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Bruce Kelly Bio: Bruce Kelly attended Michigan Technological University, receiving a BS in ElectricalEngineering in 1968 and a MSBA in 1969. He began working at Oldsmobile Division of GeneralMotors in 1969 and was involved with fuel tank assembly and sheet metal fabrication atOldsmobile and then at the General Motors Technical Center. Along the way he developed a hot air soldering process for fuel tank assembly, assembly equipmentfor aluminum hoods, and steel hoods on the same tooling. Hood assembly processes built over 1 millionaluminum hoods. With the aluminum hood assembly; came up the local circulating pump concept toget high water flow rates through tooling to support the higher cooling requirements for welding aluminum.More than 50 of these systems were installed in several different GM facilities. Bruce also picked up 3 defensive publication awardsfrom GM in lieu of patent applications for ideasrelated to resistance welding equipment. Bruce wasinvited to join RWMA in the early 1990’s to providea customer viewpoint and has continued with theRWMA Welding School (now part of AWS) thru2015, and currently chairs the AWS C1 committeeon Resistance Welding. In the AWS Detroit Section,he has served two sets of terms on the sectionexecutive committee and has been part of the SheetMetal Welding Conference committee for the last8 conferences. He received the AWS life membercertificate in 2011.
April Educational NightThursday, April 20, 2017
Resistance Welding Safety, ProcessControl and Maintenance
Special Guest: Bruce KellyLocation: Ukrainian Culture Center
26601 Ryan Rd., Warren, MI 48091$10 at the door to cover buffet
Click here forMap/Directions or see map on page 2
RSVP by April 7 to: Amanda [email protected] by phone @ (248) 512- 1803
AGENDA5:30 - 6:00pm Welcome Reception &
Networking6:00 - 6:15pm Opening Remarks:
(AWS – Detroit)6:15 - 6:45pm Dinner6:45 - 8:15pm Educational
Presentation
1 APRIL TECHNICALMEETING
2 COMMITTEE CHAIRS2 CHAIRMAN’S MESSAGE2 MEETING MAP3 MARCH MEETING RECAP4 ANNUAL AWS DETROIT
ELECTION4 COMING EVENTS4 EDITOR’S NOTE7 APRIL HOTLINE8 ASK THE WELDING
ENGINEER10 THANK YOU TO THE
LADIES’ NIGHT PATRONSAND SPONSORS
12 MEET OUR MEMBERS13 GOLF OUTING
REGISTRATION FORM14 GOLF OUTING
SPONSORSHIPS
April 2017
Inside This Issue
Follow Usawsdetroit.org
AWS Technical Nights are open toeveryone! We encourage thatmembers bring students and non-members to learn more about ourorganization and industry.
This will be our second and final Education Series for the year. Bruce Kelly (GM-ret.and RWMA Educator) will cover “War Stories” – technical issues that stumped theMaintenance Department. A short review of basic safety requirements will be addressed,followed by general principles of weld process control and weld quality criteria. Then,highlighting the night’s program will be the always paramount maintenance aspectsthe equipment package and process. Incoming power considerations, installation, andcontrols will be reviewed. Water service, cooling, and flow will be looked at. Air andhydraulic force delivery components will be discussed. Lubrication, tooling, electrodes,and spare part considerations will be covered also.
April 2017This Issue of the Bulletin
can be viewed on the web at
awsdetroit.orgLet me start by thanking everyonewho came out
and supported our 2017 Annual Ladies Night event. Wehad a great turn out this year at an exciting new venue.John Bohr and his team put a great deal of effort intomaking the event successful, we certainly appreciate hisefforts and the efforts of all those involved.
Detroit Section members can expect a ballot to be emailed to them this monthto vote on our next Detroit Section Executive Committee. The NominatingCommittee has worked hard to provide a great slate of candidates for yourconsideration. This is one of the easier ways for you to be involved in your section.The online ballot system has made it so that you are just a few clicks awayfrom making your choice for the leadership of next year’s Executive Committee.Please take the few minutes required to participate and fill these out.The coming ballot and election is a good indicator that the current session
is nearing its end. Before that occurs, keep in mind that we still have severalAWS events that deserve a spot on your calendar in the coming months. Interms of technical content we look forward to an Education Series on ThursdayApril 20, 2017 at the Ukrainian Cultural Center in Warren and our final TechnicalNight of the session to be held at United Technical Whitmore Lake on May11, 2017. For students, Friday May 12, 2017 is our Annual High School WeldingCompetition held at Washtenaw Community College in Ann Arbor. If you arelooking for a way to give back and support our industry’s future welders, theHigh School Welding Competition is the perfect opportunity. This event is alwaysin need of welding supplies, material, prizes and volunteers. If you are ableto donate time or material please contact Glenn Kay ([email protected]).Coming up in July is the last event of the session, our Annual Golf Outing.This is one of the more popular social events on our calendar, so if you’reinterested in participating or sponsoring please visit our website(www.awsdetroit .org) for more details and updates. Keep in mind that thisevent fills up fast. The American Welding Society has designated April as National Welding
Month. I cannot think of a better opportunity for you to take the time toconsider whether or not you are getting all that you want from your in -volvement with the Detroit Section. If you feel like there is more that we coulddo to support your needs and expectations please contact me [email protected] or (519) 734-8868 (x4476) to discuss.
Tyler AlexanderChairman’s Message
�Chairman: TYLER ALEXANDER
First Vice Chair: WESLEY DONETH
Second Vice Chair: MARK GUGEL
Secretary: DAVID BENETEAU
Treasurer: ANDRE YOUNG
Bulletin Editor: ROBIN MICHON
Webmaster: RODNEY BEREZNICKI
Hotline Coordinator: AMANDA DAVIS
Meeting Reservations: SUSANN MORFINO
Advertising: DONNIE CRIST
Assistants to Chairman:
JOHN SUTTER
ASHLEY WEBEL JONES
TBD
�For Advertising Opportunities
Contact Don Crist810-217-9897
Affiliated With
UkrainianCulture Center26601 Ryan Rd.,Warren, MI 48091
April Educational Night meeting location:
March Technical Meeting Re-capThe AWS-Detroit section hosted its March technical
meeting/Old Timer night at Paslin located in Warren, Michigan.As a co-host, Greg Stacey, Sales Account Manager from Paslin,gave a brief introduction of Paslin. Mr. Terry Tupper, seniorengineer from Fanuc presented his talk regarding the visionapplications in automotive industry. Terry introduced multiplecommonly used 2D and 3D laser-based and camera basedvision systems in the automotive assembly manufacturingprocess. The AWS Detroit section also recognized the old timersafter the talk, including Mr. Savatore Delisi. There were about30 attendees in the meeting. We hope to see YOU at our next meeting! Remember, everyone
is welcome.
Annual AWS Detroit ElectionThe 2017-2018 AWS Detroit Section Executive Committee
Election will once again be conducted using theAssociationVoting.com service. As in the past two years,at approximately 12:01 AM on April 1stAssociationVoting.com will send a personalized emailwith voting instructions to a list of Detroit Section members(compiled on 3/10/2017). The URL provided in the emailwill take you, at any time day or night, to the voting toolwhere you enter your last name and member number(provided in the email) to see candidate biographies beforemaking your confidential selections. A follow-up emailreminder will be sent on April 10th to members who havenot yet voted or opted out. When the vote has ended onApril 15, the Detroit Section Teller’s Committee will receivea confidential vote tally summary supported with a listingof member voting times.Please send an email to [email protected]
before April 15th if you want to:• provide an email address update• provide an email address to be usedonly for the purposes of this ballot
• cancel an unsubscribe notification entered in responseto last year’s ballot
While it will be too late for the purposes of this ballot,changes to your contact information can be made directlythrough the www.aws.org website by clicking the MYACCOUNT tab in the narrow grey bar at the top of thewebpage. You can also contact AWS Member services at:800-443-9353 or 305-443-9353.We look forward to your participation and feedback. If
you have any comments or questions pertaining to thisprocess, please direct them to: [email protected] any member of the Executive Committee.
Editor’s NotesIt’s April! And, I think we are all hoping for sunshine,
warm weather, trees, grass and flowers all to start comingback again! April also reminds us that we are winding downanother very active season in the AWS Detroit Section.We ended March with our Annual Ladies Night event!
Look for pictures in the May edition of the e-bulletin, aswell as on our AWS-Detroit Facebook page! You might getto see yourself!There is still quite a bit to look forward to in the next
few months, and we welcome anyone and everyone to comeout to the education and technical nights this month andnext!
Not to mention, we have the High School WeldingContest in May, and our annual Golf Outing coming upin July!So, there are still plenty of opportunities to come out and
get involved.Have a great month, get out there and encourage
someone to look into welding as a career, and ‘til nextmonth, remember to …Keep on Welding!
Robin
April 1•Scholarship Deadline!•HSWC Deadline!
April 5, 2017SMEDesign for AdditiveManufacturingKnoxville, Tennessee
April 20, 2017Education Series / April Tech NightUkrainian Cultural Center.Speaker: Bruce Kelly
May 8-11, 2017SMERAPID + TCT 2017Pittsburgh, Pennsylvania
May 11, 2017May Tech Night/ AwardsNightUnited Technical
May 12, 2017High School Welding ContestWashtenaw Community College
Coming Events
Fronius USA LLC in Brighton, MI,hosted a vocation night for the RivetersFirst Robotics Team from Mercy HighSchool in Farmington Hills, MI. TheRiveters competed in last year’sStronghold world competition and arementored in part by Dr. AmberleeHaselhuhn, a Researcher with GeneralMotors, and Dr. Rob Reed, a physicianand partner with HBWS, PC. Membersof the AWS Detroit Section ExecutiveBoard volunteered their time to helpmake the night memorable for thestudents. The students were given thisopportunity in order to benefit academically from exposure to welding.
The meeting started with Wesley Doneth of Fronius USA LLC, giving a45 minute lecture on aluminum welding technology. During the lecturestudents and mentors learned the basics of welding aluminum.
After the lecture the group went out into the lab at Fronius and watcheda robot application used to weld aluminum. There was also a demo setup for manual GMAW-P so they could get a feel for the process. Studentsand mentors were able to try out the GMAW-P arc welding process on6061 aluminum.
New AWS Standards Available for SustainingCompany Library’s for Spring 2017• A1.1:16, Metric Practice Guide for the Welding Industry• B1.10:16, Guide for Nondestructive Examination of Welds• B2.2:16, Specification for Brazing Procedure and PerformanceQualification
• D1.8:16, Structural Welding Code – Seismic Supplement• J1.2:16, Guide to Installation and Maintenance of Resistance WeldingMachine
RWMA/AWS Announcement Very successful annual RWMA meetings were held in San Diego Feb.21-24. One of the highlights was a full day mixed committee (RWMA/AWS)review of the current CRWT (Certified Resistance Welding Technician)certification scope documents and subject matter review. These meetingswere very successful in realigning the existing AWS-CRWT documentsto be more pointed to a technician level exam and will eventually leadto new test criteria being rolled out over the next 18-24 mos.
The AWS in conjunction with the RWMA has also rolled out a 7 moduleBasic Resistance Welding process course as part of the overall AWSWelding Process training course. This is a great way to get new personnelthat have no resistance welding experience some good basic resistancewelding process information along with other common welding processesand can be taken on line anytime! This online information can be foundvia the AWS website: www.aws.org
Also, for the first time EVER: The RWMA and AWS will be offering theRWMA RESISTANCE WELDING SCHOOL at the upcoming FabtechMexico/ Weldmex show in Monterrey Mexico in early May 2017. Thisis the SAME EXCELLENT COURSE that is given each year at the FabtechUS show BUTTTT: It to make it successful in Mexico ALL MATERIALSAND AT LEAST 75% OF THE PRESENTATIONS WILL BE DONE IN SPANISH.For those companies with “brothers and sisters” in MEXICO this is anEXCELLENT opportunity to get them some fantastic Resistance WeldingEducation including in class demos, etc. More information on specifictimes, dates and cost, will soon be available via the AWS website.
You can also ask Don Maatz ([email protected]) or Don Crist ([email protected]) of the AWS Detroit Section-Executive Committee or Don DeCorte-RWMA Education Section Chairman if you have questions. CenterLine Becomes Gold Standard WinnerCenterLine (Windsor) Limited is pleased to announce that, as a winnerof Canada’s Best Managed Companies program in 2013, it has successfullyretained its status and become a Gold Standard winner in 2017. Thisprestigious national award is sponsored by Deloitte, CIBC, CanadianBusiness, Smith School of Business and MacKay CEO Forums.“It’s much more than just financial performance,” said Peter Brown, Partner,Deloitte and Co-Leader, Canada’s Best Managed Companies program.“The ingredients to success also include overall business performanceand sustained growth. It takes dedication and commitment from theentire organization.”CenterLine congratulates its outstanding world class staff for its continueddedication to excellence and thanks its many valued customers and suppliersfor their contributions to this wonderful achievement.Contact: CenterLine (Windsor) Limited; 415 Morton Drive, WindsorOn N9J 3T8; Marc Levesque – Director, Corporate Marketing; (519) 734-8464 ext. 4459; [email protected]; www.cntrline.com
April HotlinePictured leftto right: Dr.Rob Reed,Dr. AmberHaselhuhn,MaryMarquette,EliseScarchilli,Anika JaneBeamer,JoshuaFincannon,WesleyDoneth
Wes Doneth and JoshuaFincannon manuallywelding with GMAW-P
Co-op Welding Students,Summer Interns andPart-time Welders
Contact Pat Bell:[email protected] (313) 282-8171 in Detroit
“Which type of transformer isbetter for the resistance spotwelding of sheet metal,
especially the new high-strengthmaterials that are becoming morecommon, AC or MFDC? I ask as Ihave an old AC machine that runsgreat and has handled everything Ihave thrown at it so far?”
“Now that a viable Medium-FrequencyDirect Current (MFDC) resistance spotwelding system had been developed
in the mid 80’s, how did it migrate from justa fringe element of the business then to in 2016out selling a comparable AC system to the tuneis nearly 20:1? As with most new innovationsthe process took some time. It also had to havebelievers, and more than a few bugs workedout. It also did not hurt that the entire resistancewelding world would be changing (and bechallenged) at times literally as fast as onecould speak. But, as is often the case, a bit morehistory is still in order to achieve a morecomplete picture of what transpired.
When the new MFDC power supplies werereleased to the plants there was little, if any,discussion concerning the benefits of lowerprimary power demand, nor was there anymention of the effect MFDC had on materialweldability. There are most likely two reasonsfor this. The first is that the majority ofbodyshops back in this time period wereelectrically overdesigned with regards toprimary power. Why? They were most likelyequipped to handle portable gun transformers.The primary electrical demand for portable guntransformers is huge (potentially 10x that ofcomparable MFDC unit) and since theseelectrical systems were already in place, acapital cost reduction was not possible unlessa ‘Greenfield’ facility was being launched. Asa result, there was very little cost savingsattached to the actual power system equipmentside. The second reason had to do with the factthat the MFDC technology was in its infancyand the Facilities Engineers were not going torisk downsizing a plant power system on thisnew technology. The same thinking appliedto the Welding Engineer with respect to weldquality and process robustness. Since the initialgoal was mass reduction and increasedsecondary weld current capability, folks werenot looking for, nor expecting, an improvementin material weldability.
The selection of AC vs. MFDC with regardsto facilities and tooling is based on its own
unique acceptance criteria. As with all choicesit is not entirely a black and white issue andsome knowledge of the potential compromisesand pitfalls is essential to achieve an accuratedecision. From a facility perspective the useof MFDC represents a major change in thinkingas compared to AC. The following pointsshould help illustrate the differences, andhighlight both possible advantages anddisadvantages for each type of power supply.
• MFDC permits equal three-phase currentdistribution and thus a more balanced primaryloading condition. An AC welding system onlytaps into 2 of the 3 primary bus legs andrequires a fair amount of facility planning toensure that each leg on the bus is subjected torelatively the same load. Also, because thesingle-phase loads are not synchronized,balancing the load on a three-phasedistribution is nearly impossible.
• The selection of MFDC for a large volumeinstallation, such as new bodyshop, does resultin reduced overall primary demand. This lowerprimary demand can translate into savings dueto the lower costs associated with primarypower distribution equipment (smaller circuitbreakers, wire, etc.). But since switching fromAC to MFDC requires changing from single-phase breakers and two-wire systems to three-phase breakers and three-wire systems thetrue electrical facility cost reduction may notbe what one would hope for. Anotherimportant consideration is that the typicalAC installation can get by with a primarycable rated at 600V while the same item in anMFDC system requires a higher rating betweenthe weld control and the power supply. Thisis due to the nature of 3� power associated withthe MFDC system that results in a peak valueof 650v.
• Within the world of general automotiveapplications the cost of AC transguntransformers vary in price from $900 - $1,600while the equivalent MFDC units run from$1,900 - $3,200, depending on features. Thesame disparity can be seen in the weld controlsrequired for each power supply with the MFDCalso suffering a cost penalty. However, acautionary note on costs: This is one areawhere the application and volume can havea huge impact. Prices for the MFDC equipmentused to be in excess of 2:1 over the comparableAC device but that gap has narrowedconsiderably due to the economies of scale.That being said the inherent complexity of anMFDC resistance welding power supply orweld control will most likely keep it more
expensive than its AC equivalent for theimmediate future.
• MFDC power supply water coolingrequirements are significantly higher whencompared to an equivalent AC unit, with thetypical flow rate requirements two or threetimes those required of AC. The sophisticatedinternal water paths also dictate a higherdifferential pressure, and the physicalconditioning (i.e. mechanical filtration, etc.)of the water must be better to prevent sedimentbuild up due the tortuous water flow path.Conversely the AC transformer is much moredurable and less prone to failure with respectto water issues.
• The MFDC power supply may have ashorter life expectancy than its AC counter-part. This is due to the characteristics of adiode when it is thermally cycled and the resul-tant movement between the wafers in the rec-tifier packs. In essence the ‘moving parts’ ofthe MFDC power supply wear out. The typi-cal life span averages 20-22 million thermalcycles, but can be higher. Additionally theMFDC power supply is more susceptible to fail-ure due to low water flow rates. While thissame affliction is harmful to an AC trans-former, the magnitude of the degradation ismuch less. Also, an AC power supply will oftengive you a bit of warning that it is going to fail,this event often foreshadowed by a very uniquesmell, while the MFDC power supply will workon one weld and then not on the next.
But as was eluded to, there might be moreto the story as to why the MFDC power suppliesbecame more prevalent within the industry.We will discuss these aspects in our nextcolumn.”
The author gratefully acknowledges theassistance of past AWS-Detroit sectionChairman Don DeCorte, VP Sales for RoManManufacturing Inc.
If you have more questions about this topic,Contact Don Maatz at:If you have morequestions about this topic, contact Don Maatzat:R&E Engineering ServicesA subsidiary of R&E Automated Systems, LLC17500 23 Mile Road – Suite BMacomb, MI 48044(586) 228-1900 – Office(734) 793-2304 – [email protected]
References:1) Resistance Welding Manual, revised 4th Edition
s
Ask the Welding EngineerBy Donald F. Maatz, Jr.
A:
Q:
This article is a continuation of theMar-2017 ‘Ask the Welding Engineer’
AET Integration
Airgas
“ARO Welding Technologies, Inc.”
Ashley Jones
ATI Industrial Automation
AWS Detroit Section ExecutiveCommittee
Bob & Mardell Wilcox
Bosch Rexroth Corporation
Centerline (Windsor) Limited
Changer & Dresser Corp.
Dengensha America Corp.
“Fronius USA, LLC”
FUSION Welding Solutions
Genesis Systems Group
Grossel Tool Co.
HTI Cybernetics
Industrial Control Repair (ICR)
JEC Distributors
KUKA Robotics
KUKA Systems
“LEONI Engineering Productsand Services, Inc.”
LUVATA
Mark Gugel
Matheson Gas
Milco
Obara Corp. USA
Parker Hannifin
Paslin
PROFIL System Inc
R&E Automated
“RoMan Manufacturing, Inc.”
Royal Park Hotel
SDK Engineering
Stäubli North America
The Ohio State UniversityWelding Engineering Alumni
Turck
United Technical LLC
Welding TechnologyCorporation
AWS Detroit SectionLadies Night
As with all volunteer organizations we rely onsupport from our members and valued corporatesponsors. The Detroit Section’s Ladies Night heldMarch 25th is no different. On the behalf of theDetroit Section Executive Committee and as the2017 Ladies Night Chairman I would like torecognize and thank our Section Patrons andLadies Night Sponsors whom without theresupport Ladies Night would not be a success.
AWS Detroit Section Patrons and Ladies Night Sponsors
Thank you again for your support!
John Bohr2017 Ladies Night Chair
Please see the Detroit Section website for photos from this years Ladies Nightas well as information regarding other upcoming events; www.awsdetroit.org/
Hello! Welcome to ourApril Meet our Memberscolumn. Our featuredmember this month is alsoa member of the AWSDetroit ExecutiveCommittee.
Welcome, Dan! Please tellus a little bit aboutyourself. Hello, I’m Dan Wellman. Iam the Vice President of Sales
and Marketing for the Obara Corp. USA.
Dan, what do you like about your position withObara? I love to travel and meet people, but I hate to be away fromhome… It’s a catch 22.
Why did you join the AWS?The two main reasons I joined the AWS was to continueto learn and secondly, to have the ability to network withsome of the most knowledgeable people in the industry.
Do you have a favorite AWS event? I would have to say Ladies night and Scholarship Night.
What do you like to do outside of work? I like to golf, work around the house, travel and read.
Do you have any funny moments or stories that you’dwant to share? One of the Ford plants was having trouble with watercooling a spotwelding cap. An old friend, Marvin Hayesused a five-gallon bucket of water to dip the cap in forcooling. After every couple of welds the robot would dipthe cap into the bucket, it actually worked out well.My most memorable moment with AWS was receiving myAWS Scholarship in 1978. It paid for my second year ofschool.
Do you have anything that you’d consider near/dearto your heart?The City of Detroit
Do you have any mentors that you’d want torecognize?I have had several, the two most important would be mystep father, Torb Guenther, and my welding instructor StuGalbraith at Schoolcraft College.
Dan, how did you get started in welding? My step father needed someone to do TIG welding and heshowed me how.
What do you see as the biggest challenge for weldersin the future? Besides the skills of welding they need extended educationin math, English and science. Good communication skillsare essential.
Have you ever used your welding skills outside theworkplace? I’ve worked on car bodies.
What would you tell someone who may be “on thefence” about getting into welding as a career? You never know where it will lead you if you keep learningand trying new things. You can end up anywhere.
If you weren’t involved in the welding industry, whatwould be your dream job? I’d like to be a Park Ranger.
Would you encourage more schools (high schoolsand junior high) to encourage more young people tolook into technical schools and jobs and not justdegreed positions? Yes, I would encourage it, but I also feel strongly on themaximum of learning the basics in math and English. Withthese skills, they are prepared for diversity and are moreflexible in the work place.
Dan, thank you for taking the time to be our April Meetour Members featured member!If you would like to be featured in this column, pleasecontact Daniel Galiher at [email protected]
MEET OURMembers Dan Wellman
