FABTECH Canada 2012 Conference

Tuesday, March 20

Wednesday, March 21

Thursday, March 22

10:15 AM – 12:15 PM

1:15 – 3:15 PM *

10:15 AM – 12:15 PM

1:15 – 3:15 PM *

10:15 AM – 12:15 PM

A01: Fundamentals of Laser Welding

A02: Preventing Weld-Associated Cracking in Nickel-Base Alloys

A03: Essential Tips for Welding Aluminum

A04: High Power Laser Applications in Industry

A05: The Future of the Welding Industry’s Workforce

 Refill Friction Stir Spot Welding; Nigel Scotchmer, Huys Industrial

 High Power Laser Applications in Industry; Chris Pilcher, IPG Photonics

 Green Stud Welding Saves Energy and Labor Costs; Chris Hsu, Nelson Stud Welding, Inc.

 Aluminum Filler Alloy Selection; Rob Krause, AlcoTec Wire Corporation

*Session scheduled to tentatively end at 2:00 PM

 Utilizing Technology to Address the Need for a Manufacturing Workforce; Deanna Postlethwaite, Lincoln Electric Co.

 Fundamentals of Laser Welding; Kevin Arnold, ESAB  Hot Wire Laser Cladding for Life Cycle Cost Reduction; Paul Denney

 Preventing Weld-Associated Cracking in Nickel-Base Alloys; Donald Tillack, Nickel Institute *Session scheduled to tentatively end at 2:00 PM

 Aluminum Welding Machine Selection; Thom Burns, AlcoTec Wire Corporation

F01: COMPARATIVE CUTTING: Advancements in Cutting  Advancements in Plasma Cutting Process Optimization Resulting from Cut-to-Cut Cycle Time Reduction; Derek Weston, Hypertherm  Laser Cutting Considerations for First Time Buyers; Nigel King, Elliott-Matsuura Canada Inc.

F02: LASERS: General to Advanced Laser Cutting Considerations

F03: TUBE & PIPE: Forming and Fabricating Tube & Pipe

 Laser Processing Technology Today; Jason Hillenbrand, Amada

 Tube and Pipe Mill Set U; Robert Sladky, Roll-Kraft

 NIR Laser Cutting Dynamics With High Beam Quality; Randy Paura, Dynamic Laser Solutions Inc. & Co. Presenter, Don McDonald, Fabricating Machinery Solutions

 Laser Tube Cutting; David Hach, BLM

 Fiber versus CO2 Laser Cutting; Troy Robinson, Cincinnati  Stefan Schreiber, TRUMPF

F04: ROLL FORMING: General to Advanced Roll Forming Concepts  Advanced Roll Forming of Steel Framing Components; Dave Voth, FORMTEK Metal Forming, Inc.  Modern Lubricants for Roll Form Processes; Joe Hough, Tower Oil and Technology

F05: BRAKE & PUNCH: Fabricating Sheet Metal  Press Brakes; Shane Simpson, TRUMPF  Press Brake Troubleshooting; John Kemp, BYSTRONIC

A01 – Fundamentals of Laser Welding Tuesday, March 20, 10:15 AM – 12:15 PM 10:15AM – 11:00AM Fundamentals of Laser Welding This presentation explores the basic question: What is a laser?

Learn about laser types and beam delivery, as well as application examples and advantages including tips on tube welding.

Expect an overview on:  General information on the basics of lasers  How light can be used to weld  How it can be controlled  Advantages laser welding brings to automotive and aerospace applications  The pros of laser welding in tube and pipe production  The economics of laser welding Kevin Arnold Automation Account Manager ESAB Welding & Cutting 11:30AM – 12:15PM Hot Wire Laser Cladding for Life Cycle Cost Reduction This presentation will review the technical and economic advantages of hot wire laser cladding. The hot wire laser cladding process uses a welding power supply to preheat wire and a laser to melt and bond the material to a metal substrate can achieve deposition rates similar to arc processes but with much lower heat inputs. The process at the same time can deposit greater than twice the material that laser/powder systems can at the same laser power with almost no wasted powder. The presentation will review the mechanics of the process and the justification for its use through various economic models.

Paul Denney Automation Division Lincoln Electric Company

A02 – Preventing Weld-Associated Cracking in Nickel-Base Alloys Tuesday, March 20, 1:15 PM – 2:00 PM 1:15 PM – 2:00 PM Preventing Weld-Associated Cracking in Nickel-Base Alloys Weld cracking is probably the most feared and most expensive event to occur in the fabrication process.

This presentation will explain the steps necessary to prevent cracking in nickel-base alloy welds. Included topics to be covered are:      

Recommended procedures to prepare the weld area Techniques to avoid solidification cracking during welding How to minimize microfissuring Reducing the possibility of relaxation cracking, ductility-dip cracking, and strain-age cracking How to prepare for nickel alloy welding Critical welding parameters for nickel alloy welding

Donald Tillack Technical Consultant Nickel Institute

F01 – COMPARATIVE CUTTING: Advancements in Cutting Tuesday, March 20, 10:15 AM – 12:15 PM 10:15 AM – 10:55 AM Advancements in Plasma Cutting Process Optimization Resulting from Cut-to-Cut Cycle Time Reduction New plasma cutting hardware and nesting software allows Rapid Part technology to target and optimize four elements of the total cutting process-torch retract, table motion, initial height sensing, and gas pre-flow-to significantly reduce non-cutting time.    

Reduce cut-to-cut cycle time Increase productivity from capital equipment Eliminate the need for manual process intervention Increase profitability

Derek Westin Product Marketing Manager Hypertherm, Inc. 10:55 AM – 11:35 AM Laser Cutting Considerations for First-Time Buyers Due to the high investment cost to purchase a 2-D laser cutting system, it is important to consider all factors before making a buying decision, especially for first time buyers. Factors such as new versus used, resale value, wattage, table size, drive system, and resonator type. These factors coupled with the application will help to ensure the right decision.   

First time laser buyers Laser cost justification Laser v. other cutting processes

Nigel King Product Manager Elliott-Matsuura Canada Inc.

F02 – LASERS: General to Advanced Laser Cutting Considerations Tuesday, March 20, 1:15 PM – 3:15 PM 1:15 PM – 1:45 PM Laser Processing Technology Today This presentation will review both Fiber lasers and CO2 technology and discuss how both not offer better options to be competitive in any market. Learn how fibers offer incredible speeds and energy savings, lower maintenance, and improve cut capacity & quality. Additional features for improving machine utilization and reducing part cost will also be covered.

Jason Hillenbrand Laser Product Manager Amada America, Inc. 1:45 PM – 2:15 PM NIR laser cutting dynamics with high beam quality This presentation reviews established rules of thumb for CO2 laser cutting and the different process dynamics of the new solid state Near Infra-Red lasers, such as the fiber and disk lasers. Understanding the inherent nature of the high beam quality of these lasers while selecting appropriate optic and process fiber combinations is essential to achieve the maximum performance, benefits and process robustness.  Process differences between FIR and NIR laser cutting  Process and cost of ownership benefits of new NIR laser power sources for cutting  Collation and summary review of latest research into NIR laser cutting with high beam quality  Optics and process fiber selection criteria and checklist for NIR laser cutting with high beam quality Co Presenter Randy Paura, P. Eng., CLSO President Dynamic Laser Solutions Inc.

Co Presenter Don McDonald Regional Manager Fabricating Machinery Solutions

2:15 PM – 2:45 PM Fiber versus CO2 Laser Cutting Although the majority of today's 2-D laser cutting systems use CO2 resonators, the fiber laser is slowly gaining acceptance in the marketplace with its low operating costs and fast cutting speeds, especially in thin materials. This presentation will focus on the differences between these two technologies from a cost and performance standpoint when used on 2-D laser cutting systems.  Hourly operating cost comparison  Material cutting comparison  Cost vs. performance comparison Troy Robinson International Distributor Sales Manager Cincinnati Inc. 2:45 PM – 3:15 PM [TRUMPF] Co Presenter Stefan Schreiber TRUMPF

A03 – Essential Tips for Welding Aluminum Wednesday, March 21, 10:15 AM – 12:15 PM 10:15 AM – 10:45 AM Refill Friction Stir Spot Welding This presentation will present a new machine which provides friction stir spot welds on aluminum sheet and then refills the hole left by the stirring tool on retraction. Learn how this new machine works and the characteristics of good joints made with both the friction stir welding and refill friction spot welding process.

See how the machine provides:  Stable, consistent welding of aluminum sheet  Refill friction stir spot welding - no hole  Affordable friction stir spot welding  Robot mounting Nigel Scotchmer President Huys Industries Limited 11:05 AM – 11:35 AM Aluminum Filler Alloy Selection The selection of a suitable filler alloy for joining various aluminum alloys requires the careful consideration of a number of factors. This presentation, along with case studies as examples, will discuss some of these considerations in order to properly select the most suitable filler alloy for a particular application:    

Ease of welding Strength of the welded joint Corrosion resistance Color match

Rob Krause Technical Services Manager AlcoTec Wire Corporation 11:45 AM – 12:15 PM Aluminum Welding Machine Selection The selection of welding equipment for use with aluminum requires a thorough understanding of the unique properties of aluminum. The majority of equipment supplied to the gas metal arc welding market is designed for the purpose of welding steel or some product other than aluminum. As this presentation will point out, no one machine fits all needs.

Thom Burns Director-Technical Services AlcoTec Wire Corporation

A04 – High Power Laser Applications in Industry Wednesday, March 21, 1:15 PM – 2:00 PM 1:15 PM – 2:00 PM High Power Laser Applications in Industry This presentation will review the trend in pricing and cost of new laser systems with respect to 10 micron and 1 micron wavelengths. In addition, a focus on the main key points will discuss reliability, beam quality, efficiency, and flexibility. Other topics included in this presentation are:        

New applications in plastic cutting Powertrain welding Remote scanner head cutting Remote scanner welding Supersonic welding cladding Surface hardening Drilling Future applications

Chris Pilcher RSM – Canada IPG Photonics

F03 – TUBE & PIPE: Forming & Fabricating Tube & Pipe Wednesday, March 21, 10:15 AM – 12:15 PM 10:15 AM – 11:15 AM Tube and Pipe Mill Set Up This presentation is tailored to address and strengthen the "weak links" in tube and pipe mill operations in regard to proper tube and pipe mill set up. It specifically addresses the importance of properly setting up each and every pass on the mill per the design of the tooling, helping establish a "standard" for everyone to follow. By doing so, you will be able to identify problems and implement corrective measures that will build morale, improve product quality, reduce scrap, increase the life of the tooling, and produce greater profits.    

Identification of each pass on tube and pipe mill Proper setup of each pass How you document a good setup so you can repeat the performance Problems and solutions in each section on the mill

F04 – ROLL FORMING: General to Advanced Roll Forming Concepts Wednesday, March 21, 1:15 PM – 3:15 PM 1:15 PM – 2:15 PM Advanced Roll Forming of Steel Framing Components This presentation will provide insight into the latest advancements in roll forming system technology for the Steel Framing Industry. Discussions will focus on automated equipment change-over for material thickness, cross sectional variations, punched opening locations, and part lengths. Handling of the finished product in high speed operations will be discussed. Also addressed, will be the level of operator training required. The advantages of programmable rotary punching and cutoff systems will be presented. Included, will be specific examples of these technologies being utilized in the manufacture of steel framing products.

Dave Voth Product Line Manager – B&K Systems Formtek Metal Forming Inc.

Robert Sladky Vice President Tube Mill Engineering Roll-Kraft 11:15 AM – 12:15 PM Laser Tube Cutting Understand how to design parts for the laser tube cutting process.   

Laser cutting metallic tubes Fiber laser technology Lean manufacturing via laser tube fabrication

David Hach BLM Regional Sales Manager Canada BLM Group USA

2:15 PM – 3:15 PM Modern Lubricants for Roll Form Processes Develop an understanding of the modern roll forming lubricants available that will enable you to select the best lubricant for your process.   

New VOC-Free Vanishing Oil replacement lubricants Control and monitoring roll forming coolants Lube application methods and equipment

Joe Hough VP/Director Technical Services Tower Oil & Technology Co.

A05 – The Future of the Welding Industry’s Workforce Thursday, March 22, 10:15 AM – 12:15 PM

Deanna Postlethwaite Automation Division; Lincoln Electric

10:15AM – 11:00AM Green Stud Welding Saves Energy and Labor Costs This presentation focuses on the cost savings opportunities of incorporating new green stud welding technologies that save energy consumption and labor hours associated with welding operation, and pre-weld and post-weld operations, and improve productivity and weld quality. Outlined in the presentation are specific innovations and technology improvements that save time, money and energy for fabricators using weld studs in ships, bridges, buildings, automotive and other fastening applications.

F05 – BRAKE & PUNCH: Fabricating Sheet Metal Thursday, March 22, 10:15 AM – 12:15 PM

A range of topics covered, including:  Electricity savings in stud welding  Labor savings in stud welding  Low air consumption in automotive production  New stud welding technology in construction  Examples of new stud welding technologies boosting productivity and quality in wind, solar and hydro renewable energy generator fabrication

Shane Simpson TRUMPF

10:15 AM – 10:55 AM Press Brakes Presenter

10:55 AM – 11:35 AM Press Brake Tooling Presenter

Chris Hsu Director of Engineering Nelson Stud Welding, Inc. 11:30AM – 12:15PM Utilizing Technology to Address the Need for a Manufacturing Workforce The lack of a skilled workforce is not a new topic for conversation for manufacturing. Addressing the needs of industry and taking a focused look at resolving the issues is how we will address this shortage. To deal with engaging our youth, we need to meet them at their level and implement tools and curriculum that integrates interactive elements, creative and exciting designs and challenges but also engages them. And finally, to advance as a global competitor, the need for innovation, technology and automation must be incorporated, addressed and fulfilled. Examples of schools that identified these needs and have addressed them will be covered to summarize the presentation.

TBD Wilson Tool International 11:35 AM – 12:15 PM Press Brake Troubleshooting John Kemp BYSTRONIC