# United Testing Services — Hazardous Materials Safety Interpretation

- **operation:** document
- **citation:** 23-0041
- **title:** United Testing Services — Hazardous Materials Safety Interpretation
- **source type:** guidance
- **agency:** Pipeline and Hazardous Materials Safety Administration
- **status:** guidance
- **official:** true
- **published on:** 2024-05-02
- **effective on:** Not available
- **summary:** 23-0041 response to United Testing Services concerning 178.65.
- **machine formats:** - **json:** https://regulus.evalyn.ai/document/phmsa-interpretation-23-0041.json
- **markdown:** https://regulus.evalyn.ai/document/phmsa-interpretation-23-0041.md
- **app url:** https://regulus.evalyn.ai/document/phmsa-interpretation-23-0041
- **source url:** https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/2024-05/230041.pdf
**body:**

<<<PAGE 1>>>

1200 New Jersey Avenue, SE
Washington, DC 20590
U.S. Department
of Transportation
Pipeline and Hazardous
Materials Safety
Administration
May 2, 2024
Anthony Roston
United Testing Services
Chabot Collision Building
20736 Lake Chabot Rd.
Castro Valley CA 94546-5406
Reference No. 23-0041
Dear Mr. Roston:
This letter is in response to your April 20, 2023, email requesting clarification of the Hazardous
Materials Regulations (HMR; 49 CFR Parts 171-180) applicable to Department of
Transportation (DOT) specification 39 (DOT 39) non-reusable (non-refillable) cylinders. You
ask for additional clarification of the requirements in § 178.65 which state that “[b]razed seams
must be assembled with proper fit to ensure complete penetration of the brazing material
throughout the brazed joint.” Specifically, you ask whether radiographic and photographic
images that you provided of a DOT 39 cylinder were representative of a weld with “complete
penetration” and whether a cylinder weld with voids could still be in compliance with § 178.65.
As stated in an earlier letter of interpretation we issued and that you cited (Reference No. 21-
0097), PHMSA cannot determine whether a violation of § 178.65 exists based solely on
photographic evidence. While the criteria provided in the HMR are not specific to the presence
of voids in welds, § 178.65(c)(2) specifies that for seams:
• Brazing is not authorized on aluminum cylinders;
• Brazing material must have a melting point of not lower than 1,000 °F;
• Brazed seams must be assembled with proper fit to ensure complete penetration of the
brazing material throughout the brazed joint;
• Minimum width of brazed joints must be at least four (4) times the thickness of the shell
wall; and
• Brazed seams must have a design strength equal to or greater than 1.5 times the minimum
strength of the shell wall.
I hope this information is helpful. Please contact us if we can be of further assistance.
Sincerely,
Dirk Der Kinderen
Chief, Standards Development Branch
Standards and Rulemaking Division

<<<PAGE 2>>>

Casey
23-0041
From: Foster, Glenn (PHMSA)
To: Dodd, Alice (PHMSA)
Subject: FW: 19-F-00183 (CPSC), RP120140 (D.O.T.), 21-0097 (D.O.T.), 20180519-A9E35-2147387862 (CPSC) - Request
for Letter of Interpretation (D.O.T.), and Recall Action (C.P.S.C. and D.O.T. - Handheld torch products
Date: Friday, April 21, 2023 11:53:54 AM
Attachments: 230420 UTS reporting_braze_defect_voids_NRT_Cylinders-CPSC_DOT.pdf
Alice,
Please have the attached checked in and assigned to a Specialist as a new request for a LOI.
Thanks,
Glenn
From: Anthony Roston <unitedtestingservicesllc@gmail.com>
Sent: Thursday, April 20, 2023 3:03 PM
To: Egray@cpsc.gov; Jsmith@cpsc.gov; MSchoem@cpsc.gov; section15@cpsc.gov;
jenny.mclaughlin@hc-sc.gc.ca; Ttopka@cpsc.gov; dlarue@cpsc.gov; asuchy@cpsc.gov;
Ksuper@cpsc.gov
Cc: Foster, Glenn (PHMSA) <Glenn.Foster@dot.gov>; Hillman, Kenetha CTR (PHMSA)
<kenetha.hillman.CTR@dot.gov>; Pollack, Arthur (PHMSA) <arthur.pollack@dot.gov>;
andrew@eastbaylaw.com
Subject: 19-F-00183 (CPSC), RP120140 (D.O.T.), 21-0097 (D.O.T.), 20180519-A9E35-2147387862
(CPSC) - Request for Letter of Interpretation (D.O.T.), and Recall Action (C.P.S.C. and D.O.T. -
Handheld torch products
CAUTION: This email originated from outside of the Department of Transportation (DOT). Do
not click on links or open attachments unless you recognize the sender and know the content
is safe.
Dear Mr. Gray, Mr. Foster, and
Notice Recipients:
Please see attached letter request sent to CPSC and to the D.O.T.
Sincerely,
Anthony Roston
United Testing Services
Castro Valley, CA
925-872-1850

<<<PAGE 3>>>

Mr. Eric T. Gray, Compliance
Officer, CPSC
Mr. T. Glenn Foster, Regulatory
Review, U.S. DOT, Pipeline and
Hazardous Materials
United Testing Services LLC
Chabot Collision Building
20736 Lake Chabot Rd.
Castro Valley CA 94546-5406
Tel. 916-416-5904
unitedtestingservicesllc@gmail.com
Reference:
1. CPSC Report No.
20180519-A9E35-2147387862
2. CPSC Recall file RP120140
3. FOIA request 19-F-00183
April 20, 2023
Dear Mr. Gray and/or CPSC Person of Interest,
Dear Mr. Foster and/or D.O.T. Person of Interest:
We are submitting a reporting of a defect with the BernzOmatic and Worthington
brand handheld torches, which are sometimes sold under several other names (i.e.
Sears, Lenox, etc.). The manufacturer is Worthington Cylinder Corporation in Ohio.
Their counsel, last in touch with Mr. Gray in re RP120140, is Mr. Richard Ergo, of
Walnut Creek, California. This reporting may extend to the recall, RP120140. Mr.
Foster, of the D.O.T. Pipeline and Hazardous Materials division, issued a letter of
interpretation regarding the defect on 6/23/22. We will therefore begin by asking Mr.
Foster to issue a further letter of interpretation to resolve a difference of terminology
regarding the words “complete penetration” as they related to the defect described
below. We will also ask both the D.O.T. and the C.P.S.C. to initiate a recall of the
product due to the defects stated.
The subject fuel cylinders have failed many times at the neck area, also called the
“main valve housing,” shown in the photo provided by Worthington’s engineer, Steve
Gentry several years ago:
Page 1 of 9

<<<PAGE 4>>>

Worthington Cylinder Corporation took x-ray and scan images of the two failed cylinders
shown in the photo above in 2018. Both cylinders contained the large voids and gaps shown
on Worthington’s images:
Page 2 of 9

<<<PAGE 5>>>

JPV-1
JPV-2
• Peralta cylinder, large voids
*voids do not go 360° around as stated
by Dr. Pfaendtner.
Bailey_Avonix_CyLVideo.mp4.
Cynder 2 alonment system
0 | m 1 2
IS +IE
19 - 1 mi Rosinan
247,95 deg
2-Axs Rotasor
KBV-1
(braze compound is
minimal, void quite
large)
Bailey_Avonix_CyLVideo.mp4.
Cinder 2 agent myster
KBV-2
*voids do not go 360°
around as stated by Dr.
Pfaendtner
Page 3 of 9

<<<PAGE 6>>>

Worthington’s engineer then obtained one random cylinder from Lowes Home Improvement
and took images of the brazing compound. Those images also showed the presence of large
voids as shown here:
Page 4 of 9

<<<PAGE 7>>>

We have also personally spoken with five of the victims of cylinders which failed at the neck
as shown in the photo above: (1) Kurtis M. Bailey, Bailey v. Worthington, 1"17-cv-7548-
PGR (Northern District of Illinois; (2) Jason Peralta, Peralta v. Bernzomatic/Worthington,
2:17-cv-3195-JJT (Arizona); (3) Andrew Shalaby, Shalaby v. Bernzomatic, 3:11-cv-00068-
AJB (S. Dist. CA); (4) Murray Shadbolt (Canada); and Jacob Avery (Massachusetts). The
injury victims all reported failure of the cylinder at the neck without application of any
unusual or unforeseeable forces. The manufacturer filed expert witness reports that in
essence stated that the injury victims were lying about the manner with which they used the
torches, and that the victims had to have exerted a very strong amount of force. Their expert
performed duplication tests to try to show the types of forces they had to have subjected the
cylinders to, and took videos and photographs, such as shown here:
(Photos courtesy of Worthington and its experts.)
Page 5 of 9

<<<PAGE 8>>>

Worthington’s engineer stated that he tested six non-defective cylinders. He struck five of
them on a solid sharp edge of a workbench as hard as he could, but could not get them to
fail. He then created a raised edge as shown above, and struck it as hard as he could to cause
one cylinder, the sixth tested, to fail as shown. He also stated that the torches in the two
cases he was assigned to, Bailey and Peralta, could not have possibly failed under the use
described by Mr. Bailey and Peralta, because such a failure would be impossible if they were
not defective. Mr. Bailey and Peralta have given sworn statements that the cylinders did
indeed fail under normal use and without application of any such forces. Mr. Shalaby also
stated that he was just using his torch in a normal manner, without application of any such
forces, and it failed at the neck as well. All of the victims suffered severe permanent burn
injuries. Other victims, whose families filed cases in different states, have died from their
injuries.
Mr. Foster (DOT), your letter of interpretation responded to the above-shown photos of the
voids in the brazing compound. You correctly disclosed the following:
“You ask whether the photos and videos linked in your letter illustrate a
brazed seam of a DOT 39 cylinder that does not meet the requirements set
forth in § 178.65(c)(2)(iii). Under § 178.65(c)(2)(iii), "Brazed seams must be
assembled with proper fit to ensure complete penetration of the brazing
material throughout the brazed joint."
However, Worthington’s Attorney Mr. Ergo, who corresponded with Mr. Gray regarding
CPSC recall file RP120140, provided Worthington’s interpretation as follows:
“‘Complete penetration’ does not mean the absence of voids. Rather, it
means that the brazing material (copper metal in this case), when
liquefied in the brazing furnace, flows throughout the entire joint”.
This definition appears to be inconsistent with that of the D.O.T. as well as inconsistent with
the interpretation of educational institutions, such as these:
“Effects of Capillary Attraction and Wetting on Brazing Capillary
attraction makes leak-tight joints a simple proposition for brazing. In a
properly designed joint, the molten filler metal is normally drawn
completely through the joint area without any voids or gaps, and brazed
joints remain liquid- and gas-tight under heavy pressures, even when the
Page 6 of 9

<<<PAGE 9>>>

joint is subjected to shock or vibrational types of loading.”1
Voids or porosity - an incomplete flow of brazing filler metal which can
decrease joint strength and allow leakage-often caused by improper
cleaning, incorrect joint clearance, insufficient filler metal, entrapped gas
or thermal expansion.2
The latter interpretations appear to be the same as provided by Metallurgist Dr. Robert
Anderson in the Shalaby matter on June 25, 2008, which is attached, and states:
“The brazing materials have large voids in the bulk and smaller voids in the
interface between the cylinder walls and the center valve housing as shown in
Microphotographs 6, 7, and 8. The brazing on the outer surface of the cylinder
is undercut in all three cylinders rather than forming a meniscus. The
undercutting is a sign of lack of wetting and penetration of the brazing
material with the cylinder and valve[...] The Bernzomatic one pound MAPP
gas cylinder is manufactured per Federal specification published in 49 CFR
178.65 (D.O.T. 39). The specification for non-reusable (non- refillable)
cylinders slates "brazed seams must be assembled with proper fit to ensure
complete penetration of the razing material throughout the brazed joint." The
brazed joints shown in microphotographs 6, 7, and 8 lack complete
penetration. For these three cylinders that were examined to be offered on the
market clearly establishes the failure of Bernzomatic inspection and quality
control procedures. The MAPP gas torch and cylinder is unsafe and
unreasonably dangerous as designed and manufactured.”
In addition, we discovered a defect of over-pressurization of the cylinders from
Worthington’s Engineer’s documents produced. One specification document is dated “5-19-
06" and identified as “WCW000376.” The second specification document is dated 5/14/13
and was originally produced with the identification number “WCW000083,” but also hsa
identification number “WCW000374". A version of the same document, with a revision
history showing the date “3-20-18,” is identified as “WCW000377. The specification
documents specify the working pressure, test pressure, pressure relief valve discharge
1Source 7/16/21:
https://www.asminternational.org/documents/10192/1849770/06955G
_
Chapter
_
2.pdf
2Source:
https://blog.lucasmilhaupt.com/en-us/about/blog/inspecting-brazed-joints
Page 7 of 9

<<<PAGE 10>>>

pressure, relief valve reseal pressure, and cylinder burst pressure. The specification
documents reflect facial defects in the specifications themselves, to wit:
WCW000376 WCW000374 WCW000377
5/19/06 5/14/13 5/14/13
Minimum Burst
Pressure
260 PSIG
(7-14-08 was
900 PSIG)
750 PSIG 750 PSIG
Working Pressure 260 PSIG 260 PSIG 260 PSIG
Test Pressure 325 PSIG 325 PSIG 325 PSIG
Relief Valve Start
To Discharge
260 PSIG
(7-14-08 was
380-480 PSIG)
360-520 PSIG 360-520 PSIG
Relief Valve Reseal 260 PSIG 260 PSIG 260 PSIG
The specification documents reflect that the minimum cylinder burst pressure specification
was as low as 260 PSIG on one document, while that figure was lower than the “test”
pressure, facially evidencing a defect. (See WCW000376.) The same document shows the
test pressure at 325 PSIG, which is higher than the “minimum burst pressure.” On
WCW000474, the pressure relief valve specification was 360-520 PSIG, as compared to the
much lower 260 PSIG shown on WCW000376.
Worthington’s engineer, Dr. Thomas Eagar, declared that the relief valve specification
was 360-480 PSI, which is not shown on any of Worthington’s specification documents.
The defective specifications are on the specification sheets themselves. On a report
prepared by Worthington’s Dr. Eagar, he reveals the following:
There have been over-pressurization failures in the past but not with such
violent energy releases. In each prior over-pressurization, the PRV released as
intended, performing its intended safety function.
He was referring to a cylinder that was over-pressurized, and failed with the neck (main
valve housing) having ripped a full 360 degrees around, causing shrapnel to lodge in the
neck of one Mrs. Astrid Marmont, killing her.
Based on the above information, we ask that Mr. Foster provide a new letter of
interpretation, advising whether Worthington’s definition of complete wetting and
penetration quoted above is the correct interpretation, or whether Dr. Anderson’s
interpretation quoted above, which appears consistent with ASM International’s
interpretation also quoted above, is the correct interpretation. Specifically, do voids in the
brazing compound of the subject cylinder, as shown in Worthington’s x-ray and scan photos
Page 8 of 9

<<<PAGE 11>>>

above, evidence a failure of compliance with the D.O.T.’s requirement for “complete wetting
and penetration”?
Mr. Gray, or otherwise, CPSC, and also Mr. Foster, or otherwise the D.O.T., we also
request that CPSC and D.O.T. require a full recall of the subject cylinders due to the voids
and failures noted. To aid in this process, we have now collected several of the defective and
failed cylinders, including the ones involved in Bailey, Peralta, and Shadbolt (Canada). The
remaining defective and failed cylinders are believed to be in possession of Worthington’s
counsel, Mr. Ergo, and there are quite a few.
Sincerely,
Anthony J. Roston & Manuel Marieiro,
United Testing Services, LLC
Page 9 of 9

<<<PAGE 12>>>

Case: 1:16-cv-07548 Document #: 704-2 Filed: 07/02/22 Page 1 of 6 PageID #:7454 Case: 1:16-cv-07548 Document #: 713-3 Filed: 08/11/22 Page 1 of 6 PageID #:7572
RNA Consulting, Incorporated
Specializing in forensic materials engineering and sciences
Robert N. Anderson, Ph.d~ P.E., President
Z7820 SaddJo Coun
Los Ahos HHh. CA
94622-1810 USA
Bus:- 65()..949---1092
Far. 650-949.5641
email; robettNA@aol.com
June 25, 2008
Mark D. Epstein
Alborg, Veiluva & Epstein LLP
200 Pringle A venue, Suite 410
Walnut Creek, CA 94596-7380
Re: Shalaby v. Irwin, et al.
Dear Mr. Epstein:
At your request, I have examined the 4/21/06 incident where Mr. Andrew Shalaby was
injured while using a 16 oz cylinder Bernzomatic MAPP gas torch. MAPP gas is a
trademark of the Dow Chemical Co. and is composed of extremely flammable
methylacetylene-propadiene-propane. ·
It is my understanding that Mr. Shataby was in the process of igniting logs in a fire pit,
using a TS4000 torch head and Bernzomatic MG9 MAPP gas cylinder when the cylinder
vented and he was burned. In the incident, the center valve housing, attached to the
canister by brazing material, ruptured.
Materials Reviewed:
I have reviewed the following documents:
L Deposition of Michael Ridley, Senior engineering manager, Irwin Industrial Tool
Co., taken 11/13/07. ·
2. Deposition of Steven T. Gentry, Quality Control Department Worthington
Cylinder Corp., ll/14/07. ·
3. Deposition of Andrew W. Shalaby volume I and II, Plaintiff, l 0/24/07 and
10/25/07.
4. Deposition of Warren L. Ratliff, Jr., Park ranger supervisor, Campland, 4/17/07.
5. Deposition of Randy T. Stephens, Ranger at Carnpland, 4/17/07.
6. Deposition of Joe Russo, Paramedic, 4/18/07.
7. Miscellaneous manufacturing drawings of torch parts.
8. Health & Safety Laboratory report 2006/121.
9. Bernzomatic instruction manuals 9600 l, 97090
10. Bernzomatic catalog.
1 L Investigative Report with reference to interview of Anne Carrol and David Borger
by Howard Felder 10/6/07.
12. Consumer Product Safety Commission Release# 78-088.
13. Transcribed statement of Andrew Shalaby by Joe Tancredy, 6/1/06
14. Material Safety Data Sheet for MAPP Gas.
15. Supplemental Response to Request for Production ofDocmnents (Set No. One).
16. Worthington Industries Expert Witness Disclosures.
Epstein_ Shalaby_ RNAteport.doc - 1 -

<<<PAGE 13>>>

Case: 1:16-cv-07548 Document #: 704-2 Filed: 07/02/22 Page 2 of 6 PageID #:7455 Case: 1:16-cv-07548 Document #: 713-3 Filed: 08/11/22 Page 2 of 6 PageID #:7573
17. Third-Party Defendant/Cross Claimant Western Industries, List of Expert
Witnesses.
18. Disclosure of Experts by Defendants, Bemzomatic.
19. Protective Order.
20. Defendants' Initial Disclosures.
21. Drawing 304432.
22. MAPP gas cylinder specifications.
Analysis:
The failure of the Bemzomatic MAPP gas torch Mr. Shalaby was using appears to be at
the collar or threaded area between the center valve housing and the cylinder. The center
valve housing is fastened to the cylinder by a copper-nickel brazing material. The Rangers
in the park that examined the gas torch confirm that the fuilure was in that location.
• Park Ranger Supervisor Warren Ratliff, in his deposition, comments were that there
"appeared to be a crack in the cylinder at the bottom thread level of the cylinder" page
25, lines 21-25; page 26, lines 24-25.
• Ranger Randy Stephens comments on the f!!Vure in his deposition on page 42, linesl5-
25; page 43, lines 1-ll; page 73, lines 9-25; page 74lines 1-15.
• Also, the recollection of Andrew Shalaby in his transcribed statement to Joe Tancredy
on 61!/06.
Mr. Shalaby was using the torch to ignite firewood in a frre pit and his torch would have
been partially inverted in that situation. Health & Safety Laboratory report 2006/121
(report included in test results CD) determined that the torch orientation was important
and confmned that when the cylinder was inverted, explosion could occur. The directions
do indicate "Use upright to prevent flare-ups or flashes" caused by the liquid entering the
torch. However, this orientation is impossible in some situations.
CPSC Release # 78-088 issued a notice of a recall for fuel cylinders from another
manufacture (Cleanweld Products) that separated "where the threaded connector meets the
cylinder". A flaw in this area is very serious.
A review of other MAPP gas torch failures involving lawsuits filed since January 2002
and supplied by the Defendant in their Supplemental response to request for production of
documents (Set One) had listed ?lawsuits identified below.
1. Thomas Segrest, Jr. v. Bemzomatic. (Date of injury 2/9/04)
2. Richard Gleen v. Newell Operating Co. (Date of injury l/3/06)
3. Andrew Gelzer v. Therrnadyne (Date of injury 2/13/04)
4. Melvin Wilfredo Bonilla Carranza v. Bemzomatic. (Date of injury 6/13/05)
5. Ross Pelz v. Worthington Industries. (Date ofinjury 5/29/05)
6. Mark Loewes v. Worthington Industries. (Date of injury 3/27 /05)
7. Timothy Welch v. Newell Rubberrnaid (Date of injury 7/3/06)
The Glenn v. Newall is a Ventura California case in which a Bemzomatic cylinder failed
at the braze material (Photographs 1, 2).
In addition, I have reviewed photographs for a Minnesota case called Venderlinde v. Ace
Hardware Corp., where a "Turbo Torch" failed in the braze material between the center
Epstein_ Shalaby_RNAreport.doc -2-

<<<PAGE 14>>>

Case: 1:16-cv-07548 Document #: 704-2 Filed: 07/02/22 Page 3 of 6 PageID #:7456 Case: 1:16-cv-07548 Document #: 713-3 Filed: 08/11/22 Page 3 of 6 PageID #:7574
valve housing and the cylinder. There are two Lenox cylinders (John Barrett v. Lenox and
Lemaralejo) that also failed in the same location.
Tests Conducted:
l. Metallography of the brazing material in MAPP gas cylinders.
2. Microhardness of the brazing material in MAPP gas cylinders.
3. Energy Dispersive Spectrum (EDS) ofMAPP brazing material.
4. Metallography of corrosion test of the MAPP brazing material.
5. Metallography ofbrazing material in MAPP PRO gas cylinder.
6. Microhardnes of the brazing material in MAPP PRO gas cylinders.
7. EDS of brazing material in MAPP PRO gas cylinders.
Test data are contained in a compact disc (CD) included with this report.
The braze material is a copper nickel alloy. The composition was determined to be
approximately 61 %(atomic) Cu and 39% Ni by Energy Dispersive X ray. This is 63%
Cu by weight and the specifications 011 Drawing 32600-23 call for a maximum of 60% by
weight Cu. It is possible that the brazing material is off specificatio11s.
Steven Gentry in his depositipn (page 89, line 7) states that the brazing temperature is
between 2000 and 2100 degrees Fahrenheit, which is 1093- 1149 degrees centigrade.
According to the Cu-Ni phase diagram (See Figure 1) from the reference "Hansen,
Constitution of Binary Alloys", that temperature is too low to melt the brazing alloy .
. It should be noted that the brazing material used in the Bemzomatic MAPP PRO cylinders
has been changed to all copper without the addition of nickel. Metallography of the MAPP
PRO brazing material is shown on the CD.
Conclusions/Findings:
Based on the facts of failure in the brazed area, I have exarni!led three exemplar MAPP
gas cyli11ders, (W1 OG57E, Wl1 G 152W and W8G230E), with respect to the Cu-Ni braze
between the center valve housing and the cylinder. Microhardness testing of the brazing
metal gave values of23 HRC for WlOG57E; 33 HRC for Wl1Gl52W, and 97 HRB for
W8G230E.
The cylinders have been sectioned in half and four sections have been cut from each
cylinder to show a portion of the neck piece and cylinder wall and the brazing material
between. These sections have been mounted in plastic and polished and photographically
documented. Representative examples of the microphotographs from each cylinder are
shown in Photographs 3, 4, and 5. The brazing materials have latge voids in the bulk
and smaller voids in the interface between the cylinder walls and the center valve housing
as shown in Microphotographs 6, 7, and 8. The brazing on the outer surface of the
cylinder is undercut in all three cylinders rather than forming a meniscus. The
undercutting is a sign of lack of wetting and penetration of the brazing material with the
cylinder and valve. A good meniscus shows that wetting has occurred. The brazing defects
shown in photographs 3-8 reduce the strength of the joint and make it more likely that the
valve will partially separate from the cylinder and release gas when the torch is used as
intended.
Epstein_Shalaby_RNAreport.doc -3-

<<<PAGE 15>>>

Case: 1:16-cv-07548 Document #: 704-2 Filed: 07/02/22 Page 4 of 6 PageID #:7457 Case: 1:16-cv-07548 Document #: 713-3 Filed: 08/11/22 Page 4 of 6 PageID #:7575
The outside surface of the btazing material that is undercut represents a lack of wetting
and penetration of the brazing material with the cylinder and valve housing. This flaw is
sufficient to reject the cylinder. This flaw should have been picked up by the manufacturer
with a simple visual iuspection of the cylinders.
The Bernzomatic one pound MAPP gas cylinder is manufactured per Federal specification
published in 49 CFR 178.65 (D.O. T. 39). The specification for non-reusable (non-
refillable) cylinders states "brazed seams must be assembled with proper fit to ensure
complete penetration of the razing material throughout the brazed joint." The brazed joints
shown in microphotographs 6, 7, and 8 lack complete penetration.
Corrosion tests show that the brazing material is strongly cathodic to the cylinder and
valve and will cause the steel to corrode· in a suitable moist atmosphere. The interior walls,
of the sectioned cylinders, also showed signs of corrosion. See Photograph 9, Interior
View of Cylinder WlOG57E Showing Corrosion.
In my opinion, the braze material between the center valve housing and the cylinder is the
weak element in the a.Ssembly, and subject to failure when the torch is attached to the
cylinder. The brazing material bas voids and lacks sufficient fusion to the cylinder wall
and valve housing to resist stresses placed on it when used in a normal manner. This
problein with the brazing material is due to a combination of poor cleaning of the brazing
area, contamination of the brazing material and improper process parameters such as
furnace temperature and time. For these three cylinders that were examined to be offered
on the market clearly establishes the failure of Bernzomatic iuspection and quality control
procedures.
The MAPP gas torch and cylinder is unsafe and unreasonably dangerous as designed and
manufactured.
Please call me if you have any questions.
Sincerely,
~~~
Robert N. Anderson, Ph.D., P.E.
Epstein_ Shalaby _RNAreport.doc -4-

<<<PAGE 16>>>

Case: 1:16-cv-07548 Document #: 704-2 Filed: 07/02/22 Page 5 of 6 PageID #:7458 Case: 1:16-cv-07548 Document #: 713-3 Filed: 08/11/22 Page 5 of 6 PageID #:7576
Phpto 3: W10G57E. @ 13X. Valvehpusipge>,tJth~Jppand.cylioder on
Jhe.bPtlotn with brazing material inbetw~.e.n.
' . ' .
· Epstein_Shalaby_RNAreport.doc -8-
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