An investigation of Dissimilar Welding between High Entropy Alloy and Additively Manufactured 316L: Microstructural Characterization and Hardness Evaluation

Abstract: This study presents a comparative analysis of the dissimilar welding process between a high entropy alloy (HEA) and additively manufactured 316L stainless steel. The focus of the investigation lies on the microstructural characterization and evaluation of mechanical properties. Microstructural analysis revealed distinct features across the weld interface, fusion zone, and heat-affected zone (HAZ), highlighting the refined equiaxed grain structure in the HEA side and columnar grains in the additively manufactured 316L side. Microhardness testing was employed to assess hardness variations along the dissimilar weld joint, with the HEA side exhibiting higher hardness attributed to the solid solution strengthening effect of alloying elements. The results contributed to a better understanding of hardness properties in dissimilar metal joints, enabling the development of optimized welding procedures and ensuring the integrity of dissimilar material joints in a wide range of engineering applications.

Key learnings: How to weld an additively manufactured 316L sample to a high entropy alloy. Microstructure weldment area differences. Mechanical properties of dissimilar welds.

Bio: Yahya Aghayar is a PHD student at the Marine Additive Manufacturing Center of Excellence, University of New Brunswick. Formerly a key manager at Isfahan Casting Industries Company, he's now dedicated to advancing additive manufacturing and materials research. In 2021, he published a paper on vacuum journal entitled” dissimilar welding of 304 stainless steel and Inconel 601”. Aghayar's career spans industry and academia, showcasing his commitment to shaping the future of materials science and manufacturing.

Panel Discussion: The State of the Trades/Skills Gap in Industry - Canada & USA
Hosted by: Jason Becker and Max Ceron

Abstract: Jason and Max are both educators, seasoned veterans of the steel industry, and passionate about ensuring the next generation of tradespersons have the required skills and knowledge to succeed. Industry across North America is struggling to find skilled trade workers and retain their established workforce. This presentation will focus on the similarities and differences between Canada and the United States in both training and workforce development within our industries. This informal discussion will also be open to questions from the Audience and encourage everyone to attend and interact.

Target audience: All

Key learnings: Ways to access and determine gaps in skilled training.

Bio: Jason Becker, is a highly experienced welder/fabricator with 26 years of hands-on experience in the welding industry. Jason is a U.S. Marine Corps Veteran, and served from 2001-2005. Jason is an AWS Certified Welding Inspector, Certified Welding Educator, and Certified Welder Performance Qualifier (CWI/CWE/WPQ1).

In addition to his extensive welding experience, Jason also holds a Bachelor's degree in Construction Management, which he earned from Seminole State College with honours in 2016. He currently works as a full-time welding consultant and instructor at his company Underground Metal Works and is dedicated to helping, educating, and inspiring the next generation of welders as the host of the Arc Junkies Podcast.

Welding Procedures Approval and Welding Consumables Certification

Abstract: Overview of the CWB welding procedures review process. How welding procedures are reviewed and qualified against CSA and allied welding standards? Why welding procedures must be accepted by CWB?  Why do manufacturers and distributors certify their welding consumables? Where are the CWB-certified welding consumables currently manufactured? What is the certification process? How long does it take?  How much can it cost?

Target audience: Engineers, technicians, inspectors, welding supervisors, welders, project managers, and buyers. Anyone involved in welding, where quality requirements are imposed by CSA Standards, and/or specifications referring to CSA Standards.

Key learnings:  A unique approach: the acceptance of welding procedures and the certification of welding consumables by a third-party certification body (CWB). A glimpse into the CWB welding procedures review and welding consumables certification processes. Overview of CSA W47.1, W47.2, W186 welding procedures requirements, and CSA W48 products certification.  

CSA W48:23 - Filler Metals and Allied Materials for Metal Arc Welding

Abstract: Overview of the scope of CSA W48, including testing of welding consumables, quality system requirements for manufacturers, certification of welding consumables. Summary of the changes in the 2023 edition of CSA W48 and the impact of these changes for manufacturers, CWB, fabricators and the welding industry in general.

Target audience: Engineers, technicians, inspectors, welding supervisors, welders, project managers, and buyers. Anyone involved in welding, where quality requirements are imposed by CSA Standards, and/or specifications referring to CSA Standards.

Key learnings:  Review of changes in the latest edition of CSA W48, published earlier this year.  Impact of these changes on the Canadian welding industry.

Bio: André Boulianne is the manager of the CWB Procedures and Electrodes Certification department. André graduated from École Polytechnique of Montréal with a bachelor’s degree in mechanical engineering. He is an IIW International Welding Engineer and a level III welding inspector (CSA W178.2). With over 30 years of experience at CWB, André has been involved in all aspects of welding certification at CWB. He is also an active member in multiple technical committees, including CSA W48, AWS A5, ISO TC 44/SC 3, and AWS D1 sub-committees.

Modelling Heat Input in Electric Resistance Welding

Abstract: The work to be presented is the first step in establishing a multi-physical understanding of how entrapped oxides, known as penetrators, form and are retained in ERW seams. Since ERW is a complex process involving the interactions of heat transfer, oxidation, electromagnetic effects, and molten fluid flow, understanding each of these mechanisms is crucial to further understand which ones contribute to penetrator defects. The first stage in this overarching thesis work is the analytical modelling of heat input in ERW. To date, industry and academia have largely focused on numerical simulations and industrial trials of the process; however, we aim to develop a useful set of equations for industry that model the ERW process with a minimum required accuracy over a large range of process parameters. The current model was built on, compared, and contrasted with previous work. A key concept in the model includes the contrast of thermal reference depth versus power reference depth, the larger of which is proposed to indicate whether the process is in a thermal mode or electric mode, respectively. These modes can be related to the estimated power input to the weld, further inferring which process variables are most significant in the given modes. The ability to test this model has been integrated into future experimental design, which requires full scale ERW mill trials and high-speed videography.

Target audience: Engineers, welding engineers, welding educators

Key learnings: Delivered: Electric resistance welding (ERW) has two operational regimes. At low frequencies the process is dominated by electrical effects, and at high frequencies the process is dominated by thermal conduction effects. The thermal conduction regime might facilitate process stability, thus mitigating ERW defects.

Bio: Daniele (Daniel) holds a bachelor’s degree in Materials Engineering Co-op from the University of Alberta and is currently a PhD student at the Canadian Centre for Welding and Joining (CCWJ). Prior to graduate studies, he gained experience as a project designer in both the pipeline industry and the automotive sector. Daniele started his research in late 2022, with the goal of understanding the multi-physical nature of electric resistance welding (ERW) defects. His research specifically focuses on the ERW process and a universally common defect problem in ERW, known as penetrators.

Panel Discussion: The State of the Trades/Skills Gap in Industry - Canada & USA
Hosted by Max Ceron and Jason Becker

Abstract: Jason and Max are both educators, seasoned veterans of the steel industry, and passionate about ensuring the next generation of tradespersons have the required skills and knowledge to succeed. Industry across North America is struggling to find skilled trade workers and retain their established workforce. This presentation will focus on the similarities and differences between Canada and the United States in both training and workforce development within our industries. This informal discussion will also be open to questions from the Audience and encourage everyone to attend and interact.

Bio: Max has been in the steel trades since the age of 17. Working as both a welder and fabricator, he attained Red Seal endorsements (RSE) in both and then went on to achieve Blue Seal Endorsements (BSE) in Business. Throughout his career, Max has held numerous CWB and other agency qualifications, as well as safety, 5S, LEAN, and equipment operations certificates.  Max has been in the steel trades at all levels – from welders’ helper, welder/fitter, educator, manager, business owner, and now National Director at the CWB Association. Max has also worked on training development projects across Canada and two major initiatives in Ghana (KTI, GoldFields). These projects included project scoping, lab development and design, training development, curriculum development, “train the trainer” programs, safety assessments, budgeting, and negotiating and procurement of necessary resources.
 
In January 2021, Max accepted the position of Director for the CWB Association, one of the world’s largest not-for-profit industry Associations. In this new role, Max manages 17 chapters across Canada, a membership of over 80,000 members internationally, and hosts the CWB Association Welding Podcast. Max strives to support, educate, and provide opportunities to all persons in the steel trades across Canada and beyond.

Weld Anomalies and Their Disposition

Abstract: Codes and standards include weld anomaly acceptance criteria that are often based on workmanship criteria. That is, they define the largest geometry or minimum specified properties of an anomaly (e.g., maximum undercut, misalignment, porosity, or material property). The design or acceptance of a weldment can be defined based on geometry (i.e., structural and anomaly size), applied loading and material properties (i.e., minimum specified or actual measured). This presentation will review a range of weld anomalies including geometric imperfections, material property inconsistencies and environment concerns that can be assessed for weldment acceptance for fitness for service.  

Target audience: The presentation will interest Engineers and Technologists to develop an understanding of the source and implications of weld anomalies.

Key learnings: The presentation will provide insights related to material, weld and inspection issues that need to be considered to develop sound structural systems.

Bio: Aaron Dinovitzer is a Structural and CWB Welding Engineer with a master’s degree in engineering from the University of Waterloo. He has been working in the engineering field for more than 30 years, providing engineering service and research related to structure and pipeline materials, welding and integrity assessment. This work involves both design and assessment of fabrication and in-service damage or degradation to assess the fitness for service of structures and welded connections. This work has developed tools used by the industry for material characterization, fatigue, fracture, mechanical damage, geotechnical hazard and welding practice assessment.

Effects of scan strategy to optimize the mechanical properties of cellular lattice using additive manufacturing

Abstract: This study focuses on optimizing the elastic modulus of a Body-Centered Cubic (BCC) lattice structure by incorporating additional plates additively manufactured through the Laser Powder Bed Fusion (LPBF) technology. LPBF offers precise control over the manufacturing process, allowing to experiment with various process parameters, such as laser scan speed and laser power. These parameters directly impact the melt pool size, which, in turn, influences the surface quality of the plates. Using finite element simulations, process parameters required to achieve desired mechanical properties are identified. Specifically, the aim was to minimize the melt pool size while maintaining high-quality surface characteristics. Achieving this balance is crucial to ensure the plates meet the desired standards for structural integrity and performance. The result of this study provides valuable insights into tailoring the mechanical properties of BCC lattice structures for various engineering applications, such as lightweight structural components with enhanced strength-to-weight ratios. Additionally, it highlights the potential of LPBF technology for creating complex structures with precise control over material properties, opening new avenues for innovative design and manufacturing in the field of advanced materials and design.

Target audience: All categories of Engineers, Researchers, and Students

Key learnings: Melt Pool and Cooling Rate Correlation, Mechanical Behavior of Lattice Structure 

Bio: Foroozan Forooghi is a mechanical engineer currently embarking on her Ph.D. journey at the University of New Brunswick, Marine Additive Manufacturing Center of Excellence (MAMCE), and McMaster University. Her research endeavors delve into the realm of numerical and computational modeling with a pronounced focus on phenomena inherent to powder laser bed fusion processes, encompassing the intricate domains of solidification processes, grain growth, and sub-grain growth.

Beyond her academic achievements, Foroozan brings valuable hands-on experience to her field. She spent several years as a senior designer and project manager at a metal 3D printer manufacturing company, where she not only contributed significantly but also filed a patent in metal Additive Manufacturing technology. This unique blend of practical expertise and academic excellence positions Foroozan as an asset, poised to make substantial contributions to her field's advancement.

Santé Et Sécurité Des Soudeurs

Compréhension de la dynamique de la fumée de soudage.
Qu’est ce qui influence la colonne de convection?
Comment contrôler cette colonne de convection.

Façons de protéger la zone respiratoire des soudeurs.

Les trois meilleurs façons de s’assurer que la zone respiratoire des soudeurs est bien protégée..
Ce sera toujours la captation à la source qui sera la meilleure façon de protéger la zone respiratoire des soudeurs.

Les buses de captation.
Les bras de captation.
Les pistoles Mig assistés par vacuum.

Control des émissions du procédé Arc Air

Sous certaines conditions il est possible de contrôler les émissions du procédé Arc Air
Dans un volume confiné.
Avec une buse spéciale.
Dans un espace confiné.

Bio: 

Gradué de l’École polytechnique de Montréal en 1974.

De 1974 à 1976 représentant des ventes pour Poly Réfrigération en HVAC et système de réfrigération.

De 1976 à 1987 V.P. Ingénierie pour le Groupe Henlex et Président de P.M. Wright, responsable de la R & D pour de développement de générateur d’air chaud à 4,160 volts pour le séchage ( Lait en poudre et chauffage d’air de mine )

De 1988 à aujourd’hui, président de Henlex inc.

A écrit plusieurs articles dans ( Travail et Santé ) sur le control des émissions de fumée de soudage. Membre du CWA, ISQ, GQE, CSA, AQHSST, REAI, OIQ.

Détient 3 brevets avec un sur pistolet à souder.
Orateur dans plusieurs rencontres sur la santé et la sécurité pour la protection de la zone respiratoire des travailleurs. A développé plusieurs générateurs de vacuum ainsi que des pistolets à souder qui rencontre la nouvelle demande de .02 mgr/m3 pour le manganèse.

Ar+CO2 Mixture Effects on GMAW-SP of Mild Steel

Abstract: When using the spray-transfer mode with GMAW, the most common gas blend for steel applications are mixtures of argon and carbon-dioxide (CO2).  In certain applications, CO2 levels as low as 5% (C5) are preferred, and in other cases blends with up to 15% (C15) or higher are specified. Although this process and these effects have been studied for decades, there are still a variety of opinions and misunderstandings on the selection of the ‘best’ gas for any application.  Too often the effects of the gas mix on welding outcomes are not given proper consideration.

In this presentation the effects of systematically altering this blend will be explored.  The study will examine the effects through various experiments on arc performance, bead-shape and surface appearance, weld penetration profile, deposit microstructure, and microhardness.  This selection can also have broader implications on welding cost and quality in some surprising ways.

Bio: 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 sector, 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), CSC26 (arc welding equipment), and CSAW48 (electrodes & filler metals).

Advances in Aluminum Welding Technologies

Abstract: There is an increased rate of aluminum alloys expected in coming years considering the expansion of the transportation markets, along with various other industries relying on aluminum for light-weighting of structures.  Light-weighting of electric vehicles, high speed trains, and marine vessels will continue to drive the need for aluminum joining in the coming years. New applications will also demand higher strength base materials which demand new welding filler materials and joining technologies. This presentation will outline some of the advances in these areas, including new challenges that these advances may introduce to the market. The latest filler materials will be reviewed which may help increase weldability, along with arc and laser welding technologies that offer higher productivity in high volume production applications, additive manufacturing, and reducing defect rates in conventional arc welding. Recommendations for updates to relevant welding standards are also proposed which can help guide engineers and practitioners to better exploit aluminum in production.

Target audience: Supervisors, Welding engineers, Researchers

Key learnings: New aluminum alloy filler materials and welding techniques will be showcased along with their application in high impact production examples.
 
Biography: Prof. Gerlich is a 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 leads a team of 8 to10 research associates and graduate students; he has secured more than $8M in funding for welding and materials processing. He has over 200 publications in peer-reviewed journals, and been recognized as a Fellow of the American Welding Society, along with the Professor Koichi Masubuchi Award and Adams Memorial Membership Award.

Effect of Anisotropy and Varying Parameters for Micro-Plasma Wire Arc Additive Manufacturing

Abstract: Wire arc additive manufacturing (WAAM) is a metal 3D printing process that employs the use of arc welding processes to generate parts. The advantages of this method such as high deposition rates, low cost, and suitability for the creation of large complex components highlight its potential. However, due to the intense heat input associated with arc welding processes as well as the continuous heating and cooling cycles of WAAM during fabrication, the final part created will result in large temperature gradients between the top and bottom layers, resulting in geometrical deviations from the desired dimensions as well as anisotropy within the final component. Anisotropy is an important phenomenon which can arise in WAAM, thus greatly affecting the mechanical properties and microstructures. The process of interest in this research is micro-plasma arc welding due to its very low heat input. The present work firstly evaluates the effect of anisotropy on the properties of a thin-walled structure fabricated using micro-plasma WAAM, revealing mainly uniform properties along the build and travel directions, except for the modulus of elasticity. Also presented are the volumes of material added onto the melt pool based on variations within the wire feed speed. This provided improved part quality when manually fixing any height deviations within the bead and applying proper parameter selection on the second pass. Finally, different bead overlap parameters were tested for single and multiple beads, obtaining the optimum distance between two beads for good plate fusion and best quality for building complex parts.

Target audience: Welding engineers, researchers in welding/additive manufacturing.

Key learnings: Stiffness anisotropy is significant in stainless wire arc additive parts using micro-plasma arc welding. Optimum overlap parameters and wire feed speeds for fixing of dimensional deviations were obtained.
 
Bio: Rami Hakim is a master’s student currently working at the University of Waterloo under the supervision of Professor Adrian Gerlich. He obtained his BEng in Mechanical Engineering from the Lebanese American University, before directly starting his studies in Waterloo, where he is a current teaching assistant. His research interests encompass wire arc additive manufacturing, welding processes such as gas metal arc welding and plasma arc welding and material characterization.

Buried Arc GMAW-B

Abstract: Shipyards have traditionally used submerged arc welding (SAW), flux cored arc welding (FCAW) and gas metal arc welding (GMAW) to fabricate butt joints on thick steel plate. When joining butt joints of ½” or greater, a bevel, along with multiple passes of weld are routinely required. Two-sided welding with a back gouging and grinding process prior to welding the second side is also frequently implemented. Thick section, single-pass welding is possible using a hybrid laser arc welding (HLAW) process, but this technology requires expensive equipment and stringent fit-up quality that can be difficult or costly to achieve in a shipyard environment. Buried arc GMAW (GMAW-B) is a GMAW process variant that provides the ability to weld thick plate (1/2”) in one pass using copper or ceramic backing.

Work has been completed in a previous NSRP project to develop GMAW-B procedures and benchmark the process against existing welding operations currently used in Naval shipyards. The work discussed in this presentation will pertain to the development of mechanized procedures and the implementation of GMAW-B technology on 3/8” and ½” steel plate.
 
Target audience: Shipbuilding and heavy manufacturing

Key learnings: Results from parameter development and qualification testing of buried arc GMAW. A productivity study comparing the technology to legacy SAW and FCAW processes.

Development of In-Situ Weld Cooling Rate Measurement Methods

Abstract: Some structural carbon steel welding applications have performance requirements that place limits on weld and heat affected zone hardness or require minimum toughness levels to reduce risk of environmental cracking, corrosion, and risk of unstable fracture for fatigue-sensitive structures.  A common approach to satisfy these performance metrics is to specify a weld cooling rate during weld fabrication that will achieve target hardness levels and promote desirable microstructures to enhance toughness and ductility.

EWI has been developing in-situ weld cooling rate measurement methods for arc fusion weld processes to enable collection of weld surface temperature profiles during arc welding and then estimating the cooling time from 800oC to 500oC for control of hardness and microstructure.  Commercially available infrared (IR) cameras are used and integrated into the welding system with data collection and analysis routines to provide cooling rate data.  This work is still in a feasibility proof of concept stage but is advancing to enable collection of real-time cooling rate data for weld process control and to ensure WPS requirements are met.  This paper will discuss the development approach, provide results from numerous welding trials, and discuss next steps to fully implement field-deployable systems for structural welding applications.

Key learnings:  Integration of IR instrumentation into arc welding systems for real-time measurement of temperature profiles on a pass-by-pass sequence, and data analysis to estimate weld cooling rates. Information on IR sensor placement and protection will be given along with considerations for addressing weld fume thermal masking and emissivity reflections in the weld bevel.  

Target audience: Anyone interested in arc fusion welding (GMAW, SAW, FCAW, etc.) of carbon steel for structural applications requiring control of weld and heat affected zone hardness and microstructure for resistance to environmental cracking, corrosion, fatigue, and fracture.

Bio: Jim Hansen is a Welding Engineer at EWI in the Arc Welding and Directed-Energy Deposition Processes group. At EWI, Jim’s work has focused on gas metal arc welding (GMAW), GMAW robotic arc directed energy deposition additive manufacturing, submerged arc welding (SAW) and its process variants, flux core arc welding (FCAW) and high-speed video capture of welding operations. Jim graduated with a bachelor’s degree in welding engineering from Ohio State in 2019 and a master’s in the same field in 2020.

L’importance de la certification CSA 178.2 en END

Abstract: Les essais non-destructifs sont au cœur du processus qualité des assemblages soudés en offrant un produit fini respectant les normes et les devis en vigueur. La qualification des techniciens en essais non-destructifs est capitale. L’ajout de la certification comme inspecteur en soudage CSA 178.2 permet aux techniciens de mieux comprendre les résultats d’inspection relevés, de souvent suivre toutes les étapes de fabrication et ainsi minimiser le risque de non-conformités majeures lors de l’inspection finale. Cette présentation démontrera l’importance du rôle de l’inspecteur en soudage en prévision des essais non-destructifs finaux.

Target audience: Everyone. Tous

Key learnings: The world on non-destructive testing. Le monde des essais non destructifs.

Bio: Fred has been involved into the welding and non-destructive world for 18 years. He co-founded PRECISION NDT in 2012. Fred fait partie du monde du soudage et des essais non destructifs depuis 18 ans. Il a co-fondé PRECISION NDT en 2012.

Increasing Indigenous Workers in the Skilled Trades

Abstract: How do we get more Indigenous people in the trades? Join us to find out how JEDI and CWB Foundation have been working together to promote trades to Indigenous youth. Plus, learn about JEDI’s skilled trades initiatives throughout New Brunswick. 

Bio: Gabe Isaac is Mi’kmaq from Listuguj First Nation, Quebec. He has many years of experience working with non-profit organizations, not only for his community but also for all of the Indigenous communities in New Brunswick. With an Administrative Professional certificate, Gabe excels in coordinating tasks, managing projects, and communicating effectively. Gabe’s current role as Indigenous Projects & Apprenticeship Coordinator at the Joint Economic Development Initiative has given him ample opportunity to advocate for Indigenous inclusion in New Brunswick’s Trades sector. 

The Continuum of Cultural Safety: A Tool for Indigenous Recruitment and Retention

Abstract: A discussion on the elements that make up what it means to provide Cultural Safety in the workplace such as Cultural Sensitivity, Cultural Awareness, and Cultural Competency and how this contributes to recruitment and retention of Indigenous Talent. Touching on the TRC Calls to Action and how Reconciliation impacts us all.

Bio: The Joint Economic Development Initiative (JEDI) is an Indigenous organization dedicated to supporting Indigenous participation in New Brunswick's economy. JEDI began in 1995 as a tripartite partnership between Indigenous communities in New Brunswick, the Government of Canada, and the Government of New Brunswick. In 2009, JEDI was incorporated as an independent, non-profit organization and over the years JEDI has grown into an Indigenous organization focused on working closely with its partners from Indigenous communities, organizations, government, and the private sector to foster Indigenous economic development in New Brunswick.

Nisa Kennedy is a Wolastoqey Woman from Sitansisk First Nation in New Brunswick. She has many years of community and urban experience with Indigenous youth focused on cultural initiatives. She prides herself on integrating Indigenous Knowledge and Practices into Workforce Development. As JEDI’s Provincial Indigenous Employment Coordinator, she has the opportunity to share her knowledge and bring people together to understand the perspectives of Indigenous Peoples in the territory. She is experienced in Advocation, Indigenous Cultural Awareness, and Program Development for Indigenous Peoples from Atlantic Canada to Calgary, AB (Treaty 7). Her passions are working with Youth, Indigenous Governance & Leadership, and Indigenous Capacity Development.

Effects of scan strategy to optimize the mechanical properties of cellular lattice using additive manufacturing

Abstract: This study focuses on optimizing the elastic modulus of a Body-Centered Cubic (BCC) lattice structure by incorporating additional plates additively manufactured through the Laser Powder Bed Fusion (LPBF) technology. LPBF offers precise control over the manufacturing process, allowing to experiment with various process parameters, such as laser scan speed and laser power. These parameters directly impact the melt pool size, which, in turn, influences the surface quality of the plates. Using finite element simulations, process parameters required to achieve desired mechanical properties are identified. Specifically, the aim was to minimize the melt pool size while maintaining high-quality surface characteristics. Achieving this balance is crucial to ensure the plates meet the desired standards for structural integrity and performance. The result of this study provides valuable insights into tailoring the mechanical properties of BCC lattice structures for various engineering applications, such as lightweight structural components with enhanced strength-to-weight ratios. Additionally, it highlights the potential of LPBF technology for creating complex structures with precise control over material properties, opening new avenues for innovative design and manufacturing in the field of advanced materials and design.

Target audience: All categories of Engineers, Researchers, and Students

Key learnings: Melt Pool and Cooling Rate Correlation, Mechanical Behavior of Lattice Structure 

Bio: Mohsen Keshavarzan held his bachelor's and master’s degree in mechanical engineering and currently works as a Research Assistant at the Marine Additive Manufacturing Center of Excellence (MAMCE) at the University of New Brunswick under supervision of Dr. Mohammadi. .His research covers topics like macro lattice structures, shape memory alloys, and direct metal deposition technology, and he has published papers on these subjects. In addition to his academic work, Mohsen has practical experience from working in a metal Additive Manufacturing company for several years as a manufacturing expert. This experience not only gave him a strong foundation but also made him well-versed in technical challenges in the industry. His research primarily focuses on designing the macro lattice with optimized mechanical properties.

Investigation of Defects Process Map in Friction Stir Welding

Abstract: Friction Stir Welding (FSW) has become a prominent solid-state welding process utilized in various industries. However, the presence of welding defects poses a significant challenge that necessitates attention. This presentation has emphasized the importance of comprehending the causes and formation mechanisms of FSW defects to enhance the welding process and prevent defect occurrence.

Through extensive literature review and experimental investigations, common defect types in FSW, such as voids, kissing bonds, and surface defects, have been identified. Quantitatively measuring these defects remains challenging, leading to a scarcity of comprehensive data. Most existing research on FSW defects is qualitative, lacking substantial experimental evidence or practical models for industrial implementation. In our research, temperature has been identified as a critical internal variable impacting defect formation, warranting quantitative analysis.

Target audience: People who are interested in avoiding defects in Friction Stir Welding.

Key learnings: Defect formation process and potential models to avoid defects.

Bio: Xinrui is a Ph.D. Candidate at Canadian Center for Welding and Joining at University of Alberta. After receiving his B.Sc. and M.Sc. in Aerospace Engineering, he continues his study on Friction Stir Welding, which is widely used in aerospace industry. His research focuses on identifying the critical factor for the defect formation and apply analytical models to describe the process and finally use them to avoid defect for FSW process.

Recent Developments in Welding Research at the CCWJ

Abstract: On the process area, the CCWJ has made much progress on the understanding of deposition rate in wire-based processes, with an emphasis on the generation and composition of fumes. This new knowledge is based on experiments measuring droplet temperature in free-flight transfer and detailed analysis of the physics involved. The findings also enabled the understanding of higher deposition rate in Mg-containing aluminum alloys. Significant progress was made also towards understanding the value and variations of voltage in GMAW. A model has been developed to assist in determining bead profile in laser cladding. Another area of interest in the solid-state Friction Stir Welding process, in which we are making progress towards a predictive model and defect formation.

On the materials development area, we have developed an understanding of residual stresses in low transformation temperature (LTT) alloys, identifying critical temperatures for the alloys and the effect of preheat in their ability to result in residual compressive stresses which are beneficial for fatigue life.

On the automation area. 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.

Bio: Professor 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 CWA. 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 88 indexed publications and 9 patents.

Mi'kmaw Elder, Noel Milliea of Elsipogtog, has devoted about 40 years of his life to helping people heal from alcoholism, trauma, and systemic racism. Noel sees healing as a journey that never ends and his own healing journey began in his 20s, when he became sober. Noel helped get an addiction treatment center in Elsipogtog, where they incorporate Indigenous culture in the programs. Noel has taught the holistic medicine wheel method more than 30 times across Mi'kma'ki territory, the traditional home of the Mi'kmaq in the Maritimes and helps his people see their culture as a source of healing.

An investigation of Dissimilar Welding between High Entropy Alloy and Additively Manufactured 316L: Microstructural Characterization and Hardness Evaluation

Abstract: This study presents a comparative analysis of the dissimilar welding process between a high entropy alloy (HEA) and additively manufactured 316L stainless steel. The focus of the investigation lies on the microstructural characterization and evaluation of mechanical properties. Microstructural analysis revealed distinct features across the weld interface, fusion zone, and heat-affected zone (HAZ), highlighting the refined equiaxed grain structure in the HEA side and columnar grains in the additively manufactured 316L side. Microhardness testing was employed to assess hardness variations along the dissimilar weld joint, with the HEA side exhibiting higher hardness attributed to the solid solution strengthening effect of alloying elements. The results contributed to a better understanding of hardness properties in dissimilar metal joints, enabling the development of optimized welding procedures and ensuring the integrity of dissimilar material joints in a wide range of engineering applications.

Key learnings: How to weld an additively manufactured 316L sample to a high entropy alloy. Microstructure weldment area differences. Mechanical properties of dissimilar welds.

Bio: Parisa Moazzen is a PhD student in Mechanical Engineering at UNB (University of New Brunswick). She holds a bachelor’s degree in Materials Engineering from Chamran University of Ahwaz, followed by a master’s degree in Materials Selection for Engineering Design from Isfahan University of Technology. With a strong foundation in materials science, Parisa's expertise lies in the fabrication and characterization of high entropy alloys. Currently, her research at MAMCE focuses on microstructure design through the manipulation of process parameters in additive manufacturing.  

Exploring Arc Welding Process for Additive Manufacturing in Stainless Steel Parts Production and Repair

Abstract: Wire Arc Additive Manufacturing (WAAM) is a versatile welding-driven process that offers significant applications in the production and repair of large metallic components. Its ability to add material layer by layer at a high deposition rate with precision and control makes it an attractive technique for repair applications, enabling extended component lifespan, reduced downtime, and minimized material waste. This capability is especially well-suited for industries that face challenges with expensive part replacements and service interruptions. Notable examples of such industries include oil and gas, injection molding, and extrusion sectors. This paper presents a case study focused on the feasibility of utilizing a precipitation hardening martensitic stainless steel (PH 13-8 Mo) feedstock wire for both fabricating and restoring injection molding dies using the WAAM technique. The study investigates the mechanical properties, corrosion resistance, and microstructural characteristics of the as-printed and repaired parts. The findings conclusively demonstrate the immense potential of utilizing arc welding as an additive manufacturing process for stainless steel part production and repair, effectively addressing the specific needs of the intended applications. This research was conducted at Dalhousie’s Large-Scale Additive Manufacturing Lab, which houses an MX3D-M1, the first WAAM system of its kind in Canada. The lab serves as a hub for turnkey additive manufacturing services in Atlantic Canada.

Target audience: This presentation is tailored to meet the needs of a diverse audience, including individuals from academia and various industrial sectors. It specifically targets R&D engineers who are interested in transitioning from traditional fabrication techniques to the emerging field of additive manufacturing. One specific focus of the presentation is on the repair and restoration of defective industrial parts using state-of-the-art wire arc additive manufacturing (WAAM) technique. Overall, the presentation seeks to bridge the gap between academia and industry to foster collaborations in the field of large-scale parts production and restoration.

Key learnings: The audience will gain a comprehensive understanding of the feasibility of utilizing the Wire Arc Additive Manufacturing (WAAM) process for both fabricating and restoring injection molding dies. They will acquire valuable insights into the mechanical properties, corrosion resistance, and microstructural characteristics of the as-printed and repaired parts. They will recognize the specific advantages of WAAM, including its high deposition rate, availability of feedstock materials, and low capital investment. The audience will learn more about the practical applications of WAAM, providing real-world examples that highlight its advantages in different industries.

Bio: Dr. Nasiri currently holds the position of Assistant Professor and Canada Research Chair (CRC)-Tier 2 at Dalhousie University. His expertise lies in advancing metal additive manufacturing (AM) and welding processes for large-scale parts production, with a focus on achieving tailored properties while significantly reducing production time and cost. Dr. Nasiri's research has made significant contributions to the understanding of microstructure-properties-performance relationships in advanced metallic materials fabricated through additive manufacturing. This includes high strength corrosion resistant alloys and nanoparticles reinforced high strength aluminum alloys. With over 60 peer-reviewed journal articles published in the past six years, Dr. Nasiri is recognized for his in-depth knowledge of welding and joining, as well as processing-structure-properties correlations in various engineering materials. He has also supervised numerous engineering students and researchers in their research endeavors. Dr. Nasiri's contributions to the field of advanced hybrid manufacturing have been widely acknowledged, earning him prestigious international awards such as the American Welding Society (AWS) Robert L. Peaslee Memorial Award and the Glenn J. Gibson AWS Fellowship Award.

Profitability – The responsibility of the estimator

Abstract: This presentation is directed at anyone involved in preparing and contributing to metal fabrication and erection cost estimates. Accurate cost estimating is key to profitable projects and companies. Key components of an estimate include the obvious ones: contract document review, governing standards, quality requirements, detailing, materials, and equipment. In addition, time and costs relating to welding and above all, labour productivity is often more difficult to determine. Factors that influence welding operating factor determination and factors that effect labour efficiency will be presented. The latter includes general economy, supervision, labour relations, job conditions, equipment, and weather. A selection of sources for determining these and instructions how to calculate an overall efficiency will be provided.

Target audience: Any person involved in the estimating process; Owners, estimators, shop supervisors, plant managers, engineers, etc.

Key learnings: Important Items to be considered in an estimate, especially operating factors, and labour productivity.

Bio: Chris is the president of Skarborn Engineering where he serves as a retained welding engineer for several CSA W47.1 & W47.2 Division 2 certified fabrication shops located throughout the Maritimes. He has worked closely with company founder and principal engineer, Stig Skarborn, collaborating on shop efficiency studies, inspections, and training workshops. Prior to joining the Skarborn team, Chris worked for over 15 years in the steel fabrication industry as an estimator, project manager, site manager, and eventually as a general manager of a multi-plant facility. He also holds an MBA from the University of Dalhousie.

Grade 91 & Grade 92 CSEF materials for power generation – A Practical Perspective

Abstract: The presentation focuses on a practical approach to ensure safe and reliable pressure systems by taking a hard look at the existing requirements, or lack there-of, in the ASME Code and engineering design, and the best practices to be implemented, maintained, and controlled during material procurement, fabrication, and installation.

Target audience: Engineers, welding supervisors, welders, quality inspectors, owners, technical and procurement personnel, technologists.

Key learnings: The do’s and do not’s when dealing with creep strength enhanced ferritic alloys.

Creep strength enhanced ferritic (CSEF) alloys such as Grade 91 and to a lesser extent Grade 92 have been widely used since mid-1980s in North America for applications in the power generation and petrochemical industry mainly due to their outstanding creep strength. The ensuing years have seen numerous service failures of these materials which have led to a flurry of research to identify and mitigate the causes. It was determined that previous assessment of allowable stress values for Grade 91 were overestimated, thus they were significantly reduced in 2017 and are expected to be reduced again in the newer editions of ASME B31.1. Another disturbing finding was that irregularities during steel making, fabrication, and installation resulted in Grade 91 (and Grade 92) pressure systems having substantially deficient elevated temperature properties compared to “classic” alloys such as Grade P5 or Grade P9. These issues have caused a range of reactions among users which has translated to a variety of approaches to ensure safety and reliability of such pressure systems.

Due to government policies regarding climate change, coal fired power plants are currently being upgraded or replaced with gas fired power plants, leading to a resurgence of CSEF use in design and construction.

Bio: Iulian (Julian) Radu is a welding engineer with PCL Industrial Management Inc. of Edmonton Alberta. He holds a PhD in Materials Engineering from University of Alberta. Julian has more than 25 years’ experience in research, development, design, construction, and operations in oil sands, power generation, petrochemical, heavy machinery, structural steel, offshore and shipbuilding industries.  He is vice chair of AWS D10.8 committee on Welding of Chromium-Molybdenum Alloys and AWS D10.21 committee on Welding Advanced Chromium-Molybdenum Steel Piping and Tubing. Julian has published 12 articles in technical journals and has presented at numerous national and international conferences.

Estimation of Bead Size and Catchment Efficiency in Laser Cladding

Abstract: Prediction of the geometry and dimensions of the clad bead in a laser cladding procedure is important to ensure dimensional accuracy and efficient functionality. Practical expressions for the prediction of these dimensions can reduce the burden of expertise and save time involved with the usage of numerical models among practitioners. This presentation discusses mathematical expressions developed through analytical modeling based on Rosenthal’s solutions for estimating the width, height, and catchment efficiency of clad beads from information on known process parameters. Effective thermo-physical properties of the substrate are determined to consider their variation with temperature which is often overlooked. An expression for the thermal efficiency of the cladding process taking into account the shadowing effect of the powder cloud is proposed. An improved analytical estimation of catchment efficiency based on proper integration of mass flow over the surface of the weld pool is introduced, assuming a gaussian distribution for the laser power and the powder flow with the same distribution parameters. The model developed predicts width and catchment efficiency within 10% accuracy, with the only exceptions being the highest velocity and the lowest laser power tested. The predictions of bead height show a systematic error of 18% on average.

Target audience: Welding Engineers, Laser Cladding practitioners, Researchers

Key learning: Mathematical expressions for prediction of dimensions and catchment efficiency of a clad bead from process parameters of great generality in a laser cladding procedure, using an improved model assuming gaussian distribution for laser power and powder flow and with an expression for thermal efficiency which takes into account the shadowing due to the powder cloud.
 
Biography: Nitheesh holds a B.Tech (Hons.) degree in Metallurgical and Materials Engineering (2023) from the National Institute of Technology Tiruchirappalli, India, and will be pursuing his MSc in Materials Engineering with the Canadian Centre for Welding and Joining, University of Alberta. He was a part of the CCWJ lab as a research intern through the MITACS program, focusing on the mathematical modeling of laser cladding. During his Bachelor’s degree, his research background includes welding, corrosion studies, and computational material sciences, focussing on FE simulations, crystal plasticity, and atomistic modeling.

Deposition rate in GMAW of ER1100 and ER5183 Aluminum alloys

Abstract: The reason behind the higher deposition rate in Mg-containing aluminum alloys in gas metal arc welding (GMAW) is explored. Experiments performed on ER1100 (Mg-free alloy) and ER5183 (high Mg alloys) measured current, wire feed speed, and droplet temperature. A non-linear analysis of Joule heating at the electrode extension and an analysis of the power needed to heat the consumable to the droplet temperature were performed. Analysis revealed that Joule heating is two orders of magnitude smaller than what was necessary for the higher wire feed speed. The droplet temperature measurements were done for the first time for both consumables under identical conditions, which revealed that ER5183 had a lower droplet temperature than ER1100 by almost 350 K. The higher deposition rate in Mg-containing alloys is more likely due to the lower droplet temperature than to the increased resistivity of the alloys.

Target audience: Welding engineers, Welders, and welding educators

Key learnings: The audience will understand the effect of droplet temperature on the deposition rate of aluminum alloys.

Bio: Rishiekesh Ramgopal has a BTech in Metallurgical and Materials Engineering and is completing a Masters’s Degree in materials engineering with the Canadian Center for Welding and Joining (CCWJ) at the University of Alberta. Rishiekesh joined CCWJ as a MITACS research intern in 2019 and then returned for his master's in 2021.  He is currently the student chapter chair for the University of Alberta CWB Association. His interests include wire arc additive manufacturing and understanding the droplet temperature during welding. He is committed to advancing his knowledge, teaching, and making significant contributions to the field.

Arc Length Behaviour and Welding Voltage Analysis for Aluminum GMAW

Abstract: The heat input is a key component of a welding procedure, which is dependent on 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 voltage fall is of interest to welding practitioners. Here, a series of welds using ER4043 were analyzed with synchronized data (voltage, amperage, and high-speed videography) to confirm the expected arc lengths for a given range of parameters as well as the individual contributors to overall voltage fall. The Lincoln Procedure Handbook was leveraged to determine the resulting arc lengths for a range of desired settings. The sum of the anode and cathode fall voltages were found to be approximately independent of current and can be considered constant with a value of 18.3±0.4 V and a total contribution of 64±3% to the total voltage fall. Arc column potential was found to be 0.62±0.05 V mm-1 with 34±3% overall voltage contribution at the arc column for a desired weld. This work provides a clear and practical expected voltage contribution for each fall voltage constituent. Results for carbon steel will also be discussed for comparison.

Target audience: Welding engineers, welding researchers, welding supervisors, welding inspectors, and welders.

Key learnings: The audience will learn about fall voltages, their respective contribution towards the total voltage fall in the GMAW process, and the respective arc length behaviour to voltage settings.

Bio: 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 arc length behaviour 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.

CCNB Carrefour des métiers francophones de l'Atlantique

Le campus du CCNB de Bathurst est le plus important centre d’enseignement postsecondaire des métiers francophones du Canada atlantique ainsi que le centre de formation francophone des métier Sceau rouge du Canada atlantique. Nous avons tous les types de métiers, y compris l’usinage, la fabrication et montage métallique, le soudage et la technologie du génie du soudage, mais sans oublier tant d’autres métiers et professions. Le campus du CCNB de Bathurst est également le plus important centre francophone d’examen CWB au Canada atlantique. Notre collaboration avec le secteur de FABRICATION DE POINTE d’INNOV (anciennement CCNB-INNOV) profite énormément à nos étudiants avec différentes présentations et formations sur des aspects tels que le soudage robotisé. Nous sommes à jour avec les technologies actuelles pour former la prochaine génération de main-d’œuvre et avons également une excellente relation avec l’industrie pour savoir quelles sont leurs attentes concernant les diplômés. (10 – 15 minutes) Pour la deuxième moitié de la présentation, j’aimerais me concentrer sur le programme que j’enseigne, la technologie du génie du soudage. Parlez de ce que les étudiants du programme apprennent au cours de leur programme de 2 ans ainsi que de ce qu’ils offrent à la main-d’œuvre après avoir obtenu leur diplôme du programme.

Bio: En grandissant, je n'avais aucune idée de ce qu'était le soudage. Personne dans ma famille proche ne travaillait dans ce domaine. Je me souviens de la première fois que j'ai touché un arc électrique ! C'était en 11e année, lorsque j'ai suivi le cours de "métaux" pour compléter mon semestre. J'ai tout de suite su que ce serait ma carrière ! J'ai fini par m'inscrire au cours de "Façonnage et montage métallique" en 2005, puis au cours de "soudage" en 2006. J'ai ensuite travaillé dans un atelier de fabrication de produits inoxydables à Montréal pendant un certain temps avant de revenir à Bathurst. À ce moment-là, j'ai commencé à travailler pour une entreprise familiale qui possédait également un atelier à Labrador City, destiné à l'industrie minière du minerai de fer. J'y ai construit ma carrière, tant à Bathurst qu'à Labrador City. Je suis passé de soudeur/fabricant à chef d'atelier. Après un changement majeur dans la direction, je me suis retrouvé à travailler dans le domaine des essais non destructifs, toujours à Labrador City. C'est alors que j'ai eu l'occasion de me joindre à l'équipe du CCNB de Bathurst pour occuper un poste d'enseignant dans le cadre du programme " Technologie du génie du soudage ", que j'occupe actuellement.

General Thermomechanical Model of FSW based on a Characteristic Temperature for Deformation and Heat Transfer

Abstract: This research addresses the limitations of friction stir welding (FSW) in predicting the ideal temperature required to optimize its results, as well as how welding parameters and material properties influence this prediction. The study introduces a comprehensive model that combines heat transfer and plastic deformation in FSW, incorporating factors such as the temperature near the welding pin and principles from fluid mechanics. By utilizing scaling and calibration methods based on existing data, the model improves accuracy and focuses on critical FSW conditions. A unique geometric approach is employed to calculate the temperature at the shear layer's edge, considering deformation rate, stress, and temperature. The resulting model provides equations for key parameters applicable to all metals and undergoes extensive validation. It serves as a valuable tool for predicting temperature and torque, enabling the determination of optimal procedure variables and the development of comprehensive process limit maps. This research makes a valuable contribution to the progress of welding technologies, which find applications in various industries including rocket manufacturing and others, by addressing the predictive challenges in FSW.

Target audience: Engineers, welding engineers, welding educators, researchers.

Key learnings: The development and implications of the mathematical model of friction stir welding.

Biography: Sofia is a Mechanical Engineering graduate from the University of Chile. During her final year, she was awarded the prestigious Emerging Leaders of Americas Program (ELAP) scholarship, which allowed her to conduct her bachelor's thesis at the renowned Canadian Centre for Welding and Joining (CCWJ).

Currently, Sofia is pursuing her MSc. in Welding Engineering at the University of Alberta, where her research focuses on the development of a mathematical model for Friction Stir Welding. Her dedication to the field is further demonstrated by her active involvement as a committee member of the Chilean Welding Association and her role as the president of the Student Chapter at the Alberta Section of the American Welding Society (AWS).

Energy Balance in Gas Metal Arc Welding

Abstract: This work allows to comprehend a part of the theory behind the droplet temperature at the Gas Metal Arc Welding (GMAW) process. Experiments were performed for different aluminum alloys in 0.9, 1.2 and 1.6 mm each. The droplets generated in the process were studied by measuring its heat content and by that, the droplet temperature. An energy balance was performed to reduce the error on the different measurements. The droplet temperatures allows to predict and study different behaviors in the process, such as the difference in deposition rates in alloys and the composition of the vapors present. Compositions are obtained for the vapors through a theoretical model and compared with different studies performed. Relations between current, droplet temperatures and evaporation rates and compositions are obtained and explained.

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. Vicente has worked alongside his colleagues from Chile to build an association of welding and is now the president of the CWBA Chile Chapter.

An experimental methodology to characterize load-based fracture models of third generation advanced high strength steel resistance spot welds

Abstract: Resistance spot weld failure criteria in computer-aided engineering (CAE) models are based upon a critical force that is interpolated from test data obtained in various loading conditions including different proportions of shear-tensile forces and tensile force-bending moments. The decomposition of the critical load into its respective shear, tensile, and bending moment components is influenced by the rigid body motion from their corresponding mechanical tests. Continuous tracking of the weld orientation and the deformed coupons is required for the most accurate characterization of critical failure load components at the onset of failure. This study systematically evaluates the available empirical failure prediction models for resistance spot welds with optimal and suboptimal fusion zone diameters of two grades of third generation advanced high strength steel. The experimental failure loci of the investigated spot welds were developed within shear-tensile and tensile-bending moment dominated conditions using different loading orientations of the KS-II tests and various geometries of the coach peel coupons, respectively. All mechanical tests were accompanied by full-field digital image correlation (DIC) techniques to track the rigid body rotation of coupons during the tests. New analysis methodologies using DIC were developed to properly determine the shear, normal, and bending moments acting on the spot welded joints. Results highlighted the expansion of the failure loci within combined shear-tensile load mixites due to changes in the operative failure mode of the joints. The available failure models were found incapable of predicting this experimentally observed failure behavior and suitable alternative spot weld failure functional forms were proposed. Results from coach peel tests revealed that the available RSW failure functional forms overestimated the area under tensile-bending failure contours between 41% and 120%.

Target audience: All welding professionals, welding engineers, graduate and undergraduate researchers in welding, academic supervisors, and industrial sponsors.

Key learnings: Failure surfaces of optimized and suboptimal 3G-AHSS spot welds were developed based on a novel analysis procedure for coach peel tests to resolve bending, shear and normal loads acting on the welds at the onset of failure.

Bio: Mohammad got his Bachelors degree in mechanical engineering from Noshirvani University of Technology in Iran and is now a Direct Ph.D. candidate at the center for advanced materials joining (CAMJ) in University of Waterloo under supervision of professors Elliot Biro, and Cliff Butcher. His research primarily focuses on the mechanical properties and failure behavior of resistance spot welded third generation advanced high strength steels.

Nano-Welding of Metal-Oxide Nanowires with Pulsed Lasers

Abstract: Nanomaterials play a pivotal role in diverse fields, including electronics, photonics, energy, catalysts, and environmental applications. To fully exploit their potential, efficient assembly and integration techniques are essential, enabling scalability. However, conventional integration methods often entail uncontrolled heat deposition and non-selective processing, leading to undesirable outcomes. Nanoscale welding, using short and ultrashort pulsed lasers, emerges as a promising solution, representing one of the advanced welding techniques with non-contact and precise natures to tailor nanoscale junctions with remarkable accuracy.

This research investigates nanoscale welding mechanisms and interfacial engineering of p-type metal oxide semiconductive copper oxide (CuO) nanowires. By employing short pulsed lasers in a two-stage process, we have demonstrated the capacity to form nanoscale CuO joints with good controllability, and adjust their electrical and mechanical properties. The process involves selectively breaking of CuO nanowires with an initial set of laser pulses, followed by a second set of pulses applied with an optimized orientation to enhance bonding and junction formation. The resulting networks composed of CuO nanowire junctions are employed in strain sensors with significantly enhanced gauge factor.

Target audience: Welding and joining experts, Electronics manufacturing companies, Microelectronics engineers, Nanodevice researchers and developers, Investors and entrepreneurs, Materials Scientists and Engineers, and General conference attendees.

Key learnings: In this academic presentation, we will discuss a novel approach of nano-welding of metal-oxide nanowires utilizing ultrashort and short-pulsed lasers for the purpose of constructing strain sensors.

Bio: Maryam Soleimani earned her undergraduate and master's degrees in materials engineering from the University of Tehran in Iran, with a focus on the mechanical and corrosion behavior of AHSS steels. Currently, Maryam is in the third year of my Ph.D. program at the University of Waterloo, working under the guidance of Professors Zhou and Peng in the Department of Mechanical Engineering and affiliated with the Center for Advanced Materials Joining (CAMJ). The academic journey has deepened her passion for laser nano-welding of metal oxide nanowires using advanced ultrashort pulsed lasers to understand the joining mechanisms and interfacial phenomena of joints at nano scale, recognizing its potential to significantly impact the fabrication of nano devices.

A Simplified Model for Determining the Residual Stresses in Welded Overlays

Abstract: This presentation provides a simple equation for determining the residual stress in the solidified weld metal. One of the more significant challenges in welded overlays is how the differential heating and cooling of the overlay and base metal during application can result in significant residual stresses. These stresses can reduce the lifetime of overlays by causing crack initiation and propagation through the overlay. To combat this, much work has been done on Low Transition Temperature (LTT) alloys that experience the martensite transition later in cooling. This transition impacts the residual stress by causing an expansion of the weld metal late into cooling. It has been shown that if sufficient expansion is introduced, compressive stresses can result in the deposited material, significantly improving the performance of the overlay. But, few consistent methods for determining the correct temperature for the martensite transformation to maximize this effect have been proposed. Through examination of this process, an equation is proposed that can determine the pre-heat and transition temperature required to induce the optimal residual stresses based on this effect. This is then applied to accurately predict the results of fatigue failure tests on several laser-clad repaired components with different starting
conditions.

Target audience: Welding engineers, technicians, and welding educators

Key learnings: A Simple model for designing and predicting the stress state of the weld bead.
 
Bio: Carter Trautmann holds a BSc in Engineering Physics. He 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 overlays. 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 and is an outdoor climbing instructor.

How Cobots and Artificial Intelligence are Transforming Welding Automation

Abstract: Across all industrial sectors, welding is a critical enabling technology that faces chronic skilled labour shortages.  Modern automation technologies are now filling the gaps of welder availability in a safe, reliable fashion. This presentation will explore the evolution of automation technologies, the integration of modern collaborative robots (cobots), and the innovative use of artificial intelligence (AI) and Machine Learning for industrial welding applications.

A holistic approach to automating welding and fabrication processes is critical for maximizing best practices and mitigating pitfalls on the path to success. The skilled workforce has a critical role and is essential for successful implementation of welding automation technologies.  This presentation will explore how a welding cobot is different versus traditional automation cells and why this allows the workforce to safely work alongside the cobot to enhance productivity and safety in parallel. The importance of non-arc fabrication activities such as material preparation, fit-up and handling will be explored. The ‘Smartisation” of welding via rapid adoption of AI and Machine Learning will demonstrate that these game-changer technologies are transforming modern approaches to fabrication. Case studies that illustrate the use of these novel technologies will be presented and demonstrate how Cobots and AI are enhancing productivity while improving weld quality and lowering repair rates on the shop floor.

Target audience: Owners / project managers, Quality Reps, Shop foreman, plant managers, Engineers, designers, technologists and Welders

Key learnings: How welding automation is rapidly evolving with the use of cobots and Artificial Intelligence / Machine Learning. What types of applications and weld results (inspection, NDT, materials properties) can be achieved with modern welding automation

Bio: Matthew Yarmuch MSc, PEng, IWE is a professional materials and welding engineer, involved in engineering consulting, training, and product development. Matthew is a University of Alberta graduate BSc (Materials Engineering) and MSc (Welding Engineering), and remains involved as an Adjunct Professor at the U of A. Matt is the Founder/President of MattCo Engineering Solutions Inc. and their consulting practice includes areas of materials/welding engineering, quality systems, and product development. Matthew has also trained and mentored many past students towards various certifications and professional development. Matt is the Chair of the Alberta Welder Optimization Committee (AWOC) and is also active in multiple code committees and local technical societies including the CWB - Association.

Importance of Indigenization in the Workplace

Abstract: This session will focus on the importance of Indigenization in the workplace and the important role it plays in allowing for safe space for both the clients and staff alike and create opportunities for dialogue and discussions on very tough issues such as colonization, Indigenous World Views and also partnership building between indigenous communities and industry leaders.

Importance of Indigenous Language Use

Abstract: The important role that Indigenous languages have on creating a meaningful relationship with the natural world. Indigenous languages are at major risk right now all over Turtle Island (North America) and there is much work that is being done in Wabanaki territory, but Terry will focus on his work within his home community of Bilijk which is a Wolastoqiyik community just outside of Fredericton. This presentation will allow for participants to learn some basic terms in language that can be utilized in the workspaces and in everyday life.

Bio: Terry Young is Wolastoqiyik (Maliseet). He hails from Kingsclear First Nation located in New Brunswick. For the last 15 years, he’s resided on the Kanienkehaka Territory of Tiotake (Montreal) with his husband Justin Mahoney. Young holds a Bachelor of Arts Degree from St. Thomas University, with a double major in Native Studies and Anthropology. He’s also received formal training on Community Planning and Development from Dalhousie University.

Both a pipe carrier for his people and a carrier of traditional Wolastoqew songs, Young has participated for many years in ceremonies with various Nations from all over Turtle Island. He is also a traditional ash basket maker, a craft he’s honed for over 20 years.