By André A. Odermatt

Many of our readers have been at Hobart Institute of Welding Technology and may remember the Sound Chamber sculpture that HIWT donated to the City of Troy in 2003. (See Moving Sounds in the winter 2003 issue of The World of Welding). In its place, gracing the front lawn of the Institute, is now a lighted, 40-ft. aluminum flagpole with the U.S. flag flying day and night. HIWT dedicated this as a tribute to the late John S. Bird, Superintendent of HIWT from 1982 to 1990.  (The World of Welding, Spring, 2005)

We could have selected an increasingly popular fiberglass instead of an aluminum flagpole but we decided on the historically favorite aluminum material. When unpacking the clear anodized aluminum flagpole we discovered that the weld made to attach the top end-cap was black. While the weld itself looked fine and was probably completed by a skilled welder, he or she was not a competent welder; otherwise the weld seam would have had the same color as the aluminum and would not appear as an obvious discoloration.

We took a picture and sent it to the manufacturer of the flagpole, explaining that this weld was not done properly.  We invited this company to send the welder to HIWT’s Weldability of Ferrous and Nonferrous Metals technical training course.  One of many invaluable topics that are taught in this course is exactly how to avoid this type of discoloration of the weld.  To date, we have not received a response from the manufacturer and I can only assume that the flagpoles they continue to manufacture still have this ugly black seam on top.

HIWT’s fundamental welding skill programs are creating skilled welders who are easily able to find jobs upon graduation and earn top dollars, depending on the type of industry and the geographic region. The word skilled reminds one of dexterity, craft, talent, trade and experience. Just as only the most skilled gymnasts make an Olympic Team, only the most skilled welders earn top dollars! 

Many of HIWT’s technical programs add competency to that skill. What comes to mind with this word is capability, intelligence, proficiency, knowledge, and cleverness.

The course, Weldability of Ferrous and Nonferrous Metals, helps a welder to become more competent by learning some of the basics of metallurgy, filler metals selection, different welding processes, hard surfacing, thermal cycles, joint design, weld preparation and heat treatment. In joining the different metals, it is extremely helpful if a welder has a fundamental understanding of the characteristics of the metals to be joined.

There are many companies who design parts using a welding process and fail to specify the welding procedure (WPS) to be used for the joint. They leave it up to the welder to figure it out.  Sometimes welding engineers who have had little or no actual welding experience ask the welder how best to join two parts. Isn’t it great if the welder can help the welding engineer to design the part? That is called concurrent engineering -- design the product and the process simultaneously.

If more welders would become part of concurrent engineering teams, I believe there would be less welding problems facing industry today.  A welder who has knowledge to not only join carbon and low alloy steels, but also stainless steels, nickel alloys, tool steels, cast iron, titanium, aluminum, magnesium, etc. is much more versatile and his marketability as a skilled and competent welder is very high. 

Hobart Institute’s one-week Weldability of Ferrous and Nonferrous Metals course is mandatory for all HIWT skill students enrolled in either the Structural Welding or the Combination Structural and Pipe Welding diploma programs. They will learn the tricks of how to weld aluminum and its alloys and how to avoid discoloration of the weld. Our flagpole is directly outside of my office window and I see that black weld every day, reminding me that not all welders are created equal -- some are skilled and some are skilled AND competent!