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W E LCO M E
INSIDE
NEWS 4 News: Hinkley Point C 6 Focus: Women in Welding 8 Spotlight: Women and self employment 9 Adrian Hawkins: Post furlough world 10 Training: Betterweld and Free2Learn
12 HR special: Croner advice 13 Digital special: Video and quiz 16 Solutions: Lightweight aluminium 18 President message 19 Acquisition: LTI Metaltech 20 Foster: Spot weld request 21: Awards: BOHS report 22 Red Dot: Swissair winners 24 Calendar and event focus NEW PRODUCTS 26 Product: Lorch 27 Product: Weldfast 28 Product: Extractability
E D I TO R ’ S L E T T E R The challenges really are coming thick and fast on a global scale. As if economic unrest, a global pandemic and the demand to heighten technology weren’t enough, we now have dire warnings about the future of our planet. Only the most hardened conspiracist would deny all or any of these. Instead, there is hard work ahead, not just to get back to where we were 18 months ago, but to rectify damage done and to go further and improve our status and standing. That work however is taking place, and Welding World is testimony to that. In this edition we are delighted to highlight some amazing work which is taking place. From award winning businesses to major works taking place in world-leading projects, Welding World is proud to showcase an industry which is leading the way to recovery after such a terrible 18 months. Our women in welding feature is also running apace and it is delightful to see businesses such as Lincoln take up the reins with this subject as well and support a number of projects in this field. And our focus on free2learn and Betterweld is also a sign that there is a future. So as we continue into what is a strange ‘holiday’ season and head into the back end of a stranger 2021, we can all take heart from the fact that progress is being made. DARREN ISTED Editor, Welding World editor@welding-world.com
J O I N T H E CO N V E RS AT I O N @WeldingWorld1 Welding World @WeldingWorld1 Join us on Linkedin: https://linkedin.com/in/ welding-world-awd-21293a1a8/
30 Product: EWM 32 Product: Fronius 33 Product: Jasic REGULARS 34 SifTips: Cast iron 35 And Finally: Adrian Hawkins w w w. a w d .o rg . u k
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During a visit to Darchem’s Stillington factory, EDF CEO Simone Rossi and Hinkley Point C MD Stuart Crooks met 21-year-old apprentice Declan Gordon from Hartlepool – one of the hundreds of workers engaged in the construction of Hinkley Point C.
HINKLEY POINT C Hinkley Point C’s spending with businesses in the North of England has topped £1bn, according to latest figures from the new nuclear project. The numbers come in Hinkley Point C’s “2021 Socio-Economic Impact Report” which shows spending of £1.1bn with more than 500 companies in the NorthEast, North-West, Yorkshire and Humber. The figures were highlighted by EDF’s Chief Executive Simone Rossi on a visit to Darchem engineering near Stockton-onTees. The company employs hundreds of people on major contracts to build specialised tanks, stainless steel liners and other precision equipment for the plant in Somerset. The work has played a key role in sustaining the business during the pandemic. The socio-economic report shows that Hinkley Point C will support 71,000 jobs in Britain. These include new jobs recently created at Jarrow in South Tyneside where 40 new roles are being hired by
KAEFER for specialised steel ductwork. On Humberside, Bilfinger is opening a new factory for high quality pipework as part of a contract expected to employ 350 people across Britain. Darchem has recently moved manufacturing of eight 100 tonne tanks for the project from the site in Somerset to a factory in Middlesbrough, driving efficiency with modular construction close to home. Experience gained on the first reactor unit at Hinkley Point C is also helping Darchem boost productivity. Its work to install ten tonne sump suction lines was done 40% faster on the second reactor unit – demonstrating the benefits of replication. During the visit to Darchem’s Stillington factory, Simone Rossi and Hinkley Point C Managing Director Stuart Crooks met workers, including 21-yearold apprentice Declan Gordon from Hartlepool. EDF CEO Simone Rossi said: “Hundreds
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of companies across the North of England are helping Britain achieve Net Zero with the first nuclear power station for a generation at Hinkley Point C. This effort is creating thousands of quality jobs and allowing businesses to invest in skills, productivity and industrial capacity. “Continued progress on the followon Sizewell C project is essential to give suppliers confidence to carry on investing in skills and creating jobs. “ Cameron Gilmour of Doosan Babcock, from the Sizewell C Consortium of 200 British firms, said: “These figures show just how much new nuclear can deliver for British businesses, jobs and industry. That’s why our members are united in making the case for Sizewell C and why sign off from the government on the project will mean our expert supply chain can continue the positive economic legacy of Hinkley Point C here in the North of England.” ■
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WO M E N I N W E L D I N G
WOMEN IN ENGINEERING DAY Nineteen-year-old Skye from Dereham in Norfolk recently completed a City and Guilds Level 2 NVQ Diploma in Performing Engineering Operations Apprenticeship via Poultec Training at Scoots Hire which is based in Yaxham. We interviewed Skye to get an insight into what it’s like being a woman in engineering. When did you first get into the engineering industry? Nearly 3 years ago. I started as a motor bike cleaner and was fascinated how my colleagues would turn around such damaged bikes. I would always be curious and ask questions. My colleagues recognised my interests so started me doing odd jobs around the workshop such as oil changes and changing tyres on the tyre machine. They then offered me the apprenticeship position which I was incredibly excited about. What does your job entail? Upkeep and maintenance of my works rental motorbikes, which range from 50cc to 125cc. My main responsibly is to service the bikes when needed, repair any damage to the bikes, ensure every bike is at a high enough standard to be on the road and keep our customers safe. What is the best thing about being in the engineering industry? For me personally it is the hands-on side of things. I love to be involved in all kinds of projects, such as rebuilding crashed damaged bikes. This industry has allowed me to be exposed to all sides of the field from the small things such as fixing damaged cosmetics to the complicated side such as completing an engine rebuild.
I have always had an interest in being hands on, fixing things and finding out how things work. So when I was asked if I wanted this opportunity there was no way I could decline. What advice would you give to any woman looking to do an engineering Apprenticeship? I highly recommend just going for it. I was hesitant at first but as I progressed at Poultec and at my workplace all my doubts disappeared. I grew confidence and love where I am at today. Ignore any doubts and just give it a go, you may surprise yourself! What achievements have you had within engineering? So far I have completed things I never thought I was capable of doing. At the beginning of 2020I had no idea how to repair certain issues on a motorbike or
What is it like being a female in engineering? Although I know it can be hard for women to find their footing in an engineering environment due to stereotypes, I have been very lucky. I am treated no different in my workshop and feel like part of the team just as much as anyone else. Why did you choose to become an engineer?
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what a specific service entailed. Now I can confidently diagnose and rectify most problems with the bikes that come into our workshop. Recently my colleagues have been showing me the steps of an engine rebuild so when the next one comes in I will be doing it solo handedly. Why is it good to smash stereotypes? In today’s world people are becoming more open and accepting of things. It’s still rare to see a female in the engineering industry but it is becoming more and more popular, and I think that’s a very positive thing which I am proud to be a part of. Why do you think it’s good to raise awareness about women in engineering? This allows women who may be hesitant to start their journey in the industry to realise that it is okay to not follow the stereo type and if it’s something they want to do, there are other women out there who can advise them or even inspire them to pursue their ambitions. Why are you proud to be a female engineer? I am proud to be a female engineer as when people ask what I do they are usually surprised but then congratulate me for doing what I want to do and not letting stereotypes stop me. This gives me a sense of achievement along with all the skills and knowledge I can now use throughout my life and future in the engineering industry. ■
WO M E N I N W E L D I N G
Women and self employment New research has revealed that the Manufacturing industry has the 7th lowest percentage of self employed women in the UK, with only 23.6% of the industry’s self employed workers being female. The research analysed government data to discover the industries that are seeing the most (& least) female entrepreneurs. The electricity, gas and air conditioning supply industry is exclusively ruled by men, with no women self-employed within the industry, compared to 9,000 men. The construction (3.9%), transport and storage (6.9%) and mining and quarry (9.1%) industries also have very small numbers of self-employed women, instead being dominated by men. The number of self-employed women in the UK has increased by 148% since 1984 ● 18% of females have considered starting their own business, according to new research ● In 1984 there were 646,000 women in self-employment in the UK. Fast forward to 2020 and that number has increased by 148% to 1.6 million ● South East Scotland and Edinburgh are the best locations in the UK for female entrepreneurs ● The health and social sector has the most self-employed females, with 74% of self employed people in the industry being female According to the research from Tide, CLICK HERE around 1 in 5 women (18%) have considered starting a business, which is lower than the number of men who said they have considered forming their own company (29%). Of those who have thought about starting their own business, the most common reason why they haven’t is a lack of savings or financial concerns, with women usually likely to start a business while either working part-time or after a career break, unlike men who usually start a business while working full-time and on much firmer financial footing. Edinburgh and South East Scotland takes the crown for the most female founders in the UK with 35,000 female founders making up 39% of self-employed people who are female. Followed by the North of Tyne region which includes Newcastle upon Tyne and the West of England, which includes Bristol (both 34.7%). ■
Rank Industry
Self-employed (male)
Self-employed (female)
Percentage of self-employed who are female
Electricity, gas, 1 air cond supply
9,000
0
0.0%
2 Construction
905,000
37,000
3.9%
Transport and 3 storage
298,000
22,000
6.9%
Mining and 4 quarrying
10,000
1,000
9.1%
Water supply, 5 sewerage, waste 10,000
2,000
16.7%
Agriculture, forestry and 6 fishing
135,000
36,000
21.1%
7 Manufacturing
178,000
55,000
23.6%
Information and 8 communication
170,000
54,000
24.1%
Financial and insurance 9 activities
74,000
24,000
24.5%
Wholesale, retail, repair of 10 vehicles
268,000
131,000
32.8%
I don’t have enough savings/finances
6%
The risk is too high I already run my own business
15%
35%
I don’t have the confidence Other
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20% 24%
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WILL WE FACE REDUNDANCIES OR RESIGNATIONS WITH THE REMOVAL OF FURLOUGH? It’s a strange world in which we now live, pandemics aside despite their horrid impact, we appear to have found a new confidence in the art of central government control and responsibility. For most of my business life, the British Parliament has tried to decentralise decisions moving their impact and consequences further away from centre to the regions, but more recently have appeared to relish in the delight of direct delivery. Recent funding arrangements post Covid have required the direct submission by Local Authorities endorsed by MPs, rather than the considered opinion of the region delivered by 38 LEP’s. The recent Levelling Up Fund bidding in particular will see some 343 unvetted bids direct from Local Authorities versus 38 fully vetted bids from independent LEP’s being submitted to Government, which sadly will slowly grind to a halt under such a deluge of paperwork. There suddenly appears to be a new found wealth that is driving this desire for closer proximity to the electorate. Whilst billions of pounds have been set aside to support the Covid pandemic and facilitate growth post pandemic, we appear to have found a new confidence in our ability to fund activities despite the level of debt shouldered by most G7 countries. Has our Government gone “Crypto” is the Britcoin a reality to follow the unfettered Bitcoin? Whilst I applaud the support for many businesses provided by Government during Covid, is there a plan at any time afterwards to balance the books? Will we be faced with redundancies or resignations following the removal of furlough? We are riding high on state aid for our homesteads, but once the guaranteed income is removed will businesses reach that make or break tipping point and reduce their staff levels or will they equally be faced with a deluge of resignations in a restricted labour market? It is my belief that we are facing a false dawn. Remove the enforced Covid arrangements and the new normal will be business as usual. The Hospitality sector
in particular has been the first casualty resulting from the labour shortage created by Covid where many overseas workers have returned to the safety of their families in their native countries to see out the pandemic. Returning to the UK has been made much more difficult following immigration rules introduced in the meantime created by Brexit. This has skewed our thinking around unemployment in particular and will stimulate wage increases at this end of the employment market. Rising house prices resulting from a greater appreciation of the countryside and the need for social distancing, home working offices and a garden, will place greater pressures on many other employers to increase wages. The more than a million empty homes in England and the more than one million homes with planning permission yet to be developed, might become the new wasteland of
oversupply, once the impact of higher wages finds its way to consumer pricing, driving up inflation. Those with the requisite skills will benefit from this “brave new world” ahead and really should take the opportunity to take the offer from the highest bidder to support their families new way of life. Indeed many may love the option of continued home working and others may desire a return to the old ways which may also be the arbiter of change for the future. The people will decide what is right for them and the companies likewise. Decisions around redundancies have been clearly delayed by the furlough scheme, but soon these decisions must be made as we near the opportunity for the resumption of normal service by business and the various safety nets are removed. And at the point where obfuscation becomes the order of the day, is this the moment when devolution makes more sense again? Will we see a return of decision making back to the regions once the money supply tightens and pleading poverty becomes the new order of the day? The Government will likely have little choice. We are very likely to see rising inflation, higher levels of unemployment a spate of Company closures and a continuance of some Covid measures as public sympathy for Government turns to enmity. We will require structured tendering from Regions once more as the political blame game starts again and Government hastens its departure from their previous decisions. Business as usual following the release of pent up demand will return with vengeance and it will fall to businesses across the land to foot the eventual bill for the necessary profligacy that the pandemic has incurred. It’s time to create the action plan wherever you sit in all of this and make the right play in what will be a new way of operating for us all. Adrian Hawkins OBE Managing Director, Welding World Ltd managing.director@welding-world.com
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Gary (right) his son Elliott (left) and graduates of our first group in Derby
Betterweld - Specialists in fabrication welding training Gary Gwynne has become the face of Betterweld and their specialisation in fabrication and welding and his role as a key trainer of future generations is already well known. Here we caught up with him to discuss the training of future generations, their link up with Free2Learn and his philosophy of giving everyone of any age the chance to break into the industry. “My background is as a trainer of engineers, particularly welders. I have been involved in the education and training of welders, fabricator/welders and welder/fabricators of all capabilities during a 32 year teaching career. During this time I have maintained a closeness to the industry and I have come to understand the issues faced by owners of fabrication businesses and the obvious skillsets and lack of skills which are apparent in an industry that is devoid of 10s of thousands of skilled people. “Betterweld was formed with a view to helping to bottom fill the industry with people with the desire to learn the practical skills involved with working in the fab/weld sector. We deliver a training programme that targets over 19 year oldswho are
unemployed with the objective of delivering via our training programme enough skills to be able to make a start in the industry. Currently 52% of those people who complete our course are helped into work with ongoing training. The big issue with the industry is lack of people with proper skills and education. “Our aim is to move our students into employment with ongoing training, we call this an adult apprenticeship. What we are doing with Free2learn is enhancing the pathway to higher education. “I am a massive believer that it is not just enough to be able to do something, you have to understand it as well. If you can have the skills to do something and understand the process then you have produced skilled people, problem solvers with the ability to reason things out and to be able to adapt and transfer their skills into different situations and that’s what engineering is all about. This is infinitely different from being able to complete repetitive tasks in a production environment. The industry is currently missing people who understand the theory and whom also have the level of practical skills required.” What we are doing with Free2learn
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is enhancing the pathway to higher education. In order to rectify this Free2Learn along with our help and sector knowledge and experience are developing Level 4 and 5 courses (HNC and HND) to further enhance the opportunity for our students to develop the advanced knowledge requirements. Post completion of a Level 4 course pathways are being developed with local universities. Derby University have agreed to provide access to Engineering degrees for our students who complete their access course to higher education. Meetings have taken place around this and the necessary planning and resources are being allocated by Free2Learn to make this potential pathway from Level 1 to 5 a reality. “Our joint aim is to better educate those people currently in post and provide opportunity for those wishing to work in the fab/weld industry to access structured progressive personal development pathways for the good of the industry. Successive governments have focussed on school leavers going to university and not on something which is seen as bit of a dark art. This has been going on for 20-25 years; lots of graduates have completed
N E WS their degrees and having studied hard, accumulated personal debt along the way they quite rightly seek higher end, higher salaried employment. Consequently there appears to be a void, with people not wanting to train in manual trades such as welding. As a business we have the need to remain current and aware of the demands being placed upon our employers such as BSEN 1090 CE marking, coded welding requirements, Welding Quality Management. To achieve this we have a dedicated sales force that engages on an hourly basis to discuss all issues fabrication and welding related. We are a Gold standard supplier of Weldability Sif products enabling us to provide the total solutionincluding machinery and consumables that our customers need. “I have been in this industry all of my working life,” said Gary. “The prognosis is good with investment being made in HS2 and nuclear power stations and there is more of a political emphasis on the skills side and more money is being committed in the right areas. There are certainly more apprentice opportunities and although it may take 10 to 15 years we will see the real benefits of this. “ A sure sign of this is evident in Hackney and Derby where they have 50 people every 7 weeks joining training courses and then 52% going into work with continued ongoing training afterwards.Indeed the demand is clearly there, and as Gary points out there are enough projects now in the pipeline for starters to work on. Welding is a very diverse sector where people can work on construction projects, road and rail transportation, aerospace, petrochemical food production and pharmaceuticals. Looking at the key qualities required, Gary says: “What sort of person succeeds? I always think that those in training should demonstrate a good work ethic, be somebody that is reasonably analytical, have a reasonable level of mathematics and scientific principles and communicates well. If they have that then we can teach the rest. “I always speak to our unemployed groups and ask them to tell me what they are expecting, in terms of work, qualifications and pay because if you want to work hard, are punctual and honest, then you’ll get what you want. If you are employable an employer will always train you to do a job.”
So what can someone expect across a six week course? Gary begins with online professional development and employability skills such as interviewing and good CV writing followed by an intense 5 week programme of training relating to working in a manufacturing environment with the emphasis on developing a minimum of 1 welding process eg MAGS welding. The focus is on getting trainees ready to work in a manufacturing environment and about the processes involved in working safely in a fabrication and welding company. Upon completion of the course our students are safe to work on a shop floor and would be able to make a reasonably good job of joining two pieces of metal together. In addition to having received a bespoke period of industry related training future employers will benefit from skills, knowledge and experiences gained by our students from previous employment. Why wouldn’t employers want to benefit from somebody else’s prior investment? With the combined efforts of Free2Learn and Betterweldsupporting our graduates and given the current dearth of skilled and qualified people we encourage employers to take ownership of their staffing issues and embrace the opportunity to grow your own; it’s good for the employer, it’s good for the employee, it’s good for the economy and most importantly it is the beginning of the end of the threat of lack of business continuity. A few years back Gary was asked by
someone whom he has the greatest respect for “surely you want to make a name for yourself.” His response being “no, but I do want to make a difference”, a fact backed up with many case studies where people have gone from claiming benefits of £70 per week to earning upwards of £300 per week. “As recently as June 18th 2021 a 63-year-old man who was unemployed and attended our training course in Hackneysuccessfully applied for a role which now sees him being paid £38k a year. Gary points out that “this is the whole point of what we do and why we do it. This just isn’t about youth, a 40-yearold might have 30 years of work left, I say they have good years to give and are important to the ongoing development of a skilled industry. Betterweld and Free2learn are clearly aligned in how they think as they want to make a difference with the people they are training and help with the education they receive. Gary’s final say is one of inspiration “Free2Learn and Betterweld have embarked upon a venture to develop lifelong opportunities, our commitment to the industry remains total supported by a planned schedule of investment currently across 2 cities, London and Derby with plans to develop a further site with the same level of quality learning environment and a full and achievable pathway of CPD opportunities for those who commit.” ■
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CRONER ADVICE Croner help over 14,000 businesses in the UK stay compliant, safe and successful. Here are some of the top issues they are facing right now: Conduct England has only just eased restrictions, while some remain in Scotland & Wales. That means many businesses will have just experienced their first month with full staff back in the workplace. This can be difficult for many as old tensions come to light and rivalries are reforged. The last thing you want, as an employer, is to deal with a grievance or disciplinary having only just returned to normal. We’ve seen a significant rise in queries from our clients regarding staff conduct—luckily, if dealt with early, you can stop them from escalating. Contracts Another issue that has become apparent
as people return to work is employment contract changes. Whether you need to change working hours, accommodate a flexible working pattern, or change location of work, these are all contract issues. Changing a contract without the consent of the affected individual can have serious consequences, even resulting in a claim of constructive dismissal. Include your staff in discussions regarding changes you are planning to make, no matter how insignificant the changes may seem. Furlough & Redundancy As the furlough scheme comes to an end, many are having to make difficult decisions to ensure the survival of their business. There is still some time left to take advantage of the Government’s Job Retention Scheme, but it’s important to plan for structural changes to stay afloat if your business is struggling. In some cases, that may mean
Expert support If you need further guidance on any of the topics raised above, you can receive free advice via your membership. Call 01455 858 126 today and quote Assoc No. to receive expert HR support.
Subcontract friction welding: efficient
Rotary friction welding _bi-metallic materials
KUKA’s subcontract friction welding capabilities cover many material combinations including similar and dissimilar material welding, and geometry options including bar to bar, tube to bar, bar to plate, tube to plate and tube to tube, for example. Commonly friction welded components include safety critical components such as axles, drive, beam & half-shafts, drill rods & pipes consisting of nitriding and structural steels, piston rods constructed from chromed rods and forgings as well as hydraulic cylinders and end caps, plus, stainless steel to mild steel pump shafts plus many more. Dissimilar bi-metallics such as copper-aluminium
redundancy. However, you must ensure you have explored all alternative options before settling on redundancy. And, you must carry out a fair process. That means allotting the correct amount of time to conduct a consultation and provide enough notice. Don’t wait until the last day of furlough to make big decisions, as it may cost you.
cable lugs and connectors as-well as stainless steel to aluminium, stainless steel to copper and double joints including, stainless steel to aluminium to titanium for high pressure and cryogenic applications. Friction welding is a solid state forging process which uses friction and forge pressure to join two parent materials across the entire interface Discover more: contact the KUKA subcontract team at: T: 0121 585 0888 E: frictionwelding.uk@kuka.com www.kuka.com
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The question that engineers and manufacturers ask when considering their production joining and manufacturing processes is can we do this better, cheaper and more efficiently? Joining similar, dissimilar or exotic materials directly to each other with a high integrity bond is the holy grail of industrial manufacturing. The benefits of achieving this is to reduce cost, increase quality, efficiency and reliability. All are major considerations for OEM’s competing in the global marketplace and who need to establish their positions with innovative, quality and cost-effective products. Friction welding processes provide an efficient and sustainable method of achieving high integrity similar and dissimilar material bonds. Friction welding processes play an integral role in manufacturing today. It can be used to improve performance, reduce waste and increase product effectiveness. KUKA’s subcontract friction welding solutions enable manufacturers to access friction welding technology, enhanced quality assurance, efficiency and repeatability. KUKA Systems UK Ltd 0121 585 0888
Out of the Box Such is our confidence in this technology we offer an unparalleled 5 year full warranty on all models
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PIPELINE THROUGH THE FENS As Welding World is a digital interactive title we thought our readers would be interested in Pipeline Through the Fens (1968) - extract which has been released by the BFI and is available to view on Youtube.
It’s time to test your knowledge with five multiple choice posers set by our quizmaster extraordinaire Dave Ellwood WWA/AWD board director. Just click on the quiz and using our digital interactive technology see if you can make it five out of five first time. Good luck, and if you think you have five burning questions which could provide a tough test email us at editor@welding-world.com
Click on the image here to be taken back in time. It features a pipeline which ran from Kings Lynn to Peterborough via Wisbech. The contractor was Lang Pipelines
UK and it is believed all work took four months in total. If you worked on that project we would of course love to hear from you. Email editor@welding-world.com
QUIZ 2021 Round 4 CLICK HERE TO PLAY
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NEW PRODUCT
EUROPURE PLUS 5500 – TH3 PAPR
TRAIN THE TRAINER UK MASTER INSTRUCTOR COURSE
Date: 25-29th October 2021 Dansom Ln S, Hull HU8 7LA Venue: HETA 27-31 www.heta.co.uk
MMA
Powered Air Purifying Respirator TH3 Class
Lincoln Electric respects and values the welding instructor whose knowledge and enthusiasm for the profession helps to inspire and motivate future generations of welders. As part of our commitment to offer training to help welding instructors to do what they do best, we are delighted to announce the following events scheduled to take place over the coming year.
MIG TIG
As part of our upcoming educational partnership program, we are accepting applications to attend our Train the Trainer – UK Master Instructor course. This week long course highlights; Welding Principles, MMA, TIG, MIG and FCAW processes, aiding the instructor in course delivery. Our UK Master Instructors will be given the means and method, to deliver our Train the Trainer course to others wishing to develop their teaching ability. For those interested in this exciting opportunity please contact educationuk@lincolnelectric.eu for more information.
FCAW
WELDING PRINCIPLES
28th September 2021 9th November 2021 18th January 2022 1st March 2022 10th May 2022 21st June 2022
Submerged Arc Technology Advanced MIG Processes Utilizing Modern Technology in Welding Education Developments in Welding Consumables Utilizing Automation in Welding Applications Insight into MIG Wire Manufacturing
Running at our fully equipped Welding Technology Centre in Sheffield, these single day sessions are free of charge and exclusively for welding educators. Numbers for the sessions are limited so contact educationuk@lincolnelectric.eu to check availability today.
MIG LE-S8-21EN-M970
In the coming months Lincoln Electric will be also hosting the following CPD training sessions:
www.lincolnelectric.eu
FEATURES ADF
FEATURES PAPR
• Optical class: 1/1/1/1 • Viewing area: 8 025 mm2 • Lens switching lens: 0,04ms • Lens shade: 3.5/8-13 • Independent sensors: 4 • TIG Amp rating: ≥ 2A DC & ≤ 2A AC
• 5-6 hours working / 9-15 Extended battery • 1 Hour Battery Charge • Auto-alarm System • Real-time Display Indicator • Filter Efficiency ≥99.97% – Multi-layer filtration with particle box filtration provides efficiency of up to 99.99%. The TH3 filtration prevents siphoning in toxic particles, soot and other contaminants for a safe and refreshing breathing experience.
BENEFITS • TH3 Class • Optical class: 1/1/1/1 • Viewing area: 8 025 mm2 • TIG Amp rating: ≥ 2A DC & ≤ 2A AC • Filter Efficiency ≥99.97%
Respiratory protection
Comfort
Arc sensors
Lens switching speed
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TITANIUM
400 AMP AC /DC HF TIG Feature-rich Advanced Technology TRACEABILITY - weld data capture E-TIG - constant bead SYNERGIC CONTROL - optimum welding parameters MULTI-TACK QUICK LOAD MULTI JOB DEMAGNETISATION FAST PULSE Fast Pulse (up to 20Khz) See video below.
NO.1 MANUFACTURER OF INVERTER WELDING EQUIPMENT IN EUROPE WORLD LEADER IN CAR BODY WELDING EQUIPMENT
01926 338 609
uk@gys.fr
www.gys-welding.com
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LIGHTWEIGHT ALUMINIUM CONSTRUCTION FOR INDUSTRY: ACCESS SOLUTIONS FROM ALTEC in the fields of aluminium welding and processing, he took over as plant manager of ALTEC in 2019.
PMC Ripple Drive makes it possible: unmanipulated robotic welding by vertical up seam, vertical down seam, and flat position. At the same time, the result is fine seam rippling that is in no way inferior to TIG applications
ALTEC manufactures a wide variety of largely aluminium scaffold-based access solutions, such as aircraft docking systems, by relying on welding technology from Fronius. With the CMT welding process and the Rippledrive pulse characteristic, ALTEC’s industrial production lines are fully equipped for future challenges. It is not only in lightweight automotive construction or aerospace technology that aluminium is a byword for dynamism and pushing the boundaries of accepted engineering limits. It also facilitates everyday life wherever large structures have to be moved by human hands, such as the diverse range of access solutions offered by ALTEC Aluminium-Technik GmbH & Co. KGaA. The medium-sized enterprise from Mayen in the western German state of RhinelandPalatinate has an extremely broad product portfolio: from rolling scaffolds, facade scaffolds and flat roof fall-protection systems to complete docking systems for the aviation industry and numerous special solutions. These include mobile maintenance stairs, working platforms, transitions or platform stairs for industrial applications. Certified welding company with the latest technology
In ALTEC’s warehouse, precious aluminum glints and gleams as far as the eye can see
Up to 95 percent of the metal processed and welded on ALTEC’s production lines is aluminium. Steel applications account for just five percent. Yet as a specialist welding company with EN 1090-1 and 1090-3 certification, ALTEC and its 50 employees can master even the most complex orders thanks to 35 years of experience in welding aluminium components. In order to be able to meet its customers’ demands, ALTEC has always relied on pioneering process and manufacturing technology, despite its relatively modest size. “This includes state-of-the-art CAD workstations as well as fully automated robotic welding cells and the associated high-tech welding process technology,” explains Siegfried Berenz, a certified master metalworker and international welding specialist (IWS). Having spent the past 15 years being primarily active
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Fronius welding technology moves in at ALTEC As part of an ongoing automation process, a specific aluminium framework part (AlSi1, two millimetres) that has since become required in large quantities was to be transferred from manual production to robotic welding. One of the main goals here was to achieve a high welding speed in order to gain a competitive advantage. At the same time, the structure was to be joined with the greatest possible process reliability. As a specialist in thin sheet and aluminium applications, Fronius therefore had the opportunity to beat the competition in 2018 as ALTEC found the best possible solution for its needs with the Fronius CMT (Cold Metal Transfer) process. When deployed in combination with the high-tech TPS 320i welding system platform, CMT delivers particularly high welding speeds, especially in the thin sheet range. As a result, Fronius succeeded in establishing itself in ALTEC’s production operations.
The CMT process and PMC Ripple Drive pulse welding process variant enable ALTEC to weld aluminum thin sheet applications without difficulty. Welding in every position is therefore possible, with an outstanding weld seam appearance.
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At ALTEC, traditional robot technology is combined with state-of-the-art welding technology from Fronius.
As an international welding specialist (IWS), plant manager Siegfried Berenz is thoroughly impressed with robotic welding technology from Fronius.
After 25 years of automated production, however, other areas of ALTEC’s robotic welding technology were also becoming long in the tooth. Plant manager Berenz therefore made it his mission to ensure the company’s production environment was equipped to guarantee long-term competitiveness. Following the positive experiences gained with the CMT process, the welding expert once again turned to the German sales and service team at Fronius Kaiserslautern.
challenge. Due to the round style and the semi-circular fabrication of the rung, the unmanipulated welding operation would have to produce a vertical-up, flat and vertical-down seam in a single action. One process for all positional welds was thus a basic requirement. At the same time, there was a gap of two millimetres in the flat-seam section due to the pre-processing. Particularly high gap-bridging ability therefore also had to be ensured in the future process technology. In order to be able to clearly distinguish itself from the competition in the production of scaffold and framework structures, the future welding process also had to deliver the best possible weld seam appearance. And on this basis ALTEC started its search for alternative modernisation options.
Further manufacturing challenges for ALTEC In the case of the scaffolding system concerned, the outdated welding technology from a third-party supplier was now causing up to 70 percent rework due to a steady increase in weld seam defects. Time, material and labour costs were therefore no longer in proportion, and the advantages of robotic welding were being completely cancelled out. In addition, the weld seam appearance no longer came close to satisfying ALTEC’s strict demands. However, the production volume of the component was not high enough to justify investing in a modern robot system. ALTEC’s requirements were therefore clear – a new system would first have to be compatible with the old robot technology. In addition, the greatest possible process reliability had to be ensured, which would reduce downtimes to almost zero. If possible the system should also be capable of welding in a single action in order to reduce processing times; it was this target that represented the greatest
Conversion to PMC Rippledrive Extensive welding tests conducted at the Fronius Germany competence centre for application engineering in Neuhof-Dorfborn near Fulda ultimately led to a successful conclusion. The PMC Rippledrive welding process variant, a special characteristic used for pulse welding, represented the most suitable solution for ALTEC’s welding challenges. Rippledrive works in a way that is as ingenious as it is simple. Between a number of pulses defined by the welder, defined pause times are set in which the arc is completely switched off. This gives the weld pool time to cool down, making welding possible in all positions.
The necessary gap-bridging ability of two millimetres is also guaranteed without any problems. In terms of appearance, the Rippledrive function also leaves a rippling pattern that is in no way inferior to the elegance of TIG welding. The Pulse Multi Control (PMC) functions also allow the number, shape and size of the individual welding spots to be set by precisely defining the pulse currents. The TIG-like seam pattern can thus also be varied in its final execution. TPSi compatible with all robot systems However, ALTEC also had to deal with the problem of connecting the welding technology to the robot. The task now was to mate the newly acquired TPS 320i digital high-tech welding system platform and the Fronius Robacta-Drive push-pull welding torch needed for the Rippledrive solution with the veteran but fully operational robot technology. ALTEC decided to take this step not least because of the wide range of fieldbus protocols (modern interfaces) available from Fronius, as well as the option of connecting the TPSi using conventional digital or analogue interface technology. This results in the extraordinary advantage that the TPSi is truly compatible with almost every robot. Furthermore, the high-tech power source is equipped with numerous standardised hardware and software interfaces for various robot manufacturers right from the start. This reduces the installation time required to integrate the power source into the robot system to a minimum. ■
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B OA R D M E M B E RS Brought to you by:
Welding World Ltd on behalf of the Association of Welding Distribution Adrian Hawkins OBE Managing Director Telephone: 07793 220800 E-mail: adrian@welding-world.com
Dave P. Ellwood Director & Company Secretary Telephone: 07860 258309 E-mail: dave@welding-world.com
Lee Darton Finance Director Telephone: 07734 857044 E-mail: lee@welding-world.com
Gavin Pearson, 5 Parsons Street, Dudley, West Midlands, DY1 1JJ. + 44 (0)1952 290 036 + 44 (0)1952 290 037 secretariat@awd.org.uk www.awd.org.uk Editor: Darren Isted editor@welding-world.com Design: David Walters Published on behalf of Welding World by: Tel: 07539 782979 Email: hdmdigitalsales@gmail.com www.hashtagdigitalmedia.co.uk While every effort is made to ensure the accuracy of this publication, the AWD, the editor and the publisher, Hashtag Digital Media, cannot accept liability for any statement or error, or for any claims made by the advertisers, contained herein ©Welding World 2020. They cannot be held responsible for the failure to use, or for the poor depiction of use of environmental, personal or other equipment, such as Personal Protective Equipment (PPE) and Local Exhaust Ventilation (LEV) equipment in photographs received from editorial contributors or advertisers. Best practice in the use of the correct and appropriate equipment is advocated and strongly recommended by the AWD. Hashtag Digital Media ensures that the paper used for printing this publication has been sourced from sustainably managed forests.
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PRESIDENT’S MESSAGE Well, it’s that time again, the month has flown by and it’s time for a moment’s reflection from an old and still surviving President. Another month into what has been a bizarre presidency with no real sight of getting back to normality. Brexit included. But what an interesting and turbulent time for Britain, as we embark upon the mammoth task of finding our new normal. Hinkley point C is tackling the skills shortage in the UK construction world, and with 50% of all man-made products requiring some element of welding, there is an increasing demand for welders. The construction of the nuclear plant is predicted to create a conveyor belt of training in up to 150 different roles which will benefit the industry for years to come. The same net zero campaign that is pushing forward a nuclear revival is set to continue churning out windfarms at a rate of 300 turbines a year, demanding skilled jobs in steel fabrication that will continue to create careers for years to come. Just goes to show opportunity is out there if you can see it and act now. The team at Westermans are running to keep up with demand, grabbing all opportunities we can and staying positive. Our brand new 20,000 square ft factory is on the horizon, a wonderful deal that we are most happy with and we are looking to the future. More than anything I am looking forward to spending some summer evenings with my family in my beloved garden, keep taking your tablets everyone, I’ll keep taking mine. Until the next time. PETER WESTERMAN President AWD
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LTI METALTECH ACQUIRES VESSCO ENGINEERING LTI Metaltech recently completed the acquisition of Vessco Engineering Ltd. The former owner of the Bridgend based company, Julian Vance-Daniel, will remain in the combined group in a senior Business Development role. The deal, worth £2.6m, will bolster their capabilities and facilitate access into a number of key sectors, including nuclear energy, oil and gas, utilities and food processing, having itself completed several prestigious projects including specialist fabrication assignments with Tokamak Energy & Reaction Engines. Founded in 2006, Vessco Engineering Ltd is a Tier 2 supplier to the turbine hall at Hinkley Point C, supplying large pressure vessels for GE Power Systems. The company, which employs 40 people on the Bridgend Industrial Estate, also has experience in oil & gas, power generation as well as water supply. LTi Metaltech is a major supplier to Siemens in the manufacture of pressure vessel components for its market leading
MRI Scanners. Under the leadership and direction of UK managing director, Edgar Rayner, LTi has broadened the scope and market reach of the £23m business including the hydrogen technology and aerospace sectors. The acquisition will enable them to accelerate their expansionary programme as they diversify the portfolio whilst underpinning existing capabilities in medical technology. Commenting on the acquisition, Edgar Rayner, said: “Vessco Engineering has built up a great reputation and we’ve had it on our radar for some time. We are obviously delighted to be able to bring
it into the LTi family where our combined resources and capabilities will help to broaden and strengthen our offering in a range of important industry sectors.” LTi Metaltech is based at Milton Park, Oxfordshire’s international business and science park, and has an award-winning reputation for design and innovation as well as for the quality of its premium fabrication services. Further information about LTi and Vessco Engineering’s precision fabrication expertise is available at: http://www.lti-metaltech.com/ https://vesscoengineering.co.uk/
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Carver Climate Systems Carver Climate Systems approached Foster Industrial with a specialist enquiry, of a bespoke welding set up to enable them to spot weld, for their new product line of air curtains. The enquiry was passed on to their technical sales manager, Steve Irwin, who visited the Carver Climate site to review and assess the project requirements, to find the best solution. THE ENQUIRY After developing a new product line, the Air Curtain, Carver Climate required a bespoke welding set up to enable them to spot weld cabinet chassis at depths of 600800mm, without the need for specialist jigging. They needed the ability to build and sell the product range in the UK, as opposed to procuring from outside the UK, to enable them to save on shipping costs. A well-designed solution was needed, in order to speed up production, to make the welding process run smooth. This therefore posed the challenge to find a unique solution, prioritising efficiency and reducing costs.
OUR SOLUTION After assessing the situation and understanding the requirements, the installation of the solution began. This included a 35KVA spot welder, a bespoke gun made for Carver Climate Sytems, by Sureweld, with the option of 600mm & 800mm arms available as requested, installed by our experienced engineer Tom. The gun is suspending by a counterbalance and hung from a 125KG Jib crane that was supplied an installed on our behalf by Pelloby Cranes. The welding cell was modified and made larger with the new welding bay curtains and rails and as sliding curtain door way, which was supplied by us through Tusker Industrial Industrial Safety. ‘’Had the pleasure of meeting Steve on site to review our new product application Foster Industrial were able to provide a turnkey solution to enable our existing area to be extended, Jib Crane & spotwelder to be installed whilst minimising disruption to the existing operation. The project from start to finish was managed without fuss and delivered on time which enabled our new production process to commence ahead of schedule” JASON BRUCE - CARVER CLIMATE SYSTEMS
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WHY CHOOSE FOSTER INDUSTRIAL? Fulfilling customers’ requirements, is always a top priority, regardless of the complexity of the solution. Sometimes this process isn’t straight forward, but Foster always strive to surpass expectations. If you have a unique request, or require some assistance in your welding processes, they’re always happy to help. Simply contact the team through a telephone call or email enquiries@ fosterindustrial.co.uk to start your process today. Or if you’re unsure on how you could improve your process, they also offer a free welding efficiency surveys. Looking at each process in turn, they’ll discuss, recommend & demonstrate the welding machine that offers best value in terms of productivity, budget & usability. They can assess your current kit, in terms of suitability, safety & effectiveness, looking at welding consumables along the way, with a view to improving your welding process end to end. After sales service is at the heart of their business, you will require continued support around what could be a significant change for your business. They’re always happy to assist. They are proud to have a team of knowledgeable experts and a range of premium equipment to fulfill clients request regardless of the complexity. With over 135 years in business, Foster are confident they can always supply the best solution for you. ■
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BOHS AWARDS The British Occupational Hygiene Society, a scientific charity and the Chartered Society for Worker Health Protection has once again recognised the outstanding contribution of the Health and Safety Executive by conferring on them the coveted Peter Isaac Award. The HSE’s PPE Task Force has been working tirelessly across the range of workplace health protection, including ensuring the quality of protective equipment for healthcare workers, through to practical guidance for a whole variety of workplaces. The Society has also recognised a range of other health protection experts for their contributions during 2020. Professor Noah Seixas, the Chief Editor of the Society’s world-renowned scientific and research journal Annals of Work Exposures and Health was given lifetime membership. The journal, which has been downloaded over a million times, became an invaluable reference point for researchers trying to understand what might effectively control the COVID virus. Neil Pickering, a Chartered Occupational Hygienist and HS&E Director, now a consultant, who this year was heavily involved in the authoring of a revised
Construction Health Risks Course and leads the Society’s Breathe Freely manufacturing campaign, has won the Trevor Ogden Award for his dedication and voluntary contribution to the Society. It recognises decades of volunteering in the furtherance of the science of preventing workplace health exposures. New professionals are also being celebrated by the Society, with Jessica Pearson of Armstrong Environmental Ltd winning the Early Career Occupational Hygiene (ECOH) Award for her essay on “The future of Occupational Hygiene”. In addition, the Ted King Award is to be presented to Jans Babkevičs of Syngenta and Tomas Gabor of Sysco Environmental, as the highest achievers of the BOHS Certificate of Operational Competence in Occupational Hygiene. HSE Specialist, David Towler scoops the David Hickish Award as the best candidate of the year in completion of the BOHS Diploma of Professional Competence in Occupational Hygiene. Professor Kevin Bampton, the Society’s CEO, commented: “Many people still have not heard of occupational hygiene. However, the last year has demonstrated
that the scientists and technical experts who practice are vital to saving lives. Many of this year’s winners are unsung heroes of the pandemic.” Occupational hygienists have been active in supporting a variety of workplaces to protect against COVID, as well as continuing to intervene and ensure measures are in place to protect against serious workplace exposures to cancer-causing substances like silica and protect workers from a host of occupationally derived diseases. “Without the work of occupational hygienists, such as our winners, our NHS and critical industry staff, we would have had insufficient workplace protection from the virus,” said BOHS President, Alison Margary. “Still more workers owe their health and the health of their families and loved ones to the skills and expertise of these people who enabled Britain to go back to work, while still ensuring a decrease in infection rates because of effective control of workplace transmission. The winners represent the best of the profession and discipline. They serve as an inspiration to all who seek to protect us against workplace diseases.” ■
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Red Dot Winner 2021 - Award for the revolutionary optrel swiss air blower respiratory protection system The revolutionary swiss air blower respiratory protection system from optrel has been awarded “Red Dot Winner 2021”. optrel was able to convince the international jury with the swiss air. This means that another optrel product has won an international design award, such as the optrel weldcap®, which won the Red Dot Award and the iF gold award, or the panoramaxx, which won an iF design award. The international jury of around 50 experts tested and evaluated all the products submitted according to various criteria, such as degree of innovation, aesthetic quality, utility and even functionality. According to the jury, the high degree of innovation of the awardwinning entries was striking this year. Whether cars, robots, medical technology or packaging - many of the awardwinning products solve current problems and thus contribute significantly to the further development of the global standard of living.
Slim, ergonomic, light as a feather. This is how the swiss air presents itself at first glance. A second glance reveals its technological leadership. The core element of this solution is a ventilated half-mask that completely covers the mouth and nose area and constantly supplies it with purified air (according to TH3 standard). A breathing space is created in the mouth and nose area which, thanks to positive pressure, supports the user in breathing and eliminates tiring breathing resistance. In this way, the user is in an “overpressure air system” which permanently protects the airways against contaminated air. The half mask, made of high-tech fabric, is designed in such a way that it can be excellently adapted to the individual thanks to a freely adjustable headband. This concept eliminates the need for time-consuming fit tests that are common with conventional half masks. Clean air is supplied through the Y-hose by a miniaturised blower system, which is
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comfortably carried by the wearing unit on the back. The filter unit is 45mm wide and weighs just 550g - a new record that leads to a significant reduction in neck and back pain. The intelligent control unit completes the system. UNIVERSAL APPLICATION The swiss air respiratory protection system is as versatile in its application as the tasks in industry, trade, construction, medicine or agriculture. For all activities where pollutant emissions such as smoke, soot particles, fine dusts, nitrogen oxides, ozone or viruses can be inhaled through the nose or mouth, the swiss air is the ideal respiratory protection. This respiratory protection system can be used completely self-sufficiently, allowing maximum versatility in combination with the appropriate manufacturer-independent work protection. Now available globally at all certified optrel dealers. ■
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Record, display, compare The ALX III Series Robotic Monitoring Software is designed to record, display, and compare monitored weld data. Connecting to a welding set or a robot-welding cell, it monitors the current, voltage and wire consumed in a weld and creates MS Excel reports of the monitored welds. The software displays weld data, a weld trace graph and project headings. The project comparison feature allows users to select saved projects and simultaneously display project welds for comparison. Weld graph traces The weld graph traces represent: • Amps • Volts • Wire feed The weld graph can display the data as individual plots and the zoom function allowing users to view the weld parameters in more detail. Scanning modes The software has two scan modes: • normal mode to run a single scan • comparison mode to run a scan using a saved project file as a template weld and records a series of scans to compare the recorded weld to the template
Recording appears in real-time on the weld grid and scan modes can operate with an external trigger to automatically start and stop the weld recording. Scan modes can also operate with moment switch type triggers to begin recording when a pulse signal is sent and includes a feature to swap switch inputs if required. Limits feature The software features a limit setting for weld comparison. Limits are calculated from the percentage values of a template weld and compared to the recorded weld, identifying if values are within the template percentages. • Records the number of times the limits were exceeded and the time the limits were exceeded • Limit indicator within the software changes from green to orange to red to visually show when welding is within or out of set limits Reports Saved weld project data can be used to create two types of MS Excel reports: • Basic report containing up to two projects • Analytical report showing up to ten project weld files allowing a comparison of welds against a template weld
Contact us for further information on our range of Weld Monitoring Software The Validation Centre (TVC) Limited, Unit 15, Brinell Way, Harfreys Industrial Estate, Great Yarmouth, Norfolk, NR31 0LU, UK. +44 (0) 1493 443800 sales@tvcalx.co.uk
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C A L E N DA R
FABTECH Announces Plans to Return to Chicago’s McCormick Place in September After in-person events came to a halt due to the pandemic, FABTECH will be the first large-scale manufacturing trade show to return to McCormick Place in Chicago, September 13-16. This announcement comes as the state of Illinois moves into its final reopening phase. Chicago will once again be the epicenter of the North American metal fabrication industry with the return of FABTECH. The event brings all aspects of the metal fabricating, forming, welding, and finishing industries together to showcase the technology, innovation, and solutions they provide. The economic impact of FABTECH is important to the industries it serves as well as at the state and local levels. “FABTECH is one of the largest events held at McCormick Place, bringing $73 million delegation spending to Chicago,” said Ed Youdell, President and CEO, Fabricators and Manufacturers Association, International. “Our last event in Chicago employed just short of 4,000 laborers with over 110,000 hours of work. This contributed $5.3 million dollars of labor to the overall Chicago workforce. We are looking forward to bringing these jobs back online. In addition, FABTECH will provide an important boost to the hospitality industry, utilizing over 40 hotels as well as many entertainment and restaurant outlets during the 19 days the event brings delegates to Chicago from set up through tear down.”
DATES FOR THE DIARY 2021-3 GLOBAL INDUSTRIE 6-9 September 2021 Eurexpo, Lyon. www.global-industrie.com/en
FABTECH
13-16 September 2021 Manufacturing trade show Chicago, US www.fabtechexpo.com
METAVAK
5 - 7 October 2021 Evenementenhal Gorinchem, Netherlands. Annual trade event for the metalworking industry https://metavak.nl
FABTECH facilitates connections between exhibitors and attendees in order to conduct business, share knowledge, and showcase the most advanced manufacturing equipment and technology in an unparalleled environment. Attendees will have the opportunity to explore three halls filled with cutting-edge technology, new product debuts, and firsthand product demonstrations from over 1,000 exhibitors. FABTECH has coordinated within state and local public health guidelines to develop a plan for return and anticipates more than 30,000 convention goers this fall. FABTECH is one of over 120 conventions planning to return to McCormick Place’s halls as a result of Illinois recently advancing to Phase 5 of the Restore Illinois plan – a framework to guide the reopening of the economy – which allows all industries to return to full operations without capacity restrictions. Phase 5 is based on progress made toward vaccine administration and allows for the return of all conventions, events, and activities across all industries. “As we move into the final stretch of our safe reopening strategy, I am thrilled to welcome FABTECH back to our beloved McCormick Place,” said Chicago Mayor Lori E. Lightfoot. “This announcement not only comes as great news to our local
WIN EURASIA
10 - 13 November 2021 Istanbul, Turkey. www.win-eurasia.com/en#
METALMADRID ’21
17 November - 18 November 2021 IFEMA, Madrid, Spain. The leading annual industrial show www.metalmadrid.com/en/
METALEX
17-20 November 2021 Machine tools and metalworking Bangkok, Thailand www.metalex.co.th/en-gb.html
MACH
4 - 8 April 2022 NEC, Birmingham, UK. Manufacturing Technologies Event www.machexhibition.com/
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manufacturing and hospitality industries, but our entire city, which has begun its journey of recovery from the COVID-19 pandemic. Conventions and trade shows like FABTECH are key economic drivers for Chicago and I look forward to welcoming back more of these events in the near future.” “We are proud to welcome FABTECH back to McCormick Place – one of many conventions making plans for Illinois this year as a result of our reopening,” said Illinois Department of Commerce and Economic Opportunity (DCEO)’s Acting Director Sylvia Garcia. “As our state is a major hub for advanced manufacturing – FABTECH offers an unparalleled opportunity to showcase hundreds of cutting-edge companies who have contributed to our COVID-19 response and who continue to lead on industry innovations. The return of FABTECH is also great news for our communities – with every convention powering jobs, reigniting tourism and supporting a strong economy.” McCormick Place is fully prepared and ready to welcome events back. As North America’s largest convention center, the entire McCormick Place Campus holds the Global Biorisk Advisory Council®’s GBAC STAR™ accreditation, the gold standard for clean and safe facilities. Attendee and media registration for FABTECH 2021 is open now. Visit fabtechexpo.com to register and obtain additional show details.
WELDING BRNO 2020
3 -7 October 2022 Brno, Czech Republic. International Welding Engineering Fair www.bvv.cz/en/welding/welding-2020/
EUROBLECH
25 – 28 October 2022 Hanover, Germany. 26th International Sheet Metal Working Technology Exhibition www.euroblech.com/2020/english/ exhibitors/exhibitor-hub/
SCHWEISSEN & SCHNEIDEN 11 -15 September 2023 Essen, Germany. www.schweissen-schneiden.com/ joining-cutting-surfacing/
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TIG WELD APPEARANCE AT MIG-MAG SPEED Complete demanding exposed welds twice as fast with the new MicorTwin welding process by Lorch. The new MicorTwin welding process by Lorch Schweißtechnik makes it possible to perform demanding exposed welds, which were usually still completed using the time-consuming TIG process, much more quickly and more easily by MIG-MAG welding. In addition to an outstanding weld seam quality, MicorTwin offers twice the welding speed and much easier handling than the TIG process. The TIG process used to be used in order to achieve particularly beautiful weld seams with even attractive chevrons in aluminium, stainless steel (CrNi) and thinto medium-walled steel applications. The challenge here is that the pure TIG process is time-consuming and cannot compete with the MIG-MAG process’ productivity. The new MicorTwin welding process by Lorch not only achieves twice the welding speed, but also even offers a weld appearance that lives up to the TIG welding results, as evidenced by a comparison of the weld seams. Comfortable dynamic settings make it possible to customise weld appearance and to choose from a range from fine to coarse chevrons for the weld seam. In particular parts such as frames (bicycles, vehicles), racks (tables, chairs, beds), and many other objects that depend on excellent exposed “visual” welds can be produced easily this way. Frank Knuf, responsible development welder at Lorch, says: “I never would have expected a MIGMAG process to be capable of producing such an outstanding weld appearance at such speeds.” Another advantage of MicorTwin is its simple handling. The welding programmes have been optimised for the entire area of application, allowing welding work to commence immediately without any elaborate adjustment of the welding parameters. This achieves perfect weld appearance without
losing the good control capacity of the MIG-MAG procedure. In particular in times of rising competitive pressure and costs, this solution offers great additional perspectives for companies. The prerequisite for the MicorTwin Upgrade is a MicorMIG system with the pulse process enabled. The MicorTwin is, therefore, available for all performance classes (300, 350, 400, 500 amp) of the MicorMIG Pulse series by Lorch. The innovative welding process is already part of the FullProcess package for new systems, without increasing the price. Existing MicorMIG Pulse systems (from the delivery year 2018 onwards) can be upgraded with the MicorTwin easily via an NFC-card. “The new welding process has enabled us to convert many applications where the required weld appearance was only possible using the TIG process before to the much more efficient MIG-MAG one now,” says Maximilian Hipp, responsible product manager for the MicorTwin at Lorch Schweißtechnik. In addition to the excellent weld appearance and enormous speed advantage, the procedure makes personnel deployment planning possible in a more targeted manner. Hipp continued: “The simple handling of the MicorTwin enables virtually any company to produce high-quality visually exposed welds at high productivity rates, relieving the burden on highly specialised TIG welders while giving MIG-MAG welders a new process that is simple but leads to the highest quality.” Some companies can even cease to keep double equipment at hand. The MicorTwin can achieve beautiful,
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even weld seams in particular in the connection of thin- and medium-walled sheets of 1-8 millimetres. ■
Finest weld seams at twice the speed with the innovative MicorTwin welding process by Lorch
The comparison shows that the MicorTwin (below) offers a weld appearance that lives up to the one produced by the TIG procedure (above)
The matching weld seam is only the push of one button away: The desired weld chevrons can be set from coarse (above) to normal, to fine weld chevrons (below) by the dynamic control
Even the finest weld seams in the demanding light-metal area (here: aluminium) can be welded easily and in outstanding quality with the new MicorTwin welding process
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INTRODUCING: The stunning new SYNSTAR 400TS from Cebora This remarkable H.D. Inverter based MIG/MIG PULSE power source offers outstanding performance and functionality supported by an industry leading operational duty cycle of 400 amps @ 100%. The CEBORA SYNSTAR 400TS sets a new standard for high production and industrial welding applications including perfect aesthetic and mechanical results on difficult to weld materials such as Aluminium and Stainless Steels. SYNSTAR 400TS has a sleek, ergonomic design fully complimented by the clear intuitive LCD touch screen control panel, featuring a simple select and adjust system to access all welding and operational parameters.
The optional pulse and double pulse upgrades allow the operator to achieve excellent results even on those specialist tasks. So there it is, Cebora have raised the bar with the SYNSTAR 400TS and offer these standard and optional features. So there it is, Cebora have raised the bar with the SYNSTAR 400TS and offer these standard and optional features. • 4 00 AMPS @ 100% DUTY CYCLE ( 40 deg C.) •D YNAMIC 4 ROLL WIRE FEED SYSTEM WITH COLOUR CODED 37mm DIA, ROLLERS •W ATER AND AIR COOLED OPTIONS
• TUNNEL COOLING FOR ELECTRONIC COMPONENTS • MIG SHORT • MIG MANUAL • MIG PULSE (optional ) • MIG DOUBLE PULSE ( optional ) • MMA • INTUETIVE LCD TOUCH SCREEN DISPLAY • ECO HIGH YIELD POWER SOURCE ( PFC ) • USB AND RS232 PORTS FOR SOFTWARE UPDATES • COMPLIANT WITH EN-61000-3-12 STANDARD Ask your local welding distributor for price and delivery, demonstrations available at the discretion of Weldfast UK MWA Ltd.
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Breathe Clean, Safe Air – Even in a Crowded Room During the push for “pre-pandemic normalcy” as we slowly drift back to the office and school, it is imperative that we continue to push for wellness and safety. Sitting in crowded rooms is something that still feels alien to many of us and the thought of pollutants hanging in the air – biological or otherwise – in enclosed spaces is at the forefront of everyone’s mind. In fact, recent studies have emerged proving that the indoor air quality where we spend most of our time can be 7 times dirtier than outdoors. While natural ventilation from windows and open doors has been recommended from the start, it is clear that this is insufficient as a form of protection against circulating coughs and colds. The common practice of favouring open windows over air conditioning, particularly as we approach the colder months, is notorious for collecting and then spreading bacterial and virus particles. However, it is horrifying to learn that even without recirculation via airconditioning, viruses and other particles released while sneezing can hang in the air for up to 45 minutes. With this in mind, Extractability have carefully selected three new air purification systems to offer to the UK market, specifically designed to clean pollutants such as dust and germs from the air in indoor spaces. It is possible to find impurities such as PM1 particles, VOC and Formaldehyde that threaten human health in the indoor environments where we spend most of our time. This is a huge health issue that is largely still to be
addressed, particularly with the realisation that better air quality is linked to a longer, healthier life, better immune system, and higher efficiency. This is where air purification can help. In NASA’s study on filtering particles a nanometre in diameter, they found that particles of very small size, such as coronavirus, and many other nano-sized particles can be captured by HEPA Filters. These air purification systems have been carefully designed with HEPA filters in place to cleanse the air from the following: •P M1 - Viruses, industrial emissions, vehicle exhaust emissions and some bacteria fall into this class. •P M5 - Particles with a size of 1-5 microns. The vast majority of bacteria fall into this class. •V OC Compounds - VOCs can come from a wide variety of sources. Cleaning products •a re the most known sources. • F ormaldehyde Components - CH2O is a compound with formula. It is usually exposed from carpets, rugs, and upholstery. •P M10 – They are particles between 5-10 microns in size. Pollen and many allergens fall into • this class. •N O2 Gases - NO2 gases are gases released from many industrial processes and exhausts •o f diesel vehicles. The filtration of PM1 particles is particularly significant because while we know that the human body is capable of holding coarse particles in different parts of the body
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without them getting into the bloodstream (we can hold PM10 particles in our throat and PM2.5 particles in our lungs), PM1 particles penetrate our bloodstream and cause serious diseases. Extractability are pleased be the exclusive UK suppliers of the Viroline and BOA Air purification systems designed to cleanse the air we breathe to ensure the safest indoor environment possible. The Viroline system is based on a two-stage filter concept. The contaminated air is guided through a microfilter into the stable housing. In the housing, the germs are efficiently eliminated by means of a highperformance UV-C lamp. It can be easily suspended from the ceiling or affixed to the wall as a handy space saving measure and covers up to 700 m³/h. The BOA Air Midi and Maxi systems use G4 class pre-filter to capture coarse particles, Activated Carbon Filter to capture VOC, Formaldehyde and Odours and H14 class HEPA Filters to filter very small particles such as PM1s. These systems cover up to 900 m³/h and 3000 m³/h respectively. The possibility of returning to classrooms, gyms, offices, and other work areas that have not only had surfaces sanitised, but the captive air purified is fantastic for peace of mind as well as health and wellbeing – reducing sick days and promoting efficiency. If you are ready to take the steps towards addressing the polluted air in your immediate environment, contact Extractability on 0345 130 7757, sales@ extractability.eu or visit extractability.eu for more details. ■
ARE YOU LOOKING FOR EXPERIENCED WELDERS? WE HAVE THE SOLUTION! At Free2Learn we are dedicated to tackling the global skills shortage in the fabrication and welding sector by training people wanting to enter the industry and giving them the opportunity to achieve an entry level accredited qualification enabling them to be safe and usable from day 1 of their new employment. In partnership with the Government agencies such as DWP, Free2Learn has developed a SECTOR BASED WORK ACADEMY PROGRAMME (SWAP), a specific manufacturing training course with an emphasis on MIG/MAGS welding skills. The programme is designed to help improve job prospects for those of our learners who demonstrate throughout their 3 week course aptitude, attitude and ability. We can identify these people and arrange with you to interview them helping you to fill your vacancies. We at Free2Learn have invested in providing the largest and best technical training centre in London for welding training. Our tutors are professionally trained and qualified experts taken from industry with working knowledge and coded skill sets across all welding processes, on all material groupings and in any welding position including pipe welding techniques. As an employer in this specialist sector, we want to begin and maintain a working relationship with you and invite you to contact us to discuss your particular recruitment needs. We also encourage you to visit our training centre in Hackney, London and meet our Team and view our facility. To make an appointment please contact: Lesley.wolf@free2learn.org.uk 07403747452 Lesley is our Employer Engagement Officer
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The Tetrix XQ delivers a unique welding experience Powerful, durable and easy to use – the new Tetrix XQ 230 from EWM delivers TIG welding at the highest level. Users benefit from state-of-the-art technology and achieve optimal welding results with perfect weld seams. In designing the new machine, Germany’s largest manufacturer of arc welding technology put particular emphasis on improving user-friendliness. The new controls with a 7-inch colour display are particularly well-arranged and intuitive to use, which makes setting parameters easier than ever. Welding tasks can be individually programmed and accessed again any time. The Tetrix XQ 230 is incredibly powerful and can be run directly from a single-phase 230 V power socket, which makes it very versatile in use. An ergonomic and robust casing and compatible accessories round out the innovative concept. With the new Tetrix XQ 230, EWM AG is offering its customers an unparalleled welding experience. The TIG welding machine is enormously powerful thanks to a current of up to 230 A. Furthermore, it can be connected directly to a singlephase 230 V power socket. Whether at the construction site or in industrial settings, the welding machine allows for continuous operation even on weak grids, with long mains leads or when in generator operation. Depending on the welding task, the user can choose from numerous TIG and MMA functions. Up to four pulse variants are available. Users benefit from ideal welding properties with a significantly more stable arc and optimum weld seams. The Tetrix XQ 230 is available in DC and AC/DC variants, so it covers a broad spectrum of applications. Different materials can be welded perfectly: from low and high-alloy steels, to aluminium and aluminium alloys, all the way to nonferrous heavy metals and titanium. The spectrum of applications ranges from the food industry to aerospace, from the chemicals sector to mechanical and plant engineering, not forgetting the metalworking trades.
With the new Tetrix XQ 230, EWM AG is offering its customers an unparalleled welding experience. Users benefit from ideal welding properties and versatile applications.
The new Expert 3.0 controls are operated by click wheel and are particularly user-friendly. The high-resolution 7-inch colour display shows all the parameter settings and flow diagrams.
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P R O D U CT N E WS EASY AND INTUITIVE TO OPERATE One particular advantage of the new Tetrix XQ 230 is its user-friendliness. Operators can choose between the proven Comfort 3.0 controls or the new Expert 3.0 controls with a highresolution 7-inch colour display that clearly shows all the parameter settings and flow diagrams. All functions are directly accessible and lots of illustrated instructions and quick menus provide additional support when operating the machine. The controls can be precisely set with the ergonomic click wheel. EWM deliberately designed the machine without a touchscreen, to make it convenient to operate even while wearing welder’s gloves. The user can programme five individual welding tasks as favourites and access them simply at the push of a button.
The Tetrix XQ 230 can be optionally equipped with the Cool XQ cooling unit, welding torch and trolley for transport at the construction site or in the workshop.
CLEVER DESIGN DOWN TO THE SMALLEST DETAIL A number of other details help to improve work processes. For example, the operating status is displayed at all times on the integrated LED status bar. The ergonomic design of the TIG welding machine allows for safe and easy work. The robust construction also makes the machine suitable for use in rough environments. The controls are protected against contamination by a cover cap, but the machine can still be operated with the cover cap closed. Another plus: the very lownoise, temperature-controlled fan with optimised air flow. The Tetrix XQ 230 can be optionally equipped with a cooling unit, welding torch and trolley for transport at the construction site or in the workshop. The water-based cooling system Cool XQ allows for continuous use of the welding torch even at high welding currents, under extreme workloads or unfavourable ambient conditions. ■
Thanks to the water-based cooling system, the welding torch can be operated continuously even at high welding currents and under extreme workloads.
Further information on the new Tetrix XQ 230 is available on EWM AG’s homepage
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Fronius Battery Charging Technology with Five-Year Product Warranty:
Reliable Availability of Forklift Fleets Guaranteed
Fronius offers a five-year warranty on all its battery chargers— including for the new SelectION product family, which was developed specifically for operation with lithium-ion batteries.
Reliable intralogistics form the backbone of many industrial and trading companies because they help to ensure that the required goods arrive in the right place at the right time and in the right volume. Electric forklift trucks are frequently used for internal goods transport. High availability plays a key role in their operation because this is the only way to ensure that unplanned spikes in workload can be accommodated. High-quality battery charging technology helps to maximise the availability of the forklift trucks and ensures that the forklifts are ready for operation at all times. Battery charging specialist Fronius Perfect Charging has been relying on maximum quality for more than 75 years. Battery chargers are confronted with a wide range of conditions during operation. “We don’t want to leave anything to chance and we test our battery chargers in our in-house laboratories. In these tests, they must remain reliable under various environmental influences and in various usage conditions. Only once we are certain that our devices meet higher criteria than those stipulated by conventional standards can they be supplied to our customers,” says Patrick Gojer, Business
High-quality battery charging technology helps to maximise the availability of the forklift trucks.
Unit Head Perfect Charging, summing up the Fronius quality standards. Fronius battery chargers impress customers on the market with their low failure rate of 0.3 percent on average and a lifespan of up to 20 years. This is partly due to the high-quality charging technology developed in-house and the strict testing process. It is these high quality standards that have allowed Fronius to offer a five-year warranty for
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its battery chargers. This applies to both the Selectiva 4.0 series, which is suitable for charging all types of lead acid batteries, and to the new SelectION product family, which was specifically developed for operation with lithium-ion batteries. “We want to enable our customers to achieve maximum reliability and cost efficiency in charging technology. This has been our driving motivation for more than 75 years,” states Gojer. ■
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New from World leading Welding Inverter Manufacturer JASIC THE TIG 200 AMP AC/DC MACHINES The JASIC TIG 202 Analogue Pulse AC/DC and JASIC TIG 202 Digital Pulse AC/DC are technologically advanced single-phase inverter power source suitable for medium production work. The 202 Analogue has an innovative and user-friendly analogue control panel allowing full control of the welding parameters. The 202 Digital has an innovative and user-
friendly digital control panel allowing full control of the welding parameters. The excellent technical characteristics of these models make it an ideal choice for the professionally qualified TIG welders that require precise and reliable performance. Optional water cooler and large cylinder trolleys are available. Both inverters come complete with TIG
torch & adaptor, gas regulator, work return lead and clamp. All JASIC welding inverters carry in the UK and Eire a free 5-year warranty supported by factory trained technicians offering you total peace of mind. WILKINSON STAR LIMITED Marketing Department Tel: 0161 793 8127
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S I F T I PS
SIFTIPS ADVICE TO WOMEN IN WELDING: 1941-2021
Since the beginning, Sif has been a champion of women in welding, but when a brand has been running for as long as this one has, things are bound to need updating a little. While the team were deep in the sifTIPS archives this week we came across an advice column from 1941 onwards featuring Winnie the Welder offering handy tips to women new to the welding world as part of the war effort. Most of the suggestions focused on whether it was important to maintain your femininity while working and what hurdles to this end professionals could expect to face – rather than actual welding tips. Once in a while, we all need to have a good laugh at ourselves, so we’ve chosen our favourites to share with you below! Attire. As much as one dislikes seeing women in trousers, it seems to be the general opinion that for welding in factory conditions, trousered overalls of the bib and brace type are more suitable than skirts and silk stockings; the trousers give protection to the legs against sparks and hot falling metal. Care of hands. Welding will not spoil your hands but to keep them soft and attractive wash them regularly and use a well-known
brand of cream after the day’s work is over. Nails will not get damaged if kept welltrimmed and not too long. Care of hair. There is always a certain amount of dust in any factory, so it is advisable to wear a dark coloured bandeau or beret. A good hair rinse twice a week and regular daily brushing night and morning will keep your hair silky and fresh. The regular movement of goggles during a day’s work will spoil the most permanent of hair waves and for this reason it has been found that a head cover of the beret type affords best protection whilst still retaining that feminine charm. Care of eyes. Goggles must be worn and are generally provided. As an extra aid a daily douche with a well-known eye lotion is a good tonic, although not essential. Most girls are at first somewhat
apprehensive about the daily use of welding goggles and they generally fear that their eyesight may be impaired; there is no need to worry on this score providing that they are suppled with a pair of goggles fitted with Protex grade A glasses to B.S. Specification 679. These glasses are a light shade of green and are especially recommended to give 100% eye protection when used on light gauge sheet metal welding, sifBRONZE welding and aluminium welding. Grade B Protex glasses are a darker shade of green for heavy oxy-acetylene welding, but these are rarely used by girls. Don’t forget to check our social channels for a few more throwbacks as we uncover them and we look forward to better supporting the whole welding force with some actual advice – we promise! ■
Technical advice in the original SifTips style was started in 1932. ‘Sifbronzing’ is an almost universally recognised way of describing the low temperature bronze welding of sheet steel, cast iron and other metals. This explains why Sifbronze, the company which first developed and promoted the technique, is generally considered to be a supplier of high quality welding rods, wires, fluxes and equipment. ‘Will the Welder’ was a SifTips magazine that was produced in the early 1930s. The aim was to provide users with ideas and tips on how to get the most out of their welding equipment. Sif is renowned for its UK manufacturing heritage as well as its complete range of quality welding consumables used globally for almost a century.
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A N D F I N A L LY
AND FINALLY Image by akitada31 from Pixabay
HYDROGEN DEPENDENCY For people of my age the thought of the H bomb and Zeppelins flying in the sky creates the vision of a catastrophic disaster, but prevalent in both, Hydrogen, is very much in the public eye once again. My experience with the gas was with BOC, when in the 70’s as a representative for the company, I was called to the assistance of a laboratory technician who had cross threaded a regulator into a Hydrogen cylinder valve and we had to safely release the entire contents into the atmosphere, before the cylinder could be collected, and the valve rectified. Now, Billions of pounds are to be funnelled into hydrogen production, as Britain strives to create a market in this clean-burning gas. The subsidy is expected to be funded through either higher bills or with money from the public purse. Hydrogen fuel is now viewed as a key technology by Government officials racing to meet Boris Johnson’s target of net zero carbon emissions by 2050. Millions of households are
likely to have hydrogen boilers installed, replacing natural gas, and heavy vehicles such as lorries or aeroplanes will in the future run-on hydrogen, instead of diesel. Major energy companies such as BP, Shell and Scottish Power are all planning investment in hydrogen. Linde BOC via ITM
Power have already invested. The National Grid or the eventual owners of the Gas network, will introduce Hydrogen to their supply of Household Gas at a level of up to 20% without any boiler modification and have in fact already started trials within one small location. The long-term intention is that hydrogen will provide 20-35pc of the UK’s energy demand by 2050, producing 5GW by 2030. Officials claim this could create more than 9,000 UK jobs and unlock some £4bn in investment by 2030, potentially creating 100,000 jobs by 2050. The Government says that about 45TWh of UK buildings’ heating might be supplied by hydrogen in 2035. Currently, about 434TWh of energy is used each year to heat UK homes. A fuel that leaves water as a biproduct of its energy provision is an extremely cool way of looking after our planet and for my age group an overhaul of the image Hydrogen, is long overdue! Kind regards,
Adrian Hawkins OBE Managing Director, Welding World Ltd managing.director@welding-world.com
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