was the company’s strongest and most

established brand of nearly 100 years, renowned

globally for gas equipment?

In May 2012 the company have taken a new direction

by changing their name to Victor Technologies (from

Thermadyne), in celebration of the proud heritage

within one of their strongest global brands (Victor).

By leveraging the Victor name globally and embodying

the pioneering spirit of the company, Victor

Technologies reinforces to the industry their focus on

meeting the needs of the end user customer by

providing advanced cutting, welding and gas control

solutions through each of their brands.

While the parent company has changed from

'Thermadyne' to 'Victor Technologies', CIGWELD Pty

Ltd will still operate in Australia as the trading entity

and will continue to market and promote

• CIGWELD,

• Stoody,

• Tweco and

• Thermal Dynamics branded products

throughout the Asia Pacific markets.

Innovation to Shape the World

Keeping in line with the company vision CIGWELD,

TWECO & THERMAL DYNAMICS have released a range

of innovative product solutions over the last 12mths

to enhance the end users welding and cutting

experience.

Some of these new product developments include:

• CIGWELD Transmig Multi- Process 3-in1

Inverters. Including: 175i, 200i, 250i, 350i,

450i and 550i.

• CIGWELD Comet Edge Regulators: Acetylene,

Oxygene, Argon and LPG

• CIGWELD Weldskill 200 AC/DC Portable

Inverter

• CIGWELD Weldskill Auto-Darkening Welding

Helmet Upgrade – 7 styles

• CIGWELD Weldskill 250 & 350 MIG machines

• CIGWELD AutoCraft HF650 in 5kg Handispools

• CIGWELD Ferrocraft 16 Twincoat 2.5kg Packs

• CIGWELD Metal-Cor 110 H4

• THERMAL DYNAMICS Cutmaster 10mm and

12mm manual plasma systems

• TWECO Fusion MIG Gun

New ASME IX Requirements 5

Vol 14 2012 WeldED

New Code

Requirements

for Calculating

Heat Input

BY TERESA MELFI

Welders, inspectors, and engineers should be aware

of the changes to QW-409.1 of ASME IX regarding

waveform-controlled welding

Welding waveforms are used to limit distortion, weld

open roots, and to control HAZ properties. Waveform

control is essential for common processes like uphill

GMA pulse welding. Power sources that support

pulsing (GMAW-P, GTAW- P, etc.) are the most

common waveform- controlled power sources. Those

marketed as synergic, programmable, or micro-

processor-controlled are also likely to support

waveform-controlled welding.

The correlation between heat input and mechanical

properties is blurred when heat input is calculated

using current and voltage readings from conventional

meters. This includes external meters and even those

located on the welding power source. It’s not that the

meters are incorrect — in fact, most are calibrated

and tested to NIST standards. Rather, the inaccuracy

involves the means of capturing and displaying the

data.

Conventional DC meters display average voltage and

average current. Conventional AC meters display RMS

values. To accurately indicate the energy input to a

weld, the voltage and current readings must be

multiplied together at very rapid intervals that will

capture brief changes in the welding waveforms. This

frequency is in the order of magnitude of 10,000

times per second. Specialised meters are required to

accomplish this.

Revisions to ASME Section IX provide a new method

of calculating heat input that allows comparison of

the heat input from various welding power sources

and various welding waveforms.

This will allow production welding to take place with a

welding procedure specification (WPS) that specifies

either conventional or wave- form-controlled welding,

which is supported by a procedure qualification

record (PQR) using either conventional or wave- form-

controlled welding.

Calculating Heat Input Many welding codes use the equation shown in

Equation 1 to calculate heat input. Because the

welding process (GMAW, SAW, etc.) is an essential

variable, a process or efficiency factor is not included

in the heat input calculation. The new equations that

will be in the 2010 edition of ASME Section IX are

shown in Equations 2 and 3, either of which gives

equivalent results. Both equations are shown because

some welding power sources and meters display

energy values, and others display power values.

Voltage × Amperage × 60 Travel Speed (mm/min)

Equation 1: Traditional heat input equation, ASME

Section IX QW-409.1 (a).

Energy (Joules)

Weld Bead Length (mm)

Equation 2: New heat input equation for meters

displaying energy measurement (Joules), ASME

Section IX QW-409.1 (c) (1).

Power (Joules/s) × Arc Time (s)

Weld Bead Length (mm) Equation 3: New heat input equation for meters

displaying power measurement (Joules/s or W), ASME

Section IX QW-409.1 (c) (2).

Three examples from GMA welding are shown in Fig.

1. The axial spray wave- forms are essentially

constant, and the difference between the

measurement methods is minimal. For the two

waveform- controlled procedures, there is an error

between the measurement methods that can be in a

positive or negative direction. It is clear from the

significant differences why a new measurement

method is needed.

New ASME IX Requirements 6

Vol 14 2012 WeldED

Changes in ASME Section IX

ASME codes and standards have a long history, now in

their 125th year. The rules for welding were removed

from the construction codes when ASME Section IX

was published in 1941. ASME Section IX has become a

global standard, referenced by the ASME construction

codes, owners, engineering firms, and other

fabrication and construction codes.

The ASME IX Standards Committee has

subcommittees that address procedure and

performance qualifications, materials, general

requirements, and brazing. More than three years

ago, a task group was formed to work on issues

surrounding welding with complex waveforms from

micro-processor-controlled power sources. The first

result of this group’s work will be a change to the

measurement and calculation method for heat input.

QW409.1 is the main Section IX variable that deals

with heat input. Currently, there are two ways to

calculate heat input. Method (a) is the traditional heat

input equation shown in Equation 1. Method (b) is a

measurement of the volume of weld metal deposited.

A new method (c) is added in the 2010 edition, which

includes Equations 2 and 3.

Any of the methods can be used when welding

following procedures that are not waveform

controlled. When welding following waveform-

controlled procedures, only methods (b) or (c) are

permitted. With these methods, it is possible to

determine the compliance of a production weld made

using a waveform-controlled welding procedure to an

existing qualified procedure, even when the

procedure qualification was performed using non

waveform controlled welding.

An appendix to ASME Section IX has been provided to

guide users through these code changes. The

appendix provides guidance with new procedure

qualifications, existing qualified procedures, and

comparing heat inputs between waveform-controlled

and non-waveform-controlled welding. ASME Section

IX does not mandate separate performance

qualifications for waveform controlled welding.

Fig. 1 — Heat input differences calculated using

Equation 1 vs. Equation 2.

Fig. 2 — with the proper

software installed, access

to the energy reading

entails pressing the

menu option

“Display Energy”

New ASME IX Requirements 7

Vol 14 2012 WeldED

Fig. 3 — the real-time energy is continuously incremented

while welding, and the final energy is displayed until the

next arc start

How to Comply with ASME Code Changes

To use method (c) of the code, a reading of energy

(Joules) or power (Joules/s) must be obtained using a

meter that captures the brief changes in a welding

wave- form and filters out extraneous noise. The

simplest place to obtain this is from the welding

power source. Many power sources that output

pulsing waveforms will display these readings,

although some might require software upgrades to

en- able this. Details and software upgrades for

Lincoln Electric’s Powerwave “M” series and several

other models are available free of charge at

www.powerwave software.com.

For a power source that doesn’t support the display of

energy or power, external meters are available. A

meter with demonstrated accuracy in this application

is the Fluke® 345 Power Quality Clamp Meter.

With the proper software installed, it is simple to

access the energy reading — Fig. 2. In the setup menu,

enable the option to “Display Energy.” When an arc is

started, the energy value will begin to increment. The

value will continue to increase, showing the real-time

energy put into that weld — Fig. 3.

When the welding stops, the final energy value will be

displayed; until welding resumes again. This value

represents the amount of energy that went into that

weld, from arc start to arc stop.

To calculate the heat input, the final value is simply

divided by the length of the weld — Fig. 4.

In this case, the heat input would be 22.3 kJ/3.6 in, or

6.2 kJ/in.

A detailed matrix has been developed showing how a

PQR qualified with either waveform or non-waveform

controlled welding may be used to support welding

with waveform or non-waveform controlled

procedures and QW-409.1(a) or QW-409.1(c). This can

be downloaded from www.lincolnelectric.com.

Summary

The ASME Section IX welding and brazing standard is

widely used by public agencies and private companies

concerned about the safety and integrity of welds.

Just as specifications change when new materials are

developed, ASME Section IX has changed to recognize

modern welding waveforms. The changes involve the

measurement of energy or power made at very rapid

intervals, and the use of these to calculate heat input.

These code changes establish the relationship

between heat input across a range of power sources

and welding waveforms.

Welders, inspectors, and engineers should be aware

of the new ways to calculate heat input. While no

code can guarantee good workmanship, these

changes make it easier for welders to use wave- forms

that help improve their welds. The new method will

allow flexibility in the way one compares the heat

input used in procedure qualification and in

production welding

New ASME IX Requirements 8

Vol 14 2012 WeldED

PQR qualified with:

Qualifies for welds produced with

Non-waveform

controlled welding

using conventional volt

and ammeters and QW-

409.1(a)

• Non-waveform controlled power supply using conventional volt meters and ammeters and QW-409. (a).

• Non-waveform controlled power supply displaying instantaneous energy or power measurement and QW-409 1(c).

• Waveform controlled power supply displaying instantaneous energy or power measurement and QW-409.1(c).

• Waveform controlled power supply which does not display instantaneous energy or power measurement using

external meters that display instantaneous power or energy measurements and QW-409.1(c).

Non-waveform controlled

welding using

instantaneous energy or

power and QW-409 1(c)

• Non-waveform controlled power supply us ing conventional volt meters and ammeters and QW-409. (a).

• Non waveform controlled power supply displaying instantaneous energy or power meas urement and QW-409.1( ).

• Waveform controlled power supply displaying instantaneous energy or power measurement and QW-409.1(c).

• Waveform controlled power supply which does not display instantaneous energy or power measurement using

external meters that display instantaneous power or energy measurements and QW-409.1(c).

Waveform controlled

welding using

instantaneous energy or

power and QW-409.1(c)

• Non-waveform controlled power supply using conventional volt meters and ammeters and QW-409.1(a).

• Non-waveform controlled power supply displaying instantaneous energy or power measurement and QW-409.1(c).

• Waveform controlled power supply displaying instantaneous energy or power measurement and QW-409.1(c).

• Waveform controlled power supply which does not display instantaneous energy or power measurement using

external meters that display instantaneous power or energy measurements and QW-409.1(c).

Waveform controlled

welding using

conventional volt and

ammeters and

QW-409.1(a) (qualified

prior to 2010 code

change)

• Non-waveform controlled power supply using conventional volt meters and ammeters and QW-409.1(a).

• Non-waveform controlled power supply displaying instantaneous energy or power measurement and QW-409.1 (c).

• Waveform controlled power supply displaying instantaneous energy or power measurement and QW-409.1(c).

• Waveform controlled power supply which does not display instantaneous energy or power measurement using

external meters that display instantaneous power or energy measurements and QW-409.1(c).

Note: In some cases it might benefit the user to append a PQR to show the heat input calculated using instantaneous power or

energy. This can be done by welding a simple bead on plate using the same parameters (mode or program, voltage, current, etc.)

as were used in the procedure qualification. Utilising either a welding power source or external meter that displays

instantaneous energy or power, the heat input may be calculated per QW-409.1(c) based on those readings.

Assist Chart for ASME IX QW-409

Fig. 4 — the heat input is calculated by taking the final energy value and dividing it by the length of the weld.

TERESA MELFI is with The Lincoln Electric Co., Cleveland,

Ohio. She is chair of the AWS A5B Committee on submerged arc

welding, a member of the AWS A5 Committee on filler metal

specifications, a member of ASME Section IX, including the

materials subgroup and a working group on advanced waveform

welding, and is the U.S. delegate to the International Institute of

Welding commission that covers pressure vessels, boilers, and

pipelines

Manufacturing Skills Australia 9

Vol 14 2012 WeldED

Payments for employers

and Australian

Apprentices

The Australian Government has introduced a number

of initiatives to help ease the financial difficulties

Australian Apprentices experience and to provide

financial incentives to employers of Australian

Apprentices.

Information and assistance is available through

Australian Apprenticeships Centres and by visiting

http://www.australianapprenticeships.gov.au/

The main payments available to Australian

Apprentices and employers are shown below.

Support for Australian Apprentices

Tools For Your Trade

The Tools For Your Trade payment initiative provides

up to $5500 to eligible Australian Apprentices over

the life of their Australian Apprenticeship. Eligible

occupations include apprentice Fitter-Welders, Metal

Fabricators, Welders (first class) and Sheetmetal

Trades Workers training towards a Certificate III or IV

qualification.

Living Away From Home Allowance

Living Away From Home Allowance is available to

Australian Apprentices undertaking a Certificate II or

higher level qualification if they have to move away

from their parental/guardian home for the first time

to commence or remain in an Australian

Apprenticeship, or are homeless.

The first year rate is $77.17 per

week, second year rate is $38.59

per week, and third year rate of

$25 per week.

Youth Allowance, Austudy or ABSTUDY

Australian Apprentices may also be eligible to access

fortnightly payments delivered by Centrelink:

• Youth Allowance for Australian Apprentices

aged 16-24;

• Austudy for Australian Apprentices aged 25

and over;

• ABSTUDY for Australian Apprentices of any

age and who are Indigenous Australians

Contact Centrelink for more details

Just a reminder MSA has developed a free tool for

apprentices and employees to manage their work,

skills and own e-portfolio. Go to www.myskills.net.au

and start managing your career today.

Support for employers of Australian Apprentices

Support for Adult Australian Apprentices

This is a series of payments of up to $13000 paid to

either an eligible Australian Apprentice or their

employer, based on the actual wage paid to the

Australian Apprentice. Adult Australian Apprentices

are those aged 25 or over when they commence their

Australian Apprenticeship at a Certificate III or IV level.

The payment is restricted to

trades experiencing a skills

shortage listed on the

National Skills Needs List.

Incentives for employers of existing employees who

become Adult Australian Apprentices

An employer of an existing worker who becomes an

Australian Apprentice may attract incentives of up to

$4000 for a Certificate III, IV or Diploma or Advanced

Diploma level qualification.

An existing employee is one who

has a three month or more full-

time equivalent employment

relationship with their employer.

Incentive payments are made

under the Australian

Apprenticeships Incentives Program.

Support for Australian Apprentices with disability

and their employers

Disabled Australian Apprentice Wage Support

(DAAWS) is an Australian Government incentive of up

to $104.30 per week payable to an employer who

employs an Australian

Apprentice who satisfies the

disability eligibility criteria and

who is undertaking a Certificate II

or higher level qualification.

Manufacturing Skills Australia 10

Vol 14 2012 WeldED

Australian School-based Apprenticeships

Commencement and Retention

Up to $1500 is available to

employer who commences

an Australian Apprentice in

an endorsed Australian

School-based

Apprenticeship in a

Certificate II or higher level

qualification and who

continues to employ him/her after the student has

completed secondary school.

Special Rural and Regional Skills Shortages

Commencement

A $1,000 incentive for rural and regional employers

who commence an Australian Apprentice in a

Certificate III or IV qualification leading to an

occupation listed on the National Skills Needs List in a

non-metropolitan area.

Declared Drought Areas Commencement and

Completion

Up to $3,000 incentive for employers of eligible

Australian Apprentices

who hold a current

Exceptional

Circumstances Drought

Area certificate and who

successfully complete a

Certificate II qualification

Mature Aged Workers Commencement and

Completion

Up to $3000 is available to employers of an eligible

Australian Apprentice aged 45 years or more who

successfully commences and completes a Certificate II

or higher level qualification

Inspection Equipment

Inspection Kits

Managing quality of

welds requires quality

inspection equipment.

Technoweld supplies the finest quality inspection

equipment,

whether its

inspection kits or

individual gauges

we have popular

gauges in stock.

Technoweld is committed to providing competitively

priced professional quality products.

For more Information:

Technoweld Pty. Ltd.

E: admin@technoweld.com.au

M: 0409 698 968

W: www.technoweld.com.au

CSWIP Training Course 11

Vol 14 2012 WeldED

Progress Update 12

Vol 14 2012 WeldED

Progress of the AWITM

Certification to AS 1796

A key responsibility of

the AWI™ is to provide a

credible, transparent

and user friendly

welding qualification

system for its members.

To do this the AWI™

earlier established an Educational and Certification

Working Group (E&C) to meet the following

primary objectives:

• To undertake, arrange and promote education,

training, qualification and certification for the

benefit of members of the Institute and the

welding industry as a whole

• To work closely with Australian TAFE bodies,

Registered Training Organisations (RTO’s)

related government agencies and departments

to enhance National training agendas.

The AWI™ can now offer its members and

member company staff; certification to AS 1796.

The AWI™ is also in a

position to offer

welding training for

company

management, team

leaders and

supervisors which can

be tailored to suit a company’s specific needs.

Contact admin@austwelding.com.au for further

details

Central TAFE (Perth) AS 1796/AS 2214 Welding

Supervisor Program

Photo showing [from left to right] Phil Richardson – AWI, William Koens, John McAlpine, Bryan Dalgleish and Paul Grigg - Lincoln Electric

Central TAFE (Perth) AS 1796/AS 2214 Welding

Supervisor Program has achieved excellent results and

is producing outstanding candidates.

This AS 1796 / AS 2214 Supervisors program is run at

regular intervals throughout the year and Friday 28th

September culminated in an awards presentation to a

number of students who had achieved outstanding

results for this program.

Each student was presented with a “Certificate of high

achievement” and received a copy of the Lincoln

Procedure Handbook thanks to a generous donation

from the Lincoln Electric Company.

Our congratulations to the candidates on an excellent

result and the AWI™ acknowledge the input and

dedication of Eddy Derwort and his team at Central

for a job well done.

We extend our appreciation to the Lincoln Electric

Company for their support and making the Technical

handbooks available.

AWI™ actively supports and promotes the AS 1796

and AS 2214 Welding Supervisors qualifications and

encourage all members and the Metal Fabrication

Industry to embrace these qualifications. AWI™ has

established an alliance with a number TAFE Colleges

around the country and takes pleasure in supporting

Progress Update 13

Vol 14 2012 WeldED

and promoting these Colleges and programs and are

now endorsing Welder Qualification AS 1796

Certificates 1 – 9

Application forms are available through selected TAFE

Colleges and from admin@austwelding.com.au.

AWI are finalising the application forms for

endorsement for the Supervisors AS 1796 & AS 2214

and encourage all qualified AS 1796 & AS 2214

Supervisors to express their interest to

admin@austwelding.com.au

Compliance to AS/NZS ISO 3834 -

AWI™ Guidance for Fabricators

The AWI™ has received some information revealing a

high degree of confusion regarding Certification for

AS/NZS ISO 3834 Quality Requirements for Fusion

Welding. Therefore we have decided to re-print a

previous guidance note.

Certification

Certification for AS/NZS ISO 3834 Quality

Requirements for Fusion Welding is not required. As a

standard, AS/NZS ISO 3834 simply lays down

requirements for compliance. It is not a mandatory

standard to be enforced by law.

A fabricator wishing to comply with 3834, can simply

consider the relevant sections of the standards and

satisfy themselves of their compliance, which they can

then declare to potential customers. As part of this

declaration, they are required to detail the documents

used and the controls implemented.

Developing a competitive edge

Compliance with 3834 provides a global recognition of

a fabricator’s capability, can reduce costs associated

with rework, wastage etc. and can enhance a

company’s ability to sell its products in both domestic

and international markets.

Improved client confidence

AS/NZS ISO 3834 contains three

levels of quality requirements

and the appropriate level for your company will

depend on the degree of complexity of the Company’s

welding operations.

In an endeavour to increase your company’s capability

in the welding quality market, AWI™ can assist in 3834

compliance after completion of our application

document by:

1. A review of the application documentation.

2. AWI™ will conduct an assessment of your

company’s current quality system, procedures

etc.

3. Determining which level of welding quality is

appropriate for your company and which is in the

most practical for your company to achieve and

maintain.

The outcome of the AWI™ assessment will determine

if your company’s system is in need of additional

controls and procedures or is already successful in

compliance to the relevant section/s of 3834.

We can assist in

building a 3834

document structure

and develop the

required controls and

procedures or fill in

any gaps to your

existing quality

structure.

Successful applicants

will be issued with a

“Certificate of

Compliance”

indicating which level of compliance has been

achieved. Certification can be addressed at a later

stage if the company decides it wants to address this

option.

For further details contact:

Phil Richardson on: 0438 991 860 or

contact admin@austwelding.com.au