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WELDFAB TECH TIMES www.weldfabtechtimes.com
Publisher & Editor Eliza Bhalerao eliza@weldfabtechtimes.com Group Managing Editor Amol Bhalerao amol@weldfabtechtimes.com Assistant Editor Babu Paka editorial@weldfabtechtimes.com Business Development Manager Monica Waghmare monica@weldfabtechtimes.com Designer Deepa Warang design@weldfabtechtimes.com Advertisement marketing@weldfabtechtimes.com Mob : +91-9975580309 Subscription subscription@weldfabtechtimes.com Mob : +91-9730904259
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4
WELDFAB TECH TIMES | AUG - SEPT 2017
WFTT Launches a Welding World! I had a vision to create innovative, conscious, inspiring, entrepreneurial, and knowledgeable content for a magazine which still lacks a mediator to impart latest happenings into its segment. Hence, welding and fabrication was all that stroke my mind and this is how WeldFab Tech Times (WFTT) has been introduced. My team welcomes you all to our debut edition of WeldFab Tech Times: A bi-monthly magazine designed especially for welding, fabrication, ship building, construction and other related infra segments. It has been designed especially for those people who have a knack to stay updated on its latest happenings, learn and share new techniques and trends, and never would miss any crucial updates. Our magazine commits to impart true and valuable information, get the industry well connected with each other and uplift the SMEs at a larger scale. We aim to cut through the uncertainties and give you a clear, sensible and reliable information from writers and experts whom you can trust. We promise our readers to always cater a satisfactory feel when WeldFab Tech Times gets handy. We further vow that the content shall be enabled with a wide range of news, features and regular columns. I hope you will be delighted with the first issue and we expect a fair feedback from our extensive readers. Enjoy Reading...
Eliza Bhalerao Publisher & Editor
www.weldfabtechtimes.com
CONTENTS 6
07
Indian Railways on fast track with Welding
24 There is a huge market for Welding in India. R. Srinivasan, President, Indian Institute of Welding (IIW)
WELDFAB TECH TIMES | AUG - SEPT 2017
40 Welding Automation Division: An important cog towards growth. S M Bhat, Managing Director, Ador Welding Ltd. (AWL)
44 The machine tool industry is a key to ‘Make in India'. V. Anbu, Director General & CEO, Indian Machine Tool Manufacturers' Association (IMTMA)
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MPIL’s Structure to BHEL’s Bunker
22
51
Birth of Welding
BULLETIN
11
UPCOMING PROJECTS 55
46
Low Alloy Steel in Aerospace
PRODUCT / COMPANY UPDATES
56
TENDERS
60
EVENTS UPDATE
61
www.weldfabtechtimes.com
28
TAL BRABO: Power your Future
48
Infra open doors to Weld Manish Kulkarni, Director – Strategy & Business Development, BDB India
34
Issues on Friction Stir Welding of AA5083
AUG - SEPT 2017 | WELDFAB TECH TIMES
7
TESTIMONIALS
TESTIMONIALS R. Srinivasan, President, Indian Institute of Welding (IIW)
Through WeldFab Tech Times magazine, I would like to tell especially to youngsters that welding is as good profession like that of other segments. It is a well paid profession. Today, India has very good welders. The entire Middle-East is depending upon the Indian skilled force. My humble message to the readers is that “Allow the quality to be much high then everything, ensure safety, and if you want to increase your productivity, then increase the quality of manufacturing activity. IIW would always be there to support. Your progress is the countries progress, and countries progress is the world’s progress.”
Great to hear that a Bi-monthly magazine focusing on welding, fabrication and related segments is being launched with the first issue planned in August 2017. Needless to say, this is a topic close to heart and action at an institution like our Welding Research Institute. I am glad to note that the magazine is targeted at the professionals in the various spheres of welding in India, UAE, and other international markets so could open a good communication channel among the like-minded in the field. R. Easwaran, General Manager & Head (Labs, Quality) Welding Research Institute, BHEL, Tiruchirappalli
Welding is a happening field, and with process, material, consumable, equipment, analytics improvements, there is a huge wealth of knowledge being created continually. Welding skills is another area attracting lot of concerted attention, and India should be able to spot the skills and nurture them in a big way, with a huge young population to choose from. The demand for welders across the globe is also on the increase, with many countries having issues due to ageing population. I am sure WeldFab Tech Times will scout around for the relevant information in the field and share with its expected 5000+ readership. Best wishes for a great first issue release and from then on, a continuing journey.
8
WELDFAB TECH TIMES | AUG - SEPT 2017
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TESTIMONIALS
TESTIMONIALS N.K. Sarkar Retired Deputy Chief Metallurgist, Konkan Railway
Welding is extensively applied for our nation building. From welding of mild steel structures, to deep sea hyperbaric welding and welding in outer space, this technology today span a wide spectrum. Nation’s various core sectors viz. Energy, Steel, Aerospace, Transport and Railways, Gas and Petroleum, besides, general industry all use welding technology which is crucial and is of vital importance. Innovative approach and technical knowledge are called for in the fast changing situation, where techno-economic considerations tend to get distorted or diluted in absence of proper information and documents. Newer materials and the methodologies for joining them have been evolved which need basic concepts of metallurgy and pre and post weld heat treatment of the products with proper inspection, strict quality assurance and control, safety besides productivity. I am glad that WeldFab Tech Times have come forward by bringing the bi-monthly magazine for the industry. I wish them success.
I wish ‘WeldFab Tech Times’ a great success in their new venture. There is a vacuum today in publications focusing on exclusively Welding and Fabrication industry. These industries are covered as one of the industries in their magazine by many publications. I am confident welding and fabrication industry is going to get benefitted in terms of current information, views of experts, technical papers, future plans of industry players, new technology, opportunities, challenges faced etc on periodic basis. S M Bhat, Managing Director, Ador Welding Ltd.
www.weldfabtechtimes.com
I wish them great success and best luck for their first Magazine.
AUG - SEPT 2017 | WELDFAB TECH TIMES
9
TESTIMONIALS
TESTIMONIALS C C Girotra, Managing Director, Weldwell Speciality Ltd.
Congratulations on the upcoming publication - WELDFAB TECH TIMES magazine. It is a good initiative by you. Welding industry till now had only one regular publication that is INDIAN WELDING JOURNAL published quarterly by the IIW-Kolkata office. For a large country like ours, this kind of publication by a private organisation is really a commendable step. The IIW publication cover topics related to the academic world and R&D work being done. I hope WELDFAB TECH TIMES will cover the application side of the welding technology and provide news of what’s going on in the real world. Weld Fab can become a spokesman/ messenger of the welding industry by various methods of communication, interaction forums. I wish you and your editorial team all the best.
Machine tool industry, particularly metal forming machine tools, is closely connected with welding and fabrication, and we are excited to see WeldFab Tech Times throw insight into the welding and fabrication industry. IMTMA is sure that the magazine will support the industry to further its innovation and speed up production through right channels. We are hopeful that the magazine will educate the readers more about the welding, fabrication and the machine tool industry. V. Anbu Director General & CEO, Indian Machine Tool Manufacturers' Association (IMTMA)
10
WELDFAB TECH TIMES | AUG - SEPT 2017
www.weldfabtechtimes.com
BULLETIN
Air Liquide sold welding subsidiary to Lincoln Hyundai Heavy equipment with related usual ir Liquide has finished regulatory approvals including jumps 70% the sale of Air Liquide competition authorities’ Welding with its in Korea approval. Air Liquide is announced in April 2017 with subsidiary specialised in
A
Source: www.airliquide.com
the manufacture of welding
Lincoln Electric: the leading
focused on its gas and service
and cutting technologies to
player in design, development
activities following the
Lincoln Electric France SAS
and manufacture of arc
acquisition of Airgas and also
which is the subsidiary of
welding products, robotic
on the implementation of its
Lincoln Electric Holdings. The
arc welding systems,
company program NEOS for
signed sale agreement was
plasma and oxy fuel cutting
the 2016 – 2020 period.
SAIL promotes steel use in rural areas
S
Source: en.wikipedia.org
AIL has launched a
another key step taken was
series of awareness
preparation of a SAIL Mason
programs aimed at
Directory that will enable the
increasing steel consumption.
company to again reach out
H
The move was initiated by
to participants directly in the
operating profit. Operating
the company's northern
future .The rural awareness
profit at the world’s
workshop like these are aimed
largest shipbuilder rose to
at increasing production and
Won315bn ($280m) in the
region marketing group beginning from Rewari,
Source: www.financialexpress.com
yundai Heavy Industries has reported a 70
per cent jump in first-half
Haryana. The workshop
can be used and incorporated
consumption of steel in the
first six months of 2017
apprised participants of the
in the rural infrastructure. It
country, as enhanced steel
from Won186bn IN 2016.
various uses of steel and how
also included a presentation
consumption would pave
It is the company’s first
construction in the rural
on manufacturing of various
the way for rapid growth and
earnings announcement
sector can be improved with
steel products and its usages
modernization. The workshop
after Hyundai Heavy split
the use of steel. The masons
in different walks of life
was attended by about
into four companies in
were also informed about the
especially in the rural sector.
50 masons as well as few
April. As per the company
various steel products that
As part of the workshop,
prominent local people.
reports, Hyundai, together with its two other shipping affiliates, won orders to build
Miller enhance ArcReach Technology
M
81 vessels worth $4.5bn in 2017 compared to 16 vessels
iller Electric
parameters while welding.
worth $1.7bn in 2016. Its
has enhanced
These expanded ArcReach
first-half operating profit
its ArcReach
capabilities are available by
swung to Won48bn. Daewoo
technology with two latest
pairing enhanced ArcReach
Shipbuilding and Marine
capabilities which includes
accessories with the new XMT
Engineering is also expected
Cable Length Compensation
350 FieldPro offerings from
to report an operating profit
(CLC) technology and the
Miller. The XMT 350 FieldPro
of up to Won800bn. South
Adjust While Welding (AWW)
lineup includes a polarity-
Korea received new orders
reversing model that joins the
totaling 2.83m compensated
automatic compensation
cable; while the AWW allows
larger ArcReach portfolio in
gross tonnage during the first
for voltage drop in the weld
welding operators to adjust
late 2017.
half of 2017.
technology. CLC provides
www.weldfabtechtimes.com
Source: www.millerwelds.com
AUG - SEPT 2017 | WELDFAB TECH TIMES
11
BULLETIN
Grasso school to start welding course
E
lla T. Grasso Technical
per year. The new program
High School in
would take EB’s requirement
Groton started a new
directly to Grasso Techs, so
welding program: Welding
that students could learn to
and Metal Fabrication. The
become Electric Boat Welders
curriculum was developed
specifically. The new school
in collaboration with Electric
cost approximately $134.9
Boat (EB). EB could soon
million and is state-funded.
have a build rate of up to
It's expected to be completed
three Navy submarines
by 2019-2020 school year.
New OHS welding lab considers safety
Source: www.indiannavy.nic.in
regon High School
Low Energy Air Filtration
R
the launch of its first two
licence and sign a contract
(OHS) has unveiled
WeldStation models. The
Naval Offshore Patrol Vessels
for defence ships in 2011.
its new welding lab
O
eliance Defence
Navy. RDEL is the first
and Engineering
private shipyard in India to
(RDEL) announced
obtain defence production
booths will use 80 percent less
(NOPVs) - Shachi and Shruti
According to the company
during July 2017. The new lab
energy than other welding
at their shipyard in Pipavav,
reports, the vessels would be
is built for efficiency, safety,
booth. The lab shall also
Gujarat. The two NOPVs
fitted with 20,000 KW diesel
and group learning. The OHS
feature five Reality works
are among five ships being
engine-driven propulsion
has upgraded 10 welding
Guide weld virtual reality
constructed by RDEL under
systems and can deliver
booths along the north and
welding simulators, which can
the P-21 project of the Indian
speeds up to 25 knots.
east walls, and included a
connect to any Macintosh or
metal mill, metal lathe, and
Windows computer and are
plasma cutting stations in
effective for teaching metal
the middle of the room. The
inert gas (MIG) welding as well
welding booths are designed
as shielded metal arc welding -
with a CleanAir America’s
also known as stick welding.
India to invest ` 70,000 crore for six submarines
aharashtra state
fabrication companies,
T
70,000 crore deal to build six
the RFI by September, 2017.
government has
assuring them a capital subsidy
advanced stealth submarines.
Before floating a reque st for
decided to provide
Capital subsidy for electronics fabrication units hiked
M
12
RDEL launches two naval patrol vessels
he Defence Ministry of India has initiated an estimated Rs
an Indian shipyard. The foreign shipbuilders are expected to respond to
of up to 20 per cent of the fixed
After a delay of 10 years, the
proposal (RFP), the navy will
more fiscal incentives to
expenditure for investments in
submarines, which got the
issue the NSQRs (naval staff
electronics manufacturing
these regions. According to the
government nod way back in
qualitative requirements)
companies setting up units
industry department estimates,
2007, will be built under the
to the six shipbuilders.
in the industrially backward
a fabrication unit of full capacity
Project-75 (India) program.
The selection of an Indian
regions of Vidarbha and
would guarantee an investment
Six shipbuilders from France,
shipyard for partnership
Marathwada. The state cabinet
of Rs 60,000 crore and create an
Germany, Russia, Sweden,
with foreign shipbuilders
has revised its promotion
employment opportunity for at
Spain and Japan are already
will be done in a parallel
policy for electronics
least 32,000 people.
in the fray to collaborate with
process.
WELDFAB TECH TIMES | AUG - SEPT 2017
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BULLETIN
Tata Steel to focus on India market
T
Yamaha opens training centre in Chennai
Indian market,
2035. Considering the current
achieving operational
stage of development and the
I
Manufacturing (JIM) named
The students will learn
excellence and delivering
expected growth in India’s
as Yamaha Motor NTTF
technical skills of Japanese-
value-added & differentiated
economy in the next decade,
Training Center (YNTC) in
style manufacturing, covering
products to its customers.
steel demand in India will
Chennai, Tamil Nadu. The
nine main topics such
The global market is expected
witness significant growth.
institute focuses on training
as Motorcycle Assembly,
to face headwinds due to
future shop floor leaders
Painting, Welding, Casting,
geopolitical issues. According
in the Japanese working
Machining, Parts Control,
methods and manufacturing
Quality Control, and Utility
style. So far, around forty
Techniques.
ata Steel plans to
next year and the slowdown is
majorly focus on
expected to continue through
to the World Steel Association, global steel output would taper
www.weldfabtechtimes.com
Source: www.tatasteel.com
ndia Yamaha Motor
students have been admitted
has opened its first
into the first academic year
Japan-India Institute of
of the four-year program.
AUG - SEPT 2017 | WELDFAB TECH TIMES
13
WELDING IN RAILWAYS
N.K. Sarkar, Retired Deputy Chief Metallurgist, Konkan Railway
I
Indian Railways on fast track with Welding
ndian Railways has always been the single most important agency in India’s infrastructure with the
network of railway tracks expanding for many years. The Calcutta and Delhi Metros are the finest examples of highly complex engineering techniques being adopted to lay an underground railway in the densely built-up areas of Calcutta city and over the ground in the capital city of
Shielded Metal- Arc Welding
numerous changes due to the increasing
New Delhi. Special trains viz. Rajdhani,
Earlier, most of the fabrication in rolling
popularity of Welding Industries in India
Shatabdi, Duranto, etchave been a
stocks such as coaches, wagons and
and abroad. Beside training and testing
commendation on the part of Indian
locomotives used to be of riveted design.
of welders, publication of various welding
Railways so far.
standards have achieved a greater
used as a method of repairs on Indian
measure of success in standardizing
has also been in pace with economic
Railways. Due to various constraints
the quality of consumables, machines,
growth of the country. It is true that,
– both economical and technological,
welded products, the application of
with this support, Indian Railways
manual metal arc welding was the
welding in the industry, inspection and
have emerged as the major strength
predominant method of welding on
testing of welded components.
of Indian Economy. It was reported
Indian Railways. You will be surprised
by the railways that the investments
to note that the same rutile type of
welding technologyhas aimed at
in rolling stocks especially in wagons,
electrodes was used for different varieties
higher productivity and lowering the
would be witnessing manifold increase
of steels.
fabrication cost and also with the
Introduction of welding technology
as compared to the investments made in
Traditionally, the repair workshops and
Consequently, improvements in
setting up of Chittaranjan Locomotive
earlier years. As a result, use of welding
sheds of the railways was depended upon
Works (CLW), welding was accepted
consumables and equipment will also
the use of shielded metal arc welding
as a tool for fabrication on the railways
enhance its production. Different types of
(SMAW) process and oxy-acetylene gas
for the manufacture of welded boilers
materials shall be used for different types
welding and no standard / code was
for steam locomotives followed by
of coaches and wagons where a major
available for the consumables or for the
Integral Coach Factory (ICF) for
change in the type and design of the
process / procedures.
manufacturing of coaches and Diesel
wagons is also on the cards.
14
Welding, prior to the fifties, was only
WELDFAB TECH TIMES | AUG - SEPT 2017
In the fifties; however, there have been
Locomotive Workshop (DLW) for the
www.weldfabtechtimes.com
WELDING IN RAILWAYS
manufacturing of diesel locomotives. During the introduction of welding of the boilers for the steam locomotives, Industrial Radiography was introduced in 1956 at Chittaranjan for the first time. Indian Railways used this Radiography technology to maintain the quality of the welded joints, which were most important for the safety and economy. After the steam locomotives phased out, CLW switched over to diesel- electric / electric locomotives, which were also of
Fig.3: SMAW welding is carried out on the Base frame of a diesel locomotive.
Fig.4: Hard facing of Austenitic Manganese Steel Crossing by SMAW.
welded design Gradually, the railways set
is undertaken with this process to take
Gas manufactured by BPCL which is
up two more production units viz. Diesel
care of areas which are inaccessible to
a mixture of propane and methane is
Loco Modernisation Workshop at Patiala
automatic or semi-automatic processes.
used for cutting in place of Dissolved
and Railway Coach Factory at Kapurthala
SMAW is also used for reclamation /
Acetylene on the railways. Each cylinder
where welding is carried out on a large
repair of motion components viz. equaliser
contains about 19cu.m gas. Due to its
scare in the manufacturing of diesel loco
beams, base frames (Fig.3), coupling rods,
adequate quality, inexpensiveness,
components and coaches respectively.
cam shafts, tri-mount bogies, bolsters,
less toxicity, this gas has always been
Though Steam locomotives have
knuckles of centre buffer couplers,
preferred the most.
been phased out from the main lines,
gas inlet casings, valve-seats etc. of
steam locomotives are still used over the
locomotives.
Nilgiri Mountain Railway and Darjeeling
Another area where SMAW is widely
Various processes have been used for welding of non-ferrous components on the railways. Brazing is one of the major
Himalayan Railway. Some of the Nilgiri
used is in the reclamation / resurfacing
processes used for joining Aluminum and
locomotives were heavily rebuilt and
of components like Medium Manganese
Copper tubes for the heat exchangers
converted to oil firing. New locomotives
points and crossings. Water cooling
in diesel locomotives. Silver brazing is
for the Darjeeling Himalayan Railway are
during welding is used for hard facing
worked out for the electronic relays and
being manufactured at the Golden Rock
of Austenitic Manganese Steel crossings
Armatures and also many other non-
workshops of Southern Railway.
(Fig.4) to avoid precipitation of unwanted
ferrous metal components.
The Shielded Metal Arc Welding (SMAW) process continues to be the predominant method for repair and
phases and preserve good ductility and work hardening properties. It is hardly surprising therefore that the
Plasma cutting is widely used on the railways for cutting stainless steel sheets, tough floor and heavy steel sections
maintenance of railway components.
Indian Railways too had gone for their
etc. (Fig.5). This method is also used for
This process is also used extensively in
own standards on SMA welding relating
making holes in the cast wheels (Fig.6).
the fabrication of permanent installations
to materials, consumables, processes,
like platform structures, overhead traction
applications, inspection and testing etc.
structures, foot-over bridges and similar
The Indian Railways formulated their
applications where static and / or dynamic
own specification no. IRS M-28, which
loading is involved.
covers classification, testing and approval
Subsequently, welding was also
of electrodes. The electrodes used by
extensively used for the fabrication of
the railways are periodically assessed
several components of higher capacity
and classified by RDSO as per this
BOX, BCX, BOI, BOY type wagons.
specification.
Though SMAW was mostly used initially usage has been +considerably reduced and
Gas Cutting, Brazing and Plasma Cutting
only about 50 per cent welding fabrication
About 70 percent Bharat Metal Cutting
for the fabrication of rolling stocks, its
www.weldfabtechtimes.com
Fig.5: Plasma cutting of stainless steel tough floor.
AUG - SEPT 2017 | WELDFAB TECH TIMES
15
WELDING IN RAILWAYS
service. Initially, SMAW was used for building up of worn out flanges, but this process was not very productive and also required the services of highly skilled and conscientious personnel. Besides, cracks were observed on the weld metal and the Heat Affected Zone due to faster cooling rate associated with high carbon equivalent (approx.0.60). It was therefore decided to switch over to the sub-merged arc welding method. Since mostly singlehead machines were available, these were only used. Faster welding speeds with the use of high welding currents, problems of inter-pass cleaning were minimised due to the complete absence of spatter; Fig.6: Making holes in the solid cast wheels by plasma arc.
the arc being confined within the blanket of flux, discomforts of SMAW were
block employed
eliminated. The arc and deposited metal
both SMAW and
were protected from contamination with
Sub-merged
atmospheric oxygen and nitrogen by the
Arc Welding
blanket of flux at all times.
processes. The
The quality,in terms of being
inside and outside
economical and its service of the
walls, middle and
built-up wheel flanges were found to
top decks side
be satisfactory. This prompted the
plates, fuel shelf
railways to import 3-head sub-merged
compartments, cane bearing supports and end Fig.7: Showing the locations for welding of the engine block.
plates were welded in sequence by both
Sub-Merged Arc Welding Along with the SMAW, sub-merged arc
The SAW process is enormously used
welding is also used for the fabrication
for fabrication of under frames, bogie
of rolling stocks. This process is mainly
structures, Central Pivots, side panels,
used for fabrication of longer members.
bolster bogies, etc. of the rolling stocks.
Automatic welding is used where the
The SAW process is used extensively
joints are long and uninterrupted and
at the resurrection of old diesel
semi-automatic welding for the other
locomotives, which have served for 16
locations.
years or more was undertaken at the
The Engine Block (Fig.7), the principal structural member of the diesel engine
16
SMAW as well as SAW process.
DMW, Patiala. During service, wheel flanges of the
is a composite weldment with heavy
carriage and wagon stocks wear out
steel forgings, which serves as the crank
more than the tread portion resulting
shaft housing and hence becomes
in the formation of thin and sharp
the backbone of the structure. This
flanges rendering the wheels unfit for
WELDFAB TECH TIMES | AUG - SEPT 2017
Fig.8: Showing the 3-head sub-merged Arc welding machine for resurfacing of worn out wheel flanges.
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WELDING IN RAILWAYS
automatic welding machine (Fig.8) for improved productivity and quality of weld deposit. The welding technique with this machine had to be standardised with the positioning of welding heads in such a way that the individual beads just overlapped each other half-way. It had to be ensured that neither the weld metal was over-flown from the top of the flanges nor the tip was red hot. Besides the improvement in the economics in the
Fig.10: Shows the welded Railway Bridge over the river Zuari in Goa.
reconditioning costs of worn-out flanges, the life of each reconditioned wheel would be increased at least by three
From the techno-economic studies,
metal arc welding in mild steel bridges
times. Based on the experiences gained
it was observed that the welded plate
carrying rail, rail-cum road or pedestrian
with this imported 3-head sub-merged
girders were about 25 per cent lighter
traffic has been prepared (welded
arc welding, indigenous multiple-head
and required less maintenance than
bridge code) by the railways. Similarly,
sub-merged arc welding machines have
those of the equivalent riveted girders.
IS Specification No. 1024 on code of
been developed for use on the Indian
Therefore, SAW process was used for the
practice for use of welding in bridges
Railways.
fabrication of the longer members of the
and structures subjected to dynamic
bridge girders. Fig.9 shows the assembly
loading was formulated by the Bureau of
activity on the Indian Railways saw
of the plate girder for one Railway Bridge.
Indian Standards. The railways also have
bridging of mighty rivers viz. Ganges,
The bridges over Zuari (Fig.10) and
gone for their own specification for the
Brahmaputra, Godavari, Krishna,
Brahmaputra rivers having the longest
indigenous wire-flux combinations viz.
Mahanadi etc. Most of the bridges on
span over 125 m were welded by sub-
IRS M-39 for all sub-merged arc welding
the railways were steel girder bridges.
merged arc welding using indigenous
on the railways.
Though the girders of these bridges were
steel and wire-flux combinations.
The post independence construction
of riveted design, the flooring systems
The 290 km extension of the Indian
GTAW and GMAW Processes
of these bridges were provided with
Railway network will allow a 900 km
Both electric and diesel locomotives are
welded design. SMAW process was used
journey direct from Delhi to Srinagar.
equipped with electrical transmission
for welding of the flooring systems.
Constructing the railway route to this
system with DC series Traction Motors
Longulia bridge of 4 spans of about 46
isolated region has involved significant
which has commutators on which the
m. length near Waltair (Visakhapatnam)
engineering challenges. The route
armature coils were originally connected
was an example of where the girder
includes many bridges, viaducts and
with conventional soldering method.
truss members were of welded design.
tunnels – the lower section of the railway
These joints were weak and failed in
crosses a total of 158 bridges and passes
service frequently due to increased
through 20 tunnels, the longest of which
resistance between the two adjoining
is 11km in length. The greatest single
commutator segments. These joints were
engineering challenge was crossing the
later made by Automatic TIG welding
river Chenab which involves fabrication
using a special technique of welding
of a 1,315 m long bridge by welding,
on the first circular row first and then
359m above the river bed. This bridge
automatically transferred on to the
will be the highest railway structure of its
second row and so on till the welding was
kind in the world, 35m higher than the tip
completed. There was a time gap of about
of the Eiffel Tower in Paris.
1.5 seconds between the two consecutive
Fig.9: Showing the plate girders being assembled for Sub-merged Arc welding.
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As far as welding of bridges is concerned, a code of practice for
spots. The reclaimed commutators were satisfactory in service. TIG welding is
AUG - SEPT 2017 | WELDFAB TECH TIMES
17
WELDING IN RAILWAYS
Fig.14 : Robotic welding of a coach at ICF.
Fig.11: Shows TIG welding being carried out on Aluminium Water tanks. used for the joining of Central Pivots to the bogies. TIG welding is also used for repairing of overhead aluminum and stainless steel water tanks in coaches (Fig.11). The aluminum Pistons, made of forged aluminum alloy used to get damaged in service. These used to be replaced earlier by new pistons. Later, with the
of steel andsome specialized wagons
introduction of TIG welding on the
have been introduced with stainless
railways, these damaged pistons were
steel or special alloy steels to reduce the
reclaimed by TIG welding using 1.6 mm
corrosion. Some BOBR-AL wagons have
aluminum alloy wires. RDSO have taken an Indian Patent for
Fig.13: Showing the FCAW in progress.
been made of aluminum in these, the under frame is made of steel while the
the development of filler wires for TIG
under frames and bogies of rolling stocks
rest of the body is made of aluminum.
welding of leaded bronzes in seventies
and also superstructures of carriage &
The aluminum alloy used is 'RDE-40',
and quite incidentally I have been
wagons. Rail Coach Factory at Kapurthala
and has 4 per cent zinc, 2 per cent
partnered in the Patent.
uses MIG / MAG welding with solid and
magnesium, 0.35 per cent manganese,
flux cored wires while Integral Coach
and 0.15 per cent zirconium. The under
process is used for the fabrication of
Factory at Chennai uses mostly flux cored
frame and the body of these type of
long components like bridge girders,
wires.
wagons are joined by the use of Huck
Along with SMAW and SAW, GMAW
MIG welding is used for rehabilitation
Bolting system. These aluminum wagons
of coaches (Fig.12). Almost 50 to 70
have the advantage of less corrosion in
per cent components in coaching
many circumstances. A typical rake with
stocks including chassis, under frame
aluminum wagons instead of steel ones
(for maintenance), head stock etc are
would carry almost 240t more goods.
subjected to MIG welding. Gas mixture
Fig.12: MIG welding being carried out on the side panels of a coach.
18
WELDFAB TECH TIMES | AUG - SEPT 2017
of carbon dioxide, argon and oxygen
Robotic Welding
are used for Mid Life Rehabilitation of
Robotic welding has been intiated for
coaches after its 12.5 years’ service. Flux-
the manufacture of coaches both at
cored wires are used with this gas mixture
ICF, Chennai (Fig.14) and also by the
(Fig.13).
private companies. This process is also
Except for a few special-purpose wagons,most of the wagons are made
used for manufacturing of wagons and bridge girders in a limited way. Some
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WELDING IN RAILWAYS
Stainless Steel Coaches And Wagons We all have seen the present day coaches painted in different colours. Painting is one area where climatic conditions and continued exposures to sun and elements have not allowed even the best paints to have long durability which further causes frequent withdrawal of coaches from service for repainting etc. The use of stainless steel coaches made of 409 M grade (Cr -10.8 to12.5 %; Ni – 1.5 %max.; C – 0.03% max.) have reduced corrosion considerably but these coaches require painting. In order to do away the high cost of repeated painting, the railways have decided to go for 301LN
Fig.15: Thermit welding of rail joint is in progress.
grade (Cr – 16.0 to 18.0%; Ni – 6.0 to 8.0%;
primarily objectionable because of the
C – 0.030% N -0.1%) austenitic stainless
additional maintenance expenses. This
steel in order to eliminate the need of
unpleasant sound comes from the fish-
painting. New generation EMU coaches
plated joints and if these joints could
are made of 304 grade (Cr-18.0 to 20.0%;
be eliminated, the track will give better
private companies use robotic welding
Ni- 8.0 to 10.5%; C- 0.08%) stainless
riding comforts, reduce maintenance
for fabrication of pre-welded long and
steels. Stainless Steel is also used for
costs and safe- guard from sabotage.
high height structural beams which are
inside furnishing of the coaches. FCAW
It is hardly surprising therefore that
used by the railways for their bridges and
is used at ICF while RCF uses solid wires.
the railways have gone for laying
structures. Since this is automatic, there
Delhi Metro coaches do not require
welded rails.
will be drastic changes in productivity
painting as they are made of 301L and
as the quality of welds will certainly be
304 stainless steels.
inimproved conditions.
Similarly, the stainless steel wagons
There are three main processes for welding of rail joints: Alumino-Thermic, Flash-Butt and Gas Pressure welding.
with a high pay load are designed
Friction Welding
to overcome the corrosion, body
Alumino-Thermic Welding
The Friction welding is the only method
bulging and weak stanchions. 409M
Alumino-Thermic commonly known as
for joining two portions of bi-metallic
grade Stainless Steel is used for the
thermit welding is the pioneer in-situ rail
diesel engine valves. The quality of the
construction of wagons. GMAW are used
welding process throughout the world.
joints is satisfactory and hardly any weld
with solid wires as well as flux cored wires
The process is simple and no expensive
failure has been reported. Moreover, this
and gas mixtures for their fabrication.
equipment is required. It is similar to
technique is widely used by the private
Stainless steel components are welded
steel making process (Fig.15). The weld
companies for the railways.
at some locations with dissimilar metals.
metal is produced by the exothermic
These welded joints are subjected to
reaction between aluminum and iron
Electrical Resistance Welding
some special treatments so that these
oxide, carried out in a refractory lined
ERW process is used for welding of the
areas do not require any restorations
crucible. Keeping in view the rail steel
chain links used for the break down trains
than the rest of the coaches.
chemistry and the metallurgical aspects of the weld deposit, the mixture is
and also for joining alloy steel tool bits with the mild steel shanks. Pipes
TRACK WELDING:
formulated. Besides, aluminum and iron
and tubes used on the carriage and
All of us are familiar with the clickety
oxide, steel chips, Ferro-manganese,
wagons are also welded by this same
- click sound of rail joints. This sound
Ferro-silicon, calcium fluoride, vanadium
method.
is unpleasant to the passengers. It is
etc. are added in the mixture in
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AUG - SEPT 2017 | WELDFAB TECH TIMES
19
WELDING IN RAILWAYS
Fig. 16: Flash-Butt welding machine for rail welding.
is reached. The number of making and
which is then heated by a special designed
breaking contacts are preset to achieve
burner in the shape of the rail ends to
the required temperature, which when
about 1,200°C. When the desired upset
achieved, the upsetting pressure is applied
is reached, heating is discontinued. The
to accomplish the weld. Welding is carried
upset metal is trimmed off all round the
out mostly by an automatic electric
contour of the rail section. The quality
resistance welding machine. Mobile Flash-
of the joints is the best amongst all the
Butt welders are also now available which
methods of joining of rail ends.
are used at site in some of the railways.
Quality of Rail Joints
proportions appropriate to that required
Gas Pressure Welding
In its effort to minimise train accidents
in the final weld metal. Petrol and air
Gas Pressure Welding is also another
vis-Ă -vis quality of the rail joints, the
mixture is used for preheating the rail ends
method of joining of rail ends. This
railways have pressed into service a slew
covered with refractory moulds.
process is largely used in many of the
of sophisticated devices including the
advanced countries for their high speed
state-of-the-art SPURT (Self-Propelled
Flash-Butt Welding
routes. So far, only two railways in India
Ultrasonic Rail Testing) car to detect
Flash-Butt welding of rail joints is carried
have used this process. It is a solid phase
defects in the rail and welded joints. With
out regularly in the workshops (Fig.16)
bonding process where the heating
an on board computer, this car can detect
for joining 3,5,10 and 20 rails to form
temperature never exceeds beyond the
the flaws more objectively and accurately
long welded rails as required. In this
solidus of the metals i.e. the temperature
while running at 40kmph. The other
process, the rail ends are butted against
does not reach the fusion point of the
sophisticated testing equipments include
each other without any gap while heating
metals.
full size fatigue testing equipment are used
is obtained by electric resistance by
In this method, the rail ends are butted
making and breaking contacts with each
against each other without any gap
rail end until the melting temperature
(Fig.17) in between at a very high pressure,
to maintain the quality of rail joints.
Conclusion Except for some exotic and costly welding processes developed especially for jobbing types of application in defence, nuclear and aviation industry, Indian Railways use almost all welding processes available today. As a result, welding has progressed leaps and bounds on Indian Railways and today they are the largest users of welding consumables and equipment. The railways to arrange for sufficient numbers
Rail ends being butted against each other.
Reinforcement (upset metal) after bonding.
of qualified professionals besides, training and certification of their supervisors and skilled artisans. The success of the Metro-lines has prompted other State Governments to go for metro-rail system in their big cities especially Mumbai, Bangalore and Hyderabad and Chennai. As India moves towards a relative prosperity, it will force
The joint being achieved.
Rail contour after trimming of the upset metal.
Fig.17: Gas Pressure welding of rail joint.
20
WELDFAB TECH TIMES | AUG - SEPT 2017
Indian Railways to opt for more advanced welding technology for creating Railway assets in future.
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EXECUTION
MPIL’s Structure to BHEL’s Bunker
A
Bunker Shell forms an integral part
with the help of CNC multi nozzle gas
time consuming process for the welders to
of any thermal power plant and
and CNC plasma cutting machine. These
weld two dissimilar metals. Consumables
MPIL Steel Structure was excited
plates were welded together as per the
like E7010, E8018, E6015, E308 and E309
to be the part of BHEL’s prestigious project
part drawings. They were assembled at the
were utilised. Each of the welded joint was
of a Bunker Shell for a 2 x 500 MW thermal
factory floor with the help of EOT cranes.
thoroughly inspected with 100 per cent
power plant located at Tiruchirapalli. MPIL
Due to its sheer size, the assemblies and
Radiography and Ultrasonic Test.
had successfully executed the Bunker Shell
subassemblies were shifted to MPIL’s
project in the given time frame. The bunker
open fabrication yard, where the company
given a specific part number for easy
weighed 430 MT, reaching a height of
utilized its Goliath crane along with hydras
identification and tractability. This
24.36 m from datum. The most challenging
to assemble each part together for final
increased the efficiency of assembly
aspect of this project was the sheer size of
quality inspection.
process at site. The subassemblies were
the shell; hence the fabrication had to be
22
The Bunker Shell demanded for
Each of the 23 sub-assemblies was
then loaded on to trailers according to
planned as per the in house fabrication,
combination of high grade steel material
their assembly sequence and were then
pre assembly for quality check and site
to withstand high temperature required in
dispatched to Tiruchirapalli.
dispatch. Considering the challenges,
Boilers for Power Plants. To meet the said
the shell was divided into 4 parts which
requirements the material used were as per
successfully explored great expertise in
consisted of 23 sub - assemblies. There
- IS 2062 grade E 250 and E 350 for outer
domestic and international projects. The
were more than 2,000 steel plates of varying
shell and inner liner of SS 304 SA 260. The
company has been exploring new horizons
sizes from 10 mm to 40 mm to be welded
bunker shell was composed of Mild Steel
in the Steel Structure Industries to reach
together. Each plate was cut to the size
as well as Stainless Steel liner hence, it was
new heights.
WELDFAB TECH TIMES | AUG - SEPT 2017
MPIL has come long way and has
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EXECUTION
Trial Assembly Procedure
Project – Bunker Shells (428 MT)
• Bunker Shell- 4 Parts – Total 23 Nos.
• BHEL-High Pressure Boiler Plant, Tiruchirapalli • For Neyveli Lignite Corporation (2X500 MW).
of Assemblies • Part 1 - 4 • Part 2 – 4 • Part 3 – 8 • Part 4 – 7 Plate Thickness Details (Total 2,000 Plates of varying profiles) • MS E 350 C – 189 MT (Bunker Skin Plate with its Stiffeners – 1300 Nos. of Plates) • SS 304 – 24.5 MT (Liner Material-704 Nos. of Plates) a. Bunker Skin Plate – 12 mm (E 350 C) b. Hopper Plate – 12 mm (E 350 C)
Assembly of Bunkers 1. Part 1 and Part 2 assembly will be in vertical position with only 4th hopper of Part 1. 2. Part 2 and Part 3, Part 3 and Part 4 can be done Vertical or Horizontal as per suitability. 3. Ensure the loose SS liner plate shall be laid with wall plates. 4. Proper marking on loose SS liner Plates should be done with hard Punch and painted with white color.
c. SS Liner Plate – 4 mm (SA240 TP 304) d. Bunker Stiffener Plate - 6mm to 50 mm (E 350 C).
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AUG - SEPT 2017 | WELDFAB TECH TIMES
23
INTERVIEW
There is a huge market for
Welding in India.
There are good signs of recovery for the welding industry. The growing infrastructure projects are a big business for the segment. We are almost in line with the international markets. Q. What according to you is the current market scenario of welding industry in India? Today, India is much better poised and in a very comfortable position when compared to the last three years. The present government has introduced schemes to boost the industry, the major contributor being ‘The Make in India’ campaign. India had to face recession during 2007-13, but gradually, we are coming out of the recession, though not 100 per cent. There are very good signs of recovery for the manufacturing sector
R. Srinivasan, President, Indian Institute of Welding (IIW)
and also for the welding industry. With the inflation rate slowly but steadily falling will give opportunities for reduced
24
Interest rate from the banks and from
production is about 95 to 100 million
years, which is in line with the
the lending institutions. This will spur
tonne of steel every year. Out of which,
international countries.
the growth and the introduction of
around 3 million metric tonne of steel
the GST which will eliminate the multi
is consumed for welding materials. The
tax problems, which would further
government has set a target to supply
Q. Is the Indian welding industry on par with the international countries?
encourage the industry to focus on
250 million metric tonne of steel in India
It cannot be stated that India is lacking
upgradation and adoption to newer
by 2020-2022. With the set target, it can
behind in welding, but definitely
technologies. From the last quarter of
be said that there is a huge market for
we need to upgrade ourselves. The
2017 onwards, we hope to have much
the welding industry in India. Besides,
Indian Institute of Welding (IIW) is
better progress into the segment and
the growing infrastructure projects are
largely focusing on the same. IIW is
related industries.
another big business for welding. The
an institution of professionals from
government has directed all departments
the welding industry of India. It is a
Q. What is the current market size and how much do you expect in the coming time?
to complete the listed projects before
non profitable organization under
2022. This strengthen
the section 25of the company’s act of
our view of extraordinary growth
India. IIW is the only member of the
Today, India is the second largest steel
potential in India, and the welding
International Institute of Welding in
manufacturer, probably, just reaching
industries have projected a growth of
India, with headquarters in Paris. The
towards Japan. The average steel
about 6-7 per cent over the previous
Indian automobile sector is definitely
WELDFAB TECH TIMES | AUG - SEPT 2017
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INTERVIEW
closer to the international market in
automobile & steel. We provide knowledge
important, but also the material that
terms of quality. Infact, today, the
to the training centers of these sectors.
requires into welding; because, India is a
international automobile companies
Our knowledge sharing programs are
country with variety of temperature and
are keen to have a space in the Indian
recognized and audited by NABET & QCI.
climate. This leads to challenges and we
market. So, we are competing with the
The IIW program is certified under
world into this segment, but in terms of
ISO 17024. On completion of the course
in technology is needed to reduce the
heavy engineering, we still need a lot of
curriculum, IIW acts as the assessing
manufacturing time. Once when the
infrastructure support. Unfortunately,
body, based on which we certify the
manufacturing and delivery time is
for welding, there is no basic welding
candidates. IIW also offers the course to
reduced, one can achieve profitability
research centre in India, except
train the trainers so that these trained
towards the product. Thus, a lot of
Welding Research Institute (WRI) in
trainers can develop more training
automation has been introduced in India
Tiruchirappalli, India. WRI is the premier
centers. In 2016, the entire IIW training
and much more is expected.
BHEL Research Centre of India in the
program was audited by QCI and
field of welding and allied areas.
approved (Quality Control of India). IIW
We need to have a government established or government supported
have to overcome them. Advancements
is the only institute or a company in India
Q. What is your say on the robotic automation?
certified by QCI for welding.
Robotic welding techniques definitely
welding research centre. IIW is
offer a much clear and qualitative output. In India, most of the companies, who
work closely with the government and
Q. Which countries according to you are leading in welding and fabrication?
ensure a full-fledged welding research
Japan and Korea are leading into welding
have to equally upgrade themselves on
laboratory. The government has opened
segment. China is also very strong
par with the quality of the company to
up huge opportunities through public
in welding. Canada, USA, European
which they offer their products. So, to
private partnership (PPP) project, starting
countries, and Germany are the other
reach that level, funding is required.
with defence. In the coming years, the
countries largely focusing into welding.
Today, the Micro, Small & Medium
atomic energy, aerospace segment will
India is also definitely not lacking behind.
Enterprises (MSMEs) have lot of facilities,
also boost. The industry is facing lot of
Top welding companies are located in
schemes, and incentives to upgrade
challenges. The major challenge is the
India. Various sectors in India like the
themselves. Thus, these companies have
technological gap between India and the
aerospace, automobile, infrastructure,
to make the best use of such benefits.
international market. The other challenge
etc has started taking a positive turn. The
Today all the latest technology is available
is the availability of skilled manpower,
power plants sector still needs to boost.
at the shortest possible times. It is only
working very hard in this subject. If the government gives us clearance, we can
which is a problem not only in India but
The state owned power plants are
manufacture such equipment, depend upon small vendors. These vendors also
that the industries need to take big step
globally. The entire welding, fabrication
running at an average efficiency of 40 – 45
towards technological upgradation of
and other segments are facing this issue.
per cent, which is a huge area of concern.
their facilities to meet the global needs
Inorder to overcome the challenge, Prime
Similarly, the transport sector also needs
and challenges.
Minister is focusing largely to boost
to upgrade. Shipping is one area wherein
skilled man power in India.
we need to increase our welding activities,
Q. What is IIW’s initiative in creating skill development especially into the welding and fabrication segment?
the subcontinent. We are not exploring
Q. What is IIW’s role in creating awareness on latest technology in the industry?
the possibilities of the coastal line by
In all, IIW has 14 branches. We organise
having large number of ship repair
free technical lectures, wherein we
IIW has taken up a project of creating
workshops and shipyards.
invite experts from the segment for a
since India has the largest coastal line in
discussion. These lectures are not only to
skilled manpower for about 5-6 years with
the members but all those interested in
been appointed as the knowledge partner
Q. What kind of advancements been brought about in welding technology segment?
for the capital goods sector, the
It is not only the welding that is
IIW organizes short duration welding
the Government of India, especially with the Ministry of Skill Development. IIW has
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welding. Besides, we also have a seminar at national levels and at branch levels.
AUG - SEPT 2017 | WELDFAB TECH TIMES
25
INTERVIEW
workshops in various small industrial pockets. We organize two national events – National Welding Meet (NWM) and National Welding Seminar (NWS). IIW also organizes International Welding Congress every three years. The National Welding Meet is usually held in cities other than the Four Metros. This will give an opportunity to the welding professionals present in these cities to get proper exposure to the technological developments that are happening and to interact with experts of the field. During December 2017, we will be hosting the 5th International Welding Congress IC 2017 in Chennai, along with the WELD INDIA exhibition. The Weld India is the only exclusive welding Exhibition of the country. of experts available to help and assist
designed in the history of world and
benefit for the small and medium scale
the industries and to solve their issues
the mankind, but has been developed
fabricators of welding sector, to see
relating to welding advancements. The
by India. Engineers used 100 per cent
the latest developments in the field of
experts use IIW as a forum to impart
indigenous welding technology, and
welding and in welding automation.
knowledge, and create awareness on the
that’s where the welding segment has
skill development program.
reached.
IIW organizes exhibitions for the
Q. What is IIWs role to maintain quality in welding?
chapters in some of the engineering
Firstly, India needs to upgrade its scale
colleges wherein the students can better
Q. What about the safety measures been followed in welding?
of quality. The European market has
understand welding sector and look
Safety has been one of the major
issued directives on several quality
forward as a career. Today, the general
issues in all the sectors. But today,
standards. A company which is certified
opinion of the public is that they are still
awareness has been created. The
under ISO 3834 can only service and
not aware of welding as a career.
established companies like the first top
supply the welded products to EU. This
I would only like to emphasis on
15 manufacturers in the list generally
is a mandatory requirement. This has
the fact that welding science and
follow safety very stringently, and the
given rise to the Indian manufacturers to
welding engineering has great carrier
MSMEs and small scale industries, which
upgrade their quality, skills and get the
opportunities to the young engineers.
constitute around 80 per cent of the
certification of approval.
We are proud that one of the milestone
manufacturing activities in India, need to
achievements for welding segment was
upgrade the safety precautions.
IIW from India are authorized to assist the industries who are willing to comply
the recent satellite, which off loaded 100
the EU requirements and certify them.
satellites in orbit.
In most of the cases, we also undertake
26
We have also opened up student
The satellite was fully welded. The
Large scale industries depend upon MSMEs, but here the awareness of safety needs to be improved. IIW, always
training for companies and then upgrade
companies like Bharat Forge, BHEL,
and in every seminar conclude Jana
their quality standards. We are not
L&T, Godrej and more industries were
Gana Mana along with safety subjects.
directly involved in any manufacturing
all involved in this project. What a pride
We try to inculcate the habit of safety
activities, but act as an umbrella,
moment for the welding industry is this!
in manufacturing segment. Safety in
representing the small, medium, and
One single launch vehicle carrying 104
welding is not a decorative accessory, but
large scale segments. IIW have a pool
satellite. Such project was never been
a mandatory requirement.
WELDFAB TECH TIMES | AUG - SEPT 2017
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CASE STUDY
Low Alloy Steel in Aerospace - Surendra M. Vaidya, Executive VP & Business Head, Godrej Aerospace - Hitesh A. Narsia, Asst. Manager - Welding, Godrej Aerospace
G
odrej Aerospace, the Business unit of the 120 year old Godrej & Boyce Mfg. Co. Ltd. has played a key role
in building the Liquid engines used in the rockets of ISRO including the Polar Satellite Launch Vehicle (PSLV) & Geosynchronous Launch Vehicle (GSLV). Starting in 1985, GA’s manufacturing of critical components for ISRO’s satellite marked the beginning of Godrej’s entry into the complex Aerospace manufacturing segment. The Geosynchronous Satellite Launch Vehicle (GSLV-Mk III), is the latest of the launch vehicles from ISRO, launched by ISRO in June 2017, from its spaceport at Sriharikota in Andhra Pradesh is a three-stage vehicle with two solid motor strap-ons (S200), a liquid propellant core stage (L110) and a cryogenic stage (C25) capable of launching 4 ton class of satellites to Geosynchronous Transfer orbit (GTO). Godrej Aerospace contributed to the L110 stage and the C25 stage by manufacturing the Vikas L110 engine and The Thrust Chamber for
VIKAS ENGINE
the C25 stage Cryogenic engine. Godrej Aerospace currently manufactures for the Space, Defence and Aircraft segments where Low Alloy Steel material is used.
28
Casing used in DRDO Project. The low-alloy steels constitutes a
of alloying elements such as nickel, chromium, and molybdenum. Total
The hardware’s related to Low Alloy Steel
category of ferrous materials that exhibits
alloy content ranges from 2% up to levels
material are Vikas Engine used in Space
mechanical properties that are superior to
just below that of stainless steels, which
Launching Vehicle and the Rocket Motor
plain carbon steels as the result of addition
contain a minimum of 10% Cr. For many
WELDFAB TECH TIMES | AUG - SEPT 2017
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CASE STUDY
low-alloy steels, the primary function
and nitride formers. This makes it most
over tempered condition except for weld
of the alloying elements is to increase
effective in limiting the extent of grain
repairs, where it is usually not feasible
Strength and Fracture Toughness in order
growth in welding. The higher the heat
to anneal or over temper the base metal
to optimise mechanical properties and
input during welding, the more likely the
before welding. Immediately after welding,
toughness after heat treatment. As with
carbide and nitride particles will dissolve
the entire weldment is heat treated, that
steels in general, low-alloy steels can be
and lose their effectiveness as grain
is, reaustenized and then quenched and
classified according to:
growth inhibitors. The low toughness of
tempered to the desired strength level,
• Heat treatment, such as quenched and
the coarse-grain regions of the HAZ is
or at least stress relieved or tempered to
tempered, normalized and tempered,
undesirable. The HSLA steels are usually
avoid hydrogen cracking. The weld metal
annealed.
welded in the as-rolled or the normalized
hydrogen must be maintained at very
condition, and the weldability of most
low levels; proper interpass temperatures
nickel steels, nickel-chromium steels,
HSLA steels is similar to that of mild steel.
must be maintained. In applications where
molybdenum steels, chromium-
Since strength is often the predominant
the weld metal is required to respond to
molybdenum steels.
factor in the applications of HSLA steels,
the same post weld heat treatment as the
• Chemical composition, such as
the filler metal is often selected on the
base metal in order to match the base
Low Alloy Steels used in Aerospace Industry
basis of matching the strength of the base
metal in strength, a filler metal similar to
metal. Preheat and interpass temperatures
the base metal in composition is used.
Low Alloy Steel, because of the wide variety
required are relatively low as aerospace
HTLA Weld metal has lower strength and
of chemical compositions, some steels
materials having lower thicknesses. The
greater ductility than the quenched-and
are used in more than one heat-treated
amount of preheating required increases
tempered base metal, and high shrinkage
condition, some overlap exists among the
with increasing carbon and alloy content
stresses during welding can result in plastic
alloy steel classifications. In Aerospace
and with increasing steel thickness.
deformation of the weld metal rather than cracking of the HAZ.
Industry, mainly four groups of alloy steels are addressed:
The Heat-Treatable Low-Alloy (HTLA)
• High Strength, Low Alloy Steels
Steels – HTLA refer to medium-carbon
Nickel Steel - The average steel in low
• Treatable Low Alloy Steels
quenched-and tempered low-alloy steels,
temperature environment will have
• Low temperature use steel (Nickel Steel)
which typically contain up to 5% of total
higher strength but lower elongation and
• Quenched and Tempered Low Alloy
alloy content and 0.25–0.50% carbon
toughness, thus increases the chance for
and are strengthened by quenching to
brittle fracture. If the steel is needed in
form martensite and tempering it to the
a low temperature environment, having
High-Strength, Low - Alloy (HSLA) Steels
desired strength level. The higher carbon
superior low temperature toughness is
- HSLA are designed to provided higher
content promotes higher hardness levels
essential. Any suitable steel for this purpose
strengths than those of carbon steels,
and lower toughness and hence a greater
is called low temperature service steel or
generally with minimum yield strengths
susceptibility to hydrogen cracking than
Nickel steel. Low Alloy Low Temperature
of 275–550MPa. Besides, manganese (up
the quenched and-tempered low-alloy
Service Steel is formed by adding 2.5% to
to about 1.5%) and silicon (up to about
steels. Alloys 4130, 4140, and 4340 are
3.5% of Ni in the carbon steel to enhance
0.7%), as in carbon steels, HSLA steels often
examples of HTLA steels. The HTLA steels
its low temperature toughness. Ni can
contain very small amounts of niobium
are normally welded in the annealed or
strengthen ferrite matrix while lowering Ar3
Steels
(up to about 0.05%), vanadium (up to
(third transformation temperature) which
about0.1%), and titanium (up to about
helps with fine grain formation. In addition
0.07%) to ensure both grain refinement
to the normalizing treatment during
and precipitation hardening. As such,
the production process of low alloy low
they are also called micro alloyed steels.
temperature service steel, quenching and
Typically, the maximum carbon content is
tempering are also parts of the mechanical
less than 0.2% and the total alloy content
properties improvement treatment. Nickel alloys are widely using in Cryogenic and
is less than 2%. Niobium (Nb), vanadium (V), and titanium (Ti) are strong carbide
www.weldfabtechtimes.com
Rocket Motor Casing
Semi Cryogenic applications.
AUG - SEPT 2017 | WELDFAB TECH TIMES
29
CASE STUDY
Quenched and Tempered Low Alloy
desired level. Multiple-pass welding with
is noted. Controlling production processes
Steels – It usually containing less than
many small stringer beads improves the
is an essential way to prove that operations
0.25% carbon and less than 5% alloy, are
weld toughness as a result of the grain-
have been correctly performed. This is
strengthened primarily by quenching and
refining and tempering effect of successive
more important than ever when it concerns
tempering to produce microstructures
weld passes. The martensite in the HAZ of a
processes that can’t be inspected after-
containing martensite and bainite. The
weld pass is tempered by the heat resulting
the-fact. As the industry often relies upon
yield strength ranges from approximately
from deposition in subsequent passes. As
production equipment and tooling, such
345 to 895MPa depending on the
a result, the overall toughness of the weld
as computer-controlled machinery, this
composition & heat treatment. Low carbon
metal is enhanced.
too forms part of the basis for product acceptance. When this is the case, it must
content is desired in such alloys for the following two reasons: (i) To minimize
Aerospace Standard
ensure to demonstrate the integrity of
the hardness of the martensite and (ii) to
Aerospace is a generic term that includes
the equipment, developing a process to
raise the Ms (martensite start) temperature
commercial aircrafts, planes and
provide sufficient oversight of the entire
so that any martensite formed can be
helicopters, military and defense, ground
process. Aerospace industries rely on
tempered automatically during cooling.
equipments, & space. Producing aerospace
rigorous quality requirements, advanced
Due to the formation of low-carbon auto-
parts leaves a long supply chain, creating
materials, mechanical components as well
tempered martensite, both high strength
a major challenge for the industry. As
as. The aerospace industry has a strong
and good toughness can be obtained.
this chain is so long and complicated,
certification and compliance requirement,
Alloying with Mn, Cr, Ni, and Mo ensures
it should come as no surprise that
with consequences on development cost
the harden ability of such alloys. The
Aerospace standards are so stringent with
and technology solutions.
use of Ni also significantly increases the
the expectations it has for maintaining
toughness and lowers the ductile–brittle
manufacturers. Manufacturing
AS9100 ensures aerospace manufacturers,
transition temperature in these alloys. Weld
sophisticated vehicles, such as airplanes
being up-to-date with the quality standards
metal hydrogen must be maintained at
or rockets understandably needs
is essential in order to supply parts to the
very low levels. Preheating is not required
special attention throughout the entire
industries. System Structure is complex by
due to less thickness, but interpass
production process. It needs to ensure all
disciplines, segment, component, etc. by
temperatures required Excessive heat
the correct revisions of any engineering
large system management combined with
input can also decrease the cooling rate
documentation is recorded and used
high precision. Data access and security is
and produce unfavourable microstructures
within instructions, and that performance
critical, especially on Defence and Space Programmes.
and properties. If the cooling rate during welding is too low, a substantial amount of ferrite forms. This can, in fact, be harmful since the ferrite phase tends to reject carbon atoms and turn its surrounding areas into high-carbonaustenite. Such
The fully integrated GSLV Mk-III-D1 carrying GSAT-19 at the second launch pad.
NADCAP ensures advancements in the aerospace industry continue, it is not only need to ensure they obtain the required certification, but keeping up to date with
high-carbon austenite can in turn
revisions. The standard additionally focuses
transform to high-carbon martensite and
on aerospace manufacturers being able to
bainite during cooling, thus resulting in a
improve their quality management system
brittle HAZ. Therefore, the heat input and
between their audits, which can make the
the preheating of the work piece should
certification quite difficult to maintain.
be limited when welding quenched-
NADCAP is important to all special
and-tempered alloy steels. To meet the
processes like welding, Heat Treatment,
requirements of both limited heat inputs
Surface Treatment, Non Destructive
and proper preheating, multiple-pass
Testing.
welding is often used in welding thick
30
sections of QTLA steels. In so doing, the
Customer Approval is required to meet
interpass temperature is maintained at the
the design criteria depending upon the
WELDFAB TECH TIMES | AUG - SEPT 2017
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CASE STUDY
product. Different customers have different
during handling of material. Transporting
customer specifications. Factor of safety
criteria depending upon the criticality of the
or shifting of material is also very
is very high in aerospace standards. After
product. Separate Procedures, Welders and
important from one work station to other
Welding, material must pass NDT and
Facilities need to qualify and maintained as
work station, No dent or scratch mark is
DT. Common used methods of the NDT
per the customer requirements.
acceptable and chances of rejection rate is
are DPT (Dye Penetrant Test) and RT
very high due to the lower thicknesses.
(Radiographic Examination). No Indication
Product Specific Qualification and Acceptance after Meeting specification
Thin Foam and Plastic sheets should be use for material movement.
is acceptable in DP Test. Acceptance criteria in RT is very stringent. After Clearing of NDT, Destructive Tests Like, Tensile Test,
requirements, before commencing on actual hardwares. Mock up of the
Dimensional Significance
Root Bend, Face Bend, Notch Toughness
same size need to perform and shall be
Dimensional tolerances are very
Test, Macro Examination of Weld, Parent,
resulting positive in all destructive and non
stringent; it is challenging to maintain
HAZ, Micro Examination at minimum
destructive tests.
ovality, symmetricity and other required
100X for Weld, Parent and HAZ carried out.
dimensions. During Machining Proper
For Fillet Joint Qualification, separate test
Design
Coolants are used, During Welding and
is carried out by examine the Leg Length,
Unlike any other industry but oil and gas,
Heat Treatment Appropriate Fixturing,
Weld Throat and Depth of Penetration.
which also has high temperature, pressure,
Cooper Cooing Ring, Heat Ban Paste,
and corrosion requirements, aerospace
Continuous water circulation is required
Weld substantiation and Readiness
materials themselves impact component
to minimize the ovality and dimension in
Low alloy steel having greater potential
design. No standard international accepted
stability. Advanced Metrology instruments
for distortion and shrinkage as aerospace
code is available for aerospace industry.
are used to check the required dimensions.
materials having lower thicknesses and
Design for manufacturability (DFM) is the
Maraging steel to Low alloy steel rocket
bigger diameters. To avoid this, welding
engineering art of designing components
motor casing is similar to pressure vessel,
fixtures are used at the different sub-
with a balanced approach, taking into
but it is not static and due to its critical
assembly levels. All Welding joints are
consideration both component function
function, Minimum Ovality is very
designed as single sided joints to due to
and its manufacturing requirements. This
significant.
difficult configurations, accesses and avoid
approach is being applied more and more
back chipping. Uniform tacks are welded
in aerospace component design because
Machining
to maintain the uniform gap and alignment
its components have to accomplish certain
Hardness and ductility plays a vital role in
between the parts having welded. GTAW
loads and temperature resistances, & some
deciding the wear characteristics of Low
process is often used for tacking. Tacks
materials can only accommodate so much.
Alloy Steel type and its heat treatment.
should be wire brushed or ground to clean
Significant progress has already been
metal. Up to 2.0 to 2.5mm Thickness
Handling of Aerospace Materials
achieved in aerospace and defence
square butt joint is suitable, above 2.5mm
The precautions required for handling
manufacturing including dry and hard,
thickness; joint configuration is prepared
material in Aerospace Industries are very
often high-speed, machining technologies.
such that heat input is minimized. All
important. Cleanliness is paramount.
For instance, the demand for higher
traces (Oil, Grease, Dust, Paint, etc.) of the
Contamination can cause porosity or
productivity has resulted in the wider
elements must be removed. The joint area
cracking during welding or heat treatment
application of ceramic and PCBN tools with
must be thoroughly clean before welding
may affect the mechanical properties
special multi-radii (wiper) geometry. Final
starts. The weld preparation and on
of the alloy. Material should remain in
Stage machining contains high level of
adjacent area either side of the preparation,
their packing until needed and should be
skills to maintain the accurate dimensions.
at least 50mm wide, must be degreased
separated, normally by protective materials
Machining is carried out in fixtures, at
and cleaned. For this, uncontaminated
like Oil, and Anti Corrosive Black Japan
required travel speed using coolant.
organic solvents should be applied with lint free clothes and the area dried. The
to protect from the atmosphere. Storage of welding consumable should be in Hot
Material Qualification and Testing
appearance of the cloths used for drying is a
Rooms or in inert atmosphere to avoid
Qualification of the parent material and
useful indicator of cleanliness, they should
contamination. Lint free gloves to be used
welding material is carried out as per the
free from any residue. There is no need to
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AUG - SEPT 2017 | WELDFAB TECH TIMES
31
CASE STUDY
pre-heat the base material before welding
input. The heat input should be restricted
transfer is closely controlled, providing a
unless this is necessary to ensure that base
between 0.5 to 1.5 KJ/mm.
combination of overall low heat input and adequate fusion of base material. More
material is dry. To avoid micro fissuring, interpass temperature is restricted to 150ËšC.
Conventional Welding Process
advanced synergic welding power sources
GTAW/TIG (Gas Tungsten Arc Welding)
control the detachment of the droplet
Welding
process can give very high quality welds
from the wire effectively while reducing
Low alloy steels can be welded by most
in complex joints. Welding Heat Input
the number of variables to be set by the
processes, as long as adequate precautions
in GTAW depends upon the type of
welder. Most preferred shielding gas is
are taken to avoid defects. It is important
joint and welding sequence. Separate
Argon or Mixture of Argon-Helium. Wire
to know the composition of the material,
control of heat input via the arc and filler
spool should be stored in dry condition to
either from a mill sheet or a dedicated
material addition gives GTAW, a degree
prevent contamination
chemical analysis, as composition
of flexibility, which is an advantage when
influences weldability significantly.
welding of difficult shape joints. Welding is
Specialized Welding Process
With increasing carbon or alloy content,
carried out in opposite segments to control
Friction Stir Welding (FSW) – FSW
low alloy steels generally become more
the distortion and heat input. Welding
does not involve bulk melting of the
difficult to weld as the heat affected
Down slope is kept on higher side and
components that are joined. This has
zone hardness increases. In Aerospace
minimum 20 to 25 mm overlap length is
inspired attempts to exploit it for joining
applications, defect Free and Lower Heat
required to minimise the chances of crater
materials which differ in properties,
Input welding processes are essential. To
cracks. The composition of the filler metal
chemical composition or structure, and
meet these requirements, GTAW, GMAW,
can be substantially different from that of
where fusion can lead to detrimental
EBW, FSW and LBW in special cases are
the base metal, depending on the strength
reactions. The purpose of this special issue
used. Aerospace welding depends largely
level of the weld metal required. Most of
of Science and Technology of Welding and
on skills and equipments available,
the aerospace industries are changing
Joining was to assess the status of friction
although new project may justify new
their welding process from manual mode
stir welding of dissimilar alloys and to
equipments and special training. It is
to semi auto or fully auto mode to avoid
identify the opportunities and challenges
highly desirable that welders are given a
distortion due to heat input.
for the future.
and the technique use to handle it. Clean
GMAW/MIG (Gas Metal Arc Welding)
Electron Beam Welding (EBW) - Due to
environment, Humidity Level below
welding process is faster process using
special features of EBW, e.g., high energy
50% is mandatory. Welding position is
continuous wire feeding and can be closely
density and accurately controllable beam
possible in all positions, but it is desirable
controlled with modern sophisticated
size and location, in many cases it has
to used down-hand, which allows higher
equipments. Heat Input in GMAW
proven to be an efficient way of joining
deposition rates with lower heat inputs.
depends on the mode of the metal transfer.
dissimilar metals. Since EBW is a fusion-
It is worth the efforts of manipulating the
For thinner sections, dip or short circuiting
welding process, metallurgical phenomena
sub-assemblies for down hand welding,
transfer arc is used. Pulsed arc transfer is a
associated with fusion still exist and cause
rather than attempt to operation in less
more advanced technique in which metal
difficulties. However, these are often minor
period of familiarization with the materials
favourable position. String bead technique
as compared to those in conventional are
is preferred. Long arc is avoided to chances
welding
of porosities. Welding Down slope is kept on higher side and minimum 20 to 25 mm
Laser Beam Welding (LBW) - Like electron
overlap length is required to minimise the
beam welding (EBW), laser beam welding
chances of crater cracks. Most common
has high power density (on the order of 1
used shielding and purging gas for
MW/cm2) resulting in small heat-affected
welding of Similar or dissimilar welding is
zones and high heating and cooling rates.
Ultrapure Argon Gas. (Purity 99.9997%). The general guideline for welding conditions is to avoid higher levels of heat
32
WELDFAB TECH TIMES | AUG - SEPT 2017
Dissimilar Welding of MDN250 Maraging Steel to SAE 4130 Steel using Heat Ban Paste and Copper Cooling Ring.
LBW is a versatile process, capable of welding of LAS and Dissimilar Joints. A derivative of LBW, laser-hybrid welding,
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CASE STUDY
combines the laser of LBW with an arc
as compare to maraging and Austenitic
joint in a position where its image will be
welding method such as gas metal arc
Grade materials, the additional cares are
recorded on the radiograph. Interpretation
welding. This combination allows for
taken during welding and heat treatment
of RT Films also plays a vital role and
greater positioning flexibility, since GMAW
by providing copper cooling ring, Heat
proper decision on weld rework has to
supplies molten metal to fill the joint,
Ban Paste on LAS HAZ Area. Purpose of
take. Involved customers are interpreting
and due to the use of a laser, increases
using SAE4130 Steel with Maraging steel
RT Films on daily basis to ensure the
the welding speed over what is normally
is mainly case design is usually governed
quality and internal interpretation. Factor
possible with GMAW. Weld quality tends
by the combination of motor and vehicle
of Safety in Aerospace Industry is very
to be higher as well, since the potential for
requirements. The main purpose of the
marginal. Frequent rework of the hardware
undercutting is reduced
motor casing is to store the propellant. As
can directly reject the hardware.
soon as the propellant is ignited and rocket Dissimilar Welding - In aerospace and
starts moving, a high amount of pressure
Post Weld Heat Treatment
defence sector for the space launching
and temperature. As the mass of the
For Heat Treatable low alloy steel, the
vehicles and rocket motors, dissimilar
SAE4130 material is twice of the MDN250
weldment is stress relieved or tempered
materials are used. In Vikas Engine
material, SAE4130 material is used only in
after welding. The weldment of heat-
25CD4S (High Strength Low Alloy Steel)
non pressure and firing parts.
treatable alloy steels is to be heated for
is welded with Z8CNDT (Equivalent
stress-relief heat treatment. During the
to SS316L) and KC20WN (Satellite,
Visual and NDT
stress-relief heat treatment, martensite is
Cobalt Base Alloy). Apart from cost,
After Welding, Visual inspection at 10X
tempered and, therefore, the weldment
25CD4S Material is used to maintain
Magnification is carried out, welding
can be cooled to room temperature
higher dimensional stability, abundant
dimensions are maintained as per the
without danger of cracking. It will develop
shock resistance, vibration resistance as
specification. After that Dye Penetrant and
the strength and toughness and capable of
compared to Satellite and SS material.
FPI/MPI Test is carried out. No indication
attaining optimize the microstructure and
In defence sector, in Motor Casings,
is acceptable in these examinations.
properties of the weldment. In cases where
Maraging steel is widely used with SAE
After satisfactory completion of Visual
heat-treatable low alloy steels cannot be
4130 (Heat Treatable Alloy Steel). The
and Penetrant Testing, Radiographic
post weld heat treated and must be welded
dissimilar materials welded with Low
Examination is carried out. IQI used is
in the quenched-and-tempered condition.
Alloy steels having comparatively higher
much important to indicate the overall
So PWHT is generally not recommended
strength, Filler wire of the higher strength
sensitivity of the technique to reveal the
for High Strength Low Alloy and Quenched
material are being used. Crater crack
least discontinuity. As the name implies,
and Tempered Steels. Aim of the PWHT is
welding defects are common in dissimilar
an IQI is an indicator of the quality of the
to modify the grain sizes to provide notch
alloys and these are precisely controlled by
radiographic image. An IQI is a device
toughness and strength the PWHT is to
advanced welding techniques. Since Heat
made from the same material as the test
modify the grain sizes to provide notch
Input is a critical factor in low alloy steel
specimen. It is placed on the hardware
toughness and strength.
Comparison of Low Alloy Steel with commonly used aerospace materials. Properties
LAS
Al Alloy
Ti Alloy
Ni Alloy
Fibre/ Composites
Cost
Medium
Low
Expensive
Expensive
Expensive
Weight
Heavy
Low
Medium
Heavy
V. Light
Stiffness
V. High
Medium
Medium
Medium
High
Yield Strength
V. High
Medium
Medium
Medium
High
Fracture Toughness
Low
Low
High
Medium
Low
Fatigue Toughness
Medium
Medium
High
Medium
High
Corrosion Resistance
Medium
Medium
High
High
V. High
Creep Strength
High
Low
High
V. High
Low
Ease of Recycle
High
High
Medium
Medium
V. Low
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AUG - SEPT 2017 | WELDFAB TECH TIMES
33
ARTICLE
Issues on Friction Stir Welding of AA5083
F
riction Stir Welding (FSW) is
generally attend about 80% that of the
and cooling rates as reported in [Nandan
a solid state process where
liquids temperature of the material being
et.al.2008, Russel et.al1999, Sato et.al. 2002,
consolidation of the thermally
welded. The joint produced in this process
Peel et.al. 2006).
is asymmetric about the weld line as the
the retreating side behind the tool that
material in a highly plastic state flows
transverse direction is generally non-
forms the welded joint. Temperature
differently at the two sides of the welded
symmetric with higher temperatures
distribution in the transverse direction
joint. On one side of the tool the rotational
often located on the advancing side of
was found to be non-symmetric with
direction is the same as that of the tool
the weld. Temperature distribution in the
higher temperatures located on the
travel direction. Such type of process is
longitudinal direction shows substantially
advancing side of the weld. The plasticized
referred to as ‘advancing side’ & the other
higher temperature gradients in front of
material in FSW remains not in liquid
side is referred to as the ‘retreating side’.
the traveling tool. This happens due to the
state but in highly viscous state, hence
There are Four distinct micro structural
tool pin experiencing higher friction. If the plasticized material is considered
the effect of convective heat transfer is
zones observed in FSW, moving towards
not significant. The material in the nugget
the weld line from the parent metal, the
as a fluid, then the Peclet number,
zone undergoes dynamic recrystallization.
four zones are, (i) parent metal zone, (ii)
quantifying the relative heat transfer by
The resulting microstructure and thereby
heat affected zone, HAZ, (iii) thermo-
convection to that of conduction, works
the mechanical properties of the weld
mechanically affected zone, TMAZ, and
out to ten to few hundreds. From this
joint depends on the temperature fields,
(iv) nugget zone. A complex interaction of
one may conclude that convection plays
post-welding cooling rates and the
process parameters, heat generation and
an important role in heat transfer in
straining rate. A correlation between the
dissipation and material flow due to sever
FSW. However the plasticized material
temperature attained, cooling rate as well
shearing action leads to the development
in FSW remains in highly viscous state
as the straining rate of the heated weld
of the microstructure of the nugget zone,
and not in liquid state, hence the effect of
nugget with the microstructure obtained
which primarily controls the weld quality
convective heat transfer is not expected to
needs to be worked out. It was generally
and process efficiency. The material flow
be significant.
observed that in the present work higher
that takes place can be divided in 2 distinct
The material in the nugget zone
tool rotational speeds deterioration of weld
components, (i) material in direct contact
undergoes heavy plastic deformation
quality took place. Purely by trial and error
with the tool is forced to flow around the
as well as a condition of annealing. This
it was found that near consistent results
rotating tool due to friction and shearing
leads to dynamic recrystallization, as
were achieved in the range of 500
action, (ii) threaded tool tends to push
a result of which the material strength
to 700 rpm.
the material in downward direction closer
is lowered relative to that in the base
to the tool whereas due to material-
(H131 temper condition) material. The
as developed in this work corroborates
incompressibility condition, an upward
resulting microstructure and thereby the
well with experimental measurements.
motion of the material is also produced at
mechanical properties of the weld joint
This model can be used to study the
a distance further away from the tool axis
depends on the temperature fields and
effect of peak temperatures and cooling
(Jata et.al 2000 and Nandan et.al. 2008).
post-welding cooling rates.
The dynamics of heat generation in FSW
rate on the resulting microstructure of
34
Temperature distribution in the
plasticized material takes place through
Consolidation of the thermally
the welded joints. The aspect of dynamic
plasticized material takes place at the
HEAT GENERATION
recrystallization due to the thermal cycle
region behind the tool that forms the
In friction stir welding heat is generated
and the straining rate and its effect on
welded joint. This metal transfer takes
due to plastic deformation occurring in the
the resulting joint strength needs to be
place through the retreating side. Worm
shear layer and friction at the tool-work
investigated to achieve consistency in
hole defect often is observed at the
piece interface. The heat generation due
weld quality.
advancing side near the nugget/TMAZ
to friction is the product of frictional force
Friction Stir Welding (FSW) is a solid
interface. The following are some of the
and the velocity difference between the
state process where the peak temperature
features of the FSW temperature fields
tool and the interface layer. Whereas the
WELDFAB TECH TIMES | AUG - SEPT 2017
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ARTICLE
Therefore, the total heat generation
heat generated due to plastic deformation
flow in the shear layer around the tool pin
at the tool-work piece interface is the
side surface. Therefore a state of sticking
considering both sticking and sliding at the
product of shear stress and the velocity
condition was considered to estimate the
pin side surface interface will be
of the interface shear layer sticking to the
extent of heat generation at the tool pin
given by,
tool. This velocity is actually the tangential
side surface to plate interface. The heat
speed of the tool.
generation at this interface due to plastic
Two distinct tool-work piece interface
(6)
deformation is given by Eq. (2). Since the tool traverses forward as it
surfaces are tool shoulder and tool pin (2)
side. Whereas, the contribution due
rotates, it is logical to consider the effects
to the tool pin tip surface is negligible
of shearing of metal as well as friction
(Daiela et.al. 2010) towards the total heat
remaining limited to only front half of the
generation. Q1 and Q2 are the components
pin surface. Hence, the contact parameter
of the respective heat generated from these
was taken 0.5. Therefore, Eq. (6) becomes,
interfaces as shown in Fig.1. (7) Substituting from (3) and (4) in Eq. (7) one obtains, (8) Fig. 2: Lateral force acting on FSW tool pin during welding. At the same time as the FSW tool
EXPERIMENTAL RESULTS Extensive test welds were carried out with AA5083. A typical setup is shown in
traverses along the joint, the forward
Fig.3. These were welded with varying
half of the tool pin experiences a reaction
combinations of tool rotational speeds
force F as shown in Fig.2. It is given by
(710 to 2000rpm) and traverse speeds (56
the product of the projected area of
to 225 mm/min). It was observed that
Tool shoulder – Work piece interface
the tool pin and the yield stress of
rotational speed of 1000 rpm gives fairly
The heat generated at the tool shoulder-
the aluminum alloy at the prevailing
consistent results at different welding
work piece interface has already been
temperature of pin plate interface as
speeds. Temperature recording at a
dealt with in (Pankaj et.al. 2011) hence
shown in Eq. (3). The temperature is
location 20mm away from the weld line on
not repeated here in detail. Considering
approximated about 80% of the liquid s
top of plate surface and at the weld line at
pure friction the heat generated at the tool
temperature (5700C ) of the plate material
the bottom of base plate was done using
shoulder & the plate interface is given by,
i.e. 4560C in the present case.
4700A Agilent data logger. The comparison
Fig.1: FSW tool dimensions and heat generation components on different parts of the tool.
of the recorded data with the theoretical (3)
(1) For welding of 6mm aluminum alloy
Therefore, the frictional force experienced
plates, the shoulder concavity α = 60.
by the tool pin surface will be given by as,
Tool pin – Work piece interface
ones shown in Figures 4 to 6 for different
(4)
As per the phenomenological point of view, achieving friction stir welded joints
Hence, the heat generated due to friction
material flow should happen between the
of the tool pin side surface will be,
two mating plate edges, and this is the reason why it points to the existence of
www.weldfabtechtimes.com
(5)
Fig.3: A typical FSW setup. AUG - SEPT 2017 | WELDFAB TECH TIMES
35
ARTICLE
tool traverse speeds corroborates the theoretical basis presented in this work.
Mechanical Response The welding parameters and the corresponding range of tensile strength achieved are shown in Table 1. One can observe a trend of improvement of tensile strength parameter with
Sl. No.
Weld parameters Tool traverse speed (mm/min)
1
Unwelded AA5083
304 - 315
2
1000
80
150 - 240
3
1000
112
160 - 225
4
1000
160
165 - 256
5
1000
224
108 - 153
Table 1: Weld parameters and tensile test results.
increasing welding speed up to 160mm/
Fig.4: Comparison of temperature distribution at the top of plate surface 20mm away from weld central line.
Tensile strength (MPa)
Tool rotational speed (rpm)
min. However with further increasing
brittle kind of fractured surface of the
welding speed to 224mm/min, a drastic
samples 55 & 58. As can be expected by
drop in strength was observed. The reason
observing the fractured surfaces, the
of this behavior is not yet satisfactorily
tensile strength of about 150 MPa was
established. Though it may appear from
obtained. Fig.9 shows a very interesting
the results summery that a combination
phenomenon of cup & cone fractured
of 1000 rpm and 160 mm/min weld
surface. It is not known why and how this
speed resulted in better tensile strength,
type of surface formed in some cases. In
but a better consistency of results were
Fig.10, the brittle and ductile phases at the
obtained with 1000 rpm and 80 mm/min
fractured edges are very clearly visible.
weld speed. The fractured surface of unwelded
Observations
AA5083 test sample is shown in Fig.7,
In friction stir welding the aspect of heat
wherein one can also observe near similar
generation is very important as it strongly
fractured surface of test samples 19 and
influences the entire process of welding
20. However one can clearly see the
and its resulting mechanical properties.
surface texture of unwelded AA5083 is
The peak temperature depends primarily
uniform over the entire surface whereas in
on the shoulder diameter and the tool
case of S – 19 and 20 the fractured surface
plunging force. The tool rotational speed
orientation is near identical but the
determines the straining rate, whereas the
texture is not uniform over the surface. The top and the bottom half shows ductile Fig.5: Comparison of temperature distribution for 1000 rpm and 112mm/ min welding speed 20mm away from weld central line on top surface of AA5083 plate.
fracture but in between the surface reveals brittleness. It is also well reflected in tensile strength. The tensile strength of un welded AA5083 was about 310 MPa, whereas for the S-19 & 20 about 256 MPa. The surfaces shown in Fig.8, compared to those in Fig.7, one can observe very
Fig.6: Comparison of temperature distribution for 1000 rpm and 112mm/ min welding speed at weld central line on bottom surface of C-Mn steel base plate.
36
WELDFAB TECH TIMES | AUG - SEPT 2017
Fig.7: Fractured surfaces of unwelded AA5083 and sample 19 & 20.
Fig.8: Fractured surfaces of samples 55 & 58.
Fig.9: Cup and cone fractured surfaces of sample 31.
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ARTICLE
Increasing weld speed causes less of
Fig.10: Ductile and brittle phases at the fractured surfaces.
characteristics of the welding process.
heat flow in the weld surrounding, i.e.
This will help in working out a correlation
lower rate of heat input. It leads to faster
between the peak temperature attained,
cooling of the heated material as well as
cooling rate and microstructure of weld
gives lesser time for recrystallization. It
nugget, such that consistent weld quality
was also observed that with increasing
can be achieved.
weld speed up to 160mm/min there was a general improvement of tensile
CONCLUSION
weld speed determines the heat flow rate,
strength of the welded samples, however
The heat generated in FSW strongly
thereby the cooling rate. A variation in
increasing the speed further to 224mm/
influences the entire process of welding
temperature distribution in the advancing
min caused a drastic reduction in
and its resulting mechanical properties.
and retreating side along the transverse
strength. The fractured surfaces are
The peak temperature depends primarily
direction was observed as shown in
shown in Fig.8, wherein it can be
on the shoulder diameter and the tool
Fig.11.
observed that a significant amount of the
plunging force. The tool rotational speed
material along the plate thickness in the
influences the straining rate, whereas
structure of the weld nugget which
weld nugget region constituted of brittle
the weld speed determines the heat flow
controls the strength of the welded joint.
phase. Higher cooling rate causing faster
rate, thereby the cooling rate. A variation
solidification of the plastified viscous
in temperature distribution occurs in the
temperature profile showed a good
material may have led to formation of the
advancing and retreating side along the
agreement with those of the calculated
brittle phase.
transverse direction.
All these finally determine the grain
The physical measurements of
ones based on the above formulation
As it stands, a certain minimum level of
Higher cooling rate causing faster
developed in this work. The temperature
plunging force is necessary for achieving
solidification of the plastified viscous
field created affects the metallurgy of
the full penetration of the joint as well as
material may have led to formation of
the weld nugget as well as the thermo
generation of required heat to produce
the brittle phase in the weld nugget. The
mechanically affected zone. It was
necessary plastification of the material
extent of brittle phase in the weld nugget
observed that the recrystallization of
such that adequate material stirring is
should be minimized to achieve superior
the heavily stirred zone, i.e. the weld
achieved. At the same time the plunging
mechanical properties of the joint.
nugget determines the strength of the
pressure should not exceed much such
welded joint. A correlation between
that expulsion of material takes place due
attained, cooling rate as well as the
the temperature attained as well as the
to digging in effect of the tool shoulder.
straining rate of the heated weld nugget
cooling rate of the heated weld nugget
Hence one finds that not much of play is
with the microstructure obtained needs to
with the microstructure obtained needs to
possible in variation of plunging force. It
be worked out. In the present work it was
be worked out. The extent of brittle phase
was also observed that variation of tool
observed that too high (2000) or too low
in the weld nugget should be minimized
rpm does not significantly affect heat
tool rpm (500) led to deterioration of weld
as can be seen in Fig.7 in samples 19
generation, however it does have an effect
quality. Purely by trial and error it was
and 20 to achieve superior mechanical
on straining rate. In the present work it
found that near consistent results were
properties of the joint.
was observed that too high (2000) or too
achieved at 1000 rpm.
low tool rpm (500) led to deterioration
Fig.11: Comparison of temperature distribution 20mm away of weld line at the advancing & retreating side of the weld.
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A correlation between the temperature
The dynamics of heat generation
of weld quality. Purely by trial and error
in FSW as developed in this work
it was found that near consistent results
corroborates well with experimental
were achieved at 1000 rpm. The most
measurements. This model can be used
critical parameter in case of FSW of
to study the effect of peak temperatures
AA5083 is that of weld speed because,
and cooling rate on the resulting
keeping 1000 rpm and fixing the speed of
microstructure of the welded joints. The
welding always vary.
aspect of dynamic recrystallization and its
The thermal model developed in this
effect on the resulting joint strength needs
work can be used to evaluate the effect of
to be investigated to achieve consistency
varying welding speed on the heat flow
in weld quality.
AUG - SEPT 2017 | WELDFAB TECH TIMES
37
WELDING & CUTTING MIDDLE EAST
WCME
rd
www.weldingcuttingmiddleeast.com
DECEMBER 17 - 19 , 2017, Dubai World Trade Centre, Dubai, UAE
ORGANISER
Al Fajer Information & Services P.O. Box 11183 Dubai, United Arab Emirates Tel: +971-4-3406888 Fax: +971-4-3403608 Email: rupa@alfajer.net Web: www.tekno-me.com
CO-LOCATED WITH:
MIDDLE EAST
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METAL MIDDLE EAST 13th International Trade Fair for Metallurgical Technology, Thermo Process Technology, Foundry Machinery and Metal Working
TUBE MIDDLE EAST
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WIRE & CABLE ARABIA
2nd International Trade Fair for Wire & Cable Industry
INTERVIEW
Welding Automation Division: An important cog towards growth. Our welding design team has developed many new welding automation solutions for customers spread across the country. Q. How has been the journey of Ador Welding since its inception in 1951? Ador Welding since its inception has contributed significantly towards the nation building. We have constantly strived towards ourambition to become ‘The Best in Class’. We cater to various sectors like nuclear, wind, thermal, defence, railways, infrastructure, automotive, steel and many others. Ador Welding has embarked upon a digitization program a few years back, and today, according to industry experts, we areamong the best companies. On the business front, we are the only company into the welding industry to have grown consistently both in value and volumes. Our market share has increased last year despite of the sluggishness that the manufacturing sector witnessed in the last few years. We have surpassed our best ever achievement in the last financial year and have made giant strides towards being the number one welding company in the country. We can further state that the journey has been exciting and challenging so far.
Q. What new technical advancements have you introduced into your product line? Our welding inverter manufacturing setup boasts of the only ‘Clean Room' in India that produces CE marked inverters.
40
WELDFAB TECH TIMES | AUG - SEPT 2017
S M Bhat, Managing Director, Ador Welding Ltd. (AWL)
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INTERVIEW
Our Project Engineering Business
as we are surging ahead from being a
have in-house awareness programmes
has recently executed an order for a
developing nation to a developed one.
for our employees, safety drills and many
“Mobile” flare which is a first-of-its-kind
Robotic solutions offer the much needed
other related activities that reassert our
customized flaring system developed for
skill and repeatability to critical jobson
commitment towards health, safety
a critical application when competitors
mass manufacturing lines which makes
and the environment. Ador Welding is
of international repute had backed out.
them absolutely vital in this age of
the only Indian company meeting CE
Our consumable plants have high-end
consumerism.
standards. We have CE certification for
extrusion equipment and fully equipped
The automobile industry in India
model CHAMPT400 and various other
testing facilities for making the world
is forecast to grow rapidly in the near
equipment. For complying with CE
class products.
future. Investments in high speed railway
marking requirements, the machine has
coaches, metros, defence and aerospace
to be tested for safety with respect to
Q. Any recent launches? If yes, elaborate.
manufacturing hubs are expected in line
Electrical and Fire Hazards. Apart from
with the government’s “Make In India”
these, CE marked machines should not
We have recently launched our own
programme. This bodes well for the
produce any electrical pollution like
Pulsed Migmachine Champ Pulse 500.
automation and robotic industry.
Current Harmonics and should not emit electromagnetic noise on electric supply
This indigenously manufactured high
lines. With CE marking compliance,
equipment has been conceptualized,
Q. What kind of after sales services do you offer to your customers?
designed and manufactured at our
There is an advertisement by a network
countries. We have also introduced a
Technology Development Centre in
provider which says “Wherever you go
new environment friendly packaging
Pune. This product exhibits all the
our network follows”. Ador Welding
material called Expanded Polyethylene
features of the latest inverters available
would say that “We are present even
Foam for packing the machines.
in the market. Our inverter welder
where your network deserts you”. This
Champ T 400 has won the India Design
statement is areflection of our core
award for its impeccable design. King
value; to always be with the customer
Cut Pro 2500 is the latest addition to our
during his time of need. Our network
Hi definition CNC plasma cutting range.
is spread throughout the country with
Q. Your role in welding education, as availability of trained manpower, especially in welding is a major challenge in India?
our sales and service network of more
Welding skill is a ‘Rare Skill’ today
towards Ador’s vision in achieving
than 100 engineers spread across the
not just in India but globally. It is
the best in class global standards of
country through our strategically located
therefore imperative for every welding
manufacturing and development.
area offices spread across the country.
industry to invest in skill development.
Our CCC (Customer Care Centre) at our
Ador Welding has been executing its
Q. What about introducing robotic techniques in your product range?
manufacturing plants are in constant
role towards skill development. So
touch with the sales and service team
far, we have trained over one lakh
Though we are not into manufacturing
and the customers to ensure quick
welders and engineers through our
of robotsat present, we have tie-ups
service.
industry customized welding training
quality world class inverter welding
These are some significant steps
CHAMPT400 can be sold in European
programmes. Our welding academy
with top robot manufacturers to offer
AWA is undertaking skill development
equipment as per customer needs. We
Q. What are your initiatives toward eco-friendly, health and safety in welding?
also have an exclusive development
We are a green organisation in its very
most of whom got absorbed in the
and testing facility at our Pune plant for
essence. Our organisation is an OHSAS
industry soon after the programme.
the same.
18001, ISO 9001 and 14000 certified
customized robotic welding solutions by interfacing them with our welding
programmes with NSDC. Recently, we trained a full batch of women welders
The AWA has been officially
company. Through our training academy
designated as a “TOT” (Training of
Q. How is the overall robotic welding scenario in India?
AWA, we are constantly educating
Trainer) Centre by CGSC. Through AWA,
industries on the best practices in
we intend to continue this initiative in
Automation is the need of the hour
welding safely. Besides, we continually
the future as well.
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AUG - SEPT 2017 | WELDFAB TECH TIMES
41
INTERVIEW
Q. What are the other major challenges encountered by the segment? How can it be resolved?
applied for several patents for some path
The industry today is facing a challenge
new and advanced products in the last
to achieve a sustained growth,
couple of years.
breaking work in the field of applied research. We have come up with several
The other Indian welding
while there is no or lower growth
manufacturers have the advantage of
in manufacturing sector. The other challenges that the segment faces is the
is expected grow as these projectsstart
rubbing shoulders with the top welding
availability of quality raw materials for
seeing actual work on the ground. AWL
manufactures in the world vying for
consumables within India. We still have
however is firmly on course for great
a share the Indian market which has
to depend on the import source, as we
demand on account of its two pronged
given them the right thrust towards
need to offer best and complete solution
strategy of adding new products to meet
improvement.
to our customers. However, we at Ador
market need and closing gaps in the
Welding are geared up to meet this
products portfolio and to aggressively
challenge.
work on its market share strategy.
Q. Automation in welding is rapidly capturing the market. What is your say on this?
Q. Is the Indian welding industry on par with the international markets?
Q. Government is largely focusing on the growth of infrastructure. What opportunities do you see for the welding segment in coming time?
As far as AWL is concerned, today, we
Infrastructure, railways, defence,
Welding automation offers tremendous
are at par with the international markets
shipbuilding, automobile, nuclear /
opportunities for value addition and
inbusiness due to our world class facilities
wind power offer us the biggest avenues
growth. This section is capturing the
and offerings. We have state-of-the-
for business and we have products,
imagination of the fabricator more
art manufacturing facilities, which are
approvals and firm strategies in place to
than ever before. Our welding design
constantly getting upgraded to meet the
increase our share in these sectors.
team has developed many new welding
demands of the industry. Our Chinchwad
automation solutions for customers
plant is equipped with the only 'clean
spreadacross the country. The Welding
room' for manufacturing indigenously
Q. What are Ador Welding’s future plans?
Automation Division is a very important
developed inverter welding equipment
This year we shall add a whole new
cog in our wheel towards furthering our
with capacities that are un-paralleled
plethora of products that will further
growth.We expect automation demand
among peers in the Indian manufacturing
enhance our product basket and give
to grow once manufacturing sectors
segment. We have huge capacities to
us the right impetus towards growth.
starts growing.
manufacture high alloy cored wires,
Besides, we also look forward for the
submerged arc wires and fluxes besides
growth through our bullish market share
Q. What is the current overall welding market scenario in India? How much of market size can be expected in the coming time?
having the highest extrusion on modern
increase strategy. This year too we will
hi-tech extruders and baking capabilities
maintain our growth chart like in the
for welding electrodes. Our stringent
previous years.
The present welding market scenario in
us a distinct edge.
are expected to stage a recovery with
unquestionably. We have the best and
Q. How much is your current turnover? How much do you expect in the coming year?
the huge investments in infra, defence,
latest testing equipment in the welding
For the first time in its history, AWL has
shipbuilding, railways and automobile
industry. Ador Welding has achieved CE
crossed Rs490 crore of gross sales in the
segments. The market size from the
marking for Welding Equipment
FY 16-17. With our strategies and plans
organized players is expected to be
and Welding Consumables. Our
firmly in place, we expect to touch
around Rs. 2,500 crores at present and
Technology Development Centre has
Rs. 540 crore in 17-18.
India is not very rosy, but the markets
42
quality checks, third party approvals give
WELDFAB TECH TIMES | AUG - SEPT 2017
Ador’s R&D facilities are
www.weldfabtechtimes.com
MACHINE TOOL
The machine tool industry is a key to ‘Make in India'. V. Anbu, Director General & CEO, Indian Machine Tool Manufacturers' Association (IMTMA)
44
WELDFAB TECH TIMES | AUG - SEPT 2017
www.weldfabtechtimes.com
MACHINE TOOL
‘Make in India’ program has provided a broad direction for manufacturers to invest in India, and also has focussed on the infrastructure development and enhanced manufacturing growth.
Q. According to you, what is the current machine tool market in India? What would be the expected market size in the coming years?
the industry to fulfill the demand of
sectors, the market is expected to grow
consumers.
further. Ease of FDI inflow into India has created opportunities in oil and gas sector, offshore activities, aerospace
The current market size of the Indian
Q. Your comment on the impact of ‘Make in India’ initiative on Machine Tool sector.
machine tool industry is around Rs.
‘Make in India’ policy aims to promote
the uptake of welding equipment and
11,600 crore. Domestic production
investments in the manufacturing
consumables. The demand for welding
accounts for over 45 per cent of the
sector and increase the share of
equipment in India is expected to
consumption. As per Gardner’s 2017
manufacturing in GDP to 25 per
increase in the long-term which is good
report, World Machine Tool Output
cent by 2025. The machine tool
news for the machine tool industry.
and Consumption Survey, India has
industry is the key to this flagship
been ranked 12th in Production and
initiative of the Government of
8th in Consumption. During 2016-
India, as it makes the machines
17, the demand has increased by 12
required for the manufacturing
per cent and production increased
wwsector. ‘Make in India’ program
by 23 per cent. It is expected that the
has provided a broad direction for
Q. Despite SMEs occupying majority share in the machine tool industry, they are currently facing multiple issues that are hindering its growth. Your views.
machine tool industry of India will
manufacturers to invest in India, focus
SMEs contribute to about 80 – 90 per
continue to evolve in future. Indian
on infrastructure development and
cent of all manufacturing units in India.
auto component industry is envisaged
enhance manufacturing growth. It has
The operations are largely manual,
to become the third largest in the world
changed the mindset of the machine
using low-end solutions that are
by 2025.
tool industry and given a filip to their
difficult to maintain. In this scenario, it
entrepreneurial side. As a result of
is all the more crucial for SMEs to adopt
this, the sector is now more open to
automation.
Q. The demand for high-tech and efficient machine tool is rising. Is the Indian machine tool industry capable to fulfill the rising demand?
and heavy machinery industries. These have left a positive impact on
embrace new technologies.
Q. What is the role of IMTMA in the national and international markets?
Things, 3D Printing, etc. Companies
Q. Welding and fabrication segment being another major section for machine tool industry, about how much of demand does machine tool expect from this sector?
are investing in the fourth industrial
Although the Indian welding
Association in this acclaimed endeavor.
revolution since, customers demand
market is dominated by the use of
The collaborative approach resulted
zero defect products. The machine tool
manual welding equipment of late,
in development of new products
industry embraces smart technologies
there is a shift towards the use of
which were displayed at IMTEX
and upgrades its machinery to modern
automated equipment arising from
2017 in Bengaluru. The Association
ones which are compatible with
demands by many end-users. With
also organizes group participation
Industry 4.0. We would see productivity
robust expansion of shipbuilding,
of member companies in overseas
levels moving up. This will enable
construction, energy, wind and power
exhibitions.
Indian machine tool companies have started utilising latest technologies such as Industry 4.0, Internet of
www.weldfabtechtimes.com
IMTMA has been working closely with premier institutions such as IITs to foster R&D and innovations. Government of India is supporting the
AUG - SEPT 2017 | WELDFAB TECH TIMES
45
LAUNCHES
TAL BRABO: Power your Future
T
AL Manufacturing Solutions, a subsidiary of Tata Motors launched its much-awaited TAL Brabo robot in two variants, with payloads of 2 kilos and 10 kilos. The lightweight design of
BRABO 2kg makes it a desired choice for generating high production outputs in return for a minimal investment. TAL BRABO is an articulated robot complementing human workforce by taking over dull, dangerous and monotonous jobs.Indigenously developed, the robot is a ‘Made in India’ solution, developed to cater micro, small and medium enterprises, as well as for large scale manufacturers who require cost competitive automated solutions in manufacturing. It is also suitable for welding application with the cost effective robotic welding solutions. The robot comes with a 5 axis controller with one additional axis for external configuration. The controller works on a single phase power supply which is the main USP. The teach pendant which has a very user friendly graphical user interface is easy plug and play device. Designed and styled in-house at TAL Manufacturing and Tata Elxsi respectively, Tata AutoComp has manufactured some of the critical components of the robot. Conceptualised to complement human workforce and perform repetitive, high volume, dangerous and time consuming tasks, the TAL Brabo robot, can be deployed across industries.
Uses: •
It can be used to bring in efficiencies right from
raw material handling until packaging of finished products. •
It can be programmed to operate 24/7 in all situations for continuous production. •
Performs complex functions cost
effectively with a high degree of flexibility. •
It can be used for varied applications
for tasks like pick and placement of materials, assembly of parts, machine and press tending,
46
WELDFAB TECH TIMES | AUG - SEPT 2017
www.weldfabtechtimes.com
LAUNCHES
as a sealing application, camera and vision based jobs, welding etc.
Features: • TAL BRABO is a 5 axis articulated robot. • Tal will be coming into market with its six axis 6 kg payload articulated robot by November 2017 beginning. • The 10 kg payload robot has a reach of 750mm and offers a repeatability of +/- 0.2mm. • The speed of the robot is 2,000mm/s with +/-180 deg rotation in 2axis and complete 360 degree rotation in 5th axis. • Brabo can be mounted according to industrial use flexibility, both ceiling and floor mounting is possible. • The controller which is indigenously developed in TAL Pune facility offers 16 Digital I/O‘s which can be expanded to 512 according to user’s perspective. • It also has an inbuilt PLC which makes the system more flexible without using additional PLC for integration. • There are 2 analog input cards and 4 analog output cards. The controller is capable of communicating with another devices with the communication protocols such as Can open, Device Net, Ethernet (10/100) base-T, Ethernet IP, Modbus-RTU, Modbus-TCP, RS232/ RS485, Hostlink etc. • Brabo controller can be used as a
convert the CAD data directly into robot program. • One time calibration, no need of manual calibrate even in case of maintenance. • It comes with a low power transmission drive train system with zero backlash.
virtual controller for simulation and is
The locally available spare parts and
completely an open source controller
services in PAN India make Brabo more
which can be easily linked with the
prominent among MSME in India. The
third party software’s like Labview,
cost of ownership is too low and proven
MatLab, Visual studio, Java.
to increase productivity by 15-30 per cent,
• The same controller can be used for
with a payback period of 15 – 18 months.
multiple applications thus making MSME’s to invest in the most economic
For more info:
automation deal, gain productivity
TAL Manufacturing Solutions Limited
effectively.
TATA Motors Premises,
• In addition to these features, the
Chinchwad – 411 033, India.
controller has one more feature called
Tel: +91-8006665932
CAD2Motion which helps controller to
Email: bhagyalakshmi.vs@tal.co.in
www.weldfabtechtimes.com
Amit Bhingurde, Chief Operations Officer, TAL Manufacturing Solutions, “We are delighted to launch the TAL Brabo, the first Indian made, conceptualized and designed industrial robot. A unique product, the TAL Brabo is suited not only for India, but for manufacturing units across the world. As we move ahead, we will continue to innovative not only in product development, but also in sales, marketing, customer service and in all aspects of our business, to deliver best-in-class manufacturing solutions. We thank our early customers for having entrusted their faith in us, by testing the TAL Brabo in their work streams, for some great business results.”
AUG - SEPT 2017 | WELDFAB TECH TIMES
47
COUNTRY FOCUS
Infra open doors to Weld
Welding industry expected to witness a CAGR of around 8-9 per cent for FY 2017FY2020 with the development of infrastructure in India. production systems are rising. Welding industry witnessed a growth
fledge recovery may take time as balance sheets are still highly leveraged leading to
of around 5 per cent for FY 2017.
rise in Non-Performing Assets levels. Going
Automotive, construction equipment,
ahead, we think that strong government
heavy engineering sector have been the
and public investment demand would
major contributors. Semi automatic and
eventually turn the corner for private sector
automatic systems are witnessing an
investment demand as capacity utilization
increased growth platform. Automation
rates rise across the economy.
is predominantly present in the heavy
Manish Kulkarni, Director – Strategy & Business Development, BDB India.
W
Consumables
industry. Welding automation market is
• Fragmented industry with 50 per
expected to be in the range of Rs 250 crore, wherein the CNC Laser Cutting Machine
elding is a precise, reliable,
market is expected to be in the range of
cost-effective, and high-tech
approx Rs 220 crore for current year driven
method for joining materials
by railways, earthmoving equipment,
cent being controlled by unorganised players. • Organised market is mainly controlled by established players. • Robust outlook of the infrastructure
in manufacturing industries. In fact, no
automotive, dies, defence and aerospace.
sector, welding consumables market is
other technique is so widely used by
There would be significant contribution
expected to grow at a CAGR 10-11 per
manufacturers, in India, to join metals
from the SME sector (40-50%) however; the
cent over next five years.
and alloys efficiently to add value to their
trend is towards more organised industry
• Continuous electrodes would witness
products. Most of the familiar objects in
structure. The implementation of GST will
higher growth compared to Manual
modern society, right from buildings and
be positive for organized sectors.
Electrodes.
bridges, to vehicles and medical devices,
48
engineering segment, railways, auto
Investment in welding segment
could not be made without the use of
will be driven in FY18 mainly by the
welding. Welding today is applied to a
central government which is expected
wide variety of materials and products,
to concentrate on spending on roads
using such advanced technologies as lasers
(up 11.9% YoY), railways (up 22.2% YoY)
and plasma arcs. The future of welding
and urban development. Although,
holds even greater promise as methods
overall investments are likely to see an
are devised for joining dissimilar and
improvement, it could be marginal in
non-metallic materials, and for creating
nature and a percent of GDP would
products of innovative shapes and designs.
continue to be below the levels seen
In India, welding contributes significantly
during FY12-FY16 (34.3% to 29.2%). The
to the GDP in several ways, such as welding
Gross Fixed Capital Formation (GFCF)
intensive industries, auxiliary products,
is expected to increase at around 27.5
complementary goods, employment,
per cent of GDP in FY18. Some of the
and user industries. The Indian welding
private sector companies specially in
industry was dominated by low technology
consumer durable, building material and
Equipment
and very rare technological innovation.
metal segment that are witnessing strong
• Organised market accounts for 40 – 45
However, in recent years, the demand of
demand has started working on their
per cent while unorganised accounts
automatic and semi automatic welding
capacity expansion plans. However, full
balance market.
WELDFAB TECH TIMES | AUG - SEPT 2017
Welding consumables market expected to grow over next five years.
www.weldfabtechtimes.com
COUNTRY FOCUS
airports shall be areas of growth in terms of private investments. Construction equipment and automobile sector shall see consistent growth due to infra spending and rural growth in the next 3-4 years. Enhancement in water and gas pipeline network, power transmission and distribution capacity is expected, at the same time significant focus would be given on the electric vehicle technology. Welding equipment industry expected to grow over the next five years. • Imports constitute significant portion of organised market. • The welding equipment industry is expected to grow at a CAGR of 6-7 per cent over the next five years.
Shipbuilding segment is another major contributor to economy of country. With
to 3 years (2015-18) to build the upcoming
over 40 per cent of India’s fleet of ships in
new capital city of Naya Raipur into a smart
the 20 plus age group, holds tremendous
city.
opportunity for India’s shipbuilding and
While the roads sector retains its prime
ship-repair industry.
focus, significant emphasis is on railways, rural infrastructure, urban rejuvenation,
Priority areas in infra
Opportunities in Infra
solar power and electricity transmission
Power:
Indian States are aggressively working on
and distribution. The government is
The 100 per cent electrification of villages
attracting investments and implementing
serious about its mantra of ‘public
and revamping of urban distribution
policies of central government. Andhra
expenditure-led investment in infra to kick-
networks is being done through funding
Pradesh launched Industrial Development
start the economy’. Even in a fiscal-deficit
from the Power Grid Corporation of India,
Policy (IDP) 2015 to 2020 in April 2015
challenged situation, the Finance Minister
REC Power Distribution Company, Power
to support the development of various
has proposed a 23 per cent increase in
Finance Corporation, et al. The emphasis
industries and provide financial assistance.
outlay this year, over and above the 27
has shifted from adding coal-based
The new Aerospace and Defence (A&D)
per cent increase last year. Budgetary
thermal generating plants to revamping
Policy of Andhra Pradesh is expected to
allocation is being leveraged many times
the nation’s transmission and distribution
attract investments worth USD 3 billion
over by off-budgetary funding.
by 2020. The investments are expected
The National Investment and Infra Fund
networks. And the 2021 target of 100,000 MW of solar power has been widely
from various companies such as Airbus,
epitomises this new line of thinking. Even
Essel Infra, SREI Infra, etc., which have
individual ministries are being encouraged
shown interest in setting-up defence and
to increasingly see budgetary support as
aerospace parks. Setting up Bangalore
seed funding. So, the railways sector is set
The railway sector allows for 100 per
Aerospace Park (BAP) and Bangalore
to raise capital from the Life Insurance
cent FDI under the automatic route. FDI
Aerospace SEZ (BASEZ) at Devanahalli
Corporation of India and the World Bank.
worth USD12 billion have already been
and Aerospace Parks at potential locations
The roads ministry wants to securitise tolls
received (major projects include Mumbai–
like Mysore, Hubli, Mangalore, Belgaum
and garner substantive funding under
Ahmedabad high-speed corridor project
published and is getting much traction. Railways
through PPP model has made Karnataka an
the toll-operate-transfer (TOT) scheme.
and CSTM–Panvel suburban corridor
A&D cluster. Faoxconn, Lava, Micromax,
Japanese loans are funding the bullet train
development project). China, Japan and
Karbonn and Celkon (mobile handset
project. Rural infrastructure is clearly a
Spain have shown interest in technology
manufacturers) have also signed up
much needed political-economic thrust.
transfer and technical cooperation in High
with Andhra Pradesh to set up their manufacturing facilities near Tirupati with
The government has set a target of
Speed Rail, modernisation of infrastructure
10,000 MW of wind power installations
and maintenance. Japan is expected to sign
a total investment of USD 300 million.
per year. GST shall drive the demand for
a MoU to develop 400 stations and assist
Chhattisgarh government would be
warehousing and PEB segments. Defence,
in zero-accident mission of the Indian
investing USD1.6 billion in the coming 2
ports (coastal economic zones) and
Government. Locomotive and wagon
www.weldfabtechtimes.com
AUG - SEPT 2017 | WELDFAB TECH TIMES
49
COUNTRY FOCUS
manufacturing: Indian railways awarded
Vizag Chennai Industrial Corridor (VCIC):
already developed products. Majority of
a 10 years contract to GE and Alstom for
Four nodes have been finalised; Asian
the manufacturers cannot offer to carry out
diesel and electric locomotive factories,
Development Bank has agreed
research on their own.
respectively, in Bihar at a cost of about
to prepare the master plans for 2 identified
USD 6.2 billion. Various metro rail projects
nodes.
are currently being developed across
India’s working-age population will rise
the cities of Delhi, Mumbai, Bengaluru,
Challenges
by 12.5 crore over the coming decade, and
Chennai, Hyderabad, Kolkata, Kochi
Lack of knowledge of end users
by a further 10.3 crore over the following
and Jaipur. Other cities where metro
Due to lack of knowledge of its application
decade. With its growing young workforce,
projects have been approved include
and cost economies, to a large extent,
it can look forward to decades of high
Ahmedabad, Nagpur, Pune and Lucknow.
higher productivity welding consumables
productivity, economic growth and upward
Dedicated freight corridor (DFC) is being
like CO2 continuous welding wires and flux
social mobility. By 2022, it is estimated
implemented in phases with an investment
cored wires fail to find higher demand. In
that unless action is taken, there will be a
of around USD12.5 billion. This project is
view of this it is pertinent to start vigorous
gap of 10.3 crore skilled labourers in the
expected to be completed in 2019.
marketing efforts by existing leading
infrastructure sector, 3.5 crore in auto and
manufacturers of consumables and
1.3 crore in healthcare, to name a few.
Industrial corridors
equipment to educate the users.
New corridors developed:
Indian government has given a major impetus to skilling over the last few years.
Amritsar Kolkata Industrial Corridor
No technologies for low installed
To begin with, a clear national goal has
(AKIC): Delhi Mumbai Industrial Corridor
capacities
been established — to skill and re-skill 500
Development Corporation (DMICDC)
Majority of organised sector units
million Indians by 2022 and the budget for
would prepare a feasibility report, for
have quite low installed capacities to
skilling has been ramped up several-fold to
which consultants have been appointed.
enable them to use modern machinery
more than Rs. 10,000 crore a year.
set up like computerised batching plant,
Overall, it can be concluded that with the
Bengaluru Mumbai Economic Corridor
X-ray florescent tester, etc. The welding
advent of government initiatives like Make
(BMEC): The draft perspective plan has
consumable manufacturers should arrange
in India, smart cities, cluster development
been prepared. Nodes are being identified
these technologies and try to adopt it for
programs, SME support programs, newer
alongside preparation of a master plan and
lower capacity plants if possible.
technologies and concepts of smart manufacturing; the welding community
finalisation of the perspective plan. Lack of testing facilities Chennai Bangalore Industrial Corridor
Testing facilities and quality assurance
(CBIC): The perspective plan has been
systems are inadequate in India. Approval
finalised. The Phase II Study is in progress
of inspection agencies, Indian and foreign,
and the draft final report of master
is for limited specific types of consumables.
planning for industrial nodes is under
Quality and reliability of other varieties are
consideration in consultation with
dependent on Quality Assurance Systems
stakeholders.
of the manufacturer. The manufacturers need to be exposed to international
Delhi Mumbai Industrial Corridor
practices in Quality Assurance Systems,
(DMIC): The first node/city level Special
which are desirable, in order to face
Purpose Vehicle (SPV) under DMIC Project
international competition.
has been incorporated. Work on 5 smart
50
Initiatives for Skill Development
industrial townships in Delhi Mumbai
Lack of R&D
Industrial Corridor has been initiated
R & D effort in India for welding electrodes
(Dholera in Gujarat, Shendra-Bidkin in
is fragmented among few leading
Maharashtra, Greater Noida in UP, Ujjain
manufacturers and WRI, Trichy. Very
in MP and Gurgaon in Haryana).
frequently research effort is being spent on
WELDFAB TECH TIMES | AUG - SEPT 2017
are optimistic of the future growth.
Market Size • Welding industry expected to witness a CAGR of around 8-9 per cent for FY 2017-FY2020. • Welding automation market is expected to see CAGR in the range of 11-12 per cent for FY 2017-FY2020. • CNC Laser Cutting Machine market is expected to witness a CAGR of 9-10 per cent for FY 2017-FY2020.
www.weldfabtechtimes.com
FLASH BACK
T
Birth of Welding he history of joining metals goes
arc and presented his results in 1801.
back several millennia called
In 1802, Russian scientist Vasily Petrov
“forge welding”, the earliest
created the continuous electric arc
examples came from the Bronze and Iron
and subsequently published news of
Ages in Europe and Middle East. The
“Galvanic-Voltaic Experiments" in 1803,
ancient Greek historian Herodotus states
in which he gave the description of a
in The Histories of the 5th century BC
stable arc discharge and the indication
that ‘Glaucus of Chios’ was the man who
of its possible use for many applications.
single-handedly invented iron welding".
One of the applications was melting
Welding was strategically used in the
metals which turned out to be the most
construction of the Iron pillar of Delhi
crucial invention in the field of welding
named Qutub Minar erected in Delhi,
technology. In 1808, Davy, who was
India about 310 AD and weighing 5.4
unaware of Petrov's work, rediscovered
metric tons.
the continuous electric arc. In 1881–82 inventors Nikolai Benardos (Russian)
The Middle Ages brought advances
and Stanisław Olszewski (Polish) created
in forge welding, in which blacksmiths pounded heated metal repeatedly until bonding occurred. In 1540,
The iron pillar of Delhi.
the first electric arc welding method known as carbon arc welding using
Vannoccio Biringuccio published De la
the industry continued to grow in the
carbon electrodes. The advances in arc
pirotechnia, which includes descriptions
coming centuries.
welding continued with the invention
of the forging operation. Renaissance craftsmen were skilled in the process and
www.weldfabtechtimes.com
In 1800, Sir Humphry Davy discovered the short-pulse electrical
of metal electrodes in the late 1800s by a Russian, Nikolai Slavyanov (1888),
AUG - SEPT 2017 | WELDFAB TECH TIMES
51
FLASH BACK
and an American, C. L. Coffin (1890).
20th century progressed; however, it fell
various military powers attempting to
Around 1900, A. P. Strohmenger released
out of favor for industrial applications.
determine which of the several new
a coated metal electrode in Britain,
It was largely replaced with arc welding,
welding processes would be the best. The
which gave a more stable arc. In 1905,
as there was advancement in metal
British primarily used arc welding and
Russian scientist Vladimir Mitkevich
coverings (known as flux).Flux covering
even constructing a ship, the "Fullagar"
proposed using a three-phase electric arc
the electrode primarily shields the
with an entirely welded hull. Arc welding
for welding. In 1919, alternating current
base material from impurities, but also
was first applied to aircraft during the
welding was invented by C. J. Holslag
stabilizes the arc and can add alloying
war as well as some German airplane
but did not become popular for another
components to the weld metal.
fuselages were constructed using this
decade. Resistance welding was also developed
World War I caused a major surge in the use of welding processes, with the
process. The first welded road bridge in the world, the Maurzyce Bridge was
during the final decades of the 19th century, with the first patents going to Elihu Thomson in 1885who made further advances over the next 15 years. In 1893, Thermite welding was introduced and during the same time additional welding process known as Oxyfuel became well established. Furthermore, Acetylene was discovered in 1836 by Edmund Davy, however, when the suitable torch was developed, it could not be used practically in welding until about 1900. At first, oxyfuel welding was one of the most popular welding methods due to its portability and relatively low cost. As the
Thermite Welding.
Oxyfuel Acetylene Welding torch.
52
WELDFAB TECH TIMES | AUG - SEPT 2017
www.weldfabtechtimes.com
FLASH BACK
became popular in the early 1960s. Quite recently, a variation has been developed for the use of pulsed current. It is switched from a high to a low value at a rate of once or twice the line frequency. Soon after the introduction of CO2 welding, a variation utilizing a special electrode wire was developed. This wire, described as an inside-outside electrode, was tubular in cross section with the fluxing agents on the inside. The process was called Dual shield, which indicated that external shielding gas was utilized, as well as the gas produced by the flux
Bridge of Maurzyce.
in the core of the wire for arc shielding. This process, invented by Bernard,
designed by Stefan Bryła of the Lwów
welding, which further became popular
was announced in 1954, but when
University of Technology in 1927, and
in shipbuilding and construction.
the National Cylinder Company got
built across the river Słudwia near
Submerged arc welding was invented
reintroduced, it was patented in 1957.
Łowicz, Poland in 1928.
in the same year and continued to be
In 1959, an inside-outside electrode
popular even today. In 1932 a Russian,
was produced which did not require
made in welding technology, including
Konstantin Khrenov successfully
external gas shielding. The absence of
the introduction of automatic welding
implemented the first underwater
shielding gas gave the process popularity
in 1920, in which electrode wire was fed
electric arc welding. After decades of
for noncritical work and this process
continuously. Shielding gas became a
development, Gas tungsten arc welding
was named Inner shield. The electroslag
subject receiving much attention, as
was finally perfected in 1941 which
welding process was announced by
scientists attempted to protect welds
allowed fast welding of non-ferrous
the Soviets at the Brussels World Fair
from the effects of oxygen and nitrogen
materials; however, it required expensive
in Belgium in 1958. It had been used
in the atmosphere. Porosity and
shielding gases. Shielded metal arc
in the Soviet Union since 1951, but
brittleness were the primary problems,
welding was developed during the
was based on work done in the United
and the solutions that developed
1950s, using a flux-coated consumable
States by R.K. Hopkins, who was granted
included the use of hydrogen, argon, and
electrode, and it quickly became the
patents in 1940. The Hopkins process
helium as welding atmospheres. During
most popular metal arc welding process.
was never used to a very great degree for
the following decade, further advances
In 1957,plasma arc welding and the
joining. The process was perfected and
allowed the welding of reactive metals
flux-cored arc welding process were
equipment was developed at the Paton
like aluminum and magnesium. This
newly established, in which the self-
Institute Laboratory in Kiev, Ukraine,
in conjunction with developments in
shielded wire electrode could be used
and also at the Welding Research
automatic welding, alternating current,
with automatic equipment, resulting
Laboratory in Bratislava, Czechoslovakia.
and fluxes fed a major expansion of
in greatly increased welding speeds.
The first production used in the U.S. was
arc welding during the 1930s and then
Furthermore, Electroslag welding was
at the Electromotive Division of General
during World War II. In 1930, the first all-
introduced in 1958and it was followed
Motors Corporation in Chicago, where it
welded merchant vessel, M/S Carolinian,
byelectro gas welding in 1961. In 1953,
was called the Electro-molding process.
was launched.
the Soviet scientist N. F. Kazakov
It was announced in December 1959 for
proposed the diffusion bonding method.
the fabrication of welded diesel engine
introduced during the middle of the
Another variation was the use of inert
blocks which used a consumable guided
century. In 1930, Kyle Taylor was
gas with small amounts of oxygen that
tube for welding thicker materials. In
responsible for the release of stud
provided the spray-type arc transfer. It
1961 The Arcos Corporation introduced
During the 1920s, major advances were
Many new welding methods were
www.weldfabtechtimes.com
AUG - SEPT 2017 | WELDFAB TECH TIMES
53
FLASH BACK
another vertical welding method known as Electrogas which utilized equipment
users of electron beam welding. Some other developments in welding
was originally developed at the Bell Telephone Laboratories as a
developed for electroslag welding
included: The 1958 breakthrough of
communications device because of the
with flux-cored electrodewire and an
electron beam welding, making deep
tremendous concentration of energy in a
externally supplied gas shield. It is an
and narrow welding possible through the
smaller space, it proved to be a powerful
open arc process since a slag bath is
concentrated heat source. Following the
source of the heat as it can also be
not involved. A newer development
invention of the laser in 1960, laser beam
used for cutting metals and nonmetals.
uses self-shielding electrode wires and
welding debuted several decades later,
Continuous pulse equipment is also
a variation uses solid wire but with gas
which has proved to be especially useful
available in which the laser is finding
shielding. These methods allow the
in high-speed, automated welding.
welding applications in automotive
welding of thinner materials than can
Magnetic pulse welding (MPW) is
metalworking operations.
be welded with the electroslag process.
industrially used since 1967. Friction stir
Gage invented plasma arc welding in
welding was invented in 1991 by Wayne
introduced into the US industry during
1957 which uses a constricted arc or
Thomas at The Welding Institute (TWI,
1960s, Robot welding is relatively a new
an arc through an orifice which creates
UK) and found high-quality applications
application of robotics. It is the use
higher temperature arc plasma than the
all over the world.
of mechanized programmable tools
tungsten arc, such higher temperature
Although robots were firstly
(robots) which completely automates the
can be easily used for metal spraying and
Most Recent
welding process by performing the weld
for cutting purposes.
Friction welding was developed in the
as well as handling it efficiently. The
Soviet Union which requires rotational
number of robotic usage in industries
which uses a focused beam of electrons
speed and upset pressure to provide
has been growly tremendously as, in
as a heat source in a vacuum chamber,
friction heat. It is a specialized process
2005, it had been reported that more
was developed in France. J.A. Stohr of
with many applications where a
than 120,000 robots were used in North
the French Atomic Energy Commission
sufficient volume of similar parts are to
American industry for welding purposes.
made the first public disclosure of the
be welded because of the initial expenses
process on November 23, 1957. In the
for equipment and tooling.
The electron beam welding process,
United States, the automotive and aircraft engine industries are the major
Lase welding has been one of the newest processes so far which
Quite recently, Robot arc welding has begun growing rapidly and it has been reported that about 20% of industrial robots command applications. The major components of arc welding robots
Robotic Welding.
are the manipulator or the mechanical unit and the controller, which acts as the robot's "brain". The manipulator is what makes the robot move, and the design of these systems can be categorized into several common types, such as SCARA and cartesian coordinate robot, which uses different coordinate systems to direct the arms of the machine. The robot may weld a pre-programmed position guided by the vision of a machine, or by a combination of the two methods. However, many benefits of robotic welding have proven to make it a technology that helps many original equipment manufacturers increase accuracy, repeat-ability and reach a higher standard of market.
54
WELDFAB TECH TIMES | AUG - SEPT 2017
www.weldfabtechtimes.com
UPCOMING PROJECTS
Gujarat - Gorakhpur gas pipeline
S
tate-owned Indian Oil Corporation (IOC) plans to lay the nation’s longest LPG pipeline from Gujarat coast to
Gorakhpur in eastern Uttar Pradesh. The project will cater to
Chenab Bridge
T
he Chenab Bridge is a railway steel and concrete arch bridge under construction in Jammu and Kashmir in India. The
bridge will be 1,178 ft above the Chenab River making it the
growing demand for cooking gas in the country. IOC plans
world's highest rail bridge. The length will be 1,315 m, including
to import LPG at Kandla in Gujarat and move it through
the 650 m (2,130 ft) long viaduct on the northern side. The Arch
the 1,987 kilometer pipeline to Gorakhpur via Ahmedabad
will span at 467 m (1,532 ft) with an Arch length of 480 m (1,570
(in Gujarat), Ujjain, Bhopal (in Madhya Pradesh), Kanpur,
ft). The bridge will be structured using over 24,000 tonnes of
Allahabad, Varanasi and Lucknow (in Uttar Pradesh). The
steel. In order to enhance safety and security, the bridge will be
pipeline will carry 3.75 million tonne per annum of LPG. It
made of 63mm thick special blast-proof steel as the Jammu and
will connect eight of IOC’s LPG bottling plants in Central and
Kashmir region is prone to frequent terror attacks. Designed to
Northern India.
withstand wind speeds of upto 260 km per hour, the bridge will connect Bakkal (Katra) and Kauri (Srinagar).
Mumbai Trans Harbour Link
Inland Waterways
T
M
connecting Mumbai with Navi Mumbai. The sea link will
for developing waterway facilities in Ganga. The government
contain a 6 lane highway, which will be 27 m in width, 25m in
would also invest Rs 50,000 crore for development of Paradip
height, in addition to edge strip and crash barrier. MTHL project
port. An additional amount of Rs 8,200 crore would be used for
is estimated to cost ₹17,843 crore (US$2.8 billion) and to be
developing a new port at Paradip.
he Mumbai Trans Harbour Link (MTHL), also known as the Sewri-Nhava Sheva Trans Harbour Link, is the longest
sea bridge in India at 21.8 km. It is a freeway grade road bridge
odi government has planned to develop inland waterways including rivers like Ganga, Brahmaputra and
Mahanadi. The government is spending around Rs 4,000 crore
completed by 2019.
www.weldfabtechtimes.com
AUG - SEPT 2017 | WELDFAB TECH TIMES
55
PRODUCT / COMPANY UPDATES
Super Tech Engineers
S
4. Steel industries: Hallow
uper Tech Engineers is an organization
shafts for charging and
engaged in
discharging mechanism,
manufacturing and
water cooled dampers,
supplying of spare parts for
snout chute, ducting
steel mills, sugar industries,
for hot air cold , dipper
and motor manufacturers.
plates and water
The company is a
trough, screwdow nuts,
manufacturer and supplier
pinch roller, deflected
of special equipment for
through continuous
equipment: Various
roller, pre heated hood
SPM, as well as exports
research and development.
type of equipment are
arrangement, stopper
industrial equipment. Super
The product ranges are as
manufactured, such
Tech Engineers is majorly
follows.
as Dryers – Tray type,
into press tools fabricating
1. Steam boiler: NON-IBR
Drum type, Tunnel type,
Fabrication: Online
works, machining jobs, etc.
coil type steam boiler of
Flash type, Pneumatic
valves, hydrogen tanks,
The company is supported
variable capacities from
conveyor type lime,
conveyors, ducting,
with well equipped tool
50 kg/hr to 200 kg/hr.
discharging mechanisms,
heavy custom built
storage tanks.
equipment structures.
rooms, machine shop and
2. Pressure vessels and
production units with a high
heat exchanger: Carbon
technician and working staff.
steel as well as stainless
The products are based on
steel constructions such
innovative techniques that
as recupetator, etc
suit customer requirements
assembly, all types of skid. 5. General Heavy
For More Info: F-39, MIDC, Ahmednagar - 414111, India Mob: +91 9890217710 Email: supertechf39@gmail.com
3. Chemical process plant
SAW Systems
Cladding Systems
•
•
• •
Cap Seal / Shell
- Sector wise
Tandem
Cladding
cladding of 90
Single / Twin Wire and Power Source capacity up
- Cladding with
deg elbow with
to 1600A
30 / 60 / 90 /
auto-pass
Single Wire SAW Systems
120mm strips
•
- Operating Mode: CC/CV •
- Suitable for SAW,
Complete
with ESW
systems with Column
Small Pipe Cladding
& Boom, Positioner,
- Cladding of pipes with
Cladding Head, Cooling
In-built protections
diameter starting 38mm
System, Flux Recovery
- Wide mains voltage
- Over / Under Voltage
using TIG
System etc. are available
tolerance: ±20% (Inverter)
- Single Phasing
90 Deg Elbow Cladding
as per requirement.
Gouging and Electro Slag Welding (ESW)
•
•
For More Info: KAIYUAN WELDING & CUTTING AUTOMATION INDIA PVT. LTD. Survey No. 255/1/8, Hinjawadi, Taluka Mulshi, Pune – 411057, Maharashtra, India Contact No. +91 7755900921, 7755900873 - Web: www.kaiyuan.in - E-mail: info@kaiyuan.in
56
WELDFAB TECH TIMES | AUG - SEPT 2017
www.weldfabtechtimes.com
PRODUCT / COMPANY UPDATES
Sigma Therm - IH : Pre-Post Weld Heat Treatment
T
he Sigma Therm is
multiples of 5 meters. When
an inverter based
using induction coils for pre
preheating and post
heating, it is wrapped around
weld heat treatment unit
the job with or without
especially for tubes and
any insulation protection.
pipes. Depending on the size
The coil can be protected
of the pipe, one or two units
against welding spatter with
are used. Induction coils are
insulation cloth / blanket.
placed on both the sides of
When doing post weld heat
the welding seam.
treatment, the job must first be insulated with 20 mm
Induction Heating
thick ceramic blanket after
Temperature Range
Induction: 20°C - 760°C
•
It is Clean, green and
which the coil is wrapped
Heating Power
5KW - 40KW
safest ways to pre/post
around the pipe.
Connection Voltage
3-Phase 50Hz
weld heat treatment.
•
touch screen HMI controls
Temperature Measurement and Recording
not conducted..
the Sigma therm to get the
Temperature is constantly
It has a very quick setup
desired temperature profile.
monitored with a thermo
Applications for PWHT / Pre Heating
time and can preheat
The advanced logic control
couple. If needed, the
•
much faster than gas fired
helps to achieve the accurate
temperature can be recorded
or conducted heating
heating temperature rate and
in soft format or temperature
•
Power piping
methods.
maintain the cycle as desired.
chart can be printed. Upto
•
Construction repair
It saves time.
The heating cycle can be
6 thermo couples can be
programmed to ensure
interfaced with the recorder.
•
Petro chemical
Heating Elements/ Induction Coil
correct heating rate (Degree
The temperature can be
•
Shipbuilding
C / HR), soaking temperature
recorded, graphed and
•
Heavy fabrication
Induction coils with
and soaking time, cooling
printed for reach cycle.
•
Shrink fitting
maximum length of 50 meters
ramp rate and cooling time.
can be connected to one
There are preset programs
Optional Accessories
Safety: Substituting gas
power source. Induction coils
and any new heating cycle
•
Coil
burners for pre heating of
are in ready to use lengths in
can be easily customized.
•
Heating Pad
welding joints
•
Temperature Chart
•
•
•
Induction heating
Digital Control System
induces the heat directly
PLC based system with
into the metal, the heat is
Thermocouple Attachment Unit
Components made from P91 grade materials
pipeline
Recorder/ Printer •
Cerawool Blanket
•
Thermocouple For More Info: 31, Mistry Industrial Complex, Cross Road ‘A’, M.I.D.C, Andheri [E], Mumbai 400093. India. Tel: +91-22-45410600 / 601 Email: sigmaweld@edmail.in www.electronicsdevices.com, www.sigmaweld.com
www.weldfabtechtimes.com
AUG - SEPT 2017 | WELDFAB TECH TIMES
57
PRODUCT / COMPANY UPDATES
Jayesh Group
E
stablished in 1967,
foundries and steel plants.
across the welding industry in
Jayesh Group
The company has its own
India and also export to more
is engaged in
manufacturing plants,
than 25 countries. Amongst
manufacturing, trading,
adequate warehousing
the welding industry, the
imports & exports of ferro
facilities, modern
company caters to the below
alloys, metals, minerals &
computerized infrastructure,
segments for their raw
chemicals, nodularizer &
experienced and professional
material requirements:
inoculants and steel strips.
executives and a sound
•
These products are used as
financial base, to provide a
raw materials for various
strong back-end support to
industries which include
its activities. In order to offer
welding electrode, flux cored
quality products consistently,
wire, wear plates, powder
the company sources its
metallurgy, hard metal,
products from the best of
diamond tools, special alloys,
the manufacturers. Jayesh
aerospace, colour ceramics,
Group supplies its products
•
Manufacturer of welding fluxes
•
Manufacturer of wear resistance plates
•
Manufacturer of flux cored wire.
Manufacturer of welding electrodes For More Info: 605-9, Krushal Commercial Complex, Above Shoppers Stop, G.M. Road, Amar Mahal, Chembur (W), Mumbai - 400 089. India Tel: +91 22 6703 9991 / 4074 9990 Email: info@jayeshgroup.com www.jayeshgroup.com
Pro-Arc Welding & Cutting Systems
B
eing the market
machines in public
leader in India for
sector.
CNC Thermal Cutting
•
in last year and aim to
always been the first class
sell over 150 machines
indigenous manufacturer
this year.
of the below mentioned
machines with Hi-
products:
Definition plasma,
•
Leading manufacturers
underwater plasma
of SPM ‘s , CNC Oxyfuel
cutting, triple torch oxy
and Plasma Profile
fuel rotary bevel, 5-axis
Cutting Machines .
plasma rotary bevel,
Over three decades
pipe cutting solutions
of rich experience in
and plate processing
•
providing automated solutions in welding and •
•
58
Sold over 112 machines
Machines, Pro-Arc has
•
machines 2016 – Shifted to Bigger
Dealers Network:
Facility of 32,000 sq. ft.
•
Ahmedabad
2016 – Launched Altis
•
Bhopal
– Schneiden Brand.
•
Chennai
German Technology CNC
•
Delhi
Cutting Machines.
•
Bangalore
Supplied over 650
•
Vadodara
machines.
machines across the
•
Nagpur
Provides technologically
globe.
•
Mumbai
Supplied over 150
•
Kanpur.
cutting applications.
advanced solutions such
Known for delivering
as CNC drilling and
quality products in time
tapping, rotary bevel
and at most competitive
solutions, underwater
prices.
cutting, fume extraction
Solutions include
systems, special purpose
‘state-of-the-art ‘ CNC
cutting and welding
WELDFAB TECH TIMES | AUG - SEPT 2017
• •
•
•
For More Info: Gat No. 246, Jadhav Vasti, Besides Jadhav Water Purifying Plant P. O., Chimbli, Tal. Khed, Chimbali, Maharashtra 412501 Mob: +91-9730067994 Email: veena.mulchandani@proarcindia.com
www.weldfabtechtimes.com
PRODUCT / COMPANY UPDATES
Rilox Arc 200
R
ilox Arc has always been one of the most sold products in the
market. We have selected each and every components of this product to deliver a very stable and best output to the user. With one year warranty, this machine is very cost effective and value for money.
The machine features: •
12 mosfet
•
12 diod
•
4 capacitor
•
Rilox Arc 200 is very portable & power saving.
For More Info: Rilox Weld Equipments B/406, Sheetal Soc., Apna Ghar Unit 9 CHS , Above Sasural Hotel, Lokhandwala Complex, Andheri (W), Mumbai-400053.Tel: (0091) 8097867863 Email: riloxweld@gmail.com
www.weldfabtechtimes.com
AUG - SEPT 2017 | WELDFAB TECH TIMES
59
TENDERS
Company: Department Of Labor and Employment
Company: Bharat Heavy Electricals Limited
Location: Jharkhand
Location: BHEL Trichy
Nature of Work: Supply, Installation And Commissioning Of, Tools And Equipment In Imc, Iti General, Ranchi. Plm 1 Stillson Wrench Plm 2 Cutting Pliers 1S:3650 Plm 3 Stove Melting Solder Plm 4 Soldering Iron, Copper Bit Fire Heated Straight Plm 5 Firmer Chisel Plm 6 Washer Cutter Plm 7 Mirror Plm 8 Scribing Guage Plm 9 Tool Caulking Plm 10 Taps And Wrenches ( Bsp ) Sizes Covered To Suit Pipes Of Bore Dia 6, 8, 10, 20, 25, 32, 40 And 50Mm Plm 11 Drill Twist ( Straight Shank ) Plm 12 Water Heater Plm 13 Water Meter Plm 14 Hammering Drilling Machine Plm 15 Electric Ppr Pipe Welding Machine Plm 16 Sight Rail And Bonning Rod Plm 17 Solar Water Heater System Plm 18 Ring Gauge.
Nature of Work: Nylon Safety Belt. Due Date: 4th Sept, 2017 Tender Cost: Rs 0/EMD: Rs. 0/Contact: Corporate Office, BHEL, Asiad, New Delhi Email: query@bhel.com, Tel: 23365279.
Due Date: 07th Sept, 2017 Tender Cost: Rs. 3,00,00,000/EMD: Rs. 0/Contact: Department of Labor and Employment Email: secshb3@dole.gov.ph, osec@dole.gov.ph Tel: 526-6976, 527-2121, Fax: 336-8182, 527-3494.
Company: Ordnance Factory Board Location: Ordnance Factory Badmal Nature of Work: Term contract for repairing of residential quarters of Type-IV, Type-V, Public Buildings and Dumerbahal Dam. Due Date: 7th Sept, 2017
Company: Bharat Heavy Electricals Limited
Tender Cost: Rs. 30,00,000/-
Location: BHEL Trichy
EMD: Rs. 60,000/-
Nature of Work: Outsourcing, BHEL, Tiruchirappalli invites new vendors located within 350 km from BHEL Tiruchirapalli for fabrication of steel items / boiler components such as Boiler Columns, Auto Welded Beams and Bracings, Boiler Ducts, General Fabrication of Structures, Galvanized / Painted Handrails, Stairs, Round Corners, Metallic Expansion Bellows, Punching, Pressing and Shearing Jobs, Retainers, Tapping Points, Shaped Plates / Filler Plates, Venturi-meter, Flow-meter, Buckstay, Pleated Panels, Ceiling girder, Doors, Drain oil tank, Feeders, Foundation materials, Gate, Hanger and suspensions, Machining, Oil gun assembly, Oil system, Seal box, Sheet metal works and SS fabrication and Blasting and Painting of Fabricated Boiler components.
Contact: Surendra Sinha, Ordnance Factory, Badmal, Bolangir, PIN - 767070. Email: gm_ofbol@ofb.gov.in, Tel: 06655250219.
Company: Western Coalfields Limited Location: Ordnance factory Medak Nature of Work: Open Domestic E Tender for Supply of 1.1 KV PVC Insulated Mining Type Armoured Copper and Aluminium Lighting Cables. Due Date: 9th Sept, 2017
Due Date: 28th Sept, 2017 Tender Cost: Rs 46,20,000/Tender Cost: Rs. 0/EMD: Rs 92,400/EMD: Rs. 0/Contact: Webmaster, Corporate Office, BHEL, Asiad, New Delhi Email: query@bhel.com, Tel: 011-23365279, Fax: 23340981.
60
WELDFAB TECH TIMES | AUG - SEPT 2017
Contact: A N Sarkar, Coal Estate, Civil Lines Nagpur – 440001 Maharashtra. Email: gmsystems.wcl@gmail.com, Tel: 07122510130.
www.weldfabtechtimes.com
EVENTS UPDATE
NATIONAL Event
Date (2017)
Address
Organiser
Cutting & Welding Equipment Expo
08 - 10 Sept.
Bombay Convention & Exhibition Centre, Mumbai
Indian Institute of Welding
World of Metal
08 - 10 Sept.
Bombay Convention & Exhibition Centre, Mumbai
International Trade and Exhibitions India
The Big 5 Construct India
14 - 16 Sept.
Bombay Exhibition Centre, Mumbai
DMG Events
INMEX SMM
03 - 05 Oct.
Bombay Convention & Exhibition Centre, Mumbai
Informa Exhibitions
Weld India
07 - 09 Dec.
Chennai Trade Centre, Chennai
Indian Institute of Welding
Zak Aluminium Extrusions Expo
07 - 10 Dec.
MMRDA Grounds, Mumbai
Zak Trade Fairs & Exhibitions
Machma Expo
15 – 18 Dec
Glada Ground, Ludhiana
Fortune Exhibitors
INTERNATIONAL Event
Date (2017)
Location
Organiser
Welding Equipment and Cutting Material & Services Exhibition
23 – 25 Aug
Jiexpo Kemayoran Gate 7, Jakarta, Indonesia
GEM Indonesia
Philweld
23 – 26 Aug
World Trade Center Metro Manila, Pasay, Philippines
German-Philippine Chamber of Commerce and Industry
GAWDA Annual Convention 2017
01 – 04 Oct
New York
Gases & Welding Distributors Association
Weldex
10 -13 Oct
Sokolniki Exhibition and Convention Centre, Moscow, Russia
ITE Moscow
Machine Tool & Metalworking Solutions Expo
12 – 14 Oct
Saigon Exhibition & Convention Center (SECC), Ho Chi Minh City, Vietnam
Reed Exhibitions ISG India
SMACNA Annual Convention 2017
22 - 25 Oct
Wailea, HI
Sheet Metal and Air Conditioning Contractors' National Association
AAPEX 2017 - Automotive Aftermarket Products Expo
31 Oct – 02 Nov
Las Vegas, NV
APEX
FABTECH 2017
06 – 09 Nov
Chicago, IL
Fabtech
Welding Monitoring And Diagnostics
14 – 16 Nov
Yekaterinburg Expo, Yekaterinburg, Russia
FRESHEXPO
4th International Conference on Advanced Steel Structures
16-17 Nov
Singapore
Conference series
UkrWelding Ukraine
21 – 24 Nov
International Exhibitional Center, Kiev, Ukraine
International Exhibition Centre Inc
Metalex Thailand
22 – 25 Nov
BiTEC | Bangkok international Trade & Exhibition Centre, Bangkok, Thailand
The Japanese Machine Tools Association of Thailand
Metalworking & Welding Technology
29 Nov – 03 Dec
Saigon Exhibition and Convention Center, Ho Chi Minh, Vietnam
Deutscher Fachverlag
Machine Tool Indonesia 2017
06 – 09 Dec
The Jakarta International Expo, Kemayoran, exhibition centre
Pamerindo Indonesia
Welding & Cutting Middle East
17 - 19 Dec
Dubai World Trade Centre, Dubai, UAE
Al Fajer Information & Services
www.weldfabtechtimes.com
AUG - SEPT 2017 | WELDFAB TECH TIMES
61
ARTICLE
Welding Research in India: Key Needs and Actions a pride of a place through its committed
biennial international symposiums
efforts to all the sectors of manufacturing.
brought together major manufacturing
Besides WRI, there are quite a few
organisations to come forward and address
institutions which carry out welding
their welding technology requirements to a
research in the country.
group of welding equipment, consumable
Some of them are aligned with specific
R. Easwaran, General Manager Incharge (WRI, Labs, Quality), BHEL, Tiruchirappalli
instances where there has been a drive to
research. Table 1 is certainly not a
bring to a platform the gaps in welding
comprehensive table; but has been
technology and the need for research
prepared just to give an overview of few
and development to address the gaps.
esearch in welding takes a
institutions that are actively pursuing
Undeniably, there is a greater need of this
front role in the context of the
welding research.
sustained networking as India marches
R
Government of India’s initiative
There are also two professional bodies
ahead in its ‘Make in India’ initiatives.
of ‘Make in India’. There are quite a
– Indian Institute of Welding and Indian
few institutions working on welding
Welding Society – trying to network the
Welding Research Areas of Interest:
research, but when you look closely, their
efforts of the various institutions working
When one talks of the welding arena, the
work is generally addressing a specific
in welding field and bringing them on
gamut of aspects for research is indeed
sector. Among them, Welding Research
common platform through their seminars,
wide and deep. Welding being a multi-
Institute, BHEL, Trichy plays a nodal role
conferences, symposiums, exhibitions
disciplinary field, developments in every
in welding research in India and caters to
etc. Indian Institute of Welding took an
discipline does add to the advancement
many sectors, and has evolved as a world
initiative to bring together technologists
of welding technology; be it Mechanical
class institution.
from various sectors through a Colloquium
Engineering, Electrical and Electronics
at Hyderabad and attempted to list the
Engineering, Chemical Engineering, Civil
their share of challenges in welding, and
research gap areas in the various sectors
Engineering, Metallurgy and Materials
here, power sector has been taken as an
for research establishments to take forward
Engineering, Computer Engineering,
example area and the wide and varied
based on their competence and capability.
Nondestructive Evaluation, Newer
requirements for welding research in this
Indian Welding Society during its recent
understanding in Physics, Chemistry and
Every manufacturing sector have
sector has been highlighted. It is true that similar, as well as different challenges are being faced by the other manufacturing sectors. A suggestive way forward is also brought out in conclusion; which could help prioritise the key needs and action, as India gains strength and momentum in the ‘Make in India’ initiatives.
Organisations working on Welding Research: Welding Research Institute (WRI), BHEL, Trichy is the major institution associated with welding research in the country for the last 42 years and has earned for itself
62
and allied players. These are some
sectors and some are into academic
WELDFAB TECH TIMES | AUG - SEPT 2017
Mathematics, and what have you. Welding
Table 1: List of Few Welding Research Institutions in India
technology advancements are also linked
• Welding Research Institute, Trichy • Welding Research Centre, Roorkee • Defence Establishments (DMRL, DRDL, GTRE) • Aerospace Establishments • IGCAR, BARC, ARCI • BHEL, L&T, BEML • IITs, IISc.,NITs • CEMAJOR Annamalai Nagar; Baroda, Jadavpur Universities, CIT • HAL, NAL, CAT, Tata Steel, RDCIS and CET, SAIL, RDSO.
requirements of the various sectors of
to the advancements and the emerging manufacturing be it Power, Aerospace, Defence, Nuclear, Automotive, Railways, Shipbuilding, Oil & Gas, Refinery & so on. To give you an example, let me take the power sector’s emerging requirements with regard to welding. It may be noted that take any sector, you will find similar and even more specific emerging requirements showing up as gaps. The Research has to orient itself to address these gaps.
www.weldfabtechtimes.com
ARTICLE
Power Sector – Emerging research requirements:
The revolution that is to catch India in a
Shielding Gases: There does not seem to
big way is Additive Manufacturing (3D
be any significant fundamental research
Materials: If you look at the key needs in
Printing). The gap is felt that we should
on gas metal reactions. While pre-mixed
India, one of the foremost requirements
churn out more products through the
cylinders turn out to be expensive, there
is the availability of various grades of
additive manufacturing route. India uses
are good indigenous solutions by using gas
alloy steels indigenously in various
beam welding processes only in a limited
alternators. The purity of gases does raise
product forms be it plates, pipes, forgings,
context say in organisations like CAT,
some sporadic concerns in India and this is
castings and the like. There is a need for
ARCI, BARC, HAL, WRI, ISRO and a few
an area to work on.
implementing technologies in large scale
others. There seems to be a huge potential
to meet the requirements, especially in
to reach out beyond these. There are quite
Reclamation: Welding reclamation is a
the higher alloy grades, creep strength
a few innovations which have made good
huge market and there needs to be more
enhanced ferritic (CSEF) steels, austenitic
applications across the world like Keyhole
understanding of the right consumables for
and martensitic stainless steels, nickel-base
Plasma, Deep Penetration GMAW, low
specific applications. Protective coatings,
superalloys and so on. There is also a world
heat input GMAW, Orbital Narrow Groove
Thermal Spraying and other options need
of composites and nano-materials, which
Hot Wire GTAW etc., but in India you
to be looked more intensely by the industry
yearn for research.
see only limited applications in industry
to stretch the life of the products.
practice. Low Cost Automation: This is something
Consumables: It is not only materials but their welding consumablesare to be
New Power Sources: A new breed of
the Indian industry can adapt very fast,
made in India. While it must be said to the
wave form controlled power sources are
but there is a huge scope in developing
credit of the Indian Welding Consumable
available from various reputed welding
applications to suit specific purposes.
industry that many requirements are
equipment manufacturers. These cater
This needs some popularising efforts
being met indigenously. But there is
to low heat input, spatter free, deep
still, to expand their application horizon.
a need for the industry to have their
penetration, controlled dilution industry
There are many integrators in India who
creep tested data of the indigenous
applications. But there is no Indian make
can work on these and provide the right
consumables, especially for applications
of the power source of this genre; and this
solution for any application. There is a
using CSEF steels,Inconel, stellite, metal
is an area where the welding equipment
need for the industry to look out for them.
powders etc. There is a need for making
industry should focus catering to GTAW,
self-shielded flux cored arc welding
GMAW and SAW applications. There are
Robotics and Automation: Robotics
consumables, besides consumables for
no centres in India for evaluating and
and Automation is only in pockets and
certain high strength applications. The
certifying these new generation power
there appears to be a huge potential in
packaging associated with consumables
sources for their dynamic characteristics.
India for this, especially with the price
would need to further improve.
This is an area for development.
tag for Robots having significantly come
New Processes: While it has been the innovation and automation in the existing processes that have been taking welding technology forward, one cannot say that there are significant new joining processes that are being developed. Friction Stir Welding was a new way of looking at frictional heat. The Research in India is perhaps not looking at development of new welding processes; in fact the feeling seems to be that we do not doany significant fundamental research in the welding discipline. This is certainly a gap.
www.weldfabtechtimes.com
Gleeble Physical Simulation
AUG - SEPT 2017 | WELDFAB TECH TIMES
63
ARTICLE
made, to avoid any unpleasant surprises.
down. Robots would help replace human
capability. Creep and Fracture Toughness
interventions in very hot, high fume,
are really important properties for
crammed, monotonous welding and clad
materials; but we have limited test centres
Welding Engineering: This is an important
applications. The efforts of automotive
for these. It would be worth it to have
aspect of design of components for service
industry in bringing resistance spot
national institutions to take this up in a
and also in assessing components for
welding robots in a big way, needs to be
big way, with a large battery of facilities.
their remnant life which have served for a
emulated by the other sectors for multi-
After all, we need the Indian steel and
period. It must be said that this is a fertile
pass fusion welding applications.
consumable industry to develop new
area for further research and see how
materials as techno-economic options.
we can extend the life of already serving
Modeling & Simulation: The international
components. For example, there are many
advancements in modeling and simulation
Non Destructive Evaluation: With
steel bridges and rail bridges which have
has been fantastic. While these have
advancements of processes and materials,
been in service for several decades and
kindled some interest in academia, the
it is essential that the NDE capabilities of
some even centuries. It is essential that
industry needs to tap the huge potential
Indian industry also enhances. The world
these be checked for their remnant life
for their real-life applications. FEM based
of Ultrasonic Testing has taken a giant
and service worthiness. Another related
analysis which helps in predicting heat
leap with Phased Array Ultrasonic Testing
aspect is the measurement of Residual
transfer and distortion aspects could help
and Time of Flight Diffraction techniques,
Stresses in welded components, which is
save many reworks in applications. There
which hold a huge promise of replacing the
an important aspect governing service life
is good scope for research in stretching
Radiography of many components in the
of components, especially those in fatigue
simulation software to multi-pass welds
manufacturing shops and field assemblies.
service. It does require further committed
and large components. There is also
The Industry needs to take rapid steps
research for specific applications in
scope for modeling damage mechanisms
to catch up the lost ground in this area
measurement of residual stresses and also
of welds and HAZs. Artificial Neural
in India. Computed Radiography, Micro
looking at appropriate stress reduction
Networking based approaches add to the
Focal X-Rays etc. are also transforming the
methods including heat treatment, surface
modeling capability. Today good physical
way Radiography has been looked at. With
peening and the like.
simulations are also possible, where you
advanced materials, it is also essential to
can use a small amount of material to
have competent persons who can carry out
Field Welding Applications: While you
be subjected to weld-like thermal & stress
in situ metallographic replications, which
may find lot of efforts addressing the shop
conditions in terms of heating & cooling
can help assess damage in serviced and
floor manufacturing, the application of
rates, & looking at the effect on properties
aged components.
emerging fabrication technologies for onfield applications, poses a yawning gap.
like impact, tensile and ductility properties with miniature specimens. The industry
Weldability Assessment: This goes along
This is an area requiring special attention
should make use of established research
the development / first time usage of new
in India. The field of welding still
institutions to do this work for them in
materials and consumables. It is important
continues to be manual predominantly.
understanding new materials and their
that this aspect is given due recognition, as
The use of automation is nearly unheard
weldments.
produce-ability of a component has many
of! The field of welding with its challenges
dimensions and all these should be looked
of difficulties for welder access, windy
into before the first production weld is
conditions, assembly restraints, difficulty
Reliable Materials Testing: The testing laboratories in India has certainly proliferated. But there is a need to establish
Welding Simulator used in skill training.
their credentials as reliable testing centres. The ISO/IEC 17025 certification is one way to reach and sustain the industry expectations. But there is still a large gap where good international Proficiency Tests are organised by Indian Laboratories; which would pave way for setting good benchmarks and improving the testing
64
WELDFAB TECH TIMES | AUG - SEPT 2017
www.weldfabtechtimes.com
ARTICLE
in maintaining preheats in situ heat
there is a huge scope for further work in
standards? These are real research posers
treatment and NDE need to be addressed
this field. The work done at WRI reveals
and the scope is aplenty for the researchers
by the welding technologists. Every step
that specific defects show specific current-
in this field.
in this direction will help speed up the on-
voltage signatures; and these could be
field with improved quality, safety
potentially used for detecting defects as
Conclusion
and productivity.
they tend to occur and then ways can be
Viewed in the above context, there are
found to prevent them. The day may not
plenty of scopes for research on many
Under Water Welding: It must be said
be far off, when there could be an online
fronts. In fact, many fabrication sectors
that we need to have skilled divers
quality monitoring and defect preventing
will be willing to share their wish-list of
converted into skilled welders; and this
tool in welding based on continuous
things to be done to meet the joining
is a gap rather difficult to match. There
signature analysis of welding parameters.
needs. The researchers need to interact
are no facilities for training and certifying
with them regularly and work to address
on underwater welding in India. The
Weld Overlay, Thermal Spray and Surface
the issues.Funding for research is a
emergency needs of shipyards are met
Coatings: There is a lot of activity in this
concern; but then the Government
through professionals from overseas.
field. But mainly the equipment are from
agencies like DST, DIT, DHI, many
There is scope to work in this area.
overseas, the consumables too. There are
ministries are definitely willing to fund
quite a few applicators of coatings in India.
useful projects with clear deliverables
Weld Visualisation: While the high speed
With regard to the right coating for the right
within a defined time span. It is for the
camera systems have improved over the
application, there is potential for increased
research institutions to make best use.
years, the research efforts by visualising
understanding.
the welds is by far few. The understanding
There is also an often stated need that the infrastructure for fundamental research
of metal transfer, study of spatter control,
Additive Manufacturing: Also called 3D
is not adequate in the country. The
generation of fumes are all aspects that
Printing, this is giving a new dimension to
answer would have to be in pooling of the
would need advanced studies. Definitely,
fabrication. Laser based and electron beam
resources across institutions and academia
a fertile area for academic researchers in
based metal additive printing are already
within the country and abroad. There is a
India! There is also potential to work in
being used across the world in making
need to develop a sense of synergy between
this field with international institutions
real life products. The scope is there to
institutions for a larger cause of research.
like JWRI-Japan.
make very large components. India needs
Besides, even in the applied research area
to work on this in a big way and for many
itself, there is plenty of scope to work on.
Welding Simulators: It must be said that
exotic applications.
the welding simulators have attracted the
There needs to be anintrospective technology culture and a national
attention of Indian researchers and many
Welder Health: The environment of
platform for raising current challenges and
models of welding simulators have been
welding does have issues of fumes, noise
difficulties faced by the welding industry
brought out. As a good simulator can help
and intense arc heat. It is essential
in various sectors, which should help
reduce the arcing hours in the initial phase
that the short term health hazard and
researchers to focus on niche areas. The
of training of a welder, theseare promising
long term occupational hazards are
need for increased low cost automation is
tools for the welder trainers. Many types
understood and addressed. There is a
definitely felt by the industry. Creation of a
of Simulators have come into the market
huge potential for research in this area,
national level apex group or coordinating
including virtual augmented reality
considering that we are increasingly
agency for welding research will not be
systems. For someone looking for the best,
using high alloyed materials.
a bad idea.Associations like CII, FICCI,
may be the best is yet to come or is still being perfected!
ACMA, ARAI, NIRDESH and AWPM could Welder Safety: There are many protective
support the consolidation of sector-wise
equipment available in the market for
welding research needs.
Weld Signature Analysis: With on-line
the welder to make use of. But do they
Voltage and Current capturing systems
address adequate comfort levels for the
of welding engineers from engineering
which can acquire, analyse and statistically
welder using them, are they adequately
colleges. The subject should not be just a
present weld signatures through
protecting the welder from the hazard and
small part of manufacturing / production
Probability Density Distribution tools,
are they meeting the current and emerging
engineering syllabus.
www.weldfabtechtimes.com
It is also essential to develop a new breed
AUG - SEPT 2017 | WELDFAB TECH TIMES
65
INDEX
ADVERTISER’S INDEX Company Name
EDITORIAL INDEX
Page No.
Organisation
Page No.
WeldFab Tech Times
IFC
Weldwell Speciality Ltd
10
Rilox Weld Equipments
03
Miller Electric
11
ED-SigmaWeld
05
Steel Authority of India Ltd (SAIL)
11
EWAC Alloys
13
Hyundai Heavy Industries
11
Pro-Arc Welding And Cutting System
21
Reliance Defence and Engineering (RDEL)
12
Kaiyuan Welding & Cutting Automation India
27
Tata Steel
13
MPIL Corporation Ltd
22
Indian Institute of Welding (IIW)
24
Godrej and Boyce
28
Tekno International Trade Fair
38 - 39
Cliff Kumar Engineering
43
Shanti Metal Supply Corporatio
59
Advance Institute of Welding Technology
59
Noble Electrodes
66
Indian Machine Tool Manufacturers' Association (IMTMA)
44
WeldFab Tech Times (E-Market)
66
TAL Manufacturing Solutions Ltd
46
Warpp Engineers
IBC
BDB India
48
Ador Welding Ltd.
BC
Welding Research Institute
62
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66
WELDFAB TECH TIMES | AUG - SEPT 2017
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Owner, Printer & Publisher – Eliza A. Bhalerao Printed At - Anitha Art Printers - 29,30 Oasis Ind Est., Next to Vakola Market, Santacruz (East), Mumbai - 55. India. Published At - B-3/503, Ekdanth, Gauri Estate, Near Gauri Hall, Manjarli, Badlapur (W), Dist.: Thane – Ulhasnagar - 421503, Maharashtra, India. Editor – Amol A. Bhalerao TC No.- MAHENG14325