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Environmental and Energy

Conservation issues in Welding

By

S Sankaran

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2012

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Edmund Davy discovered acetylene in 1836 First commercial oxy-acetylene welding torch at turn of thecentury

Humphrey Davy discovered the electric arc in 1801

Concerned with use of arc for illumination

Benardos & Olszewski showed in 1885-87 arc withCarbon Electrodes and its use for melting Steel.

In 1890, Slavianoff used a metal Electrode and Arc todeposit metal from the electrode.

Oscar Kjellberg invented coated electrode during theyears 1907 to 1914

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Gas metal arc weldingDevelopments

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Driving Force behind Welding Developments

Need to Join newer materials

Improve Productivity

Reliability of welds in service

Environmental Issues

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SurfaceTension

TransferWelding Cycle

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STTProduceLess fumesAnd low inSpatter

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Advantages ( Surface Tension Transfer STT)

Can replace TIG for root pass welding

Substantially reduced spatter

Lower arc radiation and fume generation

Reduced heat input on thin-gauge material

Longer operating time for robots

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Process Share of Weld Metal - Global Trend

JAPAN EUROPE USA INDIA

SMAW 20 % 30 % 35 % 70 %

SAW 8 % 8 % 8 % 8 %

GTAW 2 % 2 % 2 % 2 %

FCAW +GMAW

70 % 60 % 55 % 20 %

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Energy Conservation in Welding

FCW - Flux Cored Wire

SW - Solid Wire

CE - Coated Electrode

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Hybrid:Characteristics &

Benefits of Solid Wire& Flux-Cored WireSolid Wire

Flux-Cored Wire

Metal Core Wire

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History of FCAW

Concept of FCAW ...1911

Large Dia. FCAW Wires .. 1930s

Self-Shielded FCAW Wires)..1950s

Small Dia. FCAW Wires ........1970s

Metal-Cored Wires.......1980s

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NewerFlux Cored Wires

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Preventing lack of fusion at start of Aluminum welds

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Welding-Related Expenditure and Productivity Measurementin

U.S. Manufacturing, Construction, and Mining Industries

By

American Welding SocietyEdison Welding Institute

US Department of Commerce

May 2002

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Data from U.S. Department of Commerce & AWS survey

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Summary of welding related expenditure for major industrial sectors

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Industry Vision Workshop on Welding

By

American Welding SocietyNational Institute of Standards & Technology

US Department of Energy

June 1998

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Industry Vision Workshop on Welding

STRATEGIC GOALS FOR 2020

Reduce average cost of welding by one-third

Integrate welding with the Production Cycle

Develop welding technology along with new materials development

Assure welding is a part of six-sigma quality environment

Improve knowledge base of people taking decisions related to Welding Reduce energy use in welding by 50%

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Energy Conservation Measures

Avoid unwanted welds

Choice of Welding Processes

Selection of Welding Power Source

Handling of Welding Consumables

Pre-heating & Post-heating

PWHT

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PWHT

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PWHT

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Pre-heating & Post-heatingPWHT

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PWHT

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Weld finished with full grinding As welded with no grinding

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Total Energy Consumption in Welding Processes

Primary Energy Energy required to heat the material above melting or

forging temperature

Secondary Energy Preheat / Postheat Electrode Baking / Holding Wirefeed units, Motorised Slides, Fume Extractors Job Handling Devices - Manipulators, Gantry, Robot Weld Preparation Machining, Grinding Weld Finishing Deslagging, Grinding

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PROCESS

Material Thickness ( Length 250 mm )

1 mm 12 mm 50 mm

P S Total P S Total P S Total

SMAW 57 105 163 1420 1278 2698 17640 13035 30675

GMAW 32 52 84 1280 277 1557

GTAW 94 40 130

SAW 1450 864 2314 16200 9870 26070

LASER 112 454 466 120 4268 4388

EB 15 3230 3245 120 5283 5403 1000 7958 8958

FRICTION STIR 1100 347 1447 3680 1495 5175

RESISTANCE 35 11 46

Total Energy Consumption for making a Weld in KJ

P Primary Energy; S Secondary Energy

Data from TWI Publication

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Friction Stir Welding

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SMAW : Electrode Size from 4 to 5 mm

33% increase in deposition rate

25 % energy saving

SAW : Single wire to tandem arc

20% increase in deposition rate

TIG : Enhance Penetration Use A-TIG

MIG : Smaller size wire

Increase in deposition rate

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A

TIG PROCESSTIG PROCESS

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70 mm Diameter x 5 mm thick SS Tubewelded in 5G position with Activated flux

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CMT Cold Metal Transfer

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Wire feed Forward & Retraction in CMT

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0.8 mm AlMg3 sheetsCMT-welded

without using any clamping,or backing devices.

1.0 mm Galvanised sheetCMT-brazed joint,filler metal CuSi3.

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Power Factor =Apparent Power

Real Power

ADVANTAGES OF HIGH POWERACTOR

Increased Power Supply CapacityReduced Heat Load on Electrical CablesReduction of kVA DemandReduction in Electricity Delivery ChargeReduced Voltage Drop on CablesImproved Equipment Operation

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Inverter Rectifier Generater

6800 kwh/year 8500 kwh/year 12500 kwh/year

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Energy consumption per year for SMAW welding power sources

0

2000

4000

6000

8000

10000

12000

14000

0 50 100 150 200 250 300

Welding Current - A

EnergyConsumption

(KWH/y

ear)

Generator

Transformer

Inverter

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Advantages (Inverter Welding Power Sources)

Compact size Shop floor space free

Low weight Highly portable

High efficiency energy saving

Ripple free Smooth arc and better weld

Multi-process capability

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Recommended Storage for Electrodes

Below 50% relative humidity

Between 20 to 40 degree C

Conditioning of Electrodes before use

Drying

at 100 to 300 deg C dependingon type of electrode

Holding above 100 deg C till use

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40 50 kwh/dayCard board carton

Vacuum sealed packet

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Low velocity candle type burner(Rs. 75/Hr)

Spot burner(Rs. 90/Hr )

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Providing Insulation / hoods to retain heat at the joint

Hood to retain heatat the joint

Dished End and Nozzlecovered with Insulation

Forged nozzlePre-heating

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PID controller Infra red sensorInfra red sensormeasure preheat

temperature

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Large Furnace with Ceramic Fiber Insulation

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Energy Saved is Energy Generated

Flux Cored Arc Welding

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Welding related energy cost as percentage of total energy costs

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Comparison of the total energy consumption of welding processes.(For 250mm length weld)

Process

Material 1 mm thick Material 12 mm thick Material 50 mm thick

Primary

EnergyKJ

Secondary

EnergyKJ

Total

EnergyKJ

Primary

EnergyKJ

Secondary

EnergyKJ

Total

EnergyKJ

Primary

EnergyKJ

Secondary

EnergyKJ

Total EnergyKJ

MMAW 57 105 162 1420 1278 2698 17640 13035 30675

MIG/MAG 32 52 84 1280 277 1557 - - -

GTAW 94 40 130 - - - - - -

SAW - - - 1450 864 2314 16200 9870 26070

Laser 112 454 566 120 4268 4388 - - -

EBW (V) - - - 120 5283 5403 1000 7958 8958

FSW - - - 1100 347 1447 3680 1495 5175

RSW 35 11 46

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Concerns in Indian Context

1) Energy Optimisation in welding

2) Reduce - Rework, Repair, Rejection

Do it Right First Time and Every Time3) Enhance Image of Welding

Attract talented youth

Improved working environment

4) Knowledge Management in Welding

5) Multiple Qualifications And Certification

6) Use of IT and computer control in welding

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