highligths - GSI SLV

Business Report 2010

GSI–Company Data 2010
Employees of GSI 2007 to 2010 (average number of employees)
391
428
2007 2008 2009 2010
Participants in Training and Training Units within GSI 2007 to 2010
2.132.786
29.407
2.312.431
30.905
3.094.329
2.502.235
33.032
2007 2008 2009 2010
471
37.484
734 667 1.004
504
1.015
Training Units
Participants in Training
Participants Welding Engineer

General Development of the Business 3
Education and Training 6
Industrial Services 8
GSI within the DVS 13
Organization of GSI 15
Organization of BZ Rhein-Ruhr 16
Highlights of 2010 17
Projects – Education and Training 19
Projects – Materials Engineering 21
Projects – Quality Assurance 23
Projects – Research and Development 26
Projects – Foreign Countries 29
GSI SLV 2010
Contents
Introduction
General Part
Highlights
Selected Projects
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GSI SLV 2010
Introduction
In the business year of 2010, on a national scale, the general economic situation was replaced
by a positive economic development. The public news headlines on the economic
situation changed from „safeguarding of jobs“ to „shortage of skilled labour“. Leading up
to this there was actually a change in the market situation. In 2010 the occupancy rate
was based on attractive offers that included education. Today there is much demand for
companies to be prepared to offer funding for education.
In the last year there has been a recovery in the field of technology and materials engineering.
The positive business trend has opened up the need for expansion of existing
companies and the development of new business fields.
The development of foreign subsidiaries has been particularly pleasing. They extended the
offers of education and training to GSI and opened new markets for this core competence.
The projects started in 2010. The qualification of our staff and the further development of
the technical infrastructure were important measures considered for the upcoming demand.
In doing so the range of education, consultation, testing and research remained an
important basis for our success.
Prof. Dr.- Ing. Steffen Keitel,
Managing Director of GSI mbH

Overall Estimate
General Development of the Business
During the last business year welding in particular, was characterized by a good economic
trend at this time there was also a continuous reduction of public funding. Consequently
there was a demand on the scope of performances of the company. Therefore it was no
surprise that during the last business year the focus on education returned.
There has been a development analogous to the entire economy. For the business year
2010 the company recorded approx. 2.5 million teaching units and about approx. 33,000
participants.
Profits and Financial Situation
The course of business of the company was estimated satisfactory for the business year
of 2010. The sales revenue of the company has adapted correspondingly with the implementation
of education thus impacting on the financial situation. In areas of welding and
testing the turnover compared with the preceding year could be increased again in some
of the branches. Particularly exciting is the development of new education offer.
The annual result can be seen as a firm basis for further investment. The reason for the
difference in relation to the extraordinary result of last year is based on the sub proportionate
development of the costs in 2009 and complex training.
Investments
In this business year a total of € 6.6 million (2009: € 5.1 million) was invested for creating
and improving training facilities in Germany and abroad as well as assisting the participants
involved.
Further projects of investment with a volume of € 7.5 million will be realized during the
next few years. Due to the objective of a non-profit company the money is used for renovating
the existing facilities and for creating new training centres as well as for promoting
education and training in welding and allied processes such as joining, cutting and coating
of metallic and non-metallic materials. This has also included new training possibilities in
the fields of materials engineering and corrosion protection. The most important object
of investment in 2010 was the training centre Wilhelmshaven which required € 2.5 million.
The new building close to the recently built deepwater port, Jade-Weser Port offers
welding booths and has great potential for theoretic training such as; training courses for
welding specialists, NDT training, education in plastic engineering and different seminars.
GSI SLV 2010
General Part
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GSI SLV 2010
General Part
The opening ceremony has shown interest in the local economy with the newly offered
services, one of which is the certification of welding companies. Another field using the
possibilities and competences of the whole GSI is the supervision of the power plants
erected in the proximity. There is a team of four employees covering the scope of performance
supported by the SLV Hannover who can use the whole range of services of GSI in
case of inquiries in special fields.
On the left: „Key delivery“ by the architect Manfred Gerdes to Professor Steffen Keitel;
On the right: The new training centre in the Flutstraße
In the field of research and development there was further investment into the future of
SLV Mecklenburg-Vorpommern GmbH in the year 2010 - with two new laser systems. Since
December 2010 a 16 kW disk laser from the company Trumpf has been available for GSI
in Rostock that is mainly used with or in the field of processing maritime and other large
structures.
On the left: A 16 kW disc laser used for tests on welding of aluminium alloys at larger thickness;
On the right: REM-exposure of a UKP-laser cut CoCr stents
Another investment was a highly modern ultra short pulse laser (UKP) TruMicro 5X50 from
the company Trumpf that was intended to develop markets in the field of micro material
processing.

The laser is used in a 4 axis micro processing centre, in the company GFH, forming the
centrepiece of the newly equipped application laboratory for UKP- laser micro processing
where research and development activities are planned to be conducted on an international
level. The objective of this is to address strongly growing areas such as medical and
biosystem engineering and precision mechanics as well as micro electrical engineering
and microelectronics or photovoltaic. This joint venture research project was started in
September 2010 and will be running until the end of 2012. It is dealing with the fields of
application of such lasers in the manufacture of cardiovascular implants (stents).
In 2008/2009 the training facilities at SLV Halle GmbH were completely renovated and
included a large auditorium. The new, well-lit auditorium with about 240 seats, was complete
with the most modern audio and video technology, an interpreting unit flooded in
light, as well as an electronically controlled air condition and shadowing unit. The complex
was supplemented by another auditorium with a capacity of around 40 seats, a newly
renovated upper foyer, new sanitary facilities and a modern external lift.
The boarding centre of the SLV Halle was also subjected to a complete renovation during
the summer months of 2010. The new motto was „studying, relaxing and sleeping in one
unit.” New rooms with one and two beds including sanitary facilities, a wellness area, a
seating area, a billiard table, as well as a kitchen according to the latest-state of the art.
On the left: The new auditorium unit; on the right: Comfortable rooms are available
Investment in laser technology and the construction measures of the SLV Halle are examples
of the funding of the institutes as non-profit research institutes.
Grateful acknowledgement of the funding is given to the Federal States of Bavaria, Mecklenburg-Vorpommern
and Saxony-Anhalt as well as to the BMWi.
GSI SLV 2010
General Part
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GSI SLV 2010
General Part
Personnel
The number of staff has increased by approx. 5 % compared with the previous year. It can
be assumed, however, that the number from the year 2009 will be reached again in the
future.
At the end of the business year Dr.-Ing. Heidi Cramer was nominated deputy head of
SLV München. She will execute this job in addition to her activities as head of the department
of research and development.
The separation of the training facilities BBZ Rhein-Ruhr from SLV Duisburg led to individual
responsibilities being created for each facility. (See organization on page 16).
As from 01.01.2011 Dipl.-Ing. Frank Moll has been head of the newly created Profit Center
e-learning. He is responsible for the coordination of the products in connection with
e-learning and the development of this within GSI.
Education and Training
In the year 2010 an appreciable number of international, conferences were held in English
by GSI for the first time. These were organized and advertised on their own individual
internet platforms. The following conferences were held:
• Strahltechnik-Konferenz (beam technology) in April
• JoinTrans in May and
• The conference Welding Trainer in September.
Special honour was given to Prof Dilthey president of the International Institute of Welding
llW for the opening of the Strahltechnikkonferenz. He played an important role in
the whole separation processes of the facilities. Dilthey as an enthusiastic expert in the
application of laser and electron beams, opened the conference referring to the potential
of innovation of lasers, and also played an important role with the entire joining processes.
There was a distinctive international interest. A special guest at the conference was the
president of the American Welding Society AWS, Mr. Bruskotter.
http://www.beamtec-conf.com/
On the left: John Bruskotter, President of the American Welding Society, during his short welcoming speech at the
beam tec conference; On the right: Participants of the beam tec conference in the newly renovated auditorium

The conference Welding Trainer – The Future of Education, established another point of
contact with the American market. This conference highlighted the market leadership of
GSI with its core business being the practical education of welders. To this day, GSI is the
symbol of the special development of semi-virtual equipment very close to practical welding
and also for the competence of integrating such units with the practical education of
welders. The interest of the market is high, thus the knowledge gained from the current
research projects of Bildungszentren Rhein-Ruhr and SLV Halle expected for the DVS-Congress
2011 in Hamburg and for the 2nd conference Welding Trainer 2012, will be directly
integrated in the training programmes. http://www.weldingsimulation.eu/
On the left: Dipl.-Ing Christian Ahrens, GSI, during his presentation about new paths of education in welding and testing;
On the right: A participant of the conference during „Welding on the simulator“
On an international level, GSI provides quality assurance and technological innovation
during the welding and joining on rail vehicles. Consequently, the European conference
JoinTrans was held in addition to the German conference „Fügen und Konstruieren im
Schienenfahrzeugbau“–Joining and Designing in Rail Vehicle Construction – (May 2011).
This was the platform for the European Committee of Welding of Railway Vehicles ECWRV
to present common quality standards when applying the EN 15085. By holding the two
conferences, special emphasis on the German rail vehicle industry was underlined and the
clear way towards a common European understanding was demonstrated.
http://www.jointrans.eu/
The participants of the 1st European Conference JOIN-TRANS 2010
GSI SLV 2010
General Part
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GSI SLV 2010
General Part
Globalism and the use of the internet was in the forefront as well as further development
within the company for example the creation of the Profit Center e-learning. In the year
2011 GSI will be able to look back on a 10-year period of activities in that field. Every year
GSI gives assistance to more than 350 participants making available the training documents
to international partners on the basis of license agreements.
The classroom phases required within the scope of Blended Learning are 50 % self-study
and 50 % classroom learning. They are distributed among several SLVs in Germany in a
way that several offers can be made to the participants. This however is only available to
individuals at the beginning of the course! http://www.gsi-elearning.de/
Accompanying teaching material on e-learning on CD
Industrial Services
Research and Development
Positive economic development stimulated the interest of the economy in the R & D activities
of GSI branches at the end of the business year 2010. The basis for the economic
growth being the result of competitive projects funded by the government or by single
Federal States. In this case the specialization of the single SLVs had a positive effect; familiarity
with the specialities of single industries paid off. The loss of public funding by
economic stimulus programmes is being compensated by a larger preparedness of companies
for financing.
In an attempt to meet the change of demands the result is often new products or processes
which require research and development activities extending far into the manufacture
of the product. In this case GSI has the suitable profile and the longstanding experience
to deal with these changes. The close correlation of the very well equipped technological
areas along with the accredited material testing laboratories permits attractive R&D offers
that can actually be considered a unique selling proposition of GSI.

Quality Assurance
Construction supervising – Welding and corrosion protection
The demands on construction supervision are becoming increasingly more complex. New
requirements of non-destructive testing and corrosive protection are added to the classic
task of supervising the construction whose focus is on the execution of the welding
complying with the drawing and that the new requirements of non-destructive testing
and corrosion protection are being applied. Apparently dimensional stabilities such as
complying with the seam thickness should be verified by objective testers at least on a
random basis. Unfortunately the year 2010 has shown examples of considerable damage
caused by misunderstood judgment. In single cases the experts had to reject complete
parts. It is important to note that both qualification and experience are required for a
construction supervisor to fulfil his tasks. Clear examples over the years, from all fields of
practice, play a significant role in improving the outcome of the product.
One example of how quality can be permanently improved is a project on the standardized
recognition of progress in construction. A software called Mokobau has been developed
that gives the supervising engineer support in this area. The first pilot projects
would be implemented together with the customers.
Certification of companies engaged in joining
Certified companies engaged in metal construction represents the largest group of customers
of GSI. Due to this significance the standard EN 1090 was established. A central
standard on the quality assurance of welded construction parts set the benchmark of the
future. The welding certificate, the declaration of conformity and the monitoring of the
factory production control are the central topics prepared by the experts of GSI, regarding
the metal constructing companies. In the year 2011 the final step from theory to practical
education will be made. It is during this phase that the support of the manufacturing companies
is of utmost importance, requiring an intensive commitment by our staff.
Material Testing
Procedure specification tests and welder‘s examinations are the basic elements of the
plant utilization of all of the accredited testing laboratories at GSI. These are the prerequisites
for determining the scopes of application welding plants are involved in. According
to the requirements placed by the customers in the form of new products, they have to
be permanently monitored and further developed. Therefore, material testing is directly
connected to technological development. In addition, it has been proven to concentrate
on special tasks in the single testing laboratories.
GSI SLV 2010
General Part
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GSI SLV 2010
General Part
Thus the demand of testing dynamically loaded parts has increased. At the SLV in Halle
the measurement of the state of individual stresses leads to the complex evaluation of
structures. If necessary, the results may be compared with simulation calculations. It is
performed in coordination with the specialists at the location in Munich and may be supplemented
by statements on fracture mechanics that present one focus of development
of the SLV Duisburg. Due to this division and specialization of labour the customer gets is
a more valuable offer.
Central Offices
The central offices of GSI create an overall view of special trades and the different circles
of our customers. This is also true for the newly created coordination body. The staff of
the SLV Nord, which is surrounded by a lot of craft enterprises, is well integrated into the
Chamber of Crafts Hamburg and has a special understanding for the craftsmen. As a coordination
body they organise the activities of GSI with the introduction and implementation
of the regulations of the EN 1090.
Activities abroad
2010 was a very successful year for all of the foreign companies of GSI. There were profits
overall at the end of the year. In most cases the turnover had considerably increased.
The youngest foreign company of GSI in Kunshan (China) was established in May 2010. It
is thought that the education of welding instructors and the consultation provided by
German and other European companies have contributed to the turnover and success.
The excellent cooperation between the WTI Harbin and the SLV Duisburg has further
strengthened the basis of the successful activities on the Chinese market.
GSI SLV-TR in Ankara (Turkey) as a young branch of GSI, too, could also present its scope of
performance successfully on the IIW Conference (Annual Assembly) in Istanbul. By taking
over the distance learning course for the education of international welding engineers
and the rapid translation into the Turkish language the circle of customers so far could be
considerably extended. Moreover GSI SLV-TR together with the SLV Munich and the SLV
Duisburg organised a successful IWE training course in English for 11 African engineers.
In Prague (Czech Republic) modern lecture rooms could be rented for the theoretical education
but we are still looking for a new location. In Gliwice (Poland) practical education
has started and can now also be offered to local customers there. Both of the companies
distinguish themselves by the fact that their staff has been engaged in large-scale projects
of GSI.

In Cairo (Egypt) the international financial crisis has had a large impact. However this
could be compensated by actively participating in a large-scale state project (construction
of a training centre for welding engineering in Suez with underwater welding, nondestructive
testing and conventional welding). Furthermore, the start of a training course
for international welding engineers has been planned to start in 2011 in cooperation with
the German university in Cairo (GUC).
Planning of another foreign company of GSI has started. After 10 years of preliminary work
by the SLV Mecklenburg-Vorpommern and the foreign coordinator of GSI, it has been
planned to found a new association in the year 2011 focussing on the Russian market.
It has also been planned to found a new association in Tallinn and to extend the scope
of services of GSI to Lithuania, Latvia, Estonia, Russia, Belarus, the Ukraine and in other
countries. Important cooperation such as the one with the Russian organization NAKS was
further intensified in 2010.
Co-operating Institutes
In Germany GSI has a participation of 24.9 % at the SLV Mecklenburg-Vorpommern.
The association is in a good position having a positive result last year. The participation
of 52 % at the MPA-Kalibrierdienst GmbH Berlin was sold to the co-shareholders effective
July 1st 2010 while still having a co-operation. Due to the closed cooperation on the field
of the certification, GSI ensures the same scope of quality also in the cooperating institutes
SLV Halle, SLV Mannheim, SLV Mecklenburg-Vorpommern and SLV Nord. The same is
valid for the accredited material testing laboratories. This becomes apparent by quality of
manuals synchronized with each other. Independent from the legal entity of the company
due to history there is a wide, coordinated scope of performances with matching quality
manuals.
GSI SLV 2010
General Part
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GSI SLV 2010
General Part
Continuous Improvement Processes of GSI
Here are 3 examples of projects that have generated effects that improve the quality at
GSI:
Studying and teaching documents
Complying with their guidelines the GSI has gone on the offensive towards quality. Its content
is the improvement of studying and teaching documents defining certain objectives
for the next five years. Thus the project initiated in the faculties of education and training
and agreed by the heads of the SLV and the faculties is unique. The result is not only the
adaptation of the documents to the latest state of the art but also the concentration and
conclusiveness. The use of non-profit own funds corresponds with the objective of the
company and is continuously performed by the faculty education and training.
Quality manual QMH of GSI
Creation of a QM system is absolutely necessary for accreditations and acknowledgements
of GSI. The development and recording among the duties of the QMB – the quality
being the responsibility of GSI. In the year 2010, two of the employees from GSI received
support from the DIBT-, EBA-, ZLS- or AZWV-approvements. The QMB is the basis for successful
work.
Information on advertising – Working group printed products
Together with advertising specialists a standard was developed that is valid for all information
brochures and printed products of GSI. The Internet was used for the Corporate
Design Manual. In order to ensure the uniform application and implementation of the
standards, GSI worked together with the staff from Duisburg Halle and Munich to comprise
the written works. This working group was equipped with special graphical workstations
and relevant software that was linked with the print shops. Together with an external
design support the printed templates for different applications such as informative
flyers were worked on. With regard to the content the cooperating institutes formulate
their own demands. Thus, high-quality media with integral information for the customer
is generated cost-efficiently. This is also valid for GSI news.

Young Professionals in Research and Welding „Jugend forscht und schweißt“
An attractive example of the integration of GSI into initiatives of the DVS is the event
JUGEND FORSCHT & SCHWEISST. In cooperation with the federal associations from Saxony,
Saxony-Anhalt and Thuringia as well as the DVS project Young Professionals, a platform
has been formed where young researchers are given the opportunity to present their results
from research to the public. The contents of the presentations and posters were comprised
of engineering/design materials; the simulation to beam processes and extended
to the conventional welding processes.
The following event took place at the 80th year anniversary celebrations of the SLV Halle
„80 Jahre SLV Halle GmbH“. After the welcome words held by representatives of the city
of Halle (Saale) and the Amt für Wirtschaftsförderung the jurors made their judgment and
the best three presentations and posters were awarded.
On the left: Prof. Dr.-Ing. Steffen Keitel during the award of the winner of the presentation competition, B. Eng. Jonny Kaars,
Dipl.-Ing. Karsten Rüthrich, Dipl.-Ing. Florian Woelke (from left to right.); On the right: The winners of the poster competition:
Prof. Dr.-Ing. Eckart, representing Dipl.-Ing. (FH) Tilo Witt, B. Sc. Georg Schwab, Dipl.-Ing. (FH) Holger Schumann (from the
left to the right)
DVS-Education Voucher
GSI within the DVS
For the presentation of the DVS and GSI on the fair in September 2009 education vouchers
were submitted for the first time to the participants of the German competition „Jugend
schweißt“. From this a pilot project was formed that has had the following assignments:
Programming of a data base that would be able to be linked to the internet, technical
implementation of the education pass, data security and demands on data protection,
interfaces to the system of the DVS main office.
GSI SLV 2010
General Part
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GSI SLV 2010
General Part
According to schedule the program was completed in December 2010 and has a data
collection of approx. 450 participants. DVS education vouchers can be spent in the 4 GSI
branches documenting the demands and working processes for the issuing of these vouchers.
The participants of the pilot project, with the help of their education voucher, had
the possibility to view data on a database of GSI while getting a current documentation
of their path of qualification by a notified body. Within the course of the year 2011 further
branches and cooperating institutes will be permitted to issue the DVS education vouchers
to offer a new service to their participants.
DVS-Working Group in the Baltic
By nominating a coordinator, who is fluent in Russian, for the foreign countries, emphasis
was placed on the importance of the East European market. From this numerous contacts
have arisen and have been maintained. Besides the conclusion of commercial contracts,
several SLVs have participated in a network of welding competence. Therefore a new
DVS working group Baltic was created and founded on 29.11.2009. Today this network
coordinated by the DVS main office, like every district association (Bezirksverband), has
56 members and is contributing to a lot of the work in the DVS.

MARkETING
Head
Prof. Dr. S. Keitel
BRANCHES
CO-OPERATING
INSTITUTES
* Co-operation of GSI and SLV Halle
** Co-operation of SLV Halle
Issue 04/2011
EDP
Head
J. Wirth
BOARD OF THE HEADS OF BRANCHES
AND CO-OPERATING INSTITUTES
Berlin-Brandenburg Bielefeld
Prof. Dr. D. Paulinus H. Gehring
Bildungszentren Rhein-Ruhr Duisburg
H. Hildebrand-Peters Prof. Dr. S. Keitel
Fellbach Hannover
H. Roth Dr. R. Mittelstädt
München Saarbrücken
N. N. Dr. H. Nies
Mecklenburg-Vorpommern*
J. Hoffmann
Halle Mannheim
Dr. M. Ströfer Dr. H. Nies
TC Kleben** Nord
J. Band S. Noack
dvS
Deutscher Verband für Schweißen und verwandte Verfahren e. V. (German Welding Society)
Shareholder
GSI
Gesellschaft für Schweißtechnik International mbH
Managing Director Prof. Dr. S. Keitel ; CFP J. Wirth
OCCUPATIONAL SAFETY
OHS Officer
decentralized
BOARD OF THE HEADS OF
THE SECTIONAL GROUPS
Education and Training
Prof. Dr. D. Paulinus
CFP
J. Wirth
Research and Development
Dr. M. Ströfer
Quality Assurance
Dr. H. Nies
Materials Engineering
Dr. R. Mittelstädt
Foreign Business
C. Ahrens
QUALITY MANAGEMENT
QM-Representative
B. Tielkes
Organization of GSI
FOREIGN BUSINESS
SVV Praha, CZ
P. Flégl
GSI SLV Polska, PL
P. Gładysz
GEWC, EG
S. Hafez
GSI SLV-TR, TR
Ö. Akçam
DATA PROTECTION
DP-Representative
external
GSI SLV Kunshan, CN
C. Ahrens
GSI SLV Baltikum, EE
Dr. H.-G. Groß
GSI SLV 2010
General Part
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GSI SLV 2010
General Part
DIVISIONS DEPARTMENTS EXECUTIVE SUPPORT TEAMS
Organization of BZ Rhein-Ruhr
Issue 04/2011
QUALITY-MANAGER
Klein
TECHNICAL AND
QUALITY MANAGEMENT
Klein
· PROPERTIES
· TECHNICAL PROJECTS
· TECHNICAL NEW
PURCHASE
· HES
· MAINTENANCE
· CERTIFICATION
· DVS PROJECTS/
TASKS
ELECTRONIC DATA
PROCESSING
Eickelkamp
LOCATIONS
· BZ Duisburg-Mitte
· BZ Oberhausen
· BZ Wesel
· BZ Kamen-Heeren-Werve
· BZ Duisburg-Meiderich
· BZ Essen
· BZ Gelsenkirchen
· BZ Wuppertal
· DVS-BZ Kleve
· BK Bottrop
· BK Moers
· KHS Gelsenkirchen
· Duisburg-Duissernstr.
GSI
Gesellschaft für Schweißtechnik International mbH
Managing Director Prof. Dr. S. Keitel
EDUCATIONAL MANAGEMENT
PRODUCT DEV/DISTR
Billen
Bz RR
Bildungszentren Rhein-Ruhr
Head Hildebrand-Peters
· PROJECT CONTROLLING
· PROCESS CONTROL
· PERSONNEL PLANNING
· MANPOWER PLANNING
· PERSONNEL MANAGEMENT
DEVELOPMENT OFFICE
PUBLIC TENDERS
Sydekum
· TRANSFER AND
QUALIFICATION
COMPANIES
· TRANSFER
AGENCIES AND
CONSULTING ON
OUTPLACEMENT
ACQUISITION OF POSTS
PLACEMENT SERVICE
Pilawa
PERSONNEL TRANSFER
Schrieber
LOCATIONS
· Lower Saxony
· North Rhine
Westphalia
ADVERTISING
PUBLIC RELATION
Coda
CFP/MARkETING
VICE HEAD OF BRANCH
Wilhelm
· STAFF MANAGEMENT
· PERSONNEL DEVELOPMENT
· ORGANISATIONAL DEVELOPMENT
· CONTROLLING
· MARKETING

H I G H L I G T H S
HIGHLIGTHS
January Research scholarship granted to Mr. Fuentes, an engineer from Chile
Integration of the Schweißtechnische Kursstätte Trier and Kleve to GSI
March Discussions between the DVS, GSI with the EBA (German Railway Agency)
with its President, Mr. Hörsterr
April Research scholarships granted in Duisburg in 2010 to Dipl.-Wirt.-Ing. Regina Thiele.
Ms. Thiele will do her thesis on the main topics „Battery engineering for electro
mobility“ and „Development and manufacturing of a thermoelectrical generator“.
The representatives of the research institutions (from the left to the right) Prof. Dr.-Ing. Uwe Reisgen,
Dipl.-Wirt.-Ing. Regina Thiele, Prof. Dr.-Ing. Steffen Keitel, Prof. Dr.-Ing. Reinhard Winkler and Dipl.-Ing.
Karlheinz Hesse met about the operation agreement.
May Launch of the new headquarters of the company EWM in Kunshan, China,
and opening of GSI - association in China
June Visiting of the heads of the SLV and branches of GSI at ESAB of Sweden
Co-operation discussions held with the president of the Russian certification
company NAKS, Prof. Aljoshin
July Course for welding supervisors in Latvia with participants from Lithuania, Latvia,
Belarus and exchange of experience for welding instructors and welding
Highlights of 2010
practitioners with participants from Germany, Lithuania, Latvia, Estland and Russia
GSI SLV 2010
Highlights
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GSI SLV 2010
Highlights
H I G H L I G T H S
September Meeting of the foreign associations of GSI after the international conference
Welding Trainer in Duisburg.
Award of the Prize on Occupational Safety 2010 of the Federal State Saxony-Anhalt
by the Social Minister Norbert Bischoff for the computer based GSI-welding trainer
In place of a development team Christian Schwalenberg is awarded the ABICOR-
Innovation prize of 2010 on the topic „Application of a GMA laser beam hybrid
orbital process for orbital welding of pipelines“
On the left: Prof. Dr. Steffen Keitel accepts the prize on occupational safety by Social Minister Norbert Bischoff
in Reception; On the right: Award of the ABICOR-Innovation prize 2010: DVS-Präsident Prof. Heinrich
Flegel, the three award winners Christian Schwalenberg, Dr. Jörg Zschetzsche and Sascha Rose as well as
the manager of the Alexander Binzel Schweißtechnik GmbH & Co. KG, Dr. Emil Schubert (from the left to
the right)
November Visit of a Chinese delegation from Harbin under the direction of Prof. Xie at the
SLV Berlin-Brandenburg
December Turning the first sod on behalf of the SLW Gelsenkirchen
Frank Baranowski, Mayor of Gelsenkirchen, Prof. Dr. Steffen Keitel, Manager of GSI mbH
and Ingo Plaßmeier, manager of the Plassmeier Bau GmbH (from the left to the right)

SLV Fellbach – Education for Welding Designers in line with the Trend
The business location Baden-Württemberg offers a large number of the most unusual industrial
branches for welding designers with the focus on automotive but also mechanical
engineering with a very interesting range of offers. Here there is a large demand for welding
designers with a special knowledge of the characteristic features of welding. There
are versatile requirements of the welding designer with his emphasis being placed on
several items such as designing in compliance with loads, testing and corrosion resistance.
This means that the designer must have a basic knowledge in both welding and testing.
In 2010 (with a total number of 30 participants) the SLV Fellbach conducted tailor-made
training courses as well as a complete welding designer course according to DVS guideline
1181 as in house seminars with different companies. The basic course is the same for
all designers; the focus lies on the welding processes and the drawings according to the
standard. After that there are the advance training courses with duration of 40 lessons
each. These are related to products with the focus on tank construction and plant engineering,
with permanently or dynamically loaded parts, mechanical engineering, vehicle
construction and maritime engineering. The basic course G1 for welding designers can be
conducted either following the blended learning or the distance-learning concept.
In the distance-learning course the participants prepare themselves using the CBT documents.
There are two classroom days with consolidation of the knowledge and practical
presentations at the SLV.
Testing of welded joints on site
GSI SLV 2010
Selected Projects
Education and Training
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GSI SLV 2010
Selected Projects
DVS®-Welding Practitioner - much in Demand in Trade and Industry
DVS®-welding practitioners with their excellent knowledge and their profound theoretical
knowledge are not only in demand in educational welding institutes inside and outside
the DVS but also in trade and industry. Thus, the qualification as welding practitioner for
many of them is a stepping-stone for their further career as headman, welding supervisor
or foreman. This is also reflected by the current number of participants and in the composition
of the training courses at the SLV Duisburg. From the year 2007 with a number
of 31 welding practitioners being educated until the year 2010 with a number of 80 the
number of participants who complete their education has continuously risen. As a whole,
202 welding practitioners were educated in the last four years with the main number on
the field of TIG (77 participants) and GMA (66 participants) for steel materials and a smaller
number in manual arc welding (23 participants) and GMA (17 participants) as well as TIG
(15 participants) for non-ferrous metals. Education in gas welding was conducted by only
four participants. Surveys among the participants have shown that half of the participants
(55 %) were from trade and industry and returned to it after their education and were employed
in production. Out of the 202 participants only 5 percent made use of the followup
further education as a welding specialist. Also for the first time two women entered the
male domain specialty of welding and obtained very good results.
As can be seen from the figures, the welding practitioner is an important cornerstone in
welding engineering. To meet the high demands placed on education in the future, comprehensive
investments into the building and the equipment of the SLV Duisburg have
been planned.
On the left: Group photograph of the prospective welding practitioners from the training course in the autumn;
on the right: The first two women in the education as welding practitioners.

Virtual Technologies in the Education as a Tester –
Virtual Reality-based Representation of the Progression of Ultrasound
GSI SLV 2010
Selected Projects
Materials Engineering
It can be difficult at first for prospective material testers to understand the propagation
of an ultrasound in a work piece. In order to get a better overview on the theoretical progress
of sound, virtual reality (VR) is used to connect theory to practice. The objective of
the partial project was to enhance the instruction of the ultrasonic testers with interactive,
virtual training scenarios by means of didactical methods. VR-based teaching mediums
can relieve the instructors and intensify learning. With this the propagation of ultrasound
can be visualized in the workpiece, different failure patterns can be simulated and interactive
examinations can be performed.
The software-technical solution enables a three-dimensional representation of the propagation
of sound both in the parent metal and in the weld seam. The angle of refraction,
the test frequency and the transducer size can be varied. Flaws such as cracks, lack of
fusion and inclusions can be changed depending on their size, number, orientation and
position. The resulting progressions of ultrasound and the conditions of reflection can be
illustrated and be used interactively.
The VR based module is used in the education of a European material tester according to
DIN EN 473 as well as to a material tester with a certificate of the Chamber of Trade and
Commerce. Moreover, it is used for the training of welding supervisors and for regularly
conducted seminars on non-destructive testing with students of different universities and
professional schools.
In the future the VR representation will not only serve for making the instruction more
efficient but by simulating the progression of sound in complex geometries, testing of the
actual parts shall be better evaluated.
Detailed view and illustration of the progress of ultrasound on a lack of sidewall fusion with simultaneous A-representation.
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GSI SLV 2010
Selected Projects
Non-Destructive Testing of hot Galvanized Steel Structures
Magnetic particle testing is a practical and efficient method for testing hot galvanized
steel structures. High field strength at long magnetizing periods considerably improves
the detection of cracks under a zinc layer. For the execution equipment with special attachment
poles for commercially available. Manual yoke methods were used for the execution
equipment with special attachment poles that were commercially available. The
manufacturer of the testing devices, Karl Deutsch Prüf- und Messgerätebau GmbH & Co.
KG also manufactured these attachment poles after a series of research. Illustrations show
the attachment poles for testing of butt and fillet welds.
Manual yoke magnets with modified attachment poles for testing of hot galvanized steel structures
Non-Destructive Testing of Orthotropic Deck Plates
The high dynamic loads of bridge structures due to traffic create a special importance
on the fatigue strength of these structures. Old structures were partly designed for max.
2 million stress cycles. The traffic volume of today, in many cases, exceeds the number of
2 million lorries per year. Therefore fatigue cracks in both, stiffeners and deck plates, may
be the result (illustration on the left).
Formation of a crack
Hollow profile
Deck plate Deck plate
On the left: Formation of cracks due to fatigue at a trapezoidal stiffener; on the right: Testing by a creeping wave probe
Research and testing using common ultrasonic testing have shown that there is no testing
procedure available on the market to non-destructively test cracks of this type on bridge
structures.

Often ultrasonic testing using common angle probes is not feasible since shape echoes
from the joint root of the stiffeners cannot be distinguished from the formation of a crack.
At the moment non-destructive testing is limited to a pure surface testing by magnetic
particle or visual testing. Detecting of the above mentioned cracks are not possible using
these test methods. Therefore, cracks are detected in an advanced state. The longer the
length of the crack the lower the load bearing capacity of the structure. There is a considerable
need to repair the progressing propagation of cracks.
In cooperation with GE Inspection Technologies an ultrasound probe could be developed
for the present assignment. This creeping wave probe works with an angle of refraction of
90° (illustration on the right). The range of the creeping wave has increased tremendously
by optimizing the probe, thus detecting a crack formation in the root area of stiffeners has
become possible.
The advantage of this development is the easy realization compared with other, more
complex approaches such as the phase array technology. The testing method using creeping
waves leads to a clear, defined statement thus enabling reasonable procedures when
planning further working steps.
GSI SLV 2010
Selected Projects
Quality Assurance
New large Airport Berlin-Brandenburg International BBI – Supervision of the
Manufacturing and Corrosion Protection Works of the Passenger Flight Terminal
Based on the increasing number of flight passengers in 1996 in the federal capital of Berlin
the decision was made to construct a new larger airport in Berlin-Schönefeld. In the year
2007 the construction work on the large airport Berlin-Brandenburg International BBI was
started. The area of this airport is 1,470 ha which corresponds to the size of 2,000 football
pitches.
The construction of the passenger terminal started in 2008 and is located between two
parallel runways. There is a distance of approx. 1,900 m between each runway and they
can be operated independently from each other. The Midfield-Terminal with six floors will
first be designed for 27 million passengers per year with the opportunity to extend it to
up to 45 million passengers with 360,000 aircraft movements a year. The terminal has 16
passenger-boarding bridges at the main pier and another 9 bridges at the south pier.
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GSI SLV 2010
Selected Projects
In August 2009 the SLV Berlin-Brandenburg by order of the planning consortium Flughafen
BBI, consisting of the J.S.K. International Architekten und Ingenieure GmbH and the
gmp, entrusted the Generalplanungsgemeinschaft mbH, with the supervision of the manufacturing
and corrosion protection work for the roof structure of the passenger terminal.
For this impressive building with its length of 220 m, its width of 180 m and a height of
32 m, 10,000 t of structural steel was used 33,000 m² glass facade was used as well as
160,000 m³ concrete and 30,000 t reinforcing steel. The roof surface amounts to approx.
49,000 m². The main contractor for the roof construction works with approx. 10,000 t of
steel is the Eiffel Deutschland Stahltechnologie GmbH in Hannover. The construction and
corrosion protection works were conducted by the SLV Berlin-Brandenburg in 12 production
plants both in Germany and in Europe, i.e. in Austria and Hungary. At the same time
the welding works for the construction of the steel girders were performed on the site of
the airport BBI in Berlin.
For the supervision of the manufacturing and corrosion protection works of the self-supporting
skin glass facades of the terminal and the passenger and boarding bridges as well
as the floodlight posts, there were further orders for the SLV Berlin-Brandenburg. Main
contractors are the companies Seele GmbH in Gersthofen and Max Bögl Bauunternehmung
GmbH & Co. KG in Neumarkt. The supervision of the works in the numerous works
in Germany, Poland, the Czech Republic and on the site demanded much devotedness. In
cooperation with the SLV Munich part of the supervision of the plants for the production
of the passenger and boarding bridges was done in Germany and Bosnia Herzegovina.
The professional competence of the SLVs was in much demand to support and consult the
client, planner and architect in all matters of welding and corrosion protection. Responsibility
and quality assurance has been of much importance. The opening of the airport
is scheduled for mid 2012. The starting of the new Airbus A380 will be possible after that.
On the left: Passenger terminal in construction, centre: self-supporting skin-facade; on the right: Roof supporting structure

Acknowledgement of GSI as Supervision and Certification Body
in accordance with DIN EN 1090-1.
For implementing the European guidelines for building products 89/106/EWG it was decided
that the standard series EN 1090ff superseded the standard series DIN 18800-7 and
DIN V 4113-3. The standard series EN 1090ff has been available in three parts:
• EN 1090-1: 2009
The harmonized standards of (HEN) rules the requirements of the proof of conformity
for steel, aluminium and composite framework made of steel and concrete. These were
manufactured as series and non-series production and as assembly kits. It has officially
been introduced by publishing in the journal of the European Union dated 17.12.2010 and
indication of a transitory period of co-existence by 01.07.2012.
• EN 1090-2: 2008
Includes technical rules for the execution of steel structures and replaces all pre-standards
on this and the parts of DIN 18800-7: 2008.
• EN 1090-3: 2008
Includes technical rules for the execution of aluminium structures and replaces parts of
DIN V 4113-3. When it comes to the „metallic building products and accessories“ the conformity
certification procedure 2+ has been determined by the European Commission. It
specifies the assignments of the manufacturer and the conformity evaluation body (notified
certification body) as follows:
Responsibilities of the manufacturer
• Initial inspection of the product.
• Implementation of a factory production control (FPC).
• Testing of specimens during the construction works
according to a determined testing plan.
Responsibilities of the conformity evaluation board
• Certification by the FPC.
• Initial inspection of the works by the fabrication production control (FPC)
• Continual monitoring, evaluation and recognition by the FPC.
The recognition of the supervisory and certification body (ÜZ-Stelle) of GSI mbH by the
Deutsches Institut für Bautechnik DIBt is based on a decentralized structure with the regulation
to substitute the heads of the supervisory and the certification body. Thus it is
possible to realize supervisory and certification activities effectively and efficiently with
adequate administrative effort on behalf of all of the SLVs. The procedure applied here
is embedded into the QM system of GSI and is compliant with DIN EN ISO/IEC 17021 (Evaluation
of conformity – Demands on bodies for auditing and certifying the management
systems) and DIN EN ISO 9001. Comprehensive internal training of the auditors ensures for
a competent and professional assistance for the companies who must adapt to the new
standard within the set transitory period of time.
GSI SLV 2010
Selected Projects
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GSI SLV 2010
Selected Projects
Research and Development
Optimization of the Projection Geometry for Resistance Welding
on Newly Developed Higher to Highest Strength Steel Materials
In series and mass production, resistance projection welding during the joining process is
done very economically due to its short manufacturing periods. The shape of the projection
(e.g. the embossed projection welds) leads to a current concentration at the weld spot.
Due to the electrode force imposed and the resistance heating the projections form back
building integral bonds. Problems were developing with resistance projection welding on
higher strength steel in the running production due to the severely varying strengths and
defective nugget formations.
In the last few years the SLV Munich has gained new knowledge in this field and has applied
this information to the current matters of concern. In this case emphasis was laid on
optimizing the projection geometry for embossed and solidly deformed projections. In
order to exploit the economic advantages suitable projection geometry was planned that
has no reductions in sheet thickness in the area of the punch. For high strength materials
a ball punch with a dome shaped die plate was used to smooth transition areas in the
edge of the embossed projection. There was better fracture behaviour (increased number
of plug failures) and process reliability (lower number of strewing strengths). The findings
gathered are applied with numerous weld elements in a series production. Attention is
paid to the ball-formed shape of the punch geometry.
ISO-projection Optimized projection geometry
asymmetrical interface fracture symmetric plug failure – projection geometry
FE = 3 kN, tS = 200 ms, IS = 13,0 kA FE = 4 kN, tS = 200 ms, IS = 15,0 kA
cracks in the area of embossing, welded joint free of failures
pore and porehole, respectively
Influence of the projection geometry to the fracture pattern and nugget formation during resistance projection welding of
high and highest strength steel materials (Example: HCT690TD, tBl = 1.5 mm)

Development of a Camera System on the Online Process Control
and the Visual Evaluation of Selected Arc-Coating Processes
In technological processes conducted with the use of energy a visual control of the process
and of the material worked in real-time is not completely possible. Process parameters
are mostly determined directly via electrical parameters.
The objective of the research project was the development of a process on the online
evaluation of impulse arc processes and surfacing processes for wear and corrosion protection
in welding. The tests on welding were performed by the SLV Halle GmbH with its
project partner Hema electronic developing the necessary camera system with the pertinent
software as well as the corresponding image processing program.
The technology was to be used in process control and for seam tracking. In process control
it should be evaluated whether imperfections generated by the arc and in the weld
seam can be recognized and assigned. For seam tracking the system was to record the
course of the arc in relation to the given course of the seam. In case of discrepancies a
full online correction of the mechanical welding should be possible. The result was an
overview about the suitability of a camera system under certain process conditions (e.g.
filters and lenses) for the process control and seam tracking of certain welding processes.
Further, a first positive experience on the use of the camera system in welding education
and training could be made and evaluated.
On the left: Formation of drops GMA-impulse process; on the right: Camera system with protective housing
Testing of New Tool Material for Friction Stir Welding of Steel
Friction stir welding of aluminium is usually not a problem anymore. The customers of the
SLV Berlin-Brandenburg receive relevant consulting and assistance. If the topic, however,
is of friction stir welding of steel, the situation is completely different. There are still problems
in this area, mainly with the tools. Whereas the use of a creep resistant steel is sufficient
when it comes to the welding of aluminium, the situation is different when it comes to
the welding of steel. Also at higher temperatures (approx. 1,100) the steels must not lose
their strength and should also be resistant to wear. In order to comply with these requirements,
the SLV Berlin-Brandenburg has formed a co-operation with several partners and
developed a tool complying with these demands that is cheap and can be purchased in
Germany. The new tools have a metallic base from tantalum.
GSI SLV 2010
Selected Projects
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GSI SLV 2010
Selected Projects
The basic alloy has not shown any affinity towards steel, which is reflected in a very good
seam surface. The expectations placed on this material were exceeded for the first time.
Further alloying elements shall make the material more resistant as well as PCBN coatings
within the range of microns (company Materion). Further tests on welding have been
planned at the SLV Berlin-Brandenburg. In this case the welding speed was increased
while maintaining the seam quality. Examinations on the material (fracture mechanics)
are being performed at HZG in Geesthacht. Together with our partners a friction-stirring
tool „made in Germany“ shall be successfully developed. The first application in ship construction
has already been planned: The application of the tool in a six-metre friction stir
welding unit made by the companies IMG and Loitz-Robotik.
On the left: Application of a tool made of tantalum (new); on the right: Friction stir welding of steel at the
SLV Berlin-Brandenburg (with gas shielding in the seam area)
Improving the Process Reliability of Spot Weld Bonding of Aluminium Materials
and Determination of Joining Parameters for Construction and Simulation
The combination of spot welding and bonding has been successfully used for joining of
steel materials in the manufacture of car bodies. Joints that can be exerted to loads at
very short cycles can be produced using spot welding. A curing process is necessary to
ensure fixation of the parts to be joined. Curing of the adhesives is performed during the
KTL course at about 180°C. In the case of repairs and single production 2K adhesives are
used that also cure at room temperature. The bonding properties to be obtained enable
good use of the strength of the parent metals at cyclic endurance stress and at pulsed
shaped loads. Spot weld bonding of aluminium plates is much more problematic due
to the shorter welding time compared with steel. Solutions are needed while using the
welding control particularly developed for this project is being used. With this control
pre-conditioning of the (before the welding process) is possible. It is expected that the reproducible
conditions of resistance necessary for resistance welding can also be obtained
in combination with spot welding adhesives.

Phase 1: Pre-conditioning Phase 2: Welding
At the beginning of the welding – After obtaining of a given,
non-reproducible overall resistance overall resistance
switch to the normal welding procedure
Principle of pre-conditioning
Simulation
of a spot weld
At the same time the test results are compared with the simulation program SORAPS. The
simulations are conducted to test special effects and to be able to perform verification
with actual welding processes.
SLV Mannheim is Engaged in Ethiopia
GSI SLV 2010
Selected Projects
Foreign Countries
At the end of last year the Schweißtechnische Lehr- und Versuchsanstalt SLV Mannheim
was ordered by the Gesellschaft für Technische Zusammenarbeit (GTZ) Ethiopia and the
Gesellschaft für Internationale Weiterbildung und Entwicklung (InWEnt) Mannheim to evaluate
the measures that are necessary to implement a system on the qualification and certification
of welding personnel according to international rules in Ethiopia. A first group
of 16 welders has been trained since 2010 within the scope of the action plan worked out
for a period of two years. This group will then be educated as certified welding instructors
in 2011 if the basis for the practical skills is given. Also two welding institutes in Addis
Ababa and Mekelle will be equipped according to German standard. This will allow these
two companies to independently conduct the qualification of welding personnel in cooperation
with GSI by own Ethiopian welding personnel in the future. Further interest in
this has been shown by the visit of Mr. Niebel, German minister for Economic Cooperation
and Development, the German Ambassador in Ethiopia and delegates of the Ethiopian
government. They informed themselves in the educational welding workshop in Mekelle
on the training measures and the procedure of the programme.
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GSI SLV 2010
Selected Projects
CIM-expert Ulrich Brosch (l.) and SLV welding instructor Roland Lange with the 16 welding trainees in Mekelle, Ethiopia
EXPOWELDING 2010 in Sosnowiec, Poland
The largest welding fair in Poland (EXPOWELDING) was held in the newly built Fair Centre
(SILESIAEXPO) in Sosnowiec from the 19th to 21st of October 2010.
The significance of the fair was even more so due to the patronage of the Polish Welding
Institute (Instytut Spawalnictwa), member of the EWF and IIW, the Polish ANB and ANBCC.
Among the guests of the fair were also the President of the IIW, Professor Dr.-Ing. Ulrich
Dilthey, and the President of the EWF, Tim Jessop. During the fair simultaneously held
with the conference Advanced Welding Technologies Prof. Dr.-Ing. Reinhard Winkler from
the SLV Duisburg and Dr.-Ing. Gerlinde Winkel from the SLV Mecklenburg-Vorpommern as
representatives of GSI presented their research projects.
Fair booth of the SLV-GSI Polska on the EXPOWELDING, visitors of the fair test the welding trainer

Two years ago the Polish branch of GSI had its own booth at the fair. The main objective
of GSI SLV Polska was to inform about the introduction of the standard series EN 1090 on
the execution of steel and aluminium structures as well as on procedures on the proof
of conformity for supporting structures. Moreover, GSI SLV Polska presented its range of
services: Certifications in accordance with DIN 18800-7, DIN EN ISO 3834, DIN EN 15085,
training of welders and the execution of welders‘ examinations in accordance with DIN
EN 287-1, DIN EN ISO 9606-2, qualification of procedure tests, supervising and acceptance
of welded structures, the organization of professional seminars, consulting and expertise.
The visitors of the fair booth were given flyers on the EN 1090 and were informed on the
presentations planned by GSI SLV Polska in the different regions of Poland as well as on
the role of GSI as a future notifying body on this field. An eye catcher of the education
of welders at the fair booth was GSI SLV welding trainer of the SLV Halle. Its possibilities
and advantages in the education of welders were explained by Dipl.-Ing. Axel Börnert
from Halle. Due to the very large interest in the welding trainer a further presentation
at the Technical University of Pila (North Poland) was implemented. With the help of GSI
SLV Polska as an exhibitor on the EXPOWELDING it has become possible to present GSI’s
range of services on the Polish market. This was a very important step to a more intensive
cooperation between GSI and Polish companies in welding.
IWE-Education at GSI SLV-TR in Ankara, Turkey
In the second year of its establishment GSI SLV-TR signed an important international project.
“International Welding Engineering” training was given to 11 Nigerian engineers in
Ankara. Engineers selected from different regions and business branches of Nigeria were
educated in Ankara during May – July 2010.
The participants from Nigeria proudly present their diploma.
GSI SLV 2010
Selected Projects
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GSI SLV 2010
Selected Projects
This project is an exemplary project realized with international cooperation and under the
structure of GSI. In the scope of the course, in addition to the three SLV companies involved,
the Middle East Technical University Welding Technology Unit (METU-KTM) also took
part. Training was given by the experts of GSI SLV-TR and METU-KTM, the English lecture
notes were provided by SLV Duisburg. The verbal examinations at the end of the training
were conducted by SLV Munich, with the support of GSI SLV-TR and METU-KTM personnel.
SLV Munich again did the certification. GSI SLV-TR conducted all these courses successfully
and gained a significant experience and self-confidence in these early years of its establishment.
This successful course is a result of a excellent coordination and cooperation, as
well as the devoted and efficient working of GSI SLV-TR personnel.
As a result of a concentrated working schedule that was vivid in every aspect, 100% success
was achieved and all our Nigerian friends gained the right to be issued a diploma.
During the training process, visits were made to important industrial facilities near Ankara;
social activities were also realized as much as possible within the intense working
schedule. After the completion of the training, our Nigerian guests visited the historical
and touristic locations of Istanbul, and then returned back to their home country.
It should be noted that the successful execution of an important international project like
this by GSI SLV TR, has been based on more than 20 years of cooperation and a common
strive for success.
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