8-8:45am |
Treme |
The Gas Tungsten Arc Welding (GTAW) of Aluminum
Mark Kadlec
Miller Electric
The basic history and various deviations of the Gas Tungsten Arc Welding (GTAW) process used for fusion welding of aluminum base materials. As the technology evolved, so have the adjustable parameters. A section will be dedicated to discussing new technology and the benefits that it should offer. |
8:45-9:30am |
Treme |
Gas Metal Arc Welding of Aluminum Alloys
Mikael Carriere
Lincoln Electric
Talk considers metal transfer modes, shielding gas types, wire feed systems, and power source selection — constant voltage, constant current, pulse, or variable polarity. |
9:30-10:15am |
Treme |
Overview of the AWS D1.2 Structural Welding Code – Aluminum and AWS A5.10 Aluminum Filler Metal Specification
Tony Anderson
ITW Welding North America
The speaker is Chair of the A5.10 Committee and past Vice Chair and Advisor to D1.2. We will look at how D1.2 can be used as a basis for an aluminum welding quality system. Also, he will examine some of the more recent changes to the aluminum filler metal specification AWS A5.10 latest revisions. |
10:15-10:30am |
Frenchman Ballroom – 2nd Floor |
Coffee break |
10:30-11:15pm |
Treme |
Technology Advancements and Automation in the Aluminum Welding Industry
Kevin Summers
Miller Welding Automation
Some of the challenges associated with robotic aluminum welding are wire feed ability, material thickness, inconsistent parts, variable heat sinks due to part and fixture, and programming issues. The speaker will discuss the challenges in robotically welding with aluminum and how an advance in welding technology helps address them. |
11:15-12pm |
Treme |
Fatigue Failure Resistance of Aluminum Welds
Mike Weaver
Weaver Engineering
The presentation will introduce approaches to fatigue assessment for welds in general covering classical methods, hot-spot (structural / geometric) stress method, effective notch radius and fracture mechanics approaches. Aspects of special attention related to aluminum weld fatigue resistance will be highlighted throughout the presentation. |
12-1pm |
Frenchman Ballroom 2nd Floor |
Lunch |
Ken Johnson Vigor Industrial – Afternoon Session Chair
|
1-1:45pm |
Treme |
Repair Technologies for Sensitized Aluminum-Magnesium Alloy
Kim N. Tran
PhD Materials Engineer Welding, Processing, and NDE, Code 611
The most common aluminum alloys used in U.S. Navy ship construction are the marine grade aluminum-magnesium (Al-Mg) alloys due to their high strength to weigh ratio, good general corrosion, and affordability. The U.S. Navy uses Al-Mg alloys extensively throughout the fleet for primary and secondary structural applications. There is a continued demand for these alloys as there is a need for faster, smaller ships. A particular concern with the use of these alloy is sensitization. Aluminum-magnesium alloys containing more than 3.0 weight percent magnesium can become sensitized when a continuous network of β phase forms along the grain boundaries.In-service experience has shown extensive cracking in Al-Mg structures resulting from stress corrosion cracking (SCC). Stress corrosion cracking in Al-Mg can occur when the material exhibits a susceptible microstructure and is simultaneously exposed to a damaging environment and tensile stresses of sufficient magnitude. Repair welding of cracked Al-Mg proposes challenges because of the deleterious microstructure of the material.The material may contain micro-pits and/or micro defects that can entrap debris and moisture which affects overall weld quality. To address the sensitization issue and repair of cracked material, the U.S. Navy has developed relevant technologies for detection of sensitization, mitigation, and repair. Some of the technologies include the use of in-situ metallography to detect sensitized material, ultrasonic impact technology to treat the material prior to repair welding, and portable friction stir welding technology. The U.S. Navy has also developed specific requirements to ensure a high level of weld quality and minimize the need for rework. The welding requirements for welding sensitized material were developed to assist both the U.S. Navy and its contractors engaged in weld repair of aluminum superstructures. |
1:45-2:30pm |
Treme |
US Navy Welding Operations: Best Practices and Lessons Learned
Robert B. Mason, Jr., CEF, PMP, ACG
Principal Materials Scientist, Concurrent Technologies Corporation (CTC)
This presentation will provide an overview of the NAVSEA Welding Roadshow as well as some of lessons learned and best practices. |
2:30-3:15pm |
Treme |
Experienced-Based Approach to High Quality Repair Welding of Aluminum Ship Structure
Paul Blomquist
Technical Director, Center for Naval Metalworking Operated by Advanced Technology International Summerville, SC Business Development Manager, EWI. Inc.Nick Kapustka
Senior Engineer, EWI – B.S. Welding Engineering, M.S. Welding Engineering
While performing repair welding of severely damaged aluminum ship structure on Perry-Class Frigates, several breakthrough changes in welding procedures were implemented that resulted in vastly improved quality and reduction of thousands of hours of labor. These techniques have been carried forward to other applications with great success. The equipment, pre-weld and set-up tasks, and general procedures are discussed. |
3:15-3:30pm |
Frenchman Ballroom – 2nd Floor |
Coffee Break |
3:30-4:15pm |
Treme |
Portable Friction Stir Welder Development
Timothy G. Freidhoff, Project Manager/Engineer Concurrent Technologies Corporation
Kim N. Tran, PhD
Materials Engineer Welding, Processing, and NDE, Code 611
The presentation will provide an overview of the work performed to date to develop a portable f riction stir welder for shipboard welding of aluminum. |
4:15-5pm |
Treme |
High Quality Aluminum Welding for Shipbuilding
Nick Kapustka
Senior Engineer, EWI – B.S. Welding Engineering, M.S. Welding Engineering“Improved RT Pass Rates During Aluminum GMAW Welder Performance Qualification”
Nick Kapustka Senior Engineer, EWI & Ken Johnson, Vigor Industrial
Excessive porosity is the primary reason why aluminum welder performance qualification test plates fail radiographic testing (RT). RT pass rates using legacy gas metal arc welding (GMAW) procedures and argon shielding gas can be as low as 20% to 35%, requiring re-testing and resulting in delays getting new welders into production.
During a recent NSRP Welding Technology Panel project, semi-automatic GMAW procedures were developed for producing aluminum performance qualification test plates in the horizontal position that were demonstrated to be capable of consistently meeting the RT requirements. Procedure development was performed using advanced GMAW welding systems and shipyard implementable best practices for welding parameter selection, base material preparation, consumable validation and storage, pre-cleaning methods, and inter-pass dressing / cleaning methods. All twenty-eight test plates (100% RT pass rate) produced in EWI’s lab, and all nine test plates (100% RT pass rate) produced in Vigor Industrial’s Weld School using the developed procedures met the Class 1 radiographic testing requirements of MIL-STD-2035 with regards to porosity. |
5pm |
Treme |
Adjournment |