1 SHEET METALCONFERENCE XVI

2 CHAIRMAN’S MESSAGE2 UPCOMING EVENTS2 COMMITTEE CHAIRS3 CWI3 EDITOR’S NOTE4 PATRON’S FUND4 VoTECH UPDATES!5 HAVING A PROBLEM

FINDING QUALIFIEDCANDIDATES?

5 MEET OUR MEMBERS5 VisTaTech MAP6 SCHOLARSHIP AWARD

WINNERS8 OCTOBER HOTLINE9 ASK THE WELDING

ENGINEER

October 2014

Inside This Issue

Follow Us awsdetroit.org

The 16th Sheet Metal Welding Conference is October 22, 23, 24 at theVisTaTech Center in Livonia, Michigan. The aluminum workshop is October 21

at R&E Automated Systems in Macomb, Michigan. In addition to all the greatpresentations on welding applications and research,

Professor Alan Taub from the University of Michiganwill be giving a keynote address titled:

“Challenges In Manufacturing A Multi-Material Vehicle”

There will also be a FREE vendor exhibit and networking event on October 23from 3:30-7pm. For sponsorship and exhibition opportunities, contact SusannMorfino (586-443-8333/susann@mjmsales.com.) This is a great chance to seewhat’s going on in the sheet metal joining industry and make new contacts.

Find out all the details and sign up at www.awsdetroit.org.

MAP

What were you doing 30 years ago? The AWS DetroitSection and several of our Executive Board leaders hada brain child, The Sheet Metal Weld Conference.

Dr. Dale U. Chang suggested a conference on ResistanceSpot Welding. It only made sense as this is the “Motor

City” where more spot welding occurs than anywhere in the world. Now, after15 consecutive conferences we are about to present SMWC XVI.

You may be thinking that not much has changed since the early days ofthis conference, but in fact, a whole lot has changed. And, we’re excited tobring this knowledge to you at the 2014 Sheet Metal Weld Conference.

• Now, we are trying to weld Boron after hot stamping. It’s kind of like weldingglass.

• How do you produce 75 jobs per hour in aluminum?• Let’s try laser welding aluminum.• My favorite, “Friction Stir Blind Riveting of Carbon Fiber Reinforced

Polymer Composite and Aluminum Alloy Sheets.”• Be a part of a “hands on” workshop at R&E Automation. Industry experts

will not only show us the “How” but, you can experience joining aluminumwith lasers, spot-welding, drawn arc and more.

Innovation, new technology and implementation - this is where the rubberhits the road. You can’t do these exciting things in Europe, India, China, Koreaor even Japan. Nope, only in Detroit, and we are proud to be the “Motor City.”

Don’t forget Vendor Display Night on Thursday October 23. Visit thecompanies that make all of this work. I hope to see you there!

October 2014This Issue of the Bulletin

can be viewed on the web at

awsdetroit.org�

ChairmanDAN WELLMAN

First Vice ChairWESLEY DONETH

Second Vice ChairTYLER ALEXANDER

SecretaryDAVID BENETEAU

TreasurerANDRE YOUNG

Bulletin EditorROBIN MICHON

WebmasterRODNEY BEREZNICKI

Hot Line CoordinatorERIC PAKALNINS

Meeting ReservationsSUSAN MORFINO

AdvertisingRUSS WEBSTER

Assistants to ChairmanVIJI KURUVILLAMARK GUGELPHIL TEMPLE

�

For Advertising OpportunitiesContact Russ Webster

810-602-9748

Affiliated With

October 1, 20142014 Product Development and Technology Forum

AIAG

October 3, 2014Manufacturing Day - 2014

Engineering Society of Detroit

October 19 to October 25, 2014CWI Seminar and Exam

American Welding Society

October 21-22, 2014SAE 2014 Convergence

Society of Automotive Engineers

October 29-30, 2014International Auto Body Congress 2014 - Dearborn

Global Automotive Management Council

Upcoming EventsSee our website for a complete listing.

Dan WellmanChairman’s Message

October 16, 2014 Lasers In Automotive

Trumpf, Inc.

CWI – Certified Welding InspectorsSubmitted by Ryan Kot, CWI

The deadline to sign up for the final Certified Welding Inspector (CWI®)exam/seminar in Detroit this year has come and gone, and hopefully all ofyou interested candidates have submitted your applications! The exam willbe held on October 25, 2014, with the week-long seminar (AWS Prep. Course)being held from October 19 – October 24, 2014. Once again, both the examand seminar will be held at the Four Points by Sheraton Detroit Metro Airportin Romulus, Michigan. If you missed the deadline, don’t worry, there will betwo more exam dates scheduled in Detroit for 2015. Don’t forget, the AWSalso holds CWI exams on a weekly basis throughout the United States,Canada, Mexico, and the world!

So, why you ask? Why should I become a Certified Welding Inspector? Firstoff, and speaking from personal experience, it’s definitely a worthwhile andfulfilling career. From technicians to supervisors, Alaska to Saudi Arabia, andpaperwork to ironwork; when it comes to job title, location, and industry, thepossibilities are endless! Plus, it doesn’t require a PhD or even a college degreeto become a CWI! What is required, is a diligent work ethic and an understandingof the responsibility that comes along with a CWI certification. I’ve seen first-hand that a CWI certification isn’t for everyone. There are unfortunately avery small number of individuals who can take the certification for grantedand give the rest of us a bad name. But, if you’re the type of person with strongmorals and someone who isn’t satisfied with mediocrity, then I hope to seeyou at one of our exams!

CRAW Instruction andCertification is comingin December – check outthe coming eventscalendar on theAWSDetroit.org website!

Editor’s Notes:Welcome to the October issue of

the AWS Detroit e-bulletin! You may have noticed that

missing from our front page is themonthly Technical Meetingannouncement. But, in its place isan invitation to the SMWC XVIconference. If you can’t make theconference or the workshop, pleasestop in for the Vendor Exhibit. It willgive you a chance to meet thesponsors and view theirproducts/services, while meetingother members and even some ofthe AWS national personalities.This is a great opportunity to “mixand mingle” in the welding arena!And, don’t forget to stop by theAWS Detroit sections’ membershipbooth and say, “Hello!”

October is overflowing witheducational opportunities for all.Plus, there are all sorts of additionalactivities this month featured inour Upcoming events – check outour website’s event page atwww.awsdetroit.org.

Don’t forget many of the articlespublished in the e-bulletin alsohave additional photos and/orlinks to more information on thewww.awsdetroit.org website.

I hope you enjoy this month’sarticles! See you next month!

~ Robin

Save the Date: July 27, 2015

Click Here to be notified of whendetails are available

Patron’s Fund As the Patron’s Committee Chair,I would like to thank those generouscompanies and individuals whohave contributed so far to the fund.

2013-2014 Current Patrons

ATI Industrial Automation

Centerline (Windsor) Limited

Dengensha America Corp.

Fronius USA, LLC

FUSION Welding Solutions

Genesis Systems Group

GROSSEL TOOL Co.

Industrial Control Repair (ICR)

KUKA Robotics

LEONI Engineering Productsand Services, Inc.

LUVATA

Matuschek

Nick & Ilse Hamers

Obara Corp. USA

RoMan Manufacturing, Inc.

The Ohio State University WeldingEngineering Alumni

Vulcanmasters Welding Company,Inc.

Multi-Contact

Robert F. Cahill Memorial Fund

Prof. Hongyan Zhang Royalties

AWS Patrons collectively provide annualfunding for scholarships toward anAssociate Certificate in Welding

Technology or a Bachelor of Sciencedegree in Welding Engineering or

Manufacturing Technology. For moreinformation please contact AWS-

Patron’s Committee Chair Joe Beckham.

Patron’s FundSubmitted by Eric Lichtfusz, AWS-Patron’s Committee, Chair734.466.6504; eric.lichtfusz@roush.com

The time has come again where we are asking all members for theirgenerosity in contributing to the 2014-2015 Patron’s Fund. We will, asalways, contribute 100 percent of these funds directly towards scholarshipsfor students who are pursuing careers in Welding Engineering and WeldingTechnology. Each year the American Welding Society Detroit Section sponsorsmany students with these funds, and as you probably already know, thefuture of our industry depends on the kind of support that you help us toprovide. Because this is such an important part of giving back to theindustry that supports us, we hope you can help us by being a proudsupporter in this effort.

To be a Patron, simply send a check made out to the American WeldingSociety Detroit Section for a minimum of $100, and any increase to theminimum is greatly appreciated. Patrons are made known to the membershipin the monthly technical bulletin, on the AWS website, and are furtheracknowledged by being listed in the annual Ladies Night Program, scheduledfor Saturday, March 28, 2015.

If you are a Patron, we thank you for your support, and ask you to pleaseconsider increasing your generous contribution. Whether a longtime Patronor a first time Patron, your help will assist us in bringing about an educatedfuture workforce.

Please make contributions payable to:AMERICAN WELDING SOCIETY DETROIT SECTION

Mail to: Eric Lichtfusz, Roush Industries, 12068 Market St., Livonia, MI 48150

VoTech Updates!Submitted by Jeff Hill, education chairman DPS VoTech

The AWS Vocational tech program has been working closely withGolightly/Davis Aerospace vocational school in Detroit. This past week, DeanWilson (AWS acting president) paid a visit to the school to talk with thestudents and take a tour of their facility. He was very impressed with theirwelding lab and the school in general. He was also pleased to see howenthusiastic the students are in the welding program thanks to theirinstructor, Juan Whiting.

Robert Wilcox (District 11 director) and Don DeCorte (AWS counselor)were also on hand for the visit. I am very pleased to be working with thestudents and faculty at Golightly. It makes me proud to be a part of our firststudent chapter located within the city of Detroit.As the chairman for theirWeld advisory committee, I am looking forward to the upcoming year. Lookfor our schedule of tech meetings from the students at Golightly coming soon.

Having a Problem Finding Qualified Candidates? Submitted by Ashley Webel, S.E.N.S.E and Student Affairs

Did you know that within the state of Michigan, we have over 120 schools that have a welding program? More than40 of those schools use the AWS accredited SENSE welding curriculum. We also have at least three student chapters inDistrict 11 alone. Many of these programs participate in the Skills USA Welding Competitions as well.

The welding industry has a long history and deep roots in the great state of Michigan. Our long list of welding educatorsproves that we are still invested in this industry. If you or your company is interested in hiring a welding professionalplease consider contacting one of the welding programs near you. Listed below is a link to all of the welding programsin Michigan. http://www.aws.org/w/e/search_results.html?state=MI&browse=1

Meet Our MembersWhy haven’t we met YOU, yet? Here’s your chance! We

are always looking for members who have something toshare. You can be a long-timer, or a new-comer. Your articlesopen up a whole new world of welding to someone whomaybe hasn’t thought about it the way you do. Dan Galiherheads up our membership committee and would love tointerview YOU for an article. Send Dan an email atgaliher.daniel@towerinternational.com to become ournext featured member!

Schoolcraft College – VisTaTech Building18600 Haggerty Rd. – Livonia, MI 48152

Co-op Welding Students,Summer Interns andPart-time Welders

Contact Pat Bell:patricia.bell@detroitk12.orgor (313) 282-8171 in Detroit

AWS Student Night Scholarship AwardsCongratulations to the

2013 – 2014 American Welding Society-Detroit SectionSCHOLARSHIP WINNERS!

Congratulations on your current achievementsand best wishes for a bright welding future!

The Robert L. Wilcox ScholarshipAwarded to Bradley Anderson – Ferris State

The James W. Mitchell ScholarshipAwarded to Lyle Pompa – Ferris State

The Amos and Marilyn Winsand ScholarshipFunded by the AWS Foundation

Awarded to Steven Esders – Lansing Community College

$2000 Awards $1500 Awards $1250 AwardSean Benvin Brian Pearch Michacel Riley

Philip Brown Michael Bilbrey IIRyan Kannegieter

Andrew SteberTravis Smith

$1000 AwardsDaniel Kedroske Cody Tohm Garret Wallen

Cody Ybema Andrew Esler Luke BakerChristina Surfus Bradley Bills Mark Vlauchick

Aaron Miller Adam Dobschensky Harrington BoesJustin Ruffner Jonathan Carney Aaron KavanaghWade Dean Alex Rice Ashton Glover

Ryan Wischmeyer

The AWS-Detroit Sectionheld its annual student nighton September 11, 2014 at theVisTaTech Building ofSchoolcraft College in Livonia,MI. This year the section wasable to award scholarshipstotaling $35,000 to studentsfrom 10 different schools. The28 recipients of the 2014 – 2015Scholarships will be attendingSt. Clair County CommunityCollege, WashtenawCommunity College, FerrisState University, MonroeCounty Community College,Schoolcraft CommunityCollege, Henry FordCommunity College, MacombCommunity College, LansingCommunity College, OaklandCommunity College andPennsylvania State College.

The section’s scholarshipsare made available toMichigan and select Canadianresidents and/or studentsenrolled in a welding orwelding related programs at acollege or university in theState of Michigan. Thecandidates all submitted anapplication, includingtranscripts of their academicachievement, and a brief letterabout their background, theirgoals and ambitions, and anyadditional factors that wouldhelp the Section ScholarshipCommittee determineeligibility for an award.

The Section also heard fromDean R. Wilson, AWS NationalPresident. Mr. Wilsondescribed delivered a talk thatdetailed what the AmericanWelding Society is doing totransform professionalwelding careers.

For AdvertisingOpportunities

Contact Russ Webster810-602-9748

October Hotline

New Hand-Held Weldscope Ws-100 Provides CompleteResistance Welding Process ControlDate: August 26, 2014

Dengensha America’s new hand-held Weldscope WS-100 is designed to ensurethe accuracy and detail required by high-quality manufacturers. From the palmof the hand, it controls 15 monitoring functions and 3 selectable detection ranges.Users can monitor, measure, save and print out welding current, cycle timeand peak current from AC and DC welders, single and three-phase welders,capacitor discharge welders, AC seam welders, pulsation AC/DC welders, andinverter welders.

The Weldscope WS-100 offers manufacturers a wide range of other featuresand benefits as well. It generates upper and lower limit error signals, “Good”and “No Good” output signals, and it detects secondary cable wear. It alsoincorporates a waveform display, a zoom function, torodial coil, florescentdisplay, multiple output options, and a lithium backup battery.

Along with the capability to better control quality and accuracy bymonitoring resistance welding processes, the Weldscope WS-100 also gives theuser the ability to save the last 800 welds and then print them by way of directcable or Bluetooth to a PC. For more information about the new hand-held Weldscope WS-100, contact StevenAndrassy sholz@dengensha.com / Or visit us: www.dengensha.com

Fronius USA Personnel ChangeStephanie Gibson, US Marketing Segment Manager, gibson.stephanie@fronius.com

The Indiana based company transferred two of their System Engineersback to their Michigan location. Randy Edmonds and Matt Chynoweth bothstarted in the Michigan office before the company moved its headquarters toPortage, Indiana. During that transition, they had moved to Indiana tosupport the new office. Now they are back in the Brighton, Michigan locationto support the NorthEast customers. Fronius USA LLC - Michigan, 10421 Citation Dr., Ste 1100, Brighton, MI 48116;Headquarters: 6797 Fronius Dr., Portage, IN 46368; www.fronius-usa.com

HOMECOMING!Submitted by Mr. Tom Snow, CEO of T.J. Snow, TomSnow@tjsnow.com

In a homecoming of sorts, two electronics techs from T.J. Snow Companyof Chattanooga, Tennessee, recently flew the Mooney airplane they use forservice calls to the Mooney factory in Kerrville, Texas where it was “born.”Randy Darby and Ray Michelena routinely use a company plane to offer fast-response service on resistance welders of all types.

The purpose of this trip was to upgrade the electronic controls on a resistancespot welder used in manufacturing the speedy single engine Mooneys, which

have been built in the Texas Hill Country for decades.After being shut down for five years, the Mooney

production line was recently reactivated and much ofthe factory's production machinery is being upgradedor replaced.

T. J. SNOW // Resistance Welding Machinery & Supplies /Industrial Water Chillers; 120 Nowlin Lane, Chattanooga,TN 37421; www.tjsnow.com

Hotline continued on page 10Randy Darby, Ray Michelena and “Mooney” Airplane

Randy Darby with a Sciaky spotwelder at the Mooney plane factory

Ask the Welding EngineerBy Donald F. Maatz, Jr.

“One of our suppliers has notified us that they intend tochange to a different drawing lube. What impact couldthis have on our spot welding?”To help answer this question, I have reached out to fellow AWS-Detroit Section ExecutiveBoard member Eric Pakalnins of R&E Automated Systems, LLC. Eric is a Welding

Consultant with R&E Automated Systems, LLC and a member of AWS D8D committee onAutomotive Resistance Welding and a contributor to the AWS D8.9:2012, Test Methods forEvaluating the Resistance Spot Welding Behavior of Automotive Sheet Steel Materials. If youhave more questions about this topic, Eric can be reached at: epakalnins@reautomated.com

“There are several considerations that need to be looked at with a changefrom one drawing lubricant to another. The most fundamental is Current Break-Through (CBT). Basically, CBT is a measure of how difficult it is to initiate thepassage of current. The two extremes that can help illustrate CBT are 1) firethe welder tip-to-tip and 2) fire the welder with a piece of electrical insulationbetween electrodes. In the first case the welder has no issue with CBT, in thesecond the welder cannot pass current at all and faults out.

The CBT can vary from one situation to another but is something we canmeasure. The following is from the AWS D8.9-2012, section 12, and does a nicejob of explaining how CBT can be determined. The figures are of a currentmeter printout that details themeasured value at each half-cycle.

• Each half-cycle that is belowthe 90% limit is considered to havenot achieved current break-through. The figures (A, B, C) showtypical printouts. Figure-A shows anoutput for a material where nocurrent break-through time (CBTT)was required. The current is alreadyabove 100% of the mean (effective)current (8.92 kA) for the first half-cycle. Therefore, the CBTT is 0.Figure-B shows an example wherethe first half-cycle does not achievethe minimum threshold of 90% ofthe mean current (8.80 kA).Therefore, the CBTT of this weld is1 half-cycle. Figure-C shows anexample where the first 3 half-cycles did not pass any measurablecurrent and the next 4 half-cyclesdid not achieve the minimumthreshold of 90% of the meancurrent (13.08 kA). The CBTT ofthis weld is 7 half-cycles.

If the CBT can be quantified forthe new drawing lubricant it willbe a major step towards learningthe effect of a potential change.”

References:1) AWS D8.9:2012

Q:

A:

Send your questions to Don at dmaatz@reautomated.com

- subject line "Ask the Welding Engineer"

Donald F. Maatz, Jr., WeldingEngineer / Lab ManagerR&E Automated Systems, LLCRoMan Engineering Services32711 Glendale AveLivonia, MI 48150-1611

(734) 793-2304 - Direct (248) 585-5577 - Faxdmaatz@reautomated.comwww.reautomated.com

September Hotline (continued)KUKA Systems Develops Robotic Riveting System forBoeing 777 Wide-Body Fuselage Assembly Jane Thompson, Marketing Manager, Jane.Thompson@kukanao.com

Sterling Heights, MI, Augsburg, Germany, September 15, 2014 –When the Boeing 777X twin-aisle passenger jet goes into full productionfor its debut in 2020, each fuselage will be built using special advancedautomation technology, the result of a collaborative effort by theairplane maker and the KUKA Systems Aerospace Group.

The robotic pulse production line, known as the Fuselage AutomatedUpright Build (FAUB), will be the baseline manufacturing process for

the 777X and prior to that, for assembling fuselages for current 777 models.It’s the first time Boeing will use such technology to manufacture wide-bodycommercial airplanes. The pulse line uses guided KUKA robots equipped withend effectors manufactured by another KUKA company, Alema Automation,to do the riveting currently performed by workers using handheld tools. Therobots will work on the forward and aft sections, installing up to 60,000fasteners per 777 fuselage, quickly and with great precision.

For KUKA Systems, the project is one of the largest it has undertaken in theaerospace sector. The company’s roster of current aerospace projects includesthe automated assembly of the center fuselage of a new jet fighter, an assemblyline for a new super-medium class of commercial helicopter and roboticdrilling platforms for a new, long-range business jet. They leverage theexpertise in assembly line automation that has made KUKA Systems the largestsupplier of production technology to the North American and Europeanautomotive industries.

The FAUB system, which was pre-assembled and integrated at KUKASystems in Sterling Heights, MI, is undergoing the final phase of testing andproduction readiness in a Boeing facility in Anacortes, WA.

“This is a signature project for us, being able to join forces with such a globalleader as Boeing,” says Robert Reno, Group Vice-President, Aerospace atKUKA Systems. “Bringing KUKA’s manufacturing and automation expertiseto the aerospace sector is helping our customers realize important economiesand efficiencies from technology that also delivers unsurpassed quality.”

KUKA Systems North America LLC, 22500 Key Drive, Clinton Township, MI 48036;www.kukanao.com

Sheet Metal Welding Conference XVI Aluminum WeldingWorkshop - Tuesday, October 21Host of the 2014 Workshop is: R&E Automated Systems, LLC 17500 23 Mile RoadMacomb, MI 48044 (586) 228-1900

R&E Automated Systems (www.reautomated.com) will be hosting the AWS-Detroit Section’s Aluminum WeldingWorkshop on Tuesday, October 21st. Theevent is part of section’s Sheet MetalWelding Conference XVI and will includea Resistance Welding of Aluminum Tutorialby Dr. Hongyan Zhang of the Universityof Toledo and live equipmentdemonstrations. Click here for moreinformation aws.kukanao.com/2014_smwc_site/smwc_index.html).

The Fuselage Automated UprightBuild (FAUB) is a roboticmanufacturing system beingdeveloped by KUKA SystemsAerospace Group for The Boeing Co.FAUB will automate most rivetingon future Boeing 777s, includingthe new 777X. The robots willinstall up to 60,000 fasteners perfuselage, quickly and with greatprecision. (Photo: KUKA Systems)

Past Chairman, Carl RobertHildebrand passed awayon September 5, 2014 at theage of 87. Carl waschairman of the AWSDetroit Section for the 1983-1984 season. Carl’s familyasked that the AWS Detroitsection be notified as thiswas an extended part ofhis life. His family statedthat although he spent hisfinal days in hospice, hewas with all of those heloved and was able to tellthem so before he passed. Ifyou’d like to honor Carl’smemory, please send adonation to a charitablecause in his name. Amemorial service will beheld at a later date.