I came across this quote “Your role as a leader is to bring out the best in others, even when they know more than you” [1] and it inspired the following.
I’ve had the pleasure of delivering welding classes to many industrial maintenance and motive power mechanic groups. Often leading, classes of 18 to 24 solo; regularly consisting of only men. Where first impressions set the tone of respect.
During introductions, I recognize that I am a welding technologist not a mechanic and could learn so much from the students. Part of my teaching style is to encourage experience-based conversations to help broaden understanding on both sides. I have found that this approach evens the playing field. Providing a level of comfort for the student to share and interact more freely with the teacher.
I recall once being asked by a truck and coach apprentice what journal welding was. A process I had not heard of. As I was standing in front of this class trying to understand what was being asked, I took pause. Only for a moment, then like all technologists should, asked for more information. Talk of sand and no visible arc or fumes was presented. From this, I told my students I believe what was being described was submerged arc welding. But not to quote me, as I would have to do a bit of background research to fully understand and respond properly. So I took what little information was provided and spent some time researching.
Don’t cringe… I took to google to find out what a journal was pertaining to a vehicle. Finding that a journal is the part of an engine’s crankshaft that rotates within a bearing. Where tolerance between the bearing and the journals directly affect the engine’s oil pressure. With that said the clearance between these parts have to be monitored when possible. Where, high clearance allows oil to free flow with a result of little to no oil pressure. To low clearance running the risk of metal to metal wear and high oil pressure.[2] Needless to say an important engine component. The link below has a user friendly description of how a car works. However, this information was not cross referenced so there could be discrepancies.
https://www.howacarworks.com/crankshaft
With this information, looking further into repair where this “journal welding” hunt takes us next.
So, when a crankshaft needs repair there are many options to consider, as I am not a mechanic I will NOT be considering any. However, a company out of the U.S. has an informative website that details this specialized repair process. Where the description of their capabilities involve, material identification, magnetic particle testing (non-destructive testing method) and submerged arc welding (SAW). With welding parameter specification, pre and post weld heat treating as per each specific component may or may not require. [5] Check out this link for further information on said companies’ processing. As well as, highlighting each repair as unique, requiring different materials and procedures to complete.
DO NOT TRY THIS AT HOME!
http://ohiocrank.com/save-the-crank/
With this information I was able to report back to the class that the “journal welding” that was discussed the week before was in fact submerged arc welding (SAW) on crankshaft journals. From there we took a small sideroad covering what SAW is. For information on what SAW is and how it works check out the link below.
https://www.cwbgroup.org/association/how-it-works/what-submerged-arc-welding-saw [4]
Similarly, I have experienced mechanic apprentices discussing parts and components that they are directed to weld on by their superiors. In many cases, extreme caution is recommended. Where a conversation of how ignorance can put people into tough situations. That each person needs to be their own advocate and do their due diligence as they are responsible for the work they complete.
Good old CYA…
Furthermore, without diving too deep into the technical, welding is far more complex than many may think. That it is much more than melting metals together. Some processes don’t entail fusing metals at all, where others do. Did you know that in some cases when dissimilar materials are welded, one can induce cracking within the other upon solidification. Or welding on an engineered designed component can drastically reduce strength if not void the parts ability all together. Manufactured materials and structures are designed to take multiple stressors into consideration. Where some might think a small welded addition shouldn’t be harmful. But in turn can have catastrophic repercussions. Always, follow engineering change producers, it is a bigger deal then you think…
Also, matching mechanical properties of the filler metal to the part being welded is essential to avoid potential questionable situations. Lets walk down the path of one arbitrary material and filler combination, neither that pertain to anything mentioned within this article, just strictly as an example of complexity. Welding quenched and tempered A 533, Grade B, Class 3, running SMAW E1101X-M from there referring to AWS A5.5/A5.5M:2006, specification for Low-Alloy Steel Electrodes for SMAW. [3] As well as, low hydrogen electrodes requiring specific storage temperatures and handling. This said, there are hundreds of materials and electrode combinations. So, if that has you scratching your head, ask an expert or sub out the work to a reputable welding company. Where often certified procedures are held and followed to help ensure safety and quality. Often whispers of how expensive welding is, or that it could be done by the neighbour who has a welder is mentioned. In some cases, acceptance criteria might allow for this. But I say that gritting my teeth, because frequently it is not obvious in choosing the right combination.
There are so many variables to consider when welding. Where due diligence is required. That procedures, quality assurance and control plans are in place to ensure that, due diligence, or the slang term CYA (Cover your ASS) is established. Basically to protect the welder and company if and or when tragedy occurs. If something fails, who’s at fault? The background procedures, certifications and quality systems as well as the skilled personnel and materials is what costs. Honestly, worth every penny, to ensure due diligence and reduce potential failure. Also with the potential for providing opportunity to learn from mistakes, when they occur. Saving a couple bucks isn’t worth someone’s LIFE, not to mention, repair costs can triple the original bottom line.
The experience I described above was advantageous to myself and the students. Where I was confident in my ability to educate through knowledge of welding technology. Yet, I also respect myself and the students to admit I don’t have all the answers, but I am willing to find them.
We all have the potential of being an expert and leader. The best know, that there is far more available to learn, then one lifetime could ever alot. Where optimizing knowledge through sharing and influencing growth through seeking understanding is what forms great leaders and experts. You know the saying, two minds are better than one.
To bring things back, at first I felt that I could relate to the initial quote. But after reflecting I believe being a great leader is about maximizing the potential of all members of the team. Not categorizing one’s knowledge to another.
JEMI
Edited By WDI
Sources:
[1] D. W. Wallace, The inspirational leader Leadership first . .
[2] “How the crankshaft works – All the details,” How a Car Works. [Online]. Available:https://www.howacarworks.com/crankshaft. [Accessed: 28-Mar-2021].
[3] Welding Handbook, Volume 4 – Materials and Applications, Part 1 (9th Edition), 9th ed., vol. 4, American Welding Society (AWS), 2011, p. 64.
[4] M. Pates, “What is Submerged Arc Welding (SAW)?,” What is Submerged Arc Welding (SAW)? | CWB Group. [Online]. Available: https://www.cwbgroup.org/association/how-it-works/what-submerged-arc-welding-saw. [Accessed: 28-Mar-2021].
[5] “Save the Crank,” Ohio Crankshaft, 27-Jan-2020. [Online]. Available: http://ohiocrank.com/save-the-crank/. [Accessed: 28-Mar-2021].