Efficient Production of Welded Joints

Consideration must be given to the most varied criteria in component design to achieve low-cost production of a component. Above all these include designing the component with a view to function, stress, material and production. If the component needs to be designed as a welded structure, there are additional factors, which have an impact on the efficiency audit such as the material and finishing costs of the individual parts and welding costs. It is not possible to give any generally applicable instructions and solutions for low-cost construction of welded components although one can define a series of individual basic rules that make the work easier and save costs. The following list details such rules although the sequence does not necessarily correspond to the importance of these rules. Dimension fillet welds correctly Keep fillet welds as thin as possible Take note of fillet weld formation, use deeper penetration Provide for thin and long fillet welds Provide for double fillet welds where possible Ensure accessibility Use economic weld shapes on butt weld Deposit as little weld metal as possible Take notice of welding procedure Check weld preparation angle for MAG welding Check effect of material on weld shape Allow for back welds Utilise potential cost reductions in production Specify standard operating times Analyse times and look for possible ways to make savings Reduce the actual welding time Use more current with same electrode diameter Use thicker electrodes Use other types of electrodes Use other welding consumables Use procedures with higher output Choose more favourable welding position Mechanise Production Partial mechanisation of the welding procedure used Replace the existing procedure with a mechanised welding procedure Use special welding machines Adapt weld preparations Use weld pool backings Do not deposit more weld metal than necessary Assemble to exact size Produce more accurate flame cuts Monitor weld thicknesses and weld reinforcements Reduce downtimes More efficient organisation of production More efficient organisation of the workplace Better information provided for welders
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Bhler Schweitechnik Austria GmbH. - Economy-Efficient Production.doc

Use jigs Prevent or reduce distortion Plan allowance for distortion, pre-bend Pre-tension Draw up welding sequence schedule Check weld shape and weight of weld Use procedures with less distortion Weld from both sides simultaneously Use thicker sheet metal Reduce process-dependent interruptions and weld dressing Shorten process-dependent interruptions Make slag removal easier Reduce spatter formation by choosing correct type of electrode Reduce spatter formation by choosing correct shielding gas Prevent spatter by using pulsed arc technique with mixed gas shielding Set up central gas supply Reduce malfunctions in units Purchase quality products Operative preventive maintenance Maintain and care for unit regularly Take notice of operating instructions Save energy costs Reduce cable losses Switch off units during breaks Use energy-saving procedures Buy energy-saving power sources Train and motivate welders Improve qualifications Set up performance-related wage system as motivation Get rid of noxious environmental influences Take note of costs and quality Do not demand higher quality than necessary Do not produce higher quality than needed Save unnecessary costs by working conscientiously Take notice of the effect of defects during weld preparation on the weld quality Design with a view to testing and examination

Bhler Schweitechnik Austria GmbH. - Economy-Efficient Production.doc

This document is subject to change without notice page 2 of 2 - For updates see www.boehler-welding.com.