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    Gas Mixture

    Uploaded by

    Avinash Silimkar
    The document discusses changing the welding gas mixture from 80% Ar:20% Co2 to 82% Ar:18% Co2. It finds that using the 82%/18% ratio results in less spatter, a better weld finish, and a flatter weld bead compared to the 80%/20% ratio. A trial at Linde Gas found that the new ratio reduced spatter, welding time, gas and wire consumption, lowering costs by up to 19.5% without compromising weld penetration or quality.

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    © All Rights Reserved
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    Gas Mixture

    Uploaded by

    Avinash Silimkar
    76 views15 pages
    The document discusses changing the welding gas mixture from 80% Ar:20% Co2 to 82% Ar:18% Co2. It finds that using the 82%/18% ratio results in less spatter, a better weld finish, and a flatter weld bead compared to the 80%/20% ratio. A trial at Linde Gas found that the new ratio reduced spatter, welding time, gas and wire consumption, lowering costs by up to 19.5% without compromising weld penetration or quality.

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    Gas Mixture.pptx

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    The document discusses changing the welding gas mixture from 80% Ar:20% Co2 to 82% Ar:18% Co2. It finds that using the 82%/18% ratio results in less spatter, a better weld finish, and a flatter weld bead compared to the 80%/20% ratio. A trial at Linde Gas found that the new ratio reduced spatter, welding time, gas and wire consumption, lowering costs by up to 19.5% without compromising weld penetration or quality.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    76 views15 pages

    Gas Mixture

    Uploaded by

    Avinash Silimkar
    The document discusses changing the welding gas mixture from 80% Ar:20% Co2 to 82% Ar:18% Co2. It finds that using the 82%/18% ratio results in less spatter, a better weld finish, and a flatter weld bead compared to the 80%/20% ratio. A trial at Linde Gas found that the new ratio reduced spatter, welding time, gas and wire consumption, lowering costs by up to 19.5% without compromising weld penetration or quality.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 15

    Welding Gas Cost Reduction:

    (80%Ar:20%Co2 to 82%Ar:18% Co2)

    2017年4月24日

    Prepared By :Ganesh Patil


    Department : R&D (Welding process)
    CFT MEMBERS :

    CFT MEMBERS

    R&D Production
    Commercial Quality 1) Mr. Rajiv Ranjan
    1) Mr. Ganesh Patil
    Mr. Anup Bhandare Mr. Tarachand Jadao
    2) Mr.Shripati Chavan 2) Mr. Sachin Menkar

    2
    Why should use (82% Argon :18%Co2) ?

    We are currently using ACM (80%Ar : 20%Co2) of tolerance ±10%.


    During welding if the tolerance exceeds to positive side then the
    mixing gas ratio turn to (78% Ar : 22% Co2). If Co2 volume increased to 22% it
    dominates on the Argon & it act as a Co2 gas & it causes ;
    1) Poor weld finish.
    2) Causes more spatter
    3) Excess weld bead.

    To avoid this proportion changed to (82% Ar +18%Co2 ) ±10%.


    Here what happens if mixing ratio increased to “+ve” side then ratio will
    be (80.2% Ar +19.8%Co2). Results,
    1) Good Weld finish.
    2) Less spatter
    3) Flat weld Bead.

    3
    Observation:

    ACM (80%Ar: 20%Co2) .Vs.(82%Ar: 18%Co2) Cargon18

    1. Spatter minimization compare to ACM (80%Ar: 20%Co2) Ratio.

    2. Good weld Bead / Profile compare to ACM (80%Ar: 20%Co2) Ratio.

    3. Equivalent Penetration as compare to ACM (80%Ar: 20%Co2) Ratio.

    4. Less weld wire consumption compare to ACM (80%Ar: 20%Co2) Ratio.

    5. Reduce weld time compare to ACM (80%Ar: 20%Co2) Ratio.

    6. Less power consumption compare to ACM (80%Ar: 20%Co2) Ratio.

    7. Less shielding gas consumption compare to ACM (80%Ar: 20%Co2) Ratio.

    4
    一

    MOTO OF TRIAL :

    MOTO OF TRIAL

    Productivity Improvement Quality


    Cost Reduction  Chipping/Grinding time Reduction.
     Weld Quality Improvement.
     Reduction of welding wire.  Flawless weld (Inside
     Reduction of weld time.
     Reduction of gas mixture. /Outside)
     Spatter Reduction.
     Achieve good weld
    penetration.

    5
    Trial conducted at Linde gas

    No spatters near weld joint

    6
    COMPARISON

    Cargon 18
    ACM (80%Argon : 20%Co2)
    (82%Argon : 18%Co2)

     More spatter compare to  Less spatter compare to


    (82:18) ratio. (80:20) ratio.
     Weld finish poor compare to  Weld finish Very smooth
    (82:18) ratio. compare to (82:18) ratio.

    7
    Macro etching test

    8
    Idea list

    Weld data logger machine :

    9
    Idea list

    Weld data logger Report :

    (82% Ar : 18%Co2)

    (80% Ar : 20%Co2)

    10
    Trial taken at Linde (Based on weld data logger machine)
    Date of Analysis : 20/4/2017 Analyst: Vishal Wakale

    Application: Test Sample

    Type of joint : Fillet Joint

    Material s pec : M.S

    Material Thick : 4MM

    Power s ource: 400AMP.

    Sheilding gas 1 ACM (80:20) CORGON18 (82:18)

    Gas Flow Rate 2 12 12

    Wire diameter 3 ø1.2 ø1.2

    Wire us ed 4 52 48 M

    Weld Current 5 188 188 A

    Weld Voltage 6 22 22 Volts

    Weld Length 7 1575 1575 mm

    Weld Time 8 204.3 194.2 Sec.

    Clean up time (Spatter) 9 47 29 Sec

    Gas price /m3 10 36.5 34.5 Per m3

    Wire price/kg 11 73 73 Per Kg 11


    Trial taken at Linde gas

    Sheilding gas analysis Report


    Shielding Gas : ACM (80%Argon +20%Co2) Corgon18 (82%Argon +18%Co2) Remark

    Shielding gas flow rate, (l/min) 12 12

    Welding time ,(Sec/m) 130 123

    Weld Length, (mm) 1575 1575

    Gas Used,(m3/m) 0.0173 0.0164

    Weld Travel speed,(mm/min) 480 487

    Wire Used(KG/m) 0.46 0.37

    Wire cost (Rs/kg) 73 73

    Gas Cost per m3 36.5 34.5

    Weld clean up time, (Sec/m) 49 24

    total weld time (sec/m) 130 123

    BREAKDOWN OF COST CONTRIBUTIONS Savings


    Wire cost per meter weld 33.58 27.01 19.50%
    Sheilding gas cost per meter weld 0.622 0.55 11.57%

    Total cost (Per meter weld) 34.2 27.56


    % saving relative to FIRST PROCESS 19.40%

    12
    Comparison

    Cost Vs. Gas Mixture

    40
    0.622
    35

    30 0.55

    25

    Cost 20
    (Rs) 33.58
    15
    27.01
    10

    0
    ACM Corgon18
    (80%Ar +20%Co2) (82%Ar +18
    %Co2)

    Sheilding gas cost per meter weld


    Wire cost per meter weld
    13
    Conclusion :
    Items Before After Trial Saving

    1.Cost Reduction 36.50 Rs /M3 Approx. 34.5 Rs/m3 Approx. 2Rs /M3

    Good penetration
    2.Penetration in (82% : 18%) compare to
    (80% : 20%)

    3. Weld Profile
    Excess bead size/ Excess Flat bead Consumable consumption
    reinforcement & cost reduction

    4.Spatter Quantity Less spatter in (82% : 18%)


    without the antispatter compare to (80% : 20%)
    liquid application

    5. Grinding /Spatter
    52sec 29 sec 23 sec
    Removing Time
    6. Welding Wire
    33.58 Rs/meter 27.01 Rs/meter 6.57 Rs/Meter
    Consumption

    14
    130sec/m 123sec/m 7 sec/m
    7. Weld Time
    Quality Changes the World!

    Thank you!

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