warehouse in Alberta – Canada’s large oil patch region.Once customers recognise the quality and performanceof the products, the orders will follow quickly. Thisinventory will allow for delivery in a reasonable lengthof time, which is essential to success.Our challenges are not over. In the coming months,we have to continue to explore the US market andto follow up the many leads we have received. As webegin to book orders, we will stress our ability to handlethe volume, both in Sweden production and in NorthAmerica. The United States is a huge country, a hugemarket, which requires extensive air travel. The eventsof 11 September have made flying more time consumingand have reduced the number of options available. Althoughwe may have the best product line in the industry,we need to be realistic in a recession economy.Figure 2. ESAB Mechtrac welding tractor.Figure 3. PEMA AHMA7000 positioner.filler metals to welding machines to positioners. Our goalis to provide the total solution, not just an equipmentpackage. This lowers the customer’s risk in a project.If ESAB supplies the filler metals, we will be highlymotivated to service the customer, long after the initialcapital goods sale has been made. The customer willvalue the long-term commitment and ESAB will berewarded with both machinery and filler metals business.Of course, this approach is nothing new: ESAB Europebuilt its successful automation business by providing atotal solution for the customer. It will work in NorthAmerica, too!ESAB is gradually building inventory in NorthAmerica. We currently stock equipment such as manipulators,positioners and turning rolls. Demo machineswill be set up in the Mississauga plant and in the new•32svetsaren nr 1-2002Notable installationsESAB Automation NA has already had some notableinstallations, which demonstrate the great strengthand potential of the business. Formet Industries,Ontario, is a division of Magna, the largest automotiveframe manufacturing plant worldwide. This companypurchased a large quantity of ESAB Aristo MIGmachines, based on the performance, features andreliability of the products.Jasper Tank, a distinguished tank manufactureroperating out of Spruce Grove, Alberta, drasticallyimproved its production rate with the purchase ofan MKR column and boom, equipped with a PEHmicroprocessor weld controller. The new equipmentreduced the welding time by 40% in one particular task:welding the baffle rings inside the tanks.American Tank, Cleveland, Oh, manufacturesextremely thick-wall pressure vessels. In September,ESAB delivered another large CaB 460 with tandemwelding heads. The customer reports virtually defect-freewelding performance with its ESAB installations.ESAB is here to stayWe will survive this recession, we will emerge on theother side as a stronger company and ESAB AutomationNorth America will succeed!
ESAB in the automotive industryby Lars-Erik Stridh, EWE Segment Support Manager ESAB AB GöteborgESAB, the world’s largest welding company, obviously has an important presencein the automotive industry. ESAB, the world’s largest welding company, obviouslyhas an important presence in the automotive industry. We invest substantialresources in developing welding processes, consumables, power sources,automation equipment and interfaces with robots.ESAB does not supply robots to the automotiveindustry, but it is nonetheless a very active partner,together with robot suppliers, when it comes to findingthe optimal solution in combination in every situation.This combination involves consumables, power sources,wire-feed units, shielding gas, welding procedures,interfaces and productivity. Different customer projectsfocusing on many different applications within theautomotive industry are constantly in progress at thevarious ESAB process centres.ConsumablesThe consumable that dominates the automotive industryis solid wire, made of different material grades,depending on the parent material. These consumablesare the subject of ongoing development work designedto improve their welding characteristics. Some of thiswork focuses on optimising the chemical composition ofthe consumable in order to match the characteristics ofthe parent material as effectively as possible. Nowadays,a wide range of different grades of parent material isused in a car body. There are other requirements thatare also important and they include feed reliability,low spatter levels, low or non-existent levels of surfaceimpurity on the weld joints and problem-free welding onzinc-coated or aluminised sheet metal. The introductionof metal-cored wires in special applications in theautomotive segment is currently taking place and theywill be described at a later stage in this article.When it comes to the welding of the exhaustsystem and the catalytic converter system, extensiveresearch is being conducted to develop the most durablesystems possible, together with materials that withstandincreasingly high temperatures, in order to controlemissions as effectively as possible. This naturallyimposes the same demands on the consumables, whichhave to provide high-temperature characteristics, corrosionresistance and good fatigue strength properties.Here, too, metal-cored wires are making an entrance.Change of processThe following example shows how a change ofconsumable/process resulted in enhanced quality and,in this case, also in improved productivity.The object of this example is a catalytic converterand its outlet pipe connection to a flange. The catalyticconverter outlet pipe is made of a ferritic stainlessmaterial and it is welded to a flange made of normalC/Mn steel. Initially, the customer welded this joint usinga solid wire (1.0 mm) of an Nb-stabiliserad 409 grade.A number of problems occurred, including weldingspatter, sharp transitions to the parent material à whichresulted in poor fatigue strength and far too muchhardness in the HAZ. One of the problems associatedwith using this “matching” consumable is that theparameter range that is needed to produce a satisfactoryresult is very small. In this case, where a “mixed joint”is involved, the tolerance range requirements areextremely rigorous.As the work of finding a process that improvedthe quality and was also more “forgiving”, in orderto guarantee more stable quality, progressed, ametal-cored wire was tested. It was also of the E 409grade. The result of this test was a significant reductionin spatter and more uniform transitions between theweld and the parent material, thereby substantiallyimproving the fatigue strength. The problem of thehardness in the HAZ still remained; it was still a littletoo high and it was difficult to control it using thewelding parameters.In an attempt to control the hardness and retain thetemperature resistance and corrosion resistance at thesame time, another metal-cored wire, E 307(18/8/6),was tested. This wire has a diameter of 1.2 mm. Thehardness now declined, no individual hardness valueexceeded 225 HV10 and the transition between theferritic stainless steel and the C/Mn steel contained noundesirable microstructures.There was also an extra bonus. In addition to solvingthe aforementioned problems, the introduction of thismetal-cored wire increased the welding speed from12 mm/sec to 20 mm/sec. This then meant that thecycle time for the welding operation was reduced,thereby cutting the cost of each part that was weldedby 22%.svetsaren nr 1-2002 •33