So, who welded the space shuttle?

Imagine the thrill of working on one of the highest technologies ever produced. That's the job of the welders at Lockheed-Martin's Michoud, Louisiana Assembly Plant. But since the 2003 Columbia tragedy, those guys have been working under a cloud, since it's there that the foam that caused the accident was applied.

According to the Houston Chronicle, workers there were elated at the launch of Discovery, but "shaken" by the detached foam that fell as the shuttle launched.

It took only a few hours for welder Dwaine Payne to swing from euphoria to despair over Tuesday's shuttle launch.

Payne has worked at Lockheed-Martin's Michoud Assembly Plant for 29 years, and has helped build the external fuel tank for every space shuttle launched. So when video of Tuesday's launch revealed a large piece of foam insulation shearing off the tank during launch — not unlike the incident that resulted in Columbia's destruction in 2003 — Payne took it personally.

"I watched the launch with everyone at the plant Tuesday morning," Payne recalled. "That was fantastic!

"At the time everybody was just elated," said the 50-year-old production welder. "A lot of people were crying. It touched everybody, because we had been down for two and a half years."

See the article over at the Chronicle website...

ESAB India Ltd Sets up Chinese Manufacturing Facility

With anticipated growth opportunities in the domestic market for welding and cutting products, Esab India Ltd, a leading player in the welding industry, is setting up a welding equipment factory near Chennai with an investment of around Rs 20 crore to roll out new technology products.

The 50,000 sq ft factory, its first green-field factory in India, is to come up in the industrial hub at Irrungattukottai near Chennai. The investment includes transfer of technology. It will bring in new technology and create new product ranges including inverter machines and plasma cutting machines.

Things are moving that direction already in a number of manufacturing industries. Get a look over at Chennai Online News Service.

Mother Earth News Univeral Welding Table

This is just too cool. Check it out at Mother Earth News...

Any serious welder knows that one of the most useful—and versatile—tools in his or her shop can be the table on which the work is accomplished. That platform, you see, is often far more than just a waist-level workbench for metal fabrication. Ideally, it'll be a welding station "headquarters", set up to accommodate a head shield, clamps, chippers, and electrodes (along with the handle that fits them)... an accurate measuring device for both gauging lengths and squaring corners ... a solid foundation you can clamp components to when the job must be "just right" . . . and a base upon which other useful tools—such as bending brakes and jigs—can be mounted.

So when Leroy Richter, MOTHER'S Eco-Village director, realized he'd be doing a whole lot of metal fabrication in preparation for this summer's scheduled activities he made up his mind to build—at last!—the welding bench that'd been sorely needed in our research shop for years.

Mother Earth News has photos, diagrams, a bill of materials - everything you need to do this project. Go do it!

Newsinferno Reports Federal Judge Will Allow Plaintiffs’ to Argue Welding Fumes Cause Parkinson’s Disease

A Cleveland Federal District denied a defense motion that sought to exclude testimony that welding-fume exposure causes Parkinson’s disease, according to Newsinferno.com.

In permitting the plaintiffs to argue their theory that welding fumes cause this extremely serious neurological disorder, Judge McDonald has opened the door for some 5,000 cases premised on the same theory of liability to now move forward in several state courts as well as in some 4,500 cases which have been aggregated before Judge McDonald under a multidistrict litigation order.

According to the Newsinferno report, there are up to 500,000 welders in the United States alone, exposure to welding fumes poses a risk to millions of workers who regularly work in close proximity to welding operations in a number of major industries.

We'll watch how this one goes. It's already affecting stock prices for manufacturers, but the important question is, how much will it affect welders?

Sand Shark mechanics keep Al Taqaddum’s engines running

Here again, we can prove that some welding jobs are just more important than others. Ever complain about where you're working, what you're doing? I bet these welders are in a harder place, doing a thankless job, to little thanks. They're putting it on the line, and helping make sure more Americans come home alive....

From providing rescue and firefighting to fuel delivery services, the Sand Sharks of Marine Wing Support Squadron 371 have multiple tasks while deployed in support of Operation Iraqi Freedom. One of the most important ones is vehicle maintenance.

“Every mission out here requires vehicles,” said Lance Cpl. Joshua Deblasis, a mechanic and Cleveland native. “We contribute to every operation by fixing vehicles for anyone on base, keeping everyone combat ready.”

The mechanics and welders in the platoon work with a common purpose, to repair Sand Shark vehicles and help any other unit that needs assistance.

Read the entire article over at Military Family Network.

Welders are in demand—how can you ramp up your income?

This morning I opened my local paper to a Business section front-page story about the local and nationwide shortage of skilled welders. One local company said they’d add 30 to 50 more welders if only they could find them. There were plenty of other businesses complaining about the lack of qualified welders.

That’s here in Tulsa, with a world-class welding school, Tulsa Welding School, right in town pumping out welders every year. I can imagine it’s even worse for metal working and manufacturing companies in places without a large welding school.

Does this mean that you can automatically demand more money? No, of course not. But it’s always good to be in a business when there is a shortage of what you do for a living. Ask any nurse over the last few years. They’ll throw money at the right person, but they’ll work you a lot of hours.

So what can you do?

If you have a job, it might not hurt to look around for another one. Look, if you’re in a situation you like with a company you want to work for doing what you want to do, there isn’t necessarily a reason to leave. But if you’re good, and your company values you, there is no reason to not talk about money with them. There also isn’t any reason not to keep your eyes open for a welding job you’ll like better.

If you’re not in a situation you like, what are you waiting for? You’re in the catbird seat. They need you out there if you can handle a welder, if you’re on time and give them a good day’s work.

Get what you’re worth, get a job you don’t mind getting up in the morning to go to.

Some good news for North Carolina welder...

According to this article, John Clark, the welder whose torch sparked a deadly explosion earlier this year, won't be charged in connection with the tragedy. As tragic as it was, I'm glad that Clark isn't going to be charged.

Clark made a ton of mistakes (he wasn't even hired to do the job yet), but they weren't mistakes of malice. Still it's a cautionary tale for those in the busines. Check everything out. Don't assume you're welding in a safe environment. Know it.

Your life and the lives of others are at stake. Take care.

Welders, artists, woodworkers turn ideas for architectural elements into reality

When Sioux Falls homeowners and contractors want more than the ordinary, they turn to local welders, woodworkers and artists to create those details. Mostly, these artisans don't need to advertise. Word of mouth keeps them busy enough.

At Quality Welding, which started as a repair business 20 years ago, owners Ed Dunlap and Jim Fuglsby and six other welders now spend their time creating sculptural railings, doors and gates. "We like customers to have the ideas and kind of a way to get us started," Dunlap says.

See the entire article here...

Arizona Western College offers Welder's Certification Class

Phoenix-area welders wanting to obtain skills education for passage of the American Welding Society code can participate in AWC’s (Arizona Western College) next Welder certification class, starting in August.

The 2-credit course meets Wednesday mornings from 8 a.m. to 8:50 a.m. A lab is held from 9 a.m. to 10:40 a.m.

There is $65 fee for the course in addition to the tuition and textbook. Students will receive specific instructions on materials preparation, electrode selection and application for testing to the AWS D1.1 structural welding code for certification as an all-position certified plate welder using low hydrogen electrodes. Persons enrolled in this class should have already passed Welding 106 or have previous welder education. To receive their welding certification document at the end of the course, students will demonstrate proficiency in welding to this code before an independent welding inspector. Students can also participate in testing modules for passage of the AWS SENSE Level I certification. Successful candidates will be eligible to receive both the code certification card and the AWS SENSE certification.

Interested persons should register IMMEDIATELY for course number WLD-127-001 Welder Cert./Code App. For more information please contact Professor Colton by e-mail at samuel.colton@azwestern.edu or by phone beginning August 8.

Electronics tech at Missouri University Rolla helps team perfect space welding experiment

If you're both a sci-fi and welding buff, this is a neat story...

George Green, an electronics technician at the University of Missouri-Rolla, has been helping the UMR Miners in Space team perfect its welding experiment that will be tested aboard NASA's C-9 "Weightless Wonder."

Green describes himself as a mentor for the designing and building portion of the project. "My experience in electronics allows me to help the team when it runs into problems with the experiment," he said. "I can also help them plan for future [electrical] problems and possible solutions."

In addition to working full-time at UMR, Green spends most of his free time helping the UMR Miners in Space team work on its welding experiment. "This is a very worthwhile project," he said. "Sooner rather than later there is going to be a real need for welding in space, but more research needs to be done before that is possible."

That's where the UMR Miners in Space come in. For their experiment the students will test and compare the strength of welds performed in zero gravity to those performed on the ground.

In Louisiana, welding applicants for tank car company struggle with tests

According to the Acadania, LA Channel 10 website, Union Tank company's plans to fill hundreds of new welding jobs have hit a snag...job candidates are having trouble passing a standard aptitude test. I don't know what's on these tests, but extensive pre-hire testing has been standard procedure for companies in white collar positions for more than 20 years, and in many welding and trades positions as well.

They aren't saying these welders can't get hired, but it's a shame they aren't passing the tests.

Welding Suppliers Meet Demand for Generators in Hurricane Dennis' Wake

Some good work being done by the welding industry in the wake of Hurricane Dennis. I hope this helps out anyone who needs it...

APPLETON, Wis., July 18 /PRNewswire/ -- Miller Electric Mfg. Co. today announced that emergency power generators continue to be available at welding supply stores, a source many consumers overlook. Hurricane Dennis left more than 680,000 people in four states without electricity. Utility companies estimate some will be without power for up to three weeks. To find a store with welding generators, call 1-800-426-4553 or visit MillerWelds.com.

Like common stand-alone generators, welding generators are powered by small gasoline engines and have regular 115V and 230V electrical outlets. Used by contractors, farmers/ranchers, maintenance personnel, homeowners and metalworking artists for welding, they also provide 4,500 to 10,000 watts of power for running tools, lights and appliances. Prices are comparable to, or less than, regular generators of similar quality and power.

More Devastation Predicted

"Having a Category 3 hurricane with 120 mph winds strike so early in the year should encourage people to be prepared for more power outages," said John Leisner, Miller product manager. "Even though generators may become scarce in retail stores, we have ensured a sufficient supply of welding generators in anticipation of another rough hurricane season."

Miller recommends considering power needs before purchasing a welding generator. Critical appliances to run during an emergency include well pumps (750 watts), sump pumps (800 watts), refrigerator (700 watts), air conditioners (2,500 watts) and radios (50 to 200). Note that many appliances take much more energy to start than to run. For information on running home appliances and tools, plus a power calculation worksheet and safety instructions, visit MillerWelds.com/products/generators.

In India, Lecturer invents welding technique

Interesting stuff from India...

Vadodara-based Vishvesh Badheka, a lecturer of the Maharaja Sayajirao (MS) University, has invented new welding technique that can reach into narrow gaps.

The narrow gap gas metal arc welding machine can be used in the fabrication of pressure vessels, shipbuilding, large machinery and the construction industry.

Explaining how the system worked, Badheka said a narrow gap stand is used to reach inside less than 12 mm gaps between plates. A thick plate fabrication (50 mm to 300 mm) requires a flat torch which can enter into a narrow groove. It is widely used in fabrication of pressure vessels, shipbuilding, building and construction industry and for large machinery whereas conventional torch will not enter into such small grooves.

The welding system gives high productivity because the cross-section area of groove is small and gives high quality welds because of low heat input during welding.

TLC's "Rides" Features Lincoln Electric Welding Equipment

Dontcha just love it when a television show does a fix-up for an already-wealthy celebrity?

Lincoln Precision(R) TIG 275 used for Fabrication Work on Joe Rogan's 1970 Barracuda

CLEVELAND, July 14 /PRNewswire/ -- You've seen Joe Rogan as the host of NBC's Fear Factor tempting contestants to eat insects or perform daring feats of physical endurance. On a recent episode of The Learning Channel's (TLC) Rides show, Rogan himself is the center of attention as his restored 1970 Plymouth Barracuda, called the Sick Fish, is unveiled to him for the very first time.

As part of the show, hot rod designer Chip Foose created the Sick Fish's new design, while Troy Trepanier and the team at Rad Rides by Troy performed the fabrication work on the car. A key piece of equipment used in the process was The Lincoln Electric Company's Precision TIG(TM) 275.

According to Dan Holohan, head fabricator at Rad Rides by Troy, consistency, reliability and ease of use were the primary reasons the Lincoln Precision TIG was chosen for this application. "The arc doesn't dance around at the start like some TIG machines. With the Precision TIG, the arc starts where you point it," said Holohan. "With its MicroStart(TM) Technology, the machine produces a stable, consistent arc that is very controllable. We always look for the best weld we can possibly produce, regardless of whether we will grind the weld or leave it exposed. With this machine, we know we are achieving high quality welds."

Read the rest (and envy Joe's car) here.

Skilled labor, machinists, welders: an endangered species?

Is manufacturing in trouble? All signs say so, and here's a good take from San Antonio on it...

Manufacturers are worried.

The skilled laborers that were the backbone of American manufacturing are retiring, and there is no one there to take their place. The tool and die makers, lathe operators, metal fabricators are becoming endangered species — and replacing them could cost the manufacturing industry millions.

"We don't have a problem attracting the entry-level worker bees, the $10-an-hour-type guys," said George Schroeder, co-founder of beverage dispenser maker Lancer Corp. "But if you're spending $200,000 on a machine that machines parts, you've got to be a computer whiz to run it. They're hard to find and they come with a helluva price. You can't touch them for less than $40,000 a year."

A recent survey by Peoria Ill.-based Advanced Technology Services found that the lack of skilled labor would cost manufacturers an average of $50 million from their bottom lines. Forecasters also predict that 40 percent of the skilled manufacturing labor force will retire in the next five years.

What about for welders?

Schroeder admitted recruiting skilled labor from other companies to fill open positions. "Welders are not bad," he said. "It's pretty good for welders. Tool and die makers? Forget it. You can't find one in San Antonio. Mold makers? They're rare."

Stronger Steels Create Joining Challenges - From Design News

Interesting stuff here from one of my favorite sites:

Advanced high-strength steels are moving into the fast lane of automotive applications, thanks to the growing recognition that can help engineers reduce vehicle weight and improve crash worthiness. But the extra strength comes at a price: The strength gains that make these steels so desirable also compel designers and manufacturers to consider new welding techniques.

The reason why largely boils down to the pinchforce required to hold sheets together for in spot welding. Whereas a pinch of 400 pounds will accommodate a typical low-carbon steel, a pinch of 1,400 lbs or more would be needed for the higher strength steels. Dave Anderson, staff manager of the AISI Automotive Technical Panel, says that spot welding can successfully fabricate high-strength steel parts, but the process does require higher heat, pinch pressure, frequency and hold times. Shifting these parameters allows good welds to be made but often with weld cycles that differ from those found in industry today. Lincoln Electric Co., a global supplier of metal welding and cutting systems, is just one of the companies that has recognized the need for all-new welding systems for advanced high strength steels. Veteran Lincoln engineers, like Jim Nicklas, consumable research and development leader for gas metal arc welding (GMAW) products, are part of an ongoing research project to develop next-generation welding systems. Lincoln officials meet with original equipment manufacturers, like Ford Motor Co., and various Tier 1 companies on a weekly basis to explore new approaches to welding high-strength steel.

Read the entire article over at Design News. It's worth the time.

Welding firm must pay half a million in pipleline blast - California State Fire Marshal

According to Inside Bay Area, California's state fire marshal fined Kinder Morgan Energy Partners $500,000 for the company's role in a pipeline explosion that killed 5 people and injured 4 more in November 2004. Ouch!

The welders accidentally hit a pipeline, causing a massive explosion that caused the extensive damage.

Mayo Clinic Doctors "Find Manganese accumulating deep within the brain of welders"

This story is important to anyone interested in welding as a career or hobby...

The Mayo Clinic did a study that pinpoints the damage that fumes from welding can do. And it's not the lungs doctors are most worried about. Chemicals from those fumes collect inside a part of the brain that controls movement.

It takes a lot to melt metal on metal. With temperatures up to 11-thousand degrees, gloves, a bib, and shoes shield from the obvious.

And now a Mayo Clinic study shows that it may be even more important to protect breathing.

Dr. Patrick Bosque, a neurologist, says, "It's clear there are all sorts of toxic fumes given off by welding, and manganese is one of them."

Go read the entire story at the above link. Protect yourself - bottom line.

NIOSH Seminar Will Discuss Potential Health Effects of Welding

There is an emerging concern within the occupational health community about the potential pulmonary and neurological health effects associated with welding fume exposure.

A seminar offered at West Virginia University in Morgantown, WV, HSC Hostler Auditorium will discuss these issues.

Welders are exposed to fumes that are comprised of metals, such as chromium, nickel, manganese, and iron, which have been observed to be toxic to the lungs and brain. Numerous queries dealing with this arising occupational health issue have been received by the National Institute for Occupational Safety and Health. The proposed conference will address and discuss all aspects welding fume exposure and health.

Following this conference, participants should be able to:

• understand the various types of welding in order to recognize potential health hazards
• describe the constituents and composition of welding fumes
• describe the fate and behavior of substances inhaled from welding
• discuss the known or suspected adverse pulmonary and neurological effects associated with welding exposures

In Meriden, CT, a focus on CNC machining pays off

The machining class now running through the summer pulls its curriculum from the college's Precision Machining Institute certificate program, which commands 224 classroom hours. But students who sign up and commit to the 64-hour abbreviated program are eligible to receive a certificate in computerized numerical control programming — or CNC. This provides the necessary skills to use CNC tools used in manufacturing. The program also is open to students who are not housing authority residents.

There are fewer than 10 students in a class and the grant pays the $888 cost for each student. Instructors estimate a starting job in manufacturing can generate $11 to $15 per hour, with raises for more training and experience.

"The goal here is to make people independent and put them on the road to home ownership," Truscinski said. "Manufacturing may be in decline, but smart manufacturing will still be a part of the Connecticut economy. This is helping them understand the technology required. This has the potential to make a significant impact in their lives."

See the entire article here...

Making Sure Steam Piping Is Safe - the role of welders

Over at Parmaceutical Processing magazine, they've got a good article about keeping steam piping safe. Lots of welding tips in it - check it out. They call it "10 simple things that might keep you alive."

Some good snippets:

It is very important that you understand what you are looking at and the consequences of being wrong when it comes to evaluating piping systems. Let’s start with the pipe itself. Most pipe you will ever encounter starts its life at a steel mill in sheet form. In many cases, the mill rolls the sheet into tubes and welds it...

Pipe gets assembled to other pipe, fittings, and flanges by either welding or threading. There are specific code requirements that describe when it is permissible to thread or when welding must be used. Within the welding world, you also need to be aware of several other possibilities. Flanges and fittings come as either slip on or weld neck. Slip on fittings are just that, slipped onto the end of the pipe. The flange is then welded up around the contact points on the inside and outside of the pipe and the flange. Slip on flanges are not considered as strong a joint as weld neck or butt welded connections...

Welding on pipe, fittings, flanges, and pressure vessels must only be done by someone with the proper credentials. Welding on pressure piping must be performed following qualified welding procedure specifications. It is the responsibility of the installer to have welding procedure specifications that are certified to meet the applicable ASME code construction;(refer to ASME code Section I and B 31.1 and ASME Code Section IX for welding procedure specifications). The National Board Inspection code which is required for repairs of pressure equipment also includes AWS (American Welding Society, www.aws.org) standard welding procedures. Every detail of AWS standard welding procedures must be followed when welding or the weld can be deemed to not be a qualified weld and in jeopardy of having to be removed...

Welders must also be qualified to the requirements of ASME code Section IX. Once qualified and certified, the welder can only weld within the variables listed on their welder’s performance qualification record. The welder must also weld within the process at least once every 6 months or the qualification expires. Records must be kept to prove that the welder had welded at least once every 6 months. Welders will mark their welds with stamping to identify which person welded which joint. This stamping could be there on your system but possibly obscured with insulation...

Iowa Arsenal welders finish truck armor project for war on terror

A lot of the time, people forget how crucial the work of welders is to our safety and security. Welders and assemblers at the Rock Island Arsenal have worked at a feverish pace recently to finish 1,000-plus armor kits for U.S. Army trucks in Iraq. The project was completed Friday when the 1,115 kits were packed and shipped to soldiers fighting in the Middle East.

Hundreds of employees gave up weekends, vacations and family time as they worked 12 hours a day, seven days a week to fulfill the urgent need, said Col. Bruce Elliott, commander of the arsenal's Joint Manufacturing and Technology Center. The armor fits around the cab of the military transport vehicles threatened daily by improvised explosive devices and insurgent attacks.

Read more over at the Des Moines Register...

In Louisiana, Union Tank Car seeks welders for new plant

If you're a welder in the Baton Rouge area, this one's for you...

The Louisiana Department of Labor and Union Tank Car Co. announced Friday that the employment process for job applicants for welder positions at UTC begins Tuesday, June 14. UTC is stressing that only welders are being recruited at this time. Other positions will be announced later.

The Chicago-based company Union Tank Car is building a railroad tank car manufacturing facility and expects to hire 850 workers for a variety of jobs once construction is completed in 2006. Applicants can apply on-line at the labor department Web site www.LAWORKS.net or at any of the department’s One-Stop offices, June 14 through June 30. The One-Stop addresses and phone numbers are listed on the labor department’s Web site.

In Lexington, NC tragedy, welder won't be charged in fatal explosion

According to the Lexington Dispatch, charges won't be filed against the welder whose work on an underground storage tank caused an explosion that killed a man.

John Clark, 41, was called in May to provide an estimate on the cost to remove pipes from an underground storage tank in the parking lot of Gary's Lounge on U.S. 17, where a gas station had been in the 1970s. Clark showed up at the bar on May 20, but he wasn't hired.

He was supposed to return May 22 to speak with lounge owner Rich Hinman, but Clark went out to the pipes in the parking lot to check out the potential work site. Clark then started welding, which caused an explosion that launched large chunks of asphalt into the air. One of the large pieces fell onto the roof of a car in heavy rush hour traffic, killing the driver, Junius Stith, 52, and seriously injuring a female passenger.

It's a dangerous profession -- to welders and to others -- as this story shows. Be careful what you weld, and when.

In Wisconsin, Welding rod suits seek more than $30 million

A huge series of suits in Wisonsin on welding rod suits. Read the rest at the Madison County Record website...

Seven personal injury lawsuits seeking a combined total of $33.7 million were filed in Madison County Circuit Court on behalf of plaintiffs claiming they were exposed to manganese-containing welding fumes which resulted in their neurological injuries.

The "weld-rod" cases filed by Keith Short and Holly Reese of Goldenberg, Miller, Heller, & Antognoli of Edwardsville have all been assigned to Circuit Judge Nicholas Byron.

The plaintiffs include Ronald Kirback and Theodore Boyer of Madison County, James Anderson of Jerseyville County, John Petschonek and Carl Holden of St. Louis County, Rudy Recer of Jefferson County, Mo., and Paul Dunn of Franklin County, Mo. Their individual suits seek between $4.3 and $4.9 million.

In October 2003, Larry Elam of Collinsville was awarded $1 million by a Madison County jury in the first ever successfully litigated weld-rod case in the country.

In the suits filed June 28, the plaintiffs claimed they inhaled neurotoxic welding fumes while using welding products or were near people using welding products while they were working.