Time
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Speaker & Presentation
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| 9:00 – 9:10am |
Tom Eckardt
Senior Welding Engineer,
Kiefner and Associates, an Applus company
BIOGRAPHY
Mr. Eckardt is a Senior Welding Engineer with Kiefner & Associates, consulting on welding and asset integrity projects in the Oil & Gas industry. Previously he was an Asset Integrity Engineer for Ashland, a leading specialty chemical company. His principal functions involved fabrication inspections of new equipment, management of inspection plans, and improving fixed asset utilization. Before that he worked as a product development engineer at Select-Arc, Inc specializing in FCAW, MCAW and tubular SAW welding electrode development. He began his career as field welding engineer at the Chicago Bridge & Iron company (now McDermott), working on storage tank, pressure vessel and LNG facility projects.
Mr. Eckardt holds a BSc from The Ohio State University in Welding Engineering and is an AWS Certified Weld Inspector. He holds API 653 Aboveground Storage Tank Inspector, API 510 Pressure Vessel Inspector & API 570 Piping Inspector certifications. Mr. Eckardt is a member of the AWS A5 Committee for Filler Metals and Allied Materials, as well as the A5D & A5J subcommittees. He is also Chairman of the Columbus, OH AWS Section (036). |
| 9:10 – 9:40am |
Dr. Boian Alexandrov
Research Associate Professor,
The Ohio State University
Keynote – Types of cracking in advance alloys
The global demand for energy resources and energy efficiency has led to deployment of variety of advanced metallic alloys in the oil and gas, power generation, petrochemical, transportation, and defense sectors.
However, weld cracking and loss of properties are frequently experienced during fabrication and service of welded structures in such alloys. Poor weldability is often reported as the root cause of catastrophic failures, costly repairs, and expensive shut-downs, or as the limiting factor for implementation of new alloys.
This keynote lecture will address typical cracking phenomena experienced during fabrication and service in welds of advanced alloys, including:
- Environmentally assisted hydrogen cracking in matching and dissimilar metal welds
- Solidification, liquidation, and ductility dip cracking in corrosion resistant weld overlays
- Stress relief and stress relaxation cracking in welds of creep resistant alloys
Mitigation approaches based on materials selection and optimization of welding and heat treatment procedures will be discussed in relation to metallurgical aspects of failure mechanisms. Recent advances in the development and standardization of tests for cracking susceptibility evaluation, and in the implementation of computational modeling in materials selection and alloy development will be also presented.
BIOGRAPHY
Dr. Boian T. Alexandrov is a Research Associate Professor in the Welding Engineering Program and Director of the Center for Weldability Evaluation at The Ohio State University. He earned his M.Sc. degree in Materials Science and Engineering and Ph.D. in Welding Engineering from the Technical University of Sofia (TUS) in Bulgaria. Prior to joining OSU in 2003, he worked as Associate Professor at the Department of Materials Science and Engineering of TUS.He held an NSF-NATO fellowship at the Welding Engineering Program of OSU, and fellowships at the University of Cambridge in UK, Otto-von-Guericke University in Magdeburg Germany, University College of Dublin in Ireland, the Institute of Welding and Quality in Lisbon Portugal, and the Welding Research Institute in Bratislava Slovakia.
His primary research interests are in the metallurgy of welding, focusing on weldability evaluation, physical and computational simulation of weld phenomena, service performance of welds in advanced alloys, phase transformation analysis, compositional optimization of welding consumables, and process optimization. He has contributed towards clarification of metallurgical phenomena related to major weldability problems experienced in the oil and gas, petrochemical, and power generation sectors. His research has been supported by US federal institutions and by more than forty companies from the US, UK, Canada, Germany, France, Sweden, Belgium, Austria, Brazil, Japan, and South Korea.
At OSU, Dr. Alexandrov has advised and co-advised forty-one graduate students and eight postdoctoral researchers, and involved more than fifty undergraduate students in industry-supported research.
He has published more than forty papers in scholarly journals, sixty papers in proceedings, given twenty keynotes and invited presentations, made more than two hundred and forty conference presentations, and holds four patents.
Dr. Alexandrov is as a Fellow of ASM International (2019) and AWS (2015). He received the AWS Warren F. Savage Memorial Award (2013) and the William Spraragen Memorial Award (2012), the OSU College of Engineering Lumley Research Award of (2017, 2012), the Elmer L. Hann Award of the Society of Naval Architects and Marine Engineers (2011), and the First Place Award in Electron Microscopy of the ASM International Metallographic Society (2010).
He is a member of AWS, ASM International, NACE International, ASME, and FAS. He serves at the Technical Papers Committee of AWS and the ASM Programming Committee, is an active member of Commissions II and IX of the International Institute of Welding (IIW), and of the American Council of IIW. He is also a past Cahir and Vice-Chair, and a current member of the Joining Technology Committee of ASM International. He has served as a principal reviewer and/or reviewer for Welding Journal, Welding in the World, Metallurgical Transactions, Science and Technology of Welding and Joining, and Journal of Nuclear Materials.
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| 9:40 – 10:10am |
Dave Bajula
General Manager, Advanced NDT Services,
Acuren
High Temperature Phased Array (HTPAUT) Crack Detection, Sizing & Monitoring
Although most are aware of Phased Array technology (PAUT), many do not know that the technique has been successfully used at temperatures up to 750°F (400°C) in the performance of on-stream inspections saving owner/users millions of dollars in unnecessary downtime costs coupled with achieving enhanced accuracy in the detection and sizing of cracking and other flaws subsequently allowing for ongoing monitoring.
This presentation will detail the evolution of performing HTPAUT over the past decade including the upgrading of the equipment, probes, wedges and techniques while assuring safety of personnel in performing the HTPAUT inspections. I will also provide numerous examples of data and inspections that have been performed including a look at some of raw data for a crack greater than 50% thruwall, as shown below.
BIOGRAPHY
Employed by Acuren Inspection in the USA now for the past 20 years, Mr Bajula serves as the General Manager for Advanced NDT Services and is an in-house Subject Matter Expert on Nondestructive Testing. Over the past 35 years, Mr. Bajula has had a broad based experience in all aspects of Nondestructive Testing and Inspection Services working with companies such as Combustion Engineering and General Electric servicing the Oil & Gas, Nuclear Power and Aerospace industries. Dave is a Chartered Engineer, an ASNT Level III in 9 methods, Certified Welding Inspector (CWI) and have several API credentials.Dave’s specialty area is on-stream inspections with Ultrasonic and Electromagnetic techniques at elevated temperatures. He has published numerous papers and taught short courses on Advanced NDT and pioneered the application of Phased Array for in-service inspections on critical vessels and piping at temperatures up to 750F. He is also a past President of ASNT and a member of the Certification Management Council including the chair for ISO TAG committee as well as very active and influential on code committees including ASME, ISO, etc. |
| 10:10 -10:30am |
BREAK |
| 10:30 – 11:10am |
John Seifert, PhD
Program Manager,
Electric Power Research Institute
Formation of Damage in the Heat Affected Zone of Grade 91 Steel and its Implications on Component Behavior
Few weldability issues have been reported in Grade 91 steel. By comparison, the in-service performance of components operating in the time-dependent regime has been shown to be extremely sensitive to fabrication processes, which might introduce creep-weak material and/or the introduction of base metal heats that possess elevated metallurgical risk. Welded connections are particularly susceptible to the formation of early-in-life time-dependent damage in a heat affected zone region identified as the partially transformed zone. The formation of damage in the Grade 91 partially transformed zone is linked to metallurgical risk factors present in the parent material. These risk factors are qualitatively assessed in time-dependent testing by measurements of creep ductility, for example reduction of area, or quantitatively through advanced electron microscopy. Results detailed in this talk will demonstrate the importance of composition control and the consideration of creep ductility when screening parent metal behavior.
BIOGRAPHY
Mr. Seifert graduated from the Ohio State University with a Bachelor’s of Science degree in Welding Engineering in 2008. Immediately following graduation, John began working at the Babcock and Wilcox Research Center where he eventually coordinated research and development efforts in the welding lab. In June 2011, John began working for EPRI in Program 87, “Materials and Repair” and now manages this portfolio of research. More recently, he received his PhD from Loughborough University in July 2019. His experiences in welding research includes the examination and behavior of a wide range of materials including creep strength enhanced ferritic materials, advanced stainless steels, nickel-base alloys and dissimilar metal welds.
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| 11:10 – 11:40am |
Benjamin Sprengard
Corporate Director of Quality Assurance Welding Engineer and Metallurgist ASNT NDT Level III, AWS CWI/CRI,
Enerfab
Fabrication Methods to Prevent Corrosion in Duplex Stainless Steels.
Utilizing the correct fabrication methods and techniques for welding Duplex Stainless Steels (DSS) is critical. It could be the driving force of whether or not corrosion may or may not occur when a piece of equipment is placed in service. After attending this presentation, you will not only understand the weldability concerns with DSS, but also how to overcome them, and how to confirm results. Our solutions are a result of years of experience within the fabrication industry, not only providing new equipment, but also repairing in-service corroded equipment.
BIOGRAPHY
Mr. Sprengard is the Corporate Director of Quality Assurance for Enerfab, an industry leader in fabrication, construction, and maintenance services. Enerfab specializes in the utility and heavy industrial markets, including chemical, oil and gas, water and wastewater, and power. Along with Code compliance and materials expertise, Mr. Sprengard is responsible for continuous improvement within the organization. Recent achievements include the development and implementation of a metric-based quality program along with improving organizational effectiveness through embarking on a digital transformation of the quality department.
Previously, Mr. Sprengard worked as a Welding Engineer and Metallurgist, providing engineering solutions to metallurgical, materials joining, and nondestructive testing applications. Throughout his career, he has conducted several failure analyses and onsite investigations in power generation boilers, clean air systems, breweries, ASME pressure vessels, and API storage tanks. His responsibilities have also included providing metallurgical support for the development of welding procedures for a wide range of materials, including high temperature boiler tube steels, super duplex, precipitation hardened materials, quench and tempered steels, and Ni-based alloys.
Mr. Sprengard holds a BSc in Welding Engineering from The Ohio State University, where he specialized in welding metallurgy and nondestructive evaluation. Upon joining Enerfab, he completed his MSc in metallurgical engineering from the University of Cincinnati. His post graduate research was devoted to the analysis of mechanical properties and phase transformations in lean duplex stainless steels. Mr. Sprengard is a licensed Professional Engineer in the state of Ohio. He holds an ASNT NDT Level III in PT and VT and is an AWS Certified Welding Inspector. Mr. Sprengard is a former Chairman of the ASM Cincinnati Chapter, a member of the Materials Technology Institute (MTI), and is involved with local organizations. |
| 11:40am – 12:20pm |
Tony Anderson
Director of Aluminum Technology,
ITW Welding
How to Avoid Cracking When Welding Aluminum Alloys
An understanding of the reasons why aluminum welds crack is very important to the welding engineer who is responsible for welding operations on aluminum structures. It can prove essential when engaged in failure analysis, and during the design and development of welding procedures. We will consider the principal cracking mechanisms in aluminum alloys and the elements that can influence the probability of weld joint cracking. Such elements include material selection, the chemistry of base metal & filler metal combinations, joint design, and filler metal selection.
BIOGRAPHY
Tony Anderson is the Director of Aluminum Technology for ITW Global Welding Center in Appleton WI. Mr. Anderson is a Fellow of the TWI (British welding Institute) and a Registered Chartered Engineer with the British Engineering Council UK. He is the Chairman of the Aluminum Association Technical Advisory Committee for Welding and Joining and participates in a variety of American Welding Society committees and activities. Mr. Anderson writes a regular aluminum welding question and answer column (17th consecutive year) for the American Welding Society Welding Journal. He is also the editor and a co-author of the Aluminum Association publication Welding Aluminum – Theory and Practice (4th Edition) and author of the AWS publication Welding Aluminum Questions & Answers – 2nd Edition. |
| 12:20 -1:30pm |
LUNCH |
| 1:30 – 2:10pm |
Tapasvi Lolla, PhD
Technical Leader,
Electric Power Research Institute
Analysis of Hardfacing Weld Failures in Power Plant Valves using Advanced Characterization and Thermodynamic tools
To improve high-temperature wear properties, a layer of hardfacing alloy is typically weld-deposited on the surfaces of power-plant valve components that have metal-to-metal sliding contact. The standard industry practice is to use Cobalt based alloys as hardfacing layers on iron-based ferritic high-temperature steel grades. However, over the past decade, a series of industry-wide failures involving extensive cracking and disbonding of these hardfacing deposits have raised concerns within the power-generation industry. Until recently, the underlying reason behind these failures was not clearly understood. In an industry-wide collaborative effort initiated by EPRI, analysis of these failed components revealed the formation of a deleterious sigma phase at the dissimilar weld interface between the steel and the hardfacing layer. In this presentation, the determination of this deleterious phase using various advanced characterization tools is described. In addition, the mechanism for the formation and solutions that may prevent this phase from forming is put forth using thermodynamic tools.
BIOGRAPHY
Tap Lolla has a bachelor’s degree in Metallurgical and Materials Engineering from the Indian Institute of Technology, a Master’s in Welding Engineering and he graduated with PhD in Materials Science and Engineering from The Ohio State University, in 2014. After graduation, he worked as a materials researcher in the oil and gas industry. Mr. Lolla subsequently joined EPRI in 2016, where he is involved in advanced characterization of high-temperature materials including ferritic, advanced austenitic steels and nickel based alloys.
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| 2:10 – 2:40pm |
Richard Holdren
ARC Specialties / Welding Consultants LLC
Dispelling the Fears of Hydrogen-bearing Shielding Gas
This program will likely include presentations where cracking has occurred due to the presence of diffusible hydrogen in a crack-susceptible microstructure. We have all been taught that for certain materials, especially high-strength steels: hydrogen + stress + crack-susceptible microstructure = cracking. So, the mere mention of use of welding shielding gases containing hydrogen causes immediate panic.
This presentation will discuss work performed to show that the use of hydrogen in shielding gas will not result in absorption of hydrogen in the microstructure. The hydrogen readily reacts with any available oxides to eliminate them, resulting in significant cleaning. Diffusible hydrogen testing has shown that the diffusible hydrogen level is well below 4 ml/100 g (H4), which is considered ultra-low hydrogen. Welds made with hydrogen-bearing shielding gases are much cleaner due to the inherent cleaning action.
Further testing has shown that elimination of oxides due to this reaction will eliminate manganese and silicon oxides that form on the weld surface, providing even greater benefits.
So, rather than resulting in conditions leading to cracking, use of hydrogen-bearing shielding gases will can lead to a number of quality and productivity benefits.
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| 2:40 -3:00pm |
BREAK |
| 3:00 – 3:40pm |
Jeff Vinyard
Application Specialist – UT,
Applus RTD
IWEX Ultrasonic Crack Imaging
In the world of Non-Destructive Testing Advanced Ultrasonic Inspection is used daily in lieu of radiography to offer insight when characterizing crack like defects from other defects.
IWEX, a Total Focusing Method introduced to the inspection market in 2012 , uses Full Matrix Capture ultrasonic data by transmitting and receiving from multiple incidence points within an array probe and between multiple array probes. This data is processed in real time into high resolution cross sectional images of the weld at increments of typically 1 mm/ 0.39 in.
After a short description of how the data is collected and presented images from real weld defects, identified during research and system qualification and compared to destructive testing, will be shared to show how straightforward characterization and sizing of indications like cracks, lack of fusion, porosity, hook flaws, and laminations can be.
BIOGRAPHY
Mr. Vinyard holds level II Certifications in UT, MT, PT and ACCP LIII in UT. Currently he supports Applus RTD as an applications specialist and ultrasonic testing subject matter expert. This includes application research using IWEX and developing training material for each application. Prior to devoting much of his time to the IWEX development group, he was the phased array and ultrasonics instructor for the Applus Houston office while working in the field as a phased array specialist. |
| 3:40 – 4:20pm |
William Newell
Vice President, Engineering,
Euroweld, Ltd
Component Repairs Using Under Matching Weld Filler Metals to Avoid Cracking Problems
Repair of defects in components that have seen service typically require evaluation of original design criteria, operating history, and properties of the materials involved. Most repairs consider and unilaterally try to at least match original material properties or strength levels. In most cases, repair properties will exceed those of the original component or weldment. Extended service may even result in degradation of original material and weldment properties. The use of weld filler metals that match the existing base metal properties rather than the original material grade is gaining more acceptance and use. This is especially true in temperbead approaches where the weld metal will be left in the as-welded condition. Where materials have experienced degradation, the introduction of stresses from a repair operation can be detrimental, preheat must be minimized because of environmental or component safety considerations or post weld heat treatment is impractical or impossible all represent situations where use of under matching weld filler metal may be appropriate. In these cases, selection of an under matching composition and properties may provide adequate or even superior service. The concept, evaluation and implementation of selected case histories from the power, chemical, natural gas transmission and other industries are presented.
BIOGRAPHY
Involved in welding engineering applications and consulting in the nuclear & fossil electric power and heavy industrial arenas for nearly 40 years, both domestic and internationally. Bill is a member on national and international code bodies, a Life Member and Counselor in the American Welding Society, and a member of AWS A5N, Chair of AWS D10 Piping and Tubing, a Member of ISAC and ISO/TC 44, International Committee on Welding and Allied Processes, plus a member of ASME Standards Committee IX – Welding and Brazing Qualifications, ASME Post Construction Issues – Subcommittee on Materials and Repair, former Chair of ASME SCII/IX Subgroup on Strength of Weldments, and a member on the ASME SCII Working Group on Creep Strength-Enhanced Ferritic Steels. He is the President of W. F. Newell & Associates, Inc., and Co-Founder/Vice President – Engineering of Euroweld, Ltd. |
| 4:20 – 5:00pm |
Russel Fuchs
voestalpine Bohler Welding USA
Influences on HAC of Welds Made in Modern High Strength Pipe Steels
Traditional procedures for the welding of cross country pipelines call for the use of cellulosic coated electrodes. For cellulosic electrodes to properly shield the molten weld metal during the welding process, the moisture content of the electrode coating must be in the range of 3 to 5%. This added moisture in the electrode coating will induce a certain level of hydrogen into the weld metal. In former times, this added hydrogen did not pose a threat due to the lower strength of the pipe steels used. However, more and more pipelines are being designed using API 5L X70 grade pipe and stronger, necessitating the use of more controlled procedures to ensure the hydrogen assisted cracking threshold is not exceeded.
This presentation will discuss the various factors that influence the weld metal hydrogen content and cracking susceptibility. We will look at carbon equivalent, wall thickness, preheat, interpass temperature, heat input, and strength level, and their individual and collective influence on the as deposited weld metal diffusible hydrogen content and susceptibility to HAC. A case will be made to support the use of low hydrogen filler metals for the welding of the higher strength pipe steels prevalent on today’s pipeline construction projects.
BIOGRAPHY
Russel Fuchs is currently Sr. Technical Consultant for voestalpine Bohler Welding USA, located in Houston, Texas. His primary responsibility is technical support of the sales activities of the Company in the United States and Canada. Russel has been with voestalpine Bohler Welding for 34 years, and has a total of more than 40 years in the industry.
Russel is a life member of the American Welding Society and serves on several AWS committees. He is also active with several industry code bodies and organizations, such as ASME, API, and NACE.
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