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 welderand 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
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“You should give as much consideration to the preparation as you do to the actual welding”
Pipe welding is utilized all around the world in diverse industries. A variety of pipe sizes and material grades are joined to manufacture components of various shapes and lengths – from a few feet to many miles. Even though most pipe welding jobs have custom specifications – there are some fundamental aspects of pipe welding that form a common thread for welders and welding engineers alike in order to achieve high quality welds in pipes.
Selecting The Right Pipe Welding Equipment
Equipment selection is the top requirement for producing good quality pipe welds. The highest priorities when selecting welding equipment for pipeline welding are reliability, consistency, accuracy and process control. It is also critical that the equipment is easy to use and the controls are intuitive. In addition to equipment performance, the work environment also needs to be a key factor for equipment selection. There are pipe welding configurations designed for offshore welding, remote land based pipeline welding, general fabrication shop use and custom configured automated pipe welding systems. Selecting the right one can be a daunting task – it is always good practice to seek expert advice. Be sure to ask about the various options, capabilities and limitations of each system. When welding CRA (Corrosion Resistant Alloy) grades, it is necessary to use weld purging in order to guarantee the corrosion performance of the root run. The importance of this should not be underestimated.
Welding inspectors have a responsibility to the company they work for and the general public to ensure that weld quality is satisfactory. Failure to fulfill their duties can result in property damage, injury, and death. Most welding inspectors, therefore, take their job very seriously. Welding inspectors spend years honing their ability to detect and size welding discontinuities and defects. While they must be proficient at identifying all discontinuities and defects, some of these weld irregularities are more readily detectable than others.
1. Surface Porosity
Porosity is gas that has been trapped in the weld; this results in cavity formation within the weld. Porosity can cause reduced weld strength. Welding inspectors who are not trained in other forms of nondestructive testing are limited to viewing the surfaces of welds. So while not all forms of porosity can be detected by a welding inspector, porosity that extends to the surface of the weld can.
Red-D-Arc carries an extensive inventory of welding equipment designed specifically for pipe welding professionals. The latest pipe welding equipment can increase productivity and produce the highest quality welds. We have an extensive fleet of innovative solutions like the Miller PipeWorx Welding System, Red-D-Arc Oscillating Pipe Welder, Bug-O Systems, Orbital Welding Systems from Lincoln and Axxair, and pipe end prep equipment from H&M and E.H. Wachs.
Check out the new Pipe Welding section of the reddarc.com website to learn more.
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Welding equipment and operations can be expensive, but these costs can be lowered by making a few minor changes. Many fabricators and manufacturers are aware they have problems in their operation but struggle with quantifying the real costs associated with those problems. Some things to consider when trying to lower your costs but increase efficiency and productivity are: the type of equipment you’re using, how old the equipment is, labor costs and properly equipped welding stations.
The Airgas/Red-D-Arc Weld Efficiency Analysis program can help you find hidden costs robbing your profits. This free program helps customers understand and control the hidden costs associated with many welding operations. We will analyze your welding operations and compare your results to peer benchmarks and best practices. A three-and-a-half day class is also available, designed to help you learn from experts, reduce your operating costs by 20% or more and improve quality …all without any capital investment.
Learn more about the Airgas/Red-D-Arc Welding Efficiency Analysis program.
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