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

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.

“ 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

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 girdersSMAW and SAW

I-beamsSMAW / FCAW / SAW

EXHAUSTSGMAW or GTAW

Flat bedsGMAW / MCAW / SAW

Semi-automatic, Automatic and fixturing

TankerGMAW / GTAW / Plasma

HEAVY MACHINERYGMAW / FCAW / MCAW / Fixturing

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

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 - 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

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

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

Estimated CostSMAW– 3/8 Fillet Weld

GTAWDeposition 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

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

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

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"

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

)

FCAW - 1.6mm (.0625”)Deposition Rate Vs. Wire Feed Speed

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101112

100 120 140 160 180 200 220 240 260 280 300Wire Feed Speed (ipm)

Dep

ositi

on R

ate

(lb/h

)

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

)

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

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"

Example of Cost Comparison ToolGMAW – 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

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

)

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

)

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

)

Estimated CostMCAW – 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

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"

Estimated CostSAW – 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 Tool

End User Reports- Customized Reports-E-mailed to designated users

Example of Cap Optima Monitoring System by

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Wire feed speedAmperageVoltageShielding gasArc on timeInformation sent through hard wire or wireless system

Sample Report from CAP Optima Monitoring System

Questions?