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High Productivity Arc Welding

Project Code: 0903-01


Develop techniques for single and multiple wire MIG/MAG narrow gap welding of carbon steel plates of thickness greater than 50mm.

Develop techniques for single and multiple wire SAW welding of carbon steel plates of thickness greater than 50mm.

Provide guidance on the practical implementation of the above to achieve a combination of good weld quality and high productivity.

Evaluate the productivity benefits of the narrow gap procedures, and compare it with those of conventional welding procedures.

Project Outline

The productivity of process techniques such as tandem MIG/MAG and variable polarity SAW will be investigated for high productivity welding of sections of 50mm and above. A narrow gap technique is envisaged to gain the greatest productivity advantage. Narrow gap techniques will require optimisation of the process variables to ensure good side wall fusion combined with rapid joint completion. Initial work to assess the affects of process parameters will be carried using a combination of bead-on-plate welding followed by relatively simple joint configurations.

Advanced preparation methods such as the high speed grinding facility from Farros Blatter, will be investigated as a means of optimising welding costs. Fairly quickly, it is anticipated that work will progress to a narrow gap configuration, initially using single then multiple wire (2 wires for MIG/MAG, up to 4 for SAW). The main body of work will be carried out using solid wire, however, for comparison limited trials will be carried out using tubular cored filler wires for both MIG/MAG and SAW.

Finally, trials with the optimised welding parameters will be carried out in circumferential weld configuration. The part will be rotated under a fixed welding head in the down-hand configuration. The welding trials will be conducted on carbon steel of thicknesses in the range 50 to 150 mm, in plate and/or pipe form as appropriate. Some limited assessment of the effect of process parameters on resultant microstructure and tensile and impact properties will be carried out.

Relevant Industry Sectors

Defence, Heavy construction, Oil and Gas, Power Generation, Nuclear

Technical and Economic Benefits

Improved productivity without significant capital equipment expenditure.

Reduced costs as a result of fewer defects and associated re-work.

Reduced costs as a result of fewer defects and increased flexibility of process selection.

Industrial Member Report

Access the Industrial Member Report resulting from this programme:

Process Parameters Influencing the Melt Profile and Deposition Rate in High Productivity Arc Welding Processes for Thick Section

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