Welding Metaltech Report
- March 4, 2012
Travel carriage delivers 60 lb/hr deposition rates
Lincoln Electric’s self-propelled modular Cruiser Tractor brings increased mobility and operator-friendly features to longitudinal submerged arc welding applications common in bridge and barge decking, large tank fabrication and shipbuilding.
When used with the Power Wave AC/DC 1000 SD power source, the Cruiser travel carriage can deliver deposition rates of up to 60 lb per hour for butt and fillet joins on lengthy plate welding applications.
Rated for 1000 amps at 100 per cent duty cycle depending on gear ratio used, the feeder can handle 1.6 – 5.6 mm 1 (/16 – 7/32 in.) submerged arc wire diameters at travel speeds ranging from 0.25 – 2.5 m/min (10 to 100 ipm).
“On the fly” switch between AC/DC power
ESAB Welding and Cutting Products’ Aristo 1000 AC/DC power source for sub arc welding is an inverter power source that can be connected to a three-phase input voltage supply (from 380 to 575V at 50 or 60 Hz). This power source uses unique, patent-pending technologies to deliver the best welding performance with the lowest power consumption, claims the company. The result is a power source that will deliver more welding per kilowatt-hour.
The Aristo 1000 AC/DC allows the user to switch between AC and DC currents without stopping the welding process, perfect for automated welding, says ESAB. A DC arc is normally used for the root pass to achieve full penetration. The AC/DC’s “on the fly” switching function means operator can switch over to an AC arc without stopping the process when welding on round objects. This minimizes downtime and the risk of weld defects as the stop and re-start sequence is completely eliminated.
The new power source offers full control of the settings for AC welding. Using the Bead Profile Modeling function gives the operator full control over the AC frequency, balance and offset. This allows the user to optimize penetration profile, heat input, deposition rate, arc stability and stirring effect to suit the situation and need.
Two Aristo 1000 AC/DC units can be connected in synchronized parallel mode to deliver more welding current. This machine is designed for heavy-duty industrial environments and is ideal for welding wind tower structures, nuclear components, beams, bridge components, trailer beams, excavator components, and for general fabrication.
Mavrix Welding Automation
Dual torch shredder disc
Mavrix Welding Automation Inc. has redesigned its dual torch shredder disc rebuild system with an improved mounting system and open carriage design that reduces installation time to 30 minutes or less. The dual torch system can apply 50 lb of weld metal per hour, significantly shortening downtime, the frequency of maintenance events and cost per ton of scrap or recycled material.
Mavrix’s systems can be integrated with all hammer-type shredders with disc rotors, including those from Metso-Texas Shredder, Riverside Engineering, Newell, TSC, Wendt and American Pulverizer.
The dual torch disc rebuild system includes two weld carriages that support the weld arm and adjustable open arc torches, wire feeders and 60-lb. coils of wire. The carriage with the new opening design allows the main beam and legs to be installed first and the carriages second, significantly reducing the weight of the system and making installation easier.
Miller Welding Automation
Robotic welding cell
The PerformArc PA 350 S from Miller Welding Automation is a pre-engineered robotic welding cell designed to simplify the transition into robotic welding applications for manufacturers. Shipped pre-wired and pre-assembled, the robotic welding cell is operational within minutes of deployment and is easily relocated within a shop’s workflow simply by disconnecting the utilities. The cell features a fast Panasonic AC servo positioner that turns 180° in under 2.2 seconds, minimizing index time and maximizing productivity.
The cell comes standard with the Auto-Axcess software-driven Multi-MIG process platform, and can be further optimized with the Auto-Axcess with Insight weld data monitoring system to provide comprehensive feedback on welding activity and productivity. It can also be coupled with optional Panasonic TAWERS™ robotic solutions. A standard platen design with bolt and dowel holes provides repeatable fixture mounting when multiple fixtures are exchanged on the same work cell. An integrated operator control panel and full-color teach pendant provide full-system control, diagnostics and programming capability in one central location.
Robotic MIG guns
Tregaskiss has expanded its Tough Gun ThruArm G2 Series of robotic MIG guns to include configurations for robots from ABB, FANUC, KUKA and OTC. The series incorporates superior alignment features that help maintain tool center point (TCP), ensuring consistent and reliable welding performance.
The Tough Gun ThruArm G2 Series also includes the Low-Stress Robotic (LSR) Unicable technology. Designed for today’s through-arm robotic welding systems, the LSR Unicable includes a rotating power connection that relieves stress caused by routine cable torsion, lessening the frequency of cable changeover and reducing the associated downtime. The unicable also features protective conduit to shield the cable components from harsh welding environments. Tregaskiss guarantees the LSR Unicables with a two year limited warranty.
Wire Brake, Air Blast and Tough Gun I.C.E. options are available for select models. The Tough Gun I.C.E. hybrid feature adds the benefit of water-cooling to the series. This technology circulates water externally to the nozzle, keeping front-end consumables running cooler and lasting longer.
3-in-1 welding system
Thermal Arc, a Thermadyne brand in arc welding technology, has launched the Fabricator 252i “3-in-1” MIG-Stick-TIG welding system. Weighing 66 lb and with an output range of 5 to 300 amps (250 amps at 40 per cent duty cycle), the system is the second in a new category of welding products: multi-process, fully integrated, portable welders. With an MSRP of $2,509 for the base package, the Fabricator 252i provides three welding processes for the price of competitive MIG-only units.
Features include MIG inductance control to improve arc stability and reduce spatter, and MIG spot and stitch welding control. It also offers a Stick Hot Start to prevent the electrode from sticking, Stick Arc Force Control to adjust arc characteristics for all electrodes, and LIFT TIG for arc starts without high frequency.
Digital meters, a comprehensive set-up chart and quick-change (no tools) polarity connections make the unit user friendly. Other features include a 10-pin receptacle for MIG welding aluminum with a spool gun, burn back control, run-in speed control and wire sharp to improve MIG arc starts, downslope control to reduce crater cracking when TIG welding, adjustable pre and post-flow and 4T trigger hold control to reduce hand fatigue on long TIG or MIG welds.