EDITOR'S DESK
WELDFAB TECH TIMES www.weldfabtechtimes.com
Publisher & Editor Eliza Bhalerao eliza@weldfabtechtimes.com Group Managing Editor Amol Bhalerao amol@weldfabtechtimes.com Assistant Editor Marilyn Dias editorial@weldfabtechtimes.com Business Development Manager Monica Waghmare monica@weldfabtechtimes.com Designer Deepa Warang design@weldfabtechtimes.com Advertisement marketing@weldfabtechtimes.com Mob : +91-9975580309 Subscription subscription@weldfabtechtimes.com Mob : +91-9730904259
WELDFAB TECH AWARDS 2019 Dear Readers, WeldFab Tech Times, India’s only Welding Magazine feels delighted to announce ‘WELDFAB TECH AWARDS 2019’ introduced exclusively for the Welding Segment. For the 1st Time in India, an award is awaiting for the Welding Industry. The objective of WELDFAB TECH AWARDS 2019 is to Encourage and Reward the welding segment for their Excellence and Innovations. WELDFAB TECH AWARDS 2019 is an impartial, well researched and
EAA Publication Registered Office : Gauri Estate, Ekdant, B-3/503, Near Gauri Hall, Manjarli, Badlapur ( West ) - 421503. Dist. - Thane. State - Maharashtra, India. Mob: + 91 9975580309 / 9172546460 Email: eliza@weldfabtechtimes.com / eliza.weldfabtechtimes@gmail.com Website: www.weldfabtechtimes.com All rights reserved. While all efforts are made to ensure that the information published is correct, WeldFab Tech Times holds no responsibility for any unlikely errors that might occur. Printed, Owned & Published by Eliza Amol Bhalerao on behalf of EAA Publication, Printed at Printpoint Shop no - 5, Ground Floor, Sangeeta Skill Mill, Press bazaar, Near Shivaji Chowk, Opp. Bharat Green Lawn, Ulhasnagar - 421003 and Published from B-3/503, Ekdanth, Gauri Estate, Near Gauri Hall, Manjarli, Badlapur (W), Dist.: Thane – Ulhasnagar - 421503, Maharashtra, India. Editor: Amol A. Bhalerao The information on products on offer is being provided for the reference of readers. However, readers are cautioned to make inquires and take their decision on purchase or investment after consulting experts on the subject. WeldFab Tech Times holds no responsibility for any decision taken by readers on the basis of information provided herein.
4
WELDFAB TECH TIMES | FEB - MAR 2019
self - nominated event, with decisions from the expert jury members. The awards will be presented on 14th September 2019 in Mumbai. Nomination process will be online, starting from 15th April 2019 till 31st July 2019. So grab this opportunity!!! Nominate yourself and your company. You deserve to be a part of WELDFAB TECH AWARDS 2019. Best of Luck… Thank you.
Eliza Bhalerao Publisher & Editor
www.weldfabtechtimes.com
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TAKING WELDING INVERTER TECHNOLOGY TO THE NEXT LEVEL
CONTENTS 6
INNOVATIONS
18
Novarc Increases Autonomy of its Spool Welding Robot with breakthrough Noveye™ Software Product
ARTICLE
19
32
Welding and Post Weld Heat Treatment of WB 36 Steel
Increased Productivity in GTAW
INDEPTH
29
WELDFAB TECH TIMES | FEB - MAR 2019
36 Fumes, Health & Safety in Arc Welding
INTERVIEW
44
Thick metal sheets? Laser welding!
“ISO 3834 is not ‘Quality Management Standard’ that replaces....
www.weldfabtechtimes.com
CASE STUDY
50
The Multi-purpose Fast Neutron Research Reactor (MBIR)
LAUNCHES
TRAINING CENTER
34
54
Nitty Gritty Stainless Steel Weld Cleaners
WELDER’S PASSION
WELDING TIPS
08 24 58
EVENTS UPDATE
60 56
BULLETINS PRODUCTS UPDATE
www.weldfabtechtimes.com
Okanagan College powers up new welding building in Penticton
‘’There is always a scope for improvement & learning.’’
FEB - MAR 2019 | WELDFAB TECH TIMES
7
BULLETINS
Hypertherm to take legal actions against fake product
H
ypertherm, a U.S.
year of investigative work
that are difficult to correctly
counterfeiters are often
based manufacturer
and the involvement of law
replicate. As a result, customers
very good at mimicking the
of industrial cutting
enforcement from two Chinese
who unknowingly purchase
exact appearance of original
systems and software, is
provinces. In addition, police
these counterfeit products
products, mistakes are
pursuing legal action against
were able to seize a list of
will not achieve the same
sometimes made. Another
four manufacturers and
companies conducting business
consumable life or performance
warning sign is poor or
distributors of counterfeit
with the illegal manufacturers.
as the genuine product and are
inconsistent consumable
at risk.”
performance compared to what
product following four
To ensure you do not fall
you are used to.
separate raids, the arrest of five
Hypertherm is concerned
executives, & the seizure of tens
about the impact and safety
victim to counterfeiting,
of thousands of dollars offake
risks of counterfeit product
Hypertherm recommends
distribution partners is
Hypertherm consumables.
on our business & customers
customers only buy product
available on Hypertherm’s
and is committed to disrupting
from approved and authorized
website at www.hypertherm.
last year in China’s Changzhou
the illegal manufacture of
distributors, and exercise
com. If you suspect you are a
province, involved two of the
products that adversely
caution when coming across
victim and need help verifying
world’s largest manufacturers
impact the performance of our
abnormally low prices for
whether your consumables are
of counterfeit product and
systems,” said Brett Hansen,
“genuine” consumables and
genuine, please visit https://
their principle distributors
Hypertherm’s Intellectual
software especially when
www.hypertherm.com/en-US/
making this the biggest anti-
Property Manager. “Our
purchasing online. In addition,
customer-support/getting-the-
counterfeiting operation in
consumables are manufactured
carefully check the appearance
most-from-your-products/
Hypertherm history. The
to strict specifications and often
of consumables and packaging
counterfeit-consumables to
raids followed more than a
contain patented technologies
for discrepancies. Though
submit a report.
The action, conducted late
8
“Like nearly all companies,
WELDFAB TECH TIMES | FEB - MAR 2019
A list of the authorized
www.weldfabtechtimes.com
BULLETINS
Mazak to invest $8.5 mn in Kentucky mfg operations
W
ith an aggressive
six of Mazak’s most advanced
Multi-Tasking Machine
extremely productive Mazak
plan in
machine tools and several
and one MAZATEC Smart
iSmart Factory,” said Dan
place, Mazak
Mazak SMOOTH Technologies
Manufacturing System (SMS).
Janka, president of Mazak
Corporation has announced
– all of which will allow the
The machine tools all feature
Corp. “At the heart of that
that it will invest $8.5 million
company to satisfy growing
MAZATROL SmoothG control
forward-thinking concept
in new manufacturing
customer demand and
technology that is expected
are plant-wide connectivity,
technology for its Florence,
provide the shortest possible
to help further increase part
automation and optimized
Kentucky, Mazak iSmart
turnaround times.
production speed by as much
production flow that allow
as 30 percent.
us to significantly increase
Factory operations. The
With an expected
machine utilization, shorten
“Mazak continuously
investment encompasses the
completion date of late 2019,
installation of a new state-
the new cell will entail two
invests in its North American
throughput times, eliminate
of-the-art manufacturing
HCN 6800 and three HCN
operations, which have
non-value-added operations
cell with fully automated
8800 Machining Centers
grown and advanced
and process parts more
storage and retrieval system,
and an INTEGREX e-1250V
into a sophisticated and
efficiently.”
CWE | IMEX 2019 now in Mumbai
T
he 9th edition of CWE
this leading business event has
advancements. The event has
| IMEX EXPO 2019,
become the perfect platform
established itself as a ‘Business
is being hosted by
for showcasing the entire
Festival of the Cutting,
ITEI - The Indian subsidiary
spectrum of products and
Welding & Laser Industry’ and
of ITE Group PLC (UK)
services relating to the cutting,
supports the overall growth of
welding, laser and allied
manufacturing & fabricating
industries.
industry in the country.
from 20th-22nd September 2019 at Bombay Exhibition
welding automation, welding
Centre, Mumbai, India. It is
consumables, laser technology,
supported by reputed industry
materials testing, non-
international events have
Block your dates for this
associations and the 'World
destructive testing, machine
played a major role in
Mega Business Festival.
Metal Forum'.
tools and allied industries.
showcasing the strength of
For more info: Log on to
It is the only comprehensive
the Indian Cutting, Welding,
renowned series of exhibitions
business platform serving
Laser and allied Industry by
focusing on cutting &
the cutting, welding & laser
attracting global attention
welding technology, robotics,
industry and over the years,
to these technological
It is an internationally
CWE | IMEX series of
www.cweonline.in www.imexonline.com call:+91 9911185378, +91 9654393213
Tech Air acquires Penn. welding supply company
T
ech Air, a Danbury-
Propane Service Corp.,
as installation and repair
headquartered
based in Collingdale,
services. The terms of the
distributor of
Pennsylvania.
transactions were not made
industrial, medical, and
Scully services the greater-
public, and the acquisition is
specialty gases and related
Philadelphia region with
the 27th add-on acquisition
equipment and supplies,
residential and commercial
for Tech Air since it was
acquired Scully Welding
propane, industrial gases,
bought by the private equity
Supply Corp. and Scully
and welding supplies, as well
firm CI Capital in 2011.
www.weldfabtechtimes.com
Source: www.mazakusa.com
FEB - MAR 2019 | WELDFAB TECH TIMES
9
BULLETINS
TRUMPF benefits from e-mobility
Source: www.trumpf.com
A
t the recent
thing now is to rapidly address
Automotive
the new areas of business
Photonics technology
and technology that are
conference in Ditzingen,
emerging from this structural
auto industry representatives
transformation.” TRUMPF
presented the very latest
expects further growth for its
e-mobility technologies and
own business as a result of
manufacturing methods. One
the change in the automotive
of TRUMPF’s key contribution
industry. The company’s sales
is a new laser that is better
of products and solutions
suited to welding copper
that are channeled straight
than any other laser – a key
“Photo: TRUMPF”.
into e-mobility have doubled compared to figures for the
development driven by TRUMPF laser specialists
in the e-mobility sector. The
toward e-mobility offers
previous year. “Twenty percent
as part of the company’s
new laser offers a more efficient
some major opportunities
of our order intake from the
e-mobility strategy. Regarded
means of welding copper for
for German industry,” said
auto industry is now coming
as the most important material
applications such as the high-
Christian Schmitz, Head of
from e-mobility – that’s twice
for conducting electricity,
power electronic systems used
the Laser Technology division
as much as last year,” Schmitz
copper plays an essential role
in electric cars. “The transition
at TRUMPF “The important
says.
MTI delivers Linear Friction Welder of development parts
M
anufacturing
brings moving forward,” said
Technology, Inc.
MTI President and CEO Dan
(MTI) has shipped
Adams. “Our North American
North America’s first linear
customers in the aerospace,
friction welder capable of
automotive, defense, rail, and
full sized part development
mining industries have been
to the LIFT - Lightweight
looking for a machine that
Innovations for Tomorrow
is capable of full-scale parts.
facility in Detroit where it will
available. It will bring the
and implement education and
Previously, these customers
contribute to cutting edge
same linear friction welding
training programs to better
would have to travel all the
lightweighting research in the
technology used in aerospace
prepare the workforce of today
way to Europe. But now, they
automotive and aerospace
to achieve light-weighting
and tomorrow.
have access to this technology
sectors.
blisks and Integrally Bladed
Measuring 22' x 14' and weighing 150,000 pounds (68 metric tons) – roughly the
10
LIFT expects the welder
right here in Detroit.”
Rotars (IBR) to aircraft engines
to be utilized immediately
and the automotive industry.
upon its set up in Detroit
friction welding technologies,
by its members to complete
will run and maintain the
LIFT, one of the founding
MTI, a world leader in
same weight as a Boeing 737
members of Manufacturing
their ongoing research and
machine at LIFT’s facility
– the LF35-75 has the largest
USA, is a public-private
development projects.
in Detroit. MTI will also
tooling envelope of any linear
partnership designed to
friction welder in the world,
help develop and deploy
its kind in the world, and we
work on the machine and
allowing for the production
advanced lightweight metal
are extremely excited about
support any programs that
of the largest full-scale parts
manufacturing technologies
the possibilities this machine
LIFT has moving forward.
WELDFAB TECH TIMES | FEB - MAR 2019
“This is the only machine of
complete customer directed
www.weldfabtechtimes.com
BULLETINS
UTI to launch welding technology program at Dallas-Ft. Worth campus
U
niversal Technical
willing to pay for them. The
to aerospace, energy and
to provide educators at
Institute (UTI) is
expansion of this state-of-the
virtually every kind of
every level with skills and
pleased to announce
industry program will enable
manufacturing. By 2026,
knowledge that employers
the expansion of its Welding
us to better meet the needs of
the U.S. Bureau of Labor
demand. We are excited to
Technology Training program
employers while providing yet
Statistics projects there will
expand our products, services
to the UTI-DFW campus.
another avenue for students
be more than 458,000 job
and expertise to help the UTI
Designed in partnership with
seeking a rewarding, well-
openings for welders. Welders
team develop an outstanding
Lincoln Electric, a global
paying career."
are particularly in demand for
welding education program." The UTI Welding
welding leader, the 36-week
The addition of welding at
major infrastructure projects
course prepares students to
UTI-Dallas-Ft. Worth follows
that keep our nation moving:
Technology curriculum was
work in the transportation,
successful UTI welding
vehicles, bridges, highways,
developed in collaboration
construction, structural,
program launches in Rancho
office buildings, schools,
with Lincoln Electric and
pipe and fabrication
Cucamonga (Los Angeles,
pipelines, power plants,
prepares students for
industries. Classes begin in
CA) and Avondale (Phoenix,
refineries, spacecraft and
certification via the American
January 2019.
AZ) in 2017 and 2018. Classes
more.
Welding Society. The
"We are thrilled to be the
at both campuses opened
"Lincoln Electric has a
program is accredited by the
third UTI campus to welcome
with strong student demand
century-long commitment
Accrediting Commission of
this outstanding program,"
for the training and industry
to educating welders,"
Career Schools and Colleges
said Jesus Miranda, UTI-
demand for graduates.
said Jason Scales, Business
(ACCSC) and complements
Manager-Education, Lincoln
UTI's core automotive, diesel,
DFW campus president.
Welders are increasingly
"The opportunities for skilled
sought in industries
Electric. "With the critical
motorcycle, marine and
welders are abundant – and
ranging from automotive
shortage of welders today,
collision repair programs
employers are ready and
fabrication and motorsports
we accelerated our efforts
across the nation.
Chromalox unveils new Directconnect™ Medium Voltage Boiler
C
Source: www.chromalox.com
hromalox, a leader
The line offers voltages ranges
delivers instantaneous power
heating with the high efficiency
in advanced thermal
of up to 6,600 volts that allows
conversion to heat energy and
medium voltage is known
technologies, today
for an economical installation,
ensures all available power
for. No technology exists that
announced their new line
along with highly operational
is directly delivered to the
can match the voltage range,
of boilers with the patented
efficiency.
process.
third party certifications, and
“Our latest generation of
patented control methodology
technology at Power Gen
DirectConnect boilers operate
DirectConnect products are
of Chromalox’s DirectConnect
International. The new high
with an advanced power
unparalleled in the industry,”
medium voltage system. This
capacity steam boilers are
control system. Solid state
said Mark Wheeler, Director,
technology allows our global
uniquely designed for large
power components, along with
Global Product Manager
customers to explore safe,
industrial applications by
optimized logic control, allow
of Systems & Services at
highly efficient, emission-free,
offering steam output of up to
for an almost infinite number
Chromalox. “This offering
and cost effective electric
21,353 lbs/hr, and standard
of step controls, ranging from
is the first of its kind in the
solutions for their large process
pressures of up to 450 psig.
0-100% scalability. This setup
industry to combine resistive
heating needs.”
DirectConnect™ heating
12
Source: www.news.uti.edu
In addition, Chromalox
WELDFAB TECH TIMES | FEB - MAR 2019
www.weldfabtechtimes.com
BULLETINS
CPI Aerostructures completes acquisition of Welding Metallurgy Inc.
C
PI Aerostructures,
assemblies, large diameter
expanded capabilities and
and current customers.
Inc. (“CPI Aero®”
tube bending and integrated
an increased opportunity
Finally, consolidation of
or “the Company”)
electronic assemblies, among
set that we expect to lead
WMI’s operations and
(NYSE American: CVU)
other capabilities, to a variety
to meaningful revenue and
personnel into our facility
today announced that it has
of customers, predominantly
earnings growth starting in
will increase absorbtion of
completed its acquisition
within the defense and
2019. The addition of WMI’s
fixed overhead costs, improve
of Welding Metallurgy, Inc.
aerospace markets. WMI’s
products and processes,
the competitivess of our
(“WMI”) from Air Industries
defense customers include
particularly with respect to
price proposals and could
Group, Inc. in a transaction
Sikorsky, Lockheed Martin,
manufacturing of electronic
expand margins on current
valued at approximately $9.0
Northrop Grumman,
assemblies, wire harnesses,
programs.”
million. The Company expects
Raytheon, and GKN
and tube assemblies, not
to complete the integration
Aerospace, among others.
only provides a new avenue
provide financial guidance for
of WMI’s operations into its
CPI Aero President and
for top line growth, it also
fiscal 2019 that will include
The Company expects to
Edgewood, N.Y., headquarters
Chief Executive Officer
allows us to provide more
WMI’s contribution with
by the end of the first quarter
Douglas McCrosson stated,
CPI Aero content within
the publication of its fourth
of 2019.
“”We are excited to announce
our integrated structural
quarter and year-end 2018
the closing of the acquisition
assemblies thereby enhancing
financial results in March
as it ushers in a new era of
its value proposition to new
2019.
WMI provides specialty welded products and
Airgas completes the acquisition of Tech Air
A
14
Source: www.cpiaero.com
Source: www.airgas.com
ir Liquide announces
on February 6 of this year,
U.S. serving a variety of
equity firm, and Tech Air
that Airgas has
Airgas will further strengthen
customers safely and reliably.
management.
completed the
its distribution network,
Founded in 1935, Tech
Pascal Vinet, Chief Executive
acquisition of TA Corporate
enabling more proximity to
Air is a major distributor
Officer of Airgas, Inc. and Air
Holdings, Inc. (“Tech
local customers. Leveraging
of industrial, medical and
Liquide Executive Committee
Air”), a large independent
Air Liquide’s integrated
specialty packaged gases,
Member, commented:
distributor of industrial
model, the acquisition will
welding equipment, and
"The completion of the
gases and welding supplies
deliver significant efficiencies.
supplies. Serving more
acquisition of Tech Air is an
serving various geographies
Moreover, customers will
than 45,000 customers,
important milestone in Airgas'
in the United States. This
benefit from an expanded
the company, comprises
development. Tech Air’s
transaction enables Airgas to
offering as well as a wider
approximately 550 employees
highly professional teams and
further strengthen its network
distribution network and
and has annual revenues of
complementary distribution
in the United States with a
a leading digital platform.
approximately 190 million US
network will be strong
complementary footprint
Over the years, Airgas has
dollars. Tech Air operates 50
assets to efficiently serve our
to better serve customers
successfully acquired and
locations in California, Texas,
customers. We welcome our
while generating significant
integrated companies’
the Northeast and Southeast.
new Tech Air colleagues to
efficiencies.
operations and associates to
Airgas acquired Tech Air
Airgas and the Air Liquide
With the completion of
create an industry-leading
from CI Capital Partners,
family and now begin the
this acquisition announced
distribution network in the
a New York-based private
integration process."
WELDFAB TECH TIMES | FEB - MAR 2019
www.weldfabtechtimes.com
BULLETINS
Lincoln Electric names Michele as Executive VP, Chief HR Officer
Source: www.lincolnelectric.com
L
incoln Electric Holdings, Inc. (Nasdaq:
and Chief Executive Officer.
Kuhrt joined Lincoln
“Michele has extensive
Electric in 1997 as Director
experience with our culture,
of Taxes and later served as
announced today that Michele
the integration of complex
Company Officer and Senior
R. Kuhrt will serve as Executive
systems and collaboration
Vice President, Tax with
Vice President, Chief Human
with teams across
responsibility for Lincoln
Resources Officer (CHRO),
multinational business units,
Electric's global tax matters
effectively immediately.
which makes her a strong fit
and has worked closely with
In this role, Kuhrt will be
to lead our human resources
all of the global businesses.
joining Lincoln Electric ,
responsible for leading the
function,” stated Christopher
She most recently served as
Kuhrt was with Elsag Bailey
global human resources
L. Mapes, Chairman,
Executive Vice President, Chief
Process Automation (a unit
team, with an emphasis on
President and Chief Executive
Information Officer, a position
of ABB) and Pricewaterhouse
employee engagement and
Officer. “Her track record
she has held since 2016. In
Coopers. She holds a
development, diversity and
of developing talented and
that role, she was a member of
bachelor's and master's
inclusion, and enhancing HR
highly engaged teams will be
the Management Committee
degree in accountancy
systems and processes. She
a catalyst for us as we execute
and was instrumental in the
from Case Western Reserve
will report to Christopher L.
on our long-term strategy for
successful roll out of many
University's Weatherhead
Mapes, Chairman, President
the Company.”
global initiatives. Prior to
School of Management.
LECO) (“Company”),
New EWM administration building opened in Mündersbach
E
WM AG from
building to the highest-possible
Mündersbach has been
standard, for example by fitting
in growth for a number
the offices with ergonomic,
of years. Now the welding
height-adjustable desk systems.
technology manufacturer has
As well as modern, well-lit
opened a new administration
rooms, the spacious halls of
building in its hometown.
the new building also house
An initial 80 employees have
inviting meeting areas with
moved into the state-of-the-
standing tables. “On one
art office complex. EWM has
hand, our new administration
invested a total of four million
building gives employees the
Euros in the new 1,800 m²
chance to work in a focussed building, EWM is making a
technological leaders. Within
and quiet environment. On
long-term commitment to the
just six months, a cutting-edge,
the other, they will also have
in Mündersbach alone, the
place where it was founded.
multi-storey building was
plenty of space for productive
family company is among the
The high-tech company is
constructed in Mündersbach,
and informative discussions.
leading providers of work in
Germany’s largest producer
housing a total of 100 office
That’s a successful solution,”
the region, and this is only
of arc welding technology
workspaces. EWM put great
says Bernd Szczesny, Managing
set to increase. With the new
and is even among the global
emphasis on equipping the
Director of EWM AG.
location. With around 400 employees
www.weldfabtechtimes.com
FEB - MAR 2019 | WELDFAB TECH TIMES
15
BULLETINS
ARO launches new products in EXP Diaphragm Pump Series
A
RO®, a global
of air operated diaphragm
choice with reliable, versatile
Portfolio Leader, Diaphragm
manufacturer of
pumps. Ideal for high
and innovative solutions that
Pumps, ARO, further added,
products for the
volume transfer in industrial,
are safe and efficient. With
“India is a growing and an
management of fluids in
chemical processing and
a legacy of premier product
important market for us.
industrial operations and a
water treatment applications,
performance and service
For over 85 years, we have
brand of Ingersoll Rand®,
the ARO® EXP Series 3-inch
excellence, our team of fluid
been focusing on the unique
announced the launch of its
non-metallic diaphragm
intelligence experts have
pumping needs of many
Expert Series (EXP) 3-inch
pump is compatible with
developed diaphragm pumping
industries. We see a great
non-metallic diaphragm pump
harsh chemicals that require
solutions for customers in
opportunity as Diaphragm
in India at ChemTech 2019.
a gentler stroke to prevent
the chemical, manufacturing,
Pumps market in India is
The company also showcased
damage to fluid that can
construction, mining and
aggressively increasing due
a variety of pumping solutions,
happen with smaller capacity,
marine sectors, among others.”
to the rise in urbanisation
ranging from air operated
high-pressure pumps.
The new series is ideal to
and industrialisation. There
Sourabh Taneja,
handle shear sensitive fluids.
has also been an upsurge in
diaphragm pumps to piston pumps, and filters, regulators
Commercial Leader, Fluid
Additionally, the EXP pump
the growth in sectors such as
and lubricators (FRLs)
Management and Material
series is compatible with
pharmaceutical, chemical,
along with a virtual reality
Handling, India, Sales ARO
almost any automation system
water waste management etc.
demonstration at Stand C2A in
said, “It gives us immense
which helps in enhancing
It is our endeavour to provide
Hall No.1.
pleasure in introducing the
the electronic interface
innovative, energy-efficient
latest EXP Series diaphragm
capability, providing accurate,
and environment-friendly
Series 3-inch non-metallic
pump to the Indian market.
electronically controlled
products and the launch of the
diaphragm pump, ARO
Our objective has always been
dosing.
EXP diaphragm pump series is
has expanded its portfolio
to be the pump provider of
With the launch of its EXP
Julien Basset, Global
a step in this direction.”
First laser blanking line for Asia
A
nsteel is one of
has two high-performance
the world's largest
cutting heads and enables the
steel producers, is
production of circuit boards
considered the "cradle of the
for various components made
steel industry" in China and
of strip material with a width
has a significant share in the
Source: www.schulergroup.com
rapid economic growth of
cost-effective alternative to
the People's Republic. Now
production of body panels
and high belt speeds for
Laser Blanking Line 3.21. With
the company is Schuler's first
already in Europe - another
continuously moving coil
three laser cutting heads, this
customer to install a laser
will soon be in the USA - and
material. On the one hand,
system is particularly suitable
cutting line in Asia. It is also
are particularly suitable for
this leads to an increased
for the efficient production
the first machine in the world
production processes with
output and higher plant
of outer skin boards with a
to feature two cutting heads
frequent product changes,
availability, on the other
bandwidth of up to 2,150
for processing strip up to 1,880
since no tools are used
hand, the process ensures a
mm. It offers a wide range of
mm wide.
for laser cutting. Schuler's
material-saving transport of
options to optimally meet the
innovative DynamicFlow
sensitive materials such as
needs of customers and has
have proven their reliability
technology enables a highly
aluminum.
been successfully in operation
and high output in the serial
dynamic cutting process
Laser cutting machines
16
of up to 1,880 mm. It forms a
WELDFAB TECH TIMES | FEB - MAR 2019
The Laser Blanking Line 2.18
for several years now.
www.weldfabtechtimes.com
ƌŝƟĐĂů
t > /E'
ƐŝŶŐůĞ ƐŽƵƌĐĞ ĨŽƌ ǁĞůĚŝŶŐ ƐŽůƵƟŽŶƐ
Needs Special Products
brings Technically Advanced Welding Products to Indian Industry from Global Leaders
ƵƚŚŽƌŝnjĞĚ ŝƐƚƌŝďƵƚŽƌ͗ ϰϬϭ͕ sŝŬĂƐ Žŵŵ͘ ĞŶƚƌĞ͕ ƌ͘ 'ŝĚǁĂŶŝ ZŽĂĚ͕ ŚĞŵďƵƌ ; Ϳ͕DƵŵďĂŝ ϰϬϬϬϳϰ͕ /ŶĚŝĂ͘ d͗͘ нϵϭͲϮϮͲϲϲϰϲϮϬϬϬ ͬ ϮϱϱϬϯϮϳϬ ͗͘ ƐĂůĞƐΛǁĞůĚǁĞůů͘ĐŽŵ͕ ŶŝǀĞŬΛǁĞůĚǁĞůů͘ĐŽŵ
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ǁǁǁ͘ǁĞůĚǁĞůů͘ĐŽŵ
INNOVATIONS
www.novarctech.com
Novarc increases autonomy of its spool welding robot with Noveye™
N
ovarc Technologies announced
less time on each weld,” says Soroush
Continuum™ power source with the
the launch of a new breakthrough
Karimzadeh, CEO of Novarc Technologies.
SWR to allow customers to access familiar
vision based software product
welding processes currently in use into
because the NovEye™ integrates artificial
their manual pipe welding process,
of autonomy in Novarc’s Spool Welding
intelligence and machine vision with
including RMD and pulse process
Robot (SWR) by an order of magnitude.
adaptive control in a complete package
provided by Miller Electric.
NovEye™ uses machine learning to track
producing high quality full penetration 1G
the root pass withhigh accuracy, measure
root pass welds with minimum operator
learning curve and facilitate better buy-
the root gap and detect the tacks (stitches)
involvement.
in from operation teams for shops who
automatically. Novarc’s SWR was officially launched
18
This advantage is made possible
called NovEye™ which increases the level
“This capability is exceptional in the industry and is a major milestone for us
“This integration will improve the
require a Miller power source in their shop,” says Karimzadeh.
at FABTECH last year, and since then
and our customers. For the first time, AI
has become increasingly popular among
and machine learning are introduced to
hardware features on the SWR – including
fabricators due to its precision and
the fabricator’s shop floor and will have a
EWR, 3-line Scansonic laser scanner,
dexterity, enhanced by these new features.
meaningful impact on their bottom line.
Masterline conduit, and software features
“With the NovEye™ software product
Both options as well as many new
This is very exciting time for us as Novarc
such as pass tracking and advanced
and its features, our customers benefit
is at the forefront of the Industry 4.0
control options – will be available for
from a higher level of autonomy with
revolution with this unique offering,” says
demonstration at Novarc’s booth #C13542
less risk of defects. The advantage with
Karimzadeh.
at FABTECH, November 6-8, 2018 in
NovEye™ is SWR operators can now
The company also announced
perform more welds while spending
the integration with the Miller Auto-
WELDFAB TECH TIMES | FEB - MAR 2019
Atlanta, GA. The NovEye™ will be released in 2019 for existing & future customers.
www.weldfabtechtimes.com
ARTICLE
Welding and Post Weld Heat Treatment of WB 36 Steel The need for increasing the plant efficiencies for fossil fuel fired power plants necessitates development and use of new materials in boilers. Emission rules demands reduction of CO2 emissions and thus leads to higher operating pressures and temperatures. Once through Super Critical Boilers (OTSC) manufacturing involves higher quantum of pipes to transport high pressure and high temperature water and steam. In order to reduce the piping weight and the related supports and hangers, new material WB 36 /P36 is used in boiler feed water piping. This steel grade is mainly used in high-pressure, medium-temperature feedwater lines (close to 400 째C).WB36 exhibits excellent high-strength properties up to 450 째C. The reduced weight of the feed water S. Singaravelu piping components compared with conventional carbon steel Former AGM BHEL, Tiruchirappalli, India allows improved resistance to thermal fatigue and high level of mechanical characteristics at the service temperature. The aim of this study is to demonstrate joining of thick wall piping and to qualify a Welding Procedure Specification (WPS) by GTAW with SMAW process. Post Weld Heat Treatment (PWHT) was carried out to assess the required weld metal strength, hardness and toughness. Key Words: OTSC, WPS, PWHT, Toughness, Hardness. 1.0 Introduction
Addition of copper increases the strength
according to the steel grade for pipes for
Increasing of operating parameters
level. WB 36 seamless pipe became
an application at 370 bar 320 째C with an
(pressure, temperature) and unit size of
significant when the capacity of the newly
inner diameter of 480 mm. This clearly
thermal boilers requires the development
built power stations is increased. In the
shows the potential reduction in wall
of high strength steels. Developments
feed water applications based on ASME B
thickness of P36 in comparison to other
in steelmaking have improved the
31.1, the main advantage is the possibility
grades. Using thinner pipes allows in time
cleanliness and properties of steel. In Sub
of reduction of wall thicknesses between
and cost savings in material, welding /
critical boilers high pressure hot water
15 to 35% compared with other candidate
PWHT operations and reduces the weight
are present primarily in feed water system
materials. As an example, Table 1 gives
of structures, column and supporting
and headers, which are manufactured by
the results of calculation of wall thickness
hangers.
standard carbon steels like A106 grade B or A106 grade C pipes. For super critical power plants, this leads to very thick piping system. V&M has developed WB 36 steel (15 NiCuMoNb5-6-4) for high pressure piping of boiler feed water
Table 1 Comparison of wall thickness requirement for different grade steels Operating conditions of 370 bar /320 째C Steel grade
Minimum Wall thickness (mm)
15 NiCuMoNb5- Cl.1
58.9
15 NiCuMoNb5- Cl.2
55.1
the carbon manganese pipes. It is a low
SA 106 Gr B
109.3
alloy steel with 1.1 % Ni and 0.7 % Cu.
SA106 Gr C
90.2
system. It is designed to compete against
www.weldfabtechtimes.com
FEB - MAR 2019 | WELDFAB TECH TIMES
19
ARTICLE
2.0 Steel Properties
ASTM standard “Specification for seamless
purging of root was not carried out. Then
2.1 Applicable Standards & Product
ferritic alloy steel pipe for high temperature
the balance thickness was completed
Forms
service” under A335 P36. The specified
by Shielded Metal Arc Welding. The
• Various applicable standards and their
properties for the pipe material as per
electrodes used are diameters 2.5 and
ASTM (2005) are given in Table 3. WB36
3.2 mm and 4 mm. The electrodes are
• ASTM A 182 Grade F36 Forgings
composition has been optimized to achieve
backed at 300- 350°C before welding. The
• ASTM A 335 Grade P36 Seamless pipes
high yield and tensile strength values. The
recommendations of pipe manufacturer
• ASTM A 213 Grade T36 Seamless Tubes.
strengthening effect is obtained by means
for preheat temperatures and interpass
• BSEN 10216-2 Grade
of grain refinement through the addition of
temperatures are given in table 4.
product forms are given below.
15NiCuMoNb5-6-4 Seamless Steel
Nb. A second effect is partial hardening by
tubes
Cu- precipitates. During the development
to avoid the risk of hydrogen cracking
of WB36, it was found that a Cu/Ni-
after welding. Inter pass temperature
Preheat temperature of 120 °C was used
2.2 Chemical Composition
roughly 0.5 is needed in order to avoid hot
was maintained within 300°C. BS2633
The chemical composition of WB36
shortness during hot forming.
recommendations are similar to V&M recommendations. PWHT shall be
according to ASME is given in Table 2 along with SA 106 Gr C for comparison.
3.0 Experimental Set Up
applied directly from welding /preheat
Grade C belongs to the group of carbon
3.1 Joints
temperature without any need for cooling to room temperature. The pipe butt joints
manganese steels. The composition
Pipe butt joints of diameter 323.9 mm and
of WB36 differs in nickel, copper and
wall thickness 40 mm were made with Gas
were subjected to radiographic test to
niobium content.
Tungsten Arc Welding process for root
assess the soundness of the weld
welding. Diameter of filler rod and 2% 2.3 Mechanical properties
ceriated tungsten rods are 2.4 mm. Since
3.2 Welding Consumables
The pipe material has been included in
P36 and the filler used are of low alloy,
Welding consumables are selected to
Table 2 Chemical requirements of WB 36 (%) WB 36 /P36 C
Si
Mn
P
S
Cr
Mo
Ni
N
Cu
V
Nb
Al
Min
0.10
0.25
0.80
--
--
--
0.25
1.00
--
0.50
--
0.015
--
Max
0.17
0.50
1.20
0.030
0.025
0.30
0.50
1.30
0.02
0.80
0.02
0.045
0.050
SA 106 Gr C Min
--
--
0.29
--
--
--
--
--
--
--
--
--
--
Max
0.35
0.10
1.06
0.035
0.035
0.40
0.15
0.40
-
0.40
0.08
-
-
0.25
0.80
--
--
--
0.25
1.00
--
0.50
--
0.015
--
0.50
1.20
0.025
0.020
0.30
0.50
1.30
--
0.80
--
0.045
0.050
15NiCuMoNb5-6-4 Min Max
0.17
Table 3 Specified mechanical properties of WB36 steel Standard ASTM A 335 P36 Class 1, N & T
*YS (MPa) 440
*UTS (MPa) 620
*Elong. (%) 15
Hardness HB 265 Hv
CVN impact energy J at +20 °C -
Class 2, Q& T
460
660
15
265Hv
-
EN10216-2 WB 36
440
610-780
19 long. 17 trans.
-
40 long. 27 trans
SA106 GR C
275
485
16.5
-
-
* Specified minimum
20
WELDFAB TECH TIMES | FEB - MAR 2019
www.weldfabtechtimes.com
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ARTICLE
Table 4
thickness. Class 2 components are to be
Wall thickness mm
Minimum Pre heat Temp °C
Maximum Interpass Temp °C
held at PWHT temperature for one hour
15
80
150
per 25 mm thickness with minimum
16-30
100
180
soaking time of 30 minutes. The rate of
31-50
120
220
heating and rate of cooling rate above
> 50
120
250
315°C was maintained at 115 °C/h.
nearly match the base metal composition.
4.0 PWHT
5.0 Test Results
Weld metals are with Mn-Mo or Ni-Mo
Post weld heat treatment has to be carried
The pipe weld joints were tested as
alloyed types. For GTAW welding, Union
out to relieve the internal stresses caused
required in ASME Sec IX. The tensile test
I Mo brand (AWS A 5.28 ER 80SG) was
by welding and the tempering of heat
as per QW 150 and bend test as per QW
used, which is 0.5 Mo type as per the
affected zone is to be ensured. PWHT
180 were carried out. Location of failure
recommendations of pipe manufacturer.
was carried out in a gas fired furnace with
in tensile test specimen is parent metal
M/s Metrode recommends the use of Mn
necessary thermocouples. As per ASME B
and the ultimate unit stress reported are
Mo brand (AWS A 5.28 ER 80SD2/ER 90S-
31.1 for ASTM A335 P36 and ASTM A182
675 and 683 MPa. All the four side bend
D2) for GTAW. Welding parameters are
F36 materials, post weld heat treatment
specimens have passed the 4t,180° guided
voltage 14-16 and current 90-120 amps.
is mandatory under all conditions. For
bend test. In addition to mandatory tests
Argon is used as shielding gas with gas
class 1 material the recommended range
weld hardness measurements were taken.
cup size of 6 mm with a flow rate of 12
is 595 – 650°C and for class 2 components
The readings in Hv are given in table 7.
liters per minute. For SMAW AWS A 5.5 E
recommended range is 540 – 620°C. Class
9018 G electrodes (Brand name Phoenix
1 components are to be held at PWHT
4.1 Weld metal toughness
SH Schwarz 3K Ni) were used. Welding
temperature for one hour per 25 mm
ASME base material does not mention
current of 80-100 amperes for 2.5 mm
thickness up to 50 mm thickness with
the required toughness for P36 but the
diameter electrodes,90-140 amperes for
minimum soaking time of 15 minutes. For
EN standard specifies minimum 27
3.2 mm diameter electrodes and 140-180
over 50 mm thickness, add 15 minutes
joules at room temperature. Adequate
amperes for 4.0 mm diameter electrodes
minimum for each additional 25 mm
toughness is required for weld metal
were used. Weld Metal deposit analysis Table 7
are reported in table 5 and meets the requirement of A number 2.
Base metal
HAZ
Weld metal.
218
254
230
221
260
228
220
251
231
218
240
234
215
257
227
223
248
235
Welding consumables of both GTAW and SMAW are tested as per the applicable AWS classifications and the test results are given in table 6. Both the weld deposits exceed the minimum requirements of base metal P36/WB36.
Table 5 Process
C
Si
Mn
P
S
Cr
Mo
Ni
N
Cu
V
Nb
Al
GTAW
0.10
0.60
1.20
0.008
0.010
--
0.50
--
--
0.1
--
--
--
SMAW
0.08
0.36
1.25
0.010
0.010
0.20
0.40
0.95
--
0.08
--
--
--
Table 6
22
Process
PWHT
YS MPa
TS MPa
% Elongation
CVN Impact energy J at +20 °C
GTAW
570°C/ 120 minutes
510
603
24
95
SMAW
570°C/ 120 minutes
595
660
28
120
WELDFAB TECH TIMES | FEB - MAR 2019
www.weldfabtechtimes.com
ARTICLE
Table 8 Temp (°C)
and SMAW processes.
Yield Strength (MPa)
UTS (MPa)
250
500
629
20
350
460
620
25
450
470
Elong. (%)
References
563
29
1. Vallourec & Mannesmann Tubes “The WB36 Book (15NiCuMo)”, 2002. 2. ASME B31.1 -2016 Power Piping 3. ASTM A335/A335M-06 “Standard
during the pressure testing of the boilers.
three different test temperatures and the
specification for seamless ferritic
The weld metal has average toughness
results are given in table 8.
alloy-steel pipe for high temperature service.”
values of 120 joules.
Summary
4. ASME Boiler & Pressure Vessel Code
4.2 Elevated Temperature tensile
The material P36 has specific chemical
strengths
composition and mechanical properties
P36 weld metals are having significant
at room temperature and elevated
importance due to high temperature
temperatures. Welding consumables and
applications. The hot tensile properties of
the welding parameters are qualified to
6. BS EN 10216-2:2002 “Seamless tubes
the weld metal do not necessarily provide
match the base metal requirements. The
for pressure purposes – Technical
information on the joint properties but
test results met the ASME requirements
delivery conditions Part 2.Non-alloy
they are important because design is
and procedure qualification record
and alloy steel tubes with specified
based on yield strength and not on creep
was qualified, based on the PQR results
elevated temperature properties.”
properties. The all weld tensile tests
Welding Procedure is qualified for P36
for SMAW weld metal were reported for
material for 5-80 mm thickness by GTAW
www.weldfabtechtimes.com
IX-2017. 5. Welding Studies on WB36 for Feed Water Piping-Sathish Kumar R, Dr. T Ramesh, and Dr. K Asokkumar
7. Technical profiles October 2009 by Metrode Products Limited.
FEB - MAR 2019 | WELDFAB TECH TIMES
23
PRODUCTS UPDATE
Bobcat™ 200 Air Pak™ Diesel All-in-One for Work Trucks
M
iller Electric
500 pounds and increase
Diesel power system also
Mfg. LLC, has
available payload by up to
improves fuel consumption
announced
24 cubic feet compared to
and optimizes efficiency with
the new Bobcat 200 Air
using multiple engine-driven
industry-exclusive Auto-
Pak Diesel power system.
machines, such as a separate
Speed™ technology, which
The new diesel model is
air compressor and welder.
automatically adjusts the
In addition, by turning off
available fro Feb 2019, and
engine to run at the lowest
an enhanced gasoline model
their truck and running the
speed to match weld and
will be released in April.
Bobcat 200 Air Pak power
battery charge demands.
This engine-driven all-in-
work truck operators get a
system, truck operators
Auto-Speed technology
one solution helps work
reliable all-in-one solution
can reduce truck engine
also helps reduce noise,
truck operators consolidate
that helps them reduce
idle time by as much as 75
which enhances safety
equipment to maximize
payload yet still have all the
percent — to help minimize
and improves the work
available payload, reduce
power they need.”
fuel costs. Tier 4 diesel truck
environment.
The Bobcat 200 Air Pak
engines that use a PTO to
The new diesel offering
Diesel all-in-one maintains
run jobsite tools increase
joins the existing Bobcat 200
power capabilities in a
maintenance costs and the
Air Pak gas model, so truck
don’t have to overload their
compact, lightweight
risk of truck downtime due
operators can standardize
trucks or sacrifice tools to
footprint, allowing class 3
to unnecessary idling.
fuel type — eliminating the
stay underweight,” says Matt
to 5 work truck operators
Sherrick, Product Manager,
to consolidate or improve
Power Systems Division,
reliability of their power
Miller. “With the Bobcat 200
equipment. Truck operators
Air Pak Diesel power system,
can reduce weight by up to
fuel consumption and minimize operating costs. “Work truck technicians
The Bobcat 200 Air Pak
need to fill two tanks.
For More Info: Miller Electric Mfg. LLC Website: www.millerwelds.com
Automation & Robotics Technologies and systems for automatic and robot welding lines
S
elco has developed a
satisfy the needs of even the
sources, wire feeders,
range of all-new and
most advanced applications.
interfaces, torches and
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• Unique, new concept
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programs • Complete range of power
Over forty years of
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experience in industrial welding, combined with a lasting commitment to
24
research and development,
products, including fast
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and flexible control and
customers a wide range of
configuration systems, to
WELDFAB TECH TIMES | FEB - MAR 2019
For More Info: Sumant Corporation Mob: +91 9011680001/8275879963 www.sumantcorporation.com / www.selcoweld.com E-Mail: sumantcorporation@gmail.com
www.weldfabtechtimes.com
PRODUCTS UPDATE
REBEL™ EMP 205IC AC/DC - Available Now
W
• TFT Multilingual Display
e made the impossible
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Rebel EMP 205ic AC/
the first-ever portable, all-
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memory locations for each
with MIG, Flux-Cored, Stick,
process, multi-language
DC TIG, DC Pulse TIG, and
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inductance control, pre/
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post flow control and spot
welds aluminum. It's a TRUE
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applications • Professional TIG features
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Pulse DC. • sMIG Technology
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Optrel introduces crystal 2.0 welding helmet
W
ith light
Fields of Application
• Micro Plasma Arc Welding
transmission of
• Elektrode Welding (Stick
• Plasma Cutting
Welding, SMAW)
• Gas Welding
condition (protection
• MIG/MAG (GMAW)
• Grind Mode
level 2!) welders have for
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Optrel’s new flagship is
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This in combination with
• Plasma Arc Welding
convenient.
the almost perfect colour spectrum of the CLT2.0 for the first time allows welders to see what is really going
26
on in the weld pool, and
dimension. This is why
with a clarity that equates
welders describe this as an
to insights into a new
enlightenment.
WELDFAB TECH TIMES | FEB - MAR 2019
For More Info: Optrel AG industrie strasse 2, CH-9630 wattwil, Switzerland Website: www.optrel.com Email: info@optrel.com
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PRODUCTS UPDATE
Welding Tractors ABI-CAR
A
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28
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INDEPTH
Thick metal sheets? Laser welding! www.lzh.de/en
E
specially for shipbuilding and other maritime applications, the
The aim of the DIOMAR project is to establish new laser welding processes based on high-power lasers in the maritime sector. (Photo: Š MEYER WERFT / I. Fiebak)
further development of thick
metal sheet welding is interesting. The
arc hybrid welding, as an alternative
for thick metal sheet welding in the
Laser Zentrum Hannover e.V. (LZH),
process, requires labor-intensive edge
maritime sector. For this purpose,
together with Held Systems Deutschland
preparation and is not very flexible.
the project partner Laserline will realize
GmbH, Laserline GmbH and Meyer Werft
Particularly for large steel sheet
new diode laser beam sources with a
GmbH & Co. KG, now wants to establish
thicknesses in the range of 12 millimeters
maximum output power of up to
robust, pure laser welding processes
to 30 millimeters, no method has been
60 kilowatts in continuous-wave
for steel sheet thicknesses of up to 30
able to prevail against submerged arc
mode.
millimeters. For this purpose, diode laser
welding. The scientists at the LZH now
The aim of the project is to achieve
beam sources are to be brought to peak
want to change this together with their
high-quality joints with high welding
performance.
partners Meyer Werft GmbH & Co. KG,
speeds. The partners want to reduce
Held Systems Deutschland GmbH and
the costs for edge preparation and the
Laserline GmbH.
amount of additional material compared
The processes for joining maritime steel components have a great development potential in terms of
to existing joining methods. In that way, the costs shall be reduced eventually.
frequently used submerged arc welding
Robust, pure laser welding processes
is comparatively slow and involves
The scientists want to develop robust,
even replace the existing ones.
significant workpiece distortion. Laser-
pure laser welding processes, especially
production costs and productivity: the
The new processes shall complement or The application-oriented development takes place in parallel in a laser laboratory and in a shipyard-like test environment. This makes it possible to quickly test, evaluate and optimize processes.
Focus on laser safety The partners are particularly keen to develop concepts for ensuring laser safety for very high laser output powers of up to 60 kilowatts. This includes the handling of the expected large quantities of emitted hazardous substances. To this end, the LZH also comprehensively investigates the release New laser welding processes shall make the welding of thick metal sheets in shipbuilding more efficient and less expensive. (Photo: Š MEYER WERFT / M. Wessels)
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of hazardous substances from the laser processing zone.
FEB - MAR 2019 | WELDFAB TECH TIMES
29
ARTICLE
Increased Productivity in GTAW
G Nimesh S. Chinoy Sigma Weld, EDWPL, Mumbai
as Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG): The GTAW process is
processes such as GMAW, SAW or FCAW. Though GTAW is generally considered as the best welding process for quality,
a very versatile, all-position welding
superior joint appearance and bead
process that is widely used to join Ni-/
formation, the possibility to use in all
Co-base alloys. In GTAW, the heat for
position welds, still it is avoided as it is
welding is generated from an electric arc
considered a slow process. The energy
established between a non-consumable
efficiency of the process is poor. The skill
tungsten electrode and the work-piece.
level required for the welding is relatively
The welding quality and appearance makes it the preferred method for most of the critical and many non-critical
high, as well. The lower production rate makes it a difficult choice for shop floor where the
applications. Also for Code requirements such as pressure parts welding is needed usually the root runs are specified with TIG. Applications such as cladding and critical welding in Nuclear and Aerospace applications where high quality bonding and precision welding is required the GTAW process is recommended over other faster
32
WELDFAB TECH TIMES | FEB - MAR 2019
Figure 1 Manual GTAW Welding with Filler.
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ARTICLE
drive for productivity is now paramount.
huge savings of consumable cost. Lesser
However, GTAW has one basic advantage
number of start, stop by the welder also
that it can be automated. There are
leads to lesser grinding and saving of gas.
now productivity enhancement tools
As the welder experiences less fatigue
available which helps make GTAW a
he can weld longer lengths without
faster process. Such as cold wire feeder,
stopping, giving increased weld speeds.
weavers, oscillators, fully automated
This can also be clubbed with a HOT
systems using AVC (automatic voltage
Wire power source, which helps bring up
correctors), Hot wire GTAW, Keyhole
the temperature of the filler wire before
GTAW. This article discusses the semiautomatic methods and their use on the shop floor across the globe.
Figure 3 Comparison Cold Wire Vs Hot Wire.
entering in the weld pool. So the arc
wire for the root and 2.4mm or even
is less and deposition rate are increased
energy used to melt the wire in the pool
3.2mm for the fill up passes. This leads
significantly. With the help of Cold / Hot
Cold Wire Feeders :
to high inventory of filler wire of same
wire feeder the semi-automatic solutions
The traditional manual welding of
material but of varied thickness. Each
can double the speed of GTAW as
GTAW includes fusion and addition of
time the welder stops for changing the
compared to manual welding process.
filler material by hand into the weld pool.
filler wire the weld needs to be restarted
The filler material usually used is in cut
with an overlap, this calls for more
when welded using a 1.6mm filler wire
lengths of about a meter Fig 1. During
grinding during finishing. Also each start
manually fed by the welder takes about
welding the welder needs to stop when
stop of welding results in additional gas
1 minute 50 seconds. Same fillet size is
the filler length left to feed is too low (2
consumption of pre-flow and post flow
achieved within 1 minute 36 seconds
to 3 inches) and replaces it with the next
settings.
when welded with a cold wire feeder
For a fillet weld of 150mm length
Cold Wire feeders help feed the wire
considering Wire Size of 1.2 mm being
short to be used is discarded. This can be
directly to the weld pool using a Pen or
fed at 900mm/minute. When clubbed
typically 2 to 3 inches per meter which
special torch. A typical setup is shown in
with a hot wire power source at 40 Amps,
amounts to about 5% of consumable
Figure 2. This helps makes the process
results in the same weld completion in 1
costs which is wasted.
semi-automatic as the wire feeding is
minute 20 seconds with filler wire being
taken care by the motorized wire feeder
fed at 1100mm/min.
filler wire. The stub end which is too
To increase the rate of deposition, usually filler wires of different
while the hand movement and other
thicknesses are used in the same job, for
aspects of the GTAW are still taken
savings as the number of start / stop
example, the welder may use a 1.2mm
care by the welder. This helps increase
will reduce drastically and so will the
weld speeds as the welder doesn’t need
welder fatigue. As shown in Figure 3 Hot
to stop often for change of filler wire,
Wire has a considerable advantage in
the wire feed rate can be adjusted and
deposition rate. Significant productivity
increased for higher deposition rates.
benefits of time and material saving
Typically 1.2 mm or 1.6 mm filler wires
are seen in Cold Wire Feeding, when
spools are used. To increase deposition
combined with GTAW and Hot Wire
rate, feed rate needs to be increased, this
GTAW.
Over a longer length will result in more
reduces the inventory of varied sizes of filler wires required. The stub end losses Figure 2 Semi-Automatic wire feeding with GTAW Torch.
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are also negligible as only at the end of
For More Details:
spool the length is wasted. This results in
Email: sigmaweld@edmail.in
FEB - MAR 2019 | WELDFAB TECH TIMES
33
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• A rising concern on health and safety
the fumes during the operation and
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protects the operator from breathing
completely avoided. Clinox Power can
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fumes.
also be used for polishing of weld area
weld cleaners to make the aggressive pickling paste a thing of the past. • Electrochemical/electrolytic weld cleaning Clinox machines are the latest trend in weld cleaning process with
• No dip methods: liquid flows from the torch through pumps and cleans the
and to improve the aesthetics. • Neutralisation is very easy and safer.
weld ensuring the cleanliness of the
Job passivation starts after two hours.
workplace, and the surroundings.
Clinox Power is also used to mark logos,
• Waste cotton is used to wipe the weld
barcodes, product names and numbers.
assurance of a safer, quicker and better
area after neutralisation. No use of
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formation of oxide on the surface in
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future.
• Its features include: inverter technology; patent blow/suction system; automatic pump for dosing the liquid; saves water; environment
34
• The product advantages offered are
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• Matte finish ensures that there is no
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polishing; neutralisation/passivation;
of dangerous and hazardous chemicals
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marking/engraving and matte finish.
like hydrofluoric and nitric acids is
Email: mehtasanghvi.k@gmail.com
WELDFAB TECH TIMES | FEB - MAR 2019
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ARTICLE
Fumes, Health & Safety in Arc Welding PART – II ( Kindly refer Dec 2018 – Jan 2019 Issue for Part – I ) terms of Mn, Ni, Cr, & particularly Cr(VI).
create doubts on acceptability. However,
This remarkable investigation carried
as far as -17 class electrode is concerned,
out in the PATON WELDING INSTITUTE,
the results of investigation done at
UKRAINE, is in-depth study of the effects
Paton Institute seem to indicate that the
of covering composition in terms of ratios
two aspects run in the same direction.
of
These favourable findings should help
a. CaCO3 : CaF2 in basic type (-15 class),
to strengthen the position of -17 class in
b. TiO2: SiO2 in time-titania type
welding of stainless steels.
(-16class), c. TiO2: SiO2 intitania silicate type (-17 class). D. S. Honavar, Chairman, Honavar Electrodes Pvt. Ltd.
SMAW
Indian welding industry has been recording a steady rise in the use of solid
The results have been evaluated for:
wire GMAW for carbon steel, with the
a. total fume emission, &
current proportion being about 30% in
b. individual elements - F, Mn, Ni,
the total arc welding. While a major part
Hexavalent Chromium (CrVI) in Welding
trivalent Cr(Cr2O3) & hexavalent
of this employs100% COl as shielding
Stainless Steels:
Cr(CrO3).
gas, switch over to 80Ar-20CO2 mixture is taking place on the basis of superior
Effect of class of covering (-15). (-16) & The findings of this elaborate
performance and substantial savings
investigation have led to the conclusion
in the total cost of welding, especially
In terms of SFA 5.4 - 2007 (AWS A 5.4 -
that covering class -17 i.e. titania-silicate
in structural jobs with fillet welds
2006) a stainless steel electrode of any
type, produces the lowest levels of (a)
constituting over 60%. A case study to
particular grade can be placed in one of
total fumes, (b) Cr(VI), & (c) Mn. Further
highlight the benefits of 80Ar-20CO2
the three classes of covering:
studies at Paton Institute and any other
was a part of my key note address at IWS
-15 basic
centres may help to reinforce these
National Seminar - September 2002. This
-16 lime-titania
findings for quantitative evaluation in
case study is also a part of my Lifetime
-17 titania-silicate.
favour of -17 class covering. During
Achievement Award Lecture of November
the past 10 years, use of -17 class of
2003. There is now growing awareness of
(Effect of the three types on suitability
S.S. electrodes has steadily increased
the relative benefits of switchover to the
for cryogenic applications, has been
in Europe, USA, Korea, on account of
argon based mixture.
dealt with my Lifetime Achievement
exceptionally pleasing characteristics in
When this growing application of
Award Lecture of November 2003). As
terms of ease of deslagging, spatter loss,
GMAW is examined in the context of
the problem of hexavalent chromium is
bead profile and appearance. In fact,
weld fumes, role of copper coating on
expected to arise more in welding of S. S.
buyers of welded fabrication in S.S. seem
the wire becomes an important issue
& in use of S. S. electrodes, this is the area
to be insisting on pleasing weld bead
and the user industry, in due course, will
which we should look at closely to know
appearance, thereby necessitating use of
have to make a choicebetween copper
about the type of covering Vs. presence
-17 class. The fast changing scenario on
coated and copper free wires. I had dealt
of Cr(VI) in fumes. For that matter, one
health & environment is prompting us
with this important issue in my Lifetime
can go further and see how the main
to ask if it is safe enough in case of every
AchievementAward Lecture of 2003.
ingredients of coverings of each of the
change aimed at productivity and quality.
In view of its importance the relevant
three classes, can significantly influence
Many a time the two aspects may tend
portion is reproduced here:
the quantum of fumes and its toxicity in
to run in opposite directions and thus
“Copper Coated Vs. Copper-free Wires:
(-17) on Cr(VI) emission.
36
6. COPPER:
WELDFAB TECH TIMES | FEB - MAR 2019
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ARTICLE
It is not easy to think of copper free wires
copper free wires."As stated therein it was
in India with its vast stretches of coast
necessary to carry out investigation in to
weld metal YS, UTS & % elongation
line with a high relative humidity almost
the relative behaviour in terms of:
between copper coated and copper
round the year. The problem of rusting is
a. Copper in fumes, &
free wires, for both 100% CO2. and
sought to be addressed through copper
b. Effect on weld metal impact property.
80Ar - 20CO2
9. There is no appreciable difference in
coating, but three problems with copper coated wires are:
Hence, I had placed this issue before
The relevant results are tabulated here:-
a. difficulties in wire feed due to clogging
the Welding Research Institute (WRI). I
Chemical Analysis of Weld Metal:
of the nozzles by copper, b. health hazard through presence of higher levels of copper in the fume, c. possible adverse effect on notch
am happy to state that WRI took up this problem for detailed investigation and reported the findings for the benefit of the welding industry, through (a) report
toughness at sub-zero temperatures
in WRI Journal Vol. 29 No.2, and (b)
such as minus 29OC.
technical paper presented in SOJOM 2008.
A recent detailed study by Mr. K. P. Ananthagopal at L & T - Komatsu Ltd.,
Conclusions drawn from the
Bangalore, has yielded results which are
investigation are -
very much in favour of copper-free wire
4. Shielding gas plays a major role in
on all the three counts, namely: a. Very much smoother wire feed, b. Less hazardous fumes, c. CVN impact values of over 100 joules as against 50-60 joules at minus 29OC. In fact, the results have been so
Comparison of Weld Metal Toughness
quantum of welding fumes - gaseous as well as particulate. 5. With copper coated wire, concentration of copper in fumes increases as the CO2 percentage in
No doubt, the very much higher impact
shielding gas increases.
values with copper free wires will be of
6. In FCAW also, copper-coated wire
interest to the welding industry. Another
encouraging that L & T Komatsu are
releases more copper in fumes as
noteworthy point in the investigation
planning to switch over to copper-
compared to copper-free wire, with
made by WRI is that copper content of
100% COl or with 80Ar - 20CO2
fumes is very much higher with FCAW
7. Concentration of copper in fumes
than with solid wire, though well below
freewire for deriving all the three benefits, namely, higher productivity, lower risk of fumes and superior weld properties.
with copper-free wire, is about 50% of
TLV of 0.2 mg. m3. Similarly, gaseous
A further change based on these studies
that with copper coated wires.
concentration of fumes with 100% CO2
is in respect of the gas mixture, from
8. Weld metal deposited by copper-
shielding gas in respect of CO, CO2,
80 Argon – 20CO2 to 85 Argon - 15 CO2.
free wire has significantly higher
NO,, SO2 and Ozone are far below the
Furthermore, L & T - Komatsu are
toughness as compared to that with
respective TLV.
planning to change over from flux-
copper coated wire, under both 100%
cored wires to copper free solid wires
CO2. and 80Ar - 20CO2.
What is noteworthy is that copper content of fumes even with copper coated
with mixed gas of 85 Argon + 15 CO2 for achieving substantial saving in the final cost of welding. Will this be a trend setter? One related aspect which has to be taken care of is provision of humidity controlled store rooms (heaters + dehumidifier) so as to maintain temperature of 20°C higher than ambient temperature and relative humidity at less than 40%. In fact, this facility is a must when one plants use
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FEB - MAR 2019 | WELDFAB TECH TIMES
37
ARTICLE
wires is well within the TLV of 0.2 mg. m3 Thus copper in fumes with copper coated wires, does not become a health hazard. However, in their attempt to lower the overall fume levels, some industries may opt for copper free wires, as has been done by L & T Komastu, Bangalore.
7. Respirable & Inhalable LimitsRealistic Approach? Since 2004 indepth studies combined with a realistic approach to the complex issue of health safeguardVs. feasibility of implementation of exposure limits in industries, have led to the proposal for two levels: RESPIRABLE at lower limit & INHALABLE at higher limit. Thus; line with the limit prescribed in the USA
with the issue, based on the latest data
& UK.
available.
It is noteworthy that the Factories This is a pointer to what is in the offing
Act, 1948 contains a provision for Safety
for the Indian welding industry so as
Committee consisting of equal number of
V. WHAT MORE NEEDS TO BE DONE IN INDIA.
to prepare itself for systematic plan to
members from management and workers
In the USA, Lincoln Electric Co. has made
control fumes to minimize risk to health
to promote cooperation in maintaining
available on its website their “Guide to
of personnel.
safety & health at work in hazardous
Welding Fume Control”. It is a typical
processes for which special license is
example of how a manufacturer of welding
IV. INDIAN SCENARIO:
required to set up the manufacturing unit
consumables ought to discharge its
In India, the “Factories Act, 1948” lays
even in respect of its location. While this
responsibility in protecting the workforce
down several provisions to cover safety &
does not apply to welding industries, the
in a welding shop or site against the hazard
health aspects in manufacturing industries
relevant point is ensuring safety & health
of fumes, by issuing guidelines which
- chemical mechanical & electrical.
through cooperative effort and awareness
are no doubt within the limitations of
Chapter 4, sub 67 in which Schedule I & II
programmes at all levels of work force.
a manufacturer and based on available
(pages 124, 125) specify use of appropriate
In “The Third Schedule” (page 80) are listed the Notifiable Diseases which
the guide serve to highlight the need for
infrared radiations emitted by welding.
include Manganese poisoning, or its
appropriate action in our country:
Chapter 3 Section 14 deals with protective
sequelae.
measures in areas where hazardous dust/
Thus the provisions in Factories Act 1948
“Employers are responsible for providing a safe and healthy workplace for
fumes are likelyto be generated. THE
do cover the aspect of fumes and limits for
their employees. Under OSHA’s Hazard
SECOND SCHEDULE Section 41 F (pages
hazardous constituents. What is necessary
Communication Standards, employers
75 - 78) lays down permissible levels
is to update the provision in line with
are required to evaluate the hazards of the
ofnumerous chemical substances in work
the revised international limits. Process
chemicals in their workplace, train their
environment.
of revision in the Factories Act may be
employees in the identity, hazard, and
somewhat slow because of the procedures
means to protect themselves, and provide
fumes is 5 mg. i m3 for Time weighted
involved. Hence the need for industry
information about the hazards identified
average of 8 hours of exposure. So, it is in
and industrial safety organizations to deal
on labels on shipped containers, material
Permissible Exposure limit for welding
38
information. The following few lines from
eye protection from ultraviolet and
WELDFAB TECH TIMES | FEB - MAR 2019
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ARTICLE
safety data sheets (MSDS)and other
their respective activities. Shall I put it to
to measures for ventilation and extraction.
information available to them.
you that a student of welding engineering
In the long run, investment for good
Under OSHA’s Air Contaminant
should have some knowledge of safety&
working environment will prove beneficial.
Standards, an employee’s potential
health aspects. when he/she steps into a
Having given due attention to the
exposure is measured and comparedto
working career, along with knowledge and
numerous sources of health hazards, it is
the OSHA Permissible Exposure Limit. If
enthusiasm to handle quality, productivity
of paramount importance to help welders
a company has a policy setting its own
in welded fabrication. Is it a tall order?
&operators in particular to overcome the
Occupational exposure Limit (such as
Well the current scenario makes it an
fears about welding fumes. Imparting
the ACGIH Threshold limit Value (TLV)
elementary need, a necessity. We need not
knowledge of the inevitability of fumes,
if lower than the OSHA PEL) then the
and should not wait for the Factory Act to
& simple precautions during welding
employee’s potential exposure would
be amended to provide for more stringent
(e.g. use of head shield) will result in a
be compared to that value. Employers
safeguards in respect to welding fumes.
realistic attitude towards fumes, more
train their employees about the identity,
V. A. Need for Improvement in good
so when appropriate measures are taken
hazard, and means to protect themselves
working Environment & need for
for ventilation & fume extraction. It has
from hazardous chemicals. Employees are
imparting knowledge to the workforce.
to be a combined effort on the part of
expected to participate in their employes’
In tackling the problem of fumes as
management & workforce.
protective programs and take steps to
health hazard one has to keep in mind
protect themselves. The guide then
that the adverse effects on human body
CONCLUSION:
provides a few- details of
and health continue to be the subject
We all have to accept the harsh reality that
(a) Engineering Controls;
of intensive and extensive research,
we have a long way to go and the task has
(b) Work Practice Controls;
especially in medical. The status for
become more difficult and now costly
(c) Personal Protection Equipment (PPE).
several elements in both qualitative and
because the industry as a whole has not
quantitative terms is not clear even for
done enough in the last thirty years, and
Similar effort is being made by- ESAB,
fixing safe WES (in UK) & OES (in USA).
that too after knowing so much about
& other world leaders who are in the
Manganese and nickel, two of the most
the need to control fumes, just like the
business of welding & cutting. While
important elements are in this category.
need to guard against electric shocks and
manufacturers in our country need to
As far as Hexavalent Chromium is
ultraviolet rays. Here again, the situation
emulate their examples, the professional
concerned, the new stringent standard
tends to become complicated because of
bodies - IWS, IIW, need to draw up
calls for carefully planned and monitored
the difference in the functioning of the
and launch programmes - documents,
measures on a regular basis, especially in
organized sector and the unorganized
workshops in the required measure, to
welding of stainless steels, in respect of
sector. And then, fumes is only one
create awareness of the hazards and
quantum of generation and its effective
important part of the larger issue of safety
corresponding preventive or controlling
control in the welder breathing zone and
& health of the workforce. May I state that
measures, among the vast workforce
shop environment. In the light of such
this issue of safety & health, along with
and industrial units, especially in the
a situation combined with the growing
education, training and certification, has
SMEs who do not possess a set-up for
concern for health and environment, the
to engage the attention of professional
such efforts. It implies that technological
welding industry has to give due attention
bodies in India, just as it has been
advancement should not be separated from Safety & Health care. We members of welding fraternity expect welding operation to be integrated with the overall manufacturing process, & this is valid because of the importance of welding. By the same logic, the welding professional bodies, Industrial Training Institute and academic institutions ought to integrate health & safety aspect with technology in
40
WELDFAB TECH TIMES | FEB - MAR 2019
Investment in Good Working Environment
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ARTICLE
receiving from the bodies in the USA, UK,
about fumes. It has a lot of weightage in
said that, I wish to refer to the significant
Japan & European countries, on a priority
convincing welders who maybe prejudiced
remark made by Dr. GOLDRATT,
basis. It is a challenge to be accepted and
against fumes. I have myself used it
internationally acclaimed management
tackled with planning and adequate speed.
effectively on numerous occasions in
guru, in relation to Indian scenario in
The need is for IWS, IIW, with support from
industries with a large workforce of welders
business & industry, in 1999. Dr. Goldratt
WRI, industry & safety organizations, to
who had become agitated to the extent of
said the problem with Indian business
conduct workshops devoted to the various
work stoppage. Success in resolving such
is “you have the intuition but not the
aspects of safety & health in welding. In this
grave situations, has given me immense
method”. The professional bodies (IWS
context of welding fumes, I wish to share
satisfaction. In turn, I have earned the
&IIW) have to evolve methodology for
with you, my experience of the past few
gratitude of welders as well as senior
cooperative coordinated planning &
years in tackling the problem with regard to
executives of such industries.
working to derive the benefit of synergy in all areas of Joining Technology and
fears of welder community. In the positive measures implemented by a progressive
Finally, one message has to be loud and
particularly in safety & health and in
management, as a part of corporate HRD
clear, and we have to choose:
education & training, which have not
programme to tackle the problem of fumes
“Are welding is a safe operation, if carried
been given due attention in the past four
on the shopfloor, one has to keep in mind
out with requisite knowledge and full
decades. But then, taking a philosophical
the fact that many or majority of welders
practice of safety & health precautions,
view, it is never too late to start. Let us
(especially older generation & hence
making a huge contribution, directly &
all make a resolve that the time is now, &
senior) are likely to be partially or totally
indirectly, to industrial output, society’s
endevour to make up for the lost time, with
illiterate. Their attitude and reservations
progress and nation building. Ignoring
a sense of purpose & dedication.
based on fear psychology, have to be
the precautions can prove costly to the
addressed. In doing so, a very useful
organization & its workforce and, in turn,
Personnel Absenteeism turnover down
document is the leaflet published in 1985
give a bad name to welding, despite it
Results _ Easier Recruitment _ Lower Cost
by The Welding Institute (TWI). This leaflet
being indispensable.”. The choice is
_ Shorter Lead Time.
can be looked upon as an authoritative
obvious, but we all members of welding
source of information to tackle welder’s
fraternity need to take prompt positive
Leading to: Competitiveness &
psychology and fear & wrong notions
measures with long term planning. Having
Increased Sale.
www.weldfabtechtimes.com
Productivity up Quality up Sickness &
FEB - MAR 2019 | WELDFAB TECH TIMES
41
INTERVIEW
“ISO 3834 is not ‘Quality Management Standard’ that replaces ISO 9000 series, but very ‘Useful Tool’ for fulfilling ISO 9001 requirements.” Q1. Could you brief us on the welding market scenario in Japan?
called ‘The first year of Robotization’
consumables in Japan was 292,000
One indicator that shows the trend of the
in Japan. The welding robot system
tonnes, and the Gas-Shield Metal Arc
welding industry in Japan is a production
and the automatic/mechanized
Welding consumable was 2,37,000
of welding consumables transition.
welding equipment began to spread to
tonnes among those. Thus, the ratio of
The market trend of the arc welding
welding stage among various welding
welding consumables for Gas-Shielded
consumables in recent ten years is as
manufacturers. This welding process
Metal Arc Welding is about 81% in Japan.
follows; the production during 2008 was
with robot systems, the automation
about 350,000 tonnes in Japan. However,
and mechanization in welding became
it decreased nearly 2,50,000 tonnes
factors wherein the Gas-Shielded Metal
after the financial crisis by Lehman
Arc Welding process expanded too.
collapse, and its trend has continued
The ratio of the production of covered
Therefore, the demand of welding
Q3. What is your say on the welding market scenario in India as compared to Japan market? The demand for welding consumables
still now. But the production of welding
electrode and the Gas-Shield Arc
links with the steel consumption
consumables is expected to increase a
Welding consumables (welding wires)
(Apparent Steel Use, finished steel
little for the infrastructure maintenance,
is reversed in 1985, and the production
products), and is considered about
corresponding to Tokyo Olympics, etc.
of the Gas-Shield Metal Arc Welding
0.4%-0.5% of the consumption of steel
consumable accounts for 70% during
to be a quantity demanded for welding
Q2. How is the demand scenario for welding products in Japan?
1990's.
consumables in Japan. If it is assumed
About 70% of the welding consumable
production by the Japanese maker only.
welding consumable demand is estimated
production was covered by electrode
It is necessary to take imported welding
to be about 4,00,000 tonnes in India.
in the first half of 1970's, when the
consumables into consideration to
shipbuilding industry of Japan accounted
know the domestic demand in Japan.
consumables will increase because India
for 50% of the world share. However,
Currently, a large amount of Gas-Shield
is only one country that is increasing the
to promote the energy saving and the
Metal Arc Welding consumable (welding
steel production/steel consumption in
production efficiency improvement in
wire) is being imported by Japan from
Asia.
the welding stage, the manufacturers
countries like South Korea , China etc.
The above-mentioned trend is the
that the ratio is the same as Japan, the
So I think that the demand for welding
process from Shielded Metal Arc Welding
the domestic production of welding
(SMAW) to Gas-Shielded Metal Arc
consumables was 2,52,000 tonnes, and
Q4. What new technologies have been introduced in Japan, especially when welding is concern?
Welding (GMAW) with the Oil Crisis in
33,000 tonnes were exported among
In the field arc welding, I am paying
the latter half of 1970's.
those, and 73,000 tonnes were imported.
attention to the new control technology
of Japan greatly converted the welding
44
In addition, the year 1980 was
WELDFAB TECH TIMES | FEB - MAR 2019
According to statistics in 2017,
www.weldfabtechtimes.com
INTERVIEW
with welding power sources. I also was
standard that becomes the core of the
developing the welding power sources
quality control of welding is ISO 3834
that applied inverter waveform control
series. In Japan, the national standard,
technology in 1980’s – 1990’s. Compared
JIS Z 3400 was developed in 1999. This
with the past, there are somethings to
JIS Z 3400 is harmonized with ISO 3834
be surprised in advancement of the
series. Because ISO 3834 or JIS Z 3400 is
recent technology in arc stabilization or
not necessary widespread, even in Japan,
reducing of spatter in GMAW.
I am trying to spread these standards whenever there is a chance.
Q5. What major challenges do the welding market in Japan faces? What can be the ways to resolve the same?
Q8. What is ISO 3834? Please elaborate. How important can the ISO 3834 be for welding industry?
The personnel training, passing down
ISO 3834 is not ‘Quality Management
the welding skill is a big problem in Japan. Personnel who is related to welding has been decreasing in Japan. In each manufacturer, how knowledge and skill that the manufacturers have, are handed down to the next generation becomes big problem.
Q6. According to you, which are the best quality welding structures applied into any welding projects of Japan? As you know, the severe earthquake has occurred many times up to now in Japan. And technological development to make damage a minimum in every case has been done. I think, most of the welding structure in Japan has the best quality.
Q7. What type of international standards for welding quality management are been practiced in Japan? A lot of manufacturers in Japan have certificate of ISO 9001. However, the
www.weldfabtechtimes.com
Masaharu Sato, Expert, Qualification & Certification Department, The Japan Welding Engineering Society (JWES)
INTERVIEW
but very ‘Useful Tool’ for fulfilling ISO
Q10. JWES role towards Welders Skill Development?
important. The certificate is only evidence
9001 requirements. ISO 3834 provides
Up to now, each manufacturer has
of qualification. The qualification of
guidance for describing the capability
promoted welding personnel (especially
welding personnel, not only welder but
of manufacturer to produce welded
welders)by themselves in Japan. However,
also welding engineer, welding inspection
structures of a specific quality. And the
as mentioned above, the number of
personnel, etc., is necessary in any
customers might require certification
welding personnel is decreasing because
countries and into any manufacturing
according to ISO 3834. The certifications
of the declining birthrate and aging. So,
segment.
are often used by manufacturers or
the education/training for welders among
specified by owners to provide quality.
the manufacturer becomes difficult.
Q9. Could you brief us on the role of JWES for the upliftment of welding industry in Japan?
training program in 2018. This program
Q12. Safety in Welding is highly important. What is JWES’s role towards safety?
is a one-year training curriculum that
We are recognizing that the health and
combines OFF-JT (skill training at training
safety in welding is a very important
The JWES has been playing an important
body) with OJT (on the job training). We
aspect. We have special departmental
role to promote the coordination
want to do this program expansion in
group related to the welding health and
activities by the applied ‘Research
the future after ascertaining the training
safety. It consists of members from
Divisions’ classified into each industry
effect.
the industry field, the representative
Standard’ that replaces ISO 9000 series,
The JWES has opened a new skill
Not ‘Certification’ but ‘Qualification’ is
from universities, and governmental
and the basic ‘Research Committees’.
organization (Institute of occupational
welding and joining technologies of the
Q11. Please share some of the interesting experienes while in the role for JWES?
manufacturers. The major activities of
The JWES advances the development of
• Propulsion the countermeasure on
JWES are;
‘Common Welder Certification Scheme’
• To conduct researches/investigation
in Asian countries as a core member of
We intend to make every effort to assist the preservation and developments of
of welding and joining, and to publish
Asian Welding Federation (AWF). The
their accomplishments;
certification scheme of welder is based on
safety and health). The major activities of this group are; prevention of hazards due to dust; • Implementation of the seminar on welding safety and health;
qualification test according to ISO 9606-1, • To develop standards based on
and this scheme is aimed to qualify the
the accomplishments of research/
welders by the same rule and procedures
investigation activities;
in AWF member countries. Moreover, we have been conducting the
• To conduct qualification/certification
health and safety in welding, etc.
Closing message.
activity to introduce the JWES certification
At present, I am mainly doing the work
activities from a viewpoint of the
program for welding engineers from each
related to standardization. So, I am getting
quality assurance;
Asian countries/area cooperation with
worried about why do not Indian welding
local welding societies. The purpose of
industries apply the Indian national
this activity is to cancel the technology gap
standards on personnel qualification
the activities of standardization,
and shortage of welding engineers in Asian
more. Indian industries should think
education/training, and certification;
countries.
what is necessary to apply these national
• To contribute internationally through
• To provide the knowledge, information and education tools.
46
• Development of the standards on
WELDFAB TECH TIMES | FEB - MAR 2019
Certification in Welding plays a major
standards. Because it is the industries
role. Your say. What types of certifications
themselves that develop and use the
are mandatory in Japan? Please elaborate.
national standards related to welding.
www.weldfabtechtimes.com
CASE STUDY
The Multi-purpose Fast Neutron Research Reactor (MBIR)
R
esearch reactors have contributed substantially to the development of nuclear science
and technology for the last half-century. But today we are at the point where most of the discoveries achievable with existing research reactors have already been made. New innovations and discoveries need newer tools and more powerful research facilities based on high flux reactors with well-equipped laboratories for post-irradiation experiments and extended research options. But the world reactor fleet is inevitably
neutron projects are MBIR – currently
aging. There are less than 250 operating
will be close to their 60th anniversary by
under construction – and MYRRA
research reactors in the world. The
2020.
which is still at a design stage and will
vast majority of them are operated
But there should be a surplus capacity
be a valuable addendum to the world
for about 50 years, approaching their
to catch up with the requirements of
research potential in a longer term
decommissioning within the next couple
tomorrow and beyond.
horizon but will need test facilities of
of decades.
50
Major European research reactors
WELDFAB TECH TIMES | FEB - MAR 2019
Out of the new construction, the fast
the fast spectrum before passing on to
www.weldfabtechtimes.com
CASE STUDY
metal coolant (sodium). The facility will be equipped with a wide range of experimental devices providing for a variety of research options. MBIR reactor is a loop type facility with three cooling circuits. The facility will be equipped with the following in-core elements: • 14 cells for material testing assemblies • 3 instrumented channels • up to 3 Independent loops for different coolants • Outside the core there may be up to 6 horizontal and up to 14 vertical experimental channels (nay be used also for silicon doping, isotope pellets irradiation and NAA.
Fabrication of vessel for MBIR The AEM-technology Company (a part of Atomenergomash JSC, the mechanical engineering division of Rosatom) had the construction stage. Commercial fast
consumer properties for the following
started to fabricate a vessel for the Multi-
reactors – BNs including – may also be
tasks: carrying out reactor and post-
Purpose Fast Neutron Research Reactor
used for a range of research but they are
reactor studies, generating electricity
(the MBIR) during 2017. The MBIR is
neither intended not adapted therefor so
and heat, developing new technologies
being deployed on a SSC RIAR JSC site in
research programs will have to adapt to
for the production of radioisotopes and
Dimitrovgrad, Ulyanovsk Oblast.
the reactors’ work schedule not the other
modified materials.
Machining of the first large workpiece of the MBIR, a conical adapter for the
way round as it is with a research reactor.
MBIR research reactor facility
reactor vessel bottom, was taking place
an alternative for some time but it
MBIR is a research facility with a
at the production facility of Atommash.
is the same level of research as the
multipurpose fast neutron reactor and
Simultaneously with the turning and
Thermal research reactors may be
past 2-3 decades and efficient for the existing reactor types but with limited capabilities for innovative technological cases which are thus left with 3D modeling option – an exhibitive exercise but hardly enough for moving up to a practical application. So without new high flux research reactors providing the fast neutron spectrum within a couple of decades nuclear science and material testing may face a shortage of tools. The purpose of the MBIR construction is the creation of a high-flux fast neutron research reactor with unique
www.weldfabtechtimes.com
Source: Rosatom
FEB - MAR 2019 | WELDFAB TECH TIMES
51
CASE STUDY
boring operations, the first welding on an upper shell ring was being performed. The finished 83-ton reactor vessel is 12 meters long and 4 meters in diameter. Fourteen more workpieces with a total weight of 360 tons was planned for production at the Volgodonsk Branch, including vessel components and support structures. The AEM-technology Company is the main MBIR equipment supplier. Some pieces are fabricated at the Petrozavodskmash Branch. The Multi-purpose Fast Neutron Research Reactor (the MBIR) will be the most powerful operating research reactor in the world. The new sodiumcooled reactor will have a thermal capacity of 150 MW. The MBIR’s unique tech specs will allow to solve quite a few
MBIR - the multipurpose sodium-cooled
experimental fast reactor that has been
research problems in order to create
fast neutron research reactor during
in operation at NIIAR's site since 1969.
new, competitive and safe nuclear
2018 that is to be installed at the site
energy facilities, including fast reactors.
of the Research Institute of Atomic
chamber have been welded, AEM-
Therewith, the research periods at
Reactors (NIIAR) at Dmitrovgrad, which
Technology said, adding that the length
MBIR will be shorter compared to the
is in Russia's Ulyanovsk region. AEM-
of the welded seam exceeded 6 metres
operating reactors.
Technology is part of Atomenergomash,
and had a wall thickness of 22 mm. The
a subsidiary of Russian state nuclear
basket, which will be installed inside
Welding milestone with fast neutron reactor
corporation Rosatom.
the building of the research reactor, will
AEM-Technology has announced the
foreign collaboration, in connection
flows. It will weigh 45 tonnes, be more
completion of key welding work on
with the International Atomic Energy
than 5m long and have a diameter of 3m.
The MBIR project is to be open to
Agency's International Project on
52
The basket and the high-pressure
WELDFAB TECH TIMES | FEB - MAR 2019
divide the incoming and outgoing coolant
Yulia Chizhova, executive director of
Innovative Nuclear Reactors and Fuel
JSC AEM-Technology, said the MBIR
Cycles. MBIR will replace the BOR-60
project is unique and thus "tests the
www.weldfabtechtimes.com
CASE STUDY
comparison: the thickness of the VVER1200 reactor pressure vessel is 300 mm) there are risks of changing equipment geometry during processing. For exact observance of parameters throughout the entire production of the reactor, a special purpose tooling was used. The next steps in the manufacture of a research reactor will be hydraulic test, the assembly of a protective casing, after which the second stage of the test assembly will be completed with all the internals. “This is an interesting project for us, an opportunity to find new effective decisions,” said Igor Kotov, Director General of JSC "AEM-Technology". company’s skills and ability to meet technological challenges quickly".
cradle of 70 mm. The test assembly has been attended
You can say a new chapter in history of nuclear energy is being written today on
by a special representative of the State
our site. MBIR is a fundamentally new
Atommash performed a Test Assembly
Corporation Rosatom for international
product, and all operations performed
and scientific projects Vyacheslav
by the "AEM-technology" team are
The Volgodonsk Branch of JSC"AEM-
Pershukov. “Unique equipment is a
performed for the first time. ”
technology" (a part of the Rosatom
unique enterprise. “Atommash, of
engineering division - Atomenergomash)
course, has enough competencies,” he
equipment supplier of the MBIR reactor
has performed the first stage of the test
said. The task is rather complicated for
facility. On the basis of the Volgodonsk
assembly of the world's multifunctional
the whole Rosatom, including due to the
Branch of JSC "AEM-technology", 14
fast research reactor MBIR during 2019.
large scope of international orders. To
products will be manufactured for a
"Atomenergomash" is the main
the best of its uniqueness, MBIR is not a
multifunctional research reactor with a
in a caisson with a depth of 20 meters.
priority for us from the point of view of
total weight of over 360 tons including
During the procedure, the reactor
commerce, but it is so from the point of
internals and supporting structures.
pressure vessel was installed on a special
view of reputation.”
The test assembly has been performed
The multifunctional fast research
support using a crane, after which the
“MBIR is a unique complex project,
reactor (MBIR) will be the most powerful
height of the assembly unit exceeded
in the implementation of which several
of the existing, constructed and designed
10 meters, diameter - 4 meters with a
enterprises of the division take part:
research reactors in the world. The
reactor pressure vessel weight of 60 tons.
"Atommash", "Petrozavodskmash", and
thermal capacity of the liquid sodium
The cradle has been installed inside the
also the foundry "Petrozavodskmash",
coolant reactor will be 150 MW. The
reactor pressure vessel. It is designed to
which participated in the manufacture
unique technical characteristics of
separate the coolant flows entering and
of large-sized castings. Non-standard
MBIR will allow solving a wide range of
leaving MBIR, organize the cooling of the
equipment always requires new tools
research tasks in support of the creation
reactor pressure vessel and the internals,
and technical solutions that have been
of new competitive and safe nuclear
and also location of the additional
developed and used by our specialists,”-
power plants, including fast neutron
parts. The weight of the cradle is 25
said Andrey Nikipelov, Director General
reactors for closing the nuclear fuel
tons, the length exceeds 5 meters, and
of JSC "Atomenergomash".
cycle. At the same time, the research time at MBIR, as compared with
the diameter is 3 meters. In some areas,
In particular, due to the small metal
specialists needed to ensure a uniform
thickness of the MBIR vessel (from 25 to
currently operating reactors, will be
gap between the vessel and the reactor
50 mm with a diameter of 4 meters - for
reduced several times.
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FEB - MAR 2019 | WELDFAB TECH TIMES
53
TRAINING CENTER
Okanagan College powers up new welding building in Penticton
W
Welding Program Advisory Committee.
elders training in the South
for their training, where they can access
Okanagan now have a state-of-
services and enjoy a more rewarding
“As an employer in this community,
the-art new shop in which to
overall experience was another goal,”
and someone who has been involved in
spark their torches and test their metal.
notes Eric Corneau, Regional Dean for
watching the College’s welding program
Okanagan College officials, students,
the South Okanagan-Similkameen. “It
develop and change over the years, I’m
industry partners and community
was important to us that our welding
excited that we now have this purpose-
members gathered at the Penticton
students be able to enjoy the same
built facility to help train tomorrow’s
campus today to mark the opening of the
student experience as their peers in other
welders and meet the needs of employers
College’s new $2.2-million, 465-square-
programs.”
in the area,” says Harder.
metre (5,000 square ft.), welding facility.
The new facility will also afford the
“We are now looking to increase the
College enhanced space and flexibility to
number of apprentices we have because
Foundation students, who, under the
be able to offer other trades programs on
of this local program and would like to
tutelage of instructor Mark Stathers, will
campus.
encourage other employers to do the
Among them was a class of 16 Welder
be the first to train in the facility. The shop
“In addition to serving our welding
same.” The facility was designed and built
they’ll soon step into is one of the most
students, we’ll be able to utilize the space
advanced and sustainable in the province,
to deliver offerings like our Gateway to
by Okanagan-based builder Faction
informed by extensive input from industry.
Trades for high school students and our
Projects Inc.
“In building this facility, we had several
Women in Trades programs. Our HVAC
goals,” explains Jim Hamilton, President of
Foundation students will tap into it from
For More Info:
Okanagan College. “We set out to provide
time to time as well,” explains Steve
www.okanagan.bc.ca
the highest quality learning environment
Moores, the College’s Dean of Trades and
for our trades students and apprentices in
Apprenticeship.
the South Okanagan, to build a space that
“It will also open doors to customized
would help to meet the needs of employers
training opportunities, which we expect
in the region, and to further reduce our
will be of great benefit to local employers.”
carbon footprint in Penticton.” Previous intakes of welding students
One of those employers pleased to see the new space come on stream is
in Penticton trained in leased facilities
Brad Harder, the President of Penticton
off campus. A decade of strong demand
Fabricating and chair of the College’s
for welders in the region, along with opportunities to reduce costs and improve the sustainability factor, spurred the College to build its own purpose-built welding facility on campus. “Bringing students back on campus
54
WELDFAB TECH TIMES | FEB - MAR 2019
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WELDER’S PASSION
‘’There is always a scope for improvement & learning.’’
learning opportunities by working in different countries with different materials by different arc welding processes ensured that my passion for welding kept growing.
Q3. What type of projects you’re currently working upon? Our projects are focused on improvements in productivity and quality. Our recent work has been in improving the welding speeds of submerged arc welding fluxes and usability, eliminating the need for redrying. We are also working on improving
Kalliappan S., Chief Welder, ESAB India Ltd
user appeal for welding electrodes by developing electrodes with very low levels of diffusible hydrogen with extremely low
Q1. Tell us a little about yourself?
of welding in various parts of the world
moisture re-absorption properties. We
My early life was spent in Thiruverkadu,
has helped me develop my capabilities
also continuously conduct benchmarking
Chennai. A number of years of my early
in welding different materials by all arc
exercises to identify new features and
working life was spent in various places
welding processes.
opportunities for improvement in welding performance.
like Singapore, Malaysia, Nigeria, Brazil, to return home brought me to my current
Q2. What made you choose welding as a career?
role at ESAB as Chief Welder at the Global
The workshop next to my home aroused
R&D Centre for Consumables in Chennai.
my curiosity in welding and motivated
Q4. Can you describe on some of the mega projects you worked upon in the past?
Over 30 years of experience in the field
me to pursue a career in welding. The
I have had an exciting journey with various
Dubai, China & Netherlands. My desire
56
WELDFAB TECH TIMES | FEB - MAR 2019
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WELDER’S PASSION
milestones. My early learning came from
and its impact on weld integrity while
fabrication of 169 high pressure pipeline
balancing it with an appreciation of the
joints with zero defect in 1996. The next
importance of weld properties. Willingness
challenging project came my way in 2000
to appreciate others suggestions and
Q11. Right from the time you started your career till date, what has been your learning so far? Any new skills you have learned?
in the fabrication of special vessels for the
views as well as the importance of
I believe ‘’there is always a scope for
Salem Steel Plant expansion program.
the circumstance helped me manage
improvement and learning’’. After
My desire to share my knowledge and
those tough situations and supportedin
associating with ESAB, I have learnt how
experience led me to leading a welding
maintaining good conduct.
to characterize welding performance of
training program for 800 welders in
consumables.The trust of my colleagues to evaluate the performance of welding
industry working on projects at Singapore,
Q7. Your say on ‘Safety at Work’. How do you consider the same when on site?
Malaysia & Dubai from 2004 to 2006. Our
Reduce workplace stress, take regular
me confidence on my abilities. My
current work allows me to contribute in
breaks, use mechanical aids whenever
experience with equipment R&D team
development of productivity & quality
possible, wear protective equipment to
has taught me that welding performance
improvement product and solutions
suit the task, and Stay Sober.
is a result of the right combination of
Singapore from 2000 to 2004. My passion for travel took me to the shipbuilding
that travel to a range of industries across different parts of the world.
Q5. What challenges did you come across when at work? How do you manage to cope up with the same?
consumables for global projects across different arc welding processes gives
welding consumables, equipment,
Q8. Any anecdotes you wish to share so support the importance of safety for welders?
technique and welder skill.
Welding on Project sites pushes you
co- welders, who was doing maintenance
through a range of challenges from
welding at a height of 126 meters without
difficult welding conditions, exposure
the use of any belt and rope. Since then, I
to extreme weather, heat from welding,
always ensure safety precautions for myself
Q12. Availability of skilled welders is a major problem in India. All the skilled welders opt to work abroad. Your say. Any expectations from the government to push the skilled welders work for projects in India?
the pressure of timelines and limited
& others at work by using appropriate
Skilled welders prefer to work abroad
awareness of Health & Safety. Experience
protective equipment to suit the task.
due to salary differences. Also older
During 1998 @ Bharuch- Gujarat, I witnessed a fatal accident of one of my
with different people and cultures posed
technology and poor awareness of health & safety have limited the choices
focus on the job on hand. Maintaining
Q9. What is your greatest strength, and how does it help you as a Welder?
good rapport with them, listening and
Concentration & hand stability is my
country. However, in recent years,
understanding their needs helped me gain
strength, which supports me to do lot of
the demand of automatic and semi-
their respect.
critical jobs in different positional welding.
automatic welding production systems
Q6. Can you tell us about a time when you disagreed with your senior’s decision made at work on Welding? Why? How did you manage to handle the same?
Q10. Can you please share an incident of a toughest welding job you have come across?
investing in skill development activities
During 2005, welding @ midnight around
showcase and improve their talents.
Sometimes conflicting priorities of
from Singapore to Brazil, the sewage pipe
Closing message
weld appeal & aesthetics and properties
line burst and we needed to arrest the leak
Weld Quality is very important for the
required for service conditions cause
as soon as possible to avoid sewage water
Safety of millions of people that use
disagreements. Increased awareness of
entering engine room. We closed the gate
engineering structures in the course of
the overall requirements from welding
valve and repaired the leak within 5hrs. It
their daily life. We need to ensure that the
helped me communicate the importance
was really tough to weld when the ship is
Health and Safety of Welders remain an
of difficult to measure user friendliness
in motion and the sea is rough.
equal priority.
various challenges, but also helped my
for welders interested to return to their
are rising. Government institutions are
www.weldfabtechtimes.com
but the limited availability of work does not provide enough opportunity to
1.00AM on a container ship travelling
FEB - MAR 2019 | WELDFAB TECH TIMES
57
WELDING TIPS
Beginner Welding Tips
A
re you new to welding? If so, you
will be deposited into the puddle. This
may be looking for some expert
will end up creating a convex weld bead
advice to help you to get started.
which lacks the right penetration. It will
Getting some hands-on experience is key
also look as if it’s sitting on top of the
to learning welding, and practice and
base metal surface. Also, it will focus
time is always essential before being able
the heat towards the puddle rather that
to put your new skills to use. Here are
towards the base metal and this weakens
some top tips to help you to adjust more
the weld even more. If you weld too
quickly and more effectively to your
quickly, the bead will be too thin and
welding training.
may undercut the metal surrounding it resulting in a recessed or concave shape.
1. Leading the puddle
The bead may also be inconsistent since
The basics of welding lie in creating the
the puddle will have to try to keep up
puddle to melt the filler material in. You
with your weld.
need to practice leading that puddle If you wait too long in a single spot,
4. Calibrating the electrode size and amperage before welding
you may end up burning a hole right
The amperage will generally be
through the base metal, sometimes your
determined by the type and size of
welder may get stuck too. The distance
electrode you’re using. If the amperage is
maintained between the base and rod
too low, sticking is more likely. Also, your
and the speed that you travel at are
arc may stutter or go out, even if you’re
without needing to stretch too far and
crucial. If the distance is too close, your
holding it at the right distance. On the
always lower your welding helmet’s
rod is going to stick. If it’s too far, the
other hand, if the amperage is too head,
shield using your hands instead of
arc will be disconnected or it’ll splatter.
burn-through is possible as is excessive
jerking your head. If you’re too tense,
Again, if you travel too slow or too fast,
noise. Your electrode will usually char
muscle strains are likely, so stay as
the filler material won’t be consumed at
and this affects the flux’s effectiveness.
relaxed as possible and take plenty of
the correct rate. This will result in a weak
Also, the puddle will be too fluid and this
breaks for stretching. Choosing the
and inconsistent weld.
will make spattering more likely and the
right footwear is part of staying on task.
puddle more difficult to control.
While wearing appropriate welding
without actually trying to join the metals.
2. Care for your tools
boots is vital to guard against accidental impacts or burns, you should always
tools. If you’re TIG welding, the rod’s
5. Use an ergonomic welding solution
purity and the surface material’s
You’ll know by now that welding is very
comfortable all-day wear. With the right
cleanliness is vital to a strong and secure
physically demanding. Therefore, using
boots, your feet will be safe without
weld. You should therefore store your
your body properly to guard against
suffering from blisters or aching from
filler rods properly in a capped PVC pipe.
long-term injuries is important. You
long hours of wear.
Always care properly for your welding
can make welding more comfortable
58
Marie Swan, Writer, Rare My Welder
choose footwear which is guarantees
Follow these top tips for beginner
3. Get the travel speed right
by finding a comfortable and stable
welders and get your new hobby or
Once you’ve found the right travel speed,
working position in which you can
career off to the best possible start. If you
you’ll find the arc stays in the puddle’s
stay for extended periods, using tables
follow this expert advice, you’ll be more
leading third. If you travel too slow or too
and lifts to bring up lower work to the
comfortable and more proficient when
fast, the consequences will be different.
right level for you. Also, store your tools
you finally begin on your first welding
If you weld too slowly, too much material
where you’re able to easily access them
project. Good luck!
WELDFAB TECH TIMES | FEB - MAR 2019
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EVENTS UPDATE
NATIONAL EVENT
DATE
LOCATION
Messe Cutting & Welding India 2019
03 – 05 April, 2019
Hyderabad
Conference & Exhibition on Welding & Fabrication Technology
25 - 26 Apr, 2019
New Delhi, India
Blech India 2019
25 – 27 April, 2019
Bombay Convention & Exhibition Centre (BCEC)
WeldExpo
04 – 07 July, 2019
Pragati Maidan, New Delhi, India
Delhi Machine Tool Expo (MTX)
08 - 11 Aug, 2019
New Delhi, India
Cutting & Welding Equipment Expo (CWE Mumbai)
20 - 22 Sep, 2019
Bombay Exhibition Centre, Mumbai
International Conference On Cutting-edge Technologies in Engineering
14 - 16 Nov, 2019
SRMU Lucknow, Barabanki, India
Engi Expo
22 - 25 Dec, 2019
Rajkot, India
Engi Expo (EngiExpo)
15 - 17 Feb, 2020
Vadodara, India
IC 2020 & Weld India
06 – 09 Feb, 2020
CIDCO, Navi Mumbai
India Essen Welding & Cutting
23 - 25 Nov, 2020
Mumbai, India
INTERNATIONAL
60
EVENT
DATE
LOCATION
Welding & Cutting
09 – 12 Apr, 2019
Minsk Marriott Hotel, Minsk, Belarus
Cutting Edge Educational Remodeling Expo
09 May 2019
Atlanta, USA
Welding
21 - 23 May, 2019
Zaporizhia, Ukraine
Welding Incheon Korea
22 - 23 May, 2019
Incheon, South Korea
Engineering Machines Tool Welding
18 - 21 Jun, 2019
Nizhny Novgorod, Russia
WELDFAB TECH TIMES | FEB - MAR 2019
www.weldfabtechtimes.com
EVENTS UPDATE
Beijing Essen Welding & Cutting Fair
25 - 28 Jun, 2019
Dongguan, China
Weld County Fair
24 - 29 Jul, 2019
Greeley, USA
Exhibition of Cutting Edge Security Technologies (ASE ZITF)
17 - 23 Aug, 2019
Bulawayo, Zimbabwe
Indonesia International Welding Equipment and Cutting Material & Services Exhibition (INA Welding)
28 - 30 Aug, 2019
Jakarta, Indonesia
Philweld
28 – 31 Aug, 2019
World Trade Center Metro Manila, Pasay, Philippines
Trade fair for Joining, Cutting, Surfacing, Testing and Protecting (SCHWEISSEN Linz)
10 - 12 Sep, 2019
Linz, Austria
Hi Welding & Production Equipment
01 – 03 Oct, 2019
MCH Messecenter Herning, Herning, Denmark
Weldex
15 - 18 Oct, 2019
Moscow, Russia
Exhibition for machine tools, industrial tools, welding and cutting equipment
14 - 17 Nov, 2019
Cairo, Egypt
Welding Monitoring And Diagnostics
19 - 21 Nov, 2019
Yekaterinburg, Russia
Welding Week
19 - 21 Nov, 2019
Antwerp, Belgium
Welding Bangkok
20 - 23 Nov, 2019
Bangkok, Thailand
International Exhibition on Metalworking & Welding Technology Vietnam (Metal & Weld)
27 - 30 Nov, 2019
Ho Chi Minh, Vietnam
Welding Technologies Fair
28 Nov - 01 Dec, 2019
Bursa, Turkey
Japan International Welding Show
08 - 11 Apr, 2020
Osaka, Japan
For Weld
12 - 15 May, 2020
Prague, Czech Republic
FABTECH Canada
16 - 18 Jun, 2020
Toronto, Canada
International Trade Fair for Welding (Welding Fair Brno)
05 - 09 Oct, 2020
Brno, Czech Republic
ExpoWELDING: International Welding Fair
13 - 15 Oct, 2020
Sosnowiec, Poland
www.weldfabtechtimes.com
FEB - MAR 2019 | WELDFAB TECH TIMES
61
SECTOR WATCH: STEEL
India to leave behind US in steel consumption this year: Chaudhary Birender Singh ~Government to increase the budgetary allocation for facilitating R&D~
M
inister of Steel, Chaudhary
facilitator to the ‘Make in India’ initiative
integration with user industries makes it a
Birender Singh said that the
of the Government of India. These
strategic sector for the government as well
government is considering an
policies have resulted in savings of more
as the economy.”
than INR 8000 Cr till date”. Underlining
research and development to boost the
the importance of not showing any
in the country is likely to reach 300
steel sector.
disadvantage to the sector, he added that
million tonnes by 2030, aligned with the
they are also reviewing the DMI&SP policy
target of National Steel Policy. There is
at the 4th edition of India Steel 2019
and trying to find convergence between
an increased focus in the industry and
organized by the Ministry of Steel,
DMI&SP policy and Public Procurement
government for 2030 in terms of raw
Government of India jointly with the
Order 2017 of DIPP; “Under the ambit of
material security, demand stimulation
Federation of Indian Chambers of
the policy, 16 more steel products were
of achieving energy efficiency in the
Commerce & Industry (FICCI), Mr Singh
brought under Quality Control Order,
industry; leveraging our steel potential in
said, “We are likely to leave behind US
which now covers a total of 53 products.
building a New India. Hence, the theme of
in terms of steel consumption this year.
The endeavor is to bring more products
the event is Balancing Steel Demand and
Growth trend in steel consumption
under the Quality Control Order in an
Supply Dynamics up till 2030: Building a
in India will continue, due to strong
effort towards prohibiting production,
New India”
manufacturing sector, diversified demand
import and distribution of substandard
demographics, accelerated expenditure
products.”
Speaking with WeldFab Tech Times
on infrastructure, anticipated increase in
He further said that to strengthen the
The 4th edition of India Steel 2019 is organised on the theme of ‘Balancing Steel Demand & Supply Dynamics: Building a
GDP and strong focus on ‘Make in India’.
sector, the ministry is working through
New India’ with a focus on highlighting
A budget of around Rs. 6 lakh crores was
Steel Research and Technology Mission of
the current trends, developments,
allocated for infrastructure development
India (SRTMI) and exploring technology
challenges and prospects of the steel
in this financial year. So, based on
transfer agreements for production of
industry. The three- day exhibition has
these enabling factors and with huge
products like electrical and automotive
participation of over 250 exhibitors;
potential yet to be tapped, the per capita
steel domestically. “Ministry of Steel
providing them with an opportunity to
consumption can easily be increased from
is also trying to increase the budgetary
showcase their latest technologies in
the current levels. I am happy to share that
allocation for facilitating R&D,” said
the arena of steelmaking to over 8,000
we have been able to bring a shift in mind
Mr Binoy Kumar.
visitors. Also, there are 200 prospective
set and the work culture in these areas, as
Mr Sandip Somany, President,
international buyers from 67 countries
FICCI stated that “India is the fastest
to initiate business dialogue with Indian
growing economy in the world and
steel producers. The event will also
of Steel emphasized, “The National Steel
requires continued investments in new
witness 7000+ B2B meetings and hosted
Policy 2017 along with the Policy for
infrastructure, new and larger cities,
Reverse Buyer Seller Meet (RBSM) with
Preference to Domestically Manufactured
machinery and production to employ new
delegations from CIS, AFRICA, SAARC,
Iron & Steel Products (DMI&SP), is not
people and drive the economy forward.
and Middle East to develop, and forge
just aimed at providing a boost to the steel
Steel is one of the most crucial sectors
collaboration with potential international
industry in the country but also acts as a
and contributes to our 2% GDP. Also, its
buyers.
demonstrated by actual performance.” Mr Binoy Kumar, Secretary, Ministry
62
“The targeted steel build-up capacity
increase in the budgetary allocation for
WELDFAB TECH TIMES | FEB - MAR 2019
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SECTOR WATCH: STEEL
Important – Change in HSE Enforcement for Fume Extraction when Mild Steel Welding By Westermans (www.westermans.com)
Overview: Health and Safety have advised new requirements regarding extraction of
kidney cancer.
required to control risk from the residual fume.
• As a result there is a change in HSE enforcement expectations in relation
With immediate effect, there is a
to the control of exposure of welding
strengthening of HSE’s enforcement
Who is affected?
fume, including that from mild steel
expectation for all welding fume…
All workers, employers, self-employed,
welding.
welding fumes, to take immediate effect.
The International Agency for Research
• All businesses undertaking welding
on Cancer has brought to light new
undertake welding activities including
activities should ensure effective
scientific evidence that exposure to
mild steel, in any industry.
engineering controls are provided and
mild steel welding fumes can cause lung
correctly used to control fume arising
cancer and possible kidney cancer in
from those welding activities.
humans. Mild steel welding fume has
contractors and any others who
Issues: • New scientific evidence suggests
64
• Limited evidence also suggests link to
• Where engineering controls are not
been re-classified by The Workplace
that exposure to all welding fume,
adequate to control all fume exposure,
Health Expert Committee as a human
including mild steel welding fume, can
adequate and suitable respiratory
carcinogen (a substance capable of
cause lung cancer.
protective equipment (RPE) is also
causing cancer in living tissue).
WELDFAB TECH TIMES | FEB - MAR 2019
www.weldfabtechtimes.com
SECTOR WATCH: STEEL
With immediate effect, there is a
without any suitable exposure control
strengthening of HSE’s enforcement
measures in place, as there is no known
expectation for all welding fume,
safe level of exposure.
including mild steel welding; because
Action required:
necessary control.
1. Make sure exposure to any welding fume released is adequately controlled using
suitable engineering controls such as LEV
engineering controls (typically LEV).
(Local Exhaust Ventilation) to control the
2. Make sure suitable controls are provided
cancer risk as well as control exposure
for all welding activities, irrelevant of
to manganese, which is present in mild
duration. This includes welding outdoors.
steel welding and can cause neurological effects similar to Parkinson’s disease. This should be supplemented with RPE (Respiratory Protective Equipment) to protect against residual fume where
3. Where engineering controls alone cannot control exposure, then adequate and suitable RPE should be provided to control risk from any residual fume. 4. Make sure all engineering controls are
LEV alone does not adequately control
correctly used, suitably maintained and are
exposure. Welding undertaken outdoors
subject to thorough examination and test
will need appropriate RPE and welders
where required.
should be suitably instructed and trained in using these controls. Regardless of duration, HSE will no longer accept any welding undertaken
www.weldfabtechtimes.com
Relevant legal documents: • Health and Safety at Work etc. Act
general ventilation does not achieve the All welding indoors will require
effective in protecting the wearer.
5. Make sure any RPE is subject to an RPE programme. An RPE programme encapsulates all the elements of RPE use you need to ensure that your RPE is
1974 • Control of Substances Hazardous to Health Regulations 2002
References: • Controlling airborne contaminants at work: A guide to local exhaust ventilation (LEV) HSG258 • HSE Local Exhaust Ventilation webpages • Respiratory Protective Equipment: A practical guide HSG53 • HSE Respiratory Protective Equipment webpages • IARC Monographs on the Evaluation of Carcinogenic Risks to Humans Volume 118 • The Lancet article on IARC Monograph.
FEB - MAR 2019 | WELDFAB TECH TIMES
65
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