Campbell is a welding engineer and a Bechtel Fellow, being the first selected from the welding field. With a BS degree in Welding Engineering from LeTourneau University and a PhD in Materials Engineering from RPI, he has worked for more than 30 years in the welding industry. He is a member of various AWS and ASME committees, author of more than 20 articles, and he also teaches the CWI seminars for AWS. As an expert in stainless steel welding, he authored AWS's The Professional's Advisor on Welding of Stainless Steels.

Bechtel has been involved in construction in the energy industry for decades. As a leader in the construction field, Bechtel utilizes proven welding and NDE technologies in parallel with researching and implementing new welding applications. In the fossil fuel industry, the company has successfully utilized GMAW surface tension transfer (STT) to deposit root passes in P91/P92 piping and stainless steel piping full thickness, purge free. The company has also utilized the automatic "orbital" flux cored arc welding (FCAW) process for welding large bore heavy-wall piping, including some higher alloys. The use of these applications has improved productivity rates, reduced preparation and welding time, while maintaining the level of quality the company and our clients expect. In the nuclear industry, the company has successfully utilized narrow groove gas tungsten arc welding (GTAW) and just recently began utilizing GMAW-STT to weld stainless steel pipe allowing the root pass to be deposited purge free while maintaining the required quality and eliminating the costly consumable inert purging gas.

Orbital pipe and tube welding has had great success in all energy industries, and also has been used by Bechtel on a nuclear waste treatment plant which will process chemical and radioactive waste (from nuclear weapons production and eventually nuclear power waste). Wire-fed orbital GTAW is utilized for air lines which will feed vessels which will process radioactive liquids, and these welds require 100% radiography. Autogenously orbital GTAW is utilized for process lines which will transfer radioactive liquids and gases.

In the liquid natural gas (LNG) field, Bechtel is constructing a number of LNG export facilities including the LNG tanks. The company has successfully utilized the GMAW-STT process to deposit root passes purge free on large bore stainless steel piping. One of the welding applications being evaluated for this type of large scale work includes semiautomatic hot-wire feed GTAW. For nondestructive testing and examination, the company utilizes what is safe, provides the best quality, and is practical. The company continues to utilize conventional radiography where practical but has also utilized some of the latest technology such as automated ultrasonic testing (AUT) and computed radiography (CR), and is now evaluating value in the use of digital radiography (DR). The company continues to utilize our experience and the industry's best proven practices as well as incorporating the latest technology for welding and NDE in order to maintain a competitive edge and remain a leader in the construction industry.

Ludwig has a Bachelor of Science in Welding Engineering from Millikin University and an Associate in Applied Science in Architectural and Building Construction Technology from Thomas Nelson Community College. He has over 30 years of experience in the field of Welding Engineering. His experience ranges from structural and bridge work to the fabrication of process piping in the petrochemical industry to 26+ years in shipbuilding/ship repair as well as his current role with Fronius.

Fronius has been a member of the American Welding Society since his college days and is also a member of the ASME. He served as the past chair of the AWS D3 Committee on Marine Welding and continues to serve on several AWS committees.

Over his career, Ludwig has managed several technical projects for various research entities and has had several papers/articles published in various publications such as the Welding Journal, the Journal of Marine Engineers and the Journal of Ship Production and has presented at a variety of technical conferences.

The energy field utilizes cladding or weld overlay for a variety of reasons (wear resistance, corrosion resistance, cracking mitigation, etc.). These overlays often demand the highest quality, reliability and repeatability in order for the systems to operate in the fashion they are designed. The term 'Zero Defect' is more of a requirement than an objective for the fabricator. As a natural consequence Gas Tungsten Arc Welding (GTAW) is typically the most widespread weld overlay process. To overcome the lack of weld deposition rate of GTAW many operations incorporate a mechanized wire feed system to improve this rather slow process. In some cases where the area to be clad is large fabricators may utilize Submerged Arc Welding (SAW) but the volatile nature of the puddle increases the dilution of base metal into weld metal thus necessitating additional cladding layers to mitigate the dilution effect.

Welding technology and more importantly, control methodology, has evolved over the years to a point where equipment manufactures can created tailored waveforms to precisely control the welding arc, including the metal transfer process, in extreme details. These advanced power supplies allow fabricators to start thinking about Gas Metal Arc Welding, Tandem Gas Metal Arc Welding and Laser Hybrid Arc Welding as alternatives to GTAW or SAW.

This presentation will highlight work being accomplished in the cladding/weld overlay area that could provide those in the energy field with alternative ways to more efficiently perform cladding or weld overlays without sacrificing quality.

Pletcher is a Senior Welding Metallurgist with the Chicago Bridge and Iron Company and serves on the AWS A5 Filler Metal Committee. He has a Ph.D in Materials Science from the University of Florida with an emphasis in metals, an M.S. in Materials Science from Rensselaer Polytechnic Institute, and a B.S. in Welding Engineering from LeTourneau University.

Liquefied natural gas (LNG) storage and processing facilities utilize 9% Nickel Steels welded with Nickel-based alloys. Tank size often reaches 250' in diameter and over 100' in height creating welding challenges during the fabrication and construction stages. Export terminals are commonly in remote locations thereby limiting accessibility to well-trained welders and high quality welding consumables. Welding consumable evaluation and selection involves mechanical properties, welding appeal, and product consistency. In addition to these basic considerations: residual magnetism, complete volumetric welding inspection, and managing a remote construction project provide addition complications.

Beardsley is a graduate of the Ohio State University Welding Engineering program. He holds an MBA from Cleveland State University and is a Registered Professional Engineer with the State of Ohio. He has 23 years of manufacturing management and engineering experience and has authored welding articles for several technical publications.

Steve Peters and Paul Denney of Lincoln Electric are also involved in this development.

The use of lasers with powders for the deposition of wear and corrosion materials has been accepted by a wide range of energy related industries. Hundreds of thousands of pounds of powder are deposited each year by laser job shops and internal facilities to repair parts, improve wear resistance, and/or address corrosion issues. The advantage of this metallurgical bonding process is that heat input, depth of deposition, and dilution are all better than what can be achieved by arc or other plating/coating technologies.

This presentation will review the economics and technical advantages of a new alternative to laser powder cladding, laser hot wire cladding. It will give examples of some of the materials that can be deposited, the parameters used, and how this technology may impact the energy industry. Also presented will be the status of efforts on the technology at Lincoln Electric and potential areas of future development.

Newell has been involved in welding engineering applications and consulting in the nuclear and fossil electric power and heavy industrial arenas for over 30 years, both domestically and internationally. He graduated from The Ohio State University with a B.S. in Welding Engineering and was also awarded a diploma as an International Welding Engineer by the International Institute of Welding. He holds Professional Engineer licenses in Ohio, North Carolina, South Carolina and Tennessee, plus Alberta, Canada. Newell also has four patents on welding related technology.

Newell is a member on national and international code bodies, a Life Member in the American Welding Society, and a member of AWS A5N, Vice Chair of AWS D10; a Member on ISO/TC 44, International Committee on Welding and Allied Processes, plus a member of ASME Section IX - Welding and Brazing Qualifications, ASME Post Construction Issues - Subcommittee on Materials and Repair, Secretary of ASME SCII/IX Subgroup on Strength of Weldments, and ASME SCII Task Group Creep Strength-Enhanced Ferritic Steels.

Newell is the President of W. F. Newell & Associates, Inc., a consulting firm that specializes in welding engineering and Co-Founder/Vice President - Engineering of Euroweld, Ltd., a supplier of specialty welding consumables and technology.

Preheat, in and of itself, is oftentimes considered rather mundane. It involves heating pieces to be welded to some temperature above their ambient temperatures prior to and during welding. Modern codes usually require some level of preheat with its application criteria being material dependent. Whether preheat is required or not, preheat can provide any combination of the following benefits: Reduce shrinkage stresses in the weld and adjacent base metal, especially in highly restrained joints; Provide a slower rate of cooling through the critical temperature range, preventing excessive hardening and reduced ductility of both the weld and heat-affected zone (HAZ); and, Provide a slower rate of cooling through the 4000F range, allowing more time for hydrogen that may be present to diffuse away from the weld and adjacent base metal to avoid hydrogen cracking. Inappropriate application of local preheat too often can result in damaged material and must be avoided. Needs for preheat, benefits and ramifications of improper implementation will be presented with the aid of actual examples.

Schroeder has worked in the welding industry for 25 years starting as a welder and moving up through distribution channels to ESAB Welding and Cutting as of today. He has been with ESAB for 11 years, starting as a Territory Sales Manager and having moved into the Automation Group for the last 10 years. Schroeder have started in the wind industry in 2002 and has been in the heavy metal fabrication field for the last 8 years. One of his more enjoyable experiences in this field has been to help with the plant layouts of green field factories and see them go from a print to construction.

This presentation will cover the following items for wind tower manufacturers, both present and future builders. Developments in land based towers. Construction methods used for fitting, rolling and welding of complete tower sections. Joint designs used presently in the tower business. Obstacles for building of windtowers and how to overcome them. Methods of improving fitting and welding of towers while maintaining the high quality standards set by the industry.

Blakely has a mechanical engineering degree from Kettering University (formerly GMI Engineering and Management Institute) and an MBA from Michigan State University. He has worked in various engineering, program management, and marketing roles in the aerospace, automotive and metals industries. He has been a speaker at numerous conference and university technical presentations.

For years, explosion welding (EXW) has been employed by the energy industry when a thin layer of corrosion resistant alloy on a thicker layer of steel is desirable over solid construction. Various examples exist where EXW has been put to use to avoid corrosion and lower fabricated construction costs. The presentation will introduce the EXW process and also cover examples of its use in the oil & gas processing, geothermal, gasification for power, liquefied natural gas, solar, and direct fossil power generation markets.

Harris has conducted many projects in gas-shielded arc welding processes, including gas metal arc (particularly pulsed) welding (GMAW), gas tungsten arc welding (GTAW), and plasma arc welding (PAW) processes. He has authored over 100 reports and papers on arc welding, including many technical reports for sponsored work such as welding procedure development and evaluation of shielding gases. He was the project leader in a 3-year $380,000 group-sponsored project (GSP) on pulsed GMAW with sponsors in the U.S. and Europe, and launched another GSP in this area before joining EWI. In the power generation market, work undertaken included turbine rotor repair by the GTAW and pulsed GMAW processes, and procedure development for pulsed GMAW of beryllium copper alloys intended for the toroidal field coils of an advanced fusion power reactor.

Harris has a B.Sc. (Honors), Metallurgy, University of Surrey, England, M.Sc., Welding Engineering, The Ohio State University, M. Phil. Welding Engineering, Cranfield University, England, and a Ph.D., also at Cranfield.

Plasma GMAW is, in various embodiments, suitable for both a surface engineering tool and for welding of joints. It is suitable for welding high strength steels, stainless steels, and other high alloyed materials. As a surface engineering tool, the process generally is operated in a coaxial mode, while in a welding context for joints it is used in a hybrid in-line configuration. The equipment, capabilities, advantages and disadvantages compared to more conventional technologies will be highlighted, and some examples given to illustrate this.

Yarmuch is the Program Leader of Welding & Slurry Systems Engineering, in the Advanced Materials group at Alberta Innovates - Technology Futures (AITF). Matthew has worked in the areas of research & development, design, construction, and operations with research organizations, engineering companies, and oil, gas & oil sands operating firms. He is a Professional Engineer, and an IIW International Welding Engineer. Yarmuch is an Adjunct Professor in the Department of Chemical and Materials Engineering at the University of Alberta. He is the Special Events Chair and Past Chair of the American Welding Society - Alberta Section. He holds an MSc degree and is a PEng and an IWE.

The Alberta oil sands constitute the third largest proven oil reserve in the world, and represent a significant resource for Canada and all of its trading partners. While the "tar sands" may be a hot topic in the news, relatively few people understand the actual oil (bitumen) extraction processes, and the associated materials challenges. This presentation provides an overview of the development of the oil sands sector, the different methods used to produce the oil, an overview of materials issues encountered in this very aggressive environment, and some examples of how modern welding technologies play a role in improving the reliability of oil sands operations.

Paul has worked on material issues in various industries for 30 years. Experience includes work in the power generation, chemical process, oil & gas, automotive, and electronic industries. Early work with The Babcock & Wilcox Company focused primarily on corrosion protection of heat transfer equipment and he holds a U.S. patent in this area. Over the last 15 years his work has focused on the use of nickel-based alloys to increase reliability and extend the life of all types of process equipment. Paul is currently responsible for the introduction of new alloys and over-seeing all technical issues involving corrosion alloys, heat-resistant alloys, and weld applications. He earned his M.S. in Metallurgical Engineering & Materials Science at the University of Notre Dame.

Weld overlay materials are applied as a surface coating for boiler tubes in coal fired power plants in order to extend the life of the tubes. Corrosion of the alloy or stainless steel tubes is the main reason why weld overlays are required. The two most common corrosion mechanisms that occur in coal fired boilers are sulfidation of the waterwall tubes in the lower furnace region and coal ash corrosion of tubes in the upper furnace convection pass region. Many materials have been used over the years to reduce the effects of corrosion. The selection of a proper material depends not only on the region of the boiler but also on the boiler design and operating conditions. The various alloys used in coal fired boilers are reviewed along with the technical requirements for the various boiler designs and operating conditions.

Brad Nagy is an Applications Engineer in the Laser Processing group at EWI. His primary areas of expertise include hybrid laser-arc welding, tandem gas metal arc welding, and automated GMAW. Mr. Nagy received his B.S. in Welding Engineering from The Ohio State University.

EWI recently completed a preliminary study of the use of high-power, high-brightness lasers for autogenous and hybrid welding of thick-section materials common to the nuclear industry. These materials included A508 steel forging, 316L stainless steel, Inconel 690, and Inconel 718. The mechanical properties and quality of these welds were documented through both destructive and non-destructive testing. The effect of shielding gas composition on the quality and mechanical properties of autogenous laser welds made on these base materials was also evaluated. Industrial grade argon and nitrogen were the two shielding gas compositions used during this study.

Thompson is an Applications Engineer in the Friction Stir Welding Technology Group at EWI. Brian's area of expertise includes the Friction Stir Welding process as applied to a variety of materials including but not limited to Aluminum, Magnesium, Copper, steel, Titanium, and Nickel alloys. He also has experience with the different variations on the Friction Stir Welding process such as Friction Stir Spot Welding and Friction Stir Processing. Prior to joining EWI in 2006, Brian was employed by General Dynamics Land Systems in Lima, Ohio where he assisted in the development and implementation of Friction Stir Welding for defense applications. In 2007, Brian was a finalist for the EWI Technical Excellence Award for work he conducted on the Friction Stir Welding of Aluminum alloys and high-strength steels. In June of 2010, Brian completed his pursuit of an M.S. degree in Welding Engineering from The Ohio State University. His area of research focused on the characterization of tool degradation mechanisms in tungsten-based tool materials used for the Friction Stir Welding of high-strength steels.

Recently, there has been growing interest in applying Friction Stir Welding (FSW) to thick-section, high melting temperature materials. This interest has been seen across a broad range of industries, although the Energy Industry has been a specific focal point. Welding at these thicknesses presents significant challenges. These challenges include higher tool reaction forces and lower implicit cooling rates. A key aspect in developing FSW for thick-section, high melting temperature materials has been innovations to the tools themselves. Other developments include enhanced weld thermal management, as well as optimized tool designs and parameter selection. Recent work using tungsten-based tool materials has demonstrated full penetration welds in steel up to 0.75-in thick and Titanium up to 1.0-in thick. This presentation will summarize work conducted in these areas to develop stable welding conditions using tungsten-based tool materials in thick-section steel and titanium alloys.

Findlan's areas of interest include welding technology for large scale power plant construction including advanced welding systems for fabrication and installation, welding program development and management, and use of specialized thermal processing systems. Previously, he was with the Electric Power Research Institute and led research on welding and repair technology for power plants. He has authored industry reports on welding and materials technology for repair and corrosion control of power plants components and hold patents in welding, materials, and laser optics. He is active in ASME Codes and AWS pipe and tubing welding specifications. Findlan received a degree in Welding Engineering from Ohio State University (1978), is a registered Professional Engineer (Ohio), and an IIW International Welding Engineer.

One of the most challenging issues we have faced is the use of D1.1, D1.4 and D1.6 rules for nuclear fabrication. I think I could put together a very strong paper on the challenges and related interpretations/conservative guesstimates required to navigate these Codes for procedure qualification. Since we may be the first ones to use these codes for qualification of procedures new nuclear fabrication (requiring use of the Code words verbatim!), it has created a lot of requests to AWS for interpretations and clarifications of intent. I think it would be valuable to share this with folks so they understand the scope of work required to properly use these Codes.

Babich earned his BS in Metallurgy at Penn State.

Hot roll bonded clad plate was developed by Lukens Steel (now part of ArcelorMittal), and introduced to the industrial marketplace in 1930. Roll-bonded clad products consist of a thin layer of corrosion resistant material, metallurgically bonded to a less expensive, higher strength backing, creating an economical alternative to solid stainless steel or nickel-based alloy plate. The production of this cost-effective engineered product will be discussed with an emphasis on C276 clad for coal-fired power plant flue-gas desulphurization (FGD) equipment and stacks. The principles and practical techniques for welding C276 and similar alloyed clad plates will be described.

Schroeder has worked in the welding industry for 25 years starting as a welder and moving up through distribution channels to ESAB Welding and Cutting as of today. He has been with ESAB for 11 years, starting as a Territory Sales Manager and having moved into the Automation Group for the last 10 years. Schroeder have started in the wind industry in 2002 and has been in the heavy metal fabrication field for the last 8 years. One of his more enjoyable experiences in this field has been to help with the plant layouts of green field factories and see them go from a print to construction.

With the need to increase productivity and lower overall operating costs by increasing depositions of welded joints, Esab has developed and new patented process called ICE, for submerged arc welding. The abbreviations stands for "isolated cold electrode." This presentation will discuss the benefits of using the process while saving overall costs for the company by as much as 35%.

Dooley has been with Kennametal Conforma Clad for 11 years, having responsibility for power generation sales in the Midwest for the last 5 years. Prior to that, he was responsible for sales into the plastics industry. Before joining Kennametal Conforma Clad, Dooley held various engineering positions in the plastics and metalworking industries. He earned a Bachelor of Science in Mechanical Engineering Technology from Purdue University in 1987 and an MBA from Indiana University in 2002. Dooley lives in Hardinsburg, IN.

Power plant boilers, including pulverized coal, bubbling fluidized bed, circulating fluidized bed, and waste to energy boilers produce very corrosive and erosive environments which can significantly reduce the life of boiler tubes, fans, burners, material handling, and pollution control equipment. Kennametal offers various solutions including an infiltration brazed tungsten carbide coating, thru-hardened plate, and chrome carbide plate that can greatly reduce the corrosion and erosion on these components. This allows the plants to run longer between outages reducing maintenance cost and increasing valuable run time.