Latest news / events
- The literature search made easy....Weldasearch
- Materials issues defence and security
- Improved TWI FTIR-microscopy facility for positive identification of unknown non-metallic materials
- The biggest welding and joining related library in the world
- Top award for low-stress-no-distortion welding work
- So, you want to be a ...... Responsible Welding Coordinator
- TWI Technology Awareness Day 2010
- Materials Issues in Defence and Security
- TWI assists with critical repair at Canadian nuclear plant
- Welder Apprentice Scheme in Brunei a great success
- CBI Regional director visits TWI in Rotherham
- New thermographic inspection training at TWI
- CO-PATCH - Composite patch repair for marine and civil engineering infrastructure applications
- Diary dates - Construction and Engineering
- Where's the join....FSW adopted for invisible stainless repair
- NEW modelling demonstrations
- So, you want to be a ...Responsible Welding Coordinator
- Materials issues surfacing and particulate engineering
- Bespoke solutions, no problem...using advanced phased array
- Welding Co-ordination - The Knowledge to Comply
- Cost cutting software - predicting distortion and improving fatigue performance
- Fatigue Life Prediction for Toe Ground Joints
- Training: An Introduction to Friction Stir Welding
- Specialist Materials and Joining - A new section at TWI?
- Correlation of Phased Array Inspection and Fatigue Performance of FSW Joints
- Laser Surface Hardening with Adaptive Control
- Non-Vacuum Electron Beam Welding - Progress Report and Future Developments
The literature search made easy....Weldasearch
The ease with which TWI Members can access the largest and most comprehensive welding database in the world is quite a surprise to many first time users. In fact using the database couldn't be simpler.....as TWI's tame guinea pig recently found when he offered himself to trial the service.
Access to the database is handled by the Information Services team. It's managed by TWI's Weldasearch mastermind, Sheila Thomas, and is based on a simple but clearly defined lexicon of key terms defined by the International Institute of Welding thesaurus. For Members with a query Sheila is unquestionably the best starting point. 'We are very happy to advise on how to set up a search' she says. 'Or indeed any other aspect of Weldasearch.'
One of the most useful aspects of Weldasearch is the Alerting Service which it offers. As Sheila Thomas explains, 'If you want to be kept up to date in a particular subject area, the alerting service is invaluable. You can access it from the Weldasearch front page, it is about half way down.'
'It allows you to set up a simple search which identifies your topic, and every month we update the database with typically about 450 items. Once you have entered your search and e-mail address all the items that are added about your topic will be e-mailed to you. It is a very useful service and it's easy to set up.'
So first, a typical sample enquiry....
What is the most appropriate manual metal arc covered electrode for welding carbon steels in shipbuilding using the overhead position?
Sheila Thomas takes up the story step by step...
- "First we go to the corporate website front page and select Services from the top row, and on the next page Information Services from the vertical column. This brings us to the front page of the Information Services area.
- Click on Weldasearch. This introductory page gives you options to look at three short videos about how to use the system using 'easy search', 'advanced search' or 'set up a Weldasearch Alert'.
- To search the database click on 'search the Weldasearch database'
- At this point we have to identify ourselves. The service is only available to Industrial and WJS Members and TWI staff. So log in using your TWI website ID and password.
- This takes you to the gateway page. Click on the 'Search Weldasearch' button and this brings you to the Weldasearch interface page.
- Identify the Search option which you require...easy, advanced or expert.
For this sort of search....with several different criteria, the 'easy' search option would be inadequate. Our search is far more specific so we select the Advanced Search and we examine the key words available.
Weldasearch Advanced Search option allows you to search in specific parts of the database. We know we want a manual metal arc process, which is sufficiently common that it is likely to be a keyword, so from the first drop down box we select the 'Keywords' option. If you're not sure about the acceptable terms, look at the orange word Index next to the drop down box. The index shows us what terms are allowable.
- After clicking on Index, we type MMA into the box labelled Index Stem, and hit the Enter key on the keyboard. You can see there that MMA alone doesn't appear, so it is not a valid keyword, but that MMA WELDING and MMA SURFACING are in the displayed list.
- We have confirmed that our keyword is 'MMA WELDING' and by clicking on it we can add it to the search box. But that shows us over 14,000 items. We need to narrow it down, so let's look at our other terms.
- We know we want covered electrodes, so we can do the same thing again using the second search box to ensure that it is an 'AND' search in the next instruction. We want to make sure that the article we identify talks about the electrodes, it might just say that it involved MMA welding and not mention the consumables. The search has narrowed to 3643 references, which is still unmanageably large.
- We are interested in the overhead position, so we go to keywords again and choose 'overhead'. It narrows hugely when we include all three terms OVERHEAD POSITION and MMA WELDING and COVERED ELECTRODES.
- Now we're offered just nine references, which is easily manageable. Up to 20 references can be displayed at a time. Of course the success of the search is directly related to the specificity of the keywords. If for instance,
instead of entering OVERHEAD POSITION the words 'CARBON STEELS' were entered the search would have identified considerably more than nine references, 134 to be precise, which many a searcher would consider an unmanageable number.
Similarly the keyword 'CARBON STEELS' limits the materials to steels with more than 0.25% carbon. If instead we use the less specific 'STRUCTURAL STEELS' we embrace mild steel, namely low carbon steels, and carbon manganese steels, which incidentally are very relevant to shipbuilding, the application specified in the original enquiry.
- We now go to 'View: Marked l Unmarked l All' from the menu towards the top of the screen and click on 'All' to see the details of the items retrieved.
Our standard form of presentation is to supply the abstract, the Weldasearch record number, title, authors, bibliographic reference, any notes about translations or where the paper was presented, the abstract, and availability from TWI's library.
- Using the website the enquirer can then click on the little basket symbol to request a photocopy or an electronic copy from the library There are complex copyright issues governing what we can and can't provide as photocopies."
For more information contact sheila.thomas@twi.co.uk
Materials issues defence and security
A summary by Dr. Cem Selcuk of the WJS Materials Technical Group Meeting held at TWI Conference Centre on Wednesday 9 June 2010.
The Welding and Joining Society hosted the anticipated Materials Technical Group Meeting on Wednesday 9 June 2010 at TWI Cambridge Conference Centre and captured some of the ongoing issues and latest developments, initiatives outlined in the presentations and discussions.
This year's meeting, was the very first event of the Defence, Safety and Security Committee which was recently set up in the framework of the IOM3, joint technical sponsors of this event, alongside Materials Knowledge Transfer Network (KTN). Consequently, the programme attracted a lot of interest and was very well attended.
After a warm welcome and introduction by the chairman Dr. Peter Boothby, the event started with the keynote speaker Dr. Dan Kells from BAE Systems, who gave the audience a highly strategic insight into the MAST programme dedicated to materials and technological issues with defence applications.
It was emphasised that new members can add onto the existing skills and are still welcome as team members. It was added that the MAST team endeavours to offer an innovation and exploitation platform for technology developments with a view to addressing some crucial technical challenges that underline the defence sector, notably for Ministry of Defence in the UK.
The stage was then taken by Dr. Eoin O'Keefe from QinetiQ who presented a highly informative overview of combat identification materials that have been researched to prevent accidental destruction due to misidentification of 'friends' as 'enemies' in security operations while maintaining mission effectiveness. The talk was an excellent opportunity for newcomers into the defence industry, to appreciate the extent to which a broad range of technologies is employed in order to address maintainability, if possible at lower costs, without compromising product robustness and performance.
The last presentation of the morning session continued with a technical talk by Alec Gunner of TWI Cambridge, who captured recent advances at TWI in joining and non-destructive testing of ballistic ceramics. The lecture included some very interesting results and attracted considerable discussion from the audience.
Over lunch, delegates particularly interested in professional development were encouraged to explore potential memberships on WJS, The Welding Institute, IOM3, and Materials KTN. The available information included benefits of professional development and the registration with the Engineering Council towards for example, CEng status, plus events that can contribute to this.
The meeting continued with Diccon Booth of Royal Navy, who talked on what technology in defence meant on the ground. The presentation started with a highly interactive and awe-inspiring video and gave a compact overview of the capabilities and future requirements in terms of multifunctionality of the Navy with examples of both old and new vessel specifications that are used. It was one of the most visually effective talks that TWI and WJS Materials Technical Group has ever hosted.
The second presentation in the afternoon was by Dr Chris Munnings from Loughborough University, on characterisation of aluminium/alumina bond within interpenetrating metal ceramic composites, where a thorough understanding of the relationship between stress development and differences between thermal expansion of materials were crucial for achieving successful metal-ceramic joints.
The final speaker of the day was John Cotton of Ceram, who captured the latest developments in the frame of Materials KTN, as an interactive platform to facilitate networking, stimulate innovation from academic and industrial collaborations, and most importantly provide a medium for related dissemination and technology transfer. As part of the discussion session that followed, delegates were made aware of the benefits of Knowledge Transfer Networks in a wider spectrum. KTNs potentially influential role in the development of UK Technology Strategy Board Research and feasibility initiatives was highlighted and attendees were encouraged to consider taking part in collaborative R&D programmes.
The meeting came to a close with a final speech from the Chairman, who acknowledged the support of co-sponsors including the Defence, Safety and Security Committee of IOM3 and TWI in organising the event, which turned out to be a highly successful one.
Left to right: Secretary, Cem Selcuk (TWI) and speakers: Eoin S O'Keefe (QinetiQ), Dan Kells (BAE Systems), Chris Munnings (Loughborough University), John Cotton (Ceram), Diccon Booth (Royal Navy) with chairman, Peter Boothby (Macaw Engineering)
For further information on future meetings of the WJS Materials Technical Group, please contact directly the secretary, Dr. Cem Selcuk at (cem.selcuk@twi.co.uk) and visit the TWI website (www.twi.co.uk).
Improved TWI FTIR-microscopy facility for positive identification of unknown non-metallic materials
In 2009, TWI upgraded its FTIR-microscopy facility with a refurbished Perkin-Elmer system 2000 FTIR spectrometer with an i-series FT-IR microscope, and a new ATR objective.
This facility enables fast, inexpensive positive identification of non-metallic materials, thus avoiding the potential embarrassment of using the wrong material. It is mainly used for polymeric samples, but there are many other applications, as described below.
Sample types
Samples may be solid, liquid, thin films. Sample size can be down to 10 microns by 10 microns, or films down to a micron thick.
Typical applications
The following list gives an idea of the range of samples that have been analysed.
Polymers and rubbers
Organic liquids
Corrosion products on printed circuit boards
Multi-layer paint coatings
Thin films
Clean room contaminants
Composites and Fibres
Inorganic substances
Adhesives
Quantitative determination of crystallinity and molecular orientation
Polymer degradation
Contaminants in fuel from Formula One racing cars
Recycled polymers
Theory
Infrared spectroscopy exploits the fact that molecules absorb specific frequencies that are characteristic of their molecular structure. These absorptions are resonant frequencies, ie the frequency of the absorbed radiation matches the frequency of the bond or group that vibrates. In order for a vibrational mode in a molecule to be "IR active," it must be associated with changes in the permanent dipole.
A spectrum is recorded by passing a beam of IR light through the sample. Examination of the transmitted light reveals how much energy was absorbed at each wavelength. Using a Fourier transformation instrument enables the measurement of all wavelengths simultaneously. A transmittance or absorbance spectrum is produced, showing at which IR wavelengths the sample absorbs. Each material will have a characteristic 'fingerprint' spectrum.
For further information, please contact Sheila Stevens x9238
The biggest welding and joining related library in the world
Industrial Members are reminded the TWI Library catalogue is available to them at www.twi.co.uk/libcat
Top award for low-stress-no-distortion welding work
A distortion reduction project, headed by one of TWI's Industrial Members, has won a top research and development award with the major involvement of TWI.
The project which was part funded by the Technology Strategy Board centred on the development and application of Low Stress No Distortion Welding techniques, which use cryogenics to cool the weld pool and hence reduce distortion.
It ran for four years and concluded in February this year. As the lead industrial partner in the project ThyssenKrupp Tallent was asked to make a submission on behalf of the consortium to the MWP awards (Metal Working Production Magazine), in the R&D category.
TKT accepted the award on behalf of the consortium known as MALCO (Creating Opportunities for the MAnufacture of Lightweight COmponents).
The consortium included TWI Ltd, Bentley Motors, BOC, Comau Estil, Dytel Technologies, Komatsu (UK), Isotek, University of Strathclyde, and of course ThyssenKrupp Tallent.
The award citation read 'Very professional and well presented proposal, good alliances, strong on potential benefits'
The consortium partners are now hopeful that this success will help them secure future follow-on work to continue the development of LSND.
So, you want to be a ...... Responsible Welding Coordinator
Q: How can I become a Responsible Welding Coordinator?
A: ISO 14731 states that welding co-ordination is the sole responsibility of the manufacturer and the manufacturer shall appoint at least one responsible welding coordinator.
Responsible Welding Coordinator is a specific job role defined by the manufacturer, and assessment of the fusion welding quality activities against the requirements of ISO 3834-2 or ISO 3834-3 will seek to establish that personnel appointed as welding coordinators are competent to fulfil their allocated responsibilities.
Your competence in fulfilling that role will be assessed on a combination of knowledge, skills and experience that can be demonstrated through evidence of qualifications, certificates and log book or CV, and will be confirmed in interview.
Q: Do I need to be IWE (International Welding Engineer diploma) qualified to be an RWC?
A: There is no actual qualification for RWC, it is a role within a company and during an assessment for accreditation to ISO 3834 the RWC is assessed for their competence to carry out the required role within that particular company; RWC is not a 'portable' title.
The International Institute of Welding (IIW) and European Federation for Welding, Joining and Cutting (EWF) diplomas (I/EWE, I/EWT and I/EWS) have been accepted as satisfying the specific knowledge requirements for Responsible Welding Coordinators.
National qualifications that may be considered to demonstrate knowledge include the Cranfield University MSc in Welding Engineering, and The Welding Institute's professional membership classes of SenMWeldI, IncMWeldI and TechWeldI. Other welding and fabrication qualifications can also be relevant to the assessment.
Remember that knowledge is only one part of the competence assessment and a qualification does not guarantee that you will be considered appropriate for an RWC role. Before committing to any additional training or education, it is important to have your existing qualifications reviewed against the responsibilities you are expected to take on.
Q: I hear that there is a shortage of welding coordinators, so how do I become a consulting RWC and offer my services on a sub-contract basis?
A: The RWC role can be sub-contracted but the responsibility for welding co-ordination remains with the manufacturer. Even though you may be appropriately qualified, you cannot be recognised as an RWC without being assessed as competent against the specific job role that you are expected to fulfil, and this is done during the ISO 3834 assessment of the manufacturer.
Once a manufacturer has nominated you as their RWC, you will be assessed for the role allocated and the sub-contract terms will also be reviewed to ensure that you will have the authority to carry out the assigned tasks.
Q: My employer is seeking certification in accordance with ISO 3834 and expects me to become the RWC, where can I find more information?
A: Please review the information at www.iso3834.org, complete the Preliminary Information Enquiry Form for more guidance and a quotation, and contact the WFCS Scheme Manager if you have any further questions.
Chris Eady, Chief Executive TWI Certification Ltd
TWI Technology Awareness Day 2010: "Materials Selection and Failure Avoidance"
14 October 2010, Cambridge
Following successful events in 2005 and 2008, TWI will hold its third Technology Awareness Day on Thursday, 14 October 2010. We are very pleased to welcome Professor John Irven as our keynote speaker, who is the chairman of TWI's Research Board. This year, the day is dedicated to TWI's Structural Integrity and Materials Departments. Corrosion and structural integrity management have been an integral part of TWI for more than 60 years and TWI has established a world class reputation for supplying high calibre services to clients across all industry sectors. This event represents a unique opportunity for TWI members to get an update on the most recent research and advances in this area.
The morning session will focus on Corrosion Management & Mitigation, the afternoon on Life Extension. Presentations will cover corrosion considerations in materials selection, design and fabrication; coatings for corrosion mitigation and corrosion testing. The session on Life Extension will address advances in fatigue life management for extending service life; Engineering Critical Assessment for life extension and management of ageing assets. For a full programme and registration details please go to: http://www.eventsforce.net/10TAD. Attendees will have the opportunity to request one-to-one meetings with our experts on the registration form.
For the first time, we are also offering an interactive online option for members to attend this event. No travelling required! Watch only the topics of your interest! There is also a Q&A facility to allow you to ask questions which will be passed on to the speakers in real time. Please register here http://www.eventsforce.net/10LTAD for the online event.
The event is a membership benefit and free for TWI Industrial Members.
For further details please contact: viola.augstein@twi.co.uk
Materials Issues in Defence and Security
WJS Materials Technical Group Meeting
(Jointly with the Defence, Safety and Security Committee of IOM3)
Wednesday, 9 June 2010
TWI Conference Centre, Granta Park, Cambridge
Chairman: Dr Peter Boothby - Macaw Engineering
Secretary: Dr Cem Selcuk - TWI
Invited speakers include representatives from:
Qinetiq
BAE Systems
Royal Navy
Loughborough University
Defence and security are two important technology areas, which are closely linked, with several associated materials related issues. Materials production routes and characterisation interact strongly, and influence the outcome of any process application. A range of innovative material combinations of potential use for defence and security application, has been developed and applied over the years in several industry sectors ranging from construction and engineering, automotive, power, aerospace to medical science. Interdisciplinary research and development has resulted in advances in metals, ceramics and composites materials.that would otherwise not have been possible.
There is a continuing demand for intelligent high value added manufacturing through near net shape process solutions towards an improved efficiency in materials utilisation and performance in increasingly challenging operation conditions. These can be met by developing novel design methods and supporting innovative material technologies.
This one day event, open to everyone, will bring together experts and lead technologists, with the aim of capturing the state-of-art through presentations and discussions. The programme will present an ideal opportunity for sharing knowledge on the latest research and development, and key materials issues in this important socio-technical domain. It will also provide an invaluable forum for networking and professional development.
For further information, please contact rachel.wall@twi.co.uk
TWI assists with critical repair at Canadian nuclear plant
Nuclear expertise, developed by TWI over the last half century, has recently been called upon by a major nuclear operator.
Atomic Energy of Canada Limited (AECL) is collaborating closely with third-party welding experts The Welding Institute (TWI), UK based global specialists in materials joining technology on a highly specialised repair to an aluminium reactor vessel. TWI is helping with the development and testing of welding techniques in what AECL describes as a unique and challenging environment.
The NRU reactor is responsible for producing approximately 30% of the global supply of medical isotopes, used for radiotherapy and other medical treatments. There is virtually no published data on welding of irradiated aluminium, and TWI has been instrumental in advising AECL on development of the specialised repair techniques required for this task.
The first weld build-up inside the NRU reactor vessel was successfully performed on December 12th 2009. The weld repair was conducted remotely by operating the welding equipment from a position of approximately 10 metres above the location of the repair site.
Non-destructive examinations of the weld have found no defects, and preparations are now underway to conduct further repairs.
Welder Apprentice Scheme in Brunei a great success
Negara Brunei Darussalam is a developing nation located in one of the highest growth regions of the world but it relies significantly on imported manpower and skills.
Back in 2006, Joffren Omar Company Sendirian Berhad (JO) and Syarikat Kejuruteraan Sistematik Sendirian Berhad (SKS) embarked on a plan to train and develop local talent in the welding profession. A new purpose-built facility was built in Seria with technical advice and guidance from TWI who has been associated with JO/SKS since 2000.
A purpose-built facility was constructed to provide training facilities not only for welders but also for welding inspectors, painting inspectors and NDT professionals. The new facilities opened a year ago, in December 2008 and a Senior Supervisor and a Master Welding Instructor were hired with TWI's help.
On 8 December 2009, Joffren Omar Company Sendirian Berhad (JO) headed by Gary Young, presented the first nine 'home-grown' apprentices with a certificate of completion of the Welder Apprentice Scheme. When these young Bruneians signed onto the scheme, they had basic or little knowledge of the standards and competence required to be oil and gas welders. Yet, in a matter of months, through their own dedicated effort and supported by their instructors and supervisors, they have qualified at the highest international standards acceptable to Brunei Shell Petroleum (BSP) and Brunei Liquefied Natural Gas (BLNG), that is, CSWIP level 3 oil and gas, 6G and 6GR positions.
Through this initiative, JO/SKS continue to demonstrate their investment in Brunei's human resources development. Indeed, it is a strong indicator of the companies' commitment to BSP's Local Business Development policy. With the cooperation and support of international organisations such as TWI, and local agencies such as Immigration, Labour, Ministry of Education and others, it is hoped that Brunei will have enough skilled workers to cover its needs in the future.
For more details, please contact: Ibrahim Omar at ibrahimo@josks.com.bn
CBI Regional director visits TWI in Rotherham
News from RIDO, the Regional Investment and Development Office
Business chief sees the future - in Rotherham
Tuesday January 12 2010
One of Yorkshire and Humber's leading business figures has praised the high-tech activity at the region's Advanced Manufacturing Park, in Rotherham.
The regional director of the Confederation of British Industry, Andrew Palmer, said the Park - the only one of its kind in the UK - was a jewel in the crown not just of South Yorkshire but of the entire region.
"In fact, having seen the wide diversity of companies and nations represented here, it's clear this is an international resource," he said. "We're lucky in our region that we have so many facets to our economy, but this mix of high-quality R&D and hi-tech manufacturing has to be one of the most important."
"This is the future. I've seen it, and it is clearly working for the UK."
He was speaking after visiting several AMP companies, large and small, on a tour organised by Rotherham Investment & Development Office, the Borough Council's regeneration arm.
He took in Dormer Tools UK, Fripp Design and Research, The Welding Institute's TWI Technology Centre (Yorkshire) and the University of Sheffield's Advanced Manufacturing Research Centre with Boeing (AMRC).
Dormer, part of Sweden's Sandvik group, is a world leader in engineering cutting tools. Its premises at the AMP's Evolution development, officially opened in January 2009, incorporate a pioneering training room, a major research and development facility and an international export service to support emerging and developing markets. It employs some 45 people.
General manager John O'Donoghue said: "This is Dormer's key site for sales - in the UK and around the world - with £22m-worth of orders processed. We're also the composite drilling centre for all Sandvik companies worldwide and one of four global training centres, so this is a major operation."
Fripp Design and Research provides 3D computer-aided design, support and rapid prototyping for companies and organisations including Boots, Rolls-Royce and the NHS. It reduces customers' time-scales and costs across a range of operations and products, from highly conceptual packaging to artificial joints and heavily-engineered mass produced components in plastics and metals.
It aims to more than double its workforce on the park in 2010. Managing Director Steve Roberts, who set up Fripp Design and Research with wife Sue and Tom Fripp, said: "Being located on the AMP is of strategic importance to our business as it is the UK centre of excellence for Advanced Manufacturing and associated industries and services - everything from rapid prototyping to rapid manufacture. Our mission is to take 'best practice' in advanced manufacturing from industry and apply this within the health care sector; where we see plenty of opportunity."
TWI is one of the world's foremost independent research and technology organisations, providing industry with engineering solutions in structures incorporating joining and associated technologies. Its welding processes are among the most advanced in the world.
Sector manager Mark Roughsedge, who runs membership development, said: "Since 2002 TWI Yorkshire has helped create and safeguard 1,297 jobs and £81m in turnover for companies in the region, through a series of Yorkshire Forward-funded Technology Transfer Programmes."
The AMRC, which includes the Rolls-Royce Factory of the Future, is one of the world's leading centres of its kind. Two events in December underscored its importance. It played a leading role with Yorkshire Forward, with help from RiDO, in winning the Rolls-Royce Nuclear AMRC for the Park, and providing expertise and composites that helped Boeing's new Dreamliner aircraft take to the air.
It is not only pushing the boundaries in aerospace and other research but is helping produce Britain's next generations of high-quality engineers. Projects director John Baragwanath said that its R&D skills helped companies such as Boeing, Rolls-Royce and Airbus massively reduce their timescales - in one case from 145 hours to 19, in another, from 54 to five. The AMRC aims to double its current 108-strong workforce over the news few years.
Andrew Palmer said: "I've been so impressed not just by the expertise packed into the Park but by the sheer enthusiasm among the businesses. With people and companies like these, the region's future is bright."
New thermographic inspection training at TWI
TWI is pleased to announce the introduction of its Thermographic Inspection programme, aimed at those responsible for review and approval of thermographic inspection procedures and qualifications.
Infrared thermography is a non-contact technology where accurate temperature distributions across a surface are used to monitor machine or component condition and in some cases to predict failure. This technique is used in many industries especially in manufacturing, distribution, transmission, retail and various processing worldwide. Over recent years the technology has become more affordable to most industries resulting in the need to carry out new technology training.
There are a number of benefits to this training including reducing failures, improvement in safety standards but also a reduction in energy usage.
Also, this technology applies to all engineering disciplines and therefore promotes and enhances multi-discipline working and team building.
Thermography inspection is a diagnostic condition monitoring technique operating at three generic levels each taking five days and include practical testing:
- - Level One - Thermographic Inspector, where the main responsibility is to collect accurate qualitative condition information and reporting
- - Level Two - Quantitative Inspector, as above and in addition to interpret and analyse results, to develop quantitative thermography and produce written instructions
- - Level Three - Management and supervisory, where a thermographic programme is designed and managed or where there is a need to carry out internal training.
In addition to these, TWI will be launching new thermographic inspection specialist options such as:
- Medical
- NDT
- Buildings
- Electrical
- Mechanical
- Research and Development
- Plant Process
TWI will be introducing a certification scheme later in the year for those involved in condition monitoring or inspection of plant operation and maintenance and equipment.
Anyone with an engineering background is encouraged to attend these new exciting courses.
To find out more and register your interest please contact Customer Services on + 44 (0)1223 899500 or e-mail trainexam@twi.co.uk.
CO-PATCH - Composite patch repair for marine and civil engineering infrastructure applications
In January 2010 a consortium of 15 SMEs and RTDs from eight European countries have kick started a European (FP7) funded project on Composite Patch Repair for Marine and Civil Engineering Infrastructure Applications - COPATCH.
This is a novel effective repair and/or reinforcement method for large steel structures with defects. Two basic steel structural types will be dealt with in this work, namely marine structures (mainly ships) and steel civil engineering structures (eg bridges). Many of the major problems that these structures face during their operational life are common, with fatigue playing a predominant role among them. Repeated loading is a very common loading condition for both these structures, which, in areas of stress concentrations, leads to the initiation and growth of fatigue cracks. These cracks, if not detected and properly repaired in time, can grow to critical lengths and result in catastrophic structural failures. An additional structural problem of either marine or other large steel structures is corrosion, particularly for vessels and structures designed with thinner plating due to the use of higher-strength steels. Corroded plating or beams jeopardise the strength and stiffness of the structure and measures have to be taken to reinstate the original structural characteristics. Besides the above two major defects of the steel structures, there is often the need for upgrading the strength and/or the stiffness of a structure, enabling it to face new loading conditions or helping in mitigating initial design deficiencies.
Composite patch repairs and/or reinforcements overcome many, if not all disadvantages of the traditional repair methods like welding or use of bolted doubler plates.
- They do not involve hot works in any way and, therefore, existing deadweight loading or proximity to explosive environments has no particular consequences
- Patches can be applied directly on corroded steel members by performing a simple surface preparation, thus removing the need for replacement
- They can be completed faster
- They exhibit good fatigue resistance
- They do not cause stress concentrations
- They result in low added weight
Composite material patching is a very promising method for repairing and/or reinforcing steel structures. Composite patches prevent crack growth and extend the lifetime of the repaired structure. A composite patch works as a crack arrestor by decreasing the stress in the area of the crack tip in the case of cracked structures. A part of the applied load is transferred from the base plate through an adhesive layer to the composite patch, thus reducing the stress levels in the substrate.
Composite patching has proven its effectiveness and cost benefits by its application in the aerospace industry for several years now, since there are already several thousands of operating patches in various aluminium aircraft structural parts. However, there are several fundamental differences between the aerospace applications and bridge/marine/offshore steel applications, which dictate a separate approach and investigation of the problem.
Technical objectives
The main objectives are to demonstrate to all stakeholders that composite patch repairs or reinforcements can be environmentally stable and therefore, that they can be used as permanent repair measures on steel marine structures and
steel civil engineering infrastructure applications.
The proposed composite patch repair technology is an innovative and highly competitive product that caters to the needs of marine vessels and civil engineering infrastructures, the latter in the form of steel bridges.
It reduces quite significantly the maintenance costs of many large steel structures, and in the case of metallic bridges it prolongs their design life. The proposed technology creates a new market and it gives the partners the capability of providing high technology and high added value services worldwide, thus improving Europe's competitiveness in specialized and advanced repair works.
The consortium is currently planning to invite interested stakeholders to follow the project activities, within the framework of a relevant stakeholders' forum.
CoPatch Consortium
NATIONAL TECHNICAL UNIVERSITY OF ATHENS
TWI Ltd
BUREAU VERITAS
HELLENIC REGISTER OF SHIPPING S.A.
FRANCISCO CARDAMA S.A.
INSTITUTO DE SOLDADURA E QUALIDADE
METTLE SARL
NORGES TEKNISK - NATURVITENSKAPELIGE UNIVERSITET
UMOE MANDAL AS
ESTALEIROS NAVAIS DE PENISCHE S.A.
THE UNIVERSITY OF SURREY
ASOCIACIÓN DE INVESTIGACIÓN METALÚRGICA DEL NOROESTE (AIMEN)
CETENA S.p.A.
SHIPBUILDERS AND SHIPREPERAIRS ASSOCIATION
ALVEUS d.o.o. (AS2CON)
Diary dates - Construction and Engineering
'Ship design and operation for environmental sustainability'
Date: 10 -11 March 2010
Location: RINA HQ London, UK
The topic of the next WJS Materials Technical Group Meeting is
'Materials issues in Defence and Security'....
Date: June 2010
Location: TWI, Cambridge
Where's the join....FSW adopted for invisible stainless repair
Since friction stir welding can be used to join sheet-to-sheet it can surely be adapted for patch repair within sheet material? Yes, but how do you treat the hole created at the exit point?
So goes the traditional thinking on FSW as a patch repair process. However at TWI's Technology Centre (Yorkshire) FSW has been successfully demonstrated as a patch repair technique in 304 stainless steel, without a visible exit point.
The weld completion difficulty has been overcome by traversing the rotating tool up an artificially created ramp a few millimetres above the substrate. This ramp is then machined off once the weld is complete.
The process is expected to be ideal for repairing cracks in vessels or pipes. TWI's application uses a fixed programmable robot, but it is expected that the process will lend itself to being performed in the field.
The positive advantages are that the repair process can be operated in wet environments. The tooling is low force and can be used on portable FSW equipment. The rotating pin exit hole can be eliminated easily, and perhaps most importantly, the repair technique is programmable and repeatable.
To learn more contact Jonathan Martin on jonathan.martin@twi.co.uk
NEW modelling demonstrations
To explore examples of our core business in the modelling area and to learn more about our work and solutions offered to customers, please follow the link below to our new demonstration pages. Enjoy the animations and presentations which will give you a good overview of how we can help and add value to your company by using the latest modelling technology.
So, you want to be a ...Responsible Welding Coordinator
Q: How can I become a Responsible Welding Coordinator (RWC)?
A: ISO 14731 states that welding co-ordination is the sole responsibility of the manufacturer and the manufacturer shall appoint at least one responsible welding coordinator.
Responsible Welding Coordinator is a specific job role defined by the manufacturer, and assessment of the fusion welding quality activities against the requirements of ISO 3834-2 or ISO 3834-3 will seek to establish that personnel appointed as welding coordinators are competent to fulfil their allocated responsibilities.
Your competence in fulfilling that role will be assessed on a combination of knowledge, skills and experience that can be demonstrated through evidence of qualifications, certificates and log book or CV, and will be confirmed in interview.
Q: Do I need to be IWE (International Welding Engineer diploma) qualified to be an RWC?
A: There is no actual qualification for RWC, it is a role within a company and during an assessment for accreditation to ISO 3834 the RWC is assessed for their competence to carry out the required role within that particular company; RWC is not a 'portable' title.
The International Institute of Welding (IIW) and European Federation for Welding, Joining and Cutting (EWF) diplomas (I/EWE, I/EWT and I/EWS) have been accepted as satisfying the specific knowledge requirements for Responsible Welding Coordinators.
National qualifications that may be considered to demonstrate knowledge include the Cranfield University MSc in Welding Engineering, and The Welding Institute's professional membership classes of SenMWeldI, IncMWeldI and TechWeldI. Other welding and fabrication qualifications can also be relevant to the assessment.
Remember that knowledge is only one part of the competence assessment and a qualification does not guarantee that you will be considered appropriate for an RWC role. Before committing to any additional training or education, it is important to have your existing qualifications reviewed against the responsibilities you are expected to take on.
Q: I hear that there is a shortage of welding coordinators, so how do I become a consulting RWC and offer my services on a sub-contract basis?
A: The RWC role can be sub-contracted but the responsibility for welding co-ordination remains with the manufacturer. Even though you may be appropriately qualified, you cannot be recognised as an RWC without being assessed as competent against the specific job role that you are expected to fulfil, and this is done during the ISO 3834 assessment of the manufacturer.
Once a manufacturer has nominated you as their RWC, you will be assessed for the role allocated and the sub-contract terms will also be reviewed to ensure that you will have the authority to carry out the assigned tasks.
Q: My employer is seeking certification in accordance with ISO 3834 and expects me to become the RWC, where can I find more information?
A: Please review the information at www.iso3834.org, complete the Preliminary Information Enquiry Form for more guidance and a quotation, and contact the WFCS Scheme Manager if you have any further questions.
Materials issues surfacing and particulate engineering
WJS Materials Technical Group Meeting held at TWI Conference Centre on Tuesday 2 June 2009
The Welding and Joining Society hosted the anticipated Materials Technical Group Meeting on Tuesday 2 June 2009 at TWI Cambridge Conference Centre and captured both the historical and present issues on the subject of surfacing and particulate engineering, through discussions and presentations from Rolls Royce, Atomising Systems, Hoganas, Leicester University and TWI. The highly successful meeting was co-sponsored by the Particulate Engineering Committee of IOM3.
This one day event included a tour of TWI Surfacing facilities for a demonstration of thermal spraying as well as a visit to the TWI library for a brief introduction to the information services with a particular focus on the latest MI-21 data base (www.mi-21.com, a new service run by TWI in collaboration with NAMTEC and World Metal Index).
Delegates had a chance to network and establish contacts throughout the day. Those, particularly interested in professional development were encouraged to join WJS, The Welding Institute and IOM3, and informed of benefits of professional membership and the registration with the Engineering Council towards for example, CEng status.
For a full summary of this meeting and further information on future meetings of the WJS Materials Technical Group, please contact directly the secretary, Dr. Cem Selcuk at cem.selcuk@twi.co.uk
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Left to right: Chairman, Peter Boothby (Macaw Engineering) and speakers: Jeffrey Allen (Rolls Royce), Roger Fairclough (TWI), John Dunkley (Atomising Systems), Paul Nurthen (Hoganas) and Dave Harvey (TWI) with Secretary, Cem Selcuk (TWI) |
Bespoke solutions, no problem...using advanced phased array
The rising popularity of the phased array inspection technique appears to recognise few boundaries. It has recently seen active service in the construction, oil and gas, power generation, aerospace, automotive and even the medical industry for finding very small anomalies
Full case study
Fatigue Life Prediction for Toe Ground Joints
Weld toe grinding is a well established technique for improving the fatigue performance of welded components. Design codes, such as BS 7608, allow an increase in the fatigue endurance (fatigue life) of 2.2 times after proper weld toe grinding. It is expected that crack initiation would become a more significant component in the total endurance for toe ground joints than for as-welded joints. Although many attempts have been made to predict the fatigue endurance of welded joints by considering crack initiation and propagation, work on ground joints is limited. Furthermore, there is little convincing data in the literature to verify any model predicting the life to crack initiation.
Full report (Members only - login required)
Welding Co-ordination - The Knowledge to Comply
With the function of welding co-ordination being defined by the tasks and responsibilities set out in EN ISO 14731, and compliance with EN ISO 14731 being required by the quality standard EN ISO 3834 (Quality requirements for fusion welding of metallic materials), and product standards such as EN 15085 (Railway applications - Welding of railway vehicles and components), it is necessary for manufacturers to demonstrate that they have competent welding co-ordinators.
Responsible Welding Co-ordinators must be able to demonstrate technical knowledge at a level relative to the nature and complexity of the products for which they are responsible.
Although the standard does not require the welding co-ordinators to hold any particular qualification or certification, the International Institute of Welding (IIW) has developed a harmonized diploma course, of which the Engineer, Technologist and Specialist levels satisfy the knowledge requirements of ISO 14731 and will assist in the process of company certification. This diploma is available in the UK through TWI Training & Examination Services (www.twitraining.com) and overseas members can find local training by contacting their Authorised National Body (www.iiw-iis.org).
For those who do not hold an IWE, IWT or IWS diploma, there are other routes to demonstrate the knowledge requirements of ISO 14731. Additional training, such as the Welding Supervisors or Welding Inspectors schemes (www.cswip.com), may be relevant to supplementing existing knowledge. Also, the Welding Institute (www.twiprofessional.com) membership grades of Senior Member (SenMWeldI), Incorporated Member (IncMWeldI) and Technician Member (TechWeldI) are associated with Engineering Council registration classes of Chartered Engineer, Incorporated Engineer and Engineering Technician.
These are internationally recognised qualifications that use Professional Review Interviews to assess an individual's knowledge of welding and experience of application. TWI Certification Ltd is able to utilise these qualifications to verify a welding coordinator's knowledge as part of its ISO 3834 assessment process.
Competence comes from the combination of knowledge and experience; don't delay in gaining the qualifications that demonstrate knowledge, as you will also be required to show experience in applying that knowledge to your scope of work.
If you would like some guidance on the possible routes to compliance with EN ISO 14731, please submit the preliminary enquiry form, which can be found with supporting information at www.iso3834.org, enclosing copies of CVs of the candidates that you intend to nominate as Responsible Welding Coordinators. With these details of your intended scope of certification and staff competences, TWI Certification Ltd will identify the options available to you.
Cost cutting software - predicting distortion and improving fatigue performance
Software which enables non-expert users to predict distortion and achieve better fatigue performance in welded structures is being developed by TWI.
Optweld, as it is known, is a collaborative project, funded by Technology Strategy Board and includes Greenwich and Newcastle Universities, BVT, BAE Systems, the ESI Group, ThyssenKrupp and TWI.
It is designed to appeal to fabricators which use the arc processes to manufacture structures, out of sheet ferrous material, particularly plate thicker than 3mm. End users will include shipbuilders, train makers and land vehicle manufacturers in the military and civil sector.
One of the objectives behind the Optweld project is to promote the use of thinner sheet and sections. It is also expected to reduce the cost of associated computing.
'The main benefit of using this software is to reduce the cost of re-work during the assembly processes' says project co-ordinator Marcus Warwick. 'In other words the need to bash something straight during assembly is avoided, or at least reduced.'
The target user will be a welding engineer assigned to assembling a fabrication from the blueprint stage. The software will recommend an order of assembly, the required process conditions for welding, the weld geometry, the weld speed, the power input, and the thickness and grade of material.
Since the software is largely related to joining thin sheet using the arc processes it is expected to appeal to shipbuilders, train makers and the military and civilian vehicle markets.
The benefits of using the software include improved quality and dimensional accuracy in the finished fabrication. And, by using thinner sheet and section, material costs will be reduced and weight savings achieved.
'The software will allow the user to try different options and find out which gives the least distortion' says Warwick. 'You will be able to input different geometries, different welding conditions, and different welding assembly procedures,... for instance one could compare the relative merits of assembling from one end to the other, as opposed to welding from the middle outwards.'
Above all, manufacturing costs will be reduced in two areas. Fixed costs will be lower in the areas of re-work, fit-up time and scrap. And recurring costs will be reduced through weight savings achieved, improved fatigue performance and reduced repair costs.'
Training: An Introduction to Friction Stir Welding
The course will be an intensive mixture of classroom lectures, tutorials and practical demonstrations using both video footage and live demonstrations on TWI's equipment. There will be opportunities for individual discussions with TWI engineers.
Among the topics to be discussed will be history of the process, licensing, patents and standards, process fundamentals, process advantages and disadvantages, process control, comparison with other processes, machine technology, tool technology, materials and weld performance issues, quality control, economic benefits, current/planned applications.
Attending the course will give students the necessary knowledge to make balanced decisions about the process and to deal with confidence with suppliers of equipment or friction stir welding process providers/users.
The date for the next FSW training course at Sheffield will be 20-22 October 2009.
More information about the course.
Specialist Materials and Joining - A new section at TWI?
Well no, not really, more a case of a better description of what two existing sections, Ceramics & Microtechnology, already do.
These two sections have always been closely aligned, having many areas of common interest ranging from packaging for electronics and sensors in safety critical or aggressive environments and thermal management in hybrid vehicles through to development of special purpose coatings.
The two sections have now come together to enhance the service they can offer to Industrial Members across a range of sectors, including rail, marine, off-highway, defence, construction and fabrication.
So whether it's the development of bespoke brazing or diffusion bonding cycles, advice on ceramic materials or precision reliability in safety critical components, SMJ is here to help.
Correlation of Phased Array Inspection and Fatigue Performance of FSW Joints
Friction stir welding (FSW) of aluminium alloys is now an established joining technique and there is increasing application to joining of critical components and structures. Much emphasis has been placed on optimising tool design and process parameters to ensure joint quality but flaws may still be created in the production environment if the limits of the process window are exceeded. There is a requirement to understand the type of flaws that may be generated, and their causes, when welding conditions deviate from the optimum.
Full report (Members only - login required)
Laser Surface Hardening with Adaptive Control
Laser surface hardening was one of the first industrial applications of lasers and is rapidly developing as new and more cost-effective lasers, advanced laser optics and control systems, become available. The compact and energy-efficient direct diode lasers give a higher process efficiency and higher energy efficiency, making them more attractive to be integrated into a manufacturing line. The key factor for laser surface hardening is to maintain a constant surface temperature during the process. Variations in the surface temperature can cause fluctuations in the profile of the hardened layer. More recently, the development of new beam-forming optics and process monitoring systems has enabled the process to be controlled in real time to suit different industrial applications. Laser hardening parameters can be adaptively controlled based on the surface temperature of the sample and interactions between the laser beam and workpiece surface to achieve consistent surface properties.
Full report (Members only - login required)
Non-Vacuum Electron Beam Welding - Progress Report and Future Developments
When the phenomenon of keyhole welding, using an electron beam (EB), was discovered in the 1950s, it was a major step forward for thick section welding. Reduced distortion and elimination of costly joint preparations and even more expensive filler material were of great significance. But as beam powers and penetration levels increased, ambitions to free the process from the confines of a vacuum chamber grew. Sliding seals and local vacuum enclosures were tried with mixed success, mainly because of seal leakage problems. Partial vacuum machines became popular for small components and later Reduced Pressure EB welding minimised the risk of seal leakage. However, the tantalising possibility of projecting high power beams into the atmosphere offers even more advantages.
Full report (Members only - login required)
Archive
- Process monitoring for quality control of friction stir welding
- Low stress no distortion (LSND) modelling of aluminium alloy welds
- Welding Estimator Software
- Materials Issues in Weld Integrity
- Successful Seminars on Structural Integrity in Japan and China
- Critical review of joining processes for powder metallurgy parts
- Assessment of Bobbin Friction Stir Welding for the Joining of Aluminium Alloys
Process monitoring for quality control of friction stir welding
Friction stir welding (FSW) is a relatively new welding technology, which has been rapidly developed and implemented throughout the world, since its invention by TWI in 1991. Control methods for FSW have also developed rapidly during this period, and a number of different systems have been produced by various FSW machine manufacturers and process users. Such systems usually act to control one of the key welding parameters, most commonly z-axis position or force (although systems that control x-axis force, z-axis torque, or weld/tool temperature have also been demonstrated). A review of these different control approaches is timely in order to provide guidelines for process users on the most appropriate choice of system for a given FSW application.
Full report. (Members only- login required)
Low stress no distortion (LSND) modelling of aluminium alloy welds
Distortion of welded fabrications primarily occurs due to forces produced by differential contraction of different locations as material solidifies and cools from the non-uniform heating produced by welding. Fabrications of thin material are more prone to distortion than thicker fabrications because there is less stiffnesss against out of plane bending moments and lower resistance to buckling. Industry sectors like shipbuilding, automotive and aerospace are particularly affected since their components are fabricated from thin sheets and plates.
Full report. (Members only- login required)
Welding Estimator Software
Calculates and compares welding costs for consumables, gases and welding processes. Quick and easy weld, welding procedure and welding project cost estimation tool. To read more...
Materials Issues in Weld Integrity
The eagerly anticipated WJS Materials Technical Group meeting took place on 27 November 2008 at the Ramsay Moon conference centre situated at the TWI headquarters in Great Abington, near Cambridge.
The highly successful one-day event, supported by the Younger Members Committee of The Welding Institute, helped address Materials Issues in Weld Integrity across several industry sectors including construction & engineering. This conference also allowed useful networking opportunities between participants from industry and academia, with several graduates encouraged on the day for their professional development via membership of The Welding Institute and WJS.
The next Materials Technical Group meeting will be held in spring 2009, details for which will be available via the TWI website.
Watch this space!
For further information and related enquiries, please contact Dr. Cem Selcuk, at cem.selcuk@twi.co.uk
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Left to right: Secretary, Cem Selcuk (TWI) and speakers: Ian Scott (Joy Mining Machinery), Bob Andrews (BMT Fleet), Isabel Hadley (TWI), Alan Thompson (Corus), Norrie McPherson (BVT Surface Fleet) and John Krancioch (SFR plc) with Chairman, Peter Boothby (Macaw Engineering) |
Successful Seminars on Structural Integrity in Japan and China
In October this year TWI's Structural Integrity Group held technical seminars in Japan and China. Presentation topics included amongst others fatigue, fracture, modelling, distortion, residual stresses and risk based inspection. The Japanese Seminar in Tokyo is a well established annual event which has been successfully running since 1989. The British Embassy was once more a very welcoming and most hospitable partner and many of TWI's longstanding business friends attended the event. The idea to hold a seminar in a similar format in China was a first try this year and we were overwhelmed by the response! About 100 attendees from a large variety of companies were present at the event which was held at the Jiaotong University in Shanghai. The photos below give a little impression of the atmosphere at the seminars. Plans for 2009 are already being developed and we look forward to a long lasting and growing relationship with our Members in Japan and China.
| Attendees at TWI Seminar in Japan, British Embassy, Tokyo |
Attendees at TWI Seminar in China, Jiaotong University, Shanghai |
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For more information, please contact integrityandcorrosion@twi.co.uk
Critical review of joining processes for powder metallurgy parts
EuroPM2008 International Powder Metallurgy Congress and Exhibition
(29 September - 1 October 2008) Mannheim, Germany
Powder metallurgy (PM) processes have high productivity and are ideal for making near net-shape parts of especially complex geometries from a range of materials, which maximises material utilisation, and hence minimises or eliminates secondary operations such as machining. Secondary operations are common for components made via liquid metal processing, and result in an additional step in manufacturing with substantial cost and waste implications. Despite this obvious advantage of PM processes, however, the joining of materials synthesized from powders has been associated with difficulties related to their inherent characteristics, such as porosity, contamination and inclusions, at levels, which tend to influence the properties of a welded joint.
This paper presents a critical review of the current state-of-art of welding PM components. It also seeks to identify preferred joining processes and identify apparent technology gaps in joining of PM parts, in terms of initial processing and attendant materials issues, with an emphasis on offering solutions to welding problems.
Full paper. (Registered users only- login required)
Assessment of Bobbin Friction Stir Welding for the Joining of Aluminium Alloys
The friction stir welding (FSW) process was invented by TWI and was originally developed for industrial exploitation via a TWI Group Sponsored Project (GSP), the Sponsors of which were amongst the first to benefit from the new technology. TWI has recently developed a novel enhancement to the FSW process, which offers the potential to produce improved full penetration welding performance using significantly simplified, and therefore cheaper, equipment. The enhanced process can be implemented in two varieties named fixed and floating bobbin FSW. Bobbin friction stir welding has the potential to be a valuable high productivity manufacturing technique for structures of interest to the transport industries, offering high quality, highly repeatable welds at a competitive cost. It is proposed to develop, evaluate, and demonstrate the capabilities and benefits of bobbin FSW via a new GSP. Participants in the GSP will be ideally placed to become early adopters of the new technique and to benefit from the enhanced capabilities that it offers.
Copyright © 2009 TWI Ltd
