manufacturing and repair welding
TRANSCRIPT
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Manufacturing and Repair Welding
Weld Expo 2004Weld Expo 2004Welding SymposiumWelding SymposiumSeptember 29, 2004September 29, 2004
Andy McCartney, P.Eng.Andy McCartney, P.Eng.Manager Welding ServicesManager Welding Services
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In today’s business environment maximization and / In today’s business environment maximization and / or optimization is a key to success.or optimization is a key to success.
There are over 50 different types of welding There are over 50 different types of welding processes with sophisticated electronic controls and processes with sophisticated electronic controls and programmed automates available to you to help you programmed automates available to you to help you achieve these goals.achieve these goals.
Today we will only look at some of the processes Today we will only look at some of the processes that are close to home to see how these can be that are close to home to see how these can be optimized. We hope that today’s presentation makes optimized. We hope that today’s presentation makes you aware of several key indicators that will help you you aware of several key indicators that will help you move towards improvements in productivity in your move towards improvements in productivity in your fabrication or repair operations.fabrication or repair operations.
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“ Why fix something if it isn’t broke”“ Why fix something if it isn’t broke”
It may not be broken, but is it optimized?It may not be broken, but is it optimized?
In many cases the correct process and In many cases the correct process and auxiliary tools have been selected, but we auxiliary tools have been selected, but we have not taken the next step.have not taken the next step.
OptimizationOptimization
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Welding Processes
Selection & Productivity Potential
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What should we consider• Base Material
– Type and thickness– Can the process I have handle it
• Position– Can the parts be positioned
• Should I consider positioners / robotics
• Volume and frequency– One time or repetitive application
• Location– Shop vs Field
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What to Consider
• Have I optimized my parameters for my existing processes
• Is it the best process• Am I using the correct shielding gas• What are the client expectations of weld
monitoring and quality– Can I meet these and future expectations
with my current operation• Welder Skills Required
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What to Consider• What power source options are
there• Environment issues and pollution
control associated with the processes
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Examples of fabricated components
• What are the processes being used?
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Box girdersSMAW and SAW
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I-beamsSMAW / FCAW / SAW
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EXHAUSTSGMAW or GTAW
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Flat bedsGMAW / MCAW / SAW
Semi-automatic, Automatic and fixturing
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TankerGMAW / GTAW / Plasma
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HEAVY MACHINERYGMAW / FCAW / MCAW / Fixturing
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How do we compare?
0
10
20
30
40
50
60
SMAW FCAW SAW GMAW
CANADAUSAJAPAN
Based on a 1996 study of processes used by fabrication companies
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Shielded Metal Arc Welding
Deposition Rates Vs Amperage
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SMAW Advantages
• Variety of Base Metals It can Weld• Common Process for many fabricators• Versatility
– Shop and Field• Relatively Simple Equipment• Auxiliary gases and fluxes not required• Ability to access limited space• Can be a low hydrogen process
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Limits
• Low Deposition Rates• Resistance Heating of Electrodes• Stub Loss• Low Operator Factor
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SMAW - E7014Deposition Rate Vs. Amperage
0
2
4
6
8
10
100 150 200 250 300 350 400Amperage
Dep
ositi
on R
ate
(lb/h
)
3.2mm 4.0mm 5.0mm 6.0mm
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SMAW - E7018Deposition Rate Vs. Amperage
0
2
4
60 80 100 120 140 160 180 200Amperage
Dep
ositi
on R
ate
(lb/h
)
2.5mm 3.2mm 4.0mm
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SMAW - E7024Deposition Rate Vs. Amperage
0
2
4
6
8
10
12
14
100 150 200 250 300 350 400Amperage
Dep
ositi
on R
ate
(lb/h
)
3.2mm 4.0mm 5.0mm 6.0mm
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Estimated CostSMAW– 3/8 Fillet Weld
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GTAWDeposition Rates vs. Arc Energy
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GTAW Advantages
• Extensive range of applications• High quality welds and use on a variety of
alloys• Autogenous or Filler Metal addition• Ability to be automated• Control of heat source and filler metal
separately• All position• Low cost power sources can be used
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Limitations
• Lower Deposition rates• Operator sensitive• Low tolerance for contamination• Practical application for T<3/8”• Shielding gas required
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GTAW Deposition vs. Arc Energy
0
5
10
15
20
2 4 6 8
Arc Energy (KW)
Dep
osi
tio
n R
ate
(lb
s/h
r)
Hot Wire with Oscilation Hot Wire Cold Wire
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Estimated Cost GTAW – 3/8 Fillet Weld
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Flux Cored Arc Welding
Deposition Rates and Choices
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FCAW Advantages
• Higher Productivity– High Deposit and Operator Factors
• Less Operator sensitive than GMAW• Often more flexible and adaptable than
SAW• Requires less precleaning than GMAW• Gas Shielded or Gasless Applications• Can be a low hydrogen process
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Limitations
• Ferrous and Nickel based Alloys only• Produces a slag requiring cleaning time• Requires more complex equipment than
SMAW• Increased maintenance of equipment• May require external shielding gas• Increased fume levels when compared
against GMAW and SAW processes
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Theoretical Deposition Rates for FCAW
Deposition Rate Vs. Wire Feed Speed
0
2
4
6
8
10
12
14
16
18
20
22
100 200 300 400 500 600 700Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
.045" 1/16" 3/32"
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FCAW - 1.2mm (.045”)Deposition Rate Vs. Wire Feed Speed
0
2
4
6
8
10
200 220 240 260 280 300 320 340 360 380 400Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
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FCAW - 1.6mm (.0625”)Deposition Rate Vs. Wire Feed Speed
0123456789
101112
100 120 140 160 180 200 220 240 260 280 300Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
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FCAW - 2.4mm (3/32”)Deposition Rate Vs. Wire Feed Speed
10
11
12
13
14
15
16
17
18
140 160 180 200 220Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
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Estimated Cost FCAW – 3/8 Fillet Weld
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GMAW
Deposition rates
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GMAW Advantages
• Can be used on a wide variety of base metals
• All position capability– Can operate in short circuit / globular/ spray
and pulse modes• High Productivity
– High deposit and operator factor• Adaptable to automated systems• Minimal postweld cleaning• Considered a Low Hydrogen process
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Limitations
• Sensitive to operator skills• Requires more complex equipment than
SMAW• Increased maintenance of equipment• Requires external shielding gas• High levels of radiating heat and arc
intensity
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Theoretical Deposition Rates for GMAW
Deposition Rate Vs. Wire Feed Speed
0
2
4
6
8
10
12
14
16
18
250 350 450 550 650 750Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
.035" .045"
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Example of Cost Comparison ToolGMAW – 3/8 Fillet Weld
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MCAW
Deposition rates
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MCAW Advantages• Higher Productivity
– High Deposit and Operator Factors• Less Operator sensitive than GMAW• Often more flexible and adaptable than
SAW• Requires less precleaning than GMAW• Welder Appeal of GMAW with Penetration
Profiles similar to FCAW• Lower Fume generation than FCAW• Minimal postweld cleaning• Can be a low hydrogen process
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Limitations
• Requires shielding gases• Requires more complex equipment
than SMAW• Increased maintenance of
equipment
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MCAW - 1.2mm (.045”)Deposition Rate Vs. Wire Feed Speed
0
2
4
6
8
10
12
14
16
200 250 300 350 400 450 500 550 600 650Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
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MCAW - 1.4mm (.052”)Deposition Rate Vs. Wire Feed Speed
0
2
4
6
8
10
12
14
16
18
20
150 200 250 300 350 400 450 500 550 600Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
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MCAW - 1.6mm (.0625”)Deposition Rate Vs. Wire Feed Speed
0
2
4
6
8
10
12
14
16
18
20
22
125 175 225 275 325 375 425 475 525Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
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Estimated CostMCAW – 3/8 Fillet Weld
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Submerged Arc Welding
Deposition rates and wire speeds
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SAW Advantages
• High deposition rates• Single or multiple electrode systems• AC and DC• High travel speeds• High quality welds• Three Modes of operation
– Mechanized– Semiautomated– Automated
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Limitations
• Most applications used n Flat and Horizontal position
• Large Equipment Investment– Power sources– Material Handling Equipment
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Theoretical Deposition Rates for SAW
Deposition Rate Vs. Wire Feed Speed
05
10152025303540455055606570
0 20 40 60 80 100 120 140Wire Feed Speed (ipm)
Dep
ositi
on R
ate
(lb/h
)
3/32" 1/8" 5/32" 3/16"
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Estimated CostSAW – 3/8 Fillet Weld
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How can we optimize
• Measure • Document what you do now• Monitor your welding parameters • Look to advanced applications
– i.e.GTAW/Laser combinations• Provide process specific training and
track results• Use consultants, suppliers etc.
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Example of Monitoring Tool
End User Reports- Customized Reports-E-mailed to designated users
Example of Cap Optima Monitoring System by
������������ �������������showing Optima 400 sensor
Wire feed speedAmperageVoltageShielding gasArc on timeInformation sent through hard wire or wireless system
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Sample Report from CAP Optima Monitoring System
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Questions?