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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
Welcome 2019! Dear Readers, Greetings!! Our much anticipated Issue (Dec - Jan) of this New Year 2019 is on course. We have taken tremendous efforts to bring this edition to all our lovely readers. The Issue is filled with inspiration, innovation and information, as intended. The Dec 18 - Jan 2019 Issue features a case study of a very prestigious project in Assam – Bogibeel Bridge. We all truly believe that ‘Welding is the Soul’ of any infrastructure project and thus, to understand this better, the interview of Mr. Praveer Sinha, CEO & MD, Tata Power has been published. ‘Welding is an Art’, and this saying will get confirmed only when you engage
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4
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
yourself in reading and viewing the incredible welding art of Welder Brian. The Issue has a lot more interesting happenings for our readers, and we pledge to continuously offer top notch content in all the other upcoming issues. The year 2019 has begun. We would like to urge all our readers and the welding industry to be safe and responsible while you weld. A very Happy & Prosperous New Year – 2019! Thank you.
Eliza Bhalerao Publisher & Editor
www.weldfabtechtimes.com
Solid-state laser
TruDisk
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CONTENTS 6
INNOVATIONS
52
A fine-tuned laser welds more effectively
ARTICLE
16
POST EVENT
32
Sensitisation of heat affected zone in Austenitic Stainless Steels
Fumes, Health & Safety in Arc Welding
TRAINING CENTER
46
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
72 Panasonic Welding Systems India supports AOTS(Japan) & CII(India)...
INTERVIEW
44
Inauguration of NMAMIT-FRONIUS Centre for Welding Technology
“Welding and welding skills will continue to grow in demand.”
www.weldfabtechtimes.com
CASE STUDY
54
Bogibeel Rail-cum-Road Bridge
LAUNCHES
WOMEN IN WELDING
30
50
OCTOPUZ Inc. releases OCTOPUZ 2.0.3
BULLETIN PRODUCTS UPDATE EVENTS UPDATE TENDERS www.weldfabtechtimes.com
08 22 68
Welding is not an exception…
WELDER’S PASSION
43 64
“The old items carried a history with them, & I was inspired to use them in new ways, to create them a new story.”
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
7
BULLETINS
Evosys develops software for setting up laser welding processes
W
ith the new EvoLaP
Brunnecker, Managing Director
software, Evosys
of Evosys Laser GmbH. And:
Laser GmbH has
"EvoLap convinces by a clear
reacted to customer requests
and uniform window division
and developed an instrument
as well as the intuitive and
for creating welding processes
clear arrangement of buttons.
on Evosys systems quickly and
This enables our customers to
easily. During the development
quickly learn how to use the
of EvoLaP, the software and
software". All operating options
application engineers were
run smoothly on modern
looking for a short training
touchscreens, no mouse or keyboard required. The
period for the operator on Source: www.evosys-laser.com
the one hand, and on the
software allows any necessary
other hand focused on the
for scaling, teaching and
further complexity to the
modification of the welding
core tasks such as contour
calibration facilitate the work
software through rarely used
contour. This sets EvoLaP apart
optimization or parameter
and support the improvement
functions, we concentrated on
from other software available
adaptation. Special features
of processes. "Instead of adding
the essentials," explains Frank
on the market.
Innovative welding solution for manufacturing epoxy blades
P
ontis Engineering,
shell. These units not only
• Increased bond strength
specialist in the
enable a welded connection,
• Reduced blade mass (app.
development of
but also enable that a sharper
advanced composite
trailing edge and a more
Pontis Engineering Director
products, introduces its latest
compact connection can be
Sjef van Breugel said, “We
innovation in composite
realized.
are proud and happy that we
manufacturing solutions
Source: www.pontis-engineering.com
at the world’s biggest
In conventional rotor blade
can introduce our new and
production bonding paste
innovative technology on
wind energy trade show:
welding solution for fully
is commonly used. Pontis
this renowned international
WindEnergy Hamburg 2018.
thermoplastic rotor blades.
applied its new construc-
platform. Our mission is to
Driven by the positive
tion method to a test blade
support and guide our wind
technology enables the
results and response, the
component and found
customers in their ongoing
welding of epoxy rotor blades
engineering company
a number of significant
quest for smarter, more
by using thermoplastic resin;
has now found a welding
advantages, including:
sustainable ways to produce
a unique new method which
solution that can be used in
• Increased reliability
even larger rotor blades
brings major benefits in cycle
existing epoxy designs. Pontis
• Reduced cycle time for
with superior quality. I am
time, weight and strength.
Engineering has developed a
This breakthrough
8
3-5%)
Two years ago, Pontis
technol-ogy in which prefab
Engineering introduced
thermoplastic welding units
a ground-breaking
are implemented in the epoxy
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
bonding operation (up to
convinced that we can
90%)
help them take a significant
• Reduced total workload (app. 5%)
step further with this technology”.
www.weldfabtechtimes.com
BULLETINS
CMT Cycle step from Fronius: A new level of Welding Process Control
BrandSafway introduces BrandTech™ Precision Welding
Source: www.pontis-engineering.com
Manufactured in the United States with USA-made parts, BrandTech Precision Welding uses a drawn arc welding process, a very stable form of welding that reduces filler material and shielded gas while producing a complete fusion in less time with fewer welding layers.
Source: www.fronius.com
T
he new Cycle Step process variant for the CMT (Cold Metal
Transfer) welding process allows users to set both the
I
number of individual droplets ndustrial Specialists, a
Energy & Industrial Division
to weld around or behind
and the pause time between
BrandSafway company
at BrandSafway. “With
tubes and other obstructions
cycles. The result is a heat-
and a member of the
BrandTech Precision Welding,
without the risk of arcing.
reduced bead with clear
American Welding Society,
our clients can get the same
BrandTech also dramatically
ripples and a high degree of
is introducing BrandTech™
amount of work done with
reduces hexavalent
reproducibility. It has a wide
Precision Welding, a
two precision welders as they
chromium emissions, which
range of applications – from
modular-welding system with
did with 16 standard welders
decreases exposure risk and
visible weld seams and additive
built-in technology, which
without sacrificing quality.”
creates a safer workplace.
applications to fixation points.
An average project with
The simple set-up, rigging
guns to be used at the same
20,000 welds typically takes
and operation reduces the
a droplet melts at the end
time. Manufactured in the
80, 12-hour shifts using two-
amount of time—and number
of the wire electrode and is
United States with USA-made
welder stick welding, but the
of welders—needed to
transferred to the weld pool
parts, BrandTech Precision
same project can be reduced
complete a project.
during the short circuit phase
Welding uses a drawn arc
to just eight, 12-hour shifts
welding process, a very
with two BrandTech welders,
reduced quality and safety,
this characteristic short circuit,
stable form of welding that
significantly reducing project
but not with BrandTech,” said
the arc ignites again and a new
reduces filler material and
timelines and costs. With
Eduardo Almeida, Director
welding cycle begins. With
shielded gas while producing
five times the average pull
of Technology for Industrial
CMT Cycle Step, Fronius can
a complete fusion in less time
ratio and better control, the
Specialists. “Our precision
control these individual cycles
with fewer welding layers.
average error rate is less than
welder gives operators total
so precisely that the user can
0.5 percent.
control of welding variables,
define the exact number of
allows for one or two welding
“The industry is booming,
“Increased speed can mean
During MIG/MAG welding,
of the CMT process. Following
but a labor shortage has left
BrandTech Precision
allowing them to weld onto
droplets per welding spot, thus
our clients searching for new
Welding offers an easy-to-
existing thin plates and
representing a whole new level
ways to increase productivity
use touchpad control panel,
the ability to reach into
of control and reproducibility.
and get more done with
which gives the operator
tight and congested areas
The extent of the resulting
fewer workers,” said Dave
full control to set all welding
without damaging existing
material removal in a sequence
Witsken, president of the
parameters and the ability
structures.”
can also be set.
www.weldfabtechtimes.com
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
9
BULLETINS
CPI Aerostructures complete acquisition of Welding Metallurgy, Inc
Source: www.cpiaero.com
C
Douglas McCrosson stated,
for top line growth, it also
Inc. (“CPI Aero®”
welded products and
“”We are excited to announce
allows us to provide more
or “the Company”)
assemblies, large diameter
the closing of the acquisition
CPI Aero content within
(NYSE American: CVU)
tube bending and integrated
as it ushers in a new era of
our integrated structural
today announced that it has
electronic assemblies, among
expanded capabilities and
assemblies thereby enhancing
completed its acquisition
other capabilities, to a variety
an increased opportunity
its value proposition to new
of Welding Metallurgy, Inc.
of customers, predominantly
set that we expect to lead
and current customers.
(“WMI”) from Air Industries
within the defense and
to meaningful revenue and
Finally, consolidation of
Group, Inc. in a transaction
aerospace markets. WMI’s
earnings growth starting in
WMI’s operations and
valued at approximately $9.0
defense customers include
2019. The addition of WMI’s
personnel into our facility
million. The Company expects
Sikorsky, Lockheed Martin,
products and processes,
will increase absorbtion of
to complete the integration
Northrop Grumman,
particularly with respect to
fixed overhead costs, improve
of WMI’s operations into its
Raytheon, and GKN
manufacturing of electronic
the competitivess of our
Edgewood, N.Y., headquarters
Aerospace, among others.
assemblies, wire harnesses,
price proposals and could
and tube assemblies, not
expand margins on current
only provides a new avenue
programs.”
PI Aerostructures,
by the end of the first quarter
WMI provides specialty
CPI Aero President and Chief Executive Officer
of 2019.
GPE successfully delivers World’s tallest CCR Reactor
G
odrej Process
in oil refinery converting
successful manufacture of
Equipment (GPE), a
low value naptha to high
this equipment only adds to
unit of Godrej & Boyce
valuable products like
the achievements of Godrej
Mfg. Co. Ltd., shipped one of
Petrochemicals and Gasoline
& Boyce and its global
the World’s tallest Continuous
through various reactions
footprint.”
Catalytic Regeneration
such as Dehydrogenation,
(CCR) Reactor to Dangote
Aromatisation,
Oil Refinery, Nigeria during
Isomerisation, Dealkylation,
Godrej, Chairman and
and Business Head, Godrej
January 2019. With its height
Dehydrocyclization. The CCR
Managing Director, Godrej
Process Equipment said,
measuring a gigantic 95 meters,
Reactor is a tall column like
& Boyce stated, “We have
"Godrej Process Equipment
the CCR Reactor is 22 meters
equipment with continuous
always been in the forefront
is a leading global fabricator
taller than the Qutub Minar
moving catalyst. Very stringent
of adopting technology
of high end critical static
and weighs approximately
tolerances are required to be
to offer the best-in-class
equipment for the Process
703 metric tonnes, nine times
maintained for installation
solutions to our customers.
Industry. For several decades
heavier than a space shuttle.
of reactor internals. The
The manufacturing of this
now, customers from around
equipment being in Hydrogen
complex reactor, the tallest in
the world have come to rely on
this order, Godrej has further
service, calls for a very critical
the world, and the shipping of
Godrej for their operationally
strengthened its position as
metallurgy viz. Chromium
it in a single piece is a matter
demanding equipment needs.
a technology and innovation
Molybdenum Steel, which
of immense pride for us. It is
The CCR Reactor built for
driven company that has
leads to a very complex
a testimony to our company’s
Dangote’s Refinery in Nigeria
been continually contributing
fabrication requirement.
vast technological expertise
is the latest in the long list
Speaking about the
and also showcases Indian
of capability challenging
engineering capabilities. The
equipment built by Godrej.”
With the completion of
towards making the nation. CCR is the key process
10
achievement, Mr. Jamshyd
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
Adding to this, Mr. Allen Antao, Executive Vice President
www.weldfabtechtimes.com
BULLETINS
Sciaky to deliver EBAM® & EB Welding System to Aerospace Parts Manufacturer
S
ciaky, Inc., a subsidiary
structures and other aerospace
mm) to 19 feet (5.79 meters) in
of Phillips Service
parts.
length. EBAM is also the fastest
Industries, Inc. (PSI)
“Sciaky is excited to work
deposition process in the metal
Source: www.sciaky.com
and leading provider of metal
with this innovative company,”
additive manufacturing market,
additive manufacturing (AM)
said Scott Phillips, President
with gross deposition rates
solutions, announced that a
and CEO of Sciaky, Inc. “This
ranging from seven to 25 lbs.
Sciaky’s world-class EB
prominent Southeast Asian
strategic vision will allow
(3.18 to 11.34 kg) of metal per
welding systems have been
aerospace parts manufacturer
this manufacturer to reduce
hour. EBAM brings quality and
the industry standard for
has purchased a dual-purpose
operating costs by combining
control together with IRISS®
decades, meeting rigid military
Electron Beam Additive
two industry-leading
– the Interlayer Real-time
specifications to manufacture
Manufacturing (EBAM®)
technologies into a single
Imaging and Sensing System,
items such as airframes,
and EB Welding System.
turnkey solution. No other
which is the only real-time
landing gear, jet engines,
The one-of-a-kind hybrid
metal 3D printing supplier
adaptive control system in the
guided missiles and vehicle
machine will be customized
can offer this kind of game-
metal 3D printing market that
parts. Our internal moving
with special controls to switch
changing capability.”
can sense and digitally self-
EB welding gun is the most
adjust metal deposition with
versatile EB welding gun in
from 3D printing to welding
Delivery of the hybrid system
part to the last.
in a quick and easy process.
is scheduled for the second
precision and repeatability.
the market. The multi-axis
The manufacturer, who
quarter of 2019. As the most
This innovative closed-loop
gun motion operates at half
wishes to remain anonymous
widely scalable metal additive
control is the primary reason
the chamber volume of fixed/
for competitive reasons, will
manufacturing solution in
that Sciaky’s EBAM 3D printing
external gun systems, provides
utilize the system to 3D print
the industry (in terms of work
process delivers consistent
beam access for unusual
metal structures, as well as
envelope), Sciaky’s EBAM
part geometry, mechanical
joint configurations, and
weld dissimilar materials and
systems can produce parts
properties, microstructure, and
significantly simplifies part
refractory alloys for these
ranging from 8 inches (203
metal chemistry, from the first
tooling.
Tech Air announces acquisition of scully welding supply and propane service ech Air, a national
T
locations. This is the 27th add-on
with its existing business in
distributor of industrial,
acquisition for Tech Air under
surrounding areas.
medical, and specialty
the ownership of CI Capital.
Myles Dempsey, Jr., Chief
Founded in 1947, Scully
Executive Officer of Tech Air,
are pleased with the progress
and supplies, announced
serves Southeastern
said, “We are excited to gain
that Tech Air continues to make
today that it as acquired Scully
Pennsylvania with residential
the assets, resources, and
as it builds a truly national
Welding Supply Corporation
and commercial propane,
expertise of a group with such
business with significant gas
and Scully Propane Service
industrial gases, and welding
a strong and well-established
distribution and welding
Corp (together, “Scully”) of
supplies, as well as installation
reputation. Since its founding
supply operations from its
Collingdale, Pennsylvania.
and repair services. Scully’s
in 1947, Scully has built and
beginnings as a regional
Scully is a distributor of
large and diverse customer
expanded its services in a
company. The acquisition of
propane, industrial & welding
base across a broad region
key commercial region of the
Scully represents another high
supplies, & industrial gases
provides Tech Air with an
country. We welcome the team
quality transaction for Tech Air
servicing the greater
attractive opportunity to
to Tech Air and look forward to
as the company executes its
Philadelphia region from its four
achieve scale and synergies
sharing success as we continue
growth strategy.”
gases and related equipment
12
Source: www.techair.com
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
to build our business together.” Joost Thesseling, Managing Director at CI Capital, said, “We
www.weldfabtechtimes.com
BULLETINS
SSAB and Kemppi create a joint digi solution to speed up the welding process
Source: www.ssab.com
S
SAB and welding
storing all the information
digitalization
related to the steel all the
pioneer Kemppi have
way from its manufacturing
successfully integrated
to delivery, processing, use,
SSAB’s SmartSteel and
and recycling. Launched in
Kemppi’s WeldEye cloud-
May 2018, SmartSteel 1.0
based platforms to streamline
introduced the possibility
base material information
to scan steel, and to have
handling in welding
easy access to its material
production. The results of
certificate. Now SSAB offers
the successful pilot are now
an API through which base
available for all companies
material information and
currently utilizing both
material certificates can be
digital platforms.
sent to welding equipment
“Building cloud-based
automatically. This makes it
Juhana Enqvist from Kemppi and Niko Korte from SSAB.
platforms is a new way of
possible to reduce manual
doing business together,”
material certificates are
WeldEye, Kemppi’s welding
work, adjust the equipment
said Niko Korte, Senior
now automatically sent to
management software,
faster, increase arc-on time
Manager of Digital Business
WeldEye. Being able to scan
strives to make the process
and reduce the repair rate. It
Development atSSAB. “We
products with SmartSteel, get
smoother by collecting
also provides for automatic
are working our way towards
the certificates automatically
welding parameters digitally
documentation of the
the Internet of Materials.
and document everything
from workstations, and even
welding process.
Every initiative like this takes
gives the customer a
by adjusting the welding
Following the successful
us one step closer to creating
complete view of the base
equipment according to
pilot, SSAB customers who
a digital identity for steel and
materials in the welding
digital welding procedure
are already using Kemppi’s
complete traceability. We are
process.”
specifications (dWPS). To
WeldEye software can
automate the process one
get automatic material
look forward to partnering
documentation is time-
step further, SSAB now offers
information from the
with others to create it.”
consuming. Documents
their SmartSteel data through
SmartSteel cloud. New
excited about the future and
Collecting welding
have to be collected from
an interface (API) to be used
partners are also welcome
are promising,” informed
different source systems and
in the process.
to contact SSAB in order to
Juhana Enqvist, Chief Digital
documenting the welding
Officer at Kemppi. “The
process is done manually.
“The results of the pilot
SSAB SmartSteel is the digital identity of steel,
start developing new services around SmartSteel.
Rockford Public Library unveils virtual welding lab
P
eople who are
allows users to experience
work piece. The library hopes
can stop by any time at the
interested in welding
what it’s like to weld. Users
the new technology will
downtown library branch in
can now get a hands-
can get an idea of the many
improve the workforce in
the Maker Lab.
on experience. The Rockford
physical aspects of welding
the Rockford area. Anyone
Public Library has a new
with the use of a model
interested in trying the
virtual welding system that
welding nozzle and virtual
new virtual reality welding
www.weldfabtechtimes.com
Source: www.wrex.com
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
13
BULLETINS
Novarc launches NovEye™
N
ovarc Technologies
Novarc is at the forefront of the
has announced the
Industry 4.0 revolution with
launch of a new
this unique offering," inform Karimzadeh.
breakthrough vision based
The company also
software product called NovEye™ which increases the
announced the integration
level of autonomy in Novarc's
with the Miller Auto-
Spool Welding Robot (SWR) by
Continuum™ power source
an order of magnitude.
with the SWR to allow customers to access familiar
NovEye™ uses machine
welding processes currently
learning to track the root pass with high accuracy, measure
benefit from a higher level
package producing high quality
in use into their manual pipe
the root gap and detect the
of autonomy with less risk of
full penetration 1G root pass
welding process, including
tacks (stitches) automatically.
defects. The advantage with
welds with minimum operator
RMD and pulse process
Novarc's SWR was officially
NovEye™ is SWR operators
involvement.
provided by Miller Electric.
"This capability is
"This integration will
launched at FABTECH last
can now perform more welds
year, and since then has
while spending less time on
exceptional in the industry
improve the learning curve
become increasingly popular
each weld," said Soroush
and is a major milestone for
and facilitate better buy-in
among fabricators due to
Karimzadeh, CEO of Novarc
us and our customers. For
from operation teams for
its precision and dexterity,
Technologies.
the first time, AI and machine
shops who require a Miller
learning are introduced to the
power source in their shop,"
possible because the NovEye™
fabricator's shop floor and
said Karimzadeh.
integrates artificial intelligence
will have a meaningful impact
software product and its
and machine vision with
on their bottom line. This is
released in 2019 for existing
features, our customers
adaptive control in a complete
very exciting time for us as
and future customers.
enhanced by these new features. "With the NovEye™
This advantage is made
The NovEye™ will be
Ford EcoSport recalled in Europe, faulty welding is the reason
M
ade-in India Ford
Source: www.gaadiwaadi.com
EcoSport recalled
company hasn’t received any reports of injuries or
in Europe because
of the lower control arm
accidents caused because of
weld may not be correctly
this issue. A similar issue was
welded, which could result
also found in Sweden and the
in an accident Ford exports
Netherlands, but the company
EcoSport from India to lots of
has taken the necessary steps
global markets and the made
to solve the problem. The
in Indian EcoSport has been
exact number of units affected with the issue in the UK is
recalled in Europe because
14
this issues. Till now, the
the lower control arm weld
is very high. Because of the
loss of steering control. This
not known yet and Ford is
may not be correctly welded.
faulty weld, the front wheel
may lead to an accident and
expected to make an official
This recall was posted on the
assembly may hit the wheel
cars manufactured between
announcement soon, which
European Commission official
arch causing the front wheel
May 2, 2017, and June 20,
will shed more light into the
website and the risk level
to lock up and resulting in
2017, has been affected with
issue.
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
www.weldfabtechtimes.com
BULLETINS
Mazak advances hybrid technology with MegaStir Acquisition
M
Source: www.mazakusa.com
azak Corporation
include others such as FSW
speed and capability of the
has announced
capabilities for complete part
process.
its acquisition of
processing on one machine
a single pass. Dale Fleck will head up operations as the general
According to Dan
MegaStir, a supplier of friction
tool platform and often in one
Janka, president of Mazak
manager of the new Mazak
stir welding (FSW) tools and
setup.
Corporation, the MegaStir
MegaStir and said that
acquisition is a testament
all those at MegaStir are
Utah. With the acquisition,
with MegaStir on the
to Mazak’s rock-solid
extremely thrilled to now
Mazak continues to expand
development of the Mazak
commitment to furthering
be part of the Mazak team.
and build upon its HYBRID
VTC-800 FSW vertical 5 axis
the HYBRID Multi-Tasking
“Together with Mazak, we will
Multi-Tasking Machine
machining center and they
Machine concept. “Our goal
advance FSW’s applications
Technology. The new Mazak
recently introduced the
is to continuously explore and
not only within the oil and gas
MegaStir will provide further
Mazak VTC-300C FSW at
develop new technologies,
industry sector but also into
system advancements and
the IMTS show in Chicago.
processes and product
other new and dynamic high-
evolve into an FSW technology
Designed and manufactured
innovation that will keep
tech segments as well.”
center. A resident FSW
in Kentucky, the VTC- 300C
our customers productive,
machine in Provo as well as
FSW features Mazak’s
competitive and profitable,”
process that uses frictional
in other Mazak Technology
MAZATROL SmoothG CNC, a
he said, “and the various
heat and forging pressure to
Centers will provide
powerful 40-taper spindle, full
Mazak FSW machines are
create full-penetration, defect-
customers the potential for
traveling-column design and
perfect examples of that, as
free welded joints with greater
real manufacturing solutions
a fixed table for the machining
are the other various machine
strength than conventional
in a Done in One® capacity.
of extremely long and heavy
models within the Mazak
welding methods. The
workpieces (or multiple
HYBRID Machine Series.”
process utilizes a non-
technology located in Provo,
Through several key
Mazak first collaborated
Since 2002, MegaStir has led
FSW is a solid-sate joining
consumable tool to join two
developmental collaborations
work-holding fixtures). The
and now the MegaStir
FSW package adds friction
the industry with improved
metal plates without melting
acquisition, Mazak continues
stir welding capability to
FSW tool material innovation
the workpiece. Commonly
to pioneer the HYBRID
the spindle via a unique tool
and applications. Designed
considered a forging process,
Multi-Tasking concept. One
holder and includes closed-
for endurance and quality
FSW is well suited for joining
that extends beyond the
loop FSW process control as
welding, MegaStir tools
alloys with low melting points,
combination of additive and
well as FSW programming
consistently produce top
including aluminum, copper
subtractive processes to also
software that enhances the
quality, high strength welds in
and brass, among others.
Minimal heat input and a flawless weld seam appearance
W
ith Cycle Step, the
advantage is the clear rippling
guns. Furthermore, CMT
possible with Cycle Step.
heat input into
of the weld seam, making
Cycle Step can be used to
The Cycle Step option
the workpiece
Cycle Step ideal for high-
weld galvanized sheets or
is available as an upgrade
is minimal and can be
quality visible seams. CMT
to produce hold points
from TPS/i firmware version
effectively controlled, which
Cycle Step also enables the
for supporting bonded
1.9.0. Following the upgrade,
is particularly useful during
smallest fixation points to be
joints. Overlay welding and
the function is available on
position welding with
welded and is therefore an
applications in additive
TPS/i systems for all CMT
gap tolerances. Another
alternative to spot welding
manufacturing are also
characteristics.
www.weldfabtechtimes.com
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
15
ARTICLE
Sensitisation of heat affected zone in Austenitic Stainless Steels of M23C6 carbides. Sensitisation makes the steel susceptible to intergranular attack. The probability of the HAZ being sensitised during welding would depend on the time it spends in the sensitisation temperature range. Fig. 1 illustrates the maximum time spent by four different regions of the HAZ in the sensitisation temperature range. The region, which experiences a peak temperature of 1123 K is sensitised maximum. Below 723 K, Dr. Hasan Shaikh, Scientist (Retd.), Indira Gandhi Centre for Atomic Research, Kalpakkam
T
carbide precipitation is too sluggish to cause any concern. The residence time spent by the HAZ in this temperature range depends on the heat input, which
he more often encountered
in turn depends on the heating and
phenomenon, which degrades
cooling rates. Fig. 2 shows that for a butt
the corrosion resistance of an
weld configuration for thicker sections,
austenitic stainless steel weld joint is
increasing heat input increases the time
the sensitisation of the heat affected
spent by the HAZ in the sensitisation
zone (HAZ). Sensitisation of austenitic
temperature range. Also, the use of
stainless steel occurs in the temperature
higher interpass temperatures increases
range of 723 to 1123 K. During this high
the probability of sensitisation of HAZ
temperature exposure, depletion of Cr
[1].
to less than 12% occurs in the region around the grain boundary, due to the
Fig. 3 schematically illustrates the microstructure of a sensitized austenitic
precipitation of a continuous network
Fig. 3: Microstructures showing (a) step structure, (b) dual structure and (c) ditch structure. stainless steel after etching in oxalic acid. Optical microscopy reveals any of the three structures viz. step, ditch and dual. Step structure corresponds to clean grain boundaries and, hence, an annealed structure. Ditch structure means continuous carbide depletion and corresponds to a probably sensitized structure. Dual structure would mean discontinuous carbide precipitation.
Fig. 1: A schematic diagram indicating the effect of thermal cycling in inducing sensitisation in HAZ
16
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
Fig. 2: Relationship between heat input and maximum time spent by HAZ for welds made with 373 K and room temperature interpass temperatures
Normally, step and dual structures are screened to be non-sensitised as per ASTM standards. However, this could be a mistake since dual structure could
www.weldfabtechtimes.com
ARTICLE
[6]. The principle of this method is described in Fig. 7. The cooling curve is divided into a number small segments (ΔT) from the highest temperature (TH) to the lowest temperature (TL) of the relevant TTS diagram. The time of transit Δt is determined for each segment of the cooling curve and is divided by the sensitization time (ts) at the mean temperature T of this segment from the Fig. 4: Relationship between M23C6 precipitation and intergranular corrosion in type 304 stainless steel result in a fully ditched structure during low temperature service. Sensitization in austenitic stainless steels can takes
TTS diagram. The cumulative fraction Fig. 6: Continuous cooling sensitization (CCS) diagram for types 316 (1-1), 316N (2-2) and 316LN (3-3) stainless steel
(α) of the resident time in successive segments from TH to TL is calculated and is defined as
of carbide precipitation curve. T
TH α = Σ Δt/ts
The CCS curves are constructed from
place after long exposure at 300°C, if
the TTS diagrams by superimposing
such steels were first exposed briefly
the cooling curves. Dayal and
Sensitization takes place if α > or = 1.
in the sensitization range prior to low
Gnanamoorthy have reported a method
With this equation a critical cooling
temperature exposure. This kind of
to predict the extent of sensitization
rate (R) to cause sensitization can
thermal cycle is experienced in welded
during cooling/heating of the material
be calculated and is given as per the
stainless steels used in Boiling Water
TL
equation
Reactor (BWR) and termed as low
TH R = ΔT Σ 1/ts
temperature sensitization (LTS). Kain et al. [2] reported that type 304 stainless
TL
steel and its variants are more prone to
The value of α is not dependent on
LTS than the molybdenum containing
magnitude of ΔT. For agiven cooling rate
type 316 stainless steels. Fig. 4 illustrates
slower than the critical cooling rate, a
the relationship between M23C6
temperature can be found at which α = 1.
precipitation and IGC. It is seen that the curve indicating IGC is offset to the right
(a)
This gives one point on the CCS diagram. For different cooling curves, the loci of such points determine the continuous cooling sensitization diagram. Susceptibility to IGC caused by sensitisation in austenitic stainless steel can be determined by systematically carrying out ASTM standardized tests. The ASTM tests for IGC are either chemical or electrochemical in nature and are applicable for austenitic stainless steel and some Ni-base alloys. ASTM Standard A 262 Practice A to
(b) Fig. 5: Time-temperature-sensitisation (TTS) diagram for types 316 (1-1), 316N (2-2) and 316LN (3-3) stainless steels
www.weldfabtechtimes.com
Fig. 7: Continuous cooling sensitization diagram obtained from TTS diagram (a) principle of the method, and (b) the procedure
F are the standards for chemical and metallographic tests to determine IGC in austenitic stainless steel [7]. Table 1 gives a comparative analysis of the various ASTM A 262 Practices to
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
17
ARTICLE
suitable for field use. This technique was
Table 1: ASTM Evaluation Test for Detecting Sensitization.
standardised by ASTM to quantify the ASTM Practice
Test Environment
Potential Range
Alloys
Phases Attacked
Evaluation Criteria
DOS in AISI types 304 and 304L stainless
A
Oxalic Acid Etch
+1.76 V (SCE)
304, 304L, 316, 316L, 317, 317L, 321, 347
Carbides
YES
successfully used to quantify the DOS in
steel [12]. The EPR technique has been other stainless steel and Ni base alloys [13,14]. Table 2 gives the conditions
B
Fe2(SO4) – 50% H2SO4
+0.6 V (SCE)
321,347
σ in 321 & 347
NO
C
HNO3
+0.96 V (SCE)
321,347
Cr-depleted regions, carbides & Mo-bearing σ
NO
for the EPR test. Two versions of the EPR technique are practiced today, viz. the single loop technique (Fig. 8) and the double loop technique (Fig. 9). Double loop technique has advantage over single loop technique in that it
D
HNO3 – HF
+0.3 to –0.1 V (SCE)
316, 317, 317L
Cr-depleted region
NO
E
Cu–CuSO4/ 16% H2SO4
+0.34 V (SCE)
316, 316L, 317, 317L
Cr-depleted region
YES
F
Cu–CuSO4/ 50% H2SO4
--
Low carbon and Mobearing SS
Cr-depleted regions
NO
automatically compensates for changes in alloy composition, and in that the surface finish is not very critical, which makes it an automatic choice for on-field applications. Reactivation charge, ratio of reactivation to activation charge, peak reactivation current density, ratio of peak current densities on reactivation
detect sensitization. These standard tests
the intergranular attack in the Strauss
are commonly used as qualification/
test medium. Hence the changes
acceptance criteria during purchase/
in these properties can be used to
fabrication stage. However, non-
quantify the DOS after exposure to the
inclusion of acceptance limits in these
Strauss test solution [8]. To overcome
standards leaves the interpretation
these limitations of chemical tests, an
of results open to users. Besides not
electrochemical technique, known
quantifying the degree of sensitisation
as electrochemical potentiokinetic
(DOS), these chemical tests are also
reactivation (EPR) technique, was
destructive and slow – a situation
developed by Cihal et al. [9], Novak et al.
that is not welcome at plant site. The
[10] and Clarke et al. [11]. This technique
oxalic acid etch test (A262 Practice A)
is a quantitative, non-destructive and
is normally used as a screening test.
rapid method, which is essentially
Only if a ditched microstructure is observed in oxalic etch test, the need for confirmatory tests (Practice B to F) is
Fig. 8: Single loop technique of EPR test Table 2: EPR Test condition as used by Clarke et al. Electrolyte
0.5M H2SO4 +0.01M KCNS
test, which is popularly known as the
Temperature
300C
Strauss test. The test recommends a
Specime surface finish
1 micron (diamond paste)
Reactivation Sweep Rate
6 V/h
DOS. Electrical resistivity and tensile
Passivation Potential / Time
+200 mv for 2 minutes
properties are changed considerably by
Deaeration
Nitrogen
necessary. The most often used chemical technique isthe ASTM A262 Practice E
bend test after exposure to Cu-CuSO4H2SO4 test medium to qualify the material. However, the bend test does not give any quantitative value for the
18
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
to activation are some of the parameters
Fig. 9: Double loop technique of the EPR tests
www.weldfabtechtimes.com
ARTICLE
used to quantify degree of sensitisation.
steel, (Fe,Cr)23C6 is precipitated first
However, discrepancies exist between
at 1023 K to 1123 K. With prolonged
the DOS determined by chemical
aging, Mo is also incorporated as
methods and the EPR method [14]. The
(Fe,Cr)21 Mo2C6 which is finally
threshold EPR charge value above which
converted to χ phase. With increasing
a stainless steel is susceptible to IGC in
(a)
Mo contents, M23C6 precipitation and
ASTM A262E is not a unique number, but
IGC become increasingly influenced
depends on temperature at which the
by the precipitation of intermetallic
material was sensitised. This is because
phases. The influence of Mn is of special
the ratio of the width to depth of the Cr-
importance because in fully austenitic
depleted regions affects the reactivation
welds, this element is added. Mn reduces
charge during the EPR test. EPR tests
(b)
have an inherent disadvantage in that
the carbon activity and increases its solubility. Carbide precipitation is
they are very sensitive to changes in Cr
slowed down and hence it appears to
depletion anywhere in the alloy and
inhibit carbide precipitation [16]. Boron
cannot differentiate between matrix and
retards the precipitation of Cr-carbide
grain boundary depletion.
but depending upon the heat treatment
Sensitisation of austenitic stainless
it promotes IGC]. Si promotes IGC of
steel requires the precipitation of Cr-rich
(c)
high purity and commercial stainless
carbides along grain boundaries, which
steel. Steels containing Mo were found to
makes carbon and Cr the predominant
be much more sensitive to Si additions.
compositional variables for sensitization.
The increased susceptibility to IGC in
By reducing the carbon content in
highly oxidizing solution is due to the
stainless steel, TTS curve is displaced
segregation of Si to grain boundaries
towards longer times because carbon
[15]. Fig. 10d represents the influence of (d)
concentration in austenite becomes insufficient to form Cr-carbide readily (Fig. 10a) [15]. The limit of C content
Fig. 10: Influence of (a) carbon (b) Cr (c) Mo and (d) Si, on the sensitization kinetics.
for which steel is not sensitive to IGC
Si on the kinetics of sensitization. One of the alloying additions studied extensively in the recent years is nitrogen. Its effect is quite complex and is dependent on the
is closely connected with the presence
the austenite and must be increased with
presence of other alloying additions. N
of other alloying elements such as Cr,
increasing Cr concentration. Increasing
content up to 0.16 weight % is reported
Mo, Ni, N, Mn, B, Si as well as Ti & Nb in
the bulk Ni content decreases the
to improve sensitization resistance by
stabilized steel. The detrimental effect
solubility and increases the diffusivity of
retarding the precipitation and growth of
of C on sensitization can be reduced by
C. This effect is much more pronounced
Cr23C6 [17]. Parvathavarthini et al. have
the addition of stabilizing elements like
when Ni content is greater than 20%.
established that as the nitrogen content
Ti and Nb. These elements form TiC and
It is generally recommended that in
increases, time required for sensitization
NbC, which results in reduction of Cr
25/20 Cr-Ni steel, C content should be
at the nose temperature increases from
available for Cr-carbide precipitation.
less than 0.02% to guarantee resistance
0.5 hours (316 stainless steel) to as much
Cr has a pronounced effect on the
to IGC. Mo reduces the solubility of
as 80 hours (316 LN stainless steel)
passivation characteristics of stainless
C in austenite. Carbide precipitation
indicating the beneficial effect of N [18].
steel. With higher Cr contents, time to
is accelerated at higher temperatures
Based on numerous data in literature,
reach resistance limit of Cr depletion at
whereas at lower temperatures it is
the effect of chemical composition on
the grain boundaries is shifted to longer
slowed down (Fig. 10c) [15]. When Mo is
sensitization behaviour of austenitic
times (Fig. 10b). Higher Cr contents
present, it is also incorporated in M23C6.
stainless steels has been described by
facilitate the diffusion of Cr into depleted
Therefore, in addition to Cr depletion,
an effective chromium content, Creff,
grain boundary area [15]. Ni is required
Mo depletion is also revealed. In Mo-
by giving proper weightages to various
in austenitic stainless steel to stabilize
containing Cr-Ni austenitic stainless
elements as [19, 20]
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DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
19
ARTICLE
Creff = Cr + 1.45 Mo – 0.19 Ni – 100 C +
of cold work especially at high aging
Gnanamoorthy and S. K. Seshadri,
0.13 Mn – 0.22 Si – 0.51 Al – 0.2 Co + 0.01
temperatures.
Journal of Nuclear Materials, 168 (1989) 83
Cu + 0.61 Ti + 0.34 V – 0.22 W + 9.2 N
SUMMARY
Corrosion, 36 (1980) 104
The paper discusses the various
cooling rates. It is seen that as increases,
aspects of sensitization of heat affected
the critical cooling rate, above which
zone of austenitic stainless steels.
Book of Standards, American Society
sensitization will not occur, decreases
Sensitisation makes the steel susceptible
for Testing of Metals, Philadelphia
[19,20].
to intergranular attack. The probability
Table 3: Dependence of critical cooling rates on Creff % CW
12.57
14.36
16.03
0
365
17
0.43
of the HAZ being sensitised during welding would depend on the time it spends in the sensitisation temperature range. The kinetics sensitization during isothermal annealing could be predicted from a time-temperature-sensitisation
5
710
22
0.54
10
765
27
0.73
during welding can be predicted by a
0.76
continuous cooling sensitisation (CCS)
15
515
27
20
815
26
0.93
25
790
18
0.97
diagram (TTS); while sensitisation
diagram. Susceptibility to intergranular
out ASTM standardized tests. The various for IGC have been discussed. The effect
grain boundary area available for Cr-
of chemical composition on sensitisation
carbide precipitation increases. This
& the minimum required critical cooling
would cause the effective depletion
rates to prevent it have been discussed.
reduce. Also, Cr has to diffuse smaller
REFERENCES
distances to heal the Cr-depleted regions
1. T. P. S. Gill, Proceedings of the
to desensitize the material. Cold work
Corrosion Management Course,
is reported to increase the sensitization
The Indian Institute of Metals,
kinetics of austenitic SS at moderate
Kalpakkam, October 1995, Paper No.
cold works and decrease the kinetics
L-6
cold work, and below that of the asreceived material. The nose temperature
2. V. Kain, K. Chandra, K. N. Adhe and P. K. De, Journal of Nuclear Materials, 334 (2004) 115 3. C. J. Novak, Handbook of Stainless Steels, 1977 4. S. K. Mannan, R. K. Dayal,
corresponding to maximum rate of
M. Vijayalakshmi and N.
sensitization is also shifted to lower
Parvathavarthini, Journal of Nuclear
temperature with increasing cold work. Desensitisation is faster at higher levels
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
(1980) 737 10. P. Novak, R. Stefec and F. Franz, Corrosion, 31 (1975) 344 11. W. L. Clarke, W. M. Romero and J. C. Danko, Report GEAP-21382, GEC, California, (1976) 12. ASTM Standard G 108-94, ASTM
PA, (1994) 444 13. W. L. Clarke, J. R. Kearns, J. Y. Park and D. van Rooyen, ASTM Research Report, Subcommittee G01.08, 1989 14. P. Muraleedharan, J. B. Gnanamoorthy and K. Prasad Rao, Corrosion, 45 (1989) 142 15. E. Folkhard, Welding Metallurgy
of Cr per unit grain boundary area to
the left (shorter times) with increasing
9. V. Cihal, Corrosion Science, 20
for Testing of Metals, Philadelphia
areas. As the grain size decreases, the
of cold worked materials are shifted to
Maintenance, (1984) 47
Book of Standards, American Society
chemical and electrochemical ASTM tests
et al. [5] reported that TTS diagrams
PA, (1993) 42 8. P. Muraleedharan, Corrosion and
in austenitic stainless steel can be
boundaries because they are high energy
at higher cold works. Parvathavarthini
7. ASTM Standard A262-93a, ASTM
corrosion (IGC) caused by sensitisation determined by systematically carrying
Cr-carbides precipitate at grain
20
6. R. K. Dayal and J. B. Gnanamoorthy,
Table 3 relates Creff to the critical
Materials, 126 (1984) 1 5. N. Parvathavarthini, R. K. Dayal, J. B.
of Stainless Steels, Springer-Verla, Vienna (1988) 16. C. L. Briant, R. A Mulford and E. E. Hall, Corrosion, 38 (1982) 468 17. T. A. Mozhi, W. A. T. Clarke, K. Nishimoto, W. B. John and D. D. McDonald, Corrosion, 41 (1985) 555 18. N. Parvathavarthini, R. K. Dayal and J. B. Gnanamoorthy, Corrosion, 208 (1994) 251 19. N. Parvathavarthini and R. K. Dayal, Journal of Nuclear Materials, 305 (2002) 209 20. R. K. Dayal, N. Parvathavarthini and Baldev Raj, International Materials Reviews, 50 (2005) 129.
www.weldfabtechtimes.com
PRODUCTS UPDATE
The Future of Weathering Steel Welding Weather Resistant Cored Wires from Diamondspark by Böhler Welding
T
he latest development
Weathering steel is a group
of Böhler Welding
of steel alloys which were
Fields of application of weather resistant steels:
within its premium
developed to avoid painting.
• General steel construction
diamondspark line covers a
Named by a US company
range of weather resistant
after its main benefits
• Containers and Tanks • Chimneys and Industrial
seamless cored wires which
CORrosion resistance and
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is often called COR-TEN (or
• Architecture
CORTEN) steel.
The new weather resistant
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offers three seamless FCAW
with a total resistance against
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moisture absorption.
in comibination with two
number of alloying elements,
designed in accordance
different fluxes for weather
such as P, Cu, Cr, Ni, Mo
to those requirements. As
range Böhler Welding offers
resistant steel in their
added in order to increase
part of the diamondspark
a vast range of premium
diamondspark range:
its resistance to atmospheric
family the seamless cored
quality seamless cored
• BÖHLER NiCu1 Ti T-FD
corrosion. This is reached by
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WELDFAB TECH TIMES | DEC 2018 - JAN 2019
That steel has a certain
cored wires are not only
For More Info: voestalpine Böhler Welding GmbH Jutta Hackstock-Sabitzer Email: jutta.hackstock-sabitzer@voestalpine.com M. +43 (0)664 883 22 465 Website: www.voestalpine.com/welding
www.weldfabtechtimes.com
PRODUCTS UPDATE
How Auto Darkening Welding Helmet Filters / Lens Work
A
uto-Darkening Filters (ADF) turn dark the moment an
arc is struck and transparent
Dr Ake Hornell Sweden Inventor of Auto Darkening Welding Helmets Speedglass.
Polariser Films ( B ) Helps in Auto Darkening
again when welding stops –
strike, the filter is switched to
all the time with full UV/IR
the dark state.
protection. Auto Darkening Welding Filter / Lens was
After Welding:
invented by Dr Ake Hornell,
The filter automatically
Sweden in 1974. Each filter
returns to the light state
is a laminate of different
after welding is complete,
layers: a UV/IR filter (A),
allowing your immediate
three polarizers (B) and three
and safe inspection of
liquid crystal elements (C).
needed. Liquid Crystal
can clearly see through
the weld pool, as well as
The UV/IR filter continually
Elements (C) twist the light
the welding filter. Both of
preparation for the next
blocks harmful radiation,
on getting signal from Arc
your hands are free & the
weld. Good Quality Welding
regardless of whether
Sensors as per need through
electrode can be precisely
Helmets incorporating auto-
the filter is in the light or
Electronics. The level of
positioned.
darkening filters confirms
dark state or whether the
protection from the UV/IR
auto-darkening function
filter is constant; equivalent
During Welding:
EN 175, EN 166 and EN 379
is operational. Aided by
a shade 13 passive welding
Within 0.0001 Second ( at
as well as many National
surface-mounted electronics,
filter.
room temperature) of the arc
Standards.
to the European Standards
the liquid crystal elements act as shutters that detect
Before Welding:
and react to the welding
With the auto-darkening
arc by instantly becoming
welding helmet in the
either dark, or light, as
safe down position, you
For More Info: Aketek Industries AB Sweden R B Khatri, Director India Email: rbkhatri@aketek.com
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help deliver repeatable, high
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DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
23
PRODUCTS UPDATE
Welding Titanium with the Low Cost ‘Nano’
M
etals that
HFT® has a Family
are classed
Range of PurgEye® Weld
as ‘reactive’
Purge Monitors® for every
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nickel alloys) are sensitive
includes hand held, battery
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operated monitors and
When welding these metals,
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levels from atmospheric
PurgEye API300 Nano PHO 08C API on Pipe with Welding Torch.
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Purging in this environment
Ron continues: “All
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the weld and heat affected
Techniques HFT®’s
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Techniques HFT have
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Welding in an atmosphere of 40 ppm or less willhelp
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The PurgEye® Nano has
PurgEye API300 Nano PHO 10C Weld made with APi.
With leak-tight connectors ®
colour welds, time and time again.” As the major international
For More Info: Huntingdon Fusion Techniques HFT® Michaela Reay, Marketing Associate Email: michaelareay@huntingdonfusion.com Website: www.huntingdonfusion.com
24
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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PRODUCTS UPDATE
Micro Electron Beam processing machines
T
• § L95-chamber: 500 mm x
he system can weld
400 mm x 475 mm
turbo chargers that
dimensions. In case of further negotiations, we have to
are known to be
weldable with the electron
This leads to flexible useable
prove those workpiece
beam. Examples are:
work piece sizes of about:
sizes together with the
Stainless Steel, High Strength
• § L8-chamber: Ø150 mm
accessibility of the welding
x 150 mm
Steel, Ti, Nitinol, Ta, Al,
• § L95-chamber: 220 mm x
Cu, Bronze, Kovar, Au and
200 mm x 375 mm
path. In case of welding in vacuum with the laser for stainless steel, kovar
more. In difficult cases, the
heat input to the welded
weldability can depend on
workpiece. The ‘maximum’
the alloying content of the
penetration depth is
If the workpiece size exceeds
recognized no difference
selected material.
approximately 10mm
this limit, the position of the
in the weldability between
and high strength steel we
The system is also
for steel. This is a depth
joint becomes important
electron beam and laser.
frequently used to weld
range that fits for almost
and usable workpieces can
Laser beam welding in
dissimilar materials. Some
all applications that are
also be larger than indicated
vacuum is a new field
tested combinations are:
reasonable for this device.
boundless usable area and
the amount of tests for
can reach the chamber
weldability is still limited.
Cu @ Al, Stainless Steel @ Platinum, Stainless Steel @
The lowest welding depth goes down to 100µm.
Bronze, Stainless Steel @ Kovar. Due to the narrow
The available chamber
beam, the system has
dimensions are:
advantages in the micro
• § L8-chamber: Ø235 mm
welding because of the low
x 155 mm
For More Info: Mack International Tel.: +91 (0) 22 22855261 / 22834962 Email: jay.agawane@mack.in Website: www.mack.in
CDDP-A – Production Ready Fine-Spot Welder
S
unstone’s advanced
easily export/import them to
will not be affected by line
dual pulse CD
other machines.
voltage fluctuations. You can
Capacitive Discharge
also achieve quick energy
capabilities including weld
(CD) resistance welders
release for welding highly
monitoring, SPC tools,
have many advantages over
conductive metals such as
and a large capacitive
other welder types. Since
copper. This quick energy
touch-screen interface.
CD welders use capacitors
release is concentrated into a
The touch-screen interface
to store and release weld
small area, generating only a
provides easy access to
energy, your weld energy
small heat signature or heat
all weld parameters. In
will be highly repeatable and
affected zone.
welders offer many
26
addition, you get a visual of
welder has multiple PLC
the weld waveform graph,
protocols. You can also set
weld histograms, alarms,
up multiple machines in
warnings, and even on-
a simplified way thanks to
screen documents and
the clone feature. Cloning
videos. For automated
allows you to copy all your
production settings, the
parameters/settings and
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
For More Info: Sunstone Tel: +1-(801)-658-0015 Email: sales@sunstonewelders.com Fax: 866.701.1209 Website: www.sunstonewelders.com
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PRODUCTS UPDATE
The Power of Choice
T
RUMPF India started its operations in the year 2006 and have
response time possible. TRUMPF India is making all the possible
numerical control was the only option for engineers wishing to gain mastery over
actions to move towards the right direction
light, and they have since gathered 50
since then. TRUMPF India is catering to
leading to customer’s success and long
years of experience with this incorporeal
infrastructure and construction sectors
term relationship which leads to ultimate
phenomenon. This is a huge advantage
among others. There is a huge expansion
goal of success for everyone.
for those tackling the challenges of the
consistently recorded growth
modern world in general and data-driven
happening in the Railway sector. Laser applications in automotive industryis also
Lasers are Smart
one of the fastest -growing and promising
A laser beam is swift, flexible and direct.
sector. Aerospace and Heavy Industries are
There’s no material in the world that it
tool that meets all requirements and can
emerging as a potential market.
can’t process. Cutting, welding, marking,
be immediately put to work. It is swift,
processing surfaces – more and more
flexible and direct. Ablation, coating,
a high end ‘Experience Center’ in Pune.
manufacturing technology experts are
drilling, cutting, joining, metallurgical
The ‘Experience Center’ is a place where
valuing the flexibility, versatility, and cost
transformation, tempering glass, and
customers can experience TRUMPF
efficiency of the laser tool. At TRUMPF,
roughening, smoothing or cleaning
machines in action with customised
you will find the right laser for any task. We
demo’s and trainings. Experience centre is
offer you advice and support on how you
one stop solution for all kinds of customer
can build your Smart Factory step by step
requests simply to cater the customer
by networking your lasers with software,
needs and convert them in to customer
machines, and services, and therefore how
benefit with the least response time
to equip yourself for the digital future of
possible for best solutions. Apart from
your production facility.
TRUMPF India recently inaugurated
Pune, TRUMPF India has a branch office in
TRUMPF - Disk laser, Diode laser, Ultra-
parts, simply to be closer to the customers
shot pulse laser, Fiber laser, Marking laser,
for instant support and training. TRUMPF
Pulsed laser, CO2 laser, Scientific laser,
India plans to start another branch office
Sensor system and Processing optics.
to cater the Norther customer with least
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The laser is a fully mature industrial
Types of laser products available with
Bengaluru along with warehouse for spare
and warehouse in Delhi by June 2019, again
manufacturing in particular.
Laser material processing has digital bits encoded in its DNA. From day one,
LASER PROCESSING A thin beam of light stands between the data and the physical product. And it can do everything: ablate, coat, drill, cut, join, and anything else imaginable.
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
27
PRODUCTS UPDATE
These additions to the infrastructure will surely instil confidence and trust among our customers for a long-term technology partnership. surfaces: laser light can do it all. There’s
TRUMPF Lasers
advantages, above all due to its much
no material in the world that laser beams
From drilling the finest holes no wider than
more compact footprint and increased
can’t process: glass, plastics, organic
a hair, to welding panels in ship building,
robustness. It also has intelligent inner
compounds, and every type of metal. If
the disk lasers from market leader TRUMPF
parts. The data quality of the sensor
smart factories are in their infancy, lasers
have been used in tens of thousands of
systems which monitor all the important
are already “grown-up.”
installations around the world, impressing
parameters in the laser has been improved
customers through maximum component
significantly so that the new TruDisk lasers
LASERS DON’T CARE WHAT YOU ASK OF THEM
quality and laser reliability. Whether it be
are perfectly prepared for future Industry
a continuous wave or ultra-short pulse
4.0 services such as condition monitoring.
The trend toward ever more product
laser, disk laser technology demonstrates
The TruDisk operates economically in all
variants, special editions, personalization
its advantages in the respective sector with
laser states due to increased efficiency,
and Flexible batch sizes has spread to
both high pulse energies and high average
a new pulse function with increased
almost every sector of industry. This
powers. The lasers are particularly easy
energy efficiency, and intelligent energy
has driven up the cost of mechanical
and flexible to integrate due to intelligent
management.
tools and led to absurdly long retooling
activation concepts with high functionality. • 100% consistent power output
times – sometimes longer than the actual production process. Lasers, by contrast,
TruDisk - Advanced intelligent Solid-
Stable processes through integrated,
require neither special tools nor retooling.
state laser
active laser power control ensure reproducible results.
The major automotive companies have
• Robust against reflection
long since eliminated all mechanical machining steps downstream from the
The patented resonator design means
forming press, such as milling or drilling,
that your TruDisk can also process highly reflective materials.
and have set up laser stations instead.
• Low-spatter welding
When designing car doors, for example, the raw body part is cut in such a way that
With BrightLine Weld you can achieve
it can be used in the maximum number
high-quality welding seams with
of different models. In the subsequent
wagon version. The data package gives the instructions, and the laser executes
The TruDisk is a high-power solid-
Multiple energy-saving modes and
them immediately. Intelligent scanner
state laser for the welding, cutting, and
the power factor correction reduce the
optics require nothing more than the data
surface processing of metals. It impresses
from the 3D simulation software to direct
above all in situations which require the
the laser to the right weld spots – without
combination of high power and maximum
Choose between an integrated heat
having to be taught. The tool adapts
beam quality. The new generation of
exchanger (standard) and compressor
automatically to the workpiece.
TruDisk lasers provides you with great
cooler (optional).
to the laser whether the angles have to be flatter for the soft-top version or wider holes have to be drilled for the station
28
minimal spatter formation.
INSIDE THE LASER A look at the laser resonator: The mirrors in the optical cavity guide the pump beam emitted by the diodes through the disk crystal multiple times in order to concentrate the laser beam.
processing stages, it makes no difference
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
• Maximum beam quality As a laser medium, the disk in the TruDisk ensures brilliant beam quality up to 2 mm•mrad. • Intelligent energy management
power requirement. • Flexible cooling concept
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LAUNCHES
OCTOPUZ Inc. releases
OCTOPUZ 2.0.3
www.octopuz.com
O
CTOPUZ 2.0.3, released dated August 14th 2018, continues to build-off of the OCTOPUZ
2.0 theme. The improvements and enhancements included in this release are focused on the robot back-up capabilities and the overall user experience. The import of Fanuc, OTC, & Universal Robots back-ups have been improved now with the ability to import additional information from the controller into OCTOPUZ 2.0.3. Users can now import FANUC controller back-ups with multiple robots and a single controller allowing the users to more easily create programs and configure cells in OCTOPUZ 2.0.3. New to OCTOPUZ, users can now import Universal Robots and OTC back-ups to bring in robot parameters and improve the accuracy in offline programming. Furthermore, users who have upgraded their Mastercam package to Mastercam 2019 can now easily import their CAM
30
In addition to these main features there
• Half Plane Visualization
were other improvements made to the
• AutoSave
OCTOPUZ software including:
If you are a current OCTOPUZ
• Calculation of external values with
maintenance customer, your OCTOPUZ
default settings
license will automatically update and
paths into OCTOPUZ to leverage the newly
• Identification of post capable robots
you will be able to employ the latest
introduced features in toolpath creation.
• Storing of previous external variables
enhancements right away.
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
www.weldfabtechtimes.com
LAUNCHES
If you would like to learn more about OCTOPUZ Offline Robotic Programming
• Automatically finds the start and end of welds
automatically calculated based on userselected wire orientation
and Simulation Software contact us to
• Automatic torch flare into corners
For More Info:
set up a free demo customized to your
• Can simultaneously calculate up to
OCTOPUZ Inc.
applications and programming needs.
three external linear axes
Phone: +1 (226) 894-1253
• External rotary axes can be
Email: info@octopuz.com
Features: • Autonomous, intelligent, intuitive weld
Case Study
creation • Path creation and modification are possible with just a few clicks • Import and use a CAD model for weld creation • Implement a variety of welding strategies such as multi-layer, stitch, weave, seam tracking, touch sensing, and more • Can utilize multiple touches per path or
OCTOPUZ Customer Spotlight: Flory Industries Flory Industries is a manufacturer of nut-harvesting equipment. They invested in a Lincoln Electric Welding Cell equipt with a Fanuc robot programmed with OCTOPUZ to weld components for their harvester machines and complete mainframes. With OCTOPUZ, Flory Industries programs their Fanuc to tack weld the components first and then complete the fill arc weld routines. Using OCTOPUZ they are able simulate and program their external axes which includes a headstock – tailstock positioner using coordinated motion to allow the robot to reach all areas of the part.
global touch correction (6-dimensional) • Parametric and reusable weld creation • Fully simulated touch-sensing, multilayer, stitching, and weave
www.weldfabtechtimes.com
By taking advantage of the welding features readily available in OCTOPUZ, Flory Industries can easily create weave welds and stitch welds achieving constant push angles all within OCTOPUZ.
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
31
ARTICLE
Fumes, Health & Safety in Arc Welding practice to distribute, during my lectures
of time. A study of such particles are
at industrial centres, copies of a useful
made abroad, makes fascinating reading.
note which was published in AWS journal.
Welding fumes consist of fine particles
Another source of danger is in Oxy-fuel
& gases, which spread at a low speed
welding cutting gas cylinders and flame.
from point of welding, are rather easy to
These two are typical of the large number
capture. Dust from grinding & other metal
of hazards which arise in the day to-day
fabrication operations consists of coarse
activities linked with welding operation.
particles which move at a high sped. If
Electricity, compressed air & welding
you consider a welding particle to be the
gas are supplied by cables & hoses. In
size of one grain of sand with the speed
many shops these cables & hoses can be
of a lifting air balloon, a grinding particle
seen lying in a mess on the floor. They
can be compared to a football with the
become an obstruction to movement.
speed of an ice hockey puck. Welding
They get worn out faster because they are
fume particles stay a lot longer in the
I. Introduction:
least cared for, and may cause accidents.
air(and hence there is a large spread in
There is now growing awareness of the
While efforts are made to control wages
the workshop) than the grinding particles
need to control pollution and to protect
of welders & helpers, the losses through
before they fall down on the floor; for
the environment. This holds good equally
damage to and hence shorter life of cable
instance, from a height of one metre,
for welding shops, & adequate safeguards
& hoses, are over looked. Obviously, their
4 hours for welding fume particle as
have to be provided to prevent pollution
life is extended and cost of replacement
against 3 minutes for grinding particle.
through fume generation. Furthermore,
avoided in the simplest possible way
These vast differences have to be taken
health & safety of personnel need to be
i.e. by simply ignoring their damaged
into consideration while planning for
taken into account. Electrical hazards,
condition. Hence; the greater risk to
extraction &ventilation.
welding fumes, ultraviolet rays & heat are
personnel.
D. S. Honavar, Chairman, Honavar Electrodes Pvt. Ltd.
3. Noise & Vibration: Noise is one of the
direct outcome of the welding operation.
32
While the overall situation in these two
2. Fumes & Dust: Fumes & dust are
unavoidable evils of engineering industry
aspects of health & safety in India was far
another health hazard. A Danish study
and, for that matter, of modern society.
from satisfactory for years together, with
has shown that the lungs of welders,
Indian industry has so far been spared
more & more welding being employed,
who have done heavy duty welding for
the burden of insurance claims arising
a number of industries are making
many years without proper ventilation.
from excessive and damaging noise
systematic efforts, and providing for the
are affected to the same extent as the
levels in workshops. While noise cannot
substantial investment required, to tackle
lungs of people who smoke about 25
be avoided, it has to be controlled at
these aspects on a long term basis. And
cigarettes a day. And then many of such
reasonable levels in certain operations.
yet, these aspects need to be emphasized
welders and welding personnel are also
Grinding & arc air gouging are two such
for the reason that with quality,
smokers, and are thereby exposed to
operations which create both noise &
productivity & cost control receiving
far greater risk of damage to lungs. The
fumes which, in confined spaces, become
due attention, health & safety may fail to
standard ventilation may not be enough.
a problem. Another health hazard is
attract the attention they demand.
Instead, the welding fumes & fabrication
posed by the vibrations to which the
dust must be captured directly at the
operator’s hand is subjected during arc air
II. Hazards:
source by using fume & dust extractors
gouging and during grinding. Hand, arm,
1. Electrical & Welding/Cutting Gas:
which have to be selected for effectively
vibration syndromes (HAVS) is general
Electrical hazards are so common and
tackling the mass and size of particles
term which covers damage caused by
well known, and yet may not receive
and their velocity, together with the
vibrations transmitted to the hands and
adequate care. Hence, I have made it a
volume of pollution generated per unit
arms. It is reported to be probably one of
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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ARTICLE
the top issues with respect to claims in the
in Europe to quantify the effects and
through exposure to ultraviolet rays is
insurance aspect of fabrication business.
to lay down exposure limits, based on
known very well and dueprecautions are
Such hazards are prompting a change-
the dangerous products of thermal
taken. Information on safe distance is
over to plasma gouging/cutting. Though
decomposition of the residual solvent,
given in Table 1.
much more expensive, it produces less
during welding.
noise, less fumes, & better quality surfaces
However lower cost and effectiveness
Distance from Arc at which Ultraviolet
which require less subsequent work. One
and absence of substitutes, have kept
Radiation is reduced to US daily
would like to avoid the higher cost, but
such products in use. In the last5 years,
Threshold Limit Value for various
in many situations where noise & fumes
effective substitutes have come into
exposure times.
become health hazards demanding
market, but creating awareness in the
corrective measure, selection of plasma
user industry is a matter of time and
8. Electric Shocks - Effect of Electric
process to substitute arc air gouging will
effort. Thus inspection techniques and
Current on Humans: While the risk
be a wise one.
welding related products also pose a
is known only too well, an attempt to
safety & health hazard which has to be
quantify the risk will result in a better
taken care of.
appreciation of its seriousness and chances
4. Radiography: Inherent danger of
of proving fatal at apparently low amps.
radiation in radiography demands strict control.
7. Ultraviolet Radiation: Risk to eyes
Normal human body resistance is between
5. Risk from Solvents: Acetone in the white contrast paint used in magnetic particle inspection (MPI), is meant to promote rapid drying. In confined spaces, the acetone becomes a health & safety hazard. And yet it cannot be easily replaced, as water based paints/inks do not prove effective on account of longer drying period and also tendency to cause disbondment of the contrast paints. This being so, control of acetone vapour has to be done in confined spaces to reduce the risk to personnel; 6. Anti-spatter Products are now available in the form of sprays. Aerosol antispatter sprays are used effectively and their benefits are being appreciated leading to progressively wider application. However, in this process, what gets ignored is that some such sprays may contain dichloromethane which is known to be a carcinogenic toxic chemical and hence is a dangerous solvent. It can cause damage to blood, nervous system, liver, eyes skin. Furthermore with long term exposure, it can cause cancer. Lot of indepth studies on its damaging effects on human body have been carried out
www.weldfabtechtimes.com
Table 1.
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
33
ARTICLE
Effects of Electric Current on Men / Women.
1 lakh to 6 lakh ohms. This is reduced to 1000 ohms or even less depending on sweating condition and body parts through which circuit is completed. Accident is fatal if 100 milliamperes at a frequency of 60HZ passes through vital organs.16 milliamperes is the average current at which an individual can still release himself from the object held by hand, and with no injury due to shock. At 16 ma to 50 ma, chest muscles will be contracted and death will result from
Table:2 (Source: Accident Prevention anual, American, Safety Council).
asphyxiation when exposure is prolonged. Above 50 ma interference with normal rhythm of heart causes ventricular
II. Welding Fumes:
fibrillation. In this condition the fibres of
(A) Gaseous Component
heart muscles, instead of contracting in a
(B) Particulate Component.
fumes. e. preventive or controlling measures to counter the adverse effects, through
coordinated manner, contract separately and at different times. Blood circulation
This subject is vast and is relevant to
development of consumables, &
stops instantly. Even after ensuring that
the successful working of any industry
suitable equipment for ventilation,
welder wears proper gloves and shoes,
engaged in welded fabrication. While
dilution, extraction of fumes,
the risk even while inserting an electrode
there has been growing awareness of
combined with respirators.
into holder will persist if there is excessive
its importance, it is still not receiving
moisture due to humidity and sweating,
adequate attention, especially in the
All this was being done even 30 years ago.
and the circuit is completed because then
units of the unorganized sector. The
In my report on Japan visit in September
the full OCV of upto 90 volts is available.
aspect of safety is well covered through
- October 1983, I had stated about the two
Level of current passing through the
numerous documents on safe practices
fold effort in the welding activity in Japan
welder’s body depends on body resistance
in welding. Moreover, the various issues
to control the hazard of fumes, viz.
and applied voltage. AC power sources
are discussed in the HRD programmes
(i) extraction of fumes from about one
are still used widely, & with OCV in the
of corporates as well as workshops
metre above the arc area,
range of 80-90 volts. Wetness in which
conducted by WRI and professional
(ii) use of breathing mask by welders.
a welder operates may bring down his
bodies. Thus, a great deal of literature is
body resistance to 1000 ohms. Hence, the
available and the important point is of
The assessment of adverse effect and
current passing through his body will be
implementation of various measures in
fixing the limit of exposure together
80 - 90 ma, which is sufficient to prove fatal
a planned manner. When it comes to the
is a very complex task involving large
within 3 - 4 seconds. Such risk has to be
aspect of health of the personnel involved
expenditure which however, is justified
reduced through use of voltage reducing
in welding activity the single most
by the need to take measures for well
device in the power source. A case study
important factor is of welding fumes and
being of the welding personnel. Welding
of fatal accident while inserting electrode
it is in this area that steps are continuing
fumes is a factor which ought to receive
into holder, has been described in a paper
for :
attention of the entire welding fraternity.
presented by Cochin Shipyards Ltd. in IIW
a. accurate and rapid measurement of
That is why I wish to deal at length with
Seminar - 2007 (Ref.10) The Accident Prevention Manual
fumes, b. analysis of particulates of fumes,
this particular topic. While preparing this write-up on fumes
of American Safety Council shows in
c. assessment of adverse effects on the
I was pleasantly surprised to find that this
tabular form the risk factor in terms
human body and systems through
important topic had found a place in the
of milliamperes of current. This is
extensive medical studies,
“SIR L. P. MISRA MEMORIAL LECTURE”
reproduced in Table 2.
34
respect of every constituent of welding
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
d. laying down limits for exposure in
delivered by me in 1979, and I had dealt
www.weldfabtechtimes.com
ARTICLE
maximum exposure limit for welding
fumes of different classes of electrodes
fume, the daily amount breathed in could
of welding fumes, gaseous and
and the need to give due attention to this
be 100 grammes of particles / year or 2.5
particulate, OZONE presents a
important factor for the future of welding.
kilos in 25 years”.
somewhat different, & intriguing, picture. Unlike the numerous other
And now after 30 years, as I am dealing with this very topic, it is appropriate to
III. (A) Gases in Fumes:
constituents which become a health
re-produce the relevant text of my lecture
In the informative article on Welding
hazard in varying degree, irrespective
of 1979 (Annexure-I). This is being done
Fumes, published in the journal Welding
of proportion, ozone is required in
for the benefit of members of the younger
& Cutting 6 (2007) No. 4 Dr. D. Mckeown
the air we breath, but in very small
generation and also for co-relating the
has dealt with CO, C02, N02, Ar, He.
concentration.
present with the past. Another reason is to
1. CO & CO2: Carbon monoxide has a
point out that the issue of welding fumes
Workplace Exposure Limit (WEL) of 30
Ozone is a naturally occurring constituent
had assumed importance even 30 years
ppm (35 mg/m3) and carbon dioxide
of earth’s atmosphere. It is produced by
ago, and was a matter of concern in the
is listed at 5000 ppm (9150 mg/m3)
the ultraviolet radiation from the sun.
highly industrialized countries. Various
over a TWA reference period of 8
The maximum concentration occurs
centres - academic, industrial, safety &
hours.
at about 25 Km above sea level. The
medical – were engaged in studies of the
2. NO & NO2: The two are known
normal concentration of ozone in the air
related aspects viz.. analysis, toxicity,
collectively as nitrous gases (NOx)
which we all breath is 0.005 to 0.05 parts
adverse effects on the human body. Such
NO is a severe eye, skin and mucous
per million (ppm) and it is considered
studies have led to a better understanding
membrane irritant. NO2 is a highly
as vital. However, exposure to higher
of the risk factor in respect of total
toxic irritating gas. Yet neither feature
concentrations of ozone can adversely
quantum of fumes and of every single
in the WEL published in EH40/2005.
affect health.
constituent. Hexavalent Chromium is a
This may be because limits are not
striking example wherein the permissible
clear. However, recommended
exposure limit (PEL) has been revised
exposure limits as a chemical
drastically from 52 to 5 microgramme per
hazard in 2003 April, are 1 ppm (8 hr
cubic meter of air in the Occupational
reference period) for each gas. What
Safety & Health Administration (OSHA)
is relevant is that welding generates
standard. It is a staggering reduction
only small amount of nitrous gas, &
which has alerted the entire society and
so exposure to NOx does not pose a
Ozone is chemically very active and
in particular chemical industry dealing
problem. Exposure problems may
toxic. Contact with most solids will cause
with chromium and welding industry. All
arise during cutting operation.
it to revert to oxygen, and this makes it
concerned are now engaged indevising
3. ARGON & HELIUM: These gases are
The ultraviolet radiation emitted during arc welding, causes oxygen in air to convert into ozone. 3 O2 + 2 O3 Diatomic oxygen Triatomic ozone
difficult to measure. A conventional filter
and implementing safety and control
not defined as hazardous to health
will therefore partially remove ozone from
measures to comply with the statutory
under COSHH Regulation. However,
polluted air, unlike any other pollutant
limit of 5 microgramme perm3 in the 8
they are asphyxiants. They cannot
gas likely to be found in welding fumes,
hour time weighted average (TWA). In
be seen, and do not have a smell
which would need an absorption filter.
the light of such fast changing scenario
and hence are difficult to detect. The
The occupational exposure standard
and the systematic effort to quantify
main hazard is from accumulation in
(OES) for ozone is 0.1 ppm (=0.2 mg per
the hazard, it is relevant to note the
confined spaces. Argon is heavier than
m3) for an eight hour time weighted
information published in the USA:
air, so tends to collect in low areas
average (TWA) reference period, and 0.3
“Under normal working conditions
36
4. OZONE: In the group of constituents
with what was then known about welding
such as pits. Inhaling a gas, such as
ppm (=0.6 mg per m3) for ten minute
the respiratory rate is about 20 litres of
pure argon, which contains no oxygen
TWA reference period. These are statutory
air/minute. Over a working year (100%)
can cause loss of consciousness in
limits.
a welder breathes in about 2300 m3 air.
seconds. Workers should not enter an
In poor working conditions the air can
atmosphere that contains less than
fairly high levels of ozone which in some
contain 10 times higher levels than the
18% oxygen.
applications, has been shown to exceed
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
GMAW & GTAW processes generate
www.weldfabtechtimes.com
ARTICLE
the permissible limits, e.g. welding of
maintaining the austenite - ferrite balance
with indepth investigations, help to find
aluminum and its alloys, demanding extra
in the weld metal, so that the superior
solutions to ensure that welding industry
ventilation, or personal protection, such
mechanical and corrosion properties are
keeps moving ahead.
as dust respirator air-fed helmet, helmet
not impaired. On the other hand, such
with fan and filter or breathing apparatus
addition of nitrogen to the shielding gas
which supplies air to the breathing zone.
produces adverse effect of higher ozone
The only way to determine welder’s
level in the breathing area of operator.
exposure to ozone for comparison with
This problem is taken care of by replacing
the OES is to carry out practical trials with
a part of argon shielding gas with helium
measurements in the breathing zone in
upto 20% so as to reduce the ozone
accordance with BS 6691, part-2 (fume
concentration levels below the OES.
from welding & allied processes).
Figure-2 serves to show the relative ozone
Generation of ozone by ultra violet
levels in TIG welding of DSS with ER 2209
Fig. 2: Ozone concentration in the breathing zone during TIG welding of duplex stainless steel with ER 2209 filler wire.
radiation during arc welding is not only
filler wire. This is a typical example of
process dependent, but even shielding
how the measure meant for weld metal
gas dependent. Combination of shielding
quality through use of small proportion
III (B) Particulate Component:
gases in GMAW and GTAW can have
of nitrogen, has to be combined with
Once again, while going through my
a significant influence on the ozone
another measure to satisfy health and
technical presentations of the past 35
level as the shielding gas affects the
safety requirements through use of upto
years, I found that in 1983 (IIWNWS)I
intensity of ozone forming radiation
20% helium in the shielding gas.
had presented a paper on "Arc Welding
emitted from the arc. There are vast
Another way of inhibiting ozone
Productivity - Technological-cum-
differences in the radiation emitted by
formation is by adding 0.05% nitric oxide
Human Perspective". In emphasizing
the three shielding gases - argon, helium
(NO) to the argon shielding gas. Such a
the importance of human factor, safety,
& nitrogen. It has to be noted that the
mixture was patented several years ago, &
health and works environment, were
highest ozone forming radiation is
is being marketed.
discussed at some length, and details
emitted by the arc plasma formed with
Shall I say that this is illustrative of the
were provided in respect of TLV of some
nitrogen. This is ten times stronger than
complexity of the welding operation for
substances, as valid at that point of time.
that of pure argon arc plasma and several
ensuring due care of health and safety
Fume generation rates of different classes
hundred times stronger than that of
while achieving requisite weld quality
of electrodes were also given therein. In
pure helium arc plasma. Thus, helium
standard. The objective of achieving
view of its relevance and higher degree
can be considered as the safest for this
requisite or improved quality and
of importance today, the relevant text
particular aspect. Such vast differences
productivity, cannot be separated from
and tables are being reproduced in
need to be considered when nitrogen is
the need for appropriate precaution for
Annexure-II The particulate components
added to the shielding gas in GTAW for
health care of welding personnel. What
consist of oxide, silicate or other complex
duplex and super duplex stainless steels
is satisfying is that consistent efforts
compounds of different elements. The TLV values give
for the purpose of compensating for the loss of nitrogen (essential element
an indication of the degree of health
in DSS & SDSS) from the weld pool. 1
hazard of each constituent. These limits
- 2% nitrogen is added to argon which
are reviewed periodically by ACGIH
is the shielding gas for welding DSS. In
and revised downward, based on the
the case of super duplex stainless steels
medical studies of adverse effect of each
which have nitrogen levels of 0.25% and
constituent. That is why the permissible
higher, loss of nitrogen from the weld
limits in 2009 in respect of several
pool tends to be more and hence this loss is compensated for by including 2 - 2.5% nitrogen in the shielding gas (see Fig.1). The favourable effect of nitrogen is in
www.weldfabtechtimes.com
elements are lower than those stated in Fig.1: Relationship between nitrogen in the shielding gas and nitrogen in the weld metal for TIG welding of duplex and super duplex stainless steels.
Annexure-II Looking at the 2nd table in Annexure-II, it is evident that : (a) for rutile types (E 6013) iron oxide
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
37
ARTICLE
content is high, followed by manganese.
constituents because the proportion of
(b) for basic coated type (E 7018) and for
each such constituent in the total fumes
stainless steel types, fluoride content is
will determine the limit on total fumes.
quite high, in addition to the high iron
For example, a significant proportion
oxide content.
of the chromium in fume generated by
Both these constituents have high
stainless steel electrodes and FCW is
permissible limits and they do not pose
present in hexavalent from with a limit
a big risk to health. Moreover, adverse
of 0.05 mg/m3, which reduces total fume
effect, if any, is felt by welders in a few
OES to around1 mg/m3. That is how OES
hours or few days, through the effect on
will change in relation to the extent of
eyes, skin and hair, and so corrective
alloying i.e. from 5 mg/m3 for unalloyed
actions can be taken promptly through
steel types to 1.7 for 9Cr - 1Mo. stee1 type,
improved ventilation and extraction. In
& to 0.7 for 25Cr - 12Ni steel type.
the last few years the elements which have been investigated for relatively
Osha Exposure Concentration Limits (Mg/M3)
Fume Ratios:
Table 5.
high risk to health are copper, nickel, manganese and chromium. All these four elements are vital to the metallurgical and welding industry, especially manganese for unalloyed steels and nickel and chromium in stainless steel and nickel alloy, whose consumption is rising from year to year. That is why we need to look closely into their status as constituents of fumes.
1. Fume Generation, Constituents & their Permissible Exposure Limits: Fume generation is very much process dependent and is subject to wide variations as highlighted by the ranges in
Table 3. Chemical Composition (Proportion by Mass in %) of the Welding Fumes for various Welding Processes and Materials.
Table-3 which shows weight of fumes as percentage of weight of deposited metal. This is also reflected in the Figure-3. Similarly, proportions of common constituents of fumes in the total fume quantum vary within the wide limits as can be seen in Table-4. OSHA exposure concentration limits (mg/m3) for 8 hour TWA for few metals are given in Table-5. The occupational exposure limit or standard (OES) is calculated in milligrams per cubic metre breathing zone concentration. The control value is 5 mg/m3 maximum for the total particulates, but this value is subject to limits on individual
38
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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ARTICLE
Definitions PEL / TLV / STEL / WEL.
(b) welding consumable, &
(in USA)
(c) chemicals.
ACGIH TLV: 1.5 mg/m3 (in USA)
that any adverse findings on health attributable to nickel, will call for
COSHH WEL: 0.5 mg/m3
prompt preventive/corrective measures.
(in UK)
That is why the Nickel Institute which Fig.3: Approximate fume generation rates for various welding processes.
represents 90% of the world’s nickel
As per ACGIH, nickel is not suspected
production, has taken steps to face
as a Human Carcinogen, whereas in
the situation arising from increasing
EH40 of COSHH, nickel oxide has been
3. NICKEL:
legislation on restricting use of nickel &
noted as potential carcinogen. It is not
Today, nickel is so very closely linked
its compounds. For nickel in fumes, the
clear whether there will be any sharp
with industrial development, through
exposure limits are:
downward revision of PEL in the near future, as has taken place in the case
huge production of: (a) steels & nickel base alloys,
40
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
OSHA PEL: 1 mg/m3
of hexavalent chromium (from 52 to
www.weldfabtechtimes.com
ARTICLE
5 microgrammes/m3). But welding
in the document of American Society of
(b) 0.02 mg/m3 as manganese for
industry has to aim at controlling the
Safety Engineers. It deals at some length
Respirable particulate matter.
total fumes through efficient extraction
with the health effects of welding fumes
system.
exposure and manganese, and refers to
Obviously, the limit of 0.02 mg/m3 is
“Parkinson’s disease Versus Manganese
very challenging and the organizations
induced Parkinsonism”.
representing different industries will
4. MANGANESE: Trace amounts of manganese are
“Manganese induced Parkinsonism”
have to examine it for effect on the
essential to the normal functioning of
represents the grey area in a very
working & the feasibility of complying
the human body. It acts across abroad
complex situation. In fact, the complexity
with the limit. This issue is now engaging
spectrum of activities including a range
can be explained by the queries raised
the attention of the International
of reactions in the central nervous
by two researchers in Europe after close
Manganese Institute. One point of
system which affect mood, posture and
studies and scrutiny of large volume of
relevance is that Mn is not classified as
movement.
information available. They state:
a human carcinogen, unlike hexavalent
When it comes to welding
“The absence of evidence which was
Cr(V1). However, its effect on the
consumables manganese is an essential
repeatedly apparent in the review excites
central nervous system will continue
element, both for deoxidation and for
many questions on the toxicology of
to be investigated for and against the
strength & toughness. In special grades
manganese and its inorganic compounds
proposed (2009) TLV of 0.02 mg/m3. For
of austenitic stainless steel, it is added
in general and especially those
the welding industry and members of
in proportion of 3 - 6% to prevent hot
emanating from welding processes”.
welding fraternity, this is a pointer to the
cracking. Furthermore, austenitic
While such uncertainty surrounds
fast changing scenario on health front
manganese steel is used widely. That is
the issue of TLV-TWA values for
and the consequent need to tackle the
why effect of manganese in fumes has
manganese, the American Conference
fumes for complying with the stringent
become a subject of extensive medical
of Governmental Industrial Hygienists
TLV on manganese.
studies of respiratory system and brain
(ACGIH), have been actively engaged
control centres in several countries
in evaluation of the extensive studies
5. CHROMIUM:
abroad. Just when the welding world
on manganese exposure in the
New Hexavalent Chromium Standard:
has reconciled to the harsh reality of
workplace and health effects. Based
On February 28, 2006, the Occupational
implementing measures to adhere to the
on such evaluation, ACGIH have now
Safety & Health Administration
low limit for Hexavalent Chromium (Cr.
produced a draft proposal for new
(OSHA) published the final Hexavalent
VI), doubts are being cast on manganese
TLV-TWA. Similarly, the EU Scientific
Chromium Cr(VI) standard. The new
as neurotoxicological risk to welder vis-
Committee for Occupational Exposure
permissible exposure limit (PEL) for Cr
a-vis Parkinson’s Disease.
Limit (SCOEL) is also in the process
(VI) is 5microgrammes per cubic metre
of setting an Indicative Occupational
as eight hour time weighted average
Manganese, Manganism & Parkinson’s Disease:
Exposure Limit Value (IOELV) for Mn &
(0.005 mg/m3)
While link between manganese and
the years are:
its compounds. The adopted values over In the U.K., the limits are:
Parkinson’s disease was suspect, it
Cr03-Cr(VI)
0.05 mg/m3 (50 microgramme)
Potential carcinogen
Cr203
0.5
Not carcinogen
could not be fully established and yet
Period
Mg/m3 TLV-TWA
adverse effect of excess concentration
1948-1995
6
of manganese in the blood had become
1960-1969
5
clear, based on studies of persons
1970-1991
5
The problem of Cr(V1) is likely to arise
working in manganese ore mines. The
1995-2002
0.2
especially in welding of stainless steels.
term “manganism” was coined for
Hence, it needs to be dealt with in
manganese poisoning. Based on such
The proposal (2009) is for two separate
studies, the TLV for manganese was
values:
reduced from 5 mg/m3 to 0.2 mg/m3 in
(a) 0.2 mg/m3 as manganese for
GMAW
1995. Detailed information can be found
Inhalable particulate matter, &
Reduction in exposure to hexavalent
www.weldfabtechtimes.com
relation to GMAW & SMAW.
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
41
ARTICLE
chromium, can be achieved through
than several other elements. As far as
(a) changes in shielding gas,
Cr (VI) is concerned its level in fumes
(b) welding parameters, &
with argon rich shielding gas may be
(c) pulsed GMAW.
somewhat higher than with 100% CO2, but because the total fume quantum is
(a) Argon-rich shielding gases produce
significantly less, the hazard of Cr(VI)
less fumes than 100% CO2 and helium-
exposure is reduced.
rich shielding gas. Thus, for GMAW & (b) In general, reducing current & voltage
Ar-20 CO2 will result in a significant
will lead to a decrease in fume generation
reduction in fume generation rate.
rate. In GMAW, as arc voltage increases,
GMAW spray transfer. Hence the process
Oxidation potential of the arc atmosphere
the fume generation rate will decrease to
can be fine tuned by employing suitable
will affect both the quantum and the
a point, & then increase with increasing
power source with pulsing to achieve the
composition of welding fume in general.
voltage. This behaviour, which is related
lowest possible fume levels. Here again,
As the arc atmosphere becomes more
to arc stability, is shown graphically in
some researchers have shown that the
oxidising (such as with 100% CO2) the
respect of ER 316L, usingAR-5% CO2 in
percentage of Cr(VI) in the fume may
total quantum of fume generated will
Fig. 4.
increase with pulsed transfer . However,
increase, and these fumes will contain
42
Fig. 4 Effect of voltage on fume generation rate for ER316 L (GMAW)
FCAW, 75 Ar-25 CO2 and preferably 80
because the total quantum of fume
more of manganese and silicon which
(c) A number of studies have shown
generated is reduced, the overall potential
have much higher oxidation potential
that PGMAW produces less fume than
exposure to Cr(VI) will also be reduced.
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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TENDERS
LOCATION
NATURE OF WORK
START DATE
CLOSING DATE
TENDER VALUE EMD (Rs.) (Rs.)
CONTACT
Gujarat
Tender For Welding Goggles Type.Item List :- (1) Welding Goggles Type:- With Blue Lens Conforming To Is 1179-1967(First Revision) With Amendment No. 2 Of June '2008,For Use During Electric Arc Weld Ing / Cutting'. Amm-G Mahalaxmi Maharashtra 3.00 Numbers
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4.95 Crore
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Multi State
Tender For Procurement Of Manual Metal Arc Welding Electrode, Class E2, Etc.Item List :- (1) Manual Metal Arc Welding Electrode, Class E2, Type Of Coating: Heavy (Spec. No. Irs: M-28/17 , Code E55bg1ni26 As Per Is:13952003) Size- 5 Mm X 350 Mm.
10/01/2019
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1.64 Crore
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Tender For Manual Metal Arc Welding Electrode, Class M 4, Size 4 Mm X 350 Mm, Type Of Coating - Heavy, Specifiitem List :- (1) Manual Metal Arc Welding Electrode, Class M 4, Size 4 Mm X 350 Mm, Type Of Coating - Heavy, Specification No.-Irs: M - 28 /17, Code As Per Is: 5206 / 2003, Dy.Chief Material Haryana 171326.00 Numbers
22/01/2019
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Siswa
Civil Works For Drill Site AVAJ At Khedasa Village At Siswa Area.
25/1/2019
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55,88,900
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DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
43
INTERVIEW
“Welding and welding skills will continue to grow in demand.”
The adoption of robotic welding is on the rise, there is also a growing demand for skilled welders that continues to grow and must to be met.
Q1. Tata Power has worked on several mega projects. Could you please list down some of the recent Thermal mega projects in India or abroad?
Praveer Sinha, CEO & Managing Director, Tata Power
The two mega projects commissioned
projects coupled with mergers and
project by CGPL was commissioned
by Tata Power includes the 4,000 MW
acquisitions, Tata Power will continue to
ahead of schedule. To provide a steady
ultra mega project by our fully owned
invest in opportunities that increase our
stream of skilled manpower, Tata Power
subsidiary Coastal Gujarat Power Ltd in
footprint in the country’s power sector.
has established the Tata Power Skill
Mundra in Gujarat and the 1,050 MW
and certify manpower in various skills
objective of ‘Lighting up Lives’. Through
Q3. As the company works on various power projects, what kind of challenges do you come across (in terms of availability of manpower, land acquisition, approvals, availability of raw material, etc.) and how do you manage to cope up with the same?
new and consistently expanding existing
Our most recent 4,000 MW ultra-mega
mega power projects.
plant commissioned by Maithon Power Ltd in Jharkhand.
Q2. Any upcoming Thermal projects. Please elaborate. Tata Power is a strategic player in the power sector in India with a larger
44
Development Institute (TPSDI) to train
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
needed by the power sector and allied industries. In fact, Mundra too has a TPSDI hub which has trained over 5,500 people since its inception in March 2016. TPSDI is thus a crucial intervention for Tata Power to empower and engage with the local communities around the ultra-
www.weldfabtechtimes.com
INTERVIEW
Q4. Availability of skilled manpower is one of the mega challenge? How do you try to resolve the same?
thus improving productivity. Company
emphasise health and safety practices.
welders are trained to improve quality in welding jobs and eventually move to zero defects.
To provide a steady stream of skilled
Q9. We also find many Women in Welding. Does Tata Power also have women welders? Or what is your say on women in welding?
various skills needed by the power sector
Q7. What are the initiatives undertaken by Tata Power Skill Development Institute for welding segment?
and allied industries. Since its inception
TPSDI offers a 6-week training program
attract many women yet. This should
in February 2015, TPSDI has trained over
for unemployed youth and working
change with changing perception of
30,000 people. More than 80% of these
professionals in welding skills. TPSDI
what women can do or cannot do as
are the contractual workforce engaged
also conducts an RPL (Recognition of
perceived by society at large. At Tata
at various Tata Power sites. Thus, TPSDI
Prior Learning) program as defined
Power we consciously encourage and
plays a critical role in skilling workers
by NSDC (National Skill Development
enable greater participation of women
not just for Tata Power projects but for
Corporation) to assess and formally
in areas that have traditionally been
the entire power sector, both in India
certify experienced welders. TPSDI also
male-dominated. This is an integral and
and outside. TPSDI is thus a crucial
has specialised courses for graduate
vital part of our Diversity and Inclusivity
intervention for Tata Power to empower
and diploma engineers. TPSDI uses
priorities that we take very seriously. So
and engage with the local communities
welding simulators to hone trainees’
we will continue to push for opening up
and the region at large.
skills without wasting consumables.
new opportunities for women to enable
manpower, Tata Power established the Tata Power Skill Development Institute (TPSDI) to train and certify manpower in
TPSDI trains women in various skills where the industry is ready to hire them. Welding as a vocation in India does not
The simulator enables trainees to learn,
greater participation. This will not only
Q5. Into all the projects, welding and fabrication activities play a major role. Your say?
practice and perfect welding skills safely
fulfil our D&I commitments but also
before moving to working with field
ensure adequate availability of skilled
equipment. TPSDI’s trainers come
workforce that is not constrained by
Any project in a core industry requires
from the industry with several years of
gender divisions.
welding and fabrication. As an example,
experience thus, enabling them to train
one 800 MW boiler at CGPL Mundra
people in skills that are relevant to the
required around 32,000 high pressure
power sector and allied industries.
welding joints. CGPL has five such
Q10. What is your say on the future of Welding segment in India? Welding and welding skills will continue
boilers totalling to 160,000 welded joints.
Q8. Your say on Health and Safety?
to grow in demand. India is on a growth
These are apart from the other welding
Tata Power emphasizes safety as a core
curve with thrust on infrastructure,
requirements. Multiply these with the
value in everything it does. Training
energy, and construction sectors to
number of projects across industries,
and establishing a culture of safety is in
fuel and sustain our progress. Welding
across India and one gets an idea of
Tata Power’s DNA. TPSDI partners with
is an integral part of every industry in
the crucial part welding plays in the
Tata Power Corporate Safety to design
the manufacturing sector. While the
economy.
and deliver a series of SHE (Safety,
adoption of robotic welding is on the
Health and Environment) training and
rise, there is also a growing demand for
Q6. What are your efforts to boost the company welders? Do you offer any in-house training for upgradation?
certification programs. Tata Power
skilled welders that continues to grow
allows only SHE trained and certified
and must to be met. The organised sector
personnel on its various sites. TPSDI has
apart, the demand for skilled welders
trained and certified more than 20,000
is in the unorganised sector including
TPSDI trains company welders to both
people in SHE over the last three years.
the demand in the households and a
reskill and upgrade their skills. TPSDI
TPSDI courses weave safety as a core
large informal set up that exist as huge
also enables Tata Power to skill its
strand throughout the training. TPSDI’s
number of roadside garages spread
welders in different types of welding
welding courses also incorporate and
across the country.
www.weldfabtechtimes.com
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
45
TRAINING CENTER
Inauguration of NMAMIT-FRONIUS Centre for Welding Technology
T
he Department of Mechanical Engineering of NMAM Institute of Technology Nitte in association
with M/s Fronius India Pvt. Limited, Pune and with support from Indian Welding Society has established a centre for welding technology named “NMAMIT-FRONIUS Centre for Welding Technology”, which became operational on 28th June 2018. The centre was inaugurated by Sri S. Gopinath, Advisor NMAMIT & Adjunct Professor of Mechanical Engineering who is also the Former President of Indian
46
One-Day Workshop on “Welding for Maintenance” on 28th June 2018. representative Mr. Abhay Pai.
Welding Society and Former Executive
including Dr. G. Ravichandran- Adjunct
Director of BHEL Trichy, in the presence
Professor-NMAMIT and former General
of Dr. Niranjan N.Chiplunkar, Principal-
Manager-WRI Trichy, IWS resource
Maintenance under the auspices of IWS,
NMAMIT along with Vice Principals Dr. I.R
persons Mr. S. Singaravelu- Former
Fronius and IWS - NMAMIT Student
Mithanthaya and Dr. Shrinivasa Rao B.R.,
Additional General Manager of Welding
Chapter was organized by Department of
Registrar Sri Yogeesh Hegde, Special Officer
Research Institute Trichy and Mr.
Mechanical Engineering NMAMIT, Nitte
Sri Aravind Hegde, Dr. Sudesh Bekal-Dean
Srinivasan- Consultant from IWS. The
on June 28, 2018 in Phalguni Seminar Hall
R&D, HoD of Mechanical Engineering
event was also attended by Fronius
and the hands-on was held in NMAMIT-
Dr. Shashikantha Karinka, HoDs of
representatives Mr. Rahul Kulkarni -
FRONIUS Centre for Welding Technology.
other departments, faculty members of
Segment Manager, along with Mr. Rahul
The workshop was Inaugurated by Sri S.
Mechanical Engineering Department
Mehta joined by Fronius-Mangaluru region
Gopinath, Advisor NMAMIT & Adjunct
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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TRAINING CENTER
Fronius-Mangaluru region representative.
Professor who is also Former President of
was attended by faculty members of the
Indian Welding Society and also Former
Mechanical Engineering Department and
Executive Director, BHEL Trichy.
also by industry, academia and student
Workshop, out of which 10 were industrial
delegates.
delegates from major industries of the
Dr. Niranjan N.Chiplunkar, PrincipalNMAMIT presided over and explained
The Resource Persons consisted of Dr. G.
About 57 delegates took part in the
region such as MCF, Lamina, BASF, MRPL
about the importance of taking the
Ravichandran, Adjunct Professor-NMAMIT
etc, 12 delegates were academicians
activities of welding further through
who is also former General Manager-WRI
from engineering institutions and
smaller student work groups so that
Trichy and included the IWS resource
polytechnics of the region, 26 were student
the students are skilled enough with
persons Mr. S. Singaravelu, who is also
delegates and 9 were internal faculty
the basic welding needs. He also said
the former Additional General Manager
members. The topics covered are emerging
that the laboratory is in its first phase of
of Welding Research Institute Trichy and
trends in pipeline and casting repair and
development with only the basic needs
Mr. Srinivasan- Consultant from IWS. The
general welding processes, consumable
and would be developed further in due
technical resource persons’ support was
required for thin sheet welding, aluminum
course into an advanced centre of welding
also provided by Fronius India Pvt. Ltd
welding, stainless steel welding, alloy steel
technology.
through the representatives Mr. Rahul
welding, pre & post weld – heat treatment,
Kulkarni - Segment Manager and Mr. Rahul
hands-on on welding processes using the
Mehta along with Mr. Abhay Pai who is
Welding Simulator.
Dr. Shashikantha Karinka, Professsor and Head of Department of Mechanical Engineering and Convener of the Workshop, welcomed the gathering gaving an overview of the programme and activities related to NMAMIT-FRONIUS Centre for Welding Technology. He also breifed the delegates and informed them
Phone: 08258-281264 Fax: 08258 – 281265 DEPARTMENT OF MECHANICAL ENGINEERING
to enrol for life membership of proposed IWS-Mangaluru Centre of Indian Welding Society. Dr. Mallikappa, Coordinator of the programme proposed vote of thanks. The programme was compered by Mr. Baskar Achar P, Assistant Professor of Mechanical Engineering. The programme was attended by Vice Principals - Dr. I.R Mithanthaya and Dr. Shrinivasa Rao B.R. along with Dr. Sudesh Bekal- Dean R&D, Dr. Subrahmanya Bhat- Dean Student Welfare and HoDs of other departments. The event
48
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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WOMEN IN WELDING
Welding is not an exception… Q1. What made you choose welding as a career, which is a highly male dominated segment? My interest was slowly built in welding during the days when I was pursuing bachelors. I never considered welding as a male dominant field, it’s all about interest & preference. Women have time and again excelled in every field. Welding is not an exception. There are many Women who have established their selves well in this field which inspires me to become an expert in this field.
Q2. Could you brief us on your journey so far as Welding Engineer? The journey has just started. It’s a long way to go. From the day I joined INOXCVA, I got to learn various things such as knowledge of codes and standards, practical exposure to various welding processes, important aspects of welding etc, and I wish to continue that.
Q3. Could you quickly take us to your qualification background? I completed my graduation in Metallurgical and Materials Engineering
Jooi Bhatt, Welding Engineer, Inox India Pvt Ltd.
from Maharaja Sayajirao University of Baroda in 2016 & Masters in Welding Technology from the same institute.
50
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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WOMEN IN WELDING
at INOXCVA without a single helium
carried out on regular basis.
leak, which was appreciated by ISRO top officials. The vacuum chamber will be used for payload testing at SAC,
Q10. What kind of challenges do you come across and how do you manage to cope up with the same?
Q4. How much of total experience do you hold?
Ahmedabad.
I completed my 1 year dissertation work
Q7. Your current project.
Engineer. On field every day we face
at INOXCVA. After completion of my
I am currently working on projects for
new challenges. Coping up with the
Masters, I joined INOXCVA and currently
various applications including nuclear &
environment, trouble shooting, finding
working there since 6 months.
space.
the root cause of some technical issue
As we know, it takes a lot to be a Welding
are challenges for me. However, I am
Q5. Any welding processes you specialize into?
developing myself to deal with these
I believe welding is a vast field and being
Q8. When on site, what are the key points you follow for any project? Any suggestions.
a specialized in one particular welding
I believe, through understanding of
process is not just enough. As a welding
customer specification, knowledge
engineer, we should be conversant with
of codes and standards, good
Q11. Have you anytime faced gender discrimination, as the stream is male dominated?
all processes. However, I am working
engineering practices and compliance
Before joining INOXCVA, I have
with GTAW and PAW more since
of welding documents go hand in hand.
experienced gender discrimination,
beginning. Hence, I have little bit more
Synchronization of all these will lead to
as most of the companies prefer male
exposure to GTAW and PAW compared
good weld quality. On field, I need to be
employees over female ones. On the
to other welding processes.
focused keeping all these things in mind.
other hand, it is good that companies like
At site, effective man-management
INOXCVA exists who breaks this stigma.
and working against the adverse
I am thankful to them for giving me this
environmental conditions are keys to
opportunity.
Q6. Could you please share your experience of some of the mega project you worked upon?
challenges.
welding success.
Q12. What are your future plans?
During my working at INOXCVA, I had a
I have keen interest in material and
manufacturing of thermo vacuum
Q9. What is your say on health and safety in welding? How do you consider the same when on job?
chamber for space department. This
Health and Safety during welding is the
for defence and space requirements.
thermo vacuum chamber was 6.8 m Dia
key for safe working. At INOXCVA, we
made out of austenitic stainless steel
provide necessary PPEs to all welders
having around 250 opening. GTAW
and monitor the health of welders on
Closing message, especially to the female.
welding with control heat input was a
regular basis. For critical welding jobs,
There is nothing that a woman
major task. Chamber was fabricated
hazards are identified and analysis is
cannot do!
very good experience in understanding special welding process required for
www.weldfabtechtimes.com
welding and will like to work on exotic materials such as aluminium and titanium
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
51
INNOVATIONS
A fine-tuned laser welds more effectively By Rémy Nideröst, Swiss Federal Laboratories for Materials Science and Technology www.empa.ch
Using laser technology Empa scientists optimized a technique to weld the electronics of implantable pacemakers and defibrillators into a titanium case. The medtech company Medtronic is now using the method worldwide to produce these devices.
Cardiac pacemakers are usually housed in a titanium housing that is welded together from two parts. Empa has optimized the frequency of the working laser so that no black edges appear during welding, which would reduce the value of the medical product. Image: istockphoto
I
n Tolochenaz (Canton of Vaud) the
soot – extremely problematic for implants.
researchers demonstrated that the black
US medtech company Medtronic
Therefore, Medtronic’s Sébastian Favre
edge disappears if the laser is operated at a
produces one out of five heart
approached Empa materials specialists
different wavelength. Laser manufacturer
pacemakers available on the global market
Patrik Hoffmann and Marc Leparoux
IPG Photonics subsequently built a
and one out of four defibrillators. The
from the Advanced Materials Processing
fiber laser tailored towards the Empa
electronics of these implantable devices
Laboratory at the Thun site, who initiated a
researchers’ specifications and offered
are housed in titanium cases, which thus
project to optimize the new laser for usage
it for further tests. As these experiments
far were welded hermetically with a solid
with titanium. The project was funded by
confirmed, adjusting the laser frequency
state flash laser. However, the lasers are
Innosuisse, the former Commission for
indeed solved the problem.
high-maintenance and often the source of
Technology and Innovation (CTI).
Photonics jointly hold a patent for the
irregularities. Moreover, they require water cooling and take up a lot of space.
Titanium nanoparticles look black
optimized fiber laser. Medtronic benefits
In order to simulate production processes
from improved production processes
by US company IPG Photonics came
at Medtronic, Empa built its own «plant»
for its implants – at considerably lower
to the rescue: This fiber laser is cooled
to precisely analyze the behavior of the
costs. And Switzerland could confirm its
energy-efficiently using air instead of
laser in a controlled environment. The
status as a leading technology hub within
water, requires less maintenance, works
results revealed that an interaction with
the globally operating US multinational.
more consistently and is more compact.
the titanium vapor interferes with the
After all, the special lasers” made in
Initial tests conducted by Medtronic,
process: The black edge on the seams
Switzerland” are now being used at
however, revealed that the weld seams
turned out to be titanium nanoparticles.
Medtronic factories in Puerto Rico,
now have black edges that look a lot like
In follow-up experiments, the Empa
Singapore and the US.
A new type of laser launched in 2015
52
Meanwhile, Empa, Medtronic and IPG
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
www.weldfabtechtimes.com
CASE STUDY
Bogibeel Rail-cum-Road Bridge Bridging History
constructed over the Brahmaputra river.
Bridging River Brahmaputra has always
It is a double-deck bridge with a railway
been a daunting task. The river has
track on the lower deck and a road on
been traditionally considered extremely
the upper deck. It has a length of 2.284
difficult for bridging due to various
km and connects Jogighopa, a town of
reasons including it’s ferocious and
Bongaigaon District on the north with
unpredictable behaviour, high currents
Pancharatna, a town of Goalpara District
and turbulent waters, widespread erosion
on the south. This bridge was inaugurated
of the banks, very short working period
on April 15, 1998, by Atal Bihari Vajpayee,
and high seismicity and remoteness of the
the Prime Minister of India at that time. Recently built Dhola–Sadiya Bridge,
area.
also referred to as the Bhupen Hazarika
With the width ranging from 1.2 km to 18 km, Brahmaputra river has been
was opened to traffic in April 1962 by
Setu is the fourth bridge built over the
bridged four times in past. HCC holds
then Prime Minister Jawaharlal Nehru.
Brahmaputra river, connecting the
a distinction of building two of these
Recently, a new road bridge has been
northeast states of Assam and Arunachal
bridges and is now building the 5th bridge
constructed at Saraighat which is 1.49 km
Pradesh. The bridge spans the Lohit River,
at Bogibeel, near Dibrugarh.
long and inaugurated in 2017.
a major tributary of the Brahmaputra
Saraighat Bridge in Guwahati was the
54
Kolia Bhomora Setu at Tezpur was
River, from the village of Dhola in the
first rail-cum-road bridge over mighty
the second bridge constructed by HCC.
south to Sadiya to the north. At 9.15 km
Brahmaputra river in Assam. Although
This pre-stressed concrete road bridge
in length, it has the honour of being the
the first railway line in Assam came up in
connects Sonitpuron the north bank with
longest bridge in India.
1881, yet Brahmaputra was not bridged
Nagaon district on the south bank. The
by the British. It was bridged by HCC
length of this bridge is 3015 m, and its
Bogibeel Bridge
by building the 1.3 km long bridge at
construction went on from 1981 to 1987.
Bogibeel Bridge is a combined road and
Saraighat near Guwahati. This bridge
Naranarayan Setu is the third bridge
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
rail bridge in the Dibrugarh district of
www.weldfabtechtimes.com
CASE STUDY
Due to its location, the bridge will be of
five million people residing in Upper
strategic importance to India as it will
Assam and Arunachal Pradesh
significantly enhance India's ability to
Bogibeel is the fifth rail-road bridge on
transport troops and supplies to its border
the Brahmaputra river in Assam. Due to
in Arunachal Pradesh.
its location, the bridge will be of strategic
HCC in joint venture with DSD
importance to India as it will significantly
Brouckenbau GmbH, Germany and VNR
enhance India's ability to transport troops
Infrastructures Ltd received Rs. 987 crore
and supplies to its border with Tibet in
order from Northeast Frontier Railway to
Arunachal Pradesh. Being located in an
construct the superstructure of Bogibeel
area of intense rainfall, construction has
Rail-cum-road Bridge in November
been significantly challenges.
2011. HCC share in this order is 51%, DSD Brouckenbau GmbH 20% and
Rail connectivity
VNR Infrastructures Ltd 29%. Bogibeel
Bogibeel bridge will provide a connection
Rail-cum-road Bridge is a double decked
between the Rangia-Murkongselek
bridge having two railway tracks on the
section of the North East Frontier Railway
lower deck and a 3 lane road on the upper
on the north bank of Brahmaputra
deck flanked by footpaths on each side.
and Lumding–Dibrugarh section that
Highway alignment will meet the top level
lies to the south of the Brahmaputra.
of road deck of the bridge suitably beyond
A New Dibrugarh Railway Station,
the abutments while the rail alignment
expected to be the largest in the region,
will continue in the same line and level.
has been proposed and is to be linked to the Rangia-Murkongselek line via
the north eastern Indian state of Assam. When completed, the 4940.5 m long
Location
Chaulkhowa and Moranhat. The Railways
bridge will become the longest bridge of
The Bogibeel Bridge, situated 17 km
have initiated the gauge conversion of the
its kind in India.
downstream of Dibrugarh and Dhemaji,
Dhamalgaon to Sisiborgaon rail line to
The bridge will provide connectivity
spans the Brahmaputra river and will
the north of the bridge and commissioned
to nearly five million people residing in
connect the town of Dibrugarh in the
the 44 km Chalkhowa-Moranhat line to
Upper Assam and Arunachal Pradesh. It
south to Dhemaji to the river's north.
the south.
will also give easy and direct access to the
The bridge is located just over 20 km
upper Assam from the rest of the country
away from the Assam-Arunachal Pradesh
Project History
through the North bank, in contrast to the
border and is thus expected to act as an
The project obtained approval of the
current route through Guwahati in the
alternative to the Kolia Bhomora Setu,
federal Cabinet Committee on Economic
South bank -which is long and tortuous.
Tezpur in providing connectivity to nearly
Affairs (CCEA) in September 1997 and
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DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
55
CASE STUDY
construction began in April 2002. For the purpose of building the bridge,
using welding makes the connection between the components a permanent
Indian Railways had to construct the
one, thereby eliminating the above
expanse of the Brahmaputra river from 10
failures.
kilometres to 5 kilometres. This involved
The Bridge is a combination of fully
construction of ‘guide bunds’. The project
welded steel trusses and concrete. It
required about 505 hectare of land, which
spans 125m and has strong heavy box
was acquired across 19 villages. Major
sections throughout. It was difficult
earthworks and strengthening of the north
to turn and position the girder boxes
and south dykes were completed by June
at the construction site while welding
2011.
the joints so the company in charge of construction, HCC chose to implement
track was used to weld these butt joints
Contractors involved in the Bogibeel rail-road bridge:
GULLCO’s welding automation carriages
in vertical and overhead positions. The
to complete the GMAW welding process.
carriage is a portable, light-weight and
• The state-owned consultancy and
By incorporating welding automation
is easily mounted or repositioned to
project management enterprise
such as the KAT® all position welding
other weld joints by one welder. The
Rites (Rail India Technical and
carriage, HCC was able to produce UT
use of these carriages removes the
Engineering Services) undertook the
and MPT quality welds on site without
need of skilled welders and eliminates
pre-construction studies, geo-technical
having to worry about manipulating or
weld defects and costly repair work as
investigations and detailed design of
turning the heavy structures. They were
it ensures high quality and repeatable
the rail-road bridge.
able to achieve this because GULLCO’s
welds at increasing productivity through
carriages are designed for field welding
consistent arc on time. Mechanized
bunds and approach embankments on
applications and the equipment can be
welding makes the planning more
the south bank of the bridge.
installed directly onto the structure using
predictable, and, since it is less strenuous
• The contract for construction of
a modular system of track and mounting
for the welders, it helped this project
foundations and substructure of the
devices (most commonly magnets).
meet its production deadlines and save
bridge was awarded to Gammon India
The KAT® Oscillator carriage with rigid
money through welding efficiency which
• Bhartia Infra constructed the guide
can only be achieved through the use of
in April 2008.
automation.
• A joint venture of Hindustan Construction Company (HCC), Germany-based DSD Brouckenbau and VNR Infrastructures was awarded the contract to construct superstructure of the bridge in November 2011. • D&H Sécheron supplied SAW wire and flux.
Advantages of Welded Bridge Bogibeel is India’s first and only fully welded bridge construction. It is also for the first time European codes & welding standards were adhered to in the construction of a bridge in India. Normally in a steel bridge construction, bolts & rivets are used, which needs periodic replacement due to shear failure over traffic loads. Construction of trusses
56
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
SAIL steel for Bogibeel Bridge Steel Authority of India Ltd (SAIL) supplied around 35,400 metric tonnes of steel. This quantity is little more than 50% of the total quantity of steel supplied for the bridge. SAIL has also supplied TMT rebars, plates and structural for this 4.94 km long bridge, which has composite welded steel truss girders in its structures.
GULLCO’s KBM-28 bevelling machines also played a vital role for edge preparation of the plate used in the box sections. At a thickness of 8mm to 50mm, the bevellers produced clean machined bevels with no thermal distortion or heat affected zone. This meant that after the material was bevelled it was immediately ready for welding. Completing these bevels at a speed of 2m/min this cold shearing method of plate preparation is the most time efficient way of bevelling the plate and is 4 to 10 times faster than cutting or grinding and improves work environment by reduce noise and vibration. As more and more infrastructure projects like these get underway and the
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Needs Special Products
brings Technically Advanced Welding Products to Indian Industry from Global Leaders
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CASE STUDY
competition for these projects becomes
(GMAW). To ensure an error-free welding -
Launching: While determining the
increasingly more competitive, companies
Magnetic Particle Testing, Dry Penetration
methodology of erecting the steel trusses
will have to adopt automation into the
Testing and Ultra Sonic Testing were
on pillars, engineers had two choices —
planning phase in order to reduce cost
deployed. A specialized Beam making
lift the spans with floating cranes or erect
and increase price competitiveness when
CMM Machine from Italy is used for the
them with a launching truss. And they
bidding against others. The Bogibeel
first time in India for fabrication of Box and
have to decide based on which option
bridge is another great example of how
I-Sections using Submerged Arc Welding
would be proved more practical and
the effective use of welding and cutting
(SAW) procedure. A blasting gun was used
economical.
automation solutions can give you the
to achieve the surface roughness of SA 2½
productivity and quality necessary to meet
before applying paint. The Intermediate
the HCC team came-up with a solution
production deadlines and reduce costs.
and final spray coatings are performed in
of pulling the steel trusses with a set
a highly controlled climatic chamber with
of jacks and winches on the pillars.
spray guns.
This eliminated the need to enter the
Overall, welded bridge not only reduced the maintenance cost but also adds to
After weighing the pros and cons,
the longevity of the superstructure. It is
river, which was often turbulent during
estimated that Bogibeel Bridge is durable
monsoons. Besides, it also ensured
and serviceable for 120 years.
safer working conditions, precluded the mobilisation of giant setup on either side
Construction Methodology
of the river having a width of 4.8 km and
For the construction of this mammoth
accelerated the pace of the project. The
bridge, HCC has set-up huge facilities on
strategy is a testimony of the company’s
the left bank of the river that will have
value engineering, an important
three sequences of Fabrication, Assembly
feature of the globally-practiced ‘Lean
and Launching.
Construction’ that is changing the way projects are executed from design to
Fabrication: The Fabrication Shops
construction. A 1000 tonnes hydraulic jacks and
of 2000 MT per month capacity were set-up with two parallel Bays. The team
strand jacks linked with the substructures
had assembled customized platforms
were used for moving the steel truss over
in-house to fabricate and fit various
the pillars. Two sets of steel cable strands
joints employing Gas Metal Arc Welding
were anchored to the end cross beams of the Truss and hauled by hydraulic Assembly: Thereafter these fabricated sections are moved to the assembly shop where they are installed on their designated beds. They are guided to their correct positions through jacking and welded by GMAW process. These segments are arranged in a sequence and sent for the vertical assembly using horizontal lifters. After installation of the top and bottom girders, the final Truss Bridge Dimension Design Chambers are examined thoroughly and approved to complete the fit out. A Nose is fabricated and fitted on the first truss before launching it on the piers.
58
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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CASE STUDY
jacks. The Truss slides over the Launching
various transporters and modern tracking
testing and then shipped to Bhopal for
Bearing with the help of Sliding Plates,
systems. It allows a project manager to
the refitting of tested bearings and then
which were inserted at one end and taken
select the right transport mix to bring
finally shipped to project site. The lead
out at the other, thereby moving the Truss
heavy equipment or material to the project
time of such consignments is 6 months.
towards its desired position. In order to
site and improve delivery time. At the
Average daily consumption of welding
limit the required launching forces, the
Bogibeel Bridge project, the team used a
wire was to the tune of 2000 kg per day;
superstructure was pulled in 4 launching
combination of rail and road transport to
Grinding wheels around 5000 per day;
segments of 10 spans each. Thus the
deliver 80,000 tonnes of steel plates from
Argon + Co2 shielding gas more than 200
superstructure was pulled over the pillars
various parts of the country to the remote
cylinders per day; O2 cylinders around 500
just like a train of ten spans. With each
project site in Assam. The orders for extra
per day and around 50 BMCG cylinders
span weighing 1700 MT, the pulling
wide plates were placed in advance as
per day. Besides 4,50,000 Shear studs
force required was equivalent to pulling
per the design of the superstructure. In
were imported from Nelson, USA, (lead
26 Airbus A380 with maximum take-off
this way, the team avoided any possible
time of 3 months), High Strength Friction
weight over 650 tonnes, put together
mismatch of material and ensured
Grip bolts for around 7,00,000 quantity
without any wheels.
qualitative and timely execution of the job.
were manufactured at different sources
Finally, the launching bearings were
Steel plates and sections were procured
in India and Diamant MM1018FL gap
replaced by final bearings. The tracks were
mainly from three sources i.e. JSPL, Essar
compensation were imported from
laid and the road was constructed adapting
& SAIL. Of these 80,000 MT, approximately
Germany (lead time of 3 months).
RCC construction. After fulfilling the
20,000 MT (25% scope) was categorized
The team achieved perfect synergy
electrical and other ancillary requirements,
as ODC (Over Dimension Cargo) and
between each of these project element
the assignment was completed.
attracted special measures for transport
procurement and achieved uninterrupted
to the project site from the sources in
construction flow.
Supply-Chain Management
Hazira and Angul which were more than
Construction supply chain is a network
3200 km and 1800 km away respectively.
Most 2D Software
of suppliers, manufacturers, assemblers,
The average lead time of procuring these
The fabrication of various components,
sub-contractors, retailers, customers and
materials is 4 months. Procurement plan
using reinforcement bars and plates, has
other stakeholders. The main objective
was made according to minimum order
become an integral part of infrastructure
of effective supply chain management
quantity required for thickness-wise also
projects. Advanced software is used to
is to reduce the handling costs and
estimating future market price trends as
determine the optimum sizes of bars
on-site storage. Enterprise Resource
the order lot sizes ranges from 3500 MT to
and plates before procurement, thereby
Planning (ERP) solutions, such as
10000 MT.
reducing wastage and volume.
System Applications & Products (SAP), implemented at all HCC project sites offer
Spherical bearings were inspected
At the Bogibeel project, the HCC team
at Germany, shipped to China for load
used ‘Most 2D’ automatic nesting software
flexibility in material planning as per the
to generate efficient two-dimensional
construction sequence and help overcome
cutting plans for fabricating the steel
challenges during execution. This, in turn, minimises the idling time of equipment and material inventories and enhances the
Essar Steel for Bogibeel Bridge
efficiency of operations. HCC follows the Just-In-Time (JIT) inventory system where it produces or acquires materials and products as per demand. This is a key component of its supply chain. One of the major challenges at most construction sites is logistics management, which depends on the availability of
www.weldfabtechtimes.com
superstructure for the bridge. The nesting technology was based on advanced cutting algorithms specifically designed to optimise the cutting layouts in shearing.
Essar Steel is amongst the largest supplier of customised high grade heavy plates. The company bagged the order to supply 20,000 tonnes of high strength steel plates.
The software generates high-utilisation layouts, significantly reducing waste and maximizes productivity.
Spherical Bearings Railways have traditionally used steel rocker-roller bearings for bridges with larger spans. For the Bogibeel Bridge, the
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
59
CASE STUDY
Corrosion Protection Measures The superstructure of Bogibeel Bridge has
• And for Surface with concrete that is
been constructed using a special grade
Top Cross Girder a final coat of Metal
copper-bearing steel plates in order to
Spray Aluminum Coating was done
reduce corrosion. The average annual
again to ensure complete corrosion
relative humidity in Bogibeel is 90% which
protection.
goes up to 96% to 97%. To further reduce
• Hot Dip Galvanizing: It is the process
corrosions due to the excessive humidity,
of coating iron & steel with zinc, which
a complex Corrosion Protection System
alloys with the surface of the base
specific to different components of the
metal. It is done by immersing the
bridge has been implemented during the
metal in molten zinc at a temperature
construction of the bridge.
of around 840°F (449°C). Here a coating
• Metal Spraying – Aluminum: Thermal
of 250 uM was applied to the Stringers &
Spray, basically known as Metallizing; is a process in which metal is melted
Bracings of the bridge. • Also, all enclosed spaces were sealed
and directly sprayed onto the surface
by welding and were vacuum tested so
of another metal to protect against
that no air can go inside and initiate
initial plan was to use Pot-PTFE bearing
corrosion, heat, traction, etc. Aluminum
corrosion.
with metallic pins and guide bearings.
(Al) provides excellent corrosion
However, it was found out that the size of
resistance properties. TSA coating
Seismic Restrainers
bearing required for taking the anticipated
provides enhanced shelf life, maximum
Location of Bogibeel Bridge falls in Seismic
load cannot be accommodated in the pier
corrosion protection and very less
Zone-V. In Indian history, Zone V has
cap, hence Spherical Bearings have been
curing time compared to painting. This
been most vulnerable to earthquakes
used.
method was used for the Gusset Plates
with magnitudes in excess of 7.0. In order
and Brackets.
to offer good stability to the heavy spans
Spherical Bearing is designed to carry combinations of vertical loads, horizontal
• For the Exterior of Bottom Chord,
loads, longitudinal and transversal
Bottom Joint & Bottom Cross Girder,
movements and rotations. They are used
Hot zinc spray has been carried out
in steel and concrete road and railway
as a primer then Epoxy with MIO
bridges. These bearings are made of steel
& TIO2 coating on it and Aliphatic
elements coupled with a PTFE surface to
Polyurethane coating has been carried
allow movement and rotations. One side of the internal median plate is machined
that is the Top Chord and Top Joint, Metal Spray Zinc Coating of 80uM has
side, a flat sliding surface is obtained to
been carried out. Top Cross Girders and Diagonals a primer of Inorganic Zinc Silicate having
EN- 1337 have been used in the Bogibeel
an intermediate coat of Epoxy with MIO
Bridge. A Total of 164 such bearings have
and a top coat of Aliphatic Polyurethane has been carried out.
span is supported by 4 Spherical Bearings.
• For Interior of Bottom Chord, Bottom
These bearings had been manufactured by
Joint, Top Chord, Top Joint, Top Cross
M/s. Maurer AG, Germany in accordance
Girder and Diagonals, a primer of
with the design finalized and approved by
zinc-rich epoxy having an intermediate
Ramboll / RITES.
coat of PVC with MIO and a top coat of
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
This arrangement works like male &
• For Exterior of Top Chord, Top Joint,
system as per European bearing standard
been used to construct the bridge. Each
restrainers.
out on the top of it.
movement (rotation) whilst on the other
Spherical Bearings with 4 support
(1700 MT), they are provided with seismic
• For Surfaces in contact with concrete
as a spherical surface to allow tilting
allow displacements.
60
Water-based Polyurethane was applied.
www.weldfabtechtimes.com
CASE STUDY
female connection with female pockets
Km. Also, the train journey between Delhi
Economic Benefits: The Bridge, by
embedded on to piers and male parts
and Dibrugarh will also come down from
connecting two very important highways
arrangement on the span. For precise
37 hours at present (via Guwahati) to 34
of Assam namely the NH37 and NH52,
lowering of the span such that male joint
hours – a reduction of 3 hours.
will contribute in enhancing the intra-
fits into the female connections before
state and inter-state trade ecosystem. At
the final lowering of the span on the
Direct Access to Districts of Upper Assam:
present, any cargo generated on both the
permanent bearings, HCC team devised
The bridge will provide direct access to
sides consumes at least 10 to 12 hours
a unique circular slider frame made of
the districts of Upper Assam from the rest
before it reaches its destination.
stainless steel with jacks arrangement.
of the country through the North bank
With this, the exact movement to fit the Seismic restrainers and final lowering of
The Bogibeel Rail-Road link will
and will do away the need to take tortuous
significantly reduce this trans-shipment
route through Guwahati in the South bank.
time and will take maximum 2 hours,
the heavy spans on permanent bearings
thus saving the unnecessary extra cost of
were achieved at Bogibeel Rail-cum-Road
Boost Tourism: Tourist places of
Bridge.
Arunachal Pradesh will become more
transportation and time too.
accessible and give a fillip to the tourism
Benefits of the Bridge
industry. The bridge will also cut down the
Defense Boost: The Bogibeel Bridge will
distance to the border with China by 10
be a big boost for the defense forces as it
hours.
D&H Sécheron: An exclusive supplier of SAW Wire & Flux
will provide rapid connectivity to areas near the India-China border. This means
Better Medical Facilities: Dibrugarh
quicker movement of troops and heavy
district also houses prestigious Assam
weapons systems.
Medical College. The bridge will benefit the intra/inter-state transportation of
Time Savings: Bogibeel Bridge’s biggest
medical patients seeking treatment in
benefit is the time that it is going to save.
Dibrugarh. Currently, if any emergency
As of now a train journey from Arunachal
of super speciality kind arises along the
Pradesh to Assam’s Dibrugarh requires
northern bank, the patients need to rely on
a 500 km detour via Guwahati. Now, the
boat ferries for transportation which can
journey will be reduced to less than 100
be very cumbersome and dicey.
The Bogibeel Bridge Super Structure was welded with D&H Sécheron's exclusive SAW wire and flux. During 2012, the company received its first enquiry for application. After several meetings with the HCC-HO, and HCC-Dibrugarh (Assam) and also the QC Head’s visit to D&H Sécheron's Indore plant, the product was approved. Thus, till 2018, the company supplied around 425 tonnes of Grade A wire & SAF2 Flux, and Grade F Wire & SAF 223 Flux for the project. D&H Sécheron spokesperson said, “Its gives us a proud feeling for partnering such a unique Two Tire bridge project in India, which is around 5 Km long.”
www.weldfabtechtimes.com
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
61
WELDER’S PASSION
“The old items carried a history with them, & I was inspired to use them in new ways, to create them a new story.” Author: Brian, Welder
Q1. Tell us about yourself? I was born near Portland, Oregon, USA and have lived here my whole life. I’ve been a professional sculptor for the last 18 years, specializing in welding reclaimed materials. In my free time I enjoy painting, hiking our local trails and spending time with my wife and kids.
Q2. How did you develop the art of welding? What made you choose welding as a career? I’ve always loved creating and trying new mediums- painting, drawing, woodcarving. About 20 years ago I thought I’d give metalworking a try, so I taught myself how to weld, mostly by trial and error. Scrap metal was good to practice with (it was cheap and available) and soon I began to realize it was also really interesting material. The old items carried a history with them, and I was inspired to use them in new ways to create them a new story. This type of welding became my passion, so I quit my full-time job in the printing industry and focused on building myself a new career around doing what I loved.
Q3. Please brief us on your current business model?
64
world- from galleries and museums to
I also have a life-size grizzly bear in the
hotels and airports.
works, along with a 6 ft H face for a luxury hotel.
I’m usually booked with commissions 6-8
Q4. What type of project are your currently working upon?
months out. I have an excellent business
I have a few exciting projects lined up.
manager who handles the administrative
Right now, I’m working on an installation
Q5. Can you describe on some of the mega projects you worked upon in the past?
duties that come with owning a business,
piece for Delta Airlines: an Austin, Texas-
One of my biggest projects was a 10 ft H
giving me the freedom to just focus on
themed pair of cowboy boots for their
sculpture of Paul Revere on his horse for
the art. We have clients from all over the
lounge in the Austin International Airport.
the Revere Hotel in Boston, MA. I consider
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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WELDER’S PASSION
install. It was the only time I shipped a
Q8. What challenges do you come across when at work? How do you manage to cope up with the same?
Q11. What is your greatest strength, and how does it help you as a Welder?
completed sculpture in 4 sections, then
Working with recycled material can be
I think my greatest strength is that I
flew across the country to assemble it on
challenging at times because I’m limited
believe I can create anything. Sometimes
site. I had it all worked out in my head,
to using only what I have on hand.
a client will ask for something crazy, or
but didn’t get a trial run, so I was relieved
Sometimes I think about how much easier
something I’ve never done before, but I’ll
when it all went as planned in one try.
my job would be if I could go out and buy
always tell them I can do it. Sometimes
the specific material I may need. In my
my wife looks at me like, “Are you sure
Q6. Please describe on the most unique and interesting project? Why?
case, though, if I can’t find a piece I need,
you can do that?” But as a sculptor and a
I have to make it with what I have. This is
welder, I think having the confidence to
It’s hard to pick one since I really pride
challenging, but it also makes the finished
take on any job has pushed me to stretch
myself on the uniqueness of each
work that much more gratifying.
and develop my skills in ways I wouldn’t
this project mega not because of its size, but because of the logistics it took to
otherwise have, and has helped me
sculpture I create. I love that no two
prove to myself that I actually can make
collection of what’s on hand at the
Q9. Your say on the Safety at Work. How do you consider the same when on site?
time, and each includes unique and
Safety should be taken seriously in
intentionally placed objects. I’ve also
any hazardous, potentially dangerous
started putting a personal item in all of my
profession, and it’s a top priority in
Q12. Can you please share an incident of a toughest welding job you have come across?
sculptures, sort of like a hidden signature,
my shop. I did a lot of safety research
I made a life-sized lion once, and its mane
making them even more unique. It could
and studying before ever touching a
was probably my toughest job so far. I
be a broken tool, an old phone, even a
welder, and I always recommend taking
unwound steel cable to use as the hair,
worn-out glove. It’s my way of putting an
a welding safety class. There is a lot
and it took some arduous cutting, tedious
actual piece of myself into my work, and
of important things to know as far as
hours of welding the strands together, and
creating a true one-of-a-kind sculpture.
proper ventilation, proper attire, proper
meticulous placement, to end up with a
So, to answer your question, I guess all of
practice…it never hurts to know too
full, realistically flowing mane.
them are the most unique to me.
much about safety.
Q7. How has been the response to your creative products so far? I’m grateful for all of the positive feedback
Q10. Any anecdotes you wish to share to support the importance of safety for welders?
Q13. Right from the time you started your career till date, what has been your learning so far? Any new skills you have learned?
my work has received over the years. I
I’ve been to the emergency room a few
I am constantly learning about ways
think this type of art is fun for viewers
more times than I’d like to admit, mostly
to develop my craft, about the newer
because it’s interactive- like a 3D “Eye-
for shards of metal in my eyes, so I can’t
technology in welding, and about
Spy” game, where people search for
stress the importance of eye protection
balancing my business and life. I’ll always
recognizable items. I’ve been able to
enough. And, of course, like many
be learning, and I love that.
support my family with my art, and that’s
seasoned welders, I have a few good burn
really the best response I can ask for.
scars that tell their own stories.
sculptures I make will, or can, ever be the same. Each is made with the random
anything. (So far.)
Q14. What are your future plans? I plan to keep creating, to keep growing my business, and to keep developing as a welder and an artist. I hope my work encourages people to stop and engage- to look closer at the items they recognize and reflect on the possibilities of reuse in their own lives.
66
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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EVENTS UPDATE
NATIONAL
68
Event
Date
Address
Organiser
MESSE Cutting & Welding
21st - 23rd March, 2019
Hitex Exhibition Centre, Hyderabad
Indmesse Trade Fairs
Indus-tech Industrial Expo
08th - 10th March, 2019
Mela Ground, Bhiwadi, India
BLECH INDIA 2019
25th - 27th April, 2019
Bombay Convention & Exhibition Centre (BCEC)
Inter Ads - Brooks Exhibitions (India) Pvt. Ltd
CWE 2019
20th - 22nd September, 2019
Bombay Exhibition Center
ITEI
WorldBuild India 2019
25th - 27th April, 2019
Bombay Exhibition Center
ITE
5th Smart Cities India 2019
22nd - 24th May, 2019
Pragati Maidan in New Delhi
Exhibitions India Group
India Machine Tools Show IMTOS
14th-17th June, 2019
New Delhi, India
IMTMA
Delhi Machine Tool Expo
4th-7th July, 2019
Pragati Maidan in New Delhi
Indian Machine Tool Manufacturers' Association
WeldExpo
4th-7th July, 2019
Pragati Maidan in New Delhi
Indian Machine Tool Manufacturers' Association
BLECH INDIA 2019
25th-27th April, 2019
Bombay Convention & Exhibition Centre (BCEC)
Inter Ads - Brooks Exhibitions (India) Pvt. Ltd
INMEX SMM India 2019
03th-5th October, 2019
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
Hamburg Messe und Congress GmbH
www.weldfabtechtimes.com
EVENTS UPDATE
INTERNATIONAL
70
Event
Date (2018)
Location
Organiser
Welding Eurasia
14th - 17th Mar 2019
Tuyap Exhibition and Convention Center, Büyükçekmece, Turkey
Hannover Fairs Turkey Fuarcilik A.S.
Metalworking Welding Monitoring and Diagnostics
20th – 22th Mar 2019
IEC Ekaterinburg-Expo (Ekaterinburg-ekspo), Yekaterinburg, Russia
Perm Fair
Welding
26th - 28th Mar 2019
Targi Kielce, Kielce, Poland
Targi Kielce
Welding & Cutting
09th – 12th Apr 2019
Minsk Marriott Hotel, Minsk, Belarus
Minsk Expo
Welding Incheon Korea
22nd – 23rd May 2019
Songdo Convensia (Songdo ConvensiA), Incheon, South Korea
Metal Network Korea Company
Beijing Essen Welding & Cutting Fair
25-28 Jun 2019
Guangdong Modern International Exhibition Center, Dongguan, China
Chinese Mechanical Engineering Society
INA WELDING
28th - 30th August 2019
JIExpo Kemayoram, Jakarta Indonesia
GEM Indonesia
Philweld
28th – 31st August 2019
World Trade Center Metro Manila, Pasay, Philippines
Environmental XPRT
Hi Welding & Production Equipment
01st – 03rd Oct 2019
MCH Messecenter Herning, Herning, Denmark
Messecenter Herning
Weldex
15th – 18th Oct 2019
Sokolniki Exhibition and Convention Centre, Moscow, Russia
ITE Moscow
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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POST EVENT
Panasonic Welding Systems India supports AOTS(Japan) & CII(India) to organize Technical Seminar and Workshop on “High Precision Arc Welding Technology in India”
A
OTS, Japan (Association for Overseas Technical Cooperation and Sustainable Partnerships)
and Confederation of Indian Industry, India (CII) organized a technical seminar and workshop on High Precision Arc Welding Technology at Jamshedpur on 13-14 December. The seminar was organized at Hotel Alcor, Jamshedpur and the practical demonstration of Japanese latest welding technology was conducted at Indo Danish Tool Room (IDTR), MSME Tool Room, Jamshedpur on both the days. The training program at Jamshedpur was funded by Ministry of Economy Trade and Industry, Japan
Engineers Pvt Ltd, Ms Yukari Saisho,
this initiative is expected to foster the
(METI). This was 3rd and last METI
Program Coordinator, AOTS Japan & Mr
growth of personnel engaged in the
supported training program scheduled
Masafumi Himeno, Divisional Director –
manufacturing sector, Welders and
in this year. First program in this series
Smart Factory Solution (SFS), Panasonic
Welding Technologists in particular.
was held at Chennai (22-23 Aug 2018)
India Pvt Ltd.
and 2nd at Ahmedabad (23-24 Oct
Mr Masayuki Taga said he was happy
2018). Panasonic Welding Systems
to promote Japan’s latest high-precision
to welcome the Japanese delegates to
was an Industry Partner by providing
welding technology into India. The
the Eastern part of India. He added that
lecture and practical demonstration on
eminent faculty included Prof. Manabu
more than 1400 Japanese companies
latest welding Equipment and Robot
Tanaka (Joining & Welding Research
are operating in India out of which 700
technology to improve productivity of
Institute – JWRI, Osaka University,
plus companies are from manufacturing
Indian metal fabrication industry. Other
Japan), who delivered valuable lecture
sector. He stated that most of the
industry partners were Kobelco Welding,
on importance of high precision arc
Japanese companies are based in North,
Japan (welding consumables) and
welding technology and trends in new
West and Southern part of India but a
Iwatani Corporation, Japan (shielding
technology—Welding Mechanics and
few good Japanese companies are based
gas).
Design for Smart Manufacturing and
in and around Jamshedpur e.g. Tata
Mr Masaharu Sato, (Japan Welding
Hitachi.
Some of the key dignitaries present
72
The 2 day seminar served as a platform
Expressing his views on the occasion,
He said Government of Japan is
at the occasion were (Chief Guest)
Engineering Society-JWES, Japan), who
Mr. Masayuki Taga – Consul General
covered topics including the importance
committed to support the “Make in
of Japan in Kolkata, Mr Tapas Kumar
of welding quality control, certification
India” initiative and “Made in India”
Sahu, Convenor, CII Jharkhand MSME
systems as practiced in Japan. With an
mission by continuing these kind of
Panel, Executive Director & CEO, Highco
aim to support ‘Make in India’ vision,
workshops. Japan has already started
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
www.weldfabtechtimes.com
POST EVENT
taking significant measures to improve the human resource in India and we shall continue to support such kind of initiatives in India. Ms Yukari Saisho, AOTS stated “It is my great honor to deliver a speech on behalf of The Association for Overseas Technical Cooperation and Sustainable Partnerships (AOTS) at this Seminar and Workshop, which is funded by the Japanese Ministry of Economy, Trade and Industry (METI), which hope to assist the industrial structure and business environments in India by sharing the Japanese system, technologies and know-how, all of which have been proven effective for the economic growth of Japan.She informed that AOTS works from past 59
currently going through infrastructure
years globally and is into designing with
mode and there is going to be drastic
various industries.”
increase in steel consumption from
that understanding of welding
current 100 Million tonne per annum
technology is the most critical aspect.
Japanese technology is an ideal example
to 300 Million tonne by 2030 as per
He also explained that analysing
of best manufacturing practice giving
National Steel Policy (NSP) 2017. Steel
and contributing to the country’s
world “zero defect” principle. He also
is the foundation of infrastructure
manufacturing sector and taking it to the
said that “Welding” is most important
and proper welding is the foundation
highest potential level must be the only
event in one’s life and “Welding” is
for steel use. He also stated that He
agenda of this mission and forward.
most important event in metal working
has been a user of Panasonic welding
technology and both must be handled
robot and this robot is very helpful to
was attended by more than 130 nos. of
with care. He also said that India is
increase production speed and maintain
participants from companies like Tata
Mr Tapas Kumar Sahu informed that
consistent quality. Mr Masafumi Himeno said
The Technical workshop and seminar
Steel Ltd, Tata Motors, Tata Hitachi, Hyva India, Highco Engineers, ISWP, The Tata Power Company, TRF Ltd., Utkal Automobiles, RSB Transmissions, Maruti Suzuki, Indico Motors to name a few and institutes like Indo Danish Tool Room, MSME, Jamshedpur & Ranchi, NTTF Jamshedpur, NSTI Jamshedpur & NSTI Kolkata.
For More Info: Panasonic India Tribhuwan Joshi Tel: +91-9650111769 Email: tribhuwan.joshi@in.panasonic. com
www.weldfabtechtimes.com
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
73
SECTOR WATCH: AUTOMOBILE
By 2026, the Indian Automotive segment to surpass China & US Market Outlook The year 2018 turned out to be a mixed package for the domestic automobile industry. The Year End Review 2018 by the Ministry of Heavy Industries & Public Enterprises pointed out that the sector had attracted $16.5 billion in foreign direct investment (FDI) between April 2000 and December 2016. Out of total production volume in FY18, 81% was contributed by two wheelers, 3% each by three wheelers & commercial vehicles, while 13% was shared by passenger vehicles. Budget 2018 brought a major boost to the automotive and autoancillary industry. This year 2019, is also expected to continue on a better platform For Budget 2019. The automotive industry
infrastructure cess of 1 to 4%. The Indian Automobile sector is
Today, India is one of the most important markets for various overseas
has also proposed the government to give
expected to attract $8-10 billion more in
automakers, which includes largest
up multiple tax rates for passenger cars.
local and foreign investments by 2023.
market for Suzuki Corporation as it gets
In the past five years of Modi government,
The plan envisions that by the year
over 50 per cent of its business share
the taxes on small cars have been hiked
2026, India will be the third in the world
from here. For Honda, India is one of
from 10% to 12.5%, while for SUVs and
after China and USA in engineering,
the biggest markets in two-wheeler
large cars the taxes have been raised to
manufacturing and export of vehicles and
space, while for cars also it contributes
the highest GST slab rate of 28% besides
auto components.
substantially. The other most favourable part for India is increasing software content in the automobiles. India is emerging as one of the largest exporters of connected and software solutions for automobiles. A number of manufacturers are setting up their backend for research and development to support their global markets for this. The automobile industry is supported by various factors such as availability of skilled labour at low cost, robust R&D centres and low cost steel production. The industry also provides great opportunities for investment and direct and indirect employment to skilled and unskilled labour.
76
WELDFAB TECH TIMES | DEC 2018 - JAN 2019
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SECTOR WATCH: AUTOMOBILE
MIG-O-MAT
Turck
M
associated automation solutions. The process areas include
T
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Welding, and Automatic Welding Systems. The company
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sample welding, small series welding up to the serial start of the
the body and assembly, body in white, stamping, and powertrain
product.
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IG-O-MAT’s focus of the plasma welding is the application in the automotive field. Here, the company offers various process areas as well as the
he automotive industry demands robust products
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solutions - including sensors, industrial cordsets, distributed I/O products, and RFID - Turck is ready to tackle whatever automation challenges you are facing. Nuts are often welded onto metal parts to permanently attach components, but optoelectronic sensor technology for the detection of nuts often fails due to light reflection or oil film on the lens. The solution is Turck's unique welding nut sensor, which inductively detects For More Info:
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Turck www.turck.in
ukane is a global provider
of plastic welding
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engineers its TOUGH GUN™ and TOUGH GARD™ products to
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TOUGH GUN™ Robotic MIG Guns, TOUGH GUN I.C.E.™
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Dukane
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www.dukane.com
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equipment designed to provide professionals in the automotive industry
www.weldfabtechtimes.com
regaskiss is an industry leader in the development and manufacture of robotic MIG guns, peripherals and welding consumables. With over 20 years of experience
specializing in customized robotic welding solutions, Tregaskiss
DEC 2018 - JAN 2019 | WELDFAB TECH TIMES
77
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