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    Kaushik Sengupta
    The document discusses the history and development of welding from ancient times to modern times. It covers milestones in welding technology from the 1880s to the present day, including innovations in TIG, MIG/MAG, and other welding methods. It also discusses trends in shielding gas composition and developments that have influenced shielding gas selection.

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    PPT

    Uploaded by

    Kaushik Sengupta
    163 views18 pages
    The document discusses the history and development of welding from ancient times to modern times. It covers milestones in welding technology from the 1880s to the present day, including innovations in TIG, MIG/MAG, and other welding methods. It also discusses trends in shielding gas composition and developments that have influenced shielding gas selection.

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    The document discusses the history and development of welding from ancient times to modern times. It covers milestones in welding technology from the 1880s to the present day, including innovations in TIG, MIG/MAG, and other welding methods. It also discusses trends in shielding gas composition and developments that have influenced shielding gas selection.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    163 views18 pages

    PPT

    Uploaded by

    Kaushik Sengupta
    The document discusses the history and development of welding from ancient times to modern times. It covers milestones in welding technology from the 1880s to the present day, including innovations in TIG, MIG/MAG, and other welding methods. It also discusses trends in shielding gas composition and developments that have influenced shielding gas selection.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 18

    “Hitsauksen kehityksestä

    kaasumiehen silmin”

    Pauli Toiviainen, AGA Pohjois-Euroopan Regioona


    Already the old Egyptians…

    Welding by combination of heat and pressure has been used from at least 5000 b.C.
    This was the only method until the 1880’s
    Milestones in welding from 1880

    Electron beam

    Plasma welding

    Covered
    Metal arc TIG MIG
    electrodes
    Carbon Submerged MAG Laser
    Oxy Acetylene
    arc arc (CO2) welding

    1880 1890 1900 1910 1920 1930 1940 1950 1960 1970
    Development 1940’s-1980’s

    1940’s : Innovation of TIG and MIG/MAG in the US


    1960’s : The methods are spread commercially
    1970’s : MAG welding becomes the dominating method in W. Europe (instead of
    MMA)
    1978 : MISON shielding gases for better working environment
    1980’s : Robot welding

    Note the drum pack for filler wire (AGA 1960’s)


    Development 1990’s

    • High deposition rate MAG welding


    – RAPID PROCESSINGTM (AGA)
    – T.I.M.E. Process (Fronius) RAPID Conventional
    PROCESSING MAG
    – Twin Arc/Tandem welding
    Plate thickness [mm] 3 3
    • MIG brazing
    Welding speed [cm/min] 120 60
    Deposition rate [kg/h] 5 2,5

    RAPID Conventional
    PROCESSING MAG
    RAPID ARC®

    • High productivity MAG welding process


    • Standard equipment is used
    • Mechanized welding
    • Shielding gas with low CO2-content

    Shielding gas development (steel welding):


    • Lower CO2-content (8-10% in Argon)
    Conventional MAG, v = 160 cm/min

    RAPID ARC®, v = 160 cm/min


    Tandem-MAG

    • Higher deposition rate


    • Higher welding speed
    • Accessibility may be limited (bigger welding head)
    • More programming due to two arcs
    • Difficult to minimize spatter
    • More sensitive process
    • Harder for operator to fine tune

    Shielding gas development (steel welding):


    • Lower CO2-content (8-12% in Argon)
    • Helium addition
    Development during 2000’s

    • New variants due to better and faster electronics


    – CMT (Fronius)
    – Cold Arc (EWM)
    ”Cold” processes
    – AC-MIG/MAG (OTC)
    – Etc..

    • Hybrid welding
    – Laser-MAG
    – Plasma-MAG
    “Cold” processes - benefits

    Welding of thin material:


    – Less distortion
    – Almost no spatter
    – Possible to substitute TIG-welding
    – Better gap bridging Stainless steel, 0,5 mm
    Overlap
    – Suitable for MIG-brazing Filler metal 0,8 mm
    Welding speed: 2,0 m/min

    Shielding gas development (according to Fronius):


    • No influence of shielding gas
    – Pure CO2 (steel welding)
    – Pure Argon (brazing and Ni-base welding)

    Manual MIG-brazing
    Filler metal: 1,0 mm CuSi3
    Gap: 4 mm
    No influence of shielding gas with CMT?

    Base material: carbon steel, Filler: alloy 625, cladding


    CMT
    CMT pulsed

    Argon Ar+0,05%CO2+30%He+2%H2
    Hybrid welding with laser-MIG/MAG

    • Lower laser energy compared to laser welding


    – Arc energy is added
    – Arc decrease reflection of laser beam
    • Higher welding speed
    • Lower heat input
    • Better tolerance to gap variations
    MA
    G
    Shielding gas development (steel welding):
    • “Normal” mixtures works fine
    • Optimization still ongoing Lase
    r

    Laser-
    MAG
    Trends for shielding gases - MIG/MAG & TIG

    Driven by development of power sources


    • MAG-welding of carbon steel with pure CO2 or 82/18-mixture
    – Fast, reliable electronic control of power sources

    Driven by development of construction material


    • Nitrogen addition (TIG)
    – Duplex and Superduplex
    – Lean duplex
    • Micro additions of CO2 and O2 in Argon (MAG)
    – Ni-base alloys
    – Other high alloyed materials
    • Helium addition (TIG and MIG/MAG)
    – All high alloyed materials
    Shielding gas components, TIG

    Standard Added value

    Ar + NO + He + H2 + N2

    Base gas
    Work environment
    •Ozone reducing
    •(Arc stability)
    Productivity
    •Fluidity
    •Wetting
    •Penetration
    Productivity
    •Fluidity
    •Wetting
    •Penetration Metallurgy
    •Reducing •Corrosion
    •Strength
    Shielding gas components, MAG

    Standard Added value

    Ar + CO2 + O2 + NO + He

    Base gas
    Arc stability

    Work environment
    •Ozone reducing

    Productivity
    •Fluidity
    •Wetting
    •Penetration
    Trends for shielding gases - Laser

    Driven by development of lasers


    • CO2 Laser-welding of carbon steel
    – Helium replaced by:
    – Argon/CO2-mixtures
    – Argon/Helium-mixtures
    • Diode laser welding of carbon steel
    – Argon/CO2-mixtures
    Weld Metal consumption 1974-2006

    14000

    Gross weight 14,400 ktons Gross weight 12,610 ktons


    12000

    10000

    8000
    Tons

    6000

    4000

    2000

    0
    1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006E
    Year

    MMA MIG/MAG FCAW SAW

    •Source: ESAB
    Shieding Gases volume development, North
    Europe

    REN

    7 000 000 M3

    6 000 000 M3

    5 000 000 M3 GAR


    CORGON
    4 000 000 M3 MISON PURE
    MISON 8
    3 000 000 M3 MISON 18
    MISON 25
    2 000 000 M3 Result

    1 000 000 M3

    0 M3
    2004 2005 2006 2007 2008 2009 2010 2011 2012
    Gustav Dalen 1904

    ”Auta asiakasta parantamaan


    toimintansa kannattavuutta,
    laatua ja turvallisuutta”

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