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1 APRIL MEETING:EDUCATION NIGHT
1 MAP2 COMMITTEE CHAIRS2 CHAIR’S MESSAGE3 LADIES NIGHT UPDATE3 EDITOR’S NOTE4 APRIL HOTLINE4 GOLF OUTING: SAVE THE
DATE!6 CWI CORNER: A “WPS.”
WHAT IS IT?8 ASK THE WELDING
ENGINEER8 SAVE THE DATE: SMWC
XVIII 201810 MARCH MEETING RE-CAP
April 2018Inside This Issue
Follow Us: awsdetroit.org
AWS Technical Nights are open toeveryone! We encourage thatmembers bring students and non-members to learn more about ourorganization and industry.
Affiliated With
For AdvertisingOpportunities
Contact Don Crist810-217-9897
After TAX DAY ‘18 and the event of the year; LADIES NIGHT,please come out to learn and earn (PDHs) from one of Detroit’s veryown tool and die application-specialists companies. This promisesto be a very informative session designed to bring awareness to aniche market – often encompassing our typical everyday toolingand processing equipment. Discussion on unique consumable typesand formulations, general tool & die repair procedures, and finallythe full-circle implementation of roboticautomation of the aforementioned will bepresented.After this presentation, it is very possible
that you will never look or think about yourtooling and the repair thereof the same wayagain. Please bring your questions to challengethe night’s forum.
April Technical Meeting - Education NightThursday, April 19, 2018
Ukrainian Cultural Center26601 Ryan Rd., Warren MI 48091
Map/Directions
Tool & Die Repair:Consumables and Automation
Email or phone RSVP byApril 9 to Amanda Davis:
[email protected] (248) 512-1803
AGENDA5:30 - 6:00 pm
Welcome Reception &Networking
6:00 - 6:15 pmOpening Remarks6:15 - 6:45 pm
Dinner6:45 - 8:15 pm
Presentation by Eureka
Nate Miller
TechnicalLiaison
EurekaWelding Alloys
Sponsor
Presenter Bios begin on page 2
Well Spring is here and there is plenty going on at theAWS Detroit Section.April is designated as National Welding Month by the
American Welding Society, I encourage you to go to a greatwebsite where there is information about our industry and
all the variety it offers. www.careersinwelding.com/ Please share this witha young person who may be in search of a career for their future as there is awealth of information there that could spark their interest.The AWS National Website is also a great resource www.aws.org along
with the Detroit Section Website www.awsdetroit.orgConsider bringing a student to our education series event scheduled in
April. More information about the details are listed in this bulletin. Our oldest and most time honored social event is scheduled for Saturday
April 14, 2018 our 78th Annual Ladies Night Gala. Mark has a great eventplanned and it will be a wonderful evening and opportunity to network. Ifyou have any questions please visit our website awsdetroit.org for moreinformation – you can even purchase tickets online.I wish you a wonderful April and hope you get a chance to enjoy the
sunshine and warmer days. Brighten someone’s day and forward this bulletinon. Best regardsWesley Doneth
AWS Detroit Section Chairman – [email protected]
Wes DonethChairman’s Message
April 2018This Issue of the Bulletin
can be viewed on the web at
awsdetroit.org�
ChairmanWESLEY DONETH
First Vice ChairMARK GUGEL
Second Vice ChairJOHN SUTTER
SecretaryDAVID BENETEAU
TreasurerANDRE YOUNG
Bulletin EditorROBIN MICHON
WebmasterRODNEY BEREZNICKI
Hotline Coordinator: BRIAN PETERSON
Meeting Reservations: AMANDA DAVIS
AdvertisingDONNIE CRIST
Assistants to Chairman:JOHN PIPPIN, JR.ERIC LICHTFUSZNATHAN MILLER
Thomas WebbGeneral Manager
Eureka Welding Alloys
Presenter
Robert AddingtonV.P., International SalesEureka Welding Alloys
Presenter
Chris KerchkofSales Manager
Eureka Welding Alloys
Presenter
Thomas Webb started at Eureka in 1995 as a sales representative.Attended Macomb Communtiy College where he studiedmetallurgy and welding. Became Sales Manager in 1997 andmoved onto become General Manager in 2005. Currently headsup Eureka’s Chinese and European markets.
Robert Addington started in the Tool & Die Welding industry inMarch of 1967 at Eureka Welding Alloys Inc. With 51 years ofexperience and knowledge has made Mr. Addington an expertin this field. Currently heads up Eureka’s South Korean market.
Chris Kerchkof started at Eureka in April of 1997 as a machineoperator running production in shop area. Attended MacombCommunity College where he studied metallurgy and welding.Became a Sales Representative in 2005 and moved on to becomeSales Manager in 2014. Currently heads up Robotics Division.
Presenter Bios continued from page 1
Editor’s NotesWhere is this year going? I
can’t believe it’s April and weare almost celebrating ourannual Ladies Night eventagain. This year may actuallybe a sold-out event! Which isperfect, because not only doesit allow us to celebrate ourspouses/significant others thatsupport our welding careers,but it provides funding for ourWelding Scholarships and allowus to continue to provide for afuture in welding.This month we also highlight
education at the Educational/Tech Night on April 19th.Eureka Welding Alloys will besponsoring the night and cover -ing several topics including tooland die repair. Hope to see youat the Ukranian Cultural Centerfor education night.You may see some changes
in the bulletin over the next few months. Both columnists, Don Maatz, Jr. who provides our Ask the Weld Engineer Columns, and Eric Lichtfusz, who provides the CWI columns have been doing an excellent job at sharing information with all of us and presenting it well. With that said, there may be months where we alternate the columns and give them each a break.
Thank you for your reader -ship, and until next month…
Keep on Welding!
Robin
Career OpportunitiesWelding Engineer: Opportunity due to growth; Large & fastestplant–6B company; Doubled in size looking to triple; Multi-billiondollar international tier one automotive company located in Warren Job Responsibilities:• Hands-on responsibility for weld engineering projects such asproduction process development, weld equipment maintenanceneeds, instructions, and weld station methods.• Review and analyze production, quality assurance, maintenanceand other operational reports to identify non-conformities in productweld quality and output and resolve production problems.• Perform weld capability analysis. Troubleshoot and correct weldinstability and welding equipment capability.• Participate in initial engineering control plan and procedures toassure product process capability to achieve quality products.• Responsible for writing weld process instructions.• Hands-on responsibility for troubleshooting and repair of productionwelding equipment in support of the maintenance department.• Maintain process documentation describing control of manufacturingprocess (FMEA, control plan, operator check sheets, operator andgauge work instructions, process sheets, deviation postings, Poka-Yoke check sheets, PM check sheets, tool matrix postings).• Maintain action plan for continuous improvement for weld department,coordinate efforts for plant goals and objectives with Area Manager.• Remain current with the latest technology developments, andbenchmarking and testing of new technology.If interested please email or call the office number listed below. I havea welding engineer role with a brand new plant using cutting edgetechnology. Moeed A. Andrabi, Recruiter
O: 419.744.3297C: 419.708.5894www.endevis.com
CenterLine Named One of Canada’s BestManaged CompaniesWindsor, Canada, March 8, 2018
CenterLine (Windsor) Limited is pleased to announce that it has maintainedits status as a Gold Standard Requalified winner and has been recognizedfor overall business performance and sustained growth with the prestigiousCanada’s Best Managed Companies award.
Now in its 25th year, Canada’s Best Managed Companies is one of thecountry’s leading business awards programs recognizing Canadian-ownedand managed companies for innovative, world-class business practices.Every year, hundreds of entrepreneurial companies compete for thisdesignation in a rigorous and independent process that evaluates the calibreof their management abilities and practices.
This prestigious national award is sponsored by Deloitte, CIBC, CanadianBusiness, Smith School of Business, TMX Group and MacKay CEO Forums.
“Being amongst the best in class requires more than financial performance,”said Lorrie King, Partner, Deloitte and Co-Leader. “Achieving sustainedgrowth and strong overall business performance is the result of the combinedefforts and commitment of the entire organization.”
CenterLine congratulates its outstanding staff for its unwavering dedicationto excellence and thanks its many valued customers and suppliers for theircontributions in helping us realize this tremendous achievement.
Contact: Marc Levesque – Director, Corporate MarketingPhone: (519)734-8464 ext. 4459; email: [email protected]
April Hotline415 Morton DriveWindsor On N9J 3T8Tel 519-734-8464email: [email protected]
Whether you’re a business ownerin the welding industry, a qualitymanager, a welder, or anywhere inbetween, you may have heard of aWPS. Knowing what one is andunderstanding its purpose and originmay be another story. If you have noclue what a WPS is, fear not, becauseI’m going to share with you, not onlywhat a WPS is, but why they’reimportant. If you already know whata WPS is, read on anyway, if for noother reason than for theentertainment value. The letters WPS are an acronym
for Welding Procedure Specification,and rather than giving you a technicaldefinition for that group of words, I’lltry to explain it the way I’ve seen itexplained elsewhere, and that is, asan analogy. A WPS for welding is not
unlike a recipe in baking or cookingIf you want to bake a cherry pie fromscratch, for example, you would mostlikely want to follow a recipe. Not justany recipe, but one that has beenproven to produce a great cherry pie.After all, not all recipes are goodrecipes. A good recipe would tell youthings like what kind of ingredientsyou’ll need, the amount of eachingredient, the order in which to putthose ingredients together, what toput them into when mixing them,how long to bake it and at whattemperature to bake it. The recipemay even include instructions forcooling time after baking. It wouldmost likely give you more thanenough information for your pie tobe a huge success. Once all of thathas been completed, and if you
followed the recipe correctly, the cherrypie is ready to be enjoyed. And it’sprobably nearly identical to all theother cherry pies that have been madeusing that recipe. And, that’s not sodifferent from the purpose of a WPS.I won’t get into all the differentnational or international codes andstandards that govern WPSs. Thereare all kinds of things that are part ofa WPS called essential and non-essential variables that would becomevery specific to the industry that youmay be in. For now, I’m going todiscuss a WPS in very general terms. Typically, there are two types of
WPSs. Prequalified and those qualifiedby test. The test record is called aProcedure Qualification Record orPQR. I won’t get into detail on PQRshere either, but as the name implies,it’s a record of the exact parameters,no variables, used during thequalification process. I should tell youthat not all codes allow prequalifiedWPSs, so it will up to you to figureout what you need to do to complywith your requirements. Once you’ve
CWICORNER
A “WPS.” What is that?By Eric [email protected]/CWI 09070281
Continued on page 7
Co-op Welding Students,Summer Interns andPart-time Welders
Contact Pat Bell:[email protected] (313) 282-8171 in Detroit
established what your exactrequirements are, you’ll be on yourway to producing a WPS. But I stillhaven’t told you what a WPS is. Wellhere you go. A WPS tells the weldereverything he needs to know toproduce a weld that has been provento be effective for the intended designconditions. Don’t get this confusedwith instructions. A WPS is not aninstruction manual, a trainingmanual or a “how to” guide forwelding. If someone is not a skilledor qualified welder, a WPS won’tturn them into one. Nor will thewelds produced by an unskilled,unqualified welder miraculouslybecome acceptable just because theyused a WPS. No, a WPS simply offersa high degree of consistency andrepeatability, when used as written,by multiple qualified welders. It doesthis by grouping base materials withsimilar chemistry, thereby similarweldability, with the correctelectrodes (sometimes called fillermetal) and shielding gas (if needed),for the welding process you’re using.Then it will establish a range, orvariable, for things like joint typeand base metal preparation, basemetal cleaning, types of welds (fillets,groove welds, etc.), allowable weldingpositions (flat, horizontal, etc.),shielding gas mixtures, gas flowrates, electrical characters, travelspeeds, wire feed speeds, pre-heatand interpass temperatures,allowable maximum heat input,etc., all intended to producerepeatability in the weldedconnections. The basic essential andnon-essential variables are typicallyspecified within the code or standardyou’re working with, but other detailsmay be added to further emphasizeweld consistency and repeatability.Again, I want to be clear that a WPSis not a magic wand. Poor weldquality can still happen, even whenusing a WPS. Just like a cherry piecan be awful even when made to agood recipe. The recipe needs to befollowed by someone skilled enough
to follow the recipe accurately, justlike a WPS needs to be used andfollowed by skilled and qualifiedwelders. If you have a WPS thatworks for some welders, but notothers, then it’s likely more weldertraining may be required. If youhave a WPS that was qualified by ahighly skilled welder that no otherwelder can follow, then maybe theWPS was qualified with parametersthat are too stringent and it needsto be requalified. That happens too,but in all cases, without a WPS awelder is simply guessing atparameters and the weld quality isleft to chance. For this reason, allwelding codes and standards thatI’m aware of require adherence toqualified procedures for theproduction of welded connectionsand all welders and weldingoperators must be tested to aqualified procedure and successfullypass before being consideredqualified. The bottom line is, a goodWPS will produce repeatable qualityin welds by establishing a set ofparameters that any qualified weldercan use with a high degree of success. If this kind of thing interests you
and you’re not already an AWS CWIyou may want to consider becominga CWI. If this is a career that youwould like to pursue, the AWS-DetroitSection is hosting two AWS CWISeminars/Exams this year. Theseminar/exam dates and locationare as follows:
CWI Seminar June 3-8, 2018Exam June 9, 2018
CWI Seminar Sept. 30-Oct. 5, 2018Exam October 6, 2018
Washtenaw Community College4800 E. Huron River Dr.
Ann Arbor, MI 48105-4800
Check the AWS-Detroit e-Bulletinoften for other helpful information,at www.awsdetroit.org. For moreinformation on how to becomeproperly trained and certified by theAmerican Welding Society and toregister, you can visitwww.aws.org/certification.
A “WPS.” What is that?continued from page 6
“My company is in the process ofquoting several new assemblies
that require resistance spot weldingand I am concerned that the specifiedwidths of the flanges are too small forthe required electrodes. Are theresources for flange width designrecommendations that I can referenceso as to determine whether or not theproposed concept is capable ofsupporting the required resistance spotweld?”
“As discussed in our previouscolumns (Ref. Feb & Mar-18 ATWE),
the subject of a required minimum flangewidth is a source of continual debatewithin the resistance welding community.To illustrate this point, several designrecommendation sources were referenced(AWS C1.1, RWMA Manual, etc.,) to showthat no one really agrees on what theproper flange width should be. With thatas background, this column will start toillustrate some of the variables that toolingand product designers should be awareof as they determine how much flangewidth is necessary to support a properresistance spot weld (RSW).To better understand the relationshipbetween the welding flange and wherethe actual weld ends up, it is necessary toidentify and understand the differentvariables, or elements, that contribute tothe required minimum flange width. Toa varying degree, all of them are presentand have an effect every time a weld ismade. However, as is common in theanalysis of a complex and dynamicsituation, the hard part is often notidentifying the elements that contributeto process variability, but rather the effect,or contribution, that each individualelement has on the total variability.An example of the potential complexityone must deal with when trying todetermine the significance of any onevariable is illustrated by just attemptingto analyze the geometry on a truncatedcone (or A-nose) electrode cap as it relatesto welding near an upturned flange (blueline in Figure-1) that is bent greater than90˚. The representation in Figure-1 detailsa generic electrode cap/welding flangeinterface and the identified geometricelements that can affect mathematically
how one determines therequired minimum width.For the record, this analysiswas part of a researchproject undertaken bysomeone far more adept tothe nuances of welding andstatistical analysis thanmyself (see acknow ledge -ments below), and I onlyam using this figure toillustrate the degree ofdifficulty one couldencounter if it is decided to undertake thissort of project yourself – Good Luck!That being said, this generic electrodecap/welding flange interface will be furtherused to illustrate the actual tolerance thatmust be considered and the identifiedelements that can affect the requiredminimum width. These elements arenamed below.• Maximum Electrode Face Diameter(MFD)
• Assembly Positional Tolerance (APT)• Electrode Positional Tolerance (EPT)• Expulsion Dam (ED)• Cut Flange Tolerance (CFT)We will go into detail about each of theaforementioned tolerances in our nextcolumn.”
Acknowledgement:I would like to thank Tom Morrissett, former AWSD8 chairman, for his invaluable perspective onminimum flange width requirements, and hisability to use Excel.
Figure-1: Example of electrode clearancegeometry. The flange is the blue line and theexpanded area is shown within the red circle.
References:1) Resistance Welding Manual, revised 4th Edition2) AWS C1.1M/C1.1:2012, RecommendedPractices for Resistance Welding
If you have more questions about thistopic, contact Don Maatz at:R&E Engineering ServicesA subsidiary of R&E Automated Systems, LLC70701 Powell Road, Bruce Township, MI48065; (586) 228-1900 – Office; (734)793-2304 – [email protected]
s
Ask the Welding EngineerBy Donald F. Maatz, Jr.
A:
Q: Figure-1
This article is a continuation of the Mar-2018 ‘Ask the Welding Engineer’
The Detroit Section hosted the Patrons/Technical Night March15, 2018 at IPG Photonics (46695 Magellan Drive, Novi, MI 48377).Mr. John Sutter, executive committee member from the DetroitSection, presented the certificates to all the Patrons, 7 of whichwere present. Dr. Webster, General Manager & CTO of IPG Photonics(Canada) gave a presentation regarding the state-of-the-art inlinecoherent imaging technology to monitor the keyhole laser weldingprocess. This technology provides a direct in-line measurement ofthe keyhole penetration, joint geometry profile for the high-speedlaser welding process, along with its seam tracking function,simultaneously. The combination of functionalities given by thisthe technology brings a significant advancement of qualitymonitoring for the laser welding process. A demonstration of thistechnology was presented after Dr. Webster’s talk. In addition, Mr.Mike Klos, General manager of IPG Photonics (Midwest Operations)also gave a brief introduction of IPG’s history. There were around30 people in the audience.
March Meeting Re-cap
Patrons
Tech night@ IPG -1
Tech night@ IPG -2
Mike Klos Introducing IPG
Paul J L Webster presenting
