Weldfab Tech Times - October - November 2017 by EAA Publications

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A BI-MONTHLY MAGAZINE FOCUSING ON WELDING AND FABRICATION SEGMENT

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EDITOR'S DESK

WELDFAB TECH TIMES www.weldfabtechtimes.com

Publisher & Editor Eliza Bhalerao eliza@weldfabtechtimes.com Group Managing Editor Amol Bhalerao amol@weldfabtechtimes.com Assistant Editor Babu Paka editorial@weldfabtechtimes.com Business Development Manager Monica Waghmare monica@weldfabtechtimes.com

What’s more on welding…. WeldFab Tech Times is glad to showcase its second issue with a motif

Designer Deepa Warang design@weldfabtechtimes.com

of women’s empowerment into welding industry. WeldFab Tech Times

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articles, feature stories (hyperterm), life line of welding, news, national

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has copious amount of subject matters to be read which includes the latest happenings, case studies, project updates, traders’ updates, and international events and many more. Safety always plays a critical role in the welding activity. If ignored, it can be hazardous to one’s life and on the other hand, it can also be a thrilling experience when precautions are appropriately followed. WeldFab Tech Times is trying to bring about cognizance in riskless and safety welding. Welding has now reached its technical advancement with smart machines making welding risk free far easier than before. Since Welding has become the root for automation, construction, shipping, aerospace etc, we have reached a step forward by launching our website where the readers can view our magazine digitally any time anywhere. To make welding more

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 & Published by Eliza A. Bhalerao on behalf of EAA Publications, Printed at Anitha Art Printers, 29,30 Oasis Ind Est., Next to Vakola Market, Santacruz (East), Mumbai - 55. India, and Published from B-3/503, Ekdanth, Gauri Estate, Near Gauri Hall, Manjarli, Badlapur (W), Dist.: Thane – Ulhasnagar - 421503, Maharashtra, India. Editor: Amol A. Bhalerao The information on products on offer is being provided for the reference of readers. However, readers are cautioned to make inquires and take their decision on purchase or investment after consulting experts on the subject. WeldFab Tech Times holds no responsibility for any decision taken by readers on the basis of information provided herein.

WELDFAB TECH TIMES | OCT - NOV 2017

compelling, we have introduced exclusive tips into welding segment. WeldFab Tech Times proudly moves ahead only because of the support received from our dedicated authors, advertisers, and readers and not forgetting my diligent team of WeldFab Tech Times who with all their arduous efforts construct a solid content exclusively for our valued readers. We thank you for all your compliments and appreciate your comments as well. We welcome the reviews of our readers to enhance the WeldFab Tech Times Magazine. Stay connected and enjoy reading the second issue of WeldFab Tech Times……

Eliza Bhalerao Publisher & Editor

www.weldfabtechtimes.com

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Needs Special Products

brings Technically Advanced Welding Products to Indian Industry from Global Leaders

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CONTENTS 6

Buster Boats: The Future of Power Boating

ARTICLE

Induction Heating for Pre Weld / Post Weld applications

Lifeline of Welding: Low Hydrogen Electrodes

ISO 3834 â&#x20AC;&#x201C; The Quality Requirements for Welding

LAUNCHES

Temper Bead WeldingReview of Design Codes & Established Practices

WELDFAB TECH TIMES | OCT - NOV 2017

Influence of CO2 in Argon on MAG welding efficiency & productivity

Weldable Tungsten Carbide Tiles- Breakthrough innovative product for wear protection www.weldfabtechtimes.com

New Generation Cutting Edge Plasma by Hypertherm

INTERVIEW

WOMEN IN WELDING

EVENT INTERVIEW

Woman Welder at Parel Workshop: A Snapshot

62 09 UPCOMING PROJECTS 43 BULLETIN

55 We have equipment that are a perfect blend of man and machine V. V. Kamath, Managing Director, Fronius India Pvt Ltd

www.weldfabtechtimes.com

PRODUCTS UPDATE TENDERS

WELD INDIA 2017: Back after 6 years in Chennai

79 68 82

TEKNO 2017: An opportunity to comprehend technical aspects of the industry

OCT - NOV 2017 | WELDFAB TECH TIMES

REVIEW

Avinash Abnave, Technologist, Aaryan Enterprises

Issue : Aug-Sept, 2017 Readers Review

It’s really a Good Initiative. The first issue itself is very interesting (Specially Technical Articles) Best Luck !!!

V. Muralidharan, International Welding Technologist, Proprietor of Ennappan Consultants

WELDFAB TECH TIMES is quite interesting and will resolve issues in welding and fabrication shop fronts. The magazine will be a helping hand too. You will get full support, thus making an impact in Fabrication and Welding Industries. Without welding, the world could not move. My hearty congratulations and wish you all the very best to move further.

R. Easwaran, General Manager & Head (Labs, Quality) Welding Research Institute, BHEL, At the outset, let me Tiruchirappalli

congratulate you in bringing out a good publication in the welding field. I appreciate the excellent efforts put in by you and your team. The contents, aesthetics and presentation have come out very well. Kudos to the team!!

Viral Shah, Director, Aavishkar Sales & Technical Services Pvt. Ltd

Excellent work, keep it up.

Vasuki H.V., Deputy General Manager, Quality – Machinery Works, L&T Construction Equipment Ltd

Thanks for the magazine. For the first issue, the magazine has really come out great. I wish you and team all the success.

Rajesh Chalwadi, Deputy Director, Admin & Finance, Maharashtra Electricity Many congratulations on the launch of the magazine. The magazine is outstanding, covering Regulatory Commission the past, present and future of welding industry, giving indepth information about latest welding

technologies, with future trends. It contains foresight of the forerunners into the field, giving details on ongoing and future events. Overall the magazine has nicely covered the welding industry. The magazine will help the welding industry in gearing up with new technologies and challenges. It will open up new avenues and partnerships, and will help attract new generation in this hitherto neglected sector. I strongly recommend this magazine to not only the welding industry but to every industry, as WELDING is the bond that binds each and every industry... May all Success WELD your LIFE...

CC Girotra, Managing Director, Weldwell Speciality Ltd. Your new publication WELDFABTECH TIMES has come out well. I congratulate you for your efforts.

Vincent D’silva, Retired Senior Technician, Dubai Aluminium Congratulations and best Company (DUBAL)

wishes for your new endeavour. My support and blessings for your success in future. Wonderful magazine. Keep it up!!

WELDFAB TECH TIMES | OCT - NOV 2017

www.weldfabtechtimes.com

BULLETINS

New welding training center in Chambersburg

Kemppi appoints new CEO a long experience in global management positions from

he Franklin County

to consistently providing

ABB. He has an extensive

Area Development

custom welding training

experience in leadership and

Corporation and

programs, qualification

business, and holds strong

Phenomenal Industries Inc.

testing and providing skilled

proof of managing companies

hosted a ribbon cutting for

laborers worldwide. There are

successfully. Ville is familiar

the Welding Training Center

companies in Franklin County

with the characteristics of both

in Greene Township. The new

such as Volvo Equipment,

10,500 square-foot state-of-

Manitowoc Crane Group,

the-art facility features a 40

JLG, Olympic Steel, Bri-

seat classroom for lectures and

Mar Manufacturing, CAM

instructor-driven learning as

Superline & Johnson Controls.

well as 20 welding booths that

There is a conglomerate of

Currently, Vuori acts as the

and has experience in working

will provide hands-on learning

manufacturing facilities here

CEO of Incap Oyj. According

with many of the customer

for the students as well as the

in Franklin County and the

to the current plans, Vuori

segments important to us.

tools and environment for

area and the one need that is

will begin his work at Kemppi

From Ville’s background, he

craftsmen to succeed. Since its

consistent among all of them

by the end of this year.

has worked as a plater-welder

inception, the Slovakian-based

is that they are all looking for

Before Incap, Oyj Vuori has

before starting his studies,

corporation has been dedicated

welders.

worked as the CEO of Kumera

which means he has seen the

Drives and Finavia’s Sky

world of welding also on a

How Ltd. In addition, he has

more practical level.

Air Liquide signs a contract with PEMEX

ir Liquide recently

operate the customer’s existing

signed a new long

hydrogen production unit

term agreement

(Steam Methane Reformer-

large and small companies

Source: news.cision.com

as well as public companies

ille Vuori has been

and family-owned businesses.

appointed as the new

He is used to operating in an

CEO of Kemppi Oy.

international environment

The largest piece of the rocket built in Marshall’s Huntsville

with Pemex Transformación

SMR) in order to supply

Industrial, a subsidiary of

90,000 Nm3 per hour of

PetróleosMexicanos (PEMEX),

hydrogen to PEMEX refinery.

the state-owned oil & gas

The acquisition of the SMR is

area, will connect two major

company, to supply hydrogen

subject to closing conditions,

sections of SLS – the 27.6-foot

to PEMEX’s refinery located at

including the approval of the

diameter core stage and the

Tula de Allende, in the state of

Mexican antitrust authority.

16.4-foot interim cryogenic

are preparing to apply thermal

Hidalgo in the central region of

Expected to start operations

propulsion stage– for the first

insulation. It will be the largest

Mexico. Through a €50 million

in the first quarter of 2018,

integrated flight of SLS and the

piece of hardware that Marshall

investment for the take over

Air Liquide’s upgraded SMR,

Orion spacecraft. It is coated

Technicians have covered with

and optimization of PEMEX’s

will provide hydrogen to

with thermal insulation to

foam insulation using a manual

existing hydrogen production

PEMEX with optimal safety

protect the delicate propulsion

process. Other larger parts of

unit, this agreement will allow

and reliability to help produce

stage systems during SLS’s

the core stage are undergoing

Air Liquide to strengthen its

cleaner fuels at the Tula

ride to space. Teledyne Brown

similar manual thermal

presence in central Mexico.

refinery. Hydrogen is used in

Engineering of Huntsville,

protection system applications

According to the long term

the petroleum refining process

the prime contractor for

at NASA’s Michoud Assembly

contract, Air Liquide Mexico

to help produce cleaner

the adapter, has completed

Facility in New Orleans, which

will acquire, upgrade and

transportation fuels.

manufacturing & engineers

is managed by Marshall.

www.weldfabtechtimes.com

he LVSA, the largest piece of the rocket built in Marshall’s

Huntsville manufacturing

OCT - NOV 2017 | WELDFAB TECH TIMES

BULLETINS

Böhler Welding introduces BÖHLER SUBARC ZED Scheme T55 HP for submerged arc welding for MSMEs

brings reserve in terms of

copper-coated cored wire

SUBARC T55 HP is a basic

strength and CVN impact

in ZED Certification Scheme.

developed for the submerged

cored wire which is specially

toughness to compensate for

The objective of the scheme

arc welding of unalloyed

formulated to fully benefit

the bigger weld beads and

is to promote Zero Defect

and fine-grained structural

from the increased deposition

fewer layers that come along

and Zero Effect (ZED)

steels upto a yield strength

rate brought along by the cored

with the increased deposition

manufacturing amongst

of 460 MPa. It has a series of

wire design. In combination

rates.Increased welding

micro, small and medium

advantages over solid wire

with three different fluxes –

productivity and lower total

enterprises (MSMEs), promote

which, together represent a

UV 421 TT, UV 400 and UV

welding costs are further

adaptation of quality tools/

great potential for a reduction

306 – it forms cored wire / flux

promoted by important side-

systems and energy efficient

of total SAW welding costs and

combinations for a variety

effects such as dependable

manufacturing.

project lead times. Applicability

of applications. It allows

weld penetration and tie-in,

The scheme would

and obtainable savings

substantially higher welding

easier slag release and lower

encourage MSMEs to

strongly depend on the SAW

currents in a butt welding and

flux consumption, lower defect

constantly upgrade their

application and a thorough

higher travel speeds in fillet

rates and lower contact tip. The

quality standards in products

analysis is needed to assess

welding in situations where a

SUBARC T 55 HP wire / flux

and processes. There are 50

feasibility, in which Böhler

higher heat input is acceptable.

combinations can be applied

parameters for ZED rating

Welding specialists can support

Alternatively, users can opt for

in single wire, tandem wire and

and additional 25 parameters

interested fabricators.BÖHLER

a lower heat input at the same

twin wire SAW systems.

for ZED Defence rating under

iller metal specialist

deposition rate / travel speed

Böhler Welding has

or any other desired balance. The basic flux formulation

introduced BÖHLER

SUBARC T55 HP - a seamless,

Source: www.voestalpine.com

he Government has launched a new scheme namely

Financial Support to MSMEs

ZED Maturity Assessment

ADNOC encourage women to be key partners in the development of the nation

around 22,222 MSMEs will be rated and certified under ZED Maturity Assessment

he Abu Dhabi

and diverse workforce that

Model, 5,000 MSMEs will be

National Oil Company

matches the best international

rated and certified under the

(ADNOC) renewed

standards.As part of ADNOC’s

ZED Defence Model, 7,368

its commitment to empower

Emirati Women’s Day

MSMEs will be supported for

women in the oil and gas

celebrations, the company

Gap Analysis, Handholding,

sector as a part of its strategy

hosted two separate employee

Consultancy for improving

events, in Ruwais and Abu

their rating, etc. The total

on talent development. The

Sheikha Fatima bint Mubarak,

Dhabi, which were focused on

cost of the project is Rs.

announcement was made as

the Mother of the Nation,

women’s empowerment. The

491.00 crore (Government

the company celebrated the 3rd

and that of the leadership to

two events featured programs

contribution Rs. 365.00

annual Emirati Women’s Day.

encourage women to be key

of speeches and discussions,

crore, beneficiary MSMEs

In a speech to employees, His

partners in the development

including an address by Fatema

contribution Rs. 126.00 crore).

Excellency Dr. Sultan Ahmed

and prosperity of the nation.

Al Neaimi, Chairperson of the

Quality Council of India

Al Jaber, United Arab Emirates

ADNOC seeks to attract

ADNOC Women’s Committee

(QCI) has been appointed as

Minister of State and ADNOC

the best talent and expertise,

and Dr. JamilaKhanji from

the National Monitoring &

Group CEO, highlighted the

including women, to ensure

the Family Development

Implementing Unit (NMIU)

support of Her Highness

the creation of a competent

Foundation (FDF).

for implementation of ZED.

for smart growth that focuses

Model. Under the scheme,

Source: news.cision.com

WELDFAB TECH TIMES | OCT - NOV 2017

www.weldfabtechtimes.com

BULLETINS

Miller engine driven welder generators avails ArcReach technology

iller Electric Mfg.

weld joint without a control

welding. The same ArcReach

Co., has expanded

cord. With the addition,

accessories that work on

its ArcReach

ArcReach capabilities are

ArcReach-equipped XMT and

remote control technology to

now available or standard on

Dimension power sources

more engine-driven power

nearly all products in the Big

are now also compatible with

sources in the Trailblazer and

Blue lineup and on Trailblazer

select Trailblazer and Big Blue

Big Blue families of products.

325 models. The expansion

engine-driven power sources

ArcReach technology is now

provides greater flexibility

— so companies can expand

available on Trailblazer 325

and fleet compatibility in

use of the technology with

power sources as well as Big

heavy industrial applications,

their existing accessories. In

Blue 600 Air Pak, 800 Duo Pro

including maintenance and

addition, legacy wire feeders

so companies can fully utilize

and 800 Duo Air Pak models,

repair rigs, construction,

and stick/TIG remotes will

their existing accessories and

providing complete control

mining maintenance,

continue to work with the

equipment until they are ready

of welding parameters at the

railroad maintenance & pipe

ArcReach-equipped machines,

to replace or upgrade.

Source: www.millerwelds.com

ABB Robotics new ArcPack for high quality welds

BB’s newly integrated

cost-efficient robot with a

solution with 10

stroke and reach accurate for

times faster internal

arc welding applications. It is

digital communication speed

based on the IRB 1400, which

for robotized arc welding

has been installed in over

offers full integration of all

14,000 units worldwide out of

welding equipment, easy

which most are arc-welding

programming and powerful

applications. The welding torch, wire

performance for automated welding applications. The

feeder, bobbin plus, the

robotic welding package,

power and signal cables,

ArcPack, is designed to offer

are also integrated with the

high quality welds with

RPC power source and the IRB1410 robot. The ArcPack

minimum downtime. The Source: www.abb.com

package includes ABB’s fifth

robotic welding package

generation IRC5 controller,

suited for MIG (Metal Inert

control in MIG and MAG

provides manufacturers with

the touch screen interface

Gas) and MAG (Metal Active

welding applications. It also

intelligent controls to manage

FlexPendant, RobotWare

Gas) welding automation. The

provides synergic curves – pre-

welding applications in

Arc programming software

RPC power source internal

programmed process database

metal fabrication industries,

and an IRB1410 industrial

digital communication

that use common welding

from bicycles, sporting

robot to deliver an integrated

speed is 10 times faster than

parameters for manufacturers

goods, automotive parts to

solution for hassle-free arc

previous models. It offers

to choose.

agricultural equipment. The

welding. The package is also

faster reaction speeds and

provided with ABB’s new

consistently smooth and

the ArcPack solution is ABB’s

fabricate small and medium

RPC welding power source

reliable wire feeding for better

IRB1410, a well-proven and

size components.

www.weldfabtechtimes.com

Working at the center of

technology can also be used to

OCT - NOV 2017 | WELDFAB TECH TIMES

BULLETINS

Air Liquide sold welding subsidiary to Lincoln Electric

ESAB to support Hurricane relief efforts

subsidiary specialised in the

systems, plasma and oxy fuel

ESAB Welding & Cutting

Edge, Journeyman 450 and

manufacture of welding and

cutting equipment with related

Products announced that

Performer oxy-fuel outfits

cutting technologies to Lincoln

usual regulatory approvals

with every shipment of select

in the hopes of reaching the

Electric France SAS which

including competition

products between now and

donation goal of $250,000

is the subsidiary of Lincoln

authorities’ approval. Air

December 31, 2017, ESAB

as quickly as possible.

Electric Holdings. The signed

Liquide is focused on its gas

will make a contribution to

Contributions will go to

sale agreement was announced

and service activities following

assist the rebuilding efforts.

Operation USA, a 100-percent

in April 2017 with Lincoln

the acquisition of Airgas and

ESAB has selected some of

privately funded agency that

Electric: the leading player

also on the implementation of

its highest volume products:

has delivered more than $400

in design, development and

its company program NEOS for

ESAB Rebel 215ic and 235ic

million in aid for relief and

manufacture of arc welding

the 2016 – 2020 period.

welding machines, Thermal

development projects.

ir Liquide has finished the sale of Air Liquide Welding with its

products, robotic arc welding

o support Hurricane

Dynamics Cutmaster 60i

Harvey and Hurricane

manual plasma cutters

Irma relief efforts,

and Victor Journeyman

Lincoln Electric to open welding technology & training centre

ommemorating the

The building features a

career pathways and looks

100th anniversary

virtual reality training lab

to the industry’s future in its

of its legacy welding

with 10 VRTEX Virtual Reality

programming offerings. It also will showcase

school, Lincoln Electric®

Web Simulation Trainers,

will open its new Welding

166 welding and cutting

and integrate Lincoln

Technology & Training

booths, six seminar rooms, 13

Electric’s latest technologies

Centre, on its Euclid,

welding school classrooms,

and solutions into a

Ohio, campus in January.

a 100-seat auditorium, an

comprehensive welding

The centre’s opening

atrium and a reception area.

curriculum – making it the

Source: www.gasworld.com

The Lincoln Electric

industry’s most advanced

role of running the oldest

The two-story, 100,000 sq ft-

Welding Technology &

facility of its kind. Classes

continually-operating

plus facility doubles Lincoln’s

Training Centre is equipped

would begin in the new

welding school in the world.

welding education capacity.

to help students focus on

facility on 8th January, 2018.

maintains the company’s

De La Cruz, Lee County's first female to receive AWS certification

D 12

e La Cruz is making

Direct Industrial Products

into welding, including from

College (where she did dual

history with her

and Machining in Labelle,

her own family. Her teachers

enrollment) for spurring her

welding. Just

succeeding in a field that is

encouraged her to pursue

on to success. Cruz also credits

18 years old, De La Cruz

approximately 95 percent

welding, the fusing of metals

Future Makers Coalition for

became Lee County's first

male, according to U.S.

together. She credits Jerriel

connecting her with Direct in

female student to receive an

Department of Labor statistics.

Filler, her welding instructor

Labelle, who offered her a job

American Welding Society

She received a number of

at East Lee County High

after graduation, a job that

(AWS) certification. She is

sideways looks from people

School, and her instructors

Filler believes she is uniquely

now working full-time at

who found out she was going

at Fort Myers Technical

suited for.

WELDFAB TECH TIMES | OCT - NOV 2017

www.weldfabtechtimes.com

BULLETINS

Miller introduces new Thunderbolt 160 and 210 Stick Welding Power Sources

iller Electric Mfg.

store. Operators can work

starts, the machines deliver

Co. has introduced

smarter, not harder, by

precise, accurate and infinite

two new additions

bringing the welder to the

amperage control and heat

to the Thunderbolt lineup of

work. The Thunderbolt

output. The Thunderbolt

stick welding power sources.

160 and 210 also have up

160 model also features dual

The Thunderbolt 160 and

to 85 more amps of power

voltage with the multi-voltage

compared to the leading

plug (MVP), allowing for

and lightweight portability

work. The new machines are

competitive machine, so as

connection to 120- or 240-volt

for a variety of light industrial

nearly 100 pounds lighter

operators can weld thicker

receptacles — without the

applications including garage

than the leading competitive

materials — up to 5/32-inch

need for tools. Operators can

and job shops, farm and

machine, weighing just 15

mild steel. Equipped with Hot

simply choose the plug that

ranch, maintenance repair,

and 15.5 pounds, making

Start technology to provide

fits the receptacle and connect

and light production-line

them easier to carry and

easy, quick and reliable arc

it to the power cord.

Thunderbolt 210 offer power

Source: www.millerwelds.com

Ingalls ‘Shipyard of the Future’ upgrades welding automation

emamek Ltd. is

encompasses a state-of-the-

delivering hi-tech

art plate lengthening line,

PEMA welding

that can feed two complete

automation to Mississippi-

modern flat panel lines

based Ingalls Shipbuilding’s

simultaneously, and several

Pascagoula shipyard. The

other highly advanced solutions like robotized

extensive and technologically advanced automation solutions provide Ingalls improved panel production and enhanced workflow. To signal its decisiveness to maintain the position as

Source: www.workboat.com

In 2014 the Mississippi-based Ingalls Shipbuilding kicked off the extensive “Shipyard of the Future” initiative. Ingalls Shipbuilding partners in government and industry. The multiyear initiative

welding and integrated milling and welding applications. One of the plate joining

Now in its third year of the modernization

stations uses a laser-hybrid

implementations, Ingalls

arc welding (LHAW) process

the world’s leading and most

includes significant

Shipbuilding has agreed

combined with tandem MAG

modern shipyard, in 2014

investments in modern

with Pemamek to acquire

and is capable of welding

the Mississippi-based Ingalls

infrastructure and

large-scale PEMA welding

plates up to 60′ in length

Shipbuilding kicked off the

manufacturing equipment,

automation solutions to

from one side and starting

extensive “Shipyard of the

as well as technologically

its Pascagoula shipyard.

from thicknesses as low

Future” initiative. Ingalls

advanced procedure and

The agreed large-scale

as 4 mm. The advanced

Shipbuilding is a subsidiary

processes. The planned

automation solutions are

welding processes together

of the Huntington Ingalls

investments is designed

described as the most

with integrated milling

Industries, which is the U.S.’s

to result in raised level of

advanced not only in

will provide precise seam

largest military shipbuilding

automation, enhanced

America, but also in the

preparation and efficient

company and provider of

production quality and

entire world.

welding for the entire length

professional services to

improved workflow.

www.weldfabtechtimes.com

The extensive delivery

of plates.

OCT - NOV 2017 | WELDFAB TECH TIMES

EXECUTION

Buster Boats: The Future of Power Boating

uster Boats is a well-known

A rising R&D tide lifts Buster Boats

aluminum boats manufacturer

Today, around 70 per cent of the

and a market leader in its

production is exported from Finland. Inha

industry. They excel in producing highly

Works is Europe’s largest manufacturer

reliable, low-maintenance boats, and

of aluminum boats, and Buster, with

in R&D. Kemppi solutions, such as the

it’s already achieved iconic status and

new X8 MIG Welder, as well as joint R&D

successful performance in many tests,

are signposts on the road to success for Buster Boats.

Harri Hinttala, Director, Buster Boats

The Buster story began in 1976, when

Nordic countries, mainly Finland, Norway and Sweden. Buster Boats have been

the Fiskars group decided to move the

summer of 1976 under the names Fiskars

made to withstand even tough conditions.

manufacture of aluminum boats from

12 and Fiskars 14. The following year,

They have even been used to sail around

the Kellokoski Works to the Inha Works

the range received its own name, Buster.

the North Cape from the Arctic Ocean to

located in Ähtäri, Southern Ostrobothnia

A series of 60 Mini Busters was made,

the Atlantic.

region of Finland. The boat range varies

later supplemented by Buster, Buster

from 4m to over 9m, from 2 horsepower

R and Work Buster model. During that

persons in Ähtäri, of which 30 are welders.

(hp) up to even 700 hp. Durability,

time, exports to Sweden, Norway and

Kimmo Multaniemi, the Foreman of

safety and ease of use were taken as the

Central Europe also started. Through the

Boat Production, oversees welding and

starting points when designing the new

years, almost 1,25,000 Buster Boats have

the final frame features. “At the moment,

boat range. “The key to our success at

been manufactured for satisfied boaters

we have about 70 welding machines at

Buster Boats is based on good quality and

around the world. Buster is trusted by

the Inha Works. Of those, 60 are Kemppi

strong product development and R&D,”

both recreational and professional users.

welding machines,” Multaniemi explains.

comments Director of Operations,

Buster Boats was recently sold to Yamaha

Three boat manufacturing phases are

Harri Hinttala, Buster Boats.

Motor Europe. “The future is looking

carried out at the Inha Works premises:

bright,” Hinttala added

sub-assembly and parts manufacturing,

The first boats were unveiled in the

is the most popular boat brand in the

WELDFAB TECH TIMES | OCT - NOV 2017

The Inha Works employs about 150

www.weldfabtechtimes.com

EXECUTION

welding, and final frame features. The

acquired to the Inha Works: The first

of-a-kind Control Pad for total welding

company uses MIG and TIG welding. For

the SuperSnake was tested at the Inha

control, including the new digital WPS

example, TIG welding is mainly used in

Works for a short period on two different

feature. The wireless device is a fast and

the visible parts of the boats for neater

production lines. After the one-month

easy solution for changing system and

seams. “Our customers appreciate good

trial period ended, the welders gave

welding settings, adjusting and controlling

craftsmanship,” Multaniemi says.

feedback to both Multaniemi and

welding values, or viewing WPS content,

Kemppi. “Actually, it was the welders that

which has not been available before.

welders must have proper tools and

made the final decision. They promptly

With the Control Pad, the whole system

means. “Welding aluminum is quite

said ‘let’s take this, it’s good’. Now we use

can be operated with confidence and

demanding, and this calls for first-class

the SuperSnake on our new boat model,

unforeseen efficiency.

welding machines. One of our main

Phantom,” Multaniemi says.

To meet customer expectations, the

“What we expected to have from the X8 MIG Welder was of course new

challenges in aluminum welding is also

Shifting gears with the X8 MIG Welder

technology, something to make the

Also, all welders must be trained for the job and their qualifications are regularly

Kemppi’s new X8 MIG Welder was

and trace,” Multaniemi lists.

controlled. We have daily quality controls

warmly welcomed at the Inha Works.

and an inspection record is made of each

The outstanding performance and the

wireless user interface, Control Pad,

boat,” Multaniemi explains. “Our main

improved usability made a convincing first

enables effortless parameter setting from

reasons for cooperating with Kemppi

impression. X8 MIG Welder is developed

the welder’s post without leaving the

are exceptional customer service, good

to meet the most demanding expectations

welding area to set up the equipment.

quality and reliability. Our welders like

for welding productivity and quality. It is

“Our first experiences with X8 MIG Welder

to use the Kemppi machines because the

a system for unparalleled performance,

have been positive,” Multaniemi adds.

Kemppi customer service listens to their

usability, and management of industrial

feedback,” Multaniemi adds.

welding, enabled by the newest IoT-

keeping the workplace clean and tidy.

According to Kimmo Multaniemi,

aluminum welding processes easier to set For example, the X8 Power Source’s

Additionally, for years, Buster Boats

based technologies. The X8 MIG Welder

the key success factors for Buster Boats

solution consists of Kemppi’s unique

are quality, long traditions and good

high-duty and upgradeable power source

product development. These are also the

with all-in-one wire feeder, ergonomic

attributes Buster Boats looks for when

welding guns, intelligent welding, brazing,

choosing a partner: “Our cooperation

cladding and gouging software, and one-

with Kemppi goes a long way back and this is why we have decided to continue on this path. Kemppi has been a good supplier for us because we have also been able to participate in the R&D of new products.” The joint R&D with partners is pivotal for Buster Boats. “We want to do R&D with Kemppi to have even better machines. That benefits both of us.” Multaniemi also highly values the meaning of new innovations for the welders. “I’ve always lived by the philosophy that the easier it is for my welders to work here, the easier it makes my work for me.” A good example of this philosophy is how the SuperSnake subfeeder was

www.weldfabtechtimes.com

OCT - NOV 2017 | WELDFAB TECH TIMES

EXECUTION

New levels of usability and performance

“The wire feeder is really good. It’s placed

High-quality welding requires careful

neater to insert the wire into the feeder.”

preparation. When comparing the X8

Urrila praises the additional equipment

MIG Welder with standard MIG welding

tested at the Inha Works. “Both the work

equipment, its usability aspects in

light and the ball-and-socket joint are

terms of innovative and user-friendly

really good. It’s vital for a pushing welding

wire feeder, wireless user interface for

technique that the wire is kept straight.

power source and digital WPS speed

That’s an improvement.”

lower than in the previous models and it’s

up the setup configuration easily by 30 per cent. When you can speed up the

Main challenge

setup configuration process, you have

Even though manual welding cannot be

more time to focus on welding itself. “X8

made much faster, Buster Boats highly

used to manage welding qualifications

MIG Welder is a first-class equipment

appreciates usability that also helps to

manually and each qualification had to be

for demanding, high-quality aluminum

save time: even one minute per boat can

renewed individually. The introduction

welding in terms of both arc performance

lead to 2,000 minutes less production

of the WeldEye solution has shifted the

and usability,” Multaniemi praises.

time in one year. Buster Boats has

gears in welding management at the

analyzed all products and tasks to the

Kemppi has also shaped the welder’s

point that the workers know to the minute

management a much faster process.

most important tool, the welding gun, for

how much time they can spend for each

Multaniemi says that even though

maximum comfort. The X8 MIG Welder

operation.

manual welding cannot be made much

redefines ergonomics in welding guns:

faster, the Inha Works highly appreciates

the hand grip, mobility and stability have

Kemppi's solution

usability that also helps to save time.

been optimized to meet the requirements

Buster Boats was among the first Kemppi

Saving even one minute per boat can lead

of the most demanding welding tasks.

partners to test the new X8 MIG Welder–

to 2,000 minutes less production time

“The welding gun is really good. It feels

and to bring it into play. The joint R&D

in one year. “Many small streams make

better than the previous one. And the

with partners is pivotal for Buster Boats.

one big river,” Multaniemi aptly remarks.

most important thing for the welder is

Multaniemi explains that the Inha Works

the operational reliability,” Welder

comfort with great arc performance, and

has analyzed all products and operations

Kari Urrila comments on his first

it’s extremely suitable for challenging

openly, and all tasks have been scrutinized

experiences with the X8 MIG Welder.

aluminum welding. X8 MIG Welder

to the point that all the workers know

To meet the best usability practices,

Inha Works, making welder qualification

“The Control Pad was easy to use and

X8 MIG Welder stands for welding

redefines ergonomics in the welder’s

to the minute how much time they can

we got the needed functions to work with

most important tool, welding guns: the

spend for each operation. This is a base

it,” Urrila adds. Urrila, who has over 20

hand grip, mobility and stability have

for the performance-related pay that is

years of welding experience, was also

been optimized to meet the requirements

applied throughout the Inha Works.

impressed about the X8 Wire Feeder.

of the most demanding welding tasks.

WELDFAB TECH TIMES | OCT - NOV 2017

www.weldfabtechtimes.com

LAUNCHES

Weldable Tungsten Carbide TilesBreakthrough innovative product for wear protection

wire or electrodes, which can

proven innovation in wear

be applied in the field, but

protection

this can be time-intensive and only offers low wear

named â&#x20AC;&#x2DC;Ferobideâ&#x20AC;&#x2122; has been brought to

resistance and lower

India, thanks to the

thickness. Ferobide can

partnership between

be quicker to apply

Tenmat Limited,

and offers a greatly increased level of

blue-chip UK manufacturer, and

wear resistance over

Weldwell Specilaity

hardfacing welding electrodes/wires and give

Pvt. Ltd, the leading trusted supplier to

thickness as high as 8.0 mm.

the welding industry in India for more

Ferobide is easily cut to shape with

than 25 years.

standard grinding wheels, meaning that

Ferobide is the only product to offer excellent wear protection levels

one Ferobide tile can be customised to fit

combined with user-friendliness and

nearly any wear part design.

easy installation. It uses a hardened steel

metal tools is preserved only by welding

matrix (weldable) to efficiently bind

Ferobide.

together 1,500 HV hardness tungsten

machinery work output include

carbide particles (wear resistance). It

make Ferobide superior over other

agricultural tillage equipment, decanter

is quickly welded with standard base

options. Brazed tungsten carbide tips

centrifuge scroll flights, drag chain

material, as easily in the field as in the

are indeed wear resistant, yet only be

links in mining, cutter-head secondary

workshop.

applied by specialists using costly brazing

protection on tunnel boring machines,

equipment. This process overheats an

muller mixer blades, cement mixer

product lies in bonding with the base

entire wear part, softening large parts of

paddles, scraper blades, excavator

material which is done by welding

it. This softening reduces lifetime because

buckets, dozer blades, belt scraper

electrode and thus, provides a much

the wear part is weakened by heating

units, plough edges, road planning

stronger bond with the surface hardness

and thus less resistant. Often a wear

contact surfaces and many more similar

of tungsten carbide which provides

part body will wear out, leaving the hard

applications

unparalleled resistance to abrasive wear

tungsten edge wasted. Ferobide is welded

combined with impact.

in place, meaning no heating of the body.

ranging from 8 x 40 mm to 40 x 40 mm,

Ferobide gives longer life though its own

4, 6 or 8 mm thick. Special shapes can be

greatly improved yields and efficiency,

wear resistance, whilst the body of a wear

made upon request and large demand.

significantly reduced downtime, a single

part keeps all wear resistance properties.

Ferobide tile can be customised to fit

Ferobide can also be welded to weakened

nearly any tool, working depth and

zones of brazed tungsten wear parts to

For More Details:

profile of GETs is maintained, wear part

add extra lifetime.

Email: sales@weldwell.com

The innovativeness of this unique

Vital customer benefits include

lifetime is increased, and the hardness of

There are key technical features which

Applications where Ferobide has improved wear part lifetime and

WELDFAB TECH TIMES | OCT - NOV 2017

Another option is hardfacing welding

Ferobide tiles are flat and rectangular,

Website: www.WeldWell.com

www.weldfabtechtimes.com

FEATURE STORY

New Generation Cutting Edge Plasma by Hypertherm

everal types of metal

of cut quality, it also offers

metal. This is the principal process for

cutting solutions

high cut speeds and is highly

both handheld and mechanized plasma

exist in the market

versatile.

cutting systems.

So, what is plasma?

today, such as plasma, laser, waterjet, oxyfuel and a variety

Simply put, plasma cutting

The Plasma Advantage

of mechanical means. While

is a technology that uses a

Where metal cutting is concerned, several

all of the cutting processes

high temperature ionized

factors affect efficiency, with a critical one

gas to produce a very hot,

being cutting speed. In manufacturing,

high energy-density arc

this is especially important as it would

that can cut any electrically

mean that jobs get completed in a

conductive material. The

shorter time, leading to an increase in

plasma stream is typically

overall productivity. Compared to other

mentioned are wellestablished with a good track record, each has benefits and shortcomings that need to be considered when

Phil Parker, Marketing Manager, Mechanized Plasma Systems, Hypertherm

deciding on a cutting method.

formed by forcing such gases as nitrogen,

In Asia, plasma is fast-becoming one

oxygen, a mix including argon, hydrogen

of the more popular choices for modern

and nitrogen — or even air — through a

manufacturers, especially when it comes

narrow nozzle, while an electric current

to fabrication of metals that may not

produced by an external power supply

provide optimal results when used with

adds sufficient energy to the gas flow to

traditional cutting methods. Not only

ionize it, turning it into a plasma arc with

does plasma provide a good balance in

temperatures that can approach 40,000˚F.

terms of capital cost and an optimal mix

The plasma arc then melts and severs the

www.weldfabtechtimes.com

Hypertherm’s Powermax 85 air plasma cutting system.

OCT - NOV 2017 | WELDFAB TECH TIMES

FEATURE STORY

processes, plasma cuts at the fastest rate

that is in any condition - even rusted,

optimal mix of cut quality, productivity,

and is the most productive when cutting

painted, or grated. This confers a higher

convenience, and versatility for mild

metals that are greater than 6mm (1/4")

degree of flexibility to the cutting job as

steel, stainless steel, and aluminum

but less than 76mm (3"), due to the fact

plasma can cut a wider range of metal

across a wide range of thicknesses.

that the plasma arc is able to melt the

types and thicknesses. Even within the

Existing plasma systems are already

metal almost instantly upon contact.

cutting process, the versatility of plasma

considered competent in their own right,

Cutting speeds also increase as metal

systems is further expanded when used

but manufacturers have in recent years

thickness decreases, and this increased

in combination with specialized torches

increasingly sought more advanced

speed means that operators can cut more

and consumables. Many torch options

means of cutting in their pursuit for

parts in less time.

are now available in the market, varying

higher efficiency and better results.

Cut quality is also another critical

in lengths and torch head angles that

Coupled with the advent of technology,

consideration for companies when it

cater to different industrial needs and

there now exists a growing demand for

comes to selecting their metal cutting

applications. Plasma can also be used for

more developed and sophisticated cutting

equipment. Plasma cutting, particularly

drag cutting, standoff cutting (particularly

systems that can better meet the needs of

high performance plasma is capable

useful when cutting odd-shaped pieces, or

modern manufacturing.

of producing edges that are relatively

when trying to access a tight location) and

smooth with very little edge hardening,

even for getting high quality, very narrow

launched its latest mechanized plasma

which makes for excellent weldability.

cuts on thin materials, simply by replacing

cutting system - the XPR300TM.

Furthermore, it produces minimal

the consumable parts on a torch. This is

dross, reducing the need for secondary

an attractive feature as a single plasma

Meet the New Plasma

processes like grinding. Overall, plasma

cutting system can be employed in a

The first of its kind, the XPR300

produces high quality cuts that are

variety of applications with a simple

represents the most significant advance

cleaner and more precise when compared

change of the torch and/or consumables,

in mechanized plasma cutting technology

to oxyfuel.

without having to switch back and forth

ever. Compared to its predecessor - the

among various tools.

industry leading HPRXDÂŽline- the

In recent years, ease-of-use of technical processes has also been gaining

new system exhibits a leap in cutting

importance as a key decision factor in

can also effectively carry out alternate

performance and cost-effectiveness. It

Asia when it comes to technological

applications at the same time. One

offers unrivaled cut quality on several

investments, primarily because it

example is gouging, and typical

metals (e.g. mild steel, stainless steel,

minimizes training, improves safety,

applications of it include the removal

and aluminum), increased cut speed,

and ultimately increases profitability.

of an existing weld during repair work,

improved productivity, and a 50%

Coupled with the latest technology CNC

scrapping or dismantling, as well as

reduction in operating costs. In addition,

and software, plasma is extremely easy

â&#x20AC;&#x153;back-gougingâ&#x20AC;?, the process of removing

to learn and use with preset parameters

the slag layer for multiple-layer welds.

embedded in the accompanying CAM

Plasma cutting is therefore capable of

software, minimizing the need for

satisfying the cutting and gouging needs

operator expertise. In addition, handheld

for a broad spectrum of industries,

plasma cutting systems are highly

whether for thin or thick, ferrous or non-

portable due to their relatively compact

ferrous metals.

size and light weight. Yet another advantage of plasma

Plasma can also be used to mark materials, either with alpha-numerics

cutting is its versatility. As plasma

to identify parts or to lay in weld lines.

cutting employs a high-temperature,

Modern automated systems allow

electrically conductive gas arc to cut

you to cut and mark using the same

through any material that conducts

consumables, considerably enhancing

electricity, it can be used on ferrous and

productivity.

non-ferrous materials, and on metal

Apart from cutting, plasma systems

With that in mind, Hypertherm recently

WELDFAB TECH TIMES | OCT - NOV 2017

As illustrated above, plasma provides an

www.weldfabtechtimes.com

FEATURE STORY

newly introduced ease-of-use features and engineered system optimization make the XPR300 easier to run with minimal operator intervention, while also ensuring optimal performance and reliability. These advances are attributed to an array of new process technologies, which Hypertherm has branded as X-Definition™ cutting (see Table 1). The cut speed of a XPR set at 170 amps is comparable to that of an HPR using 200 amps of output current.

Enhanced Productivity & Profitability To most metal fabricators, there are

dependent on the material thickness, but

plasma’s ability to tackle high precision

two key benefits that they seek from

users can generally expect a 10 to 20%

applications. This class of cutting

their plasma cutting equipment:

increase on materials between 15 and 40

improves cut quality as measured using

improved performance and better cost-

mm in thickness, 38% increase on 50 mm

ISO 9013, an international standard

effectiveness. These are the main areas

materials, and nearly 50% increase when

that defines the quality of thermally cut

that Hypertherm seeks to address with the

cutting 60 mm thick materials. Such

parts. This standard uses a scale of 1 to 5,

introduction of the XPR300.

improvements in cut speeds translate to

with a Range 1 cut considered best. The

When it comes to industrial cutting,

increased productivity and profitability

new XPR300 provides ISO Range 3 cut

productivity and profitability, or a lack

since one can complete more jobs with

quality for nearly the entire lifespan of

thereof, can come down to a few things

the same amount of time.

the consumables, and its cut quality on

- Cut Speed, Cut Quality, Consumables

In addition to faster cutting speeds,

thin mild steel is consistently within ISO

Life and System Uptime. The XPR300

the XPR is more efficient than the

Range 2. In comparison, Hypertherm’s

addresses all four aspects by creating a

HPR260XD . For instance, the XPR300

HPRXD systems tend to provide Range 4

system that cuts faster, cuts better, and

only requires 170 amps to meet the

cut quality.

more efficiently using “smart” technology

cutting speed of a HPR260XD system at

and time-saving steps.

200 amps. Not only does it allow faster

Cut Speed - by having 300 amps and

cutting, the XPR consumes less energy in

63 kilowatts of power, as compared to

the process as well. Cut Quality - the differentiating

the 260 amps and 45.5 kilowatts offered by its predecessor, the XPR300 is able to

factor lies in Hypertherm’s proprietary

cut faster. The exact speed increase is

X-Definition cutting that further enhances

Thickness

Cut Speed (mm/min) XPR300

HPR260XD

XPR300 versus HPR260XD %

15 mm

3440

3130

10%

20 mm

2550

2170

18%

25 mm

1950

1685

16%

30 mm

1530

1290

19%

40 mm

940

790

19%

50 mm

560

405

38%

60 mm

385

258

49%

XPR300 cuts at 10 to 20% faster than its predecessor on metals up to 40 mm thick, and nearly 50% faster for materials thicker than 50 mm (2").

www.weldfabtechtimes.com

XPR300 300A mild steel process remains in ISO Range 3 for nearly its entire process life of 1,368 20-second cuts on 20 mm (3/4") plate, compared to ISO Range 4 for its predecessor (HPRXD). In addition to improved cut quality, the other noteworthy aspect is the consistency of the cut. The XPR can produce parts with uniform cut quality,

OCT - NOV 2017 | WELDFAB TECH TIMES

FEATURE STORY

cutting jobs in-house, without having to

electrodes used in cutting mild steel is

outsource these jobs to laser and other

unable to resolidify when an arc “snaps”

specialized cutting centers. This can lead

off . As a result, every time a ramp-

to significant cost savings, an improved

down occurs, a little bit of hafnium is

and more efficient supply chain, faster

ejected from the electrode, accelerating

delivery of jobs, and greater overall

consumable wear.

profitability. Consumables Life– The XPR is equipped with a patent-pending feature called Cool Nozzle™, which provides XPR300 80A mild steel process remains in ISO Range 2 for roughly 1,300 20-second cuts on 6 mm (1/4") plate, before moving into ISO Range 3.

liquid cooling directly to the nozzle bore, increasing consumable life. During laboratory testing for instance, it was found that XPR consumables can make close to 1,400 twenty-second cuts on 18mm (3/4") mild steel, which represents 50% improvement. The increased consumable life is further enhanced through the new Arc Response TechnologyTM, consisting Automatic Torch Protection and Automatic Ramp-

this issue through the Automatic Ramp-

In cutting, ramp-down errors

down Error Protection feature, in which

are considered very damaging to

the system senses when a ramp-down

the result of several new technologies.

consumables. These errors occur when

error is about to occur and rapidly

One of those processes, the patent-

an arc is terminated in an uncontrolled

terminates the arc in a controlled manner,

pending Vented Water Injection™

manner by running off the plate or by

enabling the hafnium to re-solidify and

(VWI), combines a nitrogen plasma gas

having an interior feature (like a hole or

greatly prolong electrode and nozzle life.

with a water shield to better align and

slot) fall away. When this happens the

While most plasma systems experience

focus the plasma arc. A second, called

hafnium emitter located at the tip of

approximately 50% reduction in

Vent-to-Shield, reclaims hydrogen from

consumable life from ramp-down errors,

the vented plasma gas and mixes it

with the XPR300 the rate is reduced to

with the shield gas. Together, these two

less than 10%. This equates to a realized

technologies produce squarer cut edges

consumable life benefit that is nearly

with less angularity, and an improved

three times longer than usual, which also

surface finish when compared to the

means more savings for the end customer.

HPRXD systems. The XPR also utilizes

System uptime – improvements to

a process called Advanced Arc Stability

consumable life as mentioned before

designed to stabilize the plasma arc, as

also contributes to system uptime. The

well as new segmentation protocols for

patented PowerPierce® technology sends

holes that surpass Hypertherm’s existing

liquid cooling to the shield, which helps

industry-leading True Hole process on

to repel molten metal during piercing,

HPRXD systems. This enables the XPR300

thereby preventing the shield from

to easily fabricate bolt-ready holes down

damage. With less time spent changing

to a diameter-to-thickness ratios of

consumables, operators gain more time

1:1. As cut quality improves, it may be

for cutting and for other value driven

possible for fabricators to perform more

activities.

The XPR300 power supply addresses

down Error Protection features.

WELDFAB TECH TIMES | OCT - NOV 2017

www.weldfabtechtimes.com

FEATURE STORY

deliver refined diagnostic codes and

to quickly plug the torch lead into the

significantly enhanced system monitoring

torch console without the use of tools,and

information. This reduces troubleshooting

a patent-pending QuickLock™ electrode

time and provides proactive data for

that delivers easy ¼ turn tightening

improved overall system optimization.

which further reduces job setup time and

In addition to automatic system monitoring, the XPR contains several Cutting costs comparison between XPR300 and its predecessor.

other features that redefine ease-of-use.

enables an operator to rapidly change a torch using just one hand. The new XPR300 also includes built-in

For one, the system is designed with fewer

Wi-Fi capability into its power supply.

consoles and connections so operators

Owners and operators can make use

can spend less time setting-up and more

of this feature to monitor the system

mechanized plasma cutting systems

time cutting. Other notable features

or perform process set-up tasks from a

to date. On-board sensors continually

include a connection device called

phone, tablet, or other portable devices.

monitor current, pressure, temperature,

EasyConnect™, which allows an operator

The Wi-Fi can also connect to the LAN for

The XPR300 is one of the smartest

and flow and compare to specifications

multiple systems tracking. Significantly,

during operation to ensure optimum

the XPR300 system supports Industry 4.0.

uptime. With a combination of faster cut speeds,

Conclusion

improved cut quality, longer consumable

As illustrated above, Hypertherm's

life, and greater system uptime, the

XPR represents the next generation of

XPR results in greater productivity and

industry-leading mechanized plasma

profitability.

cutting systems. With a combination of technology innovation and smart design,

User-centric Features

this new generation plasma system offers

In spite of the sheer volume of technology

the highest standard for performance on

found in the XPR300, the system is

mild steel, stainless steel, and aluminum,

surprising uncomplicated and user-

expanding cutting capabilities in ways

friendly. Sensors in the power supply

that was not possible before.

Latest Process Technology

Details

HyFlow Vortex or Vented Nozzle Technology

A unique two-piece vented nozzle design that aligns and focuses the plasma arc for increased arc stability and energy density, resulting in a cleaner, sharper, and more consistent edge quality on all steel – including stainless steel and aluminum.

Vented Water Injection (VWI)

A patent-pending process featuring a vented N2 plasma gas and H2O shield gas for less angularity and squarer cut edges on stainless steel and especially aluminum.

Vent-to-Shield

A process in which hydrogen from the vented plasma gas is reclaimed and mixed with the shield gas, reducing angularity and delivering more consistent edge color on stainless steel up to 12 mm.

Plasma Dampening

A feature that adds a chamber in the nozzle to absorb the pressure and flow fluctuations that create arc instability when cutting with lower current, highly constricted arcs, which are required for thin stainless applications. This eliminates wavy and irregular cut surfaces.

Cool Nozzle

A patent-pending feature on the 300-amp oxygen process in which liquid cooling is sent directly to the nozzle bore, increasing cut quality over the life of the consumables by more than 40%.

Advanced Arc Stability

A technology that modifies impingement of the shield gas for improved arc stability when coming out of a pierce hole or out of an acute angle. This can enable reduced lead-in lengths and produces improved cut quality.

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OCT - NOV 2017 | WELDFAB TECH TIMES

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Electronics Electronics Devices Devices Worldwide Worldwide Pvt. Pvt. Ltd. Ltd. Electronics Electronics D D 31, Mistry Industrial Complex, Cross Road 31, ‘A’,M.I.D.C., Mistry Ind 31, Mistry Industrial Complex, Cross Road 31, ‘A’,M.I.D.C., Mistry Ind Andheri [E], Mumbai 400093. INDIA. Andheri Andheri [E], Mumbai 400093. INDIA. Andheri [E], [E], M M Tel: +91-22-45410600/ 601 Service: +91-22-45410625 Tel: +91-22-4 Tel: +91-22-45410600/ 601 Service: +91-22-45410625 Tel: +91-22-4 Email: sigmaweld@edmail.in Email: Email: sigmaweld@edmail.in Email: sigmaw sigmaw Web: Web: Web: www.electronicsdevices.com, www.electronicsdevices.com, www.sigmaweld.com www.sigmaweld.com Web: www.ele www.ele

Induction Induction Based Based

Preweld / Postweld heat treatment

O O e kke a BBa n ggeen o ddrro y || H Hy t eeaat H sstt H o || PPo t aat e e H ee H r PPr

Sales Sales & & Marketing Marketing office: office: 608, 6th Floor, Windfall, 608, 6th Floor, Windfall, Sahar Sahar Plaza, Plaza, Next Next to to Kohinoor Kohinoor Hotel, Hotel, Jb Jb Nagar, Nagar, Metro Metro Station, Station, Andheri Andheri East East Sales Tel: +91-22-45410500 Sales - Tel: +91-22-45410500

ccllee y tt CCy a eea H H eedd z iiz m ttoom s CCuus | uutt |

TAKING TAKING WELDING WELDING INVERTER INVERTER TECHNOLOGY TECHNOLOGY TO TO THE THE NEXT NEXT LEVEL LEVEL

ARTICLE

Induction Heating for Pre Weld / Post Weld applications

hanks to the Induction Cookware,

The gas burners in the shop floor need

the concept of Induction is now

special safety precautions and are prone

fairly well known. Induction is a

to accidents. As they can be hot even after

method by which heat is generated directly

heating is off. The same is shown below

inside the metal, it is not radiated or

using an Induction System, well insulated

conducted but Inducted. What this means

coil or blanket coil can be used. Operators

is that you can heat a specific part of the

can work around the area safely. Also

object without affecting the surroundings

storing and managing Gas Cylinders in

too much.

shop floor environments needs a lot of Uniform Heating.

safely precautions and leaky cylinders can

Efficiency

cause major accidents. Induction works

Cost

Advantages of Induction heating are too

on basic electricity supply which is safety

Running cost of induction heating is way

many, for one it is one of the most efficient

ensured using MCCBs and ELCBs.

lower than resistance or gas heating. With higher efficiency and lower time taken to achieve the temperature, it is fast becoming the preferred method of pre / post Weld heat treatment.

In Conclusion With the use of more thin-wall steel alloy Heating with Gas Flame.

pipes in today’s oil and gas pipelines,

method of heating. According to a study

Quality

manufacturers and installers are turning

conducted by American Department of

Heating with Induction ensures heating

to the fast, accurate and uniform heating

Energy (US DOE) heating with gas, electric

all across the heating zone with equal

of induction heating systems. During the

heating and Induction for the same object,

heat. The heat zone from surface to center

process of butt welding, induction heating

the efficiency of heat transfer and heating

can be controlled well within 5 degrees.

is commonly used to preheat the joint area

was 44%,74% and 84% respectively. Which

Similarly over a large length or long seam

to 150-200 °C to prepare the area for a

means heating with Induction compared

of upto 12 meters we have found heating

consistent quality weld. After welding, the

to Gas is almost 40% more efficient.

to remain within 10 degrees across the

joint area is heated to 600-650 °C

Quicker heating

surface and thickness. Obtaining the same

for thermal stress relief of the weld area.

with the help of Gas can be a challenge.

Traditional gas flame and resistance

Induction, the heat is produced into the

For critical materials such as P91 and

heating systems are often impractical when

metal using eddy currents, so the operator

others the Induction Heating process also

these higher temperatures are required.

and the surrounding do not get heated

helps with achieving the pre-programmed

Not only are they too slow to meet the cycle

as much. The coil applicators which

heating cycle with temperature feedback.

times demanded by the industry, but also

generate the magnetic fields and carry the

It can heat with a settable ramp rate

the heating can be inaccurate and can lack

currents are well insulated. The Job can

say 60 Degrees / Hr or 100 Degrees / Hr

uniformity around the full circumference

be at 100 degrees while the coil is still at

and similarly it can help hold the job at

and bandwidth of the weld joint.

room temperature. Chances of accidents

the soaking temperature for as long as

are greatly reduced. Imagine trying to

required. Advantage of Induction heating

Mr. Nimesh Chinoy, Marketing Director

heat a 1 meter dia shell upto 55mm thick

is that if you want a controlled cooling off

Electronics Devices Worldwide Pvt. Ltd.

with multiple gas burners on for hours.

rate after the heating , that also is possible.

Website : www.sigmaweld.com

Safety is another major advantage with

Induction Heating.

WELDFAB TECH TIMES | OCT - NOV 2017

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ARTICLE

Lifeline of Welding: Low Hydrogen Electrodes Moisture-resistant E7018 H4R and E7018-1 H4R iron and wrought iron at Furstenwald

Achieving high quality welds

near Berlin using the Slavianoff process

Achieving high quality welds is the

and a flux of powdered glass plus 1%

objective of every fabricator and it is the

of ferromanganese. The first patent for

basic requirement of his client. Deposited

covered electrode was filed in the year

weld metal can be termed as high quality

1907 by O. Kjellberg, followed by another

weld provided the weld metal fulfills the

patent in the year 1912. Strohmenger in

following requirements.

1911 patented an electrode wound with

1. Deposited weld is free from defects.

asbestos yarn impregnated with sodium

2. Deposited weld has required

silicate. The first all-welded barge was launched in June 1918. The first version

M. P. Dhanuka, Executive Director (Marketing), General Electrodes and Equipments (GEE) Ltd.

of basic type of covered electrode was

performance. 3. Deposited weld meet required standards and specifications.

developed during the early '30s. The

lectric arc welding has been in use

covering of the electrode had a high

Types of electrodes and mechanical

in industry for a very long time.

proportion of lime and fluorspar. In

properties of the deposited weld metal

Because of its versatility, it appears

Germany, basic type of electrodes was

Various types of electrodes conforming

that this process will dominate the field

used during World War II for welding of

to respective AWS/SFA classifications

of joining metals and alloys for many

armour plates as an effective substitute

fulfill the code requirements with respect

more years. The first steps in electric arc

for the austenitic types. One of the most

to chemical composition of weld metal,

welding were taken by Bernados and

successful modern rutile-based general

mechanical properties of weld metal, &

Olszewaki in 1885 when they patented a

purpose electrode was first developed in

usability and soundness test requirements.

method of welding, using an arc struck

1941 for Welding in shipyards. It is still

between a carbon electrode and the

one of the largest selling electrode in most

requirements for various types of

workpiece. The direct use of a metal-arc

of the countries. During the 30's, 40's and

electrodes.

electrode was patented in the U.K. by

50's, a large number of electrodes were

N. Slavianoff in 1890. The first reference

developed depending on application

to a welding application in the 'Journal

requirements. Based on Flux coating

of the Iron & Steel Institute' appears in

formulations, these electrodes can be

1901 and describes the welding of cast

classified broadly as under:

Table 2 gives details of impact test

TABLE 2 AWS / SFA CLASSIFCATION

CHARPY V-NOTCH IMPACT REQUIREMENT, MINIMUM

6012, E6013, E6020, E6022, E7014, E7024

Not specified

E6019, E7028, E7024-1

27Jat-20째C

TABLE 1 TYPE OF COVERING

SFA 5.1 CLASSIFICATIONS

Cellulosic coated electrode

E6010,E6011

Acid type -High iron oxide with or without iron powder

E6020, E6022 E6027, E7027

Rutile, Rutile cellulosic type electrode with or without Iron powder

E6012,E6013,E7014 E7024, E7014-1

Low hydrogen electrode with or without iron powder in the flux Coating

E6018, E7015, E7016, E7018, E7028, E7048, E7016-1, E7018-1, E7018-M

Iron oxide with titania

E6019

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E6010, E6011, E6027, 27Jat-30째C E6018, E7015, E7016, E7018, E7027, E7048 E7016-1, E7018-1

27Jat-45째C

E7018M

67Jat-30째C

OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

Hydrogen content of the weld metal and

cracking occurs due to four factors which

amount absorbed, the size of the weld,

types of electrodes:

are as under:

the decreasing solubility and time

Only Low-Hydrogen basic type of

3. Hydrogen

temperature conditions of cooling.

electrodes such as E6018, E7015, E7016,

4. Susceptible microstructure in the

E7018, E7048, E7028, E7016-1, E7018-

coarse grained HAZ

1 and E7018M have been designed to

5. Stress

deposit weld metal having low levels

6. Ambient temperature

of hydrogen. Hydrogen content in the deposited weld metal depends on many

If anyone of the above factors is removed,

factors. These aspects will be dealt with

then it would be possible to prevent

separately in this paper.

the cracking of the weld metal or HAZ cracking Even though all the 4 factors

Hydrogen in the weld metal and

mentioned above have equal importance,

susceptibility to cold cracking in ferritic

hydrogen is an elusive element which

welds Defects in welds

affects cold cracking susceptibility in

Weld defects are broadly classified into

ferritic welds. Hence, control of hydrogen

two types:

in the weld metal is of paramount

1. Defects induced by the welder

importance.

due to low skills, difficult Working

FIG 1 - Amount of hydrogen absorbed by molten weld pool varies with concentration in atmosphere surrounding the arc. Solubility at 1,900Â°C

Hydrogen

environment etc. 2. Defects due to the metallurgical characteristics of the material.

Hydrogen in the weld metal can be introduced from a number of sources. The most likely sources are as under:

Typical Examples:

1. Moisture in the electrode coating or

Defects due to welder

Defects due to Metallurgical Characteristics

Lack of side wall fusion

Hydrogen cracking

Lack of penetration

Solidification cracking

Undercutting at toes Lamellar tearing Hydrogen induced cracking in welds

moisture in fluxes 2. Moisture on the steel surface 3. Water combined with rust, oils and other greases on the work piece or filler wire 4. Organic degreasing agents used for cleaning 5. Moisture present in the atmosphere 6. Residual hydrogen in the steelespecially in thick section Material

Hydrogen cracking in the weld metal

FIG 2 - Solubility of hydrogen in weld metal decreases as temperature falls. In general, the more the hydrogen

as well as in the parent metal has

In the case of manual metal arc welding,

been the subject of intense research

the main source of hydrogen is the

is present in the metal, the greater

for many years. However, it is still the

moisture contained in the electrode

the risk of cracking. Control over the

most common defect found in welded

coating. During welding, dissociation

hydrogen level of the weld metal may

structures. The cost of repairs due to

occurs and the atomic hydrogen thus

be achieved by minimizing the amount

hydrogen cracking is, on a worldwide

formed dissolves in the molten pool.

initially absorbed or by ensuring that,

basis, enormous. Traditionally, hydrogen

During cooling much of the hydrogen

sufficient time is allowed to escape by

cracking occurs in the hardened coarse

escapes from the solidified bead by

diffusion before the weld cools. Often a

grained HAZ region of ferritic steels

diffusion but some quantity diffuses

combination of both measures provides

but the advent of low carbon steels has

into the HAZ and the parent metal.

the best practical solution.

seen a significant increase in weld metal

The amount which does so depends

hydrogen cracking. HAZ Hydrogen

on several factors such as the original

WELDFAB TECH TIMES | OCT - NOV 2017

Moisture in the Flux coating of electrodes may be present as absorbed

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ARTICLE

water, loosely combined water of

electrodes, diffusible hydrogen test is

collected from a diffusible hydrogen test

crystallization or more firmly bound

only required when diffusible hydrogen

decreases from about 70 percent to about

molecules in the silicate structure. All

designator is added to the classification.

50 percent As the apparent diffusible hydrogen of the test specimen increased,

these forms can break down to produce hydrogen.

For Example:

the concentration of hydrogen in the gas

E 7018H4, E 7018H8 and E 7018H16

collected over glycerine increased from

Definition of low hydrogen electrode

about 55% at 6ml!100g to about 75% at

Understanding of the role of diffusible

As per the new classification system

about 10m 1/1 00 g. The remainder of the

hydrogen in delayed cracking of welds

for low hydrogen electrodes the upper

gas collected consists of other dissolved

in carbon steel and low alloy steel came

limit for diffusible-hydrogen is 16ml

gases which are displaced from glycerine

about at least as long ago as the 1940's.

100g which fits well with the correlation

by the dissolved hydrogen.

Indeed, classification of low-alloy steel

of 0.6 percent coating moisture. As per

electrodes designated as "Low hydrogen",

AWS/SFA 5.1 specification, diffusible

collected. All of the hydrogen dissolves

was introduced into AWS specification

hydrogen content of the weld metal is to

without displacing any other dissolved

A5.5-48T (ASTMA316-48T) in 1948 along

be tested in accordance with ANSI/AWS

gases. The Japanese have conducted at

with a diffusible hydrogen test using

A4.3 specification, "Standard methods

least three studies of correlation between

collection of hydrogen from a quenched

for Determination of the diffusible

the glycerine test the IIW method.

weld bead over glycerine. The Low

hydrogen content of Martensitic, Bainitic

In the first study, the test weld was

hydrogen electrode was defined as one

and Ferritic weld metal produced by Arc

quenched 30 seconds after the arc was

meeting a maximum limit of 0.1 cubic

welding". As mentioned above, diffusible

extinguished. The following correlation

centimeter of gas collected per gram of

hydrogen testing is required as per AWS/

equation was obtained.

deposited weld metal (10ml/l00g, in units

SFA5.1 specification for all Low hydrogen

Hjis = 0.64 Hiiw - 0.93 ........ (1)

commonly used today for expressing

type electrodes when diffusible hydrogen

diffusible hydrogen).

designator is added to the classification.

In the second study, the test weld was

Diffusible hydrogen limits for weld metal

quenched 5 seconds after the arc was

are given in the following table:

extinguished.

Shortly after this specification was published, Stern Kalinsky and Fenton cast doubt on the suitability of collection

At very low hydrogen level, no gas is

TABLE 3

of hydrogen over glycerine by showing that collection over mercury produced considerably more hydrogen because hydrogen is soluble in glycerine. By way of the 1954 revision of AWS 5.5, the glycerine test was withdrawn from the specification and it was replaced in the 1964 revision by definition of Low-hydrogen, as those having no more than 0.6 percent coating moisture by weight, with lower limits for

the mandatory section of AWS A5.1

Determination of the diffusible hydrogen content of the weld metal by mercury method as against glycerine method

specification in the 1981 revision. AWS

It was recognized long ago that glycerine

A5.1 specification was further revised in

dissolves not only some hydrogen but

More recently, the Japanese have moved

the year 1991 and in the year 2004. In this

it dissolves oxygen, nitrogen, carbon

to adding a run-on and run-off tab to the

specification, diffusible hydrogen test is

dioxide and water M.A. Quintana showed

test specimen. They produced a third

required for E7018M electrode, whereas

that, as the glycerine bath aged, the

equation which is a as under:

for other Low hydrogen basic coated

concentration of hydrogen in the gas

Hjis= 0.79Hiiw-1.73 ......... (3)

higher strength electrode. This definition of Low-hydrogen electrodes in terms of 0.6 percent coating moisture became

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The Second study provided slightly higher hydrogen and the equation is given below: Hjis= 0.67 Hiiw - 0.80 ........ (2)

OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

The three equations are plotted in fig

pressure of water. Based on the results,

3 which shows that there is very little

correlation between diffusible hydrogen

Correlation of diffusible hydrogen with cracking

difference among them. FIG 3

versus coating moisture for E7018 is

Evans and Christense and Christense and

plotted in fig (4). FIG 4

Simonsen examined the critical cracking stress by the implant test of a variety of steel as a function of hydrogen content of the weld metal. An example of their data is shown in fig 6. This data was obtained from a steel of O.17C, 1.36 Mn. Both rutile and basic coated electrodes were used to obtain various hydrogen levels. FIG 6A

Correlation between coating moisture and diffusible hydrogen moisture and diffusible hydrogen, it is

Effect of basic coated electrode exposure on the diffusible hydrogen content of the weld metal

important to keep in mind that correlation

As-manufactured coating moisture of the

cannot be perfect because several factors

basic coated electrode is likely to be more

can influence the relationship. Few factors

concentrated in the interior of the coating

which can influence the relationship are

than on the surface because, in baking the

as under:

electrode, moisture must diffuse outward

1. At the same coating moisture level, an

through the coating thickness in order to

In evaluating correlation between coating

electrode with a heavy coating would

escape. Conversely, moisture picked-up

deliver to the arc more hydrogen than

during exposure must enter the electrode

would an electrode with a thin coating.

coating from the outside surface, and

2. The addition of fluorides to an electrode

diffuse inwards. This surface moisture

slag system will cause removal of some

could be less tightly bound to the coating

hydrogen. As a result, similar electrodes

than the as-manufactured moisture which

at the same coating moisture level, will

survived a high temperature baking. In

yield different diffusible hydrogen levels

other words, rehydrated moisture picked-

if one is appreciably higher in fluoride

up during exposure will be less effective

than the other.

in introducing diffusible hydrogen into

HIRAI and co-workers developed a

the weld metal than the as-manufactured

predictable equation which related IIW

moisture. Dr. Evans provided the results of

diffusible hydrogen to as baked coating

basic coated electrode diffusible hydrogen

moisture (a1 percent), moisture picked

versus coating moisture on Drying and on

up by exposure (a2 percent) and partial

exposure which are given in fig 5. FIG 5

pressure of water vapour in the air at the time of welding (b, mm of Hg) for E7018

FIG 6B

The hydrogen levels reported are based upon fused metal (deposited metal plus melted base metal). Critical cracking stress is plotted in two

type electrode.

ways, directly against hydrogen content of

HD- (260al + 30a2 + 0.9b -10) ~ (4)

the weld metal and against the logarithm of the weld metal hydrogen content via a

For freshly baked electrodes, the exposure term of equation (4) could be zero and

semi-logarithm plot. For all steel examined, the critical

atmosphere condition for the welding

cracking stress, under otherwise identical

amount to about 10mm Hg partial

conditions, is a linear function of the

WELDFAB TECH TIMES | OCT - NOV 2017

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ARTICLE

logarithm of hydrogen content of the weld

atmospheric moisture at the time of

deposit. It is not a linear function of the

welding on the weld metal diffusible

hydrogen content. In particular, a small

hydrogen.

change in hydrogen content is much

The nomogram predicts, for example,

more important at a low hydrogen level

that an electrode type E 7018, which

than at a higher level.

produces 3.0ml/l00g. Diffusible hydrogen

At a given preheat temperature, the

1. Low, very low and extra low level of hydrogen in the weld metal 2. Response to redrying 3. Resistance to moisture reabsorption characteristics 4. Special Packaging.

when tested at 20째C and 40% relative

critical carbon equivalent for crack-

humidity, will produce 5.4ml/l00g. when

By using the most updated in house

free welding varies as a function of the

tested at 30째C and 80% relative humidity,

technology, the most advanced extra

diffusible hydrogen content of the weld

an increase of 2.4ml/l00g.

low hydrogen type of electrodes having

metal. Yurioka conducted experiments

But an electrode type E 7018 which

the following classifications have been

on the above lines and his result are

produces 9.0ml/l00g. When tested at. 20째C

reproduced in fig 7A & 7 B.

and 40% relative humidity, will produce

FIG. 7 A

about 10.0rill/l00g. When tested at 30째C

E7016

E7018

and 80% relative humidity, an increase

E7016-1

E7018-1

developed.

only of 1.0ml/l00g. 8.2 These electrodes have the following Following conclusions can be drawn from

unmatched properties:

the various experiments carried out: 1. The effect of atmospheric moisture

enjoy.

very Low or Ultra low hydrogen

Recently developed Low-hydrogen

electrode than it is for higher hydrogen

basic coated electrode features the

electrodes.

best easy handling characteristics in

2. Long arc during welding will have more FIG. 7 B

a) The weldability that WELDERS really

at the time of welding is greater for

all positions. The deposited weld metal

tendency to pick-up moisture from the

has uniform ripples and absolutely no

atmosphere and will produce more

spatter. An end to difficult positional

hydrogen in the weld metal.

welding and lack of fusion on vertical

3. In GMA and gas-shielded arc welding,

up welding position. These electrodes

drafts or other disturbances to the gas

deposit x-ray/ radiographic quality

shielding can be expected to increase

welds in all positions including 5G, 6G

diffusible hydrogen of the weld metal.

or 6GR.

4. In self-shielded flux-cored arc welding,

Effect of the atmospheric moisture during welding on the content of diffusible hydrogen in the weld metal

high voltage increases the arc length

b) The mechanical properties

and can be expected to increase

that WELDING ENGINEERS really

diffusible hydrogen.

appreciate. Recently, developed low-hydrogen

Welding consumables: Basic coated electrodes

basic coated electrodes guarantee high

In most of the arc welding processes including shielded metal arc welding, the

In order to minimise the risk of cold

with other non-alloy basic coated

arc is imperfectly shielded from the air.

cracking during welding of carbon

electrodes. Charpy V-notch impact

During the welding process, moisture from

steel and low-alloy steels, a lot of

values are more than 100 joules when

the atmosphere does enter the arc and the

developments have taken place during

tested at -30DC or - 46DC.

weld metal.

the last few decades. Designs of basic

c) Extra low-level of Diffusible

coated consumables cover the following

hydrogen.

four aspects:

The flux coating of these electrodes has

Ruge and Dickehut developed nomogram for estimating the effect of

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mechanical properties in comparison

OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

Metallic mercury and vapours are

a unique feature, a barrier to moisture

than 9 hours by any suitable method.

absorption and diffusible hydrogen to

The moisture content of the electrode

hazardous and can be absorbed into the

the weld metal. After 9 hrs of exposure at

covering is then determined by any

body by inhalation, ingestion or contact

27DC at 80% RH, the maximum moisture

recommended method. The moisture

with the skin. Therefore all precautions

in the flux coating is 0.20% and diffusible

content of the exposed covering

involving the handling of mercury should

hydrogen is less than 4ml!100g of the

should not exceed 0.40%, maximum

be observed during measuring hydrogen

weld metal.

specified moisture content for the

by the mercury method.

Fig 8 shows moisture absorption

On the, other hand, gas

electrode.

chromatography procedure is quite

versus exposure time for recently developed E7018 class of electrodes.

Diffusible hydrogen test

safe and is used by many European and

FIG 8

In addition to the absorbed moisture

Japanese manufacturers of basic coated

test, the basic coated low hydrogen

Low-hydrogen electrodes. Since gas

electrode designated by an optimal

chromatography procedures vary from

supplemental diffusible hydrogen

instrument to instrument, it is necessary

designator are tested according to one

to study carefully 'the instruction and

of the methods given in ANSI/AWS A4.3

calibration procedures recommended

Standard Methods for determination

by gas chromatography apparatus

of the diffusible Hydrogen content of

manufacturers.

Moisture-resistant electrodes

Martensitic, Bainitic and Ferritic steel

Recent years have seen much emphasis

weld metal.

on developing coated electrodes whose

The IIW mercury method may require 14 to 21 days for complete collection of all of the diffusible hydrogen in a test

For the purpose of certifying

coating resist moisture pick-up. Such

compliance with diffusible hydrogen

specimen at room temperature. The

developments have permitted the user

requirements, the reference atmospheric

AWS method requires 72 hours at 45째C

to test the electrodes for moisture pick-

condition shall be an absolute humidity

or 6hrs at 150째C for collection of nearly

up with a view to extending the

of 10 grains of water vapor per pound

all of the diffusible hydrogen escape

exposure time permitted by the

(1.43g/kg) of dry air at the time of

from the weld metal. Clearly elevated

structural welding code steel and

welding. The actual atmospheric

temperature speeds up the hydrogen

other fabrication standards.

condition is to be reported along with

escape from the weld deposit, but

the average values for the test according

hydrogen does escape from solid steel at

to ANS/AWS A4.3-86 specification.

room temperature.

Moisture-resistant basic coated electrodes in accordance with AWS/ SFA 5.1-91 or 5.1-2004 specifications are

Two types of analytical apparatus are

designated by adding the suffix letter "R"

used for analysis of diffusible hydrogen.

Effect of diffusible hydrogen content on

after the four digit classification number.

1. Mercury filled eudiometer

tensile and ductility of the weld metal

2. GAS chromatography

Diffusible hydrogen in the weld metal

designator used with the Low-hydrogen

The test specimen confined within

could reduce tensile and ductility in a

electrode classification. The letter "R"

its isolation chamber is held at the

slow strain rate test.

is used to identify electrodes that have

hydrogen evaluation temperature as per

been exposed to a humid environment

the following details.

As per the specification, a letter "R" is a

for a given length of time and tested for moisture absorption in addition to

Weld metal from a particular batch of E7018 electrodes which typically

TABLE 4

the standard moisture test required for classification of Low-hydrogen electrodes. As per the specification, "R" designated electrodes are exposed to an environment of 26.7째C (80째F) and 80% relative humidity for a period of not less

WELDFAB TECH TIMES | OCT - NOV 2017

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ARTICLE

3. The electrodes are vacuum packed

produces less than 5ml 100g of diffusible

absorb different amounts of water under

hydrogen averaged 27.3 % elongation in

identical conditions. Smith studied the

using special qualities of pouches and

the as-welded condition and 28.5% in the

phenomenon in detail and demonstrated

these vacuum packed electrodes are

"aged" condition.

that different brands of electrodes

further packed in plastic or cardboard

However, differences in measured tensile, elongation between "as-welded" and "aged" conditions become much

containers.

have different tolerance to moisture

The metal tin containers used for

absorption.

vacuum packing are specially designed

While manufacturing low hydrogen

more important when electrodes of

basic coated electrodes enough care

to provide protection for the electrodes

higher strength are used.

is taken during baking operation so

during handling and storage. Table 5 provide' details of moisture

that almost all quantity of moisture is Resistance to moisture absorption

removed from the flux coating. Freshly

level in the flux coating, shelf life of

characteristic of low-hydrogen basic

baked electrodes can have as low as

the electrodes for different packing

coated electrodes

0.04% moisture in the coating. Since flux

conditions.

As mentioned earlier, basic coated low-

TABLE 5

hydrogen type electrodes have been developed having moisture-resistant coating. These electrodes have been developed on some of the following measures: 1. Optimised granulametry of the coating flux ingredient. 2. A newly developed binder system. 3. Correct procedure used for removing almost entire quantity of moisture from the flux coating. coating of low hydrogen basic coated

Saving in welding cost

These electrodes after baking have very

electrode is hygroscopic in nature,

Welding costs which varies from one

low level of moisture in the flux coating.

different manufacturers use different

fabricator to another depend upon the

It is always less than 0.1 % and the

modes of packing.

following factors.

typical value is as low as 0.04%. These

1. Low hydrogen basic coated electrodes

1. Drying of electrodes

electrodes when exposed to atmosphere

are packed in polythene bags and

2. Storage of electrodes

having temp. 27Â°C +2Â°C and 80% RH

then in cardboard cartons. These

3. Preheating (Power, labour cost)

absorb moisture very slowly. These

cardboard cartons are further shrink

4. Reduced labour productivity because

electrodes are designated with the suffix

packed.

"R" letter according to AWS/SFA 5.12004 specification.

2. The electrodes are hermetically packed into the metal tin immediately following production baking. These

working on 5. Preheated work place is more difficult 6. Post weld heat treatment.

Special packaging for low-hydrogen basic coated electrodes

metal tins may have sufficient quantity of dessicant which can lower

Recently developed Low hydrogen

It was shown by Franks in 1950 that

the relative humidity in the tin to

basic coated electrodes which are either

Low hydrogen type coverings pick-up

below 8% ensuring that the electrode

hermetically packed or vacuum packed,

moisture when openly exposed to humid

coating does not absorb moisture

deposit weld metal having highly reduced

atmosphere and that different electrodes

during storage.

levels of diffusible hydrogen in the weld

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OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

metal as well as in the heat affected zone.

electrodes have kept pace with the

tin packed for eliminating cold

Such very low level of hydrogen increases

technological development taking place

cracking of the weld metal or HAZ of

tolerance to hardness in the heat affected

all over the world. They manufacture

the parent metal.

zone and stresses applied to the weld

moisture-resistant electrodes of various

metal without increasing the risk of cold

classifications and these electrodes

Conclusion:

cracking.

are now available in vacuum packed

1. Hydrogen is an elusive element

condition. Even though vacuum

affecting cold cracking susceptibility

moderate preheat is usually required

packed electrodes cost about 20 to 25%

in ferritic welds.

for eliminating the risk of cold cracking,

more than normal cardboard packed

recently developed vacuum PACKED

electrodes, these electrodes have a

BASIC COATED Low-hydrogen

much longer shelf life and can be used

criticality as the hardenability

electrodes either eliminate preheating

straight on the job after opening the

increases.

totally or reduce preheating temperature

pack. However care should be taken so

to a greater extent. Reducing preheating

that the entire quantity of the packet

or eliminating preheating results in

is consumed within 4 to 8 hours after

savings which is often equal to the cost of

opening the pack. Usually vacuum

welding consumables.

packed low hydrogen elect odes are

For many applications, where

supplied in 2.0 kg pouches. Example:

Recently developed basic coated

3. There cannot be a compromise on hydrogen control. 4. Procedural differences in measurement of hydrogen do require perfect understanding and careful

Welding of A516 Gr 70 steel plate of

low-hydrogen electrodes have improved

thickness 40 mm. For X meter length

toughness properties hence, these

of welding A516 Gr 70 steel thickness

electrodes have a unique feature called

40 mm.

resistance to ageing of the weld metal

electrodes, which are available

for manufacturing these electrodes,

in the market, deposit weld metal

electrode manufacturers adopt the

having low, very low or extra

following measures:

low level of hydrogen in the weld

1. The use of low carbon clean wire.

metal.

(a) Cost ofNormalE7018 ele ctrodes

US $ 200

(b) Cost of Vacuum packed E7018 electrodes

US$ 250

US $300

(d) Cost of storage, backing/ US $60 drying of Electrodes (30% cost of electrodes) * * Fabricators pay US $ 50 more for vacuum packed electrodes whereas he

comparative interpretations. 5. Low-hydrogen basic coated

2. The use of extremely clean minerals, ferroalloys and oxides. 3. The use of an optimized coating system with a high basicity index.

6. Moisture resistant low-hydrogen basic coated electrodes are now available in the market.

4. Control of Non-Metallic oxide inclusions in the metal which

7. In order to have longer shelf life and

controls the nucleation process

cut down cost of welding, fabricators

during solidification of the liquid

prefer vacuum packed basic coated

metal and favours the formation of a

Low-hydrogen electrodes.

more fine grained structure. 8. Recently developed low-hydrogen

saves US $ 360.

2. Hydrogen control assumes

It is expected that designers and

basic coated electrodes deposit weld

Hydrogen controlled consumables & welding consumable manufacturerâ&#x20AC;&#x2122;s capability & experience.

consultants would demand increasing

metal having improved toughness

quantities of various, recently

properties and low level of hydrogen.

developed Low hydrogen basic coated

These electrodes almost eliminate

Manufacturers of basic coated

electrodes which are either hermetically

risk of cold cracking.

WELDFAB TECH TIMES | OCT - NOV 2017

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ARTICLE

Temper Bead Welding-Review of Design Codes & Established Practices should be ‘precise’ and ‘very systematic’.

“Temper bead welding: a weld bead

This technique was originally developed

placed at a specific location in or at

for Nuclear Utilities and adopted by the

the surface of a weld for the purpose of

ASME Nuclear Design Codes (Sec-III)

affecting the metallurgical properties

and in service Inspection Code-Sec

of the heat-affected zone or previously

–XI and later adopted by other weld

deposited weld metal. The bead may

repair codes e.g. NBIC for non-nuclear

be above, flush with, or below the

applications. Due to the different

surrounding base metal surface. If

design stringencies and acceptance

above the base metal surface, the beads

considerations, multiple variations of

may cover all or only part of the weld

Temper bead repairs techniques had

deposit and may or may not be removed

been developed over last 30years.

following welding.”

This paper summarizes various

P. Goswami, P. Eng, IWE, Welding & Metallurgical Specialist, Ontario, Canada.

recommended techniques and relative

A word of Caution: Temper bead welding

pros and cons of all, as well with special

technique is never a substitute for post

emphasis on various factors related to

weld heat treatment in circumstances

this technique.

where operating conditions require a substantial reduction in residual stress

elding repair on aged and

Introduction to Temper Bead Welding

levels and meeting other requirements.

other components are always a challenge

Temper bead welding technique was

locally the fracture toughness and reduce

to welding engineers. The rationale is very

originally developed as an alternative

the peak hardness within the HAZ.

simple. Various mechanical properties

to Post Weld Heat Treatment (PWHT)

degrade over aging and service exposure.

welds mandated by design and

1. Governing Codes and Standards

Material properties in aged components

construction codes, thus to reduce

Non-Nuclear:

are always inferior that brand new

as-welded HAZ hardness. Temper bead

National Bard Inspection Code (NBIC)

components. Post Weld Heat Treatment

welding technique is one of the most

is the most common code followed for

is the Ultimate option to reduce weld

important repair welding methods for

repair and alteration by non-nuclear

residual stresses, improve ductility,

large structures for which it is difficult

industries, such as Electric Utilities,

notch toughness, and reduce hardness.

to perform the specified post weld heat

Oil and Gas Industries. As per NBIC

However, complete PWHT for in-service

treatment. The temper bead welding has

Under certain conditions, post weld

components are not always feasible

been specifically developed to refine the

heat treatment, in accordance with the

due size and location of components,

coarse grained HAZ in the parent metal

original code of construction, may be

extent of repair, and material property

by the judicious positioning of weld

inadvisable or impractical. Alternative

issues after many years of service related

beads and control of heat input.

methods for PWHT may be used in such

service exposed pressure equipment and piping and

exposures and many other constraints.

instances. One of the recommended

The definition and technique:

alternatives is Temper Bead Welding

is an attractive option for in-service

According to The American Society

Technique. NBIC Part 3, Clauses 2.5.3.2

repair of some grade of common and

of Mechanical Engineers (ASME), the

thru 2.5.3.5 are methods in which the

popular Ferritic pressure vessel steels.

definition of Temper bead technique is

welding procedure requires the use of a

Execution of this technique in field

as follows:-

temper-bead welding technique.

Weld repair by temper bead technique

This heat treatment aims to improve

WELDFAB TECH TIMES | OCT - NOV 2017

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ARTICLE

Nuclear:

diagram. These microstructural

ASME Sec-III, NB-4622.9 allows limited

changes are valid for many grades of

avoid excessive grain coarsening

weld repairs on P-No. 1 and P-No. 3

conventional Ferritic Steels (Carbon

of the ‘coarse grained’ HAZ of the

material, without PWHT or after the

& Creep Resisting) used in the used in

first weld layer;

final PWHT, provided it is impossible or

construction of power /petrochemical &

impractical to post weld heat treat the

refinery plants.

area after repair, and provided further

As per documented evidences for

requirements according to this code are

Cr-Mo creep resistant steels formation

met.

of a wider intercritical zone had led to

a. Limit heat input and pre-heat to

b. Increase heat input by a set amount for the second weld layer to grain refine the coarse grained HAZ of the underlying first weld layer; c. Overlap the placement of successive

Type-IV creep cracking in service. It is

weld beads to produce grain

2. Metallurgical Principles (Microstructural Changes) Behind Weld & HAZ

important to narrow the intercritical

refinement of the adjacent bead.

of subcritical zone to have effective

Multiple temper bead welding

Fig-1 shows the various microstructural

tempering done for the base metal, with

techniques have been developed over

changes occurring during a typical

controlled heat input and correct weld

the past 30 years. However, this paper

arc welding process. This helps to

bead placements.

discusses only the techniques popular

zones well, as to get the significant width

with the industries.

understand what takes place in the treatment, or temper bead welding.

3. Various Temper Bead Welding Techniques

The reference here is temperature

During temper bead welding, the heat

ranges vs the resultant microstructure

input, preheat and weld bead sequence

All techniques have a common goal

with respect to the iron-carbon phase

are closely controlled to:-

of tempering the coarse grained HAZ

HAZ due to welding and post weld heat

a. Half Bead Technique b. Controlled Deposition Technique

(Ref Fig-1) in the parent metal. The Fig 1: Iron – carbon phase diagram showing the transition points relating to a weld HAZ.

methods by which the weld beads are deposited vary on chosen technique as discussed below. a. Half Bead Technique (Adopted in ASME Sec-III, Nuclear Codes) Originally developed for use in the nuclear industry, but this technique has since become widely popular for repairs of high temperature piping, headers and turbine casings in conventional power plant. The SMAW technique is used and employs a series of increasing diameter electrodes, starting with 2.5 mm, then

Note: During welding, there can be up to four sub-zones within the HAZ created according to the maximum temperature reached and the duration of time at that temperature. These sub-zones are: • Sub-critical: 650 – 723oC • Inter-critical: 723 – 900oC • Fine Grain: 900 – 1000oC • Coarse Grain >1000oC < melting point. Formation of these sub-zones is determined by the transformation characteristics of the steel. The dashed lines linking the iron-carbon phase diagram on the left to the HAZ subzones indicates the transformation taking place during the welding process.

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3.2 mm and finishing with 4.0 mm electrodes. The increasing diameters provide a gradual and sufficient increase in heat input for gradual tempering from the first to the third layer. The area to be repaired should be cleaned and preheated to a temperature commensurate with the material and thickness (typically >150oC), and a

OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

The increase in heat input should be 30 to 70% for each subsequent layer, and for SMAW, increasing the electrode size by one size whilst keeping the welding technique the same generally achieves this. It is not necessary in production to use exactly the same heat input as in the procedure test, but the ratio between layers must remain the same. Part of the weld metal and HAZ of the first bead is re-melted by the second bead. How much is re-melted depends on the overlap, but typically, a 50% overlap is the aim. The temper bead technique usually involves completing the first layer first. The heat input for the second layer runs is increased so that the heat re-melts some of the first layer but re-transforms the coarse-grained area of the HAZ while tempering the intercritical region. Extreme care is needed Fig 2: Illustration from ASME Sec-III NB-4623.1 on the technique adopted for temper bead repair in nuclear construction.

third layer is a repeat of the second layer with increased heat input.

buttering technique used as a first layer

if too much material is removed from

with 2.5 mm electrodes. The use of 2.5

the first layer, the effects of the re-

mm electrodes is to produce a small,

transformation are not successful. As a

4. Qualification of Temper bead Welding Procedure

shallow heat affected zone.

result this technique has now lost favor

Temper-bead welding procedure

in Non-Nuclear Industries.

qualification nomenclature is defined

approximately half of the welded

b. Controlled Deposition Technique

in Section IX of the ASME Boiler and

layer by grinding. The third step is the

This technique was developed to repair

Pressure Vessel Code. Typically, this

deposition of a second layer using 3.2

C-Mo steels in conventional fossil fueled

technique minimizes heat input of the

mm electrodes. This effectively re-

power plants where creep embrittlement

initial beads, thus limiting heat beyond

transforms the coarse-grained heat

and re-heat cracking were potential

the weld heat-affected zone (HAZ)

affected zone and first layer.

problems during repair. It uses SMAW

of the base metal. Heat input shall

technique, and uses strictly controlled

be increased for successive beads in

deposition of third and subsequent

ratios of heat input between one weld

accordance with the rules of QW-290

layers using 4.0 mm electrodes with

layer and the next. The heat input for

for temper bead welding in ASME

further MINOR grinding after each

the second layer is 1.3 to 1.8 times

Section IX.

deposited layer as required. Each

higher than for the first layer, and is

subsequent layer transforms and

designed to produce grain refinement

section provide the requirements for

tempers the layers beneath it.

and tempering in the original heat

procedure qualification requirements,

The second step is to remove

The remaining steps are the

The six sub-clauses under this

affected zone. The ratios need to be

restrictions, essential and non- essential

is that a lot of accurate grinding is

experimentally verified for each material

variables, test coupon preparation and

required. This is time consuming and

to be welded.

testing and in-process repair welding.

The disadvantage of the technique

with placement of the final run. The

WELDFAB TECH TIMES | OCT - NOV 2017

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ARTICLE

effectiveness of the temper bead welding procedure on the materials being repaired required the following four supplementary tests are generally applied: 1. Microstructural assessment of Weld and HAZ 2. Hardness Testing 3. Charpy Vee Notch Impact Testing 4. Bend Test In order to determine the effectiveness of the temper bead welding procedure, it will be necessary to compare the temper bead HAZ results with: a. The same results obtained from the conventional welding procedure qualification test after the traditional post weld heat treatment; b. The same test results obtained from the conventional welding procedure without post weld heat treatment. Both comparisons are required to determine if the applied temper bead welding technique provides the required results.

Fig 3: Illustration on the technique adopted for temper bead repair in non-nuclear construction. Additionally, sub-clause QW-290.6 provides supplementary qualification requirements for the welders who will be carrying out the work. ASME Sec-IX is most commonly followed code for welding procedure and performance qualification. QW290 addresses all the relevant clauses for Temper bead welding. When the applicable Code Section specifies the

Upgrading Existing WPSs • QW-290.2 Welding Process Restrictions • QW-290.3 Variables for Temper Bead Welding Qualifications • Table QW-290.4 Welding Variables for Temper Bead Procedure Qualification • QW-290.5 Test Coupon Preparation and Testing • QW-290.6 In-Process Repair Welding

5. Qualification of Temper Bead Welders In addition to the usual welder qualification requirements of ASME Section IX, it is necessary for welders to complete a supplementary proficiency demonstration. This demonstration mimics the actual welding to be carried out with a sufficient amount of welding to show competency. The complexities of most temper bead welding techniques require the welder to be supervised by a competent person for the duration of

use of this paragraph for temper bead welding, QW-2 90.1 through QW-290.6

The test specimen layout as shown

the welding. Weld toe tempering can

shall apply. The appropriate clauses are

in Sec-III, NB is extracted under Fig-3

be achieved by a competent welder in

as follows:-

below.

a satisfactory manner without full time

• QW-290.1 Basic Qualification and

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In order to assess the metallurgical

supervision.

OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

6. Conclusions Temper bead is a very specialized welding technique, which is used in lieu of Post Weld Heat Treatment. Hence upon application, conformance to Code of Construction/Repair, Metallurgical factors related to base metals/ welds all have to be met so as to prevent occurrences of failures upon service. Following key factors are essential before or while implementation of any Temper bead weld repair on aged components. • Planning, • WPS Qualification, • Training of Personnel Involved, • Welder or Welding Operator Qualification or Proficiency, • Demonstration, • Inspection & Records/ Documentation.

7. References: 1. National Bard Inspection Code (NBIC)-2011, Part-3 2. ASME BPV Code, Sec-III 3. Welding Technology Institute of Australis (WTIA) publication, TGNPE-02,Temper Bead Welding, Rev0,1 Fig 4: Welding Procedure Qualification Test Plate Layout, extracted from ASME Sec-III, NB, in accordance with ASME Sec-IX.

March 2006. 4. ASME, BPV Code-Sec-IX.

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UPCOMING PROJECTS

Versova-Bandra Sea link gets Maharashtra govtâ&#x20AC;&#x2122;s green nod

Reliance, BP sanction deepwater gas project off India

state environment department. With almost all the clearances

gas development in water depths of more than 2,000 m (6,562 ft),

in place, the proposed sea link will begin from the Bandra-end

about 70 km (43 mi) offshore. The fields will be developed as a

of the 5.6km Bandra- Worli Sea Link (BWSL). A senior MSRDC

subsea tieback to the existing control and riser platform off block

official added that the MSRDC had submitted a detailed list

KGD6. The project is expected to produce up to 12 MMcm/d

of mitigation measures to the State Environment Impact

(425 MMcf/d), coming on-stream in 2020. This is the first of

Assessment Committee of the state government following which

three planned projects in block KGD6 that are expected to be

the clearance was issued. The MSRDC has invited requests for

developed in an integrated manner, producing from about 3 tcf

qualification (RfQ) and intend to complete the project by 2020.

of discovered gas resources. Development of the three projects,

n a major boost for the proposed Versova-Bandra Sea Link (VBSL) project, the Maharashtra State Road Development

Corporation (MSRDC) secured environment clearance from the

P and Reliance Industries Ltd (RIL) have sanctioned development of the R-Series deepwater gas fields in block

KGD6 offshore eastern India.The R-Series (D34) project is a dry

with total investment of about Rs. 40,000 crore ($6 billion), is

Jewel of the Creek

expected to bring a total about 30-35 MMcm/d (1 bcf/d) of new domestic gas production onstream, phased over 2020-2022.

Dubai Water Canal Project

he $816 million Jewel of the Creek project will consists of a monstrous waterfront complex, highlighting 19-story flat

apartment buildings, three office towers, two luxury hotels, a recreation centre and a convention centre with a ballroom, and additionally a marina and a huge number of retail spaces

he $545 million Dubai Water Canal Project will change Business Bay and associate the region with the Arabian

Gulf more than three stages. The task will incorporate another

for shops and eateries. The project, which is scheduled for

strip mall, four hotels and 450 eateries and in addition an

completion in the first quarter of 2017, will be located between

extravagance housing and cycling ways. The canal itself will

Al Maktoum Bridge, Baniyas Road and the Floating Bridge

measure six meters deep, while scaffolds will be bridges to built 8

covering 123,955 square meters of area.

m high to futher allow the passing of yachts and marine craft.

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OCT - NOV 2017 | WELDFAB TECH TIMES

WOMEN IN WELDING

Woman Welder at Parel Workshop: A Snapshot

Savita Subhash Chaughule, Technician-III, Trade- Welder Shop- Welding Shop

he Central Railwayâ&#x20AC;&#x2122;s Loco Workshop in Parel can be stated as the trailblazer of workshops in

Indian Railways. It had been delineated in the vicinity of a small town of Parel which is in the heart of Mumbai city. It was established in the year 1879 by M/s GIP Railway which can be further mentioned as the first of its kind for the maintenance of Steam Locos which later was transformed into a Loco POH Workshop of Central Railway. The phasing out of Steam Loco traction and the subsequent introduction of Diesel Locomotives in Central Railway demanded

Coaches (2007) in phased manner. Today, Loco Workshop is well equipped

been taken into the consideration. These processes are being realized in Loco

a diversification in the Loco Workshop

to meet the major portion of the POH

Workshop through 30 or more processes

activities. Thus, the workshop started to

requirement of Central Railways, Western

units called shop / departments.

take up activities of Periodic Overhauling

Railway and West Central Railway on

(POH) of Diesel Electric Locomotives

the above said rolling stocks. In addition

Workshop comprise of the Chief Workshop

(1974), POH and MLR of 140T Cranes for

to that, Railway Directives stated that

Manager (CWM), who is the Occupier and

ARTs (1997), Corrosion repair of Coaches

distinctive element of diesel and coach

Chief Executive Officer, a team of Deputy

(2004) and then Mid-Life Rehabilitation of

components such as bio-diesel has also

Officers and other Assistant Officers to

WELDFAB TECH TIMES | OCT - NOV 2017

The top management hierarchies of Loco

www.weldfabtechtimes.com

WOMEN IN WELDING

D, I happened to undertake the segment

into Arc Welding. We make use of hot

of Welding diligently nevertheless; it was

rods for welding with the help of advance

not my preference to become a Welder.

machineries. Safety is the most crucial

Initially, it had been a very arduous and

part when it comes to welding and we are

challenging task, however; I started

largely focused into the same.

getting involved well as a welder gradually.

Although being a male dominated sector,

Thereafter, I started rejoicing in this field.

I have always received a great support from

Mostly due to its subjugation by males, I

the entire team. I aim to learn more about

felt so uneasy and excruciating at the “I

welding. Today, females are no less than

had never thought that I would anytime

males in almost all the sectors. I too have

be known as a ‘WELDER’, a segment

started developing myself in this field and

majorly subjugated by males. And today,

I quite certainly want to weld as efficiently

people recognize me as a female welder,

as the males do, and I have been already

an astonishing part for me to believe as

doing it and will be much better in the

well. Since 2015, I have been into the field

course of time. It’s all a matter of interest

of welding. Due to the postponement

for a subject you choose, without which

from Class D, I happened to undertake

you cannot succeed.”

the segment of Welding diligently

To know more about the workshop

nevertheless; it was not my preference to

activities, WELDFAB TECH TIMES had

become a Welder. Initially, it had been

a quick conversation with the Chief

a very arduous and challenging task,

Workshop Manager. And here is what

however; I started getting involved well as

Mr. Mahesh Kumar, Chief Workshop

a welder gradually. Thereafter, I started

Manager, Central Railway Loco

rejoicing in this field. Mostly due to its

Workshop, Parel, Mumbai have to say….

subjugation by males, I felt so uneasy and

“Welding shop is one of the core shops

excruciating at the early stages, however;

of Loco Workshop. The main process of the

assist the management in day-to-day work.

I accepted it with a vigorous mindsetthat

shop is assembling and welding work of

The welders and other staffs have been

females are nowhere less than males in

locomotives, coaches, 140 T break downs

trained and deeply motivated to indulge

today’s world and why should I stay behind

cranes, repairing work and profile cutting

themselves to work effectively. One such

when it comes to welding? Thus, I began

work. The main sections of welding shop

example is Mrs. Savita Subash Chaughule

welding and today I am proud to be known

are manufacturing section and Profile

who has always been the epitome of great

as a ‘Welder’.

cutting section.

workmanship and one who shares a great

Today, I can weld no less than any

Manufacturing of ICF Coach Brake Beam

camaraderie with all her co-workers.

efficient male welder and I am the only

Assembly, Flap Door Assembly, Head stock

She is the only female welder in this

female Welder in Central Railway, Parel

Assembly of BG and Profile Cutting of

entire workshop, her journey so far, few

Workshop. The credit all goes to the

components required for coach POH, AC

takeaways and many more….

management for believing in me, for

loco POH, ICF Bogie manufacturing are

training and motivating me to accept the

the major processes of General Welding

Savita expresses, “I had never thought that

job. Besides welding, I am also into welding

shop. This involves the operations of

I would anytime be known as a ‘WELDER’,

inspection. We, at Parel workshop have to

Oxy-acetylene/LPG cutting of various

a segment majorly subjugated by

carry out different types of

males. And today, people

welding activities, majorly the

recognize me as a female

repairing of the coaches.

welder, an astonishing part

The train coaches are

components which are further required for Bogie manufacturing and Electric Arc and Gas welding of Bogie assembly. Lately, Parel workshop has been

brought to the workshop

recommended to get certification of ISO

Since 2015, I have been into

for restoration, wherein

3834-2:2005 (Quality requirements for

the field of welding. Due to

a lot of welding activities

fusion welding of metallic materials) as per

are carried out. I specialize

International Standards both in workshops

for me to believe as well.

the postponement from Class

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OCT - NOV 2017 | WELDFAB TECH TIMES

WOMEN IN WELDING

woman even if it comes to welding. When contacted, the CPRO of Central Railway, Mr. Sunil Udasi was beaming with pride. He said this was perhaps the last of the few critical areas in Railways' working which did not have women. Mr. Udasi was delighted to see a woman make a mark in the area of welding which was hitherto considered a male bastion. He went on to add that that the Railways have considered women as partners and have always encouraged women to play an active role and quoted the recent examples Mr. Mahesh Kumar, Chief Workshop Manager, Central Railway Loco Workshop, Parel, Mumbai

of 'an all women Matunga Station', women as Loco Pilots, Motorwomen, Ticket Checkers, RPF Personnel and as Artisans in

and at field installation sites. With ISO

efficiency into welding. For an instance,

the Railways' for driving home the point of

3834-2:2005 certification, we can be at

in the Chennai workshop there are many

women empowerment.

par with the international standards and

female welders, but as compared to male,

upgrade our technical excellence. We aim

the figures are less. Usually, a female

dedication and indomitable spirit of Ms.

to achieve this target very soon.

does not aim to be a welder because of

Savita Subash Chaughule in accepting the

Mr. Udasi appreciated the commitment,

Besides, we are largely emphasizing

the fear of dealing with fire. To overcome

challenges that lay ahead and for counting

on upgrading the skills of our welders in

this challenge, there is a need of positive

herself as a key member of the Welding

terms of work and safety aspects. We are

attitude. We largely encourage females in

Team at the Parel Workshop. He went

basically categorizing our welders into A,

welding and one amongst them is Mrs.

on to add that the example of Ms. Savita

B and C. Those who are the best welders

Savita. We feel proud to see Savita who has

would definitely help spur other women

are into the A category, and similarly the

debuted into a profession as a welder and

in general and the Railways in particular

welders who are average are categorised

who has extraordinarily become one of the

in taking up challenges, which are nothing

under C or D. Currently, we are focusing

crucial welders of the workshop. She has

but opportunities for showing ones mettle

on the enhancement trainings for C and D

proved with her exceptional efforts and

and move up the ladder to ultimate glory

categories. Bhopal has been categorized

there is no difference between a man and a

and success.

to possess one the largest workshop of railways. Furthermore, we also have coach factories even in Chennai. The cornerstone of Parelâ&#x20AC;&#x2122;s workshop is the maintenance of coaches and on the other hand workshop of Chennai produces new coaches They are known to be the coach manufacturers. We have four such similar factories in India; the first in Chennai, second in Kapurthala in Punjab, third in Vidarbha and the fourth in Varanasi. These institutes train our welders and upgrade their knowledge. Welding requires specialized and skilled activity. Being a male dominated sector, we do not normally find any females into welding, however; I have come across many female welders with a great

WELDFAB TECH TIMES | OCT - NOV 2017

Mr. Sunil Udasi, Chief Public Relations Officer, Central Railway, Chhatrapati Shivaji Maharaj Terminus, Mumbai

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ARTICLE

Influence of CO2 in Argon on MAG welding efficiency & productivity Ehsanullah Khan, National Expert â&#x20AC;&#x201C; Welding & Cutting, Air Liquide India

welding processes for un-alloyed carbon

Low CO2 containing gases show a finger

GMAW processes for un-alloyed

steels may contain various CO2 contents,

shaped penetration when higher amounts

carbon steels may contain various

ranging from low oxidizing (ISO 14175:

show a widened, rounded one. CO2

CO2 contents, ranging from low oxidizing

M20) to highly oxidizing shielding

additions show with higher CO2 content

(ISO 14175: M20) to highly oxidizing (up

atmospheres (up to ISO 14175: C1).

higher flexibility to fit up tolerances.

hielding atmospheres in MAG/

to ISO 14175: C1) shielding atmospheres. The content of CO2 shows an

CO2 additions into argon start to stabilize the arc at rather low contents

important influence on the various

(e.g. above 0.1% CO2), in percentage levels

drop transfer modes and affects spatter

they secure the weld soundness.

rate, weld and pool appeal, fume and

To achieve a good X-ray quality of

This is mainly due to higher arc voltages, which widen the arc and bridge so gaps. Such bigger and wider arc plume burns off easily oil and grease which occasionally may contaminate the steel surface.

gas emissions but also productivity and

the welded carbon steel, CO2 contents

surface defects.

above 5% are necessary. The higher the

The first CO2 mixtures appeared in

CO2 content the broader the penetration

the early 50â&#x20AC;&#x2122;s with mixtures containing

Using recent high speed video examinations, the presentation will show

shape at similar penetration depth.

between 25% and 18% CO2. Different

the different arc modes possible for

options had been taken by Japan, USA

various shielding compositions and the

or Europe. The reason of these different

corresponding process windows allowing

options was empirical and based

high productivity and quality welds for

mainly on habits and use of the starting

the existing arc generator technologies.

companies.

Based on the findings, a

These 3 different types of mixtures

comprehensive and optimized range of

are today the reference mixtures for the

MAG/GMAW shielding gases for un-

normative work in those countries, JIS-

alloyed carbon steels and mild steels

ISO for Japan, AWS-ISO in US and EN-ISO

allows responding to nearly all requests

Figure 1: Finger shape penetration.

for Europe. They are referenced also in

in a quality fabrication of metallic

construction codes and pressure vessel

goods, provided that the shielding gases

codes.

are supplied with a stringent quality

During the past decades, a large

specification from a cylinder supply to a

number of binary mixtures was created

liquid on-site mixture.

by the industry ranging today from 8% to 50% CO2 content. The latter was

Introduction

introduced for on-shore /off-shore

Benefits of Ar/CO2 mixtures on MAG

welding of steel piping in the oil and gas

welding process

industry. Here the gas shroud -rather

Shielding atmospheres in MAG/GMA

WELDFAB TECH TIMES | OCT - NOV 2017

Figure 2: Rounded penetration.

heavier than air- helps to compensate

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ARTICLE

the wind draft which may disturb the

steels, in order to master the process data.

The drop transfer know how 1993 In 1993 Prof. Ushio published the first

shielding during the process. Drop transfer know-how 1

information regarding the arc modes

higher than 20%, the important arc

During the diode/ transistor phase, only

which can be detected by laboratory

instabilities lead to heavy spattering, as

the short circuiting, globular and spray

means.

well as to heavy fume emission rates.

mode (streaming transfer), included

High CO2 contents also lead to higher over

rotating spray (Air Liquide 1964), was

weld issues as well as spattering, affecting

definitely known and understood.

However, when reaching CO2 contents

the productivity and the overall costs of the welded pieces. Why all these compositions? The welding generators showed during the same 4 decades the evolution from a standard diode driven generator with natural drop transfer modes to software monitored, forced drop transfers. The forced drop transfer was used to bridge the critical globular mode area by pulsing, reducing spattering and

Figure 4: Operating range for a M21 and C1 shielding gas.

improving overall weld quality. Figure 6: Drop transfer modes as ref.1.

The last generation of software controlled generators is driving a forced

These arc modes, not known before,

arc mode in short circuiting and pulsing. When diode driven generators accepted

are separating the globular area into 2

all types of shielding gases (adapting

domains:

the inductance by loop setting versus

• The Globular drop transfer

CO2 content) pulsing needs high argon

• Repelled globular transfer

contents as such pulsed generators are built with transistors not over-passing

The globular drop transfer shows an

peak currents of 450A.

irregular drop size, irregular weld surface

(The first pulsed equipments were

and spattering. Repelled drop transfer

sold in the late 70’s, being an additional

leads to heavy spattering and adherent

pulsing devise, added to the standard

spatters. Spray modes are separated into 5

diode generator.) In the end it became

different domains:

necessary to get a new and better

• Projected spray: drops at rather

knowledge about drop transfer modes and behaviors in MAG welding of carbon

Figure 5: Classic metal transfer; Ref.1

regular size are projected into the weld puddle. • Streaming transfer is an extremely regular and stable drop transfer, the one an experienced welder is able to set up easily. • Repelled spray is a mode where the liquid droplet is pushed out of the arc by electro-magnetic forces and leads to spattering.

Figure 3: Increased drop transfer know how.

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• Swinging spray transfer: at higher

OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

amperages, depending on the gas

However it was impossible still to use

avoiding the transition area, producing

composition, the arc is swinging in

such investigations to visualize in real

spattering, irregular weldments and high

the same direction of the seam. This is

time the arc phenomena.

emissions. This transition area is reaching

leading to a loss of penetration depth. â&#x20AC;˘ Rotating arc starts at very high

Only recently high speed video

from globular to repelled spray.

recording became industrially affordable

amperages and voltage and can be

and opened the door to welding process

reached by any shielding gas. The

modeling. With such investigation means,

arc starts to rotate, driven by the

it is possible now to characterize metal

electro-magnetic force. The effect is

transfer precisely.

a wide weld pool, a deep and stirred

The shown photos and sequences at

penetration but also high spattering

Fig 9 are obtained with a high speed video

and fume emissions by metal

camera, recording then arc phenomena

vaporization.

at 6- 8 000 images per second. The

Fig 12: Globular mode.

Fig 13: Globular free flight.

classification obtained is as shown, the Arc analysis methods were rather

repelled spray area being situated before

complicated to handle as during decades

reaching the streaming spray.

only high speed filming was possible. In

Natural short circuiting is used in all

Fig 14: Repelled spray.

Fig 15: Axial streaming.

Axial streaming spray is the productive

the 90â&#x20AC;&#x2122;s the laser stroboscopic analysis

position welding, for root runs, or thin

became possible and opened new

metal welding, the pulsed mode â&#x20AC;&#x201C; a forced

mode, with high deposition rates, low

investigations about arc behaviors and

metal transfer- for quality welds in all

spattering, good wetting, especially in

drop formation.

position,

fillet welds, avoiding so crack opening areas, increasing fatigue resistance. How do the different CO2 containing argon mixtures behave in this new environment?

Fig 7: Stroboscopic recording.

Fig 8: High speed video recording.

Fig10: Short arc mode.

Fig 11: Pulsed mode.

A specific investigation about arc modes was carried out recently in the Air Liquide research center CTAS for welding and cutting applications. Purpose was to define a clear and coherent answer to

Figure 9: High speed video recording: Visualized arc modes

customer drivers regarding the choice of a binary argon CO2 mixture, optimized for the process requirements currently requested. Different welding drivers WD, may request different CO2 contents.

Figure 16: Welding drivers WD versus CO2 content in argon.

WELDFAB TECH TIMES | OCT - NOV 2017

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ARTICLE

The result is the mapping of the different arc modes and range of those for each composition. A first finding is that a low oxidizing mixture, M20 as ISO 14175, and ranging from 8 to 15% CO2 is reaching a streaming spray mode far below 400A. The 8% CO2 shows the spray threshold at 250A, giving the possibility to weld at high productivity with standard generators and gas cooled torches. The globular range is reduced for such shielding gases which switch directly from free flight globular to streaming spray. When reaching the medium oxidizing content of 15% a brutal change in the arc Figure 17: Mapping method of various CO2 contents, data recording & analysis + high speed video analysis.

behavior occurs. The globular mode- with different subproperties- jumps to a broad spectrum

Mapping of metal transfer versus % CO2

adapting the voltage to the CO2 content.

of amperage. When the low oxidizing

and current

For each welding voltage, amperage was

shielding gases show a spray threshold

Each shielding composition was tested in a

recorded as well as the high speed video for

below 300A, the M21 oxidizing shielding

broad range of amperage/wire feeding rate,

arc visualization and analysis.

gases reach a threshold of at least 400A.

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OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

welding. • Mixtures with major drawbacks in spattering & oxidation: above 18% CO2. To show the consequence of the findings we’ll take in account the above requests for overall welding specifications, as welding Figure 18: 18% CO2 with still a streaming spray area. Streaming spray will need in that

the swinging spray mode. Consequence

costs, after weld cleaning due to oxides and spattering among others. A good compromise is an 18% CO2

case water cooled guns, and generators

is either continuous spattering or lack of

composition, which is the upper limit for

delivering at least 400A at 100% duty cycle.

penetration control.

streaming spray appearance, availability

The streaming spray for an 18% CO2

of generators, pulsed or not, and capability

mixture is limited to a range of 400 to

Conclusion

to weld flux cored and solid wires, rather

440 A before getting into the swinging

Type of shielding atmosphere

tolerant to gap tolerances and surface

mode, loosing here part of the penetration

3 types of shielding atmospheres can be

contaminations.

potential

considered as far as binary mixtures of CO2

Above 18% CO2 content, the standard mixtures 20 and 25% CO2 had been

It is the mixture closest to the main

and argon are concerned:

advantages of pure CO2 without its

• Mixtures with low spray thresholds

inconvenient.

qualified. These mixtures are still

lower than 300A, useful for productive

considered as medium oxidizing (M21),

and quality welds. These mixtures show

lowest oxidation rate, extremely stable arc

CO2 content below 15%. Pulsing is easy.

properties, extra low spattering and highly

but show a higher oxidation rate on the surface compared to an 18% CO2 mix.

• Mixtures with CO2 contents between 15

The 8% CO2 mixture qualifies with the

productive, as the spray threshold is at

The streaming flow area is disappearing;

and 18%, with pulsed capabilities, and

250A, reachable with any arc generator and

the repelled spray switches directly into

versatile for flux cored and solid wire

gas cooled torches. Such a composition allows easily welding at high speed in automatic mode with solid or metal cored wires. This mixture qualifies with a broad process window opening and is today the reference for MAG carbon steel welding. Here is shown the radar chart of performances when testing both of these

Figure 19: 8% CO2 with the lowest spray appearance amperag.

reference mixtures. Each criterion has been measured under similar/identical conditions. It shows the advantages of each shielding in specific conditions. 18% CO2 is applying for heavier thicknesses with good penetration and fit up tolerance control, when the 8% mix allows the high productivity and speed. Also the arc striking properties, whatever the habit of the operator appears as best with the M20 mixture. This is important in particular for robotic or automatic welding, where

Figure 20: Radar chart: weld acceptance criteria.

WELDFAB TECH TIMES | OCT - NOV 2017

downtimes due to arc striking issues have to be minimized.

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INTERVIEW

We have equipment that are a perfect blend of man and machine We have recently applied for some of the

paramount of welding automations. It has

customized welding solutions. Fronius

taken welding to a new level.

is not into the business of submerged business into duct welding. We have

Q4. Has Fronius expanded its reach to robotic welding segment?

technology from Delta stock that can

When you say automation, it includes

conduct different materials. We are also

robotic welding systems and non-robotic

going to introduce conventional reference

welding systems. We are not in the

welding with the smartest features, which

business of robotic welding systems.

will be launched soon.

We offer automation systems for oil &

welding. Recently, we have brought about

gas business. Fronius has customers

Q3. What new technological advancement have you introduced?

wanting for materials that are co-related

Fronius is known for technical

gathered where quality requirement

advancements. We make products which

is very high. For an instance, A natural

are all set for tomorrow, which are future

gas pipeline which contains high level

Q1. Could you brief us on Fronius role into the welding segment?

prone. For example, some welding

of corrosion materials need a coating

products have smart phones, which

inconel or sliding of inconel inside

We have been the leading players in

are futuristic and can perform many

pipeline. It has a single way with 4 wires,

India, Germany and Indonesia. Fronius

operations on fingertips. Our machines

so the productivity is also very high.

started in 1950, it has almost been for over

can be operated quickly and easily. We

It has a camera fitted to as long as 12

67 years in India. In Pune, we started in

have machines that are a perfect blend

meters. We have a system which can

2013. At the initial stages, welding had

between the man and machines. Quite

tag the 12m pipe while transporting

been a very demanding task, but it was

lately, we have introduced a new welding

very well interchanged. Currently, itâ&#x20AC;&#x2122;s

machine range called TPS/I, Intelligent

been over 3 years as leading players in the

Revolution. It is a new unit platform for

welding equipments. As far as quality is

welding equipment with high intelligence

concerned, Fronius has always been one

and extensive communication

of the most preferred brands.

capabilities. The TPS/I, Intelligent

V. V. Kamath, Managing Director, Fronius India Pvt Ltd

to complex parts and thus needs to be

Revolutionis an interface between a man

Q2. What type of welding equipment does Fronius includes into its product range?

and a machine. There are processes of

We are basically into the business

perform various operations on finger tips.

of welding equipment where arc is

We have introducedCold Metal Transfer

visible. We deal with TIG welding, MIG

(CMT) machines. The advancements in

Welding, Electrode Welding, and welding

CMT technology and the advancements

automated solutions like Orbital Welding.

of TPS technology has lead to the new

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speed that are semi-fast. There are unique variations in welding machines that can

OCT - NOV 2017 | WELDFAB TECH TIMES

INTERVIEW

products while doing welding. So

which contain high level of corrosion

Q5. Is the Indian market on par with the international markets?

material. So, the operator can see what

The Indian market is not at all at par with

renewable technology, we have high

is exactly happening. In this way, we

the international markets. This is because

endtechnologies that are efficient in

can almost reduce the defects. These

of two reasons. It is not because we lack

power consumption, as compared

systems have been implemented when

knowledge, and also not because we lack

to other conventional machines of

automation is concerned. We also have

skills, but we definitely lack attitude.

competitors. In this way, we contribute

a long term welding, and a set of single

Still we have the “JUGAD” in mind, due

to eco-friendly welding. Now when it

phase machines. Fronius is also capable

to which we can never be on par with

comes to health and safety, we already

to design very complex systems. ISRO

the international markets. People in

have products for protection, like the

launches many satellites and I am also

India have a behavior of doing anything

high protection glares, wide range of ultra

glad to share that, the fuel chambers

if nothing comes up. We do a proper

sonic helmets, fume attraction systems,

in these satellites are welded by using

design, but we fail in execution. Our

etc. These are few of our initiatives

Fronius automation systems. It requires

visions are on par with the international

towards health and safety. Besides, we

complex welding solution system which

markets but our execution is far below.

also conduct training programs, wherein

is designed and developed by us. So,

It is not because we are not capable, but

without fail we reserve one hour on health

we are a niche market and we do not

because of our “Chalta hai” attitude.

and safety. The people are made aware

cover anything that is robotic or systems

This is the problem in India. Besides, the

on its importance and where one needs

with robotic. We committed systems,

welding industry is facing the manpower

to protect himself / herself. Thus, welding

wherein the quality

issues. The campaigns like ‘Make in

is a biggest challenge, not because of the

India’, and also hopefully the GST will

lack of manpower but also because of

give a right competitiveness in Indian

the lack of right knowledge in welding.

market. Definitely, without welding there

Everybody knows welding, but very few

the natural gas, especially the gases

is no manufacturing and with the

trying to improve the situation by joining

automation is going to increase.

hands with various colleges. We are also

This would lead to the bright

the active members of Indian Institute of

mistakes. So when we work on any project, it has to be 100% right.

WELDFAB TECH TIMES | OCT - NOV 2017

Welding (IIW) and Indian Welding Society (IWS). Fronius sponsors various programs

requirement is is no chance of any

know what is right welding, and we are

dearth of manpower, the welding

future for automation in India. very high and there

since we are also into the business of

Q6. What are Fronius’s efforts towards health and safety?

and also encourages welding engineers

If somebody says that welding is safe

engineering college HOD’s to Austria

and healthy, then it is absolutely wrong.

to show them the engineering activities

by sponsoring them. We took almost 20

Welding is a challenging

carried in Austria and which can then be

task, mainly because

implemented in India. We have set up 4

TIG welding is

centre of excellence in different parts of

difficult. While

India ie, in North, South, East and West.

welding, the person

These are the major engineering colleges

is prone to get in

where we offer an exposure to students

contact to dust

for proper quality welding. In this way,

particles, which is

the welding fraternity can get welding

a part and parcel

experts in future. We also have a welding

of welding. But

school wherein we certify the welders.

then how can we

In most cases, we offer free welding

be eco-friendly. We

training sessions in order to attract the

need to consider

people to learn welding and opt welding

the rest of the

as a career.

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ARTICLE

ISO 3834 – The Quality Requirements for Welding

Samir Kumar Gupta, B.E.,C.E.,FIE.,FIIW., MISNT., MAE., MITD. Chartered Engineer, a Life Fellow of the Institution of Engineers (India)

Introduction

now effectively competing with industry

concerned parties. The quality policy

giants because IT can make a consortium

therefore is to exist to shape behavior

of small firms look, feel and get big,

and establish the core values in an

reaching out for customers once beyond

organization and must equate with the

their grasp. This has given rise to intense

corporate policy, no benefits are gained

competition, blurring the boundaries

from specifically expressing a quality

between domestic and global markets.

policy as separate which can not equate

Every commercial organization was

with the other corporate objectives, at

earlier focused on making profit only.

the same time ignoring other policies.

But now, in addition to making profits

It should be made clear that all policies

or even in order to make profits the

influencing the behavior must be

objectives of Manufacturing Companies

nourished as key to satisfying the needs

are to be reoriented to satisfy the total

of interested parties. To conceptualize

needs of the customer who wants:

the quality policy, a quality management

I. Products of consistent high quality.

system is to be integrated in the existing

II. Delivery on Time.

management system that will enable the

III. Full amount ordered products at the

organization to fulfill its purpose and

lowest possible cost level.

mission. Organizations should have only one system.

• Today’s economy is Global Economy. • Global Economy is Global Market Driven. • Global Markets are dominated by Global Customers. • Customers are Affluent and Quality

World Class Manufacturing [WCM] is the term for the most effective methodologies and techniques to realize

The International Quality Systems - ISO 9000

some of these objectives but not all. It

ISO 9000 is an International Standard

is increasingly becoming important to

for formalization of those parts of

understand customers' needs and wants,

the existing system that served the

and translate these into a unique value-

achievement of product quality in

Manufacturers and producers of goods

added business mission. Companies

an organization. ISO 9001 induces

and services all over the world are very

capturing and applying information

organizations to establish a quality

much aware and conscious about the

at each point of customer contact will,

system as a means of ensuring product

above mentioned axioms and now

therefore, be better off than those that

to meet specified requirements. New

consciously aligning their Systems of

do not. Thus, companies have to be

activities are introduced onto the

Operation and Products to meet the

able to apply and integrate systems and

organization such as management

needs of the customers. Globalization

information technology into the entire

review, internal audit, document

is a process that cuts across national

product process including research,

control, record control, corrective and

boundaries, integrating and connecting

design, manufacturing, distribution,

preventive action putting in place the

communities in new space-time

marketing, and after sales service.

necessary linkages to maintain system

combinations. As information

Quality is the primary need of all the

integrity. The essential elements

technology (IT) breaks down the barriers

customers for all the products and

of the standards are: management

of time and location distinctions are

services and is the strategic objective

responsibility, resource management,

also breaking down between large and

that is established to fulfill the needs

quality system, contract review, design

small companies. Small, agile firms are

and expectations of customers and all

control, document control, purchasing,

Conscious.

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OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

purchaser-supplied product, product

and inspection. With reference to the

specific requirements and regional

identification and traceability, process

quality requirements of welded products,

or international product standards,

control. ISO 9000 series is recognized

“ISO 3834 Quality Requirements for

consistently and with regard for the

and accepted by all the countries of the

Welding” has been developed by

type of product manufactured, IIW has

world as the valid and proven quality

International Standard Organization

developed specific supplementary guides

management system for operation

in association with the International

for the processes/products considered

and services industries. But, ISO 9000

Institute of Welding as International

(e.g. railway vehicle components,

System cannot certify the capability of a

Welding Quality Assurance Standard

pressure vessels and construction

manufacturer using Welding as a main

(ISO 3834). To ensure the proper quality

products), taking into consideration

manufacturing process. Within the ISO

of welded product and to optimize the

the applicable standards and best

9000 series of standards, Welding is to be

manufacturing cost, the whole welding

practice manufacturing procedures,

treated as a “Special Process” since welds

process must be controlled from the very

already shared by the main international

cannot be fully verified by subsequent

start. To take all welding quality affecting

manufacturers and customers.

inspection and testing of the product

aspects into consideration, the welding

to ensure that the required quality

shop is recommended to implement a

Summerising ISO 3834

standards have been met. Welding

quality assurance system. The standard

• An international standard created by

processes and sub processes applied

ISO 3834 sets out requirements for

at products manufactured in mass or

manufacturers to meet, in order to

assembly line productions or job shop

apply good practice to their welding

for a welded product, whereas ISO

productions are numerous. Welding

operations. There are several steps in

9001 provides the requirements for

quality is again a feature acceptable

a Welding Quality Assurance; to make

a quality management system and it

to specific customers from a level of

sure the welding shop has competent

does not establish requirements for

whatever quality is produced to six

welders, there are standardized ways

welded products, ISO 3834 on the

sigma level.

to test the welders. It is essential to use written welding instructions and/or so

Quality Requirement for Welding ISO 3834

called Welding Procedure Specifications

It is also accepted that “Quality cannot

of consistent quality.

be inspected into product it has to be

(WPS) in order to increase the possibility The WPS must be qualified, i.e.

welding professionals. • A provider of the quality requirements

other hand does. • It specifies requirements relating mainly to the quality of the welded product. • It encourages a proactive process orientated approach to managing and

built into it”. In order to make a welded

the WPS has to be based on a WPQR,

product free from major defects and to

Welding Procedure Qualification

be effective in its use it is necessary to

Record. The WPQR explains that, if the

exercise control right from the design

WPS is followed, there will have a good

stage, through selection of materials,

chance to weld a joint with the expected

process and methods of manufacture

properties. The person responsible for

In order to establish such a System and a

with stipulated inspection and process

welding, or the welding coordinator, in

Standard to be followed uniformly by the

control stages. Simultaneously, the

the welding shop, is responsible for the

European as well as other countries a

welding process and procedure

welders’ competence and the education

few rules have been developed following

have to be correctly formulated and

and the management of the welders. The

the principle of mutual recognition,

approved. It is needless to point out

coordinators´ competence requirements,

which has been agreed between the

that skilled supervision is essential for

the tasks and responsibilities, are

International Institute of Welding and

the process, procedure application

regulated in the standard ISO 14731.

the European Federation for Welding,

In the field of quality management

Joining and Cutting. Though the EWF

in manufacture and maintenance,

Manufacturer Certification System is

the general trend is clearly moving

based on the Management of Quality,

towards a product/process approach.

Environment and Health and Safety

In order to help companies satisfy

in Welding through the EN ISO 3834

WELDFAB TECH TIMES | OCT - NOV 2017

controlling welding product quality in a workshop or at site. • It is also a Factory Control System to control activities for the manufacture of the products.

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ARTICLE

7. EN 287-1 –

Qualification test of

Certification Scheme, the Environment

(TWMS) which incorporates Quality,

Certification Scheme, the Health &

Occupational Health and Safety plus

Safety Certification Scheme. The scope

Environmental Management Systems.

of the Agreement between EWF and IIW

The implementation of ISO 3834:2005

only includes, for the time being, the

Quality requirements for fusion

welders – Fusion welding (other

management of quality in welding.

welding of metallic materials forms an

metallic materials)

integral foundation for the assurance

welders – Fusion welding Part1 : Steels 8. 606-2-5 - Qualification test of

9. EN 1418 –

Approval testing of

Manufacturer Certification Scheme (MCS).

of quality production by a company,

Based on the above, the International

and local and global competitiveness.

Institute of Welding (IIW), by virtue

WTIA also supports the use of the IIW

of its unique international expertise,

Manufacturer Certification Scheme

The Certification of ISO 3834 Standard

has developed an integrated and

(MCS) for the Management of Quality

Scheme is based on the following set of

specialized Certification Scheme to

in Welded Fabrication by companies

four documents:

assure companies’ compliance with ISO

for the implementation of ISO 3834. In

1. IAB 337 - IIW Manufacturer

3834. This Scheme is referred to as the

Germany, the German Welding Society

Certification Scheme for the

IIW Manufacturer Certification Scheme

(DVS) and committees of the German

Management of Quality in

according to ISO 3834 (IIW MCS). These

Institute for Standardization (DIN) have

Rules establish the mechanism by which

accepted the fact that standards alone

Implementation of ISO 3834

the guidelines for the IIW Manufacturer

cannot generate uniform levels of Quality

requirements.

Certification Scheme (MCS) according

and also established a minimum level of

to ISO 3834 are implemented, such

Technology with gradual development

2. IAB 338 - IIW Manufacturer

that the requirements are applied

process. The Standards followed are

Certification Scheme for the

uniformly by all countries involved,

DIN EN 3834, DS 952, DIN 6700 and

Management of Quality in

and that the certificates granted are

DIN 6701 for EN 15085. ISO 3834 has

mutually recognized. This is done by

now become a globally accepted system

implementation of ISO 3834 oriented to

appointing only one organization in

for Quality Requirement for Welding,

welded products standard.

each country to act in the name of IIW,

for Welded Products manufactured for

and these organizations are assessed

domestic and international market.

3. IAB 339 - IIW Manufacturer

and monitored for compliance with the

Along with ISO 3834 the following

Certification Scheme for the

Rules. These organizations are known

Standards are required to be followed

Management of Quality in

as the IIW Authorized National Bodies

for comprehensive application of the

for Company Certification (ANBCCs).

System:

The IIW has delegated all authority

1. ISO 3834 –

with benefits for both bottom-line

Quality Requirements

for fusion welding of metallic

Authorization Board (IAB). International

materials

IIW-India through it’s International Authorization Board (IAB) as the accredited Authorized National Body for Company Certification (ANBCC) for the exclusive rights within India to operate its MCS for certification of Companies for compliance to the requirements of ISO 3834. Welding Technology Institute of Australia (WTIA) implemented a Total Welding Management System

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2. ISO 3834-2

Comprehensive Quality Normal Quality

Requirements 4. ISO 3834-4

Welding - Interpretation and

Welding - Guidance for the

Welding - Rules for ANBCC Operating Scheme.

Certification Scheme for the Management of Quality in Welding - ANBCC Assessment of Manufacturers of Welded Products.

Elementary Quality

Requirements 5. EN 15085 -

welding procedures.

4. IAB 340 - IIW Manufacturer

Requirements 3. ISO 3834-3

10. ISO 15607-15614 – Qualification of

the IIW Manufacturer Certification

for this activity to the International Institute of Welding (IIW) has appointed

welding operators

Railway applications

The objective is that IIW certified companies will have demonstrated

- Welding of railway vehicles and

that they have achieved an identified,

components

minimum level of capability over a

6. ISO 14731– Welding coordination – tasks and responsibilities

specified scope of activity, irrespective of the country in which they had been

OCT - NOV 2017 | WELDFAB TECH TIMES

ARTICLE

certified.

Key Elements Constituting the Structure of IS0 3834 In order to develop a comprehensive system where nothing or part systems

Robotic Welding

existed the following areas are to be covered to frame the Quality Welding

Effective Uses Of MS.

System:

Automobile Industry, Manufacturers of

• Review Contract. Design

Railway Coach, Wagons, Engines, Tracks,

• Welders, Operators testing and

Bridges, Structurals, Pressure Vessels,

certification (ISO 9606)

Pipe Lines, all small scale ancillary units

• Welding Coordination (EN719)

for welded components and parts for

• Qualification of welding procedures

above products, Other industries using

(ISO9956-2)

welding as main manufacturing process.

• Work instructions as per approved WPR • Procedures for the preparation and

Manufacturer of Railway Coaches & Wagons

control of documents

Procedure To Obtain ISO 3834 Certification Since the publication of the ISO 9000

• Welding consumables: batch testing,

family of standards in 1987, and then

storage and control

EN ISO 3834 in 2006 a new industry

• Storage of parent materials

has grown in its shadow. The industry

• Post weld heat treatment

is characterized by Standards Bodies,

• Inspection Personnel, inspection,

Accreditation Bodies, Certification

testing and test status

Bodies, Consulting Practices, Training

• Non-conformance and corrective actions • Calibration and validation of

Providers, Software Providers and a Mining Equipment

whole raft of publications, magazines, web sites and schemes – all in the name

measuring, inspection and testing

of quality! The manufacturer seeking

equipment

for the Certification of ISO 3834 will

• Identification and traceability and

have to check the credentials of the

Quality records

Certifying Body before appointing one.

The details of these Standards and their

After selection of the Certifying body

modes of application are essential to

the following steps are to be taken in

learn and put to practice as applicable.

sequence.

Pipe Line Welding

Step1: The manufacturing organisation, in consultation with its customer, reviews the customer’s products and requirements and decides on which of the three levels of quality requirements of ISO 3834 i.e. comprehensive, standard or basic, is appropriate. Step 2: Establish and implement a welding management system to ISO 3834. “Self assessment of quality requirements

Automotive Industry

WELDFAB TECH TIMES | OCT - NOV 2017

Ships

- Checklist and action plan” is made

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ARTICLE

available to guide through this process.

There must be a direct link between the

are explicitly encompassed and

Step 3: Request an application form

Contractor and the Manufacturer.)

registered in the Schedule.

& information pack from Certifying Body. Step 11: The initial assessment report,

5. Manufacturers can get visibility through

Step 4: Complete the application form

a review of any corrective actions and a

the Register of Certified Companies.

and return it and evidence of any existing

final report are submitted to the assessor

certification to the Certifying Body.

/accredition body.

Step 5: Based on the information in the

Step 12: Once the manufacturer has

application form, a quotation will be sent

demonstrated compliance to ISO 3834 a

to the organization by the Accreditation

certificate from the International Institute

Body / Certifying Body.

of Welding (IIW) for acceptance in the IIW

competence for its welding and

6. Clear, high profile independent verification of its compliance with ISO 3834 requirements. 7. Independent confirmation of

Manufacturer Certification Scheme (MCS)

fabricating capabilities and staff in a

Step 6: On receipt of the order from the

for the Management of Quality in Welded

defined scope of activity.

company the Certifying Body will appoint

Fabrication will be issued indicating the

the assessment team to carry out an

standard(s) against which certification

assessment.

has been achieved.

Step 7: The Lead Assessor sends the

Step 13: Surveillance will be carried

appropriate Form 3834 Document Review

out annually to demonstrate ongoing

to the fabricator.

compliance.

8. Welding quality management and fabrication capability assessments carried out by specialist assessors. 9. As a System is in practice, bottlenecks are few and on the spot decisions can be taken by lower level operators in

Step 8: The Fabricator completes the

Step 14: Reassessment against ISO 3834

document review form and submits this

will be required every five years. 10. Less rework.

together with the quality management documentation to the appointed assessor, who then carries out a preliminary visit followed by a further review.

manufacturing.

Benefits and Advantages of ISO 3834 Certification

11. Jobs completed on time.

Benefits and Advantages for the Manufacturers in getting a certification

Step 9: An on-site audit by the appointed

against the IIW MCS, can be summarized

lead assessor(s) is conducted.

as follows: 1. Increased national and international

Step 10: Part of the audit involves an

business potential through

interview with the responsible welding

demonstrated compliance with

coordinator.

internationally recognized welding quality requirements.

12. More efficient coordination of welding activities. 13. More pro-active and responsible workforce. 14. Increased opportunities and capability to bid on jobs.

(One of the criteria for an acceptable RWC is qualification, and the recommended

2. It will enable the organization as

15. Reduced surveillance audits and

qualifications are IWE, IWT or

well as the customers to be globally

inspections by purchasers with

International Welding Specialist (IWS)

recognized & connected for business.

significant savings.

in accordance with the International Institute of Welding. Other equivalent

3. Welded products are differently treated

qualifications would be considered during

according to the specific needs of the

the interview stage. If the RWC does not

welding manufacturing process used.

if that person is an outside Contractor.

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technology. 17. Satisfied employer and customer.

have such a qualification, then someone else within the Manufacturer must, even

16. Cost savings â&#x20AC;&#x201C; more efficient

4. Specific areas of competence (for personnel and companies)

18. Develops team spirit.

OCT - NOV 2017 | WELDFAB TECH TIMES

EVENT INTERVIEW

WELD INDIA 2017: Back after 6 years in Chennai Q2. What would be the key focus areas? WELD INDIA 2017 is targeting manufacturers and dealers of conventional and advanced welding equipments and consumables; electron beam, laser, magnetic pulse and diffusion welding equipments; equipments for joining of nano materials, ceramics, plastics etc., welding and hardfacing consumables; weld repair and maintenance equipments; computer aided welding equipments; welding robots and CNC machines; soldering and brazing equipments; gas, plasma and laser cutting machines; gas equipments and accessories; grinding and cutting tools; heat treatment furnaces; industrial gases; manufacturing and fabrication technologies; materials including steels, stainless steels, aluminum and other advanced materials; welding safety equipments; non-destructive inspection and testing equipments; electron and optical microscopes; welding education, training and consultancy, to display the latest in the area of welding and its allied technologies.

Q3. How is the Welding market in India? A number of world leaders in the automobile industry have their base in India. The amount of welding consumables to be used is expected to rise by about 20% in the next two years. In years to

Dr. Hasan Shaikh Immediate Past Vice President (South), Indian Institute of Welding (IIW) Retired Scientist from Indira Gandhi Centre for Atomic Research, Kalpakkam Presently, Proprietor of Industrial Training and Consultancy Services, Chennai.

come, the Indian welding market envisages extensive use of high strength steel & cross country welding consumables, low alloy electrodes with low impurities and high end grades, surfacing consumables for high temperature, shear blades, steel mill roll surfacing, and stainless steel solid/FCAW wires, electrodes for duplex stainless steel and Ni alloys and chrome-moly MIG / MAG / SAW wires. The potential requirements of the Indian welding

Q1. Could you brief us on WELD INDIA 2017 expo? What is the exhibition all about?

industry in welding equipment and machinery in the near future

On the occasion of International Congress 2017, the Indian

automatic welding machines for cross country pipe lines, portable

Institute of Welding is organizing an International Welding

trouble free inverters for SMAW/TIG, low cost, low power

Exhibition, known as WELD INDIA 2017, during 07-09 December

consuming MIG machine and equipments for Laser/EBW and

2017 at Chennai Trade Centre, Chennai. WELD INDIA is back after

other exotic processes.

involves low cost automation aids that increase productivity,

a gap of 6 years in Chennai, which was the venue to Indiaâ&#x20AC;&#x2122;s largest

in welding consumables, equipments and automation, and other

Q4. According to you, how will WELD INDIA 2017 stand out to be a great platform for both the exhibitors and visitors?

allied industries such as NDT, microstructural and properties

Weld India is a standalone exhibition for the welding industry. It is

characterization, to display their wares to attract the prospective

not coupled with any other engineering sector.

welding technology exhibition till date, WELD INDIA 2011. WELD INDIA 2017 will present an opportunity for the leaders

Indian consumer and gain a foothold in the India of the future.

WELDFAB TECH TIMES | OCT - NOV 2017

WELD INDIA exhibitions in Chennai have always been

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EVENT INTERVIEW

live demonstrations, in WELD INDIA 2011.

successful. This is because Chennai is a major manufacturing hub of the country. A lot of welding related activities happen in Chennai. This is because of the industrialization of Chennai with the presence of power production centres, such as Madras Atomic Power Station, Ennore Thermal Plant; manufacturing and infrastructure giants, such as L&T; petrochemical plants, such as Chennai Petroleum Corporation Ltd; Railways

I invite everyone to participate as an exhibitor or visitor in WELD INDIA 2017. The success of the exhibition depends on the participation. Block your dates 07-09 December 2017 to be in the enticing city of Chennai.

production shops, such as Integral Coach

Nearly, 8,000 business visitors came to the exhibition over the three days. Lot of business was transacted at the exhibition. We expect a very similar response in WELD INDIA 2017.

Q5. How has been the response so far from the exhibitors? Response from the exhibitors has been good so far. A number of new companies have booked space in WELD INDIA 2017.

Factory; Defence Production Units, such as as Heavy Vehicles Nissan, TVS Motors; Major research centres, such as Indira

Q6. As compared to last year, what are your expectations from WELD INDIA 2017?

Gandhi Centre for Atomic Research, Combat Vehicles Research

WELD INDIA 2017 will be an exhibition for exhibitors to display

and Development Establishment; Educational Institutions, such

their latest wares, particularly in the field of welding automation.

as Indian Institute of Technology Madras, Anna University and

Visitors will benefit a lot from the exhibition. Students of

a number of leading engineering colleges; welding consumables

engineering colleges will learn a lot from the exhibition. I expect

and equipment manufacturers, such as ESAB India Ltd., Fronius,

the WELD INDIA 2017 Exhibition to be a grand success with

Kemppi, Veejay Electrodes, are all located in and around Chennai.

everyone participating in it and being a winner.

Factory; automobile giants, such as Ford, Hyundai, Rennault

Also, BHEL, NLC and SPIC are located in towns and cities close to

Around 200 high profile exhibitors across the globe and

Chennai. With the presence of such a wide range of industries, the

over 7000+ industry visitors are expected at WELD INDIA 2017

welding sector has always been successful in Chennai.

Exhibition, which will bring together raw material producers,

Exhibitors and business visitors will gain a lot with their

consumables and equipment suppliers, end-users and the

participation in WELD INDIA 2017. There were nearly 200

Industry at large under one roof to provide for a comprehensive

exhibitors displaying over 5,400 sq. m. of exhibiting space, with

insight of technology and markets.

FLASHBACK: WELD INDIA 2016 >>>

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OCT - NOV 2017 | WELDFAB TECH TIMES

ion

it Ed

International Exhibition on: Welding, Cutting, Fabrication, Manufacturing, Precision Metal Forming, Chemical Coating,

THE INDIAN INSTITUTE OF WELDING

WELD INDIA 2017 International Welding Technology Exhibition

Materials, Testing, Robotics, Training & Education, Welding & Cutting Software

07 - 09 Dec 2017, Chennai, India

Concurrent Event: Dec 07- 09, 2017

The Indian Institute of Welding (IIW-India) presents WELD INDIA 2017 , the 12th International Welding Technology Exhibition covering Arc Welding, Solid State Process, Brazing, Soldering, Adhesive Bonding, Plastic Welding, Metallurgy, Materials Testing Techniques including NDT, Health & Safety, Robotics & Automation, Beam Processes & Special Processes like Nano Joining and other allied fields, to be held during 07 to 09 December 2017 at Chennai Trade Centre, Chennai, India

International Congress (IC 2017) International Institute of Welding

Concurrently the International Congress (IC 2017) will host about 700 delegates from India & abroad. Over 200 technical papers are expected to be presented at IC 2017.

weldindia.com

WELD INDIA 2017 India’s Premier Welding Technology Expo

BACK IN CHENNAI AFTER 6 YEARS 07 - 09 DECEMBER 2017 CHENNAI TRADE CENTRE CHENNAI, INDIA

THE HIGHLIGHTS

Weld India in Chennai after a gap of 6 years 12th Exhibition in the Weld India series Focussed Campaign to bring in qualified Trade Visitors Organised by The Indian Institute of Welding Held in India’s Premier Exhibition Centre, Chennai Trade Centre Weld India 2017 will feature 200+ Exhibitors and 10,000 Visitors Held in India’s Prominent Auto and Ancillary Manufacturing Hub

Organised by

The Indian Institute of Welding

For more information contact - Event Managers Exhibitions Pvt Ltd

CEC Exhibitions Pvt Ltd, #3/3, 3rd Floor, Hari Krishna Colony, Nandambakkam, Chennai - 600 089 Biju Thomas Panjikunnel Ph: + 91 94951 95000, + 91 97456 03455, E-mail: info@weldindia.com

PRE-EVENT COVERAGE

IIW all set for WELD INDIA, 2017 The Indian Institute of Welding (IIW) is organising the International Congress 2017 (IC 2017) of the International Institute of Welding during 07-09 December 2017 at the Chennai Trade Centre, Chennai. Concurrently, Young Professionals International Conference 2017 (YPIC 2017) & India's largest welding exhibition, WELD INDIA 2017, will be held during the same period.

ndia has seen a rapid rise in

of India. The ‘Make in India’ initiative

ceramics, plastics etc., welding and

industrialisation in the past few

was launched in September 2014 to

hardfacing consumables; weld repair and

decades, due its expansion in

transform India into a global design and

maintenance equipments; computer aided

markets such as pharmaceuticals,

manufacturing hub. This initiative requires

welding equipments; welding robots and

bio-engineering, nuclear technology,

highly skilled manpower to make Indian

CNC machines; soldering and brazing

informatics and technology-oriented

products globally competitive. To meet this

equipments; gas, plasma and laser cutting

higher education. India is poised to

end, Skill India campaign was launched

machines; gas equipments and accessories;

become a major manufacturing hub

in July 2015 with an aim to train over

grinding and cutting tools; heat treatment

because of the relatively low cost of

400 million people in different skills by

furnaces; industrial gases; manufacturing

production, thus, resulting in India going

2022. Welding is one of the trades in this

and fabrication technologies; materials

global. The structured liberalisation of

campaign.

including steels, stainless steels, aluminum

the Indian economy, which has paved the way for globalisation of our industry, has

Hence, the theme of International Congress 2017 is;

safety equipments; non-destructive inspection and testing equipments;

had its impact on core sectors such

electron and optical microscopes; welding

and transportation. Hence, there is an

Advances in the Science, Technology and Skill Development in Welding

imperative need for the manufacturers to

WELD INDIA 2017 will present an

display the latest in the area of welding and

maximise profits without compromising

opportunity for the leaders in welding

its allied technologies. A separate brochure

on quality and by lowering manufacturing

consumables and equipments, and

is being sent to all prospective exhibitors.

time and costs. Since, welding is the most

other allied industries such as NDT,

Delegates to International Congress 2017

widely used engineering manufacturing

microstructural and properties

will benefit immensely from the Exhibition.

process, the welding industry is also

characterization, to display their wares to

poised for a vibrant change due to the

attract the prospective Indian consumer

across the globe and over 7,000+ industry

need to introduce high productivity

and gain a foothold in India of the

visitors are expected at WELD INDIA 2017

welding processes, cost effective designs

future. This will be the apt forum for the

Exhibition, which will bring together raw

and reliable quality control methods.

manufacturers and dealers of conventional

material producers, consumables and

and advanced welding equipments;

equipment suppliers, end-users and the

to get a major thrust in India in the years

electron beam, laser, magnetic pulse

Industry at large, under one roof to provide

to come, with the launch of the ‘Make

and diffusion welding equipments;

for a comprehensive insight of technology

in India’ initiative by the Government

equipments for joining of nano materials,

and markets.

as power, steel, oil, gas, petro-chemical

Skill Development in welding is all set

and other advanced materials; welding

WELDFAB TECH TIMES | OCT - NOV 2017

education, training and consultancy, to

Around 200 high profile exhibitors

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EVENTS UPDATE

NATIONAL Event

Date (2017)

Address

Organiser

ENGIMACH

6 - 10 Dec, 2017

The Exhibition Center, Gandhinagar, Gujarat

K and D Communication Ltd.

Weld India

07 – 09 Dec, 2017

Chennai Trade Centre, Chennai, India

Indian institute of welding

Zak Aluminium Extrusions Expo

07 - 10 Dec, 2017

MMRDA Grounds, Mumbai, India

Zak Trade Fairs & Exhibitions Pvt. Ltd.

Machma Expo

15 – 18 Dec, 2017

Glada Ground, Ludhiana, India

Fortune Exhibitors Pvt. Ltd.

Industrial Engineering Expo

05 -08 Jan, 2018

Labhganga Exhibition Center

Imtex Forming

25 – 30 Jan, 2018

Bangalore International Exhibition Centre,(BIEC)

IMTMA

Asia Steel International Conference

6-9 Feb, 2018

Bhubaneswar,Odisha

The Indian Institute of Metals & Tata Steel Ltd

Fire and Security India Expo

22 – 24 Feb, 2018

Bangalore International Exhibition Centre

Cutting & Welding Equipment Expo

29 – 31 Aug, 2018

Pragati Maidan, New Delhi

International Trade and Exhibitions India Pvt. Ltd.

INTERNATIONAL Event

Date (2017)

Location

Organiser

Welding Ukraine

21 – 24 Nov, 2017

International Exhibitional Center, Kiev, Ukraine

International Exhibition Centre Inc

Metalex Thailand

22 – 25 Nov, 2017

BiTEC | Bangkok international Trade & Exhibition Centre, Bangkok, Thailand

The Japanese Machine Tools Association of Thailand

Welding Bangkok

22-25 Nov, 2017

Bangkok international Trade & Exhibition Centre

Reed Tradex

Metal working & Welding Technology

29 Nov – 03 Dec, 2017

Saigon Exhibition and Convention Center, Ho Chi Minh, Vietnam

Deutscher Fachverlag

Welding & Cutting Middle East

17 - 19 Dec, 2017

Dubai World Trade Centre, Dubai, UAE

Al Fajer Information & Services

Metalworking Exhibition Welding

30 Jan-01 Feb, 2018

Siberia International Exhibition and Business Center, Krasnoyarsk, Russia

Krasnoyarsk Fair Exhibition Co.

GRINDexpo

14-15 Feb, 2018

Expo Silesia, Sosnowiec, Poland

Expo Silesia Sp zoo Ltd

Welding Eurasia

15-18 Mar, 2018

Tuyap Exhibition and Convention Center, Büyükçekmece, Turkey

Hannover Fairs Turkey Fuarcilik A.S.

Nordic Welding Expo

20-22 Mar, 2018

Tampereen Messu- ja Urheilukeskus, Tampere, Finland

Tampereen Messut Oy

Welding & Cutting

10-13 Apr , 2018

National exhibition center BelExpo, Minsk, Belarus

Minsk Expo

Welding

10-12 Apr , 2018

Targi Kielce, Kielce, Poland

Targi Kielce

Saudi Welding & Cutting Expo

29 Apr-02 May 2018

Riyadh International Convention & Exhibition Center, Riyadh, Saudi Arabia

Arabian German For Exhibition Ltd

Beijing Essen Welding & Cutting Fair

08-11 May, 2018

Guangdong Modern International Exhibition Center, Dongguan, China

China Welding Association

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OCT - NOV 2017 | WELDFAB TECH TIMES

EVENT INTERVIEW

TEKNO 2017: An opportunity to comprehend technical aspects of the industry Q1. Could you brief us on TEKNO 2017 expo? What is the exhibition all about?

to understand the current market

TEKNO was introduced to the Middle East region by Al Fajer Information and

Q2. What would be the key focus areas?

Services (AFIS), a company specialised

TEKNO 2017 will focus on metal and

in organizing exhibitions in various

metal working, tubes, rods and pipes,

disciplines. AFIS is owned by His

wires and cables, welding cutting and

Highness Sheikh Hasher Al Maktoum, a

joining products and technology.

scion of the Ruling Family.

Experts will introduce research results,

TEKNO 2017 shall bring together all

Satish Khanna, General Manager, Al Fajer Information & Services

dynamics and its effects on the business.

market developments, solutions, and

the major aspects of the industry for 3

technologies for manufacturers and

days, from 17-19 December 2017 in Hall

users of joining, cutting and surfacing

3 of Dubai World Trade Centre.

domains.

Earlier collocated with ArabPlast,

Traditionally, the expo attracted major

TEKNO from 2017 creates its own

players from the industry, and this year

identity as a stand-alone trade fair.

will indeed prove to be no different,

With rapid industrialization and focus on heavy investments in

offering the same - if not more - for the avid delegate and exhibitor alike.

infrastructure projects, TEKNO 2017 industrial trade show exclusively for

Q3. How is the cutting and welding market scenario in Middle East?

the manufacturing, technology and

As per a report by market realist, the

solutions.

global welding product market is

shall be the regionâ&#x20AC;&#x2122;s only international

With several new projects been announced recently in infrastructure

cent until 2020. The market is expected

like pipelines, airports, real estate, and

to touch $23.8 billion by the end of 2020.

industrial sector along with government

WELDFAB TECH TIMES | OCT - NOV 2017

The welding product market in the

initiatives, the economy has received

Middle East is primarily driven by the

a major boost. TEKNO 2017 serves as

booming real estate, manufacturing and

an immediate beneficiary to various

construction industries as well as the

industrial sectors, of which tubes, pipes,

infrastructure development.

rods, wires, cables and welding, cutting,

Rupashree Singh, Project Manager, Al Fajer Information & Services

expected to grow at a CAGR of 4.5 per

Similarly, the revival in industrial

joining, and surfacing is an integral part.

demand and increased oil and gas

As such, the exhibition this year is all

facilities, heavy fabrications, export

about introduction to latest products

demand, and focus on renewable

of the industry, sharing best practices

energy usage have given an impetus for

and integrated methods for market

growth in the welding markets in the

penetration and a lucrative opportunity

Middle East. Also, the rising demand for

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EVENT INTERVIEW

equipment is surging the demand for the

Q6. Which sectors, according to you will be largely benefitted?

industry in the Middle East.

All industries will benefit from this expo.

automotive products, consumables and

However, the oil and gas, manufacturing,

Q4. According to you, how will TEKNO 2017 stand out to be a great platform for both the exhibitors and visitors?

construction, transportation, infrastructure, energy, shipping, aviation and automotive sectors will receive a boost through TEKNO 2017.

TEKNO 2017 will not only give the

them a strategic platform to network

Q7. Being bi-annual event, TEKNO was a great hit in 2015, Your comments.

and collaborate, share best practices and

TEKNO 2015 served as a catalyst to boost

learn about key trends of the industry.

the industry, and offered visitors and

Furthermore, the event will serve as

exhibitors a complete overview of all

exhibitors and visitors an insight into the latest trends, but shall also provide

an excellent opportunity to comprehend

current developments and innovations

technical aspects of the industry from

in the industry.

subject-matter experts.

Q5. How has the response been so far from the exhibitors and visitors?

Q8. As compared to last edition, what are your expectations from TEKNO 2017?

Moving away from the shadows of Arab

TEKNO 2017 will feature exhibitors and

Plast and being a first time stand-alone

visitors from 14 countries. We expect

trade fair, TEKNO has received an

a sizeable participation across various

encouraging response from the industry.

industry sectors and we are confident

We are confident that the positive

that the expo will continue to evolve in

momentum will continue.

the future editions.

TEKNO 2017 will present advance content and will provide domestic and international players an insight into the landmark success stories. We look forward to hosting this prestigious international event and bringing the international industry experts to the region. TEKNO 2017 is shaped to deliver outstanding insight, and create exceptional networking and new business opportunities, whilst ensuring a robust return-on-investment. As such, we encourage professionals of the industry to participate in this international event to boost their business and provide momentum to the industry.

FLASHBACK: TEKNO 2016 >>>

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OCT - NOV 2017 | WELDFAB TECH TIMES

Diamond Sponsor

INTERNATIONAL

INDUSTRIAL TRADE FAIR

DECEMBER 17 - 19 , 2017 Dubai World Trade Centre, UAE

PARTICIPATING COUNTRIES

*Countries so far onboard

F E AT U

MIDDLE EAST

www.tekno-me.com

Your Window to the world of Manufacturing & Technology On Display * Metal Stamping * Induction Melting Furnaces * Stainless Steel * Pipes and Tubes * Metal Extrusion * Armouring Plant * Eletrical and Power Equipment * Hardware and Tools * Welding Material / consumables /machines * Carbon Steel * Alloy Products * Alloy Steel

* * * * * * * * * * * * * *

Galvanised Steel Metal Grinding Tube Mills EVA Film Flanges Steel ERW Steel Pipes Wire & Cable Material/Equipment Steel Wire Rope Wrench Metallurgy Abrasives Building Material Metal Working Metal Forming * (This list is illustrative)

RING:

WCME

ORGANISER Al Fajer Information & Services P.O. Box 11183, Dubai, UAE Phone: +971-4-3406888 Fax: +971-4-3403608 www.alfajer.net

Rupashree Singh Exhibition Manager rupa@alfajer.net

PRE-EVENT COVERAGE

Al Fajer to Organise TEKNO 2017 Al Fajer Information and Services (AFIS) is pleased to organise TEKNO, an International Trade Fair for Manufacturing, Technology and Solutions. The event will be showcased during 17 to 19 December 2017 at the Dubai World Trade Centre. TEKNO (www.tekno-me.com) is

industry is the focus on renewable

professionals. The show shall also

classified under 4 industry sectors:

energy, construction, real estate

provide a unique opportunity to adjudge

• Metal Middle East

developments, ship building, defense,

one’s market strength and at the same

• Tube Middle East

aerospace, oil and gas, airport

time to evaluate your competitors

• Welding and Cutting Middle East

builds, and overall infrastructure

strengths!!

• Wire and Cable Arabia

developments • EMEA Welding Consumables Market

If you have set eyes on the Middle East and Africa markets then Welding

Why Dubai:

to grow at 4.3% CAGR between

and Cutting Middle East is a “must be

The impending Expo 2020 has placed

2014 & 2020 owing to the positive

there” event!!

Dubai on a fast track to ensure that it

developments observed in end-use

supplements the needs & requirements of

industries.

this gloriously rich economy. In addition, several new projects are being announced

No of confirmed exhibitors:

recently in infrastructure, pipelines,

150 to 175 global

airports, real estate, and industrial sector.

On Display • Metal Stamping • Induction Melting Furnaces • Stainless Steel • Pipes and Tubes

The government initiative of diversifying

Participating countries:

economic has given a major boost for the

India, Japan, China, Italy, Egypt,

development strategy, and the immediate

Indonesia, Korea, UAE, UK, Vietnam,

• Armouring Plant

beneficiary is the core sector that propels

Portugal, Peru, Taiwan and Turkey (list as

• Eletrical and Power Equipment

the steel fabrication & metal working

of today).

• Hardware and Tools

• Metal Extrusion

• Welding Material /consumables /

industry. Millions of Dollars is being

machines

invested to ensure that Dubai maintains

Country Pavilions:

its position as the fastest developed

China, Turkey, Taiwan and Czech

• Carbon Steel

country in the world.

Republic.

• Alloy Products

Industry Facts:

Al Fajer Information and Services (AFIS) a

• Galvanised Steel

• The market is stable in line with the

• Alloy Steel company established under the auspices

• Metal Grinding

projects coming up to host the Expo

of H.H. Sheikh Hasher Al Maktoum in

• Tube Mills

2020.

1975 is a pioneer in organizing exhibitions

• EVA Film

and building exhibition stands.

• Flanges Steel

• The objective is to drive the market beyond 2020, targeting projects to

Welding and Cutting Middle East a

support the UAE Economic Vision

show collocated with Metal Middle East,

• Wire & Cable Material/Equipment

2030- roadmap for the Emirate’s

Tube Middle East and Wire and Cable

economic progress.

Arabia under the brand TEKNO.

• Steel Wire Rope

• The rising demand for welding and cutting equipment can be attributed

will showcase welding equipment,

to the manufacturing and industrial

consumables and services under a

sectors in the Middle East

single roof providing a platform to the

• Other sectors that have added a thrust to the growth of the welding

Welding and Cutting Middle East

WELDFAB TECH TIMES | OCT - NOV 2017

suppliers to communicate, interact and share know-how with the industry

• ERW Steel Pipes

• Wrench • Metallurgy • Abrasives • Building Material • Metal Working • Metal Forming

www.weldfabtechtimes.com

SAFETY IN WELDING

Safety First to Weld

What is welding?

ADVANCE INSTITUTE OF SAFETY ENGG.

a fall caused by the reaction to a shock. Electric shock occurs when welders

Welding is the process of permanently joining two or more materials together,

touch two metal objects that have a

usually metals, by heat or pressure or

voltage between them, thereby inserting

both. When heated, the material reaches

themselves into the electrical circuit. For

molten state and may be joined together

instance, if a worker holds a bare wire in

with or without additional filler materials

one hand and a second bare wire with

being added. Thermoplastics, for example

another, electric current will pass through that wire and through the welding

can be welded together using a suitable heat source to form permanent joins.

organizations such as the American

operator, causing an electric shock. The

Many different energy sources can be

Conference of Governmental Industrial

higher the voltage, the higher the current

used for welding including gas flames,

Hygienists (ACGIH) and the Occupational

and, thus the higher the risk for the

electric arcs, electric resistance, lasers,

Safety and Health Administration

electric shock to result in injury or death.

electron beams, friction, molten metal

(OSHA) offer safety guidelines to help

baths and ultrasound. Welding includes

control, minimize or to help employers

shock is secondary voltage shock from an

joining methods as diverse as fusion

and workers avoid welding hazards.

arc welding circuit, which ranges from

welding, forge welding, friction welding,

Employers should ensure all workers

20 to 100 volts. Bear in mind that even a

braze welding, brazing, soldering

have an opportunity to comply with the

shock of 50 volts or less can be enough to

and explosion welding. Welding is

following important guidelines in the

injure or kill an operator, depending on

a potentially hazardous activity and

workplace:

the conditions. Due to its constant change

precautions are required to avoid

• Read and understand manufacturer

in polarity, alternating current (AC)

electrocution, fire and explosion, burns, electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure to intense ultraviolet radiation.

instructions for equipment. • Carefully review material safety data sheets. • Follow the company’s internal safety

The most common type of electric

voltage is more likely to stop the heart than direct current (DC) welders. It is also more likely to make the person holding the wire unable to let go.

practices.

Be Prepared: Four Potential Welding Safety Hazards to Avoid

Awareness of the most common welding

Safety is a critical consideration for any

hazards and knowing how to avoid

welding project. Arc welding is a safe

them ensures a safe, productive work

occupation when proper precautions are

environment for all.

taken. But, if safety measures are ignored, welders face an array of hazards which

1) ELECTRIC SHOCK

can be potentially dangerous, including

Electric shock is one of the most serious

electric shock, fumes and gases, fire and

and immediate risks facing a welder.

explosions and more.

Electric shock can lead to severe injury or

To help keep welders safe,

www.weldfabtechtimes.com

death, either from the shock itself or from

It’s important to remember to never touch the electrode or metal parts of the electrode holder with skin or welding clothing and insulate yourself from the work and ground. OCT - NOV 2017 | WELDFAB TECH TIMES

SAFETY IN WELDING

exposure limits (PEL) for the substances

To avoid secondary voltage shock, welding operators should wear dry

in welding fume. These limits specify the

gloves in good condition, never touch the

amount of a substance in your breathing

electrode or metal parts of the electrode

air to which welding operators can be

holder with skin or wet clothing and be

exposed every day they work over the

sure to insulate themselves from the

course of their career. Welding operators

work and ground, keeping dry insulation

should wear an approved respirator

between their body and the metal being

unless exposure assessments are below

welded or ground (such as a metal floor or

applicable exposure limits. An industrial

wet surface).

hygienist takes an air sample in the worker’s breathing zone to determine

Welding operators also should inspect the electrode holder for damage before

whether a worker’s exposure is below the

beginning to weld and keep the welding

exposure limits. If the air in your breathing zone is not

cable and electrode holder insulation in good condition, because the plastic or

clear or if breathing is uncomfortable,

fiber insulation on the electrode holder

check to be sure the ventilation

prevents contact with the electrically

equipment is working and report concerns to a supervisor so your exposure

“hot” metal parts inside. Always be sure

Welding areas require adequate ventilation and local exhaust to keep fumes and gases from the breathing zone and the general area.

to substances in the welding fume can

consumables, base metal and the base-

from coatings such as paint, galvanizing,

metal coatings, so it’s important to keep

or metal plating’s on base metals, clean

voltage shock, may occur when a welder

your head out of the fumes and use

the base metal before beginning to

touches electrically ‘hot’ parts inside the

enough ventilation and/or exhaust to

weld. See a doctor if symptoms from

welder case or the electric distribution

control your exposure to substances in

overexposure persist.

system to which the welder is connected.

the fume, depending on the type of rod

This action can lead to a shock of 230 or

and base metal being used.

to repair or replace damaged insulation before use. And remember, stick electrodes are always electrically hot, even when welding is not being done and the voltage is the highest. An even more serious shock, primary

460 volts. When not in use, but still turned on,

The specific potential health effects

be checked. This is especially important when welding with stainless steel or hard facing products. To prevent exposure

3) Fire and explosions Welding arc creates extreme

which relate to the welding consumable

temperatures, and may pose a significant

most welding equipment have a voltage

product being used can be found in the

fire and explosions hazard if safe practices

that ranges from 20 to 100 volts at the

Health Hazard Data section of the Safety

are not followed. While the welding arc

welding circuit and voltages inside the

Data Sheet available from your employer

may reach temperatures of 10,000 degrees

welding equipment may range from

or the consumable manufacturer.

120 volts to more than 575 volts, all of

Welding areas require adequate

which pose a risk for electric shock.

ventilation and local exhaust to keep

Only qualified repair technicians should

fumes and gases from the breathing zone

attempt to service or repair welding

and the general area. In most situations,

equipment.

employers will provide a ventilation system- such as a fan, and an exhaust

2) Fumes and gases

system or fixed or removable exhaust

it’s no surprise that overexposure

hoods- to remove fumes and gases from

to welding fumes and gases can be

the work area.

hazardous to your health. Welding

All welding operators should be aware

fume contains potentially harmful

that there are ACGIH threshold limit

complex metal oxide compounds from

values (TLV) and OSHA permissible

WELDFAB TECH TIMES | OCT - NOV 2017

Welding areas require adequate ventilation and local exhaust to keep fumes and gases from the breathing zone and the general area.

www.weldfabtechtimes.com

SAFETY IN WELDING

Fahrenheit, the real danger is not from

fire resistant blanket, over any flammable

position, such as applications that require

the arc itself, but rather the intense near

materials within the work area, if you

vertical or overhead welding.

the arc and the heat, sparks and spatter

can’t remove them.

created by the arc. This spatter can reach

In an elevated location, make sure

Avoid rolling up sleeves or pant cuffs, as sparks or hot metal will deposit in the

up to 35 feet away from the welding

no flammable materials are beneath

folds and may burn through the material.

space.

you, and watch out for other workers

Keep pants over the top of work boots –

below you in order to prevent dropping

don’t tuck them in. Even when wearing

to weld, inspect the work area for any

sparks or spatter on them. Even high

a helmet, always wear safety glasses with

flammable materials and remove them

concentrations of fine dust particles

side shields or goggles to prevent sparks

from the area. Flammable materials are

may cause explosions or flash fires. If a

or other debris from hitting the eyes.

comprised of three categories: liquid,

fire starts, don’t panic – and call the fire

Leather boots with 6-to-8-inch ankle

such as gasoline, oil and paint; solid,

department immediately.

coverage are the best foot protection;

To prevent fires, before beginning

metatarsal guards over the shoe laces

such as wood, cardboard and paper; gas, including acetylene, propane and

4) Injuries from insufficient PPE

can protect feet from falling objects and

hydrogen.

Personal protective equipment (PPE)

sparks. It will not be pleasant if a hot

helps keep welding operators free from

piece of spatter finds its way inside your

extinguishers are located, and check the

injury, such as burns – the most common

clothing or shoes.

extinguisher’s gauge to make sure it is full.

welding injury – and exposure to arc

If an extinguisher is not available, be sure

rays. The right PPE allows for freedom of

always be worn to protect from burns,

to have access to fire hoses, sand buckets

movement while still providing adequate

cuts and scratches. As long as they are

or other equipment that douses fire. And,

protection from welding hazards.

dry, they also should provide some

Know where the fire alarms and

know the location of the nearest fire exit. If welding within 35 feet of flammable

Thanks to their durability and fire resistance, leather and flame-resistant

Heavy, flame-resistant gloves should

protection from electric shock. Leather is a good choice for gloves. Helmets with side shields are essential

materials, have a fire watcher nearby to

treated cotton clothing is recommended

keep track of sparks, and remain in the

in welding environments. This is because

for protecting eyes and skin from

work area for at least 30 minutes after

synthetic material such as polyester or

exposure to arc rays. Make sure to choose

finishing welding to be sure there are

rayon will melt when exposed to extreme

the right shade lens for your process –

no smoldering fires. Put a fire resistant

heat. Welding leathers are especially

use the helmet’s instructions to help

material, such as a piece of sheet metal or

recommended when welding out of

select the right shade level. Begin with a darker filter lens and gradually change to a lighter shade until you have good visibility at the puddle and weld joint but it is comfortable and does not irritate your eyes. Helmets also protect from sparks, heat and electric shock. Welder’s flash from improper eye protection may cause extreme discomfort, swelling or temporary blindness, so don’t take any risks – wear a helmet at all times during welding. To protect ears from noise, wear hearing protection if working in an area with high noise levels. Doing so will protect your hearing from damage, as well as well prevent metal and other debris

Personal protective equipment (PPE) helps keep welding operators free from injury, such as burns – the most common welding injury – and exposure to arc rays.

www.weldfabtechtimes.com

from entering the ear canal. Choose ear plugs or ear muffs to protect the ears.

OCT - NOV 2017 | WELDFAB TECH TIMES

WELDING TIPS

7 Ways to Save Money on Robotic Welding important cost-saving steps companies

but the payback period is relatively short

can make. Here are some ways to achieve

and within 12 to 18 months..

those goals.

For example, a reamer (also called a nozzle cleaning station or spatter

C Sridhar, Director- Technical, Advance Institute of Welding Technology (AIWT), Chennai. Technical Resources

Tip No. 1: Add peripherals

cleaner) minimizes spatter build-up in

Peripherals — reamers, wire cutters,

the nozzle and with it the opportunity

neck inspection tools and clutches

for electrical resistance that could lead to

or solid mounts — are all additional

premature failure of the robotic MIG gun

equipment that can protect the robotic

or consumables. Failure of the gun or the

welding system investment, maximize

consumable, of course, increases the cost

its effectiveness and reduce costs. This

for replacements and requires downtime

equipment is particularly helpful in

for changeover — downtime that puts the

minimizing downtime that leads to offline

robot offline and stops it from making

maintenance or repairs of the equipment

parts and making money.

or its components (e.g., the robotic MIG gun, cables or consumables). Unfortunately, some companies view

obotic welding systems have

this equipment as an unnecessary cost

become an increasingly practical

and don’t realize that they can play an

way for companies, large and

important role in improving quality and

A clean nozzle also allows for good shielding gas flow, thereby minimizing quality issues that could be costly to repair.

small, to gain a competitive edge.

increasing productivity. Peripherals do, of

Tip No. 2: Manage and maintain your consumables properly

Assistance with everything from planning

course, require an up-front investment,

To protect consumables against costly

and implementation to training is readily available through robotic integrators or vendors, helping make the capital investment less risky and allowing companies to safeguard better results. In addition to programming the robot in a manner that ensures the accuracy, speed and repeatability needed to complete high-quality welds, there are also several steps that companies can take to increase the return on their investment. Saving money on the robotic welding systems is, after all, one of the primary reasons — apart from productivity gains and quality improvements — for implementing this technology. Minimizing downtime, reducing the need for parts replacements and preventing rework are among the more

WELDFAB TECH TIMES | OCT - NOV 2017

Saving money on the robotic welding systems is one of the Primary reasons - apart from productivity gains and quality improvements for implementing this technology. Thereare several steps companies can take to increase that return on the investment.

www.weldfabtechtimes.com

WELDING TIPS

associated with them, as well, and can help companies save money.

Tip No. 3: Implement a preventive maintenance program Preventive Maintenance (PM) is another critical way to save money on robotic welding, primarily by preventing To protect consumables against costly damage before even placing them on the robotic MIG gun, it is important to employ proper storage and handling practices.

unscheduled downtime, poor quality parts and/or costly repairs. It can even help prevent failures that require equipment replacements. The robot, as

damage before even placing them on

well as the robotic MIG gun, consumables

the robotic MIG gun, it is important to

& cables can all benefit, too.

employ proper storage and handling practices. Always keep consumables in their

Schedule time to check connections throughout the system (from the frontend consumables through the gun and

To prevent problems like birdnesting (a tangle of wire in the drive rolls) or poor wire feeding both issues that lead to downtime and added costs — it is important to select the right MIG gun liner and install it properly.

original packaging until they are ready for

power pin). This task can easily take place

use. Opening the packaging and placing

during routine pauses in welding cycles to

these components in a bin can lead to

prevent unplanned downtime. To prevent

scratches or dents, both factors that

debris build-up that may affect part fit-

metal package changeovers can be one

allow spatter to adhere the product and

up, also remember to clean fixturing on a

of the most effective ways of maximizing

can lead to premature failure. Similarly,

regular basis. Similarly, check the front-

return on investment and productivity.

removing contact tips or retaining

end consumables for spatter build-up and

Ideally, select a package that is large

heads from their packaging and storing

replace as necessary.

enough (200 / 250 kg etc) to minimize

Verifying tool center point (TCP) is

wire changeovers, but not so large that

cause dirt and/or oil to accumulate

another important cost-saving measure,

the same wire will remain on the shop

on them, which can lead them to seat

as it helps ensure that the robotic welding

floor for more than a couple of days.

improperly together.Regularly check

system continues to operate within its

Filler metal manufacturers typically ship

that the contact tips, retaining heads

proper parameters and provide the same

their products in airtight or hermetically

and nozzles are securely connected.

consistent weld quality — repeatedly.

sealed containers. Once opened, the wire

Certain maintenance can occur in

is at risk of absorbing moisture, dust, oil

them in open or dirty containers can

Solid connections help ensure reliable electrical conductivity and minimize heat,

between shifts, such as cleaning off the

or other contaminants that can affect

in turn providing more consistent weld

robot or changing consumables, for

its welding performance and ultimately

quality and helping the consumables last

example. Other activities, such as greasing

cost money to replace, not to mention

longer.In addition, always follow the MIG

the robot’s joints usually occur less

downtime to change over.

consumable manufacturer’s suggestions

frequently and during a longer scheduled

for installing these consumables and

stop. Companies should assess their

of filler metal package being used. For

use the proper tools in order to gain the

individual needs and plan the preventive

instance, recyclable filler metal packaging

best performance and reduce the risk of

maintenance schedule accordingly. For

can reduce costs and labor for properly

damaging them.

larger companies, hiring a maintenance

separating and disposing of recyclable

crew to take care of preventive

and non-recyclable packaging materials.

While these two practices may seem simple, they can go a long way toward

maintenance may be desirable.

minimizing product replacements and

It’s also important to consider the type

When possible, stocking an extra filler metal package near the robot can also

Tip No. 4: Use the best filler metal package for the job

contribute to cost savings by reducing

from reaching its optimal throughput during a shift. Both have measurable costs

Reducing downtime for routine filler

from the storage area to the weld cell.

preventing downtime that keeps the robot

www.weldfabtechtimes.com

downtime to transport a new package

OCT - NOV 2017 | WELDFAB TECH TIMES

WELDING TIPS

Tip No. 5: Select, trim and install the right MIG gun liner

These guns cost more to maintain,

To prevent problems like bird-nesting

a good PM program for them to avoid any

(a tangle of wire in the drive rolls) or

costly surprises.

however, so it’s important to implement

Hybrid robotic MIG guns are another

poor wire feeding — both issues that lead to downtime and added costs — it

option to help reduce costs, particularly

is important to select the right MIG gun

when it comes to maintenance. These

liner and install it properly. Always make sure to have the correct diameter liner for the wire being used. Using too large of a liner for too small of a wire may allow the wire to wander,

Having the right style and amperage MIG gun for the application can help minimize downtime for Over-heating and potential failure of this equipment.

a water-cooled gun, and feature water lines that run independently of the power cable, making them more accessible to repair than on a standard water-cooled MIG gun. These guns can also remain on

causing poor wire feeding and/or premature liner failure due to excessive

gun for the application can help minimize

the robot for maintenance, too, which

wear. Similarly, if a liner is too small

downtime for overheating and potential

reduces downtime for removal. Plus, if

for the wire diameter, the wire will not

failure of this equipment. It can also

there are issues with water circulation,

be able to feed smoothly, resulting in

save money by preventing the purchase

these guns can rely on an underlying

poor weld quality and potentially a

of a larger (and more costly) gun than

air-cooled unicable to provide enough

clogged liner.

necessary for the job.

current-carrying capacity to avoid a

Trimming the liner to the correct length

Air-cooled robotic MIG guns (rated at

catastrophic failure such as destroying a power cable or other components.

is also a good cost-saving measure, since

500 amps) operate comfortably in the

it helps prevent downtime and costs for

range of 200 to 300 amps at approximately

replacing this part. Some manufacturers

100 percent duty cycle with mixed

print markings on the outside of the

gases. They are good for welding thinner

Tip No. 7: Take advantage of training opportunities

weld cable to show when the cable is

materials — typically upwards of 4 mm

Many robotic integrators offer training

twisted, providing welding operators the

thick. The cost of ownership for these

opportunities not just up front, but also

opportunity to straighten it fully in order

guns is usually relatively low since they

throughout the course of ownership of

to measure for the correct liner length.

are easier to maintain and replacement

the robotic welding cell. Because robotic

Other manufacturers offer liner gauges

parts are less expensive than water-cooled

welding systems require properly trained

as a guide. Both work well to guide in the

guns. They work well for shorter welds on

operators to oversee them, it is important

correct trimming process. There are also

high-volume applications and are quite

to make sure these individuals continue

spring-loaded modules available that

durable, especially through the neck. This

to gain knowledge that will increase

work in conjunction with a front-loading

durability further reduces costs because

their programming, troubleshooting and

liner to help minimize issues if a welding

it helps the guns maintain their accuracy

preventive maintenance knowledge and

operator cuts the liner to an incorrect

and create consistent welds.

skills. In many cases, robotic integrators

length. These modules are housed in

guns are a mix between an air-cooled and

For higher-amperage applications,

offer online tutorials, troubleshooting

the power pin and put forward pressure

applications with thicker materials

information and/or additional on-site

on the liner after the welding operator

(1/4-inch or more) or those requiring

training as aftercare support. By taking

installs it from the front of the gun. They

prolonged welding, it’s necessary to

advantage of such opportunities, it will

allow up to 25 mm of forgiveness if the

have a gun capable of withstanding the

be easier for those who oversee the

liner is too short.

increased heat. A water-cooled MIG gun

robotic welding cell to act quickly should

offering 300 to 600 amps of power and

a problem result and get the robot back

Tip No. 6: Select the appropriate MIG gun

60 to 100 percent duty cycle is a good

online to product parts. It also empowers

option to help reduce costs by preventing

them to take preventive care to prevent

Having the right style and amperage MIG

gun failure or downtime for overheating.

downtime in the first place.

WELDFAB TECH TIMES | OCT - NOV 2017

www.weldfabtechtimes.com

PRODUCTS UPDATE

Maxwin: A Technology Superior Than Conventional Inverter Welding Machines

e the “Maxwin”

different than conventional

are pleased to

Inverter Welding Machines.

introduce a

The welding quality of this

Dynamic New Technology

technology is much superior

Welding Machines under the

to conventional inverter

brand name of “Maxwin”.

welding machines. We assure

Maxwin is a technology

you of Maxwin’s quality

features, timely delivery

construction structure, alloys

and all round services.

and so on. We are keen to

This machine stands out

know your interest for the

to be a perfect choice to

product. Feel free to get more

use in various sectors

information on Maxwin

such as aerospace, ship

through e-mail, and call. We

building, auto, chemicals,

will send you the catalogues

mining, construction,

and sample for your

steel machinery, steel

reference and approval.

For More Info: Unico International Gala no.1, Amar Business Center, Ram Mandir Road, Opp vakharia ind.estate Goregaon (West) Mumbai-400104 E-mail: maxwinweld@gmail.com Tel: (022) 61277487 / 8097867863

SHARP ELECTRODES PVT LTD – Manufacturers of Manual Arc Welding Electrodes

harp Electrodes Pvt

Our Managing Director

Ltd was established

Dr.(Mrs.) J. Mohanasundari

in the year 1984. The

who is a well known Women

Company has excellent

Entrepreneur is a recipient

manufacturing facilities

of INTERNATIONAL AWARD

with accreditation of ISO

namely International Women Entrepreneurial Challenge

9001:2008 quality system was established in 1992

we are continuously

Award (IWEC Award - 2013)

with accreditation of ISO

bagging award from EEPC

organised by Barcelona

engaging mostly women

9001:2008 quality system

(Engineering Export

Chamber of Commerce in

employees, reliable quality

from DNV, The Netherlands.

Promotion Council,

partnership with Chamber

SHARP brand Welding

The electrodes manufactured

Government of India) under

of Commerce of Manhattan

Electrodes, Dry Flux

are marketed in India from

various categories like Star

(New York) and FICCI - FLO

Powder and EQ Cut Wire

1984 and also exported to

Performance, Highest Export

held at LIMA, PERU, South

rods of various ranges. The

various countries including

and Export excellence award.

America.

electrodes are approved by

U.A.E, OMAN, QATAR,

Lloyd's Register, London,

MAURITIUS, AUSTRALIA,

UK and TUV Sud, South

BAHRAIN, NEPAL, U.S.A,

Asia. Our sister concern

U.K & ANGOLA.

from DNV, The Netherlands. The unit manufactures,

KAYJAY SHARP TRENDYS

www.weldfabtechtimes.com

For the past 16 years,

For More Info: SHARP ELECTRODES PVT. LTD. Website: www.sharpelectrodes.com www.sharptrendys.com

OCT - NOV 2017 | WELDFAB TECH TIMES

PRODUCTS UPDATE

Silicates & Titanates for Welding Electrodes

anufacturing of many industrial elements is

based on Welding. To deliver the best quality industrial products, the quality of welded joints has to be perfect, which depends on welding rods and to do so, the manufacturer has to carefully

different electrodes:

Titanates

select the welding additives to

1. Potassium Silicate is

Potassium, Sodium and

the composition.

Silicates

mixed TITANATES are

alloyed steels.

widely used in low hydrogen

•

Reduce spattering.

electrode, AC/DC electrode,

•

Provide fine welding line

2. Potassium Lithium Silicate is used for special

stainless steel electrode and

main welding additives and

and high-alloyed steels.

flux-cored wire.

3. Lithium Silicate is used for

that of a simple binder. Smooth Extrusion, Quiet Burning and Low Arc Spattering are some

and enhance bonding characteristics. •

Improve slag mobility.

included in flux formula-

for special and high-

tions to:

Customized Silicates

alloyed electrodes.

•

4. Sodium Lithium silicate is used for melts which

depend upon the quality of

are determined for special

SILICATES.

and high-alloyed steels. 5. Potassium Sodium Lithium Silicates.

substantially influences

These additive agents are

provide arc stability.

low emission electrodes

of the attributes, which

The type of silicates used

Reduce arc voltage and

used for soft and low-

Today, silicates are often the their function widely exceeds

chemical stability. •

the welding process and its

Silicates are available as

properties. Following are

liquids, solids (lumps)

the various silicates used for

and powders.

Enhance wear resistance

and Titanates are available to

in high temperature

meet the requirement

formulations that require

of industry.

For More Info: Noble Alchem Pvt. Ltd. No. 6, M. C. Colony, Rohtak Road, Bhiwani-127021, Haryana, India Tel: +91-1664-329520 / 290899, Mob: +91-9034059001, Fax: +91-1664-244817 Email: silicate@noblealchem.com

Automatic Girth Welder

ug-O Systems offers

our machines. This self-

the Automatic Girth

propelled submerged arc

Welder for tank

welding system can reduce

fabrication applications.

field storage tank welding

Unlike other girth welders

time by 40% by increasing

on the market, the BGW

arc on time and reducing

(Bug-O Girth Welder)

weld defects. BUG-O Girth

Series comes standard with

Welders features:

a dual drive system and

•

other features unique to

Unique Modular system that, with conversion

WELDFAB TECH TIMES | OCT - NOV 2017

www.weldfabtechtimes.com

PRODUCTS UPDATE

kit, can turn single sided

•

Mounted laser pointer

•

Can be ordered

country pipeline and many

machines into dual

that helps with weld

specifically for LNG

other on-site welding and

sided machines.

alignment saving time

solutions.

cutting applications and are continuously extending our

and money. •

Dual Drive Motor, unique in the marketplace, gives

•

Easy to navigate control

the ability to drive over

panel that makes it very

uneven plate fit-ups.

simple for any user to

We also offer Welding

help for the country building

Automation for cross

the infrastructure fast.

For More Info: Bug-O Systems International D-265, Sector- 31, Greater Noida-201310, India. Tel: +91-120-4108108, Mob: +91-9899048108 Email: indiasales@bugo.com

learn quickly. •

Adjustable Flux System uniquely adjustable with

•

Weather protection

vertical and horizontal

for the operator using

wheel system.

weather tight canvas.

BOHLER N Ti 71-T1C

impact down to even -30˚C.

öhler Welding offers •

for flux cored arc

Excellent weldability with very low spatter,

welding (FCAW)

the most comprehensive

smooth and well-shaped

portfolio of cored wires in

beads with X-ray quality. •

the world. Producing both folded and seamless cored

Optimized for 100% CO2 gas shielding.

wires, Böhler Welding is the

•

best source for all types of

Moisture pick-up resistance.

cored wires across all alloy

a rutile flux cored wire with

groups.

fast freezing slag. Excellent

Product Features: •

•

Layer wound plastic spool packing

BOHLER N Ti 71-T1C is a

welding characteristics in

rutile flux cored wire with

•

Vacuum packed

and deposition efficiency

all positions. Very good

fast freezing slag.

•

Safe and secure shipment

of Böhler flux-cored

mechanical properties,

wires lead to a significant

easy slag detachability, low

characteristics in all

reduction of total welding

spatter level, smooth and

positions.

costs through: Less welding

well shaped beads with

time, less spatter and less

X-ray-quality. Applicable in

and allows high welding

cleaning time and excellent

out-of-position welding,

speed.

•

weldability especially in all

with higher productivity

Very good mechanical

•

positions.

and less time for post-weld

The high deposition rate

Rutile folded wires provide

cleaning.

a powerful penetrating arc with high deposition

Field of Application:

characteristics, while

Suitable for butt & fillet

depositing a smooth weld

welding of hulls, storage

with minimum spatter

tanks, water wall panels,

formation.

mechanical & constructional

BOHLER N Ti 71-T1C is

www.weldfabtechtimes.com

steel structure and bridges.

•

in Pallets

Excellent welding •

Good slag detachability

properties with high

Reliable and consistent weld quality

•

Smooth welding characteristics Increased productivity Reduction of total welding costs.

For More Info: voestalpine Bohler Welding India Pvt Ltd B – 206, Universal Business Park, Chandivili Farm Road, Off Saki Vihar Road, Sakinaka, Mumbai – 400 072, India Tel: +91 /22 42284400 Email: welding.india@voestalpine.com Website: www.voestalpine.com/welding

OCT - NOV 2017 | WELDFAB TECH TIMES

TENDERS

Company: ITI Limited

Company: Bharat Heavy Electricals Limited

Location: ITI Ltd. Mankapur Gonda 271308

Location: Ranipet

Nature of Work: Tender for procurement of wires and cables.

Nature of Work: COPPER WELDING CABLE.

Due Date: 25 November 2017

Due Date: 2 December 2017

Tender Cost: Rs 1, 44,404/-

Tender Cost: Rs 0/-

EMD: Rs. 0/-

Contact: ITI Ltd, Mankapur Plant, Dist. Gonda (UP)PIN-271308 Email: iti_mkp@itiltd.co.in, Tel: 05265-274450.

Contact: Webmaster, Corporate Office, BHEL, Asiad, New Delhi Email: query@bhel.com Tel: 011-23365279, Fax: 23340981

Company: Ordinance Factory Board Location: O F Varangaon

Company: Bharat Heavy Electricals Limited

Nature of Work: Fabrication Body Building of Truck Fire Fighting Large MK Six Qty Four Nos.

Location: Haridwar

Due Date: 19 December 2017

Nature of Work: procurement of pneumatic globe valve for Vijaywada and kishnapatnam projects.

Tender Cost: Rs. 0/-

Due Date: 9 December 2017

EMD: Rs. 2,71,500/-

Tender Cost: Rs 1,80,000/-

Contact: P N PANDEY, Ordnance Factory, Varangaon, Tal - Bhusawal, Dist â&#x20AC;&#x201C; Jalgaon, Pin - 425 308 Email: pvofv@rediffmail.com Tel: 02582277815, Fax: 02582277822.

EMD: Rs. 0/Contact: Webmaster, Corporate Office, BHEL, Asiad, New Delhi Email: query@bhel.com Tel: 011-23365279, Fax: 23340981

Company: East Central Railway

Location: HJP

Company: Western Coalfields Limited

Nature of Work: E-tender notice for supply of materials modular high pressure water jet. Participation in tender through web portal of IREPS- www.ireps .gov.in.

Location: wclmajri

Due Date: 27 November 2017

Due Date: 23 November 2017

Tender Cost: Rs. 73,44,35,00/-

Tender Cost: Rs 15,88,046/-

EMD: Rs. 14,700/-

EMD: Rs 20,000/-

Contact: Controller of Stores, East Central Railway, Hajipur, Vaishali-844101 Email: dycmmecr@yahoo.co.in Tel: 916224271520, Fax: 916224274468

Contact: Office of the General Manager, WCL, Majri Area, PO-Kuchana, Dist- Chandrapur MS -442503 Email: majrisystem@yahoo.com, Tel: 07175285027.

WELDFAB TECH TIMES | OCT - NOV 2017

Nature of Work: Miscellaneous Civil Works (3 Nos.).

www.weldfabtechtimes.com

TENDERS

Company: Western Coalfields Limited

Location: wclmajri

Location: Ballarpur

Nature of Work: Construction of workshop Effluent Treatment Plan (ETP) at NMUG to OC mine under New Majri Sub Area of Majri Area.

Nature of Work: Procurement of colored helmet and harness.

Due Date: 25 November 2017

Tender Cost: Rs 37,444/-

Tender Cost: Rs 22,82,580/-

EMD: Rs. 0/-

EMD: Rs 28,600/-

Contact: Office of General Manager, Ballarpur Area, WCL, Sasti Township, Sasti, Dist- Chandrapur - (MS) 442 706 Email: brs_blr_wcl@yahoo.co.in Tel: 07173-230449

Contact: S C Swami, Office of the General Manager, WCL, Majri Area, PO-Kuchana, Dist- Chandrapur MS -442503 Email: majrisystem@yahoo.com, Tel: 07175285027

Due Date: 27 November 2017

Company: Rashtriya Ispat Nigam Limited Company: Bharat Heavy Electricals Limited Location: RINL, Visakhapatnam Location: Bangalore Nature of Work: Tender for civil foundations works of switchyard, SMBs, LA,, laying of cables, Yard fencing works, structural steel works, earthing works etc for 10 MW solar project Santaldih.

Nature of Work: Civil works for revamping of ESP for one no. boiler at TPP. Due Date: 11 December 2017

Due Date: 27 November 2017

Tender Cost: Rs 73,30,077/-

Tender Cost: Rs 74,00,000/-

EMD: Rs 75000/-

EMD: Rs. 150000/-

Contact: Projects Contracts, Room A-9, Project Office, Rashtriya Ispat Nigam Limited Visakhapatnam Steel Plant, Visakhapatnam-530031 Email: hod_projcont@vizagsteel.com, Tel: 08912518277.

Contact: Corporate Office, BHEL, Asiad, New Delhi Email: Corporate Office, BHEL, Asiad, New Delhi Tel: 23365279, Fax: 23340981

Company: ITI Limited Company: Western Coalfields Limited Location: ITI LTD Mankapur Gonda 271308 Location: Pench Nature of Work: Tender for procurement of wires and cables. Nature of Work: Procurement of Bearings. Due Date: 25 November 2017 Due Date: 29 November 2017 Tender Cost: Rs 1,44,404/Tender Cost: Rs 1,02,620/EMD: Rs 0/EMD: Rs.2050/Contact: Office of General Manager, WCL, Pench Area, Parasia, Dist. Chhindwara â&#x20AC;&#x201C; 480441 Email: generalstores.ofmk@ofb.gov.in, Tel: 07161221118

www.weldfabtechtimes.com

Contact: Pramod Kumar, ITI LTD, Mankapur plant, DIST. Gonda (UP)PIN-271308 Email: iti_mkp@itiltd.co.in Tel: 05265-274450

OCT - NOV 2017 | WELDFAB TECH TIMES

INDEX

ADVERTISER’S INDEX Company Name

Page No.

WeldFab Tech Times - Marketing

IFC

SAP Industries

Weldwell Speciality

ESI Software

Warpp Engineers

Klinweld Wires

ED – Sigma Weld

26 - 27

Sharp Electrodes

WeldFab Tech Times : e-Market

WELDFAB TECH TIMES | OCT - NOV 2017

Company Name Rilox Weld Equipments

Page No. 44 - 45

Kaiyuan Welding &amp; Cutting Automation India

Riddhi Engineering

Weld India, 2017

64 - 65

TEKNO, 2017

70 - 71

WeldFab Tech Times - Subscription

Pro-Arc Welding and Cutting System

IBC

Noble Alchem

BACK

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Owner, Printer & Publisher – Eliza A. Bhalerao Printed At - Anitha Art Printers - 29,30 Oasis Ind Est., Next to Vakola Market, Santacruz (East), Mumbai - 55. India. Published At - B-3/503, Ekdanth, Gauri Estate, Near Gauri Hall, Manjarli, Badlapur (W), Dist.: Thane – Ulhasnagar - 421503, Maharashtra, India. Editor – Amol A. Bhalerao TC No.- MAHENG14325