WELDING

JOURNAL JUNE 2023

WELDING JOURNAL ■ VOLUME 102 NUMBER 6 ■ JUNE 2023

SAFETY
MATTERS:
From Selecting
Welding Screens
to PPE
IN THIS ISSUE: AWS FINANCIALS ■ THE AMERICAN WELDER ■ TOOL DONATIONS FOR MADAGASCAR
June 2023 | Volume 102 | Number 6
CONTENTS
ALUMINUM Q&A
12 The differences between 4xxx and 5xxx series filler
metals are detailed to help you make the appropriate
selection
T. Anderson

TECHNOLOGY
14 Additive Manufacturing and Section IX
Take a look at what’s to come for ASME BPVC
Section IX
W. J. Sperko On the cover: A welder wearing protective gear
uses a GMAW gun. (Image by ABICOR BINZEL;
edited by Rachel Turner, marketing specialist.)

FEATURES
56 Choosing the Right Welding Screen or 68 Picking the Best Option for Manual
Curtain Welding Fume Collection
Several factors should be considered to The three main choices include fume arms, fume
safeguard workers near the welding vicinity guns, and backdraft/crossflow tables
A. Pfeiffer
60 Creating a Safe Environment While
Gas Metal Arc Welding 106 THE AMERICAN WELDER
How maintaining set safety standards and How to Craft an All-Terrain Welding Cart
regulations can ensure success Follow these simple DIY instructions to build a
D. Detmer et al. welding cart using a dolly
R. Bigum and Q. Sweetman
64 Welding Radiation Protection
An understanding of this hazard will help
inform proper PPE selection
A. Schrank et al.

DEPARTMENTS
5 Editorial 71 Certification Schedule 104 Personnel
6 News of the Industry 72 Coming Events 110 Learning Track
10 Press Time News 76 Guide to AWS Services 112 Classifieds
11 Education 411 77 Society News 112 Advertiser Index
18 Product & Print Spotlight 78 Tech Topics
22 AWS Financial Statement 84 Section News
CONTENTS June 2023 | Volume 102 | Number 6

WELDING RESEARCH
SUPPLEMENT
113-s The Horizontal Sonocapillary Effect in 125-s Impact of Electrode Rotation on
Ultrasonic-Assisted Soldering Aluminum GMAW Bead Shape
The sonocapillary effect was observed when This work evaluated the potential for bead
solder was sucked into a joint clearance by shape improvements and cost savings
a large negative acoustic pressure along the through the implementation of REP-GMAW
horizontal direction of aluminum using pure argon shielding gas
S. Chen et al. J. Hansen and D. D. Harwig

OFFICERS W. R. Polanin (Past President), WRP Associates AWS Mission Statement

S. Raghunathan (At Large), Saudi Aramco The mission of the American Welding Society is to advance
President Dennis K. Eck
R. W. Roth (Past President), RoMan Mfg. Inc. the science, technology, and application of welding and allied
Diversified Services & Solutions LLC joining processes worldwide, including brazing, soldering, and
K. Shatell (At Large), Pacific Gas & Electric Co. thermal spraying.

Vice President Michael A. Krupnicki L. E. Showalter (At Large), Newport News Shipbuilding
M. M. Skiles (At Large), Consultant AWS Promotes Diversity
Rochester Arc + Flame Center
AWS values diversity, advocates equitable and inclusive
R. H. Stahura (Dist. 6), ESAB Welding & Cutting Products
practices, and engages its members and stakeholders
Vice President Richard L. Holdren K. Temme (Dist. 2) in establishing a culture in the welding community that
welcomes, learns from, and celebrates differences among
Welding Consultants LLC/ARC Specialties P. I. Temple (Dist. 11), Welding Consultant
people. AWS recognizes that a commitment to diversity,
J. Thompson (Dist. 8), Consultant equity, and inclusion is essential to achieving excellence for
the Association, its members, and employees.
Vice President D. Joshua Burgess B. Towell (Dist. 19), Industrial Inspection & Services LLC
Tennessee Valley Authority Welding Journal (ISSN 0043-2296 Print) (ISSN 2689-
0445 Online) is published monthly by the American Welding
WELDING JOURNAL Society for $150.00 per year in the United States and
Treasurer Mary Bihrle possessions, $195.00 per year in foreign countries: $15.00
Publisher/Editor Annette Alonso per single issue. Not available for resale in either print or
Consultant electronic form. American Welding Society is located at 8669
Editorial NW 36 St., # 130, Miami, FL 33166-6672; telephone (305)
Managing Editor Kristin Campbell 443-9353. Periodicals postage paid in Miami, Fla., and addi-
Interim Executive Director & CEO Robert “Bob” W. Roth
tional mailing offices. POSTMASTER: Send address changes
American Welding Society Sr. Editor Cindy Weihl to Welding Journal, 8669 NW 36 St., # 130, Miami, FL 33166-
Associate Editor Katie Pacheco 6672. Canada Post: Publications Mail Agreement #40612608
Canada Returns to be sent to Bleuchip International, P.O. Box
DIRECTORS Associate Editor Alexandra Quiñones 25542, London, ON N6C 6B2, Canada.
R. Ashelford (Dist. 13), Rock Valley College Education Editor Roline Pascal AWS Claims Policy: All hardcopy editions are shipped FOB
Origin. Publisher reserves the right to investigate and make
T. Brosio (Dist. 14), Major Tool & Machine Peer Review Coord. Brenda Flores
a determination on all claims submitted for missing editions
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claim request determined to be valid will be fulfilled with a
A. Classens (Dist. 4), A. E. Classens & Associates Peer Review Editor Thomas J. Lienert
digital copy of the edition. Publisher will NOT send any hard-
J. Davis (Dist. 21), Consultant copy replacement issues for any reason.
Design and Production
R. Emery (Dist. 22), College of the Sequoias Readers of the Welding Journal may make copies of articles
Managing Editor, Digital and Design Carlos Guzman for personal, archival, educational, or research purposes,
M. Hanson (Dist. 15), Compass Electronics Solutions and which are not for sale or resale. Permission is granted to
Production Manager Zaida Chavez
R. E. Hilty (Dist. 7), Hilty Sign & Fabrication Co. quote from articles, provided customary acknowledgment
Assistant Production Manager Brenda Flores of authors and sources is made. Starred (*) items excluded
T. S. Holt (Dist. 18) from copyright.
J. Jones (Dist. 16), Evergy Inc. Advertising Copyright © 2023 by American Welding Society in both
J. Jones (Dist. 17), Harris Products Group Senior Sales Executive Scott Beller printed and electronic formats. The Society is not responsible
for any statement made or opinion expressed herein. Data
T. Kinnaman (Dist. 1), T. C. Kinnaman Welding Solutions Manager, Sales Operations Lea Owen and information developed by the authors of specific articles
T. Kostreba (Dist. 10), Erie High School are for informational purposes only and are not intended for
Subscriptions use without independent, substantiating investigation on the
D. H. Lange (Dist. 12), Northeast Wisconsin Tech. College part of potential users.
Subscriptions Representative Giovanni Valdes
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[email protected]
W. F. Newell (At Large), Euroweld Ltd.
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aws.org
D. Peterson (Dist. 5), Central Maintenance and Welding
8669 NW 36 St., # 130, Miami, FL 33166-6672
N. Peterson (At Large), Miller Electric Mfg. LLC
(305) 443-9353 or (800) 443-9353
 EDITORIAL

Rising to the Challenge

In 2022, the post-pandemic financial recovery continued to face major head-
winds, as illustrated by several economic measurements. The stock market’s
performance was the worst since 2008, inflation remained high despite the
Federal Reserve Bank’s efforts, and by the end of 2022, contraction occurred
in manufacturing activities. However, looking at the trends in the economic
data, there is evidence that inflation is declining and there is a return to growth
in the U.S. economy.
Despite the continuing challenges in the business environment, AWS experi-
enced favorable revenue growth and strong surplus performance.
Revenues for 2022 were $39.1 million, representing an increase of $1.5 mil-
lion, or 4.1% higher than 2021. The increase in revenue was driven by the Atlanta
FABTECH trade show that occurred in November 2022. Highlights of 2022
included the Atlanta FABTECH show’s success with increased exhibitors and
attendance as well as strong engagement and positive feedback. Exposition
Mary Bihrle
revenue totaled $2.8 million in 2022. In addition, the AWS Foundation awarded
AWS Treasurer
1600 scholarships totaling a record $2.4 million.
In addition to the growth in revenue from FABTECH, the Accreditation and
Educational Services business units experienced growth over the previous year.
Other business units declined modestly or remained flat. Standards Development
book sales were down slightly (as anticipated) in the third year of the five-year “The extraordinary
cycle of AWS D1.1. We anticipate a decrease in each subsequent year of the cycle. commitment of the AWS
The surplus for 2022 was $8.6 million, representing a decrease of $1.1 million, staff and volunteers and
or 11.4% lower than 2021. The lower surplus was principally driven by salaries
and benefits from increased head count, investment in strategic initiatives,
their ability to rise to
and resumption of activities such as travel and program events. Cash and cash all challenges has been
equivalents in 2022 increased over the prior year and supported a transfer of critical to the organiza-
$6.1 million from AWS operations to the Foundation. tion’s continued success.”
The AWS reserve fund was $89.5 million, representing a decrease of $22.7 mil-
lion, or 20.2% lower than 2021. The AWS Foundation’s net assets also decreased
to $96.1 million, a decrease of $18.3 million, or 16% lower than 2021.
The largest driver of the decreases was the negative market investment
changes consistent with the stock market’s overall performance.
In 2022, the financial performance and strong financial reserve position
demonstrated the long-standing discipline of the organization to manage
revenue and expenses and to overcome challenges in volatile business times.
Fortunately, our past ability to save for a rainy day allowed us to weather the
multiple economic storms we encountered throughout the year. More impor-
tantly, the extraordinary commitment of the AWS staff and volunteers and their
ability to rise to all challenges has been critical to the organization’s continued
success. Thank you, with sincere gratitude, to the AWS staff and volunteers for
their relentless dedication.
Our 2023 priorities are underway and are focused on providing welding
professionals and the welding industry with education, training, and technical
resources. We are confident that we are well positioned to overcome unexpected
challenges, and we look forward to the future. WJ

JUNE 2023 | 5
 When using the GMAW process, you
must wear an appropriate face shield.

Creating a Safe Environment While

GAS METAL
ARC WELDING
Following safety procedures in the workplace can improve the
productivity and well-being of employees

BY DAVID DETMER, PHIL MONTEZ, AND RACHEL TURNER

H
ow can you make sure that you are following the best safety in the manufacturing industry comes with a pretty long
preventative measures when working with the GMAW list of requirements. It is crucial for employees to be aware
process? While safety is important in every environ- of any potential harm and injury that can arise when working
ment, in this article we will describe how to create a safe with heavy-duty equipment. Practicing safety standards is
welding environment while GMAW. key to creating a safe and efficient work environment for
Many welding and/or cutting processes produce fumes and yourself and others.
gases that could be harmful to your health. Not surprisingly,

60 | WELDING JOURNAL
 An apron is an additional preventative and
fire-resistant form of PPE.

Best Preventative Measures When

GMAW
People are vastly different, but when it comes to the way
they follow safety regulations, there are set standards to
follow.

Understand Your Equipment

The very first step in creating a safe space for GMAW is
to understand your welding equipment. This means making
yourself familiar with the torch, settings, buttons, program-
ming, etc. It is also important to know which types of metals
are commonly welded to make sure you are using the correct
consumables for your unit to get the best result.
“A lot of GMAW torches are durable and can withstand day-
to-day use, but they can still become damaged, sometimes
without you even knowing. It is a good practice to perform
routine maintenance and inspect all your welding equipment
before you start work for the day,” said David Detmer, national
sales manager, ABICOR BINZEL. basic first step is to clean it so it’s free from rust, oil, and
other particles. Some materials or weld joints may need some
Having a good understanding of your equipment prevents
sort of weld joint preparation, like a bevel or groove. Make
hazardous situations that could arise when the user lacks
sure you check your work area for exposed wires, damaged
knowledge about the product. Be sure the unit is grounded
cables, loose consumables, cracked handles, or anything
and properly installed.
that affects the integrity of the unit or torch.

Test Unit Safety

Safety While Welding
After familiarizing yourself with your welding equipment,
it’s important to physically test the safety of the unit. This CHEMICAL SAFETY
means reviewing all testing reports and even preforming a Be aware of the chemicals being used and how they can inter-
test if deemed necessary. act with other properties. Learn the hazard symbol and know
“You know, it’s your safest bet to check your equipment when and where to dispose of toxic chemicals.
first before you can even start welding. That’s going to be
the main thing. Because there are times where people don’t ELECTRICAL SAFETY
realize that somebody has a slit in their cable or they’re put- According to OSHA.gov (Ref. 1), “The following hazards are
ting electrical tape around a copper cable and it’s not good,” the most frequent causes of electrical injuries: contact with
stated Phil Montez, district sales manager, ABICOR BINZEL. power lines, lack of ground-fault protection, path to ground
Check the inventory of the products being used to ensure missing or discontinuous, equipment not used in manner
there is enough on hand for the entirety of the project. This prescribed, and improper use of extension and flexible cords.”
will save time and make the project more efficient. For your When welding, it is crucial to follow the specific regulations
equipment, talk to your original equipment manufacturer regarding electrical safety. Remember to unplug your unit
or welding supply representative. Ask them to take a fresh immediately after welding to prevent electrical hazards.
look at your shop floor and see if they notice anything that
could be done to get more out of your production. Chances
PERSONAL PROTECTION EQUIPMENT (PPE)
are they’ll have a few recommendations to try, and you’ll be
better off long-term for testing something that could lead Following the guidelines provided by AWS Safety and Health
to big gains. Fact Sheet No. 33, Personal Protective Equipment (PPE) for
Welding and Cutting (Ref. 2), “Welding and cutting can pro-
duce hazards such as sparks, spatter, radiation (infrared,
Check the Work Area ultraviolet, and blue light), slag, heat, hot metal, fumes and
gases, and even electric shock. Since these hazards may
Ensure the surface area is clean of any contaminants, as cause burns, injury, or death, it is important to wear proper
well as free from anything that may ignite or become flam- PPE at all times.”
mable. It is also important to prepare the base material. The

JUNE 2023 | 61
 Wear proper
PPE when
holding a
welding gun.
Personal Protection Post-Welding Safety
Equipment
It is important to ensure that post-welding safety processes
Next is a list of proper are also followed. Always unplug your welding machine as
PPE that should be worn at soon as you are finished welding. This prevents potential
all times while welding. electrical hazards. Be sure to store your welding equipment
1. Eye and face protec- in a safe place to prevent picking up potential contaminants.
tion: Wear a helmet with a filter Never hang your welding gun by its trigger, as this can weaken
lens and cover plate that com- the gun and cause damage.
plies with ANSI/ISEA Z87.1, American
National Standard For Occupational And Edu-
cational Personal Eye And Face Protection Devices.
Why Follow Welding Best Practices?
Make sure to have a pair of safety glasses handy. There
Following safety practices is important for several reasons,
are several lens shades/colors that offer a variety of
including preventing harm or injury, saving time and money,
protection depending on the work being performed.
and increasing well-being and productivity.
Use ear plugs, and make sure your hair is tied and
pulled back and out of the way. Following welding safety procedures can prevent injury
to the operator, bystanders, or even the equipment itself. It
can also prevent avoidable accidents.
2. Foot protection: Wear boots that are steel toe or meet
By following welding regulations, the welder can save time
the requirements of ASTM F2413, Standard Specifi-
and money by providing a clean start-to-finish welding pro-
cation for Performance Requirements for Protective
cess. This cuts away any wasted time that may have gone
(Safety) Toe Cap Footwear.
into fixing another issue that could have been prevented.
Being safe also increases the well-being and productivity
3. Hand protection: Wear hole-free, insulated welding of the operator. When the operator feels safe, there is more
gloves that are in good condition. Do not use electrical freedom to focus on the task at hand and get the job done
tape to repair gloves. quickly and efficiently.

4. Respiratory protective equipment: A respirator is

needed when necessary to prevent chemical overex- Conclusion
posures. See OSHA’s Respiratory Protection Standard,
29 CFR 1910. 134, and The National Institute for By maintaining set safety standards and regulations, we
Occupational Safety and Health’s (NIOSH) National are ensuring that we are doing our best to keep ourselves and
Personal Protective Technology Laboratory (NPPTL). those around us safe. Creating a safe welding environment is
Companies should consider using a fume extraction crucial to the overall success of a welder’s projects.
system to improve the health of welders. So, how can you make sure that you are following the best
preventative measures when GMAW? Always understand
your equipment, test the unit’s safety, check your work area,
5. Head and ear protection: Wear a fire-resistant weld-
wear proper PPE, and be aware of preventative measures as
er’s bump cap underneath the helmet with a filter lens.
well as what to do in case of an emergency.
When GMAW, just a few small tweaks can lead to huge
6. Body protection: Wear durable, long pants that cover improvements in comfort, cost reduction, time savings, and
all potentially exposed areas. Sleeves are necessary to productivity. Keep this in mind for your next project. WJ
protect your arms and neck from skin burns or radia-
tion. Keep your flame-resistant clothing dry.
Sources

Workplace-Specific Hazards 1. Occupational Safety and Health Administration. Retrieved from

osha.gov/electrical.
Every workplace has specific regulations that welders 2. American Welding Society, Safety and Health Fact Sheet No.
need to be aware of. Be sure to keep a lookout for moving 33, Personal Protective Equipment (PPE) for Welding and Cutting.
machine equipment or other moving parts. This means paying Retrieved from aws.org/library/doclib/fs33-201404.pdf.
attention to all corners of the shop to avoid collisions. Ask
your plant operator where the nearest and most-updated DAVID DETMER ([email protected]) is national sales
rules and regulations are located to ensure that all precau- manager, PHIL MONTEZ ([email protected]) is district
tions are being taken into consideration. Safety vests and sales manager, and RACHEL TURNER ([email protected])
reflective clothing material are also good to wear when in a is marketing specialist at ABICOR BINZEL USA, Frederick, Md.
manufacturing workplace zone.

62 | WELDING JOURNAL