Australian Welding Q3 2015

AUSTRALIAN 1

WELDING Q3 | OCTOBER 2015 www.wtia.com.au

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AUSTRALIAN WELDING | OCTOBER 2015

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CONTENTS Q3 2015

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The Government’s Plan for Naval Shipbuilding.

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Steel Construction Boom in New Zealand.

P10 CONTENTS

Q3 2015 From the WTIA CEO

Why Digital Transformation is Critical to Mining.

P36 Subscription to the Australian Welding Journal is a WTIA member benefit included in annual membership fees. It is also available through the WTIA at a cost of AU$220 (or NZ$230) per annum within Australia, or $265 internationally.

All rights reserved. No part of this publication may be reproduced or copied in any form without the written permission of the WTIA. The WTIA and its agents are not responsible for statements or opinions expressed by contributors in this publication, which are not necessarily those of the WTIA. Publication of any advertisement does not constitute endorsement by the WTIA of any product, nor warrant its suitability.

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Inside the Industry Breaking News Letter to the Editor International News Company Profile Business Essentials

Training & Certification Health & Safety Issues in Steel Weldability WorldSkills Competition Flame Straightening Porosity in Aluminium Welds Project Spotlight

6 7 10 14 16 18 20 22 24 26 28 30

New Developments CSIRO Masterplan Naval Shipbuilding 3D Printed Spine Implant Mining Technology

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Inside the WTIA Q&A With a WTIA Member SMART Industry Groups WTIA Hotline Report For Your Diary AICIP Certifications

44 46 48 50 51

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AUSTRALIAN WELDING | OCTOBER 2015

From the

WTIA CEO Additive manufacturing has the potential to revolutionalise production of complicated, highly specialised parts. However, a number of barriers still surround this technology, from certification of parts produced using additive manufacturing, through to commercialisation of the technology itself. It is for this reason that the WTIA has established the Additive Manufacturing SMART Industry Group.

Additive manufacturing of metal parts is essentially a welding process and, as such, the WTIA is the most appropriate organisation to represent those businesses and individuals with an interest in growing additive manufacturing applications in Australia.

In additive manufacturing, material is added in successive layers to build up a part.

Computer controlled 3-D printers

and welders are used to fuse wire or powder feed using a plasma arc, electron beam, or laser.

High performance metal alloys such as titanium, cobalt and nickel, as well as stainless and carbon steels can all be used, enabling production of parts and devices that would otherwise be expensive and time-consuming to produce using traditional manufacturing techniques.

Geoff Crittenden, WTIA CEO.

Little to no modification is required to produce different designs, making limited or even one-off production runs viable.

Not only that, additive manufacturing uses less raw material and energy than traditional manufacturing methods because waste is minimal; production is achieved by building material up, rather than machining it down from

WTIA NATIONAL OFFICE

TECHNOLOGY MANAGER

TRAINING MANAGER

Unit 50, 8 Avenue of the Americas Newington, NSW 2127 (PO Box 6165 Silverwater, NSW 1811) T: +61 (0)2 8748 0100 E: info@wtia.com.au

Bruce Ham T: +61 (0)418 391 534 E: b.ham@wtia.com.au

Nic Bothma T: +61 (0)2 8748 0100 E: n.bothma@wtia.com.au

QUALIFICATION & CERTIFICATION MANAGER

MEMBERSHIP MANAGER

CHIEF EXECUTIVE OFFICER

Annette Dickerson T: +61 (0)2 8748 0121 E: a.dickerson@wtia.com.au

Geoff Crittenden T: +61 (0)2 8748 0100 E: g.crittenden@wtia.com.au

Donna South T: +61 (0)2 8748 0107 E: d.south@wtia.com.au

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FROM THE WTIA CEO

a larger size, which usually leaves behind waste and scrap materials.

The potential of additive manufacturing for both the production and repair of parts is enormous, particularly legacy parts where the cost of either manufacturing them from scratch or repairing any other way is prohibitive.

For complicated, highly specialised parts that need to be as light as possible (often requiring manufacture using titanium), additive manufacturing offers huge advantages, not least of which is cost-effective batch production.

Given these advantages, there are enormous opportunities for this technology across a wide array of industries, from defence, power generation and aerospace, right through to the automotive and biomedical industries.

being used by Boeing and the Department of Defence to produce aerospace parts. And, the American Welding Society is already in the process of developing a standard for this important new process.

At the 68th IIW Annual Assembly and International Conference in Finland earlier this year, an IIW Working Unit, dedicated to additive manufacturing, was established. Clearly, the importance of additive manufacturing to the welding industry is gaining momentum.

However, a number of barriers still exist. There are issues surrounding non-destructive testing and certification of parts created using additive manufacturing. And, most importantly, Australian industry needs to commercialise additive manufacturing technology, and broaden its practical applications.

the Additive Manufacturing SMART Industry Group, which is free to all members.

This Additive Manufacturing SMART Industry Group will: • Advocate for government and industry support • Facilitate the formation of consortia to commercially develop research • Advise on capital raising and access to equity • Provide the opportunity to promote technology to other industry groups and partner with them to identify applications • Act as a focal point for industry marketing and networking • Explore the opportunity for participation in a proposed Welding Technology Hub The WTIA is also establishing an additive manufacturing facility as part of our new welding technology plan for South Australia.

In America, additive manufacturing is already

To aid in the development and commercialisation of this vital technology, the WTIA has formed

ADVERTISING

EDITORIAL SUBMISSIONS

ABOUT THE WTIA

George Zervas T: +61 (0)2 8748 0110 E: g.zervas@wtia.com.au

The WTIA welcomes editorial submissions, technical papers and media releases.

EDITORIAL

All editorial submissions should be submitted electronically to sally@wordly.com.au, and must be accompanied by at least one high resolution JPEG image file at 300dpi.

A not-for-profit, membershipbased organisation, the Welding Technology Institute of Australia (WTIA) represents Australia’s welding profession. Our primary goal is to ensure that the Australian welding industry remains locally and globally competitive, now and into the future. WTIA is the Australian representative of the International Institute of Welding (IIW).

Sally Wood T: +61 (0)434 442 687 E: sally@wordly.com.au

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AUSTRALIAN WELDING | OCTOBER 2015

Inside the Industry:

Breaking News BOC and Viridian Extend Partnership BOC and Viridian Glass, a division of CSR Building Products, have extended their already long-term partnership, with the two companies recently signing a new 10-year supply agreement. The deal will see BOC supply the ongoing compressed air, hydrogen and nitrogen gas needs of Viridian’s Dandenong site, which is the only float glass manufacturing facility in Australia.

US Submarines Recalled With Welding Issues The United States’ three most modern nuclearpowered attack submarines (USS Minnesota, North Dakota and John Warner) were placed under ‘restricted operations’ as welding defects within vital pipes directing steam from the reactor to the turbines are examined. The 25cm pipes have weaknesses in elbows,which will now be carefully examined for quality control.

As part of the agreement, BOC’s nitrogen plant in Dandenong, which is connected to Viridian’s site through a pipeline, will receive a significant upgrade. Its capacity is expected to increase by as much as 20% to directly support Viridian’s growing production needs. BOC will also supply hydrogen from its Altona site, and air through an onsite compressor which is vital for the heating and cooling of glass production.

AWS Launches WeldLink: Career Management Platform The American Welding Society (AWS) has launched WeldLink, an innovative career management system, which will bring together individuals, businesses, and schools in the welding industry.

AWS WeldLink is designed to address the complete lifecycle of professional welder development. The system allows individuals to create an online profile to help them map their current skills and knowledge by tracking certifications, education, and work history. It then uses that information to match them with welding career paths, locate welding programs, and directly enroll in training programs through AWS’s online education program. Users can also view open positions in top companies with direct connections to apply.

For more information, visit www.awsweldlink.org

Welding Information Platform Launched Kemper GmbH, a manufacturer of extraction and filter systems for metal processing based in Vreden, Germany, has launched a new welding information platform. Targeted at welders and their employers, the website focuses on hazards that exist in welding and how to prevent them.

The portal offers an overview of current laws, case studies and effective extraction and filter technology from a practical business standpoint.

For more information, visit: www.safe-welding.com

INSIDE THE INDUSTRY: BREAKING NEWS

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NASA On Track to Send Astronauts to Mars NASA is another small step closer to sending astronauts on a journey to Mars. Recently, engineers at the agency’s Michoud Assembly Facility in New Orleans welded together the first two segments of the Orion crew module that will fly atop NASA’s Space Launch System (SLS) rocket on a mission beyond the far side of the moon.

The primary structure of Orion’s crew module is made of seven large aluminum pieces that must be welded together in detailed fashion. The first weld connects the tunnel to the forward bulkhead, which is at the top of the spacecraft and houses many of Orion’s critical systems, such as parachutes that deploy during reentry. Orion’s tunnel, with a docking hatch, will allow crews to move between the crew module and other spacecraft.

Image Caption: At NASA’s Michoud Assembly Facility in New Orleans, engineers recently welded together two sections of the Orion spacecraft’s primary structure that will fly on Exploration Mission-1, the first flight of Orion atop the agency’s Space Launch System rocket. Image credit: NASA.

Letter to the Editor Australian Welding welcomes editorial contributions from its readers, WTIA members, and Australia’s broader welding and fabrication, and industrial and manufacturing communities.

Readers are encouraged to express their viewpoints on any issues related to welding and fabrication, and respond to specific, timely news and events or articles that have recently appeared in Australian Welding.

Letters to the Editor should be quite short (approximately 300 to 400 words), and are subject to review and editing by Australian Welding’s editorial team.

Submit Your Letter to the Editor Please submit your letters to sally@wordly.com.au.

Disclaimer: The views, opinions, positions, and strategies expressed by the authors and those providing comments are theirs alone, and do not necessarily reflect the views, opinions, positions, or strategies of the Welding Technology Institute of Australia (WTIA), its employees, and its members.

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AUSTRALIAN WELDING | OCTOBER 2015

Inside the Industry:

Breaking News Fronius Improves Mobile TIG Welding Fronius has expanded its range of battery-operated welding solutions to include a variant for TIG welding. Weighing 10.9kg, the AccuPocket 150/400 TIG offers powerful functions such as a two and four-step switchover to facilitate the welding of thin sheets.

The TIG pulse function of the new AccuPocket is of central importance to TIG welders, as this ensures reduced heat input, improved gapbridging ability and a better weld seam appearance. This can also be used to achieve a weave pattern in the weld seam typical of TIG welding, in which the two components are to be joined without the use of filler metal (autogenous). With the TAC function, welders can quickly and safely join the base material at the start of welding, as well as during setting out and tacking. For details, visit: www.fronius.com Lincoln Electric Acquires Specialised Welding Products (SWP) Lincoln Electric Holdings has announced its acquisition of Specialised Welding Products (SWP), a privately held provider of specialty welding consumables in Australia and New Zealand. SWP’s leading team of technical representatives and metallurgists provides fabrication, maintenance and repair services for alloy and wear resistant products used in the mining and energy sectors.

SWP is headquartered in Melbourne, Australia and will continue to operate independently as an entity of Lincoln Electric Australia. SWP will broaden Lincoln Electric’s presence and specialty alloy offering across the Asia Pacific region. The terms of the transaction were not publicly disclosed.

CSIRO developed Keyhole-TIG Customer Documented savings of in excess of 90% Single pass in 13mm Stainless Steel

For more information

02 8708 0200

• • • •

Single Pass up to 16mm thick No V-Prep Minimal Consumables For more materials – Titanium, Inconel, Stainless Steels, Duplex, Hastelloys, Nickel Alloys, Super Alloys, and others

www.InnovativeWelding.com.au

INSIDE THE INDUSTRY: BREAKING NEWS

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BOC Launches Scan-to-Order Mobile App

New Instrument Breaks Welding Boundaries

Gases and engineering company BOC has unveiled its innovative new BOC Scan to Order Mobile App for iOS and Android that will allow customers to order their gas cylinders, equipment and safety products more quickly by scanning the product bar-code using a mobile phone.

A Weld Purge Monitor® Gas Detection and Analysing Instrument has been developed that reads from atmospheric level of oxygen down to one part per million (ppm), breaking all technological boundaries in one instrument.

Daniel Whittle, BOC eChannel Manager said the App integrates BOC’s extensive cylinder and product bar-coding system, and offers a unique all-in-one mobile solution for busy customers working in fast-paced industries including welding, manufacturing and construction. The App can even be used to browse pricing and order from the entire BOC product range.

The BOC Scan-to-Order App is free to download from the iTunes App store or Google Play store.

The PurgEye® 600 from Huntingdon Fusion Techniques has a full range of measurement reading from atmospheric concentration (20.94%), down to 1 ppm, accurate to 10 ppm.

The instrument provides an on-screen graph of the oxygen levels throughout the entire welding process. An internal electromechanical pump draws samples of purge gas automatically over the sensor before discharging it to the atmosphere. The lifetime sensor eliminates annual cell changing.

For information, visit: www.huntingdonfusion.com

WIA Launches Portable Inverter Welders WIA has launched a new range of portable inverter welders, including the Weldarc 180i Arc and TIG welder, and the Weldmatic 200i MIG welder.

Weighing just 6.5kg, the compact Weldarc 180i offers portability and performance required for onsite and field maintenance applications. It suits long extension leads and will keep welding successfully despite a voltage drop.

WIA’s new portable inverter welders.

The Weldmatic 200i is a versatile and portable multi-process inverter with VRD. With 200 Amps of MIG, 170 Amps of Stick and 200 Amps of Lift-Arc capability, the Weldmatic 200i suits a wide range of applications for successfully welding mild steel or aluminium to a very high professional quality.

Both machines are fully compliant with Australian Standards and come with a 2-year unlimited warranty on the power source.

For information, visit: www.welding.com.au

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AUSTRALIAN WELDING | OCTOBER 2015

International News:

Steel Construction Boom in New Zealand

By Alistair Fussell, Manager, Steel Construction New Zealand.

In New Zealand, steel is currently enjoying strong demand in construction. Investment in innovative production methods and a modelling tool to match capacity and demand are backing this growth.

Steel design on the Manukau Institute of Technology building in Auckland.

INSIDE THE INDUSTRY: INTERNATIONAL NEWS

Led by the rebuild of Christchurch and a fast-growing Auckland, New Zealand’s construction industry is experiencing its busiest period in over 40 years. In response, industry must meet the demand for quality, capacity and innovative construction solutions.

Canterbury Demand High In the past two decades, demand for steel construction solutions has grown substantially. Today, structural steel’s market share is more than 50% nationwide, and in Christchurch, due to its seismic performance, its share of the multi-level construction market has grown to almost 80%. This is up from virtually nil before the Canterbury earthquakes.

Driving this growth has been the industry’s focus on innovation, particularly in steel fabrication.

Investment in High-Tech Fabrication The current appetite for prefabricated structural steel is similar to the 2007 peak. Since then, New Zealand structural steel fabricators have kept pace and invested substantially in high-tech fabrication technology.

BIM Use Spreading There have been significant advances in machinery design,

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robotics, data management and 3D scanning. These have been driven by the challenge to build projects faster and cheaper using technologies like building information modelling (BIM) and tablets.

While structural steel detailers have been using BIM technology for 15 years, it is unfamiliar to the balance of the industry, which is now getting up to speed. This is revolutionising the way buildings and infrastructure are planned, designed, built and managed.

Steel fabrication management software StruMIS harnesses BIM-related project information to manage the massive amounts of data required to cut, drill and build steelwork, and its uptake in New Zealand workshops is increasing.

Integrated with the latest computer numerical controlled (CNC) machines, it provides costand time-saving efficiencies, project status, budget transparency and increased productivity.

For example, where 2D drawings are required for each section of steel, the entire model can be exported to the CNC machine, sidestepping the shop drawing stage. This reduces human intervention and errors.

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3D Laser Scanning Improves Precision 3D laser scanning is another exciting development. It digitally captures the dimensions and spatial relationship of objects using laser light. The scanner outputs a point cloud image, replicating the scanned objects.

Driven by the need for precision, steel fabricators are embracing 3D scanning. It allows them to easily determine the accuracy of on-site construction. For example, 3D scanning can identify the precise position of cast-in bolts fitted on site by the builder. The fabricator can then

compensate for any variation before the steelwork leaves the workshop.

Automated Welding Increasing Quality Automated welding is also having a significant impact in local workshops. Semiautomated processes such as submerged arc welding have increased quality, consistency and productivity compared with other welding techniques.

Analysis of Statistics New Zealand data shows there is a clear swing from manual welding to automated alternatives.

Steelwork on the new Forte Health building, in Christchurch.

The New Zealand Steel Industry At A Glance • • • •

•

Industry capacity is circa 100,000 tonnes of structural steel per annum.

80 structural steel fabricators nationwide.

Six new state-of-the-art workshops built across the country since 2007.

One independent, expert quality assurance scheme launched in 2014 – Steel Fabricator Certification.

Structural steel framing has over 50% market share of the national multi-level construction market and 80% in Christchurch.

These advances in fabrication technology are substantially improving the local industry’s competitiveness.

New Model Forecasts Demand The steel construction industry is developing a capacity model to forecast demand. Using fact-based labour resource data combined with construction intelligence sourced from the Ministry of Business, Innovation and Employment, engineers, builders and developers, the industry is building a project database.

INSIDE THE INDUSTRY: INTERNATIONAL NEWS

This will allow the structural steel industry to anticipate demand and make informed decisions about future investment in training, plant and equipment, recruitment and collaboration.

Industry Collaboration Locally and Trans-Tasman Collaboration, too, is playing a growing role in the successful delivery of structural steel projects. For example, steelwork for the Forsyth Barr Stadium was fabricated in Auckland and Christchurch and transported and erected on site in Dunedin.

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The industry is also exploring how it can collaborate with Australian operators, particularly when looking to resource the sizable Auckland projects in the pipeline.

Clients will benefit from having a local fabricator on the ground to oversee the project while tapping in to additional capacity across the ditch, when necessary, to ensure an uninterrupted supply.

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Certification Tackles Compliance Issues The recent boom in construction has seen more imported steelwork entering New Zealand, increasing the risk of noncompliance. There have been cases of missing paperwork or steelwork that doesn’t meet the specification, leading to costly project delays.

Steel Fabricator Certification (SFC) is an industry-led quality assurance scheme to address this compliance issue. Launched last year, SFC ensures participating fabricators manufacture product to the specified quality standard and have appropriate personnel and quality management systems in place.

As with other construction materials, the current compliance regime for structural steelwork relies largely on self-inspection and self-certification. Based on international best practice, SFC raises the bar by providing independent, expert certification of New Zealand fabrication companies.

Importantly, SFC creates a point of difference for locally fabricated steel. This provides procurers and specifiers – such as engineers, architects and contractors – with certainty of product quality and significantly reduced compliance risk. © BRANZ. Reproduced with permission from Build 149, AugustSeptember 2015.

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Company Profile:

LaserBond A long-established, innovative company with operations in both Sydney and Adelaide, LaserBond has developed and implemented advanced surface engineering techniques that dramatically reduce the maintenance and operating costs of industrial sector clients.

LaserBond specialises in the manufacture and reclamation of components and assemblies for a broad range of capital intensive industries, often for critical applications, which require optimised surface properties.

LaserBond commenced trading as HVOF Australia in 1992, which coincided with the development in thermal spraying known as High Pressure High Velocity Oxy Fuel (HP HVOF).

By initially concentrating on this new application and then supporting their development with an extensive in-house metallographic laboratory, LaserBond quickly established itself as a technical leader in Australia’s thermal spraying industry.

In 2001, after significant research, LaserBond commissioned its first laser cladding system in order to further broaden its capabilities, and to provide its customers with access to coatings and overlays with a full metallurgical bond.

This technology permits the deposition of precision layers of material, with minimal heat input, and no unfavorable metallurgical side effects.

Above: Arc Wire and Combustion Metal Spraying.

Below: Restoration of Gear Castings.

Further Information T: 1300 527 372 E: info@laserbond.com.au W: www.laserbond.com.au The LaserBond Process The LaserBond process produces deposits with a full metallurgical bond, utilising a precisely focused laser beam, which provides infinite control of the energy and heat transfer to the base material.

Temperature sensitive components and materials, such as hardened shafts and gears, can be repaired with minimal risk of distortion or other undesirable heat effects.

The metallurgical bond allows applied layers to be used in high impact, heavily loaded situations with no risk of spalling or separation of the overlay. The infinite controllability of the laser energy allows minimisation of undesirable thermal decomposition of hard phases such as carbides, resulting in optimum wear resistance. Due to the extremely low dilution with the substrate, thin layers of high performance corrosion and wear resistant materials can be applied. High performance layers from 0.3mm are possible. Thick overlays for significant repairs of up to 20mm can also be applied in multiple passes.

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INSIDE THE INDUSTRY

New Release

Portable Welding Solutions

welding.com.au

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AUSTRALIAN WELDING | OCTOBER 2015

Business Essentials:

How to Enhance Workplace Productivity The need to ensure and enhance employee productivity is a reality that no business can ignore these days. If you run your own business, you’ll know that it’s almost inevitable you’ll encounter issues that, from time-to-time, weaken or even completely extinguish employee motivation, dampening overall productivity. Obviously, you need to mitigate these productivity-killers. The first step is identifying these issues, so you can prevent them from emerging, or eradicate them if they’ve already crept into your day-to-day operations.

Strengthen Your Leadership When it comes to strengthening productivity, begin with your leadership team. Effective leadership requires a clear vision of

where your business is heading. It’s about identifying new opportunities, inspiring your team to pursue those opportunities, and giving your team the chance to identify and implement their own ideas.

Eradicate Productivity Killers Identify any productivity killers that already exist within your workplace. Closely observe your workshop or building site, and pinpoint any issues that seem to be dampening employee morale. It might be a lack of communication, a particularly aggressive team member, a lack of learning and development opportunities, or something as simple as a shortage of supplies.

Once you’ve identified the issues, eradicate them one-by-one.

Foster A Positive Culture

Positive relationships between employees, teams and managers are a defining feature of productive workplaces.

Positive relationships between employees, teams and managers are often a defining feature of productive workplaces. A positive working environment motivates people and helps them feel like a valued member of the organisation. Employees are more likely to feel encouraged to ‘go the extra mile’.

INSIDE THE INDUSTRY: BUSINESS ESSENTIALS

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Value Employee Ideas

Set Clear Standards

Invest in Your Employees

As a manager or a business owner, it’s important that you value your employee’s insights, experience and knowledge.

Ideas from employees who are carrying out the same tasks day-in and day-out can improve your processes and procedures, making your business more innovative, cost-effective, and productive.

Ensure that all employees are familiar with what the company expects from them. They should be 100% clear on assigned tasks and their overall role. Clearly define expectations, and employee tasks and responsibilities.

The more skills your employees have, the more productively they can work. More highly skilled workers make less mistakes, require less supervision, and are more likely to adapt to new technologies. So, invest in your employees skills training and development.

Encourage Innovation Innovation is key to improving workplace productivity.

Productive workplaces are innovative in the way they use technology, and plan and organise themselves. They usually employ more highly-skilled and highly-paid workers and through innovation they are able to increase their market share.

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Without clear expectations, people find excuses when they fail to achieve targets.

Get Organised Productive workplaces have processes, procedures and a structure that enables growth (rather than contraction) as technology, clients and markets change. A well-organised workplace is more likely get the best out of its employees.

Communicate Clear lines of communication should be available at all times throughout your workplace.

Employees should know who to approach if they need help, or have an idea to improve productivity.

Company goals should be clearly and regularly articulated.

Ensure all employees have the information they need to operate as productively as possible.

Maximise Your Earning Potential.

Did you know? You may be eligible for internationally recognised qualifications without any further training or exams, particularly if you gained any of the following: Prior to January 2007 > WTIA Welding Inspector

Prior to July 2005 > Any AS 1796 Certs 1-9

Prior to July 2003 > AS1796 Cert 10 > AS2214 Welding Supervisor

> WTIA Welding Supervisor

Give Your Company the Edge.

Stand out from the crowd. Companies certified to ISO 3834 enjoy increased credibility in today’s global market. Certification improves customer satisfaction, and gives your business an edge.

Get certified by the WTIA. Show the world: You’re a cut above the rest.

Want to know more? Phone +61 (0)2 8748 0121. Email: a.dickerson@wtia.com.au Welding Technology Institute of Australia

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AUSTRALIAN WELDING | OCTOBER 2015

Training & Certification:

Training in an Economic Downturn In the wake of the recent global economic downturn, businesses and government bodies have come under sustained pressure to cut costs in order to survive, with implications for investment in training.

Many individuals face similar pressures to cut back on nonessentials – like self-funded education and training – while others look to training to help them in an increasingly competitive labour market.

According to Peter Wilson, Chairman of the Australian Human Resources Institute, “Most organisations survive tough times by the skill and work of their people, so investing in them with appropriate training is the right approach. During the GFC, smart companies didn’t slash training on a knee jerk basis, but they did change its nature, such as from strategic courses to things like selling in tough times, and sensible and lean approaches to cost management,” said Wilson.

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When tough times are over, firms with the well trained staff that they have bent over backwards to save during a recession, are usually the first to accelerate out of the downturn.

“Such companies also often secure greater market share from competitors who have been tempted by earlier slash and burn survival techniques, only to find they don’t have any one to do the work after the recovery starts,” said Wilson.

Why Invest in Training During an Economic Downturn?

Reduce costs: training employees so they understand how to deliver high quality welds, welded products and services, lowers overall costs and improves the experience you deliver to your customers, thereby generating revenue.

Increase employee satisfaction: employee satisfaction levels are closely linked to customer satisfaction, as well as overall sales and profit. An Investment in your employees is an investment in the success of your business.

Demonstrate your commitment to developing and improving your staff, and you’ll be rewarded with employee loyalty.

Improve competitiveness: during global downturns, competition for customers becomes increasingly fierce, leading to a need for greater quality products and services and ability to engage customers. This can often be achieved through company-specific training and development programs.

Maintain compliance: regardless of the economic climate, there is a requirement for a minimum amount of training, due to industry-specific regulations. For instance, if you wish to maintain certification to WTIA Welding Coordinator, Supervisor, or Inspector levels, training may be a non-negotiable.

INSIDE THE INDUSTRY: TRAINING & CERTIFICATION

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During an economic downturn, you tend to find training at the top of the list for budget cuts. For many companies, it is an easy decision to make—they decide to deliver training only when it is essential, such as for induction purposes. But, what is the impact on cutting training budgets, particularly once the economy starts to gain momentum once more?

Keep up with welding industry transformations: the effects of changes in public investment and consumer demand during an economic downturn often force companies to diversify in order to survive, venturing into new markets, new production methods and processes. These changes usually require either recruitment or retraining.

For instance, during (and immediately following) the recession of the early 1990s, recovery in many countries was led by a shift from natural resources manufacturing to high tech manufacturing, particularly in Finland, Sweden, and Japan. This shift required huge training programs designed to retrain workers so that they could use and understand new technologies.

Be ready for the upturn: whilst the current economic climate is tough, it will come to an end.

When it does, the most successful companies will be those ready to take advantage of the upturn, with highly skilled and trained employees.

Sources: Shamash, J. and Sims, C. (2011), Training in Economic Downturns, London: City & Guilds Centre for Skills Development.

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AUSTRALIAN WELDING | OCTOBER 2015

Health & Safety:

Company Officer Liability In nearly all Australian jurisdictions, there is a positive obligation on company officers to exercise due diligence in relation to health and safety. Officers can be personally liable for breaches of this duty, with the penalties including imprisonment and substantial fines.

Rebecca Davies, an Australian Institute of Company Directors course facilitator and a former lawyer, outlines key considerations for company officers when it comes to health and safety.

Recent changes to Workplace Health and Safety (WHS) laws everywhere but Victoria have renewed the focus on the responsibilities that directors and senior managers have for WHS issues. And, in Victoria too, these remain an important area for focus.

Some key things to be aware of: • The duties relate to workplaces, so once there is a workplace, a director or senior manager has responsibilities to those who work there, including employees, subcontractors, volunteers, and even visitors.

• The duty is to eliminate risk to health and safety so far as is reasonably practical.

• Directors and senior managers have a positive obligation to be aware of the health and safety risks in their workplaces, and to consider how to best eliminate them or reduce their impact.

• Penalties for breach of WHS legislation can be substantial, with maximum fines of $600,000 for individuals and / or 5 years imprisonment.

To best protect the health and safety of your workplace, and to give you a ‘due diligence’ defence

Company officers can be personally liable for workplace health and safety breaches.

if faced with prosecution, ask yourself: • Do you provide regular updates to directors and senior managers on the risks of the workplace? What is going on in the industry generally?

What problems have others experienced and how do you know it isn’t happening in our own company?

• Do you have WHS policies in place? Are they up to date and well understood?

• Do you understand the people for whom you have responsibility? Are you managing WHS risks for them? For instance, do

•

•

you issue directions in the languages understood by your workforce? Do you know what WHS policies your subcontractors have?

Are you investing appropriately in equipment and training to reduce or eliminate risks?

Are you tying pay to safety performance?

Are you monitoring whether the policies you have in place are actually working?

Are you receiving reports on safety incidents, workers compensation claims, return to work, and lost time? Are you monitoring the trends and taking action if needed?

INSIDE THE INDUSTRY: HEALTH & SAFETY

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At A Glance: The Workplace Health and Safety Act According to the Work Health and Safety (WHS) Act, any company officer, whether volunteer or paid, must exercise due diligence to ensure that the organisation complies with its health and safety duties. This means that company officers must ensure that their organisation has appropriate systems of work in place and they must actively monitor and evaluate health and safety management within the organisation.

Exercising due diligence requires company officers take reasonable steps to: • Continuously learn about and keep up to date with work health and safety matters.

• Have an understanding of the nature of the work the organisation does and stay aware of the risks workers and volunteers may face when working for the organisation.

• Ensure and verify that the organisation has available for use, and uses, appropriate resources and processes to eliminate or minimise risks to health and safety.

• Ensure and verify the organisation has processes in place for communicating and considering information regarding health and safety, and responding to that information.

• Ensure and verify the organisation has, and implements, processes for complying with any duties and requirements under workplace health and safety law.

Who is an ‘Officer’?

Under the WHS Act, an officer includes: • A director or secretary of a company • A person: who makes, or participates in making decisions that affect a substantial part of the business; who has the capacity to significantly affect the company’s financial standing; or who gives advice to company directors.

• A receiver or manager of the company’s property.

• An administrator or liquidator of the company.

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AUSTRALIAN WELDING | OCTOBER 2015

Issues in Steel Weldability:

Boron Content

Over the last year, it has become increasingly clear that low and medium strength structural steels containing undisclosed amounts of boron are being imported into Australia. Boron is a powerful hardenability agent, which may have a powerful adverse effect on the weldability of steels. The failure to disclose the boron content in structural steels can cause a myriad of issues when it comes to the welding process.

Boron is an element traditionally used to achieve high hardenability in alloyed steels for subsequent heat-treatment.

Notably, only a very small level of boron in steel is needed to substantially increase the hardenability of steel.

In Australia, the addition of boron has primarily been used for quenched and tempered steel

grades used for high strength and abrasion or wear resistant applications. It is also used in specialty high formability steels to assist with forming and deep drawing properties, however, these steels are typically not welded and are not used in structural applications. In structural steels, boron does not provide any benefits to these steel types, while it is significantly

Join the WTIA

deleterious to their weldability, through increasing the hardness of the weld heat affected zone.

Recently, boron has been found in some imported structural steels in elevated amounts.

It is important to note that steels containing boron can be welded, provided that the fabricator is aware of the presence of boron

Welding Technology Institute of Australia

Help secure the future of Australia’s welding and fabrication industry: become a WTIA member today.

The WTIA is dedicated to providing members with a competitive advantage through access to industry, research, education, government, and the wider welding community. Our primary goal is to ensure that the Australian welding industry remains both locally and globally competitive, now and into the future.

www.wtia.com.au

INSIDE THE INDUSTRY: ISSUES IN STEEL WELDABILITY

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Boron is added to unalloyed and low alloyed steels to enhance the hardness level through enhancement hardenability. Boron added to high-speed-cut steels, for example, containing 18%W, 4%Cr and 1%V, enhances their cutting performance, but reduces their forging qualities.

and can modify their weld procedure accordingly.

For example, quenched and tempered steel (containing boron) manufactured to AS 3597, can be safely welded when welded in compliance with AS/NZS 1554 Part 4, while for boron-free structural steels AS/NZS 1554 Part 1 is applicable.

In the situation where steels contain boron, even at very low levels, the boron is known to suppress the formation of normal micro-structural products encountered in the weld heat affect zone of structural steels, such as soft and ductile ferrite, and promote the formation of hard and brittle martensite and bainite. This significantly increases the hardness of the weld heat affected zone.

These hard brittle microstructures in the weld heat affected zone are susceptible to hydrogen induced cold cracking when welding consumables containing

higher levels of hydrogen are used to weld these steels, without modification of the weld procedure to slow the cooling rate.

Slowing the cooling rate promotes the formation of more ductile microstructures and allows the diffusion of any excess hydrogen.

Boron additions can cause serious weld cracking, unless necessary adjustments to welding procedures are made.

The WTIA recommends that fabricators who are using, or who have been supplied with, steel where the boron content is undisclosed seek guidance from their supplier on the recommended welding procedure requirements for these steels.

All purchase documentation given to steel suppliers should specifically require that the boron content be disclosed and limited to not more than 0.0008 wt% (8ppm) boron. This is consistent with ISO, European and North American industry best-practice

for weldable structural steels.

Fabricators should be aware that the preheat calculation methods used in the AS/NZS 1554 standard series were originally developed by the Australian Welding Research Association (AWRA). The method was first published by the AWRA in their Technical Note 1 in 1972 and later incorporated into AS/NZS 1554 Part 1 in 1980. This Technical Note 1 (now published by the WTIA) was originally developed in the 1960s and 1970s utilising boron free steels.

The rules for the welding and weldability of structural steels currently used in Australia therefore do not consider the presence of boron.

As a consequence, fabricators required to weld structural steels that contain boron should seek specialist advice from the manufacturer or supplier. If you are in any doubt, contact the WTIA Hotline on 1800 620 820.

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AUSTRALIAN WELDING | OCTOBER 2015

2015 WorldSkills Competition

Welding Final in Brazil Twenty year-old welder, Kallon McVicar recently joined Australia’s best apprentices, trainees and students in São Paulo, Brazil, representing Australia in the ultimate trades and skills showdown: the 43rd WorldSkills Competition.

“I found it a real challenge. The competition was probably the hardest four days of my life.

But, working that hard brings out the best in you. My welding, particularly my efficiency and my technique, has improved so much,” said McVicar.

In Brazil, Kallon had to complete eight welding projects including four test coupons, a pipe coupon, a 10mm and a 16mm butt weld.

He also had to build a stainless steel and an aluminium vessel, welded in position. All this (and more) had to be completed within 18 hours; Kallon finished with just 20 minutes to spare.

Kallon’s welds had to look seamless, meet international codes, and stand up to hydrostatic pressure and X-ray tests.

Paul Condran, WorldSkill’s Chief Expert in Welding, and Kallon’s mentor, was extremely proud of Kallon’s performance, “Kallon performed to the best of his ability, competing against competitors from 37 countries. During the four days of competition, Kallon maintained his composure and resilience to finish in 14th place and receive a Medallion of

Excellence, which is awarded to competitors who have demonstrated the skills and ability to produce the highest quality products,” said Condran.

“The WorldSkills experience not only positively influences the competitor at the international, level but also funnels through to the national and regional levels.

This is evident when youth who have competed return to their employers with increased skills and confidence. The flow on effect from every competitor at every level is without a doubt invaluable to the welding industry,” said Condran.

Kallon has worked at Mainteck in Port Kembla for the past five years. Mainteck’s General Manager, Tim Moss, couldn’t be prouder of Kallon’s achievements, “Kallon’s involvement with WorldSkills, and in particular his achievements in Brazil, has been very positive for Mainteck. We see his success as a reflection of the skill and training that Mainteck fosters in all our apprentices and his involvement at the international level confirms that we are preparing highly competent young tradesmen. Through this program,

Mainteck has gained a highly competent young tradesman with experiences that very few will be exposed to.”

“Kallon’s journey to Brazil has been closely followed by the company and in particular the younger tradesmen and

INSIDE THE INDUSTRY: WORLDSKILLS COMPETITION

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Kallon McVicar competes at the 43rd International WorldSkills Competition in Brazil.

About WorldSkills WorldSkills Australia is one of over 60 WorldSkills International member countries. Every two years, participating members converge at the world’s largest skills competition – the WorldSkills International Competition.

Competitors have to advance from the regional to the national level to prove their commitment and skills in their chosen field and to secure a place in the Skillaroos team; the International Competition is the ultimate test.

Members of the Skillaroos team become ambassadors not only for their skill, but also their local region, state and country.

The 43rd WorldSkills Competition in Brazil saw over 1,200 of the globe’s top tradesmen and skilled people compete for the coveted title of World Champion across 50 skills categories. apprentices. We feel that his experience has demonstrated to his co-workers and peers that with a little extra effort and focus, great things can be achieved and we would certainly encourage any of our employees to follow a similar course,” said Moss.

The WTIA was proud to support Kallon, who has been working for two years to compete in Brazil. His journey started in 2013 with his local WorldSkills Australia Regional Competition. His medal-winning

performance there lead him to Perth for the 2014 WorldSkills Australia National Competition, where he stood out from the crowd of almost 500 competitors.

He was subsequently offered a place on the Skills Squad, and undertook months of training, before competing at the inaugural WorldSkills Oceania Competition in New Zealand earlier this year.

His outstanding performance there secured him a spot on the Skillaroos team.

WorldSkills Australia’s team of 26 competitors proved to be fierce competition for the other 60 countries in attendance, earning three silver and two bronze medals.

Ten of the Skillaroos received a Medallion of Excellence for achieving an overall score of 500 or above, without receiving a medal.

For more information about WorldSkills, please visit: www.worldskills.org.au

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AUSTRALIAN WELDING | OCTOBER 2015

The Golden Rules of

Flame Straightening Welding and other manufacturing processes where heat is introduced leave stresses in the metal during the subsequent cooling, causing distortion or warping. Flame straightening is an efficient and long established method of correcting the distorted parts. It is based on the principle that metals expand when heated and contract when cooled. If expansion is restricted, compressive stresses build up and result in plastic deformations if the temperatures are high enough. Upon cooling, the plastic deformations remain.

In practice, an oxy-acetylene flame is used to rapidly heat a well-defined section of the workpiece. Upon cooling, the metal contracts more than it could expand when heated and any resulting distortions can therefore be straightened out.

The technique works on the basic principle of differential heating of surface areas of a reasonably thick plate along a straight or a curved line.

An oxy-acetylene burner is used for the purpose of heating. As the burner raises the surface temperature of the plate locally, the stress caused by heating exceeds the yield point of the material. During cooling, shrinkage forces are generated in the upset zone, which lead to the desired change of shape.

“

Flame straightening can be used to restore components whose geometry has been changed, by the action of heat during welding, to their desired shape.

Warped, bent, twisted and dented workpieces are straightened with the flame rapidly, and without impairing the material.

each other. The extent of upsetting determines the contraction and hence the straightening effect.

A precondition for upsetting is a good heat build-up.

The material has to be heated locally to obtain a certain thermal expansion with a considerable decrease in yield strength. For instance, in the case of steel, it must be heated to over 550°C. To enable visual determination, the practical specialist heats to ‘cherry red’, which is usually between approximately 600°C to 650°C, but below 750°C.

In order to ensure an adequate heat build-up, appropriate torches have to be used. If too much heat is conducted into neighbouring zones, the heated area becomes too large and will not be upset, but deformed. The surrounding cold metal confines thermal expansion.

If the thermal expansion stresses in the heated area exceed the strength of the material, upsetting occurs.

Heating Techniques There are four commonly-used heating techniques in flame straightening: • Heat Spot: is used for straightening plates.

• Heat Oval: is used to straighten pipes and shafts.

• Heat Line: is used in straightening of angular warp and heavy plates.

• Heat Wedge: is used for straightening of severe distortions and sections.

These various types of heating are used in combination with

By contraction matching the extent of the upsetting effect, the work piece is drawn into the desired shape during cooling. The straightening effect is measurable only when the work piece has cooled to ambient temperature, because the forces of contraction continue to act up to that point.

To the extent that the material permits it, the cooling time can be shortened by cooling with compressed air or water.

Sources: Linde Gas News, No. 38, Dec 1993.

Flame Straightening by Professor Volkmar Schuler

INSIDE THE INDUSTRY: FLAME STRAIGHTENING

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The Golden Rules of Flame Straightening When it comes to flame straightening, there are two golden rules: • The heat must be applied quickly.

• A local heat build-up must be achieved.

Tips for Effective Flame Straightening 1. Check the admissible deviations in the specification.

2. Put the structure in a ‘neutral’ position (to avoid incorrect measurements due to the structure’s own weight deformations).

3. Define ‘points of reference’ on the structure.

4. Measure the member to establish the degree of distortion in mm. The ‘long side’ (the one that has been shortened) must be identified.

5. Provide restraint for the thermal expansion (clamping devices).

6. Apply the heat as quickly as possible to localise thermal expansion.

7. Cool down the structure as quickly as possible (material dependent).

8. Measure the effect of straightening only after complete cooling to ambient temperature.

9. Assess the effect of what has been achieved and think carefully about the next step.

10. Follow the heating patterns on the structure.

11. Continue straightening if needed, heating intermediate points.

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AUSTRALIAN WELDING | OCTOBER 2015

Reducing Porosity in

Aluminium Welds Caused predominantly by the absorption of hydrogen in the weld pool, porosity can be a significant problem when welding aluminium. While there are a number of causes of porosity, minimising its effect is possible, with the proper cleaning, preparation, tools and techniques.

Causes of Porosity While solid aluminum has a very low solubility for hydrogen, molten aluminum has a very high solubility. When the weld metal is in a molten state, it absorbs a significant amount of hydrogen. It will then try to expel this hydrogen as the weld metal solidifies. If the weld is solidifying quickly, it is unable to purge the hydrogen, which forms porosity.

Sources of Hydrogen Common sources of hydrogen include moisture and hydrocarbons from contaminants (such as oil, grease, solvents and lubricants) on the parent metal, filler metal, the atmosphere, and even surfaces that come in contact with the weld area.

If any of these contaminants come into contact with the welding arc, the heat from the arc breaks them down, reducing them to hydrogen and a number of other foreign substances.

Another common source of hydrogen in welding aluminium

is its resilient refractory oxide film—the material that makes aluminium resistant to corrosion.

Oxide film must be removed prior to welding, not only to eliminate the risk of hydrogen absorption, but also because of its high melting point—over 2,000°C, compared to the 660°C melting point of aluminium.

Avoiding Porosity in Welding In order to avoid porosity while welding aluminium, it is essential that the surface of the material is thoroughly cleaned, either through mechanical cleaning or chemical etching. This cleaning process will remove the oxide film, as well as other surface contaminants. Particular care should be taken to remove all oil, other hydrocarbons, and loose particles from sheared edges.

Once all surfaces have been thoroughly cleaned, welding should occur as soon as possible; the interval between cleaning and welding should not exceed six hours. If it does, oxide film will re-form, and the cleaning process will need to be repeated.

MIG or TIG Welding Aluminium When MIG or TIG welding, it is also important to check the cleanliness of filler wire. Ideally, filler wires should be kept in their packaging until needed; wire that is left out in the open in workshops has a tendency to absorb moisture into its oxide layer. Wipe each filler wire prior to use with a clean rag dipped in acetone to ensure its cleanliness.

All filler wire should be purchased in accordance with the recognised standard (in either a shaved or double-shaved format) to ensure that the residues from drawing lubricants (the primary source of hydrogen in aluminium filler wire) are removed.

Tools for Welding Aluminium When it comes to tools for cleaning and welding aluminium, the most important thing to remember is to use specific tools for aluminium only. This will help reduce cross contamination, thereby reducing one of the most common sources of hydrogen.

Special attention should also be given to the gas supply system, including the quality and integrity of welding torches. Gas supply lines and hoses should be of a high quality and, where possible, made from non-hygroscopic materials (like neoprene) or metal.

INSIDE THE INDUSTRY: POROSITY IN ALUMINIUM WELDS

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Tips to Prevent Porosity in Aluminium Welding Sound Preparation. To avoid porosity, maintain a clean workspace and materials. Ensure that the part and filler wires are degreased before welding commences—wipe down the surface of the material with a clean rag dipped in degreasing solvent, such as acetone. Alcohols are not good degreasers and should not be used for pre-weld cleaning. Following degreasing, deoxidize the aluminum by using a stainless steel wire brush.

Correct Shielding Gas Flow Rate. For gas metal arc welding, the flow rate should be at least 10 to 35 Litres/min, depending on the thickness of the material. Argon and helium gas mixtures require even higher flow rates. For gas tungsten arc welding, the flow rate should be 6 to 15 Litres/ min, depending on the thickness of the material.

Reduce Nozzle-to-Work Distance. The distance between the nozzle and the material should be as small as possible, preferably 1cm to 2cm. Larger distances can draw in air and other contaminants.

Ensure Proper Gun Angle. Aluminum welding requires a leading gun angle. If a drag angle or 90-degree angle is used, porosity will appear.

Sources: • Armao, F. ‘Defining, stopping porosity in aluminum welds’ in Practical Welding (Sep-Oct 2015) • www.twi-global.com • www.airproducts.com

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AUSTRALIAN WELDING | OCTOBER 2015

About the Ichthys LNG Project INPEX Australia discovered the giant Ichthys gas and condensate field in the Browse Basin in 2000.

Located approximately 220 kilometres offshore Western Australia, Ichthys represents the largest discovery of hydrocarbon liquids in Australia in 40 years.

Currently under construction, the Ichthys LNG Project is ranked among the most significant oil and gas projects in the world.

With production expected to commence at the end of 2016, the Project is expected to produce 8.4 million tonnes of LNG and 1.6 million tonnes of LPG per annum, along with more than 100,000 barrels of condensate per day at peak.

The Ichthys onshore LNG facilities at Bladin Point, August 2015.

INSIDE THE INDUSTRY: PROJECT SPOTLIGHT

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Ichthys LNG Project

Gas Plant and Pipeline The Ichthys LNG Project selected Bladin Point in Darwin as the location for its onshore processing facilities in 2008. Construction of the liquefaction plant, which will cool gas from the Ichthys Field and transform it into liquid for transport, commenced in 2012.

The gas will come to Darwin via an 889 kilometre gas export pipeline (GEP) from the central processing facility (CPF) in the Browse Basin.

The lchthys Project GEP will be one of the longest subsea pipelines ever built. The pipeline is 42-inches in diameter, composed of approximately 700,000 tonnes of steel and coated with 550,000 tonnes of concrete.

Welding and Fabrication Local Darwin contractor, Fingers Specialised Metal Fabrication (SMF), has provided welding and fabrication work for the Ichthys Project onshore LNG facilities, since construction began in 2012.

Their involvement has included the cutter heads and dredging vessels for Van Oord, as well as the construction of the embedment plates for the CH2MHill-UGL Joint Venture on the Project’s combined cycle power plant.

In conjunction with Donaldson Europe and GE, Fingers SMF has provided staffing to facilitate painting of the five gas turbine filter house units.

On behalf of the Kawasaki-Laing O’Rourke Joint Venture, Fingers SMF has supplied personnel to weld out the 89 metre diameter aluminium suspended ceilings for the plant’s two cryogenic LNG tanks and has carried out work on the propane and butane tanks.

Fingers SMF Managing Director Mark Taylor, has enjoyed being involved in this major project, “It’s been a great project, particularly having been involved since the very beginning”, said Taylor. “I even made the stainless steel shovels that turned the soil when the project first kicked off.”

Latest Developments After years of intense engineering and fabrication work, the Ichthys Project entered the offshore installation phase in November 2014. Mooring installation works commenced in May 2015. The first of 49 foundation piles was safely deployed and driven into the seabed on Wednesday 6 May 2015 in a water depth of 250 metres. Each pile is approximately 66 metres long and weighs more than 450 tonnes.

Currently under construction, the central processing facility and floating production, storage and offloading facility, will be towed to the Ichthys Field once completed in 2016 and moored for the life of operations – about 40 years – by 40,000 tonnes of chain secured to about 20,000 tonnes of foundation.

Marian and Mark Taylor of Fingers Specialised Metal Fabrication.

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AUSTRALIAN WELDING | OCTOBER 2015

About the Busselton Bridges Located in south-west Western Australia, Busselton is one of the fastest growing areas of Western Australia. The municipality has a current resident population of approximately 34,000 with an average annual growth rate of 4%.

The Vasse Wonnerup Wetlands lie to the east of the Busselton town site and receive flow from the Vasse, Sabina, Abba and Ludlow rivers. The wetlands have many important natural values, particularly as waterbird habitat.

Each year over 30,000 birds of 90 different species utilise the wetlands.

Note: this is a stock image only.

It is these wetlands, and their associated rivers that the Busselton Pedestrian Bridges cross.

The Toby Inlet Pedestrian Bridge.

INSIDE THE INDUSTRY: PROJECT SPOTLIGHT

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Project Spotlight:

Busselton Bridges Project Overview • • • •

Company: Welding Technology Institute of Australia (WTIA) Client: Australian Steel Institute Date: August 2015 to current Services Provided: welding inspection and development of weld quality recommendations.

Project Background In August 2015, the WTIA carried out visual examination of three pedestrian bridges in Busselton; the Buayanup Drain Bridge, the Toby Inlet Bridge, and the Vasse Diversion Drain Bridge.

The examinations informed a detailed report on weld quality. The Australian Steel Institute state manager, James England, requested the report after spotting hazards in the design, welding, workmanship and galvanising of the bridges, indicating both compliance and longevity issues.

The contract for the pedestrian foot bridges was awarded to a local Osborne Park based contractor. However, the fabrication work was undertaken in China.

“There is the issue of double standards in procurement, this project was sent out for tender to local firms who bid in the expectation they were on a level playing field,” England said.

“Government should be seen to be an informed and exemplary purchaser setting a good example to private enterprise, this is anything but a good example and local firms have a right to feel cheated,” said England.

Report Findings In line with the original tender document that referred to AS5100, the three bridges were all constructed from steel hollow section. In accordance with AS4100-1998 (clause 11.1.5 and Table 11.5.1(4)), welding of these sections must “conform with Category SP as defined in AS/ NZS 1554.1”. The thickness of the hollow section members was not measured, although ‘hammer testing’ indicated that they were less than 5mm.

Examination of the pedestrian bridges by the WTIA found that many of the welds were not compliant with the permissible levels of imperfections for Category SP welds as defined in AS/NZS 1554.1.

It was also discovered that many components and welds were galvanised, thereby concealing other features that would usually help to determine weld quality.

The weld joint profile of a number of weld types indicated that nonstandard joint preparations and welding practices had been used.

A number of welds were excessive for the relative thickness of the steel sections; excessive welding is known to be a potential origin of defects that can greatly affect the integrity and life of the weld.

Other issues were also evident across the bridges, including overroll, undercut, incorrect bead shape, excessive porosity, lack of fusion, excessive grinding, poor surface finishes, and excessive spatter which was not removed before galvanising.

Given these findings, it is unsure whether qualified welding procedures, supervisors and welders were used during the fabrication of the bridges.

Sources: www.busseltonmail.com.au

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AUSTRALIAN WELDING | OCTOBER 2015

CSIRO Launches

Science Masterplan In its strategy for 2015 to 2020, Australia’s Innovation Catalyst, the CSIRO outlines how the organisation will become a global collaboration hub and help boost the country’s innovation performance. The CSIRO’s masterplan is designed to improve upon Australia’s record in innovation and help the country respond to global changes in technology and digital disruption.

“Australia currently ranks 81st in the world when it comes to innovation efficiency - the bang for our buck we get when we transform innovation investment into results,” CSIRO Chief Executive Dr Larry Marshall said.

“If that was a team sport ranking, we’d be outraged. As a country, we need to work together to improve this result.

Australia’s prosperity, health and sustainability is closely bound to our capacity for innovation – and CSIRO has a key role to play here.”

“CSIRO is Australia’s largest patent holder. We’re the people behind fast Wi-Fi, part of the global team which developed extended-wear contact lenses, designer polymers using RAFT technology and the Hendra vaccine – but this is the tip of the iceberg when it comes to the value we offer the Australian people,” said Dr Marshall.

In a novel approach for the 90-year-old science body, it crowd-sourced ideas and suggestions from more than

7,000 people including its research partners, other collaborators, its own staff and the public to help determine the direction of the strategy.

“

For CSIRO the question is really, what does Australia need?” Dr Marshall said.

“The crowd sourcing helped answer this question by asking people to consider a range of challenges and opportunities ahead and asking how we should respond,” said Dr Marshall.

The CSIRO’s new strategy has already been shared with staff, and represents a new era for the national science agency.

Part of the push for greater collaboration and co-ordination

by CSIRO will be increased colocation with universities and other research organisations and a greater emphasis on international connections.

NEW DEVELOPMENTS: CSIRO MASTERPLAN

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CSIRO’s Strategy 2020 will focus on customers and finding ways to solve their technology and innovation challenges.

Here, CSIRO staff member Barbara Sowa is at Nissan’s factory, where a partnership with the science agency helped the manufacturer develop new casting technology.

Global Megatrends Shaping Australia’s Future More from less: Innovation in meeting human needs by more efficient use of resources in light of escalating demand and constrained supply.

Planetary pushback: Changes in earth systems from the global to microbial are creating challenges such as climate change.

The silk highway: Rapid growth of emerging economies, urbanisation, geopolitical change and the transition from industrialisation into technologically advanced service sectors.

Forever young: The rise of the aging population, retirement savings gap, lifespans, healthcare expenditure, diet and lifestylerelated illness.

Digital immersion: Exponential growth in computing power, connectivity, internet users, artificial intelligence and technology.

Porous boundaries: Changes in organisational models, governance systems and employer-employee relations in a more agile, networked and flexible economy.

Great expectations: The rise of the experience factor as consumers have rising expectations for personalised, positive experiences.

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AUSTRALIAN WELDING | OCTOBER 2015

The Government’s Plan for

Naval Shipbuilding The Federal Government recently delivered a long-term plan outlining the way forward for a strong, sustainable naval shipbuilding industry. This plan included investment of $89 billion by the Government over the next 20 years into ships and submarines for Australia’s Navy. However, with the ushering in of Malcom Turnbull as our new Prime Minister, the future of naval shipbuilding is once again uncertain.

In August 2015, the Government announced that the Future Frigate program (SEA 5000) to replace the ANZAC class frigates would be fast-tracked, with a continuous onshore build program commencing in 2020 – three years earlier than expected.

Construction of Offshore Patrol Vessels (SEA 1180) to replace the Armidale class patrol boats was also brought forward by two years, to commence in 2018. The fast-tracking of these two projects was expected to save 900 jobs and reduce risks commonly associated with a ‘cold start’.

However, the leadership coup that saw Malcolm Turnbull appointed as Australia’s new Prime Minister in late September, has also resulted in the selection of a new Minister of Defence: Senator Marise Payne.

Facing the press after being sworn in as Australia’s first female Defence Minister, Senator Payne acknowledged the importance of domestic involvement in shipbuilding. When asked about the competition between states to

be involved in the construction of the new Offshore Patrol Vessels, Senator Payne confirmed that she wants to maximise local involvement in naval shipbuilding.

“

I would take the approach of ensuing that we build the best capability possible for the Australian defence forces and that we support Australian industry as far as we possibly can in doing that,’’ Senator Payne said.

“I know that there is a competitive line of state premiers and industry ministers out there who are very keen to engage on those issues.’’

Senator Payne refused to comment on the Abbott Government’s Competitive Evaluation Process that would have been used to award shipbuilding contracts, as well as Japan’s chances of winning the Future Submarines construction contract.

NEW DEVELOPMENTS: NAVAL SHIPBUILDING

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Naval Shipbuilding Fast Facts Naval shipbuilding is an important contributor to Australia’s economy: • Directly employs 6,000 people.

• Indirectly employs 15,000 people.

• Contributes up to $2.3 billion to the Australian economy per annum.

• Of this potential $2.3 billion, the majority comes from production ($1.3 billion); however, the contribution from the total life cycle is still highly significant ($975 million).

• Annual revenue is estimated at $4 billion.

• Defence-related markets generate more than three quarters of industry revenue (78% in 2013), followed by commercial shipbuilding (at 17% in 2013).

• Revenue is estimated to have risen at an annualised rate of 6.6% over the last five years.

• Directly supports over 430 businesses, which use more than 4,800 suppliers.

Sources: • IBIS World (2015), Shipbuilding and Repair Services in Australia: Market Research Report (C2391).

• Acil Allen Consulting (2013), Naval Shipbuilding & Through Life Support Economic Value to Australia.

• Jean, P. ‘New Defence Minister Marise Payne wants to maximise Australian involvement in shipbuilding projects’ in The Australian (22 September 2015).

Australian Submarine Corporation Air warfare destroyer HMAS Hobart in the construction dock at Port Adelaide.

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AUSTRALIAN WELDING | OCTOBER 2015

Australia’s First 3D

Printed Spine Implant RMIT’s Centre for Additive Manufacturing has worked with a medical device company and a neurosurgeon to successfully create Australia’s first ever 3D-printed vertebral cage for a patient suffering from severe back pain. Made from a titanium alloy, the piece was designed to replace cancerous bone removed in surgery. Its lattice structure mimics the density and weight of human bone, enabling the implant to carry blood and encouraging healthy bone to grow into it.

When an abnormal structure of the fifth lumbar vertebra and severe degeneration of the adjacent disc was causing Amanda Gorvin constant lower back pain she was referred to spine surgery specialist Dr Marc Coughlan, at the North Gosford and Prince of Wales Hospitals.

Coughlan’s opinion was that spinal surgery was an option, but because of the unusual shape of Gorvin’s vertebrae, a standard, off-the-shelf implant would possibly only give her slight relief.

“

An advantage of 3D printing is that a custom implant can be made of any shape and complex internal architecture for a reasonable cost.

It has been three months since the surgery and Gorvin has resumed normal activities without any significant pain.

3D printing is proving to be a game changer for manufacturing in the healthcare industry.

Specialist teams at Anatomics and RMIT used a CT scan of Gorvin’s spine to create a customised implant. Medical device supplier, LifeHealthcare provided parts.

He then turned to Melbourne medical device specialists, Anatomics, who worked with Professor Milan Brandt and his team at RMIT’s Centre for Additive Manufacturing at the Advanced Manufacturing Precinct to design and develop a custom-made spinal implant using 3D printing (or additive manufacturing).

“Usually, replacement spinal cord parts are flat, with two parallel sides. Gorvin’s surgeon wanted a disc that would fit exactly into the space left between the two remaining vertebra.

By going down the additive manufacturing path, we were able to use an x-ray of Gorvin’s spine Australia’s first 3D-printed vertebral cage. to design a replacement disc that fitted exactly into her vertebrae,” said Brandt.

“This revolutionary process allows the implant to be built layer by layer, adding successive layers of material under computer control – as opposed to the subtractive manufacturing techniques of casting, fabrication, stamping and machining,” Brandt said.

As a result of this perfectly snug fit, Gorvin’s surgeon did not have to undertake any additional work in terms of chipping away bones in the surrounding area—the replacement disc fitted without any of the further medical procedures that are usually required.

NEW DEVELOPMENTS: FIRST 3D PRINTED SPINE

“Individual bones and implants will eventually be manufactured while the patient is on the operating table—that is the ultimate goal of our research,” said Brandt.

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Printed titanium lattices in a model of the bone.

“If you have one of these 3D printing machines in a hospital, a surgeon can cut out a cancerous tumor, scan the volume of the bone or tissue that has been removed, and then send the scan to the manufacturing department. The manufacturing department can then produce the replacement part and sterilise it, before the surgeon inserts it.”

“The whole process happens quickly and easily on-site. It saves patients from having multiple procedures—a spinal implant can be performed in a single operation,” said Brandt.

“This technology is still in its early stages, but there are clearly myriad applications—it enables tailored production and mass customisation in a way never before possible,” said Brandt The ability to create unique and complex titanium implants for specific conditions, such as the abnormal shape of Gorvin’s vertebral cage, indicates that additive technology could be used to provide ongoing support for patients with chronic pain.

Brandt is currently collaborating with Australian surgeon and cancerous bone specialist Professor Peter Choong from St Vincent’s Hospital. Using a

patients’ own CAT or MRI scans, Brandt and Choong are working to generate exact 3D-printed replicas of the cancerous bone removed.

“While it depends on the type of cancer and how aggressive it is, we can tailor an implant that fits exactly, and that has the same load carrying capacity as the bone that has been removed. Additive manufacturing is enabling the production of patient-specific and bonespecific implants,” said Brandt.

Lattices in a model of the pelvis.

The Centre for Additive Manufacturing, part of the Advanced Manufacturing Precinct, at RMIT’s Melbourne City Campus supports research in a range of areas including bioengineering, aerospace and automotive. Its research is driven by market requirements. It is focused on design, materials, manufacturing and system development, particularly shape and topology optimisation algorithms, bio-inspired design and connectivity between additive manufacturing and industrial design industry.

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AUSTRALIAN WELDING | OCTOBER 2015

The expansion of Riot Tinto’s Pilbara operations at Cape Lambert to 290 Mt/a capacity. Image: Copyright © 2014 Rio Tinto.

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FEATURE: MINING TECHNOLOGY

Why Digital Transformation is

Critical to Mining

Mining companies are under more pressure than ever to get more materials from the ground at the lowest possible cost and the highest possible grade. Hence, mining companies are looking for new ways of doing things­—profit maximisation is the top business concern of mining companies as they work to improve the cost and efficiency of their operations. This is an environment of change within which the role and importance of technology is becoming a critical enabler for mining operations.

The mining sector is facing enormous challenges. The fall in prices across commodities continues to impact the cost, asset and debt projections required by miners. Globally, productivity has been falling despite wide-spread supply chain investments.

It’s not surprising then that in the recently released Energy Insights’ survey, the top priority for miners was cost savings. Undertaken by International Data Corporation, the survey included insights from more than 190 miners globally. An overwhelming 83% of surveyed mining companies stated that their technology budgets will increase (or at the bare minimum, stay the same) in the 2015-2016 financial year.

Top objectives for global mining companies this year include automation of assets, mine operations, management and control systems.

The survey found that 69% of mining companies are looking at

innovations for remote operation and monitoring centres. New mining methods are an area of concern for 56% of miners, while 29% are looking into robotics, and 27% at the use of unmanned drones.

Growth in the use of bulk materials handling products and technologies is indicative of a market drive towards technological advancement.

According to a report published

by Transparency Market Research, the international bulk materials handling market is expected to reach a net worth of $62.36 billion by 2020. With the current market valued at $57.60 billion, that is a compound annual growth rate of 1.2% over the next five years.

While this projection isn’t predicated just on the mining industry, (other sectors, such as oil and gas and construction, all use bulk materials handling utilities), mining companies are traditionally the highest

contributing end-users, accounting for 29.4% of the market share in 2013.

Miners are also investing heavily in communications and IT advancements that enable the connection of the physical with the virtual. A raft of technologies, sensors and solutions are helping mining companies become more transparent.

The transformation we are seeing in the mining sector is not just about transparency, and being able to see what is happening across the mine, but about creating the ability to control and to respond predictively to a range of circumstances.

The future of mining will include the ability to manage the mine as a system—through an integrated web of technologies such as virtualisation, robotics and sensors that command, control and respond remotely.

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AUSTRALIAN WELDING | OCTOBER 2015

The Mining Industry’s New

Technology Landscape According to Mining Journal, the traditional mould for mining industry technology suppliers was broken last decade. A range of factors, including supply-sector consolidation and new research and development partnerships, altered tier-one mining company procurement strategies and increased their demand for cutting-edge technology.

In fact, Mining Journal’s recent review of more than 100 key technology suppliers for mineral exploration, mining and processing, revealed that some of the world’s largest technology companies (including the likes of Microsoft, IBM, Oracle and SAP) grew their mining industry reach considerably over the last decade on the back of surging demand for information and communication technologies.

Talia Flagan, Quarry Manager of the Paulding Cement sector of Lafarge.

A number of specialised mining software and communications companies have similarly grown exponentially, although none faster than Maptek or Mine Site Technologies. Similarly, privatelyowned Australian companies, such as Immersive Technologies and RCT have enjoyed increased success as the demand for simulator-training, equipment control, and advanced surveying technologies has grown.

Lafarge determined that, due to the extent of the workings, a traditional survey would take more than three months and also be very costly.

Traditional methods would have been adequate for the as-built needs but timing and cost were major factors leading to the choice of laser scanning. With more than 600 scan locations, it was a big survey job, requiring 10 days of scanning across 10 to 12 hours a day.

Maptek: Advanced Surveying Technology in Action

The I-Site 8200 laser scanner was ideally suited to the underground survey task. The 125° scanning aperture ensured good overhead coverage. Data could be collected at up to 500m, with multiple point density settings for different purposes. The minimum range of 1m allowed scanning of the tops of the pillars on the double benched areas; this provided important data for later model creation.

In late 2014, the extensive northern underground workings of the Lafarge Conco limestone mine near North Aurora, Illinois, were surveyed using the Maptek™ I-Site™ 8200 laser scanner.

‘Our main objective was to complete old mine maps of historical workings and catch up to current production,’ explained

Limited staff on site meant there was not always time to survey the pillars. Lafarge needed a map of the existing underground workings with accurate pillar locations. They wanted to ensure that the mine design was being followed, and also that the pillars were not being undermined from the level below.

Lafarge now has a comprehensive 3D map of its underground workings for planning, operations and closure studies. The data collection phase of ten days, plus a further two to three weeks processing, was a significant reduction on the three months estimated for conventional survey.

Immersive Technologies: Simulating Mining’s Future Immersive Technologies, the global leader in simulation based training for mining, has seen a year of growth in its customer base, product and service offering, and most importantly in the results their customers are achieving.

Immersive has invested heavily over the last two years to grow their extensive simulated machine range, recently adding graders, surface drills, road headers, shuttle cars and continuous miners.

In addition to the expanded product range, Immersive Technologies has also supported the uptake of autonomous mining with the development of a training centre for autonomous haulage at Codelco’s Gabriela Mistral “Gaby” copper mine in Chile. The adoption of autonomous mining by major miners creates a need to train personnel to think and work differently, while interacting with the new systems.

FEATURE: MINING TECHNOLOGY

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Maptek’s underground surveys of the Lafarge Conco limestone mine in Illinois.

Immersive Technologies’ Fuel Savings Immersive Technologies’ PRO3- B Advanced Equipment Simulator.

Cipta Kridatama, one of Indonesia’s leading mining contractors, improved haul truck fuel efficiency by 6.9% using simulation based training from Immersive. Fuel records for 30 haul truck operators were collected over a one month period and 18 of the 30 were over the budgeted litres per hour consumption. All operators were assessed using an Immersive Technologies Advanced Equipment Simulator to establish a baseline, simulation based training then occurred followed by a reassessment.

Once operators passed the reassessment they were put back in the field. After one month operators were assessed again to confirm retention of the new haul truck operating techniques.

A comparison of fuel records between pre-simulation and post-simulation based training showed an improvement of 6.3% in one month. On site fuel usage went down each month thereafter with the last reported usage showing a 6.9% overall reduction.

The site is now operating 5.8% under the budgeted litres per hour fuel consumption.

“Production time was not affected with these improvements and we believe, with a conservative estimate, we can save $500,000 per year through this training initiative,” Perdana said.

The haul trucks have a standard refueling schedule and with tanks being fuller a secondary improvement was also calculated with refueling taking less time, thereby increasing production time. The fuel efficiency initiative showcased unique insights into how changes to operator behavior affect cost savings through reduced fuel consumption.

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AUSTRALIAN WELDING | OCTOBER 2015

Q&A With a WTIA Member:

Andy Sales Andy Sales is the Director of Research and Development at K-TIG, in Adelaide. With more than 25 years experience in the fabrication and construction industry, the majority of Andy’s experience has been gained in medium to large scale projects across the oil & gas, refining and mining industries. His expertise includes welding engineering, metallurgy of metals, and mechanical engineering.

Recently, Andy has held positions in quality assurance and control, with a heavy focus on welding, for companies such as United KG, Aker Kvaerner, Clough, McDermott, Woodside, BP and ConocoPhillips.

He has worked throughout the world, including Papua New Guinea, Bolivia, Mongolia, Egypt, Germany, Denmark, Tanzania, Ghana, and Indonesia.

Describe your job.

I am Director of Research and Development for K-TIG in Adelaide.

We have a relatively new welding process called keyhole TiG (K-TIG).

It is an autogenous, high speed, full penetration process that delivers some dramatic productivity gains, particularly in corrosion resistant materials. I manage the direction of research, focused on optimisation of the process. This involves studies on arc physics, keyhole physics, control and sensors, structural integrity and metallurgical analysis. Our focus is on the more exotic materials that exhibit high strength and high corrosion resistance, such as austenitic stainless, duplex, nickel and titanium.

Andy Sales, Director of Research and Development at K-TIG.

How did your career in welding begin?

I started out with an apprenticeship as a fitter and welder. I was exposed to a few welding processes (MMAW, GTAW, FCAW, GMAW and Brazing), which gave me a great start to my welding career.

From there, I worked in various industries, including agriculture, forestry, shipping, mining maintenance and construction, refining and oil and gas. In the late 1990s, I slowly moved off the tools and worked in inspection and supervision, before moving into management roles from the mid-2000s. All of these roles were closely related to welding.

What do you enjoy most about working in welding?

My father was a chief marine engineer and towards his retirement he mentioned to me that in engineering you never stop learning. That analogy applies to my interest in all aspects of welding engineering; I am always learning something and find that there is always something that I don’t

know. Working with like-minded people who are passionate about welding is what I enjoy the most.

What is the most interesting project you’ve worked on to date? Why? While I find my current role immensely interesting, a few past projects also come to mind. The most satisfying project I was involved with was the Kipper Tuna Turrum project in Bass Strait between 2010-2013. I acted as the Quality Manager for the project on behalf of McDermott.

The project included the fabrication and installation of two jacket modules, six topside modules, two bridges, subsea coolers, manifolds, three pipelines totaling 48km, and finally a hook-up and commissioning campaign.

The Kipper Tuna Turrum project was interesting because the welding program was so diverse, from pipeline welding qualification by ECA (Engineering Critical Analysis), structural welding to AWS D1.1 for permanent and temporary

structures, through to a major qualification campaign for the hook-up process piping.

Materials involved were heavy structural plate and sections up to 70ksi grade, 350 and 450 pipeline grades including Inconel clad pipe spooling, LTCS, monel, super-austenitic (6Mo), duplex, super-duplex and copper-nickel.

The management of all on and off-site welding of these materials was my responsibility, and certainly kept us on our toes. As a group, we learnt a lot; I had 17 inspectors and two coordinators on rotation in the department, and we all got along well as a team.

What is the biggest challenge for the welding industry?

I’ve always thought that education is the key to being successful at

SAVE THE DATE:

INSIDE THE WTIA: MEMBER Q&A

45

what you do. Unfortunately, there aren’t many full trade courses these days and people in industry are trained by fast tracked courses.

Quite often there’s a lack of good skill levels and diversity. The problem is bigger than this, of course; manufacturing is waning in Australia as it’s cheaper to do so overseas. This is the biggest challenge for the government.

Since being in Adelaide, I’ve quickly realised that there are very good skilled trades available, but job opportunities are limited.

want to be good at something, read about it – it’s stuck with me. Once I found I had an interest in welding, I started to educate myself, whether it be informally or by coursework and have done so since – you should never stop learning.

What is your biggest piece of advice to people new to welding?

Education is important. Years ago in the mid-1980s, when I was playing sport as a teenager, an old coach once told me that if you

I have since gone from attaining my humble trade qualification to undertaking most inspection and supervisory courses, two advanced diplomas, and a Masters degree.

Just this year, I started a second Masters in Engineering, which will support improvements to mechanised welding.

If you want to be good at what you do and have the passion for it, then educate yourself. There are plenty of resources available nowadays… not just books!

69th IIW Annual Assembly & International Conference 10 to 15 July 2016 Melbourne, Australia www.iiw2016.com

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AUSTRALIAN WELDING | OCTOBER 2015

An Update from:

SMART Industry Groups About SMART Industry Groups WTIA’s SMART (Save Money and Re-engineer with Technology) Industry Groups provide a facilitated private forum where industry-specific members can discuss and analyse weldingrelated challenges and issues, and source potential solutions.

For details, contact Paolo Corronca on p.corronca@wtia.com.au.

SMART Procurement Group The WTIA has recently introduced the SMART Procurement Group.

This Group will address the issues associated with the growing number of non-compliant welded products, originating both locally and from overseas suppliers.

More and more, once welded products arrive on-site for commissioning, they require remedial work, that often equates to as much as the fabrication original cost. Apart from the immediate overrun, this remedial work is causing project delays.

This is compounded by concerns over the level of knowledge that overseas manufacturers have when it comes to Australian Standards.

This skills gap often leads to welded products that do not meet expected quality standards.

The WTIA SMART Procurement Group will bring procurement professionals and engineers together, to define industry-wide risk management guidelines.

The guidelines will address steel sourcing, transport, shipping, inspection requirements, previous experience, knowledge of Australian Standards, welding

quality management systems, insurance, finance, project control and contract law. WTIA will assemble the best possible resources to draft these guidelines, which will then undergo peer review by members and a risk management professional.

SMART APT Group The SMART APT Group held its 50th meeting in late July at CS Energy in Brisbane.

Representatives from CS Energy, AGL, EnergyAustralia NSW, ANSTO, GDF Suez, Synergy, CB&I, ALS Industrial, HRL and Quest Integrity attended.

Smart Group Consolidation The WTIA SMART APT Group may be consolidated with the Pressure Equipment and Alumina Process Groups. The two latter Groups have experienced a slowdown in activities due to the changing market. As the Groups share similar challenges, technologies, materials,

equipment, procedures and standards, an integrated group that facilitates the sharing of knowledge and experience will be beneficial.

Remlife Software Launch An updated 3.8 version of Remlife has recently been released. The launch of the Enterprise version (4.0) is expected over the coming months, with testing almost complete. During the meeting, the implementation of new modules was discussed, including a module to estimate bolting remaining life.

Potential Future Projects WTIA SMART Industry Partners have proposed two new projects for consideration by members.

Both of these projects could have an immediate outcome for the welding and fabricating industry.

Development of Advanced Diffraction Analyses for Material Damage Assessment The aim of this project is to prove that the Electron Back-

INSIDE THE WTIA: SMART INDUSTRY GROUPS

Scatter Diffraction (EBSD) technique can be used to identify the heterogeneity of plastic deformation (dislocations), grain orientation (texture), and the grain size across ferritic welds microstructure.

When combined with EnergyDispersive Spectroscopy (EDS), EBSD provides spatial chemical analysis to identify present inclusions, impurities and creep voids. This method will reduce the time required to assess samples to less than a week, with improved automation and accuracy. The project would involve a set of interrupted creep test specimens, (performed by ANSTO) using the EBSD/EDS analysis to validate the methodology and gain more understanding of creep damage in ferritic steels.

Validation of AET in Induced Creep in High Temperature Pressure Piping Materials Acoustic Emission Testing (AET)

has been used in power stations for a number of years to identify creep and cracking in high temperature pressure pipelines.

A SMART APT Group Member has been working with WTIA’s Technology Support Centre on a blind trial to identify creep using AET. During this trial, creep (and cracking not associated with creep) has been identified through analysis of acoustic waveforms.

The project will determine how to identify the different stages of the creep deterioration process, and how the measured AET response relates to actual damage present in the steel. The project will refine the technique and increase confidence in risk based assessments of pressure lines that show creep activity.

The project will include three trial stages, covering low alloy steels (Grade 22), welded materials and creep-strength enhanced ferritic (CSEF) steels (Grade 91).

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SMART Road and Rail Group This Group convened for two days in early September, with NSW Roads and Maritime Service, Queensland Transport and Main Roads, VicRoads, the WTIA, BlueScope Steel, the Australian Steel Institute and OneSteel all in attendance. The two day meeting was an important milestone in the development of the single, harmonised Austroads specification for steel structures.

Each Australian state has its own State Road Authority (SRA), with its own technical requirements for the design, manufacture and procurement of steel structures.

These state-specific requirements create a barrier to consistent manufacture of products. The aim of this project is therefore to create harmonised technical specifications, shared across all SRAs, that will allow a competitive national tendering process guided by national standards.

EXPAND YOUR AUDIENCE. GROW YOUR BUSINESS. Advertise with the WTIA Today WTIA offers you the opportunity to promote your products and services directly to the decision makers in the welding and fabricating industry­. We have a range of cost effective advertising and editorial packages available in Australian Welding, our monthly newsletter Weld Connect, and the WTIA website.

Welding Technology Institute of Australia

Want to know more? Contact George Zervas on g.zervas@wtia.com.au or +61 (0)2 8748 0110

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AUSTRALIAN WELDING | OCTOBER 2015

Latest Issues from the

WTIA Hotline The WTIA Hotline update covers a number of queries encountered by the Hotline over the last few months. Whilst accuracy in welding is critical, it is impossible to report in detail the full circumstances of each query. As such, references are provided if further information is required on each topic.

What is the shelf life for welding consumables?

Shelf life is an important issue, particularly when it comes to Manual Metal Arc Welding electrodes. Low hydrogen electrodes require specific care in terms of storage and drying prior to use. For all welding consumables the ‘First-in-firstout’ (FIFO) rule applies.

Welding electrodes should preferably be kept in a heated insulated room with a maximum relative humidity of 55% at a temperature of 25˚C minimum.

Shelf life for coated electrodes is not well defined, but the table opposite forms a good basis for guidance.

Type of Package

Heated Room

Non-Heated Room

Sealed

1 year maximum

Preferably not stored; 6 months maximum

Hermetically Sealed 3 years maximum 1 year maximum

The wires for Submerged Arc and Gas Metal Arc welding are generally copper coated to increase contact tip life, improve electrical conductivity and extend the shelf life.

Definitions

Deteriorated copper coating or visible rust on the surface indicates that consumables are beyond their shelf life, and should not be used.

References

Sealed: these are containers, which after opening, are used again after closing by staples, adhesive tape or cardboard type boxes.

Hermetically sealed: this type of container is usually a cardboard box coated with plastic film, soldered tins or sealed plastic boxes.

WTIA Technical Note 3 – Care & Conditioning of Arc Welding Consumables – Comprehensive Quality Requirements

INSIDE THE WTIA: WTIA HOTLINE

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Can you provide details on the calculation of range on the heat input as per the Welding Procedure Specification?

The heat input range shown on the Welding Procedure Specification is calculated from the welding amperage, welding voltage and welding travel speed range, developed during the welding procedure qualification.

Heat Input (welding energy) is based on the following formula: Q = E x I x 60 V x 1000

Q = welding energy input, kJ/ mm E = arc voltage I = welding current V = welding speed, mm/min During the procedure qualification process, the minimum and maximum amperage, voltage and travel speed are recorded.

The minimum recorded voltage and amperage divided by the maximum travel speed will provide the lowest heat input and vice-versa for the highest heat input.

Care must be taken to ensure the resultant heat input range on the Welding Procedure Specification does not fall outside any prescribed ranges. For example, when welding stainless steel, it is not uncommon to have a maximum allowable heat input that must not be exceeded, regardless of what range is calculated by this method.

What is the role of pre-qualified and fabricator qualified welding procedures with respect to tolerances?

Pre-qualified joints (such as those given in Table E1, E2 and E4 of AS/ NZS 1554.1) are proved and qualified through many years of application.

Dimensional tolerances provide the allowed variations based on ideal size and shape. Table 5.2.2 of AS/NZS 1554.1 gives allowable joint tolerances on the pre-qualified joints, which are based on many years of successful application. A macro test is used to verify the pre-qualified procedure, provided the tolerances are specified in the table.

For a pre-qualified butt weld preparation, the tolerance of -5° and +10° on the included angle are completely adequate for a prescribed angle of 60°. Once the fabricator chooses to adopt the pre-qualified route, he must comply with the rules. If the pre-qualified joint calls for nominal 60°, the tolerance on the angle is 55° to 70° when using AS/NZS 1554.1. If the fabricator chooses to qualify his own procedures from scratch, and the macro needs an angle of 63.5°, then the tolerance of -5° and +10° can be applied to the 63.5° (58.5° to 73.5°). However, if the fabricator qualifies a ‘narrow gap’ procedure with an included angle of 40°, this would be outside the scope of the pre-qualified joint preparations. Care would be needed to apply appropriate tolerances to such angles, to achieve consistent results.

References • •

AS/NZS 1554.1:2014 – Welding of steel structures WTIA Technical Note 11-04 – Commentary on the Standard AS/NZS 1554 Structural Steel Welding

About the WTIA Hotline Corporate Members have access to the WTIA Hotline, which is manned by WTIA Technology Manager, Sasanka Sinha. To reach the WTIA Hotline for technical advice and consultancy services, phone 1800 620 820.

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AUSTRALIAN WELDING | OCTOBER 2015

For Your Diary

Upcoming Events Whether you need to brush up on skills learnt years ago, want to try your hand at something new, or crave some networking opportunities, there is an industry event for you. For further information on any of the events listed below, or any WTIA events, please email events@wtia.com.au or phone +61 (0)2 8748 0100.

October 2015 YPIC International Conference for Young Professionals in Welding 7 to 9 October, Budapest www.ypic2015.com Brazil Welding Show 22 to 23 October, Sao Paulo www.brazil-welding-show.com 5th IIW Welding Research and Collaboration Colloquium 28 to 30 October, Munich www.iiwelding.org November 2015 AWS Fabtech 9 to 12 November, Chicago www.fabtechexpo.com Electron Beam Welding Conference 10 to 11 November, Chicago www.aws.org Underwater Technology Congress 10 to 11 November, Hamburg www.die-verbindungs-spezialisten.de Corrosion & Prevention 2015 15 to 18 November, Adelaide www.acaconference.com.au Materials Innovations in Surface Engineering Conference (MISE) 24 to 25 November, Brisbane www.mise2015.com.au

Event Spotlight: WTIA Conference & Awards With the theme of ‘Making Australian Welding Internationally Competitive’, the 2015 WTIA Conference and Awards will be the premier event for welding and fabricating professionals.

For further information about the conference and awards and to register, please visit: www.wtiaconference.com.au Two keynote speakers have been confirmed for the Conference and Awards: Senator Nick Xenophon and the Hon Karen Andrews, MP. Both are advocates for manufacturing and industry in Australia, regularly speaking out on the importance of keeping welding jobs on Australian shores.

Senator Nick Xenophon Senator Xenophon has continued to prove himself a steadfast advocate for manufacturing and fabrication in Australia. In May 2015, along with Victorian Independent Senator John Madigan, Senator Xenophon proposed new legislation aimed at giving Australian manufacturers a fair go. The legislative move follows a Senate inquiry last year instigated by Senator Madigan and Senator Xenophon, which found serious flaws in the Commonwealth Procurement Rules

and how they were implemented.

The proposed legislation would see Commonwealth Government procurement rules radically overhauled to give local manufacturers a “fighting chance”.

The Hon. Karen Andrews Karen brings her experience in engineering, industrial relations and running her own business to her roles as Parliamentary Secretary and Federal Member for McPherson in Queensland.

Karen was elected as the LNP candidate for McPherson at the 2010 election, and was re-elected in 2013. Following the election, she took on the position of Chair of the House of Representatives Joint Standing Committee on Public Works. She served in this capacity until December 2014, when she was appointed as Parliamentary Secretary to the Minister for Industry and Science, a role which suits her passion for engineering, maths and science.

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INSIDE THE WTIA

Latest Certified

AICIP Personnel It is with great pleasure that we list AICIP renewals of certifications and offer our congratulations to all successful AICIP In-Service Inspector (ISI) and Senior In-Service Inspector (SISI) candidates. For more information about the AICIP, please visit: www.aicip.org.au.

New In-Service Inspectors (Certified in May 2015) Name

Reg. No.

New In-Service Inspectors (Certified in June 2015) Name

Reg. No.

10 Year Re-Certification of In-Service Inspectors Name

Reg. No.

Shahid Ali

0624

Mark Blacklock

0648

David Acton

0222

Ashley Brooks

0620

Cameron Chaffey

0642

Edgardo Bautista

0238

Venkatesh Biraju

0636

Nam Do

0649

John Blakey

0202

Brian Casson

0640

Matthew Gibson

0646

Glenn Dean

0242

Justin Cavanagh

0626

Paul Grosser

0645

David Piper

0206

Shannon Costa

0622

Alan Lambert

0644

Santhosh Chacko

0628

Bobby Puthumana

0643

Antony Crampton

0637

Ali Raju

0650

James Driver

0629

Sanjay Sonar

0641

Name

Haitao Han

0633

Sandor Tessenyi

0647

Michael Hann

0625

Peter Bellis

0399

John Horsley

0394

Dante Garcia

0401

Michael Gray

0402

Barry Lister

0390

Mitchell Nairn

0397

Steven Raynel

0395

Mark Rutar

0396

Phillip Schoeman

0393

Duncan Smith

0392

Paul Vandeberg

0400

Jayson Webb

0389

Reiaz Yunus

0410

New Senior In-Service Inspectors (Certified in May 2015)

Mark Hogan

0627

George Loomes

0630

Roy Munday

0623

Name

Ryan Souter-Robertson

0632

Stuart Jeayes

0256

Hartley Strugnell

0635

Emil Mandyczewsky

0542

Vikasraj Sunehra

0634

Stephen Otto

0232

Greg Taylor

0638

Andrew Wai

0639

Mitchell White

0631

Rizwan Younus

0621

Reg. No.

15 Year Renewal of Senior In-Service Inspectors Name Leslie Martin

Reg. No. 0099

Five Year Renewal of In-Service Inspectors Reg. No.

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AUSTRALIAN WELDING | OCTOBER 2015

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