Wise Create a more productive result - Kemppi

WiseCreate a moreproductive result

Wise

Wise decisions createa more productive resultWelding equipment continues to evolve. The application andintegration of the latest electronic components and digitalprocessing techniques has and will increase welding productivityand quality well into the future. However the pace of changeprovided from hardware alone is only part of the story.Today, electronics software is as much a part of our daily lives asbread and water. Home media, personal and business communication’s,transportation, education and medical care are but afew areas revolutionised by systems and techniques driven andsupported by software.Kemppi Wise products are exciting and new welding software solutionsthat provide customers a range of useful benefits. Dividedinto two groups, Wise products either influence the efficiencyof welding performance, OR provide a completely new weldingprocess technique. Wise products enable new levels of weldingperformance that otherwise would be impossible to achieve withthe standard Mig/Mag welding process.WISE products family includesWiseRootWiseThinWisePenetrationWiseFusionAttractively priced according to their performance influence andbenefit, Wise products can be loaded to new Kemppi weldingequipment prior to delivery, or added later by simple field programequipment, as and when your needs demand.The introduction and commercialisation of Wise products isheavily connected to the Kemppi FastMig equipment family andKemppi DataGun. The latest model in the FastMig range, theimpressive and recently launched FastMig Pulse 350/450, allowsthe use of all Wise products, and Kemppi DataGun enables simpleand effective field software upgrades.WISE AutomationIn addition Kemppi’s automation customers can also enjoy Wiseprocess products when used together with KempArc automationequipment range. So it’s simple to make a Wise purchasing decision,and quickly enjoy a more productive welding result.WISE tested by industryThe Wise solution product family has been developed overseveral years with significant industrial partners. Finding thebest solution’s to real welding cases greatly benefitted Kemppiwelding engineers throughout each project, proving and refiningeach Wise product inside a customer production environment.Although Wise products are generally new to the wider globalmarket, the technology has now been commercially used forseveral years, carrying the endorsement of significant businesspartners from different welding disciplines.

WiseRootWiseRoot in process. Simple touse, reliable and fastTypical WiseRoot maintenance application approved by Deutche Bahn | Deutche Bahn ICE train

An effective tailored short arcprocess for root pass weldingWiseRoot is a highly efficient and unique tailored short arcprocess for manual (WiseRoot) and automated (WiseRoot-A) rootpass welding.Designed for the effective closure of root joint areas and also theaccommodation of gaps created by poor joint fit-up, WiseRoot isthree times faster in root closure than TIG welding, is easy to learnand use, and saves time on rework costs.Traditionally, weldingengineers have been reluctant to employ the standard Mig/Magprocess for quality root welding, due to known quality issues.However Kemppi WiseRoot is everything but traditional and isnow a proven root welding solution.WiseRoot advantagesThree times faster than TIG weldingEasy to learn and useSaves rework costsAllows wide root gap toleranceNo need for backing ring or ceramicsProduces high quality root weldsCan decrease joint volume in thick materialsreducing required filler materials volumeWiseRoot application caseDeutche Bahn has approved WiseRoot process for rail vehiclemanufacturing and maintenance, following thorough tests andwelding procedure qualification.WiseRoot application caseHollming Works Oy’s Pori unit manufactures Rolls-Royce propulsionengines whose steel bodies have very high quality requirements.Mr Ari Ahto, the welding engineer at Hollming Works,considers the deployment of the WiseRoot process as a significantstep in the development of manufacturing technologies.Mr Ahto says: ‘For us the benefit is particularly evident in situationswhere it is difficult or impossible to do the root welding onthe inside of the structure, and whenever ceramic root supporthas traditionally been used.’ ‘The savings in time and expenseswith WiseRoot are definite and measurable.Ahto adds: ‘One surprising feature has been the flawlessness ofthe welding seams. The majority of the products welded withWiseRoot are carefully inspected via nondestructive testing, andno errors have been found in the root passes. Also, the majorityof the welders require minimal training to use this method. Thismakes the deployment threshold much lower.’ The operatingexperiences with Hollming Works have been so good that thecompany is continuously looking for new uses for the WiseRootprocess.For more information, contact the nearest Kemppi representativeor visit our Web site at www.kemppi.com.Production manager Pekka Suomi (left) from Hollming Works andsales manager Kalevi Koivusalo from Kemppikoneet investigate a rootpass welded with WiseRoot process.Oil drilling platforms can have up to five satellite-controlledpropulsion engines maintaining the platform’s position. Weld qualityis essential.

WiseThinAutomotive manufacturers widely use coated thin materials thattypically present difficulty for traditional weld processMr Timo Partti, Ensto work’sSupervisor is pleased with WiseThin benefits

A tailored cold arc process forthin sheet welding and brazingWiseThin is a tailored cold arc process for manual (WiseThin) andautomated (WiseThin-A) thin sheet welding and brazing. Typicalapplications include quality light plate fabrication in ferrous andnon ferrous materials including automotive manufacturing.WiseThin advantagesReduces spatter with all materials including zinc-coated platesProvides 10-25% lower heat input than normal MIG/MAG welding,reducing post weld material distortion.WiseThin application caseEnsto Enclosures and Components group, Ensto Control Oy, purchasedthe WiseThin process, achieving better quality and moreproductivity for welding corners of terminal strip enclosures andswitch cabinets. Timo Partti, Ensto work’s Supervisor explained‘We manufacture more 100,000 cabinets per year for markets includingthe USA and Japan. Quality and productivity are essential,and WiseThin has increased the welding speed and productivity.Additionally, the process maintenance cost is lower than withother methods,’ he says.For more information, contact the nearest Kemppi representativeor visit our Web site at www.kemppi.com.Excellent weld pool control with varying joint geometry and fit-upReduced post weld reworkIncreased welding speed in many applicationsEnsto Enclosures and Components group achieve better quality and more productivity with WiseThin process.

WisePenetrationStick out variation25 mm 30 mm 35 mmStandard 1-MIG -process1-MIG -process withWisePenetration-functionWisePenetration accommodates stick out variation and improves weld quality

An optional function fordelivering constant weldingpower regardless of changesin the stick out lengthWisePenetration delivers consistent power to the weld poolregardless of changes in welding gun orientation or distance betweenthe welding gun and work piece. Suitable for both manualand automated synergic MIG/MAG welding, WisePenetrationsolves some age old problems.Normally in MIG/MAG welding the power to the weld pool ischanging as the operator or weld piece dictates the distancebetween the joint and welding gun nozzle. These deviationscan result in quality issues such as lack of fusion, incomplete orinconsistent penetration, changes in weld profile and of coursewelding spatter.WisePenetration advantagesBetter weld quality - reduce the risk of lack of fusion andincomplete penetrationSave labour time and rework cost through reductions in weld defectsReduce the need for welding parameter adjustment - easy to useand deploy into productionSuitable for use with long or short cable setsWisepenetration software solution solves these issues and reducesthe need for post-grinding and repair work. It is available formanual MIG/MAG welding as an option to the FastMIG Synergicand FastMIG Pulse product families, and automated MIG/MAGwelding as an option to the KempArc and KempArc Pulse productfamilies. Option can be purchased also afterwards, so it’s easyto deploy into production. Better weld quality, reduced labourtime, easy to use - WisePenetration is certainly worth a closer look.WisePenetration is designed to perform with long or shortcable lengths between the power source and wire feed unit. So,whether you’re welding at the work bench or at distance from thepower source via long interconnection cables, you’ll get consistentweld quality with WisePenetration.WisePenetration application caseAker Solutions Verdal in Norway, specialize in the fabrication oflarge and heavy offshore structures with significant quality targets.Having already deployed Kemppi WiseRoot to 30 x FastMigmachines, Aker production and welding departments agreed totest and comment during the development of the WisePenetrationsolution, recognizing the ‘commercial and quality benefits’ fortheir industry and projects. The images show a typical and recentAker Verdal project that adequately describes the challengesfaced by their welding team.For more information, contact the nearest Kemppirepresentative or visit our Web site at www.kemppi.com.Multibrid M5000 Windmill sub-structures. Weight: 700t, Steel grade: S355, Tube diameter main pipe: 4000-6000mm,Tube diameter branch: 2000-4500mm, Wall thickness main pipe: 90mm, Wall thickness branch: 30-40mm

WiseFusionVertical up Aluminium weld seam. Optimal short circuit characteristics in pulse Mig/Mag welding.

A tailored function for ensuringconsistent weld quality inall positionsWiseFusion creates and maintains an optimal short circuit characteristicin pulsed MIG/MAG and spray-arc welding applications.Keeping the arc length optimally short for manual (WiseFusion)and automated (WiseFusion–A) welding, WiseFusion ensuresconsistent weld quality in all positions, and once set, eliminatesthe need for regular parameters adjustments.WiseFusion is an optional fuction for FastMig Pulse and KempArcPulse welding machines.WiseFusion application caseBuster manufacture a range of work boat and leisure craft.Manufacturing high quality, high speed boats requires skill andattention to detail, and is typical of welding business activity thatbenefits from using Kemppi WiseFusion.Positional aluminium welding, plus difficult and restricted jointaccess demands much of welding personnel, ensuring the correctarc length parameters are set and reset to meet the requiredwelding quality in differing and changing conditions. But asmany customers are discovering, Kemppi WiseFusion relievesthe frustration of constant and unwelcome arc length parameterchanges, making for easy and automatic arc length regulationwhen changing from one welding position to another.WiseFusion advantagesFor more information, contact the nearest Kemppi representativeor visit our Web site at www.kemppi.com.Automatic arc length regulationExcellent weld pool control for positional weldingNarrow and energy dense arcImproved weld quality and appearanceBuster produce a range of aluminium boatsBuster aluminium boat production

WiseWise – Ordering information and equipment relationshipWise products Ordering Codes KempArc Syn. KempArc Pulse FastMig Syn. FastMig PulseWiseRoot 6265011 x xWiseRoot-A 9991011 x xWiseThin 9991013 x xWiseThin-A 6265013 x xWisePenetration 9991000 x xWisePenetration-A 9991010 x xWiseFusion 9991014 xWiseFusion-A 9991015 xPlease contact us for moreinformationKemppi OyPhone +358 (0)3 899 11info@kemppi.comwww.kemppi.comKemppi (U.K) Ltd.Phone +44 845 6444201sales.uk@kemppi.comKemppi Australia Pty Ltd.Phone +61 2 9605 9500info.au@kemppi.comAD235EN0940