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Copyright of Thermal Spray Bulletin is the property of DVS Media GmbH and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

The globally great demand for welded products from installation engineering and from pipeline and tank construction as well as the simultaneous shortage of experienced and qualified manual welders in this sector suggest that the manufacturers are increasingly interested in fully mechanised, economically viable and reliable welding processes as alternatives to the processes utilised until now. In the Research and Development Department of the GSI mbH, Branch SLV Munich, the plasma- GMA process in serial coupling was systematically investigated on the basis of welding tests, modern process simulation and high-speed recording technology and was refined for utilisation in installation engineering and tank construction. [ABSTRACT FROM AUTHOR]

Several letters to the editor are presented in response to articles in previous issues including an article related to the comparison of church with corporation, an article related to the Australian politics, and an article by Paul Daley on a series of unsustainable assertions about the implications of the British government's decision to reduce by 1600 its troop numbers in Iraq.

The article discusses the new stud welding in the radial-symmetric magnetic field. It can make a vital distribution to the improvement of the arc stud welding efficiency by repeatable, good welding quality, basically without blow effect problems. A characteristic feature of SRM stud welding reduced spatter formation and a small bead.

To extend the possibilities of innovative lightweight construction, increasingly stronger steel sheet materials are being developed by steel manufacturers and increasingly used by the sheet metal processing industries. Typical representatives of this group are the so-called multiphase steels. Due to their higher strength compared with non-alloyed or low-alloyed steels, they allow the implementation of new design and safety-relevant aspects. Major applications are components made from cold-formed sheet metal, i.e. in automotive engineering for door impact beams or for strengthening the B-pillar as well as in the design of cranes or for wear-stressed components, for example in transport vehicles or agricultural equipment. This means that the sheet metal is subjected to a forming process before welding for virtually all applications, i.e. by bending or deep drawing. The changed material properties as a result of cold forming and stretching, such as increased springback behaviour and local changes in structural/stress conditions and hardness, may impair the suitability for welding or soldering. As part of a research project [1] at the Welding Training and Research Institute SLV Munich, investigations were therefore conducted into the laser welding and soldering of non-deformed and specifically deformed highstrength steel sheet and analysed with regard to changes in process and materials behaviour and bonding properties in terms of the fields of application. The effects on the suitability for laser welding are presented in the following. [ABSTRACT FROM AUTHOR]

The utilisation of modern, electronically clock-pulse-controlled welding devices with innovative digital process control and regulation techniques permits a heat input adapted to the joining task and optimised metal transfer methods in the GMA arc. "CMT", "coldArc", "Cold Weld", "STT", "SpeedPulse", "PCS", "forceArc", "Rapid Weld", "SpeedArc", "DeepARC" etc. are process names from various device manufacturers and designate modern arc processes and their metal transfer methods in the case of gas-shielded metal-arc (GMA) welding in different power ranges. Due to the large number and diversity of the process names, even the well-versed users have difficulties in finding an overview and, above all, a classification and assignment of the new arc technologies for the previously well-known arc types and metal transfer methods since the modified metal transfer methods have not yet been taken into consideration in standards and technical bulletins at the moment. This article is intended to give an overview in an independent and neutral form and to provide assistance with regard to the assignment of the new process names to the previously well-known arc types such as the short, pulsed and spray arcs. [ABSTRACT FROM AUTHOR]

Welding simulation offers the metal-processing industry a great potential for reducing the development times and costs. In this respect, a stress-free initial condition is generally assumed for simplification purposes. Since this assumption does not apply to the welding of deep-drawn sheet parts, it may be necessary to define the component condition from a forming simulation as the initial condition. Moreover, accuracy losses may occur during that transfer of results from the forming simulation to the welding simulation which is required to this end because, in both simulations, different models are used, for example, for the material behaviour. The accuracy losses are expressed, for instance, in the falsification of the geometry and of the stress condition. The objective of the presented investigations was to answer the questions: not only "On what influences do these accuracy losses depend?" but also "When is it necessary to take account of forming results in a welding simulation as the initial condition?" [ABSTRACT FROM AUTHOR]

In series and mass fabrication, resistance projection welding is a very economically viable joining process because of its short fabrication times. One decisive advantage of the process technology lies in the fact that several joints can be manufactured in one operation [1...5]. However, the resistance projection welding on the advanced high-strength to ultrahigh-strength sheets which have been introduced into fabrication in the meantime [6] is leading to great difficulties at the moment, amongst other reasons, because the projection geometry is not optimum. The strength of the joints is frequently lower than in the case of conventional soft deep-drawing steels and also exhibits a wide scatter. Moreover, fractures in the joining plane (shear fracture) occur very frequently. In the research project entitled "Optimisation of the geometry of embossed projections for the resistance projection welding on advanced high-strength to ultrahigh-strength steel materials" which is being promoted by AiF, investigations into the optimised designing of the projection geometries were conducted at SLV München and werecompared with the projections according to DIN EN 28167. Results with the HCT690TD and HCT780TD TRIP steels, with the HCT780CD complex-phase steel as well as with the DX54D+Z100 soft deep-drawing steel (all sheet thicknesses: 1.5 mm) are presented within the framework of this publication. The welding was carried out with identical materials and in various mixed combinations. The welds were executed on a medium-frequency projection welding machine from Dalex, model: PMS 32-5 MF. [ABSTRACT FROM AUTHOR]

Standard elements are joined by means of welding technology in conventional process chains for the fabrication of sheet metal parts mostly after the forming on the individual sheet metal part outside the pressing tools. This spatial separation of the processing steps requires complicated handling operations and exerts a detrimental effect on the positioning accuracy of the joining part. The challenges of integrating the joining process into the forming tool relate, above all, to the handling of the welding emissions and the tool soiling associated with these as well as to reliable welding monitoring. While merely solutions for integrated resistance welding have been known until now, a tool technology in a reliable process for the functional integration of initial contact capacitor discharge (CD) arc stud welding was developed in a research project. This technology is particularly wellsuited to integration into sheet metal working tools, amongst other reasons, because of a high joining speed, a low energy input and a high process reliability. In endurance tests, this new technology can be used in order to manufacture high-quality stud welds with a high robustness to disturbing variables at the same time, not least due to the fact that the extraction of welding spatter was tried out for the first time. [ABSTRACT FROM AUTHOR]

Rotational friction welding is the most widespread friction welding process for metals. The joints exhibit outstanding properties - not only when materials with the same or similar compositions are joined but also in the case of materials with restricted fabrication weldability (cast materials or materials manufactured by means of powder metallurgy) and of dissimilar material joints, e.g. steel/titanium and steel/aluminium. However, the rotating relative movement causes the weldable geometries to be restricted to quasi-rotationally symmetrical cross-sections. Orbital friction welding in particular offers good process engineering prerequisites for joining also non rotationally symmetrically cross sections. [ABSTRACT FROM AUTHOR]

An interview with Heidi Cramer, the managing director of Research & Innovation at GSI, is presented. She discussed the necessary future developments in welding technology, explaining the close relationship between materials, construction, and joining processes, and how digitalization aids in making welding processes more efficient and safer. She emphasized that joining technology cannot be viewed in isolation as it is part of the value chain.

Information on the "US/European Welding Standards" conference, orgnised by the American Welding Society (AWS) and Gesellschaft für Schweißtechnik International mbH, that was held at the AWS headquarters in Miami, Florida from January 26-28, 2014 is presented. Topics discussed include the economic treaty between the U.S. and Europe, manufacture of construction products, and the role of welding supervisor. Among the participants are professors Heidi Cramer and Georg Wackerbauer.

The article announces the appointment of Heidi Cramer as director of Gesellschaft für Schweißtechnik International mbH.