TPT July 2016

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24 July 2016
T E CHNOLOG Y
New welding process for
advantages in efficiency
THE new forceArc puls welding process
from EWM AG combines the strengths
of forceArc with the advantages of a
pulsed arc, enabling wide applicability,
low heat input and higher welding
speeds.
The new MIG/MAG welding process is
suitable for the welding of both unalloyed
or low-alloy steels and chrome nickel
steels. Its deep penetration makes it
especially suitable for root welding with
single- and double-sided full penetration.
In comparison to pulsed arc welding,
the process enables up to 20 per cent
higher welding speeds with an identical
throat thickness.
The new process is also
characterised by a lower heat input,
reducing discolouration and minimising
distortion. As the arc is also nearly
spatter-free, this reduces reworking
and straightening work by up to 50 per
cent – a particular advantage when
working with CrNi steels.
Switching from standard
GMAW welding to the new
process is also easy. The
excellent wetting of the
process makes it easy to
handle, requiring almost
no practice time, and a
reduction in welding fumes
brings high operator acceptance levels.
Pierre Mack, managing director of
Mesa Metall-Stahlbau, commented, “We
have managed to reduce production
times for welding and grinding by an
incredible 57 per cent.” His company
had required 781 working hours for the
production of four water containers for
fire and rescue trains using conventional
welding technology; the introduction of
the new EWM arc and EWM technology
required only 339 hours. “We would miss
out on a lot of contracts if we weren’t able
to weld in this way,” added Mr Mack.
forceArcpulsalsobringstechnological
advantages in a range of applications.
Users working in accordance with EN
1090 find the depth of penetration
enables higher strength values in the
joint. The effective and total weld seam
thickness is higher than the nominal
seam thickness, making welding often
possible with just a single pass.
EWM AG – Germany
Fax: +49 2680 181 244
Email:
Website:
forceArc puls achieves up to
20 per cent greater penetration
depth compared to the pulsed arc
Photo credit: EWM AG
For ty seven bends in 140 seconds
THE production of lines for braking
systems, air conditioning units and
similar devices with a length of 1,500mm
and diameters of as little as 18mm
represents a challenge when it comes
to bending technology, specifically with
regard to handling. To be economical,
production processes also need to be
swift, and precision and quality are
factors that are just as important. As part
of a recent project the team at transfluid
developed a tube processing system that
involves robot handling of the material
and that can bend tubing in lengths of
up to 4,500mm – 47 bends in a time of
around 140 seconds.
Another specification that the team had
to meet when developing the solution
was that the tubing would be already
shaped or fitted with flanges.
The process involves inserting into a
feeder a bundle of tubes, which are then
individually orientated by symmetrical
rotation according to the positioning of
the flanges. Each tube is then picked up
by one of the two robots, which transfers
it to a moveable spanning device with
an appropriate high retaining system
designed for longer tubing.
The spanning device allows the
robots to process the tubes on one or
even on two sides in parallel. This also
speeds up the procedure. The time
required for processing each tube, even
at this length, is constantly less than
three seconds. Both robots have seven
axes with drive systems, and can bend
right/left. Another advantage of this tube
bending concept is that isometric data
can be uploaded directly online from a
CAD system.
transfluid Maschinenbau GmbH –
Germany
Email:
Website:
The combination of a tube bending system with robot handling
allows tubes with a length of up to 4,500mm to be processed