1 WELDING · 2017-10-04 · Welding Apprentices Fortress Resistors Women in Welding K-TIG Pipeline in Argentina WeldQ & the AWCR Victoria State Focus Inside the WTIA SMART Industry

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Guess who’s back? The TrueView optics that forever changed the way welders see are now available in the welding helmet that changed everything.

Visit the new AWS website to find out who’s returned.

www.awsi.com.au

2017 Welding Journal Advert 9002NC.indd 1 28/07/2017 4:56:50 PM

Welding Technology Institute of Australia

JOURNAL OF THE WELDING TECHNOLOGY INSTITUTE OF AUSTRALIA

Q3 | SEPTEMBER 2017www.wtia.com.au

WELDING AUSTRALIAN

AUSTRALIAN WELDING | SEPTEMBER 20172

Subscription to Australian Welding Journal is a WTIA member benefit included in annual membership fees. All rights reserved. No part of this publication may be reproduced or copied in any form without the written permission of the WTIA. The WTIA and its agents are not responsible for statements or opinions expressed by contributors in this publication, which are not necessarily those of the WTIA. Publication of any advertisement does not constitute endorsement by the WTIA of any product, nor warrant its suitability.

Apprentices: How to Spark A Career in Welding

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WTIA NATIONAL OFFICEBuilding 3, Level 320 Bridge StreetPymble, NSW 2073(PO Box 197, Macquarie Park BC, NSW 1670) T: +61 (0)2 8748 0100E: [email protected]

QUALIFICATION & CERTIFICATION MANAGERAnnette DickersonT: +61 (0)2 8748 0170E: [email protected]

ABOUT THE WTIAA not-for-profit, membership-based organisation, the Welding Technology Institute of Australia (WTIA) represents Australia’s welding profession. Our primary goal is to ensure that the Australian welding industry remains locally and globally competitive, now and into the future. WTIA is the Australian representative of the International Institute of Welding (IIW).

CHIEF EXECUTIVE OFFICERGeoff CrittendenT: +61 (0)2 8748 0100E: [email protected]

How to Maximise Your Supply Chain

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P14Advanced Training Technology Narrows the Skills Gap

3CONTENTS Q3 2017

Q3 2017From the WTIA President

Inside the Industry

Breaking NewsThe Future of Training Advanced Training Technology WorldSkills International Business Essentials Health & SafetyAustralian Standards Welding ApprenticesFortress ResistorsWomen in WeldingK-TIG Pipeline in ArgentinaWeldQ & the AWCRVictoria State Focus

Inside the WTIA

SMART Industry GroupsWTIA Hotline Report Meet the WTIA CouncilMember Directory Upcoming Events

Women in Welding

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CONTENTS

P12The Future of Training: Augmented Reality

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4244464851

TRAINING MANAGERPaul JamesT: +61 (0)2 8748 0150E: [email protected]

MEMBERSHIP MANAGERDonna SouthT: +61 (0)2 8748 0130E: [email protected]

ADVERTISINGDonna SouthT: +61 (0)2 8748 0130E: [email protected]

EDITORIALSally WoodT: +61 (0)434 442 687E: [email protected]

EDITORIAL SUBMISSIONSThe WTIA welcomes editorial submissions, technical papers and media releases. All editorial submissions should be submitted electronically to [email protected], and must be accompanied by at least one high resolution JPEG image file at 300dpi.

K-TIG Pipeline in Argentina

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A Message From The WTIA President

I personally led the two recent revisions to the WTIA’s Constitution, which were needed to provide us with the right legal framework in which to operate.

Why would I bother? I am retired, and (while my wife may disagree!) have earned the right to relax. The answer is that I am passionate about the WTIA and the broader industry that it serves.

My involvement with the WTIA goes back to 1980. At that time, working at the BP (then Amoco) Refinery in Brisbane, I needed independent technical advice. I found it through the Australian Welding Research Association (AWRA), which was one of the two bodies that later amalgamated to form the WTIA. The quality of the technical knowledge convinced me that the Refinery should join the AWRA.

Throughout my career, I had much to do with welders and welding. Enough to know that the WTIA is an organisation that supports its members throughout all phases of their careers.

This support for members is clear in many of the WTIA’s programs. Recently introduced online training courses and new qualifications are part of our drive to promote career development and overcome the tyranny of distance, which I know prohibits many of you attending training. The WTIA is very much aware the pressures many of you are under in your work environment

and are doing everything we can to help.

Similarly, over the past two years, we’ve significantly improved member communication tools, namely our quarterly printed journal Australian Welding, and our monthly e-newsletter Weld Connect.

The purpose of Australian Welding is to offer authoritative insight and to discuss global and domestic welding industry issues through a distinctly Australian perspective. Australian Welding provides a medium for the publication of technical information and views on the latest welding processes, products and services.

Weld Connect is designed to foster a local Australian welding community, to highlight the activities and achievements of members and to report on state-specific branch events and activities.

However, as with any organisation, you only get out what you put in. We can only tailor our services to your requirements if you give us feedback, both positive and negative.

The WTIA regularly conducts surveys asking for your opinion, so please take the opportunity to tell us what you think. Furthermore, if you have any ideas that you wish Council to discuss please use the ‘Contact Us’ facility on the WTIA website.

I think it is important to understand that, whilst the WTIA is managed by a group of talented full-time

employees, your elected Council maintains strict oversight of all Institute activities.

Our Councillors endeavour to ensure that the WTIA is financially viable, properly managed and constantly improved to protect and enhance the interests of all members.

You will find profiles of all your Councillors on pages 46 and 47 of this edition of Australian Welding. Although the WTIA Councillors do not formally represent their state of residence, if you wish to provide your feedback personally, you are welcome to contact your local Councillor.

Roger GriffithsWTIA President

Roger Griffiths, WTIA President.

I have now served on the WTIA Council for nine years, including as President for one year. The last few years have been challenging, with rapid and far-reaching change in the industrial and political environment in which the WTIA operates. And yet, despite these challenges, the WTIA has successfully implemented many programs, all of which have been designed to support members.

Roger Griffiths, WTIA President.

CrossLinc Technology,Full Control, Fewer Cables.

The Lincoln Electric Company (Australia) Pty. Ltd. | 35 Bryant Street Padstow NSW 2211 Australia Ph: 1300 728 720 (AU) | 0800 728 720 (NZ) | www.lincolnelectric.com.auWTIA | 09/17 | © The Lincoln Electric Company (Australia) Pty Ltd | All Rights Reserved.

Look out for our new products • REALWELD® trainer

• Torchmate® 4400 and 4800 CNC cutting tables

• Aspect 300 TIG welder

Reliable• Built on industry proven design elements of other popular

Lincoln Electric welders.• Components designed to run cool for long life in high temperature environments.• Fully encapsulated and environmentally protected electronics.• Engineered for outdoor use and harsh environments (IP23 rated).

Flexible• Compatible with across-the-arc, analog, digital or CrossLinc™ feeders.• Premium multi-process arc characteristics work with all DC wire, stick

and TIG processes.• Choice of models to fit any application and budget.• Lightweight and portable.

Simple• Streamlined operator panel minimizes setup time with easy

process selection.• Plug in to any 380-600V 3 phase power.

CrossLinc™ Technology• Full functionality without control cables.• Enables remote procedure setting at the feeder to improve

weld quality.• Increase arc time with fewer trips to the power source to

adjust settings.• Improves safety by reducing jobsite clutter.

It does not get much simplerOn the construction site or in fabrication shops, it pays to keep it simple. The Flextec platform is designed for that kind of environment. These multi-process welders are easy to setup and easy to operate, yet rugged and flexible enough to be used in construction, fabrication, shipbuilding and other heavy-duty applications.


Furphy Wins WTIA Fabricator AwardThe WTIA would like to congratulate the team at Furphy Engineering on receiving the 2017 WTIA Fabricator Award.

This award recognises and applauds Furphy’s outstanding performance in market success, health and safety record, quality assurance, community engagement, demonstrated innovation and commitment to the training and development of employees. We’re delighted to count Furphy Engineering among our members, and thrilled to honour them with this thoroughly well deserved award.

Adam Furphy, Furphy’s Managing Director said, “On behalf of the fantastic team here at Furphy Engineering I would like to thank the Welding Technology Institute of Australia and acknowledge their excellent work in representing Australian manufacturing and industry.”

“Manufacturing and servicing of stainless steel tanks has welding at its very heart and we are proud of our investment in both machinery and skills to continue to improve Australia’s stainless steel liquid storage. Many thanks for this wonderful award.”

Inside the Industry:Breaking News

The award was presented to Furphy Engineering at the Gala Dinner of the Australian Steel Convention in September. J. Furphy & Sons is an Australian engineering icon. Established in 1864, it is still family owned (fifth generation) and operated from its base in Shepparton, Victoria. The company is renowned for its historical links to rural Australia and in particular its most famous product - the Furphy Water Cart. Today, the company is much different.

Engineering is the core business and is predominantly responsible for the company’s growth and the profile it enjoys today - one of Australia’s premier and most unique metal trades companies. Its client base includes many of industries most reputable multi-national and domestic companies.

The Furphy Engineering division designs, engineers and manufactures high quality, stainless steel storage tanks, processing tanks and pressure vessels. It supplies multi-national and domestic businesses across the food, dairy, brewing, manufacturing, oil and gas industries.

For more information: www.furphyengineering.com.au

Artists impression of the Pacific Patrol Boats. Source: Austal.

Furphy Engineering’s stainless steel tanks.

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BOC to Collaborate with CSIRO on Revolutionary $3.4 million Hydrogen ProjectBOC, one of the world’s leading gases and engineering companies, will support CSIRO during its $3.4 million ammonia to hydrogen cracking and membrane purification project that is set to revolutionise the global supply chain for hydrogen.

As part of a recently signed collaboration agreement, BOC will contribute in-kind gas products and technical expertise worth in excess of $100,000 for the two-year project now underway at CSIRO’s test site in Brisbane.

BOC will supply ammonia, which will be cracked and purified into pure hydrogen by the modular membrane technology unit developed by CSIRO. BOC engineers will also assist with compressing the hydrogen and storing it in special cylinder packs, then distributing it to customers on the Australian east coast for use in hydrogen fuel cell vehicles.

The project will build on CSIRO’s expertise in separating pure hydrogen from mixed gas streams, in this case converting ammonia to high-purity hydrogen for use in fuel cell vehicles. CSIRO’s membrane reactor technology will fill the gap between hydrogen production, distribution and delivery in the form of a modular unit that can be used at, or near, a refuelling station.

Currently, the transportation and storage of hydrogen is complex and relatively expensive, making export commercially challenging. The membrane will allow hydrogen to be transported in the form of ammonia (which is already being traded globally), and then reconverted back to hydrogen at the point of use. The thin metal membrane allows hydrogen to pass, while blocking all other gases. In the final stages of development, the device is being further refined, ready for commercial deployment.

General Manager Hydrogen, Alex Dronoff, said BOC is proud to be working with CSIRO researchers as they take a significant step forward in hydrogen technology, paving the way for a renewable hydrogen export market that could meet rising demand in emerging markets Europe, Japan and South Korea. “As the only global organisation with expertise and technology that covers the entire hydrogen supply chain, BOC and The Linde Group are committed to working with Australian researchers and industry to help advance the global transition towards clean hydrogen for mobility and energy,” said Dronoff.

INSIDE THE INDUSTRY: BREAKING NEWS

Artists impression of the Pacific Patrol Boats. Source: Austal.

Strategies to Reduce Exposure to Welding FumesDuring welding, microscopic particles of buoyant hot metal and gases are released from the welding arc and rise in a cloud of metal fume into the workplace air. This fume is then able to be inhaled by the welder or others close to the source. There can be significant exposures to workers if effective controls are not in place, potentially leading to significant short and long term health effects. The exact level of risk from the fume will depend on what metals are involved in the work. Different metals can have a different toxic effect on the body so exposure needs to be effectively controlled. AWSI has released a white paper that outlines strategies to help reduce exposure to welding fumes.

For more information: www.awsi.com.au/literature-videos

Guess who’s back? The TrueView optics that forever changed the way welders see are now available in the welding helmet that changed everything...

Visit the new AWS website to find out who’s returned...

www.awsi.com.au

BOC to work with CSIRO on $3.4 million hydrogen project.


Inside the Industry:Breaking NewsShell Prelude Arrives in AustraliaShell Australia recently confirmed that its Prelude Floating Liquefied Natural Gas (FLNG) facility arrived in Australian waters. Prelude is the first deployment of Shell’s FLNG technology, that will see a 488m long floating facility extracting and liquefying gas at sea, before it is exported to customers around the globe. The project is located approximately 475km north-north east of Broome in Western Australia.

Shell Australia Chairman Zoe Yujnovich said the arrival of the Prelude FLNG facility signalled a new era for the Australian LNG export industry, with the first floating liquefaction facility deployed in local waters. “Prelude’s arrival is a clear demonstration of Shell’s long standing commitment to investment and development in Australia – delivering significant economic benefits to the nation.”

Yujnovich said Shell had awarded a majority of Prelude contracts to Australian contractors, including the contract awarded to Australian engineering company Monadelphous for maintenance and modification services valued at $200 million.

“Prelude is an Australian project and Shell has recognised how important it is to build strong partnerships with Australian industry,” said Yujnovich. “To develop and maintain a safe, high performance culture on the facility, Shell has partnered with South Metropolitan TAFE in Western Australia to develop specific training for Prelude technicians. One hundred and fifty technicians have been trained across a broad range of critical skills, including helicopter landing and refuelling skills, rigging, scaffolding and first aid.”

“West Australian based company CIVMEC, a construction and engineering services provider, constructed the four massive anchor piles for Prelude’s subsea flowlines from their facility in Henderson.”

WTIA Releases Revised Version of Technical Note 15The WTIA has recently released a revision version of Technical Note 15: Welding and Fabrication of Quenched and Tempered (Q&T) Steel.

This Technical Note provides basic information on the types of Q&T steels commonly encountered in Australia, and presents general recommendations and guidance on the selection of welding process, care and choice of consumables, welding procedures, and related fabrication operations such as flame cutting, plasma cutting, laser cutting, water jet cutting, shearing and forming.

Steels covered by this Note include a range of structural, pressure vessel and abrasion resistant grades, normally containing less than 3% total alloying elements such as manganese, nickel, chromium, copper and molybdenum.

Q&T low alloy steels, particularly in plate form, are being used in Australia in both structural and abrasion resistant applications. The continuing increase in usage is due partly to greater local availability since the establishment of a domestic manufacturer, and partly to a greater appreciation of the advantages these steels can offer when selected, fabricated and used correctly.

Welding is by far the most common means of fabrication and attachment, and may be involved in over 80% of applications of Q&T steels. Appropriate welding procedures and fabrication practices are required to ensure the full potential of these steels is realised. The current edition of the Australian and New Zealand structural steel welding standard AS/NZS 1554.4 provides useful rules for the welding of a wide range of welded components and constructions using high strength Q&T steels.

For more information or to purchase a copy, visit: https://shop.wtia.com.au

Prelude FLNG being towed to Australia. Image courtesy of Shell Australia.

9INSIDE THE INDUSTRY: BREAKING NEWS

Thales Australia Partners with University of SydneyThe University of Sydney will develop transformational industry projects in aerospace, defence, security and transport fields together with global technology leader Thales Australia.

In a recently signed Memorandum of Understanding (MOU), the University of Sydney and Thales Australia have committed to work closely together over the next five years to develop new technologies and capabilities. The MOU was signed by the University of Sydney Vice-Chancellor and Principal Dr Michael Spence and Thales Australia Country Director and CEO Chris Jenkins.

Jenkins said, “Thales Australia’s long-term relationship with the University has contributed to breakthrough technology in underwater sensing and Thales’ sovereign capability in fibre laser sensors. Recognising the pace of innovation, especially in digital technologies like big data, machine learning and artificial intelligence, it is critical for Thales to partner with leading universities.”

K-TIG to Fabricate GE Gas Turbine ComponentsK-TIG has gone into production for the fabrication of mission-critical components of the GE 7HA, 7FA and 9FA - the world’s largest and most advanced gas turbines.

The components being welded using K-TIG are high temperature alloys used in the combustion and exhaust system of GE’s gas turbine engines, which generate up to 544MW output. The K-TIG welding system is being used to produce x-ray quality, defect-free welds in a fraction of the time and at a fraction of the cost of previous processes.

A high energy density variant of GTAW, K-TIG (Keyhole TIG) is a high speed, single pass, full penetration welding technology that welds up to 100 times faster than TIG welding in materials up to 16mm in thickness, and typically operates at twice the speed of plasma welding.

ASC West Facility Upgrade Boosts Australia’s Submarine CapabilityAustralia’s sovereign submarine capability was recently strengthened with the opening of an innovative major upgrade to ASC’s Western Australian submarine maintenance facility. The upgrade is part of ASC’s continuous improvement of the maintenance of Australia’s Collins Class submarine fleet, as part of the Submarine Enterprise, which has achieved international benchmark performance this year.

The $12.5 million redevelopment will improve productivity and reliability through a maintenance support tower, sky bridge and new amenities and office areas, significantly cutting the time workers spend accessing a submarine under maintenance.

Finance Minister Mathias Cormann and Defence Industry Minister Christopher Pyne jointly opened the redevelopment at ASC West, in Henderson, at a ceremony attended by ASC management and personnel, senior Defence Department, Royal Australian Navy (RAN) and defence industry leaders. “This major redevelopment at ASC’s Western Australian facility lays a solid foundation for ASC’s future as a key sovereign asset delivering Australia’s submarine capability,” said ASCInterim Chief Executive Officer Stuart Whiley.

“It is an exciting development that comes at a time of significant investment and commitment to growing Australia’s future submarine capability by the Federal Government. ASC looks forward to being a key part of delivering that capability growth.”

The redevelopment comes after ASC and the Defence Department agreed a further five year performance period for the sustainment of the Collins Class submarine fleet, which commenced on 1 July this year.

Finance Minister Mathias Cormann and Defence Industry Minister Christopher Pyne open the upgraded submarine maintenance facility at ASC West. Photo courtesy of ASC.

GE’s 7HA gas turbine.

/bocsouthpacific /bocsouthpacific /user/boclimited

BOC LimitedRiverside Corporate Park, 10 Julius Avenue, North Ryde, NSW 2113 AustraliaABN: 95 000 029 729 | boc.com.au | 131 262BOC is a trading name of BOC Limited, a Member of The Linde Group. © BOC Limited 2017. MP17-0121 |RW|AW|0917

BOC delivers a new generation of welders ...

TIG EWM Tetrix 230 AC/DC VRD l MIG/MAG Smootharc Advance II MIG 400R Smootharc Advance II MIG 250R Smootharc MIG 181 l MULTIPROCESS EWM Phoenix 405 Progress Pulse BOC Smootharc Multiprocess 180 l MMA BOC Smootharc MMA 131VRD BOC Smootharc MMA 171VRD

...with advanced electronics and digital control that focus on delivering improved safety and quality.• New TIG, MIG/MAG, MMA and Multiprocess machines

• Fully compliant to AS/NZS and European standards

• Excellent reliability and performance

• BOC offers gas, welding and technical expertise

• Call in to any of our BOC Gas & Gear stores across Australia and New Zealand

Call 131 262 (Aus) or 0800 111 333 (NZ)

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BOC delivers a new generation of welders ...

A Member of The Linde Group

TIG EWM Tetrix 230 AC/DC VRD l MIG/MAG Smootharc Advance II MIG 400R Smootharc Advance II MIG 250R Smootharc MIG 181 l MULTIPROCESS EWM Phoenix 405 Progress Pulse BOC Smootharc Multiprocess 180 l MMA BOC Smootharc MMA 131VRD BOC Smootharc MMA 171VRD

www.boc.com.au or www.boc.co.nz


The Future of Training:Augmented RealityIn the digital era, new technologies like augmented reality have started to play a key role in several sectors, including education and training. The new paradigm in vocational, technical and industrial training, augmented reality training enables future welders to acquire the skills and the self-confidence they need before moving into the real workshop. Augmented reality training is student-focused, allowing individual students to progress at their own pace. This type of training is proven to be efficient, sustainable, safe and secure and allows training centres and industry to save costs and time whilst training professional welders. The WTIA and BOC (The Linde Group) have formed a partnership with Seabery to introduce their augmented reality training system—Soldamatic—to Australia.

What is Soldamatic?Seabery’s Soldamatic Augmented Training is the first augmented reality welding educational technology solution in the world.

According to Antonio Fernández,Seabery’s International Business Development Manager, “We started applying augmented reality to welding because welding is used across so many industrial sectors, from oil and gas and infrastructure, through to the automotive and energy industries. And yet, there is an enormous shortage of skilled welders worldwide, in both emerging economies, as well as developed nations such as America, where more than 300,000 new welders will be required by 2020.”

“Soldamatic enables training institutions, governments and welding associations to attract young people to industrial careers to close this ever-increasing gap between the market demand for qualified welders, and the available workforce,” said Fernández.

In 2014, Soldamatic’s first year on the market, 25 units were sold in India, Canada, Hungary, Poland, Russia, South Africa and the USA. Today, just three years on, over 1,500 units have been sold in more than 40 countries.

The software has been adopted by some of the world’s largest manufacturers, including Mercedes-

Benz, Volkswagen, Siemens and John Deere, as well as a number of government bodies and international educational institutions.

This rapid, widespread adoption of the technology is not surprising, given the results that the Soldamatic system has already achieved, particularly in terms of reducing training time and costs.

Soldamatic conducted tests comparing their augmented reality technology to traditional welding training. These test were conducted in collaboration with GSI-SLV (a major German welding training centre), the Spanish Welding Association (CESOL), and large industrial companies (including Volkswagen).

The results demonstrated that 34% more welders were certified in 56% less time, saving up to 68% on the overall cost of welder training. In

addition, Soldamatic increases the time on arc by three to five times, and enables training institutes to educate four times more students while maintaining their existing lab infrastructure.

There are a range of other benefits offered by augmented reality training technologies, such as Soldamatic. The augmented reality world can contextualise job-specific training, giving students the opportunity to experience the consequences of their decisions in a safe environment—mistakes simply invite exploration, rather than resulting in health and safety risks.

The acquisition and retention of knowledge and skills is similarly improved, with hands-on practice provided in conjunction with theoretical study. For a student, processing information that may already be perceived as tedious is

Seabery’s Augmented Training Lab in England.

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unlikely to result in positive learning outcomes. Augmented reality training transforms training from boring theory and text books into high-quality interactive, experiences that capture the imagination.

Soldamatic is also environmentally friendly, offering significantly reduced CO2 emissions when compared to traditional welding training.

Soldamatic Augmented Training becomes more efficient when used in a classroom, connected to a central server that enables instructors to monitor students’ progress in real time. These types of classrooms are known as an ‘Augmented Lab’, a training centre that combines augmented reality welding simulation with real-world welding experience for the acquisition and improvement of manual skills.

Seabery opened its first Augmented Lab in Spain, followed by England and Korea, with other labs planned worldwide. These labs are open for use by companies, institutions, associations, and society at large to help ensure the next generation of welders has the skills and knowledge required for the highly-demanding international market.

The Introduction of Soldamatic to AustraliaGeoff Crittenden, WTIA CEO, is looking forward to the introduction of Soldamatic to Australia. “I first

saw Soldamatic at the 69th IIW Annual Assembly and International Conference in 2016. I was really impressed with the quality of the training experience it gives.”

“It’s not just the equipment of Soldamatic that impressed me, but also the support and depth of information in relation to all aspects of the system is quite extraordinary.”

“Subsequently, we formed a partnership with BOC to introduce Soldamatic into Australia. We are in the process of bringing Soldamatic into our technical schools, particularly for training welders for defence projects. We are really looking forward to introducing Soldamatic into Australia, where we believe it will make a huge impact on the training of our welders,” said Crittenden.

BOC is demonstrating Soldamatic in Melbourne throughout September. BOC’s Technical Manager Peter Kuebler said, “Soldamatic is attracting a lot of interest from training colleges and young people who are unsure about welding as a career.”

“Once students try it, Soldamatic rapidly develops their hand-eye coordination and gives real time feedback on areas requiring practice. The teacher software enables teachers to easily tailor exercises to suit each student’s capability and then record their performance.”

About the Soldamatic System

SimulatorThe shape of the augmented reality simulator is inspired by real welding power sources. It supports all four manual arc welding processes, inlcuding MMA / SMAW, MIG-MAG / GMAW, FCAW and TIG / GTAW.

Augmented Reality HelmetThe ergonomic design of the augmented reality helmet ensures easy display of the welding space and provides a similar effect to a real welding mask.

CouponsFive different PVC standard coupons are included as standard in the system (with customised workpieces available on request): V-butt 150NB pipe, lap joint, T-fillet joint, V-butt in plate and pipe to plate fillet joint.

TorchesThe system includes GMAW, GTAW and SMAW torches.

SoftwareCustomised developed simulation, server and teacher software accompanies the equipment, as does a student e-learning platform. The easy-to-use software helps instructors manage the training process, allowing them to monitor the activity of each student in real-time, for quick and easy evaluation, and generation of detailed reports.

ContentAll theoretical content is compliant with the guidelines of the International Welder Program by the IWS, the Sense Program by AWS, and German DVS Media, CESOL. Instructors can create exercises based on real Welding Procedure Specifications (WPS), and customise the difficulty level and welding parameters for individual students. There is also a range of pre-prepared multiple-choice exams.

For more information, contact Peter Kuebler (BOC Technical Manager) on [email protected] or visit www.soldamatic.com.

INSIDE THE INDUSTRY: SOLDAMATIC’S AUGMENTED TRAINING

Seabery’s Augmented Training Lab in England.


Unlike virtual reality training solutions designed for classroom use and limited to ‘virtual’ welding, REALWELD is designed for in-situ use in a real-world welding booth, in either arc-on or arc-off modes. REALWELD teaches multiple welding processes (MIG, stick and flux-cored) in a number of welding positions (1F, 2F, 3F, 4F, 1G, 2G and 3G) and joints (lap, tee, groove, flat plate) on 25.4mm plate, and 152mm or 457mm coupons.

Practicing on these longer welds replicates common field conditions more closely, better preparing students for work in the real world. Instructors can configure REALWELD’s ‘sweet spot’ parameters associated with proper welding technique using a built-in, instruction-set feature known as Welding Procedure Specifications (WPS) for each weld to be performed. They also have the ability to adjust tolerances to lenient, moderate, or stringent settings.

As a user welds, the system analyses and scores every attempted weld trial and provides embedded, on-screen information that students can access in the booth. This includes the ability to review such things as how-to videos, WPS documents and even instructor handouts (on topics such as safety data sheets), without ever leaving the welding booth.

“REALWELD is more than an augmented reality trainer. It

is a hands-on learning tool that enables companies and TAFEs to train welders faster and more efficiently, attracting and engaging the next generation of welders.”According to Paul Howe, Lincoln Electric’s Sales Manager for Hard and Flexible Automation in Australia, “The most effective learning experience by far is the one that engages multiple senses.”

“REALWELD engages all the senses, particularly with its in-built audio coach that provides guidance on weld speed, angles, aim, contact tip to work distance, arc length and position in the weld.”

Advanced Training Technology Narrows the Skills GapWorkforce development training needs to educate tomorrow’s employees and help today’s workers improve upon their existing skill set. The result – a better trained, more knowledgeable worker at all phases of the employment cycle. This is particularly true when it comes to educating workers in skilled trades such as welding, regardless of whether they are on a construction site or working in an advanced manufacturing facility. Incorporating new training technologies designed to narrow the skills gap, such as Lincoln Electric’s REALWELD Advanced Trainer, can help prepare graduates for real-world work in specific production processes.

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“It’s like having a teacher’s assistant right in the booth helping to advance every student toward their career goals. These audio cues can be turned off at any time, allowing the student or prospective employee to quickly demonstrate learned behaviours.”

The result of these embedded features? Trainees receive immediate, objective, data-driven feedback. Instructors can track progress or immediately see bad habits being repeated. All of this can be done without the need for an instructor to hover over any particular student’s shoulder.

When used with advanced welding equipment like Lincoln Electric’s Power Wave C300, REALWELD exposes students to advanced manufacturing technologies used in industry today.

REALWELD can even be used to create an unlimited number of customisable Welding Procedure Specifications (WPS) and allows for the creation and modification of WPS tolerances.

With a slim, vertical design it will fit in just about any weld booth, and the operating system software is available in 12 languages.

INSIDE THE INDUSTRY: LINCOLN ELECTRIC

Lincoln Electric Launches Flextec with CrossLinc™ TechnologyLincoln Electric’s new Flextec range of multi-process welders with CrossLinc™ Technology have been designed to solve several complex on-site welding issues. These multi-process welders are easy to setup and operate, yet rugged and flexible enough to be used in other heavy-duty applications. The Flextec range has workers safety, weld quality, productivity and equipment reliability in mind.

It is typical for a welder to work closely with a rugged, compact, lightweight wire feeder, connected to a weather-resistant power source located hundreds of metres away. Until now, portable wire feeders have been available in two configurations: basic ‘across-the-arc’ models or portable feeders equipped with an added control cable.

‘Across-the-arc’ models are powered by the weld cable. This configuration provides the benefit of fewer cables running back to the power source, but voltage control at the point of use is not possible. The addition of a control cable to the system allows the operator to adjust voltage at the point of use, but these cables can be costly and add additional complexity to the production environment. There had to be a better way.

CrossLinc™ feeders enable voltage control at the feeder, while eliminating the extra cable. The result is greater safety, quality, productivity and system reliability. With CrossLinc™, you get voltage control at the feeder without an additional control cable. CrossLinc™ technology is designed to send voltage information hundreds of metres using a standard weld cable.

According to Paul Smith, Lincoln Electric’s Marketing Manager, “The Flextec machines are the new standard in welding productivity. The CrossLinc™ technology will redefine the welding landscape and solve site welding issues.” “Greater operator control makes it easy to meet Welding Procedure Specifications. With full voltage control at the feeder you get correct settings for every weld. It can accurately compensate for voltage drop across long cable runs and eliminate unintentional machine adjustments by operators. This enables you to work faster, reduce movement and minimise rework with faster setup and fewer cable connections,” said Smith.

Lincoln Electric’s new Flextec multi-process welders with CrossLinc™ Technology.


Dylan Bolch, a welder at Macquarie Manufacturing in Rathmines, will compete at the 44th WorldSkills International in Abu Dhabi.

NSW Welder to Compete in WorldSkills InternationalA young welder from Woodrising has been named by WorldSkills Australia as a member of an elite team of young Australian trades people who will compete against their international counterparts in Abu Dhabi in October. The team, known as the Skillaroos, was chosen after a four-day Global Skills Challenge. The challenge saw over 100 participants from 16 countries test their skills in 21 trades in the lead up to the 44th WorldSkills International in Abu Dhabi.

Dylan Bolch, 22, who was a student at TAFE NSW Hunter Tighes and is employed by Macquarie Manufacturing in Rathmines, will compete in the Welding category.

He has been training towards possible selection to Abu Dhabi since late last year, and has worked closely with mentors Paul Condran, who works for BlueScope Steel and Mark Williams who works for Ben Furney Flour Mills.

“Sometimes it’s tough juggling everything, but I don’t mind making these sacrices in time as I know I am fully committed to being the best welder I can be. The best thing is I see my skill level increasing each day. At work, we sometimes get jobs just

because of my skills and what I can do which I really enjoy,” said Dylan.

He is also benefitting from extra training by 2013 Bronze Medallist Lachlan Mayled. “I spent a couple of weeks with Lachlan and he ‘smashed me’ every day. We really worked hard, plus he was also able to give me pointers about competing at an international level as he has been there himself.”

The Skillaroos, aged 19 to 22, includes the highest ever female representation. The trades and skills to be represented include bricklaying, patisserie and confectionery, heavy vehicle mechanics, hairdressing, landscape gardening, refrigeration and air-

conditioning, carpentry, wall and floor tiling.

The 44th WorldSkills International Competition to be held in Abu Dhabi, from October 14 to 19, will see more than 3,000 participants, including competitors, experts and officials, from 77 countries compete in 51 skills. Australia, currently ranked 12th in the world, is aiming to finish in the top 10 in 2017.

WorldSkills Australia CEO Brett Judd congratulated Dylan on his selection saying it had been based on an arduous training regime, his success at the national WorldSkills competition held in Melbourne late last year and his performance at the Global Skills Challenge.

“Dylan has consistently shown the dedication, commitment and excellence we require of our Skillaroos,” said Judd. “I applaud his determination and congratulate him on their selection as a Skillaroo.”

Judd said WorldSkills Australia was nurturing and developing the skills of young Australians, and highlighting the opportunities available to those pursuing a trade or skill.

“These young people are excelling in their fields and being rewarded with international experience and opportunities,” he said. “Their trades are really taking them places.”

www.wtia.com.au | [email protected] | +61 (0)2 8748 0100 | Building 3, Level 3, 20 Bridge Street, Pymble NSW 2073

NOW’S THE TIME TO

INVEST IN THE FUTURE OF YOUR BUSINESS


DOES YOUR BUSINESS USE WELDING? JOIN THE WTIA

The Welding Technology Institute of Australia (WTIA) is committed to supporting and advocating for Australian industry, and dedicated to providing members with a competitive advantage

through access to industry, research, education, government, and the wider industrial community.

A WORD FROM OUR CORPORATE MEMBERS

“The most valuable aspect of our membership is the fact that we have built relationships with, and are now able to call on, the WTIA’s various technical

officers.” ~ Adam Poole, K-TIG

“The WTIA has assisted in the international accreditation of our welding processes and

procedures on the Collins Class submarines and in the development and certification of our welders to

ISO 9606. This has put us in good stead as we move onto fabricating the submarines.” ~ Daniel Miller, ASC

“Our membership has afforded us a level of industry awareness and exposure that would not otherwise

have been possible.” ~ Justin Suwart, Bisalloy

HOW CAN THE WTIA HELP YOUR BUSINESS?

Remain diverse and resilient in ever-changing and increasingly challenging domestic and global markets.

Share resources for engineering innovative solutions to enhance safety, manage risk, reduce cost, and

optimise operating efficiency.

Access the WTIA’s expert advisory services, delivered by a team of highly qualified welding engineers and

materials specialists. Our advice can help you increase the operational life of plant and equipment, significantly

reducing maintenance and repair overheads.

Receive substantial discounts on WTIA events, seminars, training and advisory services.

Find out more at www.wtia.com.au/membership


How to Maximise Your Supply ChainRapidly evolving technology, global economies and consumer demands have vastly impacted on the way in which supply chains are managed in the Australian manufacturing industry. At its core, a supply chain remains the system in which materials are obtained from a supplier by a manufacturer for the creation of goods. In the welding and wider manufacturing industries, integrated supply chains are being utilised due to the shifting demands from the marketplace. An integrated supply chain is one in which manufacturers and suppliers work together to create, distribute and market a product, rather than operating as separate entities within the supply chain.

There are various reasons for the shift to an integrated model—cooperative partnerships enable individual businesses to thrive in an increasingly competitive landscape, technology has vastly improved the efficiency and costs of internal operations with manufacturers seeking greater synergy with suppliers to maintain lower overheads, and customers expect goods to be of a higher quality and customisable in a shorter turnaround time. An effective integrated supply chain will not only enable individual businesses to operate successfully, but ensure the longevity and relevance of manufacturers and suppliers. There are several ways to maximise a supply chain so that all stakeholders are working cohesively to produce high-quality goods sustainably.

19INSIDE THE INDUSTRY: BUSINESS ESSENTIALS

Strengthen Quality ManagementSystemised quality management is key to ensuring all parties in the supply chain meet their shared objectives. Standardising processes is vital to the smooth running of a complex supply chain network and in creating a quality product.

Developing and utilising a quality management system that outlines standardised operational guidelines streamlines processes and makes the responsibilities of each stakeholder transparent. This, in turn, encourages better teamwork and accuracy.

Improve Your Supply Chain RelationshipsEffective supply chains are those that nurture a shared trust and meet the objectives of both the manufacturer and supplier. As supply chains become a more integrated network of people and technologies, it is vital that strong relationships are maintained.

Working collaboratively with your suppliers, manufacturers or customers, depending on where you sit in the supply chain, has many benefits. If a shared common ground has been established, a supplier may be more likely to deal with a change in demand from a manufacturer. Similarly, any supplier issues, such as a missed part in a delivery, are more likely to be dealt with swiftly and at no expense.

For all involved in the supply chain, the ability to step back, analyse issues and then work together to solve these issues whilst employing a give-and-take mindset, go a long way in building solid working relationships.

Utilise Quality Software to Monitor PerformanceOpen communication and transparent processes are essential in facilitating a mutually beneficial relationship with suppliers. However, it is still crucial to monitor supplier performance to ensure a quality

end product. Face-to-face quality inspections of suppliers have become an outdated practice given the time taken to perform such inspections and the room for human error. Using software to monitor supplier performance through a variety of metrics is an invaluable and fair way of ensuring all stakeholders in the supply chain are operating effectively.

Widen Your Supply Chain NetworkWith the skilled labour shortage affecting the welding industry and the increasingly globalised marketplace making it easier to procure offshore goods and services, it is important to act locally where possible. Manufacturers sourcing local goods and services invest in local resources such as infrastructure and technology.

Implement Real-Time Inventory Tracking Traditional methods of inventory tracking (such as maintaining spreadsheets and hand-checked lists) are time-consuming and ineffective methods for sharing information.

Introducing software to track your inventory centralises the information, ensuring that you know—at all times—the exact quantity of any given product on your shelves. Inventory tracking software can also be configured to provide alerts on items that you might need to reorder, as well as additional information such as the location and quality of goods in their raw and finished states. Such software can also be used to automatically replenish regularly-used stock, freeing up your employees to perform other duties.

Educating your employees on how to use software to systematically log inventory information ensures its effectiveness as a real-time central tracking system.

Apply the Just-In-Time PrincipleApplying the just-in-time principle to your business is an excellent

way to lower overheads, such as warehousing costs. Using inventory software and ensuring your suppliers deliver the right amount of goods at the right time will help ensure your stock levels are adequate, reducing expensive and unnecessary warehousing of oversupplied goods.

Streamline AccountingEffective supply chains feature accounting systems that track payments to and from suppliers and customers, and within businesses.

Having such systems in place decreases the likelihood of invoicing errors and excess paperwork. A sophisticated accounting system will also detail payment terms and conditions for those involved in the supply chain, including when and how payments should be made.

Prioritise Lean Continuous ImprovementPracticing lean continuous improvement within your supply chain is worth prioritising. Using outdated processes and methods—simply because they have worked in the past—can prevent your business from becoming more efficient and cost-effective, and less wasteful.

Continuous improvement (such as identifying opportunities for process streamlining and reducing waste) can lead to lower overheads, process efficiencies and the manufacture of higher quality goods with fewer product returns.

Identify Trends. Forecast Demand.Utilising social media, point-of-sale information and other marketing feedback to observe changes in trends and demand will enable your supply chain to respond quickly to lulls and surges in the market.

Honing your forecasting skills based on your target market’s changing needs will ensure your supply chain is able to successfully roll out new products that attract a new customer base, while maintaining existing customer loyalty.


Composite systems broadly consist of two types. The first is a pre-cured composite that is bonded into place using a structural adhesive, used for applications of simple tubular shapes such as pipe diameters. The second is a flexible woven cloth of fibre that is impregnated with resin and cured at the repair site. This is most suited for repairs involving an irregular shape or fitting, or if the repair is in a bend with a radius less than three times the diameter of the pipe.

Composite repairs are not only advantageous as a cost-saver, but are also efficient and safe. They can be used as a permanent repair for external, blunt defects and to reinforce dents. They can also be used to repair internal defects, if the source of the defect is eradicated.

The repair must have mechanical properties and composite architecture appropriate to the repair task. Mechanical properties will determine both its effectiveness and durability. Properties to consider and test are tensile strength and modulus of the composite, strength (lap shear) of the adhesive and compressive strength filler material.

The composite should have durability data that demonstrates adequate strength at the end of the design life of the repair. Each composite repair should be reviewed to ensure minimal moisture absorption, given moisture is one of the primary factors in degradation.

Validation testing should be conducted on the same materials

Health & Safety: Composite Repairs for Pipelines

and under the same service conditions as would be expected of the repair in operation.

The design of the repair must follow a proven methodology, with reliable engineering tests completed to show that the methodology can be used. Pipelines are designed to operate at a pressure that limits the stress in the pipe wall, based on various safety factors. The pressure inside a pipeline acts at right angles in all directions on the pipe wall, causing the steel in the pipe wall to be in tension. At a defect location (wall thinning), the steel in the thin ligament of the defect will be under a higher stress level than the sound pipe and may therefore yield beyond its safe limit.

A composite repair works by sharing the hoop load at the defect site, thus limiting the strain in the pipe, and therefore the stress, to a level that is safe for the Maximum Allowable Operating Pressure (MAOP) of the pipeline. The steel will still yield, but the extent of yielding will be controlled by the externally applied composite so that the MAOP can be maintained safely.

The steel and composite share the load due to internal pressure provided a suitable, non-compressible material is used between them, such as a two-part, filled epoxy resin. The load is shared in proportion to the stiffness of the two materials. The stiffness of composite material is generally lower than that of steel. The full properties of the composite are only used if the

The use of composite systems as a repair strategy for pipelines has the potential to significantly reduce costs. However, despite their increased usage there are no standards in place to regulate their design and installation. In lieu of such standards, it is recommended that the supply, installation, quality assurance and inspection of each system be reviewed on its own merits to ensure welder health and safety.

steel is allowed to yield, which is the designer’s responsibility to ensure.For a typical blunt defect such as external corrosion, the defect should be assessed to establish whether the repair will be effective. In the case of external corrosion, the defect area should be thoroughly cleaned to bare metal. The area is filled with a hardenable filler material to enable load transfer from the pipe to the composite. The composite is then wrapped around the damaged pipe and held in place with an adhesive.

Composite repairs can be used to reinforce plain dents as long as the void between the composite and the pipe is filled with a hardenable material. Stress concentrators or blemishes within the dent must be removed by grinding and the area then inspected for cracks.

Installation ConsiderationsThe installer should provide a written method statement detailing how the repair will be applied, following equivalent procedures to those used to complete validation test reports. The materials used in the repair and method of application (including surface preparation) should be the same as those used to complete validation test reports.

The method statement can be based on: risk assessment; working conditions; design information; line operating conditions and layout; design of repair; and materials information.

Repair system suppliers should provide full installation instructions.

21

These instructions should include: environmental conditions of site at time of repair; material storage; surface preparation; resin mixing; laminate lay-up and consolidation; cure; and key hold points. Installers should have approximately two years experience in pipeline maintenance, fabrication or laminating composite materials and have completed sufficient training. For repairs to be permanent it is vital that close attention is paid to surface preparation. After repair, a system pressure test may be conducted.

Quality AssuranceEach repair should be given a unique reference. After surface preparation, monitor and record surface roughness and cleanliness to ensure they compare to those used for validation testing. Temperature and humidity at time of application should be monitored and recorded. It is normal to follow painting guidelines in ensuring application does not occur if the relative humidity is above 80% or the temperature of the pipeline is less than 3°C above the dew point. This may be relaxed if the supplier can demonstrate long-term performance of repairs applied in conditions outside of this.

It is important to record the types, quantity and batch numbers of material used. Some of the materials used will have a specific shelf life and also temperature limitations for storage and use. These issues should be considered before repair. The number of layers applied and the dimensions of the repair (compared against the design) should also be recorded, with a visual inspection completed and documented after application. Cure can be checked by comparing the hardness of the adhesive against a known standard; Barcol hardness measurements are often used.

InspectionThere are no proven methods of inspecting the composites, nor the bond to the steel pipeline. It is therefore critical that careful attention is paid to the application process. The steel pipeline can be inspected from the inside by pigging. Ultrasonic, radiography and pulsed eddy current inspection techniques have both had reported success in inspecting the steel through the composite repairs. The repair supplier should always be consulted for their expert advice.

INSIDE THE INDUSTRY: HEALTH & SAFETY

For further information, refer to the WTIA’s Water Technical Guidance Note One: Composite Repairs for Pipelines and Water Technical Guidance Note Two: Benefits of Composites for Pipeline Repair.


The Changing Face of Australian Standards

Building and ConstructionThe Building and Construction sector has been active over recent months with a number of drafts of Australian Standards due to go to public comment shortly, new revision projects approved, and new Standards published. In the design sector, the Standards Australia Committee BD-001 is due to meet in the coming months to commence work on revisions to AS4100 Steel structures, and updates to the recently released AS/NZS 5131 Structural steelwork - Fabrication and erection. These

All Australian Standards are periodically reviewed, with amendments and revised editions published. The last few months have seen a variety of reviews take place, particularly in relation to Standards that pertain to the building and construction industry and pressure equipment. Just some of the Standards recently undergoing revision include AS/NZS 2980 Qualification of welders for fusion welding of steels, AS4100 Steel structures, and AS/NZS 5131 Structural steelwork - Fabrication and erection.

updates will remove the fabrication requirements from AS4100 and refer instead to AS/NZS 5131. As AS/NZS 5131 will become a secondary reference in the Australian Building Code, minor amendments will be required to satisfy regulatory requirements in Australia.

In the structural steel welding sector, Committee WD-003 has completed the review of public comments on the proposed amendments to AS/NZS 1554.3 Structural steel welding - Part 3: Welding of reinforcing steel, and balloting is underway. The committee has also approved a number of correction

amendments to AS/NZS 1554 parts 4 and 5, which are due for publication in the coming months. Separate to these projects, the long awaited draft of the revision of AS/NZS 2980 Qualification of welders for fusion welding of steels, was released for public comment in August. The public review draft for the adoption of ISO 9606-1 as AS/NZS ISO 9606-1 Qualification testing of welders-Fusion welding Part 1: Steels, has now been released for public comment.

It is important to note that the new AS/NZS 2980 will defer to the proposed AS/NZS ISO 9606-1

The Parker B300S Contour Probe is a rugged high performance instrument for Magnetic Particle Inspection. Built to accepted non-destructive testing standards,

the polyurethane filled glass/epoxy housing stands up to harsh operating conditions. Featuring fully adjustable legs (maximum spacing of 300mm) that allow

the strong magnetic field to be “focused” at the precise area of inspection, a duty cycle of 2 minutes on - 2 minutes off and weighing only 3.4Kg, the Parker B300S

has become an industry standard and is a must for every technicians’ toolbox.

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23

for much of its core content with important exceptions being retained within AS/NZS 2980. In the Bridge sector, Committee BD-090 has completed its work on the bridge code and AS 5100 Bridge design, was published in 9 parts on 31 March. Work on this revision has been ongoing for a number of years due to the size of the project. Part 6 Steel and composite construction, has been adopted in New Zealand as AS/NZS 5100.6. Readers should note that Part 6 is the first Australian and New Zealand standard to normatively reference AS/NZS ISO 3834. Pressure EquipmentUnder the direction of WTIA volunteers, a working group has commenced the revision of AS 3788 Pressure equipment – In-service inspection. This is a major revision and it is anticipated that it will take considerable time to complete. Outcomes are likely to include a new technical note on the repair of pressure equipment, a draft revision to AS 3788 prepared for submission to Standards Australia, and a commentary on the standard.

ISO UpdateISO Committee TC167 will meet in late October in Courbevoie (France) to review comments on ISO/DIS 17607 Execution of steel structures, which is similar to the Australian Standard AS/NZS 5131 and European Standard EN 1090-2. Australia will be represented by Dr Peter Key from the Australian Steel Institute. In late February 2018, ISO subcommittees TC44/SC10 and SC11 will meet in Miami (Florida, USA) to continue their work on a number of revisions, including ISO 14731 Welding coordination - Tasks and responsibilities, and ISO 9606-1.

In the case of ISO 9606-1, with the increasing importance and usage of this standard in Australia and New Zealand, it is likely that Australia will have additional comments for submission to the drafting committee to improve its usability. Accordingly, plans are underway for Australian representatives to attend this meeting.

Nominating Organisations ForumStandards Australia has recently completed a series of forums around

Australia seeking feedback on a number of issues including the future publication of Australian Standards.

With SAI Global’s exclusive contract to publish standards expiring in 2018, alternative publication methods are under consideration. Standards Australia has indicated that they will move away from the current MS Word and PDF format, to a new XML publication platform for all standards. This platform will be similar to that used by ISO and a number of other standards bodies throughout the world. This will allow for improved access to standards across multiple platforms, ranging from mobile phones and tablets through to computers.

With this change, the current Standards Hub used by Committees and for public comments is being updated and replaced. Considerable feedback from forum attendees was compiled and provided to Standards Australia. The opportunity to submit comments on many of the items addressed through the forums is currently available through the Standards Australia website.

Australian Standards are developed by balanced committees comprised of technical, business, academic, government and community experts who debate how a product or system should perform and how it should be made. Before finalisation, every Standard is subject to public comment.

INSIDE THE INDUSTRY: AUSTRALIAN STANDARDS

The Parker B300S Contour Probe is a rugged high performance instrument for Magnetic Particle Inspection. Built to accepted non-destructive testing standards,

the polyurethane filled glass/epoxy housing stands up to harsh operating conditions. Featuring fully adjustable legs (maximum spacing of 300mm) that allow

the strong magnetic field to be “focused” at the precise area of inspection, a duty cycle of 2 minutes on - 2 minutes off and weighing only 3.4Kg, the Parker B300S

has become an industry standard and is a must for every technicians’ toolbox.

For further information please contact:

Parker B300S Contour Probe

UNIT 21, 3 BOX ROAD TAREN POINT NSW 2229TEL: (61-2) 9524-0558 • FAX: (61-2) 9524-0560

Email: [email protected] • Web: www.ndt.com.au


Since then, the trades sector has been further regulated to include competency-based training and assessment at Technical and Further Education (TAFE) institutes or Registered Training Organisations (RTOs), which provide the theoretical component of an apprenticeship, as well as shorter apprenticeships and options for part-time and school-based apprenticeships.

However, apprenticeships have steadily declined in popularity while university intakes have boomed. And yet, the employment market is becoming increasingly hostile for university graduates while a skilled labour shortage unfolds.

Costly and lengthy degrees are no longer able to provide the security often promised to students by parents and teachers during secondary school years. According to recent research conducted by the Skilling Australia Foundation, only 69% of bachelor degree graduates are in full-time employment compared with 92% of apprenticeship graduates.

In spite of this, students forge ahead in this trajectory, believing a

university education to be of greatest value. These same students will likely have five careers in their lifetime, retrain or upskill by way of further study, work only a contract or part-time basis and spend much time and money thereafter in the pursuit of their dream career.

Poor public perception and a limited awareness of the value of the Vocational Education and Training (VET) sector, as well as a complacency about the changing job market, preclude many individuals from entering into an apprenticeship. What is unfortunate is that the significant number of students with a love of robotics, welding, or electronics will often shun these pursuits in favour of a university education that they may not ever use.

For those confused about their options post-secondary school, there are several excellent reasons to consider an apprenticeship.

As opposed to university studies, an apprenticeship provides an opportunity to earn an income while studying and gain practical experience with qualified tradespeople. The average university

student will finish their degree with a debt of $20,937, while award earnings over a four year welding apprenticeship in the construction and engineering industries can average approximately $130,000.

Qualified welders now face an abundance of choice on finishing their apprenticeships. A welding qualification can be used in a dynamic range of industries, such as the automotive, marine, aerospace, energy and mining industries. Given that welding is part of almost everything humans manufacture, the scope for welding careers is immense, with no shortage of local and overseas opportunities.

Once qualified, a welder may find themselves working on an offshore oil platform, conducting underwater welding on ships or pipelines, working on bridges, high-performance vehicles or wind turbines, conducting research or creating artisanal furniture and interiors. The vocational and hands-on nature of an apprenticeship is key to building the practical foundations for any of these applications.

Apprentices: SparkingA Career in Welding Apprenticeships were once considered to be the foundation of gainful employment in Australia, with university studies out of reach for most until the 1980s. The system of training apprentices was brought to Australia with European settlement in 1788, establishing an enduring tradition of developing tradespeople. In the decades before and after World War II, conditions for apprentices were heavily regulated and conditions improved with government awards and institutionalised training. In 1973, the National Apprenticeship Assistance Scheme (NAAS) was implemented, whereby the Australian Government provided payments to apprentices and employers.

25INSIDE THE INDUSTRY: WELDING APPRENTICES

The skilled labour shortage also means that a welding job is almost guaranteed on completion of an apprenticeship. Skilling Australia has found that nine out of ten occupations listed by the government as having the highest job growth are from the VET sector, and nine out of ten apprentices find work at the conclusion of their apprenticeship.

In the United States, the American Welding Society estimates a shortage of 400,000 welders by 2024. The reasons for the projected shortage are largely due to the ageing population and a lack of interest from young people in trades. For similar reasons, fewer than two-thirds of technician and trade vacancies were successfully filled (63%) between 2015-2016 in Australia, leaving almost two in every five job requests unfilled (37%). In the construction trades, only 55% of positions were filled.

Employers have cited a lack of qualified and specialised applicants as a reason for being unable to fill positions. Given the changing nature of industry worldwide, particularly in the welding industry where

automation and technology are being used at a rapidly developing rate, a broad range of skills is desirable. For welders, being able to use problem solving skills and think critically and creatively is essential—skills that can only be learnt through experience on the job.

In addition, changes to the Temporary Work (Skilled) Visa 457 program announced in April 2017 mean Australia can no longer rely on migrants to fill skilled labour positions. With the removal of more than 200 eligible skilled occupations, there will be a greater reliance on Australians to fill the labour gap.

The earning potential in the trades should be another consideration for school leavers. A VET or apprenticeship graduate will earn a median income of $56,000 in full-time employment, as opposed to $54,000 for a university graduate. The medium income of a welder will vary according to the industry they are working within. However, given the vast scope of work available to those ambitious enough, there is money to be made.

Besides educating the public on

the value of the VET sector for the sustainability and growth of the Australian economy, the myths young people have been led to believe about the trades must be dispelled. Not only are careers in the trades secure, in abundance and a necessary solution to the skilled labour shortage, they are also dynamic, fulfilling and rewarding careers in which one can develop and exercise skills in technology, leadership and problem solving.

Young Australians should be encouraged to pursue their passions with a realistic understanding of the changing job market, so that they are better armed when making career decisions. More than ever, it is crucial that students understand the benefits of an apprenticeship and the endless possibilities one can offer.

Thankfully, positive initiatives are being taken to raise the profile of the VET sector and the importance of skills training for future proofing job security. Students are increasingly being made aware of the vast array of career options available to them, while being exposed to the realities of globalisation and fast evolving technology.


P-TECH: Pathways to TechnologyOne such initiative is P-TECH (short for Pathways to Technology), an educational model established to meet the increasing need for science, technology, engineering and mathematics (STEM) skills in the labour market.

P-TECH originated in New York City, as a means of providing an industrial pathway to STEM-based careers for students in senior secondary school. The New York City Department of Education, The City University of New York, New York City College of Technology and the IBM Corporation collaborated to create a replicable model for education. The first P-TECH High School was opened in Brooklyn, New York City in 2011.

In the P-TECH model, students attend school from Years nine to 14, the last two years additional to standard secondary schooling. P-TECH schools are established and run by a university, public school district and employer, who work collaboratively to develop the school’s curriculum. During the six years at a P-TECH school, students complete four years of high schooling, followed by two years of an associate degree in applied science.

Subjects are divided into core academic skills, technical skills and professional skills, ranging from project management and programming to communication, ethics and leadership, and critical thinking and problem-solving. Traditional subjects such as English and the Arts are also taught. However, the focus is the acquisition of technical skills that will develop workforce-ready students. For example, the first P-TECH school in Brooklyn has IBM as a partner. As such, skills required by IBM for roles such as Software Specialist, Quality Analyst and Mechanical Engineering Technician are part of the curriculum.

The growing number of P-TECH schools in the US and abroad is testimony to the model’s success and relevance in preparing students for the global job market.

P-TECH in AustraliaWith the partnership of IBM and the support of the Skilling Australia Foundation and the Australian Government, the P-TECH model is gaining traction in Australia.

The first two schools to implement a P-TECH pilot were in Victoria, at Newcomb Secondary College in Geelong and Federation College in Ballarat. In May 2016, the Australian Government announced it would increase funding to $5.1 million to support the expansion of the P-TECH pilot into a further 12 schools.

The pilot has been established to test and adapt the original P-TECH model to the varying needs of each school or region, suitable to the local industry. Five schools commenced the implementation of the pilot in 2017, with the remaining seven schools to roll out the P-TECH model in 2018 and 2019.

In Australian P-TECH schools, students have the benefit of working with industry partners from Year nine onwards on project based activities in STEM subjects.

At Newcomb Secondary College, there are plans to implement more formal qualifications in STEM as part of the Victorian Certificate of Education (VCE) and Victorian Certificate of Applied Learning (VCAL). At Federation College, students can now extend their P-TECH studies to achieve a STEM-related diploma or degree.

For the trades sector, P-TECH is an excellent means by which to encourage students to pursue an apprenticeship. Students in the P-TECH program receive an early appreciation for practical work while studying and an awareness of the benefits of skills-based learning. They are also brought face-to-face with industry partners to fully understand their career options from those at the forefront of industry.Learning the practical applications of technology, mechanics and mathematics will no doubt encourage students to consider the

VET sector, where they can continue to learn in a practical setting.

According to the Skilling Australia Foundation, the role of industry in the P-TECH model is vital.

“The support and opportunities provided through the P-TECH style model are particularly important for those young people living in communities with high youth unemployment and where the labour market is shifting to a modern knowledge and skills-based economy.”

“Collaboration between the education and industry sectors strengthens the connection between student learning and the skills that employers need. In addition, the relationships students develop with their mentors and the school’s industry partners improve their prospects when employment opportunities are available with a partner organisation, or within the partners’ broader business networks.”

St Patrick’s Technical College, AdelaideSt Patrick’s Technical College in Adelaide became the first school in South Australia to adopt the P-TECH model. With Defence Industry pathways the key focus of the program, students will learn the skills and gain the qualifications required for jobs across a range of defence industry projects of national significance, particulary in areas such as engineering, electrotechnology and information technology.

To achieve this goal, St Patrick’s Technical College is working collaboratively with TAFE SA, Defence Teaming Centre and locally-based employer partners, including Century Engineering.

Engineering students at StPatrick’s Technical College now undertake projects designed by the team at Century Engineering. Projects span Century’s capabilities in South Australia including water, defence, rail, power, resources and energy applications.

27INSIDE THE INDUSTRY: WELDING APPRENTICES

Key personnel from CenturyEngineering, including engineers and technicians, work with students on projects and as mentors throughout the program. Students also visit and undertake work experience at Century Engineering’s facility in the Edinburgh North Smart Industries Precinct and with other local defence industry employers.

Once their technical studies are complete, students may opt to undertake apprenticeships with defence industry employers, or take advantage of direct entry to TAFE SA Associate Degree programs in Civil and Structural Engineering.

As a result of this practical, hands-on approach to learning, students at St Patrick’s Technical College will have direct access to employment opportunities and apprenticeships within the defence industry. Given the Australian Government’s commitment to construct 12 Shortfin Barracuda submarines for the Future Submarine Program in Adelaide, this is a win for both students and the Australian defence sector.

According to South Australian Senator Scott Birmingham, “Critical to the success of that (defence procurement) is, of course, having a skilled workforce and so the

partnership that we’re supporting here through the Pathways in Technology program, that St Pat’s will be able to afford with the Defence Teaming Centre and its members will provide real opportunities for students to see the different career pathways they can take, to learn about them early on, to be mentored, to work alongside people in those businesses coming in to St Pat’s, their skilled employees and of course students going out on site into those businesses.”

“It will compliment what is already happening here in terms of the apprenticeship pathways that are available by providing a richer and more diverse source of potential pathways,” said Birmingham.

Perhaps the best example of the pathway from P-TECH to apprenticeship is Rhys Ferrari from St Patrick’s Technical College. In a state where youth unemployment has reached 17%—the highest unemployment rate in the nation—acquiring the skills to work in thriving local industries is critical for young people. Rhys commenced an apprenticeship at BAE Systems, directly benefiting from his school’s partnership with the defence industry.

In an interview with The Advertiser, Rhys said, “I enjoy working with defence systems and it’s a good future for the defence force. The defence industry is going to open up a lot more apprenticeships for all the future students at St Patrick’s.”

Similarly, at the first P-TECH school in Western Australia, Cecil Andrews College in Perth has a focus on the defence and engineering industries. The school has built the first ‘STEM Centre’ among Australian P-TECH schools and is working in collaboration with locally-based employers such as WA ship builder Austal, Thales Group, Civmec Construction & Engineering, Deloitte Australia and Datacom Australia.

With the support of federal and state government, local communities, educators and parents, the proliferation of initiatives such as the P-TECH model can only be positive, not only for students seeking diverse and exciting career paths, but also for the Australian labour market.

Referenceswww.afr.comwww.businessinsider.comwww.education.gov.auwww.ptechnyc.orgwww.ptech.org.auwww.saf.org.auwww.adelaidenow.com.au www.abc.net.au

“Collaboration between the education and industry sectors strengthens the connection between student learning

and the skills that employers need.”


According to Phil Newman, Managing Director of Fortress Resistors, “We decided to introduce a new range of resistors with a considerably smaller design, and different shape and profile to provide cost savings for our clients.”

“On introducing this new range of resistors, we identified that the method of welding required for their assembly and installation featured key differences to our existing welding methods.”

“We wanted to ensure that our welding processes and procedures were appropriately qualified. We knew we needed to improve our in-house skills and quality systems, but we needed some support to pinpoint what we should be looking to achieve, and how to go about it. “

“Having worked with the WTIA previously, we sought their assistance with technical support to generate weld procedures and welder qualifications in accordance with AS/NZS 1554.6 for our new range of austenitic stainless steel and ferritic stainless steel resistors,” said Newman. In-Service ConditionsThe first step in defining welding processes and procedures was a review of anticipated in-service conditions. It was expected that both the austenitic and ferritic stainless steel resistors would experience various in-service conditions, depending on their application.

The two worst case in-service scenarios (that all welding processes and procedures had to account for) were expected to be:• Up to 810°C for a short period

of time (expected to be no longer than 60 seconds), as a one off application

• Up to 600°C continuously These increased temperatures are caused by the flow of current through the resistor and therefore through any associated welds. Austenitic Stainless Steel ResistorsThe main issues in welding austenitic stainless steels is the avoidance of hot cracking, intergranular corrosion, loss of ductility due to intermetallic phase precipitation, and distortion during welding. To combat these potential issues and overcome any associated in-service problems, filler wire selection and the specification of low heat inputs—as prescribed in AS/NZS 1554.6—were essential.

The most appropriate filler wire was selected based on the WRC-1992 Diagram (austenitic stainless steel welds have to solidify as primary δ (delta)-ferrite to ensure adequate resistance to hot cracking).

In addition, to combat solidification cracking, low heat input was maintained at a maximum of 1.5kJ/mm and interpass was a maximum of 120°C.

Fortress Introduces NewRange of ResistorsFortress Resistors is built on the original Brifel and Electroswitch resistor brands, which have an Australian manufacturing history dating back to the 1950s. Today, Fortress manufactures high power resistors for a range of industries, including oil and gas, mining, electrical distribution and, increasingly, for wind power and solar power generation. With the introduction of a new range of resistors to their already expansive product portfolio, Fortress needed to update their welding procedures, processes, and welder qualifications.

Filler wires with low carbon contents were specified, particularly given that the carbon content of austenitic alloys is the most significant factor in determining the ultimate susceptibility of an alloy to intergranular attack in a potentially corrosive environment.

However, due to the fact that any ferrite in the weld metal may transform to sigma phase during operation (this happens during continuous service of 500°C to 900°C for austenitic stainless steel), the ferrite content had be restricted towards the bottom of the 3FN to 8FN range in the WRC-1992 diagram. This way, discontinuous network of ferrite in the weld metal will be formed.

Ferritic Stainless Steel Resistors The main issue in welding ferritic stainless steel is embrittlement caused by grain growth and second phases. If a ferritic stainless steel is held in the δ (delta)-ferrite region around 500°C for a significant length of time (such as during the weld thermal cycle), rapid grain growth occurs.

To overcome this, a maximum interpass of 100°C and a maximum heat input of 1kJ/mm were specified. In addition, to overcome the risk of intergranular corrosion, a filler with low carbon content, and stabilisers such as titanium, niobium (columbian) and tantalum was specified.

29

“As a result of the assistance provided by the WTIA,

we’ve seen a massive improvement across our business. As we progressed further and further into the project, a number of challenges arose. I was glad we had the support of the WTIA to help guide us through these challenges.”

“I was really quite surprised that we could talk to the WTIA and get the help we needed straight away, without having to go looking for it. I’ve been really pleased with the entire process,” said Newman.

INSIDE THE INDUSTRY: FORTRESS RESISTORS

ABOUT FORTRESS RESISTORSWith expert engineering, conscientious personnel and a broad product range, Fortress Resistors has a range of experience in large oil and gas, mining, electrical distribution, wind power and solar power generation projects.

The Fortress product range includes:

Neutral Grounding: Neutral Earthing Resistors (NERs) – sometimes called Neutral Grounding Resistors – are employed in AC distribution networks to limit the current that would flow through the neutral point of a transformer or generator in the event of an earth fault. NERs limit fault currents to a value that does not cause any further damage to switchgear, generators or transformers beyond what has already been caused by the fault itself, and in some cases limit touch and step potentials to safer values than a solidly grounded systems.

Dynamic Braking: Dynamic braking resistors dissipate braking energy for overhauling loads or stopping conditions for AC electric motors.

Motor Control: Fortress manufactures resistors for a number of types of motor control applications including: wound rotor AC motors with slip ring starting resistors; star-delta closed transition starting resistors; squirrel cage AC motor resistors; crane control systems; DC series wound motor resistors; and field discharge resistors.

Load Banks: Stationary convection or fan cooled load banks based on our advanced element design allows more kW in a smaller package.

Harmonic Filters: Harmonics increase the amount of power required by a system. Filtering of harmonics can reduce the overheating of equipment, nuisance tripping of circuit breakers and fuses and reduce power costs.

For further information, visit: www.fortressresistors.comOne of Fortress’ new resistors.

AUSTRALIAN WELDING | SEPTEMBER 201730 INSIDE THE INDUSTRY: WOMEN IN WELDING

Can Gender Diversity Bolster theWelding Industry’s Future?

According to Welding Technology Institute of Australia CEO Geoff Crittenden,“Women account for less than 1% of Australia’s welding and fabricating workforce. Greater participation of women will not only benefit the industrial sectors, it will boost Australia’s economy.”

The link between female employment

and the Australian economy can be no better illustrated by the fact that the rise of female employment rates since 1974 has improved economic activity in Australia by 22%.

The female labour revolution that took place during World War II marked the beginning of a shift towards economic independence for

women. It was at the time that the earliest female welders were working to fill gaps left by conscripted men. In the United States, the aviation industry saw the largest uptake of female workers, who constituted 65% of the industry’s total workforce in 1943. Fictitious characters such as ‘Rosie the Riveter’ and ‘Wendy the Welder’, symbols of a newfound feminism, were created at this time to empower these women and inspire other women to take up trades.

However, fast-forward to 2017 and any positive implications of this revolution have not been felt long-term in the welding industry, as reflected by the current number of female welders. Encouraging the participation of women in a male-oriented sector such as welding is long overdue in ending the cycle of employment disparity.

“It’s a great time to be female in the welding and industrial sector,” said Catherine Blake, Quality Manager at Australian Precast Solutions. “It is my opinion that gender issues are disappearing rapidly in the industry and the focus is now where it should be—on competence, skill, safety.”

“I admire women in male-dominated industries that understand that they are the best person for the job and don’t worry about anything else, as they are too busy doing it. If a woman is interested in the welding or industrial sector and has the skills, there are good organisations

The trades have long reflected the cultural diversity that exists in Australia. With each wave of immigration the industrial sectors have offered employment and a means of integration for the many who have made Australia home. Yet historically, trades have largely been considered a ‘male’ pursuit. Welding is no exception. A much-needed shift is occurring, although to a lesser degree in the welding industry when compared with other trades. Increasing the number of female welders is now not only necessary in broadening diversity, but also vital for the survival of the industry.

Rachel Abbot, Technical Sales Representative at Lincoln Electric, said, “Welding has given me a career and drive like nothing else. I feel like, at times, it was the only thing keeping me on track. It has inspired me to be a better person than the path I was heading down.”

31INSIDE THE INDUSTRY: WOMEN IN WELDING

fostering this interest with opportunities,” said Blake.

Crittenden agrees. “There are many advantages waiting for women who opt for a career in welding. There are significant economic benefits for women in non-traditional trades, from increased choice and availability of jobs, through to improved job security. Male-dominated trades are also generally better paid than female dominated trades—when it comes to welding, women are actually paid 30% more when compared to their male colleagues.”

The welding industry is fast evolving. The advent of automation and other progressive welding technologies are paving the way for the manufacturing of high-tech equipment for the aerospace and defence industries, among others. Welding itself is no longer the precarious, thirsty work of men in dark workshops, but the precise work of the technically minded in bright, open workspaces.

“More and more, welding is becoming a high-tech trade. The modern welder must be skilled in robotics, computer programming and engineering. They must have an affinity for maths and science, as well as artistic and spatial skills that enable them to quickly and easily conceptualise ideas,” said Crittenden.

“Plus, they must have the patience and temperament for precise, exacting work. Given all these

specialist skills, welders have access to extremely well-paid jobs that offer the flexibility and mobility that modern women—particularly working mothers—need.”

However, a recent Australian employment outlook survey shows that skilled workers are scarce, with 38% of Australian employers admitting that filling job vacancies is increasingly difficult, largely due to lack of experience (23%) and a shortage of applicants (21%), as well as lack of skills (2%).

The welding industry is further affected due to the fact that 32.9% of Australia’s existing welding workforce is aged over 45 years. The projected increased demand for welders in growth industries means that a large proportion of current welders will leave a gaping hole in the workforce on retirement—an issue likely to be faced in all industrial sectors.

The Australian Government has projected that the number of job openings for structural steel and welding trades will be above average until November 2019. An employment growth rate of 7.2% is expected over the next five years for structural steel and welding trade workers.

For Crittenden, the solution is clear. “Increasing diversity in the workplace is possibly the best way to alleviate the looming skills shortage. Every effort needs to be made to encourage women to become welders.”

Welder Charley Barrett sheds some light on the current climate for female welders. “After completing my trade I felt more confident and just as capable as a man to do any job. When I first started welding I was just 15. I walked into a workshop of only men; they were ‘old timers’ and doubtful on seeing a female in the industry. I felt very out of place and nervous, but this made me more determined. I worked hard to prove them wrong and to be the best fabricator I could be.”

“Five years later and things are totally different. My recent start at South32 has made me realise how much has changed. There are many other females around the site and in my work crew. There is plenty of opportunity for advancement and a lot of support,” said Barrett.

“The welding industry is adaptive and dynamic, with endless career paths from welding and engineering to robotics. I encourage any female interested in the welding trade to give it a go. It’s challenging but extremely rewarding and worth every minute.”

Rachel Abbot, a welder since 2008 and now a Technical Sales Representative for one of the world’s largest welding supply firms, Lincoln Electric, is further testament to the value of supporting female welders.

“The main inspiration and drive that got me into welding was my desire to be successful in life, and to have a valuable trade that could see


communicating quality management requirements including solutions to problems.

The manufacturing of precast units involves welding of steel in accordance with AS1554.1, structural steel stud welding in accordance with AS1554.2 and welding of reinforcing steel in accordance with AS1554.3.

As Quality Manager (and Welding Inspector), I am involved in the management of welder prequalification, inspection and surveillance. I also liaise with the client in regards to weld details, weld inspection and weld surveillance. What inspired you to choose a career in the welding and industrial sector?After studying Geology at university I headed into the mining industry, mostly in Far North Queensland. During this time, I studied as a postgraduate in metallurgy. In the last 10 years I have ‘drifted’ into quality management, and welding processes and inspection took my

me through any economy or city. I decided I needed to be different and do something that was challenging, yet rewarding. I wanted to be a truly independent, strong woman who could achieve anything I wanted.”

“Welding has given me a career and drive like nothing else. I feel like, at times, it was the only thing keeping me on track. It has inspired me to be a better person than the path I was heading down. I owe my life to welding,” said Abbot.

There are a myriad of benefits to attracting more women to welding and nurturing their career development in the industry. Highly skilled, passionate and progressive individuals are now needed to support this fast-evolving trade and provide the talent pool required.

Narrowing the sizeable gender gap and making welding a legitimate career choice for women is now crucial in widening that pool. And with the challenges facing the skilled labour workforce, it is the only viable solution for the sustainability of the welding industry in Australia.

Describe your job.I’m employed by Lendlease as a Quality Manager. My current role is at Australian Precast Solutions (APS), Lendlease’s precast concrete facility on the mid north coast of New South Wales. My role incorporates responsibilities as a WTIA Certified Welding Inspector, as well as managing the APS NATA accredited concrete testing laboratory.

APS manufactures a range of prestressed and reinforced concrete products, including concrete girders, planks, super-T bridge beams, noise walls, barriers, arches and other precast products. We are currently manufacturing headstocks and abutment sill beams for the Woolgoolga to Ballina (W2B) Pacific Highway upgrade.

My role involves managing the product and process conformance of the precast facility, including inspection and testing, identification of and reporting quality issues, ensuring corrective action is implemented and effective, and

Catherine Blake, Quality Manager, Australian Precast Solutions.

Spotlight: Catherine Blake, Quality Manager, Australian Precast Solutions


fancy. For the past six years I have been involved in weld surveillance with Lendlease on different projects. I enjoy applying scientific and quality knowledge to practical processes where operator skill is often an art, not just a trade.

Why do you think more women should look to a welding and industrial sector career?It’s a great time to be female in the welding and industrial sectors. It is my opinion that gender issues are disappearing rapidly in the industry and the focus is now where it should be; competence, skill, safety. I admire women in male dominated industries that understand that they are the best person for the job and don’t worry about anything else as they are too busy doing it. If a woman is interested in the welding or industrial sector and have the skills; good organisations are fostering this interest with opportunities.

What do you believe is the biggest challenge for the industry at the moment?The biggest challenge is maintaining workmanship skills through the transition to automation. The transfer of knowledge from skilled workers to people wanting to learn the trade is essential. It’s important that this transfer of knowledge includes the ‘pride in work’ aspect, as well as understanding the art and science of the industry.

What do you believe is the biggest opportunity for the industry at the moment?It’s a good opportunity for Australian skilled welders, welding processes and Australian steel to be the

benchmark for quality internationally. The technology available today can be applied locally in Australia to keep skilled workers available and boost local communities.

APS is one of the biggest employers in our local area. We are committed to maximising our use of Australian steel, Australian consumables and local skills. This contributes to the pride in one’s workplace, which fosters a healthy quality culture and makes for a great work environment. What is the most interesting project you’ve worked on? Why?When I moved from the mining industry into construction quality management with Lendlease, I worked on a wastewater treatment plant upgrade project on the Gold Coast. The project was to increase the treatment plant capacity by 25%. There was lots of cutting-edge mechanical, electrical and instrumentation design and construction. This was my introduction to AS4041 pressure pipe welding in a corrosive, aggressive environment and the learning curve was fantastic.

Who or what has inspired you the most professionally?I have been very fortunate to be mentored by some technically-advanced and diverse people in my career.

I had a wonderful role model growing up. My older sister is a Mining Engineer and has managed major projects around the globe. I remember some of the experiences that she had in a male-dominated sector, which displayed a gender inequality that would not be accepted now. That was only 20 years ago. It’s amazing how quickly a culture can change when everyone wants it to. What gives you the most satisfaction at work?Working on a quality issue with a problem-solving team and implementing corrective actions that effectively nail the root cause is a very satisfying part of my work.

Further to this, a precast facility is a manufacturing environment that lends itself nicely to continuous improvement. One of the most satisfying aspects of my role is being able to strip any superfluous tasks, controls, processes that do not add value to the end product. I like the quote from Leonardo da Vinci, “Simplicity is the ultimate form of sophistication”. What are your greatest achievements?I think back to different quality issues that I’ve faced in different roles and being part of the management team controlling these issues successfully has contributed to achievements that I’m most proud of. As Quality Manager, having a healthy, challenging and innovative quality culture in the workplace is a great source of pride.

Gaining my WTIA Certified Welding Inspector qualification was also a proud achievement for me.


Describe your job.I am a sheet metal fabricator and coded TIG welder at South32. Sheet metal is cutting, bending, welding and rolling of metal into a desired part or structure. My job can be complex, as there are many different aspects to learn in metal work. I get a lot of job satisfaction from my work when looking at a finished product that has been carefully formed and welded from a drawing. My sheet metal trade has offered me many opportunities, including the chance to work at the world’s largest and most efficient alumina mining company.

My new position entails predominantly maintenance of the processing facility at South32 Worsley. Some of my day-to-day duties include, but are not limited to: repairs on pumps and motors, replacing valves, fabricating and repairs of plant equipment.

At South32 we are encouraged to upskill in a number of areas, including dogging, rigging and crane work. There is plenty of opportunity for advancement in my new role. I work in a crew of nine people, and my workmates are always helpful and willing to teach me new skills in the field.

What inspired you to choose a career in welding?I grew up on a property where I needed to be hands-on and help with jobs around the farm. It was my dad who first inspired me to weld at a young age. I would help Dad with repairs on the stables and round yards for the horses. My dad is a boilermaker by trade, so he was always giving me tips on how to do things. I loved being outside with Dad. He helped me believe in myself and encouraged me to try my best.

Later in school I chose metal work as a subject, where I was able to increase my skills even further. From then on I knew I wanted a career in

welding, that way wherever I found myself in the future I would always have a valuable trade to help me through any economy.

Completing my apprenticeship has helped me to be mechanically-minded inside and outside work. When I first moved out of home I was living alone and felt confident and able to do my own repairs around the house, whether it be welding or just a small plumbing fix-up. My trade has made me independent and eager to challenge myself in every aspect in life.

Why do you think more women should look towards a career in welding or boilermaking?

“I encourage any female interested in the welding trade

to give it a go. It isn’t easy. It’s hard work and challenging, but extremely rewarding and worth every minute. After completing my trade I feel more confident as a person and I am just as capable as a man to do any job.

When I first started I was just 15, I walked into a workshop of only men, they were ‘old timers’ and doubtful to see a female in the industry, I felt very out of place and nervous, This made me more determined. I worked hard to prove them wrong and to be the best person and fabricator I could be. Five years later and things are totally different.

My recent start at South32 has made me realise how much has changed. There are many other females around site and on my work crew. There is plenty of opportunity for advancement and a lot of support. The fabrication and welding industry

is adaptive and dynamic with endless career paths, from welding and engineering to robotics.

What do you believe is the biggest challenge for the industry at the moment?There is an increase in the importation of pre-fabricated equipment and infrastructure, which results in local jobs and opportunities for apprentices being lost.

There is a struggle to remain cost-competitive with the increasing price of raw materials. These factors don’t just affect the construction and mining industries; our economy as a whole is struggling, but I do believe things will get better.

What do you believe is the biggest opportunity for the industry at the moment?In general, the welding and construction industry has been very slow to adapt to change and new techniques. I believe if we take the opportunity to embrace new technology, productivity will then increase. Making use of new technology will help the way we design, operate and maintain infrastructures. 3D printing and drones have been a massive breakthrough. 3D printing allows us to speed up the process of producing components and drones are allowing us to monitor projects and safety around sites.

What is the most interesting project you’ve worked on?The most interesting project I worked on was in the third year of my apprenticeship. My teacher Allan Inder-Smith at Challenger TAFE gave us the project of building a rocket stove. A rocket stove can be made from clay, steel or wood. We made ours from steel. The stoves are wood burning and very efficient. Our stoves cooked faster, used 80% less wood and produced very

Spotlight: Charley Barrett, Welder, South32


little smoke. This project was more interesting for me as the aim was to produce a product for use in poorer countries. More than four million people a year die from respiratory problems caused by open fires.

Earlier this year, my teacher took the rocket stove to India and taught people in villages and orphanages how to build and use the rocket stove. I am grateful to have been involved in creating our rocket stoves. Allan has helped many families and underprivileged people live a little better.

Who or what has inspired you the most professionally?My teacher Allan Inder-Smith at Challenger TAFE is my professional inspiration. He has worked in many places and in many areas of metal work, and has a lot of experience and knowledge that he has passed on. Allan didn’t just educate me on the theory of sheet metal work, he also encouraged me to go to night school for welding. With every level passed he would encourage me to go further and push my limits.

As my mentor, he taught me how important goal-setting is. This has helped me to succeed in my career and also my personal life. Every apprentice needs an Allan!

What are your greatest achievements?My greatest achievement so far has been representing Australia in the International Tetrathlon in Ireland in 2016. Tetrathlon is the combination of running, swimming, horse riding and shooting in one event. I’ve been doing this for nine years and I’m very passionate about it. I would not have been able to achieve what I have in sport if it wasn’t for the values that my apprenticeship has taught me. I learnt to overcome fears and challenge myself, and now have the drive to succeed in whatever I set my mind to.


About Acueducto Gran San JuanThe Acueducto Gran San Juan consists of the installation of a new drinking water system to transport water from wells located approximately 25km west of the city of San Juan to complement the existing water system. The new system will require construction of a water treatment plant (to ensure the water is fit for human consumption). This plant will be located in the Andes mountains, at 1,200m above sea level.

The system will also require the construction and installation of stainless steel and High Density Polyethylene (HDPE) pipelines. These pipelines will raise the volume of water being transported from 1.5m2 per second to 3.2m2 per second.

Of the 50km of pipeline, 15km will be fabricated in stainless steel that is 1,600mm in diameter and 9mm thick. Known as Acueducto Gran Tulum, this 15km stainless steel pipeline represents almost half of the project’s total investment. It is being undertaken by Industrias Metalúrgicas Jaime SRL, who has assembled over 4,600 tons of stainless steel to fabricate the pipeline.

Stainless Steel Pipeline SecuresSan Juan Water Supply The population of San Juan in west-central Argentina is currently estimated at 680,000. However, this is expected to grow to over one million in less than 50 years. One of the key concerns of the Argentinian Government is securing drinking water supply for this increased population. As such, the Argentinian Government has commenced work on the Acueducto Gran San Juan. This 50km US$170 million pipeline will reinforce existing drinking water supply to San Juan and surrounding areas, and expand the supply of drinking water to localities that are currently without water, including some areas of Zonda and Rivadavia.

The project is being jointly funded by the Kuwait Fund For Arabic Economic Development (US$51 million), and the Argentinian Government (US$127.6 million).

K-TIG and Acueducto Gran TulumAccording to Gustavo Gonzalez (one of the owners of Puertotrans SRL), Industrias Metalúrgicas Jaime SRL approached him prior to project commencement.

“Before they started the project, Industrias Metalúrgicas Jaime SRL came to me asking for the best welding method available in the market. They wanted to use the

ultimate in technology because of the magnitude of the project and what it represents for the people of San Juan and Argentina—there is no other pipeline in Argentina, or even South America with the same characteristics. They also wanted to reduce costs whilst still achieving the best possible quality,” said Gonzalez.

“Two years ago, the best welding method we had for this project was submerged arc welding. It seemed that this would be the best welding process to use. But, after some Two K-TIG longitudinal seam welding stations.

K-TIG welded water pipes awaiting pickup.

37INSIDE THE INDUSTRY: SAN JUAN WATER SUPPLY

What is K-TIG?A high energy density variant of GTAW, K-TIG (Keyhole TIG) is a high speed, single pass, full penetration welding technology that welds up to 100 times faster than TIG welding in materials up to 5/8in (16mm) in thickness, and typically operates at twice the speed of plasma welding.

K-TIG works across a wide range of applications, and is particularly well suited to corrosion resistant materials such as stainless steels, nickel alloys, titanium alloys and most corrosion resistant and exotic materials. It easily handles longitudinal and circumferential welds on pipe, plate, spooling, vessel, tank and other materials in a single pass.

K-TIG’s extremely fast welding times result in dramatic reductions in labour costs, welding cycle times, rework and repair costs, gas and power usage. K-TIG’s single pass, full penetration welds significantly reduce or eliminate grinding and reworking. The K-TIG process dramatically reduces or eliminates the need for wire, eliminates edge bevelling, and requires only a square butt joint, but can also weld into all standard GTAW preparations. No root gap is required.

For more information, visit: www.k-tig.com

“The fabrication of the pipeline began four months ago. I am pleased to report that what we had heard about the speed, productivity and quality of K-TIG welding is true. K-TIG delivers very clean and smooth weld seams and perfect roots. There is no weld preparation needed. It is extremely fast, uses a fraction of the gas normally required and a tiny fraction of the wire consumables we would have consumed with any other process. The productivity that it is delivering for this major project is remarkable - it is at the highest level.” “The productivity of the K-TIG process is allowing us to fabricate an average of eight stainless steel tubes per day. Each of these tubes is 12m long, 1.6m in diameter and 9mm thick. The timeframe in which we had expected to complete the fabrication of all 1,300 12m tubes is 720 days (indeed we are contracted to this timeframe). The use of K-TIG has transformed the economics of the project - we will complete the fabrication in 162 days, which is a fantastic result for us, the Government and the people of San Juan,” said Gonzalez.

research on new welding technology, I found K-TIG. This was a major turning point. The more I studied K-TIG, the more I needed to know.”

“K-TIG appeared to be an almost magical solution

that would help us achieve all our goals in record time and at the lowest cost possible.”

K-TIG welded water pipes awaiting pickup.

K-TIG circumferential welding station.

K-TIG’s single pass welding of 9mm thick stainless steel.

AUSTRALIAN WELDING | SEPTEMBER 201738 INSIDE THE INDUSTRY: WELDQ & THE AWCR

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RRP $3,199 (Incl.GST) + Freight if applicable.

Weight of Power Unit: 25.5Kg

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Weight of Power Unit: 23.5Kg

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WTIA Ad.indd 1 7/09/2017 9:39 AM

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Run on the WeldQ platform (a fully cloud-based system with a supporting mobile application), the welder qualification functionality of the AWCR has been operational since March 2017. In the last six months, more than 400 Australian welding related personnel have registered on the AWCR. This has allowed welders, for example, to qualify via the AWCR for welding within the tunnel boring, transport, pressure equipment, and general welding industry.

While some early teething problems were encountered, these were quickly resolved. In fact, according to feedback received to date, by affording independently verified welder qualifications, the AWCR is able to reduce both costs and risks for employers in Australian industry.

Employers are able to confirm the competence level of any RW against an internationally recognised standard, minimising the need for welder testing. This is particularly beneficial for employees who are required to move from site-to-site; they do not need to be re-qualified, resulting in a huge cost savings for employers.

In addition, the WTIA has given a number of presentations to industry groups on the operation of both

WeldQ and the AWCR, with very positive feedback received in relation to cost savings, improved record keeping and access to an unparalleled skills database, all without comprising weld quality or evidence of welder capability.

QualificationA number of qualification programs have been developed and are undergoing testing within WeldQ to suit specific industries, as well as specific roles. One such program is that for the certification of welders and welding supervisors to AS 1796. The WTIA will develop additional, tailored programs as the need arises.

The WTIA is currently preparing to transition all their qualifications and training courses to WeldQ. For personnel who hold existing qualifications, discussions are underway to import these records directly into WeldQ in the most efficient and timely manner possible. This will allow existing qualifications to be verified by employers looking for evidence of qualifications held by prospective and existing employees. CertificationThere are numerous certification programs available now within WeldQ, including those for

welding inspectors, supervisors, technologists, engineers and welding practitioners.

The key benefit offered by WeldQ is the ‘Work Diary’ functionality of the Professional Development tab. This allows users to log their work history. This greatly simplifies both certification application and assessment processes.

Reporting and PrivacyThe WTIA is currently developing a range of reports within WeldQ that will enable companies to search for qualifications and certifications held by employees and any other person linked to their company. These independent records will simplify record keeping for quality management, particularly as auditors will be able to search and view evidence in real-time online.

It should be noted that privacy issues were considered during the development of WeldQ and its search functionality. The private details of welders do not automatically appear in a search. If a company wishes to contact a registered user, they must first seek the user’s permission through the WTIA.

INSIDE THE INDUSTRY: WELDQ & THE AWCR

Developed and managed by the WTIA, the Australian Welder Certification Register (AWCR) provides a national framework for qualifying and testing welders to International Standard ISO 9606-1. It allows qualified and certified Registered Welders (RW) to be able to work on any site without further testing resulting in a significant cost saving to industry; provides industry with access to a database of welders with up to date certification and details of their career history; and generates data for a skills gap analysis which will allow the development of a detailed suite of training initiatives to upskill the workforce.

An Update on WeldQ & the AWCR

For more information, visit: www.awcr.org.au


State Focus: Victoria

World Class Victorian Defence Hub for Next Generation Army VehiclesBAE Systems Australia will build a world class defence hub in Victoria, consolidating the company’s Victorian Maritime, Aerospace and Land businesses into a single facility that will foster collaboration and innovation, delivering sustainable jobs over multiple projects for decades to come. The defence hub at Fishermans Bend will be the biggest of its type in the nation and is where BAE plans to manufacture the Australian Army’s Armed Combat Reconnaissance vehicles. The defence hub will enable up to 1,000 engineers and highly skilled technicians to design, develop, deliver and maintain new defence platforms and systems for the Australian Defence Force. More than 200 people will be employed during the build phase of the LAND 400 program. Integral to the development will be a bespoke LAND 400 advanced manufacturing centre that will include a simulation, training and test facility. Once in service, the centre will be used to upgrade and maintain the vehicles over their 30-plus year service life. The defence hub will be a centralised point of collaboration with the Commonwealth for Land programs and possible future export customers.

Whilst South Australia and Western Australia have both been in the limelight recently, Victoria is also a contender when it comes to some of Australia’s upcoming defence industry projects. Victoria’s defence sector contributes up to $8 billion to the state’s economy annually and is comprised of more than 300 businesses, employing approximately 7,000 people. And it is poised for further expansion, with Victoria’s leadership in advanced manufacturing, engineering, design, digital technology, cyber security, robotics and R&D directly underpinning the capabilities of Victoria’s defence industry. Victoria is set to provide a reliable source of 21st century skills and leading edge technology that match both the domestic and global defence industry needs.

41INSIDE THE INDUSTRY: VICTORIA STATE FOCUS

A Boston Consulting Group study found that Victorian businesses account for 49% of Australian R&D spend in advanced manufacturing. The state also boasts a sizeable base of architectural and engineering design firms, and a growing number of construction, transport and defence SMEs that Boston Consulting describes as “innovative, collaborative and globally-oriented”.

These businesses provide the vital links in the supply chains that support major defence projects in Australia and internationally.

Many global companies have manufacturing operations in Victoria and have established R&D and design facilities in the state, including BAE Systems, Lockheed Martin, Siemens, IBM and Microsoft.

Recently, Lockheed Martin established its first multidisciplinary research laboratory outside the United States. The Lockheed Martin Science Technology Engineering Leadership and Research Laboratory (STELaR Lab) in Parkville will undertake research in areas such as hypersonics, autonomous systems, robotics and command, control, communications, computer, intelligence, surveillance and reconnaissance (C4ISR).

Melbourne is also home to Australia’s Defence Materials Technology Centre, which focuses on new material technologies and manufacturing processes, and the Defence Science Institute.

Recognising the defence sector’s vital contribution to the state’s economy and the nation’s defence capability, the Victorian Government has developed the Defence Technologies Sector Strategy to support the future of this vital sector.

A key initiative supporting this strategy is the development of an advanced manufacturing and research precinct: a new home for the skills and technologies of

tomorrow situated just 5km from the Melbourne CBD.

In 2016, the Victorian Government acquired a 37 hectare site at Fishermans Bend with the aim of creating a world-class design, engineering and technology precinct. The technology hub will become a centre of excellence attracting cutting-edge innovators in the areas of aerospace, defence, marine design and automotive design.

High-skilled jobs will be central to the precinct, ensuring that Victoria – and Australia – has a new home for the skills and technologies that will drive economic growth well into the 21st century. The Government is in advanced talks with major global companies and Victorian universities to become cornerstone partners in the new development. The Fishermans Bend precinct will support 60,000 jobs by 2050 and will build on Victoria’s strengths in defence, education and advanced manufacturing.

As part of its commitment to strengthening Victoria’s global reputation as a centre of defence excellence, the Victorian Government, in cooperation with over 20 leading universities, research and industry organisations, has also proposed the creation of a new research institute, the Australian Maritime Innovation Centre (AMIC).

AMIC would operate as a national R&D centre and support shipbuilding operations in South Australia and Western Australia as well as support the Navy’s future submarine and surface-ship programs.

The proposed operational model for AMIC provides a unique framework that will facilitate and enhance collaboration between the Department of Defence and key partners. Governance, program management and research coordination arrangements will ensure that Defence and Navy have tactical, strategic and security

oversight of all activities.

The proposal has been developed for the consideration of the Australian Government and the Department of Defence and the Victorian Government has already received positive feedback from industry stakeholders.

Victorian Defence Industry Supply Chain ProgramVictorian defence supply chain businesses will have access to funding to help secure contracts and create new jobs under a new Government initiative: the $2 million Victorian Defence Industry Supply Chain Program.

The Program will give businesses across Victoria the best possible opportunity to secure work in defence and national security. In particular, the Program will help local businesses gain relevant accreditations, prepare tenders and meet industry specific compliance requirements. This will ensure local defence supply chain companies are locally and internationally competitive and are tender-ready.

According to Minister for Industry and Employment, Wade Noonan, “Victoria has a proud history of defence capability and excellence, and we are getting on with the job of growing this important industry. Supply chain businesses play a particularly critical role in delivering the country’s biggest defence projects. This program will put these companies in the best possible position to capitalise on future defence contracts.”

Funding is available to Victoria’s small to medium enterprises that are currently supplying to defence or national security related supply chains and those looking to enter the market. Grants of up to $50,000 are available to businesses under the program which requires applicants to provide matched funding cash co-contribution.


SMART Road & Rail Industry GroupThe SMART Road & Rail Industry Group recently met in Sydney, and was attended by representatives from Roads and Maritime Services (New South Wales), VicRoads (Victoria), Transport and Main Roads (Queensland), Department of Planning, Transport and Infrastructure (South Australia), Main Roads (Western Australia) and the WTIA.

Andrew Walker (Manager, Construction Materials at VicRoads) provided a overview of progress on the Austroads Steel Fabrication Specification (ASFS). The ASFS has been reviewed and made ready for final formatting and proofing.

Currently, each Australian state has its own State Road Authority (SRA), with its own technical requirements for the design, manufacture and procurement of steel structures.These state-specific requirements create a barrier to consistent manufacture of products. The aim of the ASFS is therefore to create harmonised technical specifications, shared across all SRAs. This will allow a competitive national tendering process guided by consistent national standards.Houman Hatamian (Welding Engineer at Roads and Maritime Services) gave a presentation on the development of Austroads

Stainless Steel and Aluminium Fabrication Specifications. These specifications will set out the minimum requirements for the preparation, welding, inspection and testing, and final acceptance of stainless and aluminium structures and components.

Kumar Ponnampalam (Senior Bridge Engineer at Roads and Maritime Services) gave an excellent presentation on current practice and critical infrastructure activities in relation to the execution of steel work. He emphasised the concept of ‘Technical Capability Assessment’ of skilled tradesmen, as well as the importance of product conformity assessments, based on:• Materials: ATIC 10 (Australian

Technical Infrastructure Committee Scheme 10) / ACRS

• Welding: AS/NZS ISO 3834.2 Certification

• Fabrication: ATIC 22 (Australian Technical Infrastructure Committee Scheme 22)

• Bolting: ATIC 21 (Australian Technical Infrastructure Committee Scheme 21) / AS/NZS ISO17065

• Protective Coating: PCCP / By CSIRO APAS

• Erection: ATIC 22 (Australian Technical Infrastructure Committee Scheme 22)

Geoff Crittenden (WTIA CEO) also spoke about the importance of certification to AS/NZS ISO 3834. As a factory production control system, certification to AS/NZS ISO 3834 helps businesses operate more efficiently, improving client satisfaction. AS/NZS ISO 3834 certification increases the likelihood of global supply chain opportunities and repeat business, bolstering profitability. It helps Australian businesses demonstrate their ability to deliver a compliant, quality fusion welded product on time and to budget.

AS/NZS ISO 3834 is the minimum benchmark for welding quality globally. As more companies become certified, those without certification will find it harder to win work from local and international suppliers.

The next SMART Road & Rail Industry Group meeting will be held in late October.

SMART Defence Industry GroupAdvanced Welder Training CentresSince the last SMART Defence Industry Group meeting, the WTIA has been working on a number of projects designed to enhance the capability of Australian welders in delivering defence equipment.

INSIDE THE INDUSTRY: SMART INDUSTRY GROUPS

An Update from the WTIASMART Industry GroupsThe WTIA’s SMART (Save Money And Re-engineer with Technology) Industry Groups provide a forum for technology transfer and research and development, linking members with industry and research organisations. The WTIA works with SMART Group members to ensure they remain diverse and resilient in the ever-changing and increasingly challenging domestic and global markets. SMART Group members engineer innovative solutions that enhance safety, manage risk, reduce cost, and optimise operating efficiency, by: sharing the cost of implementing new technologies; developing best practices; and providing a forum to brainstorm common needs and effective solutions.

43

Following unanimous support for the qualification and certification of welders to ISO 9606-1 via the Australian Welder Certification Register (AWCR), the WTIA has submitted proposals to all state governments to establish advanced welder training centres.

Phase one of the centres will utilise the latest welder training technology from Europe and the United States, including augmented reality simulators supplied by BOC. Not only do these simulators provide efficient, cost effective training for trade qualified welders, they also have the potential to quickly upskill non-trade transitional workers. For more information on these simulators, see pages 12 and 13.

Once students have graduated from these augmented reality simulators, they will move onto the latest REALWELD training technology from Lincoln Electric. REALWELD is designed for in-situ use in a real-world welding booth, in either arc-on or arc-off modes. REALWELD replicates common field conditions closely, better preparing students for work in the real world. As a user welds, the system analyses and scores every attempted weld trial and provides real-time feedback, helping to prevent the formation of bad habits. For more information on

REALWELD, see pages 14 and 15.In phase two, the WTIA intends to develop a robot training capsule, which will teach welders how to program robotic machines to deliver high quality welds according to the appropriate welding procedure. To establish this capsule, the WTIA is working with the University of Wollongong and member company Robot Technologies-Systems Australia (RTA).

The third and final phase of the project will see the establishment of a laser laboratory that will allow students to learn about laser tracking devises, laser weld inspection and 3D laser scanning technology.

The purpose of the advanced welder training centres is to quickly qualify welders to the standard required by ISO 9606-1. This will ensure a strong supply of capable welders, ready to deliver defence industry projects.

The WTIA intends to establish 20 advanced welding training centres around Australia to support defence prime contractors, as well as SMEs looking to join the global supply chains of these prime contractors.

Victorian Skills Commission Steering CommitteeGeoff Crittenden (WTIA CEO) is chairing a steering committee for

the Victorian Skills Commissioner. This steering committee has been charged with developing the curriculum that will be taught at the advanced welder training centres.

The steering committee members include representatives from TAFE Victoria, the Victorian Skills Commissioner, Rob Vernon from the WTIA’s Victoria Division, and Louis Victor Blain (Lead Welding Engineer at Bombardier). It is the steering committee’s intention to have the curriculum accredited to the Victorian scheme by the end of October 2017. Once accredited to the Victorian scheme, the curriculum can then become nationally accredited, and taught by any licensed Registered Training Organisation (RTO) in the country.

Although the initial curriculum is focused on GMAW mid-steel welding, the steering committee is already considering the use of other welding processes and materials, including stainless steel, aluminum and titanium.

INSIDE THE INDUSTRY: SMART INDUSTRY GROUPS

Further InformationFor further information about becoming a WTIA SMART Industry Group Member, contact us via: [email protected] or 02 8748 0100.


The WTIA Hotline was recently asked to provide advice regarding weld repairs to Interlloy 4317/E110.

Interlloy 4317/E110 is a 1.8% chromium - nickel - molybdenum high hardenability, case hardening (carburising), heat treatable steel. It is generally supplied in an annealed condition, with a maximum brinell hardness of 229 (Rc22).

Perfect for medium to high strength applications, this steel is characterised by high core strength and toughness with case hardness up to Rc62 when carburised, hardened and tempered.

Interlloy 4317/E110 is readily weldable in the annealed (as supplied) condition, and welding should always be carried out using

low hydrogen electrodes. Following welding, as soon as the work piece has sufficiently cooled, it should be stress relieved at 630°C to 650°C. In terms of post-welding procedures, the work piece should be subjected to a maximum cooling rate of 100°C per hour, down to 100°C, followed by cooling in still air. If possible, it is recommended that the work piece is buried in sand or dry lime.

Typical uses of Interlloy 4317/E110 include heavy duty bushings and bearings, cam followers, clutch dogs, compressor bolts, extractors, fan shafts, heavy duty gears, pump shafts, sprockets, tappets, wear pins, and wire guides.

A successful repair requires the removal of the case hardening from the entire weld repair area, with an

“Weld repairs to Interlloy 4317/E110

(when in the case hardened and heat treated condition) are not recommended. However, they can be performed, so long as the necessary precautions are undertaken. additional 5mm beyond into the substrate. The additional area thickness can be restored with Inconel (ERNiCr-3) and the hardfacing can be produced by welding with Stellite 20.

There are two weld repair options:• Gas Tungsten Arc Welding • Laser welding

The required weld repair needs to achieve the following:• Restore the dimensions that

were removed;• Have a final hardness in the last

2mm of 58 – 60 RC (Rockwell C); and

• Have a final surface with no cracks and specific dimensions.

Recommended Weld Repair Process for Interlloy 4317/E110In order to perform a successful

Latest Issues from The WTIA HotlineThe WTIA offers a ‘Hotline’ service to all Corporate Members. The purpose of the Hotline is not to provide a solution, but to advise the enquirer on practical next steps. For further advice, the WTIA’s highly experienced welding consultants can speak to you on the phone or visit your site in person. If you have a Hotline query please complete our online contact form and we will respond as soon as possible: www.wtia.com.au/hotline.

Restock and hard surface weld pass.

45

10. Continue across the surface until it is covered with the Inconel filler material. Weld the hardfacing layers with Stellite 20:

10.1. Maintain preheat at 150°C.10.2. Weld dilution should be

minimised.10.3. Deposit stringer beads, do

not weave.10.4. Ensure a 250°C interpass

temperature.10.5. Weld deposit 2 to 3mm

thick beads, overlapping by 50%.

10.6. Weld 2 to 3 layers with the Stellite 20 so that sufficient material thickness is left after machining or grinding to leave at least 2mm of undiluted Stellite.

11. Once welding is complete, wrap under insulation for slow cooling to ambient temperature.

12. Conduct Dye Penetrant Testing (DPT) on surface to check for any cracks before and after grinding.

weld, the WTIA Hotline recommended that the following steps were implemented:1. Remove the case hardened

layer, 5mm beyond the weld repair area, by machining if possible.

2. If machining is not possible, then preheat to 100°C before carbon arc gouging is started.

3. Confirm removal with hardness testing by a NATA accredited laboratory and recommend oversight by welding engineer or metallurgist.

4. Conduct magnetic particle testing (MT) on the surface to confirm that no surface cracks are present.

5. Dress any surface cracks and retest with MT to confirm removal.

6. Thoroughly clean the surface to prevent contamination that could lead to hot cracking, by removal of all oils, grease, paint or lubricants.

7. Preheat the component to 150°C. Critical note: do not do any welding without the preheat applied throughout the entire piece requiring repair.

8. Once welding is started, continue until completed. Should welding be interrupted for any reason, preheat of 150°C has to be maintained to prevent cold cracking of the 4317/E110 substrate material.

9. Complete the weld build-up with Inconel ERNiCr-3:9.1. Maintain preheat at 150°C. 9.2. Weld across the 96mm

surface.9.3. Weld dilution should be

minimised.9.4. Deposit stringer beads, do

not weave.9.5. Weld deposit 2 to 3mm

thick beads, overlapping by 50%.

9.6. Ensure a 250°C interpass temperature is not exceeded.

9.7. Weld slightly convex beads to prevent hot cracks due to contraction stresses.

INSIDE THE WTIA: HOTLINE REPORT

This WTIA Hotline update covers a specific query encountered during the last few months. Whilst accuracy in welding is critical, it is impossible to report in detail the full circumstances of the query. As such, the WTIA recommends that further technical advice is sought in relation to specific, individual circumstances.


Meet Your WTIA Council MembersThe WTIA is governed by a Council (Board of Directors) elected from its members. Our Councillors are experienced industry professionals, whose primary responsibilities are to monitor the performance of the Institute and the implementation of Council approved strategies and policies. WTIA Councillors act with independence and in the best interests of members in all decisions to ensure that the Australian welding industry remains locally and globally competitive, both now and into the future. To help you ‘put a face to the name’, you’ll find a brief introduction to each of the WTIA’s Council members below.

Australian Welder Certification Register CR

HOW TO REGISTER1. Go to www.awcr.org.au2. Click on ‘Click Here to Register’.3. Click on ‘Create An Account’.4. Enter your contact details.5. Verify your email address.6. Login and complete your profile.

02 8748 0100 | [email protected] | www.wtia.com.au | www.awcr.org.au

REGISTER NOW:AUSTRALIAN WELDER CERTIFICATION REGISTER

Dr Frank Barbaro, Technical Consultant (NSW)Frank is an international authority on the manufacture and application of strong, tough weldable steels. After a long career in the steel and pipeline industry, Frank is now based at the University of Wollongong and is sought after for his expertise in microstructure-property relationships and quantitative research methodologies for the achievement of valuable steel and welding related research outcomes.

Roger Griffiths (President), Retired Refinery Inspection Manager (QLD)Roger managed BP’s Brisbane refinery inspection department for 28 years, initiating and leading several world-class innovations. Associated with the WTIA for over 30 years, Roger has been a member of the Pressure Vessel Panel and the Pressure Equipment SMART Group, and has contributed to many WTIA Technical and Guidance Notes, and Australian Standards. He joined the Council in 2008.

David Lake (Deputy President), Managing Director, ATTAR (VIC)David is ATTAR’s Managing Director, in addition to being President of Forensic Engineers Australia, and a member of AINDT, Australasian Corrosion Association, Engineers Australia and Materials Australia. For many years David was a Metallurgist and weld inspector, writing and approving weld procedures and specifications in the mining and refining industries. David joined the WTIA Council in 2013.

47INSIDE THE WTIA: MEET THE WTIA COUNCIL

Ralph Villarosa, Chief Engineer, AGL Energy (SA)Ralph is a professional senior engineer with over 30 years’ experience in power generation design, construction and operation. Ralph has post graduate qualifications in finance and business management and is the Chairman of the SMART Power Technology Industry Group. Ralph joined the WTIA Council in 2012.

Doug Hawkes, Director, Structural Integrity Engineering (QLD)As Managing Director and Principal Structural Engineer of Structural Integrity Engineering, Doug has over 20 years’ experience as a practicing engineer. His experience includes structural design, site supervision, contract management, local and offshore workshop quality assessment, independent design auditing and expert witness services. He joined the Council in 2017.

Mick Cudmore, Manager, Nix Sheet Metal Engineering (WA)With 45 years’ experience, Mick has been a welder, welding inspector and supervisor, project manager, client’s representative and technical advisor. Mick has been associated with the WTIA since 1991, including as Chairman of the SMART Water Industry Group, and member of the Qualification and Certification and West Australia division committees. He joined the Council in 2006.

Arun Syam, Business Development Manager, OneSteel (NSW)With 33 years experience and a Bachelor and Masters in Engineering, Arun joined OneSteel in 2000. His prior work included structural engineering, senior technical positions at AISC, and authoring publications such as Steel Designers’ Handbook. A WTIA Fellow, he is a member of the GAA Board and many Standards Australia committees. Arun joined the WTIA Council in 2002, and was President from 2007 to 2013.

Richard Fowles, Strategic Marketing Manager, BOC (NSW)At BOC Richard manages a multi-million dollar welding equipment and consumables market. He was previously a senior manager in a welding consumables factory, and a Lead Assessor for ISO 3834 welding management systems. An IWE, Richard holds a Masters in Metallurgy and Materials Engineering, and a Masters in Welding Engineering. He joined the Council in 2014.

Madeleine du Toit, Professor, University of Wollongong (NSW)Madeleine is a Professor in the Welding Engineering Research Group at the University of Wollongong. An IWE, she was President of the Southern African Institute of Welding from 2010 to 2014 and is actively involved in the IIW. She coordinates the training of International Welding Engineers and International Welding Technologists in collaboration with WTIA. She joined the Council in 2015.


AGL Energywww.agl.com.au131 [email protected]

ANSTOwww.ansto.gov.au+61 2 9717 [email protected]

ASCwww.asc.com.au+61 8 8348 [email protected]

Ausgridwww.ausgrid.com.au+61 2 4951 [email protected]

CB&Iwww.cbi.com+61 8 93245555www.cbi.com/contact

CS Energywww.csenergy.com.au+61 7 3854 [email protected]

Energy Australiawww.energyaustralia.com.au133 [email protected]

IPM Operation & Maintenance Loy Yangwww.gdfsuezau.com+61 3 5177 2000www.gdfsuezau.com/contact-us/Contacts

Transport and Main Roads (Queensland)www.tmr.qld.gov.au+61 7 3066 [email protected]

Member Directory The WTIA is dedicated to providing members with a competitive advantage through access to industry, research, education, government, and the wider welding community. When you join the WTIA you become part of a network of engaged companies and individuals, with whom you can share technology transfer, best practices, and professional opportunities. For further information, please contact [email protected] or 02 8748 0100.

Newcrest Miningwww.newcrest.com.au+61 3 9522 [email protected]

NRG Gladstone Operating Service www.nrggos.com.au+61 7 4976 [email protected]

Stanwell Corporation www.stanwell.com1800 300 351www.stanwell.com/contact-us

Synergywww.synergy.net.au+61 8 9781 [email protected]

Thales Australia www.thalesgroup.com+61 2 8037 [email protected]

Transport for NSWwww.transport.nsw.gov.au+62 2 8202 [email protected]

Vales Point Power Station (Delta)www.de.com.au+61 2 4352 [email protected]

VicRoadswww.vicroads.vic.gov.au+61 3 8391 [email protected]

02 8748 0100 | [email protected] | www.wtia.com.au

SMART (Save Money And Re-engineer with Technology) Industry Group MembersWTIA hosts and administers the SMART (Save Money And Re-engineer with Technology) Industry Groups, providing a forum for technology transfer and R&D, linking members with industry and research organisations. The SMART groups: represent a source of vital technical welding information; optimise welding practices through standard development and tools; and assist members to prepare specifications.

49INSIDE THE WTIA: MEMBER DIRECTORY

Premium Corporate MembersALS Industrialwww.alsglobal.com/au+61 2 4922 [email protected] Ultrasonics Australiawww.appliedultrasonics.com.au+61 2 9986 2133 [email protected] (One Steel)www.onesteel.com1800 178 [email protected] Shipswww.austal.com+61 8 9410 [email protected] Steelwww.bluescopesteel.com.au1800 800 [email protected] www.boc-limited.com.au+61 2 8874 [email protected] Welding Solutions http://callidusgroup.com.au+61 8 6241 [email protected] www.cigweld.com.au1300 654 [email protected] http://coregas.com.au+61 2 9794 [email protected]

Hardchrome Engineering www.hardchrome.com.au+61 3 9561 9555 [email protected]+64 9 262 [email protected] Australiawww.howden.com+61 2 8844 [email protected] Technology Group www.hrlt.com.au1800 475 832 [email protected] Australiawww.kemppi.com+61 2 87852000 [email protected] Electric www.lincolnelectric.com+61 2 9772 [email protected] http://lmats.com.au+61 8 9200 [email protected] Roads Western Australiawww.mainroads.wa.gov.au138 [email protected] Hitachi Power Systemswww.anz.mhps.com+61 7 3878 [email protected]

+61 3 9288 [email protected] Group www.monadelphous.com.au+61 8 9316 1255 [email protected] www.qenos.com+61 3 9258 [email protected] Integrity Groupwww.questintegrity.com+61 7 5507 [email protected] www.santos.com+61 8 8116 [email protected] Management www.tronox.com+61 8 9411 1444 [email protected] Pty Limitedwww.ugllimited.com+61 2 8925 [email protected] Corporation of WAwww.watercorporation.com.au+ 61 8 9423 [email protected] Industries of Australia (WIA)www.welding.com.au1300 300 [email protected] Sugar www.wilmarsugarmills.com.au+61 7 4722 [email protected]


02 8748 0100 | [email protected] | www.wtia.com.au

HELP SECURE THE FUTURE OFAUSTRALIAN WELDING.

JOIN THE WTIA TODAY.


Corporate Members3M Australia: 3m.com.au4 Ken : 4ken.com.auA&G Engineering: agengineering.com.auAben Technical Services: aben-tech.com.auAdept Inspections & Training: adeptengineering.com.auAerison: aerison.comAitken Welding: aitkenwelding.comAllstruct Engineering: allstructengineering.com.auAllthread Industries: allthread.com.auAncon Building Products: ancon.com.auAntec Group: antec.com.auARL Laboratory Services: arllabservices.com.auArup: arup.comASME Projects: asmeprojects.com.auATTAR: attar.com.auAustal: austal.comAustral: australtechnologies.com.auAustralian Infrastructure Manufacturing: ausim.com.auAustralian Rail Track Corporation: artc.com.auAustralian Welding Academy: australianweldingacademy.com.auAustralian Welding Supplies: awsi.com.auAztec Analysis: wga.com.auBAE Systems: baesystems.comBarker Hume Homes: N/ABaxter Institute: baxter.vic.edu.auBDR Stainless: bdrstainless.com.auBen Baden Services: craneconnection.com.auBerg Engineering: bergengineering.com.auBetter Wear Welding: betterwear.com.auBisalloy Steels: bisalloy.com.auBMC Welding: bmcgroup.com.auBombardier Transportation: bombardier.comBradken: bradken.comBrezac Constructions: brezac.com.auBroadspectrum: broadspectrum.comBrosco Enterprises: brosco.com.auBusicom Inspections & Training: busicomsolutions.com.auCaltex Refineries: caltex.com.auCCR Group: ccrgroup.com.auCoastal Steelfixing Australia: coastalsteelfixing.com.au

CQ Industries: cqind.comCQ Steel Industries: cqsteel.com.auCrisp Bros Haywards: haywards-steel.comCullen Steel: cullensteel.com.auCustom Built Stainless: cbstainless.com.auD&L Engineering Services: fabinox.com.auDGH Engineering: dghengineering.com.auDiverse Welding: diversewelding.com.auDT Hiload Australia: dthiload.comE&A Contractors: ottowayfabrication.com.auExcel Marine: excelmarine.net.auExtrin: extrin.com.auFIELD Engineers: fieldengineers.com.auFlexco: flexco.com.auFortress Systems: fortressresistors.comG & G Mining Fabrication: ggminingfab.comGlobal Engineering & Construction: globalec.com.auHowell Davies: howelldavies.com.auHVAC Queensland: hvac.com.auINDT: indt.com.auIndustrial Installation & Maintenance: iimaust.com.auIngal EPS: ingaleps.com.auJ Furphy & Sons: furphys.com.auJacmor Engineering: jacmor.com.auJB Specialised Engineering: jordbellows.com.auJR’s Marine Engineering: jrsgroup.com.auKenro Products: kenrometal.com.auKeppel Prince Engineering: keppelprince.comKnox Engineering: knoxeng.comK-TIG: k-tig.comLaserBond: laserbond.com.auLD Engineering Services: ldo.com.auLoadarm Australia: loadarm.com.auLoclur Engineering: loclur.com.auLSW Group: lswgroup.com.auMechanical Maintenance Solutions: mms.auz.netMechanical Testing Services: N/AMelco Engineering: melcoeng.com.auMidway Metals: midwaymetals.com.auMillmerran: intergen.comMonash University: monash.eduNewmont Asia Pacific: newmont.comObadare: obadare.com.auOrrcon Manufacturing: orrconsteel.com.auOSD Pipelines: osdlimited.com

Outdoor Fabrications: outdoorfabrications.com.auPrecision Metal: precisionmetalgroup.comPurcell’s Engineering: purcells.com.auQSM Fabrication: qsmfabrication.com.auQuality Handling Systems: qhs.com.auQuality Process Services: qpspl.com.auQueensland Nitrates: N/ARadio Frequency Systems: rfsworld.comRCR Energy: rcrtom.com.auRJB Industries: rjb-industries.comRobert Vernon: N/ARobot Technologies-Systems Australia: robottechnologies.com.auRoss Engineering: rossengineering.com.auRussell Mineral Equipment: rmeglobal.comS&L Steel: slsteel.com.auSamaras Group: samarasgroup.comSaunders International: saundersint.comSchenck Process Australia: schenckprocess.comSMW Group: smwgroup.com.auSmenco: smenco.com.auSnowy Hydro: snowyhydro.com.auSouthern Cross Industrial Supplies: scis.com.auSP McLean Engineering: spmclean.com.auSteel Mains: www.steelmains.comStructural Integrity Engineering: siepl.com.auSupagas: supagas.com.auSWA Water Australia: swawater.com.auTas Gas Networks: tasgas.com.auTaurus Mining Solutions: taurusminingsolutions.comTesting, Inspection & Calibration Services: ticsndt.comThe Bloomfield Group: bloomcoll.com.auTopline Steel Fabrications: N/ATrade and Investment NSW: industry.nsw.gov.auUneek Bending: uneek.com.auVehicle Components: vehiclecomponents.com.auVictorian Testing & Inspection Services: victesting.com.auWalz Construction: walzgroup.bizWDT Engineers: wdtengineers.com.auWelding Guns of Australia: unimig.com.au

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Upcoming EventsWhether you need to brush up on skills learnt years ago, want to try your hand at something new, or crave some networking opportunities, there is an industry event for you. For further information on any of the events listed below, or any WTIA events, please email [email protected] or phone +61 2 8748 0100.

INSIDE THE WTIA: UPCOMING EVENTS

October 2017PacRim Stainless 201710 to 11 October, Gold Coastwww.assda.asn.au

Welding Additive Manufacturing Conference10 to 11 October, New Yorkwww.aws.org

International Conference on the Fabrication and Use of P91 Steel11 to 12 October, Cairnswww.etd-consuling.com

5th International Conference on Scientific & Technical Advances on Friction Stir Welding & Processing11 to 13 October, Metzwww.fswp-2017.com

APGA 2017 Annual Convention and Exhibition14 to 17 October, Cairnswww.conferenceco.com.au/APGA

6th International Conference on Material Science and Engineering Technology20 to 22 October, Seoulwww.icmset.com

November 2017Auckland Build 20172 November, Aucklandwww.aucklandbuildexpo.com

FABTECH6 to 9 November, Chicagowww.fabtechexpo.com

Corrosion & Prevention 201712 to 15 November, Sydneywww.corrosion.com.au

13th International Conference on Materials Science and Engineering13 to 15 November, Las Vegaswww.materialsscience.conferenceseries.com

15th Asia Pacific Conference for Non-Destructive Testing13 to 17 November, Singaporewww.apcndt2017.com

Transport Welding and Diagnostics 14 to 15 November, Ekaterinburgwww.rus-ntso.ru

XI Conference on Steel and Composite Construction17 to 24 November, Coimbrawww.cmm.pt/congresso11

ACAM 9 - 9th Australasian Congress on Applied Mechanics27 to 29 November, Sydneywww.acam9.com.au

The Stainless Steel World Conference & Exhibition 201728 to 30 November, Maastrichtwww.stainless-steel-world.net

December 20171st Asia-Pacific International Conference on Additive Manufacturing (APICAM)4 to 6 December, Melbournewww.apicam2017.com.au

16th ISTS: Tubular Structures Symposium4 to 6 December, Melbournewww.monash.edu/engineering/ists16

WTIA & IIW EXAM DATESIWS and WTIA Welding Supervisor9 and 10 November 2017

IWI-B and IWI-S2 and 3 November 2017

For further information about WTIA exams, qualification and certification, please contact [email protected].

WHO SHOULD ATTEND?

The courses are perfect for students and professionals who want to learn or brush up on skills as diverse as: • Basic maths skills and how they apply to various

aspects of welding.• The nature of metals and the metallurgical

phenomena involved in welding.• Inspection, supervision and quality control of

welded parts and projects.• The science, terminology, equipment, variables,

materials, safety, and applications of resistance, plasma arc, electron beam, and laser beam welding.

• The latest safety and health regulations and practices.

For further information, contact [email protected] or visit: https://net.wtia.com.au/OnlineCourses.

WHY OPT FOR AN ONLINE COURSE?

• Comprehensive: Each course has 15 to 18 hours of instruction divided into easily manageable modules.

• Easy to Access: You can access the courses 24/7 from any computer with an internet connection.

• Easy to Use: Pause, advance, and rewind navigation features give you complete control.

• Easy to Understand: Audio narration, animated graphics and video footage make even the most complex topics engaging and easy-to-understand.

• Proven Methods: Interactive elements, practice problems, and quizzes facilitate the mastery of concepts and measure content retention.

• Reliable: Course content was developed by industry experts and the American Welding Society’s education and e-learning professionals.

In conjunction with the American Welding Society (AWS), the Welding Technology Institute of Australia offers a number of online courses, designed to help develop your welding knowledge. Available any time, day or night, the courses are all self-paced, allowing you to complete them in your own time.

WTIA’S EASY TO USE, UNDERSTAND & ACCESS

ONLINE TRAINING COURSES: WELDING EDUCATION YOU CAN TRUST


NON-DESTRUCTIVE TESTING WELDING FUNDAMENTALS WELDING SAFETY

SALES REPRESENTATIVE WELDING SYMBOLS

HELPING SECURE THE FUTURE OF AUSTRALIA’S

WELDING INDUSTRY.

02 8748 0100 | [email protected] | www.wtia.com.au | Building 3, Level 3, 20 Bridge Street, Pymble, NSW 2073

ECONOMICS OF WELDING FABRICATION MATHS METALLURGY

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1 WELDING · 2017-10-04 · Welding Apprentices Fortress Resistors Women in Welding K-TIG Pipeline in Argentina WeldQ & the AWCR Victoria State Focus Inside the WTIA SMART Industry