WELDING specialization

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Hello everybody.I am writting you because I work in a Welding research and development center in Spain which has different welding departments like, arc welding, laser welding, frictionstir welding etc.Now we have to launch a Welding Specialization plan in my area, which is dedicated to the good ol´ arc welding.To have an idea, here in Spain the arc welding is about the 75% of the total welding. (More or less like in the rest of the world). And inside de arc welding, the GMAW welding is about the 75%.The  idea is not to choose the more widely used welding process, the idea is to choose some processes to become more expert and make research and development with them. Allways thinking to give support to companies and make investigation projects.In a first moment we are thinking about the GMAW innovative processes (like CMT,Coldarc, STT and more). We see other interesting and innovative processes like PTA for example, but I would like to hear you opinions in this issue. Every one will be welcome.Thanks in advance pals.Bye!
Reply:I think that there may be some thing lost in translation. If what I think your asking is what your asking im in no position to answer your question as im a noob. But if a may suggest you give us in one sentence exactly what the question is?? My interpratation is you want is recomendations for what type of welding to teach that falls inside the arch welding arena. I would ask my self only two questions what would give my students the highest level of employability right out of my course and two what would give my students the  biggest exposure to new technology that will give them a edge in the industry in the future. But then again like i said i dont really understand what your asking.
Reply:Originally Posted by B.A.BaracusHello everybody.I am writting you because I work in a Welding research and development center in Spain which has different welding departments like, arc welding, laser welding, frictionstir welding etc.(snip)In a first moment we are thinking about the GMAW innovative processes (like CMT,Coldarc, STT and more). We see other interesting and innovative processes like PTA for example, but I would like to hear you opinions in this issue. Every one will be welcome.Thanks in advance pals.Bye!
Reply:a friend of mine was doing graduate research looking into welding in Zero GsWeldanpower 225 G7Ironworkers Local #24
Reply:Friction stir and thermal stir are the future of welding. Get into that if you can.Two turn tables and a microphone.
Reply:Hello Teljkon and everybody, and thanks for your answers.First of all let me try to explain a bit better my inquiry. (Not very easy believe me).We are a company which gives support in everything related with welding. We have a Technological Services department which does welding qualification (Asme IX, API, ISO, UNE EN…), welding quality certification ISO UNE EN 3834, 15085…… We also do non destructive inspections like UT, DP, MP, VI…, welding related destructive tests…..We also give support to companies with welding problems like crackings, porosity or other welding failures……..We have also a design department which calculates welding structures, weld related distortions, thermal conductivities etc.Also a department who makes template-tools and automation items to buy welded subsets for automotion, trains, building industry etc…And concrete welding areas like friction, laser and arc welding.In this last but not least one, I have to give a reorientation or specialization plan based on arc processes to my department. That´s the question more or less.We have to define innovative arc welding processes to help companies improve their weld related quality and solve lot´s of problems like: –How can I weld this strange materials? Which process can I use?-Can I do this hardfacing without crackings?-How can I join this two different materials?-How can I standardize the weld parameters to don’t have an usual mess in welding?-How can I weld this materials without been out of tolerances?-Why has this heavy metal structure overthrow?That´s the idea more or less, these projects could be short or very long, and can be subsidized or not by government or autonomous communities.So the idea is to specialize in value added technologicaly  atractive and effective arc welding processes. Always thinking that they also have to be very productive for the companies, especially in this hard days.We have to decide also which areas are interesting and suitable to make investigation projects like for example: similar or disimilar welding, thick ir thin thicknesses, WHICH SECTORS give more opportunities to do those welding jobs…. More or less where to redirect our efforts. I think this one is the most dfificult thing.In welding education we don’t give general formation to welders normally. Except that very specific welding formation to some factoyes, in that cases we build a custom formation for the factory. For general welding formation here is a Welding School near us which gives practical and theorycall  welding formation on processes like, GMAW, GTAW, SMAW mainly and also Robotized GMAW, PTA, Thermal proyection, SAW and oxyacetylenic welding.I don’t have to forget that we also impart classes and do exams for the International welding engineer or technician (IWE-IWT) master.I hope that my question has been explained better now, but it´s no easy, so don´t hesitate to ask any question.Thanks again!
Reply:Hello Matt and thank you very much.As you say, I also think that there is only one US manufacturer doing low energy mag work (and this really scares me! -Are European manufacturers clueless or beating around the bush?). I have proved Lincolns STT and it really works, didn´t know Case (only the folding trapper style knives).Generally the low energy GMAW are used to weld (or also braze) thin section plates (similar, dissimilar, galvanized or metalized or no…) and generally max 0,117 inches thick. Then the welds are completed with conventional gmaw in the same power supply. If not, you can have lacks of fusion or poor productivity.As you say, construction is not very interesting place to us where develop those innovative technologies, we have to narrow which ones and were we can apply, with the advantages you say.Bye!
Reply:Originally Posted by tenpinsa friend of mine was doing graduate research looking into welding in Zero Gs
Reply:Your question is a bit open ended, so it's difficult to know where to start with regards to an answer. However, Lorch have developed a couple of variations of pulsed MIG/MAG welding that may be of some interest to you. LINK. I'm sure that if you contact them, they would be more than happy to demonstrate their technology to you.Last edited by Baila La Pinza; 04-04-2011 at 05:00 AM.
Reply:Originally Posted by PangeaFriction stir and thermal stir are the future of welding. Get into that if you can.
Reply:I will say only this. Most of this is a above my head and I will bow out the conversation from hear on out.Low energy would be the cats meow in my opinion just beacuse of the way energy prices are going nuts. Also there is a smalle airplane company that went bankrupt that had some intresting welding technology that may be on the market its in the area of friction stir welding.
Reply:Hello again B.A.And brother, you are on a long journey. There are a good number of people using low energy, it's just that I only know of JI Case Tractor in Burlington, IA. USA, from first account.Miller also has a player program for inverters, and I'm sure ESAB can step up too (not with STT but close enough). John Deere tractor uses Millers, but to my knowledge is happy with GMAW Pulse.In manufacturing this seems to be going to wave form control, the problem is no two pieces of parent material are exactly the same, no two days are exactly the same in conditions, etc...Looking at your storyboard / bullet list;–How can I weld this strange materials? Which process can I use?-Can I do this hardfacing without crackings?-How can I join this two different materials?-How can I standardize the weld parameters to don’t have an usual mess in welding?-How can I weld this materials without been out of tolerances?-Why has this heavy metal structure overthrow?
Reply:Originally Posted by Baila La PinzaYour question is a bit open ended, so it's difficult to know where to start with regards to an answer. However, Lorch have developed a couple of variations of pulsed MIG/MAG welding that may be of some interest to you. LINK. I'm sure that if you contact them, they would be more than happy to demonstrate their technology to you.
Reply:Originally Posted by TeljkonI will say only this. Most of this is a above my head and I will bow out the conversation from hear on out.Low energy would be the cats meow in my opinion just beacuse of the way energy prices are going nuts. Also there is a smalle airplane company that went bankrupt that had some intresting welding technology that may be on the market its in the area of friction stir welding.
Reply:Originally Posted by Matt_MaguireHello again B.A.And brother, you are on a long journey. There are a good number of people using low energy, it's just that I only know of JI Case Tractor in Burlington, IA. USA, from first account.Miller also has a player program for inverters, and I'm sure ESAB can step up too (not with STT but close enough). John Deere tractor uses Millers, but to my knowledge is happy with GMAW Pulse.In manufacturing this seems to be going to wave form control, the problem is no two pieces of parent material are exactly the same, no two days are exactly the same in conditions, etc...Looking at your storyboard / bullet list;I would say for the first four topics nothing can work better than a human network and not being afraid to call people who supply machinery and materials. In past years, the welding machine factory stores and local welding stores had people who could put the right maker and user together for these things. These days it seems local knowledge is scare. The sales people in stores today don't seem to have much knowledge of the welding process itself??? In our local Praxair store the manager came from a beverage distributor??? Nice enough guy, but not what you need to build a widespread successful user base (I think)...The last two are much harder (if I read the them right, the big deal is reduction or altering properties in the parent materials "like with HSLA steel overheat"). I think managers will be dealing with that long after I'm gone. There is at least as much to be considered with the material itself and conditions where the welding will be done, long before the machine and tradesman go to the task.At 10,000 hours the engineer and tradesman can be very good, but not as good as they will be after 40,000 hours of dedicated work and learning.So, if consulting to users and buyers is your goal, building a network of makers to put together with your clients is a lifetime of work. At least it was for the old guys I used to know, but most of them did well, very well.Matt
Reply:I hope you engineers do not fill this forum with all this junk. It is a WELDING forum.Just like the American Welding Society Magazine has parts that are almost unreadable to the average welder.And you do not seem to be able to put things in SIMPLE terms. I have to read your "abstracts" or "extraccts" three times to find out you were doing an EXPERIMENT.When you do build a welding machine (IF YOU EVER DO) please make it reliable and not a piece of computerized junk.We have work to do.Friction stir welding !!  The two pieces of metal still have to get red hot to melt together.And a few years from now you will "discover" that the torque and twisting when hot will have caused other problems. Also how much energy was spent spinning the metal the get it hot enough to fuse? I bet it is more than if it had just been welded. No torque induced cracking either! Just wait till you start to see those cracking torque problems.Why don't you make the 50 different welding processes we have now MORE reliable. Inverters are still breaking down all the time.AWS certified welding inspectorAWS certified welder
Reply:Originally Posted by Donald BranscomI hope you engineers do not fill this forum with all this junk. It is a WELDING forum.Just like the American Welding Society Magazine has parts that are almost unreadable to the average welder.And you do not seem to be able to put things in SIMPLE terms. I have to read your "abstracts" or "extraccts" three times to find out you were doing an EXPERIMENT.When you do build a welding machine (IF YOU EVER DO) please make it reliable and not a piece of computerized junk.We have work to do.Friction stir welding !!  The two pieces of metal still have to get red hot to melt together.And a few years from now you will "discover" that the torque and twisting when hot will have caused other problems. Also how much energy was spent spinning the metal the get it hot enough to fuse? I bet it is more than if it had just been welded. No torque induced cracking either! Just wait till you start to see those cracking torque problems.Why don't you make the 50 different welding processes we have now MORE reliable. Inverters are still breaking down all the time.
Reply:Originally Posted by PangeaYou really, really don't know much about friction stir welding at all, do you.
Reply:[ame]http://www.youtube.com/watch?v=niVsJPFlg1Y[/ame]Friction stir welding of a pipe.AWS certified welding inspectorAWS certified welder
Reply:Friction stir welding isn't the only thing Donald doesn't seem to know much about.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:I do this everyday. It is tested every way that you can test metal. The values are higher with solid state welding than those of fusion welding.Two turn tables and a microphone.