Weld Process Efficiency AnalysisThis interactive seminar will cover why a welding

process analysis is important. It will look at whatinformation and process variables are needed to assessa weld process and the overall efficiency and economicsthereof. We will work through the factors that impact weld process efficiency, such as:gas to filler metal ratio, weld size, weld quality, operating factor, filler metal to weldingtorch consumption ratios, and shielding gas mix selection.The action of benchmarking and how to test for and evaluate the economic impact

of these different factors will be discussed. Information will be shared on the technologythat is available to aid in production monitoring and further analysis of Shop Floor control.

November Technical Night/Educational Series SeminarThursday, November 10, 2016“Weld Process Efficiency Analysis”Schoolcraft College, VisTaTech Center18600 Haggerty Rd, Livonia, MI 48152

Map/Directions

RSVP by Nov.6Nate Miller

(989) 245-4105 or emailN8miller14@gmail.com$10 refundable depositto ensure your seat!

AGENDA5:30 - 6:00pm Welcome Reception &

Networking6:00 - 7:00pm Dinner7:00 - 9:00pm Educational Presentation9:00pm Adjourn

Ed Warzyniec Jared Nevel

Nathan Moyer Dale Albertson

1 NOVEMBER TECHNICALMEETING

2 COMMITTEE CHAIRS2 CHAIRMAN’S MESSAGE2 NOVEMBER HOTLINE2 COMING EVENTS3 CHRISTMAS PARTY

INVITATION3 TECH NIGHT

PRESENTERS’ BIO4 CHRISTMAS PARTY

SPONSORSHIP FORM6 SMWC RE-CAP8 MEET OUR MEMBERS11 ASK THE WELDING

ENGINEER12 EDITOR’S NOTE12 SAVE THE DATE FOR

LADIES’ NIGHT

November 2016

Inside This Issue

Follow Usawsdetroit.org

AWS Technical Nights are opento everyone! We encourage thatmembers bring students and non-members to learn more about ourorganization and industry.

Presenters

See “presenter’s bios” on page 3VisTaTech Center

November 2016This Issue of the Bulletin

can be viewed on the web at

awsdetroit.org

Affiliated With

As I’m sure those who attended would agree,it would be foolish for me to move forward without firstthanking Elizabeth Hetrick and her team for thetremendous work they did in organizing another greatSheet Metal Weld Conference (SMWC). Working ondrastically compressed timing, the SMWC committee

delivered an event that is truly unique to the industry at a fantastic new venue.It is important to keep in mind that all of the individuals involved with thisprocess are volunteers, who take time out of their personal and professionalschedules to coordinate an event that draws an international audience. I’dlike to personally extend my thanks to the SMWC committee for all theirdedication in making this conference a rousing success. Looking forward, we now need to appoint a Chair for our next Sheet Metal

Weld Conference in the fall of 2018. If you are interested, or know someonewho might be, please do not hesitate to contact me or any member of theAWS Detroit Section Executive Committee. We want to ensure that the nextChair is appointed in time to receive a proper hand off. If the SMWC Chairis more than you want to take on, but you still have an interest in participatingas a volunteer, I encourage you to consider putting your name on the ballotfor the Detroit Section Executive Committee. Each year we strive to fill theballot with new names from the industry for election. We need everyone’shelp to keep the section and its activities relevant and serving the needs ofour membership. Please, do not hesitate to contact me directly if you’d liketo be considered.November is usually one of the busier months for the Section and this

November will not disappoint. November 10th is our first “EducationSeries” event of the season focused on “Welding Process Efficiency,”November 16th-18th is FABTECH in Las Vegas, and the month closeswith US Thanksgiving. It is a busy time of year for sure. On behalf of all of the members of the Detroit Section Executive Committee

I would like to wish you and your family a safe and happy Thanksgivingholiday. Respectfully,Tyler Alexander

Tyler AlexanderChairman’s Message

Coming Events To view more events, please visit theawsdetroit.org website, EVENTS page.

11/9/2016 SMART Manufacturing Seminars1415 N. Cherry Ave, Chicago, IL 60642

11/16 – 11/18/2016 FABTechLas Vegas Convention Center, Las Vegas NV

11/17/2016 SAE Detroit Section 2017 GMC Acadia Vehicle EventPresented by SAE, San Marino Club, 1685 E. Big Beaver Rd, Troy, MI

12/6/2016 Additive Manufacturing: 3D Scanning and ImagingDetroit, MI

12/10/2016 AWS Detroit Annual Christmas PartyWestern Country Club, Redford MI

Oddly enough there were no submissions to the Hotline this month. Is “No news, good news?”

If you or your company has a newsworthyevent to share, please contact AmandaDavis at amanda.davis@fcagroup.com.

�Chairman: TYLER ALEXANDER

First Vice Chair: WESLEY DONETHSecond Vice Chair: MARK GUGELSecretary: DAVID BENETEAUTreasurer: ANDRE YOUNG

Bulletin Editor: ROBIN MICHONWebmaster: RODNEY BEREZNICKI

Hotline Coordinator: AMANDA SCHERZERMeeting Reservations: SUSANN MORFINO

Advertising: DONNIE CRISTAssistants to Chairman:JOHN SUTTERASHLEY WEBEL

TBD

�

For Advertising Opportunities Contact Donnie Crist

810-217-9897

November Hotline

Mr. Ed Warzyniec attendedWashtenaw Community Collegeand Eastern Michigan University. Edbegan his career in welding in 1977.Over the course of his career hehas held various positions workingwith thermal cutting and weldingprocesses including laser cuttingand welding. He is currently a WeldProcess Specialist with Air Gas anAir Liquide Company servingcustomers in SoutheasternMichigan. Ed served on theAmerican Welding Society C4Committee, Oxy/Fuel Gas Weldingand Cutting and the CompressedGas Association, Industrial GasesApparatus Committee. He haspublished several articles on gases,welding and cutting. He is a 28year member of the AWS and is aCWI, CWE and CWS.

Mr. Jared Nevel graduatedfrom Ferris State University in 2011with a Bachelor of Science in Weld-ing Engineering Technology. Hebegan his career as a Welding Engi-neer in Monroe, MI at a start-upwind tower manufacturing facility.There he gained experience withSubmerged Arc Welding as well asAWS D1.1., Welding Procedure Spec-ifications, and Performance Qual-ification. Jared joined Airgas,an AirLiquide Company in 2014 as a Weld-ing Process Specialist serving cus-tomers in Northern Ohio and South-eastern Michigan. In this role he isresponsible for providing processimprovement services to customersto aid business growth. Jared is amember of the American WeldingSociety and a CWS.

Mr. Nathan Moyergrad uatedfrom The Ohio State University inwith a Bachelor of Science inWelding Engineering in 1999. Overthe course of his 17 year career hasworked with a wide variety of metalfabrication facilities covering manyprocesses, materials, filler metals,gases and equipment. His exper -ience also covers many levels ofautomated cutting and weldingapplications and various weldingcodes. Nathan works as a WeldProcess Specialist with Airgas, anAir Liquide Company servingcustomers is Central Ohio. He hasa passion to increase weld qualityand thus increase productivitywhile lowering costs for his clients.Nathan has been a member of AWSsince 1996 and is a CWI and CWS.

Mr. Dale Albertsongraduatedfrom Ferris State University with aBachelor of Science in WeldingEngineering Technology in 2006. Hebegan his welding engineeringcareer with John Deere HarvesterWorks in East Moline, Illinois. In2009 he relocated back to WesternMichigan as a District Manager forMiller Electric. In 2013 he assumedIndustrial District Managerresponsibility for Miller Electric andHobart Brothers in Eastern MI. Heis a CWI as of 2015 and enjoysexpanding his knowledge ofwelding and joining processes.

Presenter’s Bios

The AWS-Detroit Section hosted the 17th iteration of its biennialSheet Metal Welding Conference. The conference was preceded bya one-day Workshop hosted at AET Integration, Inc., in Troy,Michigan. The event featured an informative lecture, case studies,and active welding demonstrations including joining process,weld characterization, and quality assessment for both steel andaluminum sheet metal. Presenters from EWI, Fronius U.S., IPG,Stanley Engineered Fasteners, AET Integration, FCA US LLC, FordMotor Company, General Motors, and Tessonics took part in thepresentations.

There were 55 “students.” The event was organized by 14committee members and put on by 18 speakers/teachers all of whomwere volunteers.

The Sheet Metal Welding Conference in cooperation with ALAW(Advanced Laser Applications Workshop), AET Integration Inc., andEWI was held Wednesday and Thursday, October 19th and 20th.The event was kicked off by three Key Note speakers providing insightinto the Department of Energy’s perspective on the challengesand opportunities of dissimilar materials, a European viewpointon 21st Century BIW joining challenges, and the need for advancedjoining technologies for a mixed material vehicle. Held over twodays at the Laurel Manor Convention Center in Livonia, Michigan,this year’s conference was attended by over 218 welding professional

participants. Forty-one papers focused on resistance spot weldingof steel and aluminum in separate sessions as well as laser andmechanical joining processes which represent the latestdevelopments used in sheet metal joining.

All conference attendees and the public were also able to attendthe popular Vendor Display Night. This year visitors could viewover 31 displays. As with all other Detroit Section events, all theproceeds from the Conference and Vendor Display Night benefitour scholarship and educational activities throughout the year.

Thank you to everyonewho came out to theconference, whether aspeaker, a participant or avolunteer. This event was asuccess and we hope every -one found it to be informa -tional and educa tional aswell as comfortable andinviting. The AWS DetroitSection and SMWCcommittee hope to see youattend the 2018 SMWC.

SMWC Re-Cap

MEET OURMembers

Hello Sarah, welcome to the Meet ourMember Column for the AWS DetroitSection. If you don’t mind, would youstart off our interview with a little bitabout yourself?Hello AWS Detroit, my name is SarahGambill. I am a Welding Engineer/Welding Instructor at Oakland CountyTechnical School’s Southeast Campus.

Could you tell us what you like aboutthe position you hold as a WeldingInstructor/Engineer?I love working with the kids, and givingthem the option to work in a hands-onenvironment. They have a bright futureif they enter the welding field with the rightskills and knowledge to support them.

Why did you join AWS? I earned a scholarship from the AWSStudent Welding Competition atSchoolcraft Community College in 2007.I was automatically enrolled and I enjoyhaving resources that AWS can provide,such as textbooks, training and net -working with other welding professionals.

Everyone in our section has a favoriteAWS Detroit Event, what is yourfavorite event?The AWS student welding competition(for my own students!)

What do you like to do outside ofwork? I enjoy Brazilian Jiu-Jitsu.

This is one of my favorite questionsto ask, because we get a variety ofanswers. What is the funniestmoment or story that you wouldshare about your experience withwelding?When I started my first welding job, theguys in the shop had me looking for amissing key to the downstairs area of theshop for about an hour. I asked for the keyfrom every single person, before I realizedthat we had fork-trucks driving over ourfloor and it wasn’t possible for our smallwarehouse building to have a basement…

What would be your most memorablemoment, thus far?I was training another employee on thejob and he said to me that he thought Iwould be a great teacher.

If you could share some-thing with your studentsor others that you see asvery dear to your heart ofa very important subject,what would it be?I make it very clear to mystudents that if their weldsfail in the field, people can dieas a result. 100% effort is the minimumrequirement you need to make it in awelding career. Welding is somethingthat you put your heart into and if youare not willing to do so, pick anothertrade.

Do you have someone who has mentoredyou that you would like to mention?Yes, a former coworker of mine, WaltSisler. I worked with him as a welder aftergraduating high school and heencouraged me to earn my B.S. in weldingengineering technology at Ferris StateUniversity. I owe him my career.

Sarah, how did you get your start inwelding?I started out welding at Flat Rock HighSchool’s welding vocational programunder Miles Tilley. He encouraged me tocompete in Skills USA and helped mefind a job after graduation.

What do you see as the biggestchallenge for the welding communityin the future? Creating more welders of course! We allknow that there is a shortage but did youalso know there is a shortage of qualifiedteachers? There are plenty of studentswilling to learn but it is very difficult tolure in professionals from the field to theclassroom. Sometimes welding pays TOOwell!

What would you tell someone whomay be “on the fence” about gettinginto welding as a career?I’m not even 30 years old yet and I havepaid off all of my student loans. I’m nowpaying for my M.S. degree in cash and I’vepurchased a house and a new car. Whatis there to be on the fence about? –Do youwant to earn a good living? Get intowelding.

Congratulations, Sarah! THAT isawesome… Not many adults can saythat. That’s a real incentive to lookinto the field of welding.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?Absolutely. Welding is really a no brainer;you can work as a blue collar professionalas a Boilermaker or Pipe Fitter and stillmake just as much money as a weldingengineer working on the plant floor ordesigning cars in an air-conditioned office.Every level of our industry is hiring andpaying well.

Finally, if you weren’t involved in thewelding industry, what would be yourdream job?I would work as an archaeologist and/orresearcher at the Museum of NaturalHistory in Vienna, Austria. Fortunately,there are plenty of high-paying jobsavailable in welding, unlike archaeologywhere most graduates in the field cannotfind a job in the field at all.

Thank you, Sarah, for taking sometime to be our featured member thismonth! It’s been a pleasure meetingyou and learning a little about yourworld in welding!

Sarah Gambill

If you’d like to be a featured member in ourMeet our Members Column, please contactDan Galiher who heads up the membershipfor our AWS Section. Dan’s email is:galiher.daniel@towerinternational.com

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

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

“We were looking at changing our steel source forseveral of the parts we produce. However, one of thenew materials is not approved by the automotive

OEM. What approval process are they talking about asthe proposed replacement appears to be the same as ourexisting one?”

This month we will review a few of the elements that can comeinto play with Laser Welding (LW) during the characterizationprocess.

Characterization Methodology (LW)While the predominate method utilized by all of theautomotive OEM manufacturers for material welding

characterization is still Resistance Spot Welding (RSW), with GasMetal Arc Welding (GMAW) gaining some momentum, the LWprocess has really begun to come to the fore with regards tomaterial weldability characterization, particularly when thematerials in question are the Advanced High-Strength Steels(AHSS). This is no surprise as the LW process presents someinteresting advantages with regards to the joining of Body-In-White (BIW) components.Similar to the GMAW characterization process, the automotiveOEM’s have adopted a more generic approach towards LWweldability characterization. A partial list of these unique LWmanufacturing elements that are specified could include:• Laser Type: There are several possibilities here, includingCO2, YAG and Disc. Each one has its own inherent quirks,benefits, pros and cons. Regardless, as with any of the differentcharacterization procedures, whatever is specified is what isused.

• Laser Power: Despite the capability of the equipment thatmay be utilized to perform the laser weldability evaluation,most procedures are going to place some sort of constraint onthe power that can be used by the facility to perform theactual evaluation. As with our GMAW constraint on wiresize, this limitation on laser power can be a real challenge.As an example, at a mandated output of 4.0 kW, you maydiscover that your travel speed while welding 2.90 mm materialto itself is just a bit slower than you might expect to see in aproduction environment.

• Beam Focal Diameter: This critical parameter may alsobe specified. With values of 600 µm fairly common, the beamfocal diameter, along with output power, quickly determineshow a material is going to be welded, and what parameterswill be adjusted in order to make a weld that meets therequirements of the qualification procedure. A fixed beam focaldiameter also means that the focal length of the laser is avariable that is not controlled as part of this procedure.

• Fume Extraction/Plume Suppression: Both fumeextraction and plume suppression are critical to the laserwelding process, but for different reasons. The first is for thehealth & safety of the folks doing the welding. But the second(plume suppression) is an essential variable that can directlyaffect the power of the laser that is reaching the material and

not being absorbed and/or misdirected. In other words, youcan dramatically alter your weld geometry just by changingthe plume suppression.

• Travel Speed: If the output of the laser is fixed and the beamfocal diameter cannot be changed, then altering the travel speedof the beam across the part becomes your chief means ofadjustment. It is here that one can see a wide range of valuesas the laser technicians and engineers adjust their equipmentto weld a variety of gauges (and coatings) that could vary from0.60 mm all the way up to 3.0 mm. And remember, as this ischaracterization welding, all materials are welded tothemselves.

• Part Gap: The lap welding of coated parts will drive the needfor a controlled gap so that the resultant outgassing can berelieved. However, as one might assume, the amount ofallowable gap is often specified by the procedure. Accurate,robust tooling, and good quality panel samples are an essentialpart of maintaining a consistent gap.

• Other LW elements such as the addition of a welding wire,or the use of a shielding gas, are mentioned in many of thecharacterization standards, but they are to be used only if thereis no other means to obtain a weld that meets the requirementsof the standard. Much more often than not, they are notneeded.

An important point to keep in mind is that no one character -ization evaluation can cover all possibilities. In fact, despite theperformance of a thorough weldability characterization, it maybe difficult to predict the necessary weld setup parameters forproduction operations. The reason for this is that each test is asingular condition among many possibilities and cannot accountfor the potential litany of material combinations, gap or fit-upconcerns, general condition of the tooling, or other productionvariables. However, if the weldability characterization is conductedin a consistent manner, the process will allow for the deter min -ation of significant material traits that, when compared toother similar materials, can reveal where deviation from the normhas occurred and thus permit the OEM to screen for potentialissues.

A special thanks to Jeff Dreffs, Engineering Manager-Laser at R&E AutomatedSystems, LLC, for his assistance with this article.

If you have more questions about this topic, Don can be reachedat:R&E Engineering ServicesA subsidiary of R&E Automated Systems, LLC17500 23 Mile Road – Suite B, Macomb, MI 48044(586) 228-1900 – Office(734) 793-2304 – Directdmaatz@reautomated.com

References:1) AWS D8.9:2012

s

Ask the Welding EngineerBy Donald F. Maatz, Jr.

This article is a continuation of the October 2016‘Ask the Welding Engineer.’

A:

Q:

Editor’s Note:Well, it’s November already. We

made it through another Sheet MetalWelding Conference, and I think weall may have become a little more“enlightened” about alternativemetals and welding procedures –especially, aluminum. The Vendorevent night was a great success.SMWC had several new vendors, andfaces at the show. We were honoredthat Efram Abrams from AWSNational in Miami came to supportour section and the SMWC.Looking at our calendar, activities

really start to ramp up over the nextfew months. This month is FABTechin Las Vegas, where what happens inVegas stays in Vegas, unless it’s somegreat new welding technology, AWSmembers being honored for theiryears’ of participation in the society,or some of the interesting vendordisplays at the show. If you or yourcompany are able to go to this event,please feel free to let us know whatyou thought of it, send pictures, etc.We’d love to get our members feed -back about these events.This month we have one of our first

educational night series for thisseason. Hosted by Schoolcraft collegewith presenters from Airgas. If youmissed signing up, go back to pageone (1) and get your seat reserved! Next month, it’s time for our

annual Holiday/Christmas partyevent. So be sure to check out theinvite, and get yourself, your signifi -cant other, friends and colleaguesregistered for this event. Enjoy what’s left of autumn, and

remember to make “Thanksgiving”an event in your life each and everyday! Show some kindness, encouragesomeone, maybe talk to a studentabout welding, manufacturing,engineering or teaching in thewonderful world of welding!And, until next month…Keep On Welding!

Robin Michon – e-bulletin editor(Robin.Michon@kukanao.com)