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 the century Humphrey Davy discovered the electric arc in 1801 Concerned with use of arc for illumination Benardos & Olszewski showed in 1885-87 arc with Carbon Electrodes and its use for melting Steel. In 1890, Slavianoff used a metal Electrode and Arc to deposit metal from the electrode. Oscar Kjellberg invented coated electrode during the years 1907 to 1914
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Environmental Issues
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Advantages ( Surface Tension Transfer STT) Can replace TIG for root pass welding Substantially reduced spatter
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Process Share of Weld Metal - Global Trend JAPAN SMAW 20 % EUROPE 30 % USA 35 % INDIA 70 %
SAW
GTAW
8%
2% 70 %
8%
2% 60 %
8%
2% 55 %
8%
2% 20 %
FCAW + GMAW
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Solid Wire
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Flux-Cored 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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Welding-Related Expenditure and Productivity Measurement in U.S. Manufacturing, Construction, and Mining Industries By American Welding Society Edison Welding Institute US Department of Commerce May 2002
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American Welding Society National Institute of Standards & Technology US Department of Energy June 1998
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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
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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P
SMAW GMAW GTAW SAW LASER EB FRICTION STIR RESISTANCE 35 112 15 57 32 94
S
105 52 40
Total
163 84 130
P
1420 1280
S
1278 277
Total
2698 1557
P
17640
S
13035
Total
30675
16200
9870
26070
1000 3680
7958 1495
8958 5175
S Secondary Energy
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TIG PROCESS
ATIG PROCESS
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0.8 mm AlMg3 sheets CMT-welded without using any clamping, or backing devices.
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Power Factor =
Apparent Power
Real Power
ADVANTAGES OF HIGH POWERACTOR
Increased Power Supply Capacity Reduced Heat Load on Electrical Cables Reduction of kVA Demand Reduction in Electricity Delivery Charge Reduced Voltage Drop on Cables Improved Equipment Operation
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14000
Energy Consumption (KWH/year)
12000 10000 8000 6000 4000 2000 0 0 50 100 150 200 250 300
Welding Current - A
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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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40 50 kwh/day
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PID controller
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Comparison of the total energy consumption of welding processes. (For 250mm length weld)
Material 1 mm thick Process MMAW MIG/MAG GTAW SAW Laser EBW (V) FSW
Primary Energy KJ Secondary Energy KJ Total Energy KJ
Material 12 mm thick
Primary Energy KJ Secondary Energy KJ Total Energy KJ Primary Energy KJ
Material 50 mm thick
Secondary Energy KJ Total Energy KJ
57 32 94 112 -
105 52 40 454 -
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 Time 3) 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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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) 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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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) 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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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) 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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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) 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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