African Fusion March 2015

Contents

March 2015 FEATURES 4 SA’s Young Welder, 2015

Published four times a year and mailed out together with Mechanical Technology by:

Jaco vanDeventer, a product of Steinmüller’s appren- ticeship scheme, has won this year’s Young Welder of the Year competition, which was held at the SAIW during February. 5 Changing of the guard Following the resignation of Jim Guild, this article looks at his accomplishments since his tenure began back in 2000. 6 Introduction to thermal spray coatings During January, the SAIW and the Thermal Spray As- sociation of Southern Africa (TSASA) hosted thermal spray specialist, Heidi Lovelock to present a one-day seminar at Emperor’s Palace. African Fusion sum- marises the opening session. 18 Small bore pipe socket weld inspection using phased-array UT This paper from the 67 th IIW Conference is about the use of phased array ultrasonic testing (UT) for small- bore pipe socket welds on nuclear power plants. 24 Microstructural study of trial weld joints for steam turbine rotors Also from last year’s IIWConference, this paper details procedure development for welding turbine rotors for steam power plant using creep resistant rotor steels and the hot-wire GTAW welding process. 28 Wind Tower fabrication: the DCD way African Fusion visits DCD Wind Towers in the Coega industrial development zone (IDZ) and talks to pro- duction manager, Leonard Jauka. 32 Robot welding, catalytic converters and PE African Fusion visits Yaskawa PE and takes a tour of a local state-of-the art catalytic converter manufactur- ing facility. 35 Welding of super duplex stainless steels This article outlines voestalpine Böhler Welding’s super-duplex stainless steel (SDSS) solutions and consumables for the oil and gas industry. 36 Weco’s HSL solution: the smarter choice African Fusion attends the launch of Smarter Weld- ing Africa’s Weco brand and talks to Smarter’s CEO, Fernando Amaral and Weco director Giorgio Toniolo. REGULARS 3 Jim’s comment 12 SAIW News 16 Front cover story: Total solutions for tank fabrication 36 Welding and cutting forum 40 Component refurbishment using the PTA process

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Editor: Peter Middleton E-mail: mechanical@crown.co.za Advertising: Norman Welthagen E-mail: normanw@crown.co.za Publisher: Karen Grant Director: Jenny Warwick Cover design: Air Liquide Production & layout: Gail Smith Circulation: Karen Pearson Subscriptions: Wendy Charles Printed by: Tandym Print

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For thewelding of large storage tanks, a partnership between local automation specialist Mazolutions, Lincoln Electric and Chinese-based All Time is dramatically improving the quality and productivity of storage tank construction for the oil and gas sector. African Fusion talks toAndrewMasuret, MD of Mazolutions, about the technology.

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March 2015

AFRICAN FUSION