Advanced Welding Processes: Technologies and Process Control

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Table 11.1 Robot applications Welding automation and robotics 235 Applications Material Process Robot Reason Ref. Ornamental Hot-rolled GMAW 5 axis Cost and 270 gates mild steel artic. arm productivity Hydraulic BS 4360 GMAW 6 axis Reduced cost 270 hoist parts 43A steel 10–12 mm artic. arm Hospital Square- GMAW 5-axis Reduced cost, 270 beds section artic. arm improved steel tube quality Dashboards Aluminium Spot Modular Increased 270 Cartesian output Nuclear boiler Steel GMAW Gantry- Quality 270 panels suspended artic. arms Domestic boilers Steel GMAW Twin arm Skill shortage 270 Military 3-mm-thick Spot Cartesian Economic 270 storage Tenform system XK-350 Vehicle Pressed GMAW 16 artic. Improved output 271 chassis steel arm and quality Vehicle Steel GMAW Artic. arm Increased output 272 exhaust manip. and improved systems plus FMS quality Turbine Stainless Pulsed 6-axis Quality and 273 diaphragm steel GTAW artic. arm integration with filler into CIM Space shuttle Nickel-based, Pulsed Various Quality 274 engines cobalt-based, Ti alloy and stainless steel GTAW Car bodies Low-carbon Spot 6 axis artic. Output and 275 steel arm quality Engine Low-carbon Laser 6-axis artic. Output and 275 support steel arm quality are important. For these reasons, reasonable batch sizes are expected to justify the investment in robotic automation. Robotic power beam welding The use of robots for laser and electron beam welding applications is at an early stage of development. Trials of robotic systems for out-of-vacuum
236 Advanced welding processes NVEB are taking place, whilst industrial applications of laser welding are in progress; for example in the welding of engine support frames for the Fiat Tipo. [278] Specially designed robots have been produced for laser welding with either mirror or fibre optic beam delivery systems incorporated in the arm. 11.6 Modular automation As the cost and limitations of fully dedicated automation have become clearer, attempts have been made to design lower-cost flexible systems which may be configured to suit a range of applications. This has led to the development of modular automation systems. Modular systems comprise a kit of common mechanical components, which can be assembled into any configuration to suit the application. The modules consist of support beams, slides, carriages, pivots, linear and rotational drives, torch holders and control systems. The advantages of this approach are rapid system design, simplicity and low cost. A welding automation system may be developed very quickly using this approach and costly design studies are eliminated. The standard parts are easily interchangeable in the event of damage or breakdown and the total cost of the installation is kept to a minimum. The system may be used for most of the common arc welding processes and is particularly suitable for GMAW, GTAW and plasma welding. Control of position and operating sequences and interface with the welding equipment is provided by a simple electronic logic system. The capabilities of the system may be extended by using a standard industrial programmable controller. 11.7 Programmable control The control systems approach used for robotic welding may be applied to special-purpose, dedicated and modular automation systems to improve their flexibility. This approach has been adopted, for example, on orbital GTAW equipment to allow complex welding procedures to be developed and stored for specific joints. In this case, a computer control system is usually incorporated in the power source or as an interface between the welding power source and the welding head. For more general applications with dedicated and modular automation, flexible computer control systems have been developed. [279] These systems have the following facilities: ∑ positional control; ∑ weld process control; ∑ cell management.
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Advanced welding processes i
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Advanced welding processes Technolo
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Contents Preface ix Acknowledgement
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Contents vii 10.4 Automated control
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Welding has traditionally been rega
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Acknowledgements I would like to ac
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1.1 Introduction Welding and joinin
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An introduction to welding processe
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Stage 1 Stage 2 An introduction to
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Slag deposit on weld surface An int
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∑ no heavy slag - reduced post-we
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Electro slag SAW multi wire SAW FCA
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Weld metal used (kg m -1 ) 40 35 30
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Advanced process development trends
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% consumed 70 60 50 40 30 20 10 Adv
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Advanced process development trends
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Mains input Power regulation Contro
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Welding power source technology 29
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Three-phase transformer Three-phase
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Mains input Welding power source te
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Off line storage Operator interface
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4.2.1 Improved toughness Filler mat
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Filler materials for arc welding 47
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Flat strip Solidified slag on weld
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Gases for advanced welding processe
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CVN impact energy (J) 200 150 100 5
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∑ argon plus 15-25% carbon dioxid
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25 23 21 19 17 15 13 11 9 7 20 18 1
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Ozone emission (ml min -1 ) 4 3 2 1
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Table 5.3 Continued Argon + 1 to 7%
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Advanced gas tungsten arc welding 7
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Power source Advanced gas tungsten
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Number of arc starts 35 30 25 20 15
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Water cooling 6.7 Dual-shielded GTA
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∑ low current: 0.1-15 A; ∑ inte
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Surface tension Surface tension Adv
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7.2.1 Globular drop transfer Metal
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Gas metal arc welding 103 projected
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Droplet forming 7.6 Drop spray tran
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Number of counts 100 80 60 40 20 0
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Metal cored Rutile Basic Self-shiel
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F d Fem F v F st F g 7.13 Balance o
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Gas metal arc welding 113 is the cu
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Stick out Dip transfer Pulse/spray
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Gas metal arc welding 117 V = M + A
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Voltage (V) 50 40 30 20 10 Gas meta
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Pulse current t p 7.23 Pulsed trans
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Gas metal arc welding 123 The mean
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Wire feed rate (m min -1 ) 11 10.5
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Gas metal arc welding 127 Improveme
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Gas metal arc welding 129 and a num
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Current (A) 500 400 300 200 100 0 G
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Pulse amplitude (A) 500 400 300 200
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Gas metal arc welding 135 otherwise
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High-energy density processes 137
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High-energy density processes 139 P
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Arc voltage 30 25 20 15 10 High-ene
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High-energy density processes 143 N
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Reflecting mirror Laser cavity Powe
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High-energy density processes 147 H
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Laser beam Gas lens Plasma control
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High-energy density processes 151 P
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High-energy density processes 153 M
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High-energy density processes 155 a
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High-energy density processes 157 l
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High-energy density processes 159 p
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8.4.5 Practical considerations High
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Sliding particle stop Undeflected b
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9.1 Introduction 9 Narrow-gap weldi
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6-16 mm Parallel-sided with backing
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Water cooling Main Shielding-gas po
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Narrow-gap welding techniques 171 T
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9.7 ‘Twist arc’ narrow-gap GMAW
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GMAW torch The NOW process GMAW tor
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Narrow-gap welding techniques 177 T
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10.1 Introduction 10 Monitoring and
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Monitoring and control of welding p
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PROJECT: WELDING CODE : WELDING PRO
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Page 204 and 205: Data RAM ADC I/O device Monitoring
Page 208 and 209: Current I(A) 150 140 130 120 110 Mo
Page 210 and 211: Table 10.5 Stability criteria Monit
Page 224 and 225: CCD camera Travel direction Torch M
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Page 256 and 257: ∑ evaluate alternatives; ∑ eval
Page 258 and 259: Option Manual metal arc Gas metal a
Page 260 and 261: Appendices Appendices 247
Page 262 and 263: Arc Metal arc Manual metal arc Resi
Page 264 and 265: Tensile strength Appendices 251 Des
Page 266 and 267: Appendices 253 Exx16 Basic low-hydr
Page 268 and 269: GMAW stainless steel c Wire feed sp
Page 270 and 271: Appendix 4 American, Australian and
Page 272 and 273: Appendices 259 Carbon Manganese ste
Page 274 and 275: Consumable type Features Applicatio
Page 276 and 277: Appendix 7 Plasma keyhole welding o
Page 278 and 279: References [1] British Standards In
Page 280 and 281: References 267 [40] Anon, 1989 ‘S
Page 282 and 283: References 269 [88] Boughton P and
Page 284 and 285: References 271 Century Conference (
Page 286 and 287: References 273 [178] Benn B, 1988
Page 288 and 289: References 275 [224] Philpott M L,
Page 290 and 291: References 277 [269] UK Patent 8411
Page 292 and 293: Activated TIG (A-TIG) 91, 97 adapti
Page 294 and 295: digital measuring systems 189-90 di
Page 296 and 297: high-frequency high-voltage arc ini
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current measurement 194-6 determina
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carbon dioxide 63-4, 64-6 chlorine
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Advanced Welding Processes: Technologies and Process Control

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