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
14th September, 2019 in Mumbai
NOMINATE TODAY!!! WeldFab Tech Times feels delighted to announce ‘WELDFAB TECH AWARDS 2019’ exclusively for the Welding Industry. For the First Time in India, an Award is in store the Welding Segment. The objective of the Award is to Encourage and Reward the welding industry for their Excellence and Innovations. The welding and related sectors will be a part of this show.
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 2019
NOMINATION STARTS ONLINE FROM 27th May 2019 till 22nd July 2019. We would be very happy if the Welding & Fabrication segment nominates in suitable category, thereafter enabling us to forward the same to the Jury. So grab this opportunity!!! Nominate yourself and your company. You deserve to be a part of WELDFAB TECH AWARDS 2019. Best of Luck…
Scan To Nominate
Eliza Bhalerao Publisher & Editor
www.weldfabtechtimes.com
Organized by
3rd AnnUAL
Bengaluru, India
03rd - 04th July 2019
Event Overview
Confirmed Speakers
India will become the third largest aviation market in the next seven years. India has 57 new airports under development or consideration at a known total value of USD16 billion, out of a total of USD147.8 billion in Asia. That is slightly more than in the whole of Africa. There are three over USD2 billion – Navi Mumbai, Delhi Noida and Pune. Overall, USD 10 billion will be spent on developing airport infrastructure over the next five years by the government alone. Airports Authority of India will partner with the State Governments to develop some of these airports for regional connectivity. Similarly, 10 of the 25 non-functional air strips with the Airport Authority of India are also to be developed. Only a handful of big airports have been privatized and Airports
Philippe Delaplace Senior Vice President ADP Ingenierie
Adam Young Marketing Director Asia Pacific Embraer Commercial Aviation
Vikas Gupta CEO & CTO GrayMatter Software Services Pvt Ltd, India
Ms. Liberatha Kallat Founder & Managing Director DreamFolks
Authority of India, which operates 137 airports, remains a very significant player and the state generally is still very much part of the set-up. We TraiCon Events Pvt Ltd have executed two consecutive Airport Modernization Summit 2017 and 2018 which were very successful. Now we TraiCon Events are proud to announce the 3rd Annual Airport Modernization Summit 2019 scheduled on 3rd & 4th July 2019. This forum will bring together key government and private aviation sector stake holders, Government Bodies and Authorities under one roof to discuss on the challenges and opportunities in developing and modernizing the Indian Aviation sector.
Our Partners & Sponsors Gold Sponsors
Lanyard Sponsor
Airport Lounge Sponsor
Official Magazine Partner
Strategic Partner
Official OEM Sponsor
Keynote
Exhibitors
Supporting Associations
India’s Premier Aviation Magazine
Media Partners
For Sponsorship Opportunities Adrian White | Head - Production | Mob: +91 96205 71845 | Email: neil.white@traiconevents.com
CONTENTS 6
WOMEN IN WELDING
56
Arc welding processes are our core competency, an area in which we are Germany’s largest manufacturer
ARTICLE
26
32
Importance of various shielding gases used in TIG welding for exotic...
Weld Cost Analysis: Simplified perspective on Cost Components of...
INDEPTH
22
WELDFAB TECH TIMES | APR - MAY 2019
36 Plate Edge Beveling Processes & the advantages of Automated Mechanized..
INTERVIEW
46
Zircalon 30 – A New Grade of FractureResistant Zirconia for Welding
FARO’s portfolio of 3D measurement provides turnkey solutions for...
www.weldfabtechtimes.com
CASE STUDY
40
Karish & Tanin – A Transformational Project in Israel
LAUNCHES
INNOVATIONS
58
60
Yaskawa Smart Series product line is ideal for new robot users
WELDER’S PASSION
BULLETINS
08
PRODUCTS UPDATE
50
SECTOR WATCH: AEROSPACE
66 62
www.weldfabtechtimes.com
Welding breakthrough could transform manufacturing
“Safety in welding is not a decorative accessory, but a mandatory requirement.”
APR - MAY 2019 | WELDFAB TECH TIMES
7
BULLETINS
Air Products appoints Mr. Anand Chordia as MD of ProdairAir Products India Joerg Linsenmaier, Vice
“Air Products’ commitment
where since 2017 he was
President. Global Project
to India is stronger than
Global Delivery head – Plant
Execution, Manufacturing,
ever and there are many
Engineering Business Unit
Construction & Start-Up, said,
opportunities for growth that
for L&T Technology Services
“I am very pleased that Anand
we are actively exploring,”
and was responsible and
has joined Air Products.
added Richard Boocock,
accountable for leading a
Anand brings extensive
Air Products’ senior vice
business unit with over 1000
experience in the EPC
president, chief information
staff based across Vadodara,
industry, both domestically
officer, and president, Air
Mumbai and Chennai,
ir Products
and globally. He also has
Products India. “We are
India. Prior to that, Anand
announced that it
an exceptional business,
confident that Anand will
served as Vice President –
has appointed Mr.
A
technical and functional skill
bring strong leadership to
Project Execution for Linde
Anand Chordia as Managing
set gained during a career
help shape and define the
Engineering India Pvt. Ltd.
Director, ProdairAir Products
spanning over 26 years within
next stage of Air Products
India Pvt. Ltd; as well as head
engineering and project-
‘contributions in India,
degree in Mechanical
of Air Products’ world-class
related disciplines. We are
building on the successes we
Engineering from M.S
Engineering, Procurement and
excited to have Anand join our
already have and enabling us
University, Vadodara, India.
Construction (EPC) center in
organization and look forward
to create new opportunities
He is also a certified internal
Pune, India.
to the strength his leadership
into the future.”
auditor for ISO processes and
Commenting on the appointment, Air Products’
will bring to our India-based EPC center.”
Anand joins Air Products from Larsen & Toubro,
NFR to add additional coaches to increase capacity in many trains
I
8
Source: www.airproducts.com
Anand holds a Bachelor’s
a certified green belt for SixSigma methodology.
Source: nfr.indianrailways.gov.in
w.e.f. 25thMay 2019.
(one) AC 3 tier coach will be
• 3(three) General second
• 4 (four) General second
added in the 15711 / 15712
Class coaches will be
Class coaches will be
Katihar – Howrah – Katihar
passenger of N.E. Region,
added in the 55803 / 55804
added in the 55681 / 55682
Express from Katihar w.e.f.
N.F. Railway has decided
passenger, 55809 / 55810
passenger and 55683 /
to augment the capacity
passenger and 55817 /
55684 passenger trains
of many long distance as
55818 passenger trains
running between Agartala
be added in the 15715 /
well as passenger trains
running between New
and Garjee w.e.f. 25thMay
15716 Kishanganj – Ajmer
o¬n permanent basis. All
Bongaigaon and Guwahati
2019.
Garib Nawaj Express train
the additional coaches will
w.e.f. 25th May 2019.
• 1 (one) General second
be added permanently this
• 4 (four) General second
Class coaches will be
n line with the effort to provide more and more berths to railway
train w.e.f. 6th May, 2019.
13th May, 2019. • 1 (one) AC 3 tier coach will
from Kishanganj w.e.f. 14th May, 2019. • 1 (one) AC 3 tier coach
month as per details provided
Class coaches will be
added in the 55679 / 55680
below:
added in the 55893 /
passenger train running
will be added in the 15721
• One AC 3 tier coach will
55894 passenger and
between Agartala and
/ 15722 New Jalpaiguri –
be added in the 55615 /
55895 / 55896 passenger
Dharmanagar w.e.f. 25th
Digha Express train from
55616 Guwahati – Silchar
trains running between
May 2019.
New Jalpaiguri w.e.f. 17th
– Guwahati Fast passenger
Rangapara and Rangiya
WELDFAB TECH TIMES | APR - MAY 2019
• 2 (two) Sleeper class and 1
May, 2019.
www.weldfabtechtimes.com
Pro - MIG
Modular Architecture
Full Digital Control
Pro - TIG(DC)
Pro - TIG (AC/DC) Special Programs
IP 34
Duty cycle 100%
Safety
100% @ 40˚C
NORMAL ROOT JETARC DAC-MD
ROOT-MD R-PIPE PULSE FORCE ARC
Advanced AC/DC, DC Pulse TIG, Synergic MIG and Pulse MIG power Sources with value added features such as Parameter locking, Data Logging and Online monitoring.
ed iz
cle Cy t a He
om st
ke
ro yd
n ge
Ba
t Ou
u |C
H t| ea H t
e Pr
| at He
s Po
Induction Based
Preweld / Postweld heat treatment
Electronics Devices Worldwide Pvt. Ltd. 31, Mistry Industrial Complex, Cross Road ‘A’,M.I.D.C., Andheri [E], Mumbai 400093. INDIA. Tel: +91-22-45410600/ 601 Service: +91-22-45410625 Email: sigmaweld@edmail.in Web: www.electronicsdevices.com, www.sigmaweld.com
Sales & Marketing office: 608, 6th Floor, Windfall, Sahar Plaza, Next to Kohinoor Hotel, Jb Nagar, Metro Station, Andheri East Sales - Tel: +91-22-45410500
TAKING WELDING INVERTER TECHNOLOGY TO THE NEXT LEVEL
BULLETINS
Yaskawa Motoman collaborative robots offer flexible & affordable task automation
F
eaturing power
models offer intuitive robot
optimized based upon risk
and force limiting
programming with a quick
assessments and process
technology, Yaskawa
and easy learning curve.
requirements. Both models offer a 10-kg
Motoman’s HC10 and HC10DT
Utilizing the Smart Pendant,
robots work safely with, or in
the HC10 can be hand-guided
payload and 1,200 mm reach
close proximity to humans
for easy positioning of the
and can perform a broad range
by stopping the robot in
robot. The HC10DT (direct
of material handling, machine
the event of contact with
teach) offers intuitive robot
tending or light assembly tasks.
an operator. Dual channel
path programming through
Function-specific tooling and
torque sensors in all joints
the use of three easy-to-use
accessories are available from
voltages ranging from 380VAC
constantly monitor force
programming buttons.
various Yaskawa partners.
to 480VAC. The YRC1000 is
Source: www.motoman.com
compact (598 W x 490 H x 427
Precision hand-guiding
The HC10 collaborative
The HC10 and HC10DT are
for teaching new program
robot leverages Yaskawa’s
D mm), resulting in reduced
six-axis collaborative models
paths allows the HC10
long history of building robots
space requirements. The
designed to eliminate operator
and HC10DT to be quickly
that are durable and reliable,
HC10DT is controlled by the
pinch points while through-
deployed or redeployed on
resulting in minimal downtime.
ultra-compact YRC1000micro
arm utilities hide cabling and
demand, decreasing system
increase safety by reducing the risks of snagging or interference with other equipment.
to quickly react to contact.
Ideal for novice robot programmers, both
The HC10 robot is
controller. Its small footprint
downtime and increasing
controlled by Yaskawa’s
(425 W x 125 H x 280 D mm)
ROI. Whether operating at
high-performance YRC1000
and lightweight cabinet are
full speed on industrial mode
controller that is built to a
ideal for factories with high-
or collaborative speed on
global standard and does not
density layouts, where stacking
PFL mode, cycle times are
require a transformer for input
of controllers may be required.
EWM AG opens a location in France
E
Titan XQ MIG/MAG multi-
WM AG, Germany’s largest manufacturer of
Source: www.ewm-group.com
process welding machine yields a competitive advantage.
arc welding technology,
opened a location in the city
“There is a tremendous
of Tours, France, on 4 April
amount of interest in France
2019. Managed by Stéphane
in innovative, future-oriented
Lemaire, a French national,
welding technology. We
the purpose of the location is
can win companies over by
to provide service and product
delivering the highest quality,
training, demonstrations
with recommendations from
and welding support for
satisfied customers and with
France's welding technology
our guarantee promise: three
professionals.
years for welding machines as well. Alongside the
also offering new technologies
and five years for rectifiers
is thus keeping its word
company’s efficient arc
for Industry 4.0 to the French
and transformers – with no
on staying close to its sales
welding technology tailored
market. Especially the Welding
operating hours limit, even in
partners and customers
for customers’ requirements
4.0 welding management
three-shift operation,” says
with advice and service
and a complete range of
system ewm Xnet 2.0 used in
Stéphane Lemaire, Manager
offerings – now in France
welding accessories, EWM is
combination with the new
France for EWM AG.
The family-run company
10
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
BULLETINS
Flash butt welding plant inaugurated at New Bongaigaon
Source: www.sentinelassam.com
A
flash butt welding
ESAB sponsors 2019 student career day
Manager of N.F.Railway,
E
Maligaon. The plant has been
than 15 AutoRama®/World of
constructed to convert free
Wheels/Cavalcade of Customs®
rails into long panels in order
events held throughout the
to achieve good quality of
U.S. and Canada. Presented
plant was inaugurated
SAB Welding & Cutting
at New Bongaigaon
Products will sponsor
by NK Prasad, General
the 2019 Student Career
Day event taking place at more
rail joints in the stationary
welding 10/20 rail panels with
plant which is being set up
stacking area of 15000 MT.
at New Bongaigaon yard.
single rails at a time and 22000
constructed in record time
Association (ISCA), Student
This plant has adequate
MT. of 20 rail panels could
during the financial year
Career Day exposes students and
infrastructure facilities with
be stacked and dispatch to
2018-19. The construction
instructors to a wide range of
modern mechanized loading/
different construction projects
work of the plant was
opportunities in the automotive
unloading of rail using
of N.F.Railway/Construction
started on July 14,2018 and
industry through speakers,
motorized gantries.
and Open line as well as other
completed at a cost of Rs.44
corporate support and event
neighbouring zonal railways
crores.
participation.
The plant has also facilitate
on their demands. The plant has been
by Summit Racing Equipment and the International Show Car
During each event, ESAB will award a Rebel™ EM 215ic MIG
Kemppi acquires Italian Trafimet Group
K
school, with the winner drawn randomly on the day of the
emppi has acquired
position especially in the
customers, but I believe
event. The Rebel unit provides
100% share of the
welding torch and consumable
that being under the same
a MIG output of 20 to 220 amps
Italian welding torch
aftermarkets. In addition
ownership will bring sourcing
and enables users to switch
manufacturer Trafimet Group
to the torches, the Trafimet
and logistics synergies. An
from 230V to 120V primary
S.P.A. The contract was signed
product range includes
owner with a long history in
power simply by connecting the
in Italy on Friday March 1st.
welding accessories such as
the welding market will be able
supplied adapter plug.
Both companies will continue
welder’s safety products. The
to offer good development
Werhman notes that Rebel
as separate businesses.
company has a long history
possibilities also in the long
is perfect for students because
and its’ brands Trafimet, Sacit
run and support our growth
its sMIG (“smart MIG”) feature
strategy and the acquisition
and Ferro hold an established
strategy”, he continues.
takes away the doubt of welding
is a natural part of that. The
position in the market. Both
The acquisition does not
businesses and competencies
companies will continue as
have direct personnel effects
can focus on good gun technique
of the two companies
separate businesses also after
or immediate changes in the
and become productive more
complement each other well
the acquisition.
organization or operations of
quickly. With sMIG, users begin
either company. Trafimet has
by setting metal thickness and
”Kemppi has a strong growth
and Trafimet’s product range
”Having a strong European
with incorrect settings so users
strengthens Kemppi’s position
actor in the welding industry
been a supplier of Kemppi
selecting wire diameter, then
especially in the aftermarkets
with us will benefit both
for several years and the
Rebel will automatically adapt
of the welding business”, says
companies in the future”, says
sourcing cooperation will be
to any popular filler metal/gas
Ville Vuori, CEO, Kemppi Oy.
Attilio Imi, CEO of Trafimet
strengthened further after the
combination to provide a stable
Group. “Trafimet and Kemppi
acquisition.
MIG arc and superior welding
The acquisition brings in a company with a strong
12
welder to one participating
continue to serve their own
WELDFAB TECH TIMES | APR - MAY 2019
Source: www.kemppi.com
performance.
Source: www.esabna.com
www.weldfabtechtimes.com
BULLETINS
Kaiyuan Resistance welding machines available in Pune Demo Centre
K
AIYUAN has 30
spot welder and seam welder.
years of history
Almost 90% transformer
for manufacturing
radiator manufacturer are
resistance welding machines.
using Kaiyuan product line or
The products are widely used
individual machines in China.
in automobile parts, aviation
Kaiyuan resistance welding
parts, low-voltage apparatus
SPM for automobile parts
parts etc in manufacturing
manufacturers such as a
industries. Kaiyuan made
generator, transmission,
resistance welding machines
damper, door & window,
are known higher reliability,
seat, breaker, silencer etc.
low maintenance cost &
welder:100kVA / 160kVA
80SAJ which is 80kVA MF three-
are accepted by some global
with Quality welding with
Both KAIYUAN controller
phase spot/projection welder
companies such as Johnson,
repeatability for joint after
and PANASONIC controller
with KAIYUAN controller.
Faurecia, Tenneco, Bosch, Aisin
joints. Kaiyuan offers full range
are optional for KAIYUAN
of resistance welding machines
resistance welding machines.
as follows:
LIVE demonstration for the
Our expert will explain the features of the machine, will
resistance welding machines
the welding performance,
on KWAI Chakan plant.
will show the design and
70kVA / 100kVA / 160kVA /
Following models are included
structure of the machine, will
200kVA
as listed below:
discuss with the customer and
• MF three-phase spot
DTN-50SAJ which is 50kVA single phase spot/projection
as per customer’s welding
50kVA / 80kVA / 160kVA
welder with KAIYUAN
component.
/320kVA / 480kVA
controller, DTN-50SPJ which
100kVA / 160kVA • MF three-phase seam
Kaiyuan also provides very
is 50kVA single phase spot/
popular transformer radiator
projection welder with
automatic manufacturing
PANASONIC controller, DTBZ-
line with building in multi-
Sirfull Technology raises 2 Million Euros
A
Lingyun, VKV etc.
recommend the suitable model
projection welding machine:
• Single phase seam welder:
Seiki, Weifu, Exedy, Minth,
operate and weld to show
welder: 35kVA / 50kVA /
• Single phase spot projection
Source: www.sirfull.com
fter acquiring the
in France and will launch its
Framatome, Solvay, Emerson,
is simple: invest in order
company 2iO in July
activity in Germany and in
Storengy.
to provide our customers
2018, and in order
Europe. SiRFULL technology
This new step confirms
who trust us every day with
to continue its development,
offers a simple and intelligent
the strength of SiRFULL
innovative and qualitative
the company announces:
asset management platform
technology model, the
services and strengthen the
“the success of its fundraising
for process industries and
relevance of its strategic vision
confidence of those who
realized with Wille Finance
opens the door to predictive
and investors confidence in its
join us every month. We
AG, Demeter, and SCR
maintenance.
growth potential.
will continue to invest in
Alsace Creation; its historical investor.”
The digital tools designed
innovation including semantic
by SiRFULL technology
Jean Claude LAMBOLEZ,
analysis or AI to allow our
now equip more than 100
CEO and Founder of SiRFULL
customers a strong ROI in
SiRFULL technology will
industrial sites in France with
Technology declares:
the management of their
accelerate its development
70 customers such as GRT Gaz,
“The goal of this operation
maintenance operations.”
Thanks to this contribution,
14
Source: www.kaiyuan.in
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
BULLETINS
NWF State College Welding Earns Accredited Test Facility Designation
N
orthwest Florida
education and aim to be
State College Welding
Florida’s best welding training
recently earned the
and testing center,” said Dr.
designation of an Accredited
Devin Stephenson, president.
Test Facility (ATF) by the
“Scottie Smith and his team
American Welding Society
have significantly raised the
(AWS). NWF State College is the
profile of our program and
only ATF between Tallahassee,
continue to find innovative
Florida and Mobile, Alabama,
ways to enhance the workforce
making it the exclusive welding
and career educational
testing location on Florida’s
pathways available to our
Emerald Coast.
students and the surrounding
Source: www.nwfsc.edu
communities of Northwest
“NWF State College has a
Florida.”
very well organized welding
be a fine addition to the ATF
and qualify welders. Once
training facility that is staffed
program and one of which
accredited, ATFs are able
by extremely well-qualified
AWS can be exceptionally
to test and qualify welders
was also recently honored as
personnel and management,”
proud.”
on behalf of the American
the Top Educational Institution
NWF State College Welding
AWS evaluated NWF’s
Welding Society and their
by the American Welding
American Welding Society
welding program on their
strict standards for quality
Society at the Excellence in
Auditor & Senior Certified
facilities, personnel and
fabrication.
Welding Awards in Atlanta,
Welding Inspector. “This will
equipment’s abilities to test
said Lyndsey Deckard,
“We are a leader in welding
Georgia.
Jec Distributors establishes Mexican headquarters to support growing expansion
J
EC Distributors,
Automotive OEM and Tier
headquartered in
1 manufactures on a global
Burlington, Ontario,
scale. JEC Distributors has
Canada, has established JEC
facilities in Canada, the
Auto Group de Mexico in
United States, Mexico, India,
Puebla to support the growing
China and Europe, focusing
expansion of our customer
on electrode management
base in response to the
in automotive spot welding,
meeting their need.
including their patented
JEC’s focus is based on
Source: www.jec-inc.com
customer support and “being
Changers and cutter blades
there when they need us,” says
Produced by Canada’s premier
Distributors has been offering
along with Tip Dressers and
President, Joe Ruggiero.
businesses and current affairs
innovative solutions in
holders. JEC Distributors is
JEC distributors was recently
media brands, the Growth 500
joining products related to
also the exclusive sales and
ranked 125th by Growth 500, a
ranks Canadian businesses on
the automotive industry.
service agent for ARO Welding
definitive ranking of Canada’s
five-year revenue growth.
JEC Distributors staff offer
Technologies in North
technical advice to the
America and India.
Fastest-Growing Companies.
18
Copperhead brand of Cap
For 18 years JEC
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
Nivek Agencies
401 Vikas Commercial Centre, Dr. C. Gidwani Road, Chembur, Mumbai - 400 074. Website: www.weldwell.com Branches: Baroda | Pune | Surat
+91 22 66462000 / 25205523 +91 22 25206789 Sales@weldwell.com nivek@weldwell.com
BULLETINS
Emerson’s New Ultrasonic Welding Platform Meets Challenges of Critical Small Plastic Part Assembly
E
merson has launched
combines servo-mechanism,
range of models to be
a new generation of
software optimization and
launched over the next two
ultrasonic welders
proprietary dynamic follow-
years, each designed to suit
that support the growing
through to enable a broad
the needs of specific customer
demand for the assembly of
range of weld forces up to
applications. The platform
smaller and more intricate
2,500 newtons. The advanced
can be configured for all
plastic components such as
actuation system also enables
customer environments,
those used within medical
the GSX to perform faster,
ranging from standalone
devices and consumer
high performance welding
benchtop systems to
electronics. The Branson GSX
of very fragile and intricate
semi- and fully-automated
Ultrasonic Welding Platform
components.
manufacturing lines. By
is an advanced and intuitive
digital environments, coupled
flexible joining solution,
welding platform enables
designed to optimize and
customers to accommodate
and intuitive software,
with easy data transfer
ensure quality welds, while
many different parts and
supported by 4 inch and
methods, the GSX Platform
helping manufacturers
application types by using an
12 inch touchscreen HMIs,
is Industry 4.0/IIoT-enabled,
meet project timelines and
array of welding parameters
which enable operators to
providing access to actionable
deliver expected return on
and actuation modes during
perform faster, correct set-
performance and diagnostic
investments.
a single weld. This ensures
ups and reduce application
data, supporting production
better, consistent, quality
testing time. This leads to
efficiency and traceability
the medical, electronics,
welds leading to fewer rejects.
faster start-up and set up
that complies with industry
and automotive industries
Using a multicore processor
times which can result in up
regulatory standards such as
are becoming increasingly
and a linear encoder drive,
to 60% savings in operator
FDA 21 CFR Part 11.
miniaturized, with embedded
the multi-tier advanced
time while assuring weld
electronics, intricate designs
actuation system can be
quality and production
manufacturers must bring
and thinner plastic walls.
instantaneously adjusted
efficiency. Replacing a
products to market faster
Conventional welders
based on real-time feedback.
stack and tooling for a
to maximize profitability,”
with high or crushing weld
This ensures the same level
conventional ultrasonic
said Tarick Walton, global
forces inhibit safe welding
of precision and repeatability
welder can take over an
ultrasonics product manager,
of small and fragile parts.
across multiple welders,
hour to complete. Using the
Emerson. “The Branson GSX
To meet this challenge,
with post weld tolerance and
new quick stack exchange
supports faster start-ups and
Emerson has developed
part variability measured in
system of the GSX, which
provides best in class quality
an electro-mechanical
microns.
Plastic components across
“To remain competitive,
ensures tooling alignment,
control, process repeatability,
Increasingly challenging
this procedure is reduced
traceability and increased
that provides unprecedented
production timelines, that
to less than five minutes.
production throughput to
control and position accuracy
must be met to ensure a
The ability to execute faster
ensure successful delivery of a
and delivers the industry’s
project’s expected return on
changeovers enables a variety
product line’s expected return
lowest trigger force of five
investment, are inhibited by
of components to be welded
on investment.”
newtons. The advanced
a loss of operator experience
with limited disruption to
actuation system leverages
and expertise. Helping to
production schedules.
over 70 years of ultrasonic
bridge any potential skills
application experience and
gaps, the GSX features simple
advanced actuation system
20
offering easy integration into
he highly configurable GSX
WELDFAB TECH TIMES | APR - MAY 2019
The modular GSX Platform forms the basis for a wide
Source: www.emerson.com
www.weldfabtechtimes.com
INDEPTH
Zircalon 30 – A New Grade of Fracture-Resistant Zirconia for Welding www.syalons.com
Zircalon 30 Weld Location Pins.
I
nternational Syalons are pleased to
distinct crystal microstructures that are
that has demonstrated outstanding levels
announce the availability of Zircalon
dependent upon forming temperatures
of performance for fracture-resistant
30 a new grade of zirconia-based
and the presence of dopants and
control pins in weld assemblies.
advanced ceramic with greatly improved
stabilizers such as cerium (Ce) or
fracture toughness, which is ideal for
yttrium oxide (Y2O3); each of which is
What are Zirconia and Zircalon 30?
induction welding applications.
believed to impart different mechanical
Zircalon 30 is a co-stabilised zirconia and
characteristics.Typically, yttrium-doped
aluminum oxide (Al2O3) matrix based
dioxide (ZrO2), is a high-strength
zirconia reaches higher compressive
composite ceramic, which is reinforced
advanced ceramic with outstanding
strength values (>2000MPa) while cerium
by self-grown alumina-based platelets.
impact- and wear-resistant properties.
imparts greater fracture toughness[1].
This microstructure achieves the same
It is usually present in one of three
Zircalon 30 is a new grade of zirconia
mechanical benefits of zirconia products
Zirconia, also known as zirconium
22
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
INDEPTH
stabilized with yttrium additives albeit
fuses the nut to the sheet by introducing
forming is attributed to the complex
with vastly improved fracture toughness
a voltage differential between the upper
and demanding mechanical conditions
in the region of 14 – 15MPa m½. Zircalon
and lower domains of the welding unit –
of high-throughput processing.
30 also boasts an increase in impact
after which, the non-conductive control
Occasionally weld location pins
resistance of up to 50% compared to
pin can be easily retracted.
fabricated from zirconia products are
yttrium-stabilized zirconia (YSZ).
Steel control pins are problematic as
preferable to silicon nitride in facilities
the material’s electrical conductivity
where high impacting forces are a factor
which has been developed for industries
can cause arcing between the product,
in the long-term performance of the weld
and applications requiring exceptional
the workpiece, and the pin itself. This
assembly.
wear resistant characteristics for
can cause a build-up of slag material on
electrically-insulating materials. It is
the pin which may inhibit the retraction
upon the established benefits of
predominantly used in metal forming
process. They are also susceptible
existing zirconia-based control pins,
and welding applications, chiefly as non-
to metal contamination and weld
with comprehensively enhanced
conductive weld location and control
corrosion, known as pitting, which
mechanical performance characteristics.
pins.
results as a visible porosity that gradually
Already, Zircalon 30 control pins are
renders the component inoperable.
outperforming products manufactured
resistant properties and good
Corroded control pins must be replaced,
from Zircalon 10 – which previously
biocompatibility of YSZ, this advanced
resulting in loss of production and
set the benchmark for strength and
ceramic has seen significant growth
avoidable maintenance costs[4].
toughness properties of zirconia. It also
Zircalon 30 is a new grade of zirconia
Owing to the outstanding strain-
within the dental and orthopedic sector.
Technical ceramics have become
Zircalon 30 is poised to improve
exceeds the thermal transfer coefficient
Currently, zirconia-based cores for
the prevalent material for fabricating
of 2.5 W/(mK) established by Zircalon
fixed partial dentures on anterior and
weld location pins, with demonstrable
20 – a magnesia-stabilized zirconia
posterior teeth are challenging titanium
improvements in terms of ongoing
(MgSZ) engineered for improved thermal
as the primary material of choice for
operating performance. A major
performance.
oral implantology[2]. Its commercial
European automotive manufacturer
The operating conditions in a weld
viability as a suitable material for hip
determined the lifespan of their steel
assembly are extreme, comprising peak
head prostheses is still under clinical
location pins at approximately 70,000
flame impingement temperatures of
evaluation, with further studies exploring
operations before irreversible failure. By
3,500°C (6,500°F), elevated ambient
the biological and mechanical capacities
comparison, control pins manufactured
temperatures, and potentially hazardous
of novel zirconia implants[3].
using Syalon 101, an innovative silicon
agents such as ionized gases and
nitride (Si3N4) derivative, performed
particles. Control pins engineered from
Issues with Established Weld Pin Materials
over 7 million operation cycles without
Zircalon 30 can reliably perform high-
exhibiting noticeable wear or reduced
throughput welding operations with
Control pins for welding assemblies
functionality[5]. Subsequently, Syalon
substantially increased resistance to
are used to secure sheet metal and
101 weld control pins are among the
fracture caused by unavoidable impacts
additional components, such as nuts, in
primary components used in metal
while lining up the sheet metal aperture,
place throughout the welding process.
forming applications.
placing the nut on the pin, or retracting the component from the end-product.
This operation is typically carried out
Zircalon 30 is also anticipated to advance
preformed aperture in the sheet. The nut
The Emergence of Zirconia Weld Pins
is then centered around the pin by the
The emergence of zirconia in
and jigs in other types of welding
force of gravity and the welding assembly
engineering spaces such as metal
assembly.
by feeding the location pin through a
www.weldfabtechtimes.com
the performance of additional fixtures
APR - MAY 2019 | WELDFAB TECH TIMES
23
ARTICLE
Importance of various shielding gases used in TIG welding for exotic materials in Aerospace Industry
Surendra Vaidya Executive Vice President & Business Head, Godrej Aerospace.
Ashok Kumar Sindhu Chief Technical Officer, Godrej Aerospace.
Hitesh Ashwin Narsia Deputy Manager Welding, Godrej Aerospace.
Godrej Aerospace, the Business unit of the 120 year old Godrej & Boyce Mfg. Co. Ltd, has 30+ years of experience in precision manufacturing of metallic systems for Space, Defense and Aircrafts Applications. Over these years Godrej Aerospace has evolved to be trusted partners for the prime customers in these segments of Aerospace Business. It has established an integrated manufacturing facility by continually developing its competencies to provide a value-added product to the customer. Manufacturing of built-up systems for liquid engines for PSLV, GSLV & ULV rockets of ISRO, requires high quality welding of multiple exotic alloys wherein minor variation of less focussed parameters like welding gasses can play a very determent role. The Purpose of this paper is to describe the importance of different shielding gases used in aerospace industry to weld challenging materials and their effect on welding parameters, heat input, weld repairs, bead profiles, and their mechanical and metallurgical properties.
26
1. INTRODUCTION
non-essential) are equally important
penetration and weld bead profiles.
Aerospace designs are continually
to meet the desired requirements. It
Selection of appropriate shielding gas
optimized in terms of the multiple
is more significant due to control of
is important as it should not affect the
exotic materials used and functional
Weld discontinuities, Heat Input and
mechanical, chemical and metallurgical
requirements in defense, space and
Weld Distortion in Aerospace materials.
properties of material. As for example,
aviation sectors. Joining of exotic
Shielding gases plays an important role in
Small amount of H2 with Argon will be
materials is often more difficult than
number of aspects of welding, including
very helpful in welding of austenitic SS
joining of common materials. For welding
arc characteristics and the microstructure
and Nickel base alloys, but if the same
of aerospace materials, all variables
of weldments. The application of different
gas is used in CS and LAS, Hydrogen
(essential, supplementary essential and
shielding gases can result in different
Embrittlement and failure will occur.
WELDFAB TECH TIMES | APR - MAY 2019
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ARTICLE
2. AEROSPACE STANDARD REQUIREMENTS Aerospace is a generic term that includes
Treatment, Surface Treatment, NonDestructive Testing. c. Customer Approval is required to meet
commercial aircrafts, planes and
the design criteria depending upon
helicopters, military and defense, ground
the product. Different customers have
equipments, and space. Producing
different criteria depending upon the
aerospace parts needs a long supply
criticality of the product. Separate
chain, creating a major challenge for
Procedures, Welders and Facilities need
the industry. As this chain is so long
to qualify and maintained as per the
and complicated, it should come as no surprise that Aerospace standards
customer requirements. d. Product Specific Qualification and
Fig (1) Commercial Argon Gas
are comes with stringent expectations
Acceptance after Meeting specification
from the manufacturers. Manufacturing
requirements, before commencing
sophisticated vehicles, such as airplanes
on actual hardwares. Mock up of the
and lessening the chances of porosities
or rockets, understandably needs
same size need to perform and shall be
in the weld. Apart from mechanical and
special attention throughout the entire
resulting positive in all destructive and
chemical properties understanding and
production process. It must ensure to
Non-destructive tests.
maintaining dimensional requirements
UHP Argon gas ensures quality weld
are equally important. First Time Right
demonstrate the integrity of the across
(FTR) results are necessary in aerospace
starting from raw material to finished
3. SHIELDING GASES USED IN AEROSPACE INDUSTRY
part. The aerospace industry has a strong
Shielding gases fall into two categories –
as rework cost is very high. Materials
certification and compliance requirement,
Inert or Semi-inert. Only two of the noble
weld with this gas are Austenitic SS,
with consequences on development cost
inert gases, helium and argon, are used
Ni Alloys, Co Alloys, Titanium and its
and technology solutions. Few of the
in welding. The latest developments in
alloys, Aluminium, Maraging steel,
mandatory certifications are listed below:
shielding gas technology have included
Maraging steel to SAE4130 steel, 15CDV6
a. AS9100 ensures Aerospace
the complete manufacturing process
industries as compare to all other sectors
semi-inert gases with new additions
Steel, 25CD45 Steels used in different
manufacturers, being up-to-date with
of Hydrogen, Nitrogen, and mixtures
applications of Space, Defense and
the quality standards, is essential to
of these. Most of these gases, in large
Aviation sectors.
supply parts to the industries. System
quantities, would damage the weld, but
Structure is complex by disciplines,
when used in small, controlled quantities,
3.1.2 Helium having high Thermal
segment, component etc. by large
can improve weld characteristics.
conductivity, is not easy to ionize hence requires higher voltage to start the arc. Due
system management combined with high precision. Data access and security
3.1 Universally used Inert Gases
to higher ionization potential it produces
is critical, especially on Defence and
3.1.1 Argon - Argon is the most popular
hotter arc at higher voltage which helps
Space Programmes.
shielding gas and is often used for both gas
produce wide deep bead, advantageous
metal arc and gas tungsten arc welding.
for welding of aluminum, magnesium, and
aerospace industry continue, it is not
Excellent welds are often produced using
copper alloys. In comparison with argon,
only need to ensure they obtain the
pure argon as a shielding gas. Argon gas
helium provides more energy-rich but
required certification but keeping up
produces a narrower penetration profile,
less stable arc. Helium is more expensive
to date with revisions. The standard
which is useful for fillet and butt welds. All
than argon and requires higher flow rates,
additionally focuses on aerospace
materials (except Cu of higher thickness)
so despite its advantages it may not be a
manufacturers being able to improve
are easily weldable using Argon Gas.
cost-effective choice for higher-volume
their quality management system
Aerospace industry uses a much higher
production. Pure helium is not used for
between their audits, which can make
purified form of Argon i.e. Grade5 UHP
steel, as it then provides erratic arc and
the certification quite difficult to
(Ultra High Purity) Gas. To ensure the gas
encourages spatter.
maintain. NADCAP is important to all
purity and check the dew point of the gas,
special processes like welding, Heat
AWSA5.32 method is used.
b. NADCAP ensures advancements in the
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Apart from shielding gas, Helium gas is widely use in purging of difficult to access
APR - MAY 2019 | WELDFAB TECH TIMES
27
ARTICLE
form pores in the solidifying weld of Nickel
side walls to get fuse properly. On the
alloy. Oxygen is also a cause of porosity in
other side, keeping higher H2 content
certain circumstances when it combines
will generate gas bubbles due to high
with carbon in the weld pool to form
turbulence, chances of tungsten inclusions
carbon monoxide. A further characteristic
will increase in weld. Hence, for above
of nickel alloys is that the amount of
limitations, for this material addition of H2
penetration is less compared to carbon
with Ar gas is fixed to 5%.
or stainless steel. Increasing the welding current will not increase penetration
3.2.2 Argon – Helium Mixture -
proportionally.
Addition of Helium supplies more heat
To counter these conditions, addition
Fig (2) Argon Grade-5 Ultra High Pure Gas
input to the base metal and causes an
of H2 seems to be the solution. Generally,
increase in the welding rate, penetration
reference case studies suggested addition
and weld puddle fluidity. Greater fluidity
of H2 with Ar within 2 to 10% range.
of the weld pool can facilitate the escape
area in Copper to SS, SS to Nickel and
Keeping low H2 content will lead to
of hydrogen gas bubbles, which are
Stellite Final Joints.
formation of the viscous and adherent
the source of weld porosity in the weld
scum on the surface of the weld pool.
pool. Addition of helium in the shielding
3.2 Improvised Unconventional Mixture
This sluggish weld pool does not flow
atmosphere results in an increase in
Gases
freely, may result in lumpy bead and
impact energy and decrease in the crack
3.2.1 Argon – Hydrogen Mixture -
will not allow weld metal to wet the
growth rate.
Hydrogen (H2) can be added to shielding gases for GTA welding of austenitic stainless steels, Nickel base alloys to reduce oxide formation. The addition
Test Plate of 15mm thick welding carried out using Pure Ar (UHP) and Ar+5% H2 Gas. Comparison is shown below: Weld Parameters
Ar (UHP)
Ar+5% H2
No. of Weld Passes
09
07
Current (A)
125 - 130
90 – 95
Voltage (V)
10.5-11.5
12.5 – 13.5
Travel Speed (mm/min)
45
55
hydrogen addition is beneficial due to
Heat Input (KJ/mm)
1.99
1.39
its reducing effect of oxygen which will
Shrinkage (mm)
2.5
1.5
improve the fluidity of weld molten pool
RT Defects (Out of 6 Segment)
2
0 (FTR)
also means more heat in the arc and a more constricted arc, which improves penetration. It also gives a smoother transition between weld bead and base metal. For root protection purposes,
and reduce the viscosity. Experimental Procedure Semi cryogenic engine - The second largest thrust generating engine produced till date, has one of its key material as high Strength Nickel Alloy having UTS of 930MPa. Weld thickness varies from 7mm to 21.5mm and joint accessibilities are also poor due to complex designs. Manual or Auto TIG mandate for this generates higher heat inputs, resulting in shrinkage and distortion. Secondly, porosities and linear indications are problem with the nickel alloys, the main culprit being nitrogen. As little as 0.025% of nitrogen will
28
WELDFAB TECH TIMES | APR - MAY 2019
Procedure Qualification Testing carried out having values listed below. Apart from regular testing, wet chemical test IS 228 carried out to ensure Hydrogen level in Weld and parent and results shown satisfactory. Testing carried out
Specified
Achieved
Tensile Test UTS (MPa)
930
965 – 1024
Tensile Test 0.2%PS (MPa)
550
671 – 677
%Elongation
15
16.4 – 17.4
Side Bend Tests (85mm Former Dia)
No Crack
No Crack. Accepted
Micro/Macro
Satisfactory Fusion. Defect Free Weld and HAZ
Satisfactory Fusion. Defect Free Weld and HAZ
H2 in weld and parent
<0.5ppm
<0.5ppm
• Heat Input reduced by 30%, Zero defects and Controlled Shrinkage/Distortion. Mechanical properties Maintained.
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ARTICLE
Experimental Procedure
in VIKAS Engine. While using UHP
visibility. Trails carried out using Ar80% +
a) Welding of Aluminum (AA2219) Material
argon as shielding gas, it was difficult to
He20 % Gas and having satisfactory Depth
Welding of aluminum and its alloys
fuse the joint edges due to difficult joint
of Fusion on both Copper and SS sides.
encounters more difficulties than welding
configurations and lack of fusion defects
of steels. Major concerns are cracking
was encountered. To overcome these,
and porosity, due to the high solubility
Mixture of Argon (80%) +Helium (20%) was
of the hydrogen in the molten metal and
used for shielding.
the relatively high thermal expansion coefficient, which causes large changes in
b) Welding of Copper to SS.
volume upon solidification. Due to surface
One of the assemblies of Semi Cryo
oxide film formation during welding, it’s
Engine has copper to SS joint before
very difficult for the welder to identify the
brazing. Thickness of the joint is 2mm.
weld pool. Helium when added to Argon
Qualification attempts done using pure
improves oxide breakdown performance
Argon & Pure Helium were unsuccessful.
and restricts hydrogen entrapment in
When welded using Pure argon, the
the weld pool, thus resulting in better arc
copper edges were not getting fused where
stability and weld quality.
using Helium very concentrated arc was
AA2219 (Al-6%Cu) is a material used
generating which limited the weld pool
Fig (5) – Micro Photograph of Cu #SS Joint using Ar80:He20. Leg Length (Cu)
Leg Length (SS)
DOP (Cu)
DOP (SS)
1.6mm
2.6mm
0.9mm
0.5mm
As shown in Fig (5) Fusion is satisfactory and weld and HAZ are free from defects. DOP and Leg Length Values are acceptable, and this procedure is also approved by LPSC, ISRO.
4. Conclusion Proper Penetration between two meting parts
Fig (3) - Penetration using different Shielding Gas.
Fig (4) - Penetration using Ar80:He20 Shielding gas
As shown in figure (3) Argon yield arc gives deeper penetration whereas pure He gives wider penetration. Appropriate Mixture of Argon and Helium gives penetration of correct depth and width. (Ar+O2/CO2 is not used in GTAW, it is useful in GMAW) Figure (4) showing actual joint, welded using this mixture gas, having penetration of 0.5 to 1.0 mm as per the drawing requirements. Details of welding trials & results are given in below table:
• To meet the First-Time Right results in aerospace applications, shielding gas playing an important role along with other variables. • Desired requirements Physical, Chemical, Fusion and Dimensional are meeting with the selection of appropriate shielding gas against the material. • Ar+ H2 Gas has shown improved
Weld Parameters
Ar (UHP)
Ar80 : He20
performance in High Strength Nickel
No. of Weld Passes
02
02
alloys. In Future, ASS and Cobalt base
Current (A)
210-225
160-185
alloys trails to be conducted to confirm
Voltage (V)
11-13
11-13
Travel Speed (mm/min)
70-80
75-85
Heat Input (KJ/mm)
2.50
1.92
Shrinkage (mm)
NA
NA
Defect %
~ 6-7%
< 1%
With these parameters, Procedure qualification carried out having satisfactorily. This WPS and PQR is approved from LPSC, ISRO. • Heat Input reduced by 20 %, reduced defects and Controlled Distortion. Mechanical properties Maintained.
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the outcome. • Ar + He gas has shown better performance in Aluminium, Copper to SS materials in which fusion was very difficult. • Experimentation backed with metallurgical knowledge is must to utilise the individual characteristics of gases for applicability in exotic alloys of Aerospace Industry.
APR - MAY 2019 | WELDFAB TECH TIMES
29
Lasting Connections
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voestalpine Bรถhler Welding www.voestalpine.com/welding
ARTICLE
Weld Cost Analysis: Simplified perspective on Cost Components of GMAW Acknowledgements: This study has been carried out over different profile of Welding companies using sheet metal to medium thickness plate components. The Industrial segments of the users were boilers, sugar machinery, agri machinery, construction equipments etc. The base materials used by these companies are mostly mild steel. The research had been carried out by Air Liquide group for welding and cutting applications. We wish to express our gratitude to all persons involved in this study. Abstract: The aim of this work was to propose, apply and evaluate a methodical approach to optimize welding processes Ehsanullah Khan, International Expert – Welding & Cutting, in a usual welding company where GMAW is the main welding Air Liquide India. process. Very basic and simplified approach was taken to understand the cause/s & concern/s of the cost components by the CFO, CEO, Owners, VP, etc. Our extensive research and based on market requirements of Quality and Costs, the best way to categories cost around Labor, MIG Wire, Shielding Gas & Electric Power excluding the capex & infrastructure related investments. A case study was used, using one WPS and weld was performed at three different factories using GMAW. Welders and welding environment were the variable components to simulate different welding cost given the welding environment of each factory. For Quality analysis geometrical aspects of the beads were considered. Costs evaluation was done, showing to be most obvious area of improvement while implementing optimization process in the factory. Pre / post weld treatments & NDT checks were also excluded. Introduction Generally speaking, there are two types of welding companies and their behavior is just opposites: • Large Scale. Design first, Cost Next • Small Scale. Cost First, Design Next And there are three types of Costs involved in Welding: • Direct Cost. o Raw Material Cost » Component / material to be welded
32
WELDFAB TECH TIMES | APR - MAY 2019
» Mig Wire » Shielding Gas
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ARTICLE
o Labour Cost (Normally overhead & admin cost = Welder Cost; i.e. Labor Cost = 2 x Welder’s salary) » Welders / Operators (Direct) » Over heads (Indirect) • Insurance, Allowances, safety, security etc » Admin. Expense (Indirect) • Supervisor, foreman etc o Expenses » Electric Power (Direct) Source: https://www.thefabricator.com/article/ automationrobotics/analyze-your-arc-welding-cost
» Welding machine, Depreciation etc (Indirect) » Accessories & Spares (Indirect)
Indian Perspective: In this Cost distribution, for ease of calculation & understanding we exclude Cost of component, Cost of welding machine & its depreciation as fixed costs. Also, excluded accessories & spares cost which follows the company environment, if process is optimized, this cost is also optimized. After that we can sum up mainly four categories of weld cost:
Although, Indian labor is quite economical compared to its
• Mig Wire
counterparts in US, Europe etc, still it is the single biggest cost
• Labor (= 2 x Welder salary)
contributor in welding operation which is most neglected part in
• Gas
most of Indian metal fabrication companies.
• Power
Management Perspective: Welder perception: “If little is Good, bigger is Better” Is this true for weld bead ?
Weld cost equation: TWC = MC + GC + LC + EPC Where;
TWC = Total weld Cost MC = Mig wire cost GC = Gas cost LC = Labor & overhead cost EPC = Electrical Power Cost
Think & think twice before planning your cost reduction strategy, would you like to actually save or would like to be ‘penny wise
Global Perspective:
pound foolish’
Case: • 3 welders at 3 different companies • 5 meter of 5 mm fillet weld per welded part • 250 amps & 26 Volts as per WPS
Cost basis: Source: Airgas USA (Although Equipment Cost is included in this case, and since it’s only 4%, if excluded it will not change much of the overall cost distribution.)
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• Cost calculation in each case is extrapolated for monthly basis • working days in a month is taken as 25 • Wire price is considered to be ~ 90/kg
APR - MAY 2019 | WELDFAB TECH TIMES
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ARTICLE
it is actually because of variations from company to company e.g. welder behavior, machine performance, company environment etc.
Analysis: Situation / shop floor environment
Wire + Labor (A)
Gas + Power (B)
Cost Distribution (A) vs (B)
Welder “A”
70 k
12 k
85 :15
Welder “B”
114 k
16 k
88 : 12
Welder “C”
302 k
29 k
91 : 9
Conclusion: • Electrical Power price is considered as ~ 10/unit
Having SOP, WPS etc is good but not sufficient, its implementation
• Gas Price is estimated as ~ 65/m3
varies company to company and welder to welder and thus
• Gas used is ARCAL 5 and the flow rate is 16.5 LPM
variation in performance of company. An inefficient operation
• Workers wage including all direct & indirect expenses is considered as ~125/hr
not only creates “hidden factory” but the losses tend to increase exponentially and major cost centre (wire + Labor) not only dominates inside the “hidden factory” also but further increases
Welder “A”
overall cost share of itself i.e. 85:15 to 91:9.
Wire
40k
Gas
6k
Labor
30k
Power
6k
Total
70k
Total
12k
And minor Cost centre (Gas + Power) is automatically optimized if one optimizes major cost centre, i.e. if (for a given job) welding travel speed is increased so time of weld has reduced. This leads to reduced power & gas cost (gas flow & power consumption will occur for that particular welding time when ARC
• Follows WPS – 250 amps & 26 V (5 Kg / hr) • 45% arc-on time
was ON) however MIG Wire consumption will remain same as per
• Completes 5 meter of 5 mm fillet weld in 8 hours
job demand Moreover the other gain will be available labor time
• Welding Costs:
which can be utilised by welding extra jobs. Hence, a little focus on productivity leads to all around savings in any welding shop.
Welder “B”
Air Liquide as an expert solution provider can add value to
Wire
46k
Gas
8k
Labor
54k
Power
8k
Total
114k
Total
16k
the customer process by either “Weld Efficiency Analysis” - a comprehensive audit program with efficiency as the main theme or “Unlocking Hidden Cost of welding” - A dedicated programme focusing on cost optimization in weld. Investments in such
• Welds made at 225 amps 24V (4.0 Kg / hr)
programs will not only improve the aesthetic & ease of working but
• 35% arc-on time
the ROI for these investments are very fast, most of the time it will
• Complete 5 meter of 6 fillet weld in 14.5 hours
pay off within few months.
• Welding Costs: Note: Two cost centres indices may change slightly for low sheet
Welder “C”
metal thicknesses and for very high thicknesses i.e. grooved joints
Wire
70k
Gas
18k
Labor
232k
Power
11k
Total
302k
Total
29k
and multi pass or multi layer welding. For grooved joints and multi pass / multi layer welding the major cost centre (Labor + MIG Wire) will be even more heavier because of the additional processes added to it e.g. groove preparations, pre & post weld treatments etc.
• Welds made at 180 amps & 19 volts (2.5 Kg / hr)
34
• 20% arc-on time
References:
• Complete 5 meter of 8 mm fillet weld in 62 hours
Ref.1: Unlocking hidden cost of welding; Airgas USA.
• Welding Costs:
Ref.2: https://www.thefabricator.com/article/automationrobotics/
Note: variations in parameters and fillet size is not a planned one,
analyze-your-arc-welding-cost.
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
ARTICLE
Plate Edge Beveling Processes & the advantages of Automated Mechanized Cold Beveling due to other factors as productivity, limited accuracy, and higher indirect costs. Most commonly used Bevelling options are shearing and Milling processes (Non Thermal processes). Basically, three types of bevellers are
P
late edge beveling is one of the
the selection of either of these processes. Milling inserts are quite effective Bevelling tool at a reasonable price. In this type only inserts need to be changed which works out to be quite
and automatic ones.
economical. However, in the shearing type of machines, the complete cutter
types, milling process is the most
needs to be changed which works out to
preferred one as it offers ease of
be very expensive as far as running cost
operation and economy. These are
is concerned; additionally inventory cost
good for profile bevels, smaller jobs and
also goes up considerably.
radius bevels too. These come handy for small size pipe bevels also.
very important processes in the
For large plate bevels, shearing and
metal fabrication industry. For
The automatic cold Bevelling process offers some very important benefits, Viz, A. Elimination of HAZ: Ensures the weld
Milling both options are used. However,
joint strength since the micro structure
a better quality fabrication, welding
the latest trend is to use milling process
remains unchanged around beveled
plays vital role and the correct and
as it offers distinct cost benefits, gives
edge. The cold beveling eleminates the
accurate beveling is the first step towards
best smooth bevelled surface without
heat input andconsequently thermal
obtaining the best welds. We are going to
any marks, dead accurate bevel angles
stresses and improves the weldability.
study various beveling process options
and consistent root face besides big
and their comparative advantages and
range of continuously variable bevel
B. Accurate bevel angles: Ensures
disadvantages in this paper.
angles.
optimum weld metal deposition.
There are various process options for
The milling type bevellers are preferred
Reduced heat input, which ensures
Bevelling such as,
since these can be used on practically all
minimum distortion. Further, it saves on
1. Oxy Fuel bevelling.
the materials including weldox/hardox,
weld metal deposition as every degree
2. Nibbling
SS, low and high alloys including super
increase in the bevel angle, increases
3. Grinding
alloys like inconel, hastalloy and even
the molten metal deposition by about
4. Shearing
armoured steels, aluminium and range
12-20%. This not only increase the direct
5. Milling
of carbon steels..
costs for welding consumables but also
However, milling and shearing
36
The economic considerations in terms of cost of the tool plays important role in
available. Hand held, Table top models For hand held and bench mounted
Rajiv Deshmukh, Technical Director, Mehta Sanghvi & Co
based on the material composition.
adds up indirect fixed and variable costs like power, manpower etc..
The first process is thermal process
processes have their own advantages and
and usually creates Heat Affected Zone
limitations. These are to be considered
(HAZ). Therefore, depending on weld
based on the mechanical properties
C. Accurate and consistent root
joint serviceability and the material
of the material to be bevelled, the
face over the entire length of bevel.
composition, it is cautiously used.
bevel angles needed and the bevelling
This ensures the correct fit-ups most
However, it's use is now tapering down
environment. Also, the Bevelling speeds
important for automated welding which
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
ARTICLE
needs to have consistent root gap and
The shearing machines also run a risk
always chances of reduction in accuracy
no mismatch. The success of welding
of higher maintenance cost due to the
and hence the total included angle may
automation largely depends upon the
possibility of breaking of cutter or else of
increase resulting in extra weld material
joint fit-ups.
bevel gear/gear box.
in the joint, further resulting in extra
D. Smooth bevelled surface. This avoids
shearing machine cost per meter of bevel
and other costs like grinding wheels,
possible contamination on the surface
will be about 15% higher.
gases etc. Also, increase in time and
Compared to the milling machines the
welding consumable, power, manpower
to be fused, thereby avoiding the foreign
Above guidelines are to be kept
particle entrapment causing the typical
in mind for the selecting the correct
weld defects. This also ensures uniform
beveller for your specific job. The
and homogeneous deposition giving
important factors are - Quality, speed,
b. Mechanized Bevelling: This process
good side wall fusion and eliminating the
operating cost, maintenance cost and
is suitable from 0°up to 80° and in some
hair line cracks and allied defects.
tensile strength of material and lastly
cases more. Therefore, it can cover
variety of bevel angles involved.
practically entire range of recommended
E. Minimum operator skill. These
In conclusion, milling machines are
therefore increased throughput cycle time.
Bevelling angels. Automated Bevelling
automatic Bevelling Machines are very
more cost effective over wider range
using Milling process can be used on a
easy to operate and eliminates human
of materials and thicknesses as against
wide range of plates starting from 5 mm
skills. It also reduces skilled manpower
shearing machines which work betterin
to 200 mm, although the general range
cost.
the limited range of thicknesses and are
is 8 to 100 mm. By extending the bevel
generally good up to mid level tensile
angle range up to 90° the automatic
strength plates.
beveling by milling process offers the
However, speed and finish plays important role in making a choice of shearing OR milling process. One can get higher speeds by using
Few points of comparison between
decladding option which can be very
Thermal Bevelling and cold mechanized
useful for large and thick cladded plates,
Bevelling using milling process.
used in heavy fabrication for critical and super critical applications such as
shearing process but the costs are very high. Shearing is generally used
1. Applicability
reactor vessels, heavy machine building,
effectively for plate thicknesses up to
a. Thermal Process (oxy fuel cutting)
super critical thermal power and atomic
max 40 mm in multiple passes. Beyond
This process is not suitable for special
power stations, armoured vehicles etc,
these thicknesses milling certainly is a
alloys, high tensile steels and other
etc..
cost effective method. Besides, generally
thermal sensitive materials, as it will
it can be used on almost all metals as
create a HAZ which changes the grain
consistent root face (land) and
seen in the foregoing paragraph.
structure. Therefore, applying thermal
mirror finished smooth bevelled
A typical example based on
Bevelling has to be done very carefully
surface. Therefore, the joint fit ups
and selectively.
are exceedingly good, avoid gaps and
computation of all direct working costs
It offers very accurate bevel angels,
mismatches and such fit ups are best for
like tool cost and power cost on a specific type of materials for milling process
b. Mechanized Bevelling: The
automated welding. The weld quality
shows the approximate Bevelling cost per
automated cold Bevelling process by
and aesthetics is best.
meter is about Rs15 to Rs. 25 per meter
milling process is suitable for almost all
going from low tensile to high tensile
materials including high tensile steels,
welding consumables and other costs
materials. Higher the tensile, higher the
super alloys, titanium and other sensitive
are eliminated thereby making it cost
cost. Also higher the thickness, higher
materials as well. It does not alter
effective and fast process, not to forget
the cost but comparatively less than
metallurgy of the parent material and
very clean process as well.
shearing process.
therefore it's very safe.
Extra and unwarranted costs of
3. Bevel Speed
This is the reason that for higher thicknesses milling type bevellers are
2. Range of bevel angles
a. Thermal Process: Speeds are limited
better; offering benefits of optimum
a. Thermal Process: It is best suited for
as any increase in speeds beyond a
speed and cost.
angels up to 45°. In angels >45° there are
recommended speed will affect the
www.weldfabtechtimes.com
APR - MAY 2019 | WELDFAB TECH TIMES
37
ARTICLE
quality of bevel. It will also need extra
cutting), accuracy of angle, indirect costs
obviously therefore the mechanized
heat input which will be detrimental to
of extra weldment, extra consumables,
Bevelling is a preferred option.
the plate being beveled as it will create
gas etc.
Conclusion
bigger HAZ. b. Mechanized Bevelling: Direct costs
In conclusion we can say that cold
b. Mechanized Bevelling: This is high
of inserts and nominal cost of power
mechanized Bevelling is faster, cleaner,
speed bevel process. This does not get
are involved. Most indirect costs due
reliable and easy to handle process as
restricted by manual operator skills
to factors as explained in thermal
compared to thermal Bevelling.
or any other factors. The bevel speed
Bevelling are avoided. Therefore, it's an
remains consistent and can be adjusted
economical process. The cutting costs
Cold Mechanized Bevelling therefore
for optimum output depending on the
by this method compared to thermal
is considered most acceptable process
material being bevelled. Usually, max
cutting are lower by about 15-40%
for ensuring higher productivity,
speeds up to 2.6 to 3m / min can be
depending on various operating factors
improved quality at an optimum cost.
obtained depending upon the bevel
already explained.
In cold beveling processes shearing and
process chosen.
38
milling are the options and milling is
5. Productivity
a better option for quality, workability
4. Cost of Bevelling
a. Thermal Process: Considering the
over a wide range of materials, higher
a. Thermal Bevelling: Basic cutting cost
factors stated above, the productivity
thicknesses, wider choice of continuously
constitutes of manpower, gases, grinding
of thermal Bevelling is lower compared
variable bevel angles (0°-80°) and choice
wheels, cutting nozzles, grinding, two
to mechanized Bevelling by about 20-
of beveling for all types of bevel preps
operators (one each for grinding and
45% based on all the operating factors,
including J bevels..
WELDFAB TECH TIMES | APR - MAY 2019
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CASE STUDY
Karish & Tanin â&#x20AC;&#x201C; A Transformational Project in Israel
E
nergean Israel is the Operator of the Karish and Tanin leases, offshore Israel. The fields are
world class assets with 2.2 TCF of natural gas and 31.8 million barrels of light hydrocarbon liquids independently audited 2P reserves plus 5.4 BCM of gas and 1.0 mmbls of liquids 2C resources. Moreover, NSAI has audited 2.94 TCF of gas plus 78.8 mmbls of liquids unrisked prospective resources.
Development According to a CPR produced by NSAI in June 2018, the Karish Field contains 282.2 mmboe 2P reserves plus 34.7
40
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
CASE STUDY
mmboe 2C resources (70% net to
THE FIELD
upthrow side of a large down-to-the-
Energean).
The Karish and Tanin fields,
north fault and is defined by 3D seismic
approximately 40 km apart, are located
data (2009 and 2010 Noble surveys). The
Decision for the development project
in the north of Israel’s exclusive
Karish main field was evaluated by Noble
in March 2018, after having signed 12
economic zone (EEZ).
in 2013 using a single discovery well
Energean made Final Investment
Gas Sales and Purchase Agreements for
Both fields are part of the prolific Early
(“Karish-1”) which was drilled by Noble
4,6 BCM in total annually and secured
Miocene Tamar Sands play. The fields
to a depth of approximately 4,800m (true
financing for the project. The Karish
are located north of the Tamar field, in
vertical depth subsea (“TVDSS”)). The
main field will be the first asset to be
water depths exceeding 1,700 metres.
discovered hydrocarbons within the
developed in the Karish and Tanin
Karish and Tanin Leases are contained
blocks by the Group. Karish was selected
with the Early Miocene submarine fan
as the initial development as it is the
deposits of the Tamar Sands. Seismic
largest discovery, is expected to provide
data further suggests continuity of
the highest yield of liquid per volume
the main Miocene sands between the
of produced gas and is the closest
Leviathan, Tanin and Karish fields. The Tamar Sands are further
discovery to shore. The assets required
subdivided into more detailed reservoir
to develop this field will be installed and commissioned by early 2021 with the
The Karish main field, located within
units (A-D Sands, with A being
intention of introducing a second source
the Karish lease, was discovered in 2013
stratigraphically the youngest). The C
of gas supply into the Israeli market as
and is located 25km northeast of the
Sands at Karish are approximately 130m
soon as practicable.
currently-producing Tamar field. The
TST and are interpreted to be extensive
Karish main field is approximately 16km2
across the entire structure. The fluid in
sum EPCIC Contract. Stena Drilling has
with a maximum estimated hydrocarbon
the Karish C reservoir is substantially
been awarded the contract to drill three
column of 300 to 400m.
richer than that discovered in the other
TechnipFMC has been awarded a lump
development wells plus optional wells
The Levantine Basin, in which the
Levantine basin fields such as Tanin,
into the Karish discovery during 2019.
Karish and Tanin assets are located,
Tamar and Leviathan. The B sands at
contains up to 10,000m of Mesozoic and
Karish, while thinly bedded, can be
both the Karish and Tanin fields using
Cenozoic rocks above a rifted Triassic-
identified on the available image logs.
an FPSO (Floating Production Storage
Lower Jurassic terrain. The northern
Offloading) that will be installed 90 km
boundary of the Levantine Basin is
and well understood as it is analogous
offshore, making it the first FPSO ever to
defined by Cyprus and the Larnaca
to the reservoir sands at Tamar and
operate in the Eastern Mediterranean.
Thrust Zone, and its northwestern
Leviathan and the 3D seismic data
The FPSO will have a gas treatment
margin by the Eratosthenes Seamount.
available is of excellent quality.
capacity of 800 MMscf/day (8 BCM/per
The Nile Delta Cone and the East
annum) and liquids storage capacity of
Mediterranean coast define its
amplitude anomaly associated with the C
800,000 bbls, which the Company believes
southwestern and eastern margins.
sands has been identified. This anomaly
The Company has decided to develop
provides a flexible infrastructure solution
The pressure volume-temperature
The reservoir at Karish is well defined
Within the Karish field a seismic
was tested by Karish-1, and other similar
and, potentially the scope to expand
models carried out in Karish demonstrate
anomalies have been observed in the
output for potential additional projects.
normal temperature and pressure
Karish North Upthrown prospect and the
for the depth of the reservoir. The
Karish Northeast prospect
First steel was cut on the FPSE in
NSAI CPR (June 2018) certified
Cosco yard, in Zhousan, China on
field has strong vertical and lateral
November 26, 2018. Keel laying took
connectivity with faulting not expected
2.497 TCF of gas plus 39 mmbls of
place successfully on 13th April 2019.
to compartmentalise and a single gas-
light hydrocarbon liquids un-risked
water contact has been evidenced by the
prospective resources (70% net to
(First Phase) is estimated at US$1.6
seismic available for the Karish main field.
Energean). Energean has decided to drill
billion. Production from the field is
The Karish asset itself is a large two-
Capex for the Karish development
expected to commence in Q1 2021.
www.weldfabtechtimes.com
way closure that sits on the southern
an exploration well in Karish North in March 2019.
APR - MAY 2019 | WELDFAB TECH TIMES
41
CASE STUDY
The onshore pipeline segment and up to 10 km ashore, will form part of the national transmission system, will be operated by INGL and will provide the connection possibility offshore to additional suppliers. Therefore, the actual connection point to the transmission system will be carried out offshore, around 10 km ashore. At this connection point, valves will be installed on the main offshore pipeline, which will enable the connection of future
Figure 9 â&#x20AC;&#x201C; FPSO â&#x20AC;&#x201C; General Arrays
suppliers without interruption to the
Offshore/onshore development mix
control systems will be installed, that will
ongoing operation of the system, which
According to TAMA 37/H section
work in constant contact with the INGL
is proposed in accordance with the
6.2, priority should be given in the
and the national transmission system,
Government's decision as a result of the
development plan to the location of
and will enable control over pressure
desire to reduce future pipeline work and
offshore treatment facilities over onshore
and gas quantities when the pipeline
additional shorelines by other suppliers.
installations. According to this section,
reaches the shore and connects to the
prior to making a decision regarding
transmission system.
The coastal facilities will include an underground pipeline, an underground
the development plan, the Petroleum Commissioner will summit the proposed development mix to the National Council for approval. The development plan includes production and treatment facilities in the deep sea that will be located close to the Karish gas reservoir, about 90 km ashore, and includes full treatment facilities on Floating Production Storage and Offloading (FPSO), which will include gas treatment facilities, condensate separation, as well as operational storage volumes for condensate. The storage volumes will allow continuous gas production while separating the condensate, storing it and unloading it from the storage tanks on the FPSO to a shipping vessel to transport it to the end consumer. The natural gas will undergo full treatment on the platform and from there, it will be transmitted underground until the pipeline will be connected to the national transmission system. On the FPSO, electric compressors, flow meters and pressure and flow
42
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
CASE STUDY
station (CVS) about 300m from the
production facilities and a pipeline
coastline and a gas station (PRMS) in
system for collection and delivery to the
Production wells, main wells, manifolds and subsea pipelines
favor of the connection to the existing
treatment facility, offshore treatment
Karish development includes at the first
transmission system close to Ma'ayan
and storage systems (FPSO) and a
phase, three production wells. Additional
Zvi sewage treatment plant.
pipeline system of natural gas to connect
drillings will be carried out in accordance
to the national transmission system.
with the surveys’ findings and the actual
The components of the gas station – PRMS include end fittings for the
production quantities. The system
pipeline, valves and pressure and flow
Components of the offshore system
includes a wellhead and a marine
control systems as well as operational
The main components of the offshore
pipeline connecting each wellhead to
flow meters. A larger breakdown of
system, with an emphasis on a Karish
the manifold. From the manifold a 10”
this station appears in the System
field, are located about 90 kilometers
diameter pipe ring is planned for the
Description section further, in
offshore and at a water depth of about
flow of all the production products (gas,
this document. In conclusion, the
1,700 meters. The FPSO is located above
condensate and water) to the FPSO
construction of the treatment system
the Karish field, which is planned for
for further separation and treatment.
on a floating platform close to the
development in the first stage. The FPSO
The development of Tanin, around
production wells avoid abolishes the
will be anchored to the seabed through
40 kilometers southwest of Karish will
need for additional treatment facilities
anchors and will remain in place for
include two production wells, a manifold
and simplifies the production process.
development and production from the
and a pipe ring with a diameter of 12”
The development mix does not include
Tanin field. The main components of the
to FPSO. The drilling array is presented
treatment facilities on the territorial area
system are:
in the following two figures. Additional
of the State of Israel, neither offshore nor
• Production wells, main wells,
drilling will be carried out as needed
onshore. The gas that will flow to the shore will be launched as a
manifolds and subsea pipelines. • FPSO – an offshore production,
final product at the INGL's national
treatment and storage facility, as well
transmission system.
as condensate loading systems on transport vessels.
according to the actual production rates and the system’s development.
Floating Production Storage and Offloading (FPSO)
Description of the system
• Communication and control systems.
This is a floating platform anchored at
Most of the components of the system
• Transmission pipeline of natural gas
the seabed by 14 anchors. The length
are offshore. The system includes subsea
www.weldfabtechtimes.com
from the FPSO ashore.
of the platform is about 230 meters
APR - MAY 2019 | WELDFAB TECH TIMES
43
CASE STUDY
pipe in deep water. Approximately 15 kilometers from the shore, the diameter will be increased to 30-inch in order to enable the connection of future suppliers and to increase the transmission capacity. The pipelines will be wrapped in polypropylene and in a shallow concrete shell in shallow water up to a depth of 400 meters. The pipeline will be planted 1.2 meters below the seabed from 60-meter depth and until the shore. The connection between the FPSO and the pipeline will be carried out by means of 16 risers. Between the connection of the risers to the deep water pipeline an SSIV remote control valve will be installed as well as a facility for conductors transfer in the pipeline and the width is about 50 meters.
• Treatment and stabilization of the condensate and its storage in the
The route of the pipeline passes through
approximately 160,000 cubic meters
storage tanks located in the FPSO's
the northern part of the pipeline corridor
(about 1,000,000 barrels), and the
abdomen
according to TAMA 37/H and north of
maximum number of workers is about
• Separation of MEG from the water by
the Leviathan pipeline and the existing
72. In practice, it is estimated that there
boiling and evaporation of the water
INGL pipeline on landing at Dor Beach.
will be about 35 production workers
and returning the MEG (in a closed
On the rise to the continental shelf, the
circulation system) to the process.
pipeline passes through the northern
and about 15 security guards. The FPSO will be designed to treat approximately
• Storage of excess production and
part of the Dor interference. Three
4 billion cubic meters of gas per year
handling before discharge into the
communication lines will be shared
(BCM/y), and with the ability of a simple
sea.
during the laying of the pipeline. The location and route of the crossing
expansion to upgrade its capacity to about 8 billion cubic meters of gas a year.
It should be noted that due to the
will be determined during the detailed
On the FPSO, the gas is separated from
proximity of the FPSO to the production
planning and in coordination with
the liquid and undergoes treatment, flow
wells, there is no need for MEG injection
the relevant infrastructure elements.
and pressure control and counting prior
at the wellhead. This greatly simplifies
About 10 kilometers from the shore
its discharge onshore. Before reducing
the treatment of MEG and water on
will be installed on the pipeline from
the gas pressure on the FPSO, a MEG
the FPSO. The MEG is injected after
marine bodies, connection points for
chemical is injected to prevent hydration
separation of the initial production
future suppliers. This installation is
and freezing. The fluid separation that
and condensate at the FPSO, prior to
designed to reduce the need to another
is separated from the gas is transferred
reducing the gas pressure.
coast crossing in the future if there are
to a parallel dedicated treatment system where the following main actions are
Here are some technical details, simulations and views of the FPSO.
• Water and condensate separation and treatment system of produced water. • Condensate separation from the water and MEG (Mono Ethylene Glycol)
WELDFAB TECH TIMES | APR - MAY 2019
additional suppliers. The connection point to the national transmission system will be carried out offshore,
performed:
44
for maintenance and control purposes.
The total volume of liquids storage is
Natural gas pipeline from the FPSO ashore
around 10 kilometers ashore. The coastal
A 90-km-long transmission pipeline
HDD horizontal drilling about 50m north
to the coast, a 24-inch diameter steel
of the Leviathan pipeline crossing.
crossing will be carried out by means of
www.weldfabtechtimes.com
40,000
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INTERVIEW
QUAH Beng Chieh, Head of Marketing (Asia Pacific), FARO Technologies
FARO’s portfolio of 3D measurement provides turnkey solutions for manual & automated inspection and analysis. 46
WELDFAB TECH TIMES | APR - MAY 2019
Q1. Could you brief us about FARO? Founded in 1981, FARO is the world’s most trusted source for 3D measurement, imaging and realization technology. The company develops and manufactures leading edge solutions that enable highprecision 3D capture, measurement and analysis across a variety of industries including manufacturing, construction, engineering, and public safety.
Q2. Can you share about details on the functionality of FARO technologies especially into the welding and fabrication segment? FARO’s full portfolio of 3D measurement
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INTERVIEW
hardware and software provides turnkey solutions for manual and automated
by a single computer. Apart from that, our latest
welding accessories, equipment, tables, and fixtures; complete with hydraulics,
inspection and actionable analysis
FARO®Quantum series delivers
pneumatics and programmable logic
of any part, component, or final
maximum measurement performance
controller (PLC) systems. Part of Tokai’s
assembly, to streamline and maximize
and consistency for contact and
state-of-the-art manufacturing unit is
efficiencies across the manufacturing
non-contact requirements in every
a high precision, portable coordinate
process. With the improvements in tool
working environment. The welding and
measurement machine (CMM) – the
manufacturing standards and testing
fabrication industry can rely on the
FaroArm. The measurement arm allows
methods; highly accurate and reliable
Quantum for inspection and quality
Tokai to confidently verify that its
inspection checks in almost every part
control, as well as added capabilities
products are within tolerance.
of the process has become essential,
like point cloud comparison with CAD,
including the welding and fabrication
rapid prototyping, reverse engineering,
and user-friendliness increased the
industry. Some applications that the
and 3D modeling of free-form surfaces.
productivity for Tokai in multiple
welding and fabrication segment might
In addition, the FARO® TracerM3D laser
ways. For instance, having replaced
find useful include dimensional analysis,
projection technology can be used within
traditional hand tools with the FaroArm,
CAD-based inspection, non-contact
the welding and fabrication industry to
Tokai achieves higher accuracy levels
inspection, and alignment.
aid with part positioning and assembly,
in its inspections and dimensional
as well as visual verification.
calculations, providing tighter
An example of a business that yielded
The FaroArm’s high levels of precision
tolerances on their jigs and fixtures.
better welding performance with FARO’s
In addition, as a portable device, the
FARO’s support, the company managed
Q4. What is the role of FARO® Focus Laser Scanner into metal, welding, and fabrication industry?
to enhance the precision and stability
The FARO Focus Laser Scanner Series
harsh conditions yet still providing
of its welding and assembly equipment
enables the users to capture accurate
precision measurement results. This is
systems, as well as improve the overall
measurements of complex objects and
in contrast with fixed CMMs that require
precision of its production line and
buildings in a quick, straightforward
a controlled environment in order to
conveyor systems.
manner. For metal, welding, and
function accurately.
solutions is MH Robot & Automation Co. Ltd, a Chinese systems integrator. With
®
arm can be deployed right where production takes place, withstanding
fabrication applications, the Focus
Q3. Any specific technology designed by FARO for the welding and fabrication industry?
Laser Scanner offers highly accurate forging inspections, allowing users to
Q6. Can you please elaborate on FARO® Freestyle3D Scanner and FARO® QuantumS FaroArm®?
Several FARO solutions are well suited
improve the quality of their products
The FARO® Freestyle3D Scanner is
for the 3D measurement requirements
and boost productivity at any stage
another solution suitable for metal
within the welding and fabrication
in a manufacturing process. FARO’s
scanning. It is a high-precision handheld
industry. For example, the FARO® Cobalt
solutions — including the Cobalt Array
scanner that quickly and reliably
Array Imager is a metrology-grade non-
Imager, Quantum series ScanArms,
documents the objects in 3D and
contact scanner equipped with dedicated
and TracerM 3D laser projectors—help
creates high-definition point clouds.
on-board processors – an industry first.
businesses improve the quality of the
The handheld 3D scanner maximizes
The smart sensor allows unique multi-
product during the inspection process,
user’s productivity — offering fast data
imager array configurations, enabling
which leads to a reduction in rework and
acquisition, real-time visualization,
industrial manufacturers to significantly
increased throughput and ROI.
and the largest scan volume on the
non-contact scanning even for hot
market.
improve productivity and operations in a
the handheld scanner is highly mobile
array configurations virtually anywhere
Q5. Any recent project wherein the FARO technology has been used at its best?
in a manufacturing process – all
Tokai Engineering (India) is a specialist
scans in tight and hard-to-reach areas
scanning simultaneously and controlled
toolmaker that supplies a wide variety of
or around corners where there is limited
way never before possible. An unlimited number of 3D imagers can be placed in
www.weldfabtechtimes.com
With its lightweight carbon fiber body, and it boasts the ability to perform
APR - MAY 2019 | WELDFAB TECH TIMES
47
INTERVIEW
visibility. Equipped with a memory-
by up to 40%. Advanced wireless
with the ‘Make in India’ program
scan technology, the Freestyle3D allows
capability ensures that the reliability
firmly in place, India is reforming
users to pause and resume scanning at
of cable-free scanning and probing is
to become the third largest global
any time, and also possesses an auto
comparable to scanning and probing
economy by 2030. For these reasons,
leveling function for greater precision in
with a cable attachment. Furthermore,
we continue to see India as a key part
measurement.
the availability of dual, hot swappable
of FARO’s business, and our three
batteries supports continuous operation
offices in New Delhi (India head office),
anywhere.
Chennai, and Pune are prepared to
Earlier this year, we introduced the FARO QuantumS FaroArm — the ®
offer comprehensive support to our
latest member of our best-selling
customers in this region.
offering best-in-class performance and
Q6. FARO is one of the leading players in the 3D measurement industry. How do you think the global 3D market scenario is doing currently?
durability, enhanced ergonomics, and
According to Report Linker, the 3D
are adopting higher standards and
extreme portability.
metrology market is forecasted to grow
demanding greater precision and
from ~$11.3 billion in 2017 to ~$17.0
speed in their operations, especially
-12:2016 certification (the most rigorous
billion by 2023, at a compound annual
for inspections and quality checks. To
international measurement quality
growth rate (CAGR) of 7.10 per cent
support customers in this regard, FARO
standard in existence) and International
between 2017 and 2023. Asia Pacific
continues to invest in its R&D activities
Electrical Commission IEC 60068 -2
continues to grow at a maximal rate,
to develop even more innovative
standards for shock, vibration and
which is likely due to the high economic
and high performing measurement
temperature stress relief. Apart from its
increase in countries such as China and
technologies.
exceptional ruggedness, the QuantumS
India. The 3D measurement industry
We also frequently gather feedback
also delivers maximum measurement
is a competitive market and requires
from customers at trade events – which
consistency and improves end-user
constant innovation to stay ahead of the
directs our R&D projects. India is an
productivity by capturing more data in
competition. As a result, emphasis on
important market to FARO, and we
richer detail with the FAROBluTM Laser
research and develop is paramount, and
remain committed to the manufacturers
Line Probe HD.
is the very core of FARO’s existence and
here, supporting them with our
it is one of our top priorities.
advanced metrology technologies.
Q8. Your future plans?
the operator. This dramatic increase in
Q7. How has been the Indian market for FARO? What are the major challenges and how do you overcome them?
both comfort and portability increases
India is one of the fastest growing
in moving up the technology ladder
operator productivity by facilitating
economies in Asia. With the India
and improving their productivity and
continuous use over extended periods
government pushing for infrastructure
efficiency. Our R&D team will continue
during the workday.
investments, the immediate future
to work on innovating new solutions to
product line — to the market globally. With this launch, FARO extended its leadership in value and performance for manufacturing inspections by
The QuantumS passed both ISO 10360
Equipped with advanced man-
We observe that the Indian manufacturing industry is maturing, and companies have become more discerning. Increasingly, manufacturers
machine interface and enhanced ergonomics, the QuantumS is a virtual extension of the human arm and enables up to 15% less effort and fatigue for
Last but not least, the QuantumS
48
In 2018, FARO will continue to introduce high-precision portable solutions to more customers, so as to assist them
is bright for companies operating
address industrial manufacturers’ real,
advances the concept of true portability
in the industrial manufacturing and
felt needs, and we will launch them as
and ensures additional floor reach
construction segments. Additionally,
soon as they are ready.
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
Tekno AD-2019-21-28.5.pdf
C
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MY
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3/26/19
3:25 PM
PRODUCTS UPDATE
X3 MIG WELDER â&#x20AC;&#x201C; Tough and Reliable panel locking, hard ignition, hot stop, pre-gas and post gas.Creep Startfunction prevents disturbances at the start of the weld by slowing down the wire feed speed just before the arc ignites. Burn Backfunction prevents
(a) Ilhar Ul Hassan M S, Solution Engineer, Kemppi India Pvt Ltd
(b)
(c)
Control Panels (a) Power Source (b) WF 300 (c) F10
filler wire from sticking to the work piece at the end of weld, making it easier to continue welding. Hard Ignition makes
wire feed mechanism and
offers precise adjustment for
the arc ignition stronger by
3 MIG Welder
wire spool while F10is an
voltage and wire feed speed.
increasing welding voltage
is a tough and
open type feeder. Kemppi
Wire inch function isalso
at the start of the weld and
reliable inverter-
X
gas-cooled welding torch
included as standard in the
Hot Stopfunction makes tack
based MIG/MAG welding
available in different length
panel. In the power source a
welding easier and faster.
machine from Kemppi, the
can be selected as per
110-volt auxiliary
Panel lock feature
Finnish manufacturer of
the requirement. WF300
voltage supply
allows locking of
quality welding equipment.
and F10 wire feederscan
is available for
the all welding
Kemppiâ&#x20AC;&#x2122;sIGBT inverter
accommodatea wire spool of
CO2 shielding
parameters
technologyreduces energy
maximum 300mm diameter.
gas heater. The
ensuring
costs and brings profitability.
It accepts a wide range of filler
ergonomically
consistent welding
Its delivers outstanding arc
wire diameters from 0.8 to 1.6
positioned handles
throughout the
stability and weld quality
mm for solid and cored wire.
and light weight
production.
with a gain in productivityby
The user interface is
make it easily
X3 MIG Welder
bringing down spatter levels
designed for quick and easy
portable.Optional
is a set of high-
which write off the post
setting. X3 power source has a
wheel sets and
quality welding
weld grinding operation.
large back lit LCD display that
undercarriage
equipment that
This is achieved even with
clearly presents the pre-set
available further
inexpensive CO2 shielding gas.
wire feed speed and welding
facilitate the transfer of the
on even in the toughest
voltage parameters. The
machine.
situations. When working
X3 MIG welder power source comes in two power
control panel in wire feeder
Optimum arc dynamics
you can rely
in tough conditions at a
levels, 400A and 500Awith a
can be setsimplyby the
construction site, shipyard,
rated duty cycle of 60%. At
press of a button in the
metal fabrication workshop,
100% duty cycle they deliver
power source for Argon/
or doing maintenance
310A and 390A respectively.
CO2 mixture gas or pure CO2,
welding on a pipeline site in
Both the models support
ensuring you get the best
extreme temperatures, you
carbon arc gouging.Euro
welding characteristics for
need a companion that you
torch connectable X3 wire
the shielding gas used. Other
can fully trust on.X3 MIG
feedersare durable and
functions included are crater
Welder is surely a trustworthy
ensure undisturbed and
fill, creep start, burn back,
partner for a serious welder.
consistent wire feeding. WF300 wire feeder is a closed feeder protecting both
50
WELDFAB TECH TIMES | APR - MAY 2019
For More Info: Website: www.kemppi.com
www.weldfabtechtimes.com
PRODUCTS UPDATE
WELDLOGIC AWS-200 Computer Controlled G.T.A. Welding System “Fully Integrated” for Automatic Welding
T
he AWS-200 Advanced
optically isolated I/O 8
• Synchronized current,
Welding System is a
voltage, travel and wire, if
microprocessor-based
• Remote pendant
desired
system designed and built
• Torch and back up gas
to provide a high quality,
flow meters, valves and
economically priced, very
• Programmable operator
welding system. This is a Dual use system i.e. it can be used for TIG
additional special feature • Can be used for Plasma
overrides 0 - 100%
Welding, by integrating a
• Minimal operator skill
Plasma Console into the system
required
Welding as well as for Plasma
has expansion for 11 buttons
gas fault sensors
accurate and repeatable, total
inputs & 8 outputs
• Manually selected or
Welding. The AWS-200 is a
automated multi-pass
Higher current capacity
highly refined field proven
capability
models, AWS-400 and AWS-
product. Its software base and
800, are also available in the
• Detects and indicates
product range.
hardware are the end result
faults, i.e., gas flow
of 20+ years of designing and
temperature, voltage, etc.
manufacturing precision
Features:
automatic computer
• Close Loop Servo Control
remote control & weld
UK and sold, installed and
program selector
serviced in India by M/s.
of Weld Current, Travel
systems.
Speed, Arc Distance
• Programmable high
Control & Wire Feed
frequency protected
supply allows options for a
manufactured by Weldlogic
• Very operator friendly
controlled G.T.A. welding This precision D.C. power
These systems are
Weldwell Speciality Pvt. Ltd., Mumbai.
• Internal memory holds
travel rate servo, arc distance
up to 60 multi-level
control and wire feed servo all
multi-function weld
in a single, rugged modular
schedules key switch
enclosure.
protected
For More Info: Mr. Navin Badlani Mob: +91 93235 05918 Email: nivek@weldwell.com
Welding Electrode Machine by Logos Weld Products Electrode Machine.
various specifications as
Features:
This electrode
per the requirements of
• Hassle free operation
machine is known
customers. We are giving
• Longer service life
for its trouble free
this electrode machine to
• Rigid construction
performance for
customers at very affordable
longer period of time
price within a stipulated
and globally accepted
time frame.
Specifications:
manufacturing
I
techniques at our
n order to meet the
sophisticated manufacturing
requirements of the
unit.
clients, we are providing
a wide array of Welding
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The provided electrode machine is accessible in
Model
1 Ton
2 Ton
3 Ton
5 Ton
8 Ton
Conveyor
CV 1 T
CV 2 T
CV 3 T
CV 5 T
CV 8 T
For More Info: Website: www.logosweldproducts.com
APR - MAY 2019 | WELDFAB TECH TIMES
51
PRODUCTS UPDATE
AL-ARM 450 F: Handheld Welding Laser Manual Welding Laser AL-ARM 450 F
T
he AL-ARM laser
welding area is augmented
the high safety requirements
system enables quick
and the process-relevant
for performance level d is
and flexible vehicle
data, such as the cross-hairs,
included.
body repairs on pores, bleed-throughs, and offset
are displayed directly.
Technical Accessories
This laser system has no
seams. In molding, you can
resonator, but instead a
weld directly in the press or
handset with automated wire
ALPHA LASER quick-
milling tool – without any
feeding for wire thicknesses
clamping system: For
setup time.
up to 0.6 mm. The wire is fed
quick and safe clamping of
• Manipulator table with
automatically. The handset
the workpiece.
The AL-ARM is different:
weighs only 1.5 kg and is
With this welding laser, the
connected to the supply unit
allowed when the handset
For two-dimensional
welding process is monitored
via a 3.5 m long energy chain.
touches the workpiece. This
representation of the
It is easy to handle and very
prevents uncontrolled laser
welding process. The 3D
through 3D visualization
• Monitor + HDMI cable:
instead of customary
flexible during operation. The
radiation emissions. The
laser protection goggles
microscope attachments.
welding seam width can be
safety concept verified by
and monitor can be
This is realized via (pass-
variably adjusted during the
TÜV for compliance with
operated simultaneously.
through) 3D laser protection
welding process.
goggles, which allow you
For More Info: Tel: +49 (0)89 890237-200 Email: laser@alphalaser.de Website: www.alphalaser.de
A lot of emphasis was
to keep an eye on the
placed on safety: Integrated
environment and the welding
workpiece detection
task at the same time. The
ensures that welding is only
Branson GVX-3HR
T
he GVX-3HR, equiped with Clean Vibration Technology,
to support high-speed,
clean welds with
automated applications
minimized particulates,
represents a new level
lift table (1070 x 600 mm)
of precision, speed, and
than traditional vibration
consistency in vibration
welders
welding. It includes all the
contaminants. • Local, rapid-response technical expertise and repair service supported
• User-friendly industrial
major options packages to
PC control with improved
by Branson’s worldwide
• Actuation: Servo
maximize performance.
operator experience
network of facilities
• Certifications: Designed to
• Servo actuation offers
•
CE, ISO, and ANSI norms
Features
reduced maintenance,
Specifications
• Improved weld quality
increased uptime, and
• Head Drive Power Rating:
and consistency through
around 35% less energy
continual feedback from
use than similar hydraulic
closed loop sensors that
machines.
ensure accuracy and repeatability • Lightning-fast cycle time
52
flash, or other visible
• Smaller footprint yet larger
• Equipped with dual-axis infrared pre-heat, for applications requiring
WELDFAB TECH TIMES | APR - MAY 2019
30 kW • Lift Table Max Speed: 500 mm/s
• Communication Protocol: CANOpen • Cooling System: Air cooled • Data Interface: USB (qty 4), Ethernet.
For More Info: Website: www.emerson.com
www.weldfabtechtimes.com
PRODUCTS UPDATE
weldCare: Finishing Chemicals Finishing Chemicals for all steps in the post-weld and surface treatment of stainless steel!
S
industrial applications.
tainless steel retains its
• Cleaner 401: Superficial
beautiful finish thanks
rust, grease and lime
to a protective layer
that forms on the surface.
deposits can occasionally
Experience the benefits of
appear on any stainless
these products:
steel surface. Cleaner 401 will eliminate these spots
Longer Lasting
with ease, restoring the
The pickling pastes and
surface and returning
sprays are highly effective
your stainless steel to its
and can be used in thinner
original finish. Cleaner
coats than many other
401 is used both for
pickling products. Thanks to
maintenance and precleaning.
the colour and consistency Paste 130: BlueOne™
recommended for
consumption – already
Pickling Paste 130 is
immersion pickling of
The products above,
treated surfaces and residues
patented worldwide and
small objects and for
BlueOne™ Pickling Paste
left after rinsing are easily
is especially intended
pickling surfaces that
130, RedOne™ Pickling
recognized. The result is
for brush pickling of
are time-consuming to
Spray 240, Pickling Bath
lower consumption per
weld seams and smaller
brush or spray pickle.
302, Cleaner 401 and
running metre of welded joint
surfaces. It offers a perfect
It can also be used for
FinishOne Passivator
or per square metre of treated
paste consistency that
circulation cleaning of
630, cover most needs
surface.
gives good adhesion
pipe systems. To optimize
and can be used for most
to difficult surfaces
the performance and the
applications. For special
and reduces the risk of
cost efficiency of the bath,
cases we have alternative
splashing.
chemical analyses are
products.
Fume reduction during pickling
• RedOne™ Pickling Spray
crucial. Here we have the
The company’s Finishing
generated during pickling
240: RedOne™ Pickling
know-how to help you.
Chemicals are made in
have a number of harmful
Spray 240 is intended for
• FinishOne Passivator 630:
effects on health and
most applications and
FinishOne Passivator 630
modern, automated process
environment. By using
is suitable for pickling
contains no nitric acid,
plant. All products have
modern pickling products
larger surfaces. It has a
is pH-neutral and can be
full traceability from raw
such as our BlueOne™
thixotropic consistency,
used at room temperature.
material to finished product,
Pickling Paste 130 and
which makes it stick to
It also improves the
which gives the total control
RedOne™ Pickling Spray 240,
the surface and hence
pickling result and
of the product quality. The
the toxic fume levels can be
facilitates the application
diminishes the risk of
quality and environmental
reduced by up to 80%.
even in difficult
discoloured surfaces after
management systems are
The toxic nitric fumes
Malmö, Sweden, in its own
positions. The product
pickling. In general it
certified according to the
It is recommend for
is specially developed to
offers good results and is
ISO 9001 and ISO 14001
Pre-Cleaning, Pickling,
reduce emissions and
suited to a wide range of
standards.
Passivation & Maintenance following Products: • BlueOne™ Pickling
54
• Alternative products:
of the products, they reduce
consumption. • Pickling Bath 302: Pickling Bath 302 is
WELDFAB TECH TIMES | APR - MAY 2019
For More Info: Website: www.voestalpine.com
www.weldfabtechtimes.com
PRODUCTS UPDATE
Making GTAW Faster : Automated GTAW (AVC, Weavers and ColdWire Feeders)
O
ne of the key
a larger area. This can help
quality welds using AVC
challenges in
take care of slight fit up
based automation system.
Automating GTAW
mismatches and capping
The joint was welded in 2
runs as well.
pass, root with filler and
is the consistency of fit up
capping pass. This system
and ovality of the work piece
Using AVC Slides we can
/ joint. As when the torch is
do root welds in Automated
replaced the existing practice
fixed and the job is rotating
GTAW. This can be coupled
of welding root with GTAW
any change in the tungsten
with Weavers, Oscillators to
and then fill-up with GMAW.
to work piece will result in
get wider weld beads along
a change in voltage. As the distance reduces the voltage reduces and if the distance increases so does the voltage.
Auto GTAW with AVC, Weaving and Cold wire feeder Setup
This AutoTig Head
with Cold / Hot Wire feeding.
consisting of AVC, Weaving,
This can bring up welding
Cold Wire Feeder can be
speeds and deposition rates
added on to any existing
for GTAW process. For
Column / Boom Setup to
Any change in voltage can
piece to maintain the same
example in Figure 1 we can
make a complete automated
result in inconsistence weld
arc voltage. Similarly when
see a 300mm dia. pipe to
GTAW welding. This can
penetration.
the work piece gets away
pipe joint made for Auxiliary
speed up the welding speeds
from the tungsten, the voltage
piping of power plant skids.
upto 150mm/min to 200mm/
Corrector is a motorized
increases from the set level,
The 8mm thick pipes were
min. With repeatable results
slide controller which helps
the motorized slide starts
welded together to get X-Ray
on quality and productivity.
maintain the same voltage
moving back towards the
by altering the arc gap. This
work piece to maintain the
ensures constant voltage,
set voltage level. The speed
constant arc gap during
at which this correction
welding. So when the work
happens can be adjusted to
piece moves closer to the
suite the welding speed and
tungsten, the arc voltage
avoid unwanted movement
reduces from the set level,
of the torch.
Automatic Voltage
the motorized slide moves upwards away from the work
Weaving or oscillating the torch setup can help cover
For More Info: Electronics Devices Worldwide Pvt Ltd Nimesh Chinoy, Marketing Director - SigmaWeld 31, Mistry Industrial Complex, Cross Road 'A', MIDC, Andheri East, Mumbai -400093, INDIA Tel: +91-22-26879215/26870318, Mobile : 9820785022 Email: nchinoy@edmail.in, sigmaweld@edmail.in URL: www.sigmaweld.com Company Presentation : http://www.youtube.com/ watch?v=9cQnMMhIDkM
FLEX-FAB robotic cells Boost your production capacity with robotic welding technology
L
incoln Electric offers a ready to use solution for robotic welding,
and options • An advanced welding equipment, POWER
key to optimize productivity,
WAVE® R450 with a large
flexibility & quality for
choice of MIG/MAG
welding applications in
processes
metal construction and
• An optimized wire feeding
manufacturing:
system with high quality
• A high performance arc
consumables
robot with several features
www.weldfabtechtimes.com
• CHECKPOINT™ software
equipment
solution to manage data and traceability
• Fixture on demand, depending on the application
• A fume extraction and filtration for a better
The advanced and affordable
environment
Flex-Fab robotic welding cells
• Assistance, service and
are the optimal solutions for
maintenance of your
small to medium size parts.
For More Info: Website: www.lincolnelectric.com
APR - MAY 2019 | WELDFAB TECH TIMES
55
WOMEN IN WELDING
Arc welding processes are our core competency, an area in which we are Germany’s largest manufacturer
Susanne Szczesny-Oßin The First Female President of German Welding Society President of the Koblenz Chamber of Industry & Commerce Chairperson of the Supervisory Board of EWM AG
Q1. Ms Szczesny-Oßing, what led you to seek a career in such a maledominated industry? After having studied business administration, how did you get into welding technology?
where they can contribute meaningfully to
another milestone, as we now cover the
the firm.
entire process chain. We offer welding
It has mainly to do with my family
As a young woman, I never thought about the industry being male-dominated,
even management consulting using the
I was mainly interested in the family-
EWM maXsolution. EWM has developed
run aspect to the company. And I was in
significantly over the years, and I am
a position to benefit from that in part,
grateful to have been a part of that with
background. I got into welding technology
as there are few women in managerial
my family members and to continue being
sort of by osmosis through our family
positions in the welding technology
part of that development.
company EWM. So it made sense to
industry in Germany.
make a career in this field. We have both
Q3. What welding technology processes have you become specialised in at EWM AG?
People basically do their job well
Q2. Could you briefly talk about some of the biggest milestones and key experiences you have had in the field of welding technology?
because they like the work and really put
When I got started at EWM, we were
Germany’s largest manufacturer. This
themselves into it, so nobody in our family
still a classic component manufacturer.
technology is deployed across the board
has ever pushed anyone into a direction
We gradually evolved into a machine
in MIG, MAG, TIG and microplasma
they were not inclined toward. On the
manufacturer, and I look at that as a
welding. Now we are concentrating
contrary, family members have been
milestone of which I was part. Then EWM
on other joining technologies as well,
supported to pursue careers wherever their
evolved further into what we are today – a
as indicated by our EWM Award, for
natural talents lie and employed in areas
full-service provider – which represents
example, which is presented entirely
engineers and managers in our family, a blend that makes us a great team capable of running EWM as a successful company.
56
consumables, intelligent welding arcs and
WELDFAB TECH TIMES | APR - MAY 2019
Arc welding processes are our core competency, an area in which we are
www.weldfabtechtimes.com
WOMEN IN WELDING
suitable for the purpose.
independently of any welding procedure.
high tolerance limits, faster control
The Award is a way to bestow recognition
technology and a long service life, to
Sometimes consulting with our
on talented young individuals active in
name a few. Our machines also meet
customers in this fashion leads to
welding process research.
high sustainability standards, are
a complete redesign of the original
manufactured using resource-saving
component to afford more economical
Q4. What would you say has been your ‘mega-project’ in the last several years?
methods and are of superior quality. 100%
operation.
EWM has successfully grown from being number of component manufacturers into
Q7. What about health and operational safety issues relevant in welding?
a mechanical engineering firm respected
These are high-priority issues at EWM.
We aim to continue being a major
throughout the industry. It has been a
With our machines, users can enjoy lower
player in the industry despite the rapid
privilege to be involved in managing
emissions as they work. Example: The
pace of market change and high-tech
business aspects of and communications
EWM forceArc puls welding process
advancement. The keys are to focus on
for this crucial process of positioning
reduces welding smoke emissions by
communicating the advantages of using
EWM as a welding technology brand,
up to 75 percent versus conventional
our products, which are becoming more
though it has certainly had its challenges.
processes for welders working with high-
apparent with the rise of digitisation,
The principal challenge in this, however,
alloy metals, such as CrNi steels.
in international markets and to keep
a company known exclusively to a small
has been to develop a range of excellent
made in Germany.
®
Health issues are also taken seriously
welding machines using our components.
within our organisation, which is why we
The work of our Research and
have a health management programme
Development department has obviously
in place. As part of this, gym membership
played a key role.
discounts, wellness offerings and courses on cooperation with various health
Q9. What big plans for the future do you have at EWM AG? We are a proud family company, and nothing should change about that.
growing as a company.
Q10. You work in a male-dominated industry. Have you ever experienced gender discrimination, and do you think that this is commonplace in the industry?
Q5. What is your most important project ongoing right now?
insurers are available.
The key objective for EWM as a welding
occur in our industry. The environment
the company’s positioning amidst a field
Q8. What challenges is the welding technology industry currently facing?
of strong competitors, who also cover
On the one hand, there are constantly
one in which I was able to earn respect
wide swathes of the overall process chain,
new materials, like high-tensile steels,
through my work and my authenticity.
in fast-paced times as technologies are
coming on the market, and, on the other
Nonetheless, I have experienced gender
becoming ever-more sophisticated.
hand, welding is being done at ever-
discrimination. I try to address such
Internal knowledge management is also
higher elevations across a spectrum
situations with composure.
an important project for us relevant to
of areas, like crane manufacturing.
that objective. What structures are to be in
Metals that were hard to weld some
place for us to pass on knowledge within
years ago now fall within the range of
the company to younger generations? In
our specialised expertise. Our work has
Q11. Is there anything you would like to tell our readers, particularly women, as a parting shot?
what ways will we leverage the possibilities
also changed in that for a long time now
I have always found authenticity to be
unlocked by digitisation, automation,
it has no longer been about selling a
beneficial, and I would recommend both
robotics and artificial intelligence?
machine or a process, but rather getting
women and men to strive for that. It also
involved with our customers, even down
helps that I have a quick wit, am thick-
Q6. What do you see as the most important characteristics of an arc welding machine in field usage?
to the design level. This means that we
skinned and won’t easily let others put me
advise our customers by looking at what
off track. And I’m able to get things done,
specifically is to be welded and which of
even without the approval of all parties
Process-reliable welding characteristics,
our machines and processes are most
concerned, in some cases.
technology leader is to further consolidate
www.weldfabtechtimes.com
I am well aware, of course, that it does also I grew up in, however – no doubt due to being in a family company – was
APR - MAY 2019 | WELDFAB TECH TIMES
57
LAUNCHES
Yaskawa Smart Series product line is ideal for new robot users
I
ntroduced specifically for
protect workers from potentially harmful
efficient implementation. Providing a
manufacturers branching out into
contact situations. It features hand-
simple learning curve for novice robot
robotics, the new Smart Series
guided teaching for fast deployment or
users, Smart Pendant’s built-in Smart
suite of products allows quick and easy
redeployment on demand, and it is easily
Frame technology allows the robot to
implementation of a robot system.
integrated with existing automation.
adapt to the programmer’s position,
The Smart Series product line includes
Weighing only 7 kg, the MotoMini is the
eliminating the use of conventional
Yaskawa’s HC10DT, MotoMini, GP7, GP8
industry’s smallest and lightest six-axis
coordinate (X, Y, Z) frames while enabling
and GP12 robots as well as the Smart
robot. It is easy to carry and ideal for
user-friendly operation.
Pendant and the YRC1000micro robot
tabletop-, floor-, ceiling- or wall-mount
Ideal for a variety of inspection,
controller.
installations, saving valuable floorspace.
machine tending and other handling
Unlike traditional more complex
Compact and efficient, the GP7, GP8
applications, Smart Series products
robot execution that requires significant
and GP12 robots offer exceptionally fast
are easily adaptable to changing
upfront investment in training, Smart
axis speeds and acceleration capabilities
manufacturing requirements and can
Series technology offers simple, intuitive
to reduce cycle time and increase
readily be redeployed.
robot programming methods for novice
production output. The GP7 and GP8
users.
Smart Series products are available
robots feature an IP67 rating with an
through Yaskawa’s authorized Smart
The industrial strength HC10DT
easy-to-clean surface; each model offers
Series Distributors.
(direct teach) robot offers four modes
an NSF-H1 certified food-grade lubricant
of collaboration, including Power and
option. The GP12 robot has an IP67-rated
For More Info:
Force Limiting (PFL) technology to
wrist and IP54 body (IP65 optional).
Yaskawa America, Inc.
Easily connected to peripheral
Motoman Robotics Division
devices, the ultra-compact lightweight
100 Automation Way
YRC1000micro is the smallest robot
Miamisburg, OH 45342
controller in its class. A space-saving
Phone: 937-847-6200
design enables installation in either a
Website: www.motoman.com
vertical or horizontal position, as well as within a 19-inch rack. The easy-to-use, tablet-based Smart Pendant radically changes the way a robot is programmed, providing simplified yet powerful programming for fast and
58
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
INNOVATIONS
Welding breakthrough could transform manufacturing Scientists from Heriot-Watt University have welded glass and metal together using an ultrafast laser system, in a breakthrough for the manufacturing industry. “Being able to weld glass and metals together will be a huge step forward in manufacturing and design flexibility,” said Professor Duncan Hand
V
together will be a huge step forward in
as quartz, borosilicate glass
manufacturing and design flexibility.
and the welds remained intact, so we
and even sapphire were all
“At the moment, equipment and
know they are robust enough to cope with extreme conditions.”
successfully welded to metals like
products that involve glass and metal
aluminium, titanium and stainless steel
are often held together by adhesives,
using the Heriot-Watt laser system, which
which are messy to apply and parts can
working with a consortium led by Oxford
provides very short, picosecond pulses of
gradually creep, or move. Outgassing is
Lasers, a laser micromachining systems
infrared light in tracks along the materials
also an issue - organic chemicals from the
integrator and Coherent Scotland,
to fuse them together.
adhesive can be gradually released and
laser specialists; and Leonardo and
can lead to reduced product lifetime.
Gooch & Housego, both end-users of
The new process could transform the manufacturing sector and have direct
“The process relies on the incredibly
Professor Hand and his team are
the technology to develop a prototype
applications in the aerospace, defence,
short pulses from the laser. These
for the laser processing system and
optical technology and even healthcare
pulses last only a few picoseconds - a
take it closer to commercialisation.
fields.
picosecond to a second is like a second
Two other partners, Glass Technology
compared to 30,000 years.
Services and the Centre for Process
Professor Duncan Hand, director of the five-university EPSRC Centre for
“The parts to be welded are placed in
Innovation, provide additional routes
Innovative Manufacturing in Laser-based
close contact, and the laser is focused
to commercialisation, including in
Production Processes based at Heriot-
through the optical material to provide a
packaging of OLED devices.
Watt, said: “Traditionally it has been
very small and highly intense spot at the
The project is funded by Innovate UK,
very difficult to weld together dissimilar
interface between the two materials - we
Heriot-Watt University and contributions
materials like glass and metal due to
achieved megawatt peak power over an
from additional industry partners.
their different thermal properties - the
area just a few microns across.
high temperatures and highly different
“This creates a microplasma, like a
For More Info:
thermal expansions involved cause the
tiny ball of lightning, inside the material,
Heriot-Watt University
glass to shatter.
surrounded by a highly-confined melt
Email: mediaenquiries@hw.ac.uk
region.
www.hw.ac.uk
“Being able to weld glass and metals
60
“We tested the welds at -50C to 90C
arious optical materials such
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
WELDER’S PASSION
“Safety in welding is not a decorative accessory, but a mandatory requirement.” Mr. Tanaji Yadav, Welder, Ador Welding Ltd.
Q1. Tell us a little about yourself?
in Alfa Laval, I learned all types of welding
I basically belong from Kolhapur, but it
techniques.‘Sky is the Limit for Welding
has been since 15 years that I am residing
Sector’ is what I truly believe. The sector
in Pune. Since 2007, I started working
has huge scope, and thus, I preferred to
in Ador Welding Limited inthe Welding
choose Welding as a career.
Equipment division.
Q4. Please brief us on some of the mega, unique and interesting projects you worked upon in the past?
Q3. What type of projects you are currently working upon?
In the year 2015,I was appointed to work
Currently I am working on projects like
gave me hands on experience to work on
IGPL-SS 316L, Assam Flare Tip 8825,
complex equipments like Burners, Heat
I studied ITI in welding from Kolhapur.
BPCL Flare Tip 8825, and KOC Flare Tip
Exchanger & Columns, etc. It was very
Thereafter, I completed NCTVT from Alfa
310. These are projects being executed
challenging &fascinating project I ever
Laval, Kasarwadi, Pune.During my tenure
by Ador Welding’s Project Engineering
worked upon.
Q2. How did you develop the art of welding?What made you choose welding a career?
62
Division at its Pune plant.
WELDFAB TECH TIMES | APR - MAY 2019
on the Bio Diesel Project. This project
www.weldfabtechtimes.com
WELDERâ&#x20AC;&#x2122;S PASSION
moving forward. Life is about your
on this job, as it was placed in an open air.
resilience and your ability to go through
Instead of severe weather conditions, I
your life and all of the ups and downs
have completed this rework of 10 nozzles
with a positive attitude. I am very much
successfully.
positive in my real life.Positivity and bold attitude always helps me in my work.
Q6. Any anecdotes you wish to share to support the importance of safety for welders?
Q10. Right from the time you started your career till date what has been your learning so far?Any new skills you have learned? In my 14 years of work experience,
Safety in welding is not a decorative
I learned various types of welding
accessory, but a mandatory requirement.
techniques like MMAW welding, GAS
Welding is a safe occupation when proper
welding,SAWwelding, TIG welding,Plasma
precautions are taken. But, if safety
cutting, Gas cutting.But it was truly
measures are ignored, welders face an
unique and amazing experience working
array of hazards which can be potentially
on TIP TIG welding machine launched by
dangerous.Welder should use welding
ADOR Welding.
mask, ear plug, hand gloze, apron, leg guard, hand guard & welding screen.
Q11. What are your future plans? I want to become the worldâ&#x20AC;&#x2122;s best welder.
Q7. Describe an experience where you took appropriate safety precautions.
Closing message.
For the Kuwait Project, I was welding
professional has increased main folds in
in the overhead position, as the job
the last few years and there are enough
was static.Here, we were facing a major
opportunities for youngsters to make a
spatter issue. But I was well equipped
career in this fast emerging and long-
with all the safety measures and thus I
lasting field. There is no dearth of work
could manage to perform the welding
for the learned certified welder in the near
without any harm.
future and that too with good financial
The scope of welding technology
returns.
Q8. What are the major challenges in welding and how can you manage to cope up with the same? Recently, you have won the award for
The major challenge in welding is proper
best structural welder at a national level
penetration though joints. For that, it is
competition organized by AWPM & IIW.
very important to maintain the root gap,
Congratulations. Please elaborate.
root face, welding current, filler size,
I performed single V butt joint 3G
temperature of Job and joints.
position, vertical MIG welding on 10mm thickness plate and made a fillet joint in Best Structure Welder Competition.
Q9. Can you please share an incident of a welding job you have come across?
Q5. What is your greatest strength and how does it help you as a welder?
I remember a job wherein I was assigned
Life is about accepting the challenges
on IGPL (D445) column as per client
along the way, and choosing to keep
requirements. It was very tough to work
www.weldfabtechtimes.com
to shorten the length of 10 nozzles
APR - MAY 2019 | WELDFAB TECH TIMES
63
EVENTS UPDATE
NATIONAL EVENT
DATE
LOCATION
WeldExpo
04 – 07 July, 2019
Pragati Maidan, New Delhi, India
Delhi Machine Tool Expo (MTX)
08 - 11 Aug, 2019
New Delhi, India
Cutting & Welding Equipment Expo (CWE Mumbai)
20 - 22 Sep, 2019
Bombay Exhibition Centre, Mumbai
International Conference On Cutting-edge Technologies in Engineering
14 - 16 Nov, 2019
SRMU Lucknow, Barabanki, India
Engi Expo
22 - 25 Dec, 2019
Rajkot, India
Engi Expo (EngiExpo)
15 - 17 Feb, 2020
Vadodara, India
IC 2020 & Weld India
06 – 09 Feb, 2020
CIDCO, Navi Mumbai
India Essen Welding & Cutting
23 - 25 Nov, 2020
Mumbai, India
INTERNATIONAL
64
EVENT
DATE
LOCATION
Engineering Machines Tool Welding
18 - 21 Jun, 2019
Nizhny Novgorod, Russia
Beijing Essen Welding & Cutting Fair
25 - 28 Jun, 2019
Dongguan, China
Weld County Fair
24 - 29 Jul, 2019
Greeley, USA
Exhibition of Cutting Edge Security Technologies (ASE ZITF)
17 - 23 Aug, 2019
Bulawayo, Zimbabwe
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
EVENTS UPDATE
Indonesia International Welding Equipment and Cutting Material & Services Exhibition (INA Welding)
28 - 30 Aug, 2019
Jakarta, Indonesia
Philweld
28 – 31 Aug, 2019
World Trade Center Metro Manila, Pasay, Philippines
Trade fair for Joining, Cutting, Surfacing, Testing and Protecting (SCHWEISSEN Linz)
10 - 12 Sep, 2019
Linz, Austria
Hi Welding & Production Equipment
01 – 03 Oct, 2019
MCH Messecenter Herning, Herning, Denmark
Weldex
15 - 18 Oct, 2019
Moscow, Russia
Exhibition for machine tools, industrial tools, welding and cutting equipment
14 - 17 Nov, 2019
Cairo, Egypt
Welding Monitoring And Diagnostics
19 - 21 Nov, 2019
Yekaterinburg, Russia
Welding Week
19 - 21 Nov, 2019
Antwerp, Belgium
Welding Bangkok
20 - 23 Nov, 2019
Bangkok, Thailand
International Exhibition on Metalworking & Welding Technology Vietnam (Metal & Weld)
27 - 30 Nov, 2019
Ho Chi Minh, Vietnam
Welding Technologies Fair
28 Nov - 01 Dec, 2019
Bursa, Turkey
Steel Fab
13 - 16 Jan, 2020
Expo Center Sharjah - UAE
Japan International Welding Show
08 - 11 Apr, 2020
Osaka, Japan
For Weld
12 - 15 May, 2020
Prague, Czech Republic
FABTECH Canada
16 - 18 Jun, 2020
Toronto, Canada
International Trade Fair for Welding (Welding Fair Brno)
05 - 09 Oct, 2020
Brno, Czech Republic
ExpoWELDING: International Welding Fair
13 - 15 Oct, 2020
Sosnowiec, Poland
www.weldfabtechtimes.com
APR - MAY 2019 | WELDFAB TECH TIMES
65
SECTOR WATCH: AEROSPACE
Trends in Aerospace Sector Prepared by, BDB India Pvt Ltd Overview
doing business. India therefore faces
military. Similarly, Boeing entered into a
Indian aerospace manufacturing sector
stiff competition from places like China,
JV with Tata Advanced Systems in 2015
could become the sunshine sector for
South East Asia, Latin America, and
focused on manufacturing the fuselage
India and create thousands of high-end
Eastern Europe in addition to the home
of Apache Helicopters in India. In 2016,
jobs if it is nurtured by the right policies
countries of the global OEMs.
Lockheed Martin announced interest
and actions. It is at an inflection point,
in moving its entire production of F-16
eased foreign direct investment (FDI)
fighter jets to India to reap the benefits
three and two decades back respectively.
norms for the Defence sector, permitting
of lower cost of production, enabling
It would require sustained support from
foreign companies to own 100% of
them to lower the selling price and
government to develop critical mass,
domestic ventures with the approval of
increase the global demand for F-16s.
skill sets and research and development
the government when access is provided
As the sector opens up further, there
(R&D) capability.
to modern technology. The term
will likely be an increase in global A&D
“modern technology” is not specifically
companies entering the Indian market,
Aerospace sector to grow in coming
defined in the policy and could be
either through JVs or independently,
years. India has a unique advantage of
subject to interpretation by various
with 100% FDI now allowed in the A&D
being one of the biggest markets for
Indian regulatory agencies.
sector.
There is a great potential for Indian
Commercial Aviation as well as Defence.
Coupled with progress that India
Major OEMs are now actively looking
has made in space technology and
Aerospace sector value chain
to develop supply chain in India and
commercial aerospace manufacturing,
The aerospace value chain comprises
source Engineering services as well as
incentives under the government’s
activities ranging from design and
components & assemblies. Driven by the
Make in India initiative, as well as recent
assembly to, ultimately, MRO services
Make in India initiative and powered by
escalation in security concerns, are
(see below figure). As OEMs and
State Government support, potential for
creating ripe conditions for significant
tier-1 suppliers struggle to improve
growth is foreseen.
progress in the aerospace sector in India.
profitability, tier-2 and tier-3 products
Global Aerospace sector companies
will likely shift to emerging markets
perhaps the highest degree of fail-
have been directing capital to India to
such as India and China. The Indian
proof quality standards. This combined
benefit from strong long-term growth
aerospace supply base is fairly new.
with unpredictable demand, lumpy
prospects. There have been various JV
While Indian companies have a
orders and extreme pressure on
announcements in the sector during
significant advantage in engineering
pricing makes the risk of aerospace
2015–2016, prior to the relaxation of
and design, they do not yet have the
business significantly high. Aerospace
FDI norms. After the relaxation of FDI
capabilities to handle highend design
manufacturing for the defence sector is
regulation, the Indian Aerospace sector
and development. The government
even tougher given that there’s only one
is likely to record an increase in JVs, as
owned Hindustan Aeronautics Limited
ultimate client per country - the Ministry
well as a rise in foreign firms establishing
(HAL) operates across the value chain.
of Defence
manufacturing facilities in India.
However, no other Indian company
The aerospace sector demands
(MoD); the orders are even more
Major Aerospace companies such
boasts integrated capabilities.
unpredictable and lumpy; and the
as Airbus, Boeing, Lockheed Martin,
negotiations, approvals and payments
and Safran already have a footprint in
Design: Several Indian information
can be really test one’s patience.
the Indian market, and some of them
technology firms have been operating in
are planning further investments. For
the aerospace sector over the past few
where capital will flow to the most
example, Airbus announced a JV with
years, with HCL, Infosys, TCS, Honeywell
attractive destination in terms of
Mahindra Defence Systems last year to
and Wipro leading the pack. These
sustained order-book, cost and ease of
manufacture helicopters for the Indian
firms have been providing design and
We are living in a globalized world
66
In June 2016, the Indian government
like the automotive and telecom sector
WELDFAB TECH TIMES | APR - MAY 2019
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SECTOR WATCH: AEROSPACE
titanium and Inconel, to be used in manufacturing single aisle, brackets and hinges, avionics racks , wiring harnesses, mountings, blades and vanes, to be the key growth area in this segment. This is similar to the evolution in the Chinese aerospace supply base, which leveraged joint ventures with Boeing and Airbus to supply $1 billion in components from 1995 to 2008. Aircraft sub-assemblies: HAL is the only company with complete aircraft manufacturing capabilities, and companies like Mahindra Aerospace, integrated software for the aerospace sector.
The emergence of Indian suppliers
Tata Group, Taneja Aerospace are
with integrated tier-1 and tier-2
ramping up to compete in the segment.
capabilities will allow global aerospace
To meet industry demands, several
companies. Indian IT firms, however, are
companies to leverage India as a low-
private firms plan to enter the market
expected to develop their capabilities to
cost option, thus increasing their ability
both organically and via mergers
offer higher end complex design services
to honor the offset agreements.
and acquisitions. Moreover, several
Development services to major aircraft
in the near future.
Indiaâ&#x20AC;&#x2122;s skilled labor wage rates are
automotive firms may enter aircraft
up to 60% lower than the United States
component manufacturing. Reliance,
Infotech, Wipro etc are already gearing
and Europe. Key to cost savings is
Tata, Mahindra, MRF, Lumax and Minda
up to emerge as aircraft design and
the ability to develop manufacturing
have already announced plans to do so.
development houses.
processes using automation and labor
Global aerospace majors have started
productivity improvements while
focusing on India to source components
Component manufacturing: Indian
ensuring quality standards. For example,
for their Indian & Global requirements
companies were primarily tier-3
tier-2 components suppliers offers a 15
and Auto component manufacturers in
suppliers till the entry of large organized
to 30% cost advantage to supply product
India, with their proven manufacturing
players like Aequs Aerospace, Dynamatic
like landing gear components due to a
capabilities make ideal candidates as
technologies in the component
labor intensive manufacturing process
supply chain partners in Aerospace &
manufacturing which have significant
while delivering similar quality levels. In
Defence.
manufacturing capabilities along with
aircraft assembly, assessments indicate a
in-house design and development
potential cost advantage of 15 to 25%.
Companies such as Honeywell, L&T
capabilities. However still majority of the manufacture parts as per specifications
It is expected that manufacturing
MRO services opportunity: INDIA, with its growing aircraft fleet size, strategic
of small structural components, hard
location, rich pool of engineering
metal components aerospace steel,
expertise and lower labor cost, has
provided. Further, there are only a few companiesâ&#x20AC;&#x2122; large companies like Aques Aerospace in this segment, as the component industry is still fairly new. With more business expected to flow into India due to offset agreements, tier-1 and tier-2 players will no doubt have a larger role in the global aerospace value chain.
68
WELDFAB TECH TIMES | APR - MAY 2019
www.weldfabtechtimes.com
SECTOR WATCH: AEROSPACE
a huge potential to be the global
(AIESL) for MRO facility at Nagpur. Key
are the key aerospace clusters in India
Maintenance, Repair and Overhaul
players in the Indian MRO market are
primarily driven by the presence of
(MRO) hub on a long-time horizon. The
Air India, Lufthansa, Boeing, Taneja,
established end users, talent pool and
current market size of MRO is estimated
HAMCO, Eaton Aerospace, Air works,
supportive policies. Karnataka is the key
at about $700-800 million which is
Max Aerospace, Thales International,
state which has given special attention
expected to reach $1.2 billion by 2020.
Sabena Technics, Jupiter Aviation,
to the aerospace sector including the
India has the potential to become the
Mas Aerospace etc. who operate
aerospace policy and the aerospace park
third largest aviation market by 2020
independently or through a JV.
being set up in Devanahalli. Karnataka is
and the largest by 2030. The growth of
the only state in the country which has
the industry is being propelled by the
Key private players in the Indian
formulated an aerospace policy and is
development of airports, presence of
Aerospace Manufacturing sector are:
home to several aerospace component
several low-cost carriers, a liberalized
1. Tata Advanced Systems (TASL),
manufacturing units.
FDI policy, increasing adoption of
Hyderabad
Systems Controls, G.L. Polyurethane
information technology and focus on
2. Mahindra Aerospace, Mumbai
Company Private Limited, Micron
improving regional connectivity.
3. Reliance Naval and Engineering Limited,
Engineers, Priyaraj Electronics Limited
With over 1,000 aircraft on order, India is poised to become the third
Mumbai 4. Tata Automation Limited, Pune
largest buyer of commercial passenger
and Pacific Natura Biotech Private Limited are ready to invest in aerospace component units in the aerospace SEZ
planes in the world, with only the US
Other private participants in the
at Devanahalli. Hindustan Aeronautics
and China ahead of it. Having received
aerospace manufacturing sector.
Limited’s (HAL) proposal to set up
huge orders from Indian carriers,
Below are some of the key component
a ₹2,095 Crore unit in Devanahalli to
aircraft manufacturers such as Airbus
manufacturing companies catering to
manufacture aero-engines and provide
plan to build MRO facilities in India. In
the aerospace sector:
MRO facilities. Aerospace and Precision Engineering
from Boeing and has tied up with Air
Key clusters for aerospace manufacturing:
India Engineering Services Limited
Bengaluru, Nagpur and Hyderabad
district near Hyderabad, and has also
January 2017, Spice Jet finalised a deal worth $22 billion to buy 205 aircraft
Telangana boasts of the country’s first
Company
Location
Triveni Hitech
Bengaluru, Karnataka
Dynamatic Oldland Aerospace
Bengaluru, Karnataka
SEZ at Adibatla in Ranga Reddy announced plans to set up two more similar aerospace parks to accommodate prospective companies. Currently, several home-grown and multi-national companies such as
Moog Control
Bengaluru, Karnataka
Titan Company Limited
Bengaluru, Karnataka
Wipro Infrastructure Engineering
Bengaluru, Karnataka
S.K.M Technologies Pvt Limited
Hyderabad, Andhra Pradesh
and Lockheed Martin have operations
Recaero India Private Limited
Bengaluru, Karnataka
at the Aerospace SEZ.
Dynatech Tools & Devices Private Limited
Bengaluru, Karnataka
Indo US MIM Tec Private Limited
Bengaluru, Karnataka
Pranita Engineering Solution
Bengaluru, Karnataka
B C Instruments India
Anand, Gujarat
SEZ to Nova Integrated Systems, a Tata
Aerospace Engineers
Salem, Tamil Nadu
enterprise, 25 acres to Punj Lloyd, 20
Alpha Tocol
Bengaluru, Karnataka
BFW
Bengaluru, Karnataka
Indo Schottle
Pune, Maharashtra
www.weldfabtechtimes.com
Zen Technologies, Tata Advanced Systems Limited (TASL), Mahindra & Mahindra, Sikorsky, Pratt & Whitney
Currently, the aerospace SEZ is spread across 350 acres of which only 250 acres has been notified as SEZ. Besides TASL, the state had allotted 30 acres in the
acres to Mishra Dhatu Nigam (Midhani) and 96 acres to Samuha, a consortium of manufacturers including MTAR Technologies Pvt Limited.
APR - MAY 2019 | WELDFAB TECH TIMES
69
SECTOR WATCH: AEROSPACE
Piaggio Aerospace signs contracts for 45 Million Euro
P
iaggio Aerospace, one of the leading
Air Patrol Team “Frecce
of further agreements
players in the business aviation
Tricolori” and the flight
signed with other Italian
and security & defence sectors, has
school of the 61° Stormo in
institutions. These include
announced the signing of maintenance
Galatina (Southern Italy). The
the Department of Public
agreements valued at approximately 45
contract includes both the
Million Euro. The deals have been signed
maintenance of the Viper engines installed
the Interior Ministry (3-year contract),
with the main Italian national institutions
on the above-mentioned aircraft and the
the Italian Army (12-month agreement,
and cover activities lasting from 12 to 36
purchase of spare parts. The Air Force also
operational after the expiration of the
months.
signed an agreement for integrated logistic
current service agreement), and the
support for the fleet of P.180 twin-engine
National Coast Guard, directed by the
is worth 39.3 Million Euro in the next
turboprop aircraft designed and produced
Ministry of Infrastructure and Transport
12 months, was signed by the Italian
by Piaggio Aerospace in its centre of
(2-year contract).
Air Force to support and maintain the
excellence in Villanova d’Albenga (Italy).
The most significant agreement, which
operability of the Aermacchi MB.339 aircraft, used by the National Acrobatic
Safety (State Police) of
The integrated logistic support for the P.180 fleet is the common element
Source: www.piaggioaerospace.it
MTC playing major role in pseudo-satellite project
T
he autonomously-controlled
for hardware components including
Phoenix aircraft has undergone
pumps and actuators provided by TCS
successful test flights and has the
Mircropumps. In addition, support was
potential to take the lead in the world
provided to the flight trials including
development of pseudo-satellites.
assembly, piloting and testing.
Pseudo-satellites are able to fly,
MTC technology director, Ken Young
remotely-controlled or autonomously
said the Innovate UK-funded Phoenix
at very high altitudes for long periods
project was an exciting collaborative
of time – often months. The can fly
venture at the cutting edge of aerospace
above commercial aircraft routes and the National Composites Centre and the
complement conventional satellites and
Centre for Process Innovation. University
technology has been used before
can be used for earth-mapping, scientific
partners included the University of
for remote controlled underwater
observation and intelligence gathering.
Bristol, Newcastle University and
vehicles but has never been used for
the University of the Highlands and
the propulsion of a large aircraft. The
time as a heavier-than-air aeroplane and
Islands. Industrial partners were Banks
power for moving the flight-control
the other as a lighter-than-air helium
Sails, Stirling Dynamics, IQE and TCS
surfaces, the valves and pumps comes
balloon. The repeated transition between
Micropumps.
from a battery charged by an array
The 15m-long Phoenix spends half its
these two states provides its sole source of propulsion.
MTC engineers made extensive use
“The variable-buoyancy propulsion
of lightweight flexible solar cells,”
of National Instruments’ hardware and
he said. “The technology involved in
software suites to build, programme
this project is truly cutting-edge and
consortium of industrial partners,
and test the aircraft’s control system,
has the potential to take the UK into
universities and members of the High
including hardware-in-the-loop tests of
the lead when it comes to this kind of
Value Manufacturing Catapult. From the
its autonomous pilot system developed
innovation.”
Catapult centres there were the MTC’s
by Stirling Dynamics. The MTC has also
advanced production systems group,
provided testing facilities and expertise
Phoenix has been developed by
70
technology.
above turbulence and moisture. They
WELDFAB TECH TIMES | APR - MAY 2019
Source: www.aero-mag.com
www.weldfabtechtimes.com
SECTOR WATCH: AEROSPACE
Philippines' Top-ranked Aeronautical University FEATI helps protect the future of aerospace engineering
M
SC Software Corporation, a
Software tools to analyze and predict
accredited skill testing facility for aircraft
leading simulation software,
stress and strain, vibration and
mechanics. Therefore, we are delighted
and service provider (part of
dynamics, acoustics, and thermal
to note that the future aerospace
Hexagon), today announced that it has
analysis. As a leading educator
engineering in the Philippines will have
signed an agreement with Manila-based
in Aviation, Aerospace and other
an opportunity to be trained on MSC
FEATI University. to provide students
engineering disciplines, we believe in
Software before they embark on their
access to training programmes in MSC
giving our students the best exposure to
professional careers."
Software starting this year.
industry-leading tools and technologies
Over the years, FEATI University
to prepare them for their careers. This
has collaborated with government
members trained and certified by MSC
tie-up with MSC Software is another step
and private institutions in Research
Software and will subsequently include
in this direction."
and Development, including some
The University will get select Faculty
MSC tools in its academic syllabus/
Sridhar Dharmarajan, Managing
pioneering experiments on rockets,
curriculum for Finite Element Methods
Director, Indo-Pacific Region, MSC
ultra-light planes, aircraft made of
courses. The University will also dedicate
Software, said, "FEATI University is a
indigenous materials, and alternative
a lab with MSC tools for students to
highly respected institution. The Civil
fuels. It is also working with the
practice and conduct training.
Aviation Authority of the Philippines
Department of Science & Technology
(CAAP) has also certified the University
(DOST) of the Philippines Government
Francis Segovia, CEO, FEATI University
as an accredited aviation training
on the development of an unmanned
said, "The Aerospace industry relies
organization of good standing. Also, the
aerial vehicles (UAV).
heavily on some of the leading MSC
University's Professional School is an
Speaking on the announcement,
Source: www.mscsoftware.com
Adani Defence & Aerospace & Elbit Systems inaugurate Aerial Vehicles manufacturing facility at Hyderabad
A
dani Elbit Unmanned Aerial
and aerospace has a deep personal
Vehicles Complex (UAV), was
significance for me. I want us to be able
inaugurated by Hon’ble Home
to look back and reflect that the Adani
Minister of Telangana, Shri Mohammad
Group did its bit to help build a more self-
Mahmood Ali in presence of Shri Jayesh
reliant India – the nation that is second
Ranjan, Principal Secretary – IT &
to none in its defence manufacturing
Industries, State of Telangana, Mr. Pranav
capabilities – the nation that is stronger
Adani, Director, Adani Enterprise Limited,
in its ability to defend itself. As an Indian
Mr. Karan Adani, CEO, Adani Ports and
The factory shall start operations with
- there could be nothing more gratifying.
Special Economic Zone and Mr. Bezhalel
the manufacturing of complete carbon
It is a critical milestone for the trusted
Machlis, President and Chief Executive
composite aerostructures for Hermes 900,
and strategic relationship between our
Officer, Elbit Systems.
followed by Hermes 450, catering to the
nations - India and Israel. This joint
global markets and will be further ramped
venture facility for the manufacturing of
would be the first UAV manufacturing
up for the assembly and integration of
Unmanned Aerial Vehicles is a testament
facility in India and the first outside
complete UAVs.
to Elbit’s commitment to our nation and
The 50,000 sq. ft. state-of-the-art facility
Israel to manufacture the Hermes 900 Medium Altitude Long Endurance UAV.
www.weldfabtechtimes.com
Gautam Adani, Chairman, Adani Group commented, “Our foray into defence
the ‘Make in India’ programme” Source: www.adanidefence.com
APR - MAY 2019 | WELDFAB TECH TIMES
71
SECTOR WATCH: AEROSPACE
Boom Supersonic closes $100 Million Series B to develop overture, its revolutionary Mach-2.2 Airliner
B
oom Supersonic, the Colorado
class— widening horizons for tens of
aircraft flying similar routes today. Boom
company building a radically faster
millions of travelers. Ultimately, our goal
is currently assembling XB-1, a ⅓-scale
commercial aircraft, announced
is to make high-speed flight affordable to
manned prototype of its Mach-2.2 airliner.
that it has closed a $100 million Series B
all.” “Our interest in Boom is driven by its
XB-1 will be piloted by Chief Test Pilot Bill
investment round, bringing total funding
vision to enable greater human connection
“Doc” Shoemaker and is set to fly later this
to over $141 million. Investors, led by
and more empathetic natural and
year.
Emerson Collective, include Y Combinator
cultural experience through ecologically
Continuity, Caffeinated Capital, and SV
conscientious design.
Angel as well as founders and early backers
Boom has the leadership, values, and
As history’s first independently developed supersonic jet and the fastest civil aircraft ever built, XB-1 will
of transformative companies like Google,
potential to accelerate many advances—
demonstrate in flight the key technologies
Airbnb, Stripe, and Dropbox.
lightweight carbon composites and
for mainstream supersonic flight: efficient
greener fuels— that will reduce the
aerodynamics, advanced composite
round, which include $56 million in
climate impacts of aviation,” said Andy
materials, and an efficient propulsion
new investment as well as previously-
Karsner, Managing Partner at Emerson
system. Boom is growing quickly as
announced strategic investments, allow
Collective and leader of Elemental, its
it ramps up development. Today, the
the company to advance the development
energy and environmental affiliate.
company has a full-time team of more
of its Mach-2.2 commercial airliner called
“We’re thrilled to partner with a company
than 100 & anticipates doubling this year.
Overture. “This new funding allows us to
that’s committed to revolutionizing
advance work on Overture, the world’s first
travel responsibly.” Overture will be the
and development of Overture, Boom
economically viable supersonic airliner,”
most community- and environmentally-
recently relocated to a large, state-of-
said Blake Scholl, founder and CEO of
friendly supersonic jet ever made. Thanks
the-art facility in Centennial, Colorado.
Boom Supersonic. “At Boom, our vision is
to advanced aerodynamics and engines,
Selection efforts are ongoing for the
to remove the barriers to experiencing the
the carbon footprint will be similar to
manufacturing site for Overture, which will
planet.
flying international business class today.
begin passenger service in the mid-2020s.
The proceeds of Boom’s Series B
To accommodate the assembly of XB-1
Moreover, Overture is being designed to
Future customers include Virgin Group
distance travel prevent us from connecting
accommodate next-generation sustainable
and Japan Airlines, which have pre-
with far-off people and places. Overture
alternative fuels. At landing and takeoff,
ordered a combined 30 Overture airliners.
fares will be similar to today’s business
Overture will be as quiet as the subsonic
Today, the time and cost of long-
Source: www.boomsupersonic.com
Russia's Hypersonic Ballistic Missile & Laser System in Final Tests, Putin Says
R
ussia is entering the final testing
unveiled Satan-2 with an array of
phase of its nuclear-armed
other nuclear-capable weapons at his
intercontinental ballistic missile
annual speech to both chambers of
dubbed Satan-2, President Vladimir
parliament in March 2018.
Putin said. Russia announced plans in 2013 to develop the ICBM to replace a Cold War standby known in the West as “Satan,” or the RS-20B Voyevoda in Russia. Putin
72
WELDFAB TECH TIMES | APR - MAY 2019
Source: www.themoscowtimes.com
www.weldfabtechtimes.com
SECTOR WATCH: AEROSPACE
Tzar Aerospace, an India-based Aerospace and Defence Startup, Raises $15B USD
B
rain child of Mr. Priyam Mohanty,
founder of Tzar Aerospace said, “It’s a
new job opportunities and making India
Tzar Aerospace Research Labs
matter of tremendous pleasure and great
strong. Tzar Aerospace has been taking
is a registered start-up company
pride for us that we have successfully
up the projects under the category of
known for its modern and innovative
marked our presence in the field of
Swachh Bharat, renewable energy, drone
Aerospace solutions to its commercial
Aerospace market. Our start up has been
manufacturing, aerospace engineering,
as well as civil customers. The primary
very successful in establishing the trust
biochemical and robot technology etc.
business theme of Tzar Aerospace is
among its clients and because of this
to design and develop a conceptual
trust recently we have raised $15 billion
exceptional leadership potential of Mr
unmanned Hypersonic Research Aircraft
USD for 37% private equity from leading
Mohanty helped investors for such a
with new computational approaches and
companies.”
phenomenal investment in Aerospace
Startup India is an Indian government’s
methods. On this occasion Mr. Priyam Mohanty,
initiative to promote start-ups, creating
Positive feedback from industry and
and Defence sector in India. Source: www.tzaraerospace.com
Marshall signs 14 years contract to support Royal Netherlands Air Force C-130H
M
arshall Aerospace and Defence
look forward to providing a world class
a joint capability for more predictive
Group has secured a contract
service to the C-130H fleet as we sustain
maintenance and logistics. A contract like
with the Royal Netherlands Air
the aircraft through to the end of their
this can only rest on a strong strategic
operational service.”
partnership and that is what I value
Force to sustain its C-130H fleet through to its out of service date. The contract was
in particular. I am looking forward to
Ministry of Defence for the trust they have
extending the successful and inspiring
the Eindhoven Air Base in the presence of
shown in Marshall to be their long-term
cooperation with Marshall."
senior officials from the Defence Materiel
partner for both this C-130 sustainment
Organisation (DMO) and the Royal
project and also the recently signed DVOW
contract for the C-130H fleet will see
Netherlands Air Force.
contract,”added Mr McPhee.
Marshall deliver a turn-key solution to
Marshall’s bid was confirmed as the
Representing the Royal Netherlands
The multi-year total sustainment
the Royal Netherlands Air Force covering
most economically advantageous tender
Air Force at the signing ceremony in
aircraft maintenance, engine maintenance
following careful and thorough verification
Eindhoven, Air Cdre Richard Laurijssen,
and supply chain management. Marshall
and evaluation of the international tenders
Director of Sustainment and Logistics &
has already carried out a major Cockpit
submitted for the sustainment of the
Commander Logistics Centre Woensdrecht
Upgrade Programme on the fleet and
C-130H fleet,
said, "This contract is a further step into
currently holds the Engineering Support
modern sustainment and logistics for our
contract. In the delivery of this contract
ceremony, Alistair McPhee, Chief
C-130 fleet. Our job is about availability
Marshall will again be working with the
Executive Officer Marshall Aerospace and
and affordability for the RNLAF and this
local defence industry in the Netherlands.
Defence Group said,
modern approach is needed for that.
Commenting at the contract signing
“This is a very important contract for the
74
“We wish to thank the Royal Netherlands
signed this morning during a ceremony at
“The new contract comprises a lot
At the beginning of December Marshall also signed a contract worth in excess of
company and further builds on the 22-year
more than previous separate contracts
£100 million to supply the next generation
history that Marshall has in supporting
and defines a future collaboration where
of containers to the Dutch Armed Forces
the Royal Netherlands Air Force. The
more will be achieved by combining
under the Defensiebrede Vervanging
relationships between Marshall and the
our collective knowledge and skills. It
Operationele Wielvoertuigen, or DVOW
Netherlands are extremely strong and we
will help to fulfil my ambition to build
programme.
WELDFAB TECH TIMES | APR - MAY 2019
Source: www.marshalladg.com
www.weldfabtechtimes.com
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