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How Welding Automation Can Bridge the Skill Gap in the Manufacturing Industry

06 October, 21 3:48 pm · Leave a comment · Geoff Campbell
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Welding automation

Welding automation has been around for a while, but recently its role has grown exponentially in manufacturing. For years, the welding industry has faced a skill gap, which is expected to grow wider in the coming years. To combat this, employers are adopting automated welding equipment to increase the efficiency of weld operations.

What Is the Skill Gap?

The “skill gap” describes a discrepancy between the skills held by job seekers and the skills employers need. This leads to a paradox where there’s a large pool of applicants, but companies aren’t able to hire workers with the appropriate knowledge and skill set. This has led to increasing welder salaries as manufacturing businesses compete to attract skilled workers, and even then, many positions are left unfilled.

Why Is It Happening?

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Robots vs. Cobots: What’s the Difference?

13 August, 21 2:50 pm · Leave a comment · reddarc
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welding with the botx cobot

Over the years, robotic welding has been utilized in various industries to increase productivity by automating production and ensuring consistent quality. Traditionally, robotic welders required large investments in equipment and in personnel training.

Why Robotic Welding?

Some of the reasons for using robotic welding are as follows:

  • Production automation
  • Cost reduction
  • Quality improvement (consistency and repeatability)
  • Improved health and safety (personnel are not exposed to hazardous fumes or radiation)
  • Address shortage of skilled welders (an operator is required—not a welder)
  • Increased flexibility (versus hard automation)
  • Efficiency improvements
  • Reduce repetitive strain injuries

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Welding Cobot Solves Production Challenge for Ontario Auto Parts Manufacturer

30 June, 21 3:11 pm · Leave a comment · reddarc
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When a major auto parts manufacturer asked an Ontario fabrication shop to weld 50,000 parts in just 2 months, they took the job immediately; then they had to solve the problem of how to get that much welding production done within such a short time time period.  Read about how the adoption of welding cobots helped them deliver in this article from Shop Metalworking Technology magazine.

“If you turn this down once, you will never see a job like this again.”

 
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Webinar – Manufacturing: The Next Generation

18 November, 20 11:43 am · Leave a comment · Geoff Campbell
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webinar on collaborative robotics

The Impact of Collaborative Robotics

Collaborative robots like the BotX Welder are shaping the future of manufacturing.  Rob Goldiez of Hirebotics joins robotics investor Marc Cuban and Enrico Krog Iverson of OnRobot to discuss the impact of collaborative automation technology.

November 19 at 1:00pm ET

Manufacturing: The Next Generation — through collaborative automation’ 

This virtual event will see the robotics thought leaders discuss their powerful visions of the future of manufacturing. The expert panel will share insights on how collaborative automation helps future-proof manufacturing companies, helping to build resilience and reduce risk as the world navigates unprecedented COVID-19 challenges where uncertainty is now the only constant.

 

Register Here

 

10 Ways to Reduce Costs and Boost Productivity with TIG Welders

08 June, 20 10:38 am · Leave a comment · Geoff Campbell
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TIG Welding is a cost-effective manufacturing process. However, several factors can significantly increase or reduce the cost-effectiveness and productivity of a welding project. These range from operational efficiency to the use of consumables.

In this article, we’ll go through 10 ways to significantly reduce welding costs and boost the productivity of welding projects.

1. Avoid Overwelding with TIG Welders

Overwelding occurs when a weld is larger than it needs to be. This is a common occurrence in the welding industry, especially with inexperienced welders. An overweld may result when there is no specified size in a design, when there is no fillet gauge, or when a big weld is created just to play it safe.

 

Overwelding is a significant resource drain; it uses more arc time, labor, shielding gas, and filler metal, which leads to higher costs. To put this waste into perspective, consider a 1/4″ overweld instead of a required 3/16″ weld: This results in a 78% increase in both weld metal deposition and arc-on time. This goes up to 177% when the overweld is 5/16″.

Increased cost and time are not the only negative implications of overwelding. Bigger-than-required welds tend to distort more because of the increased heat input. Also, excessive convexity may increase the likelihood of a weld failing due to fatigue. In groove joints, excessive reinforcements do not create stronger welds compared to welds that are flush (or just above) the base material surface.Weld Automation

To save resources and time, stick to weld specifications in designs, make use of a fillet weld gauge, and avoid excessive reinforcements on groove joints. A change in wire diameter may also be used to avoid overwelding.

2. Employ Weld Automation 

 

Weld automation is the use of equipment that automates part or all of the welding process. Human operators, no matter how skilled, are susceptible to fatigue. They can also make errors during welding or other related activities (e.g., positioning and handling pieces of the weldment). These factors, coupled with safety concerns, can affect the productivity of welding.

There are numerous types of automation equipment that can greatly increase productivity and save cost. However, different levels of automation can be applied in welding, and the term automation doesn’t necessarily mean robotic welding. For example, hard automation is the use of weld positioners, manipulators, and turning rolls to keep a weldment in place. There are also fully automated setups in which the actual welding is carried out by robotic arms—this is known as robotic welding.

The use of automation makes welding safer, faster, more productive, and more cost-effective. Compared to humans, machines are quicker, more consistent, and less prone to errors. Machines are also easily programmable, thus reducing the cost of hiring, managing, and training human workers.

 

3. Use the Right Welding Process

stick welding process

Weld aesthetics To effectively boost productivity, it is important to review all these factors before selecting a welding technique. For example, welding is more precise than metal inert gas (MIG) welding but requires more skill. If aesthetics is an important consideration, a TIG Welder should be used, as MIG would cause you to spend more time later on in finishing. There is no need to select the submerged arc welding (SAW) process, with its high deposition rate of, when your project only requires the 5 lb/hr deposition rate of stick welding.

To make sure that you are not consuming more resources than necessary you need to review all considerations. Also, selecting the wrong process may lead to the production of rejects.

 

4. Handle and Arrange Materials Properly

The proper handling of materials during welding is crucial to improving productivity. Valuable time is wasted when a welder has to stop a welding process, go somewhere else to look for (and procure) a needed welding accessory, return to the welding spot, and resume welding. Even more time is wasted when weldment pieces are scattered around the welding area. While these short interruptions may seem trivial, they add up to significant time-related costs.

Before welding begins, all consumables, welding accessories, and parts to be welded should be sorted out and arranged in proximity to the welder.

5. Properly Maintain All Welding Equipment

Welding Equipmen

The importance of having equipment in excellent condition for productivity and cost savings can hardly be overemphasized, as faulty equipment may consume more resources while generating more waste. Frayed cables and faulty appliances can lead to voltage losses, wire feeding problems, and erratic arcs. Likewise, faulty gas systems can lead to gas leakage. All these contribute to the potential inefficiency of welding operations. There is also the problem of defective equipment producing poor-quality welds, which may lead to more rejects, compromised worker safety, and costly downtime. Investing in a comprehensive preventive maintenance program reduces costs in the long run.

 

6. Prepare Joints and Gaps Properly with TIG Welders

Adequate preparation of joints is required for a hitch-free welding process. To start, welding operators should carefully clean the surface of the base materials. This will help prevent contaminants, such as dirt and oil, from entering the weld puddle. Next, welding operators must ensure they have the right fit-up and no excessive gaps.

A poor fit-up can have numerous negative consequences. One example is the potential for distortion or burn-through, which compromises the strength of welds. Poor fit-up also leads to overwelding, as gaps increase the size of weld required to achieve the same load-bearing capacity. For example, a 1/4″ fillet is required for a joint when there is no gap. A gap of 1/8″ in that same joint would require a new fillet size of 3/8″ to achieve the same strength. That amounts to a 124% increase in filler metal consumption.

 

7. Control the Use of Consumables

Control the Use of Consumable

Consumables such as shielding gas, filler metals, anti-splatter compounds, grinding wheels, back bars, and gun components account for a noteworthy portion of the total welding cost. As a result, their proper use is important in keeping costs low. Certain consumables should only be used when necessary.

Gas delivery systems should be checked regularly so that leaks can be identified and sealed off. Surge turbines and surge guards can be attached to the end of welding guns to measure gas surge and reduce pressure, respectively.

 

8. Boost Efficiency

Labor cost is the largest cost variable in any welding project. One way to reduce this cost and boost welding productivity is by ensuring efficiency in all operations. The following operations are all time-dependent activities that can be optimized:

  • Preparing the metal for welding
  • Preparing the joint
  • Assembling components
  • Preheating, if required
  • Tack welding components, if required
  • Positioning/repositioning, if required
  • Moving between welds
  • Interpass cooling, if applicable
  • Grinding spatter
  • Inspecting and testing for
  • Reworking/repairing of welds and subsequent
  • Post-weld heat treating, if applicable

It is evident that a lapse in one operation can have a domino effect on the operations that follow it. For example, poorly prepared joints can lead to overwelding, which in turn can lead to avoidable grinding and polishing. Likewise, poor positioning may lead to reworking and repairing of welds.

While inefficiencies in operations may be difficult to track and measure, the rewards are worth the effort. An effective way to spot inefficiencies is as follows: If step 2 is a required process for step 3, then all is in order. However, if step 2 is carried out to correct or optimize step 1, then there are inefficiencies inherent in step 1.

welding project

Another way of boosting productivity is by using technology that enhances efficiency. One of which is with cable length compensation (CLC™), adjust while welding (AWW™), Auto-Line, and SuitCase™ wire feeder which delivers smooth wire feeding with accurate, consistent speed. These boost productivity and reduce labor time and cost.

 

9. Minimize Rejects and Reworks

When a reject is produced, 100% of the filler material, shielding gas, electricity, labor, and time used is wasted. This is terrible for cost savings. Reworks also result in wasted time, resources, and labor. Ensure that through skill and efficiency, rejects and reworks are eliminated when using TIG welders.

 

10. Prioritize Welding Safety

While they do not directly contribute to welding costs, workplace accidents are never desirable nor do they contribute to the efficiency of any production environment. Worker safety should always be a top priority in any company, especially when working with TIG welders.

Ensure that you take all necessary precautions and follow the pertinent guidelines and regulations to maintain the safety of welding operators throughout a welding project. High-quality safety gear and comprehensive safety plans help to prevent injuries and save costs in the long run.

A Solution to the Skilled Welding Labor Shortage

31 October, 19 9:57 am · Leave a comment · Geoff Campbell
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An Industry In Distress

The manufacturing industry is in distress. There is a shortage of skilled talent and this gap is only widening. While manufacturing companies are able to make goods faster and cheaper than ever, there is a growing lack of skilled manufacturing employees to ensure that production continues. Industry projections from Deloitte and the Manufacturing Institute, among other industry analysts, predict that over the next decade, more than 2 million manufacturing jobs will go unfilled across the U.S.welder shortage infographic

This decline in skilled manufacturing workers is a result of two issues:

1. A very large portion of workers at or near retirement age
2. Incoming generations that are far less interested in the manufacturing industry

Welding is perhaps one of the susceptible areas in manufacturing to this trend because of the skill welding requires. The lack of skilled welders is causing large inefficiencies in the manufacturing industry due to understaffing and also causing pay rates of skilled welders to go higher and higher. Since it does not appear that upcoming generations will have a large participation rate as welders, the solution to the problem will likely be solved by the implementation of automated welding solutions.

  • Automated Welding Solutions That Deliver ROI
  • Automated Welding Solutions Come in a Variety of Forms

Automated welding robot machines, automatic welding bugs, automatic orbital welding machines, and even automated resistance welding equipment are being used to help combat the void created by a lack of skilled welders.

The lack of skilled welders is causing large inefficiencies in the manufacturing industry

Although full-auto arc welding machines are part of the remedy, they are not a panacea. Fully-automated welding solutions often require high capital expenditure, require expensive skilled programming personnel, and pose significant safety risks if not set up properly. The trade-off between the benefits of fully-automatic welding machines and their disadvantages led to the development of a new type of automated welding solution: the welding cobot.

 

Enter: The Cobot (a Collaborative Robot)

botx collaborative robotic welding table
The name cobot is short for “collaborative robot”. The increase of cobot development and deployment is revolutionizing the manufacturing industry. Welding cobots are unique welding tools that hold many advantages over other automated welding machines, especially traditional welding robotic systems. Cobots have special mechanisms and move in such a way that enables them to require little to no safety fencing.  While the potential for increased safety without extra costs is an excellent benefit, the most important benefit of cobot use in an automated welding cell is the reduced costs associated with installation and programming.

Robotic Welding Just Got Easier

Traditional automatic robotic welding machines require a high level of skill to program. Oftentimes many years of knowledge and experience are required to set up an automated weld cell; for this reason, many companies elect to hire contractors to do this work for them, adding to the already high cost. With cobots, the programming of the machine is much simpler. The programming software is engineered to be user-friendly, vastly decreasing the instruction time required to train a programmer. This not only lowers the initial costs of programming but also enables a cobot to have a high degree of flexibility. The decrease in programming time and safety equipment and the increase in flexibility typically result in a very short ROI timeline and reduce the dependency on skilled welders and automated welding robot programmers.

Red-D-Arc understands that many of our customers are not immune to the trends affecting the manufacturing industry as a whole. We know that maintaining a technological advantage is key to success. In order to help our customers fight increasing costs associated with the decline in skilled welding employees and complicated automatic welding machines, Red-D-Arc offers collaborative welding robot solutions.

Introducing The BotX-Welder:  The Robotic MIG Welder Solution

2 welders working with a cobot

The BotX-Welder is our cobot product solution for our customers. The BotX-Welder package comes with a UR10e cobot arm created by Universal Robots, a leader in cobot development. In conjunction with this robot arm, the Bot-X Welder system also comes with an XMT350 MPa MIG welder and S74 MPa Plus wirefeeder, both made by Miller Electric. A MIG welder torch and a welding fabrication table are also included to complete the cobot welding cell. While the hardware is state-of-the-art, it is the software in the BotX Welding cell that truly sets it apart. The robot arm in the Bot-X automated welding system is controlled by the Hirerobotics application, which can be used with either iOS or Android operating systems. The Hirerobotics app is much easier to use than a traditional automatic robotic MIG or TIG welding machine teach pendant.

A Welding App With All The Robotic Welding Routines You Need

 

What’s more is that the Bot-X Welder also comes with an expansive library of welding routines, with weld parameters made to fit almost any application. Welding can be automatically monitored and recorded through cloud connectivity. This allows remote users to view weld data from anywhere in the world as long as they are connected to the network.  The cost and risks of  new technologies are often high. Red-D-Arc eliminates the risk of failed robotic welding implementations by only charging our customers by the productive hour when using the Bot-X Welder. This enables users to try the machine out, use it as much as they need it, and get rid of it when it the work slows down. This probably won’t be a problem, since you’ll be able to keep customers happy with a quick rate of output and very high weld quality.  The pay-as-you-go system is much easier and more cost-effective than the traditional hiring and firing of personnel.

Maintaining a technological advantage is key not only to prosperity in the manufacturing industry, it is essential to survival. As more and more efficient means of weld, production is developed and as the number of skilled welding laborers declines, the pressure is on to adapt.

Red-D-Arc has always and will continue to support our customers through industry shifts. The Bot-X cobot MIG welder system is another way we help you keep ahead of the competition.

See the BotX Welder in action live at Fabtech 2019.

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Axxair Orbital System Makes Welding Small Pipes Easy

18 October, 18 3:12 pm · Leave a comment · reddarc
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multi pipe welded array
Welding small diameter tubing can be difficult.  The tight radii often require expert welders to deliver precise torch manipulation with finesse.  If the welder is not skilled enough, the out of position areas are at risk of poor quality due to gravity affecting the weld pool and ineffective torch angles.  If out of position welds cannot be completed satisfactorily, the part must be rotated.  However, some assemblies can’t be rotated because of size constraints or they might rotate off of center.  If a mechanized welding solution is desired for small diameter components, look no further than our Axxair Orbital Fusion Closed Welding Head Systems.
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92% Improvement – Turning Problems into Possibilities with a Custom Welding Package

31 August, 18 11:30 am · Leave a comment · reddarc
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Induction Heating with Submerged Arc Welding

When one of our customers was tasked with an electrical motor shaft rebuild that required them to weld new fins onto a 7” diameter shaft, they called on Red-D-Arc’s team of experts for assistance. The job required the shaft to be preheated to a temperature of 400°F and welded using a submerged-arc process (SAW). Using the Miller Proheat 35 and Lincoln’s LT7 sub arc package, a job that was originally bid at 40 hours took just 3 hours to complete.
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Red-D-Arc Feature in Tank Storage Magazine

30 January, 18 4:49 pm · Leave a comment · Colin Brown
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AGW Automatic Girth Welder 3 Oclock Welder - Tank Storage Mag
Red-D-Arc was featured in the December/January issue of Tank Storage Magazine in an editorial titled “Rental welding equipment for storage tank fabricators”. Tank Storage Magazine is an industry leading publication, reporting exclusively on the bulk liquid storage tank and terminal sector.

The storage tank construction industry is highly competitive and fabricators gain a significant advantage by leveraging Red-D-Arc’s rental fleet of automatic tank welding equipment. Red-D-Arc supplies specialized automatic storage tank welding equipment to companies in the tank fabrication industry for projects all over the world.

Along with our specialized tank welding equipment comes a highly knowledgeable and experienced team of Red-D-Arc technicians. Sayer Hendricks – storage tank welding equipment specialist at Red-D-Arc is quoted in the article: “A fabrication company without prior knowledge of the equipment, is able to rent a turn-key tank welding automation system and increase their welding productivity by 40-50%. With on-site training, service and support, our customers are up and running quickly and making 100% x-ray quality welds without fail”

The full article is available here: Rental welding equipment for storage tank fabricators

Welding Equipment Assists With Offshore Wind Farm Projects

17 November, 17 3:20 pm · Leave a comment ·
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image-2143

A Red-D-Arc customer based out of the UK was awarded three large offshore wind farm projects …all commencing simultaneously. This manufacturer was comfortable taking on so many large scale, specialized projects because they have a reliable, knowledgeable, tier 1 supplier capable of meeting all of their welding and weld automation equipment needs! Red-D-Arc was able to quickly accommodate all of the welding equipment requirements for the project, providing more than 150 welders and a variety of weld automation equipment. The equipment consisted of multi-operator welding paks, diesel welders, advanced power sources, wire feeders, submerged arc welding packages, and rotators.

Two Red-D-Arc technicians were assigned to the facility to install, service and maintain the equipment to minimize downtime. The facility allocated a permanent workshop and storage container for back-up equipment which could be used to quickly replace any equipment as necessary. With Red-D-Arc’s support, the customer was able to work on all three projects simultaneously and avoid lost time due to equipment breakdowns.

Submerged Arc Systems Increase Productivity by 250%

28 October, 17 1:49 pm · Leave a comment ·
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IMG_4031 medium

A metal fabrication company located in Charlotte, North Carolina received an order for 300 small I.D. vessels for titanium molds. At the time they were using FCAW and back gouging the inside and outside of the vessels to achieve 100% penetration. On average they were producing 2 vessels per hour with 2 welders.
They reached out to Red-D-Arc to find a faster and more efficient way to produce these vessels. After discussions with Red-D-Arc the fabricator decided to purchase a turnkey submerged arc system. The custom designed system came complete with a small I.D. sub arc welding head mounted on a 9’x9′ manipulator, flux recovery system, NA5R automatic wire feeder, DC600 multi-process welder and 5 ton turning rolls. The system also included a laser and camera for precise control and monitoring of the submerged arc welding process.
The submerged arc system increased productivity by 250%. They were able to produce 5 cans per hour with half the labor cost. The safety of the work place was also significantly increased for a number of reasons:
• Back gouging was eliminated which in turn reduced the risk of fire
• Turning rolls replaced manual rotation of the vessels on tables
• Welders no longer had to weld inside the confined space of the vessels
The customer and the Red-D-Arc team were beyond pleased with the results. The customer plans to purchase two more of these systems for future projects.
Submerged arc welding can increase the efficiency and quality of many industrial welding projects regardless of the size or complexity. Red-D-Arc has all the equipment, expertise and experience to provide you with a submerged arc system to fit your needs – available for sale, lease and rent

Read more on welding efficiency

Red-D-Arc Turnkey Packages Support the World’s Largest Offshore Wind Farm

23 October, 17 11:23 am · Leave a comment ·
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Red-D-Arc recently supplied a variety of equipment to a UAE based company that is fabricating pile piping and jackets for the largest offshore wind farm project in the world. The company had to meet a strict time line of only 6 months, and would require a massive amount of welding and weld automation equipment immediately. Through consultation with Red-D-Arc, the customer determined that renting the majority of the equipment would be the most economical option. Red-D-Arc was able to fulfil the customers equipment needs immediately thanks to our vast and diverse fleet of equipment.

This massive order involved equipment and support from Red-D-Arc North America, Red-D-Arc UK and Red-D-Arc Middle East. The order consisted of a variety of welding and weld automation equipment including:
• 23 column and booms with single and tandem submerged arc welders
• 20 submerged arc tractors
• 200 rotators
• 167 jack-up rotators
• 400 CC/CV inverter welders
• 200 FCAW wirefeeders
• 10 Induction Heating Systems

By renting the majority of the equipment the fabrication company avoided the need to invest heavily in specialized equipment and ensured they would meet their deadline. Red-D-Arc works with customers to address their unique challenges and develops specialized solutions. Learn more about customized turnkey packages here.

weld automation button

New Red-D-Arc Branch in Regina, Saskatchewan

09 June, 17 2:43 pm · Leave a comment · Colin Brown
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Red-D-Arc Regina Saskatchewan Branch

Red-D-Arc has opened a new Branch in Regina, Saskatchewan to serve the growing demand for welding, weld automation and power generation equipment rentals in Western Canada.

Cody Sauer is the branch coordinator at the new Regina location. Coming from the oil, gas and potash industry, Cody is very knowledgeable and looking forward to helping our Saskatchewan customers with their welding needs.

The next time you need welding equipment or advice in the Regina area be sure to stop by the branch, or give them a call at 306-522-1874.

Red-D-Arc Company Overview Video

11 May, 17 9:13 am · Leave a comment · Colin Brown
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Red-D-Arc is recognized around the world as the welder rental specialist. We have been renting welding equipment for more than 60 years and our welding-equipment fleet is now more than six-times larger than our closest competitor. But did you know that Red-D-Arc is a leader in Weld Automation, Diesel Generator Rental, Induction Heating Systems, Pipe Welding Equipment, Blast Cleaning Equipment, Specialty Equipment, and Cutting Tables? Over the past 20 years we have been listening to our customers and continuously adding new products and services to meet their needs.

We produced a short video showcasing some of our many products and services. Enjoy!

Efficient Pipe Welding with the Red-D-Arc Process Pipe Cell

13 February, 17 1:11 pm · Leave a comment · reddarc
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Red-D-Arc has launched an exciting new product designed to increase the productivity and efficiency of pipe welding. The Red-D-Arc Process Pipe Cell with oscillating welding torch is a dual wire feeder, multi-process welding cell.

The system is easy to set up and operate and reduces weld operator errors, reduces welding time, and increases deposition rates, productivity and arc-on time.

A variety of welding power sources and wire feeders can be used with the system including Miller RMD PipeWorx 400 and Lincoln STT S350, S500 and S700 Power Wave systems, with all welding functions controlled via a remote interface.

Root passes can be performed manually with solid wire using either RMD or STT technology (instead of manual GTAW or SMAW) followed up by hot passes and cap passes either solid-wire or flux-cored) with the jammer-style weld oscillator.

Choose the welding positioner, welding chuck, turning roll set or headstock to suit your specific needs. All positioning functions including welding head manipulator, oscillator, welding positioner and turning rolls are managed via a single control.

Contact a Red-D-Arc Weld Automation Expert to learn more or request a demo: 1-866-733-3272 | Contact Sales

See more welding turntablespipe welders and pipe welding positioners

Orbital Welding in Opelika: Demo of Orbitalum’s powerful pipe welder

12 August, 16 9:16 am · Leave a comment · reddarc
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“We were grateful to be able to see a product demonstration for the Red-D-Arc (Orbitalum) system. The machine lived up to its expectations and the technical team was invaluable”

—Rob B. (customer)

Update: Red-D-Arc now offers Orbital Welding Equipment from Axxair. 

One of our clients, a machine shop based out of Opelika Alabama, needed a solution for welding stainless steel tubes and elbow sections efficiently that would be able to withstand hydrostatic testing of up to 300psi. After taking the time learn about their requirements, specialists from the Red-D-Arc branch in Austell Georgia, worked alongside experts from Airgas to demonstrate how the Orbitalum enclosed orbital welding system would help solve their challenges.

Red-D-Arc welding specialist Gregory Bellamy showed how the extremely narrow design of the Orbiweld 76S enclosed weld head was ideally suited for working in situations where space is limited. The Orbimat 76s was fitted with clamping shells (which are available for all dimensions of pipe) to ensure an exact match and strong hold. The pipe on this application was stainless steel tubing 1.500″ with a .035″ wall, diameter tubing (straight tube) and stainless steel elbow 180 degree 1.500″dia. with a .049″ wall. When the welds were complete, the welded pipes passed the hydrostatic testing at upwards of 300psi.

Thanks to Gregory Bellamy and Rob Storch from Red-D-Arc as well as Wayne Blamire and Bill Hatter from Airgas for their support on another successful orbital pipe welding customer demo.

Read more on orbital welding

Red-D-Arc 30 ft Boom Manipulator

22 April, 16 4:35 pm · Leave a comment · Colin Brown
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Red-D-Arc designed and built a custom made manipulator with a boom length of 30 ft for a leading tank manufacturing company in the Netherlands. The Red-D-Arc facility had to be customized with a raised roof section to accommodate the height of the large column. The raised roof was later opened, allowing for a crane to hoist the manipulator out of the manufacturing facility and then shipped to the customer.

The manipulator was part of a welding system provided by Red-D-Arc. The system featured a compact welding head designed for welding in narrow spaces, touch screen controls and a high resolution weld monitoring system to allow the operator to monitor the welding process from a safe distance.

Extending the Legs of a Large Seabound Work Platform

21 April, 16 3:33 pm · Leave a comment · Colin Brown
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A Red-D-Arc customer shared some interesting photos which document the process of extending the legs of a large seabound work platform and also feature several Red-D-Arc turning rolls. The platform is used for cleanup activities on the seabed and in order to work at greater depths; the legs of the work platform needed to be extended. The massive cylindrical legs were placed on Red-D-Arc turning rolls and rotated while the cutting and welding processes were carried out. Once the extensions were completed the legs were then returned to the platform.

Spring Deals on Used Welding Equipment: April 1-June 30th

06 April, 16 4:53 pm · Leave a comment ·
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Red-D-Arc is running a limited time, special offer on Quality-Checked used welding equipment. Until June 30th, a selection of pre-owned welders are available at significantly discounted prices. These welders are in “like new” condition, include a 12 month warranty and are in stock – for fast delivery. Don’t miss out! See the flyer for more details.

PDF Used Equipment Flyer

Red-D-Arc Installs Weld Overlay Cladding Facility in Scotland

30 March, 16 11:41 am · Leave a comment · Geoff Campbell
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Red-D-Arc supplied equipment and installation services for a new weld overlay cladding facility in the west of Scotland for one of the leading global distributors of raw material for wellhead and completion equipment to the oil and gas industry. After discussions with the client, Red-D-Arc designed a solution to meet the specific needs of their project. It was determined that the new cladding facility would consist of six Compact Cladding Cells and four Butt Welding Stations.

“We regularly develop specialized solutions alongside our customers…”

Layout of the facility began with our experienced engineers installing the six Red-D-Arc Compact Cladding Cells. Each Compact Cladding Cell consists of an automated system controller, 2m x 1m cross slide, 3 tonne turntable with built-in slip ring for preheating, and a Miller power source. Next, the four Red-D-Arc Butt Welding Stations were installed. Each station consists of an automated system controller; 3m x 3m travelling column and boom; 300mm x 300mm oscillation slide; 3 tonne headstock, 2 travelling support pipe idlers and a Miller power source.

The Red-D-Arc Weld Automation team has extensive experience across diverse sectors of industry. We regularly provide weld process recommendations and develop specialized solutions alongside our customers to address their unique challenges. Red-D-Arc Weld Automation Systems are designed for optimized reliability and productivity, and come complete with installation, onsite training, services and support.

View our entire range of pipe welding positioners

Growing Line Systems Used for Wind Farm in Adriatic Sea

02 March, 16 4:21 pm · Leave a comment ·
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Growing Line Systems

Red-D-Arc contributed several Growing Line Systems to be used during the production of wind tower foundations for a wind farm in the Adriatic Sea. In addition to the Growing Line Systems, Submerged Arc Welders were supplied along with camera systems that are equipped with a monitor and touch screen for optimal control of functions. Red-D-Arc equipment was used because the foundations must be long and strong to withstand the depth of the Adriatic Sea.

To learn more about Red-D-Arc Growing Lines and Fit Up Stations watch our video: reddarc.com/videos

MacAljon Increases Thin-Wall Tank Productivity by Over 50%

12 August, 15 1:21 pm · Leave a comment · Colin Brown
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Red-D-Arc RDA MFUB-TW
MacAljon, an industrial general contracting firm, has increased the productivity of its thin-wall tank manufacturing operation by more than 50% using the Red-D-Arc RDA MFUB-TW (fit-up bed for thin-wall cans). Fit-up time has been decreased by 20% and the use of spider bracing is no longer required. With no spider bracing to get in the way, a manipulator is now used to perform SAW ID circumference welding which has increased productivity by 30%.

The RDA MFUB-TW system is specially designed for the construction of thin-wall vessels ranging in size from 10′ to 15′-6″ in diameter (custom sizes are available). Our patented system is fitted with independently-adjustable vertical-rolls to support, align and compensate for tank non-concentricity when assembling multiple thin-wall sections which eliminates the need for spider bracing.

If you work with vessels that require the use of spider bracing or that have a wall thickness of between 3/16 – 3/8″ contact the Red-D-Arc sales team to learn more about the RDA MFUB-TW and how it can increase the productivity of your thin-wall tank manufacturing operation.

Read more about the RDA MFUB-TW here.

Global Welding Equipment Market 2015-2019

01 April, 15 1:53 pm · Leave a comment ·
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Research and Markets, a leading market research firm, has released a research report titled Global Welding Equipment Market 2015-2019. The report highlights the growing need for the automation of welding processes. An analyst involved in creating the report commented: “One key trend upcoming in the market is the automation of the welding equipment. There has been a continuous shift from manual to automatic welding in the welding industry in recent years. The need to automate manufacturing processes is one of the major requirements of the Global Welding Equipment market.”

As a leading supplier of weld automation equipment Red-D-Arc is ready to meet the ever-evolving needs of the welding industry. We are your one-stop-shop for sales, lease and rental of welding positioners, manipulators, turning rolls and other weld automation products, available through our global distribution network. We also design and build complete turnkey weld automation packages which can include integrated controls – such as digital touch-screen interfaces and camera systems – for your complete project requirements. Our team of engineers will provide you with weld process recommendations and set up all your equipment for optimized reliability, functionality and productivity.

Learn more about Red-D-Arc Weld Automation products and services.

For more information on the Global Welding Equipment Market 2015-2019 report visit the Research and Markets website.

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D&D Power Oilfield Services

19 February, 15 3:43 pm · Leave a comment ·
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As one of the leading power generation rental and service providers in the southwest U.S. D&D Power, a Red-D-Arc company, has the capability to keep your oilfield power generation equipment running. With over 40 service technicians covering the shale plays of Texas, Oklahoma and southeast New Mexico, we offer critical response service 24 hours a day, 7 days a week, 365 days a year. We usually have equipment back up and running in under 2 hours.

D&D Power offers rental diesel, natural gas and hybrid bi-fuel generators along with generator paralleling systems and portable light towers. Visit the Oilfield Services web page to learn more.

Read more articles on diesel electric generators

Sub Arc Welding Heads and Controls

19 February, 15 3:28 pm · Leave a comment ·
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Single and tandem (multi-wire and multi-arc) submerged arc welding heads are available for sale, lease and rent. Tandem systems include multi-arc heads with up to 6 welding arcs and multi-wire heads capable of up to 4 wires, all of which are available to accommodate deep groove and narrow gap applications. We have extensive experience designing special purpose, custom welding heads to suit any requirement.

Red-D-Arc’s tandem welding system provides a touch screen interface for data monitoring and provides full welding control. The multi-arc central console system provides control of up to 6 weld heads and allows welding parameters to be saved and downloaded. An ergonomic hand held pendant allows the operator flexibility to observe the weld and adjust parameters “on the fly”.

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Airgas, an Air Liquide company, is the nation's leading single-source supplier of gases, welding and safety products. Known locally nationwide, our distribution network serves more than one million customers of all sizes with a broad offering of top-quality products and unmatched expertise.