Practical Welding Today - May/June 2009

THE REAL WORLD FOR WELDING PROFESSIONALS

An Official Publication of the

Fabricators & Manufacturers Association, International^®

May/June 2009 / Vol. 13 No. 3

12

PRACTICAL WELDING TODAY STAFF

President & CEO, FMA Gerald M. Shankel

Group Publisher Edward Youdell

Editor-in-Chief Dan Davis

PWT Associate Editor Amanda Carlson

Senior Editor Tim Heston

TPJ Editor Eric Lundin

SJ Editor Kate Bachman

Assistant Editor Michael Bishop

Contributing Editor Amy Nickel

Senior Copy Editor Teresa Chartos

Graphic Designers Jennifer Paulson, Margaret Clark,

Mary Mincemoyer, Janell Drolsum

Graphic Designer/Marketing Support Bryan Garrett

Publishing Services Manager Karen Peterson

Publishing Coordinator Jean Thompson

Director of Circulation Kim Clothier

Circulation Manager Brenda Wilson

Data Verification Specialist Rhonda Fletcher

Senior Fulfillment Specialist Anna Peacock

Web Content Manager Vicki Bell

Multimedia Specialist Sherry Young

Senior Web Developer Jason Bartholme

Web Developer Johanna Albee

PRACTICAL WELDING TODAY ADVERTISING SALES Associate Publisher Jim Gorzek • jimg@thefabricator.com Senior Account Representatives

Michigan/Northeast Sean Smith • seans@thefabricator.com Midwest/South Shirley Petty • shirleyp@thefabricator.com Ohio/Southeast/Intl. Mike Lacny • mikel@thefabricator.com Minnesota/Iowa/Canada Amy Hudson • amyh@thefabricator.com West Tony Arnone • tony@thefabricator.com Classified Advertising Patricia D’Amico •

patriciad@thefabricator.com

Director of Accounting Bob Young

Accounts Receivable Mary Simons

HOW TO CONTACT PRACTICAL WELDING TODAY

833 Featherstone Rd., Rockford, IL 61107
Phone: 815-399-8700 • Fax: 815-484-7700
E-mail: info@thefabricator.com
Web site: www.practicalwelding.com

STATEMENT OF POLIC Y

As a publication of the Fabricators & Manufacturers Association, International, Practical Welding Today recognizes the need and importance of disseminating information about modern metal welding and joining techniques, machinery, tooling, and management concepts for the metalworking professional. The policy of the publisher and this journal is to be nonpartisan, favoring no one product or company. The representations of facts and opinions expressed in the articles are those of the author and are not necessarily endorsed by the publisher and this journal. By including information on new products, new literature, news of the industry, articles, etc., this impartiality is strived for and extends to the mention of trade names. Unless product identification makes the reference unavoidable, the generic name is used. We acknowledge that on occasion there may be oversights and errors; the editors regret such oversights and re-emphasize their policy to be impartial at all times. The Publishers reserve the right to refuse advertising they deem inappropriate for publication in Practical Welding Today, including ads for classes of products and services not considered of significant interest to the readership. Standard Rate & Data Service lists our advertising rates in Section 156. Consult SRDS or our current rate card for full rates and data.

Publications of FMA Communications Inc. maintain a policy of keeping editorial and advertising separate to ensure editorial integrity that most benefits our readership. Editorial content, including feature articles and press releases, is determined solely by the publisher. Editorial content cannot be purchased, nor can it be used as a benefit of advertising dollars spent. Editorial is free-of-charge, subject to space availability, and open to all interested parties that submit items meeting our editorial style and format as determined by the publisher.

Note: Some photographs printed in this publication may be taken with safety equipment removed for photographic purposes. However, in actual operation, it is recommended that correct safety procedures and equipment be utilized.

4 Editor’s Corner
6 Readers’ Forum
7 Calendar of Events
7 Industry News
Spotlight: Research &
Development
12 The pressure’s on!

For an excursion to Challenger Deep, the deepest spot in the Pacific Ocean off the coast of the Marianas Islands, Massachusetts-based Woods Hole Oceanographic Institution fabricated a hybrid remotely operated vehicle able to withstand the pressure more than 35,000 feet under water.

( Cover photo courtesy of Miller Electric Mfg. Co., Appleton, Wis.)

Systems & Equipment
16 Weld fixturing from virtual
to reality

A Florida job shop saved on material costs by integrating modular fixturing set up in Solid Works^®. The CAD-friendly system allowed NCAD Products Inc. to define the fixture and the completed weldment before it hit the shop floor.

Cutting & Weld Prep

24 Cutting aluminum with plasma? Using the plasma process to cut aluminum poses its own set of challenges. Following three simple tips can make the process much easier.

26 Aluminum Workshop

Using 4043, 4643 when welding 6061-T6

Frank Armao answers a reader’s question regarding heat treatment of 4043 and the use of 4643 filler wire when welding 6061-T6.

27 Consumables Corner Changing to metal-cored wire in SAW Michael Ostaffe guides a reader through some of the advantages of changing over to metal-cored wire in SAW applications.