An Industrial Journey from Welding Vision to Smart Eyes

Abstract: Automation and smarting are now pervasive and the welding industry is embracing solutions to empower welders with these advanced tools. The journey of smarting can take many forms. The authors share their experiences when they started this journey with solving some basic needs for weld automation and how the path evolved toward smarting a welding system for a spool-welding robot (SWR). The first step was a monitoring system including a camera that enables welders with a live stream of the arc, puddle, and weldment without protective equipment and safety concerns. In general, welders are well receptive to this tool, so telewelding and telemonitoring are growing in various welding applications. Seam tracking becomes the next typical automation need. Many technologies are available to address the market, including arc sensors, laser, vision, ultrasound, electromagnet, infrared, and tactile. We talk about our experience in integrating these tools with SWR, including the advantages and disadvantages from our client's point of view. We continue talking about our journey to add advanced features to go beyond the expectation of welders and deliver an extraordinary performance by adaptive control and automation algorithms in the tool. Finally, the journey expands toward developing smarting capabilities to train the machine over time for continuous improvement using an extensive data set of SWR machines' performance around the globe.

Biography: Mahyar Asadi Ph.D., PEng, PMP, IWE is the Vice President of Innovation at Novarc Technologies, directing smart welding technologies using industry 4.0 platforms, machine learning, intelligent vision systems, digital twins, IIoT, and simulation tools for welding automation and autonomy. His industry-leading work has resulted in more than 110 published papers and significant awards from the International Institute of Welding, the CWB Association, The American Society of Mechanical Engineers, and Canada's Natural Sciences and Engineering Research Council. Mahyar has a Ph.D. in Computational Weld Mechanics and high-profile experience applying his knowledge to the automotive, aircraft, marine, medical devices, energy, oil & gas, and heavy machinery industries. He holds a Professional Engineering License, PMP certificate, IWE designation, ASME FFS, Digital Twins, and Machine Learning Certificates. He is also an adjunct professor in the Materials Department at the University of British Columbia, teaching a signature course on "Welding and Joining of Materials."

Walters Group: Building Exceptional Project Experiences

Abstract: Founded in 1956, Walters Group is a family-owned steel construction company that designs, fabricates, and constructs commercial and industrial projects throughout North America. From industry leading Architecturally Exposed Structural Steel (AESS) and high-end architecturally fabricated structures, to the latest in lightweight flooring technology, we’re able to bring innovative ideas and solutions to our clients.

Having navigated a global pandemic our commitment to acting as a true partner and delivering an exceptional experience has never been more critical, so please join us as we demonstrate how combining people, planning & performance has helped our clients realize their vision.

We will provide a profile of the company as it grew from its roots to its current integrated network of companies. Showcasing some of the projects that we have completed, with a focus on those that provided some interesting challenges.

Key Learnings: Helping Clients realize their vision

Target Audience: Engineering, planners, designers, welders, estimators, etc.
 
Biography: Sam is a decisive, dynamic, and highly motivated construction & management professional with a ‘get it done’ attitude. He began his career as an undergraduate structural design engineer, serving the UK and Irish structural steel market with Severfield NI Ltd.

He later joined Walters Inc. as a Project Coordinator and very quickly moved into a Project Manager position. Having led teams on numerous complex projects across a wide variety of sectors, Sam is proven to excel in high pressure environments and actively seeks new and creative ways to overcome obstacles. In his current role, Sam leads group pursuits on projects across North America, big and small. He is an excellent collaborator and communicator who is focused on building long standing relationships with team members, customers, and suppliers.

High Speed Videography of Welding: Fundamentals and Techniques

Abstract: This presentation introduces modern methods, challenges, and practical implementations of high-speed imaging of metal transfer in welding. Challenges to high-speed imaging of metal transfer in welding are the fast time constant of phenomena observed, and the intense light emissions that result in very high contrasts. With high-speed cameras becoming more affordable and dedicated commercial weld vision systems being available, the presentation will provide a comprehensive overview of core elements contributing to successful high speed weld vision. Topics include light emissions from the arc and molten metal, considerations for camera types and sensors, filter, and video digital files, and the three main lighting techniques used: backlighting, front lighting, and natural radiation. The presentation will also discuss examples of the current implementation at the Canadian Center for Welding and Joining.

Target Audience:  Industry practitioners, researchers, QA, robotics, automation

Key Learnings:        
- Core techniques of high-speed videography
- Light emissions from arc and molten metal
- Use of filters
- Lighting techniques

Biography: Goetz Dapp is the Associate Director of the Canadian Centre for Welding and Joining (CCWJ). He has an eclectic interdisciplinary background and a great interest in welding. Goetz holds a welding certificate from the German Welding Society (DVS), a PhD in Theatre Studies from the University of Amsterdam, degrees from the University of Toronto and the Johannes Gutenberg-University in Mainz, Germany, and a Professional Acting Diploma from Sheridan College, Oakville, Ontario.

Prior to becoming Associate Director, Goetz was Postdoctoral Fellow at the CCWJ, and a Sessional Instructor at the Department of Drama at the University of Alberta. Goetz has a lot of experience in weld vision, multimedia applications and technology; his interest in pursuing interdisciplinary research has seen him work as a consultant on several multimedia projects; direct, create, and work on numerous theatre performances and concerts; work in film and television; and pursue a research project that brings together Welding and Theatre.

Advancements in GMAW Technology for Zinc-Coated Steels

Abstract: Automotive requirements for improved corrosion resistance on frame/chassis components have created a challenge for OEMs/suppliers to increase corrosion life of painted welds, particularly on zinc-coated components.  Corrosion life is linked to surface silicates, which are multi-component oxides formed on the weld surface via chemical reactions between the shielding gas and deoxidizing elements in the base metal/consumable.  Zinc-coating also increases welding difficulty as zinc vapor can be trapped in the weld metal as porosity.

Lincoln Electric has developed a low silicon GMAW wire, SuperArc® XLS, to lower surface silicate formation for improved paint adhesion while improving porosity performance on zinc-coated steels.  SuperArc® XLS accomplishes these improvements through a mixture of deoxidizing and surface tension modifying elements with minimal silicon.  When combined with an appropriate waveform, this process solution provides low spatter, high speed welds while maintaining a low level of porosity.

This study compares welds made on automotive grade, zinc-coated steels with SuperArc® XLS versus an industry standard GMAW wire.  The results from porosity analysis of those welds showcases clear improvement by the low silicon wire.  A secondary study compares corrosion resistance of welds made with SuperArc® XLS versus an industry standard GMAW wire.  The welds were subjected to 120 cycles of a cyclical corrosion testing, and testing results showcase the improvement in corrosion resistance of the low silicon wire.

Target Audience: Engineers and designers from the automotive community (specifically OEMs and tier 1 suppliers)

Key Learnings: Both the formation of surface silicates during the welding process and the difficulties related to welding on zinc-coated components present challenges for efficient, structurally-sound welds with good corrosion performance.  An engineered low silicon wire (paired with an applicable waveform) can mitigate many of those challenges to decrease porosity formation, increase efficiency, and increase paint adhesion and resultant weld corrosion resistance.  

Biography: Taylor Dittrich is a wire products engineer in the Consumable Research and Development department at Lincoln Electric.  Her primary focus has been the development of innovative wire welding products, the sustainment and improvement of legacy products, and manufacturing process development.  

Before joining Lincoln Electric, Taylor graduated from The Ohio State University with a Bachelor of Materials Science and Engineering with Honors Research Distinction.  While at Ohio State, Taylor conducted research at the Impulse Manufacturing Laboratory under Professor Glenn Daehn, focusing on microstructural analysis along impact weld interfaces of Vaporizing Foil Actuator Welds (VFAW).  

Weld Cameras as an Enabling Technology in Welding Automation

Abstract: Xiris weld cameras are an enabling technology that are used across a wide variety of welding automation applications. As we know, critical welding applications need to be continuously monitored to verify that input parameters are being optimized and the best quality welds are being achieved. Often, this means a qualified welding personnel needs to be placed near the weld source to visualize what is going on. A better and more innovative solution is to introduce a weld camera into automated welding processes.

Xiris Automation weld monitoring cameras have been implemented on numerous hard automation applications such as a longitudinal seam welder joining together two plates of a large pipe, as well as flexible automation applications such as a 3D printing project for metal structures in construction. When placed near the process, the weld cameras can capture the details of the weld, as well as its immediate environment, allowing the operator to completely monitor the process remotely and help steer the welding automation or manage material inputs.  Weld cameras have proven to provide significant health and safety and productivity improvements and are becoming a necessary component for automatic welding processes.

Target Audience: Supervisors and inspectors, engineers, owners, and operators from all industries including education.

Key Learnings: The audience will learn how weld cameras can address challenges or risks in monitoring welds by using real-world use cases and video when weld cameras have been integrated on both hard and flexible automation applications and the objective benefits that arise as a result.

Biography: After receiving his Master of Business Administration from the University of Calgary, LeRoy went on to work in business development, HR consulting in the manufacturing sector and corporate strategy before joining the Xiris team. LeRoy Douglas has been directly involved with numerous educational and training facilities across the US and Canada, helping them achieve goals in revolutionizing welding education by providing the ability to visualize and record weld demonstrations. With over 10 years of experience in the manufacturing and education sector, LeRoy’s focus is on growing Xiris’ presence in the education market.

Wire Arc Additive Manufacturing – Structural Steel Alloys

Abstract: Wire arc additive manufacturing (WAAM) using the gas metal arc welding (GMAW) process (or GMAAM) to produce large-format components from structural steel alloys is an emerging technology. Much work needs to be done to develop a better understanding of the process variables, shape control, structural integrity, productivity rates, the requirements for quality assurance, and secondary processing requirements.

To help address some of these concerns Conestoga College in Cambridge, ON, has recently completed a project to produce a series of thin-walled plates (where the thickness is less than 10% of the height) with the WAAM process using three different alloy feedstock electrode wires. The pieces were destructively tested using standard methods. Results from tensile, hardness, impact toughness, guided bend tests, and other analysis will be reported.

Before the structural steel engineering and design community will seriously consider the use of these components in their structures it will also be necessary to prove the structural integrity of large-format prototypes, determine essential variables and acceptance criteria, and establish a practical qualification framework.

The AC Component of Direct Current Arc Welding Machines

Abstract: It is widely believed internationally that at the same no-load voltage (or OCV) alternating current (AC) arc welders are more electrically hazardous than direct current (DC) machines. In some standards AC welding machines are limited to less than 25V (rms) for wet location welding whereas for the same work, DC machines of up to 70V (plus 10% ripple) are allowed. Other standards allow the use of up to 113V peak when using a DC welder in an environment with an increased risk of electrical shock.
To better understand the actual waveform, peak voltage, and ripple factors produced by typical DC welding machines, Conestoga College in Cambridge, ON, sampled 40 separate models capable of DC-SMAW. The study sampled traditional transformer rectifiers, modern inverters, 3-phase and 1-phase machines, and engine drive machines, typical of the Canadian machine inventory.  (The machine model names will not be publicized.)
The current edition of the Canadian standard CSAW117.2-19 (Safety in welding, cutting, and allied processes) does not differentiate between machines with AC or DC output in assessing the secondary electrical shock hazard to welding personnel. The primary purpose of this study is to raise awareness in the international community of the potential hazards from the AC waveform component of typical DC output welding machines.

Biography: Jim Galloway is a Professor and the Coordinator of Welding Programs at Conestoga College in Cambridge, Ontario.  He holds a B.A.Sc. in Industrial Engineering Technology, is a Certified Engineering Technologist, and is a graduate of Conestoga’s weld tech programs.  He is also a Journeyman Welder (Red Seal) and an International Welding Technologist (IWT). Over his 40-year career he has worked as a welding inspector and R&D technologist in the power generation industry, a technical manager in the rail-car manufacturing industry, and the manufacturing manager for an automated production machinery manufacturer.  Jim also volunteers with several CSA Technical committees including CSAW117.2 (welding safety), CSA C232(CSC26) (electric welding equipment), and CSAW48 (electrodes & filler metals).

Wire Arc Additive Manufacturing using Advanced Pulsed Waveform Gas Metal Arc Welding

Abstract: The use of advanced pulsed waveform control during gas metal arc welding is evaluated for the application of additive manufacturing, often rereferred to as 3D printing. Producing metal components with this technique is commonly done with powders, however, this is slow and costly, and so the use of arc welding for deposition of material is an alternative, known as wire arc additive manufacturing (WAAM). Although there are systems available for performing WAAM using gas metal arc welding, the output that can be achieved using the latest advanced waveforms are seldom discussed. This investigation will use a water-cooled base, and two modified wave shapes, operating in the short circuit transfer mode. The walls were build using carbon steel (ER70-S electrode wire, 0.035” diameter), with a length of 12 in, and 5in tall, and with thickness ranging from 4 to 5 mm. The produced walls are compared in terms of bead geometry, surface roughness, microstructure and hardness.

Target Audience: Supervisors, Welding engineers, Researchers

Key Learnings: The latest advanced waveform control used in gas metal arc welding can allow much higher precision of control in weld bead shape. This can be used to build up parts layer by layer as a form of 3D printing.

Bio: Prof. Gerlich is an Associate Professor in the Department of Mechanical and Mechatronics Engineering, University of Waterloo, and Director of the Centre for Advanced Materials Joining. Gerlich is an expert in materials science, microscopy, welding and material characterization. His most significant recent contributions are in the area of the joining of dissimilar materials and friction-stir welding. Gerlich has led a research team of an average of 10 research associates and graduate students; he has secured more than $2.9M in operational funding and $5M in infrastructure for welding and materials processing. He has over 170 publications in peer-reviewed journals and has been recognized by the American Welding Society on multiple instances, including the Professor Koichi Masubuchi Award and Adams Memorial Membership Award.

Effect of Relative Dimensions for Weld Pool and Powder Cloud on Laser Cladding Catchment Efficiency

Abstract: Laser clad overlays provide enhanced corrosion and/or wear performance for new production and repair of components across a wide range of Canadian industries, including automotive, oil & gas, agriculture, aerospace, and mining. Compared with other welding processes, lasers offer improved control over deposition and heat input, low thermal distortion, minimal dilution, and avoidance of undesirable metallurgical changes in the materials. The use of powder feed enables deposition with complex multi-component systems; however, the superior cost and performance enabled with custom powder alloy blends often comes at the expense of a reduced material usage efficiency compared to wire-fed processes. In the current work, a general model was developed to predict the powder catchment efficiency based on the relative dimensions of the molten weld pool and the distribution of powder incident on the workpiece. A novel experimental apparatus was used to obtain direct in-situ measurements of the process powder distribution. Comparison between the measured distribution and the known weld pool geometry was used to identify the most significant sources of catchment inefficiency. Based on this new understanding, a custom laser module was designed to permit a relative shift between the origin of the powder distribution and the laser beam. The effect of this relative shift was evaluated in an industrial cladding trial, where a measurable improvement in the powder catchment efficiency was observed.

Target Audience: Welders, welding inspectors, welding engineers, and welding educators

Key Learnings: The essential variables that control powder catchment efficiency in coaxial laser cladding, implementation of these variables in engineering expressions for process design, and suggested methods for optimizing catchment.

Biography: Mitchell holds a BSc in Mechanical Engineering (2015) and a Ph.D. in Materials Engineering (2021) from the University of Alberta. His thesis research was conducted on the topic of Predictive Expressions for Welding Residual Stress and Distortion. Mitchell is currently a postdoctoral researcher at the Canadian Centre for Welding at Joining (CCWJ), in partnership with the industrial welding and manufacturing company, Apollo-Clad Laser Cladding. His current work is focused on applying analytical modelling to optimize catchment efficiency in powder-fed coaxial laser cladding. Mitchell has been a member of the CWB Association since 2013 and is presently serving as administrator for the CWBA Edmonton chapter.

Friction welding of 304-stainless steel and zirconium alloy tubes

Abstract: Many nuclear applications rely on zirconium (Zr) alloys and stainless steels (SS) for key cooling system components including future designs such as a supercritical water cooled reactor (SCWR). In the present work, tubular sections of Zr and SS with a 55 mm nominal diameter were rotary friction welded at 1000 RPM and 1200 RPM with a 20% variation in burn-off pressure. The developed joints contained a micron-thick interface reaction layer, with specimens extracted by electrical discharge machining in order to perform tensile testing. Joint strengths ranged from 300 to 414 MPa, however ductility was limited to <3%, due to a difference between the material properties of the two metals causing increased deformation being focused in the Zr side. Analysis by transmission electron microscopy reveals that a sub-micron scale reaction layer contains several sub-layers with different phases combining zirconium, iron and nickel while evidence of minimal diffusion limited to this reaction layer.

Target Audience: Welding engineers, Researchers

Key Learnings: Welding dissimilar metals like zirconium with stainless steel is possible using friction welding. Controlling temperatures and time helps to reduce brittle properties.

Biography: Nazmul Huda is a professional with high profile education and work experience in power generation, welding process, material and metallurgy, and weld failure analysis. His education consists of B.Sc in Mechanical Engineering, M.Sc in Welding /Joining Engineering  and Ph.D in Material Engineering. Nazmul has experience in working various multi-national power generation companies, and was also lecturer at BGMEA University, Bangladesh. Nazmul is currently working as post doctoral fellow at the University of Waterloo, focusing on different welding processes (Gas Metal Arc Welding, Linear Friction welding process, Rotary Friction welding process etc.), material characterization, mechanical properties evaluation and failure analysis.

Recent Developments in Welding Research at the CCWJ

Abstract: On the Process area, the CCWJ has developed a methodology to predict welding features for carbon steels, stainless steels, aluminum, superalloys, magnesium alloys, and others. The welding features predicted include cooling rate, HAZ width, melting efficiency, solidification time, residual stresses, distortion, voltage, and deposition rate.

On the Materials development area, we have developed an understanding of austenization temperature in microalloyed steels. This is relevant because modern welding processed can have a fast heating rate that raises the austenization temperature, resulting in smaller HAZ than expected. Smaller HAZ is desirable, but not knowing the reason means we can lose the advantage without control over it. Another project aims at developing alloys to surface railroad wheels.

On the Automation area, we have demonstrated a system for robotic laser repairs of worn equipment without programming. In this system, the robot determines a path of action based on a 3D scan of the part that needs to be rebuilt. Artificial intelligence has also been applied to quantify metal transfer from high-speed videos. The CCWJ is also leading an initiative consolidating Canadian laser cladding operators and their supply chain (upstream and downstream) into a consortium.

Target Audience: All welding professionals

Key Learnings: This presentation will summarize the recent discoveries and developments in welding research at the Canadian Centre for Welding and Joining. Progress can be roughly divided in three categories: Process development, materials development, and automation.

Biography: Prof Mendez is the Weldco/Industry Chair in Welding and Joining and Director of Canadian Centre for Welding and Joining at University of Alberta. His teaching and research focus on physics and mathematics of welding and materials processing, including heat transfer, magnetohydrodynamics, arc plasma, thermodynamics, and kinetics. Applications include wear protection for mining, and oil extraction, alloy development, procedure development, new welding processes such as laser cladding, casting, solidification, and direct metal additive manufacturing using semi-solid processing. Before joining the University of Alberta in January 2009, he taught and researched at the Colorado School of Mines. Before that, he was a consulting engineer at Exponent Inc. In 1995 Dr. Mendez co-founded Semi-Solid Technologies Inc. in Cambridge, MA.  Prof. Mendez holds a Ph.D. and a M.S. degree in Materials Engineering MIT, and a Mechanical Engineer degree from the University of Buenos Aires. He is a Fellow of the AWS and the CWBA. Awards include, UofA Outstanding Mentorship in Undergraduate Research, AWS William Irrgang Award, IIW Kenneth Easterling Award, the ASM Brian Ives Award, the NSF CAREER Award, the MIT Rocca Fellowship, and UBA Research Fellowship. He has 79 indexed publications and 9 patents.

Evaluation of AHSS Thin Sheet Gas Metal Arc Welds Utilizing DIC Technique

Abstract: Automotive producers are trying to increase the use of advanced high strength steel (AHSS) in frame applications, allowing thinner gauges of steel and reducing the vehicle weight. Gas metal arc welding (GMAW) is one of the joining techniques used to join thin sheets of AHSS for automotive applications. However, the gas metal arc welding (GMAW) process will produce heterogeneous mechanical properties throughout the joint due to the thermal weld cycle. In addition, the joint current standard testing procedure, such as the lap joint test, will impact the mechanical performance of the joint due to promoting bending stress, which will lead to sample rotation during testing. In this work, the digital image correlation (DIC) technique and hardness mapping were used to characterize the local mechanical properties of the butt and lap joint configurations for three different AHSS alloys. The microstructure and hardness were correlated to understand the effect of welding consumables and zinc coating on the local properties on the joint performance. Finally, a novel and easy testing procedure were suggested to reduce the rotation of the specimen during the lap shear test, which could be adopted to avoid the unaccounted bending effect and improve the simulation predictions.  

Target Audience: Welding engineers, quality control staff/inspectors, researchers, Canadian standards committee members who review the automotive weld testing procedures.

Key Learning: Welding thin advanced high strength steel sheets using the GMAW process. The methods of how to measure weld metal local mechanical properties. In addition, how the weld strength and the hardness distribution could affect the failure location.

Biography: Abdelbaset Midawi is a Research Associate at the University of Waterloo. He joined the Centre of Advanced Materials Joining (CAMJ) at the University of Waterloo in 2013. Dr. Midawi's area of expertise is characterizing the post-welded properties of weldments. During his Ph.D., he developed a technique to measure the local strength of weld zones of GMAW/GTAW welds in welded structures using instrumented indentation technique. Currently, Dr. Midawi is working to optimize the strength of spot weld and GMA welds state-of-the-art third generation advanced high strength automotive steels by understanding the link between welding parameters, local microstructure, and mechanical properties; in addition, developing novel experimental techniques to characterize the AHSS spot weld mechanical properties. This research aimed to improve industrial competitiveness and reduce the environmental footprint of new vehicles.

Weld Integrity of High Strength Steel Pipelines: Challenges and Design Opportunities

Abstract: Increased use of higher grade of steels, i.e., X70 and X80, with higher yield and tensile strength for pipelines has induced an unintended weld strength under-matching as a likely possibility, thereby compromising the integrity of pipeline welds, especially those with crack-type flaws. It is well understood that pipelines weld integrity is primarily influenced by three parameters, namely: (i) steel metallurgy, i.e., alloy design and TMCP processing, (ii) welding procedure specification, and (iii) loading conditions during pipeline construction and operation. This situation is of greater convolution when conducting integrity assessment for pipelines with heavier gauges (≥ ~15 mm) for strain-based design applications where a complex condition of steel’s centerline and non-uniform microstructure, increased number of weld passes, and loading/crack conditions can coexist as compared to the lighter gauge pipelines. Accordingly, this study is aimed to elucidate the challenges associated with designing strain-based pipelines and define potential opportunities for a greater weld integrity through evaluation of a series of different grade pipelines subjected to different welding scenarios. Fabricated welds were analyzed in terms of tensile strain capacity, hardness mapping and local brittle microstructure across the weld joints. Steel composition and welding heat input impacted the strain capacity of the weld joints; however, selection of an appropriately designed welding consumable revealed to be of greater importance to ensure pipeline weld integrity.

Key Learnings: Amongst all primary contributing factors to pipeline joint performance, a combination of appropriately designed welding consumables has revealed to be of greater importance to ensure pipeline weld integrity.
Target audience: All engineers dealing with pipeline weld integrity assessment.

Biography: Mohsen is a Materials and Metallurgy Research Engineer with NOVA Chemicals. He has been working on several major pipeline projects aimed to address evolving and high demanding industry challenges, such as mill and field girth welds integrity and fracture mechanics. Among his responsibilities is assessment of materials integrity and reliability for a diverse range of applications in energy industry. He enjoys playing soccer and tennis, and spending time with his little son.

Filler Metal Certification Testing Compared to Production Welds

Abstract: Welding electrode manufacturers are required to maintain conformance certification for various agency such as CSA W48, AWS A5.X, ABS, LR, DNV etc. These documents are useful for relative comparison of expected weld metal mechanical properties and chemistries. These documents and results should not always be relied upon to predict real-world production welding results. The significant factors that can cause production mechanical results to diverge from conformance certificate results will be discussed in detail.

Key Learnings: Understand the variables that affect can affect production and PQR weld metal properties. They include but are not limited to pass sequence, heat input, cooling rate of the weld and HAZ, base material chemistry, shielding gas, and multi-pass vs two run pass sequences.

•    The differences between Conformance test plates and typical production joint designs will be reviewed.
•    The differences between joint designs for conformance test plates and those used in production will be reviewed.
•    Techniques to optimize PQR and production weld metal properties will be discussed in detail.
 
Target Audience: Fabricators, Welding Engineers, Technologists, and Welders. Heavy fabrication, shipbuilding, offshore, general fabrication, oil and gas, Petrochemical, and structural industries.

Biography: Ken Mui is the Application Engineer for the Lincoln Electric Company. He has been with Lincoln for over 28 years and has a broad range of experience in all arc welding processes and welding metallurgy.  

Changing the Gear Ratio: Women in the Automotive Industry

We will discuss the importance of engaging women into the trades to support the transforming dynamics of the developing automotive and manufacturing markets in North America. By looking at educators, entrepreneurs, welders, fabricators and mentors from all sectors we will assess how we can increase the ratio of women to men in the workplace, some of the supports needed, and how to change the image of the trades as a “men only” forum.
 
Panellists:

Taylor Dittrich – Wire Products Research Engineer: Lincoln Electric Company

Biography: Taylor Dittrich is a wire products engineer in the Consumable Research and Development department at Lincoln Electric.  Her primary focus has been the development of innovative wire welding products, the sustainment and improvement of legacy products, and manufacturing process development.  Before joining Lincoln Electric, Taylor graduated from The Ohio State University with a Bachelor of Materials Science and Engineering with Honors Research Distinction.  While at Ohio State, Taylor conducted research at the Impulse Manufacturing Laboratory under Professor Glenn Daehn, focusing on microstructural analysis along impact weld interfaces of Vaporizing Foil Actuator Welds (VFAW).  

 
Stephanie Hoffman: Owner-Underground Metal Works

Biography: Stephanie Hoffman is an accomplished welder, educator, and trades advocate. With over 20 years of industry experience, starting from the bottom and working her way to the top becoming the face of the American Welding Society, creating industry content, and touring the country promoting careers in welding. When not on the road Stephanie has built a well-respected name for herself owning and operating Underground Metal Works, a custom fabrication company and welding school located in Forked River NJ. You can also find Stephanie on the all-new original series Metal Shop Masters on Netflix.

 
Nikki Noble - Coordinator and Professor of Welding: Lambton College

Biography: Starting her passion in 2001, it was love at first spark. Nikki is a Journeyperson Welder with over 30+ welding certifications. She has dedicated her career in helping others achieve their goals. Her automotive journey follows with a 68’ Beaumont, trailer repairs and new builds, and working for General Dynamics Land Systems in the Military Vehicle Repair program. Representing numerous events in support of young workers in welding, females in the trades, social media industry and more: Nikki has a fuel of enthusiasm that illuminates her passion in education and the trades.

 
Leanne Jefferies - Vice President, Assured Performance Network/Certified Collision Care

Biography: Leanne Jefferies is Vice President, Assured Performance Network/Certified Collision Care, overseeing business operations and OEM relationships in Canada and the US.  Assured Performance Network/Certified Collision Care manages and administers OEM Certification programs for 12 OEMs in Canada, and 4 OEMs in the US. The Assured Performance certified network includes approximately 3500

Fiber Laser Welding Advancements in the Automotive Industry

Abstract: This presentation focuses on the laser welding process in an automotive environment and its benefits to future welding techniques and current implementations.

With more attention being focused on fuel economy, lightweight vehicles, lower emissions, and electric vehicles, manufacturing has come under increasing pressure to offer faster and more cost-competitive solutions.  Globalization and the rising cost of labour have placed increasing pressure on companies to automate and offer faster yet more accurate manufacturing.  

With the inception of fiber laser technology, the price of the one-micron wavelength has reduced to approximately one-tenth of the price since 2006.  This reduction is also complimented by higher laser reliability.  Laser welding is now at the forefront of many industries including communication, mining, automotive, medical and nuclear.  Laser processing includes cladding, welding, cutting, cleaning, and heat-treating.  

Biography: Chris Pilcher is the Regional Sales Manager for IPG Photonics in Canada, the largest supplier of Fiber lasers worldwide.  He has held similar positions at Trumpf Canada and Rofin-Sinar.  In addition, Chris was President and CEO of Welding and Cutting Solutions who were responsible for the integration and installation of specialized systems.

Mr. Pilcher served as the Director of Automation and Engineering Manager at Liburdi Automation Incorporated.  He has over 30 years of experience in the welding and systems integration field and holds a degree in Mechanical Engineering from the University of Waterloo, as well as, a degree in Computer Science.  His experience has spanned many industries including Nuclear, Aerospace, Automotive, Mining and Medical. 

Zero Programming Repair with Laser Cladding

Abstract: Laser cladding has found intense use in the manufacturing industry, thanks to its capabilities of rebuilding pieces with tailored and enhanced properties. This has led to an increased necessity of correctly controlling one or multiple of the involved parameters in this process such as dimension of the pool, layer height, dilution, laser power, powder flow, gas flow, etc.

The main objective for this work is to automate the use of the machinery involved in the process reducing the input from the on-site engineers for manually tuning design parameters during dry run and the actual process execution and increases engineering efficiency and practicality. Obtaining a system capable of manufacturing or repairing low volume high value parts with the aid of 3D scanning techniques and parametric programming of a Kuka manipulator.

We have successfully put together all the systems with a complex but functional integration of the robotic manipulator, 9Kw laser, coaxial and optics zoom, powder feeder; all controlled by our system PLC. This setup is unique in the sense that no programming of the robot is intended, and the system should reconfigure itself according to the operator inputs by using the embedded models and empirical verification to automatically set the correct parameters to achieve the desired results.

Test results have shown the successful repair of complex geometries in worn out parts directly from our partner industries that have led to open new doors in optimizing this new technology not only for research purposes but with aims of technology transfer to industries for their benefit and efficiency gain.

Biography: Dr. Ramirez is a postdoctoral fellow at the University of Alberta at the Chemical and Materials Engineering Department. With a Mechatronics degree and a PhD in Artificial Intelligence in Robotic Systems for control purposes. His research experience extends overseas to the UK and Sweden and his working experience at Tenaris.

Determining Systematic Error in Voltage Predictions vs. Voltage Settings for GMAW Welding Procedures in the Lincoln Procedure Handbook

Abstract: The heat input is a key component of a welding procedure, which is dependent on the several fall voltages that compose the total voltage fall. As current practice is primarily reliant on trial and error to determine voltage settings for a desired heat input, having a means to predict the voltage fall is of interest to welding engineers. To predict heat input, the fall voltages (along with their respective systematic error) that make up the total voltage fall in arc welding must be understood.

To gain an understanding of systematic error in voltage predictions, welding voltages were calculated in this study by considering fall voltage contributions in the arc and compared to over 150 welding procedures with different parameters, transfer modes and base metals (carbon steel, stainless steel, aluminum, and copper). The concept of self-regulating arc in GMAW was used to define arc length in relation to wire diameter. An equation was derived for GMAW-Sp and a definition of half the wire diameter was considered for GMAW-S. Cathode and anode fall voltages proved to contribute to ~80% of the total voltage with noticeably less for aluminum (~65%). Arc column fall voltages were verified to increase with current. Error in predictions were highest with GMAW-S with ~7.2% and ~30% error for carbon and stainless steel, respectively. Predictions for GMAW-Sp had smaller errors using the calculated arc length with ~1, 3, and 2% for carbon steel, aluminum, and copper, respectively.

Target Audience: Welding engineers, supervisors, inspectors, and welders.

Key Learnings: The audience will learn about the several fall voltages and their respective contribution towards the total voltage fall in the GMAW process.

Biography: J. Eduardo Alvarez Rocha is a MSc Student in Welding Engineering at the University of Alberta. His research focus is on validating models to create design tools for welding procedure development by understanding and predicting fall voltages across the arc. Prior to his MSc studies at the University of Alberta, Eduardo worked as a Mechanical Engineer, Welding Inspector, In-Service pressure equipment inspector, and B-pressure welder over his 15 year career in the Alberta energy sector.

Similarity Analysis of Temperature and Fluid Flow in the GTAW Arc

Abstract: This study developed a new mathematical model to quantify the width and length of the plasma arc in GTAW. This novel estimation process allows to obtain immediate results and without convergence problems. The methodology is based on similarity analysis of the non-isothermal Landau-Squire solution, which is an exact solution of the Navier Stokes and energy equations for a round laminar jet. While the Landau-Squire solution had been used before to approximate velocities in the arc, its application to the prediction of temperature had not been successful. The challenge overcame in this work, is to make a better systematic assessment of the power that must be assigned to the point heat source. The ultimate goal of this project is to obtain general expressions to predict the shape and temperature of the GTAW arc. The plasma behaviour is modelled parametrically, with a critical temperature dividing the conducting and non-conducting behaviour. For argon, this temperature is 7,200 K. Numerical simulations that account for temperature-dependent plasma properties were run to compare with the analytical treatment for the case of argon. The maximum error observed was 33 % for a current of 300 A.

Target Audience: Welding engineers, welding designers, welders, chemical engineers, materials engineers, GTAW-related industry people.

Key Learning: It has been developed simple equations that allow calculating the width of the plasma arc in the GTAW process, setting the minimum size of the piece that we can weld with a fixed current and for a specific type of gas.

Biography: My name is Stefano Sacco, I am from Chile, and I studied Mechanical civil engineering at the Universidad de Chile. Nowadays, I am an M.Sc. student in Materials Engineering at the University of Alberta, working at the Canadian Centre for Welding and Joining and developing a hydrogen concentration model for steelmaking and welding procedures. My interest topics are renewable energies, nuclear power, additive manufacturing, artificial intelligence, and its different applications. It has been developed simple equations that allow calculating the width of the plasma arc in the GTAW process, setting the minimum size of the piece that we can weld with a fixed current and for a specific type of gas.

Energy Balance in Gas Metal Arc Welding

Abstract: This work allows us to comprehend a part of the theory behind the droplet temperature at the Gas Metal Arc Welding (GMAW) process. The development of an energy balance on the electrode is made to understand the power at the anode and by it the droplet temperature. To obtain the value and understand its behaviour, it is necessary to understand the mass that evaporates from the droplet. The models that were generated allows to understand the behaviour of the droplet, its evaporation, temperature, and deposition rate. The composition of the mass evaporated from the droplet is obtained, and the amount of energy lost in the process. The composition of the mass evaporated varies from one electrode to other, and so the amount of mass that evaporates or stays as a droplet. A relation between the current and the Wire Feed Speed (WFS), evaporation rates and anode fall voltages is generated for different wire compositions. These relationships can be used to reduce evaporation and increase deposition rates, as also to study the behaviour on new alloys and different conditions of voltage and WFS.

Target Audience: Engineers, welding engineers, welding educators

Key Learnings: The composition of the droplet evaporations at the GMAW process is possible to predict.

Biography: Vicente holds a Mechanical Engineer degree from his home country at the University of Chile and is currently starting a MSc. In Materials Engineering at the University of Alberta, working at the Canadian Centre for Welding and Joining (CCWJ).  Vicente started his research in 2021 when he received the Emerging Leaders of Americas Program (ELAP) scholarship, reason why he could travel to Canada and develop his thesis at the CCWJ. He is currently a graduate student at the laboratory and his research is focused on the understanding of the droplet temperature at the GMAW process. For the near future he is looking to build some strategies to help engineering students to different projects.

The Mechanics of GMAW Arc

Abstract: In many high-productivity joining applications such as thick-section welding, the overall deposition rate is a critical economic factor. The deposition and wire feed rate during arc welding is mainly coupled to the arc current. However, the metal transfer mode, and ultimately the maximum arc current that can be applied is limited by issues with arc dynamics. This presentation will explore a number of solutions that have been explored recently to develop more consistent high deposition rates, by modifying the electrode design, metal feed method, and control of the current. The prospects for emerging applications such as additive manufacturing will also be discussed.

Target Audience: Welding engineers, Researchers

Biography: Emanuel Santos is currently a research associate at the Centre for Advances Materials Joining (CAMJ) for Advanced Materials Joining (CAMJ) at Department of Mechanical and Mechatronic Engineering of the University of Waterloo. Previously, Emanuel was a member of the Welding Engineering team at Liburdi Automation Inc, a division of The Liburdi Group of Companies, for 4 years, where he worked on the development of welding procedures for various industries, including nuclear and oil and gas, as well as the development of proprietary welding processes. He holds a Master's of Applied Science degree from the University of Waterloo, and received his Bachelors in Mechanical Engineering from the Federal University of Pará, Belém, Brazil. During his bachelors he was an undergraduate research scholar from CNPq (National Council for Scientific and Technological Development) developing his activities at the facilities of the Laboratory of Characterization of Metallic Materials (LCAM) at Federal University of Pará.  

Influence of Electrode Force on Liquid Metal Embrittlement Cracking During Resistance Spot Welding of Third Generation Advanced High Strength Steels

Abstract: The third generation of advanced high strength steels (3G-AHSS) with high strength and ductility has been developed to address the demands of the automotive industry to produce safer, lighter, and more environmentally-friendly vehicles. When joined with resistance spot welding (RSW), zinc coating on these steels, used for corrosion protection, melts and can penetrate grain boundaries (GB) under thermal tensile stress. The resulting loss of strength at the GBs may lead to liquid metal embrittlement (LME) cracking. The industrial implementation of 3G-AHSS has been limited by concerns with their susceptibility to LME, thus its mitigation has become a priority for automotive manufacturers. The variation of electrode force during RSW is known to influence LME, however, the mechanism of this influence is not fully understood.

This work studied the influence of electrode force variation on LME cracking during RSW of 3G AHSS. The electrode force was variated between 3.5 and 5.5. kN. The resulting location of cracks in welds and crack severity were measured. Additionally, numerical process simulation was used to study the effects of electrode force on stress and temperature changes during welding and to correlate these changes with the LME occurrence.

Target Audience: engineers, welding supervisors, NDT experts.

Key Learnings: the audience will learn about the phenomenon of liquid metal embrittlement during resistance spot welding of 3d generation advanced high strength steels and how changes in electrode force influence LME cracking.

Biography: Shiyuan Song is a graduate student at the Center of Advanced Materials Joining at University of Waterloo. After receiving her diploma with honours in Chemical Engineering at the Northern Alberta Institute of Technology and a bachelor’s degree with honours in Energy Engineering at the University of Calgary, Alberta, she investigates Liquid Metal Embrittlement in third generation advanced high strength steels.

Use of Low Transition Temperature Steel Alloys In Welded Overlays for High Wear Applications  

Abstract: This presentation provides a summary of the mechanism and applications of Low Transition Temperature (LTT) stainless steel alloys in high-wear applications. Surface cladding continues to be a popular method of repair and fabrication of components in high-wear environments. One of the greater challenges is how the differential heating and cooling of the overlay and base metal during application can result in significant residual stresses. These stresses can significantly reduce the strength and lifetime of overlays by causing crack initiation and propagation through the overlay. To combat this, work is being done on LTT alloys that experience the martensite transition later in cooling. This transition helps reduce the residual tension introduced by differential cooling by causing a volume expansion of the weld metal late into solidification. If sufficient expansion is introduced, compressive stresses can result in the deposited material, significantly altering the performance characteristics of the overlay.  With discussion on the mechanism, design, and application of these materials, we hope to present opportunities for designers and manufacturers to significantly increase the lifetime of parts experiencing exceptional wear conditions. In particular, the application of these alloys through plasma transferred arc welding as a manufacturing step for railway wheels.

Target Audience: Welding engineers, technicians, and welding educators

Key Learnings: The mechanism and applications of welded steel alloy overlays, with increased lifetime and performance due to low martensite transitions temperatures.

Biography: Carter Trautmann holds a BSc in Engineering Physics and Is currently completing a Master’s Degree in Materials Engineering with the Canadian Center for Welding and Joining (CCWJ) at the University of Alberta. His research focuses on plasma transferred arc welding applications and overlay metallurgy, with additional Interest in high-speed video capture and plasma physics. Involved with the CCWJ since 2020. Carter also works and volunteers with different makerspace initiatives, directed a team designing and racing fuel cell electric vehicles during his bachelor’s degree and is currently acting as chair of the University of Alberta CWB Association student chapter.

Efficient Buildup of Inconel 718 on Additive Components with Thin-Wall Geometries Using Electrospark Deposition

Abstract: Repair of out of tolerance or damaged metals during use is mostly achieved through welding techniques. However, parts with special geometries are repaired with special welding techniques. Most common welding techniques have a power input that is so high that it changes the properties of the more fragile parts, which in turn leads to erosion and secondary damage to the part. In this study, the electrospark deposition (ESD) technique was used to repair damaged parts with thin-walled properties, and to simplify the process, the thin metal walls were made by metal 3D printing. The effects of key parameters on deposition rates and defect rates were studied during the manual deposition process, and the properties of samples with parameters of practical application, such as cross-sectional hardness and heat-affected zone (HAZ), were investigated. At the same time, automated ESD has been studied in a cursory manner and the results are quite different from those of manual ESD, which means that a completely new research program on automated ESD can be established.

Target Audience: Working on additive manufacturing, aerospace, auto industry.
Key learning: Inconel 718 deposition on thin wall geometries. Low energy welding on small components. Repair of thin-wall geometries using manual or automated process.

Biography: Jihui Yan received HBSc degree in Materials Science from the University of Toronto in 2021. He is currently first-year master student in the Department of Mechanical and Mechatronics, Centre for Advanced Materials Joining at the University of Waterloo, supervised by Prof. Norman Zhou and co-supervised by Prof. Peng Peng. Jihui Yan’s research activities and interests are in the general area of materials science and processing technologies for aerospace applications, specialized in micro joining, and high entropy alloy.

Resistance Welding Safety: Fume Collection Best Practices

Abstract: Resistance welding is widely used in the auto industry. Is fume collection needed? Many welders assume the answer is no since it does not produce the volume of visible fumes common to stick welding methods. But resistance welding can still produce dangerous fumes—especially when welding galvanized steel or coated metals commonly used in automotive. In this presentation, we will discuss:
- Volume and composition of resistance welding fumes compared to stick welding, with special emphasis on galvanized steel, coatings and lubricants
- Permissible exposure limits (PELs) and dangers of exposure to resistance welding fumes, especially with galvanized metals
- Considerations in design of a weld fume collection system for manual or robotic resistance welding for automotive suppliers, including discussion of source capture and ambient options
- How to handle fumes that include gaseous emissions such as zinc oxide from galvanized metals or gas phase emissions from coatings and lubricants
-Standards and regulations for air filtration system design

Target Audience: Welders, Industrial Hygienists, Health & Safety personnel, safety equipment buyers

Key Learnings: Dangers of resistance welding, special considerations for galvanized steel, best practices for fume collection welder safety

When to Use a Fume Gun (And When Not To)

Abstract: Used correctly, a high-quality fume extraction gun (or torch) can remove 90-95% of weld fumes right at the source, before they enter the welder’s breathing zone. But is it always the best choice? We take a closer look at considerations when choosing between a fume gun and other fume extraction options. (This presentation is non-promotional and applies to any brand/model of fume gun.) We’ll cover:
- Pros and cons of fume guns and alternatives for weld fume collection, including fume arms and backdraft tables
- Proper use of a fume gun: applications, technique and selection
- Expected fume capture efficiency for different scenarios
- How to determine whether you need a secondary backup air filtration or ventilation solution
- What type of dust collector is needed when using a fume gun

Audience: Welders, Industrial Hygienists, Health & Safety personnel, safety equipment buyers

Key Learnings: What is a fume extraction gun/torch, how they are used, best applications, dust collectors for fume guns

Biography: Alysha is an experienced Manufacturing and Design Engineer with a passion for making manufacturing environments safer and healthier. She has a proven track record of creating effective, safe and efficient industrial air filtration and ventilation solutions to help clients meet or exceed OSHA standards for indoor air quality. As the Director of Engineering for RoboVent, she oversees a team of engineers and system designers and guides the company in the development of new, innovative air quality solutions. Alysha holds a Bachelor of Engineering in Mechanical Engineering from the University of Colorado – Denver and is currently seeking a Master’s in Materials Science and Engineering from Wayne State University.