welding fumes maskClick image to enlarge

Shop Metalworking Technology takes a look at some of the latest welding advances in this special tech focus.

Capacitor discharge resistance welding systems

T.J. Snow 3 arm edit 2Click image to enlarge

The Capacitor discharge resistance welding process is ideal for quick and repeatable mass production processes that require tight dimensional tolerances. Capacitor discharge resistance welding is ideal for projection, press-fit and annular ring projections up to 114.3 mm (4.5 in.) in diameter. Low marking welds can be better achieved due to the small heat affected zone. Since the CD resistance welding process utilizes stored energy rather than conventional processes which use direct demand on incoming power, the welding times are short – typically in 10 milliseconds or less. An upgraded power service to your building is often not needed as the high electrical energy required is not taken directly from the power distribution network but from a bank of capacitors, which stores the energy and recharges between welds.

T.J. Snow Capacitor discharge resistance welding systems

Capacitor discharge resistance welding offers many benefits:

  • Instantaneous high secondary currents
  • Minimal heat affected zone
  • High operating efficiency
  • Ideal for show surfaces
  • No alteration of work piece metallurgy
  • No surface deformation
  • No spatter
  • No power service upgrades necessary
  • Long electrode life (usually does not required cooling due to low heat impact)
  • Quality measures
  • Low equipment maintenance
  • An effective solution for welding dissimilar materials
  • Carbonized steel and hardened steel
  • Monitoring and documentation standard in all models

These systems are ideal for mass produced products in the automotive, appliance, electrical sectors and more.


Monitor welding data

Lincoln Electric Check PointClick image to enlargeLincoln Electric CheckPoint

Lincoln Electric has launched the fifth generation of its CheckPoint Weld Data Monitoring solution, featuring a fresh redesign to further improve the ability to turn weld data into action.

With the new redesign, the tool delivers improved dashboards and reports, all purposely designed to help users make the most of the real-time weld data they collect to drive productivity, quality and efficiency around the clock.

This latest generation of CheckPoint moves users beyond overwhelming amounts of raw information and dated reports, using clean, powerful dashboards to deliver essential weld data faster and easier.

Upgraded features include:

  • Improved dashboards that provide essential, industry-specific Key Performance Indicators to track productivity, including trend projections, Operating Factor, and real-time OEE calculations.
  • Improved charting and graphing, including dynamic data-point breakdowns, and chart filters.
  • Optimized reporting that helps track key quality metrics down to the individual welding station or robotic cell.
  • Real-time shift planning to help visualize shift schedules and planned downtime.

Available as a standard feature on existing and new Power Wave and PIPEFAB welding systems, CheckPoint weld data monitoring has no software to install and no hidden costs. The cloud-based platform can be easily accessed on a web browser, allowing users to quickly connect and visualize weld data anywhere, at any time.


Weld fume extraction for cobots

Translas weld fume extractorClick image to enlargeTranslas weld fume extractor

The 8XR MIG Extractor from Translas is made for cobot and semi-automatic welding solutions.

The 8XR’s unique nozzle design provides the best results in taking away the fumes directly at the source. The nickel-plated contact tips are designed for a longer lifetime and are available for all types of wire and sizes.

The 8XR will fit almost every marked known torch holder and easy to clamp in a track.

Prolonged exposure is like inhaling ultrafine metal dust which can lead to cancer of the lung, damage to the brain and kidney damage. Certain gases, such as helium, carbon dioxide and argon, displace oxygen and argon can pose suffocation risks, particularly in enclosed work areas.

The 8XR Cobot MIG Extractor integrates the most efficient fume extraction structure in the welding industry. The torch comes with four different angles: 22°, 35°, 45° and straight.

Combined with the ClearO2 W-series 100 and 200, it captures up to 98 per cent of welding fumes directly at the source.


Laser processing workstation

amada wlseriesClick image to enlarge

Amada Weld Tech’s new WL-300A laser processing workstation is configured for nanosecond pulsed fiber laser applications.

Typical applications include marking of metals and select plastics for medical, electronic components, battery, and aerospace applications.

It’s available in bench top or floor standing units with standard options including an XY table, rotary stage, cover gas module, fume extraction, bar code reader, and camera systems to tailor the machines to the specific process.

Featuring fast and precise motorized Z-axis for easy focus adjustment, easy access to parts and tooling, and an optional XY table for step and repeat motion, the WL-300A offers a large viewing window for easy visual observation. Lens options include F-Theta 100 mm, 160 mm, 254 mm, and 420 mm for marking a wide variety of parts and sizes. An optional compact motorized rotary axis makes marking and welding cylindrical parts easy and fast. The workstation also provides easy part fixturing using the M6 threaded hole pattern mounting base plate. A fume extraction port is included with flexible tubing to extract harmful fumes created during the laser process

The WL-300A can handle a wide variety of mark types, including line-art graphics; shaded graphics; TrueType fonts; single point or drill object arrays; and Data Matrix or QR code barcodes; as well as MS AutoDate, MS TextMerge, serialization, and barcode marks. Though primarily designed for laser marking and engraving applications, the laser source can also be used to weld and cut thin metals up to 0.010-in. (250 microns).


Flux for submerged arc welding

ESABClick image to enlarge

ESAB has improved its OK Flux 10.99, an agglomerated neutral basic flux designed for submerged arc welding in heavy industrial environments.

It’s perfect for tasks in petrochemical plants, offshore construction, transport, LNG and LEG tanks, pressure vessel, and pulp and paper industries.

The enhanced formula of the flux works, in combination with selected austenitic and nickel-based wires, performs equally well with either AC or DC+ current, and provides significantly improved slag release, increased productivity and better weld quality.

As a neutral flux, it will not contribute any alloying elements to the weld metal. When combined with nickel-based products, such as ESAB’s OK Autrod NiCrMo-4, hot cracking is significantly decreased. Its low silicon content provides good mechanical properties and weld deposits. OK Flux 10.99 achieves superior tie-in, toe angles and bead appearance on interior and exterior applications.

Welding with OK Flux 10.99 using an AC output increases productivity by up to 15 per cent with the ability to use higher wire feed speeds. It provides moisture and corrosion resistance. In addition, its high weld quality reduces scrap and its increased slag release decreases clean-up time.

OK Flux 10.99 has a grain size of 0.2 to 2.0 mm and a basicity index of 2.1, making it ideal for pressure vessel, chemical and petrochemical plant applications and other industrial environments requiring multi-run welding and unlimited plate thicknesses. It combines well with many submerged arc wires, OK Autrod 308L, 309L, 316L, 316LMn and NiCrMo-4.

OK Flux 10.99 is available in 25 kg bags. For increased moisture protection and decreased risk of packaging damage, 25 kg steel buckets are also available. There is no need to redry the flux prior to use onsite because the packaging protects the flux from any moisture absorption during transport and storage.


New Thulium fibers enable production of high power fiber lasers at 2 µm

A new range of Thulium doped fiber optic components from Coherent | Nufern enables construction of fiber lasers and oscillators operating at ~ 2 µm with higher output power than was previously possible, claims the company.

Auto-Darkening Filters for Welding Helmets

Weldcote’s auto-darkening filters feature clear, true-colour blue, high-definition technology that enhances the visible spectrum for optimal clarity and reduced eye fatigue.

Automated hybrid laser processing machine

TRUMPF has introduced the TruLaser Center 7030 fully automated laser processing machine.

MIG and TIG weld cleaning system

Walter Surface Technologies has recently introduced the Surfox 305, a patented electrochemical MIG and TIG weld cleaning system.

Welding helmet with integrated flip-up grind shield

Lincoln Electric has introduced the Viking 3250D FGS Welding Helmet.

Double column machining centre

Okuma has launched the new MCR-BV double-column machining centre.

Flap discs with extended flap design

Polifan-Strong flap discs from PFERD remove more material in less time than most other consumable abrasives for angle grinders.

Three flute indexable drill

Iscar recently unveiled the new SUMO3CHAN advanced three flute indexable drill.

Drilling systems offer faster drilling and increased tool life

M4 Sciences has expanded its line of TriboMAM drilling systems using Modulation-Assisted Machining (MAM) technology.

Software automatically generates part programs for inspection

Mituotyo's MiCAT Planner is new software which automatically generates part programs for inspection for CNC CMM users.

Machinery evaluation program

Fives Group has introduced a new machinery evaluation program to assess machine tools.

Expanded press brake tooling CleanBend

Mate Precision Tooling has expanded its press brake tooling product line with the addition of CleanBend forming technology.

Carbon arc gouging torch

The Arcair brand of ESAB has been expanded with the addition of the AirPro X4000 torch and cable.

Automatic welding helmet

ESAB has developed a new automotic welding helmet that incorporates ergonomic headgeaur and adjustablity to increase productivity, functionality and useability, claims the company.

Weld visualization technology and 3D welding helmet

SRI International has partnered with Kawada Technologies and Kawada Industries to introduce weld visualization technology and a 3D welding helmet.

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