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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

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.

WELDFAB TECH TIMES | AUG - SEPT 2018

Celebrating 1 Glorious Year of Success!!! With this very issue, the WeldFab Tech Times magazine marks its One-Year Anniver-sary. As we begin a new volume for 2018, we want to say “THANK YOU” to the people who have made this 1 year possible. A year ago, WeldFab Tech Times was started with an objective to promote the Indian welding industry in both the national and international market. Today, the magazine has been successful in meeting the set targets. The magazine has reached almost all the mega segments like welding & fabrication, railways, automobile, steel, aerospace, etc. The readership has crossed 10,000+ both through the print and digital medium. All the credit goes to our esteemed writers who are contributors of articles, advertisers, and the WeldFab Tech Times team. The welding industry experts have always been enthusiastic about sharing their knowledge about welding to the industry either through articles, case studies, inter-views, product write-ups, news, etc. ‘THANK YOU’ very much for all your support. It is all because of your editorial contribution towards the magazine, that our readers were able to resolve most of their challenging welding tasks at site. The special ‘THANK YOU’ also goes to our wonderful readers, globally. The vast con-structive feedback received from our valued readers, the encouraging comments with regards to our year-old magazine and the website and the frequent letters/ emails to the editor indeed motivates the entire WeldFab Tech Times team. WeldFab Tech Times would like to extend a great big ‘THANK YOU’ to all our advertis-ers. We would like you to know that your partnership is important to us. To help drive more customers to your business, we will continue to strive, to improve and innovate to meet your changing needs. WeldFab Tech Times aims to also largely focus on promot-ing our advertisers digitally. Thus, we will soon launch E-Market, wherein you can now sell your welding products online. Video Ad space on our website (www.weldfabtechtimes.com) will surely help you showcase your brand in the market. Again, thank you for choosing Weldfab Tech Times for your advertising and marketing needs. Weldfab Tech Times aims to be the ultimate source of all your welding needs. With your continued partnership, we look forward to another year of growth. Thank you.

Eliza Bhalerao Publisher & Editor

www.weldfabtechtimes.com

A BI-MONTHLY MAGAZINE FOCUSING ON WELDING AND FABRICATION SEGMENT

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CONTENTS 6

INDEPTH

Revolutionizing underwater welding repairs since 1974

INNOVATIONS ARTICLE

Hypertherm launches Robotmaster V7

Lean Welding – An Approach to Best Welding Practice

TRAINING CENTER

WELDFAB TECH TIMES | AUG - SEPT 2018

Welding Consumables in India – Current status, trends, & objectives

INTERVIEW

ABB to invest €100 million in global innovation and training campus

“Our welding engineering has over 1,900 qualified procedures.”

www.weldfabtechtimes.com

CASE STUDY

Head Hardened Rails

WOMEN IN WELDING

Sector Watch POWER

Malaysiaâ&#x20AC;&#x2122;s first female underwater welder - Izzati

BULLETIN PRODUCTS UPDATE WELDING TIPS FLASHBACK www.weldfabtechtimes.com

08 16 43 56

ARTICLE

RAILWAY DOER

Welding applications in the field of power plant maintenance

Exciting New 16kW Laser Welding System

AUG - SEPT 2018 | WELDFAB TECH TIMES

BULLETINS

Airgas to build two production facilities in California

irgas USA, LLC, an

CA will produce liquid CO2 and

Air Liquide company,

support the manufacturing

constructed within the existing

Airgas production facilities

announced plans

The ASU expansion will be

to bolster our network of

of dry ice used in a variety of

facility, an energy-efficient ASU

throughout the region in this

to increase its presence

customer applications, from

first inaugurated in 2011 by

important and growing market.

in California with the

water treatment and food

Air Liquide. This ASU benefits

The facilities will enhance our

construction of a new

chilling to freezing systems

from Air Liquide’s innovative,

gas supply chain output and

liquid carbon dioxide (CO2)

and brewing and winemaking.

cutting-edge technologies to

fortify long-term reliability for

production facility in Stockton,

The plant’s process will

operate efficiently, enabling

our packaged and merchant

CA and the expansion of an

use CO2 by-product from

Airgas to minimize power

gas customers throughout the

air separation unit (ASU) in

Pacific Ethanol’s nearby

consumption and overall

western United States.”

Etiwanda, CA. Once on-

ethanol production facility.

production costs.

stream, the two facilities will

With the additional plant in

significantly increase the

Stockton, Airgas will have three

Chief Executive Officer

company’s merchant gas

strategically located CO2 plants

commented, “with these two

capabilities in the state.

in Northern, Central, and

new production facilities in

Southern California.

California, we are continuing

The new facility in Stockton,

Source: www.airgas.com

Pascal Vinet, Airgas

CN welding operation sets up in Squamish

N has launched a rail

The operation, which began

welding operation at

this spring, takes, for example,

Source: www.squamishchief.com

the Squamish rail yard

24 metre (80 foot) lengths of rail that arrive by ship at

on Track Seven.

Squamish Terminals and

“Crews are welding sections of rail together to make longer,

welds them into quarter-mile

stronger rail which will be

lengths that are shipped out

used in BC Capex projects.

by rail. About 12 workers are

Instead of rail being shipped to facilities in Winnipeg for

being done in B.C closer to the

installed,” Patrick Waldron, of

employed by the operation,

welding together, that work is

projects where the rail will be

CN public affairs.

Waldron said.

MIAT introduces welding programs & electro-mechanical technology programs

IAT College of

6, and MIAT’s first Electro-

Committees with both

Technology is now

Mechanical class began in

campuses.

offering Welding

Canton on Sept. 10. All MIAT career education

Technology programs

programs are developed

at its Houston campus

and Electro-Mechanical

Detroit metropolitan area.

collaboratively with idustry

Technology programs at

MIAT’s first Welding class

representatives who serve

its Canton campus in the

began in Houston on Aug.

on Program Advisory

WELDFAB TECH TIMES | AUG - SEPT 2018

Source: www.businesswire.com

www.weldfabtechtimes.com

BULLETINS

GAZ-SYSTEM approves new welding technique for gas pipelines

- The Strachocina-Pogórska

utomation, faster

Andrzej Fedor, the manager

the investor’s supervision team

welding and lower

of the technical department

and the contractors of building

Wola gas pipeline with

consumption of

of GAZ-SYSTEM Branch in

works on the Strachocina-

diameter DN 1000 and working

additional material are the

Tarnów. Additionally, the

Pogórska Wola gas pipeline.

pressure 8.4 MPa will be

main advantages of the new

technology by CRC Evans

The approval of the 135

located in Subcarpathian and

welding technique approved

uses special bevelling, which

method technology of pipe

Lesser Poland Voivodeships.

by GAZ-SYSTEM. The

reduces four times the

coupling Ø1,016 mm with

Its completion will improve the

Company used it for the first

consumption of the additional

wall thickness 22.2 mm took

technical conditions and the

time during the construction

material necessary for welding

place at the Dutch seat of

security of gas transport in the

of the Strachocina – Podgórska

comparing to standard

CRC Evans. The destructive

area of south-western Poland

Wola gas pipeline.

bevelling.

and non-destructive tests of

- said Artur Zawartko, the Vice

the welds were performed

President of GAZ-SYSTEM.

Welding using the

The approval of the method,

It will also enable

technology by CRC Evans is

i.e. its acceptance by GAZ-

in June at Palab laboratory

carried out automatically by

SYSTEM, takes place in several

accredited by the Polish

the transport of gas to

six welding heads placed inside

stages. The most important

Centre for Accreditation and

Subcarpathia and Slovakia

the pipe being welded plus

one is making welds in

the Technical Supervision

using planned inter-system

by four external heads. The

precisely specified conditions

Office. The tests confirmed

Poland - Slovakia connection,

automatism of that method

and the control of their quality

the correctness of welds, and

as well as towards Ukraine, i.e.

allows for high repeatability of

in a laboratory. The first

the contractor of the building

in the direction opposite to the

the quality of the welds. The

stage was completed in May

works has recommended

current one. Gas will also be

additional benefit is the speed

2018 with the presence of the

the use of the method

transported westwards, directly

of work. - One weld on a DN

representatives of the technical

developed by CRC Evans

from the Underground Gas

1000 pipe is completed about

department of GAZ-SYSTEM,

during the construction of the

Storage Facility in Strachocin.

three times faster than in case

the Technical Supervision

Strachocina-Pogórska Wola gas

of use of the old methods - said

Office, the team of CRC Evans,

pipeline.

Source: www.en.gaz-system.pl

Vern Lewis Welding Supply opens Phoenix Distribution Center

need to have the space and

can be easily accessed from

supply and industrial gas

and purchasing and hard

location to serve our retail

both highways, as well and

distributor, has announced

goods warehouse. The

locations and customers

Grand Avenue. All mail and

the opening of a new central

new distribution will add

on a high level" stated

remittance can now be sent

distribution center in

a tremendous amount of

management. The fill plant

to 1333 North 21st Avenue,

downtown Phoenix.

advantages to the fast growing

will be the last addition to the

Phoenix, AZ 85009. See the

department.

ern Lewis Welding

is centrally located near the

"As the company grows, we

Supply, Inc. an independent welding

I-10 and I-17 interchange and

company by centralizing

building at the end of 2018,

website at www.vernlewis.com

facility has undergone

deliveries, interdepartmental

and will be a hub for route

for hours of operation for each

a remodel to house the

transfers, and a convenient

delivery trucks and transfer

department.

corporate and billing office,

location for customer to visit

trucks.

rental and repair division,

the in-house rental and repair

The 34,000 square foot

www.weldfabtechtimes.com

The new distribution center

Source: www.inddist.com

AUG - SEPT 2018 | WELDFAB TECH TIMES

BULLETINS

ARO joins forces with JEC to accelerate in India

RO Welding

precisely where ARO delivers

Technologies France,

superior and efficient welding

a world leader in

solutions. JEC has a solid

resistance welding systems,

experience in resistance

has announced a strategic

welding and quickly appeared

partnership with JEC

as the best partner to support

Distributors (JEC), a service

our customers across India.

provider to the automotive

We already know JEC from

industry and suppliers of the

a successful partnership in

Copperhead range of welding

North America, and their

products as ARO's exclusive distribution partner for India

approach of the Indian

Source: www.arotechnologies.com

market is consistent with our

effective from April 10, 2018. Headquartered in Southern Ontario, Canada, JEC is an established distributor

customer’s needs.” Jean-Yves David, President France (seated left) with Joe Ruggiero, President JEC. Back row left to right: Philippe Barray, Sales Director ARO France; Garry Siskos, CFO JEC; Nicolas Picq, Area Manager. ARO India; Martin Smith, JEC International development.

Nicolas Picq, Area Manager. ARO India commented, “We are delighted JEC is

of welding products in

will be responsible for the

manufacturing footprint.

representing ARO in India.

other territories including

distribution and servicing

In order to comply with

ARO products are at the

Germany, China and India,

of all ARO equipment to

upcoming CO2 and

forefront of resistance

supplying major OEM

the automotive and other

crash regulations, car

welding and setting

manufacturers and Tier

manufacturing sectors in

manufacturers are going

standards worldwide. We are

suppliers. JEC's Indian

India.

to increasingly rely on

excited about the emerging

advanced materials such

opportunities in the Indian

operation is principally

Jean-Yves David, President

located in Chakan, near Pune

of ARO, said, "India is a

as high strength steel, hot

market and look forward

with facilities in Chennai,

country with a strongly

formed steel, and eventually

to a long and successful

Delhi and Ahmedabad. JEC

growing automotive

aluminum. And that is

relationship.

JEC Distributors Ranks No. 125 on the 2018 Growth 500

anadian Business

in a special print issue of

Aarts, Growth 500 Program

and the dedication of our

and Maclean

Canadian Business published

Manager. “As we celebrate

team, we have celebrated

has ranked JEC

with Maclean’s magazine and

30 years of the Canada’s

18 years of growth in the

Distributors number 125th

online at CanadianBusiness.

Fastest-Growing Companies

automotive industry and

on the 30th annual Growth

com and Growth500.ca.

program, it’s encouraging to

expect to continue on a

see that entrepreneurship

global trajectory to service

Canada’s Fastest-Growing

2018 Growth 500 are truly

is healthier than ever in this

our customers around the

Companies. Produced by

remarkable. Demonstrating

country.”

world.”

Canada’s premier businesses

foresight, innovation and

and current affairs media

smart management, their

honoured to be on the

brands, the Growth 500 ranks

stories serve as a primer for

Growth 500 ranking,” says

Canadian businesses on five-

how to build a successful

President Joe Ruggiero.

year revenue growth. Growth

entrepreneurial business

“This achievement reflects

500 winners are profiled

today,” says Deborah

the strength of our product

500, the definitive ranking of

“The companies on the

WELDFAB TECH TIMES | AUG - SEPT 2018

“JEC Distributors is

www.weldfabtechtimes.com

BULLETINS

Cammell Laird wins £1.5mn tender for Electron Beam Welding

erseyside shipyard

of more than a decade of

and engineering

development initially under

services company

the umbrella of TWI’s Core

Cammell Laird has won

Research Programme and

a £1.5million tender with

latterly at Cambridge Vacuum

Innovate UK to develop

Engineering with TWI’s

electron beam welding

support. This represents a great

technology in the ship

opportunity to demonstrate

building, offshore and nuclear

the effectiveness of this

sectors.

powerful manufacturing

Cammell Laird will act as

process in nuclear fabrication

primary contractor to test the

for use in the UK power

equipment at its Birkenhead

industry and expanding export

site using its team of welders

where the two parts are fused

thinner sections of a ship’s

and engineers, together with

together by a heat generated

hull the electron beam’s lower

partners TWI Limited which

by a beam of high-velocity

energy input reduces distortion

Engineering Managing

will provide research and

electrons. If we can show it

and the need for corrective

Director Bob Nicolson said that

support in welding codes

can work in a production

action after welding. On certain

the large scale electron welding

and standards. The third

environment on large welded

jobs we see that electron beam

machine will now begin

partner, Cambridge Vacuum

structures, our project will

welding could save tens of

construction following the

Engineering will manufacture

mark a massive change in the

hours of labour time. It also

winning of the tender and will

the electron beam machine.

fabrication industry across

provides an opportunity for

be delivered to Cammell Laird

the maritime, renewables and

our highly skilled welders

in around 12 months.

nuclear industries.”

to upskill to more advanced

John Eldridge, Principal Engineer at Cammell Laird

market.” Cambridge Vacuum

“Our revolutionary EBFlow

technology led welding roles.

technology is fully developed

will assess whether electron

at TWI have shown huge

It is great to see Cammell

and pioneered in Britain, will

beam welding can be made

potential benefits of large scale

Laird spearheading world-

transform the productivity

to work in a large-scale

electron beam welding.

leading innovation, a role we

of fabrication processes

have played for generations

throughout the world of heavy

said, +the two-year project

production environment

Mr Eldridge said lab tests

“At present if you are

such as shipbuilding and the

welding the thick-walled tube

in the maritime industry

engineering. In many cases

construction of nuclear power

vessels for a nuclear power

by, for example, making the

the speed of welding can be

plants.”

plant, or monopiles on a wind

first all steel ship, the first all

30 times faster than current

turbine you would typically

welded ship and the first screw

methods. By reducing the

this competitive tender with

use arc welding which is time-

steamer to cross the Atlantic.”

cost of ‘thick section’ steel

our partners,” he added. “Work

consuming and expensive.

is already under-way and

The electron beam, however,

group manager said, “It is

in nuclear as well as a range

although the technology has

makes a weld in a single pass

particularly encouraging to see

of other industrial sectors,

been around for decades it has

which improves quality and

the installation of local vacuum

EBFLow will help play a vital

been only used on relatively

slashes the time and energy

EB welding technology, on-site

role in the development of the

small size applications.

consumption required in

at a significant steel fabricator

global low carbon economy.”

Electron beam welding is a very

traditional welding. For

of the calibre of Cammell

clean form of metal joining

example, if you are welding

Laird. This is a culmination

“We are delighted to win

www.weldfabtechtimes.com

Chris Punshon TWI industry

structures commonly used

Source: www.clbh.co.uk

AUG - SEPT 2018 | WELDFAB TECH TIMES

BULLETINS

Air Industries announces termination of the Sale of Welding Metallurgy Inc., to CPI Aerostructures

ir Industries Group,

the transaction by June. Air

plan during our next quarterly

an integrated

Industries gave CPI more

conference call,” added

manufacturer

than adequate time, access

Melluzzo.

of precision equipment

and assistance to close this

assemblies and components

transaction timely. The

for leading aerospace and

contract had a termination

defense prime contractors,

date of June 19, 2018 and we

announces that it has

granted CPI an extension and

terms of our agreement.

while disappointed in the

terminated its previously

offered concessions. It has

Air Industries and our

distraction this process has

announced sale of its Welding

become increasingly apparent

management team continue

created, the company remains

Metallurgy Inc., subsidiary

that CPI was simply not

to reposition our business

confident in the inherent

(“WMI”) to CPI Aerostructures

going to be able to close this

to obtain profitability and

value of WMI. WMI is a

Inc (“CPI”).

transaction on a timely basis,

positive cash flows and we

good business, a real asset,

if at all.”

are pleased with the efforts

with some terrific customers

Air Industries CEO,

Source: www.airindustriesgroup.com

endeavored in good faith to close this transaction, and

we have taken to-date. All of

and people we value; we are

“We entered into a definitive

the best interests of Air and

our businesses are showing

happy to keep it as part of the

agreement on March 21,

our employees to cease efforts

signs of improvement. We will

Air Industries family. We wish

2018 for CPI to purchase

in closing the transaction,

announce additional details

CPI, its leadership, employees

WMI and anticipated closing

in accordance with the

regarding our repositioning

and shareholders well”.

Luciano Melluzzo stated,

Air Industries Chairman, Michael Taglich stated, “We

“We have decided it is in

WELDFAB TECH TIMES | AUG - SEPT 2018

www.weldfabtechtimes.com

INDEPTH

Revolutionizing underwater welding repairs since 1974

n the early 20th century, it would

in the welds, and the bubbles burst

developed new equipment that makes it

have been considered suicide for a

out, untamed. With the help of others,

much easier to monitor and test the weld

diver to shoot an electric arc into the

Khrenov devised a waterproof coating for

seams. This has been done by our in-

the electrodes and stable power source.

house R&D department who cooperate

water. Though professional diving was already an established industry and had

closely with our diver/technician teams.

been for hundreds of years, underwater

experimentation in the labs, Khrenov

Together they help us invest in the

welding was not. That all changed when

traveled with engineers to the Black

research required to keep evolving the

Konstantin Khrenov, a Soviet engineer,

Sea for further successful testing.

available welding techniques.

invented a method to join and cut metals

Underwater welding was born.â&#x20AC;?1

underwater.

However, it was not until the 1970s

Training of our divers consists of both theoretical classes in the course

that the first underwater wet welding

room and practical drills on our

weld underwater for quicker vessel

procedure was qualified to AWS

premises. There they have access to

repairs. WWI had ended, but WWII

standards by White Grubbs and Dale

a wide range of underwater tools and

was beginning to brew and the USSR

Anders of Chicago Bridge & Iron (CB&I)

various other equipment, including a

was mobilizing their fleets. As Khrenov

and the commercial development of

dry welding training area and three dive

discovered, one of the largest hurdles to

underwater electrodes began.

tanks in which to practice underwater

Khrenov wanted to find a way to

successful wet welds lie in the sporadic

In 1932 after successful

Hydrex has been at the forefront of

welding. Welding exams are taken in-

outflow of gas bubbles from the point

wet welding for well over 40 years. In

house in attendance of a representative

of contact with the arc and metal.

this period we have regularly introduced

of the class.

This reaction caused major porosity

new welding techniques. We have also

WELDFAB TECH TIMES | AUG - SEPT 2018

New divers also get the opportunity

www.weldfabtechtimes.com

INDEPTH

to assist veteran team members during

during a detailed inspection, they were

spotted during an underwater inspection

operations. The training enables

positioned and secured underwater by

before they caused problems for the

them to become experienced divers/

our certified diver/welders. All water was

ship. This once again shows the benefits

technicians and take advantage of the

then emptied from the damaged ballast

of having regular inspections carried

technical know-how and practical

tank. The crew performed an inspection

out by competent divers, followed by

knowledge we have accumulated

of the tank and confirmed that the

comprehensive and accurate reports. Our

over the last 45 years. Below we give

compromised hull was once again fully

teams can detect any problem so that

a summary of just a few of the many

sealed.

they can be corrected early and prevent

underwater welding repairs that we

Thanks to the installation of the

carried out over the last couple of

doubler plates the ship could safely

months.

start its contract. A permanent solution

Hull repair on drill ship

the more costly repair which neglect and further damage would bring about. This was illustrated when the damage

can now be planned at a more

to two of the thruster brackets of a

opportune time.

278-meter container ship was not discovered in an early stage. Both

The transit flap of a 225-meter drill

Wet welding repairs of rudder and thruster cracks

brackets were almost completely

dangerously. This caused damage in the aft bulkhead and a leak in the ballast

A 228-meter vehicle carrier had several

class surveyor we proposed a temporary

tank situated behind the moonpool

cracks along the hinges connecting the

underwater repair plan that would keep

hull. The vessel was located in Dakar.

rudder flap to the main rudder blade.

the thruster safe from further harm. The

A fast solution was needed to prevent

Fortunately most of those could be

plan consisted of the installation of four

further damage.

repaired by grinding them away and

steel plates: one on the top of each crack

filling the area with clad welding.

and one on the bottom.

ship came loose and started swinging

We mobilized a team of diver/ technicians. After an inspection of the

Three of the cracks were too big and

damage, they disconnected the transit

needed a different approach. Our diver/

flap. It was then brought to shore, cut in

welders first drilled arrests on all sides

three pieces and taken away. The divers

of these cracks to prevent them from

also took all the measurements needed

spreading. They then positioned a

to design a repair plan for the second

C-shaped plate over each of the cracks

phase. Because of the instable condition

and secured it with wet welding.

cracked. In communication with the

of the flap, it was essential to keep to the highest safety standards, especially during this first part of the operation. This meant that the owner could keep his schedule without the hassle and financial setback of an unplanned drydock visit.

Summary When we send a team out on the road we This allowed the owner to sail the

know that they can perform underwater

vessel without having to worry about the

welding work to the highest quality

condition of the rudder. He can have a

standard and this on a daily basis. This

consisted of the installation of six

permanent repair carried out during the

is very important because our customers

doubler plates over the damaged

shipâ&#x20AC;&#x2122;s next scheduled drydock visit at a

pay to get the best result without any

areas in the aft bulkhead. Constructed

more convenient time and location.

unnecessary loss of time. So that is what

The second part of the operation

with the exact measurements taken

www.weldfabtechtimes.com

Luckily the cracks on the rudder were

we deliver always.

AUG - SEPT 2018 | WELDFAB TECH TIMES

PRODUCTS UPDATE

AMADA LCG-3015 CO2 Laser A New Benchmark for Performance & Price. • Lower centre of gravity allowing higher speeds • New helical rack drive with high torque motor which allows for faster and precise material processing Reliable Automated Operation • Proven automation options

MACHINE TYPE: LASER

• New 3.5kW CO2

Amada introduces the

Oscillator - highly tuned

• Improved surface quality

STANDARD FEATURES

new LCG3015 flatbed laser

for quality and stability

• Oil shot pierce – prevents

• ActiveCut

cutting machine. Setting

• Energy saving - ECO

a new benchmark for

Cut and reduced power

performance and price at

consumption

this level of investment, the

• VPSS software solution

machine ensures optimum

pack for seamless

productivity and value.

part processing and

Aimed at any sheet metal

programming

high speed cutting of thin

BENEFITS:

to mid-thick materials, the

Compact & Efficient

LCG3015 sets new standards

• Reduced servicing and

for quality and value on a flatbed laser cutter. In fact, the CO2 machine is capable of processing mild steel up to 20mm thick, along with

maintenance • ECO Cut – 38% higher processing speeds with smaller nozzles • Reduced processing

10mm stainless steel and

times and 45% less assist

8mm aluminium.

gas usage

• Rapid feed rates: 170m/ min, the fastest in class • Lightweight Y-axis carriage with low centre

Easy Operation • AMNC touch screen control • One touch lens change

• New helical rack drive ensures high speeds and smooth operation

quality

• Aluminium cutting (AluCut) • AMNC touch screen

Fast & Easy Part Processing • VPSS software solution pack • Production Designer quickly and accurately • Connected to SDD database • DR ABE Blank – Fully

control • Automatic gas pressure control • Automatic pallet changer with shuttle table • Bar code reader • Chiller • Contact free HS cutting head

automatic programming

• Dust collector

and nesting

• ECO Cut

• Bar Code Reader – Fast program loading

• High pressure cutting (CleanCut) • Integrated air purge

Fast & Precise Material

system

Processing

• NC auto focus control

• Rapid feed rates: 170m/

• Oil shot function

min - the fastest in class • Lightweight Y-axis carriage - 30% weight reduction

of gravity - 30% weight reduction

splatter and improves

– process 2D/3D files

shop looking to achieve

beam density

• One touch lens exchange • Power save mode • VPSS software solution pack.

Excellent Cut Quality • New 3.5kW AMADA tuned CO2 Oscillator • 30% improvement in

WELDFAB TECH TIMES | AUG - SEPT 2018

For More Info: Email: info@amada.co.uk Tel: 01562 749 500

www.weldfabtechtimes.com

PRODUCTS UPDATE

Inductive Sensor Series for Welding Applications Fortron PPS Sensing Face Resists Thermal Breakdown, Minimizes Downtime

eld spatter

completely market-driven,"

burn-through

says Shawn Day, product

is a constant

marketing manager for

challenge with inductive

Balluff. "We at Balluff are

sensors in automated

constantly listening to the

welding applications. Balluff

expectations of our customers

is pleased to announce an

in the automated welding

all-new series of inductive

industry, and they told us that

flatpack sensors with the

tougher sensors are needed."

active sensing surface made

Typical plastic sensing

through

thermal breakdown in hostile

• Die-cast zinc housing

welding environments.

combats adhesion of weld

The new housings having

from Fortron, a high-

face materials suffer from

performance polyphenylene

erosion and degradation due

the same form factor as the

sulfide (PPS) material. These

to repeated impingement of

standard flatpack sensors

new BES R01 flatpack sensors

hot weld spatter. The closer

making installation simple.

jacket protects conductors

help to combat the hostile

the sensor is placed to the

Equipped with additional

from weld-spatter burn

conditions found in welding

welding electrode, the shorter

features designed specifically

through

environments.

the sensor's life expectancy.

for welding applications,

The Fortron PPS sensing face

Balluff's new Fortron PPS

eliminates typical LED

these new welding-oriented

on Balluff's new flatpack

flatpack sensors can help

burn through on sensor

inductive sensors is

sensors effectively resists

plant operators reduce

"The development of

spatter • High-temp silicone cable

• LED in the connector

housing

downtime occurring due to

• Weld-field immune (WFI)

premature sensor failure.

option for stable operation

• Fortron PPS sensor face

near electrical welding currents

resists weld spatter burn For More Info: www.balluff.com/services

Model WS625 Weld Shaver

S625 Weld

head to a position to remove

Features:

Shaver is

the base material in a very

• Double Insulated

clean, fast, efficient manner

• Adjustable handle

Heck Industries to machine

that is much safer than

flat surface butt welds flush.

grinding.

The company has used replaceable carbide inserts installed

• Milling Cutter head with 8 replaceable carbide inserts

positions for comfortable

• Fast cutting at 6 feet per minute

operation • Trigger operation with

• ½” Width of cut in a single pass

lock • Specially designed gear drive motor

• 4 HP, 110 Volt, 50/60hz • Weight 24 pounds.

on a revolving milling type cutter head that has an adjustable height of cut to allow the user to lower the

www.weldfabtechtimes.com

For More Info: Tel: 1-810-632-5400 E-Mail: HeckInd@ameritech.net

AUG - SEPT 2018 | WELDFAB TECH TIMES

PRODUCTS UPDATE

New approach to TIG welding

ronius International began in 1945 as a oneman operation now

sets technological standards in the fields of welding technology, photovoltaics and battery charging. Today, the company has around 3,800 employees worldwide and 1,242 patents for product development show the innovative spirit within the company. Sustainable development means for us to implement environmentally relevant and social aspects equally series is the TransTig 230i

TIG devices can be used in

Highly versatile power sources for AC welding

many different ways.

Whether in pipeline or

just 15.9 kilograms, it is

with economic factors. Our

and maintenance – the new

goal has remained constant throughout to be the innovation leader. We have

container construction,

especially light. This manual

for processing stainless

power source is suitable

of hours of TIG welding

Fronius launches new TIG series on the market

steel or vehicle repair and

for all welding applications

experience and condensed

Austrian technology leader

maintenance – the new

apart from aluminium. As

into few simple operations.

Fronius has expanded its

Fronius TIG welding systems

with the MagicWave 230i,

A clean TIG weld seam

portfolio of manual power

have a whole range of uses.

the power source can also

requires two things: A

sources with three new

The most powerful power

be supplied with an optional

high degree of skill and

devices for Tungsten Inert

source is the MagicWave

water-cooling system. Using

countless hours of practical

Gas welding (TIG). The

230i for AC welding. It has

Bluetooth, WLAN and NFC,

experience. We‘ve packed all

MagicWave 230i, 190 and

one particular advantage:

the TransTig 230i can also

this experience into our new

TransTig 230i are extremely

it can communicate with

connect wirelessly to devices

TIG series. With its intuitive

practical, powerful and

other devices via Bluetooth,

such as an intelligent welding

menu navigation, users are

quiet. Thanks to their rapid

WLAN and NFC technology,

helmet, remote control or

able to access the correct

signal processors, they

and can be networked with

even a smartphone.

parameters in just a few steps

always achieve the exact

them. The MagicWave 190 is

and can then concentrate

current curve that allows for

ideal for welding materials

fully on what they‘re best at.

maximum arc stability with

such as steel, stainless steel

Optimum user customisability

The functions can also be

the lowest possible noise

or aluminium. The AC power

The multilingual operating

customised and extended,

emissions. With its intuitive

source features gas cooling

concept of the manual

facilitating efficient manual

menu navigation, users are

and is the best choice for a

power source with a 4.3-inch

welding.

able to access the correct

wide range of uses.

full-colour display allows

managed to put thousands

From pipeline and

for DC welding. Weighing

parameters in just a few steps

for intuitive and extremely

container construction,

and can then concentrate fully on what they’re best at –

Lightweight for DC welding

simple operation. Using the

through stainless steel applications to vehicle repair

achieving a clean weld seam.

An integral part of the new

can easily retrieve and set

WELDFAB TECH TIMES | AUG - SEPT 2018

favourite’s button, welders

www.weldfabtechtimes.com

PRODUCTS UPDATE

• Direct connection to

parameters that they often

cooling system in the

use. The modular design is a

power source

particular advantage: users can expand these devices

• Multi voltage versions

as desired with different

(MV) for worldwide

function packages. These

deployment.

include the job function, which can store up to 999 jobs

MODULAR TORCH DESIGN

at the same time, the PulsPro

THANKS TO MULTILOCK

package to obtain all pulse

SYSTEM

functionalities, additional

• Easily configured and individually customisable

data documentation and limit monitoring. The latter aids

entirely on their task and

the user in setting a defined

achieve excellent results.

welding torch

gloves

• One hosepack for various

• Favourites button for quick access to the most

parameter window and parameters. USB ports

ADVANTAGES OF THE NEW TIG SERIES

allow software updates to be

IMPROVED WELD PROPER

COMMUNICATIONS

installed and welding data to

TIES

CAPABILITY, PLUS

be documented.

• High open circuit voltage

ADDITIONAL FUNCTIONS

keeping to certain welding

New welding torch for precise handling

torch bodies • Gas-cooled torch body

important parameters

can be changed during operation without any tools • Rapid reconfiguring of the

and ample power reserves

CAN BE ADDED

user interface in the grip

improve HF ignition

• The MagicWave230i

possible.

behaviour

and TransTig 230i

multivoltage version. Using

standard on all devices;

with peripheral devices

About Fronius India Pvt Ltd

the Fronius Power Plug – a

the PulsPro function

via Bluetooth, WLAN and

Fronius India Pvt Ltd is

lockable plug connector

package can deliver a

NFC

headquartered in Pune with

on the rear of the power

pulse frequency of up to

Every device is available as a

source – the mains cable or plug can be changed quickly

• 2 kHz pulse welding as

10 kHz • Saving and editing of up

communicate Wirelessly

• Adaptable to customer

33,000 Sq ft Application

requirements using

Development Centre, with

optional function

Robotic, Manual Stations

and easily depending on

to 999 jobs using the Job

packages that provide

for customer trials &

where the device is being

function package

the power source with

application development.

additional, customised

Fronius India also has a

functionality.

world class training facility

used. This means it can be used anywhere in the world

QUICKLY AC HIEVE A

– even with different mains

CLEAN TIG WELD SEAM

voltages. Fronius has also

THROUGH SIMPLE

EASY TO USE AND

of Welding operators and

redesigned the welding torch:

CONTROLS

MODULAR DESIGN

Engineers. There are 23,000

an ergonomic grip combined

• Multilingual menu

• Lightweight and easy to

Fronius Machines installed

with a torch changing

• Intuitive and self-

system as standard increases

explanatory menu

comfort and convenience,

navigation

and allows for even more

• A bright 4.3” colour

precise handling. The

display makes parameters

integrated, high-performance

easier to set and read

LED illuminates the seam

• Operation of rotary and

area efficiently, leaving

push button also possible

the welder to concentrate

when wearing welding

www.weldfabtechtimes.com

to address the Training Need

transport

and working in the field of

• CU 600 t water cooler with

Indian Market. Fronius has

20% more power than the

regional sales teams in Delhi,

earlier model available

Mumbai, Pune, Bengaluru

separately

and Chennai.

For More Info: Tel: + 91 982605297 / +91 2135 677400 Email: Sales.India@fronius.com; Service.india@fronius.com

AUG - SEPT 2018 | WELDFAB TECH TIMES

PRODUCTS UPDATE

Linde MIG 250GS Arc Welding Machine

inverter-based Mig

stainless steel U groove

& Stick machine.

for use with soft wire

It delivers smooth

such as aluminium

he Linde

V groove for use

DIY jobs.

MIG 250GS

with solid carbon

• Package includes: MIG

machine is an

manganese and

machine • 3-year warranty covers

that will help you complete high quality welds. This

• Ground clamp and return lead • MIG gun

parts and labour. Excludes

• Tool box and torch holder

torches and consumable

• Gas hose

for Flux Core wire.

items. Warranty will not

• Spare feed rolls

Ideal for sheet

apply if operating and

• Operating manual

metals, stainless

service instructions are

• MMA Electrode Holder.

and knurled rollers

arc characteristics

machine comes

250GS arc welding

not followed. • Power cable and plug

steel and aluminium

complete with three

fabrication. Suits light

type of wire feed rollers;

industrial, maintenance and

For More Info: Website: www.linde.com

MS soniMAC MULTI

he machine concept

adherence to tolerances

MULTI is designed

due to workpiece

by MS Ultrasonic

clamping

Technologies Group for processing in multiple positions in a single part handling. • Several machining positions and process

optimized process flow due to parallel loading and machining sequence • Precise positioning and

process • High productivity through

• Reproducibility and quality monitoring via

shorter cycle times • Modular design for

process documentation • Optimized solution for

optimal flexibility • Up to 60% of all standard

series production of

work pieces can be

complex components

processed • Punching process can

steps in a single machine • Short sequence times and

parallel to the welding

our benefit • Several processing steps in single parts handling • Optimal cycle time: loading and unloading

be combined with

other processes such as welding, deburring or embossing • Low-maintenance drive with electronic control of the punch module

For More Info: Telephone +49-7424-701-0, Fax +49-7424-701-63 Email: info@ms-ultrasonic.de

2400 Series of welding reels

he 2400 Series of reels from Hannay Reels are available with

manual or power rewind. These reels are designed

• Standard outlets: are male

• MX rewind reels supplied

9/16"-18 threads. Right

with pinion brake • Power reels not supplied

to handle twin 1/4" through 3/8" welding hose & may be used in oxy or fuel

with brake • Standard inlets: 90° ball bearing swivel joints with 1/2"

welding.

female NPT threads.

• MX chain drive

Oxy/acet brass

crank rewind or

available

WELDFAB TECH TIMES | AUG - SEPT 2018

inlet adapters are

hand for oxygen, left hand for gas • Rollers may be purchased. Specify roller position (mounting brackets are

necessary) • Pressures to 300 psi (21 bar) • Temperatures from -40° F to +200° F (-40° C to +93° C) • Type of gas used MUST be specified.

For More Info: Hannay Reels Inc. 553 State Route 143,Westerlo, New York 12193 USA FAX: 518.797.3259 / 800.733.5464

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

e Pr

at He

t os |P

at He

om st

le yc tC a He

g ro yd H |

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

INNOVATIONS

Hypertherm launches Robotmaster V7 New Software Rewrites the Future of Robot Programming

obots are capable of so much

preventing collisions between one or

more. Imagine if you could easily

more robots, parts, and tooling. Finally, a

harness that power and flexibility.

software engineered as brilliantly as the

What if you could exploit the full capabilities of any robotic cell, no matter

robots themselves is available. This paradigm shift did not come easily.

how many robots or axes are involved, regardless of the number or types of

The Making of a Revolution

processes performed, or the variety of

It began as an ambitious goal, to bring

tooling? Envision the possibilities.

robotics to the masses. Especially to the

Now, picture a software with no limits.

Mr. Chahe Bakmazjian, Business Development Manager (Robotics Software), Hypertherm

small- and mid-sized businesses that

A software with unmatched flexibility and

make up 90 percent of manufacturers

configurability. A software built from the

â&#x20AC;&#x201D; those that have yet to harness the full

ground up to eliminate the constraints of

potential of robotic automation. This

complex robot programming. Whether

would be akin to how Microsoft BASIC

you are a first-time robot user or an

helped propel the mainstream market for

experienced integrator, you get error-free

personal computers, and how modern-

results. Deployment happens in days, not

day apps simplify the use of everyday

months.

computing devices on our desks and in

A revolution is in the making. It starts with Robotmaster V7 software. This

our pockets. Robot programming can be

is a task-based robot programming

complicated. Complexities such as

platform built around the user, for the

singularity, reach issues, joint limits, and

user. Robotics expertise is no longer

collisions can trip not only the novices up,

a prerequisite. Navigate complex part

but also the seasoned robot users.

geometries and optimize robot paths

The goal, withRobotmaster V7,

while synchronizing movements and

was to create the ultimate software interface to optimize the programming of robotic tasks, to create an intuitive tool that anybody could use, with or without robotics expertise. It would cater to process experts, to make robot programming easy and intuitive even for first-time robot users. To make robots practical for the everyday manufacturer and still productive for sophisticated users with complex robotic cells, the development team at Hypertherm Robotic Softwareknew the architecture would require a significant change. The Robotmaster software was already renowned for its legendary ease of use. It

WELDFAB TECH TIMES | AUG - SEPT 2018

www.weldfabtechtimes.com

INNOVATIONS

was the platformâ&#x20AC;&#x2122;s optimization tools that

trying to understand all the different ways

videos until they had a good idea of the

put Robotmaster on the map in 2008. By

robots are currently used and may be used

framework for the task-based approach.

creating software that enabled users to

in the future.

With a clean slate, and having gathered information on everything that people

visualize and optimize robot trajectories, the developers were able to help demystify

User-Centric Architecture

told them they wanted to do with robots,

robot programming.

The Robotmaster team found that the

the team recognized the need to create a

future is increasingly populated with

brand-new architecture and rewrite the

robots drilling airplane fuselages at Boeing

multi-robot cells, where the robots are

software line by line.

and Airbus, polishing automotive dies at

performing more than one type of task.

Daimler, and adding value to the myriad

It is often a combination of processes,

that working on a new architecture also

of processes at family-owned job shops

including material removal, welding, and

meant they would need a new team.

around the world. The developers knew

polishing. While the current software

The existing Robotmaster team largely

the future still held far more promise.

supported one robot for one task, the new

comprised mechanical and electrical

Like other leading robotic offline

robot programming software would need

engineers. Their vision for the new

programming tools of the day, the

to support multiple tasks. It would need to

software would require other disciplines

platform was built on early machining

support more than one robot, more than

in order to create the user-centric

ideals and piggybacked on CAD/CAM

one tooling and process, in multiple types

interface integral to the new task-based

software. This architecture assumed

of settings, and with any number of tasks.

programming solution.

Today, Robotmaster software is used on

a basic understanding of robotics and

It was daunting, and they understood

Until then, robot programming software

CAD/CAM tools. It would take a major

was created from a purely robotics point

One-Click Ease of Use

disruptive change to make robotics

of view. The Robotmaster team would

Seeing the need for an influx of new

practical for more users.

instead focus their attention on the

knowledge, know-how, and a new way

The team watched thousands of hours

userâ&#x20AC;&#x2122;s perspective. The team focused on

of doing things, the Robotmaster team

of video footage on robotic applications,

the user and neatly categorized all the

recruited experts from other disciplines,

studying the different scenarios, and

different scenarios they were seeing in the

including those in mathematical

www.weldfabtechtimes.com

AUG - SEPT 2018 | WELDFAB TECH TIMES

INNOVATIONS

“Importing CAD models is where the challenge has begun, because creating the perfect trajectory for welding seams has been a tedious and highly iterative process of identifying programming problems, and subsequently correcting them. This was precisely the impetus for Robotmaster’s new V7 architecture. The new platform has successfully integrated offline programming, simulation, and error free path trajectories. The user downloads the program to the robot and runs it. No more finger-crossing and hoping that the many ‘bridges’ between the CAD models and programming deliver proof-outs that would work. With optimization who understood AI and deep

software release will allow for welding and

Robotmaster V7 architecture, a welding

machine learning, and even simulation

contouring, including trimming, cutting,

expert with no previous experience is

and game experts who were passionate

and deburring. Subsequent modules

empowered to deliver error-free results

about user interaction and wanted to

will enable additional tasks, including

every time!”

apply their skills to the industrial space.

assembly, surfacing, 3D milling, additive

In order to achieve the one-click ease of Robotmaster V7, the team had to

The framework allows additional

Future-Proof With this new software architecture,

design an intuitive user interface, which

modules to integrate seamlessly within

Robotmaster V7 is able to exploit the full

included designing the on-screen menus

the application, so users can inject menu

capabilities of robots, and maximize their

with non-technical users in mind. CAD/

options or items within the application,

flexibility and configurability for a variety

CAM jargon is replaced with terms anyone

without the impression that this is an

of tasks. Its user-centric, task-based

can understand. With a CAD model of a

extension. There is a coordinated look,

programming will propel the Robotmaster

part on the screen, one can simply hover

feel, and workflow.

V7 software into the future. Subsequent

the cursor close to an edge. The software

Designing a software that is intuitive

software releases will add capabilities

understands what the user wants to do

for first-time robot users, but still remains

for programming multi-robot cells and

and displays all the relevant choices. The

flexible enough to manage more complex

seven-axis robots. Future additions will

robot path is created with one click.

processes and scenarios, is a challenging

incorporate Industry 4.0 capability.

endeavor. When developers try to make

Software bridges will allow existing users

also sought out professional software

software flexible enough to easily change

of Robotmaster software to leverage their

engineers with a passion for robotics

features and add functionality, they

own CAD/CAM tool of choice, or take

to ensure the application’s modularity,

often sacrifice robustness. The software

advantage of the integrated CAD/CAM

flexibility, and quality control. The new

becomes buggy. With Robotmaster V7, the

functionality of Robotmaster V7.

architecture is a reflection of this multi-

multidisciplinary team was able to create a

disciplinary team that learned how to

balanced product that achieves flexibility

need to be easier to use. They need to be

respect each other’s disciplines and work

and maintains robustness.

practical for SMEs & large multinationals

To round out their team, Robotmaster

together in an agile manner.

“As fabricators move toward

To bring robotics to the masses, robots

alike. With the Robotmaster V7,

automation, there have been several

harnessing the true flexibility of robots is

two-year period, the development team

challenges with welding applications,”

now anyone’s domain.

built a flexible framework that allows

shares Chahe Bakmazjian, Business

for additional modules to be released

Development Manager (Robotics

For More Info:

over time. The initial Robotmaster V7

Software), Hypertherm.

www.hypertherm.com

Working in three-week sprints over a

manufacturing, and inspection.

WELDFAB TECH TIMES | AUG - SEPT 2018

www.weldfabtechtimes.com

ARTICLE

Lean Welding – An Approach to Best Welding Practice consumables and automation. In

3. WELDING MACHINES

association of these developments, codes

Gas welding Torch, Transformers,

and specifications, quality management

Rectifiers, Inverters, Pulsed Welding

systems, testing and inspection, operator

sets, Spot and seam Welders, Plasma

training and testing are also developed.

welding setup, Electro Slag Machine, All

The outcome of these efforts and toil

these Welding equipment have again

cannot be articulated and documented

multi variation models in Moving Core,

in this limited scope. But at least an

Fixed Core, Thyristor Controlled, Engine

attempt can be made to frame the overall

driven Motor Generator sets.

scenario prevailing at present.

Manufacturers of these machines are very many and capacities and

1. DESIGN

range of parameters covered are

Product design in respect to weld design

wide. Obviously, the parts of these

has become a sophisticated process.

machines manufactured by different

INTRODUCTION

In place of manual design and use of

manufacturers are of different shapes,

Today product innovators and

empirical formulae applicable over a

sizes and designs.

entrepreneurs want the designers,

wide range of materials and service

technologists and engineers involved

conditions with standard consumables,

in manufacturing and fabrication to

computer soft wares have been

4. MECHANIZATION AND AUTOMATION

produce the intended marketable

developed for specific material, specific

Along with the technological advance of

product in the shortest possible time

service condition, specific loading

the processes dependence on manual

with superior quality & at the least cost.

condition and other factors. It is of

operation is being reduced with a

course essential for the designers to have

target of eliminating it altogether.

best meteoric growth next to IT in

in depth knowledge of materials and

Use of Templates, Jigs and Fixtures,

Technological perspective. It is all

their behavior, structural stress analysis,

Manipulators, Rotators, Positioners,

pervasive – from minor household

computer soft wares and of course

Hydraulic Clamping, Electronic

equipment to gigantic structures

practical applicabilty of design.

Indexing, Robotic welding are the

Mr. S. K. Gupta. B.E., C.E., FIE., FIIW., MISNT., MAE., MITD.

Welding today can claim the second

in buildings, bridges, tunnels, rail road, motorways, mining sea faring

2. WELDING PROCESS

ships, air ships, inter planet voyage

Starting from the year 1887 (?) when

vehicles, satellites and not to speak of

Lavoisier discovered use of Oxygen and

IT equipment, welding is used as the

used it in industry for welding; and later

5. MANUFACTURING SET UP – PREPARATION

major assembly process and technique.

on with the introduction of coatings

Efficiency and Effectiveness of a welded

Products differ from manufacturer

on bare rod electrode in 1907, welding

joint in a job executed by any process

to manufacturer and products have

processes have been innovated to

or technology solely depend upon the

different models and variations of

cover a very wide range of application.

accurate preparation of the joint and

design.

Soldering and Brazing, Gas welding.

the fitment prior to welding. Shearing,

SMAW, MIG/MAG, TIG, Electro Slag

Machining, Gas Cutting, Plasma Cutting,

of toil of Innovators, entrepreneurs,

welding, SAW, PLASMA, Electron Beam

Bending, Sawing manually conducted

technologists and engineers covering

welding, Resistance welding, Friction Stir

before are being done by CNC machines

a wide range of design, technology,

Welding, Orbital Welding are only a few

to conform to the Joint Specification as

machineries, equipment, process,

to name.

accurately as possible as per WPS.

This has been the outcome of years

outcomes applied for increasing

WELDFAB TECH TIMES | AUG - SEPT 2018

production and productivity.

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6. INSPECTION/ QUALITY CONTROL/QUALITY ASSURANCE – CODES & SPECIFICATIONS

others not so well equipped.

designed to provide the optimum framework for efficient and effective production. The lean production system

Possible defects in a weld conducted

focuses on the reduction of waste from

by any process are more or less same

the value stream in order to remain

with less or more in extent. In order to

competitive. Lean manufacturing is

attain the ultimate objective of defect

lean because it provides a way to do

free welding (Six Sigma?) it is necessary

more and more with less and less—less

to use proven Codes and Specifications.

labor, less equipment, less time, and less space—while coming closer to providing

These codes and specifications direct the weld producing organizations

RESULTING FIRE FIGHTING AT ALL

customers with exactly what they want.

STAGES

to formulate Inspection procedures, Guidelines. IS, BS, ISO, DIN, ASME, AWS

Standard, Uniform and Single Welding Process

are a few only to mention from a large

The Approach to Best Welding Practice

contingent

may start with lean welding becoming

Quality Control and Quality Assurance

the Focal Point when the organization

7. OPERATORS AND SUPERVISORS – KNOWLEDGE AND SKILL

may commit to use a Standard Single

Whatever may be the welding process,

above starting from design to welding

machineries and equipment, automation in use, knowledge and skill of the

Process for all criteria described WHAT WE NEED TO APPROACH FOR THE BEST WELDING PRACTICE

management system in the whole of the supply chain in operation. The steps may

supervising staff and most importantly

be stated in the following order:

of the operators or welders are of prime

1. Welding Management System – ISO 3834 is the ideal to adopt for global

importance. Today, skill development

application.

through structured National Operational

2. Standardize the Design Codes,

Specification curriculum, National Certification of Vocational Training

Specification and Auto Cad system.

are available at a minimum or no cost

Eliminate manual and Rule Of Thumb

at all to willing young generation and

processes. 3. Standardize the Welding Procedure

experienced workforce. The BEST PRACTICE in welding can be

Specifications and WPR in single

8. WELDING MANAGEMENT SYSTEM

simply defined as the most EFFECTIVE

Welding as an operational entity covers

The term “EFFECTIVE” refers to the

the most difficult decision to make.

a plethora of subjects and that to in

method which utilizes the resources

Selection of a single welding process

great details. It starts with the customer

to the optimum extent and the term

apparently is not possible in a

contract and covers the total supply

“EFFICIENT” refers to the method

manufacturing situation. Even if we

chain till customer satisfaction. The need

of Right First Time with minimum

select two or three processes out of

for a Welding Management System like

wastage. In addition an approach for

many for specific applications still

ISO 9001 has been felt earlier and now in

Continuous Improvement will pave the

it is acceptable. But there must be

a position to accept and implement.

way for adopting the BEST PRACTICE in

a rationale behind the selection by

Welding.

calculating percentage use of different

All the above mentioned scopes,

and EFFICIENT method to weld a joint.

format. 4. Standardize the Welding Process –

types of weld, positional approach

criteria, variables, implications are in

CONCEPT OF “LEAN WELDING” IN RELATION TO THE BEST PROCESS

and productivity factor. Selection of

knowledgeable to access for the best, but on the other hand creates confusion to

“Lean” is a manufacturing concept

Welding, TIG, FSW, Plasma or

one hand opened up opportunities to the

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SMAW or MIG/MAG, SAW, Resistance

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ARTICLE

Electron Beam Welding for specific

with use and age; meters on the

application may definitely be selected,

machines and the Regulating Knobs

but should be confined to the specific

will not indicate correct setting

application only.

of parameters. Such a condition

5. Once the welding process/processes

impedes productivity quality, and

(recommend Pulsed MIG, if MIG is selected) operation • Better puddle control with locked in current and voltage

are identified and selected, the next

operator’s morale, increases degree of

important part is to Standardize

supervision, delivery period and cost.

Machinery and Equipment for that

Outputs of all the Welding Sets in

• Less spatter with current control

specific process. For example, if 80

terms of steady current and voltage is

• Improved arc stability through

percent of the weldment need MIG

essential. Any fluctuation or variation

then we must select one make, one

in these parameters will adversely

model, one capacity specific units

affect quality production and

of single type of Power Packs, Wire

productivity. Even a skilled worker

Feeders, Torches for all the weldment

working with such variations will not

to be covered by MIG irrespective of current and voltage requirement for different joints. 6. Once the machinery and equipment

be able to produce a good weld. 10.

Safety, Maintenance

and Inspection of Arc Welding Equipment in Use. Standardized

• Reduced distortion due to low heat input

reduction of controlled parameters locked in. • Operators are confident to produce high quantity weldment with quality. • Welding Training will be simplified and of shorter duration on knowledge and use of limited brand machines and accessories focusing more on techniques and productivity.

are standardized, all consumables are

Welding Machinery, Equipment and

also to follow suit – one brand, one

Accessories after calibration needs

with Standard productivity in

type, one size of electrode from one

regular inspection and maintenance

different Work Stations having

supplier, one type of gas or gas mix,

to sustain exposure to optimum

Standardized Set Ups.

one type, one brand and one size of

uses with minimum probability of

slag from one vendor.

failure. In addition, the health and

performance (higher production rates

safety of the operators are ensured

with fewer errors and better morale).

7. Standardizing Jigs, Fixtures, Rotators,

• Provide flexibility to deploy welders

• Immediate improvement of operator

Manipulators, Positioners, Clamping

by this process of Inspection and

• Eliminate sources of variability in

devices and arrangement should run

maintenance of work equipment

quality and productivity between welding stations in different shifts.

parallel. It is understood that for each specific job or part or subassembly

Process related benefits

different types of Jigs-Fixtures

As welding is standardized through

is greatly simplified and streamlined

are needed, but locating, holding

standard fit ups, single process with,

by drastically reducing parts count;

positioning means and devices must

in standard positional set ups on new

maintaining 200 to 300 Welding

be standardized.

welding technology, numerous process-

Sets of the same design enables

related benefits are generated, such as:

maintenance to become very

8. Lean Welding requires minimum wastage of materials and consumables, less labour, low production time. As the correct Fitment for a Joint depends solely

• Eliminating variability in primary power fluctuation (with Grouping as in Auto-Line technology) • Ability to limit or “lock-in”

• Maintenance planning and execution

proficient. • Change the typical vendor-supplier relationship into a vendor-partner relationship where each party

upon the preparation process and

functionality within scope of specific

contributes more to the value chain

accuracy, standardization and

requirements

and benefits accordingly.

automation is desirable to eliminate

• Multi-MIG process capability using

manual preparatory methods and

one type of wire and one type of gas

Vendor – Partner Relationship

introduce CNC Gas, Plasma, Shearing,

mixture.

The traditional relationship between

Bending, Slotting, Punching, Drilling, Edge Planning operations. 9. Calibration of machinery. Output of Machines and equipment diminishes

• Less heat input through pulse

WELDFAB TECH TIMES | AUG - SEPT 2018

• Ability to weld thick or thin metal with same set up. • Improved travel speed with lock in function.

a Manufacturer and the suppliers of Machineries, Accessories and Consumables is just a buyer and a seller for a particular transaction. The main

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ARTICLE

interest common to both the parties is

and production work with welding as a

the PRICE and the payment. Instead,

major or minor process are outsourced.

understanding each other’s needs, goals

Work is contracted out to contractors.

and long-term objectives must be given

Engagement of a Contractor must be

priority over price and delivery

based on his knowledge of welding and

CATEGORY

IDEAL SITUATION

III

fabrication and an attitude towards

should develop into a joint venture of

continuous improvement. In most of the

Lean Journey to include:

Manufacturing Workshops we will find:

• Supplier-managed inventory for

Once such a relationship starts it

Skilled Welders, qualified as per

productivity it is imperative and

accessories and spares at Vendor’s

ASME / EN / AWS / IS standard

absolutely necessary to facilitate a

stores.

and performing welding to the

continuous “On The Job Training” to all

best of their knowledge and ability

the Welders. The Training Contents at

customer requirement for a long span,

producing good quality welds to the

different stages of Welding are outlined

rather than to a short forecast.

specified productivity norms – very

below:

few in number !

I. ON THE JOB – Functions, Operations,

• Planning and building inventory to

• Daily on-line inventory replenishment for delayless supply. • Ability to build and ship even customer specific products in one day • Same-day shipping of replacement parts • Building facilities for some circuit

ii. Skilled Welders, qualified as per

a. Setting the Welding Set Up

performing welding in a lackadaisical

b. Striking the Arc

attitude producing average quality

c. Maintaining the Arc for

welds with some rectifications to

Welding

production norms – many in number!

d. Gas Flow – Setting,

boards to be built in-house.

iii. Semi-skilled Welders without formal

• A flat, responsive and reactive

qualifications through tests and

organizational structure. • Employees at supervisory levels empowered to make decisions. • Line employees/ operators engaged in production, inspection and

Regulating, Adjusting

certification engaged in welding

II. INSPECTION – Before

producing good quality welds to the

Welding - Check

productivity norms – quite a few in

a. The JOB

number!

b. Jigs / Fixtures / Rotators /

iv. Semi-skilled Welders without formal

maintenance empowered to manage

qualifications through tests and

their own business areas.

certification engaged in welding

Manipulators c. Safety at Work – Follow up

producing poor quality welds with

III. During Welding – To Carry out

Welding system performance is

large number of rectifications and

welding properly

important, but more value should be

naturally with below par productivity

a. Welding to start on the extension

placed on finding a responsive welding partner with similar organizational

norm – few only in number! v. Unskilled workmen engaged mainly

piece or on the joint itself. b. In Butt welding electrode should be forced for penetration

philosophies, structures, objectives and

as Manual Welder for tacking work in

goals. This type of relationship, where

the fitment of parts and components

c. For Root welding, a 2.5 dia. Electrode

both parties are aligned for mutual

in Jigs and Fixtures prior to welding –

in SMAW and 1.2 mm wire in MIG/

success, enables the parties to manage

quite a few in number !

product’s use.

In an IDEAL situation the percentages of the above

Making of a Welder

categories working with strict

The most important part in the approach

supervision should be:

to best welding practice is making of

In addition to “Off The

an Welder and his performance on

Job Training”, to sustain continuous

the job. Today most of the fabrication

improvement in weld quality and

WELDFAB TECH TIMES | AUG - SEPT 2018

MAG are effective. d. Correct weaving motion and direction

better the challenges that arise with any

Safety

ASME / EN / AWS / IS standard and

of travel to be selected for effective Bead shape and form. e. Craters to be removed by back tracking weld beading. f. Ends of joint should be locked. g. Welding size must as per WPS – No oversize beading should be

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ARTICLE

encouraged / entertained h. Torch angle to be maintained at 90

CONCLUSION

applicable for the product. Lean Welding

Welding Technology is advancing at a

as defined in this article is a vast subject

deg. to horizontal and 20 deg. to

very fast pace. For every welding process

covering all the aspects of product

vertical in the direction of travel for

innovators are introducing newer

manufacturing through the special

best result.

sub processes every day with special

process – WELDING.

i. At the beginning of the working shift it

applications as well as for generalized

Organizing such an approach initially

is better to make a trial run on a scrap

techniques. Welding engineers must

may cost time, energy and money, but

plate for adjustment of settings.

take lead to introduce a systematic

in the long run it will pay back with rich

approach for the Best Process of Welding

dividends.

DIAGRAMS TO SHOW A FEW WELDING PROCESSES, POSITIONERS & FIXTURES

IV. AFTER WELDING – CHECK a. Visual Checking b. Size of Weld c. Defects on the surface d. Appearance of Beading e. D.P. Test procedure and conduction f. Rectification of defects. V. PERFORMANCE EVALUATION – SELF

Few Welding Processes

AND PEER – 12 POINT ANALYSIS 1. Starting Time of Work 2. Finishing Time of Work 3. ARC ON Time 4. Length of Welding / Vol of Weld Deposit made 5. Weld Position worked 6. Volume of Consumables used 7. Scrap / Wastage / Rework 8. Supervision Needed 9. Cleanliness of Machines & Workplace 10.Safety Awareness 11.Team Working 12.Making Reports

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Rotators Positioners & Fixtures

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ARTICLE

Welding Consumables in India – Current status, trends, & objectives the need for intermediate annealing of

temperature time PWHT cycles.

wire during drawing down from the 5.0

5. E 8018XX & E 9018XX classes for

or 5.5 mm to the requisite size of finished

combination of high strength & high

wire, before copper coating and spooling.

toughness, i.e. 600 MPa & 700 MPa UTS

One can visualize the savings in cost &

and CVN impact energy of 50 joules

production time brought about by the

minimum at -50oC. This is required to

elimination of intermediate annealing

weld HSLA steel developed for warship

operation.

and air defence ships. 6. Progressively lower levels of diffusible

D. S. Honavar, Chairman, Honavar Electrodes Pvt. Ltd.

FCAW:

hydrogen. What is significant is the

What is noteworthy is fairly rapid progress

growing awareness in the welding

in setting up manufacturing units for

fabrication industry about the importance of control on hydrogen.

FCAW wires. In technological terms there has been steady progress in the

In many areas of special fabrications,

development and production of wires for

SMAW becomes the choice, more so if it is

Filler Materials for GMAW:

stainless steel and hard facing, and the

for a limited number of jobs, many of them

The current share of GMAW in the arc

industry is on the right track preparing

to be tackled for the first time. Change

welding activity is likely to be about 30% to

itself to face the increasing competition

over to continuous wire processes will be

35%. With increasing use of ER 70S-6 wire

from imported products. The share of

attempted for repetitive jobs.

for welding of structural jobs in carbon

FCAW in the total welding activity may be

steel, this has been rendered possible

at about 5% and moving towards 10% in

welders use sound welding practices to

by availability of appropriate grade of

the next five years.

minimise wastage and to prevent rework. We all have to try and bridge the gap

steel wire rods by TATA Steel (Grade large numbers of SMEs are contributing

Trends in Shielded Metal Arc Welding (SMAW):

to requisite production of filler wire ER

(A) In SMAW the emerging trends relate to

70S-6 leading to self sufficiency and self

modifications with fine tuning for meeting

(B) Recent advances.

reliance in this important consumable.

increasingly stringent specification.

1. While the electrode industry has been

The growing competition has brought

Following are some of the examples:-

making steady advances for meeting

down the cost progressively and the

1. E 7018-1 electrodes meeting all the test

new and stringent quality requirements,

WR-3M). Apart from the major players,

between the high and the low in terms of quality standard.

user industry today has a wide choice of

requirements after prolonged SR with

one of the most successful advances

sources for the wire. The continuity in

holding periods of 12 hours or more.

has been the outcome of a joint effort

production & supply of ER 70S-6 wires to the welding industry, can be expected to

2. Higher level of CVN impact values at

with total support from Indian Navy, coordinated through Naval Materials

-45oC or even -50oC. 3. Higher level of UTS well beyond code

Research Laboratory (NMRL).This relates

of the input material of steel wire rod coils

requirements after SR with holding

to development of consumables (SMAW,

by Tata Steel at 80,000 to 1,00,000 tonnes

period of 5 hours, i.e. 540 MPa as

GMAW & SAW) for welding for warship

per year , and by Jindal Steel at 40,000 to

against 490 MPa required in SFA 5.1

using the indigenously developed steel

4. E 8018B2 & E 7018-A1 – to achieve CVN

“DMR249A” having exceptionally good

be maintained, based on the production

50,000 tonnes per year. What has to be

In short, it has to be ensured that

mentioned as a special achievement of

impact values of 54 joules at

the steel producers is the elimination of

oC after different combination of

WELDFAB TECH TIMES | AUG - SEPT 2018

-18

properties (tensile, low temperature impact, and corrosion). Electrodes of AWS

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ARTICLE

classification E 8018-C1 for higher levels

use, especially in the foundry industry.

hence also of consumable manufacturers.

of strength and toughness have been used

Availability of indigenous grades has

Requirement of these two put together

successfully to the extent of more than

helped to reduce dependence on

may be in excess of 200 tonnes per year,

1000 tonnes by Naval Dockyards, Garden

imported products, and the choice is

with progressive rise linked with the

Reach Shipbuilders & Engineers, Cochin

determined by cost competitiveness.

growth of the power sector. This serves to

Shipyard Ltd. Capabilities of the electrode

In technological terms, there has been

underline the importance of this particular

manufacturers as well as NMRL have

significant advancement in this group of

group of electrodes.

been tested and utilized for technical and

consumables.

SAW:

monetary advantage to Indian Navy to such a degree that this achievement can be

Nickel Base Alloys:

The share of SAW is at 5 – 6% in line

looked upon as a milestone of Indian Navy

This is another area in which there has

with the situation for most of the

– Industry partnership.

been good progress in development

highly developed countries. While

The success of the new developments

of several grades of electrodes to the

the application of SAW for involving

has set the pattern of Indian Navy –

satisfaction of fabrication industry. On the

CrMo steels, low alloy steels, and even

Industry Partnership with a high level

basis of the satisfactory experience several

stainless steels continues to rise in the

of mutual confidence. The welding

indigenous brands are rated at par with the

shops of leading fabrications such as L

consumables industry has played its part

imported ones, thereby giving opportunity

& T, BHEL, Godrej, ISGEC, it has to be

well and fulfilled the expectation of the

to the manufacturers to compete.

noted that the major part of consumable

Indian Navy. More such cooperative efforts are expected in the next few years.

that matter even in the area of saw pipes

5.5 for welding of P-91 grade of Steel:

with huge production the welding flux

Duplex and super duplex stainless steels.

This is the latest consumable which has

used is imported. Thus, development

engaged the attention of several Indian

and production of flux for such special

Successful development and marketing

manufacturers to offer an acceptable

application has not kept pace with the

of electrodes for welding DSS and SDSS

equivalent against imported brands

needs, in an area which does call for more

is another noteworthy achievement.

which have been well accepted by the

intense attention. The requirement of flux

For several years AWS A 5.4 provided

power sector on the basis of fairly long

for this application may go up to about

classifications of E 2209 and E 2553 in the

experience abroad and then in India.

5000 tonnes per year.

duplex category. Production and supplies

The foreign brands have the advantage

of the SDSS grades on an increasing

of being backed by data relating to creep

Review:

scale during the period 1995 – 2005, was

properties, which is time related, to the

In reviewing the progress of the

duly recognized by AWS in revising and

extent of 30,000 hours and more. Indian

consumable manufacturing in India, we

issuing A 5.4 in 2006. The classifications

manufacturers have made considerable

may state that;

for SDSS are E 2594 & E 2595 to cover the

headway in securing approval of

a. Developments in SMAW have kept

new grades of steel with higher levels of

BHEL, the leading high pressure boiler

pace with the needs of the industry to

nitrogen and addition of W & Cu. The

manufacturer.

the extent of, may be, 90% in technical

higher levels of YS & UTS of the DSS

While approval and satisfactory

were combined with higher corrosion

performance are a matter of time, but

resistance, especially pitting corrosion

not in doubt, there will remain a question

resistance indicated by pitting resistance

mark on the commercial viability due to

equivalent number (PREN) at 40 or higher,

the high cost of the imported raw materials

as compared to PREN at 35 – 36 (38 max)

combined with the aggressive marketing

for DSS.

of the established imported brands.

(PREN = % Cr + 3.3 X %Mo + 16 X %N + 3.3 X half the % W) The classes E 2594 & E 2595 achieving PREN of 40 – 42 have already come into

requirement is met through imports. For Electrodes E 9015/9018-B91 As Per SFA

WELDFAB TECH TIMES | AUG - SEPT 2018

The next one in this group will be the

terms. b. In development in GMAW – MAG, the industry has done extremely well. c. In FCAW progress has been good despite keen competition from imported products. d. Developments of SAW have not kept pace with the needs of the industry in

electrode E 9015/9018-B92 for welding of

several applications even in carbon

P-92 grade. This grade is now attracting

steel, especially in the welding of pipes.

the attention of the power sector and

Reasons have to be looked into.

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Future Requirements & Objectives:

IS : 2062, IS : 2002, ASTM A 516 Gr.60

losses, with the sole objective of benefit

In reviewing the current status and trends

& 70 and 537 Cl.1 steels continue to

to the society at large. Suitable incentive

we have to accept the harsh reality of

dominate in welded fabrication, Indian

on the lines already mentioned, is not

huge imports at highly competitive prices.

consumable manufacturers have the

out of place or irrelevant because it will

We are already witnessing the adverse

capability to meet increasingly stringent

help to motivate the effort and thereafter

effect on Indian Steel industry which has

specifications of welded fabrication as

consolidate technological advancement

made this country proud by displacing

required by service conditions. This

in the manufacturing sector with

the USA from the third place in the year

calls for fine tuning and tighter controls

emphasis on indigenous production and

2015 with a production of 89.6 Million

in E 7018 & E 7018-1 classes and hence

job creation.

Tonnes and, furthermore, recording

the need for a superior grade of steel for

an increase of 2.6% over the previous

core wire in the Indian Standard IS: 2879.

capabilities developed through closely

year 2014 at a time when all the other

I have strongly advocated in my Misra

monitored advancement with availability

countries in the top ten category have

Memorial Lecture of 1979 and Lifetime

of funds for indigenous development.

recorded a drop, with 2.3% in China and

Achievement Award lecture of 2003 that

Funds and an appropriate mechanism are

10.5% in USA. If such a strong and well-

Indian steel majors ought to accept this

required to promote such development

built sector of steel industry has suffered

challenge of producing the superior grade

efforts of manufacturers with proven

the adverse effect of indiscriminate

of steel to help the consumable industry

technical capability. This is an area in

imports, how can one expect the welding

to meet the requisite higher standards. I

which we ought to consider steel industry

consumable and equipment industry to

have proposed to the Bureau of Indian

and consumable manufacturing industry

withstand this trend, especially with its

Standards to initiate action for this

together because the two have to work

fragmented structure. Such a situation

exercise to motivate the steel industry

together with the twin objective;

gets aggravated because as the industry

to produce the superior grade. Success

a) producing the grade of steel required

is moving into new grades of materials

in doing so will be a very significant step

for the welding consumable for critical

of construction, Indian industry has

in our technological advancement, and

application such as;

to depend heavily on imported steel

great benefit will accrue to consumable

grades for developing the appropriate

manufacturers through use of

consumables.

indigenously produced superior grade.

We have only to look at Indian Nuclear

superior grades of stainless steel (with low impurities).

ii. low alloy steel grades such as for welding of P-91, P-92.

The typical latest example is of SMAW

In the highly competitive business

electrodes (AWS E 9015-B91) for welding

world today, one has to pay attention to

of P-91 grade steel which is being

the scale of production to make the effort

consumed in increasing quantities by

viable in monetary terms. This is a valid

the power sector, to the extent of, may be

point which cannot be ignored, and yet

b) motivating consumable manufacturers

200 tonnes per year. Hence, in planning

the need is of technological advancement

to develop indigenous welding

for the future development and growth

in the field of welding, as a part of overall

consumables which in turn will promote

of industry, technological development

manufacturing activity, based on “Make

marketing of the respective new grade of

can be and will be achieved by Indian

in India” objective. The Government

steel, in India and abroad.

industry but at prices which may not be

departments concerned viz: Science &

For technological advancement to

acceptable to the fabrication industry

Technology and Industry, have to find

promote and strengthen the “Make in

which has ready access to cheaper

a way to financially support the effort

India” drive on continuous long term

imported products. This vital issue has to

to indigenise any important / vital raw

basis, the need is for the steel industry

engage our attention and this is where we

material through a funding mechanism,

and the welding consumables industry to

need to take active cooperation of Indian

if effort of any steel producer in the

join hands for cooperative effort aimed at

steel industry. Let us start with the most

development and production of special

these stated objectives, and then for the

common grade of carbon steel for core

grade of base material, calls for such

Central Government to back it up with

wire which is covered by Indian Standard

incentive. Over the past several decades

whatever is required for implementation.

IS:2879.

subsidies for several consumer items

We, members of the welding fraternity

became a practice regardless of the huge

have to hope for this to happen.

In the group of carbon steel grades

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iii. high alloy steel such as duplex stainless steels.

AUG - SEPT 2018 | WELDFAB TECH TIMES

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Conclusion

facilitate development of flux formulation.

will keep researchers, designers, welding

The future of joining technology

The R & D work will be propelled by:

technicians, inspection agencies &

The 21st Century holds out vast, exciting

a. The need to join materials of

standardization bodies busy in their

progressively superior strength,

welding – physics of the arc, chemistry

cryogenic toughness, elevated

of fluxes, metallurgy of metals and alloys

temperature properties, corrosion

concerted massive effort, & growing

(base materials and filler materials),

resistance, resistance to stress corrosion

cooperation among nations at different

thermal cycles, role of interstitial elements,

cracking;

levels in a globalized economy. It will

inclusions. Such research will lead to a very much better understanding of the related aspects, thereby facilitating new flux formulation based on scientific study, instead of findings based on a

b. Increasing stringency of specification even for the existing filler materials; c. Higher productivity levels in existing

The next decade will witness a

offer to welding personnel opportunities to participate in & contribute to advancement of welding technology and

processes GMAW, SAW, & even GTAW

welded fabrication in a wider working

through innovations.

environment, aided by rapid sharing

series of experiments with only limited

The next few years will witness wider

of knowledge and information through

understanding of the role of each

application of plasma, electron beam,

modern electronic gadgets. As far as

ingredient or radical, as has been the case

laser, and the latest one – friction stir

welding consumables are concerned

for over fifty years. We know that the

welding – which has been generating

development in power sources will

efforts and investments in manpower and

tremendous amount of interest and

continue to enhance the scope for using of

money necessitate these findings to be

development work to extend its scope for

GMAW in terms of productivity as well as

treated as trade secrets to face competition

wider application.

innovative applications, thereby widening

and make profits. These studies will

respective areas of activity.

s cope for research in the science of arc

WELDFAB TECH TIMES | AUG - SEPT 2018

The new materials of construction

the role of joining technology.

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CASE STUDY

Head Hardened Rails Introduction:

transportation lifeline of India. With the

hardened (NHH) rail that is continuously

India is the world’s third-largest producer

new impetus on railway infrastructure

slack-quenched by air after being

of crude steel (up from eighth in 2003)

development there is a pressing

subjected to induction heating. In 1979,

and is expected to become the second-

need for indigenous capabilities to

the company developed NS-II rail (Super

largest producer. The steel sector in India

be enhanced in order to meet the

rail), the purpose of which was to prevent

contributes nearly two per cent of the

growing requirements of a billion plus

the welded joints from softening.

country’s gross domestic product (GDP)

population in India. Industrial growth

and employs over 6, 00,000 people. The

and development warrants that Indian

of sustainable development of any

growth in the Indian steel sector has

Railway facilities continually innovate

developing country particularly in India

been driven by domestic availability

and steel manufacturers play a pivotal

which have huge population and world’s

of raw materials such as iron ore and

role in contributing to the overall holistic

fastest growing countries. Railways have

cost-effective labour. Consequently, the

development of rails in India.

most contributing and play an important

steel sector has been a major contributor

role for economical, safe and large

to India’s manufacturing output. The

freight car capacity aimed at improved

quantity transportation of goods and

Indian steel industry is very modern with

efficiency, rails are subjected to severer

human. For healthy transportation rails

state-of-the-art steel mills. It has always

conditions than ever. The tonnage of

of the best quality are necessary to ensure

strived for continuous modernisation and

trains has increased markedly, and

the reliability of the track. To meet the

up-gradation of older plants and higher

the axle load and tangential force or

current requirement of transportation

energy efficiency levels. Presently, India’s

impact force applied to the rails by the

more and more trains with higher loads

crude steel capacity is around 126 Million

wheels have become exceedingly great.

and higher speeds results chance of wear

Tonnes (MT) and Production of crude

Recognizing the increasingly severe

and tear in rail tracks.

steel was 97.4 MT during 2016-17.

service conditions for rails, in 1976

Jindal Steel & Power Limited is of

Nippon Steel developed a new head

India’s leading steel producer with a

The Indian Railways is the

Because of increases in train speed and

Transportation is one of the pillars

WELDFAB TECH TIMES | AUG - SEPT 2018

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CASE STUDY

significant presence in power generation, mining and infrastructure. With an

highly symmetrical cross sections with superior quality.

annual turnover of US $ 3.38 billion as on

• With the state of art technology and

31st March, 2017, JSPL’s business orations

facilities, producing uniform rails.

span across Asia, Africa & Middle East and

• JSPL produces high performance rail

Australia. Since 2003 JSPL has been manufacturing rails for more than 14 years. JSPL rails are highly rated in India and Abroad. They meet the domestics demand as well as international

transcends across all our operations. JSPL is the first and the only indigenous steel major to have developed the head hardening facility; which is a game changing initiative in the rail industry.

products in various specifications like

Hitherto, head hardened rails were being

UIC, IRST-12(2009), EN13674-1 and

imported from Europe and Japan for use

other international specifications.

in Metro Rail and new projects in India.

• Inspection of rails by third party agency RITES. • Welding of Rails by world’s top class

standards. JSPL rails are available in

technology by Flash butt welding with

various sizes and grades so that they can

stringent quality norms by RDSO.

JSPL being the only producer of Head Hardened Rails in India is poised to play a significant role in the growth of India’s Rail Infrastructure.

High Speed Train:

be used for diverse applications such as

Tandem Mill Facilities at JSPL Raigarh:

In keeping in mind with the

The JSPL Mill has the distinction of being

we envisage increased demands of rails

significantly growing rail sector in India

one of its kinds and produces structural

for use in high speed, heavy haulage

as well opportunities in infrastructure

products like beams, columns, channels,

and mass transit lines, which require

development JSPL has established and

angles, sheet piles, H- beams and Rails

maximum durability against wear and

produced world’s longest 121m rail

(Track rails & crane rails). We also have

material fatigue caused by escalating train

tracks. JSPL has developed and improved

NABL accreditation for testing of rails

frequencies, speeds and axle loads. Head

operation efficiency for producing longest

viz. residual stress, Fatigue test, and TLT,

Hardened Rails are used in high speed

rail 121 m in 13 m class A rails for DMRC

USFD and fracture toughness. Its strong

rails (> 250 KM/Hr.) for Bullet Trains.

and Kochi metro as per IRST 12 (2009)

focus on quality assurance systems are

These Rails are also used in heavy traffic

specification and successfully dispatched

equipped with modern testing facilities

and axle loads for freights and Metro rail.

260m welded long rail panels to DFCC for

for online and offline testing conforming

These Rails with enriched wear resistance

the first time in India.

to stringent quality standards.

are used for high speed, Metro Rail, Bullet

track rails, crane rails and high speed rails. Keeping in view the importance of the

In pursuit of bringing the world’s

Government’s - Make in India Program,

train and Heavy Haul applications.

best to India, production of rail at

JSPL established in setting up Online

JSPL was commenced with technology

Head Hardened Rail with technical

collaboration with M/s NKK corporation

consultation with SMS Meer, Germany

(now known as JFE corporation). Further

and successfully commissioned its

in line with international practice

Head Hardened Facility in May 2016.

with to flash butt weld rail panel at

JSPL started the commercial production

manufacturing plant itself, an integrated

in 2017 for the first time in India and

long rail flash butt welding line is in installed. The state of the art steel making

Tandem Mill facilities at JSPL Raigarh.

obtained the TUV NORD Certification for Head Hardened Rails of grade 1080 HH

Development of Head Hardened Rails in JSPL Raigarh:

and 350HT grades. The Head hardened

inclusion levels in rail steel meeting the requirement of national and international

JSPL has played a pioneering role in

after tandem mill, Induction Heating

standards of rails such as IRST 12 (2009),

the indigenous product development

as required and water spraying through

EN 13674-1 (2011) and UIC 860R.

of Rails and is embracing state of

Selective Cooling technology. These

the art technology to produce world

would have higher resistance to wear and

JSPL Rail Manufacturing Features:

class rails. Innovation and new

is made possible with greater hardness of

• Rails are produced by the Universal

product development lie at the core

rail head, which is the upper part of a rail

of our Business culture and this ethos

and supports the wheels of railroad cars.

technology insures high quality low

modern Rolling mill which ensures the

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process would include Tilting of Rails

AUG - SEPT 2018 | WELDFAB TECH TIMES

CASE STUDY

Selective Cooling by Rail Cool Technology by SMS Group:

• Length of single piece rail is 80m. • HH Rail Profile: UIC-60, UIC-60E1, IRS-52 etc.

• Homogenization of the temperature profile • Minimisation of the intrinsic stresses

Certifications:

• Improvement of the rail straightness

• BSI-London for Quality (BS: EN

• Heat treatment in line downstream of

9002:2000)

the rolling mill

• Environmental management system (BS EN 14001: 1996)

JSPL Raigarh produces head harden

JSPL Raigarh Produced Head Hardened Rail.

rails having excellent metallurgical and

withstand increased wear from trains

mechanical properties such as higher

travelling faster, at greater frequencies

• NABL accreditation lab for testing of

wear resistance due to top of the rails

and with heavier cargo. With hardness

Rails: All Qualifying and Acceptance

having higher hardness and finest grain

levels of 340-390 BHN, head hardened

tests for Rails are done at JSPL as per

structure and size. Micro-structural

rails have a longer lifespan and are

IRS-T-12(2009).

evolution has been control by selective

safer. Continuous improvement on the

cooling system at top of the rail. JSPL

speed and loads of the passing trains are

produced rail having higher ability to

placing more and more demands on the

handle axle load with low deformation

performance of the rail. It is significant

due to good operational control during

to prolong the service life of rails in a cost

manufacturing process.

effective manner – this can be done by

Head Hardening technology is a

• RDSO (Indian Railways) – For Flash Butt welding parameters.

improving the properties of the rail, which

cost-effective and efficient method

is fortified by the Rail Head Hardening

for extending the service life of rails

process.

by improving mechanical properties. The higher resistance to wear is made possible with greater hardness of rail head hardening. To meet the demand of faster high speed rails, JSPL has opted

Specification of Head hardened Rail: SPECIFICATION

GRADE

HARDNESS

UTS (MPa)

IRS T-12 (2009)

Normal Grade (1080)

≥260 BHN

880

Head Harden Rail (1080HH)

340-390 BHN

1080

Normal Grade (R-350)

260-300 HBW

880

Head Harden Rail (R-350HT)

350-390 HBW

1175

new application technology “Rail Head Hardening” with sophisticated laboratory facilities. Head hardened rails can

Certificates of TUV NORD for head harden rail.

EN 13674 (2011)

The head hardened rails are different from normal rails. First, Head Hardened Rail can withstand increased wear from train travelling at high speed (>250 km/ Hr) and greater frequency with heavy axial load. The higher wear resistance is made possible by increasing hardness at head of the rails which also gives good abrasion resistance. Second, longer and sturdier rails with fewer joints are needed on the track. Third, cost effective with higher lifecycle and better weldability etc. Selective Cooling at top of Rail (Rail Cool Technology JSPL Raigarh).

WELDFAB TECH TIMES | AUG - SEPT 2018

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CASE STUDY

Process Flow Diagram of Rail Manufacturing:

Installation of New Straightening Machine in JSPL Raigarh. • Low residual stresses • Prolonged service life and enhanced safety • Economical and Cost Efficient with High Lifecycle • High resistance to deformation caused by compression

Cross Section profile of UIC-60 and UIC60 E1:

• High resistance to brittle fracture • Low residual stresses after manufacturing and straightening • Good weld ability.

Indian Railway Development Plans and Projects in 2018: Finance Minister in the Union Budget 2018 speech said that developing infrastructure – including railways – would continue to a priority for the government. From world-class train sets to bullet trains and revamp of signalling systems and providing CCTVs and Wifis – FM portion of Union Budget speech dedicate to Railway Budget helped several promises that aim at transforming Indian Railways.

Installation of New Straightening Machine:

change systems which gives the maximum mill utilization, and process

These are the main points that the

JSPL installed straightening machine

flexibility to produce a wide range of

budget for Railways 2018 focused on:

supplied by SMS-Meer with Level-

sizes and grades, resulting in products of

• Rs 1.48 lakh crore has been allocated

2automation for straightening of Rails

high quality in tolerance, metallurgical

and Structures with the state of the art

properties and surface condition.

pitch for controlled residual stresses in

Advantages of Head Hardened Rails:

finished rails. Change-over times are

• High Strength

reduced to a minimum by automated

• High Wear Resistance

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will be dedicated to capacity creation. • For Mumbai local trains, an amount

technology. The 9 roll horizontal and 9 roll vertical straightening variable

for Indian Railways. Most of this capex

of Rs 11,000 crore has been allocated to add 90 km of double line tracks. • 18,000 km of doubling, third and fourth line works and gauge

AUG - SEPT 2018 | WELDFAB TECH TIMES

CASE STUDY

conversion of 5,000 km would be

high speed rail projects will be set up

support advances in train technology,

done in order to eliminate capacity

in Vadodara, as the foundation stone

as well as meeting the longer in-

constraints. In addition to that,

of Mumbai-Ahmedabad bullet train

service product life and reduced

complete conversion of entire network

project, India’s first high speed rail

maintenance costs demanded by rail

into Broad Gauge to take place.

project was laid last year.

network operators. • The rolling mills at JSPL use the

• Track infrastructure is necessary as safety point of view so for that the

Conclusion:

latest process technology, computer

government has targeted over 3,600

• Continuous innovation in

modelling, computer-controlled

plant, technology, research and

heating and cooling, and novel roll-

development, combined with the

pass design to produce exceptional

suburban network is being planned at

unrivalled metallurgical knowledge

quality head hardened rails. The

a cost of over Rs 40,000 crore, which

and track design expertise, ensure

advanced testing and finishing

will include elevated corridors on

that JSPL Steel delivers the high-

systems that complete the JSPL rail

some sections.

performance rail demanded by

manufacturing process ensure that all

today’s rail operators.

rail products meet the high standards

km for track renewal. • In addition, 150 kilometres of

• A 160 kilometres suburban network at an estimated cost of Rs 17,000

required for all rail applications –

crore is provided for the growth of the

development initiatives at JSPL are

from high-speed and heavy-haul

Bengaluru metropolis.

focused unwaveringly on delivering

networks to urban and industrial

the high-performance rails required to

railways.

• An institute to train manpower for

• Process innovations and product

WELDFAB TECH TIMES | AUG - SEPT 2018

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WELDING TIPS

Good looks arenâ&#x20AC;&#x2122;t everything especially in welding A good combination of tool, process, and technique for weld preparation contributes to making robust, defectfree welds Modern welding goes back nearly 100 years, but despite the many advances

Figure 1

in welding technology, weld quality is still dependent on the thoroughness of

This concerns not just the welding

weld preparation. Making welds that are

process, but weld preparation steps.

robust enough to stand up to the rigors of

cutting edge of technology, the stage

accuracy and solid consistency in the weld

prior to welding, weld preparation,

preparation steps.

often is neglected or is performed with

Pipelines structures will be built in the C Sridhar, Director-Technical, Advance Institute of Welding Technology, Chennai, Tamilnadu

Despite using welding stations on the

many modern demands requires extreme

inappropriate techniques. The materials

coming decades, both in replacement

must be properly dimensioned and

and new construction. Most of them will

cleaned (see Figure 1). Otherwise, the

reach replacement age if they havenâ&#x20AC;&#x2122;t

result is likely to be a poor-quality weld,

gotten there already, and the need of

even though the weld might look good

additional pipelines, Pressure & storage

on the surface.

Vessels, Structures will be huge. These projects will require countless welds. Furthermore, essentially every branch

Cracking: Cracking is one of the most common

of industry has embraced welding, and

defects in welding. It is caused by

many have been using welding in metal

excessive mechanical stress in the

assembly work all along. Techniques

weld bead. The most common types of

and materials are improved every year in

cracking are hot and cold cracking.

the search for increasing efficiency, and

The design of the weld assembly,

the growing skill of many welders has

specifically the bevel land width, is

raised this industrial process to an art

one of the factors that increases the

form. However, in welding, an attractive

likelihood of hot cracking. As its name

appearance can hide a defective weld.

implies, this type of cracking occurs when the metal is still hot and in the process of solidifying. As the bevel land width decreases, the mechanical stress that results from the metal solidifying increases. If this stress is too high, cracking occurs during the change in phase. Cold cracks appear after welding (immediately, several hours later, or even several days later). This defect type is

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AUG - SEPT 2018 | WELDFAB TECH TIMES

WELDING TIPS

caused by a simultaneous combination

ultrasound or radiography.

be eliminated by highly accurate

of three factors: a temper structure that

Similarly, a bevel land thickness

positioning. If the parts to be welded are

is hard and fragile, residual mechanical

that is incompatible with the welding

not perfectly parallel, unequal clearance

stress (related to clamping, for example),

parameters can lead to incomplete

between the parts gives rise to localized

and the presence of diffusible hydrogen

or excess penetration. Incomplete

points with excess or incomplete

in the weld bead. The last factor may be

penetration often is characterized by

welding. Accurate facing is critical.

related to poor edge preparation. When a

an un-melted zone at the root of the

Proper land thickness also is critical

rusty or poorly degreased part is welded,

weld; excessive penetration causes a

for proper penetration. For example, if

the hydrogen present in the rust or the

surplus of molten metal at the base of

the welding parameters call for a land

hydrocarbons in the grease decomposes

the welded joint. These two defects are

1.5 millimeters thick, using a land that

in the weld. Stresses then appear when

caused by improper welding parameters

is too thin (perhaps 0.5 mm) results

the metal is cooling down. Although the

(current, voltage, or welding speed)

in excessive penetration, whereas a

stresses are small, as the concentration

and dimensions—improper clearances

land that is 2.5 mm thick will lead to

of stresses increases, so does the

between the parts or poorly controlled

incomplete penetration.

likelihood of a crack.

land thickness.

When accompanied by other

A closeup of a tube or pipe weld joint

Bevel land consistency also is critical (see Figure 2). If the pipe is out of round,

precautions such as drying the electrodes

shows the three main dimensions of a

using an automated beveller creates a

in ovens or preheating parts to be

joint: wall thickness, bevel angle, and

consistent bevel on the outside diameter,

welded, dry machining the joint edges—

land. A strong joint depends on proper

but the ID needs a corresponding

that is, without a coolant—reduces or

joint design, preparation, and weld

process—counter boring—to make

eliminates the presence of hydrogen,

procedures. Often the middle step, weld

the ID round. This ensures a land

reducing the probability of cold cracking.

prep, doesn’t get enough attention,

that is consistent around the entire

resulting in substandard welds.

circumference.

Fusion and Penetration Problems:

Insufficient clearance leads to

Contamination:

Lack of fusion is poor adhesion of the

incomplete penetration. When the

Foreign matter in many forms can lead

weld bead to the base metal, the result

distance between the parts is too small,

to weld contamination and result in a

of an unmolten contact area. One cause

molten material doesn’t flow into the

substandard joint.

is improper bevel land thickness. A

gap. On the other hand, too much

bevel land that is too thin relative to the

clearance allows too much molten metal

Blowholes:

electrode diameter is likely to disturb

to flow into the gap and protrude into

A poorly prepared surface can cause

the arc, causing it to lean toward one of

the tube or pipe’s inside diameter (ID).

blowholes to appear in the weld. The

the walls. As a result, fusion occurs on

In certain cases, these defects can

presence of water, rust, or grease leads to

one of the edges and the bevel fills with molten metal, but fusion is incomplete or lacking on the other edge. Because the arc has reached the root directly and the other side of the bevel, the zones in question are not melted but merely covered by a layer of filler metal. The weld may appear to be good, but in fact it doesn’t have the metallurgical continuity it needs for a structurally strong joint. Because these defects usually are located inside the welded joint, a visual inspection is unlikely to detect them. Finding them requires inspection techniques such as

WELDFAB TECH TIMES | AUG - SEPT 2018

Figure 2

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WELDING TIPS

the formation of gas bubbles liable to be

point. Significant heat input changes the

adjustments to compensate for alignment

trapped inside the bead. As is the case in

material’s physical characteristics, which

defects and slight variations in the bevel

cold cracking, dry machining reduces the

causes significant changes in a weld’s

or land, but an automated system doesn’t

probability of this defect.

strength. The area in question requires

have this capability.

another step, machining, to eliminate the

Corrosion: Stainless steels, aluminum alloys,

HAZ. Using a tool designed for a specific

Remedies: Welding is always a delicate operation.

and other metals that aren’t prone

purpose—in this case, for beveling

Many parameters have to be known and

to corrosion are at risk of iron

saddles—helps to ensure consistency

mastered for obtaining the best possible

contamination, which can lead to

in bevel angles and dimensions, which

results; any factor that isn’t optimal is

corrosion. The problem is galvanic

assists in making welds that are robust

likely to cause a defect. Despite upgrading

corrosion, which occurs when iron

and durable.

techniques and expanding knowledge on

particles are in contact with an electricity-

the subject, nonconforming weld joints

conducting medium, such as damp air.

Close-fit Weld Preparations:

continue to plague the industries that

Galvanic corrosion causes the passive

While good weld preparation contributes

rely on welded tube and pipe assemblies.

layer of stainless steel to deteriorate

to the quality of every weld, joining

The consequences of a poor weld can

progressively, which often leads to pitting.

materials with a high-density energy

be disastrous in both schedules and

It likewise can leave unsightly rust spots

source—laser or electron beam—

budgets. Repairing a welding bead can

on other alloys.

highlights just how critical weld

take several hours or even several days in

preparation is. These processes use a

the case of a major assembly.

Iron particle contamination often comes from using equipment for carbon

beam aimed accurately and focused

steel and other metals. Keeping tools

tightly. The ratio of bead width to

designing the weldment correctly and the

separate is a good shop practice, so

penetration depth can be extreme, rarely

importance of accurate and consistent

anything that contacts a stainless steel

more than 5 mm wide and often several

machining of bevels and lands, and

workpiece—clamps, vises, saw blades,

hundred millimeters deep, for a joint

counter-bores when they are necessary.

machining tooling, grinding wheels,

welded in a single pass.

Automated Processes, whether done

and deburring brushes—must be used

Assemblies welded in this way do

This highlights the importance of

with a machine or a hand tool designed

for stainless steel only. Using such tools

not require bevels, but they do need

for the specific purpose, are necessary

for both carbon steel and stainless steel

extremely accurate facing. For example,

for achieving the necessary dimensional

results in contaminated stainless steel.In

preparation for laser welding is

accuracy and consistency.

some cases, direct contact isn’t necessary.

acceptable if the misalignment is less

Carbon steel particles can become

than0.01 mm.

airborne, so carrying out machining or

Moreover, parts must be free of any

Whether using a beveller on straightcut ends or saddles, using a facing process to create a land, or using an ID machining

grinding operations on carbon steel near

contamination, especially electron

tool to create a counter-bore, the tools

another metal can be enough to lead to

beam welding. Because electron beam

and machines designated for these tasks

cross-contamination.

welding operations are carried out

provide the accuracy and consistency

in a vacuum, the workpiece must be

that meet or exceed modern fabrication

Deterioration of the Material’s Properties:

thoroughly degreased and dry. Water and

norms. It’s a matter of learning about

hydrocarbon residues interfere with the

all of the tools and machines that are

When cutting is carried out by a thermal

process of establishing a vacuum.

available and ensuring that the operators are trained in their use.

process, such as oxy-fuel, plasma,

Even common welding processes,

or laser, the cut quality may prove

such as gas tungsten arc welding or gas

to be satisfactory when made by an

metal arc welding, need extra attention

Knowing when to use a coolant or a

experienced operator or with the help of

in the preparation step when the welds

lubricant, and when not to, is just as

an automated system. However, in most

are carried out by automated processes,

important as separating the tools and

cases, these techniques create a heat-

such as orbital or robotic welding.

work areas used for carbon steel from

affected zone (HAZ) close to the cutting

An experienced welder can make

stainless steel.

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Good shop practices also are required.

AUG - SEPT 2018 | WELDFAB TECH TIMES

INTERVIEW

“Our welding engineering has over 1,900 qualified procedures.”

Mr. Allen Antao, Executive Vice President and Business Head, Godrej Process Equipment

WELDFAB TECH TIMES | AUG - SEPT 2018

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INTERVIEW

Q1. Godrej Process Equipment is among the leading players in fabricating industries. How has been the journey so far?

critical equipment to thermal, geothermal,

design team will also significantly enhance

solar and nuclear power plants.

Godrejâ&#x20AC;&#x2122;s design capabilities in this space.

We have been manufacturing critical

We have always been in the forefront of

equipment like Reactors, High pressure

adopting technology to offer the best in

Started in 1976, Godrej Process Equipment

vessels, Columns, Heat exchangers to all

class solutions to our customers. The

(GPE) has been in business for more than

Oil and Gas majors worldwide. To name a

acquisition of technology from SPX

four decades. GPE manufactures the

few projects, we executed globally- GASCO

is another step in this direction and

entire range of process equipment for

OGD III project wherein we supplied large

coupled with our proven manufacturing

end-users in core industry segments like

solid SS Demethanators through Bechtel;

capabilities, it will help us offer advanced,

Refineries, Petrochemicals, Fertilizers, Oil

for SABIC we have been supplying critical

comprehensive solutions to our customers

& Gas, Chemicals, Pharmaceuticals, Power

equipment for most of their projects from

and Water around the world.

SAFCO-I to SAFCO-V, Ibn Zarh, Yanbu Petrochemicals; KNPC for their Clean Fuel

Q5. What are your expectations from the acquisition?

rate of more than 10 per cent CAGR. The

project, heavy reactors for Petrobras and

With this acquisition, Godrej will be

business is a leader in fabricating unit

for domestic market, projects for Reliance,

capable of providing end-to-end solutions

static equipment for process industries

IOCL, BPCL, HPCL among others.

in the field of heat exchange auxiliaries

Since 2004, GPE has been growing at a

and most of its revenue comes from

in the power generation sector. GPE was already producing feed water heaters

2016, the company had inaugurated a

Q3. Any specific sector that you largely aim to focus, or is working on any sectors maximum projects?

new world-class manufacturing facility in

We shall continue to focus on Oil & Gas,

ownership of the technology. Using

Dahej, Gujarat. It expanded its footprint

Fertilizers and Power Sectors. Now with

Yuba technology, in the past, Godrej has

internationally by opening a new office in

Yuba & Ecolaire acquisition, we shall

already supplied feedwater heaters to

Houston, Texas in June 2015.

provide end-to-end solutions in the Heat

various power producers like Nuclear

Exchanger Auxiliaries space in Thermal,

Power Corporation of India, Tata Power,

Geothermal, Solar and Nuclear power

Gujarat State Electricity Corporation,

plants.

NTPC, and even to main plant equipment

exports. Today, it has its presence in all the continents except Antarctica. In

Q2. The company manufactures the entire range of process equipments for various sectors. Could you quickly take us through some of your mega projects?

using Yuba design and technology. Now, by acquiring the brand, Godrej has direct

suppliers like Toshiba, GE. Godrej will be manufacturing heat exchange

first one to manufacture Pressure Vessels

Q4. Godrej Process Equipment has recently acquired the Yuba and Ecolaire brands and design technologies from SPX Heat Transfer. Please elaborate?

tested at a pressure of 1500 bar.

Godrej Process Equipment, a business

significant capital expenditure planned at

unit of Godrej & Boyce Mfg. Co. Ltd.,

the Dahej plant.

We are the 1st company in India to be accredited with ASME U3 Stamp and

We have been manufacturing highly critical Heat Exchangers, Vessels, Reactors

has recently acquired the Yuba and

and Columns for more than 42 years.

Ecolaire brands and design technologies

Our references for Supercritical Power

from SPX Heat Transfer, a subsidiary

Plants are also established for Feedwater

of SPX Corporation, USA, a global

Heaters.

supplier of highly engineered products

auxiliaries, mainly feedwater heaters and surface condensers, at the Mumbai plant as well as that in Dahej in Gujarat. These acquisitions also help leverage the

and technologies. With this strategic

Q6. The company has worked for various projects, globally. How has been the Indian market as compared to the international markets?

Ecolaire brands and design technologies

acquisition, we have positioned GPE as

We see India and Asia-Pacific in

from SPX Heat Transfer LLC, a subsidiary

a significant player in the Power sector;

general growing. In India, we have seen

of SPX Corporation, USA. This acquisition

an independent, global player providing

accelerated growth. When the economy

positions Godrej Process Equipment as

critical equipment to thermal, geothermal,

grows at this rate, it has an automatic

a significant player in the Power sector;

solar and nuclear power plants. Addition

beneficial impact on core sectors. India

an independent, global player providing

of key people from the SPX Heat Transfer

is one place that will provide us huge

GPE recently acquired the Yuba and

www.weldfabtechtimes.com

AUG - SEPT 2018 | WELDFAB TECH TIMES

INTERVIEW

volume of demand. At the same time,

welding positions have been qualified

development which is essential in order

in the developing countries in the Far

under reputed inspection agencies like

for the industry to realize its full potential.

East like Vietnam, Myanmar, Indonesia,

LAS, DNV, BV, TUV, etc.

The Government’s “Make in India”

we see a lot of new investments both in

Our welding engineers have developed automatic welding processes for internal

be enunciated in support of it. ‘Local

of refineries etc. The Middle East has

bore overlaying of small internal

Content’ requirements are also being

always been one of the primary markets,

diameter, tube-to-tube sheet welding by

mandated globally. This is great from a

this region has always provided a lot

orbital TIG, long seam welding on long

domestic standpoint but not much from

of demand opportunities. Some of the

seamers, nozzle welding, strip cladding

an exports standpoint. Brand ‘India’ is

countries that were not on the industrial

by SAW and Electroslag processes, narrow

only becoming stronger, which means that

map for many years are now seeing an

gap welding for thick circ-seam and long-

Indian Companies will have to continue

upsurge in demand.

seam joints. Retaining skilled workforce

to work hard to reinforce the positive

has resulted in our success and we are

values of this brand and a sustained good

look very optimistic right now, we believe

confident of growing with our most

performance should work.

that the future will be very bright. Hence

import asset i.e. people.

Although the global market does not

East, India and some countries in the Far East, which will give us a huge volume opportunity.

In terms of global demand, we are a major player in the field and we rank

we are currently looking at the Middle

initiative is laudable and policies must

terms of fertilizer, upgrades and revamp

Q9. What are the major challenges you witness? How do you aim to resolve the same?

amongst the top fabricators in the world. We export 85 percent of what we make, so we have access to global markets that we

The process equipment industry, like

have built over the years. However, it is a

Q7. Welding sector plays a major role into the manufacturing of any equipment. Your say.

any other has its own set of challenges. It

challenge to build that channel with new

is an industry that is heavily dependent

players. For that, you have to constantly

on specialized skills not only on the

keep yourself upgraded in terms of design

Welding is a technique which is widely

shop floor, but also in managerial

capabilities, manufacturing capabilities,

used by manufacturers in India due to its

functions such as project management

engage with your clients in a very

precision, reliability, cost-effectiveness

and estimation. The Pressure Vessel

responsive manner, letting them know

and the high-tech method used for

grades of steel that the Industry requires

how you are upscaling your capabilities,

joining materials in manufacturing

is not currently produced by India and

ensuring that you have the right skill

industries. Objects that we see around

a large portion of the critical materials

set, upgrade working environment, etc.

on daily basis, right from buildings to

must be imported, thus imposing time

These are the things we do at Godrej and

bridges could not have been possible

pressures on Indian manufacturers

these are our competitive strengths in the

without welding thus proving that it plays

that are not faced by their foreign

market.

an essential role in our day-to-day life.

competitors. The introduction of GST

India’s GDP, to some extent is also relying

has helped levelling the field to a large

on the welding industry.

extent and has enhanced competitiveness among players. The continued growth

Q10. ‘Safety at site’ is one of the key factors. What are your efforts towards safety?

Q8. Availability of skilled welders is one of the major challenges in India. How do you manage to cope up with the same, as Godrej Process Equipment has a huge team of well qualified welders?

of the economy should enable the

Safety is of prime importance to us and

government to reduce rates in the near

it is visible in the way we operate. HSE

future. This will boost the economy.

practices that are followed in Godrej

While infrastructure is improving, we

Process Equipment are of global standard

still have miles to go before we reach

and we encourage our workforce to

the standards of countries like South

contribute in building a better and safer

Our welding engineering has over 1900

Korea, where many of our competitors

workplace. We look for opportunities

qualified procedures for a wide variety of

are based. Competition from China

to go beyond the standard to provide

metallurgies from ferrous to non-ferrous

is also greatly increasing. Companies

additional safety features to our

grades. Welders capable of welding in 6G

are increasingly investing in skill

engineers.

WELDFAB TECH TIMES | AUG - SEPT 2018

www.weldfabtechtimes.com

INTERVIEW

Q11. Apart from the manufacturing unit in Mumbai, the company also has its unit in Gujarat. Can you brief us on the Gujarat unit?

end-to-end capabilities to manufacture

of precision machined parts for various

aircraft engine components for global

ISRO projects. Over the past three

requirements.

decades, Godrej Aerospace has been

Our strategic new facility in Dahej creates

ISRO and this has resulted in increased

customers. Dahej facility being in SEZ, we

Q13. At the same time, aerospace facility was also inaugurated for the manufacturing of sheet metal brackets. (Investment, total area, location, capacity, purpose, etc)

aim to improve our revenue from exports

The company has recently launched

systems. Significantly, the MARS mission

even further. We also look at venturing

a new facility in Mumbai i.e. – Center

saw the 25th (Silver Jubilee) flight of the

into new products which have great

of Excellence (CoE). The aim of the

PSLV.

potential throughout the world. Having

Centre of Excellence is to support

our own water-front jetty also allows us

Godrej Aerospace in strengthening

to manufacture equipment with no size

it’s the foothold in the aerospace

Q15. Do you have more plans for tie-up, in the coming time?

restriction.

sector. The CoE will be instrumental

Wherever business demands technology

in expanding Godrej’s capabilities

tie-ups, we never think twice about it.

many opportunities for us enhancing our manufacturing capabilities and thereby offering a complete package to our

entrusted with increasing work from

Q12. Recently, Godrej Aerospace had bagged 200 crore Rolls-Royce deal. Please elaborate. What would be the nature of work?

in civil aerospace by having internal

participation, especially for complex equipment such as liquid propulsion engines for PSLV and GSLV rockets, thrusters for satellites and antenna

aircraft engine components for global

Q16. Any upcoming project? Can you list down any three?

requirements. The facility will be

Investments in the field of Oil & Gas,

Godrej first bagged a contract from

capable of meeting the diverse needs of

Fertilizer and Power are increasing,

Rolls-Royce in 2014 for manufacturing

aircraft manufacturers, and can cater to

therefore providing strong demand

unison rings. Since then, it has also

fabrication, machining, assembly as well

for process equipment. With refineries

started complex sheet metal fabrication.

as testing of special processes required

moving to upgrade their capacities

Godrej’s partnership with Rolls-Royce

in aerospace and defense applications.

in sync to produce BS-VI, there will

necessitates it to manufacture unison

We are hopeful that with the help of

be increased investment in process

rings, complex fabrication and external

our facility, we will be strengthening

equipment, machinery, production

brackets and will supply 600 different

India’s position in the Global map in the

lines and training man power. This

parts to Rolls-Royce's civil aerospace

aerospace sector. It will be supporting

upgradation to BS-VI fuel will provide

engine portfolio. The company has

Government’s vision of Make in India.

the process equipment industry with

end-to-end capabilities to manufacture

huge business opportunities, however, it

secured the contract to make the parts

will only be limited to those players that

shave off 20-30 per cent of its costs,

Q14. The company largely contributed also to the Mangalyaan spacecraft project. Can you elaborate on that?

compared to what it would have incurred

For the launch of Mangalyaan, Godrej

Q17. Your expansion plans?

in another country, hence, fabricating

Aerospace built mission-critical items

Our existing product portfolio offers us

brackets is just the beginning of a great

for this launch such as the liquid engine

great opportunity to increase revenue

journey to manufacture long beam

used in the Polar Satellite Launch

further and with the inclusion of Yuba

longer on, which generally is the floor

Vehicle (PSLV), precision components

and Ecolaire, we are well positioned to

beam, the very foundation, and forms

for the orbiter thruster as well as the

achieve our target. Investments in Oil

the basis of the aisle in wide-bodied

ground system antenna together with

& Gas and Power Sector are providing

aircraft. With this partnership we

on board antenna. Godrej Aerospace’s

momentum to our business and we are

position G&B as an important player in

association with ISRO goes back a long

venturing into new products to further

the civil aerospace sector having internal

way, beginning in 1985 with the supply

encash on our decades of experience.

at its new facility in Mumbai over the next five years. Godrej's partnership with Rolls-Royce would help the latter

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technologically upgrade themselves to meet modern standards.

AUG - SEPT 2018 | WELDFAB TECH TIMES

TRAINING CENTER

ABB to invest €100 million in global innovation and training campus • ABB makes largest organic investment in industrial automation at home of B&R in Austria • €100 million investment shapes ABB’s leadership position in machine and factory automation • Investment in the development of the factory of the future to create 1,000 new jobs • State-of-the-art innovation and training campus to be built in Eggelsberg, Austria, by 2020 • ABB builds on the B&R success story on the first anniversary of the acquisition announcement ne year after announcing its

AbilityTM, in which production will be

art facilities. Alongside ultra-modern

acquisition of B&R (Bernecker

undertaken autonomously by smart

R&D laboratories, which will develop and

+ Rainer Industrie-Elektronik

and cloud-connected machines and

test new automation technologies, from

GmbH), ABB is to invest €100 million

robots. With this investment, ABB is

industrial control systems up to machine

in Austria to build a state-of-the-

delivering on its Next Level strategy,

learning and artificial intelligence, there

art innovation and training campus

which defines innovation as a key driver

will be an Automation Academy to train

at the home of B&R in Eggelsberg,

of profitable growth. The company

and educate customers, partners and

Upper Austria. It is the largest organic

invests $1.4 billion in R&D annually, and

employees in these technologies. The

investment in industrial automation in

has a team of around 30,000 R&D and

ground-breaking ceremony is planned

ABB’s more than 130-year history and

application engineers. B&R has more than

for this summer, and the new campus

lays the foundation for around 1,000 new

1,000 employees working in R&D and

is expected to be up and running in

high-tech jobs in Austria.

application development.

the course of 2020. Once complete, the

The new innovation and training

The new research and development

campus will develop technologies for

campus will cover 35,000 m² and be home

the factory of the future, based on ABB

to a significant number of state-of-the-

WELDFAB TECH TIMES | AUG - SEPT 2018

Eggelsberg site will be one of ABB’s largest research and development centers. With the new campus, the world’s

www.weldfabtechtimes.com

TRAINING CENTER

second-largest provider of industrial

Sebastian Kurz. “With our €100 million

technology

automation solutions will further expand

investment, we are strengthening this

leadership,” said

its leadership position in machine and

dynamic and the pillars of this success

Hans Wimmer,

factory automation. The development

story: innovation and people. In addition

Managing Director

of disruptive technologies will enable

to the new research and development

of B&R.

ABB to better serve the highly attractive

capacity, our investment will expand

$20-billion machine and factory

B&R’s Automation Academy, offering

for B&R,” said Josef Rainer, Co-founder of

automation market segment.

customers, partners and employees

Bernecker & Rainer Industrie-Elektronik

globally unique education and training

GmbH. “The smooth integration shows

programs.”

that the company Erwin Bernecker and

ABB acquired B&R, then the largest independent provider of product- and

“This is a great day

I founded 39 years ago is in excellent

software-based open-architecture

“With this clear commitment to the

solutions for machine and factory

Eggelsberg location, ABB has established

hands. I am delighted that ABB continues

automation worldwide, in July 2017.

itself as the market leader in automation

to write and accelerate our success story

Today, B&R is integrated into ABB’s

in Austria,” said Chancellor Sebastian

with this historic investment.”

Industrial Automation division as its

Kurz. “True to its word, the company

global Machine & Factory Automation

is now making an investment that is

technology leader in electrification

business unit. With the combined

of tremendous importance to Austria

products, robotics and motion, industrial

portfolios, ABB is today the only industrial

as a business location of international

automation and power grids, serving

automation provider offering customers

standing. This is the starting signal for a

customers in utilities, industry and

the entire spectrum of technology and

location offensive in the key segment of

transport & infrastructure globally.

software solutions around measurement,

digital industry. It is an important impulse

Continuing a history of innovation

control, actuation, robotics, electrification

for the creation of highly qualified new

spanning more than 130 years, ABB

and digitalization.

jobs and the positioning of Austria as a

today is writing the future of industrial

high-tech location.”

digitalization with two clear value

“B&R has had an excellent start within ABB and has

“This will also be beneficial for the

ABB (ABBN: SIX Swiss Ex) is a pioneering

propositions: bringing electricity from any

exceeded our

country's educational landscape.

power plant to any plug and automating

expectations. We

Further strengthening our good

industries from natural resources to

are well on track

relationships with universities,

finished products. As title partner of

to achieve our

universities of Applied Sciences and

Formula E, the fully electric international

goal of revenues

higher technical education institutes

FIA motorsport class, ABB is pushing the

of more than

is part of our innovation and research

boundaries of e-mobility to contribute to

$1 billion soon,” said ABB CEO Ulrich

strategy. This way we can further

a sustainable future. ABB operates in more

Spiesshofer, at a press conference in

accelerate our speed of growth and

than 100 countries with about 135,000

Linz with the Austrian Chancellor,

innovation as well as extend our

employees. www.abb.com

www.weldfabtechtimes.com

AUG - SEPT 2018 | WELDFAB TECH TIMES

WELDERS PASSION

“I never loss hope in whatever I do.” Q1. Tell us a little about yourself ?

Personal Protective Equipment (PPE).

I am Bhunja Shankar Durga from Dharamgarh (ODISHA), working at Kemppi India Pvt Ltd as a welding demonstrator.

Q6. You were awarded the Best Welder in India under the structural category by IIW. Congratulations. Please share your experience.

Q2. What made you choose welding as a career?

I was in cloud nine when I got a first price

After my completion of 10thstandard, I

With this, I would like to suggest all

started working in SEPCO III as a welding

the junior welders to always study and

helper. I thought of working for 6 -7

understand the process, and practice well.

for Best welder in Structural Category.

months and then to continue my further

my studies. I never lost my hope, and thus

Q7. Your also represented India at the Arc Cup held in Shanghai during June 2017. Please elaborate.

started focusing on welding as my career.

After I got selected as a Best Welder for

studies. But due to some family problems & financial issues, was unable to continue

Q3. What type of projects you’re currently working upon?

for Arc Cup, which was held in Shanghai

Currently, I am a welding demonstrator,

the competitors, I was a little nervous. But

Q10. Right from the time you started your career till date, what has been your learning so far? Any new skills you have learned?

wherein I demonstrate advanced welding

then I just closed my eyes and realized my

There are many things which I learnt

equipment’s to customers from various

strength. After that, we went to TAYOR

during my career. Some of them are like

sectors like ship building, structural

INSTUTITE for the practice session,

Spoken English. When I joined Kemppi,

application, presser vessel, automobile

wherein I got some idea and learned about

I was unable to speak English. But today,

and general fabrication industries. Besides,

time management to complete the job.

I can very well manage to speak English

Structural Category, I represent India (China). During the 1st day when I saw all

I also provide product welding training to our customers.

Q4. Can you describe on some of the mega projects you worked upon in the past?

in front of the customer and explain

Q8. What is your greatest strength, and how does it help you as a Welder?

them about our products. Besides, I have

My strength is my hand steadiness and I

MIG welding, aluminum welding, pulse

have confidence in myself. As a welder, I

welding, etc.

learnt various welding processes like

never loss hope in whatever I do.

Q5. Your say on Safety at Work. How do you consider the same when on site?

I was a TIG welder. This type of welding

Q11. Availability of skilled welders is a major problem in India. All the skilled welders opt to work abroad. Your say. Any expectations from the government to push the skilled welders work for projects in India?

application was totally new to me. Despite,

The skilled welders in India are getting

my quality engineer told that I did all

very less salary. This is the reason why

Safety is very important in welding, before

the pipe joints with 100% RT pass. I was

the welders usually prefer working

you start welding, one need to check all

amazed. This was one among the toughest

abroad. Government should take

the electrical wire connection, if they are

welding job for me. With this project, I

necessary actions inorder to promote

proper, the work area should be clean, and

gained a lot of experience and confidence

skill development in welding and

the most important one is to wear all the

thereafter.

increase employment opportunities.

Yes. I worked in Vedanta 9x135 MW power

Plant (900 MW), wherein I worked as a IBR

Q9. Can you please share an incident of a toughest welding job you have come across?

Qualified-TIG welder.

When I was working for Aditya Birla

plant at Jharsuguda district of Odisha. The other project was the Aditya Birla Power

Power Plant project under Bhawani Infra,

Bhunja Shankar Durga, Welder, Kemppi India Pvt Ltd

WELDFAB TECH TIMES | AUG - SEPT 2018

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FLASH BACK

Welding Equipments & Processes â&#x20AC;&#x201C; Journey So Far Birendra K. Mishra, Director â&#x20AC;&#x201C; Weldman Synergic Pvt. Ltd. (www.weldmansynergic.com) HISTORICAL DEVELOPMENT

process using a metal electrode. About

became very important tool for joining the

Welding plays an important role in the

the same time, N.G. Slavianoff, a Russian,

metal as it gave good quality, defect free

development of our society and mankind

presented the same idea of transferring

weld. The popularity of GTAW initiated

as a whole. One of the indexes used for

metal across an arc, but to cast metal in a

the work on GMAW.

measuring the prosperity of a country is

mould.

due to the effort of C. L. Coffin, H. M.

the par capita steel consumption. Higher the production of steel, the greater is the

1900

Hobart and P. K. Devers. The gas shielded

role of welding.

Oscar Kjellberg of Sweden invented a

metal arc welding (GMAW) process

covered or coated electrode during the

was successfully developed at Battelle

period of 1907 to

Memorial Institute in 1948. The initial

Historically the welding was developed in the ancient times and can be traced during the Bronze Age when the lap joints

1914. Stick electrodes were produced by

introduction of GMAW was for welding nonferrous metals.

were made by heating and hammering the

dipping short lengths of bare iron wire in

two metal pieces. During excavation, parts

thick mixtures of carbonates and silicates,

and tools have been found, which were

and allowing the coating to dry. This

the process on steel. The cost of inert gas

welded by pressure welding during the

marked the beginning of modern welding.

was relatively high and the cost savings

The present welding processes and

The high deposition rate led users to try

were not immediately available.

time as back as 1000 B.C. 1919

equipments as we see today, took time to

Around 1919, American Welding Society

1950

come to this stage. Let us have a look to

was formed as a non-profit organization

In 1953, Lyubavskii and Novoshilov

find out how this happened:

dedicated to the advancement of welding

announced the use of welding with

and allied processes.

consumable electrodes in an atmosphere

1800

of CO2 gas.

Sir Humphrey Davy in 1800 produced an

1920

arc between two carbon electrodes. In

In 1920, automatic welding using bare

welding in 1957. This process uses a

1836 Edmund

wire was invented by P. O. Nobel. Initially

constricted arc or an arc through an

it was used for rebuilding the worn out

orifice, which creates an arc plasma

In the mid-19th century, gas welding &

parts. The arc voltage was fed to the

that has a higher temperature than the

cutting were developed. Welding using the

wirefeed motor to regulate the arc and

tungsten arc. It is also used for metal

carbon arc and resistance welding came

construction industries. Around the same

spraying and for cutting.

into existence sometime in 1885. Nikolai

time, automatic submerged arc welding

The electron beam welding process,

N. Benardos and Stanislaus Olszewski

was developed and became very popular

which uses a focused beam of electrons

developed an electrode holder and got it

for manufacturing pipes.

as a heat source in a vacuum chamber,

Davy of England invented acetylene.

Robert F. Gage invented plasma arc

was developed in France. J.A. Stohr of the

patented, which marked the beginning of 1940

French Atomic Energy Commission made

Gas tungsten arc welding (GTAW) was

the first public disclosure of the process

1890

developed during this time and it took

on November 1957.

In 1890, C.L. Coffin of Detroit was awarded

nearly one year to perfect the process.

the first U.S. patent for an arc welding

During this time, the GTAW welding

carbon arc welding.

Initially, the GTAW came to perfection

WELDFAB TECH TIMES | AUG - SEPT 2018

The Electroslag welding process was announced by the Soviets at the Brussels

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FLASH BACK

World Fair in Belgium in 1958. It had been

developed at the Bell Telephone

the globalization of the market, everyone

used in the Soviet Union since 1951, but

Laboratories as a communications device.

is free to sale anywhere in the world.

was based on work done in the United

Because of the tremendous concentration

Also, India being a developing country,

States by R.K. Hopkins, who was granted

of energy in a small space, it proved to be

the growth rate for welding equipment

patents in 1940. The Hopkins process

a powerful heat source.

and consumable market will be higher

was never used to a very great degree for

Friction-stir welding (FSW) is a solid-

compared to the other section of the

joining. The process was perfected and

state joining process (meaning the metal is

equipment was developed at the Paton

not melted during the process) and is used

Institute Laboratory in Kiev, Ukraine, and

for applications where the original metal

reason for worry as far as the market is

also at the Welding Research Laboratory

characteristics must remain unchanged

concerned. The pressure on the price

in Bratislava, Czechoslovakia.

as far as possible. It was invented and

is expected to be very high hence the

experimentally proven by Wayne Thomas

manufacturers will have to streamline

1960

and a team of his colleagues at The

their production process and come out

Prior to 1960, most of the welding was

Welding Institute UK in December 1991.

with innovative design concepts.

it was realized that each gas has some

MARKET SCENARIO:

EXPECTATION OF THE MARKET:

advantages and disadvantages. For

Even during the recession, the production

In order to maintain the growth rate the

example, CO2 gas has advantage of giving

of steel and the market of welding

manufacturer will have to tune themselves

better penetration, bus has disadvantage

equipment and consumable has been

as per the requirement of the market. The

of spatter and poor bead appearance.

able to sustain its growth, may be at a little

market requirement in the coming years

Argon gas has the advantage of good bead

lower pace than expected. But certainly

will be as follow:

appearance and practically no spatter but

there was a better market demand

has the disadvantage of poor penetration.

compared to other industrial goods.

world. Hence there should not be any

done using one particular gas. Soon

Scientists started experimenting with gas

The rate of growth will reduce a bit in

ELIMINATION OF PRE & POST HEATING: During the recent seminar at

mixtures to maximize the advantages and

the years to come because the market

Jamshedpur, a paper was presented by

minimize the disadvantages. Gas mixtures

is already matured. In order to sustain

Dr. T. K. Paul, a well-known metallurgist,

were developed to ensure homogeneous

the growth in such a mature market, the

wherein he discussed on an electrode

mixing of the gases.

manufacturers should continue to actively

which will eliminate pre & post heating.

The Arcos Corporation introduced

pursue new opportunities in different

The idea looked strange to many

another vertical welding method, called

segments where at present the welding

audiences but any innovative idea when

Electrogas, in 1961. It utilized equipment

is not used and continue to add value to

heard for the first time, it is found to be

developed for Electroslag welding, but

their existing welding techniques.

difficult to accept.

employed a flux-cored electrode wire and an externally supplied gas shield.

We have to find out ways to replace

Here, emphasize is on innovative ideas

more designs to steel. We should look

for production-cost reduction making

around and find out the items which

fabrication more viable.

Most Recent

can be changed to steel and items which

Friction welding, which uses rotational

are not fabricated at present but can be

CONSUMABLE QUALITY: Fabrication

speed and upset pressure to provide

of fabricated design in future. The good

will shift from MMAW to Semi Automatic

friction heat, was developed in the Soviet

example for this is the bridges & flyovers

Welding. It will be necessary to have

Union. It is a specialized process and

which were earlier made by concrete are

continuous solid or tubular consumable

has applications only where a sufficient

now mostly fabricated structures.

having perfect cast and helix with uniform

volume of similar parts is to be welded

Seeing the trend of steel production and

diameter to have minimum hassle in

because of the initial expense for

the market demand, it is expected that the

feeding. This will eliminate interruption

equipment and tooling. This process is

requirement of welding equipment and

and will result in higher arc on time,

called inertia welding.

consumable in the world during the year

thereby increasing the productivity.

Laser welding is one of the newest processes. The laser was originally

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2009-10 will be approximately 775 billion rupees, i.e. 16.5 billion USD approx. With

INNOVATION IN STEEL: The steel

AUG - SEPT 2018 | WELDFAB TECH TIMES

FLASH BACK

manufacturers should work in close

SOFTWARE: The use of micro controller,

welding technocrats including inspection

association with welding equipment

micro processor with good quality

personnel should have uniform

and consumable manufacturers.

software can reduce the set up time. The

internationally accepted education and

Unfortunately, in India, at present the

proper record of the weld parameter for

qualification duly certified.

importance of the same is not fully

a particular job can be stored and reused

realized. The basic idea is that the steel

in future. The software should be able to

Institute of Welding, a member of

manufacturers should be able to produce

calculate on-line fabrication cost.

International Institute of Welding, is Authorized National Body, which is

steels which will give the same or better properties at a lower thickness, reducing

INTERNATIONALLY ACCEPTED

the weight of steel thereby the weight

EDUCATION & CERTIFICATION

of the fabricated structure. Whenever a

SYSTEM: Demand for above will increase

per ISO 3848 for quality production and

new steel is produced, the challenge is

every year. For better communication,

export of their items.

thrown to the consumable manufacturers

it is essential that the welders and the

to come out with suitable consumable and it is passed on to the equipment manufacturers to produce welding

IMPROVEMENT REQUIRED

GTAW

Mostly manual Semi automated system Manual root pass Simple GTAW Automatic voltage control system

- Semi automatic or Automatic - To achieve perfection - High amperage hot/cold wire system - High penetration GTAW - To be made more sophisticated but to be available at cheaper cost

SMAW

Electrode needs re-drying All position electrodes Pipe welding electrode Low moisture pickup & low-hydrogen

- Vacuum packed electrode to eliminate / reduce re-drying - Should be user friendly - Easily weldable - Welder friendly consumables

GMAW

Semi automatic welding Mostly CO2 gas used Mixed gasses in cylinder Limited range of consumables

- More automatic welding - Use of more mixed gasses - Gas mixture both portable & High volume for mixing of the gas at site. - More varieties with different gas mix

FCAW

High cost Mostly semi automatic Low hydrogen and low fume generating wires Uniform filling of flux

- Low cost - More automation - To be developed at cheaper cost - To be perfected

SAW

Single wire Low speed welding Process limitation of downhand welding Narrow gap welding Reclamation with round wire. Advanced wire-flux combination

- Use of multi wire - High speed welding using tandem Wire - Use of Manipulator and welding aids to bring the weld in down hand position. - To be perfected - Use of strip electrode for better deposition. - To be perfected for higher deposition

OTHERS

High cost of friction stir welding Guiding systems Oscillation system Accessories for welding automation Such as magnetic rail with special trolley. Welding of large vessels/penstock pipes.

- Cost reduction - To be developed indigenously. - At cheaper cost - To be developed indigenously at lower cost - Innovative design of welding aids to reduce the cost.

AUTOMATION: The demand for few years and will keep on increasing to improve the productivity and to reduce the requirement of skilled labourer. The degree of automation depends on the quantum of production and investment. MATERIAL FOR FABRICATION: The growth of use of steel will reduce and that of aluminium and stainless steel will increase. We have satisfactory consumables and machineries for fabrication of steel but the same is not true for aluminium and stainless steel. Both equipment and consumable manufacturers should look into this. PRODUCTIVITY: Requirement of improvement of productivity shall be considerably high in the years to come. Cost of following inputs in fabrication has to be reduced: a) Machines and automation cost. b) Labour cost. c) Consumable cost. d) Energy cost.

WELDFAB TECH TIMES | AUG - SEPT 2018

The fabricators can also be certified as

CURRENT STATUS

after using such consumable.

automation has been increasing in the last

imparting such education and training.

PROCESS

machines which will give perfect result

I am pleased to inform that Indian

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FLASH BACK

IMPROVEMENT REQUIRED OF

different workshops & training institutes,

iii) Technical back up on application

EXISTING WELDING EQUIPMENTS AND

providing training to the welders even in

iv)Efficient after-sales service

PROCESSES IN INDIA:

remote areas, helping them to improve

v) Increased product life

India being a developing country,

their skill and finally examining their

considerable investment is expected

skill for issuance of certificate. Number

The above are the present requirements.

in the next few years in infrastructure

of Authorized Training Bodies has been

The future requirement can be following:

development. In order to popularize the

appointed and few more are in the process

welding, let us look at what is the current

of appointment for giving training to the

curvature and fit-up and giving signals

status and what improvements are

welders as per the international standard

to the welding machine for correction.

required:

laid down by the International Institute of

ii. Joining of coated steels

Welding.

iii. Joining of dissimilar metals

WELDING INDUSTRY IN TOTALITY:

Another way to solve the problem of

The industry consists of three parts:

shortage of trained welder is to depend

more on automation and robotic welding.

The direct labour, i.e. the welder, who

iv. Better welded design and process management v. Recording and evaluating the weld cost.

perform the actual welding operation. ii. The manufacturer of welding

Sensing the welding profile in terms of

THE MANUFACTURER: The

equipments and consumables, who

manufacturers depend on distributors for

WELDING SETUP: It consists of following:

provide service & facility needed by

the sale of their products. The problem is

i) Welding Consumables

the welder.

that though the most of the distributors

ii) Power Sources

are able to sale in volumes and pay in time

iii) Welding Equipments

welding and joining process to get

but very few of them have technical staff

iv) Aids for Automation

manufactured their end products.

trained to help customers select the best

iii. The client who depends on

processes for their needs or to solve their

WELDING CONSUMABLES: Welding

The manufacturing of welding

technical problems quickly. Recently,

consumables are the materials which are

equipments and consumables depends

some suppliers have realized that lack of

used up during welding, for example â&#x20AC;&#x201C;

both on the welders and the end users,

technical expertise makes them look like

consumable electrodes, filler wires, fluxes

to pursue their goal of higher growth and

commodity suppliers to their customers,

and externally applied shielding gasses.

better market.

and they are moving to improve their

They influence the welding operation,

THE WELDER: There is a big shortage

service.

heat input, solidification, bead shape and

of trained welder in the national and

The welding is hi-tech engineering

weld metallurgy. This is being a complete

international market. The shortage of

hence it is necessary that both the

subject by itself; we will not discuss it

trained welders can also affect the growth

manufacturers and the distributors have

further. A metallurgist can do the justice to

of other industrial products since the

the full knowledge of the product, process

this topic.

welding is an important tool for final

and application to give full value of the

assembly. The welding is a specialized

money spent by the client.

skill and needs training for perfection.

The manufacturers will have to keep

POWER SOURCE: All welding processes require electrical power which depends

In India, there are number of training

on introducing new products having

on the thickness of the job. The supply

institutes for training welders such as

increased performance and still better

of current together with proper voltage

The Indian Institute of Welding and

quality. At the same time the product

for maintaining the arc is necessary. The

some of the other agencies. But the

must be affordable both for the initial

current can be Alternating (AC) or Direct

entire training program is still not very

investment and the overall life cycle cost.

(DC) depending on the process. But it must have the means for controlling

systematic and professional. This needs a very serious attention because the growth

THE CLIENT: The expectations of the end

the same for obtaining the desired

of fabrication industry depends on easy

users or the clients which a manufacturer

Volt- Amps Characteristic for maximum

availability of skilled welders.

has to satisfy are:

weld efficiency. The device which gives

i) Better innovative design

required Volt-

The Indian Institute of Welding is doing lot of work in this direction by visiting

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ii) Lower cost

Amps characteristic with precise control

AUG - SEPT 2018 | WELDFAB TECH TIMES

FLASH BACK

is called the POWER SOURCE.

booster circuit for higher OCV, hot start

• Low Hydrogen Electrod

for easy arc striking, anti freeze avoiding

• Non-Ferrous Electrode

CLASSIFICATION OF POWER SOURCE

sticking of the electrode with the job and

depending on OUTPUT:

also has arc force control. Has good power

Alternating Current (AC) only:

i) AC or DC

factor and efficiency. It is the cheapest DC

• TIG Welding of Aluminium

ii) AC – DC

welding power source. Alternating Current (AC) preferred:

iii) Constant Current (CC) iv) Constant Voltage (CV)

iv) Chopper based – Advanced power

v) Variable Volt-Amp Characteristic

source, higher efficiency and power factor, has very good tolerance to supply

welding • To counter Arc Blow

CLASSIFICATION OF POWER SOURCE

surges, not difficult to maintain, bigger in

depending on DESIGN:

size compared to Inverter based power

Alternating Current (AC) & Direct

i) Magnetic Leakage type

sources.

Current (DC): • High speed welding

ii) Magnetic Amplifier type iii) Thyristor Based

v) Inverter based – Advanced power

iv) Chopper Based

source, has high efficiency & power factor

POWER SOURCES USED IN INDIA:

v) Inverter Based

and is light in weight and compact in size.

• A.C. POWER SOURCE: Almost all

Bad input supply condition with surges

the power sources used are Moving

SELECTION OF POWER SOURCE:

can create problem. A good machine is

Core type, suitable for connection to

The most important factors to be

costlier compared to Thyristor based or

two phase of three phase supply. The

considered in selecting the power source

Chopper based power source.

design is simple and output can be varied even when the welding is in

are the performance, the type of power

DEPENDING ON THE OUTPUT VOLT-AMPS CHARACTERISTIC:

operation unlike tap choke design.

enable better welding at lower cost. The power source should be able to withstand

Depending on the Output Volt-Amps

• D. C. POWER SOURCE: Since majority

rough input supply condition with surges

Characteristic, the power sources can be

of the welding is done using D.C. Power

and should be easily maintainable and

classified as following:

Sources, we will examine this in little

repairable in case of accidental failure.

i) Constant Current (CC) for Manual

more detail. Three types of D.C. Power

source which will do the job easily and

Metal Arc (MMA) & TIG Welding.

DEPENDING ON THE EASE OF MAINTENANCE:

Sources are used namely:

ii) Constant Voltage (CV) for Semi

Thyristor type

Automatic & Automatic Welding.

ii)

Chopper based

iii)

Inverter based

Depending on the ease of maintenance, the power sources can be classified in

DEPENDING ON THE PROCESS:

following order, from simple to difficult:

Depending on the Process, the following

THYRISTOR TYPE: The input supply is

i) Magnetic Leakage type – needs very

may be used as guide for selection of

connected to a step-down transformer,

less maintenance but output Volt-Amps

Alternating or Direct Current Power

output of which is connected to a

characteristic is not accurate and is not

Source:

Thyristor Bridge.

immune to supply voltage fluctuation, has

Direct Current (DC) only:

The rectifier in a conventional

low efficiency & power factor.

• Gas Metal Arc Welding

welding power unit is essentially a

• Flux Core Arc Welding

static component. It simply accepts the

ii) Magnetic Amplifier type – easy to

• TIG Welding of Stainless Steel

alternating current from the transformer

maintain and immune to supply voltage

• Exx10 type Electrode

and converts it to DC without exercising

fluctuation but has low efficiency and

• Exx15 type Electrode

any control. If a Thyristor is used in place of the conventional rectifier, however, the

power factor.

• Iron Powder Electrode for down hand

Direct Current (DC) preferred:

current flow can be altered in response to

iii) Thyristor based – most popular, is

• The out of position welding

a remotely controlled command signal.

immune to supply voltage fluctuation, has

• Welding of Stainless Steel

WELDFAB TECH TIMES | AUG - SEPT 2018

A Thyristor is a solid-state device which

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FLASH BACK

allows current to flow in one direction, i.e., it behaves as a normal rectifier.

are used to improve the flow of current.

DC to provide a high frequency more than

DC voltage is applied through a solid

50 Hz. This high frequency voltage is then

However, in the appropriate half cycle

state switch, which controls the welding

applied to the primary of a transformer.

it will conduct only after being â&#x20AC;&#x2DC;firedâ&#x20AC;&#x2122; by

arc by opening and closing, regulating the

The secondary output of the transformer

a voltage pulse applied to the control

amount of current that is applied to the

is then rectified and filtered to supply a

terminal. Current will then flow for the

arc. When the switch is closed, current

DC welding voltage and current.

remainder of that half cycle, until its

is applied through the inductor to the

direction reverses and the Thyristor ceases

arc. When the transistor switch is open,

required magnetic components like

to conduct. In a typical AC waveform, the

current stored in the inductor sustains

transformer and choke become small.

mean current depends on the time, during

current in the arc. The reception of this

Higher the frequency, lower will be the

which current is flowing.

cycle of switch closure is at least 20 KHz,

size of transformer and choke. As a result

which allows fast control of the arc.

of this, the Inverter base power sources

Being a machine whose output is

are light in weight and compact in size.

controlled electronically; its functions can

The Chopper based power source has

be enhanced to various requirements. The

excellent tolerance to surge voltage as the

Because of the high frequency, the

rectified output passes through a choke

3- phase mains is connected to a normal

response to changed arc condition is very

and a free-wheeling diode circuit to give

transformer. It is very useful where the

fast. It is a machine with full of electronics

smooth DC.

input power is supplied through a Diesel

and most of the times has a micro

Generator Set or where the input voltage

controller/micro processor to give the

CHOPPER BASED: Chopper based

keeps fluctuating heavily in a badly

desired output under various conditions

power source is the simplest form of high

networked industrial site.

of the welding. Efforts should be made to manufacture

The cost of Chopper based power

frequency power conversion. In case of Chopper based power source, a 3-phase

source is cheaper and has almost all the

this machine totally indigenous. At

mains is connected to a step-down

practical advantages of an Inverter based

present, most of the Inverter based

transformer working at 50 Hz. the output

power source except that it is bulky.

power sources available either imported or assembled, making the availability of

of which is fed to a 3-phase rectifier bridge. Then the output is chopped to

INVERTER BASED POWER SOURCE:

a lower output voltage, and a choke is

In this case, the input supply is applied

placed in the path of the output to smooth

directly to a bridge circuit where it is

current variation.

rectified and filtered to produce a pure DC

COMPARISON BETWEEN DIFFERENT POWER SOURCES:

voltage. Solid state switches then chop the

From the above, it is clear that while going

A capacitor and a free-wheeling diode CRITERIA Volt-Amps characteristic Immunity to voltage fluctuation

DIODE

Range of output Weldability of different electrodes

spare parts difficult and costly.

THYRISTOR TYPE

CHOPPER BASED

Non-Resonance

Resonance

Not accurate but acceptable

Accurate

Not available

Good

Moderate

Good

Generally Multi Range

Single Range

Poor, specially low hydrogen

Good

Moderate

Good

Very good

Arc striking

When used as Power Source for GTAW

Because of the high frequency, the

INVERTER BASED

Cost of spare parts

Cheap

Moderate

Costly

Size

Bulky

Moderate

Compact

Weight

Heavy

Moderate

Not so Light

Light

WELDFAB TECH TIMES | AUG - SEPT 2018

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FLASH BACK

Power consumption in KW of 400 Amps. machine: At 200A at 28VAt-

10.40

8.15

6.80

6.30

300A at 32VAt-

16.50

13.60

12.50

11.30

11.20

350A at 34V-

20.50

16.87

15.27

14.80

13.78

for a sophisticated power source, one should be looking to the following aspects:

moves below it. In case of automatic welding, lot of

AIDS FOR AUTOMATION: These are required to ensure good quality

• Country of origin.

variation is possible as shown in the

weld with minimum of skill and are tools

• Technology used.

figure. The figure shows variation in

for automation for better productivity.

• Initial cost involvement.

submerged arc welding equipment. The

Examples of some of them are given

• Availability of after sales service.

same is true for other processes also.

below:

• Cost of spare parts.

ROTATOR: For rotating a circular job for automatic circular seam. Advanced

All the above problems with Inverter

rotators are fitted with sensor to avoid

based machine will be eliminated

drifting of job.

when the machine is manufactured indigenously, which we are quite capable of doing. EQUIPMENT: Equipments are the means for feeding consumable electrode. These can be divided in three categories: MANUAL WELDING: For Manual Metal Arc Welding where the maintenance of the arc voltage and the positioning of the arc both are manual, an Electrode Holder is the only equipment besides standard

MANIPULATOR: For positioning

accessories.

the job for down-hand welding. C. G. & eccentricity of the job should

SEMI AUTOMATIC WELDING: In case of

be considered while ordering the

Semi Automatic Welding, the arc voltage is

manipulator.

maintained constant automatically by the flat characteristic of the power source and the positioning of the arc is manual. The equipment required here is a Wirefeeder with a Welding Torch fitted in it besides other standard accessories. AUTOMATIC WELDING: In this case, both the maintenance of arc voltage and the positioning of the arc are automatic. The Wirefeeder is mounted on a trolley and it moves over the job. Alternatively, the wirefeeder is kept stationary and the job

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AUG - SEPT 2018 | WELDFAB TECH TIMES

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COLUMN & BOOM: When a welding

welding of joints with bi-dimensional

head is fitted on a Column & Boom, it

copying.

is capable of moving up & down and is able to travel to & fro, making it ideally

TRI-AXIAL GUIDE SYSTEM: The system

suitable for pressure vessel industries.

carries out the complete welding of

The Column of some of the machines

circumferential (or longitudinal) joints

are also capable of rotating along its axis,

of vessels with continuous automatic

making the machine more useful.

evolution of welding, in a groove of many forms, from the bottom to top. The above are some of the common welding aids. The list is long. Anything that increases the weld-on time & helps in doing the welding in down-hand position or increase the automation of welding can be termed as Weld Aid.

CONCLUSION: The past of welding technology was good, the present is encouraging and FIT-UP GAP SENSOR: In Fit-up Gap

the future is excellent. The expectations

MONO-AXIAL GUIDE SYSTEM: The

Sensor, a photo-electric device is kept

of clients shall be high and the pressure

electronic probe positioned in front

below the joint which measures the

on price will be heavy in future. The

of the welding

light coming out from the joint which is

welding manufacturers shall have to

arc explores the

proportional to the gap. It gives signal to

be innovative to accept the challenge.

joint to be welded

an Oscillation unit and Power Source for

The expected requirement for qualified

and converts

manipulation of the weld parameter for

welders and welding personnel shall

proportionally any

satisfactory weld.

be very high. The revolution in design

vertical deviation

of power sources and improvement is

from a neutral central

MAGNETIC OSCILLATOR: Magnetic

processes will be the call of the day.

position ('zero')

oscillation is useful for oscillating the arc

The market of weld automation will be

into an electrical

either in X-axis or in Y-axis and in some

increasingly demanding to achieve high

signal, which suitably

instances it can even rotate the arc to get

quality defect free weld with minimum

amplified, controls

desired weld bead.

skill requirement.

the servo-meter of the axis Y, so as to maintain the distance of Torch from the welding surface constant. BI-AXIAL GUIDE SYSTEM: The system is normally used for welding circumferential and longitudinal joints of vessels or more in general, for the

WELDFAB TECH TIMES | AUG - SEPT 2018

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ƌŝƟĐĂů

t > /E'

ƐŝŶŐůĞ ƐŽƵƌĐĞ ĨŽƌ ǁĞůĚŝŶŐ ƐŽůƵƟŽŶƐ

Needs Special Products

brings Technically Advanced Welding Products to Indian Industry from Global Leaders

ƵƚŚŽƌŝǌĞĚ ŝƐƚƌŝďƵƚŽƌ͗ ϰϬϭ͕ sŝŬĂƐ Žŵŵ͘ ĞŶƚƌĞ͕ ƌ͘ 'ŝĚǁĂŶŝ ZŽĂĚ͕ ŚĞŵďƵƌ ; Ϳ͕DƵŵďĂŝ ϰϬϬϬϳϰ͕ /ŶĚŝĂ͘ d͗͘ нϵϭͲϮϮͲϲϲϰϲϮϬϬϬ ͬ ϮϱϱϬϯϮϳϬ ͗͘ ƐĂůĞƐΛǁĞůĚǁĞůů͘ĐŽŵ͕ ŶŝǀĞŬΛǁĞůĚǁĞůů͘ĐŽŵ

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ǁǁǁ͘ǁĞůĚǁĞůů͘ĐŽŵ

WOMEN IN WELDING

Malaysiaâ&#x20AC;&#x2122;s first female underwater welder - Izzati

NUR Izzati Athirah Mohammad Yusoff, Assistant Instructor, Weldzone Training Centre Sdn Bhd

WELDFAB TECH TIMES | AUG - SEPT 2018

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WOMEN IN WELDING

Q1. Could you brief us on your education background? I am currently 21 years old, born in Selama, Perak. I am graduated from Kolej Vokasional Taiping with Diploma of Welding and Fabrication and continued with my passion in Welding Industry when Weldzone Training Centre Sdn Bhd sponsored me a scholarship in Commercial Diving & Underwater Welding Course and upgraded my certifications to Instructor level with International Technical Diving Agencies (ITDA/UK/Europe) certifications in 2017.

Q2. What made you choose welding as a career, which is a highly male dominated segment?

are male. I like taking up challenging task and aim to upgrade myself.

I never had a dream to make a career when I was a student at Kolej Vokasional

Q3. What is you say on safety in Welding?

Taiping in Kamunting, Perak. I was

Safety is one of the key factors when

the only female student who studied

welding is concern. When we put the

welding there in 2013. I actually had

health and safety as a priority in every

no idea about welding when I started

work not only for welding, the project

the course, but I just wanted to try

can be handled in a proper ways. Being

something new and challenging.

very specific towards underwater

Infact, even during my final year, I still

welding, one has to be mentally and

was not sure what I want to do after

physically strong because the job is

college. But all such mixed thought

very tough and risky. While getting the

just changed my mind after we had

job done, you have to be alert to your

a field visit to Weldzone Training

surroundings and for safety. There are

Centre. Located in Seri Manjung,

times when we face insufficient oxygen

Perak, Weldzone Training Centre offers

in water, or a sudden loss with my buddy

Q4. What are your future plans?

courses in commercial diving as well

during diving. Thus, alertness is a must.

I want to upgrade my skills in

in underwater welding, but it started

as underwater welding and underwater

during any heavy tasks.

underwater welding.

and its concept of welding under the

Q3. Have you anytime faced gender discrimination on site, as the stream is male dominated?

Closing message, especially to the female.

sea. Thus, I planned to opt for a career

Although the industry being a highly

I hope that every female open up their

in underwater welding. Today, apart

male dominated segment, I have never

mind to choose their ambitions nicely.

from being an underwater welder, I am

experienced any such incidents. Infact

Once when you choose the right career,

also an assistant instructor at Weldzone

the team highly respect me and my

your hard work will surely make a good

Training Centre, where all my students

work. Many a times, they also help me

way and a good job.

cutting. I was highly impressed with a demonstration on underwater welding,

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AUG - SEPT 2018 | WELDFAB TECH TIMES

LAUNCHES

Laser welding in XXL

The XXL version of the TruLaser Weld 5000 processes parts up to 4 meters in length. In addition to the turnover positioned for large components, there is room in the interior for positioners for smaller parts.

Enlarged version of TruLaser Weld 5000 // Automatic laser welding of components up to four meters in length // New developments in optics and programming.

he welding robot of the new, enlarged version of TruLaser Weld 5000 processes parts up to four

meters in length. There is enough space in the booth of the XXL system for large assemblies, such as big casings or water tanks. Users benefit from the advantages of the laser even when working with components on this scale. Whether robust or attractive welds, the laser does Through a door measuring 4 meters in width, even longer parts can fit inside the cell.

both and saves on rework.

Positioners for various requirements

turning axis, which the positioner uses to

booth is up to 9.4 meters long, accessed

The robot of the TruLaser Weld 5000

align assemblies for the welding robot.

by a door four meters wide. Its interior

travels along a linear axis, which means

Parts with dimensions of up to 4,000

accommodates additional component

it can cover a large work area. As a

millimeters in length, 1,500 millimeters

positioners, such as a table that can turn

complementary feature, the system also

in width and 1,000 millimeters in height

and tilt. Thanks to this feature, users can

possesses a four-meter-long turnover

can be welded with the new system;

weld complex parts without having to

positioner with a carrying capacity of up

depending on the position of the seam, it

interrupt work to reclamp them. Another

to 1,000 kilograms. It owes its name to a

can handle even larger components. The

positioner allows users to load the system

WELDFAB TECH TIMES | AUG - SEPT 2018

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LAUNCHES

from the outside while the welding robot

version of TruLaser Weld 5000 facilitates

many parts that users may have originally

works in the cell.

three different laser welding methods.

designed for conventional welding

The component decides which is the most

methods. As a result, FusionLine provides

New developments in optics and programming

cost-effective solution. Heat conduction

an easy introduction to the world of laser

welding joins together thin-walled parts

welding and enables users to increase the

In addition to the larger format, there

and produces seams of very high surface

capacity utilization of their machines.

are also new developments in the optics

quality. In many cases, this eliminates the

Without retooling the TruLaser Weld

of the TruLaser Weld 5000: a built-in

need for any subsequent grinding and

5000, users can easily switch between

sensor system during operation monitors

polishing of the seam. Deep penetration

FusionLine and other laser welding

whether, and to what extent, dirt has

welding produces deep, narrow, high-

methods, even during the processing of a

accumulated on the protective glass.

strength weld seams. It can be used

component.

LEDs on the optics and messages on

with both thin and thick-walled metal

the system's user interface display the

sheets - and gets the job done fast.

resolution are available to illustrate this

degree of contamination. In this way,

Heat conduction and deep penetration

press release. They may only be used for

the sensor system supplants visual

methods offer the best quality when it

editorial purposes. Use is free of charge

inspections and saves time. Also new, via

comes to laser welding. To achieve this,

when credit is given as "Photo: TRUMPF".

the welding program, users can set the

components generally have to possess

Graphic editing – except for dropping out

amount of shielding gas and the strength

very low tolerances. However, the

the main motive – is prohibited.

of the compressed-air crossjet at the

FusionLine technique can be used to join

optics. There is thus no need for manual

components that have somewhat larger

For More Info:

intervention.

gaps. It smooths out any unevenness

TRUMPF Group

during the welding process and closes

Dr. Andreas Möller

One system, three welding methods

gaps up to one millimeter wide. This

Email: andreas.moeller(at)de.trumpf.com

Like the standard version, the enlarged

makes it possible to use the laser on

Tel: +49 7156 30336824.

Digital photographs in print-ready

Thanks to the rotary axis, the turnover positioner aligns parts so that the welding robot can comfortably reach the seams.

WELDFAB TECH TIMES | AUG - SEPT 2018

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Sector Watch POWER

SECTOR WATCH: POWER

India has the fifth largest power generation capacity in the world Market Outlook: Power is one of the most critical

generation capacity to 60 GW by 2022.

is expected to reach 330-441 GW by 2040.

India has also raised the solar power

The 2026 forecast for India's non-

components of infrastructure, crucial

generation capacity addition target by

hydro renewable energy capacity has

for the economic growth and welfare of

five times to 100 GW by 2022. The Union

been increased to 155 GW from 130 GW

nations. India’s power sector is one of the

Government of India is preparing a 'rent

on the back of more than expected solar

most diversified in the world. Sources of

a roof' policy for supporting its target of

installation rates and successful wind

power generation range from conventional

generating 40 gigawatts (GW) of power

energy auctions.

sources such as coal, lignite, natural gas,

through solar rooftop projects by 2022. All

oil, hydro and nuclear power to viable

the states and union territories of India

country to use LEDs for all lighting needs

non-conventional sources such as wind,

are on board to fulfil the Government of

by 2019, thereby saving Rs 40,000 crore

solar, and agricultural and domestic waste.

India's vision of ensuring 24x7 affordable

(US$ 6.23 billion) on an annual basis.

Electricity demand in the country has

and quality power for all by March 2019.

The government’s immediate goal is to

increased rapidly and is expected to rise

India could become the world's first

Total installed capacity of power stations

generate two trillion units (kilowatt hours)

further in the years to come. In order to

in India stood at 343.79 Gigawatt (GW) as

of energy by 2019. This means doubling

meet the increasing demand for electricity

on April, 2018.

the current production capacity to provide 24x7electricity for residential, industrial,

in the country, massive addition to the installed generating capacity is required. India has the fifth largest power

The Road Ahead

commercial and agriculture use. The Government of India is taking a

The Government of India has released its

generation capacity in the world, as per

roadmap to achieve 175 GW capacity in

number of steps and initiatives like 10-year

the IBEF report. The country ranks third

renewable energy by 2022, which includes

tax exemption for solar energy projects,

globally in terms of electricity production.

100 GW of solar power and 60 GW of

etc., in order to achieve India's ambitious

During May 2018, India ranked 4th in the

wind power. The Union Government of

renewable energy targets of adding 175 GW

Asia Pacific region out of 25 nations on an

India is preparing a 'rent a roof' policy

of renewable energy, including addition of

index that measures their overall power.

for supporting its target of generating 40

100 GW of solar power, by the year 2022.

Electricity production in India reached

gigawatts (GW) of power through solar

The government has also sought to restart

1,201.543 Billion Units (BU) during FY18.

rooftop projects by 2022.

the stalled hydro power projects & increase the wind energy production target to 60

The Government of India’s focus on

Coal-based power generation capacity

attaining ‘Power for all’ has accelerated

in India, which currently stands at 192 GW

GW by 2022 from the current 20 GW.

capacity addition in the country. The Indian power sector has had eventful

Total Installed Capacity (As on 31.06.2018)

developments in not only generation &

Source: Central Electricity Authority (CEA)

transmission capacity addition, but also

Fuel

from the distribution reforms aspect. The

Total Thermal

sector witnessed 9.6% growth in installed capacity with an addition of approx 28,788 MW. Renewable energy is fast emerging as a major source of power in India. Wind

% of Total

2,22,693

64.8%

Coal

1,96,958

57.3%

Gas

24,897

7.2%

Oil

838

0.2%

45,403

13.2%

Hydro (Renewable)

energy is the largest source of renewable

Nuclear

6,780

2.0%

energy in India, accounting for 49.33 per

RES* (MNRE)

69,022

20.1%

cent of total installed capacity (69.02 GW). There are plans to double wind power

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Total

343,899

* Installed capacity in respect of RES (MNRE) as on 31.03.2018.

AUG - SEPT 2018 | WELDFAB TECH TIMES

SECTOR WATCH: POWER – ARTICLE

Welding applications in the field of power plant maintenance 1. Foreword

mention the following:

Welding represents an essential element

» Shortening the time of restoring the

in the process of power equipment

dimensions and operating capabilities

fabrication. Nevertheless, this element

of the component; » Reducing the stock of the spare

has its special importance in the process of maintenance of this equipment as

equipment from the power plant ware

well. Sometimes, it represents the only

house; » Relaxing the planning process of the

option for keeping in service some critical components during the outage

damaged equipment replacement,

time [1], [2], [3]. In the last years, the

temporary or permanently repair becoming the first option;

importance of welding in this process

» Huge savings of the power plant

increased significantly once the decrease Mr. Cristian Delamarian, ASME Authorized Inspector, DP Industrie Service (Romania)

of maintenance costs of the power equipment became an issue of a major importance. Initially used as a permanent

On the other side, there are some

joining method for replacing the damaged

the water resources in their reservoirs for

limitations as well of this solution:

components, gradually, it became the

water supply purposes of the population

» Some components may be strongly

basic element for the reconstruction

in Manila and in the surrounding areas.

damaged beyond any repair;

of the initial shape, dimensions and

Consequently, the thermal power plants

» Some weld repair methods are

operational characteristics of the damaged

were forced to cover the energy demand

complicated to apply or the weld

components. The paper presents several

through out a total availability of their

quality hard to evaluate (e.g. because of

field applications of welding on the repair

units.

of damaged power equipment.

In order to comply with such a critical

lack of physical space); » Weld repair may require sometimes

demand coming from the client side

Post Weld Heat Treatment, operation

2. Introduction in the welding engineering applications in the power plant maintenance

(sometime even from the government

hard or even impossible apply to some

Power plant maintenance has a local

periods of time, one should ensure that the

cannot anymore be compared with a

strategic importance for the power plant

equipment is able to operate at the design

new one, the first one could anytime

itself, as well as general one for the whole

parameters for at least the period of time

suffer during plant operation damages

economy of a region or even of a country.

between two consecutive planned outages.

at much higher rates just because of the

A very good example in this direction is the

side), which requires the plant to operate

heavy big or complicated components;

in base load system at its full load for long

» A weld repaired component sometime

Replacement of the damaged equipment

weld repair.

energy crisis that stroked Philippines at the

which no longer partially or totally fulfills

Nevertheless, despite the all

beginning of 2010. Thus, following a long

its designed functions represented so far

disadvantages, the weld repair will win

dry season and a pore raining season at

a usual option. Considering the novel

more and more supporters among the

the end of 2009, the month of January 2010

welding technologies, materials, and

power plant maintenance personnel in the

became for Philippines a critical time in its

equipments as well as tougher and tougher

coming years.

economic and social life. The hydropower

conditions where these solutions can

plants which usually deliver 25-30 % of the

apply, the alternative of repairing this

power demand in Philippines were forced

equipment became the first option.

to shut down their units because of the above mentioned reasons in order to save

maintenance costs.

WELDFAB TECH TIMES | AUG - SEPT 2018

The advantages of this alternative are numerous. Among others one may

3. Field applications of the welding in power equipment maintenance Following, one shall discuss some examples of field applications of welding in

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SECTOR WATCH: POWER â&#x20AC;&#x201C; ARTICLE

the power plant maintenance. Approached subjects shall exclude the investigations conducted for the assessment of damage causes, this subject being beyond the purpose of this presentation. The paper will be oriented exclusively on the repair approaches and will include the judgment that supported each technical solution separately in order to describe to the reader the internal mechanisms of these

Figure 1.1

Figure 1.2

Figure 1.3

Figure 1.4

Figure 1.5

Figure 1.6

Figure 1.7

Figure 1.8

complex processes. 3.1. Example 1: Weld repair of a steam coil air heater flash tank A Steam Coil Air Heater Flash Tank (see Figure 1.1) was found severally damaged during a regular annual inspection (see Figure 1.2). It was also found that a big patch was welded at the bottom the tank (see Figure 1.3) to compensate wall thickness losses recorded couple of years ago. Analyzing the situation, it was taken the decision to remove the old patch (see Figure 1.4) in order to thoroughly check the existing situation. The results of this approach revealed through-wall penetrated corrosion damage (see Figures no. 1.5 and 1.6). The damaged area was cut off and replaced. The vessel shell was initially made of carbon steel plate. Considering the severe damage encountered only after 8 years of operation, the replacement of damaged are with a stainless steel plate was considered. The plate (8 mm thick) was rolled and a Vweld preparation fabricated (see Figure 1.7). It was chosen a WPS combining PNo. 1 (carbon steel) with P-No. 8 (stainless steel) base materials with one side, fully penetrated weld with no backing support

related with the quality of this weld (see

Pressure Control Valve was found severely

(see Figure 1.8). It was performed by

Figure 1.9).

damaged during boiler operation. Any actions on closing this valve during

means of SMAW using stainless steel

electrodes and the WPS was qualified

3.2. Example 2: Weld repair of an

operation had no significant results.

according to ASME Section IX rules [4].

auxiliary cold reheat desuperheater

Therefore, during boiler shutdown, the

After 2 years in operation a visual inner

pressure control valve

valve was disassembled (see Figure 2.1)

side inspection revealed no problems

An Auxiliary Cold Reheat Desuperheater

and the valve seat was found severally

WELDFAB TECH TIMES | AUG - SEPT 2018

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SECTOR WATCH: POWER â&#x20AC;&#x201C; ARTICLE

Figure 1.9

Figure 2.1

Figure 2.3

Figure 2.4

Figure 2.5

Figure 2.6

damaged. The solution chosen was to remove the old seat and replace it by means of welding with a new one (see Figure 2.2). There was a problem on conducting this procedure, namely the valve body was made of P-No. 4 material which normally requires PWHT. In order to avoid PWHT which was not applicable because of logistic circumstances at the time of weld repair, a WPS using a Ni-based alloy without PWHT was used. The new seat was fit in its location and the seat surface was protected by a metal cap (see Figure 2.3). Once the weld was finished (see Figure 2.4), PT was conducted on the repaired surface (see Figure 2.5). Unfortunately, properly conducting PT was a real challenge because of space limitations (see Figure 2.5). Nevertheless, the PT revealed no cracks in the new seat which was the biggest issue on

was opened because of leaking reported

mm deep (see Figure 3.4). Further on, all

this procedure. The rest of the weld

by the operation people, encountered

three tubes were plugged. The plugs were

was visually checked for cracks (the PT

during boiler operation. Following

fixed at least 25 mm deep under the tube

results were beyond any acceptable

the visual checking severe damage of

plate surface. The tube plate material was

interpretations) and it was taken the

the tube plate was noticed. In order to

P No. 1 (carbon steel) and the thickness

decision that no visually detectable defects

thoroughly check the damage extension,

was about 173 mm. The tubes material

were found in this seal weld.

it was decided to conduct a pressure test

as well as the plugs material was P No.

at 100 psi on the shell side. Two leakages

8 (stainless steel). Once the plugs were

2.6) was conducted to assess the sealing

were encountered during this test (see

fixed in their places, the weld repair with

capability of the valve, test which was

Figures no. 3.1 and 3.2). It was chosen

stainless steel weld metal was conducted

passed successfully. This test confirmed

the weld repair as the only alternative

(see Figures no. 3.5 and 3.6). All ends of

the proper orientation of this seat

solution for this problem. The damaged

the leaking tubes on the upper half as well

perpendicularly to the disk axis.

area was grinded in a triangle shape to

as on the lower half of the heater were

allow weld repair to be conducted in this

plugged (see Figures no. 3.7, 3.8, and 3.9)

3.3. Example 3: Weld repair of a boiler

tight location (see Figures no. 3.3 and 3.4).

and the plug heads were cut at the tube

heater

The tubes no. 1, 2, and 3 were cut below

limit level and than completely welded

During a regular annual outage a Heater

the surface of the tube plate about 50

(see Figure 3.10).

Therefore, a blue ink check (see Figure

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AUG - SEPT 2018 | WELDFAB TECH TIMES

SECTOR WATCH: POWER â&#x20AC;&#x201C; ARTICLE

found to have on both sides of the disk steam cuts in several locations. Because of lack of spare parts, it was decided to conduct a weld repair on the valve disk. Thus, the cracks were completely excavated by grinding (see Figures no. 4.1 and 4.2) and a weld repair was conducted Figure 3.1

Figure 3.2

after that. The weld repair consisted of one buttering layer done by means of GTAW with a stainless steel wire and a completion weld with a hard facing electrode by means of SMAW (see Figure 4.3) [4]. After the weld repair, the disk was machined and lapped at its initial shape (see Figure 4.4).

Figure 3.3

Figure 3.4

3.5. Example 5: Weld repair of some elements on boiler feed pump recirculation line UTG (UT thickness measurements) were conducted on a Boiler Feed Pump (BFP) recirculation line, on two elbows and a straight section (spool) before entering into the Deaerator Storage Tank â&#x20AC;&#x201C; DST

Figure 3.5

Figure 3.6

- (see Figure 5.1) in order to monitor the erosion process taking place here. The measurements were compared than with the ones from last years obtained on this line. Considering the UTG results on the elements of the BFP Line, it was recommend the replacement of the spool between the two elbows entering the DST. Furthermore, considering the fact that

Figure 3.7

Figure 3.8

the new spool was only available as a carbon steel material, an inner stainless steel overlay was recommended to be performed in order to avoid further erosion of this section (see Figure 5.2). The same solution was recommended for the discharge section entering into DST which was found also eroded (see Figures no. 5.3, 5.4, and 5.5). After inner side weld

Figure 3.9

Figure 3.10

overlay of the spool, and reweld of the spool on its initial place, PT and UT flaw

3.4. Example 4: Weld repair of a steam

to have a pore operation during boiler

detection were conducted on these new

control valve

functioning and therefore it was

welded joints (see Figure 5.6). After NDT

A Steam Control Valve was reported

disassembled and checked. The valve was

passed, UTG measurements were taken

WELDFAB TECH TIMES | AUG - SEPT 2018

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SECTOR WATCH: POWER – ARTICLE

from the replaced sections of the pipe as “0” reference for future measurements comparison basis.

4. Conclusion As one may see from the above examples, the applications of welding in power plant maintenance activities are very diverse. Figure 4.1

Figure 4.2

Welding technique and weld material are selected on a case-by-case basis. Proper selection of the weld material is an essential ingredient in the success of the weld repair and therefore, it requires a proper judgment before taking this decision. Component operating parameters and conditions must also be considered during the weld metal selection.

Figure 4.3

Figure 4.4

Welder’s skills are becoming of a growing importance. PWHT became more as an “option” instead of a “must” basically because of a huge advantages given by the weld material applications. Currently, there are only few situations during a major shut down of a usual 10 years old 460 MW unit which requires component replacement as the only

Figure 5.1

Figure 5.2

alternative. Furthermore, weld repairs initially thought as temporary solutions, were found to be as good as the replacement one, and therefore, repaired components are no longer replaced in due course but just monitored at regular time intervals.

References 1. Cristian Delamarian – Manual pentru Figure 5.3

Figure 5.4

mentenanţa şi retehnologizarea instalaţiilor termoenergetice şi industriale, Ed. Sudura, Timişoara, 1999 2. API 579 – Fitness for Service, January 2000 3. API 580 – Risk Based Inspection, 2000. 4. ASME Section IX – Welding and Brazing Qualifications, 2007 Edition, 2009 Addenda 5. ASME Section XI – Rules for Inservice Inspection of Nuclear Power Plant

Figure 5.5

WELDFAB TECH TIMES | AUG - SEPT 2018

Figure 5.6

Components 2007 Edition, 2009 Addenda.

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POWER DOER'S

Exciting New 16kW Laser Welding System

yan Tecâ&#x20AC;&#x2122;s advanced technical capabilities underpin the launch of its new 16kW laser system. The

highly flexible, high-power laser cell is already driving state-of-the-art projects at the Nuclear Advanced Manufacturing Research Centre. The impressive scale of this 8m x 10m x 7m laser system reflects growing industry demand for laser systems with advanced handling capabilities. Cyan Tecâ&#x20AC;&#x2122;s team of innovative, multidisciplined engineers have succeeded in delivering a system capable of achieving high-quality welding joins, from around 15mm, over lengths of several metres, driving forward advanced welding applications in industries such as nuclear,

new system reportedly minimizes heat

table capable of handling products up to

marine and aerospace.

distortion and thermal stress to achieve

15 tonnes. User friendly HMI and digital

high-quality welds for stainless steel,

dual screen display enable operators to

aluminium, titanium and alloy products.

control and monitor in-cell processing.

Cyan Tec claims an enviable reputation as a manufacturer of complex automated laser systems for welding, cutting,

The Cyan Tec laser system delivers

In addition to launching advanced laser

ablation, additive manufacture and

travel speeds of 10m+ per minute, with

systems, Cyan Tec has a dedicated team

surface modification. This exciting

a six-axis gantry and 2-axis manipulator

of development engineers responding to demand for made-to-order laser solutions for special applications. Manufacturers considering incorporating advanced laser solutions into production lines value specialist inline equipment expertise from advanced integrators such as Cyan Tec who have a demonstrable record of successful large scale, complex high-powered laser solutions. Such dedicated integrators can offer the advice, support and technical solution required to ensure successful integration of in-line laser solutions.

For More Info: Tel: +44 (0)1509 815186 Email: sales@cyan-tec.com

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AUG - SEPT 2018 | WELDFAB TECH TIMES

POWER DOER'S

Power Plant Construction made easy with Welding Automation

ullco International was formed

and the new swivel devise for the magnet

For More Info:

in 1954, to serve the demands of

assemblies.

Visit www.gullco.com

the emerging welding industry

The work is to make very high quality

Mr. Gaurav Lakhera

with its world headquarters located in

butt joints in a special steel using GMAW

Email ID: gaurav@gullco.com

Newmarket, Ontario, Canada. Gullco

process of welding. The single bevel butt

Mob:-9920414253

International serves the entire world

was made with Gullco's ceramic backing.

market through its companies in Canada,

There was a 5mm gap and 5mm root face.

United States, United Kingdom, India,

The photos were in the laboratory

Australia, and China as well as its strong

at Andritz Hydro, Germany during

worldwide distributor network with high

completion of the procedure trials. Those

quality automated welding machines

trials were completed successfully and

for welding and cutting applications.

now the engineers are busy applying

Gullco International is engaged in a

this work to their applications within the

continuous research and development

factory.

program to provide weld automation equipment and systems geared to the fast changing needs of the welding industry and equipment that can stand up to the tough environments in the field. Gullco is dedicated to providing productivity, cost savings, durability and service. Andritz Hydro, Germany has successfully completed the development program for welding automation using Gullco equipments. The images clearly reveals the work that our Group company, Gullco, UK, did after supplying welding carriage trolley, KAT with special remote control, seam tracker and oscillator along with flex tracks high temp magnet assemblies

WELDFAB TECH TIMES | AUG - SEPT 2018

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POWER DOER'S

Thick Plate Welding Method

AUTHORS: Wei Zhanlin, Managing Director / Shaikh Qamar Ali, General Manager - Sales & Technical Support Kaiyuan Welding & Cutting Automation India Pvt. Ltd.

ith the ever challenging industrial demand & rapid development of

India economy, the heavy industry are growing fast such as pressure vessels, boilers, ships, heavy machinery structures, railways, bridges, building steel structures, power thick-walled pipelines, ocean engineering, etc., In the manufacturing process, the thick Fig 1. Single power source with single wire SAW.

plate joint is usually welded through conventional welding by large groove with multi-layer and multi-pass in traditional automatic welding method to ensure the high quality of welding. This leads to an increase in welding workload, increased consumption of filler materials, low production efficiency and long production cycle, which in return increases manufacturing costs because of raw materials and energy consumption.

Fig 2. Tandem welding (one DC power source + one AC power source).

To increase the productivity and reduce the running cost, KAIYUAN offer

The order of welding torch

Front DC torch inclines ahead a little is

the complete range of systems for the

arrangement of Tandem system: the

beneficial for penetration. Rear AC torch

thick plate. Here after will introduce the

front torch uses DC power supply,

inclines backwards a little is beneficial

popular methods which is Tandem SAW

high current, low voltage, for efficient

for covering with more wide and smooth

and Narrow gap welding.

penetration. The rear torch uses AC

welding bead.

power supply, with small current, high

Tandem welding deposition rate much

Tandem SAW welding

voltage parameter, for surface covering

higher than single wire SAW, it is around

Submerged ARC welding method is

(Fig 3).

double than single wire welding. Means

widely used in thick plate welding. It is more efficient than conventional welding process like MIG/SMAW welding. Single wire SAW ( Fig 1) increase the productivity compare with the pre mentioned conventional welding but with the introduction of Tandem the deposition rate can be increase to double of the single wire SAW (Tandem = 1416kg/hr with 4mm wire) with number of passes reducing relatively. To increase the productivity, Tandem welding will bean ideal solution (Fig 2).

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AUG - SEPT 2018 | WELDFAB TECH TIMES

POWER DOER'S

Steel/PEB Fabrication:

Fig 3. Tandem torch arrangement and welding bead. productivity will be more than 2 times

Shipyard panel welding:

increased if considering other associate time like slag cleaning (Fig 4).

Fig 4. Deposit rate comparison.

KAIYUAN Standard configuration for single wire:

Some of the KAIYUAN Single/ Tandem applications: Wind Tower welding:

Thyristor base

Inverter base

ZD5-1200EJ

KID-1200EJ

Tractor: MZC1200F30

Boom mounted head: MZ91200B11

Control cable 15m

TLE2115-03

Rail 2m

KWA00001

Power source

Pressure Vessel Industry:

Welding head

KAIYUAN standard configuration for Tandem:

DC Power source

KID-1200 (Inverter)

AC/DC Power source

KIA-1000 (Inverter)

Welding head

Tractor: MZC-1250M13 Boom mounted head: MZ9-1250B13

Control cable 15m TLE2115-03 Rail 2m

WELDFAB TECH TIMES | AUG - SEPT 2018

KWA00001

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POWER DOER'S

Adopt small or medium heat input parameters welding. It is possible for full position welding also. Narrow gap welding method is suitable for thickness more than 30mm with groove less than plate thickness. Usually the gap is less than 20mm for the plate thickness less than 200mm and the gap is less than 30mm for the thickness of the plate more than 200 mm. KAIYUAN offer Narrow Gap system Tractor mounted Tandem Welding head

in all the 3 welding process. Narrow gap welding technology usually includes • Narrow gap MIG welding (NGGMAW); • Narrow gap TIG arc welding (NGGTAW); • Narrow gap SAW (NG-SAW); The key issues of narrow Gap Welding need to be solved as follows” 1) Reliability of uniform fusion of side wall of welding groove Because the slope angle is around 1

Tractor mounted Tandem Welding head

/ 100, even parallel groove, vertical and downward arc can guarantee the

Narrow Gap welding method

penetration of both sides of the wall,

Narrow gap welding method is another

which is the most important of narrow

high efficiency, high quality method

gap welding.

for thick plate welding which use small

KAIYUAN narrow gap MIG welding

groove to reduce the filling material

system (Fig 5) adopt deforming the

and reduce the heat input. This method

welding wire to the specified shape

is used in the welding of large, critical

before entering the contact Tip which

components/structures, which has broad

makes the arc oscillate regularly and

application prospects. Narrow gap welding has the following characteristics: • It is a special technology based on traditional arc welding methods. Most of them adopt I-shape groove, and the angle of groove depends on the deformation.

Fig 5. Narrow gap MIG.

• The number of welding passes: 1 layer 1 pass for the Narrow GAP TIG and

achieves the purpose of good fusion of

Narrow GAP MIG system and Narrow

the two sides of the wall.

GAP SAW it will be 1 layer 2 passes.

WELDFAB TECH TIMES | AUG - SEPT 2018

KAIYUAN narrow gap TIG with hot

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POWER DOER'S

wire welding system (Fig 6) adopt electrode oscillation to guarantee the fusion of wall. KAIYUAN narrow gap SAW system (Fig 7) adopt one lay two pass welding method. One pass face to one side wall to guarantee the fusion.

Weld bead with the Narrow GAP SAW 2) Narrow gap welding spatter In the narrow gap groove, the welding torch has a very small distance between the two sides of the groove, and the welding spatter may stick to the nozzle, which will reduce the gas flow protection performance and the normal wire feeding, thus affecting the stability of the welding process, especially the splashing Left

Mid

metal particles sticking to the inner

Right

Fig 6. Narrow gap TIG - Electrode swing.

Conventional groove

Narrow GAP SAW Groove

wall of the groove. The welding torch will be difficult to move, or even short circuit. This is also a narrow gap welding problem need to be solved. The solutions are as follows: â&#x20AC;˘ Adopt narrow gap submerged arc welding, no spatter; â&#x20AC;˘ Surface tension transition technology to reduce spatter; 3) How to guarantee the stability welding parameters and the Arc position during Welding process In the welding process, the stability of

Left / right torch position

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welding parameters and the accuracy

AUG - SEPT 2018 | WELDFAB TECH TIMES

POWER DOER'S

Narrow gap hot wire TIG for 2G position

Fig 7. Narrow gap SAW. of the arc position seriously affect the

Compared with conventional wide

fusion quality of the side wall.

groove:

KAIYUAN narrow gap system has

1. Groove profile can reduce 36%~70%.

unique Groove width self-adaptation

The wire and flux consumption

technology to suitable for the width

decrease by more than 35%.

change of groove except normal vertical

Narrow gap MIG for Box girder

2. Groove profile and layer reduction can decrease residential stress and

and horizontal AVC tracking. Take narrow gap TIG system as an example, the Groove width selfadaptation technology tracking as

hydrogen content, then improve ability of crack resistance. 3. Under same total weld efficiency, it can reach to lower heat input.

follows:

Conclusion: With the growth of economy, largethickness steel plate will be more and more widely used in the production of various industries. To increase the productivity and reduce the cost, Tandem SAW and Narrow gap welding method will be perfect solution, along with the Kaiyuan India expertise team & with Kaiyuan’s 30+ years of experience to

The efficiency of Narrow gap welding process.

Narrow gap welding is widely used

work jointly with the industry to develop

in many industries, such as pressure

& offer right solution. LET’s WORK AS

Take narrow gap SAW as an example as

vessel and boiler industry, heavy-duty

TEAM INDIA , WITH KAIYUAN INDIA.

follows:

machinery, marine engineering and shipbuilding, power sector etc. Some of

Traditional wide groove

Narrow groove

Narrow gap

KAIYUAN Narrow gap system application

References:

cases:

1. 锅炉压力容器焊接使用手册/中国焊接协

Narrow Gap SAW welding system on

会编机械工业出版社，2016.5

boiler steam tank

ISBN987-7-111-53764-9 Manual for Boiler Pressure Vessel Welding / Edited by China Welding Association

Multi-pass in one layer

One layer two pass

WELDFAB TECH TIMES | AUG - SEPT 2018

China Machine Press, 2016.5 ISBN987-7-111-53764-9.

www.weldfabtechtimes.com

EVENTS UPDATE

NATIONAL Event

Date

Address

Organiser

Economic Times Acetech Mumbai

15th - 18th November, 2018

Bombay Exhibition Center

Asian Business Exhibition & Conferences Ltd.

India Essen Welding & Cutting

27th- 29thNovember, 2018

Mumbai

Messe Essen GmbH

Wire & Cable India Mumbai

27th- 29thNovember, 2018

Bombay Convention & Exhibition Centre

Messe Düsseldorf GmbH

Rajkot Machine Tools Show 2018

28th Nov - 01st Dec, 2018

Aji Industrial Area, Rajkot,

K and D Communication Limited

Zak Doors &Windows Expo & Windows Expo

06th - 09th December, 2018

MMRDA, Mumbai, India

BAUMA CONEXPO INDIA

11th - 14th December, 2018

Delhi

Messe München GmbH

India Steel 2019

22nd - 24th January, 2019

Bombay Exhibition Center

FICCI

Tooltech Bengaluru

24th - 30th January, 2019

BIEC Bengaluru International Exhibition Centre in Bengaluru

Indian Machine Tool Manufacturers' Association

IMTEX 2019

24th - 30th January, 2019

BIEC Bengaluru International Exhibition Centre, Bengaluru

Indian Machine Tool Manufacturers' Association

INTERNATIONAL Event

Date (2018)

Location

Organiser

Boilers and Burners

02nd - 05th October, 2018

St. Petersburg, Russia

Farexpo

BI-MU Machine Tools, Robots and Automation

9th - 13th October, 2018

Milan, Italy

EFIM-ENTE Fiere Italiane Macchine, 31.BI-MU

Aluminium

9th - 11th October, 2018

Dusseldorf, Germany

Reed Exhibitions Deutschland

BI-MU

9th - 13th October, 2018

Milan, Italy

EFIM-ENTE Fiere Italiane Macchine Spa

Metalex Vietnam

11th - 13th October, 2018

Saigon Exhibition and Convention Center (SECC), Hochiminh City, Viet Nam

Reed Tradex Company

ExpoWelding Int'l Welding Fair

16th - 18th October, 2018

Gliwice, Poland

Expo Silesia

Weldex

16th October, 2018

Moscow, Russia

MVK International Exhibitions

indometal

17th - 19th October, 2018

Jakarta International Expo, Jakarta, Indonesia

Messe Düsseldorf Asia

Fabtech

6th - 8th November, 2018

Georgia World Congress Center, Atlanta, USA

AWS

www.weldfabtechtimes.com

AUG - SEPT 2018 | WELDFAB TECH TIMES

Lasting Connections

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Owner, Printer & Publisher - Eliza Amol Bhalerao Published At - B-3/503, Ekdanth, Gauri Estate, Near Gauri Hall, Manjarli, Badlapur (W), Dist.: Thane – Ulhasnagar - 421503, Maharashtra, India. Editor – Amol A. Bhalerao, RNI No.- MAHENG/2017/75007

Kemppi India Pvt Ltd Lakshmi Towers, 2/770 Kazura Garden, First Street Neelankarai, Chennai, Tamil nadu 600041

Kemppi India Pvt Ltd Robotic Welding Application Center Plot No P-84, D II Block, MIDC, Chinchwad, Pune, Maharashtra, 411019. E-mail: sales.india@kemppi.com