Manufacturing and Repair Welding Weld Expo 2004 Welding Symposium September 29, 2004 Andy McCartney, P.Eng. Manager Welding Services
In today s business environment maximization and / or optimization is a key to success. There are over 50 different types of welding processes with sophisticated electronic controls and programmed automates available to you to help you achieve these goals. Today we will only look at some of the processes that are close to home to see how these can be optimized. We hope that today s presentation makes you aware of several key indicators that will help you move towards improvements in productivity in your fabrication or repair operations.
Why fix something if it isn t broke It may not be broken, but is it optimized? In many cases the correct process and auxiliary tools have been selected, but we have not taken the next step. Optimization
Welding Processes Selection & Productivity Potential
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
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
What to Consider What power source options are there Environment issues and pollution control associated with the processes
Examples of fabricated components What are the processes being used?
Box girders SMAW and SAW
I-beams SMAW / FCAW / SAW
EXHAUSTS GMAW or GTAW
Flat beds GMAW / MCAW / SAW Semi-automatic, Automatic and fixturing
Tanker GMAW / GTAW / Plasma
HEAVY MACHINERY GMAW / FCAW / MCAW / Fixturing
How do we compare? 60 50 40 30 20 CANADA USA JAPAN 10 0 SMAW FCAW SAW GMAW Based on a 1996 study of processes used by fabrication companies
Shielded Metal Arc Welding Deposition Rates Vs Amperage
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
Limits Low Deposition Rates Resistance Heating of Electrodes Stub Loss Low Operator Factor
SMAW - E7014 Deposition Rate Vs. Amperage 10 Deposition Rate (lb/h) 8 6 4 2 0 100 150 200 250 300 350 400 Amperage 3.2mm 4.0mm 5.0mm 6.0mm
SMAW - E7018 Deposition Rate Vs. Amperage 4 Deposition Rate (lb/h) 2 0 60 80 100 120 140 160 180 200 Amperage 2.5mm 3.2mm 4.0mm
SMAW - E7024 Deposition Rate Vs. Amperage 14 Deposition Rate (lb/h) 12 10 8 6 4 2 0 100 150 200 250 300 350 400 Amperage 3.2mm 4.0mm 5.0mm 6.0mm
Estimated Cost SMAW 3/8 Fillet Weld
GTAW Deposition Rates vs. Arc Energy
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
Limitations Lower Deposition rates Operator sensitive Low tolerance for contamination Practical application for T<3/8 Shielding gas required
GTAW Deposition vs. Arc Energy Deposition Rate (lbs/hr) 20 15 10 5 0 2 4 6 8 Arc Energy (KW) Hot Wire with Oscilation Hot Wire Cold Wire
Estimated Cost GTAW 3/8 Fillet Weld
Flux Cored Arc Welding Deposition Rates and Choices
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
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
Deposition Rate (lb/h) Theoretical Deposition Rates for FCAW Deposition Rate Vs. Wire Feed Speed 22 20 18 16 14 12 10 8 6 4 2 0 100 200 300 400 500 600 700 Wire Feed Speed (ipm).045" 1/16" 3/32"
FCAW - 1.2mm (.045 ) Deposition Rate Vs. Wire Feed Speed 10 Deposition Rate (lb/h) 8 6 4 2 0 200 220 240 260 280 300 320 340 360 380 400 Wire Feed Speed (ipm)
FCAW - 1.6mm (.0625 ) Deposition Rate Vs. Wire Feed Speed Deposition Rate (lb/h) 12 11 10 9 8 7 6 5 4 3 2 1 0 100 120 140 160 180 200 220 240 260 280 300 Wire Feed Speed (ipm)
FCAW - 2.4mm (3/32 ) Deposition Rate Vs. Wire Feed Speed 18 Deposition Rate (lb/h) 17 16 15 14 13 12 11 10 140 160 180 200 220 Wire Feed Speed (ipm)
Estimated Cost FCAW 3/8 Fillet Weld
GMAW Deposition rates
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
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
Theoretical Deposition Rates for GMAW Deposition Rate Vs. Wire Feed Speed 18 Deposition Rate (lb/h) 16 14 12 10 8 6 4 2 0 250 350 450 550 650 750 Wire Feed Speed (ipm).035".045"
Example of Cost Comparison Tool GMAW 3/8 Fillet Weld
MCAW Deposition rates
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
Limitations Requires shielding gases Requires more complex equipment than SMAW Increased maintenance of equipment
MCAW - 1.2mm (.045 ) Deposition Rate Vs. Wire Feed Speed Deposition Rate (lb/h) 16 14 12 10 8 6 4 2 0 200 250 300 350 400 450 500 550 600 650 Wire Feed Speed (ipm)
MCAW - 1.4mm (.052 ) Deposition Rate Vs. Wire Feed Speed Deposition Rate (lb/h) 20 18 16 14 12 10 8 6 4 2 0 150 200 250 300 350 400 450 500 550 600 Wire Feed Speed (ipm)
MCAW - 1.6mm (.0625 ) Deposition Rate Vs. Wire Feed Speed Deposition Rate (lb/h) 22 20 18 16 14 12 10 8 6 4 2 0 125 175 225 275 325 375 425 475 525 Wire Feed Speed (ipm)
Estimated Cost MCAW 3/8 Fillet Weld
Submerged Arc Welding Deposition rates and wire speeds
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
Limitations Most applications used n Flat and Horizontal position Large Equipment Investment Power sources Material Handling Equipment
Theoretical Deposition Rates for SAW Deposition Rate Vs. Wire Feed Speed Deposition Rate (lb/h) 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 0 20 40 60 80 100 120 140 Wire Feed Speed (ipm) 3/32" 1/8" 5/32" 3/16"
Estimated Cost SAW 3/8 Fillet Weld
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.
Example of Monitoring Wire feed speed Amperage Voltage Shielding gas Arc on time Information sent through hard wire or wireless system Tool End User Reports - Customized Reports -E-mailed to designated users Example of Cap Optima Monitoring System by showing Optima 400 sensor
Sample Report from CAP Optima Monitoring System
Questions?