Defalco

By Jeff Defalco Business Manager

Welding Automation

2 Welding Automation


Increased Shareholder Value

– Higher margin opportunities through cost reductions from sustainable results (Consistency) and better quality.

– Improved perceived value of a company as the leading innovator of process solutions.

– Increased Productivity = Faster ROI


Secure a Company’s Future Growth

– Differentiator with competition (Both global and domestic) in a mature market.

– Lead in introduction of premium products.

– IP and commercial barriers to entrance of new competitors.

– Prepare for new industry/government safety and environmental regulations.


Welding Industry Forces

– Lack of skilled welders

– Safety

– Repetitive Strain Injuries


Available Automation Levels

Low Automation: Tractors, semi-automatic.

High Automation: Disruptive welding processes

Medium Automation: Column&booms, robotic, seamers, gantries

Welding Automation


Hybrid Laser Welding

Laser • Small spot size • Very high energy

density • Low total heat input • Deep penetration • High welding speed • Arc stabilization

Wire Filler • Control of weld metallurgy • Improved gap tolerance

Gas Metal Arc • Improved optical

coupling • Added energy to

melt wire • Broadened fusion

zone at surface • Slower weld cooling


Hybrid Laser Welds

• Weld Characteristics – Smooth Surface Contours – Small Heat Affected Zone – Fine Grain Structures – Low Base Metal Dilution – Acceptable Hardness

• Process Characteristics – High Productivity – Low Consumable Costs – Some Gap Tolerance – Some Edge Quality Tolerance – Some Contaminant Tolerance


Advantages of Hybrid Laser Welding

• HLAW enables new methods of achieving strength without large weld volume

Partial Penetration GMAW Fillet Full Penetration Laser Fillet


Thick Plate Butt Welding

• Typical Single-Side SAW Butt Weld Joint Preparation on 1.25” Plate

• ½” Laser Root Pass with Conventional SAW Finish

= 64% reduction in volume

• ½” Laser Root Pass with HLAW Finish

= 85% reduction in volume


Results of Hybrid Laser Welding

• Low Distortion – Up to 90% lower heat input – 50% less residual stress (magnitude) – Very small HAZ

• Uniform Welds – Average fatigue life improvement- 2-3 times – Low amplitude life improvement- 10 times

• High Productivity – 6 mm (1/4”) penetration at up to 5 m/min (200”/min) – Up to 12.5 mm (1/2”) butt, single pass, single side at 2 m/

min (80”/min)


Advantages of Hybrid Laser Welding

• Improved Process Efficiency – HLAW can reduce welding consumable costs by up to

90%

– Typical fillet welding example:


Friction Stir Welding (FFSW)

Metals are “Stirred” together with the use of a rotating tool Material is not melted, but rather softened, stirred, and forged together

Benefits:

• Elimination of solidification defects,

• low heat input,

• improved weld properties over arc welding,

• no filler material,

• and zero fumes


Micro-diagram


FSW of High Melting Temperature Materials

• ESAB markets, sells, and supports systems for welding steels, stainless steels, nickel base and other high temperature materials

Stir Zone


High Temp Alloy Applications

Grain refinement exhibited in Ni alloys

Breaks in base material (Supermartensitic Stainless Steel)

Grain refinement in Duplex Stainless Steel




• Focus-point on surface • Shielding gas Ar 20 l/min • Welding speed 0,30 m/min

• Focus-point - 3mm • Shielding gas Ar 20 l/min • Welding speed 0,35 m/min

YAG-laser welding of C-Mn steel t = 15 mm and P = 9 kW Considered for pipe-welding


Today. . .

Tomorrow


• Features. – Incorporates longitudinal

stiffening into panel. – High rigidity and flatness. – Eliminates poured deck

levelers, insulation, etc. – Manufacturing process is fully

automated.

• Benefits. – 50% less weight than

comparable beam-and-plate structure.

– 1/10th – 1/15th the weight of concrete.

– 2/3rd reduction in structural volume.

Courtesy of Meyer-Werft

Courtesy of Meyer-Werft


• Thickness 6 mm (1/4”) • Welding speed 1,8 m/min • No backing needed!

• High strength steel (UTS 640) for beam construction


FSW Pipeline Applications

12 mm - X100 pipeline steel

X65 - Weld Properties exceed base material


FSW High Melting Temp. Alloys

Stainless Steel finished goods

Transmission Pipelines

Nuclear Container, Refineries

Tubes, cylinders


Welding Aluminum

Range of applications ranging from ship building, automotive, nuclear storage, and aerospace




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Jeff Defalco [email protected] 843.664.5616

Welding Automation

Defalco

Business

increased productivity

faster roi welding automation

welding automation2

cost reductions

better quality

improved perceived value