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Wire shavings during the feeding process with standard aluminum wire versus Indalco
EDITOR'S DESK
WELDFAB TECH TIMES www.weldfabtechtimes.com
Publisher & Editor Eliza Bhalerao eliza@weldfabtechtimes.com Group Managing Editor Amol Bhalerao amol@weldfabtechtimes.com Assistant Editor Marilyn Dias 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
New Horizons for women in Welding!! These days, there are increasing opportunities in the field of trade for women. For those women, who aim for a new and interesting career, welding can be one among the best choices. Welding is a promising industry and a career that can offer various benefits like decent wages, job variety, advancements in working patterns, job stability and the chance to work in a non-traditional environment. There is a rising demand for skilled and certified welders. As welding becomes a more high-tech trade, demand may especially increase for welders with robotics, engineering and computer programming knowledge. The women in India make minimal percent of welders, as compared to other countries. Women welders are becoming more common in other communities /countries. One of the reasons could be due to the programmes designed specifically for their success, no community
EAA Publication Registered Office : Gauri Estate, Ekdant, B-3/503, Near Gauri Hall, Manjarli, Badlapur ( West ) - 421503. Dist. - Thane. State - Maharashtra, India. Mob: + 91 9975580309 / 9172546460 Email: eliza@weldfabtechtimes.com / eliza.weldfabtechtimes@gmail.com Website: www.weldfabtechtimes.com All rights reserved. While all efforts are made to ensure that the information published is correct, WeldFab Tech Times holds no responsibility for any unlikely errors that might occur. Printed, Owned & Published by Eliza Amol Bhalerao on behalf of EAA Publication, Printed at Printpoint Shop no - 5, Ground Floor, Sangeeta Skill Mill, Press bazaar, Near Shivaji Chowk, Opp. Bharat Green Lawn, Ulhasnagar - 421003 and Published from B-3/503, Ekdanth, Gauri Estate, Near Gauri Hall, Manjarli, Badlapur (W), Dist.: Thane – Ulhasnagar - 421503, Maharashtra, India. Editor: Amol A. Bhalerao The information on products on offer is being provided for the reference of readers. However, readers are cautioned to make inquires and take their decision on purchase or investment after consulting experts on the subject. WeldFab Tech Times holds no responsibility for any decision taken by readers on the basis of information provided herein.
4
WELDFAB TECH TIMES | APR - MAY 2018
barrier, etc. Many institutes internationally are aiming to offer an apprenticeship welders programme for women to help close a genderbased skills gap and give them a boost in the economic standing. Both men and women are finding success in becoming professional welders. While men take up majority of the positions across the country, yet the demand for professionally trained welders has led many women to enter this field. Cheers to all the women, who are into welding and have plans to opt for this career in the near future‌.
Eliza Bhalerao Publisher & Editor
www.weldfabtechtimes.com
CONTENTS 6
38
Welding robots complete 3D-printed steel bridge
ARTICLE
17
International standards for welder qualification
28
WELDING ERGONOMICS
TRAINING CENTER
64
ISO 3834 – The Quality Requirements for Welding
LAUNCHES
42
New ArcTig Welding Process from Fronius
36 22
WELDFAB TECH TIMES | APR - MAY 2018
Kemppi’s new Robotic Center in India and China
www.weldfabtechtimes.com
24
Safety in focus
INTERVIEW
TRAINING & CERTIFICATION WELDING
52
TIPS
Training and Certification in Welding
62 BULLETIN
34 Copper: Reign of the metal Sanjeev Ranjan, Managing Director, International Copper Association, India
www.weldfabtechtimes.com
PRODUCTS UPDATE PROJECTS UPDATE WOMEN IN WELDING
11 Reasons: Why Welders Don't Follow Welding Procedures
08 STUDENTS 14 CORNER 26 50 60
Annamalai University plans to start UNICPROSPER: Need support and guidance
APR - MAY 2018 | WELDFAB TECH TIMES
7
BULLETINS
Improve Weld Quality with Precision Ground Tungsten Electrodes
I
mprove weld quality
can be extra hazardous not
with other sizes catered for on
with precision ground
only for safety, but also for
request.
Tungsten Electrodes
personal health. To overcome
Savings can be achieved
using non-radiotoxic
these conditions, whilst
because of the increased
MultiStrikes and The TEG-
maintaining a very high life
life of properly ground
1000 Tungsten Electrode
expectancy for the Tungsten
Tungsten Electrodes. With
Grinder.
Electrode we manufacture
the special collect accessory
Back by popular demand,
on the TEG-1000, shorter
blue-tipped MultiStrike
Huntingdon Fusion
Tungsten Electrodes that
for welding aluminium with
Tungsten Electrodes can be
Techniques HFT had re-
contain non-radioactive rare
the AC process, as well as
held significantly increasing
initiated the manufacturing of
earth elements, eliminating
steels and alloys with the DC
the length of life of each
the famous TEG-2 Tungsten
the risk to health posed by red
process, which allows the
Tungsten Electrode before it
Electrode Grinder, under the
tipped radiotoxic thoriated
welder to have just one type
is discarded.
new name of TEG-1000.
Tungsten Electrodes.”
of Tungsten Electrode to
Repeatable high quality
weld all materials and reduce
TIG welding requires
HFT said, “Ensuring your
work at higher temperatures
the amount of stocks and
Tungsten Electrodes to
Tungsten Electrodes are
so their oxide additions
purchasing requisitions.
have perfectly ground and
sharpened correctly can help
(mostly radioactive) burn
to improve weld quality.
out, or evaporate much faster
Grinder with HFT’s well
1000 provides these, time
Tungsten Electrode Grinders
than those non-radioactive
established and technically
after time, to exactly the
are a convenient, safer and
ingredients in MultiStrike,
popular Multi Strike Tungsten
same size and shape. The
more accurate way than other
so much so that MultiStrikes
Electrodes will give repeatable
diamond wheel grinds
methods of grinding Tungsten
give at least 10 times more
Tungsten Electrode points
the Tungsten Electrodes
Electrodes.”
arc striking capacity over
every time, enabling
longitudinally, preventing arc
other Tungsten Electrodes,
consistent repeatable arc
flicker or wander caused by
Tungsten Electrodes with
when tested under the same
performance and welding
circumferential lines or ridges
open air belt and disc
conditions.
results. Sizes 1.0 to 3.2 mm
found on electrodes, which
can be ground as standard,
have been ground incorrectly.
Ron Sewell, Chairman for
“Grinding thoriated
grinding tools for example
Other Tungsten Electrodes
MultiStrikes can be used
The use of the TEG-1000
polished tips. HFT’s TEG-
Dukane acquires KVT
P
lastics welding
nice cosmetic appearance
equipment supplier
Maresch shows a part with
and the ability to join
Dukane announced
complicated geometry
complicated geometries. Hot
at NPE2018 that it has
bonded using hot gas
gas welding delivers on all
acquired German plastics
welding.
three requirements,” said
bonding equipment provider
8
Dukane's Vanessa
“Industry wants
Johnston. There is global demand
Dukane's Vanessa Maresch shows a part with complicated geometry bonded using hot gas welding.
KVT (Bielefeld). KVT offers
particulate-free assembly
a wide variety of bonding
technology,” said Dukane
for hot gas welding, added
technologies, the most
CEO and President Mike
Johnston, and KVT has been
important of which is its
Johnston during a press
successful in marketing the
suggest that KVT will double
patented hot gas welding
conference at booth W3763.
technology worldwide. In
its revenue in 2018, according
system.
“It also wants parts with a
fact, current projections
to Dukane.
WELDFAB TECH TIMES | APR - MAY 2018
Source: www.plasticstoday.com
www.weldfabtechtimes.com
BULLETINS
Airgas recognized by Boeing with ‘Supplier of the Year’ Award
Improve Weld Quality with a low cost Trailing Shield®
Trailing Shields ATS PHO 68C Titanium Tube Weld Using ATS.
T Source: www.businesswire.com
A
Trailing Shields ATS PHO 71C ATS Group with TIG torch.
he quality of welds on
connected to the argon gas
tubes, pipes and flat
supply, diffusing gas evenly
sheet metal can be
without turbulence through the
dramatically improved with
multi layers of stainless steel
the addition of a low cost Weld
mesh built into the body of the
Trailing Shield®.
shield. At each side, replaceable
Experts in Weld Purging,
silicone rubber side shields
irgas, an Air Liquide
being recognized for modeling
company, has
a zero-injury mindset,
Huntingdon Fusion
provide a barrier to prevent
been recognized as
investing in and implementing
Techniques HFT® have
the argon escaping sideways
‘Supplier of the Year’ in the
a formal, measurable safety
designed and developed flat
and remaining over the weld
Safety category by The Boeing
program. Airgas has been a
and radiused Trailing Shields®
metal. As the welding torch
Company. Airgas was one of
supplier to Boeing for more
which simply attach onto any
is moved forward, the weld
13 companies honored on
than 25 years and provides
TIG/GTAW, PAW/Plasma and
remains under an argon gas
April 11, 2018 for distinguished
industrial gases, welding hard
MIG/GMAW welding torch,
shield until the welded metal
performance in working with
goods, safety products, and
providing an additional inert
has cooled below its oxidation
Boeing. As the award recipient
dry ice to support key projects
gas coverage duringthe seam
temperature.
in the Safety category, Airgas is
across the full enterprise.
welding of stainless steel,
Forney introduces four new welding machines
Trailing Shields® are
duplexes, titanium and any
reusable, with a temperature
other reactive metal where
resistance of up to 230ºC. They
discolouration or oxidation
prevent re-work, eliminate the
needs to be eliminated.
need for an expensive purge
Luke Keane, Technical
chamberand allow for faster
F
Support for HFT said: “These
welding. For manual welding,
Industries has
the 140 FC-i flux-
lightweight, easy to use Trailing
the welder finds that with this
introduced
cored inverter
Shields® pay for themselves in
lightweight and low cost tool,
four new machines
machine, which
just one weld! They are perfect
there is no difficulty in dragging
to expand its Easy
welds plate up to
for manual welders, as well as
it along the surface being
Weld line. These
¼ in.; the 140 MP
automatic machines by helping
welded. One further benefit is
to cover the weld with an inert
that it carries the welding torch
gas coverage during and after
at 90º to the weld.
orney
The line includes
Source: www. for GMAW, SMAW, cutting machines are canadianmetalworking. and GTAW with com
welding and plasma
0.030-in.-dia. wire;
®
welding, producing bright,
Radiused Shields are
yourselfers, auto enthusiasts,
the 100 ST SMAW and lift-arc
shiny, oxide free welds time
designed to suit the exact
metalworking artists, and
GTAW machine that welds
and time again and eliminating
diameter of the pipe or vessels
hobbyists. The machines
up to 5/16 in.; and the 20 P
the expensive post weld
being welded. Flat models are
can be used in a garage with
plasma cutter, which cuts up
cleaning process.”
available for sheet and plate
standard 120-V power.
to ¼-in. mild steel.
suitable for do-it-
www.weldfabtechtimes.com
The Trailing Shield is ®
welding.
APR - MAY 2018 | WELDFAB TECH TIMES
9
BULLETINS
TÜV Rheinland India to spur its ‘Make in India’ initiative by investing in testing facility within AMTZ TÜV Rheinland India has now
significantly reduce the
opted for the Andhra Pradesh
cost manufacturing thereby
MedTech Zone (AMTZ) to
creating world class diagnosis
pursue its Make in India
with quality products
programme by investing in
accessible to the common
testing facility within the
man at affordable prices.
Kapurthala Rail Coach Factory orders welding wire, gets bricks, stones instead
Varma also expressed that
complex. During the recent
the quality of service rendered
CII Partnership summit, Andhra Pradesh chief minister
Source: www.businesswire.com
Chandrababu Naidu, honored
from TÜV Rheinland facility in AMTZ, Visakhapatnam
Source: www.nyoooz.com
TÜV Rheinland India with the
“Medical equipment
concessionaire agreements of
manufacturers can have
as having testing and
both EMI/EMC & Electrical
various advantages,
certifications from any of
Safety and Bio-material
incentives and opportunities
the TÜV Rheinland branches
R
scientific projects.
by having their production
globally.
bricks and stones in at least
The company had signed
facility within the AMTZ,
will carry the same credibility
He also appreciated the
ail Coach Factory (RCF), Kapurthala, one of the largest in
the country, has received five sealed cartons instead of
an agreement and entered
the country’s first Medical
concept of having complete
Stainless Steel (SS) welding
into a partnership with
Technology Manufacturing
medical equipment
wire, which they had ordered
AMTZ last year to set-up a
Park, established at
ecosystem under one roof
from a Mumbai-based
comprehensive state-of-
Visakhapatnam over an
of AMTZ which would
company. Thereafter, a stock
the art facility providing
area of 270 acres by the
reduce the overall product
of 243 cartons, kept at the
one-stop shop solutions for
government of Andhra
developmental life cycle,
shop, was checked jointly in
a wide variety of medical
Pradesh,” said Kalyan Varma,
logistics charges and
the presence of store officials
devices. The facility will
Vice President-Products,
turnaround time to market
and stones were found in three
have a 5 meter measurement
TÜV Rheinland India, a
thereby reduction in cost for
more welding wire cartons.
table with 5 tonnes capacity
service provider in the
total healthcare.
The matter came to light a
Electro-Magnetic Interference
testing, training, inspection,
(EMI/EMC), Electrical Safety
consulting and certification
facilities will help the medical
sealed cartons of SS welding
& Biomaterial scientific
industry.
equipment manufacturers
wire spools of 1.2 mm diameter
meet the international
were received by the RCF.
facilities. It will also include
AMTZ will house modern
“Our world class testing
few days ago when around 81
one 10m Semi Anechoic
250-300 independent
standards for quality and
“The incident clearly proves a
chamber with a measurement
manufacturing units,
safety. AMTZ along with
highly unethical, irresponsible,
range upto 40GHz, two 3m
each over a built-in ready
TÜV Rheinland is taking
malafide intention and willful
semi Anechoic chamber with
to use area at a very cost
initiatives to educate
fraudulent act of the concerned
a measurement range upto
effective long-term lease. In
medical manufacturers on
firm supplying the SS welding
40GHz, precision acoustics
addition the park will have
the new regulations as well
wire to our organisation,
facility for measuring sound
in-house high investment
as inform on the testing
having an international repute.
pressure and sound power
scientific facilities,
facilities available in AMTZ”,
Though the RCF authorities
from medical devices and
including state-of-the-art
said Thomas Fuhrmann,
did not reveal the cost of these
many other testing facilities
testing laboratories, which
Managing Director, TÜV
boxes, they said that it is a
within the zone.
would help manufacturers
Rheinland India.
matter of breach of trust by a renowned supplier.
10
WELDFAB TECH TIMES | APR - MAY 2018
www.weldfabtechtimes.com
BULLETINS
Build with Blue Spring Savings: Featuring Rebates up to $700
M
• Syncrowave® 210 TIG
iller Electric Mfg. LLC, a leading
Welder ($2,539 after $300
worldwide
rebate): Ideal for both
manufacturer of arc welding
light-industrial applications
equipment, is offering its spring
and personal users, the
rebate program just in time for
Syncrowave 210 does not
Father’s Day and graduation.
compromise power or
With the Build with Blue Spring
performance for affordable
Savings promotion, customers
inverter technology.
can take advantage of two
Source: www.millerwelds.com
rebates totaling up to $700. Now through June 30, 2018,
of products:
those purchasing a qualifying
• Millermatic 211 MIG
• Trailblazer® 325 EFI ($5,629 after $300 rebate): No other
cutter can be used on the
compact, engine-driven
job or at home. At just 19
machine in the 300-amp
Miller product will receive a
Welder ($1,149 after $50
pounds, the Spectrum 375
class delivers more welding
rebate of up to $500. By adding
rebate) : Welds material
offers easy connection to
power or more auxiliary
other Miller accessories or
from 24 gauge to 3/8-inch-
120V or 240V and can cut up
power with better fuel
Hobart filler metal, customers
thick in a single pass.
to 3/8-inch mild steel.
efficiency and less noise.
may qualify for another rebate
Multi-Voltage Plug (MVP™)
of up to $200. This offer is
provides the versatility to
Welder ($1,639 after $500
Customers can also take
valid only at authorized Miller
use 120 V or 240 V input
rebate): Perfect for the
advantage of more savings
power.
personal user, this AC/DC
when purchasing additional
TIG machine upgrade has
Miller accessories and Hobart
distributors. Customers are eligible for
®
• Spectrum® 375 X-TREME™
• Diversion™ 180 TIG
the following rebates when
($1,319 after $100 rebate):
both 115V and 230V input
filler metals (excludes welders
purchasing from the below list
This lightweight air plasma
power capability.
and plasma cutters).
Moraine company sold to international firm
A
irgas, which has about
into its business,
Cichocki, Airgas Chief
18,000 employees
including a new fill
Operating Officer.
at 1,100 locations,
plant, which opened
Jim Weiler,
has acquired Weiler Welding
in May 2014, that let
President of
Company’s assets and
it control its costs,
Weiler Welding,
operations as of April 30.
turn around orders
said that,“the
Weiler Welding is a Moraine-
faster, and blend
joining of the two
based gas distributor that
gases in-house for
companies will
caters to the welding industry,
specific orders.
create tremendous
craft brewers and more. Weiler
Airgas, a subsidiary
value for our
Welding has six locations,
of Paris-based Air
associates and our
including its Moraine office,
Liquide, stated that
and services Southwestern
Weiler Welding is the
Ohio and Southwestern
company’s 500th acquisition
and competency for us and we
foster opportunities for our
Indiana. Weiler’s 70 employees
since it was founded in 1982.
remain committed to pursuing
associates and we look forward
acquisition opportunities in
to continuing to serve our
the years to come,” stated Andy
customers as a part of Airgas.”
are now part of Airgas. Weiler
“Growth through acquisition
has made recent investments
has always been a core strategy
www.weldfabtechtimes.com
customers. We feel Source: www.whio.com
that this culture will
APR - MAY 2018 | WELDFAB TECH TIMES
11
BULLETINS
Robotic welding arms cut ship construction time and costs
S
outh Korean
$4.2 m in construction costs
shipbuilding companies
for each vessel, and have
Hyundai Heavy
prompted development of an
Industries and Daewoo
even smaller welding robot
Shipbuilding & Marine
weighing 14.5 kg.
Engineering are using
Some Hyundai Heavy
robotic welding arms to
vessels require 200 people
reduce welding times and cut
to build, unlike the car
construction costs.
manufacturing industry,
Hyundai Heavy’s 670
where around 70% of tasks
kg industrial robot, which
are completed by machines.
resembles a robotic arm, can
The shipbuilding industry
curve and weld steel plates
has adopted automation
for the front and back of
more slowly than other
vessels, and is controlled using
manufacturing industries
separate design software. The
due to variations in the
arm was designed and tested
specifications and functions of
in-house, and is scheduled to
individual ships.
begin operation next year. The
Bombardier receives EN 15085 Railway Applications for Welding
Falling ship prices and
Welding at Bombardiers, Dandenong site in Australia. Source: www.marketwired.com
R
ail technology
to manufacture carbodies
leader, Bombardier
to the latest European
Transportation in
Standards. Bombardier offers
Australia has received EN
welding courses for internal
15085 Railway Applications
and external candidates and
arm will cut welding time by
increased demand have
for Welding of Railway
the Dandenong facility has
two-thirds and save around
forced the industry to adapt.
Vehicles and Components
trained and qualified over
$9.4 m annually, according to
A 10% fall in ship prices since
Certification, the first rail
40 Bombardier welders in
a company spokesperson.
2014 has made employing
company in Australia to
addition to several key supply partners.
large numbers of staff
achieve this certification.
has been using five 16 kg
unsustainable, and both
With the announcement, the
robotic arms since 2016
Hyundai Heavy and Daewoo
Welding Training Centre at
has been active in Australia
to weld steel parts in the
Shipbuilding have received
Bombardier's Dandenong
for more than 60 years as
construction of ice-breaking
more contracts – 29 up
site in Victoria is now
a complete rail solution
natural gas carriers. The
from 21 and 21 up from four
an accredited facility for
provider. With local design,
arms, nicknamed ‘Caddy’,
respectively – this year than in
securing and growing local
engineering, manufacturing
have saved the company
the same period in 2017.
welding capabilities and for
and delivery capabilities, it
delivering industry-recognized
also provides solutions for
certifications to staff, external
signaling, propulsion and
suppliers, and industry
control technology, asset
partners in Australia.
management and through-life
Daewoo Shipbuilding
Over the years,
Source: www.ship-technology.com
12
Con Sakellaridis, Lead Welding Engineer, Bombardier Transportation, Australia.
WELDFAB TECH TIMES | APR - MAY 2018
Bombardier Transportation
support to our customers. With
Certification EN 15085 has
more than 1,000 employees
become the standard for
spread across every state,
railway manufacture and
Bombardier has delivered an
repair worldwide. This
extensive and diverse portfolio
certification enables the
of winning mobility solutions
Dandenong site in Australia
for Australia's rail ecosystem.
www.weldfabtechtimes.com
PRODUCTS UPDATE
X8 MIG Guns: Ergonomically designed industrial MIG welding guns with great performance
X
8 MIG Guns
is available as an
welds. With design, mobility
are a powerful
accessory for adjusting
and stability, X8 MIG Guns
combination of
welding parameters
maximize ergonomics.
and managing memory
Their innovative design
ergonomic and technical
channels
reduces wrist loading and
Strong gun shield hose
welder fatigue, while the
Available in both gas-cooled
material optimizes cable
cable's ball-and-socket joint
and water-cooled models,
mobility by reducing
balances the welding gun.
the X8 MIG Guns feature
friction
Add a perfect touch on the
The gas-cooled X8 MIG
trigger, and welding has
Gun range features
never felt better.
welding performance for •
industrial MIG welding.
•
interchangeable spare parts, and consumables that are easy to fit and maintain. Their innovative
spare parts •
Just wait until you get your
easy to fit and maintain
Excellent Welding Performance
Improved cooling and
The X8 MIG Guns are in
Guns are equipped with an
gas shield compared to
their own league compared
integrated LED work light,
consumables that are
precise operation of the •
compared to standard MIG guns. Designed with superb
•
balance, the X8 MIG Guns reduce wrist loading and welder fatigue. The
•
detachable pistol grip handle provides stability
hands on this one. X8 MIG
standard MIG guns
to standard MIG guns. Their
which illuminates the area
Excellent arc ignition
innovative neck design and
around the welding gun's
with the Touch Sense
structure enable precise
tip whenever you need it
Ignition feature
wire line operation, a stable
the most. This feature is
LED work light for
shield gas flow, and better
especially helpful when
illuminating the area
cooling. With 20% lower
doing pre-weld positioning
near the tip of the pistol
gas nozzle and 30% lower
or post-weld inspections.
K emppi Gun Connector
contact tip temperatures,
Never again will dim lighting
welding longer welds while
guarantees a firm
X8 MIG Gun consumables
ruin your welds.
ensuring perfect touch of the
connection to the
last longer and stay in better
trigger. An additional remote
wire feeder and offers
shape. Less costs, better
Key Applications
control is also available for
enhanced mechanical
bottom line.
•
General Mechanical
easy adjustment of welding
and electrical properties
parameters. For dimly lit
together with real arc
Ergonomics to the Max
•
Component
•
Pressure Vessels And
and extra comfort for
•
work conditions, the X8 MIG
Engineering
voltage measurement
The welding gun is the
The cable’s ball-and-
welder's most important
work light to aid pre-weld
socket joint balances the
tool in creating quality
positioning and post-weld
welding gun and reduces
visibility.
torque on the welder’s
Guns feature a handy LED
•
wrist
Benefits •
•
Detachable pistol
Available in both
grip handle improves
gas-cooled and
ergonomics in different
water-cooled models
welding positions
with interchangeable
14
Light It Up
High quality
neck technology guarantees wire line and better cooling
exchangeable necks
•
Manufactu¬ring Boilers.
For More Info: Kemppi India Pvt .Ltd. Ms. Shamna 3/462, 1st St, Phase-1, Kazura Garden, Palavakkam, Chennai, Tamil Nadu 600041 Tel: 044 45671217 Email: sales.india@kemppi.com
X8 Gun Remote Control
WELDFAB TECH TIMES | APR - MAY 2018
www.weldfabtechtimes.com
PRODUCTS UPDATE
Introducing Fiberstar CNC Laser Systems
L
aserStar presents the
cuts and/or laser
Software. This air
laser system configuration
3901 & 3903 Series
welds on a wide
cooled CNC laser
to accomplish the desired
FiberStar CNC Laser
variety of materials,
system is available
results. Designed and built in
System. The state-of-the-
while maintaining
in 150 & 300 Watt
America.
art CNC laser platform is a
low operating costs
models.
•
benchtop System (available
for rapid return on
in two sizes) with the ability
investment. The
solution provider,
•
to laser cut or laser weld using
state-of-the-art,
LaserStar’s
•
an interchangeable laser
fully integrated laser source
Applications Specialists will
head for material processing.
provides excellent beam
evaluate your laser welding
•
Aerospace and Electronics
This system provides a
quality while producing many
or cutting requirements,
•
Automotive and Micro
compact footprint and offers
years of reliable performance.
define the application goals
FiberStar systems come
an economical option for
Medical Device and Instruments
As a turnkey
Prototyping Components Jewelry (Gold, Silver, Platinum, Titanium)
Components
and objectives, specify and
•
Complex Industrial Alloys
businesses, while providing
with 4-Axis (X/Y/Z and
verify the correct technology,
•
Tool & Die Components
one machine than can both
optional Rotary) CNC system
and define a complete
•
Ceramics and Plastics.
cut and weld.
controller, an integrated For More Info: LaserStar Technologies Corporation Website: www.laserstar.net
computer with Windows
FiberStar CNC Laser Systems produce high quality,
operating system and ready-
dimensionally accurate laser
to-use LaserStar MotionFX
Gouging Torch / Gouging Electrode Holder (DSH Series) Model DSH Series
Max. AMPS
Max. Carbon
DSH - 22D
2200 Amps
20 mm Ø Carbon
DSH - 22P
2200 Amps
25.4 mm Ø Carbon
DSH – 22G
2200 Amps
20 mm Ø Carbon
•
EQUIPMENT- POWER •
An ordinary Arc Welding machine, DC Motor Generator
•
or Engine Driven Welder and
Strike the arc on the job
can be used. Most application
and maintain adequate
require 80 to 100 lbs PSI
arc gap. Adjust hand
air pressure. For higher
travel speed to produce
duty torches 80 PSI may
continuous hissing sound
be adequate. Heavy Duty
for smooth cutting action.
Torches would require as
To shut down, turn off
much 125 Ibs PSI. Air hose
electrical power first.
should have minimum base of
Turn off air supply after
¼ inches diameter.
Air Compressor capable of
the air connection nipple
electrical power is shut
giving a pressure of 80/125lbs
and the joint should be
down.
•
Set the correct amperage
AIR SUPPLY
considered only as general
in accordance with the
An ordinary air compressor
guide:-
Operation
diameter of electrode
•
being used as per
The current cables from
recommended currents.
the power supply should be of adequate capacity,
•
valve on the Torch fully.
insulation damages. The compressed air line is to be firmly attached onto
www.weldfabtechtimes.com
Turn on the compressed air supply and open the air
free of joints, kinks and •
conditions and should be
free of leaks.
PSI will be required for using the Metal Arc Torches.
NOTE: The above data is based on the following
•
Turn on the current supply.
Electrode stick out
90 mm
Air pressure
80/100 lbs PSI
Torch to west angle
45o
Arc Volts
35 to 45 volts
For More Info: B.R. Kumar & Sons 499 Haveli Haider Kuli, Chandni Chowk, Delhi 110006 E-mail: sales@metalarc.in / sales.west@metalarc.in Ph.: 0011 43080688, M: +91 9810100911 / +91 9890882033
APR - MAY 2018 | WELDFAB TECH TIMES
15
PRODUCTS UPDATE
Lincoln Electric Launches VIKING 3250D Welding Helmet Enhanced field of view and safety offered with 4C lens technologya
L
incoln Electric's
windows. These features can
quality standard in the world
VIKING 3250D
not only reduce the amount
(EN 379). The 12.5-square-
Welding Helmet
of time needed to conduct
inch auto-darkening viewing
features an Integrated Flip-
material setup, inspection
area is the largest for this
Up Grind Shield to increase
and weld operations, but
product type industry wide,
the operator’s field of view
may minimize any potential
making it ideal for a range of
in both open and closed
hazards that come from
industries that use multiple
positions.
having to frequently remove
welding processes.
Cleveland – Lincoln Electric® has introduces a new single helmet solution to
the helmet and store it at the worksite. The VIKING 3250D FGS
Lincoln Electric designed
4C stands for the following attributes:
this VIKING helmet
•
with a multitude of key
help enhance productivity,
Welding Helmet also boasts
Clarity – Optical clarity
features that can improve
safety and optic clarity: the
an industry leading optic
at the highest EN379
productivity, enhance optic
VIKING™ 3250D FGS™
design, 4C® Lens Technology,
1/1/1/1 levels
quality, revamp comfort and
Welding Helmet.
which eliminates blur,
•
Color – Real color view
promote safety to position
distortion and eye strain by
•
Carat – Lightweight auto-
the VIKING 3250D FGS
darkening filter
Welding Helmet as the only
Cut – Even shade from
welding helmet professionals
any angle
will ever need.
Designed for the professional welder, this
reducing color saturation
helmet features a Flip-Up
in the liquid crystal display
Grind Shield to increase the
(LCD) while also providing
operator’s field of view in both
a consistent shade at any
open and closed positions
angle. This technology scores
through the integration of
a perfect 1/1/1/1 rating on
a clear face shield and side
the only auto-darkening lens
•
For More Info: Lincoln Electric Company (India) Private Limited Website: www.lincolnelectric.com
Shape Cut Easy Series
W
16
arpp Engineers
Cut Easy & Shape Cut Fine
Pvt. Ltd.,
Series CNC cutting systems
a leading
which can be configured for
solution for welding and
either flame, plasma or for
cutting industry has wide
both. These cutting systems
range of cutting solution
can be built with different
to different industry need.
controller and different
automization will go a long
product quality, consistency
We understand that cutting
plasma power source as per
way in increasing your
and productivity.
is the first step to move
customer requirement. Our
towards automatic welding
20 years of experience in
and to help industry take
welding and cutting industry
their first step towards the
backed by good pre and
automation. Warpp has come
post sales service will ensure
out with Portable Shape
that your first step towards
WELDFAB TECH TIMES | APR - MAY 2018
For More Info: Warpp Engineers Pvt Ltd Survey no 36, House no 15/3, Unique Industrial complex, Dhual Nagar,Waliv, Vasai (E), Palghar - 401208 Tel: 08080808737 , Email: salessupport@warpp.co.in Website: www.warpp.co.in
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ARTICLE
International standards for welder qualification "ISO 9606 series- Qualification test of welders -Fusion welding-Part 2: Aluminum and aluminum alloys�: Non-Conformities the pipe must be fixed , the weld axis is vertical and weld is horizontal (Figure 1). Alireza Samimi Mottaghi, Welding Engineer-Responsible Welding Coordinator, Precision Metal Group Aust., SydneyAustralia
The question is why the pipe must be fixed, and what if it is rotating and the weld axis is vertical and weld is horizontal, is n, t it PC position, if we have a component that is rotating on a welding positioner then what is the welding position and on the other hand, in ISO 6947 that is the Welds-Working positions-Definitions of angles of slope and rotations there is not mentioned that in PC position the pipe must be fixed
I
(Figure 2). SO 9606 standards are series of international standards
The point is that the same notification is in AWS standard but
for welder qualification on different materials. Therefore,
not in ASME standard. This non-conformity is repeated in 1998
the welder who is qualified according to these standards
and 2004 versions of this standard.
shall fulfill the requirements of these standards independently from the place, examiner and the type of product. However, in this review we will discuss about non-conformities in these international standards and their results that could cause differences in the condition of qualification according to examiner decision with refer to unclearness and mismatches in these standards. These non-conformities are about the use of shielding gasses, range of approvals, normative references and evaluation of imperfections etc.
Introduction Welder qualification standards define the qualification tests for welders. These standards must provide a set of technical rules for a systematic qualification test of welder, and enables such
Figure 1: Butt welding position on pipe ISO9606-2:1994.
qualifications to be uniformly accepted independently of the type of product, location and examiner/examining body. When qualifying welders, the emphasis is placed on welder ability to manually manipulate the electrode/welding torch/ welding blowpipe and thereby producing a weld of acceptable quality.
Welding positions In 1994 version of this standard we have some pictures that clear the welding positions for qualifying the welders , we have butt welding on pipe in PC position and it is written that
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Figure 2: Butt welding position on pipe ISO6947:1990.
APR - MAY 2018 | WELDFAB TECH TIMES
17
ARTICLE
Welder approval test certificate Annex A
However, in ISO9606-2: 2004-dashed line are added in the
According to ISO 9606-2:1994 and 1998, the table of range of
table of range of approval for shielding gasses and auxiliaries
approval is empty to fill according to the standard (Figure 3).
(Figure 2). There are two deductions from this dash line in this table: The dash lines mean that only the gas used in the welder qualification test is acceptable and the welder is not permitted to weld with any other gases, in result there is no meaning for the grouping system of the welding gases according to the EN 439 standard if a welder test is with one of the gas mixtures it is not acceptable to weld with the other one and etc. The second deduction could be a very superficial conclusion that the dash lines mean there is no limitation for the welder to use any type, percentage, or mixture of gases while there are deep differences when a welder use for example an Ar gas or He in welding of aluminum. These changes are made from 2004, the dash lines are added to this table, why, what is the main reason, and meaning is a question.
J-L welding positions In all these years and different versions of this standard from 1994 to 2004 we cannot find J-L positions that are inclined position with fixed axis of pipe and welding in downward position we can find H-L045 (inclined position with fixed axis of pipe and welding in upward position in this standard), figure 1, however we have the downward welding position PG and PJ for aluminum but there is no signification of this welding Figure 3: ISO 9606-2:1994, 1998 Annex A.
position (Figure 5, 6). As an international standard, we can find it in AWS D1.2 that is for welding of aluminum.
Figure 5: J-L045 in ISO6947.
Range of qualification for welding positions In normative references in ISO9606-2:2004, there is EN ISO 6947 :1993 represented as the reference standard for welding positions (see figure 7).In this standard , PE and PC welding positions are pictured for butt welded joint and not for fillet Figure 4: ISO 9606-2:2004 Annex A.
18
WELDFAB TECH TIMES | APR - MAY 2018
welds. (Figure 8)
www.weldfabtechtimes.com
ARTICLE
Figure 6: Table 6 of ISO9606-2.
Figure 8: EN ISO 6947:1993.
While there were no mismatches in 1994 and 1998 in range of qualification for welding positions (figure 9), according to ISO 9606-2:2004 where a welder weld in PD position, the welder is qualified to weld in PA, PB, PC, PD, PE, PF (plate ), see table 6, Figure 10. On the other hand when we look more precisely in table 7, we can see there is a note " b" for welding in PB and PD positions that is: "welding position PB and PD are only used for fillet welds (see 5.4 b) and can only qualify fillet welds in other welding positions�, while PE and PC are qualified and these positions were shown for butt weld. When welding engineers are confronted with these mismatches, some of them draw a conclusion that PE and PC welding positions can be used also for fillet welds, but on the other side the reference standard show something else and in result, it is important that on which side you are, contractor or subcontractor? In addition, who you are dealing with. This
Figure 9: Table 6 of ISO 9606-2:1994.
could result in a need to a new welder qualification test or an acceptance according to a self-decision, not according to the standard.
Figure 10: Table 6 of ISO 9606-2:2004.
Figure 7: Normative references of ISO 9606-2:2004.
Forward of 9606 parts In Figure 11, you can see the mistake happen in the definition
www.weldfabtechtimes.com
Figure 11: Page IV of 9606-2:1994 and 1998.
APR - MAY 2018 | WELDFAB TECH TIMES
19
ARTICLE
of the 9606 parts in 1994 and 1998 in the left side of the picture and on right side of picture, the correct one that must be.
Repeated non-conformities If we try to exaggerating mismatches , there are a lot of minor mismatches, there are some non conformities in this standard and other versions that are repeated for many years and different revisions which results in self decisions, discussions and ‌ . Example No.1: There is a sentence in this standard shown in Figure 12.
Figure 14: Normative references of ISO9606-2:2004.
Figure 12: Part 6.3 of 9606-2:1994, 1998, 2004. In this part, we have a sentence that refer to minor imperfections but what are the MINOR IMPERFECTIONS and where that have been defined. Who must decide between two welding engineer that for example an imperfection seems a minor imperfection for one of them and for the other one is not a minor imperfection. Example No.2: is another sentence repeated in 1994 and 1998 table 7 note 4 that was up to the examiner to decide if PT test is required for supporting fracture test or not (Figure 13). Again, it was a cause to discuss always between the contractors and subcontractors, if it is necessary, there is no reason to make any doubt in standard and if not, it should be omitted from the standards as if it happened in 2004.
Figure 15: Normative references of 9606-2:1994, 1998. Figure 13: Table 7 of 9606-2:1994, 1998.
Acceptance criteria
ranges for example less than 3mm thicknesses (Figure 17). In conclusion, standards must be clear in a way that users do
In Normative references of 9606-2 (figure 14, 15) quality
not need to interpret and discuss, furthermore if the standard
Level for imperfections are according to EN 30042 or
is a new one so there could be some missing, faults and needs
ISO10042:1992 .according to the scope of this standard
to improve corrections. So, it can be suggested to improve new
(figure 16) the material thickness is between 3 to 63 millimeter.
ways to decrease repeated mismatches in worldwide mostly
However, the range of qualification of welders are out of
20
this range and what if we want to qualify a welder on thickness
WELDFAB TECH TIMES | APR - MAY 2018
used welding standards.
www.weldfabtechtimes.com
ARTICLE
Figure 16: Scope of ISO 10042:1992.
Figure 17: Range of qualification of material thickness.
References 1. Qualification test of welders - Fusion welding-Part 2: Aluminium and aluminum alloys ISO 9606: first edition 1994 2. Qualification test of welders - Fusion welding-Part 2: Aluminium and aluminum alloys ISO 9606: edition 1998 3. Qualification test of welders -Fusion welding-Part 2: Aluminium and aluminum alloys ISO 9606: edition 2004 4. Welding & allied processes - Welding Positions ISO 6947:1993 5. Arc-welded joint in aluminum and its weldable alloysGuidance on quality level for imperfections, ISO 10042 : first edition 1992.
www.weldfabtechtimes.com
APR - MAY 2018 | WELDFAB TECH TIMES
21
TRAINING CENTER
Kemppi’s new Robotic Center in India and China
K
emppi opens up a robotic
processes. The visitors can also try the A7
welding application center in
MIG Welder’s unique web browser-based
Pune, India to respond to the
interface in practice and experience its
Kemppi’s wide range of robotic welding
increasing needs for welding automation.
ease of use and how much it saves time in
equipment and robots from well-known
The center provides complete and
system setup.
robot manufacturers. In the center the
innovative solutions and services to the
A similar robotic welding application
continues. The center in China is equipped with
visitors can see the state of the art A7 MIG
integrators and end customers. Kemppi’s
center was opened in Beijing, China
Welder, KempArc Pulse 450 and KempArc
experienced welding engineers help the
during December 2017. “Robotic welding
SYN 500 welding automation systems in
customers to optimize their welding
and Asia are both strategic focus areas for
action. They can witness the efficiency
applications, and offer comprehensive
Kemppi. Kemppi made its first deliveries
and quality reached with Kemppi’s
training, covering all aspects of welding.
to China already in the late 1980s and has
application-optimized Wise welding
invested significantly
processes, try how easy the unique, web
helps to speed up our growth in Asia,
in the development
browser based user interface for A7 MIG
which is one of Kemppi’s strategic target
of robotic welding
Welder is to use, and how much it saves
areas. Kemppi India Private Ltd. started
solutions during the
time in setup.
its operations in Chennai in 2011, and the
past years. The robotic
“The robotic welding application center
new application center is a natural next
welding application
robotic welding”, says Ville Vuori. “The
Hannu Jokela, center is a natural Vice President APAC and Export next step in serving Sales, Kemppi Oy. the important and
center gives insight to increase customer
fast-growing robotic welding markets in
understanding and helps in serving the
China and Southeast Asia even better”,
important markets in India even better.
says Hannu Jokela. “Local expertise is
Local expertise is a key business factor for
the key business factor for Kemppi,” he
step in the market where the accelerating automation increases the popularity of
A7 MIG Welder
Kemppi”, he continues. The Pune center is equipped with Kemppi’s state-of-the-art A7 MIG Welder and KempArc robotic welding systems integrated with robots from well-known robot manufacturers. The systems are presented in action to demonstrate the efficiency and quality that can be reached with Kemppi’s Wise optimized welding
22
WELDFAB TECH TIMES | APR - MAY 2018
www.weldfabtechtimes.com
EXECUTION
Safety in focus CLOOS robots weld children's vehicles by Puky
H
AIGER/WÜLFRATH – Puky has
for many decades. Recently, Puky put
always represented ‘unique
two new QR-CC-6 compact cells by
safety’ in children's vehicles.
CLOOS into operation where the QIROX
In the case of welding, the company
robots weld the handlebars and frames
has trusted in technologies by CLOOS
for the children's bicycles. The use of the two new compact cells guarantees high process reliability and an excellent product quality.
development, construction and
Because of the two-station design, the machine can be charged alternately – an enormous saving in time for the process run.
production of vehicles for children. Since
110 employees at the headquarters in
its foundation in 1949, the company
Wülfrath Puky produces more than
has steadily grown, at first with the
700,000 children's vehicles per year. The
brand name Puck and from 1956 on
product range comprises small ride-
with the name Puky. With more than
on vehicles, tricycles and learner bikes
Puky GmbH & Co. KG has more than 68 years of experience in the
The CLOOS robots weld the frames and handlebars for the children's bicycles by Puky.
24
WELDFAB TECH TIMES | APR - MAY 2018
www.weldfabtechtimes.com
EXECUTION
cells by CLOOS. These are turnkey systems and dispose of a 2-station workpiece positioned with horizontal change and turning and swiveling movement. The loading area is protected by a lateral safety fence and a light barrier during the cycle. All robot and
The welding robots guarantee a constant process quality.
positioned axes are fully synchronised.
The vehicles must have perfect weld seam in order to fulfill the high safety standards.
as well as 24" bicycles. All vehicles are
Maximum process safety at high flexibility
designed, constructed and produced in
The two CLOOS systems are currently
with the new systems. "We estimate the
Germany.
used to the full in two-shift operation.
easy operation of the robot systems,"
Safety is the first priority
The robots of one compact cell are
says Guss. Even employees with
The Puky vehicles have a high-quality,
welding about 140 bicycle handlebars
less robot experience could quickly
well-thought-out and child-friendly
per hour.
familiarise.
design. "Safety is our top priority",
Due to the change to automated
Puky completely trusts in CLOOS
explains Florian Guss, Industrial
welding, Puky is now able to further
regarding welding. Beside the two robot
Engineer at Puky. Thanks to the high
increase the safety of the production
systems, they also work with more than
quality standard, the Puky vehicles
processes. Thanks to the exactly
30 manual welding power sources of the
have a high resale value. To ensure
reproducible welding results the
Haiger welding specialists. On-the-spot
the high product quality Puky has its
expenditures for reworks could be
support is provided by long-standing
own monitoring and test laboratory.
reduced considerably. Besides, the
CLOOS sales and service partner Lixfeld
Furthermore, the production is oriented
company benefits from the flexible
Schweisstechnik which guarantees short
at the Kaizen system with which the
application possibilities of the compact
reaction times.
production processes are continuously
cells. Bicycle handlebars and frames
optimised.
can be welded on both systems. In
extensive tests of sample components
addition, the welding robots can be used
in the CLOOS Technology Centre in
Automated welding with flexible compact cells
spontaneously for other components
Haiger over design up to production
and also for small batch sizes. "As the
and service, CLOOS as market leader
Due to increasing quantities Puky
product life cycles become shorter and
in the field of welding technology
has strongly invested in automated
shorter we need systems which can be
offers everything from a single source,"
production technology for the last years.
flexibly adapted to our components,"
emphasis Guss. "From the beginning we
In the past, the vehicles were all welded
explains Guss.
have been cooperating very faithfully
manually. For the production of the
Last but not least Puky could
bicycle handlebars and frames Puky now
considerably increase the production
works with two QR-CC-6 QIROX compact
capacities by means of automated
"Starting from the planning with
and are looking forward to continuing this in future."
welding. Thus, the company does not longer depend on subcontractors and suppliers. As they now produce according to their needs, they could also reduce the inhouse inventory significantly. For More Info:
The workpiece positioner consistently brings the component into the optimum welding position.
www.weldfabtechtimes.com
Single source supply
Carl Cloos Schweisstechnik GmbH
CLOOS trained the Puky employees
Tel. +49 (0)2773 85-478
comprehensively to familiarise them
E-Mail: stefanie.nuechtern@cloos.de
APR - MAY 2018 | WELDFAB TECH TIMES
25
PROJECTS UPDATE
Hong Kong–Zhuhai–Macau Bridge
Lagos-Calabar coastal railway line
T
N
islands, spanning the Lingdingyang channel, that connects Hong
comprise Port-Harcourt, Calabar, uyo and Aba. However, the first
Kong with Macau and Zhuhai, three major cities on the Pearl
segment of the rail project is expected to be ready within 2 years.
River Deltain China. The 55-kilometre (34 mi) link is expected to
Additionally, when completed, the proposed coastal railway line in
cost 110 billion yuan ($15.9 billion). It is among the longest fixed-
Nigeria will link all sea ports. The project is also expected to create
links in the world and is a major landmark in the area. Originally
business hubs meant for commercial activities.
he Hong Kong–Zhuhai–Macau Bridge (HKZMB) is a Bridge– tunnel system, which consists of a series of three cable-
stayed bridges and one undersea tunnel, as well as 3 artificial
igeria and China have concluded a contract agreement worth US$11.117bn for the construction of the Lagos-Calabar
coastal railway line in Nigeria. The first segment of the rail line will
set to be opened to traffic in October 2016, the structure was completed during November 2017 and is planned to open to vehicular traffic in July 2018.
Thalkirchen geothermal heating project
Telangana Super Thermal Power Project
C
onstruction has started on the Thalkirchen geothermal heating project in the city of Munich in Bavaria/ Germany.
T
26
With a planned 50 MW of thermal, the plant when ready will not
elangana Super Thermal Power Project (TSTPP) is located at
be only the largest geothermal heating plant in Munich, but also in
Ramagundam in Telangana, India. The power plant is under
Germany. The plant is planned to supply geothermal heating to up
construction with power capacity of 1600 MW (2x800 MW) in first
to 80,000 residents of Munich. For the new geothermal plant, a total
phase and in total planned capacity of 4000 MW. It is the second
of six drill wells will be drilled in a star shape from a drilling site to
the coal based power plant in the Ramagundam of National
a depth of 2,800 to 3,100 meters. After 900 meters, they are to be
Thermal Power Corporation. The first power plant is NTPC
drilled horizontally. The drilling work should be completed by the
Ramagundam with installed capacity of 2600 MW. The first unit
end of 2019. Then the plant will be built. Subsequently, long-term
of 800MW is expected to be completed by May 2020 and the next
pumping experiments and the fine adjustment of the system begin.
would follow in six months.
By 2020, it will finally go online.
WELDFAB TECH TIMES | APR - MAY 2018
www.weldfabtechtimes.com
ARTICLE
WELDING ERGONOMICS and Method to suit worker capabilities
physiology, biomechanics, psychology,
and not changing worker. It does not try
anthropometry, industrial hygiene and
to make workers adjust to the workplace.
kinesiology.
When a workplace is designed properly, the worker feels comfortable. Quality and production increase. Everyone benefits.
OBJECTIVES OF ERGONOMICS • Reduce injuries and disorders • Ensure worker Safety • Ensure worker Health S. K. Gupta, Technical Director, Jupiter Wagons and Jupiter Alloys & Steel India Ltd. Director Quivan Skills Empowerment Pvt. Ltd.
• Reduce Absenteeism • Ensure worker Productivity
CAUSES OF THE PROBLEMS • Reaching
INTRODUCTION
• Bending
The word Ergonomics has several
• Heavy Lifting
meanings. The first is literal. Derived
• Using continuous Force
from two Greek words: Ergo = work; and
• Working with Vibrating Equipment
Nomos = laws. Therefore, ergonomics
• Repetitive Motions
literally means the laws of work. But the
• Awkward Postures
practical meaning of Ergonomics is fitting
• Temperature
the task and work environment to the try to design tasks and workplaces to suit
PROBLEMS FROM POOR ERGONOMICS
the capability of the human. In most
• Musculoskeletal Disorders (MSD)
of our workplaces layout design and
• Repetitive Motion Injury
selection of production processes there
• Worker Dissatisfaction
are many tasks, work environments, and
• Increased Absenteeism
even products, which do not take human
• Increased Turnover rates
human physical limitations. Ergonomists
capabilities into consideration. Ergonomics is the science of designing
SYMPTOMS OF MSDS
and arranging plant, machinery,
• Less Gripping strength
equipment and positioning of job
• Less Range of Motion
for efficient and effective workout by
• Loss of Muscle function
operators. It is also named as Human
• Painful Joints
Factors Engineering. It is the science and
• Pain, Numbness in body Limbs
relationship interaction between worker
• Shooting or Stabbing Pains
and workplace environment. Ergonomics
• Swelling or Inflammation
attempts to make the workplace
• Stiffness or Burning sensation
MUSCULOSKELETAL DISORDERS (MSD)
with minimum fatigue of body and limbs.
Ergonomics includes many different
Discomfort and pain are common in
Ergonomics focuses on designing Process
scientific disciplines such as:
human-work activities. Workers working
comfortable to the operators to work
28
WELDFAB TECH TIMES | APR - MAY 2018
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ARTICLE
in the industrial sector are prone to be
likely to cause MSD problems include the
of the shoulders, arms, hands, wrists,
exposed to such risk of discomfort and
following:
backs, and legs of workers during a typical
pain resulting injuries. Occupational
• Exerting excessive force more than
working day. When present for a sufficient
risk factors are the most common entity to cause health problems. Exposure to occupational hazards adversely affect the functioning of human body and in turn reduce worker productivity and product/
normal; • Continuous and excessive repetition of movements that can irritate tendons and increase pressure on nerves; • Forced awkward postures, or
duration, frequency, or magnitude MSDs will result from these risk factors. Additionally, environmental conditions such as working in extreme temperatures may contribute to the quick development
work quality and increase musculoskeletal
unsupported positions that stretch
of WMSDs. Personal risk factors, such as
problems.
physical limits, can compress nerves
physical conditioning, preexisting health
and irritate tendons;
problems, gender, age, work technique,
MSDs, or musculoskeletal disorders,
hobbies and organizational factors (e.g.,
are injuries and disorders of the soft
• Static postures, or positions that a
tissues of the human body (muscles,
worker must hold for long periods
job autonomy, quotas, deadlines) may
tendons, ligaments, joints, and cartilage)
of time, can restrict blood flow and
also contribute to, but do not cause,
damage muscles;
development of WMSDs.
including the nerves and tendon sheaths, and most frequently involve the arms
• Abrupt motion, such as increased speed
and back. Occupational safety and health
or acceleration when bending and
The Nature of Welding
professionals have called these disorders
twisting, can increase the amount of
Welding is a versatile manufacturing
in variety names such as:
force exerted on the body;
process in metal fabrication industry and
• Cumulative trauma disorders
• Compressive forces from grasping sharp
plays a vital role to produce almost all the
• Repeated trauma
edges like tool handles, can concentrate
Engineering products. Welding is estimated
• Repetitive stress injuries
force on small areas of the body, reduce
to contribute to almost 50% of the nation’s
• Occupational overexertion syndrome.
blood flow and nerve transmission, and
gross national product.
These are painful, and often occur as
damage tendons and tendon sheaths;
disabling injuries. Such injuries generally
• Inadequate recovery time for tissue
Welding often requires awkward body positions continued over a long period of
develop gradually over a period of weeks,
repair due to overtime, lack of breaks,
time thereby causing high prevalence of
months and years. MSDs usually result
and failure to vary tasks.
musculoskeletal complaints and injuries
from exposure to multiple risk factors
• Continuous and excessive vibration,
including back injuries, shoulder pain,
that can cause or accelerate the disorders.
usually from vibrating tools, can
tendonitis, and reduced muscle strength.
MSDs are not caused from a single event
decrease blood flow, damage nerves,
On this context, there is lot of scope for
and contribute to muscle fatigue.
improvement in the operating (welding)
or trauma such as a fall, collision, or entanglement. Frequently, workers lose
• Vibration of the whole-body such
postures which in turn will help to reduce
time from work to recover; some never
as from driving trucks or operating
discomfort and pain, thereby increasing
regain full health. MSDs can cause a
subways, or continuous chipping can
productivity, worker safety and quality of
number of conditions, including pain,
affect skeletal muscles and cause low-
work in welding-industry. Problems are
numbness, tingling, stiff joints, difficulty
back pain; and
actually in the mismatches between man
moving, muscle loss, and sometimes
• Working in extreme hot or cold
and machine, improper layout design,
paralysis .These disorders include:
temperatures can adversely affect a
unhealthy work environment and mainly
• Carpal tunnel syndrome
worker’s coordination and manual
ignorance among top to bottom.
• Tendinitis
dexterity and cause a worker to use
• Sciatica
more force than necessary to perform
dictated by the design of the item being
• Herniated discs
a task.
worked. In almost all cases welding in
• Low back pains
Most of the tasks welders perform are
the field requires the welder to adapt to These risk factors, either alone or in
the workplace, rather than adapting the
Work Related Musculoskeletal Disorders
combination, can cause thousands of
workplace to the welder. This is because in
repetitive twisting, forceful, or flexing
many cases, the materials are big, heavy,
Work situations and conditions that are
motions to the muscles, tendons, cartilages
and might be covered with dirt, rust, and/
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APR - MAY 2018 | WELDFAB TECH TIMES
29
ARTICLE
or grime and it is easier to have the welder
Ergonomics Stressors Compression: Leaning on a hard surface Awkward & Static Posture: Holding the arms away from the body for long durations
assume an awkward posture, than move the Job. Welding also is hot work and generates harmful metal fumes. The use of proven ergonomic principles can improve the way a particular task is performed, thereby reducing welder exposure to risk factors. This generally translates to a healthier workforce, improved morale, greater productivity and
Welding with the hands in front of the body.
increased product quality. Common WMSDs for welders include:
Ergonomics Stressors: Awkward & Static Posture: Extension of the neck, static loading in the arms and shoulders.
• Back Injuries – From strains and sprains to degradation of the vertebral disks. • Bursitis – Inflammation of a saclike bodily cavity, containing a viscous lubricating fluid located between a tendon and a bone or at points of friction between moving structures (i.e. inflammation of a bursa). • Carpal Tunnel Syndrome – A complex disorder that starts with the inflammation of the tendon sheaths in the wrist and progresses into the degradation of median nerve • Tendonitis – Inflammation of the tendons. • Tenosynovitis – Inflammation of tendon sheath. • Thoracic Outlet Syndrome – A disorder in which blood vessels and nerves in the upper shoulder region are compressed and cause pain. This condition is sometimes caused by chronic postures associated with overhead work. • Trigger Finger – Tendons in the fingers ‘lock down’ due to injury to the tendons. Spinal disc and vertebra
30
Consider lower back vertebral disk
out and can place pressure on a spinal
degeneration. The vertebral disk is made of
nerve causing severe pain.
flexible cartilage and contains a semi-liquid gel. The cartilage is in the form of rings.
Ergonomics Stressors: Awkward & Static Posture
When a person performs lifts beyond their
A few of the following photographs show
capability, these rings can degrade. If the
various awkward and strained body
person continues performing such lifts the
postures during welding which invariably
disk can rupture. When it ruptures it bulges
cause ergonomic stresses.
WELDFAB TECH TIMES | APR - MAY 2018
Welding at ground level
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ARTICLE
Ergonomics Stressors: Awkward & Static Posture: Extension of the neck, static loading in the arms and shoulders
Ergonomics Stressors: Awkward & Static Posture: Statically Holding a stooped
Such welding postures can be avoided by improvements in Jigs, Fixtures and Positional welding. This is absolutely essential where manufacturing / production of welded parts , components and sub assemblies are conducted day in and day out for weeks, months and sometimes in years together.
Working in a stooped posture
ERGONOMIC SOLUTION APPROACH Welding above shoulder height Ergonomics Stressors: Awkward & Static Posture: Hot work in a static posture caused by the constrained space Compression: Leaning on a hard surface
Ergonomics Stressors: Awkward & Static Posture: Working with the back bent forward and holding the arms away from the body Compression: Resting the arms on a hard surfaces
Ergonomic solutions for welders describe changes to equipment, work practices and procedures (administrative controls) that can address ergonomics-related risk factors, help control costs, and reduce employee turnover. These changes will also increase employee productivity and efficiency because they eliminate unnecessary movements and reduce heavy manual work.
Working with the back bent forward Welding in constrained spaces
However, there are numerous job aids such as fixtures, jigs, and part holders
Ergonomics Stressors: Awkward & Static Posture: Working with the back bent forward and wrist in extension Compression: Leaning on a hard, sharp surface
Welding with back bent forward Ergonomics Stressors: Awkward & Static Posture: Working with the back bent
Working with the back bent forward
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APR - MAY 2018 | WELDFAB TECH TIMES
31
ARTICLE
available to aid welders in doing their jobs and reduce the risk of injury. In addition, special chairs and/or creepers are available that provide body support while performing tasks so that an awkward posture is avoided.
• Have any improvements created new risks or other problems?
• Provide sufficient rest. • Utilize jigs and fixtures.
• Have any improvements impacted production or quality? • Are implemented improvements supported by training?
Action Plan for Implementing Solutions
WORKSTATION DESIGN FACTORS Some factors to consider: • Position of the work. • Physical ability of the worker.
Use suggested PRACTICAL SOLUTIONS
• Design and weight of the tools.
of the work for acceptable Ergonomic
• Body mechanics of the operation.
Step 1: Look for clues
Postures as shown in the photographs
• Type of protective equipment used.
• Observe work activities
below.
• Workspace / environment (size,
to Reduce Workplace Risk Factors;
• Risk factors
lighting, temperature, noise, vibration,
• Tool / equipment modifications
POSSIBLE SOLUTIONS TO PROBLEMS
• Increased absenteeism
• Recognize that often Repetitive Motion
• Worker fatigue
• Decreased production
Injury is mistakenly felt to be a type of
• Bottlenecks / missed deadlines
short-term weakness or fatigue. Actually
• Talk to workers (form ergonomics
it is the start of potentially more serious
action teams or designate an ergonomic
etc.). • Physical requirements of the job (lifting, turning, reaching, etc,). • Mental requirements (motivation, alertness, concentration). • Strength and size of the workers.
injuries. • Address complaints in a timely manner.
CONCLUSION
• Use assessment tools
• Get employee input.
In India, small, medium and large scale
• Risk factor physical check list.
• Interact with the worker. Discuss
industries using welding as Manufacturing
point of contact)
possible solutions. Give the employee
Process must understand and appreciate
Step 2: Prioritize job for improvement:
ownership of any new plans. Promote
the fact that “Welding Is A Special Process”
Consider
employee acceptance of solutions.
and Welders are human beings with
• Frequency & severity of the risk factors
• Redesign the workstation with the
specially trained skills carrying out the
• Frequency & severity of complaints
employees’ help. Employees should feel
said process. In order to aim for higher
• Injuries
part of the process.
productivity and better quality we must
• Workers’ ideas
• Utilize gravity when it can help move
• Timeframe for making improvements
material to the work area or station. This
• Difficulty in making improvements
helps to prevent unnecessary
nurture the well being of the welders for maintaining and improving the skills.
material handling. Step 3: Make improvements – Improve
• Talk to various employees
PRACTICAL SOLUTIONS— HOW TO AVOID THE HAZARDS
• Contact other industries
• Avoid fixed work positions.
the fit between task demands & worker capabilities
• Consult ergonomics experts • Use internet resources
They reduce the blood supply to muscles. • Keep elbows close to the
Step 4: Follow-up: • Has each improvement reduced or
• Avoid positions where arms
eliminated the risk factors, fatigue,
are raised above shoulder
discomfort symptoms or injury
level.
reporting? • Has each improvement been accepted by the workers?
32
body.
WELDFAB TECH TIMES | APR - MAY 2018
• Use lighter hand tools. • Suspend tools. • Support your elbows.
www.weldfabtechtimes.com
INTERVIEW
Copper:
Reign of the metal
Sanjeev Ranjan, Managing Director, International Copper Association, India
Q1. How according to you is the overall copper market in India?
decrease the operational costs across all
wiring, electrification of vehicles, etc.
industries. It is important to note that
This not only gives a boost to their
The copper market has seen a steady
the performance of the copper industry
madden project, “Make in India” but
growth in the country, a major boost
is highly dependent on the performance
it also lifts the copper sector in the
for the industry has come in from the
of sectors like power, construction,
country. With this rate and progress, we
implementation of GST, which was
telecom, and automobiles; thus, they
are assertive that copper in the Indian
probably the most awaited reform to-be
cannot be overlooked.
markets will soon become a game-
implemented by the Government of
34
The government has positively
changing metal.
India. Though GST is still in its early
encouraged various push into numerous
stage, it has simplified the tax structure
sectors for the growth of renewable
and thus has improved the ‘ease of doing
energy making India energy efficient
Q2. Is the industry on par with the international markets?
business’, it has also been planned to
by 2022, norms for safer circuitry and
Copper markets will continue to see
WELDFAB TECH TIMES | APR - MAY 2018
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INTERVIEW
persistent growth in demand from
~1,812 kt by FY26. Incremental demand:
growing young population, rapid
countries like China, India and those
~840 kt. The electricalsector would
urbanization, huge infrastructure
from South East Asia. Indian exports
account for ~56% of the total demand.
projects and investments, proposed
of manufactured / engineering goods
Based on the planned capacity additions,
industrial corridors and electricity
continue to be extremely poor. The
the total capacity for refined copper in
grids. Currently, ~50% of the copper
government of India had signed various
India will increase from present 1,000
demands’ met through supply from
trade agreements with an intention
kt to 1,400 kt. It ismeasuredagainst a
domestic refined copper producers
to scale-up the domestic industry by
total copper demand of ~1,812 kt. ~40%
with ~30% met through imports. Wires
stimulating exports, but it is proving to be
is estimated to be met through supply
and cables account for ~44% of the
highly ineffective. FTAs has led to tax-free
from domestic refined copper producers
electrical products demand. Copper
imports from countries in ASEAN, Japan
with the rest expected to be met through
is widely used in sectors like motors,
which are proving to be cheaper than
imports. There exists a potential gap of
automobiles, transformers, alternators,
domestically produced goods and this is
~230 kt between demand and supply.
agricultural pumps, consumer
impacting the domestic manufacturing
The copper sector in India is constantly
appliances, construction, transportation
sector like copper tubes, copper rods,
blooming and we are sure that in the
and renewable. Almost, 25% of the total
motors and wire/cable markets quite
coming years the market will just get
demands’ met through recycled copper
adversely. The main reason for this is the
bigger for more opportunities and
in the country.
inverted duty structure, which we have in
businesses.
for their inputs (copper concentrates)
Q4. Which sectors are the major consumers of copper?
Q5. Is the use of copper on demand into the welding sector in India? Your say on this.
compared to imported finished products.
Copper is not only used in our homes
In the past, the Indian welding industry
This is a serious concern as it may
and offices but also in the circuitry,
was dominated by low technology and
render domestic manufacturing to be
connectors and components that make
very rare technological innovation.
uncompetitive and is likely to impact the
virtually all electronic devices function
However, in recent years, the demand
‘Make in India’ policy in the long run.
due to its ductility that is valued for its
for automatic and semi-automatic
place, domestic manufacturers of refined copper end up paying a higher duty
high thermal and electrical conductivity.
welding electrode production machine
Q3. What can be the approximate market size? Expectations in the coming year.
In fact, the metal's usage in a wide-
has been rising. Simultaneously, low
variety of core industries has resulted
budgets and recession have marked
in the investment community turning
the ongoing popularity of manual,
Based on a third-party report
to copper prices as a sign of overall
economical techniques. Increased FDI
commissioned by ICA India, the current
economic health, impelling the name
equity inflow in India has contributed
demand for copper in India is ~970 kt
'Dr. Copper'. Evolving in line with the
to the rise in projects. Just like
with the electrical sector accounting
‘Make in India’ initiative, India has
copper, welding has it key application
for ~54% of the total demand. The total
all the ingredients that can help boost
in segments like automobile &
copper demand is expected to reach
copper demand; given its billion-plus
transportation, building & construction,
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APR - MAY 2018 | WELDFAB TECH TIMES
35
INTERVIEW
marine applications, power sector, oil &
challenges, as the government needs to
fossil fuel vehicles. Thus, demand for
gas, wear plate and other applications
re-examine the Free Trade Agreement
copper from battery electric vehicles will
such as repair & maintenance, and
(FTA) that has created complications
increase. Also because copper is a highly
pipelines among others. The growth
for export and raised customs duty for
efficient conduit, it is used in renewable
and expansion of end-user industries
downstream products so that it does
energy systems to generate power from
such as automobile & transportation,
not affect the domestic industry in
solar, hydro, thermal and wind energy
building & construction has given a
the country. Another, most important
across the world.
boost to both these industries. The
challenge is high capital cost. The
India has one of the best standards
welding and copper industries are
interest rates in India are very high
comparable to the best in the world but
interrelated and interdependent on one
(8-9%) as compared to the European
lack of quality marking and absence of
another. Thus, the rising demand for
countries (1%). High volatility in the
enforcement of standards & codes have
copper is constantly promoting the use
price of copper is also a big challenge.
definitely been significant hurdles for the
of modern and unique uses of copper,
Government’s inverted duty structure
copper industry and its usage in India.
simultaneously increasing the demand
under which finished products are taxed
The copper industry has undergone
of welding equipment in the country.
at lower rates than raw material; which
technological and innovative changes to
hits the manufacturing sector. The
provide better usability to its end users.
Q6. Your expectation from the welding industry, when copper is concern?
government also needs to pay attention
Small diameter (shift from 7mm to 5mm)
as a lot of copper scraps are coming from
inner groove tubes for the condenser coils
producers who do not have machines to
of the room air conditioners will make
Copper welding is not hard. The heat
remove impurities from copper. Copper
the products more cost effective and
required for this type of welding is
scrap, druid, residues and dross get
energy efficient, which will benefit both
approximately twice that required
converted to a low purity wire bar and
– the manufacturer and the consumers.
for steel of similar thickness. Copper
thereafter into low purity copper wires
Similarly, the die-cast copper rotors in
has a high thermal conductivity.
and cables. These cables pose a safety
place of fabricated copper rotors have
... Oxygen-free copper (deoxidized
hazard. In addition, with the usage of
increased the productivity of pump
copper rod) should be used rather than
low-quality copper, energy efficiency level
manufacturers and helped provide better
oxygen-bearing copper for gas welded
will come down and it breaches safety
quality pumps to the farmers.
assemblies. Copper availability in all
standards.
36
As the Indian economy is constantly growing (based on the per capita
forms is not a challenge anymore in India. The use of right quality of copper
Closing message.
income), growth in disposable income,
based on the end application is very
Being a superconductor, copper is
increasing urbanization is resulting in the
essential for providing the best solution
applied to building management, home
formation of large megacities and new
to the end users. This will provide
automation system, data centers and
cities, the infrastructural push led by the
then with a trouble free and reliable
other verticals for its properties. Copper
government through various strategies
operation.
demand will proliferate due to surging
and policies. We are sure it would lead
battery electric vehicles as well as
to a rise in copper demand across all
Q7. What are the major challenges the copper industry faces? How do you manage to cope up?
government’s initiative to make India
verticals of businesses. This surge in
energy efficient through renewable
demand will witness more innovation
resources. India and many countries in
that will outgrow the industry to adopt
The copper industry faces many
the world plan to reduce (and even ban)
energy efficient copper alternatives.
WELDFAB TECH TIMES | APR - MAY 2018
www.weldfabtechtimes.com
CASE STUDY
Welding robots complete
3D-printed steel bridge
A
t the airport in San Francisco, on
are bound to discover new techniques.
our new workshop. It has been great to
our way to discuss with our first
Autodesk, too, was thrilled to come
add ArcelorMittal, ABB Robotics, Lenovo
main sponsor Autodesk their
aboard, and the project was born during
and Air Liquide to our team!
involvement in MX3D, we brainstormed about what the ultimate poster project
June 2015. October 2015 marks the official
The final location was set in December 2015, upon the crossing of the Oudezijds
would be for showcasing all of the
launch of the Bridge Project. A big thank
Achterburgwal and the Stoofsteeg. In
facets of our technology. We reached
you goes out to the City of Amsterdam
other project-related news, we are proud
the conclusion that a bridge over one
for becoming an actual customer of
to add Plymovent and Oerlikon to the
of the old canals in Amsterdam would
this unique bridge. And thank you to
team! And thank you Leap3D for making
be a fantastic metaphor for connecting
Elderwoman Kasja Ollongren and CEO of
this scan!
the technology of the future with the
Heijmans, Bert van der Els, for opening
We finalised the design at last during
beautiful city’s past in a way that would reveal the best aspects of both worlds. It would look like it defies gravity; layer by layer we deposite metal that solidifies until the bridge is ready. The bridge project, to a large extent, was a learning process; wherein we were unaware how long it will take, but we are certain we can develop the software and hardware to make this project happen. In any case, it was a great adventure and we
38
WELDFAB TECH TIMES | APR - MAY 2018
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CASE STUDY
much as possible. Hoping to make this happen quickly!
Solution After a serious setback, we were back on track at last. In order to reduce complexity, we employed an entirely new approach. In November 2016, Arup joined our rockstar team and we began discussing a sheet-construction approach rather than the previouslyattempted one centred around volume optimization. The benefits of the sheet concept were that it works primarily with compression forces using stress analysis software to generate force lines through the object. A highly detailed 3D scan demonstrated that the bridge heads are not entirely parallel. As a result of this new found information, we chose to give the bridge an asymmetrical shape, inplan. This increases the dynamic shape and allows showing that our proprietary technology is not bound by traditional, symmetrical forms. By making the entire bridge design parametric, the design adapts automatically with every design iteration; believe it or not, we could even make changes to the design after the May 2016! The initial design concept was
software and 3D printing, clashed
focused on a very pure application of
with the traditional world of typical
topological optimization. This particular
construction engineering. The
technique was employed extensively early
engineering software used to address
on in Joris Laarman Lab’s pioneering
the various functional, and safety
process of engineering, designing, re-
Bone Furniture collection. The software
requirements could not handle our
engineering, re-designing, discovering
is programmed to reduce the required
complex geometry. Additionally, there
the world behind permits, safety
material to a minimum when generating
remained many unknowns yet to be
measures, canal wall renovation, re-
the most efficient shape for a specific
taken into account; amongst other
designing, programming, fundraising,
task – just as a bone will optimize itself
factors. It was unclear how much
test printing, re-designing and re-
in nature. The Bridge design employed
stress the medieval canal walls could
programming, the actual printing of the
Autodesk’s Dreamcatcher software
withstand and it also turned out to be
bridge finally started during March 2017.
in collaboration with the engineering
near-impossible to define the material
We are printed large parts of roughly
expertise of Heijmans.
properties of the printed geometries.
one metre, which were then assembled
robots start printing! The final design was finished in February 2017! After a challenging 18 month-long
This means, we have to start all over
together after they’ve been printed. The
Challenges
again… Basically, we had to reduce
initial production pace was fast enough
The modern world of optimisation
complexity and avoid tension stresses as
to finish by early 2018 – exciting times!
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APR - MAY 2018 | WELDFAB TECH TIMES
39
CASE STUDY
The first tests with the robot printing in-situ were promising. We managed to print a nice part horizontally; but there were still many issues to resolve. Soon, we attempt to move the robot on the bridge and allow it to continue to print. With close to a third of the bridge printed at the time of writing, we were well on track to be finished printing early 2018. By now, we’ve also mounted a robot directly on the bridge. What a great moment!
stainless steel, along with 1,100 km (684 miles) of wire.
At Present
The bridge will now be subjected to
In April 2018, the full span of the bridge
load tests in order to verify its structural
has been finalized, although it still has
integrity, before being installed at the
to actually be placed over the water. To
canal.
build the bridge, the company used four of its MX3D-Metal robots. These consist
MX3D Bridge
Laarman Lab, Arup is the lead structural
of a robotic welding arm that lays down a
MX3D is 3D printing a fully functional
engineer, ArcelorMittal provides the
blob of molten metal, then adds another
stainless steel bridge to cross one of the
metallurgical expertise, Autodesk
blob on top of it once it's hardened, and
oldest and most famous canals in the
assists with their knowledge on digital
continues that process until it's created
center of Amsterdam, the Oudezijds
production tools, Heijmans is our
an entire metal column. By controlling
Achterburgwal. We equip typical
construction expert, Lenovosupports
the point in space at which the welds
industrial robots with purpose-built
us with computational hardware, ABB
are made, it's possible to control the
tools and develop the software to control
is the robotics specialist, Air Liquide
orientation of the columns, even getting
them. The unique approach allows us to
& Oerlikon know everything about
them to interlace with one another. No
3D print strong, complex and graceful
welding and lastly, Plymovent protects
supporting materials are needed, and
structures out of metal. The goal of the
the air our employees breath whilst AMS
quite large structures can be created.
MX3D Bridge project is to showcase the
and TU Delft do invaluable research.
potential applications of our multi-axis
Gemeente Amsterdamis the first
3D printing technology.
customer of our collaborative bridge
The finished bridge is 12.5 meters long (41 ft), and took six months to print. It's composed of 4,500 kg (9,921 lb) of
The Bridge is designed by Joris
building department.
TIMELINE
40
WELDFAB TECH TIMES | APR - MAY 2018
www.weldfabtechtimes.com
LAUNCHES
New ArcTig
Welding
Process from Fronius
Exceptional cooling to ensure the best possible welding results.
W
42
WELDFAB TECH TIMES | APR - MAY 2018
hen welding, it is not only
The ArcTig welding process from
seam quality that matters,
Fronius is based on the principle of
speed plays a significant
tungsten inert gas welding, or TIG
role too. Both of these help the welder
welding for short. In this process, an arc
to work more efficiently and so reduce
burns between a non-melting tungsten
costs. With the modified TIG process,
electrode and the metallic workpiece
ArcTig, Fronius has developed an
in an oxygen-free, reactionless gas
innovation for mechanised joint welding
atmosphere. The current flow heats the
that addresses these requirements. A
electrode, resulting in an electron flow.
special welding torch allows the TIG
This reduces the combined resistance,
arc to be focused in a targeted manner
producing a soft, wide arc. The inert
and its energy density is significantly
protective gas shield means there are no
increased. Users can weld up to ten-
chemical reactions with the liquid weld
millimetre-thick, high-alloy sheets
pool. This enables users to produce a
and pipes without extensive seam
perfect weld-seam appearance without
preparation, to an exceptionally high
tempering colours and spatter as well as
quality standard and much quicker.
the best weave pattern. TIG welding is
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LAUNCHES
suited to a variety of different materials
equipment required is the new welding
and applications, including tricky
torch and an additional heat exchanger
materials like titanium.
to provide the cooling capacity and the
The ArcTig welding process is designed for applications in container and pipeline construction, in the
required temperature stability. ArcTig is also available as a complete system. The electrode is extensively stretched
manufacture of turbines and the
with the aid of the newly developed
construction of special machines, cranes
electrode clamping system. Only one
and tanks. The key innovation here
clamping element is needed for simple
is the optimised welding torch with
clamping and changing of the electrode
is required for the ArcTig process.
an electrode clamping system, which
(minimum length 20mm). Moreover, the
This cuts down on rework to a large
enables the electrode to be cooled right
electrode end is freely adjustable, what
extent, since the weld seam is raised
to the tip. This increases the combined
changes the characteristics of the arc or
to a minimal degree and there is very
resistance and creates a high arc voltage.
achieves improved accessibility.
little distortion due to the reduced heat
Electron emission now takes place over
Tolerances for prefabrication are
input. This enables users to accelerate
a small area but at an extremely high
around +/- 10 % of the material thickness
processing times considerably, while
density. This makes the arc narrower
for gap and offset (similar to plasma).
the welding process also permits higher
and more targeted, allowing the user to
In combination with a water chiller,
welding speeds. What's more, material
achieve exceptional weld seam quality.
the electrode is strongly cooled as the
costs are lowered as the weld seam
Another advantage of the cooling is that
water chiller enables increased cooling
volume is reduced.
it prevents overheating of the electrode
performances and temperature stability.
during welding, providing increased arc
This in turn leads to an even more
terms of operation: because it is very
stability and ensuring a longer service
focused arc and improved welding
similar to TIG welding, users do not
life and improved ignition. Users can
properties.
have to adjust to a new process and
upgrade all TIG power sources from Fronius above an output of 220 amperes to the ArcTig process with ease. The only
The ArcTig process also impresses in
can weld immediately without carrying
Shorter processing times and lower filler metal costs
out any time-consuming teaching-in.
The focussed and high-pressure arc
and prevents incorrect operation by
means the ArcTig can be used to weld
the welder, as just a few parameters
components in one layer to a material
need to be set. Users can make use of
thickness of up to ten millimetres. In
standard TIG electrodes that are quick
conventional TIG welding, several layers
to change and can easily be re-ground as
are often needed. Additionally, it is
necessary. The new electrode clamping
frequently the case that users no longer
system clamps the electrode over a
need to do time-consuming preparation
large area. To make the weld seam
work on parts. As there is no gap during
more accessible and enable the arc to
seam preparation, no weld pool support
be manipulated better, the free end of
This minimises the need for training
the electrode can be adjusted as desired depending on the requirements. For more Info: Fronius India Private Limited Mr. Amlan Saha Gat No 312, Nanekarwadi, Chakan, Khed District, Pune - 410501, India Mobile: +91 73 9109 5722 Email: saha.amlan@fronius.com
www.weldfabtechtimes.com
APR - MAY 2018 | WELDFAB TECH TIMES
43
EVENTS UPDATE
NATIONAL Event
Date (2018)
Address
Organiser
Roof India Exhibition 2018
7th - 9th June, 2018
Chennai Trade Centre
ITEI
OSH India India’s Occupational Safety and Health Exhibition
28th - 29th June, 2018
Hitex Exhibition Centre, Hyderabad, India
UBM India Pvt.Ltd
NATIONAL WELDING MEET NWM-2018
03rd - 04st August, 2018
Vadodara, Gujarat
CWE
29th - 31st August, 2018
Pragati Maidan, New Delhi, India
ITEI
TECH INDIA
29th - 31st August, 2018
Pragati Maidan, New Delhi, India
ITEI
Indexpo Hyderabad 2018
31st August - 2nd Sept, 2018
Hitex, Hyderabad
Indore Infoline Pvt. Ltd.
GRI India Summit
11th - 12th September, 2018
Bombay Convention & Exhibition Centre
Global Real Estate Institute
Capex 2018
19th - 21st September, 2018
Bombay Exhibition Center
Fairfest Media Limited.
Economic Times Acetech Mumbai
15th - 18th November, 2018
Bombay Exhibition Center
Asian Business Exhibition & Conferences Ltd.
The Big 5 Construction
26th - 29th November, 2018
Dubai World Trade Centre
dmg events Middle East
INTERNATIONAL
44
Event
Date (2018)
Location
Organiser
Welding Poznan 2018
5th to 8th June, 2018
Poznan, Poland
Poznan International Fair Ltd.
Welding Int'l Welding Exhibition
5th to 8th June, 2018
Poznan, Poland
Pozna International Fair (MTP)
SIGN CHINA
19th - 21st September, 2018
Shanghai,China
UBM Trust Co Ltd
26th KIOGE – Kazakhstan International "Oil & Gas" Exhibition and Conference
3rd to 5th October, 2018
Atakent Expo, Almaty, Kazakhstan
ITE Eurasian Exhibitions FZ LLC and Comnet Exhibitions
BI-MU Machine Tools, Robots and Automation
9th to 13th October, 2018
Milan, Italy
EFIM-ENTE FIERE ITALIANE MACCHINE, 31.BI-MU
ExpoWelding Int'l Welding Fair
16th to 18th October, 2018
Gliwice, Poland
Expo Silesia
Weldex Int'l specialized Exhibition of Equipment, Technologies and Materials for Welding
16th to 19th October, 2018
Moscow, Russia
MVK International Exhibitions
Welding. Monitoring and Testing
20th to 22th November, 2018
Ekaterinburg, Russia
Ural Exhibitions
WELDFAB TECH TIMES | APR - MAY 2018
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PRE-EVENT COVERAGE
Show Preview – CWE 2018
C
WE is an internationally
fabricators for technology & knowledge
renowned series of exhibitions
transfer, identifying alternate suppliers
focusing on welding technology,
of machinery & spares, new source of
already geared up to exhibit their latest
robotics, welding automation, welding
investments, face to face interaction with
technologies at the exhibition with new
consumables, materials testing, non-
industry players, identifying new market
applications offered, focusing on Industry
destructive testing and allied industries.
opportunities etc.
4.0 including robots and automation
The world's leaders in the sector are
It is the only comprehensive business
CWE series of international events
platform serving the welding industry
have played a major role in showcasing
and over the years, this leading business
the strength of the Indian Welding,
A complete conclave of CEOs,
event has become the perfect platform
Cutting and allied Industry by attracting
Plant Managers, Material Manager,
for showcasing the entire spectrum of
global attention to these technological
Maintenance Managers, Welders &
products and services relating to the
advancements. CWE event has established
Welding Heads, Factory Managers, Quality
welding and allied industries.
itself as a “Business Festival of the Welding
Heads, Production Managers, Industry
Industry” and support the overall growth
Experts and Distributors associated with
Welding industry there is an urgent need
of manufacturing & fabricating industry in
Design, Metal Working, Metal Forming &
for a Unified Business Platform which can
the country.
By keeping in mind the growth of Indian
connect the Welding Industry of India
46
and allied Industry sector.
CWE 2018 edition once again will
with the Global Welding Industry. The key
showcase the latest trend in the cutting,
objective of this business platform to help
welding & joining Industry to fulfil the
the Indian manufacturing industry and
demands of ever increasing manufacturing
WELDFAB TECH TIMES | APR - MAY 2018
technologies. Over the years, CWE has become-
CWE – The Trusted Platform to Showcase and Buy Solutions for the Manufacturing & Fabricating Industry in India!
www.weldfabtechtimes.com
PRE-EVENT COVERAGE
Fabricating and Allied Industries. CWE series of exhibitions have always received appreciation from all over the industry and proved to be the best
opportunities for Suppliers of Welding Automation, Welding Consumables, Finishing Tools etc. 4. Expected 12,000+ Quality Business
business platform for the Cutting &
Visitors/Direct Buyers form the various
Welding in India. CWE 2018, 8th edition
business segments of Manufacturing,
is planned with other 5 specialized
Metal Working, Metal Forming and
concurrent exhibitions for creating a Mega Business platform for Metal Working,
The event is jointly organized by World Metal Forum and ITEI, the Indian subsidiary of ITE Group PLC (UK) with support of Rajkot Engineering Association and Society of Manufacturers of Electric Vehicles (SMEV).
Fabricating Industry 5. From the Industry Segments i.e.
working, metal working and
Metal Forming, Manufacturing and
Aerospace, Agriculture Machinery,
manufacturing solutions in Asia as well as
Engineering Solutions.
Automotive & Automotive
in CIS Countries. Some of the exhibition
Components, Boilers, Construction
brands include METALTECH – Malaysia,
Few Highlights of the events are:
& Infrastructure, Defence, EPC
MASHEX – Siberia, MACHEXPO –
1. The pure B2B platform in the region
Companies, HVAC, Plants (Cement,
Kazakhstan, AUTOMEX – Malaysia,
serving Design, Metal Working, Metal
Power, Sugar etc.), Railways & Rail
MACHINERY CENTRAL
Forming, Fabricating and Allied
Coach Factories, Refineries, Fabricators
ASIA – Uzbekistan, WELDEX – Russia and
Industries
and many other.
many more………..
2. A complete showcase of cutting, welding & finishing industry 3. CWE – provides un-paralleled business
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ITE Group specializes in organizing
Get detailed information about all events
international exhibitions for metal
at www.ite-exhibitions.com
APR - MAY 2018 | WELDFAB TECH TIMES
47
PRE-EVENT COVERAGE
India Essen Welding and Cutting
I
NDIA ESSEN WELDING & CUTTING,
Symposium (IWS 2K18) staged by
the leading Trade Fair in the Indian
IWS- Indian Welding Society and DVS -
market for Joining, Cutting and
German Welding Society. The conference
Surfacing Technology will take place
will promote the exchange of knowledge
at Bombay Convention and Exhibition
between manufacturers, users and
Centre, Mumbai from November 27-29,
researchers. The Metallurgy India, Tube India and
2018.
the wire & Cable India will also be held
IEWC is jointly organised by Messe Essen and Messe Duesseldorf India.
concurrently with the INDIA ESSEN
The event will also be supported by DVS
WELDING & CUTTING. Together these event portfolio form India's largest
- German Welding Society and IWS – Indian Welding Society. The 8th edition of IEWC will attract
The USP of the show is Vendor
metal fair platform for welding, cutting, surfacing, tubes, pipes and metallurgy
over 140 exhibitors from 7 countries
Development Program which would
with an anticipated audience size of
provide an opportunity for the
14,000. The event would be a prominent
manufacturers to understand the
will be an incredible meeting point for
platform for exhibitors to present
procurement processes of PSUS like L&T,
exhibitors and visitors to learn, exchange
their latest products, services and
Golden Rock Workshop Railways, BHEL
ideas and network with the Welding
technologies related to Automation
Haridwar, Navel Research Materials
community.
industry, Robotics, CNC machines,
Laboratory, Godrej & Boyce, NPCIL etc.
Cutting Machines, Surfacing, Laser
48
Measurement and Testing Technology.
Anotherhighlight of the event will
sector. INDIA ESSEN WELDING & CUTTING
For further information on
Cutting Machines, Safety Equipment,
be a first-class, specialized supporting
India Essen Welding & Cutting,
Health and Safety, Quality Assurance,
programme, International Welding
visit: http://www.iewc.in
WELDFAB TECH TIMES | APR - MAY 2018
www.weldfabtechtimes.com
STUDENTS CORNER
Annamalai University plans to start UNIC-PROSPER: Need support and guidance
A
nnamalai University established
planned:
a “Centre for Materials Joining
i.
relevant projects in industry;
2007 under AICTE-NAFETIC scheme.
ii. Providing opportunities to B.E/M.E/
This Centre is carrying out Research & Development (R&D) work on Materials
Ph.D students to undergo one month
Joining (Welding) field for the last
Inplant Training during summer or winter vacation;
15 years with the support of various
iii. Organizing Guest Lectures/Expert
funding agencies such as DST, DRDO, DAE, ISRO, UGC, AICTE etc. So far, the
industries. Some of the industries such as
Lectures by the Industry People for
University has completed more than 30
ADOR Welding, Fronius India, Weldwell
the benefit of students, scholars and
R&D project works worth of Rs. 10 crores
Speciality, Honovar Electrodes, Mailam
teachers;
and 5 more project works worth of Rs. 3
India, MATCON, R.V. Machine Tools
crores are being implemented. Through
supported this program. Each contributed
drive to the B.E/M.E/Ph.d students
this project, world class welding, testing
Rs. 2 lakhs towards the fellowship and
to assure 100% Placement to the
and characterization facilities have been
thus 15 students were admitted in 2016
students those pursuing Welding
created in the Centre. Moreover, there
and they are all in 4thsemester now
Education & Research;
are good numbers of qualified faculty
doing project work at industries. Also,
members expertised in this field.
during the second batch, 15 students
Industry Relevant R&D projects and
were admitted and they are in first
submitting to the funding agencies
utilize the infrastructure facilities and
semester. This program is a huge hit
as a Joint Projects to get financial
expertise of faculties available in the
among the Universities and all the visiting
assistance;
Centre effectively, a new PG program on
accreditation committees appreciated
Welding Engineering, i.e., M.E (Welding
this novel effort in an industrially
Programs on specific topics for the
Engineering) was started in 2016. The
backward area.
benefit of Practicing Engineers as well
Under these circumstances, to
concept of this program is; during the
50
Providing opportunities to the B.E/M.E/Ph.D students to do industry
& Research (CEMAJOR)” in
In continuation to this effort,
iv. Conducting on-campus recruitment
v. Providing Inputs to formulate
vi. Conducting Short Term Training
as to the University/College Teachers; vii. Conducting National Level Annual
first two semesters, the students will be
Annamalai University have planned
studying at Annamalai University and
to start a consortium of Annamalai
Convention for the students and
they have to complete 14 theory papers
University and Industries (mainly welding
scholars to display their inventions
and 2 labs. In the next two semesters,
and fabrication related industries) to
and innovations related to welding
students will go to welding or fabrication
support this program in long run. For
industry and do project work. So at the
this purpose, Annamalai University
end of the two years, student will be
look forward for your support and
students on the importance and
awarded PG Degree and through this
guidance. The consortium will be named
opportunities in welding education
scheme the student will have a PG Degree
as “University-Industry Consortium
and research by conducting Quiz
with one year industry experience. For
for Providing Opportunities & Support
Programs, Technical Seminars;
these students, Annamalai University
for Pursuing Welding Education and
offers a stipend of Rs. 6,000 per month
Research (UNIC-PROSPER)”. Through
Programs on Welding Inspectors,
and these stipend were sponsored by
this consortium, following activities are
Welding Supervisors, Welding
WELDFAB TECH TIMES | APR - MAY 2018
and fabrication; viii.Creating awareness among the
ix. Conducting Certificate/Diploma
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STUDENTS CORNER
The permanent members are requested
Engineers through Centre for Skill
Chennai and 75 km south of Pondicherry
Development, Annamalai University;
amd 200 km north of Tiruchirappalli),
to donate or contribute Rs. 25,000 every
a humble request to all the esteemed
year, for the effective functioning of this
indigenous development of processes,
readers, to become the Permanent
consortium, preferably before 30th May
consumables, equipments etc related
Member of this Consortium inorder to
every year.
to welding and fabrication industries;
support, help and guide the students.
x. Creating an Incubation Center for the
xi. Providing Financial Support to the
Annamalai University has planned
Annamalai University is a State Government University and all your
Students those who are doing Welding
to inaugurate this Consortium during
donations will be exempted from TAX
related projects (For UG students: Rs.
1st week of July 2018. Members of the
under 80-G. Your donations will be used
2,500 per month; For PG students:
Consortium will meet at Annamalai
to carry out the above listed activities
Rs. 5,000 per month and For Ph.D
University once in six months (July
under the banner of the consortium
scholars: Rs. 10,000 per month)
and January) to assess the activities
(UNIC-PROSPER).
xii. Providing solutions to the problems
of the consortium. Please accept
of Welding and Fabrication Industries
this noble and novel initiative and
For More Details:
through Consultancy projects.
support magnanimously to uplift the
Dr. V. Balasubramanian
downtrodden student community.
Professor & Director,
As the University is geographically
Expecting your willingness to become a
Centre for Materials Joining &
located in a socially, economically and
Permanent Member of this Consortium
Research (CEMAJOR) Department of
industrially backward area (located in
and swift response in this regard is very
Manufacturing Engineering,
Chidambaram which is 250 km south of
much appreciated before 15th May 2018.
Annamalai University
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APR - MAY 2018 | WELDFAB TECH TIMES
51
TRAINING & CERTIFICATION
Training and Certification in Welding Welding Applications
without using some sort of transportation.
Welding is a very diverse trade; there are
Welding is very important to our
more than 80 processes with all kinds
economy.
of conditions, from working in an airconditioned shop to working in the air or
Importance of welding
even on the ocean floor.
Welding is both an art and a technology
Welding fabrication has grown rapidly
weld pool and a thorough knowledge of
major industrial groups that represent the
welding processes and the characteristics
welding industry use welding extensively
of the type of material being used. The
but in different ways under different
reliability and safety of many products
working conditions on different metals
depends on the integrity of welding and
and according to different codes and
joining.
specifications.
K. Suresh Kumar, Welding Engineer, Sumeka Welding Institute
requiring the skillful manipulation of the
because of its speed and economy. The
We can assume that in the 21st century
Welding has made a significant
continued widespread use of welding
impact on quite a large number of major
technology and ever – increasing global
industries, by raising the operational
competition will create new challenges
Introduction
efficiency, productivity and service life of
for employers and welding professionals.
Welding is one of the most common
the plant and equipment involved. A few
So welding professionals will need
method of joining metal parts. Heat is
of them which are highly relevant to India
to be better educated to fill new job
applied to the pieces to be joined, melting
are listed below: (Fig-2)
categories and be more flexible so they
and fusing them to form a permanent
can respond to the changing knowledge
bond. Welding is a precise, reliable,
and skill requirements of existing jobs.
cost-effective and high-tech method for
Welding professionals include welders,
joining materials. No other technique is
supervisors, educators, inspectors and
as widely used by manufacturers to join
engineers. Workers who do the actual welding
metals and alloys efficiently and to add
have usually learned their skills on
value to their products. Welding is a regular process in any
Fig – 2
engineering industry. Many people think
the job, only occasionally through apprenticeships or formal welder training.
that welding is just putting two pieces
1. Structural
Others employed in the industrial field
of metal together, but there is a lot more
2. Field-erected vertical storage tanks
have been educated in a variety of
analysis put into welding engineering. It
3. Pressure vessels
disciplines, but rarely in welding.For our
requires high amount of skill, patience
4. Piping and pipelines
industry to grow and prosper, individuals
and commitment to accomplish a good
5. Power generating plant
capable of becoming trained and
weldment. (Fig-1)
6. Chemical plant
qualified are needed for all job categories.
7. Ships 8. Railways
Welding Career
9. Automotive
Among job candidates, there is a negative
10. Machinery construction
perception of welding trade. This is
11. Oil refineries
especially true of welding field, which have long struggled with an unpleasant
Welding touches nearly every aspect
Fig – 1
52
WELDFAB TECH TIMES | APR - MAY 2018
of our lives. We don’t leave our homes
and dangerous working conditions. Due to the misguided view many
www.weldfabtechtimes.com
TRAINING & CERTIFICATION
people hold towards any type of manual or skilled worker, parents and others who
and procedures. The training of welders and welding
above the ground and underwater. They use a large number of welding and cutting processes.
guide individuals toward a career choice
technologists will be more comprehensive
are directing young people away from the
and scientific. The welding industry is
welding, technical and construction fields
very much aware of the need to improve
procedures, a welder should acquire
and directing them toward white collar
trainee skills.
as much technical and theoretical
professions, many of which do not pay
Training defined as “the act, process
In addition to the manipulative
information related to welding as
as much or offer the same employment
or method to impart knowledge or
possible. This knowledge is most helpful
opportunities.
experience to acquire or to teach as to
in learning the craft of pipe welding and
make fit, qualified or proficient. This
in progressing upward on the job.
In truth, there are tremendous opportunities within manufacturing
teaching type refers to a particular
A skilled, certified welder with
and present jobs in this sector are more
set of skills. Well-educated welding
additional training, education and
demanding than ever of modern and
engineers and scientists need well-trained
experience can lead to supervisory
developing skill sets.Each type and level
technicians and operators to do their jobs.
positions such as welding inspectors,
of welding application has increased
Welding is creative, challenging and
instructors. A steady hand and attention
earnings potential for those who advance
interesting. Nevertheless, the need for
to detail could land you a great career
through various levels of supervision and
practical education persists.
in an industry that’s heating up the job market.
management. Being successful in the welding fields
Welder
requires only three things:
The most important part of the welding
Welder Shortage
• Willingness to learn new techniques
system is the welder. Welders are
Trade professions like welders and
• A good work ethic
people who must have skill and ability
carpenters are seeing a shortage all
• To not be afraid of hardwork and
to manipulate equipment to produce
over the country. The power plants that
welding.(Fig-3)
produce electricity, automobiles are
getting dirty.
welded together. Everybody wants their A career in welding technology might be
child to be very successful, not knowing
a great fit for you. Job opportunities are
that you can be very successful in the
wide ranging. Some of the possibilities
welding trades.
include working in fabrication shops,
For the past ten years, an increasing
maintenance shops, steel erection
number of high school students have
operations, ship building yards or oil
diverting industrial training institutes
fields.You could even open your own
(ITI) in order to get a three-year diploma.
shop and be your own boss. India has opportunities waiting for welding professionals like you all over
Fig – 3 : Welder Welding is unique in the intense level
For fabrication like welding, that means fewer qualified employees. The welding industry is facing a problem. It’s quickly
the region in a variety of industries.The
of eye / hand coordination required. To
losing its older workforce and we haven’t
welding industry is a place where higher
be able put on a helmet, block out the rest
had an influx of enough students to make
pay is possible.
of the world and concentrate on creating
up for that. Welding is learned through
uniform ripples in molten metal where
hands-on training and practice. That
Training
any variation or loss of concentration is
being said, there are no DVD’s, videos,
The success of a project involving
evident for the discontinuities.
simulators, books or websites that can
welding as a critical component is highly
The welder maintains the arc, feeds the
teach you how to weld without real life practice. It’s just like driving a car!
dependent on the skill and talents of
filler metal and provides travel and joint
the personnel involved and relies on a
guidance. This requires a high degree of
team (welding professionals) effort. They
manipulative skill. Welders work under a
and takes 1000’s of hours to learn. Anyone
have to know the basics and understand
variety of conditions: outdoors, indoors
who can master and perfect this skill can
welding safety, interpretation of drawing
in open areas, in confined spaces, high
easily make a doctor’s salary or more!
www.weldfabtechtimes.com
Welding is a very highly skilled trade
APR - MAY 2018 | WELDFAB TECH TIMES
53
TRAINING & CERTIFICATION
Welders are among the high paying jobs
a) It is important that a welding instructor
maintaining related equipment, but
that do not require a degree. Personally,
be able to actually weld the welding the
the soft skills of safe conduct, respect
there are plenty of work opportunities
process they are teaching, that they can
for fellow employees, attentiveness to
here in India and abroad.
do effective demonstrations of the right
responsibilities, engagement.
and wrong ways to do a weld.
Welder training
There are a host instructors out there
e) It is ideal than an instructor be able to
Teaching welding class with about five to
who have golden arms and can make high
weld, to be proficient in the areas he are
ten students in each class. The benefit of
level welds, but do not have the ability to
teaching and to be fully engaged with
having small classes is that instructor can
communicate their riches in talent to the
their students for safety and instructional
spend more one-on-one time with each
student learners.
purposes.
individual student. It would appear that in most training facilities that offer the basic shielded
There are less skilled intructors that
Most pipe welders can make a stop
have better measured results because
then restart with no problem, but these
they are well trained or gifted as teachers.
locations are sites for possible defects. At each of these locations, there is an
metal arc welding training, the end result is that the trainee pass a particular weld
b) It is important that an instructor spend
increased risk for slag inclusions and
assessment for entry level welders.
time in the welding booth watching
other quality defects that might have to be
students weld, so they can critique and
repaired at a later date. If we don’t teach
correct important techniques. (Fig-4)
that to the youth, they won’t know any
A good example would be a course of 250 hours would result in successful
better.
qualification with 15 mm plate in 1G, 2G,
“Stay focused on your work. Once the
3G, 4G positions with the E 7018. How one gets to that point is generally the
helmet comes down, let go of all of your
direction of the instructor, who following
problems and just focus on welding”. Skilled welders aren’t easy to find.
a set curriculum of objectives, guides the student to successful qualification.
Completing the training program in
This training will hopefully become the
weeks instead of months is not achieved
foundation to a successful career allowing
by cutting corners in safety and quality.
the individual to progress with a variety of processes.
Fig – 4 : Welding Instruction. Students need daily reinforcement
The Fifteen Essentials There is no better career path for
Welding Instructor
of the safety and the hazards they are
yougsters than ‘welding’. Teaching
Welding instructor generally should
working with and how to use the tools
welding theory is necessary and
have coupons that they personally weld
they are being introducedto.
important, but job-ready welding skills are learned in the workshop, not in the
up with their welds staggered to show layering and proper build up as well
c) An instructor should have some
classroom. Following are 15 important
as different techniques to achieve the
experience in more than one
things to train beginner welder, to help
desired results. They should have pipe
environment. The basic environments
them improve their skills and stay safe in
that was welded in 6G that they did one
where welder / instructor can work:
the process. (Fig-5)
side with stringers and one side with a
fabrication shop and field work in
1. Make safety a first priority
weave, same for plate groove welds.
the manufacturing of pressure parts,
2. Know the material properties
structural, piping, pipelines and
3. Understand the importance of filler
The students like that, and gives them something to look at and compare.
maintenance.
metals
Keep in mind that we do not only teach
54
practical based welding classes but also
d) One of the most important elements of
fabrication, drawing reading, tools, safety,
instruction, is modeling professional work
theory and much more. We have to be
place behavior. This is not just limited
able to communicate effectively in all
to the hard skills, such as producing
areas.
acceptable welds and setting up and
WELDFAB TECH TIMES | APR - MAY 2018
Fig – 5 : Weld Beads.
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TRAINING & CERTIFICATION
4. Handle consumables properly
by radiography or by bend tests
a qualification test to a specific code.
5. Selection of correct electrode
and found acceptable meeting the
It implies that a testing organization,
acceptance criteria. (Fig-7)
manufacturer, contractor has witnessed
diameter 6. Welding current
the preparation of test welds, has
7. Welding arc length and its effect
conducted the prescribed testing of the
8. Travel speed
welds and has recorded the successful
9. Electrode angles
results of a test in accordance with
10. Cleanliness is critical
prescribed accepted standards. Welders cannot be qualified or certified
11. Follow welding procedures 12. Stay comfortable
on their own. Normally manufacturers,
13. Visual inspection of welds
contractors certify that a welder is qualified on successful completion of
14. Learn how to troubleshoot
Fig – 7 : Radiographic Images.
15. Maintenance makes a difference
specific test welds. This means that
The bend specimens were removed
recertification or qualification is normally
Welder Qualification Program
from the correct location and same
required when welders change employers.
Welder training and qualification tests
test coupon. Weld reinforcement and
Certification adds value to a person’s
are given to ensure that each welder has
backing, if any, may be removed flush
marketability in the work place. Further
adequate skill and is able to produce
with the surface of the specimen. The
these certifications allow you to prove you
sound welds. Welders are, therefore,
specimens were bent in the test jig
are qualified without the need for further
constantly being tested for their
(180o). (Fig-8)
training. Certification is not an assurance of future competence or ability. What
qualification. Each manufacturer shall qualify
the customer needs is not a certificate
each welder for each welding process
to be shown to him but provision of an
to be used in production welding. The
improved product and service which
welder qualification test shall be welded
Fig – 8 : Bend Test.
in accordance with qualified welding procedure specification (WPS).
is by itself the best certificate that any organization can get.
h. If all test results are satisfactory, the welder is deemed qualified to perform
Safety
welding within the limits of that
Safety should always come first on thejob
qualification.
site and investment in preventative
The results of the tests, as well as a
measures is vital in eliminating accidents
description of thewelding procedure
and maintaining job site efficiency. Work
used, are listed on a report form to
place safety starts from the footwear. The
d. Fill passes monitoring
certify that the welder has satisfied the
welding work may require heavy personal
e. The final (cover) pass visual
qualification requirements.
protective equipment for working with
inspection met with the acceptance
Certification, however applies
molten metal and suitable clothing for
criteria without requiring repair to do
to document which support this
working outdoors.
so.(Fig-6)
qualification.
a. Test coupon fit-up met with the WPS requirements. b. Test coupon position was maintained from start to finish
i.
c. The root pass visual inspection and found acceptable
j.
To start a positive safety culture, people
Each qualified welder shall be
must learn how to “see” safety problems
assigned an identifying number by the
and know what it takes to resolve them
manufacturer
without hindering overall productivity.
k. Monitor production welding
• Provide appropriate personnel
Welder Certification
• Comply with appropriate standards
protection
Fig – 6 : Cover Pass. f.
Have strict time limits on welding
In the welding field the certification is
tests.
the signed document that attests to the
g. The test coupons may be examined
www.weldfabtechtimes.com
fact the welder has successfully passed
and regulations. • Communicating with senior management
APR - MAY 2018 | WELDFAB TECH TIMES
55
TRAINING & CERTIFICATION
An accident also has indirect costs, such
the training policy and coordinating
all arc welding processes as per applicable
as plant floor interruptions, time that
vocational training throughout India.
codes such as IBR, AWS, BS, ISO, API, etc.
it takes supervisors to manage a safety
Welder trade under CTS is one of the
situation and the time it takes to do an
most popular courses running on pan
The Indian Institute of Welding – IIW
accident report. Combine ergonomics
India through Government and Private
India
with safety to increase productivity. Good
Industrial Training Institute (ITI). The
The IIW is a professional body devoted
safety is good business. Good safety
day-to-day administration of the ITI is
to the promotion and advancement of
practices should build the foundation of a
rests with the State Governments/Union
welding science and technology in India.
modern manufacturer’s culture.
Territories.
Established in 1966, with its head quarters
The course is of one year (02 semesters) duration. It mainly consists of trade (skills and knowledge) and core area (workshop
in Kolkata, operates through 13 branches spread across the country. IIW organizing workshops, seminars,
calculation and science, engineering
refresher courses, training programmes,
drawing and employability skills).After
conferences and exhibitions across
passing out of the training programme,
India. A division of IIW India has been
the trainee is awarded National Trade
accredited by International Institute
Certificate (NTC) by NCVT which is
of Welding (IIW) as its only Authorized
recognized worldwide.
National Body in India to operates its above international scheme and award
Advanced Training Institute – ATI
International Diplomas to welding
Advanced Training Institutes are running
personnel at various levels from
in our country for the last 50 years and
skilled welder to the highest level of
conducting Craft Instructor Training
professionals.
Scheme (CITS). There are 14 institutes
Fig – 9 : Welder PPE.
Training Organizations in India and Abroad
imparting training in 34 trades (including
Indian Welding Society – IWS
welder) of long term and more than 100
The IWS, a leading professional body
nos short-term courses were skillfully
dedicated to the cause of welding in India,
designed for students passing out from
was formed by welding professionals
ITI, Polytechnic, Engineering colleges
from the fabrication industries,
etc..,
welding equipment and consumable
Industrial Training Institute – ITI
manufacturers, educational and research
In the Government of India, the
Foremen Training Institute – FTI
institutes, etc. with the idea of providing a
Ministry of Skill Development and
Two years Technical Diploma in Welding
forum for propagating the developments
Entrepreneurship is an apex organization
Technology course is proposed to be
in welding technology.
for the development and coordination
introduced in the FTI, Bengaluru.
The Ministry conducts the vocational
Welding Research Institute – WRI
consisting of different regional centres in
training programmes through the
The WRI was established in the year
the north, east, west, south and central
Craftsmen Training Scheme (CTS),
1975 under the joint auspieces of the
zones of India.
Apprenticeship Training Scheme (ATS),
Government of India and Bharat Heavy
Modular Employable Skills (MES) and
Electricals Ltd as an adjunct to the
organizing courses on welding and allied
Craftsmen Instructor Training Scheme
complex of BHEL, Tiruchirappalli.
areas, national/international wokshops
(CITS) to cater the needs of different segments of the labour market. The National Council for Vocational Training (NCVT) acts as a central agency to advise Govt of India in framing
56
With its head quarters at New Delhi, the society has a federal structure
for the vocational training in our country.
WELDFAB TECH TIMES | APR - MAY 2018
WRI offers training in welding and
Since its inception in 2002, it has been
/seminars, symposium, evening lecture
allied areas through in – house short term
programmes, training programmes,
certified programmes for engineers and
throughout the year.
supervisors. Training and certification of welders in
American Welding Society – AWS
www.weldfabtechtimes.com
TRAINING & CERTIFICATION
One of the best ways to advance your
The situation today is a lack of quality
the one great fact in the universe, then
welding career is by earning a specialized
manpower.
alone with doubts vanishes and crooked
certification. This opens up opportunities
Sumeka Welding Institute which was
things become straight. This is true
for more money, leadership roles and
established in 2007 is imparting education
practice.
higher level career challenges. AWS is the
in the field of welding technology and
• Our business is to educate the welding
source for qualification and certification
this institute is an industry oriented
of welding personnel.
training and becoming a leader in welding
AWS offers nine different certification categories from inspectors, supervisors
technology and expertise. (Fig – 10) SWI is located at Perambalur, 55 kms
and educators to radiographic
away from ‘Temple of Welding’ Trichy,
interpreters, welding engineers and
India.
technology. • A career in welding offers numerous opportunities to advance in the industry. The participants of our course, are an ambitions bunch and the SWI perfectly understand this and has an array of
fabricators.
courses to prepare them for the real
For those who are interested in the inspection side of welding and the
welding world. The course details are
certification of welding personnel, there
followed here for your information.
are the AWS certification programs,
Fig – 10 : Welder Training.
featuring the AWS certified welding
4. Course timings
inspector, the AWS certified welder and
2. Aim
The session timing will be from 10.00 am
the AWS accredited test facility. AWS
Education and training increase the
to 5.00 pm.
is doing a great job in educating and
knowledge base of all people employed
training others around the world.
in the welding industry, at every level,
5. Evaluation
enabling them to make decisions that will
At the end of the training programme,
The Welding Institute – TWI
result in utilization of the best welding
the participants would have to undergo a
The certification scheme for welding
technology for each application.
written test in multiple choice questions
inspection personnel (CSWIP) is a comprehensive scheme which provides for the examination and certification of individuals seeking to demonstrate their knowledge and/or competence
To attract more people to the field of welding in the workplace and in academia
to determine participants understanding of welding technology.
To train more specialists in fields related to welding A work force that is appropriately
6. Certification Certification adds value to a person’s marketability in the work place.
in their field of operation. The scope of
educated at all levels will drive a
CSWIP includes among others, welding
technological revolution in welding for
inspectors, welding supervisors, welding
our country. The prestige and promise of
be issued on successful completion of
instructors, etc., CSWIP is administered
welding as a career will grow as welders
training. (Fig – 11)
by The Welding Institute (TWI), United
are certified to gurantee their capabilities
Kingdom.
and engineers gain greater appreciation
Certificate and welder identity card will
of the potential use of welding.
SUMEKA WELDING INSTITUTE – SWI
3. About the course
1. Introduction
We read many books, but that does
Welding plays a key role in every
not bring us knowledge. Theoretical
Services
manufacturing process in a wide range
knowledge is easy enough to get, any one
“Welding is a building block for one’s
of industries. To sustain in the global
may get that. What we want is practical.
future. Most welding professionals go
competition, industries are looking for
Our idea is practical works.
on to expand their careers through
enhancing the quality of their product.
There is no knowledge without
One of the ways of enhancing quality
experience. You can get the welding
is by improving the practical and
knowledge here by practical experience.
theoretical skill of welding professionals.
www.weldfabtechtimes.com
When man has come face to face with
Fig – 11 Welder ID Card.
continuous education and experience”. We have a workshop, equipments, welding consumables, technical support details and faculty with more than
APR - MAY 2018 | WELDFAB TECH TIMES
57
TRAINING & CERTIFICATION
30 years of experiences in the weld
themselves, their work and people at the
different. Make a difference. SWI, calling
fabrication industries worked in India and
workplace.
for welding education, training. For
SWI aims to provide relevant content
abroad. One of the aspects of SWI’s program is
detailed information, visit us at www. sumekawelding.org.
the blend of hands-on with the theoretical
content is focused on welding technology
learning.
required for faster career growth.
Conclusion
SWI could help individuals become
Quality is needed at every step of the
employable with articles from industry
welding process. Welders are a critical
The institute offers the following welding technology courses: Sl. No
part of the process. If we do not have
Course Title
Duration
1
Welding Technology for Fresh Engineers
6 Days
and development, specifications,
2
Welding Technology for Supervisors
6 Days
procedures and management techniques will produce a quality product.
welders of quality, no amount of research
3
Welding Inspection Technology
6 Days
4
WPS/PQR/Welder Qualification
5 Days
An effective welding professional
5
Quality Assurance/Control
4 Days
should be able to make a right quality
6
ITI Welder-NCVT
1 Year
weld at the first time and every time so
7
Evening course on Welding Technology
15 Days
that we can reduce the cost of scrap,
SWI specializes in producing welding related services like: Perform welding inspection of various
experts. We want them to get familiar with what they will do on the job site. But
reworks and warranty. The quality will be there if the welders/supervisors are properly informed and trained. Industries turning out the next
products in accordance with industry
it’s not just practical skills that SWI
generation of welding professionals and
codes, customer provided specifications
instructors help trainees with, they also
it is our duty to produce the best qualified
or design drawings.
try to instill the right attitude to have on
workforce that our resources/institutions
the job. (Fig – 12)
will allow.
Develop written quality systems for organizations utilizing welding as a part
SumekaWelding Institute wants to
of their manufacturing, construction or
partner with many industries such as
maintenance.
manufacturing, construction as well as
• Provide vendor survey inspections
with the trades, educational institutions,
in accordance with customer requirements. • Develop course outlines and
Fig – 12 SWI Training Shop. “It’s not just a job, it’s a career”. Most
individuals and government entities. By working together, we can face the future with confidence that the
supporting content for welding
training centres teach “how” to weld, but
infrastructure of welding society will
inspection and qa/qc topics.
rarely teach “about” welding and metals.
be improved.
• Prepare written procedures supporting quality policies related to welding and fabrication. • Provide training on the AWS-CWI, TWI-CSWIP preparation. • Preparation and review of WPS/PQR/ WQT documents.
How SWI is Skilling Young India
There is a big difference. It is one thing to learn “how” to do something and another “what” to do with what you have learned. We teach ‘both’. We should be willing to explain why we are proud to say ‘I got my career start by welding and this profession has provided
1. AWS Welding Journals Dec 2000, Apr 2003, April, June 2013, Dec 2015, Nov 2017 2. AWS Membership Network dated 24/08/2016 and 01/11/2016 3. Weldwell Spectrum Apr – June 2013
Join the Sumeka Welding Institute. It
4. Paul.W.Cameron article ‘Become the
not only trains, educates and employs
of the workforce comprises of young
you, but also gives you a lifestyle that’s
professionals. It is critical that they are
enviable and honourable.
WELDFAB TECH TIMES | APR - MAY 2018
References:
me and my family a solid life for 34 years’. In India, approximately 50 percent
ready with required skills to manage
58
for those young professionals. The
Don’t settle for anything less. Be
Qualification Guru of Choice’ dated 21/09/2016 5. AWS Inspection Trends – Jan 2012 6. The Fabricator Nov – 2017.
www.weldfabtechtimes.com
WOMEN IN WELDING
A woman welder often welds better than most of the men in the piping trades. I served 4 years apprenticeship program and graduated.
Q4. Any welding processes you specialize into? I believe my best work is w/heliarc, TIG and MIG welding. I can weld almost all the phases. I have my own cutting rig.
Kathleen Boyle Kennedy, Retired Welder, USA
Q1. What made you choose welding as a career, which is a highly male dominated segment?
any of my safety equipments when on job.
Q5. Could you please share your experience of some of the mega project you worked upon?
Welding is an interested and a risky work,
Welding for a nuclear powerhouse is
results.
among the mega projects. I have welded
and a welder have to first consider safety, and it’s only after that, you can offer better What kind of challenges did you come
Initially, I was into the welding of
SS Pipes for nuclear power projects. I
across and how do you manage to cope
ornamental plant and pot holders. One
have also done structural welding, w/
up with the same? Have you anytime
fine day, my brother informed me that
stick welding using both 6010 and 7018
faced gender discrimination on site, as the
locally 230 plumbers and pipefitters were
series rods depending on the job. I can also
stream is male dominated?
hired on apprentices. This incident took
handle welding stick w/, the largest rod.
place during 1974, after the law in US was
And my currently project is of welding the
a challenge. Accepting a woman as a
passed for apprentice. Thus, I too applied
boot racks, and lawn art projects. I am also
welder was indigestible, but there was no
for the pass, and luckily I was able to
designing and making ornamental small
other choice, as during my time, there
succeed in almost all the tests. I was rated
hen houses.
was an acute shortage of skilled welders. There was a project of drilling oil and gas
2nd in the eye hand coordination test w/200. My motive was to earn, inorder to support myself and family.
Q2. Could you brief us on your journey so far into welding?
Gender discrimination was always
Q6. When on site, what are the key points you follow during welding for any project?
pipelines. The project wanted welders, and
The most important point, I always
Closing note.
consider is Safety on Site.
When I started welding, a female welder
I could fit in the criteria.
was not so common, just the way we find
Currently I am at the age of 64, and a
it now. I feel proud to see more and more
welding is still the same. I have not given
Q7. What is your say on health and safety in welding?
up. I am now welding boot racks, just to
Health and safety is one of the important
If a woman is a good welder, and wants to
keep me connected with welding. During
aspects for welders. I never miss to use
be a welder, she will have no problems on
retired female Welder. But my passion for
female entering into welding as a career.
my welding journey, I was a welding
job, as the employer always look for good
teacher, along with an experience of
welders. It does take a lot of time, efforts
practical welding on sites. I am a certified
and practice to become a good welder.
MIG, TIG, STICK and gas welding.
But do not give up. In fact, I believe, that a woman welder often welds better than
60
Q3. Could you quickly take us to your qualification background?
most of the men, especially the heliarc
I hold 4 years college accredited degree
WELDERS.
WELDFAB TECH TIMES | APR - MAY 2018
welding. Best of luck to all the WOMEN
www.weldfabtechtimes.com
WOMEN IN WELDING
Welding program for women in town
S
ix Nations Polytechnic
include career awareness,
will offer an
team building, soft and life
apprenticeship welders
skills, welding, employment
program for women at its
readiness and empowerment
Brantford campus to help
and a paid work placement.
close a gender-based skills
The curriculum content plus
gap and give them a boost in
workshops and resources
economic standing.
aim to remove barriers, build
Polytech has been approved
First Class Graduates from New Prison Welding Program
confidence, acquire skills
for funding up to a maximum
and prepare participants
of $307,295 over two years to
for a career as a welder. The
deliver the We Are Welders
program is offered tuition-
Program to low-income
free and the first cohort is set
women under the Women’s
to start in June. Interested
Economic Security Program,
applicants will soon be able to
Rebecca Jamieson, President
apply through Polytech and
T
hours of hands-on training to
in two weeks. Brackett hopes,
and CEO, announced.
community agencies.
obtain an American Welding
as a single mother of three,
Society certification through
the training will allow her to
the program. Jessica Brackett
provide for her kids.
The 28-week course is made up of six modules that
Source: www.brantfordexpositor.ca
RPCC awards first female welder apprenticeship
T
he welding program at the
he women from
is one of the graduates. She
Madison Correctional
already has a job lined up for
Facility underwent 80
when she starts work release
West Virginia Northern Community College appoints Killeen
A
River Parishes
Community College Technical College
s a student in West
student and
Virginia Northern
decided
Community College’s
to switch
Gonzales Campus
welding technology program,
over. I
awarded the first female
Brandy Killeen has now
worked for
apprenticeship to Kaitlyn
become the teacher. The
Williams Lea as a legal
Purpera of Sunshine. She
college recently hired Killeen
document specialist for five
as its first female welding
years. I was working there
technology instructor. The
while I was getting my degree
received scholarships
Source: www.weeklycitizen.com
through the American Welding
Source: www.theintelligencer.net
Society and Zachry, meaning
Purpera noted that being a
welding technology graduate
here,” Killeen said. One of
her education is now entirely
woman in a male-dominated
— and now educator — is a
Killeen’s goals for the college
paid for. Purpera currently
field comes with added
single mother to a 5-year-old
is to attract more female
works two days a week at
pressure. She said she wants
son. “I actually started here
students in all applied science
Zachry, and she spends the
to show other girls who are
for business at Northern and
classes. She is proud to be the
rest of her time in school
interested in the field that they
realized that they had welding
first woman to lead the way in
finishing her education.
can achieve great things too.
classes while I was a business
this profession at the school.
www.weldfabtechtimes.com
APR - MAY 2018 | WELDFAB TECH TIMES
61
WELDING TIPS
11 Reasons: Why Welders Don't Follow Welding Procedures of any welding quality management
equipment. Chances are the arc voltage
system. So why is it that many welders
will be within range, but the welding
don’t follow them? Here are the top 11
machine will be reading something much
reasons we run into in the field as to why
higher. Inspectors will not measure your
welders do not follow WPSs. These are not
arc voltage, they will take the machine
in any particular order.
reading. They may go a step further and measure the output at the studs, but this
Reason #1: There are no welding procedures specifications.
does not account for voltage losses in the welding lead or work cable.
As important as it is to have written WPSs most fabricators don’t have them.
Reason #5: The welder wants to increase productivity.
Reason #2: They are not given a copy at their work station.
We are yet to walk into a shop where a
This is very common at fab shops where
or slow as desired, and to not worry if the
welding procedures specifications are
daily quota is met. A welding procedure
only developed to satisfy a customer
will dictate your maximum deposition
requirement. Copies of these WPSs are
rate, the rate at which you deposit weld
kept on file at the front office and never
metal. This deposition rate has a huge
ailing an audit due to welding
make it out the welders. The welders are
bearing on productivity. A welding
outside of WPSs can be a big
left with no choice but to select whatever
procedure limits this so it limits how fast
problem that can cause delays
welding parameters they feel are best.
something can be welded. In order to
C Sridhar, Director-Technical, Advance Institute of Welding Technology, Chennai, Tamilnadu
F
speed up, welders have to make changes
and huge losses in lost production blame think again. Most of the time it is
Reason #3: Following the WPS creates problems.
management's fault. The main reasons
This can be spatter, an inconsistent
why some of our customers fail audits.
arc, cold lap, burn through and many
Reason #6: Welders know better.
other problems. This is a sign of a poorly
They may actually know how to develop a
procedures specifications (WPS) is to
written WPS. The welder then has to make
better welding procedure; however, being
ensure quality. This is accomplished
adjustments that puts him or her outside
in violation of a WPS is never
by giving the welder a detailed set of
of the ranges allowed by the welding
good. Some welding procedures have
instruction on how to deposit weld metal
procedures in order to deposit a good
limits to comply with the rules and
for a specific joint. Consistent quality can
weld.
requirements of a prequalified welding
time. If you think welders are always to
The purpose of having welding
be achieved, but there is one caveat. The
that put them outside of the welding parameters set in the WPS.
procedure specification. Others have limits to prevent excessive heat input (or
A poorly written welding procedure
Reason #4: The welding equipment is faulty.
can be as bad, or worse, than having no
A well written WPS will have tight ranges
that make no sense. When a welder
welding procedures at all. Other than
for different variables such as amperage,
increases his parameters because the
ensuring quality a welding procedure can
voltage, travel speed, etc. However, if the
ones on the WPS seem to hamper
have a significant impact (and it usually
equipment is in disrepair and the welder
production, he or she may be exceeding
does) on productivity.
is experiencing problems such as voltage
or not meeting other requirements. The
drop, he or she will be forced to adjust the
welder is trying to help, but this can
welding procedures must be well written.
Welding procedures are the foundation
62
welder is told to take his time, weld as fast
WELDFAB TECH TIMES | APR - MAY 2018
not enough). Others have limits
www.weldfabtechtimes.com
WELDING TIPS
development of a WPS will have a list of
Reason #7: They have never had a failure.
Reason #9:Management does not provide adequate training and/or information as to why the WPS must be followed.
We see this a lot. A shop finally
If welders are told a compelling reason as
decides to develop WPSs and get them
to why they should always abide by the
implemented. The welder may be used
WPS provided they typically will. However,
Reason #11: The welding machine is not capable to run procedures called for in the WPS.
to running parameters which are not
in some shops the welders believe the WPS
If a WPS calls for 1.2 mmER70S-6 GMAW
allowed by the new WPS. Since the welder
is simply a recommendation or a starting
wire at 10. 50 mt per minute, wire feed
has never had any problems with his or
point, not a requirement.
speed and a contact tip to work distance of
create a violation of welding procedures.
her own procedures they opt to disregard
changes to essential variables that would require a separate WPS.
20 mm, the resulting current will be about
the WPS.
Reason #10: The welder makes a change to an essential variable.
310-330 amps. If the welder has to use a
Reason #8:Management does not enforce the WPSs.
A welder may be running wire feed speed,
current.
This is very common too. A WPS may be
angle and work angle all according to
of a contract, or a catastrophic failure for
in place but management dare not mess
the WPS. But instead of welding vertical
management to realize the importance of
with the welders. They depend so heavily
up he or she welds vertical down. Unless
developing sound welding procedures and
on the welders that they don’t want to
there is a separate WPS for this change
implementing them in their shop. Don’t
rock the boat. This problem arises from
in weld progression the welder would be
wait for that to happen. Look into your
the lack of understanding of the welding
in violation of the WPS. Whatever code
welding procedures, if any, and how they
process by people running the company.
or standard has been followed for the
are being followed (or not) in your shop.
www.weldfabtechtimes.com
voltage, contact tip to work distance, travel
250 Amps machine he cannot get to this In many cases it takes an audit, the loss
APR - MAY 2018 | WELDFAB TECH TIMES
63
ARTICLE
ISO 3834 - Need of Fabrication Industry addition to Quality Management System.
alone and with or without the use of filler
Some of the European Standards like EN
material".
1090 & EN 15085 are recommending ISO
According to ISO 9001: 2008, section
3834 as their prerequisite to their sector
7.5.2, the validation of any processes for
specific quality requirements.
production is necessary in which the
The need, necessity, advantages and
conformity to the requirement of the
application of ISO 3834 is discussed in
resulting product cannot beverified by
this paper taking into consideration
subsequent monitoring or measurements
fabrication industry at large.
and as a consequence the deficiencies become apparent only after the product is
Mr. Satish Keskar, International Welding Technologist, AWSCertified Welding Inspector, Welding Trainer, ISO 3834 Trainer / Consultant / Auditor, Pune, INDIA.
Introduction of ISO 3834:
in use. Such processes are generally called
American Welding Society (AWS) defines
as “Special Process”
fusion as "a materials joining process
When Special processes like Welding
which produces coalescence of materials
and Heat Treatment are used in the
by heating them to suitable temperatures
product manufacturing, it is difficult to
with or without the application of
ensure the quality of finished products
pressure or by the application of pressure
only through final inspection. ISO
W
elding is the most important pprocessing fabrication industry and also called as a
“Special Process”. Traditionally, welding was looked in a limited way and covered qualifying welding procedures and certifying welders. Besides this, no much more attention was given in fabrication industry. It was resulting into increase in rework cost to fabricators and third party inspection cost to clients. ISO (International Organization for Standardization) introduced first revision of ISO 3834 in the year 1994 and laid down Quality requirements for fusion welding of metallic materials. The current revision of this ISO 3834:2005 and contains six parts providing complete set of requirements of welding quality and helping fabrication industry many ways. ISO 3834 is complimentary to ISO 9001 requirements and brings together a complete solution of Quality requirements related with welding in
64
WELDFAB TECH TIMES | APR - MAY 2018
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ARTICLE
3834 helps in validation of Welding
implementing ISO 3834
process and specifies down the quality requirements for welding. However, ISO 3834 is not replacing to ISO 9001.
• By manufacturers - establishing
Advantages of ISO 3834 to Fabricators : • Less rework hence job completion on
ISO 3834 series of standards: ISO 3834: 2005 “Quality requirements for fusion welding of metallic materials” consists of 6 parts: • ISO 3834-1:2005- Criteria for the selection of the appropriate level of quality requirements • ISO 3834-2:2005 : Comprehensive quality requirements • ISO 3834-3:2005 : Standard quality requirements • ISO 3834-4:2005 : Elementary quality requirements
time • Local & international recognition as a competent organization • More efficient coordination of welding activities
ISO 3834-4 • ISO/TR 3834-6:2007 : Guidelines on
and maintenance of welding quality requirements • By committees drafting manufacturing codes or application standards - by specification of welding quality requirements • By organizations assessing welding quality performance, e.g. third parties,
• More pro-active and responsible workforce • Increased opportunities and capability to bid on jobs • Cost savings – more efficient technology • Reduced surveillance audits and inspections by purchasers
• ISO 3834-5:2015 : Documentations to claim part ISO 3834-2 or ISO3834-3 or
of welding quality requirements
Steps for obtaining ISO 3834 Certification : • Appointment of Responsible Welding Coordinator (RWC) • Gap analysis by RWC or Certification body, • Training to Welding related staff, Welders, including suppliers if needed
Advantages of ISO 3834 to Purchasers:
• Documentation of all welding related
• More assurance of contract delivery
• Review, upgrade & approve existing /
dates • Greater assurance of the quality of welded products • Greater reliability and performance of products • Reduction in maintenance costs after installation • Reduction or elimination of third party inspection costs • More competent suppliers of welded products
activities new suppliers • Own welding related personnel: Dy.Welding Coordinator, Inspectors, Supervisors, NDT personnel etc. • Qualification of WPS, Certification of welders/ Welding Operators • Review, audit & upgrade present welding related requirements • Appointment of Certification Body • 1st Stage Certification Audit by Certification Body • 2nd Stage Certificationaudit by
Applications of ISO 3834:
Certification Body
• In Fabrication Industries
• Award of Certificate (Validity : 5 years)
• In Construction companies i.e. on-site
• Surveillance audits (every year)
work
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• In Repair and maintenance contractors
Conclusion:
• For Manufacturers of products
The fabrication industry needs to upgrade
• Perquisite for other standards e.g. EN
their Welding Processes in line with
1090, EN 15085 (Railway applications)
the requirements of ISO 3834 and get
etc.
benefited.
Uses of ISO 3834 in following situations:
References:
• In contractual situations - specification
2. ISO 3834 : 2005.
1. ISO 9001 : 2008
APR - MAY 2018 | WELDFAB TECH TIMES
65
INDEX
ADVERTISER’S INDEX Company Name
EDITORIAL INDEX
Page No.
WeldFab Tech Times
IFC
Cotmac Industrial Trading Pvt. Ltd.
03
Klinweld Wires Pvt. Ltd.
Page No.
Tungsten Electrodes
08
05
Dukane
08
Veepees India
13
Air Liquide company
09
Rilox Weld Equipments
21
Forney Industries
09
Noble Alchem Pvt. Ltd.
23
Warpp Engineers
27
Air Liquide company
09
Omega Weldrod Systems
33
TÜV Rheinland India
10
Sharp Electrodes Pvt. Ltd.
37
Miller Electric
11
Pro-Arc Welding And Cutting System
41
Kemppi India
14, 22
Cutting & Welding Equipment Expo
45
India Essen Welding and Cutting
49
National Welding Meet - 2018
59
LaserStar Technologies Corporation
15
B.R. Kumar & Sons
15
Weldwell Speciality Pvt. Ltd.
IBC
Lincoln Electric Company
16
Kemppi India Pvt. Ltd.
BC
Warpp Engineers
16
Precision Metal Group
17
Quivan Skills Empowerment
28
International Welding Technologist
64
Carl Cloos Schweisstechnik
24
International Copper Association, India
34
Fronius India
42
CWE 2018
46
India Essen Welding and Cutting
48
Annamalai University
50
Sumeka Welding Institute
52
Retired Welder
60
River Parishes Community College
61
West Virginia Northern Community College
61
Advance Institute of Welding Technology
62
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Needs Special Products
brings Technically Advanced Welding Products to Indian Industry from Global Leaders
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