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14th September, 2019 in Mumbai Dear Readers, Hope you all took the pleasure in reading the preceding April – May, 2019 Issue. We now introduce you the June-July edition with attention-grabbing articles and other editorial content. With the forthcoming Aug – Sept 2019 Issue, WeldFab Tech Times feels great to announce the victorious completion of 2 Years. Thanks to all our esteemed advertisers, subscribers, authors and readers.
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4
WELDFAB TECH TIMES | JUNE - JULY 2019
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CONTENTS 6
WOMEN IN WELDING “I just get started doing what I know and figure out the surest as I go along.” Barbie Parsons, Welder from Barbie The Welder, Metal sculpture design & creation
48 ARTICLE
INDEPTH
14 An experimental approach on friction stir welding process parameters & tool design for dissimilar joints
30
Collaborative robots offer manufacturers a safer cutting edge
INTERVIEW
34
WELDFAB TECH TIMES | JUNE - JULY 2019
“ARO 3G technology is more competitive than customers may perceive...”
Scan For Digital Magazine
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INNOVATIONS
44
Nanotechnology enables engineers to weld previously un-weldable aluminum alloy
LAUNCHES
WELDER’S PASSION
40
38
“We all have own ways to weld.”
Pandrol Connect Welding App
BULLETINS
10
PRODUCTS UPDATE
28
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JUNE - JULY 2019 | WELDFAB TECH TIMES
7
BULLETINS
Welding: Advanced Ultrasonic Servo Presses
G
ermany’s MS
cleanroom environments that
and speed when changing
Ultrasonic
are standard in the medical
parts. The homogeneous
Technologies Group
and pharmaceutical industries,
plasticizing resulting from the
(U.S. office in Webberville,
yet also can be used for other
use of this technology is said
Mich.) has launched a new
industries.
to ensure enhanced welding
family of ultrasonic servo presses that are said to
The absolute path Source: www.ptonline.com
results, irrespective of how
measurement is said to take
complex the challenges of the
place throughout the possible
parts to be welded turn out
advantages. Features of the MS
connectivity, an integrated
work stroke of over 400 mm,
to be. The tool-free exchange
soniTOP family—models Opus,
tensile test and the simple and
intuitively adjustable and
of nests and resonant units
Nexus, Fusion and Genesis,
quick changing of the resonant
automatically positioned. This
functions quickly and in a
range from an integrated
unit. The company’s presses
is also the case for the trigger
straightforward way. The
servo drive to intuitive
reportedly also ensure the
and work positions,which can
corresponding welding
operation up to MS paralliCer-
greatest possible yield with
be saved. The high speed of
recipes for new products can
Technology—a patented
reduced scrap rate because
movement of 240 mm, enables
be selected automatically
innovation that works without
of their unique functions.
greatly improved productivity.
or manually. Automatic
loss of parallelism between the
The integrated servo drive,
The integrated servo drive
indexing after the quick change
sonotrode and workpiece.
compared to pneumatic
delivers outstanding efficiency
reportedly ensures consistent,
units, forgoes compressed air
due to reduction of cycle times
high-quality welds from the
entirely and is ideally suited for
and allows maximum flexibility
first part and avoids rejects.
offer users a wide range of
Other advanced features include far-reaching
Permit for Welding Academy MAGIC Camp Exposes Teen supported by Union Plan Girls to Heavy Equipment, Board Welding
A
Union Planning and Zoning
training ground for aspiring
R
Girl in Construction (MAGIC),
certification through the
Commission despite the
welders.
conducted her ninth annual
program.
permit request for a
Rob Knoll, representing
new welding school
American Welding Academy,
was supported by the
said the facility would be a
objection of one neighbor.
The facility would be built
day” on Monday. An OSHA
national executive
safety director also helps the
director of Mentoring a
girls earn their 10-hour OSHA
construction camp for girls
As the week goes on,
on land formerly owned by
ages 14 to 18 last week.
campers are exposed to
voted unanimously to back
the Union Development
According to an article in the
skills in heavy equipment,
a request from the American
Corporation (UDC) at the
Daily Tribune, the camp gives
carpentry, electrical wiring,
Welding Academy to operate
intersection of Progress
high school girls a preview
and welding. After learning
a training facility at 3 Progress
Parkway and Prairie Dell
of what it might be like to
about each construction
Parkway. The board’s
Road.
The plan board Monday
have a career as a carpenter,
medium, the girls put their
recommendation is now
welder, electrician, or heavy
skills to the test creating things
passed along to the board of
equipment operator.
like a candle holder, and a
aldermen, which will have
According to the article,
the final say on awarding the permit.
10
enee Connor, the
WELDFAB TECH TIMES | JUNE - JULY 2019
the girls always start the Source: www.emissourian.com
weeklong camp with “OSHA
Mason jar lamp. Source: www.constructionequipment.com
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BULLETINS
Advanced laser welding solutions for electric vehicle battery enclosures
KPC welders to replace Chinese, Nigerians after graduation
B
function properly and retain
T
their life span. This process,
training that will ease the
known as fluid cooling,
skills shortage that forced the
skills shortage in the sector
requires airtight seals to keep
country to ship in Chinese,
that recently pushed Kenya
Nigerian and Lebanese
to ship in about 50 foreign
welders.
welders while building new
atteries used in electric vehicles must be actively cooled to
pipeline welders
an 820-kilometre crude oil
have completed an
pipeline between Lokichar
Laser welding is
methods can be used to weld
traditionally only used with
The Kenya Pipeline
plastic battery packaging
translucent or optically clear
Company (KPC) welders
components, those that do
plastics. Now, however,
completed the six-months
not require external agents
Covestro and Leister
training that saw them
are less complex and more
Technologies have extended
sit examinations in Spain
cost-efficient.
use of this joining technique
Of these techniques,
retardant Bayblend® PC+ABS
to laser welding as it allows
blend from Covestro, while
for larger parts, does not
achieving the same level
require a pre-treatment
of weld strength. Flame-
and offers high-precision,
retardant plastics are
repeatability and control.
preferred and often required
Covestro LLC worked with
for battery enclosures as they
Leister Technologies LLC to
can help prevent or delay the
develop process and material
spread of fires.
The upgrade comes amid
Sh43 billion Nairobi-Mombasa pipeline.
Source: www.businessdailyafrica.com
Jean-Pascal Tricoire appointed to the Board of the United Nations Global Compact
fluid-cooled battery modules
FR3010 PC+ABS blend,
used in electric vehicles such
we developed effective
as new passenger vehicles,
and reliable laser welding
U
electric buses, trucks and
solutions for production-
Global Compact France and
other utility vehicles.
ready battery modules that
Chairman & CEO of Schneider
"This joining technique
and Lamu for export.
to include opaque flame-
manufacturers often turn
solutions for laser welding
"Using Bayblend®
N SecretaryGeneral Antonio Guterres has appointed Jean-
Pascal Tricoire, President of
can withstand battery abuse
Electric, to the United Nations
provides the accuracy
testing, including UN38.3,"
Global Compact Board. The
needed for welding in tight
said Terry Davis, principal
UN Global Compact Board
locations and around other
engineer, Covestro LLC.
plays an important role in
strategic and policy advice for
components in fluid-cooled
"With this material, battery
shaping the strategy and
the initiative. Board members
systems," said Fernando
manufacturers can create
policy of the initiative, which
are considered champions
Santillana, senior project
reliable and leak-free battery
acts as the United Nations
who are willing and able to
manager – Midwest, East
enclosures."
flagship for responsible
advance the mission of the
Coast, Caribbean and Latin
business action. Designed
UN Global Compact. They act
America, Leister Technologies
as a multi-stakeholder body,
in a personal, honorary and
the Board provides ongoing
unpaid capacity.
LLC.
12
ahead of Kenya building
international accredited
fluids contained and avoid spills. While several joining
en Kenyan oil
WELDFAB TECH TIMES | JUNE - JULY 2019
Source: www.covestro.us
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ARTICLE
An experimental approach on friction stir welding process parameters and tool design for dissimilar joints Abstract: In the present investigation, dissimilar materials electrolytic tough pitch pure copper to aluminum (6061-T651) welded with the favourable process parameters by friction stir welding (FSW).Tool pin profile and shoulder to pin diameter ratio parameters considered as tool design parameters. Rotational speed, welding speed, tool pin offset and tool tilt angle considered as process parameters. Four set of experiments were carried out to analyse tool design and process parameters of dissimilar copper (Cu) – aluminum (Al) FSW. Visual observation, macro structure, microstructural characterization and analysis of mechanical properties evolution used to identify favourable parameters after each set of experiment. The results revealed that cylindrical tool pin profile gives sound dissimilar Cu-Al friction stir welding. FSW process parameters of rotational speed 1500 rpm, welding speed 40 mm/min, tool pin offset 2 mm, tool tilt angle 2˚ with plunge load range 600-850 kgf enhance mechanical strength of 133 MPa and macro hardness of 181 VH (in the nugget zone) without any defect. Keywords: Dissimilar materials, Friction Stir Welding, Process parameters, Weld properties
Kush P. Mehta, Department of Mechanical Engineering, School of Technology, Pandit Deendayal Petroleum University, Raisan, Gandhinagar-382007, Gujarat, India.
1. Introduction
14
differences in melting temperature,
soften (i.e. plastically deformed) the area
chemical compositions and physical
under tool shoulder and stirring of tool
properties. Despite of this, dissimilar
pin helps to move the soften material
Cu-Al joining is applied widely in
from front to rear [1].Joining of Cu and
many industries in order to take
Al materials together is also difficult
technical and economical advantages.
by FSW technology [2] but feasible [3].
Different industries such as electrical,
Microstructure of dissimilar Cu-Al FSW
nuclear, aerospace, chemical, solar and
shows that it has vortex like and swirl
electronic use dissimilar Cu-Al joints
flow under the area of tool [4]. Mixing
for different applications. Friction stir
of Cu and Al together is difficult due
welding (FSW) successively applied to
to differences in plastic deformation
join Cu-Al together since last few years.
temperatures and vortex like flow
FSW is a solid state welding invented in
between Cu-Al [2-4]. Generation of hard
1991 by W. M. Thomas at the welding
and brittle intermetallic compounds
institute (TWI) to join Al alloys [1].
(IMCs) like Al4Cu9, AlCu, Al2Cu cannot
As the name implies, friction as well
be avoided for dissimilar Cu-Al FSW.
as stirring is responsible for making
More the IMCs generate more defects,
weld in solid state by non-consumable
which leads it to produce low strength
Dissimilar welding of copper (Cu) and
rotating tool, which has specially
joint [2 - 15].Therefore, it is necessary to
aluminum (Al) is a challenge to perform
designed shoulder and pin. Friction
reduce volume of IMCs for getting defect
as both of these materials are having
between tool shoulder and work piece
free-sound dissimilar Cu-Al FSW joint.
WELDFAB TECH TIMES | JUNE - JULY 2019
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ARTICLE
A thin-continuous and uniform layer of
Esmaeilli et al [10]observed that change
materials of 6.3 mm thickness were
intermetallic compounds improve the
in rotational speed affects IMCs and
used to butt type join by friction stir
strength of dissimilar Cu-Al FSW joint [6,
mechanical behaviour of dissimilar
technology. Chemical compositions of
8, 12, 16 - 17].Uniformity and continuous
brass-AA1050 joint. Xue et al [16] studied
base materials are shown in Table:1.
layer of IMCs of dissimilar Cu-Al joint
different parameters like fixed location,
Tool steel of M2 grade (heat treated
depends on the process parameters
pin offset, rotational speed, welding
and 62HRC hardened) material was
optimization in friction stir welding [9,
speed on mechanical properties and
used in present investigation. Chemical
16]. Variation in IMCs layer also varies
microstructure of dissimilar Cu-Al
composition of tool is shown in Table:
metallurgical and mechanical properties
FSW. Larger tool pin offset toward Al
2.Experiments were carried out by
of Cu-Al FSW joint. Researchers
side helps to allow more stirring action
keeping Cu at advancing side and Al at
observed that tool design, tool pin
at Al side and only small Cu particles
retreating side as shown in Fig: 1. Load
offset, rotational speed, welding speed,
scratched from Cu work piece, which
location of Cu and Al in fixture (like Cu
makes defect free joint by easy mixing
requires to be fixed at advancing side
of Cu into Al matrix [8, 16]. It is reported
and Al requires to be fixed at retreating
that harder material copper require to
side for dissimilar Cu-Al FSW) are major
fixed at advancing side in the fixture
process parameters which affects the
while performing dissimilar Cu-Al FSW
IMCs and quality of dissimilar Cu-Al
so that, it can be easily transported
FSW joint. Akinlabi et al [18] found that
and mixed with aluminum matrix and
varying shoulder diameter affects heat
reduces defects in nugget [16, 19].
Fig: 1 Position of workpiece materials in fixture.
input conditions which also varies IMCs
It is well documented that, there is a
and mechanical properties of Cu-Al FSW.
need to optimize process parameters to
Optimum shoulder diameter 18mm
achieve highest strength with uniform
cells were located below the fixture
produces highest strength (208 MPa)
IMC layer. Present investigation is
which reports the variation of axial
with appropriate material flow in stir
carried out to detailed analysis for
plunge load throughout the dissimilar
zone out of three diameters 15 mm, 18
different process parameters like tool pin
FSW.
mm and 25 mm for dissimilar AA5754
profile, tool pin offset, rotational speed,
to C11000 FSW joint [18]. Abdollah [5]
welding speed, tool tilt angle and axial
into four set of experiments. Tool
observed that increase in rotational
plunge load for dissimilar (electrolytic
design, tool pin offset, welding speed,
speed or decrease in welding speed
tough pitch copper to AA6061-T651)
rotational speed, tilt angle and axial
increase the amount of IMCs and reduce
materials. This study also includes
plunge load are studied and optimized
its strength, whereas extremely low
optimization of all these parameters
during experimental work. First set of
rotational speed results in imperfect
through experimental approach.
experiment was carried out to study tool
joints. Galvao et al [9] observed that ratio
Experimental work is divided
pin offset and tool design with taper pin
of rotational speed to welding speed
2. Experimental Procedure
profile. First set of experiment studies
directly affects the heat input, IMCs and
Aluminum 6061-T651 and electrolytic
three experiments by varying tool pin
mechanical strength of dissimilar Cu-Al
tough pitch copper (~99.9 purity)
offset 1 mm, 2 mm and 3 mm wherein
Table: 1. Chemical composition of base materials Materials
Si
Fe
Cu
Mn
Mg
Cr
Zn
Ti
Impurities
Al
Al 6061-T651
0.56
0.30
0.17
0.12
1.03
0.11
0.08
0.03
0.04
Balance
-
Electrolytic copper
-
-
>99.9
-
-
-
-
-
Balance
-
97.15% Conductivity
material. Optimum ratio of rotational speed to welding speed produce efficient defect free joint with higher strength.
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Table: 2. Chemical composition of tool Element
C
Cr
V
W
Mo
Co
Cb
Percentage (%)
0.80
4.00
2.00
6.00
5.00
_
_
JUNE - JULY 2019 | WELDFAB TECH TIMES
15
ARTICLE
Table: 3 Process parameters for first set of experiment. Set of experiments
Rotational speed (rpm)
1
Welding Speed (mm/min)
1500
second set of experiment. In addition
Tilt angle (°)
30
Tool Pin Offset (mm)
to this, rotational speed kept 1500 rpm
1
second set of experiment based on the results of first set of experiment. Visual
2
0
and tool pin offset was taken 2 mm for
checking and macrostructure test was
3
taken after welding same as first set of
Table: 5 Third set of experiment. Set of experiments
Rotational Speeds (rpm)
Welding speed (mm/min)
Tilt angle (°)
Tool Pin Offset (mm)
40
0
1
Welding speed (mm/min)
Tilt pin offset (mm)
Tilt angle (˚)
1500 1300
1
1050 Table: 6 Fourth set of experiment. Set of experiments
Fig: 2 Tool design 1.
Rotational speed (rpm)
0
keeping other parameters constant
1
like tool dimension, rotational speed, welding speed and tilt angle as tool: 1
1
1300
40
0
2
(as shown in Fig: 2), 1500 rpm, 30 mm/
3
min and 0˚ respectively as shown in
4
Table: 3.These three test coupons were checked visually and then subjected
is having cylindrical tool pin profile with
experiment for conforming quality of
to macrostructure testing. For macro
increased dimensions as shown in Fig:
welding. Based on it, the best result was
structure testing polishing of joint was
3. Tilt angle was also increased to 2˚ for
taken as constant parameters for next set of experiment.
done on grit paper 120 and 320 one by
Third set of experiment was carried
one. Based on its testing, changes in parameters were carried out and best
out to study different rotational
result was taken as constant parameters
speeds 1100 rpm, 1300 rpm and1500
for next set of experiment.
rpm (Table: 5).Based on the results of second set of experiment, 40 mm/min
Second set of experiment was carried out to study four different welding
welding speed is taken for third set of
speeds 40 mm/min, 55 mm/min, 70 mm/
experiment and other parameters kept
min and 95 mm/min (Table: 4).Based
constant such as rotational speed, tool
on results of the first set of experiment,
pin offset and tilt angle kept 1500 rpm,
tool design was changed and new tool:2
Fig: 3 Tool design 2.
Table: 4 Second set of experiments. Set of experiments
Rotational speed (rpm)
Welding Speeds (mm/min)
Tilt angle (°)
Tool Pin Offset (mm)
40 1
1500
55 70 95
16
WELDFAB TECH TIMES | JUNE - JULY 2019
2 mm and 2˚ respectively. Specimens were checked visually and then tested by macrostructure analysis as well as mechanical and metallurgical analysis (like tensile testing, hardness testingand microstructure analysis) was carried
0
1
out. Tensile specimens were prepared on miniature of lathe machine as per standard ASTM E8.Vickers macro
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ARTICLE
hardness was measured within the indentation of every 2 mm along the transverse cross section of specimen with 10 kg load value as per standard ASTM, A370-07.Based on it, the best result was taken as constant parameters for next set of experiment.
Fig: 6 Macro results of first set of experiment; rotational speed 2000 rpm, welding speed 30 mm/min, tilt angle 0˚ and tool pin offsets (A: 1 mm, B: 2 mm and C: 3 mm). tool pin offset increases the average
particles scratching which hard to mix
carried out to study different tool tilt
plunge load value decreases because
with aluminum matrix because of its
angles 0˚, 1˚, 2˚, 3˚and 4˚. Based on
the tool is more at softer material side
low flow ability and high conductivity.
the results of third set of experiment,
i.e. aluminum side requires less force to
This led to the poor surface bonding and
process parameters for fourth set
stir the pin into it. Surface morphologies
the formation of many big voids. On the
of experiment are rotational speed
of all the samples were having minor
other hand, for sample C the tool pin
1300 rpm, welding speed 40 mm/min
hair cracks on it which is because of
is almost at Al side as the pin offset is
andtool pin offset 2 mm (Table: 6).
lack of heat input and lower value of
3 mm. It was observed that joint is not
Specimens were checked visually and
plunge load. Macro results for first set
proper at all from bottom side because
then tested by macrostructure analysis
of experiment shown in Fig: 6 which
the tool pin offset 3 mm was too large to
as well as mechanical and metallurgical
show that all the joints were having
weld 6.3 mm thick dissimilar Al-Cu FSW
analysis same as analysed in third set of
defects in their bottom of the nugget
joint. For 3 mm offset, sufficient mixing
experiment.
zones. Sample A and B big pores were
of material cannot occurs because of very
Fourth set of experiments was
observed whereas sample C there was
large pin offset as whole pin displaced
3. Results and Discussion
not a joint at all from bottom side. Taper
at aluminum side. So, it is observed that
3.1 First set of experiment
tool pin profile allows non uniform
pin offset 2 mm is more appropriate
Visual examination was carried out from
scratching of copper particles from top
compares to other two offsets (i.e. 1 mm
front side as well as rear side of tested
to bottom. Top side the copper particles
and 3 mm). It indicates that sufficient
coupons of first set of experiment as
scratched more and at bottom of pin
copper particles are scratched at 2 mm
shown in Fig: 4. Average axial plunge
copper particles scratched less. Because
offset which allows proper mixing with
load value for first set of experiment
of non-uniform scratching mixing of
aluminum matrix.
shown in Fig: 5. It shows that as the
copper particles into aluminum matrix is
Fig: 5 Average axial plunge load value for first set of experiment.
The large copper particles mix with
also non-uniform. So, the joints were not
aluminum matrix and forms non-
proper from the bottom side of nugget.
uniform intermetallic compound layer
Sample B (i.e. 2 mm tool pin offset)
causes defects. This could be also the
was found better than sample A and C.
reason for more defects at nugget. First
Pin offset was only 1 mm for sample
set of experiment suggest that taper tool
A which means that tool pin remains
pin profile is not suitable for dissimilar
more touched (2 mm) with copper base
Cu-Al joint. More heat input and plunge
material.
force recommended for getting sound
This allows more amounts of copper
dissimilar weld. 3.2 Second set of experiment Recommendations from first set of experiment have been applied before second set of experiment. Toll pin profile changed from taper to cylindrical for achieving uniform penetration in nugget
Fig: 4 Welded coupons of first set of experiment; rotational speed 2000 rpm, welding speed 30 mm/min, tilt angle 0˚ and tool pin offsets (A: 1 mm, B: 2 mm and C: 3 mm).
18
WELDFAB TECH TIMES | JUNE - JULY 2019
zone. In addition to this tool pin size and shoulder size also increases as shown in
www.weldfabtechtimes.com
ARTICLE
would not achieved because of low heat input. From second set of experiment parameters of sample AC3 i.e. rotational speed 2000 rpm, welding speed 40 mm/min, tool tilt angle 2˚ and tool pin offset 2 mm recommended for further investigation on effect of rotational
Fig: 7 Welded coupons of second set of experiment; rotational speed 2000 rpm, tool pin offset 2 mm, tilt angle 2˚ and welding speeds (AC3: 40 mm/min, AC4: 55 mm/min, AC5: 70 mm/min and AC6: 95 mm/min).
Fig: 9 Macro results of second set of experiment, rotational speed 2000 rpm, tool pin offset 2 mm, tool tilt angle 2˚ and welding speeds (AC3: 40 mm/min, AC4: 55 mm/min, AC5: 70 mm/min and AC6: 95 mm/min).
speed and tool tilt angle. 3.3 Third set of experiment Third set of experiment carried out by keeping constant variables like tool design having cylindrical tool pin profile, welding speed 40 mm/min, tilt angle 2˚,
diameter increases. Maximum plunge
tool pin offset 2 mm and rotational speed
load 734.87 kgf at welding speed 95 mm/
varied 1500, 1300 and 1100 rpm based on
min shows that as increasing value of
the results of second set of experiments.
the welding speed the tool requires more
Visual examination was carried out from
force for stirring hence plunge load
front side as well as from rear side of
value increases. Macro structure results
tested coupons of third set of experiment
of second set of experiment shown in
as shown in Fig: 10. Average axial plunge
Fig: 9 in which defects of first set of
load value for third set of experiment
experiment eliminated successfully and
shown in Fig: 11. At rotational speed
increased penetration level as shown
1100 rpm, the spindle stopped after
in sample AC3. Uniform penetration
plunging and before feed applied
Fig: 3 to increase plunge load value. Tilt
achieved with cylindrical tool pin profile
because the load or torque taking
angle increased from 0˚ to 2˚ and travel
in which uniform scratching of copper
capacity of spindle found less enough
speed also increased from 30 mm/min
particles from top to bottom in nugget
to rotate the tool. Rotational speed
to 40 mm/min to increase the value of
allows proper bonding of Cu particles
1100 rpm does not results in successful
axial plunge load. Visual examination
with aluminum matrix and form defect
was carried out from front side as well as
free joint.
Fig: 8 Average axial plunge load value for second set of experiment.
rear side of tested coupons of second set
Defect free joint reported only with
of experiment as shown in Fig: 7. Average
welding speed 40 mm/min whereas
axial plunge load value for second set of
for other welding speeds 55, 70 and
experiment shown in Fig: 8.
95 mm/min defects were observed.
The heat input is high at lower welding
Welding speed 40 mm/min allows more
speed which makes base material
time to soften the aluminum material
softer and results in less value of axial
as the tool is more at aluminum side.
plunge load compare to welding speed
Copper particles scratched from copper
95 mm/min. The heat input is low at
workpiece side flows easily as aluminum
high welding speed which increases the
get softer which lead it to improve
value of axial plunge load as it requires
metallurgical bonding and mixing of
more force for stirring. Results shows
both materials and make defect free
improved surface morphologies with
joint.
coupons of second set of experiment.
At higher welding speeds i.e. 55, 70
Value of axial plunge load also increases
and 95 mm/min the defects were more
(in the range of 520 to 730 kgf) as tilt
because of lower heat input. Proper
angle, welding speed as well as shoulder
mixing of Cu particles into Al matrix
www.weldfabtechtimes.com
Fig: 10 Welded coupons of second set of experiment; tool pin offset 2 mm, tilt angle 2˚ and welding speed 40 mm/min, rotational speed (AC3: 2000 rpm and 7: 1700 rpm).
Fig: 11 Average axial plunge load value for third set of experiment.
JUNE - JULY 2019 | WELDFAB TECH TIMES
19
ARTICLE
Fig: 12 Macro results of third set of experiment; welding speed 40 mm/min, tilt angle 2˚, tool pin offset 2 mm and rotational speeds (AC3: 2000 rpm and 7: 1700 rpm). welding because the tool was not able to Fig: 15 Tensile strength results for third set of experiment.
rotate with 1100 rpm. Variation of plunge load with different rotational speed is because of variation in heat input. As the rotational speed decreases the heat input also decreases and requires more force to stir at lower heat input. This is the reason for getting higher value of plunge load at 1300 rpm with compares to 1500 rpm. Macro structure results of third set of experiment shown in Fig:
Fig: 14 Microstructure results for welding speed 40 mm/min, tilt angle 2˚, tool pin offset 2 mm and rotational speed 2000 rpm (a: at Al-Cu interface, b: at weld metal-top, c: at Al-Al interface, d: at weld metalbottom).
12. It shows that as rotational speed
nugget zone whereas lower rotational
changes from higher to lower size of stir
speed results in narrower nugget zone
zone also changes from higher to lower.
because of weak stirring action. In
Larger nugget zone is reported with
addition to this, no defects were reported
rotational speed 1500 rpm and narrower
in macro structure result of third set of
reported with rotational speed 1300
experiment.
rpm. Higher rotational speed generates
Microstructure results for third set of
stronger stirring action which enlarges
experiment shown in Fig: 13 and Fig: 14. Four distinct microstructure zones were
20
WELDFAB TECH TIMES | JUNE - JULY 2019
Fig: 17 Fracture locations of tensile specimens for third set of experiment.
reported in aluminum-copper friction
finer whereas for lower rotational speed
stir welding like Stir zone, Thermo
stirring action is weaker and weld zone
mechanically affected zone (at Al-Al
grains are coarser. This is the reason that
interface and at Al-Cu interface) and
at rotational speed 1500 rpm weld zone’s
base material. The microstructure of
grains are finer than the rotational speed
copper and aluminum has an obvious
1300 rpm. In addition to this, higher
boundary and the metal in stir zone
rotational speed 1500 rpm results in high
shows obvious plastic combination
heat input generates more and more
between copper particles and aluminum
intermetallic compounds at weld zone.
matrix. Different copper particles
For lower rotational speed 1300 rpm
distributed randomly in aluminum
generation of intermetallic compounds
matrix such a way that it looks like
is less.
islands in different sizes. Differences Fig: 13 Microstructure results for welding speed 40 mm/min, tilt angle 2˚, tool pin offset 2 mm and rotational speed 1700 rpm; (a: at Al-Cu interface, b: at weld metal-top, c: at Al-Al interface, d: at weld metalbottom).
Fig: 16 % elongation results for third set of experiment.
Tensile strength and % elongation
in grain structure of stir zone or weld
results for third set of experiment shown
zone for different rotational speed is
in Fig: 15 and Fig: 16 respectively.
because of differences in stirring action
Increased tensile value 133 MPa reported
as well as differences in heat input. For
with rotational speed 1500 RPM compare
higher rotational speed stirring action is
to tensile value 124 MPa at rotational
stronger and makes weld zone grains are
speed 1300 RPM. As it is already
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ARTICLE
rpm. At rotation speed 1500 rpm, more heat is generated compare to 1300 rpm which also results in more formation of intermetallic compounds. It is obvious that the presence of more IMCs at the nugget gives high hardness value. 3.4 Fourth set of experiment Fourth set of experiment carried out under different tool tilt angles 0˚, 1˚, 2˚, 3˚ and 4˚ while other parameters kept constant as rotational speed 1300 rpm, Fig: 18 Macro-hardness results for third set of experiment.
welding speed 40 mm/min and tool pin offset 2 mm based on results of third
discussed that softening of aluminum
TMAZ of aluminum-copper interface. It
set of experiments. Visual examination
should be proper as it acts as matrix and
shows that aluminum-copper interface
was carried out from front side as well
scratched copper particles mixed with
is weaker microstructure zone out of
as from rear side of tested coupons of
that matrix. Larger stir zone also allows
all four microstructures. Most weak
fourth set of experiment as shown in
copper particles to flow free in aluminum
zone is TMAZ of aluminum-copper
Fig: 19. Surface morphologies of all the
matrix. At higher rotational speed 1500
interface because of brittle layer of
rpm nugget zone is larger as well as
IMCs generated at interfaces between
proper softening of aluminum achieved
aluminum and copper.
which is the reason for achieving
Hardness variation for third set of
high tensile strength value. Improper
experiment shown in Fig: 18. Hardness
mixing between copper particles and
value observed high at the nugget area
aluminum matrix forms large brittle
in both the samples because of presence
and hard intermetallic compounds in
of intermetallic compounds. On the
nugget zone as rotational speed low
other hand, the macro-hardness value
(1300 rpm) compares to1500 rpm. Large
at the nugget is increases as the rotation
brittle and hard IMCs cause defects in
speed increases from 1300 rpm to 1500
Fig: 20 Average axial plunge load value for fourth set of experiment.
nugget and reduces the tensile strength up to 124 MPa. Higher value of axial plunge load would also results in lower value of tensile strength. Fracture to elongation reported 4.4 % which is lower at rotational speed 1300 rpm whereas 11.5 % reported at rotational speed 1500 rpm. Lower elongation percentage is because of formation of large brittle non-uniform IMCs in nugget. Fracture location of tensile specimens for third set of experiment shown in Fig: 17. All the specimens were broken from thermo mechanically affected zone (TMAZ). Only one specimen was broken from TMAZ of aluminum-aluminum interface and others were broken from
22
WELDFAB TECH TIMES | JUNE - JULY 2019
Fig: 19 Welded coupons of fourth set of experiment; rotational speed 1700 rpm, tool pin offset 2 mm, welding speed 40 mm/min and tool tilt angles (G: 0˚, F: 1˚, A: 2˚, D: 3˚ & E:4˚).
www.weldfabtechtimes.com
ARTICLE
weld material better to fill the defects and consequently increases the weld strength as shown in Fig: 22. Fracture to elongation results for fourth set of experiment shown in Fig: 23. Higher tensile strength 116 MPa reported with 4˚ tilt angle and lower tensile 100 MPa value reported with 1˚ tilt angle. Fracture to elongation reported maximum 6 % for Fig: 21 Macro results of fourth set of experiment;rotational speed 1700 rpm, tool pin offset 2 mm, welding speed 40 mm/min and tool tilt angles (G: 0˚, F: 1˚, A: 2˚, D: 3˚ and E:4˚).
tilt angle 3˚ and 4 % reported for rest of others. Lower value of overall fracture to elongation again proves the presence of
coupons shows that as tool tilt angle
intermetallic compounds in the nugget
increases the flash out effect of materials
zone. Fracture location for tensile test
decreases. As tool tilt angle varies, the
for fourth set of experiment shown in
vertical and horizontal flow of material in
Fig: 24. Results of fracture locations were
stir zone also varies. Average axial plunge
consistent with third set of experiment
load value for fourth set of experiment
broken almost from TMAZ of copper-
shown in Fig: 20 in which increase in tilt
aluminum interface. It also proves the
angles also increases the plunge load
weakest location in copper-aluminum
value. Increases in forge load pushes material inside towards stir area and
Fig: 23 % elongation results for fourth set of experiment.
interface. Large amount of IMCs present at copper-aluminum interface makes it
reduces flash out effect. Macro results for fourth set of
dissimilar FSW joint is copper-aluminum
zone is also varying with variation in tool
weaker zone. As it discussed earlier that material
experiment shown in Fig: 21, in which
tilt angle. Base of triangle size increases
samples of 0˚ and 1˚ tilt angles having
as well as top cone size decreases with
flow varies with change in tilt angle
minor defects in nugget zone whereas
increases the value of tilt angle.
which also prove that intermetallic
samples of 2˚, 3˚ and 4˚were defect free.
The reason for this is different vertical
compounds also varies with different tilt
It shows that as tilt angle increases the
and horizontal material flow in weld
angles. Higher amount of IMCs produce
defects decreases because tilt angle 2˚
nugget with variation of tilt angles.
higher hardness at nugget. Hardness
or more than it provide enough forging
Increasing the tilt angle, improves the
variation for fourth set of experiment
force as well as uniform material flow
flow characteristics of the weld material
shown in Fig: 25.Increase in tilt angles
from top to bottom at nugget whereas
and hence, tool movement forges the
also increases the value of hardness at
low tilt angle provides low forging force as well as non-uniform vertical material flow from top to bottom nugget. Additionally, triangle shape of the stir
Fig: 22 Tensile strength results for fourth set of experiment.
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Fig: 24 Fracture locations of tensile specimens for fourth set of experiment.
JUNE - JULY 2019 | WELDFAB TECH TIMES
23
ARTICLE
50:1–78. 2. J. Ouyang, E. Yarrapareddy, R. Kovacevic. Microstructural evolution in the friction stir welded 6061aluminum alloy (T6-temper condition) to copper. Journal of materials processing technology 2006; 172:110-122. 3. A. Elrefaey, M. Takahashi, K. Lkeuchi. Preliminary investigation of friction stir welding aluminum/copper lap joints. Welding in the world, Issue 3-4 Fig: 25 Macro-hardness results for fourth set of experiment.
2005; 49: 93-101. 4. L. E. Murr, Ying Li, R. D. Flores,
nugget area. Maximum macro-hardness
speed: 40 mm/min, Tool tilt angle:
Elizabeth A. Trillo. Intercalation
186 VH is observed at nugget with tilt
2°-4° Tool pin offset: 2 mm, Axial
vortices and related microstructural
angle 4°. Minimum macro-hardness 58
plunge load range: 650-850 kgf
features in the friction stir welding of
VH is observed at nugget with tilt angle
3. Stir zone or nugget area size varies
dissimilar metals. Material Research
0°.It proves that increase in tilt angle
with different rotational speeds.
Innovations 1998; 2: 150-163.
also increases the IMCs at nugget zone.
Higher rotational speed produce
5. A. Abdolla-Zadeh, T. Saeid, B.
Additionally, all the specimens were
larger stir zone and lower rotational
Sazgari. Microstructural and
hardened from nugget area as same as
speed produce narrower stir zone.
mechanical properties of friction stir
reported with third set of experiment
4. Weakest zone of dissimilar Cu-Al FSW joint is thermo mechanically
Journal of alloy and compounds
brittle IMCs at nugget.
affected zone (TMAZ) as tensile
2008; 460: 535-538.
specimens almost fractured from
4. Conclusions The influence of tool pin profile and
TMAZ of copper-aluminum interface. 5. Micro-structure stir zone consists of
6. P. Xue, B.L. Xiao, D.R. Ni, Z.Y. Ma, 2010. Enhanced mechanical properties of friction stir welded
process parameters for dissimilar
composite structure with variously
dissimilar Al–Cu joint by
material (Copper to 6061-T651
sized particles dispersed in the
intermetallic compounds. Materials
aluminum matrix.
Science and Engineering 2010; A 527:
aluminum) friction stir welding was analysed successfully. The following conclusions can be made. 1. AA6061-T651 and electrolytic touch pitch copper were successfully welded by friction stir welding technology by cylindrical tool pin profile. On the other hand, taper
6. Increase in rotational speed and tilt angle increases the value of macrohardness. 7. Flash out effect of dissimilar
5723–5727. 7. T. Saeid, A. A. zadeh, B. Sazgari. Weldability and mechanical properties of dissimilar aluminum–
materials FSW reduced by increasing
copper lap joints made by friction
the tilt angle 2º to maximum 4°.
stir welding. Journal of Alloys and
8. Maximum macro-hardness 188 VHN
Compounds 2010; 490: 652–655.
tool pin profile was not suitable to
and lower fracture to elongation at
produce defect free Cu-Al dissimilar
the nugget area proves intermetallic
Sauvage, and G. Racineux. Interfacial
FSW joints.
compounds at the nugget zone of
reaction during Friction Stir Welding
dissimilar Cu-Al FSW joint.
of Al and Cu. Metallurgical and
2. Optimum process parameters based
8. C. Genevois, M. Girard, B. Huneau, X.
materials transactions 2011; 42A:
on maximum tensile strength (133
24
welded aluminum/copper lap joints.
which is because of presence of hard
MPa) for dissimilar AA6061-T651
References
to electrolytic tough pitch copper
1. R. S. Mishra, Z. Y. Ma. Friction stir
2290-2295. 9. I. Galvao, C. Oliveira, A. Loureiro
friction stir welding as below.
welding and processing. Material
and D. M. Rodrigues. Formation and
Rotational speed: 1500 rpm, Welding
science and engineering: R:Rep 2005;
distribution of brittle structures in
WELDFAB TECH TIMES | JUNE - JULY 2019
www.weldfabtechtimes.com
ARTICLE
friction stir welding of aluminum
interfacial intermetallic compounds
Z. Y. Ma. Effect of friction stir welding
and copper: influence of process
in a dissimilar Al 6082-T6/Cu friction
parameters on the microstructure
parameters 2011; 16: 681-689.
stir weld. Metallurgical and materials
and mechanical properties of the
transactions 2012; 43A; 4655-4666.
dissimilar Al-Cu joints. Materials
10. A. Esmaeilli, H. R. Zareie, M. Sharbati, M. K. Besharati, M. Shamanian.
science and engineering 2011; A528: 4683-4689.
Kokabi. Butt joining of Al-Cu bilayer
intermetallic compounds formation
sheet through friction stir welding.
and mechanical behaviour of friction
Transaction of nonferrous metals
aluminum-copper sheet material by
stir welded brass/aluminum 1050
society of china 2012; 22: 2925-2929.
friction stir welding and cold rolling.
couple. Intermetallics 2011; 19: 17111719. 11. J. Kandasamy, M. Manzoor Hussain,
14. M. Akbari, R. Abdi Behnagh. Dissimilar friction stir lap joining of 5083 aluminum alloy to CuZn34
17. S. Kahl, W. Osikowicz. Composite
Journal of materials engineering and performance 2013; 22: 2176-2184. 18. E. T. Akinlambi. Effect of shoulder
S. Rajesham. Hetrogeneous friction
brass. Metallurgical and materials
size on weld properties of dissimilar
stir welding: Improved properties
transactions 2012; 43B: 1177-1186.
metal friction stir welds. Journal
in dissimilar aluminum alloy joints
15. C. W. Tan, Z. G. Jiang, L. Q. Li, Y. B.
of materials engineering and performance 2012; 21:1514-1519.
through insertion of copper coupled
Chen, X. Y. Chen. Microstructureal
with external heating. Materials and
evolution and mechanical properties
manufacturing processes 2012; 27:
of dissimilar Al-Cu joints produced
Loureio, D. M. Rodrigues. Analysing
1429-1436.
by friction stir welding. Materials and
the challenge of aluminum to
design 2013; 51: 466-473.
copper FSW. 9th friction stir welding
12. M. N. Avettand-Fenoel, R. Taillard, G. Ji, D. Goran. Multiscale study of
26
13. R. Beygi, M. Kazeminezhad, A. H.
The role of rotational speed on
WELDFAB TECH TIMES | JUNE - JULY 2019
16. P. Xue, D. R. Ni, D. Wang, B. L. Xiao,
19. I. Galvao, D. Verdera, D. Gesto, A.
symposium 2012.
www.weldfabtechtimes.com
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PRODUCTS UPDATE
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JUNE - JULY 2019 | WELDFAB TECH TIMES
29
INDEPTH
Collaborative robots offer manufacturers a safer cutting edge Novarc, which has 16 full-time employees, brought its robots to the market in 2016. The firm is finishing its sixth and seventh units. The cost of a Novarc Spool Welding robot varies, but starts at about US$250,000. The company states that payback on that investment “is usually one to two years and could be as little as six months,” thanks to increased productivity and lower labour cost. The company’s first customer was Canmet Materials in Ontario, a research laboratory within Natural Resources Canada.
N
ovarc Technology’s next
400,000 welders by 2025 and that story
testimonial: “Novarc’s SWR (spool welding
generation of robots can take
reverberates everywhere across the globe.”
robot) system met all of our requirements,
workers out of harm’s way and
Novarc robots are not designed to
and their team was extremely helpful in
help to address a looming global shortage
replace workers. They work in pairs –
providing the support we required during
of experienced welders.
operator and robot – with the operator
the testing and evaluation period executed
setting and supervising the robot as it
through our Build in Canada Innovation
industry which is using technology to
tackles the manual weld part of the job. The
Program (BCIP). We also found Novarc’s
create “smart factories” fit for long-term
machines can be used in sectors including
collaborative robot to be extremely
global competitiveness.
the oil and gas, shipbuilding, chemical and
intuitive to operate and the entire project
nuclear industries.
was a great success.”
The series: We look at the manufacturing
Vancouver-based robot company Novarc Technologies Inc. is creating some heat
“With technology such as adaptive
Novarc has been shopping the robot
and light of its own in the pipe-welding
robots and collaborative robots, junior
around to trade shows in North America
industry. A looming global shortage of
welders can basically do as much as two
in the past year. “We launched in Chicago
experienced welders is a prime driver
to three highly skilled welders an hour.
and we’ve had very good traction in the
behind Novarc’s collaborative welding
The robot works as a productivity tool to
U.S. and with companies in the U.S.,”
robot, designed to semi-automate the pipe-
enhance the capabilities of existing welders
Mr. Karimzadeh said. The business has
welding process, company Chief Executive
and operators with very little training.
been slow to attract attention, however, in
Officer, Soroush Karimzadeh said.
That’s different than traditional robots
Alberta, a natural market for pipe-welding
where you replace workers.”
applications.
“Pipe welders have to go through more than 10 years of work experience and
Traditional autonomous robots, like
“We would want to help pipe
training to do this kind of job. With that
those used in the automotive industry
manufacturers [in Alberta] to become more
comes a cost. But the biggest problem
for years, are designed for “high-volume,
competitive. Alberta is a little bit behind the
we’re trying to solve is there’s not
low-mix” tasks, repeating the same task
ball on this, but this could change quickly,”
enough of these welders currently in the
over and over with no change. The new
Mr. Karimzadeh says.
marketplace,” Mr. Karimzadeh added.
generation of co-bots specialize in low-
“The American Welding Society projects that there is going to be a shortage of
30
Canmet provided Novarc with a
WELDFAB TECH TIMES | JUNE - JULY 2019
Investment in Novarc has come from
volume, high-mix work, where each task
Canadian government and private
may vary somewhat from the task before it.
sources, he says. “We’ve been fortunate
www.weldfabtechtimes.com
INDEPTH
the Canadian government has been
future welds,' Soroush Karimzadeh,
reasons and drivers behind the creation of
supporting our efforts in helping us
CEO of the Vancouver-based robot
the Advanced Manufacturing Supercluster.
develop this product through different
company, says.
We recognize as a whole we need to do a lot better job of embracing technology to be
programs and we appreciate that. … We’ve had angel investors and strategic investors
NOVARC
and the founders themselves have been
That said, Seaspan has no commitment to
able to fund the company to this point.”
more competitive.” Novarc’s spool welding robots are a
continue a commercial relationship with
niche application, he admits. But the
Novarc landed $1-million in seed
Novarc. “We’ve invested in them as part
coming shortage of skilled welders makes
funding from Seaspan shipyards with
of our investment to Canada without any
them a compelling technology. And Mr.
participation from BDC Capital in March
precondition of a downstream relationship,
MacFarlane says he isn’t concerned about
of 2017. Seaspan’s investment, in turn,
but that’s not to suggest we’re not
the potential of lost jobs in the trades.
hinges on its commitment to the federal
interested …” Mr. Page says.
government’s shipbuilding strategy.
The Seaspan Vancouver Dry Dock did
“When we look at case studies of companies that have implemented
use Seaspan robots in the installation of a
automation, the companies have almost
Government of Canada under the national
new ballast water treatment system on a
always grown in size. Jobs will change. The
shipbuilding strategy, we are intent on
cable-laying vessel in the spring.
types of jobs will change but the companies
“As part of our commitment to the
identifying partners that can help regrow
Jason MacFarlane, head of the advanced
themselves will become more efficient,
the industry here,” says Tim Page, vice-
manufacturing cluster at the MaRS
stronger and more competitive and
president of government relations for
Discovery District, a global innovation hub
typically they grow."
Seaspan.
in Toronto, says Novarc’s experience of a
The collaborative robot also takes
“Novarc is one of those parties that we
mix of government and private funding is
workers out of the way of harmful work
find has a very interesting technology that
fairly typical in advanced manufacturing
environments as well, he adds. The
we believe can be useful to our business
technology firms in Canada.
spool welding robot for instance, allows
downstream at a minimum, and more generally applied to the AI and robotics
Canada needs to adopt these types of technologies more quickly, he says.
the human operator to stay at a greater distance from the arc and heat of the weld.
“I would love to see our home-grown
“Removing humans from dangerous
that we thought worthy to invest in and
technologies adopted widely in Canada.
situations is probably a fantastic driver
we’re delighted to have done so.”
Hopefully it’s a matter of time til they
behind autonomous robotics. You see high
[Canadian pipe fabricators] see the
interest in it for it in the mining industry.”
community. They came to us with an idea
Novarc is now doing research and
Novarc is now doing research and
development on a machine learning and
payback & the real applications of using
intelligent robot project. 'Our vision is to
Novarc’s technology and they will adopt it,”
development on a machine learning and
launch a more autonomous version of the
Mr. MacFarlane says.
intelligent robot project.
robot that can basically use the learning it
“In general, Canada has been slow
“Our vision is to launch a more
has had in the past about what a good weld
to adopt advanced technologies in
autonomous version of the robot that can
and bad weld is and use that learning in
manufacturing. That’s one of the biggest
basically use the learning it has had in the past about what a good weld and bad weld is and use that learning in future welds,” Mr. Karimzadeh says. Novarc’s robots record each of their welds now, creating the data set needed for the next generation of robots. “With this information we can launch a product that’s going to be an updated version of the existing collaborative robot, but it’s going to be more autonomous. There will be less supervision required by the operators.”
www.weldfabtechtimes.com
JUNE - JULY 2019 | WELDFAB TECH TIMES
31
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INTERVIEW
“ARO 3G technology is more competitive than customers may perceive...”
Martin Smith, Vice President, JEC Distributors International Inc General Manager JEC Distributors Pvt Ltd
Q1. Could you brief us on JEC’s role into the welding segment?
welding solutions for customers to
products for High Strength Steel
improve quality, save time and money in
and Aluminium spot welding in the
JEC origins in Ontario, Canada started
production with highest quality, lowest
automotive sector.
as a distributor of welding technology.
cost ownership of resistance welding guns
The Owner and Founder, Mr. Joe
and related technology.
for reducing Carbon emissions, wherein
Ruggiero achieved success by obtain
lightweight and electric vehicles are
technologies that he was servicing to the
Q2. What type of welding equipment does JEC includes into its product range?
NAFTA Auto Industry. Joe has worked like
ARO Welding Technologies have an
high strength steels and aluminium
me in the industry for more than 25 years.
innovative system which is the ‘3G
combinations, and ARO is the market
Robotic Resistance Welding Gun’. This
leader in this field.
exclusive agreements and contracts that led to expansion and acquisition of the
Today, the main Technical Partners are
targeted to achieve. There are challenges in welding the
ARO Welding Technologies from France,
product is a very smart, modular and
where we provide complete service
maintenance friendly spot weld gun
support in North America and India and
which is a leading technology in its field
Q3. What new technological advancement have you introduced?
our own Copperhead range of welding
and JEC’s own brand “Copperhead”
JEC introduced to North America the
electrode tip management solutions such
Automated Electrode Tip Dressers and
MKW 308 Mechanical Cap Changer. It
as tip dressers and changers.
Changers. These technologies form the
has become the GM standard due to
kernel of the company’s synergistic
its reliability and efficiency. Its major
Service is the role we play, providing
34
This is a very important development, since the Indian Government demands
WELDFAB TECH TIMES | JUNE - JULY 2019
www.weldfabtechtimes.com
INTERVIEW
benefit is that it has no power. It uses the
and we are willing to demonstrate this in
of the welding caps means that operators
robot to achieve functionality and as the
the robotic welding segment.
no longer have to enter the robotic cell and walk around the robot, tooling and
Robot is already in the production line,
production line to access the weld gun
accuracy to achieve efficient time saving
Q5. Is the Indian market on par with the international markets?
operations, thus freeing trained electrical
Yes and no. It is on a par with the
integrated E4N system and water control
engineers to focus on other important
demands of the industry, but not in the
ensures minimum water escape, thus
maintenance operations.
breadth of variation demanded in other
minimising exposure to the operators
markets. It is changing, the dynamics
to the chemicals in the water that are
technology developed and manufactured
in India are astounding, innovative and
present and necessary in preventing water
in Germany for the global market. The
driven. Being involved in the market with
pollutants contaminating the cooling
accuracy of the blade production and
our presence here has taught us patience
system for the welding and production
adherence to strict tolerances provide a
and from that a success that many
zone.
repeatable long-life performance that is
colleagues and customers are willing to
creating a new benchmark in the industry.
participate with us in achieving, based
it is utilising existing technology and
Secondly, JEC has an advanced cutter
available from the Indian market. There is
Q7. What according to you is the current market scenario of welding industry in India?
a fantastic marketing video with a tag line
The market is very fluid and many and
‘Incredible India’ and it certainly is.
varied customers are using ARO product
on improved perceptions of the quality
Q4. What is your say on the rising competitions? How do you manage to cope up?
already and are interested in the newer
JEC has always been involved in robotic
Q6. What are JEC’s efforts towards health and safety?
technology that we are promoting. There
strength that is behind the company’s international expansion and technical
Our technology offering for spot welding
industry will demand higher quality
partnerships. We are present in Canada,
guns and electrode tip management
technology to match the expectations.
America, Mexico, India, China, South
products feature numerous design
Local manufacturers are working hard to
Africa and Europe.
elements that make handling,
match the requirements, but exposure
maintaining and using the technology
to the technological demands are a drain
industry game changer for robotic
safer and healthier. For example, the
on resources and increase costs to match
welding and is complimented with
Copperhead E4N Combined Automated
existing proven technologies already
the ARO iBox for resistance welding
Electrode Cap Changer and Tip Dresser
available in the market place.
procedures and permits an adaptive
is a system that collects 98% of the
operation and function to be achieved for
contaminated swarf and debris that
sector will occur. You only have to look
high quality consistent performance.
is machined from the spot face of the
at the forward plans for new production
welding cap and deposits it into a
facilities in Delhi, Gujarat, Pune and
collection chamber.
Chennai and you can see clearly that the
welding and it is this knowledge and
The ARO 3G Welding system is the
We know that here in India, as in other countries, there are many competitors from overseas, principally Japan, Korea
This is achieved by the unique design
is an awareness that the changes in the
It is clear that significant growth in the
investments strategies and infrastructure
and North America as well as from local
of our gearbox housing with a double
changes are being implemented to meet
manufacturers. However, the ARO system
blow off valve and high force venturi that
the demand.
by comparison may not be the lowest cost
creates a dynamic air flow to remove
to purchase, but it does have the lowest
the swarf or debris from the cutting
cost of ownership.
area into the collection system. This prevents debris from contaminating
Q8. Which countries according to you are leading in resistance welding?
at a premium price, when we can
the production zone. Thus, the amount
France, Germany and Japan are clearly
demonstrate the lowest cost of ownership,
of clean up is minimised and operator
leading the market. You only have to
performance and function. Shall we
exposure to the contaminated debris is
observe their overseas partner operations
just say that ARO 3G technology is more
minimised.
to understand the motivation to match
We make no excuse for selling quality
competitive than customers may perceive
36
to remove the electrodes. Thus, with the
WELDFAB TECH TIMES | JUNE - JULY 2019
Additionally, the automated exchange
market requirements.
www.weldfabtechtimes.com
INTERVIEW
Q9. What are the major challenges you witness? How do you aim to resolve the same?
satisfaction and fun.
transfer are the two important areas in
Q10. Apart from your Office and Warehouse in Chakan, Pune you have service teams in Chennai, Gujarat and Delhi, what is the initiative behind that?
India as I see requiring attention. We can
I can’t reiterate this enough. ‘Service’ Many
foundation of our company.
achieve resolution by good service and
years ago I was made aware that Nachi
provision of technical excellence in there
Robotics opened operations in the UK, but
Q11. Your expansion plans?
understanding of the technology available
the first thing they did was send a service
We have expectations and discussions
to help them meet the quality criteria that
engineer and that was before they had any
ongoing all the time, some are organic
is going to arise.
real UK exposure or sales personnel to visit
and self-generating and others are by
customers & expand their business. Whilst I
acquisition. But they all have to make
coupled to service and with a wealth of
had my own view on service and I believed
financial sense. I am blessed that the
experience in electrode tip management I
in it very strongly from my previous
company owners have foresight and I am
am transferring a lot of my knowledge to
experiences in a different industry, it is
aware of there ambition. My focus is India
the JEC Team on a global basis, not just
service that built my business success.
and here expansion will be organic and
in India, but of course the Team we have
Service = regular visits and contact
will be based on the Team of great local
Customer understanding and knowledge
Knowledge transfer is a key element
Pune, Chennai, Gujarat and Delhi are the epi centres of automotive growth and it is beholden upon JEC to be present to provide excellence in service, it is the
in India is extremely important to JEC
= reliability and trust = customer
people, all highly qualified and skilled that
Globally and to me personally.
appreciation and response = mutual
make the difference.
JEC DISTRIBUTORS Created January, 2000 JEC Distributors has
Copperhead brand of Cap Changers, Tip
GLOBAL
serviced the automotive manufacturing
Dressers, Sensors, Weld Gun Covers, and
Copperhead Industrial GmbH.
sector for 17 years, as a distributor of
Cutter Blades and Holders.
Munich, Germany
automation.JEC Distributors currently
Service
JEC Distributors India Pvt. Ltd.
offers its own line of products under the
JEC’s affiliated 50,000 sq. ft. service facility
Pune, India
Copperhead brand. The Copperhead
currently repairs all makes and models
lineup includes weld cap changers, tip
of mig welders, servo motors, robots,
JEC Distributors (China) Ltd.
dressers, a combination tip dresser/
teach pendants & also offers circuit board
Shanghai, China
changer unit, tip dresser cutter blades and
repair.
welding products, accessories, tools, and
PRODUCT LINE
holders, weld gun covers, and force gauges.
Sales
• CAP CHANGERS
electrical and technology solutions by
JEC staff act as technical advisors and
• TIP DRESSERS
Electricomm, tools by Moutz, lift assist and
sales agents to the Tier 1 automotive
• CUTTER BLADES & HOLDERS
rail systems by Packers Kromer, liquid and
manufacturers and the major automotive
• WATER SAVERS & RETRACT
gas control by Parker Hannifin, weld cap
manufacturers across North America.
As a distributor JEC also supplies
reconditioning by RECAP, flow valves by
ACTUATORS • WIRE WIZARD WELDING PRODUCTS
ROCON, Tessonics Resistance Spot Weld
JEC Advantage
• RESISTANCE SPOT WELD ANALYZER
Analyzers, & Watteredge power products.
JEC Distributors Inc. holds a unique
• R&D ERGO
competitive advantage of having 6 direct
• WORBO INC.
Products
OEM vendor codes with the major North
• MIG TRANSIT SPRAY
JEC’s main product line includes the
American automotive manufacturers.
• SIGMUND TCP SYSTEM
www.weldfabtechtimes.com
JUNE - JULY 2019 | WELDFAB TECH TIMES
37
LAUNCHES
Pandrol Connect Welding App
P
androl Connect is a mobile app designed to support aluminothermic welders through
the weld process, capture live data about the weld, save time and improve the traceability of welds for contractors and rail network operators. Pandrol Connect consists of three modules: a mobile version for welders to record on-site data and for welding controllers to review data, an online monitoring app to review weld information from the office, and an online administration tool to apply settings to local standards. All data is hosted in the cloud for easy sharing. Pandrol Connect can also be connected to preheating equipment to increase documentation.
Technical Features • Designed to record data before, during and after welding • All data from the app is stored in the
to preheating equipment to increase
Advantages
documentation
• Developed to overcome issues of weld
• QR codes to allow consumables to be scanned • Contains a welding instruction
traceability which can be a major challenge in terms of identifying defective welds and for gathering,
cloud for easy sharing, which means
manual, which is then available at the
trending and spotting anomalies in
information can be transmitted
contractor’s fingertips
data about weld performance
to contractors and the network automatically • Pandrol Connect can also be connected
• A reliable reporting function, which can be completed on location • Available for Android
• Enables cost optimisation and enhanced customer service across the supply chain • Provides a customisable cost-effective app with no capital outlay • Saves time for all users and drastically cuts down paperwork • Encourages efficiency and innovation through an incorporated news function
For More Info: Railtech Welding and Equipment India Pvt. Ltd, Plot Nos. 12-20, Urla Industrial Area, Sector A URLA, Raipur – 493221, Chhattisgarh, INDIA Tel: +91 771 4247700
38
WELDFAB TECH TIMES | JUNE - JULY 2019
www.weldfabtechtimes.com
WELDER’S PASSION
“We all have own ways to weld.” Q1. Tell us a little about yourself? I am 31 year old Russian born in Latvia. Moved to United Kingdom in the end of 2011.
Q2. What made you choose welding as a career? I didn't really picked up welding, welding picked up me. Life made me to do everything to keep food on the table and
Aleksandrs Jefimovics, A Multi-skilled Welder, Fabricator. Currently working for Parry Catering Equipment (Midlands) Ltd Evening's as a Delivery Driver for Pizza shop. Currently trying to sort out his own little company ( www.i-weld.co.uk )
bills paid. Started at some little company in Latvia as a labourer, doing anything
financial difficulties and I had to search for
I've been told to. At some point, a welder
next job.
wasn't able to do as much as needed and
When I was at school, I used to spend
he suffered from problems with alcohol. I
my summer holidays working as a polisher
just went for it, Just took a welding torch
at the shipyard, preparing and finishing
and started playing with different scrap
other welders welding. After finishing
metal off cuts. Management noticed that
school I went to that little business. So
I am doing good enough for jobs they
when they got struggling, I contacted
wanted to be done and I became a main
people from shipyard to see if they could
of them regarding welding. Only now I
welder at that company . Unfortunately
get some job for me, of course I said that I
understand that we all have own ways to
after a certain period, business got in
was a welder already, doing different odd
weld. So at some point, our department
jobs. When I got my welding test at the
was short on welders and manager did set
shipyard, I completely failed it. It was an
me to the ship wheelhouse welding deck
absolutely and completely different level of
from underneath, overhead but weld. That
welding. I been told by shop floor manager
was an nightmare and challenge.
"no worries Alex, we will teach you." My
After a very bad welding for
thoughts after failing was " what should I
approximately one meter, somehow it
do now, how do I survive with current rent
did work in my head how to do it and I
and bills".
managed to get very good welding results.
I've been doing welding on scrap off cuts for weeks to get good results. Whoever
Further, further and further... I joined best welding team at the shipyard.
tried to help me with advice, been telling vertical or overhead welding, no one will
Q3. What type of projects are your currently working upon?
let me doing these positions before me
Currently, I am working on mainly
getting perfect welding at the bottom
bespoke and custom design projects
positions.
for commercial catering equipment
me that I shouldn't be worried about
All the advice was different from all
40
WELDFAB TECH TIMES | JUNE - JULY 2019
manufacturer in UK . Of course with
www.weldfabtechtimes.com
WELDER’S PASSION
amount of my skills and experience I do a lot more, I had to learn to fix cars, machinery, get into a CAD and more ... I am a top welder with a full case of skills but unfortunately without paperwork and British qualifications... so I'm officially just a welder on the contract. After main work, I do pizza delivery for Domino's and at the weekends I do jobs on my own with own equipment, welding cars and other odd jobs whenever I get these jobs ...
Q4. Can you describe on some of the mega projects you worked upon in the past?
rough but it did teach me discipline
Mega project was to build a military ship
shop floor, when I disagree with some
at our shipyard which now patrolling
ideas, they get changed to suit me. When
Baltic seas. Made out of aluminum, shape
someone else disagrees with my opinion,
reminds catamaran. I have also built
my answer is, if we doing this your way,
walkway between two buildings and stairs,
you are responsible for this job then and I
all made by myself, design, preparation
am not touching it. If management wants
welding / fitting. The only day I had to hire
me to do the job, it's got to be done my
my mate, was to lift support posts for that
way, straight forward.
and respect. Now as a top man on the
walkway... (I have different pictures, they can also be found on my LinkedIn page)
Q5. What challenges did you come across when at work? How do you manage to cope up with the same?
Q7. Your say on Safety at Work. How do you consider the same when on site?
Q8. Right from the time you started your career till date, what has been your learning so far? Any new skills you have learned? I started as a joiner, when went into metal.
Currently I don't work on sites at the
Welding, fabrication, CAD, car mechanic /
company. So being inhouse, we all follow
welder, ventilation system, ductwork, I do
Well, working mainly on custom and
health and safety rules. It's very, very strict
everything myself at home. if I didn't have
bespoke design products I have almost
in UK. There is nothing to complain about,
spare money to pay someone else to do
every week some challenges. How do I
it's our life's.
something for me, I had to do it myself.
cope? I don't know, there is no way how to.
When I am working on my own, I don't
Now, I'm still doing everything myself
I'm just doing what I have to do to make
know how but, I just don't do anything
because no one else will do it better than
things look good.
silly. Again, it's a long way through the life
me. For example; recently I have been
that reached me to be careful...
quoted on 1300£ British pounds to replace
Q6. Can you tell us about a time when you disagreed with your senior’s decision made at work on Welding? Why? How did you manage to handle the same?
clutch and flywheel on my car, I did it
That is quite difficult question for me
myself and replace other things.
myself and it cost me 400 pounds plus. I did replaced couple other parts that needed to be done while car stood on stands without gearbox. I will inspect it
... majority of my life I was learning, in Latvia. I was working mainly with Russian
Closing message
people... even if they wouldn't be right, I
I wish every welder, less wind, less rain!
had no rights to disagree. It might sound
Clean steel and pay RISE!
www.weldfabtechtimes.com
JUNE - JULY 2019 | WELDFAB TECH TIMES
41
INNOVATIONS
Nanotechnology enables engineers to weld previously un-weldable aluminum alloy By UCLA Samueli Newsroom (www.samueli.ucla.edu)
Super-strong but lightweight, AA 7075 now could be more widely used in automobiles and other manufacturing thanks to UCLA research
A
n aluminum alloy developed
they’re measured in units equal to one
study, post-welding heat treatments,
in the 1940s has long held
billionth of a meter — into AA 7075
could further increase the strength of AA
promise for use in automobile
welding wires, which are used as the filler
7075 joints, up to 551 megapascals, which
manufacturing, except for one key
material between the pieces being joined.
is comparable to steel.
obstacle. Although it’s nearly as strong
A paper describing the advance was
as steel and just one-third the weight,
published in Nature Communications.
it is almost impossible to weld together
battery efficiency, so it’s already often
using the technique commonly used to
used to form airplane fuselages and
assemble body panels or engine parts.
wings, where the material is generally joined by bolts or rivets rather than
That’s because when the alloy is heated during welding, its molecular structure
welded. The alloy also has been used for
creates an uneven flow of its constituent
products that don’t require joining, such
elements — aluminum, zinc, magnesium
Using the new approach, the
and copper — which results in cracks
researchers produced welded joints with
along the weld.
a tensile strength up to 392 megapascals.
as smartphone frames and rock-climbing carabiners. But the alloy’s resistance to welding,
(By comparison, an aluminum alloy
specifically, to the type of welding used
School of Engineering have developed a
known as AA 6061 that is widely used
in automobile manufacturing, has
way to weld the alloy, known as AA 7075.
in aircraft and automobile parts, has a
prevented it from being widely adopted.
The solution: infusing titanium carbide
tensile strength of 186 megapascals in
nanoparticles — particles so small that
welded joints.) And according to the
Now, engineers at the UCLA Samueli
44
Because it’s strong but light, AA 7075 can help increase a vehicle’s fuel and
WELDFAB TECH TIMES | JUNE - JULY 2019
“The new technique is just a simple twist, but it could allow widespread use
www.weldfabtechtimes.com
Solid-state laser
TruDisk
TRUMPF INDIA Pvt. Ltd. · Raisoni Industrial Park, S.No. 276, Hissa No. 1 · Pune – 411 057 · India ∙ www.trumpf.com · Phone: +91 20 667-59800 · Marketing@in.trumpf.com ·
INNOVATIONS
have to incorporate this super-strong aluminum alloy into their manufacturing processes, and their products could be lighter and more energy efficient, while still retaining their strength.” The researchers already are working with a bicycle manufacturer on prototype bike frames that would use the alloy; and the new study suggests that nanoparticleinfused filler wires could also make it easier to join other hard-to-weld metals and metal alloys. The study’s lead author is UCLA graduate student Maximilian Sokoluk. The other authors are Chezheng Cao,
Graduate student Maximilian Sokoluk; laboratory mechanician Travis Widick, holding a demonstration bike frame welded using aluminum alloy 7075; & Professor Xiaochun Li.
in December, and Shuaihang Pan, a
of this high-strength aluminum alloy
Raytheon Professor of Manufacturing and
current UCLA graduate student. Li holds
in mass-produced products like cars or
the study’s principal investigator.
faculty appointments in mechanical and
bicycles, where parts are often assembled together,” said Xiaochun Li, UCLA’s
46
who earned a doctoral degree from UCLA
WELDFAB TECH TIMES | JUNE - JULY 2019
“Companies could use the same processes and equipment they already
aerospace engineering, and in materials science and engineering.
www.weldfabtechtimes.com
WOMEN IN WELDING
Barbie Parsons, Welder from Barbie The Welder, Metal sculpture design & creation
“I just get started doing what I know and figure out the surest as I go along.”
48
Q1. What made you choose welding as a career, which is a highly male dominated segment?
Q2. Could you brief us on your journey so far into welding?
for a six-month welding program at our
At the time of finding welding I was
I was hired at a local custom fabrication
Seeing the woman welding the giant angel
unhappily married to a man who
shop and worked in the sheet-metal
wing sculpture in the movie Castaway
wouldn’t support his family and we
department for five years. In the first
starring Tom Hanks spoke to my soul and
were living on the $10,000 a year. I was
four years, I worked there, I divorced my
I knew from that moment that I needed
able to earn hauling scrap metal and we
husband, fixed my credit, bought a house
to be a metal sculptor. It was only a 15
were living in the projects. Against my
for the garage, and then saved up for
second clip in the movie but it has shaped
husband’s wish I saved for nine months to
welders and equipment for the garage so I
the last 11.5 years of my life.
get the $1200 it would cost to go to school
could start welding art. Over the next year
WELDFAB TECH TIMES | JUNE - JULY 2019
local BOCES school. From that program
www.weldfabtechtimes.com
Tekno AD-2019-21-28.5.pdf
C
M
Y
CM
MY
CY
CMY
K
1
3/26/19
3:25 PM
WOMEN IN WELDING
I worked full time at the custom fab shop and part time at home making art after work and on the weekends. On September 1, 2014 I quit the job, as I loved very much to be a full time metal sculptor. As a full time artist, I have failed my way to success. Along the way I have made many business mistakes, had many hard lessons, and worked thousands of hours but going back to work for someone else was never an option for me. So as I was teaching myself how to create art, I also taught myself how to run a successful business with heart. To date, I have created sculptures for businesses and clients in 15 different countries, written three books that sell worldwide, and teach people to weld art through my YouTube Channel which is viewed by people in 53 countries, all from my one car garage.
Q3. Could you quickly take us to your qualification background?
Q4. How much of total experience do you hold?
anniversary, I presented Harley Davidson
I have 11.5 years of total welding
at home. I got to go back up on stage in
experience.
front of thousands of people to present
the second sculpture which I had made
the sculpture!
6 months welding education at BOCES in
Q5. Any welding processes you specialize into?
Q7. Your current project?
Elmira, NY 5 years working experience in
MIG and TIG Stainless, steel, and
I am currently creating a sculpture
the sheet metal fabrication department
aluminum
titled ‘Bridge To The Future’ for Weiler
of Cameron Manufacturing and Design I earned my Journeyman in Iron Plate and Sheet Metal
Abrasives. It is a three foot long futuristic
Q6. Could you please share your experience of some mega project you worked upon?
bridge with a man standing on one end
Last year, I was commissioned to create
add to the futuristic theme.
looking towards the other side. The bridge will be lit up with neon lights to
two sculptures for Harley Davidson, one
Davidson’s 115th anniversary. The HOG
Q8. When on site, what are the key points you follow during welding for any project? Any suggestions.
sculpture was my first masterpiece
Safety, vision, pride in craftsmanship,
sculpture that I created live. During
and joy are the four points that are very
Sturgis Motorcycle Rally in Sturgis South
important while I’m working. Safety
Dakota, I worked from 7:30 am to 9:00
while cutting, grinding, and welding.
pm for 7 days to create the sculpture and
Vision to create things that have never
then I presented it to Harley Davidson
been done before. Pride in craftsmanship
on stage during the Jackyl concert at
ensures that my clients get the best
Full Throttle Saloon, the worlds largest
possible sculpture I am capable of
biker bar, in front of thousands of
creating and allows me to feel great at
people! Three weeks later in Milwaukee
the end of each day. Joy knowing, I am
Wisconsin at Harley Davidson’s 115th
doing what truly feeds my heart and soul.
to celebrate HOG (Harley Owners Group) anniversary and one to celebrate Harley
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WELDFAB TECH TIMES | JUNE - JULY 2019
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WOMEN IN WELDING
Q9. Please share some of the interesting anecdotes during your career?
Q10. What is your say on health and safety in welding? How do you consider the same when on job?
During my second year, I was a full
I always think about my health and safety
time artist. I had been making several
while I’m working. If I was to hurt myself
sculptures out of horseshoes when a
I would not be able to weld anymore and
friend volunteered to take a couple
that is unacceptable to me!
pictures of them for me. One of the of not being seen for my skills. In
likes on Pinterest (how I’m not sure!)
Q11. What kind of challenges do you come across and how do you manage to cope up with the same?
A few weeks later I get an email from a
Each time I create a sculpture for a
I worked, treated me with respect as a
publisher asking me if I could write a
client it is a challenge because no two
valuable employee.
book about how to weld horseshoe art,
sculptures are alike and I’m self taught as
which I sincerely thought it was a joke! I
an artist. In art as well as any fabrication,
Q13. What are your future plans?
responded that I was capable of writing
there is a tremendous amount of
Today, I am in the process of writing
a book, still thinking it was a joke, but
problem solving involved. I just get
my fourth book. I am creating an online
they sent me a check and said write it! I
started doing what I know and figure out
school for artists, teaching them how to
didn’t know the first thing about writing
the surest as I go along.
be successful as business owners and
pictures taken was of a horseshoe wine rack that ended up getting over 12,000
welding, I have been very fortunate to not have faced any sexism. The company
thrive, and am pushing myself as an artist to create larger and more elaborate sculptures I love. I am in the process of creating my own product line and I am saving up to purchase land to build a larger shop.
Closing message, especially to the female. In the beginning when I decided to be a metal sculptor, I had no garage, no experience of welding, no art education, and no business experience. There was no evidence anywhere that said that this was a good idea and I’ll be successful, in fact all signs pointed to this is going to be a huge failure. It doesn’t matter what your background, education, or starting point is, you can do anything you decide to do. Find something you love and get laser focused on making it happen no matter what!! I’m stunned by the experiences and opportunities I’ve had because I chose
Horseshoe Crafts’ was published and
Q12. Have you anytime faced gender discrimination on site, as the stream is male dominated?
is available for purchase at Barnes and
I dealt with sexism in auto mechanics
living a life beyond my wildest dreams
Noble, Amazon, several online retailers,
(my chosen career out of high school)
and if I can do it with all those odds
and Tractor Supply!
and left after seven years of frustration
stacked against me anyone can!
a book so I had to Google it! In August 2017 my first book called ‘How To Weld
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WELDFAB TECH TIMES | JUNE - JULY 2019
to relentlessly pursue my crazy desire to become a metal sculptor! Today, I am
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