July 13-14, 2004 Orlando, Florida. Also Inside: information on the Friction Stir Welding Conference August 10-11, 2004, in Orlando

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1 July 13-14, 2004 Orlando, Florida This conference is critical to design/ production/materials engineers involved with the welding of titanium, aluminum, and stainless steels and especially to those having difficulties getting an effective equipment and procedure plan to rev up to high volume (and economical) manufacturing or fabrication. American Friction Welding, Welding Journal, May 2001 Also Inside: information on the Friction Stir Welding Conference August 10-11, 2004, in Orlando

2 Getting Economical Weldability From Titanium, Aluminum, and Stainless Steel and Their Alloy Enhanced Versions. Tuesday, July 13 Session I Welcoming Remarks Robert R. Irving, Chairman Stephen Luckowski, Co-chairman 8:30 AM 12:15 PM 1. Manufacturers still can t produce a welded plane Challenges to Welding Critical Aircraft Structure Larry Perkins, Wright-Patterson AFB, Dayton, OH A discussion of the barriers to implementation of large-scale welding for aircraft. Such items as design and certification methodologies, legacy materials usage, infrastructure barriers, and aircraft program development issues will be covered. 2. Using GMAW-pulsed when titanium replacements are needed fast The Application of GMAW-P Titanium Welding in Army Armament Systems Stephen Luckowski, U.S. Army, Picatinny Arsenal, NJ The use of titanium in Army armament systems is steadily rising to meet rapid-deployment requirements. Fabrication of these systems requires highproductivity GMAW to make the use of titanium affordable and compatible with traditional manufacturing methods. This paper discusses the development of pulsed gas metal arc welding of titanium and successful applications of the technology. Morning Break 3. When there s a need for reduced magnetic signatures Welding of Stainless-Steel Advanced Double-Hull Structures Michael Wells, Naval Surface Warfare Center, West Bethesda, MD, and John N. DuPont, Lehigh University, Bethlehem, PA The U.S. Navy is investigating non-magnetic stainless steels for construction of advanced double-hull combatants, as well as a substitution for high-strength steels in selected areas of conventional ship designs to further reduce magnetic signatures. This paper presents the results of work on the characterization of dissimilar welds between AL-6XN super austenitic stainless steel and two Ni-base filler materials, including weld metal properties, weldability, corrosion resistance, and fume generation. 4. Eliminating problems in fracturecritical structures Electron Beam Welding on the F-22 Fighter Plane James K. McClaflin, Boeing Integrated Defense Systems, Renton,WA This presentation will cover Boeing's F/A-22 experience with welded aircraft structure from a designer's viewpoint. Boeing has successfully used electron beam welding for the assembly of major portions of fracture-critical structure. Gas tungsten arc welding is used extensively for the repair of detail and test hardware. 5. How to avoid contaminating titanium Flux Cored Arc Welding and Flux-Assisted Gas Tungsten Arc Welding of Titanium Stephen Liu, Colorado School of Mines, Golden, CO Being extremely reactive with oxygen and nitrogen, welding of titanium and titanium alloys requires suitable consumables that will protect the weld pool and weld bead from the atmosphere, and clean the weld metal from these contaminants. Using a flux cored electrode, researchers accomplished great progress in producing quality titanium welds. In addition to flux cored arc welding, these researchers also investigated flux systems for gas tungsten arc welding that significantly improved the penetration of titanium welds. U.S. Marine Corps, Welding Journal, Mar 2003

3 12:15 PM 1:30 PM Lunch Session II 1:30 PM 5 PM 6. Tools to predict distortion and the WPSs to handle them Control of Weld Distortion for Fabrication of Lightweight Ship Panels Harvey R. Castner, Edison Welding Institute, Columbus, OH The use of thin steel panels is an important design feature to reduce the weight and improve the mission capability of Navy ships. EWI has extensive experience in reducing weld distortion during the fabrication of lightweight ship panels. This includes development of finite element analysis tools to predict distortion as well as practical welding procedures to control distortion. 7. Pre- and post-welding QC to eliminate repair problems Weld Repair Issues of 6A1-4V Safety-of-Flight Titanium Castings Al Patterson, Lockheed Martin Aeronautics Co., Marietta, GA Titanium 6Al-4V castings are being used in primary safety-of-flight structural applications on the F/A-22. Damage tolerance analysis requirements for titanium castings entailed significant upgrades in (1) welder qualifications; (2) weld repair property verification (procedure qualification records or PQR and welding procedure specification or WPS), (3) general NDE requirements; and (4) reliability of NDE processes (probability of detection analysis or POD) as it relates to prior usage in aeroengine applications. This is a chronicle of the maturation of weld repair issues for the F/A-22 air vehicle. Afternoon Break 8. Use FSW on aluminum to avoid fatigue cracking and corrosion Friction Stir Welding of Aluminum Lithium Alloy for Army Trailer Application Kevin Colligan, Concurrent Technologies Corp., Harvest, AL The U.S. Army depends heavily on small trailers for transporting supplies to support mission requirements, but to date these relatively low-tech accessories have been prone to failures from fatigue cracking and corrosion. Concurrent Technologies Corporation, funded by the Combat Vehicle Research program, developed a prototype trailer frame that used high-strength aluminum-lithium alloy plates and extrusions, joined by friction stir welding. The prototype trailer employed an organic composite shell and a new Davis suspension to reduce the number of subcomponents, eliminate the use of rivets, and greatly simplify the design. 9. Refurbish and/or repair surfaces using LBW Laser Beam Welding and Surface Modifications Richard P. Martukanitz, Pennsylvania State University, State College, PA The presentation will cover various active programs within the Applied Research Laboratory at Pennsylvania State University (ARL Penn State) to develop and implement laser beam welding and surface modifications for naval applications. Discussions will include welding of structural shapes and stiffened structures, and laser surface modifications for refurbishment and repair. Wednesday, July 14, 2004 Session III 8:30 AM Noon 10. Behind the scenes of AWS newest structural code Development of Titanium Structural Welding Code John Lawmon, Edison Welding Institute, Columbus, OH With the increasing use and availability of titanium alloys, it has become increasingly evident that a need exists for a structural welding code to support the procurement, design, manufacture, and inspection of a wide range of structural titanium fabrications. A draft code is being prepared for consideration under the guidance of the American Welding Society, based on the principles contained in the internationally recognized D1 series of codes. While this series provides an excellent set of models on which to base the titanium code, the material s physical properties, historical practices, and new applications have posed some interesting challenges. Among them, the committee developing the code has had to understand the mechanical strength and fatigue performance of titanium welds, consider titanium's special protective shielding requirements, and evaluate and consider "standard" nondestructive acceptance criteria against titanium's unique properties. 11. How FSW is being applied and will be applied Friction Stir Welding of Airframe Structures Raj Talwar, Boeing Phantom Works, St. Louis, MO This presentation will examine the applicability of friction stir welding to weapon systems and advanced aircraft structures.the process will be described, and the benefits of the process will be presented. Present and future applications will be discussed. Morning Break

4 12. Reduce weight, gain strength with new steel alloy by using LBW-assisted GMAW Laser Assisted Gas Metal Arc (Hybrid) Welding of HSLA-65 Steel Paul A. Blomquist, Applied Thermal Sciences, Inc., Sanford, ME New designs for surface combatants have focused on maximized performance at minimum weight. The use of a new controlled-rolled alloy, HSLA-65, has provided the opportunity to attain substantial weight savings in the use of plate and shapes. Since this alloy cannot be rolled into structural sections, stiffeners for ship production must be welded from plate pieces. Laser beam welding combined with the gas metal arc welding process (often called "hybrid") allows welding at high speeds with outstanding accuracy. 13. A corrosion-resistant, weldable new high-strength titanium alloy Welding of Magnesium-Lithium Alloys and Portable Aluminum Weld Repair Consumables David L. Olson, Colorado School of Mines, Golden, CO Light alloys are being applied aggressively to defense structures and assemblies to enhance the mobility and effectiveness of rapid deployment forces. Ultralight Mg-Li alloys, which are either BCC or dualphase (BCC/HCP) in their constitution, offer the possibility of both increased formability and weldability over traditional magnesium-based alloys. Further work to increase weld penetration and to promote improved passivity is in progress. An effort to develop a self-shielding flux cored aluminum wire that can be welded using a 24V DC automotive power source is in progress. The various concepts and progress to achieve self-shielded aluminum welding wire will be reported. 14. Deposition-free shaping Titanium Alloy Ti-5111 for Naval Applications Ernest J. Czyryca, Naval Surface Warfare Center, West Bethesda, MD Titanium and its alloys are finding increased use on U.S. Navy ships and submarines for increased reliability with reduced maintenance and reduced weight. NSWC, in cooperation with TIMET Corp., developed the Ti-5Al- 1Sn-1Zr-1V-0.8Mo (Ti-5111) alloy as a weldable, highstrength marine alloy. The results of tensile, fracture toughness, seawater corrosion, and stress corrosion cracking tests demonstrated that Ti 5111 GTA welds possess high strength, good fracture toughness, and excellent resistance to seawater corrosion. Noon 1 PM Lunch Session IV 1 PM 4:45 PM 15. Get needed mechanical properties Free Form Deposition of Ti 6Al-4V Kevin T. Slattery, Boeing Phantom Works, St. Louis, MO Because of its ability to make complex shapes with minimal tooling or die costs, Free Form Deposition of Ti-6Al-4V is of great interest to the aerospace industry. A range of scale and a variety of energy sources, including laser, electron beam, and arc are being investigated. This paper will compare the processes, their mechanical properties, and microstructures. 16. Use FSW to build up, including complex curvatures Friction Stir Welding for Army Weapon System Components William J. Arbegast, South Dakota School of Mines and Technology, Rapid City, SD Friction stir welding is being developed at the South Dakota School of Mines and Technology s Advanced Materials Processing Center in cooperation with the Army Research Laboratory and the Edison Welding Institute. Specific attention is being paid to complex curvature and built-up structures, rapid reconfigurable and flexible tooling, induction preheating of titanium and steel, and friction stir spot welding (FSSW) of aluminum alloys. Examples of technology advances and hardware developments for DOD applications will be presented. Afternoon Break 17. Use micro-welding processes to repair "unweldable" materials Advanced Engine Repair Technologies James Reynolds, Edison Welding Institute, Columbus, OH Restoration of gas-turbine engine components is highly influenced by two primary contributors: selection of a joining process and the proper filler metal. Micro-welding processes have been developed that enable many of these high-performance materials, previously considered to be unweldable, to be welded successfully. This presentation will acknowledge several of the micro-welding processes and highlight repair applications. 18. How tooling and procedures were developed for FSW Friction Stir Welding for Defense Applications Harvey R. Castner, Edison Welding Institute, Columbus, OH This presentation will include development of the friction stir welding process for application to aluminum armor for combat vehicles and to titanium alloys for aircraft engine components. The work includes development of tooling, welding procedures and the demonstration of conformance to mechanical property requirements. Conference Adjournment

5 Top Defense Industry Welding Experts Will Share Breakthrough Welding Information With You at This Two-Day Conference. THESE ARE THE DEFENSE INDUSTRY EXPERTS WHO WILL BE THERE: William J. Arbegast South Dakota School of Mines and Technology, Rapid City, SD Mr. Arbegast is director of the Advanced Materials Processing Center at the South Dakota School of Mines and Technology, where research includes friction stir welding and friction stir spot welding technology development of aluminum, titanium, and steel alloys for industrial applications. Mr. Arbegast also directs the National Science Foundation Industry/University Cooperative Research Center on Friction Stir Processing. Earlier, he spent 25 years at Lockheed Martin Corporation, developing advanced materials and processes for aircraft, launch vehicles, satellites, and interplanetary probes. He earned a Bachelor of Science degree in metallurgical engineering from the Colorado School of Mines in Paul A. Blomquist Applied Thermal Sciences, Inc., Sanford, ME Mr. Blomquist, director of manufacturing technology at Applied Thermal Sciences, has over 25 years experience in shipbuilding and heavy industry, and is the author of several novel concepts in this field. Before joining ATS, he was research engineer and manager of maritime technology programs at Pennsylvania State University s Applied Research Laboratory. He is a member of the Laser Institute of America, the Welding Panel SP-7 of the National Shipbuilding Research Program, and the American Welding Society. He chairs the AWS C7C Sub-Committee on Laser Beam Welding and Cutting and is vice-chair of the AWS C7 Committee on High Energy Beam Processes. Harvey R. Castner Edison Welding Institute, Columbus, OH Mr. Castner directs the Government Programs Office at Edison Welding Institute (EWI), including the Navy Joining Center (NJC), a Navy Manufacturing Technology (MANTECH) Center of Excellence for materials-joining technology. He manages research-and-development and education-and-training programs for the U.S. Navy, Department of Defense, and other government agencies. Kevin J. Colligan Concurrent Technologies Corp., Harvest, AL Mr. Colligan is principal engineer at Concurrent Technologies Corporation, supporting friction stir welding development for combat-vehicle applications. He has worked in manufacturing research and development throughout his career, starting at The Boeing Company in He specialized in machining research and development, and formed a machining laboratory supporting Boeing's military-aircraft business. He began FSW research in 1994, and in 1999 he joined Lockheed Martin Corporation, supporting development of FSW of the space shuttle's external-tank program. He moved to Concurrent Technologies in Mr. Colligan received a Bachelor of Science degree in mechanical engineering in 1982 from Texas A&M University, and a Master of Science degree in mechanical engineering in 1993 from the University of Washington. Ernest J. Czyryca Naval Surface Warfare Center, West Bethesda, MD Mr. Czyryca is a senior research project manager in the Metals Department of the Naval Surface Warfare Center, Carderock Division. He holds degrees in metallurgical engineering (Drexel University), civil engineering (Johns Hopkins University), and engineering mechanics (Pennsylvania State University). In his 40- year career with the Navy, he has been involved in or managed research-and-development programs in naval structural metals, alloys for machinery applications, metals processing, mechanical metallurgy, welding metallurgy, fatigue of metals and structures, fatigue design, fracture properties and fracture mechanics, and failure analyses. He has over 25 published papers. He is a member of the American Welding Society,American Society for Metals, American Society for Testing and Materials, and International Naval Research Organization. John N. DuPont, Ph.D. Lehigh University, Bethlehem, PA Dr. DuPont is a professor in the Materials Science and Engineering Department at Lehigh University, where he directs industrial and government-sponsored research in laser engineered net shaping (LENS), welding process modeling and optimization, solidification modeling, weldability, mechanical behavior of welds, and erosion/corrosion behavior of weld overlays. He has written over 100 publications, edited three books and one book chapter, co-organized three international conferences, and has one patent. Robert R. Irving Irving & Associates, Yardley, PA Mr. Irving heads his own consulting firm specializing in production of engineering conferences and writing technical articles. Earlier, he was materials editor and technical editor of the national weekly magazine Iron Age. While at Iron Age, he received awards and commendations for articles on product liability and research. He also spent several years on the staff of the Welding Journal. He served on a panel appointed to study the state of the American steel industry and submit findings to the U.S. Senate. Mr. Irving earned a Bachelor of Arts degree in English at the University of Pennsylvania and studied metallurgy at Drexel University. John Lawmon Edison Welding Institute, Columbus, OH Before joining EWI, Mr. Lawmon spent 25 years in a heavymanufacturing environment, involved in quality, design, machining, casting, production engineering, and cost reduction. He has managed, consulted, and worked directly on large projects for the nuclear, armament, and commercial sectors. More recently, he has led projects to improve welding processes, develop new technologies, implement production lines, reduce production costs, and write manufacturing specifications for EWI member companies. A key element of his work is the development of mechanized welding procedures for the fabrication of large titanium structures subject to high strain rate and fatigue loading. He has developed plasma, GTAW, and GMAW welding procedures that led to creation of fatigue design guidance rules for grade 5 and grade 23 materials. Stephen Liu, Ph.D. Colorado School of Mines, Golden, CO Dr. Liu is a professor of metallurgical engineering at Colorado School of Mines and director of the Center for Welding, Joining and Coatings Research. He is editor-in-chief of the ASME Journal of Offshore Mechanics and Arctic Engineering, and is active in the American Welding Society; ASM International; The Minerals, Metals and Materials Society; American Society of Mechanical Engineers International; and the Japan Welding Society. He is also a professional member (MIM) of the Institute of Materials and a Chartered Professional Engineer (CEng) registered with the Engineering Council in the U.K. He received his Ph.D. degree in metallurgical engineering from the Colorado School of Mines. Stephen Luckowski U.S. Army Armament, Research, Development, and Engineering Center, Picatinny Arsenal, NJ Mr. Luckowski is chief engineer for the Prototype Manufacturing Team and manager of the Army Manufacturing Technology Program "Low-cost Titanium for Lightweight Armaments." He is an AWS member and chairs the D1.9 Structural Titanium Committee.

6 Richard P. Martukanitz, Ph.D. Pennsylvania State University, State College, PA Dr. Martukanitz has extensive experience in laser processing technology for welding, cladding, cutting, surface modification, and forming applications. At Penn State, he is head of the Laser Processing Division, assistant director of the Applied Research Laboratory (APL), and director of the Laser Processing Consortium operated by APL. Previously he worked for Metalworking Technologies, Inc., and Alcoa. Dr. Martukanitz has published over 40 papers on joining and manufacturing technology. He holds three patents and has filed for a fourth. He is principal reviewer and a member of the AWS C7C Subcommittee on Laser Beam Welding and Cutting. He earned a Ph.D. degree in materials science and engineering from Pennsylvania State University in James K. McClaflin Boeing Integrated Defense Systems, Renton, WA Mr. McClaflin was the Boeing lead engineer responsible for the design of the F/A-22 welded forward booms, consisting of 21 titanium structural elements the largest electron beam welded aircraft structure since the F-14. He became the project manager for the F/A-22 electron beam welded wing side of body fittings, which was a cost-effective replacement for two large titanium castings. David L. Olson, Ph.D., P.E. Colorado School of Mines, Golden, CO Dr. Olson is the John H. Moore Distinguished Professor of Physical Metallurgy at the Colorado School of Mines. He performs research into the physical metallurgy of welds, joining processing science, and advanced nondestructive evaluation of weld microstructure, phase stability, and properties. He has authored, co-authored, and edited numerous technical papers, reports, and books, and holds five patents. Dr. Olson is an AWS Fellow, ASM Fellow, and Foreign Member of the National Academy of Sciences of the Ukraine. His awards include the AWS Adams Lecturer and the IIW Arata Prize. He is a university affiliate of Los Alamos National Laboratory. Al Patterson Lockheed Martin Aeronautics Co., Marietta, GA Mr. Patterson, senior staff engineer at Lockheed Martin Aeronautics, is assigned to F/A-22 materials and processes engineering with primary responsibility in titanium investment castings and welding. He has helped develop structural titanium investment castings (allowables and processing parameters) for primary safety of flight applications for military aircraft. He chairs the Aerospace Metals Engineering Committee, a branch of SAE-AMS Commodity Committees that write and update AMS specifications. Larry P. Perkins Wright-Patterson Air Force Base, Dayton, OH Mr. Perkins is a technical advisor to the Metals, Ceramics and NDE Division of the Materials and Manufacturing Directorate in the Air Force Research Laboratory at Wright-Patterson Air Force Base. He participates in developing and introducing advanced technology into emerging and existing weapons systems. For over 20 years, he has been involved with materials and process issues on defense systems, including turbine engine components, structural aircraft parts and accessories, space systems, munitions, support equipment, and infrastructure. He has written articles for American Society for Materials (ASM) handbooks on materials selection for aerospace systems and failure analysis of joining processes for electronic assemblies. Mr. Perkins participates in accident investigations and gives expert testimony on welding, materials, and failure analysis. He has authored over 250 reports and articles, and often presents papers at national and international conferences. James Reynolds Edison Welding Institute, Columbus, OH Mr. Reynolds is a project engineer at Edison Welding Institute, specializing in weld repair of difficult-to-weld materials. He earned a Bachelor of Science degree in welding engineering from The Ohio State University and has significant manual welding experience. Kevin T. Slattery, D.Sc. Boeing Phantom Works, St. Louis, MO Dr. Slattery is senior principal engineer at Boeing Phantom Works, Freeform Fabrication Synergy team leader, and program manager for the MAI-DUST Laserforming Program. He has worked on advanced low-cost titanium processing technologies, and in materials development on nuclear fusion programs including advanced hot isostatic pressing. He also has worked on naval aircraft (F/A-18 E/F and A-12) programs, determining the effects of defects in composite structures, NDE method development, and validation of NDE acceptance criteria. He holds four patents in materials processing, and has seven applications pending. He earned a Doctor of Science degree in materials science and engineering from Washington University in St. Louis, MO, with a dissertation on modeling of hot isostatic pressing of W-Cu composites. Raj Talwar Boeing Phantom Works, St. Louis, MO Mr. Talwar manages the Unitized Metallic Processes group at Boeing Phantom Works, focusing on technologies such as friction stir welding, superplastic forming, aluminum and titanium castings, and grid-lock assemblies. He also manages three programs aimed at implementing low-cost design, materials, and manufacturing technologies for Air Force and Navy aircraft, and he leads several industrial-participation projects to transfer advanced metals technology to foreign countries. He has spent 17 years at Boeing in structural design, analysis, material processing, and structural validation. A registered professional engineer in California, he earned a Bachelor of Technology degree in civil engineering and computer science, and a Master of Science degree in engineering management and engineering mechanics from the University of Illinois at Chicago. Michael E. Wells Naval Surface Warfare Center, West Bethesda, MD Mr. Wells, a senior project engineer at the Naval Surface Warfare Center, is responsible for programs relating to use of titanium, aluminum, and non-magnetic stainless steels in fabrication of hulls and structures for naval vehicles. He also serves as the Naval Sea Systems Command representative to commercial shipyards and contractors on fabrication, welding, and inspection of titanium components on newer surface ships and submarines. He has received two patents, written on nonferrous fabrication technology, and is active in several AWS subcommittees.