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An official publication of the Fabricators &

Manufacturers Association, International

www.practicalwelding.com

July/August 2013

THE REAL WORLD FOR WELDING PROFESSIONALS

2013

PWTeacher

of the Year

Scott Schreiber,Green River Community College

An official publication of the Fabricators &

Manufacturers Association, International

www.practicalwelding.com
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www.thefabricator.com/pwtv

Amanda Carlson

Associate Editor

Practical Welding Today

Join the Welding Revolution! With over 59,000 video plays, Practical

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PRACTICAL WELDING TODAY July/August 20134 www.practicalwelding.com

THE REAL WORLD FOR WELDING PROFESSIONALS

PRACTICAL WELDING TODAYSTAFF

President & CEO, FMA Edward Youdell

Group Publisher Dave Brambert

Editor-in-Chief Dan Davis

PWT Associate Editor Amanda Carlson

Associate Editor Sue Roberts

Senior Editor Tim Heston

TPJ Editor Eric Lundin

Green Manufacturer Editor Kate Bachman

Contributing Editor Amy NickelSenior Copy Editor Teresa Chartos

Graphic Designers Jennifer Paulson, Margaret Clark,

Mary Mincemoyer, Janell Drolsum

Publication Coordinator Kelly Palmer

Director of Circulation Kim Bottomley

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 TODAYADVERTISING SALES

Associate Publisher Jim Gorzek, [email protected]

Senior Account Representatives

Michigan/Northeast Sean Smith, [email protected]

Ohio/Southeast/International Mike Lacny, [email protected]

West/Arkansas/Louisiana/Mississippi Tony Arnone

[email protected]

Minnesota/Iowa/Illinois/ Indiana/Iowa/Minnesota/

Missouri/Wisconsin/Canada Amy Hudson, [email protected]

Alabama/Florida/Illinois/Tennessee Michael Scott

[email protected]

Classified Advertising Patricia DAmico, [email protected]

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:[email protected] Web site:www.practicalwelding.c

STATEMENT OF POLICYAs a publication of the Fabricators & Manufacturers Association, Intertional, Practical Welding Todayrecognizes the need and importance of dseminating information about modern metal welding and joining techniqumachinery, tooling, and management concepts for the metalworking profsional. The policy of the publisher and this journal is to be nonpartisan, faing no one product or company. The representations of facts and opinioexpressed in the articles are those of the author and are not necessaendorsed by the publisher and this journal. By including information on nproducts, new literature, news of the industry, articles, etc., this impartiais strived for and extends to the mention of trade names. Unless prodidentification makes the reference unavoidable, the generic name is usWe acknowledge that on occasion there may be oversights and errors; teditors regret such oversights and re-emphasize their policy to be imptial at all times. The Publishers reserve the right to refuse advertising tdeem inappropriate for publication in Practical Welding Today, including for classes of products and services not considered of s ignificant interesthe readership. Standard Rate & Data Service lists our advertising rateSection 156. Consult SRDS or our current rate card for full rates and data

Publications of FMA Communications Inc. maintain a policy of keepeditorial and advertising separate to ensure editorial integrity that most befits our readership. Editorial content, including feature articles and prreleases, is determined solely by the publisher. Editorial content cannotpurchased, nor can it be used as a benefit of advertising dollars spent. Edrial is free-of-charge, subject to space availability, and open to all interestparties that submit items meeting our editorial style and format as demined by the publisher.

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

16

An Official Publication of theFabricators & Manufacturers Association, International

July/August 2013 / Vol. 17 No. 4

6 Editors Corner

8 Calendar of Events

8 Industry News

16 Accepting the torch,carrying a legacyPWTeacher of the Year winnerScott Schreiber, head weldinginstructor at Green River Com-munity College, Auburn, Wash.,possesses an innate ability toconnect with his students, a te-nacious drive for excellence andcontinuous improvement, ingenu-ity, and a commitment to improv-ing the welding trade. (Cover photocourtesy of Bruce Ikenberry Photogra-

phy, Lacey, Wash.)

22 Angle grinding 101In fabrication shops across Amer-ica and around the globe, powertoolsmore specifically, anglegrindersare often used in animproper and unsafe manner.Taking the time to learn the dosand donts of cutting and grindingcan help prevent serious injury toyourself or those around you.

26 Joining aluminumwith laser

As the automotive industry takessteps to increase fuel economy,fabricators and suppliers will be

looking to aluminum to help light-en the load. Properly addressingthe troublesome attributes of alu-minum and its alloys will help youto avoid potential issues duringthe laser welding process.

30 Previewing Schweissen& Schneiden 2013Planning on making the trip to Es-sen for the show? Weve got ev-erything you need to know beforeyou go.

32 Aluminum WorkshopFrank Armao explains why 7075and 2024 alloys shouldnt, undermost circumstances, be welded.

34 Consumables CornerNino Mascalco guides a readerwho is experiencing weld rootpenetration issues in single- andmultipass welds.

36 Product News

44 AdvertorialRead about the latest productsoffered by PWTadvertisers.

53 Classified Ads

53 Advertisers Index

54 Arc Welding 101A reader asks Paul Cameronfor clarification regarding whatis written about cosmetic welddiscontinuities in the AWS D1.1Commentary section.

COMING NEXT ISSUE Get a sneak peak at FABTECH2013.

Learn about different types ofcontact tips and where they are bestsuited.

Find out how to choose the rightgas delivery systems.

26
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PRACTICAL WELDING TODAY July/August 20136 www.practicalwelding.com

Editors Corner |Amanda Carlson

FMA Officers & Directors

Chairman of the BoardBurke Doar,TRUMPF Inc.

First Vice ChairmanCarlos Rodriguez-Borjas,Feralloy Corp.

Second Vice ChairmanEdwin Stanley,GH Metal Solutions

Secretary/TreasurerAl Zelt,ASKO Inc.

Immediate Past Chairman of the BoardDave Barber,The Wilmington Grill Co.

Directors

Teresa Beach-Shelow, Superior Joining Technologies Inc.

Robert Clark, Clark Metal Products

Vivek Gupta, Texas ProFab Corp.

Rick Hargrove, American Strip Steel/Marino\Ware

William Jeff Jeffery, IRMCO

Dan McLeod, Brenco Industries Ltd.

Lyle Menke, Peddinghaus Corp.

Carlos Mendizbal Prez, Industrias Selbor S.A. de C.V.

Ed Severson, SB Specialty Metals

Gregg Simpson, Ohio Laser LLC

Jerry Ward, METCAM Inc.

President & CEO

Edward Youdell, Fabricators & Manufacturers Association Intl.

Practical Welding Today Editorial Review Committ

Tony Anderson, ITW Global Welding Technology Center

David Bell, Witt Gas Controls LPPaul Cameron, PWC Inspection Service

J. Gerard Doneski, Lors Machinery Inc.

James Feil, Energy Steel & Supply Co.

Michael Francoeur, Joining Technologies LLC

Kenneth Frye, Air Liquide America Corp.

Bennett B. Grimmett, AREVA NP Inc.

Steve Hidden, Miller Electric Mfg. Co.

Richard Holdren, Greenfield Professional Services LLC

Bob Hollingsworth, Consultant

Mike Jacobsen, Genesis Systems Group

Chuck Keibler, Genesis Systems Group

Ken Lee, The Lincoln Electric Co.

Greg Metko, Miller Electric Mfg. Co.

Andre Odermatt, Hobart Institute of Welding Technology

Mike Pankratz, Miller Electric Mfg. Co.

Dean Phillips, ITWHobart Bros.

Marty Rice, Dale Jackson Career Center

FMAs Certified Education Centers

Advanced Manufacturing Institute (AMI)Manhattan, Kan.,www.amisuccess.com

Anoka Technical CollegeAnoka, Minn.,www.anokatech.edu

Austin Polytechnical AcademyChicago, Ill., www.austinpolytech.com

British Columbia Institute of TechnologyBurnaby, BC Canada,www.bcit.ca

College of the CanyonsSanta Clarita, Calif., www.coc.ca.us

(EWI) Edison Welding Institute,Columbus, Ohio, www.ewi.org

Fresno City CollegeFresno, Calif. www.fresnocitycollege.edu

Harper CollegePaletine, Ill. www.harper.edu

Illinois Central CollegeEast Peoria, Ill., www.icc.edu

Kalamazoo Valley Community CollegeKalamazoo, Mich., www.kvcc.edu

Kirkwood Community CollegeCedar Rapids, Iowa,www.kirwood.cc.ia.us

Kwantlen Polytechnic

Surrey, British Columbia,www.kwantlen.caLong Beach City CollegeLong Beach, Calif., www.lbcc.edu

Moraine Park Technical CollegeFond du Lac,Wis., www.morainepark.edu

Northeast Alabama Community CollegeRainsville, Ala. www.nacc.edu

Ogden-Weber Applied Technology CollegeOgden, UT, www.owatc.edu

Ranken Technical CollegeSt. Louis, Mo. www.ranken.edu

Rock ValleyCollegeRockford, Ill., www.rockvalleycollege.edu

Thomas Nelson Community CollegeHampton, Va., www.tncc.edu

Triton CollegeRiver Grove, Ill., www.triton.edu

Waukesha County Technical CollegePewaukee, Wis., www.wctc.edu

For more information on FMAs Certified Education Centers,

visit our hotlink atwww.fmanet.org/cecs

BUSINESS PUBLICATIONS

AUDIT OF CIRCULATION

Last August Forbespublished an articletitled 5 Ways Leaders Must Build aFamily Environment to Achieve Excel-lence. The title itself is a mouthful, butthe message is very simple: A leadersability to build relationships based ontrust and the promise that each individ-ual persons efforts contribute to a high-er cause is crucial. A leader does this bycreating an environment where group

members feel a sense of ownership, haveeach others backs, know whats expectedof them, feel comfortable voicing con-cerns or asking questions, and have aclear idea of how to attain their personalgoals.

Other than parenting, there is nohigher responsibility than that of ateacher. Teachers are leaders and rarelydo they just teachtheir job requiresthem to wear many different hats.

Whether they like it or not, teachersplay a part in developing the whole per-son, not just a particular skill set.

When I read the article I immediate-ly thought of my visit to the Green RiverCommunity College welding lab in Au-burn, Wash., headed up by Scott Sch-reiber, this years PWTeacher of the Year.As I spoke to students, instructors, ad-ministration staff, advisory board mem-bers, and others who know Schreiber, itwas very clear that he treats those around

him like family. Why is that important?As the article stated, leaders who candevelop a family environment achievemore in the short term and build a foun-dation of hard work, determination, andperseverance for the long run.

This is something Schreiber is acutelyaware of and takes incredibly seriously.

As you read more about Schreiber,youll find that communication, ac-countability, and trust are the founda-

tional elements of his teaching philoso-phy. It is through these elements thatyounger students cut their teeth on real-life expectations, work ethic, and how toconduct themselves as professionals.

The line of communication that wehave is healthy, very open, and that inturn brings it back around to the stu-dents when they do have a problem. Webecome the counselor. A lot of times on

a personal level were the only ones theyfeel like they can talk to, Schreiber ex-plained.

The instructors care about eachstudents individual goals and they areservice-minded. That example rubs offon students, explained Devin Wheeler,a 20-year-old Green River weldingstudent.If anyone ever needs help withanything, theres no one here that wouldsay no. If someone needs help with

something, everyone jumps in.Schreiber and his staff have cre-ated an environment where everyone islearning together and supporting oneanother. Its not a perfect environmentby any means, but what family is? Asthe article summed up perfectly, In theend, its about leadership and the abilityto manage the moving parts and sustainmomentum.

A family of welders

Send comments and technical

questions in writing to:

Amanda Carlson, Associate EditorPractical Welding Today833 Featherstone RoadRockford, IL 61107-6302

Fax:815-484-7788E-mail:[email protected]
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facebook.com/speedglas

3M and Speedglas are trademarks and The Power to Protect Your World is a service mark

of 3M Company, used under license in Canada. 2013 3M. All rights reserved.

www.3M.com/Speedglas

ATributeto Service

3MSpeedglasWelding Helmet Series 100 -Tribute

Designed to honor the servicemen and women who protect our freedom, and for the

American welders that build our country. Dedicated to those who have sacrificed all.

Wear it with respect.
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Calendar of Events Industry News

Hypertherm hosts Building America Conference at

New Hampshire headquarters

U.S. manufacturers productivity has

tripled, and products of value are stillmade in the U.S. That was the mes-sage that Evan Smith, president ofHypertherm Inc., Hanover, N.H., gaveto attendees at the companys BuildingAmerica Conference in early May.

Smith went on to point out thatAmerican workers are increasing pro-ductivity throughput with fewer work-ers than their Chinese counterparts11million compared to Chinas 110 mil-lion. And a lot of that has to do with

substituting capital for labor. The U.S.is second only to Japan in the use of in-dustrialized robots. Spending on equip-ment and software has increased by 31percent, Smith added.

The two-day seminar provided at-tendees with tips to promote continu-ous improvement, operational excel-lence, and leadership and a peek at whysome businessesdespite being led bysmart individualsfail. Hyperthermemployees presented on topics such asbranding, lean manufacturing, strategicplanning, cutting efficiency, and the fu-ture of air plasma.

Kevin Duggan, president of DugganAssociates, author of Design for Opera-tional Excellence, and a consultant toHypertherm, spoke on the importanceof integrating a continuous improve-ment plan--a series of improvements andsustaining measuresinto a business.

Companies that move forward are

the ones where its leaders have the same

answers to the tough questions. If you

want to achieve operational excellence,you create flow only to know if flow isstopping. Any good company can createflow, but great companies know what todo when flow stops, Duggan said.

He went on to say that operationsexcellence isnt just about creating flow,its about creating self-healing flow andimmune systems for flow to ensure thatyour operations are able to start everytime.

Sydney Finkelstein, professor of

management at the Tuck School ofBusiness at Dartmouth College and au-thor of Why Smart Executives Fail, cau-tioned attendees, saying even good lead-ers make bad decisions because they letemotions overcome rational thinking.

Sometimes the same things thathave led to your success will eventuallylead to your demise, Finkelstein said.

He said that leadership capabilitiesthat differentiate winners from losers in-clude intellectual honesty, adaptability,self-awareness, and accountability.

Hypertherms Building Americamessage is one that it has taken to heart.With 12 facilities in New HampshiresUpper Valley Region, the companymanufactures 90 percent of its owncomponents stateside. Hyperthermfounder and CEO Dick Couch toldattendees about the companys meagerbeginnings and how it developed overtime into one of the best places to

work in the U.S. Among an aggressive

Sept. 4-5Arteaga, Mexico

The FABRICATOR en Espanl

Leadership Summit

Sponsor: Fabricators & Manufacturers

Association International Phone: 888-394-4362 Web: www.fmanet.org

Sept. 10-12Chicago

Design & Manufacturing Midwest

Sponsor: UBM Canon Phone: 310-445-8535

Web: www.canontradeshows.com

Sept. 11-12Schaumburg, Ill.

Lasers for Manufacturing Event

Sponsor: Laser Institute of America Phone: 800-345-2737 Web: www.laserevent.org

Sept. 16-21Essen, Germany

Schweissen & Schneiden

Sponsor: German Welding Society Phone: 49-0201-72440 Web: www.schweissen-schneiden. com/en/schweissen_ schneiden/index.html

Oct. 4

North AmericaManufacturing Day

Sponsor: Fabricators & ManufacturersAssociation International

Phone: 888-394-4362 Web: www.mfgday.com

Nov. 18-21Chicago

FABTECH

Sponsor: FMA, SME, AWS, PMA,CCAI

Phone: 888-394-4362 Web: www.fabtechexpo.com
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July/August 2013 PRACTICAL WELDING TODAY 9

Industry News

strategy to incorporate continuousimprovement strategies in-house, thecompany also has a no-layoff policyone that garnered some attention whenthe economy tumbled late last decade.

Watching companies hire workersonly to then lay them off during hardtimes made me realize that it would betough to have positive moral. After all,theyre people with families, not ma-chine tools, Couch explained.

Hypertherm designs and manufac-tures hand-held and mechanized plasmacutting systems and consumables used

in a variety of industries, including ship-building, automotive, and metal manu-facturing.

Amanda Carlson, Associate Editor

Harris Products Group adds

video to YouTube channel

The Harris Products Group, a Mason,Ohio-based wholly owned subsidiary

of the Lincoln Electric Co., has addeda 5-min. video to its YouTube channelat www.youtube.com/user/harrisprod-uctsgroup/featured that gives viewers aglimpse of its century in product manu-facturing, its quality, and its productportfolio.

The channel also includes a varietyof industry-related resources, such as in-formational videos on new products andinstructional videos on brazing and cut-

ting applications.The Harris Products Group supplieswelding and cutting products for theaerospace, offshore, HVAC, heavy fabri-cation, and automotive industries.

Surface Finishing Solutions

1-800-700-5919 www.csunitec.com

Rolei BE5Sheet metal deburring machine2-sided deburring up to 0.20" thick, achieved with one operation

PTX Eco SmartShadow-free satin finishup to a mirror polishLinear grinder utilizes slip-onabrasives, saving time and money

PIPE-MAXSander/Grinder/PolisherRenders weldseams invisible onflat surfacesand pipeup to14" dia.

Integrated dust collection port

LargestDry-cuttingMetal Saw

on the Market!

Super Dry Cut SawDry cut up to 43/4" depth125/8" dia. blade cuts steel,sandwich panels, trapezoidalsheets, conduits, metal pipesand more without coolant

COR-MET, INC.PH: 800-848-2719

FAX: 810-227-9266

[email protected]

ManufacturingFlux Cored

Welding Wire

Cobalt

Nickel

Hardface

Stainless

Alloy Steel

Tool Steel

New ProductsFlux Cored TIG

Flux Coated TIG

Visit COR-MET at Schweissen and

Schneiden, Sept. 16-21

Hall 8, Stand B123

(continued from page8)
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11/57

www.practicalwelding.comPRACTICAL WELDING TODAY July/August 201310

Industry News

Hobart Institute adds online course, expands welding training area

Hobart Institute of Welding Technol-ogy, Troy, Ohio, has released a new on-line course called Discontinuities andDefects, designed for people involved inarc welding inspection, quality control,engineering, and supervision.

The online course, found at www.welding.org/c-54-e-courses.aspx, con-

tains five video segments, totaling a runtime of 70 minutes. These segmentscover weld inspector responsibilitiesrelated to discontinuities and defects,as well as identification and definition

of weld discontinuities and defects.They also present the common causesof discontinuities related to shape, size,

contour, internal inconsistencies, weldmetal irregularities, and weld and basemetal properties.

The institute also has broken groundon a 6,360-sq.-ft structure that willhouse 50 to 60 additional arc weldingbooths equipped for all processes and afume exhaust system.

Revenue from skill training at HIWThas more than doubled in the past eightyears. To accommodate that capacity,

the organization has made more effi-cient use of existing space and added asecond shift. This new construction willenable the Institute to accommodate upto 60 additional students on each shift.

People news

Fronius USA LLC, Portage, Ind., amanufacturer of welding equipment,

has hired MattChynoweth as asales/system engi-neer and promotedVadim Nakonech-nyy to area salesmanager for thesoutheast region.

Chynoweth didpart of his intern-ship at the companybefore graduating

from Ferris StateUniversity. Heholds an appliedscience degree in

welding technology

Chynoweth

Nakonechnyy
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www.practicalwelding.com July/August 2013 PRACTICAL WELDING TODAY 11

Industry News

and a bachelors degree in welding tech-nology. Nakonechnyy has worked as anapplication engineer out of the Chat-tanooga, Tenn., office since April 2012.His territory includes Georgia, Florida,South Carolina, North Carolina, WestVirginia, and Virginia.

CenterLine (Windsor) Ltd., Wind-sor, Ont., has addedGreg Van Dyke toits sales team as anaccount manager

specializing in resis-tance welding con-sumables and auto-mation componentproducts. Van Dyke

has more than 10 years of resistancewelding experience in sales and servicewith Resistance Welding Products Ltd.and the Tuffaloy Group of companies.He holds a marketing diploma, major-ing in international marketing.

Science Channel named officialmedia partner for second annual

Manufacturing Day

Science Chan-nel, Silver Spring,Md., has beennamed the officialmedia sponsor forthe second an-

nual Manufacturing Day, a broad-basedgrassroots effort created to drive publicawareness of the U.S. manufacturing in-dustry and manufacturing careers. Thenetworks How Its Made manufactur-ing series was named official programpartner for the event, which takes placeOct. 4, 2013.

Manufacturing Day 2013 will fea-ture several hundred manufacturers,educational institutions, and other part-ners offering open houses, public tours,career workshops, and other activitiesto share the technology, ingenuity, and

innovation exemplified by U.S. manu-facturing. The event is co-produced bythe Fabricators & Manufacturers Asso-ciation Intl. (FMA), the National Asso-

ciation of Manufacturers (NAM), The

Manufacturing Institute, the NationalInstitute of Standards and Technologys(NIST) Hollings Manufacturing Exten-sion Partnership (MEP), and Industrial

Strength Marketing (ISM).

INDESTRUCTIBLE HANDLEHigh strength N-66 Handle is engineered with special impact additives.It will stand up to all the abuse you can give it.

ONE TOUGH GOOSENECKAn insulated full metal jacket protects the gooseneck from damage inthe war zone that you call the shop.

GUARANTEEDWere so confident, we honor a Lifetime Warranty on handle and triggerswitch.

GOOD FOR A LIFETIME

DESTRUCTIVE TESTINGsee the video atwww.mig-slam.com

MIG GUNbyAmerican Torch Tip

Van Dyke

(continued from page8)
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Industry News

Victor contests recognize users of oxyfuel, plasma cutting equipment

Victor Technologies, St. Louis, haslaunched two contests as part of its cel-ebration of the 100th anniversary of itsVictorbrand of cutting and gas controlequipment.

The A Cut Above contest, open tostudents in cutting, welding, and relatedprograms at secondary and postsec-ondary schools, will award more than$30,000 in equipment and cash prizes.

Beginner students will write a 500-wordessay supporting the contest theme,while advanced students will submit ateam metal fabrication project that in-corporates an oxyfuel, air-fuel, or plas-ma cutting process.

The Show Us Your Innovations2014 calendar contest will award 12Medalist 250 cutting outfitsand aThermal Dynamics CUTMASTER

42 plasma cutter as the grand prizeforthe best photos and associated captionsof the entrant using any Victor or VictorThermal Dynamics cutting equipment.

Both contests run through September.They are open to residents of the U.S.and Canada (excluding Quebec). Contestdetails and entry forms are available at

www.victortechnologies.com/victor100.

Miller Electric introduces robotic

welding cell rental program

Miller Electric Mfg. Co., Appleton, Wis.,has introduced a new robotic welding cell

rental program for companies interestedin trying robotic welding technology.The program also is suitable for compa-nies that receive contract work for shortruns of parts that dont warrant the capi-tal expenditure for a robotic welding cell.

Rental contracts are for a three-month minimum. The company alsorents robotic welding cells on-site andwill oversee short runs of parts in itsown facility.

As part of the program, the companyoffers a full assessment before rental todetermine that the parts to be weldedare repeatable and able to benefit fromautomation.
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Industry News


AccuBilt celebrates 25 years in business

AccuBilt Inc. of Jackson, Mich., marks25 years in business in 2013. Foundedin 1988, the company is a turnkey sys-

tems builder and integrator, providingdesign, build, installation, and supportof robotic and dedicated automation

systems for welding, assembly, materialhandling, and automation support.

In 2012 the company expanded its

facility by 15,000 sq. ft. and added sev-eral new employees.

Handy & Harmans Lucas-

Milhaupt Inc. acquires Wolverine

Joining Technologies

Global diversified manufacturer Handy

& Harman Ltd., White Plains, N.Y., hasannounced that Lucas-Milhaupt Inc.,Milwaukee, an indirect wholly ownedsubsidiary, has acquired the assets ofWolverine Joining Technologies, War-wick. R.I., a wholly owned subsidiary ofWolverine Tube.

The acquired company, which willoperate as Lucas-Milhaupt WarwickLLC, provides Lucas-Milhaupt withboth a primary domestic mill for braz-

ing consumables and an expanded cus-tomer base in key market sectors.Wolverine Joining Technologies

manufactures a variety of silver- andcopper-based brazing and soldering fillermetals and fluxes for the appliance, con-struction, and metalworking industries.

Lucas-Milhaupt supplies brazingand soldering materials to the electri-cal/electronic, appliance, transporta-tion, construction, and mining marketsworldwide.

Hypertherm facilities recognized

as OSHA VPP Star worksites

The U.S. Department of Labor has rec-ognized four Hypertherm facilities asOSHA Voluntary Protection Program(VPP) Star worksites.

The program recognizes workplacesfor operating outstanding safety andhealth management systems for employ-ee protection. These worksites are self-sufficient in identifying and controlling

workplace hazards. To be recognized asa VPP Star worksite, an employer mustoperate a comprehensive safety andhealth management system that is inte-grated into a worksites operations.

Hypertherm, Lebanon, N.H., de-signs and manufactures hand-held andmechanized plasma systems and con-sumables, fiber laser and waterjet prod-ucts, CNC motion and height controls,and CAM cutting software.
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Industry News

Flux-cored wire use expected to rise

The use of flux-cored wires across a va-riety of end user sectors is expected torise, according to Frost & Sullivan, withadoption levels projected to be particu-larly strong in sectors such as energy andconstruction.

New analysis from the San Antonio,Texas-based firm, Global Flux CoredWires Market, finds that the marketearned revenues of $1,811.2 millionin 2012 and estimates this to reach$2,560.7 million in 2017.

The ability to support higher pro-ductivity, enhanced versatility, and

properties such as corrosion resistanceare spurring demand for flux-cored

wires, noted Frost & Sullivan Indus-trial Automation & Process ControlProgram Manager Archana Chauhan.An increase in investments is expectedin the next two years, positively impact-ing on market prospects.

Market expansion will be largelydriven by infrastructure developmentsin emerging economies such as Indiaand China and the growth of end usersectors such as energy and construc-tion, remarked Chauhan. Renewableenergy sectors in EMEA and NorthAmerica are also central to the long-

term growth strategies of flux-cored wiremanufacturers.

Lincoln Electric Mexicana earns

TS-16949 certification

Lincoln Electric, Cleveland, has an-nounced that the Torreon manufac-

turing operations of Lincoln ElectricMexicana S.A. de C.V. has earned ISO/TS-16949 certification, applicable tothe design and manufacture of weldingconsumables.

In general, the technical specifica-tion applies to the design, development,production, and installation/servicing ofautomotive-related products. The certi-fication enables Lincoln Electric Mexi-cana to mesh its quality systems with

those of its automotive customers andsuppliers.

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Industry News

Camfil APC opens U.K. manufacturing facility

Camfil Air Pollution Control (APC),Jonesboro, Ark., a manufacturer of dustand fume collection equipment, has

opened a 40,000-sq.-ft. facility in Hey-wood, Greater Manchester, U.K.

The facility has a current staff of 40,

with plans to grow to 100 employees inengineering, manufacturing, and sup-port positions. The plant includes a

four-bay welding area, fabrication area,powder paint line, assembly area, andstorage space.

AlcoTec offers aluminum welding

technology program

AlcoTecs Schoolof Aluminum

Welding Tech-nology: Theory& Practice Pro-gram is designedto incorporate

both a theoretical and practical approachto welding aluminum alloys. Designedfor welding engineers, product designengineers, and sales personnel, the pro-gram includes comprehensive classroominstruction combined with hands-on

laboratory applications.In this three-day program, studentslearn metal preparation, weld proce-dures, inspection procedures, processesfor joining aluminum, and much more.Metallurgical, welding, and quality en-gineers and technicians with years ofaluminum manufacturing experienceeducate participants in the theory andgeneral characteristics of various alumi-num alloys and tempers.

AlcoTec, Traverse City, Mich., is a

subsidiary of ESAB Welding & CuttingProducts. For more information, visitwww.alcotec.com/weldschool.

Sciaky enters partnership with

Evobeam GmbH

Sciaky Inc., a Chicago-based subsidiaryof Phillips Service Industries (PSI), hasentered into a business partnership withEvobeam GmbH of Mainz, Germany,to further expand its electron beam (EB)

welding product portfolio.Sciaky provides large-vacuum-cham-ber EB welding systems with internalmoving guns. The systems, which uselow voltage and high power, are suitablefor large-scale parts. Evobeam supplieshigh-throughput, small-vacuum-cham-ber EB welding systems with externalguns. Using low voltage and low power,the systems are designed for rapid pro-duction of small-scale parts.
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Cover Story

Scott Schreiber left his job doing weld repair totake over as welding instructor at Green RiverCommunity College for his mentor. He hasntlooked back since. Photos courtesy of BruceIkenberry Photography, Lacey, Wash.
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By Amanda Carlson, Associate Editor

As Scott Schreiber sat in his officenicknamed thefishbowl for its four walls of windows that open up toevery angle of the shopand reflected on his relative-

ly short 12-year teaching career at Green River Community

College in Auburn, Wash., he was almost constantly inter-rupted by students who either needed keys to a storage closet,had questions, wanted to share a joke or an observation, orjust wanted a chance to hear what their teacher had to say forhimself.

Yeah, youd betterput that back, he said to a student re-turning a tool to its proper place. Almost always these stu-dents, who range in age from early 20s to early 50s, were metwith a fatherly, or in some cases brotherly, ribbing that wasfriendly, not biting. The positive dynamic, the energy, and thecomradery between the four walls of the Green River weldinglab are palpable.

Schreiber, the 2013 PWTeacher of the Year, took over awelding program that was good to begin with and made it bet-ter. For the last 12 years he has surrounded himself with a loyaland passionate staff to help him expand an already good pro-gram built by his mentor into a bigger, more modern version.

Schreiber demands excellence, continuous improvement,and is always in search of creative and meaningful learningopportunities for his students. He is committed to the weld-ing trade and asserts ownership over a program that has meantso much to him throughout his entire adult life. But mostimpressive is his ability to connect with each of his students

in the way that they require to be successful. They arent justbodies taking up spacethey are people with goals, problems,strengths, weaknesses, and personalities. Each individual is anintegral part of something bigger than themselves and evenbigger than Schreiber.

Making a Good Program BetterSchreiber always knew he wanted to be a welding instructor,he just didnt know when or where the opportunity wouldpresent itself. He finally got the call after spending 17 years asa heavy equipment repair welder for an excavating companyin eastern Oregon.

It was 2001 and longtime Green River welding instructorand Schreibers former teacher-turned-mentor, Al Croppi, wasexperiencing health issues that threatened to force him intoretirement. Croppi called his protg and offered him the op-portunity to take over the welding program. Despite the factthat his family was in Oregon and that hed be taking a sig-nificant pay cut, Schreiber accepted the position in his home-town, not wanting to see the program that he cared deeply forfall into the wrong hands.

Immediately Schreiber realized he was taking over a well-cared-for program with immense growth potential.

When I got there, we had 18 students in a class that ranfrom 8 a.m. to noon, five days a week. Just one class. The shopwas shut down until the 5:30 p.m. to 10 p.m. class that ranfour nights a week. That class also had 18 students. That wasit. The lab was shut down more than it was open, Schreiberexplained.

the torch, carrying

Welding, people, and a commitment to the trades

fuel 2013 PWTeacher of the Years success

Accepting

a legacy


19/57


He envisioned growing the pro-gram to the point where it was pushingthrough as many welders as it could han-dle in an efficient manner. And growthdid take place, gradually, with the addi-tion of a three-credit class from noon to1 p.m. every weekday to fulfill the basicwelding requirements of degree-trackstudents not necessarily heading towarda career in welding.

Things picked up in 2008 when the

economy took a nosedive, resulting inmass layoffs in the region. Enrollmentin the welding program exploded to thepoint that it developed a wait list up-ward of 100 people.

That triggered the idea to start upan afternoon session. We had the spaceand the facility to do it, and with thattime slot from 1 p.m. to 5 p.m. free, itwas the perfect scenario to start anotherfull-time, 13-credit section.

Schreiber brought onboard a formerboss, Ed Vesser, to teach the afternoonsession. Not long after implementingthe afternoon session, the program againdeveloped a wait list, so he hired CasperFox, a former student, to lead weekendclasses on Friday nights, Saturdays, andSundays.

Today, even with all four sessions ator slightly over capacity, they still arentable to keep up with demand. Approxi-

In Their Words

Students, industry peers, and colleagues share their thoughts andperceptions about Scott Schreiber as a friend, mentor, and instructor.

Its obvious that his program means a lot, if not everything, to him. The

success of it comes first for him, and when I say that I mean the studentsand theirsuccess. David Ornsby, street and vegetation manager, city

of Auburn

At a community college we see a lot of people just starting out or pressingthe reset button. It takes a special type of person to shepherd themthrough learning a valuable skill and at the same time getting them throughthe program. He also ensures that the graduates are of the utmost quality,so that when someone calls Green River and wants to talk about welding,

they know the candidates coming out of the program are going to beoutstanding employees. Josh Clearman, dean of instruction: tradesand technology divisions

Scotts a funny guy. Hes always there to help, but hes not afraid togive you lip if youre slacking. Hell make sure to let you know that yourewrong and tell you how you need to fix it. Hes just an awesome guy. Devin Wheeler, 20, welding student

Hes tied to industry and is very conscientious to the needs of industry.Since I first met Scott two years ago, Ive seen things that tell me hesgoing above and beyond for the school and for his students. Tim Honn,technical sales representative, Lincoln Electric Co.

I will never be able to touch his welding skill. I guess thats why hesgot the big office. Steve Harrison, 53, welding student, Green Riverwelding lab aide

I couldnt be prouder. Hes done it all on his own and he makes Green

River shine in his own way. The reputation of the welding departmentreally isnt falling on administrations roles, it really is shining because ofScott and the other instructors who are working over there. Eileen Ely,

president, Green River

Its like welding is his second nature or an extension of who he is. We arelucky to have him because he pretty much knows everything about gettingus to understand the process. Brian McCorkle, 47, welding student


20/57


mately 115 people are on the wait list.Plans for a new building to house weld-ing, automotive, auto body, carpentry,and manufacturing classesapproval isdue this summerwould allow the pro-gram to double in size.

The ever-expanding welding pro-gram is just one clue that Schreiber andhis staff have built a solid program thatgives people a skill. Approximately 80to 85 percent of students are hired by

unions or fabrication shops. Much ofthat is due to the programs reputationfor developing strong, independent,competent, and responsible welders.And that sentiment is echoed by lo-cal industry representatives like ReneJohnsen, training coordinator for HelacCorp., a fabricator of hydraulic helicalrotary actuators. Johnsen, a Green Riverwelding program graduate who now sitson its advisory committee, calls Sch-

reiber first when she needs to fill a slot.Eighty percent of our welding crew

came from Green River. For the mostpart, we end up hiring and keeping amajority of the people Scott sends us.Theyve showed consistency and pridein their work, and we see that immedi-ately. I know a lot of that comes fromScott, Johnsen asserted.

Schreibers philosophy is very simple:Come to class, be on time, well do the

Top left: Cameron Nelson practices his overhead GMAW technique. Approximately 80 to85 percent of Green River welding students find employment with local fab shops or areplaced with local unions after graduation.

Bottom left: Schreiber and weekend instructor Casper Fox (far right) pose with the weld-ing students in the morning session. The program runs morning, afternoon, and eveningsessions Monday through Friday and weekend sessions Friday night through Sunday.

Below: Devin Wheeler (center) and two classmates perform a repair on a drift trike.Schreiber bases half of their grade on attendance and punctuality in an effort to hammerhome the soft skills.


21/57


rest. Meaning, students who are com-mitted, serious, and open-minded willsucceed. In fact, half of a persons gradeis based on attendance and his or herability to show up on time.

Their grade is something for themto lose. Even though I still have to be

critical of their assignment and tellthem whats wrong, it always ends on apositive note. I think they respect that.I wouldnt ask them to do anything thatIm not willing to do.

Schreiber also knows the value of thestruggle. To become free-thinking, ac-countable, and confident welders, theyhave to learn how to problem-solve andcommunicate. He encourages the weld-ers to help each other figure things out

through group think.Weve found that as we pull awayfrom them as instructors and let themstruggle a little so that they have to startto think, they start to work together asa group, comparing notes. Then we cango back in and talk to these guys aboutwhat theyre doing, and they get theconcepts that much quicker.

If they can problem-solve, they canbe successful, Schreiber added.

Learning Through ServiceYou can tell a lot about a leader by his orher ability to serve others. One projectin particular involved assisting the cityof Auburn in curbing rampant copperwire theft from city street light junctionboxes. David Ornsby, street and veg-etation manager for the city of Auburn,said in one year these thefts have cost thecity about $170,000 in labor and ma-terial. After considering their options,Ornsby inquired about the welding pro-gram at Green River. After a few phonecalls he and Schreiber met with othercity personnel to hatch a plan to put thestudents to work welding shut the streetlight boxes that contained the copperwire. The plan meant valuable work ex-perience for students and an economicalfix to the problem for the city. Schreiberwas thrilled.

I couldnt get back to the collegequick enough to tell my dean. I wasnt

going to ask I just told him what wewere going to do. Sometimes that getsme in trouble, but if you wait and gothrough the process, you risk losing it.Theres not enough time for all of that,Schreiber explained.

He, Vesser, and Fox assembled the

students, put them through a step-by-step training session, and got city em-ployees up to speed on safety consider-ations. City trucks were outfitted witha gas-driven welding power source, andstudent welders were paired with cityemployees. Fifteen business days later,the Green River welding students suc-cessfully sealed 1,833 boxes. Ornsby wasamazed.

Once they started figuring out arhythm and how they were going togo about it, it went very smoothly. Ofcourse, like with any project, the startwas a little slow, just getting the detailsworked out, but once it started rolling,it went incredibly smooth. I told Scottthat if any other cities approached himto send them my way, because I will tellthem all about the program and I woulddefinitely recommend his studentsagain, Ornsby said.

The students efforts garnered the at-tention of local media outlets and wasthe source of praise from Dr. Eileen Ely,president of Green River, who said theinitiative was above and beyond any-thing shes ever witnessed in any profes-sional technical program.

The project had nothing to do withme, nothing to do with the dean; it wasall the instructors efforts of going out

and taking the extra step on behalf ofstudents. To me, he really is a masterteacher, Ely said.

And it gave students like 20-year-old Devin Wheeler an opportunity toget real-world experience outside of thetypical controlled classroom setting.

We were outdoors where there waswater, wind, and people around. Beingable to weld on rust, galvanized, paint,there were actually some boxes that Iwelded that were submerged in waterand all I could do was push as much ofit away as I could with my hand. It was alot different. I knew how to do it right,but with those other factors, it definitelychanges things and requires a whole newset of skills, Wheeler said.

Championing the Trades

Schreibers service extends to othertechnology programs beyond his own.He feels that it is his responsibility as aGreen River employee to make sure thecollege as a whole continues to adaptand grow to meet industry demands.Many of those industry demands re-volve around aerospace, thanks to Boe-ing plants in nearby Renton and Everettand their 330 supplier companies.

But over the last several years, ex-plained Josh Clearman, dean of instruc-tion: career and technical education atGreen River, Boeings workforce hasaged. The company expressed a desirefor area colleges to offer short-term cer-tificate programs (lasting roughly twoquarters, or six months time) based onspecific knowledge, skills, and abilities(KSAs) that it needed entry-level ap-plicants to possess. In particular, Boe-ing was looking for workers with skillstraining in precision machining, qualityassurance, and machine maintenance.

The Puget Sound area is the fourth-largest manufacturing sector in thecountry. Our fortunes arent tied to Boe-ing, but it is important that they be ableto get what they need from the work-force here. The fear was if we couldntprovide a good workforce, Boeing wouldgo somewhere else. It mobilized the col-leges, the government, and businesses

Schreiber demandsexcellence, continuous

improvement, and is

always in search of

creative and meaningful

learning opportunities

for his students.


22/57


into action, Clearman explained.Even though the short-term certifica-

tion was not welding-related, Schreibergot involved anyway. Why?

I have an obligation to industry asan instructor to provide qualified per-sonnel to fill the slots that are in high

demand and that are being left vacant byretirement. Its my way of giving back.We have a pretty good reputation at thecollege of providing qualified person-nel, and its not just in my class; its inall of the classes. We want to maintainthat level of excellence so that industryand local shops we deal with, when theyneed someone, were the go-to source,Schreiber said.

He and several other college rep-

resentatives met with Boeing and itssuppliers; he then helped write a grant,secured the instructors, and assisted inwriting the curriculum.

The result was the creation and im-plementation of an aerospace manufac-turing program at Green River in 2012and three brand-new short-term certifi-cate programs in 12 other colleges acrossthe state, and in record time.

They went from an idea to classesin 100 days. At a college, thats light

speed, Clearman added.That sense of obligation has led to

108 people walking away from GreenRiver with a short-term certificate, em-ployable skills, and subsequently jobswithin aerospace manufacturing.

Hes got a great pulse on all parts ofmetal fabrication. I dont encounter peo-ple too often with such a broad knowl-edge base who are enthusiastic, who aregiving freely of their time. Its hard to seeanything that hes not helping or beingsuccessful with, Clearman said.

Forward Progress

Schreiber has a reputation among hisstudents and colleagues as having un-paralleled welding skills. Hell be thefirst to admit that his welding ability isa product of repetition and a tenaciousdrive to one-up himself, no matter howgood the weld looks or how structur-ally sound it is. It should be no surprise

that he applies the same approach to hiswelding program. No matter how wellthings are going or how much the pro-gram is growing, hes never satisfied, andhe never wishes to remain stagnant.

Even though Schreiber is proud thathis program is in such high demand, the

fact that it is currently running at 112percent capacity with 115 people on the

wait list is a challenge in terms of re-cruiting. After all, how do you convincesomeone that a two-year wait is worth it?

Maybe the actions and direction setforth by its leader are the reasons. n

Associate Editor Amanda Carlson can bereached [email protected].

Green River Community College, 253-833-9111,www.greenriver.edu

32 Haviland Street, Unit 2C South Norwalk, CT 06854(212) 889-6330 Toll-Free (888) 528-7852 Fax (212) 545-8327

www.industrialpress.com E-mail:[email protected]

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Technology Overview

By Terry Tuerk

T

o do or not do to, that is the question. When it comesto cutting and grinding with professional-grade elec-

tric power tools, the answer to that question couldmean the difference between a safe work environment and anaccident waiting to happen.

In fabrication shops across the U.S. and around the globe,power toolsmore specifically, angle grindersare beingused in an improper and unsafe manner, especially by work-ers who are less experienced in metal fabricating. Taking thetime to learn the dos and donts of cutting and grinding canhelp prevent serious injury to yourself or those around you.

The Background on Angle Grinders

Over the past several years, the small angle grinder has be-come the most versatile tool in a fabrication shop. The toolused to be considered bulky, heavy, and hard to manipulate,but a lot has changed. Power tool design engineers haveworked hard to make angle grinders lighter, safer, more ergo-nomic, and more powerful. This is particularly true for smallangle grinders now offered with 12 amps or more of power,as well as for cordless versions that can deliver up to 100 ampswith an 18-volt lithium-ion battery.

The design advances of todays angle grinders have in-creased the number of applications you can use them for.

Quality angle grinders usually have industry-standard

safety features such as a toolless, easily positioned wheel guardthat allows you to quickly reposition the guard rather thanremove it entirely. Safety slip clutches also are available onmany industrial-grade angle grinders. The safety slip clutchhelps to protect you from kickback should the wheel bindor snag.

All angle grinders are equipped with a side handle, whichhelps you to better control the tool while it is in operation,especially when performing heavy grinding or cutting. Anti-vibration side handles and side handles that are offset from 90degrees are safe, ergonomic, and allow you to work for longperiods of time without fatigue. By keeping two hands onthe tool, not only will you work safer, but youll work moreefficiently too.

Safety First

All humans become complacent at one time or another, es-pecially when we have done a job over and over and overagain. Im sure youve experienced a moment when youvethought, Whats the worst that could happen? It will onlytake a second.

This invariably translates into ignoring the written orunwritten rules of whatever you are doingin this case,


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ignoring basic safety by using a cuttingor grinding disc that is not meant for theapplication you are performing, or sim-ply deciding not to attach a wheel guard

or a side handle to a grinder. It seems be-nign, harmless even, but if done enoughover a period of time, sooner or later anaccident will happen. So, how do weavoid complacency?

First, familiarize yourself with therules of operating your angle grinder,and second, follow those rules. Under-lying translation: Read the instructionmanual!

The owners manual not only offers

excellent information about the tool andhow to operate it safely, it also gives youall the information you need, from howto care and maintain your tool to how toselect the appropriate accessories.

It should be no surprise that becauseangle grinders are being used in a widervariety of applications than ever beforesuch as removing metal, deburring,cleaning, brushing, sanding, finishing,polishing, and cuttingthe number ofoperator injuries has increased. By sim-

ply taking the time to read the manualand becoming familiar with all of thetools safety guidelines, you can avoid amajority of these injuries.

Accessorizing Your

Angle Grinder

As a power tool user, you really need tothink about your application and prop-erly match the accessory to the grinderitself. Its important that whatever youchoose falls within the manufacturerstool and accessory recommendations.

Accessories always should be rated ator above the no-load speed of the anglegrinder. Start by choosing the correctgrinding wheel size for your angle grind-er. By using wheels that are oversized,yo

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