Improving Global Quality of Life

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5. Needs and challenges in welding and joining technologies The introduction of new or high-cost welding/joining technologies (such as laser beam welding, large scale robotic welding line etc.) into industrial production needs to be justified with economical consideration. New and advanced joining technologies are needed in some regions or nations, while others may need more fundamental developments to support existing technologies and still achieve higher quality and reduced production time. Hence, needs and challenges will be identified from these perspectives. 5.1 Innovations in welding and joining processes There is fast development of different joining technologies, which is obvious in the automotive industry (Figure 5.1). MIG/MAG welding 3% Tailored blanks 1% Laser soldering 1% Joining the Porsche Cayenne BIW (mm) Gluing 37% Gluing 37% Resistance spot welding 53% Laser welding 3% Mechanical fixturing 3% MIG/MAG welding 1% Laser soldering 1% Joining the Audi A3 BIW (mm Gluing 25% Laser welding 14% Resistance spot welding 53% Other 1% Joining the Golf V BIW (mm) Laser welding/ soldering 45% Gluing 7% Resistance spot welding 45% MIG/MAG welding 3% Figure 5.1 Joining processes used in automobile industry (Reproduced courtesy: TWI Ltd) 5.1.1 - Robotic welding Most of the joining operations will of course be made close to the major markets but also moved to the lowlabour-cost countries like China. Every country will, however, relentlessly defend its workload by introducing more efficient processes. Robotic welding will continue to increase the productivity and quality to the fabrication industry. In 2006 robot sales increased by 10.3 %. The problem has been that current technology has not allowed for an efficient manner of applying robotic welding to large-scale, low-volume fabrication. In an EU-project NOMAD this restriction has been eliminated by: 36 Improving Global Quality of Life Through Optimum Use and Innovation of Welding and Joining Technologies
Use of manufacturing simulation for automated process planning and real-time system monitoring Autonomous robot transport vehicle (RTV) navigation for high accuracy positioning of a robot arm in an industrial manufacturing environment. Design and build of an industrially rugged RTV with the accuracy and stability required for welding tasks. Use of specially developed welding consumables, welding procedures and sensor systems designed to allow “all positional” robotic welding with a degree of control and dexterity unmatched by current systems. Figure 5.2 illustrates the developed system. Figure 5.2 Robot with all its equipment mounted on a RTV welding a large structure (Reproduced courtesy: TWI Ltd) The system can be equipped with several sensors: Torch collision unit, contact sensor for searching start and endpoints for the welds. Laser sensor system for joint tracking and through-the-arc system for joint tracking as well as a camera system for monitoring the complete station. The application also includes a CAD-based system for simulation of the whole process and off-line programming. This solution with the welding system moving to and around the large work piece can become a new concept instead of manipulating the work piece to get the best welding position for the robot. Simulation software are becoming powerful tools. ABB is marketing a programme named VirtualArc® for simulation of the arc welding process. Robot Studio is another simulation package for movement of the robot offered by ABB. The two programmes can easily be justified due to the high savings that can be achieved. 5.1.2 Renaissance for EB welding Thanks to the great interest in laser beam welding and the increased number of applications, the electron beam (EB) welding process has been rediscovered and considered to be complementary to laser welding. Earlier the EB was judged to have many advantages when considered alongside more conventional multipass arc welding processes for fabrication of heavy section structures and components. Figure 5.3 Comparison of single pass EB weld profile with multi pass submerged arc welded joint in 100 mm thickness C-Mn steel (Reproduced courtesy: B. Pekkari) Through Optimum Use and Innovation of Welding and Joining Technologies Improving Global Quality of Life 37
Page 1 and 2: Improving Global Quality of Life Th
Page 3 and 4: Foreword Dr Baldev Raj Mr Chris Sma
Page 5 and 6: In alphabetical order (Continued) D
Page 8 and 9: 6.3 Job, skill, career and competen
Page 10 and 11: 9.6.3 Welding processes and challen
Page 12 and 13: Executive summary “ Welding is an
Page 14 and 15: Editors’ Preface Improving Global
Page 16 and 17: Scope and objectives 1 an important
Page 18 and 19: Welding industry 2.in the world 2.1
Page 20 and 21: 2.2 Today’s welding industry and
Page 22 and 23: 2 Welding industry in the world IIW
Page 24 and 25: 3.welding Signifi cance of and join
Page 26 and 27: 3.3 Welding and joining in sustaina
Page 28 and 29: An example of the value of welding
Page 30 and 31: 16 Improving Global Quality of Life
Page 32 and 33: 4. Needs and challenges in welding
Page 34 and 35: Welding thick walled steel componen
Page 36 and 37: The trend towards light-weight desi
Page 38 and 39: Up-to-date, titanium alloys have be
Page 40 and 41: Needs for weight reduction in aircr
Page 42 and 43: Finally, testing of welds will be e
Page 44 and 45: As another most important item, the
Page 46 and 47: In order to make the developments i
Page 48 and 49: Reduction and/or elimination of dis
Page 52 and 53: The productivity in EB welding has
Page 54 and 55: The potential applications are for
Page 56 and 57: 5.2 Higher automation, productivity
Page 58 and 59: In submerged arc welding one can re
Page 60 and 61: From a practical perspective, the n
Page 62 and 63: Acceptance levels are not included
Page 64 and 65: 5.5 NDT and structural health monit
Page 66 and 67: IIW can help companies to get their
Page 68 and 69: 6. Needs and challenges in health,
Page 70 and 71: welder against Cr6 is a very import
Page 72 and 73: is considerable national concern fo
Page 74 and 75: important in meeting needs with res
Page 76 and 77: 7. Legal codes, rules and standardi
Page 78 and 79: In national or regional legal codes
Page 80 and 81: 7.4.2 Optimum laws Laws applying in
Page 82 and 83: IIW needs to help ISO and others cl
Page 84 and 85: structures. It is unlikely in the s
Page 88 and 89: 8. Needs and challenges for global
Page 90 and 91: infrastructure to develop multiple
Page 92 and 93: Table 8.1 Key actions and key activ
Page 96 and 97: 9.7.1 Hot topics ..................
Page 98 and 99: New discoveries tend to be in deepw
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Proved reserves at end 2004 Trillio
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easily weldable, the life expectanc
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9.1.3 Hot topics Reducing negative
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Following these codes assures initi
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9.1.5 Hot topics Development and up
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9.1.8 Power - Renewable Rising fuel
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9.2.2 Production using joining tech
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still sometimes an unanswered quest
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2. To an increasing extent, joining
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nature and not specifically related
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9.3.2 Hot Topics The following issu
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industry have resulted in the need
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technology based on the existing pi
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general investment climate, includi
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10 000 Eq. SS range, MPa 1000 100 1
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Globalisation: PEI is operating in
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At the same time as automakers are
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On the other hand, when looking at
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9.7.2 Welding in the minerals proce
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Finland Poland Rest of the world Cr
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This situation is unsatisfactory an
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implementation of smart systems. In
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9.9.2 Hot topics Raising and enforc
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9.10.2 Welding industry role As des
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While items and directions may vary
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9.11.2 Hot topics In spite of these
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9.13.2 Preheat Preheating is carrie
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The electronic products industry se
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Portable power: In the Portable Pow
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the HRI report which accounted for
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9.16.2 Joining live tissues and coa
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(material removal, welding, surface
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Furthermore, in the field of dissim
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9.20 Small and medium enterprises
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and assessment. Multi-material desi
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0. Short, medium and long-term stra
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10.3.2 Typical hot topics In the me
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10.4 Long-term strategic agenda IIW
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162 Improving Global Quality of Lif
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[16] Mayr P et al., “Long-term cr
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IIW White Paper - Edition 2012 ISBN
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