International Conference on Welding Technology

8th Edition of International Conference on Welding Technology

https://welding-conferences.sciencefather.com/

Award Nomination - https://x-i.me/arunom

Abstract Submission- https://x-i.me/arumem

Accurate Data Capture for Welding Process Reporting to the Military




Manufacturing for the military requires the capture of an immense amount of detail from the conceptual stage to the finished product. Each entity working on a project—suppliers, manufacturers, quality control, auditors—is handed specifications that must be followed to a “T,” and every step of their processes must be meticulously documented. By automating these processes, data can be captured as the part is being made, simplifying reporting and creating a more accurate product.

Our customers are metal fabricators performing welding operations on heavy-duty parts that fit into larger systems or vessels, missile tubes built into a defense mechanism, or deflection devices for a ship, for example. They invest in our modular automated welding systems for a variety of reasons, chief among them the accuracy and precision of the weld itself.

A fully automated system also offers traceability on parts via laser scanning technology that provides direct data feedback about every square inch of weld metal fill volume. Laser scanning can be used to check for weld metal volume, verify the amount of weld metal deposition, detect where the metal is being deposited, and note whether there is any deformation in the part resulting from the deposit. Additionally, it measures thermic temperatures during the weld process determining pre-pass and inter-pass temperatures allowing accurate determination of heat-affected zones.

Customers can set our machinery to operate in any way they prefer. Once they enter specifications mandated by the military customer, customers can set up their own parameters. Some of our customers program the machinery to set off an alarm and automatically stop the welding process. Other companies prefer to set the alarm to go off when the data is within 10% of the pre-programmed maximum/minimum range, but the entire operation continues to move.

For example, take a large tube application in which 12 layers of fill are necessary. On the sixth layer, and at 12 degrees past datum, an anomaly is detected where the heat range drops significantly—from 900 amps to 400 amps—and weld metal volume is lost. The operator needs to go back and fill in that void. An alarm sounds, and the operator repairs the weld.

The system records the point in the weld at which this occurs so that when the robot makes future weld passes, it’s documented that there was an anomaly at level 12. In the end, the part will pass inspection more easily because the records are accurate and generated in real time. On the other hand, when doing manual welds, the welder may take a break but there is no documentation as to where, when, and how long the break took. There is no record of the stop and start point of the weld, whether a void was created, or the degree of adhesion.

One of our customers, a contractor for the United States Navy, has five of our systems installed, from column and boom to gas metal arc robotic welding (and the software that controls it) to perform a root pass on extremely thick alloys. An inside and outside pass is done on a tubular structure while weld volume, inner-pass temperature, and outer-pass temperature are measured, ensuring the pre-set heat range is met. The workpiece is then X-rayed as part of the inspection process. Data is analyzed to ensure there are no deficiencies or anomalies that fall outside of their set range.

Qualifications for new manufacturing processes can take two to two and a half years on average. An automated laser scan system can help streamline approvals and eliminate extra time because they are able to pre-prove a lot of these processes.

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