Author: Deidre Moon, AEDC/PA/released April 5, 2021

Pipe fitter Billy Joe Emberton performs tack welding before fully welding the flange to a section of the pipe in the model shop at Arnold Air Force Base, Tennessee, on March 4, 2021. April is National Welding Month. (Photo of the US Air Force by Jill Pickett)

On March 4, 2021, in the model shop at Arnold Air Force Base, Tennessee, pipe fitter Dustin Williams (right) fixes the flange in place while pipe fitter Billy Joe Emberton (Billy) Joe Emberton) is doing tack welding. April is National Welding Month. (Photo of the US Air Force by Jill Pickett)

On March 4, 2021, in the model workshop at Arnold Air Force Base, Tennessee, the welding completed by the craftsmen of Arnold Air Force Base fixed the flange to the pipe elbow. April is National Welding Month. (Photo of the US Air Force by Jill Pickett)

Pipe fitter Billy Joe Emberton performs tack welding before fully welding the flange to a section of the pipe in the model shop at Arnold Air Force Base, Tennessee, on March 4, 2021. April is National Welding Month. (Photo of the US Air Force by Jill Pickett)

Welding is the process of fusing metals together using high temperatures. At Arnold Air Force Base, the headquarters of the Arnold Engineering Development Complex, the model and machinery workshop has boiler manufacturers, pipe fitters, blacksmiths, sheet metal workers, and mechanics specializing in welding skills.

In recognition of those who possess this ability, the American Welding Association (AWS) celebrates National Welding Month every April to raise awareness of the industry and its available career paths. According to the AWS website, the welding profession plays an indispensable role in ensuring people's safety and improving the global quality of life.

Warner Holt, manager of the AEDC Manufacturing Services Group, agrees with the important work of Arnold's welders to ensure that they not only support testing, but also support operations through tasks such as building new infrastructure or repairing existing infrastructure.

"Whenever our customers in the mission area of ​​the base need to make items for testing, no matter the item is large or small, they usually contact us at the model shop to complete it first, because they know that we can complete it in time and with The cost of competitiveness," Holt said.

The 40 welders in the model workshop are distributed in different process groups, but they all support Arnold's testing and general operations. This number does not include maintenance and operation personnel scattered around the base, who can also perform welding as needed.

The welder on the base can perform various types of welding, including tungsten inert gas (TIG), which is a welding method in which the arc is maintained by a tungsten electrode and protected by an inert gas to prevent air Enter. They also perform metal inert gas welding or MIG, which is a method of filling metal to provide current to maintain the arc. Like TIG, in MIG welding, the arc is shielded by an inert gas (usually argon) and does not come into contact with air.

"Bar welding" is another form of welding performed here. This method is a manual arc welding process that uses consumable electrodes covered with flux to lay the weld.

Welders perform these processes on different types of metals, including aluminum, stainless steel, and carbon steel.

Like many skilled workers, a person will not become a welder overnight. Welders usually complete apprenticeship programs, classroom teaching, and field trips before engaging in full-time welding jobs.

Every welder in the model workshop must first pass the welder certification exam as a condition of employment. As part of the test, the welder needs to perform welding that connects several test pieces together. After the weld is completed, our non-destructive inspection inspectors will inspect the weld to determine whether the weld meets all applicable requirements.

“Welders must remain certified throughout the entire employment period,” said Brad Reid, deputy manager of manufacturing services. "The certification is based on the material to be welded and the welding technique that will be used. Maintaining the certification includes welding while you are here.

"The code on the time card system tracks the content and time of each employee's welding. This data is used to verify whether the welder has performed a specific welding process. We call this information the welder continuity report."

Some of the methods that Model Shop welders support testing at Arnold are through manufacturing pipes, meshes, and other items used in cross-site test cells. The product required depends on the type of test and the facility where the test is conducted. The pipe used for one test may not be used for subsequent tests in the same facility, which means that welders are often required to make necessary changes.

The welder makes as many as possible in the machine shop according to the provided plan. However, if necessary, Model Shop welders do enter the testing facility for final positioning welding and modification of the product. 

Reid said that without the basic work of a welder, basic operations cannot be completed.

"Without our welders, you cannot maintain and build this place," he said. "Therefore, in addition to the National Welding Month, we also want to commend our welders and all our skilled craftsmen and thank them for all their hard work in supporting the mission of AEDC."