Environmental and Energy Conservation issues in Welding

By S Sankaran

27 April 2012

2012

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 Edmund Davy discovered acetylene in 1836 First commercial oxy-acetylene welding torch at turn of the century Humphrey Davy discovered the electric arc in 1801 Concerned with use of arc for illumination Benardos & Olszewski showed in 1885-87 arc with Carbon Electrodes and its use for melting Steel. In 1890, Slavianoff used a metal Electrode and Arc to deposit metal from the electrode. Oscar Kjellberg invented coated electrode during the years 1907 to 1914
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Gas metal arc welding Developments

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Driving Force behind Welding Developments

Need to Join newer materials Improve Productivity Reliability of welds in service

Environmental Issues

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Surface Tension Transfer Welding Cycle

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STT Produce Less fumes And low in Spatter

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Advantages ( Surface Tension Transfer STT) Can replace TIG for root pass welding Substantially reduced spatter

Lower arc radiation and fume generation

Reduced heat input on thin-gauge material Longer operating time for robots

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Process Share of Weld Metal - Global Trend JAPAN SMAW 20 % EUROPE 30 % USA 35 % INDIA 70 %

SAW
GTAW

8%
2% 70 %

8%
2% 60 %

8%
2% 55 %

8%
2% 20 %

FCAW + GMAW

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Energy Conservation in Welding

FCW - Flux Cored Wire SW - Solid Wire CE - Coated Electrode

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Metal Core Wire

Solid Wire
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Hybrid: Characteristics & Benefits of Solid Wire & Flux-Cored Wire

Flux-Cored Wire
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History of FCAW
Concept of FCAW ...1911
Large Dia. FCAW Wires .. 1930s Self-Shielded FCAW Wires)..1950s Small Dia. FCAW Wires ........1970s Metal-Cored Wires.......1980s

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Newer Flux Cored Wires

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Preventing lack of fusion at start of Aluminum welds

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Welding-Related Expenditure and Productivity Measurement in U.S. Manufacturing, Construction, and Mining Industries By American Welding Society Edison Welding Institute US Department of Commerce May 2002

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Data from U.S. Department of Commerce & AWS survey

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Summary of welding related expenditure for major industrial sectors

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Industry Vision Workshop on Welding

By

American Welding Society National Institute of Standards & Technology US Department of Energy June 1998

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Industry Vision Workshop on Welding STRATEGIC GOALS FOR 2020

Reduce average cost of welding by one-third

Integrate welding with the Production Cycle Develop welding technology along with new materials development Assure welding is a part of six-sigma quality environment Improve knowledge base of people taking decisions related to Welding

Reduce energy use in welding by 50%

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Energy Conservation Measures

Avoid unwanted welds Choice of Welding Processes

Selection of Welding Power Source

Handling of Welding Consumables Pre-heating & Post-heating

PWHT

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Energy Conservation Measures

Avoid unwanted welds Choice of Welding Processes

Selection of Welding Power Source

Handling of Welding Consumables Pre-heating & Post-heating

PWHT

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Energy Conservation Measures

Avoid unwanted welds Choice of Welding Processes

Selection of Welding Power Source

Handling of Welding Consumables Pre-heating & Post-heating

PWHT

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Energy Conservation Measures

Avoid unwanted welds Choice of Welding Processes

Selection of Welding Power Source

Handling of Welding Consumables Pre-heating & Post-heating

PWHT

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Energy Conservation Measures

Avoid unwanted welds Choice of Welding Processes

Selection of Welding Power Source

Handling of Welding Consumables Pre-heating & Post-heating

PWHT

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Energy Conservation Measures

Avoid unwanted welds Choice of Welding Processes

Selection of Welding Power Source

Handling of Welding Consumables Pre-heating & Post-heating

PWHT

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Energy Conservation Measures

Avoid unwanted welds Choice of Welding Processes

Selection of Welding Power Source

Handling of Welding Consumables Pre-heating & Post-heating

PWHT

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Weld finished with full grinding

As welded with no grinding

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Total Energy Consumption in Welding Processes

Primary Energy Energy required to heat the material above melting or forging temperature Secondary Energy Preheat / Postheat Electrode Baking / Holding Wirefeed units, Motorised Slides, Fume Extractors Job Handling Devices - Manipulators, Gantry, Robot Weld Preparation Machining, Grinding Weld Finishing Deslagging, Grinding

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Material Thickness ( Length 250 mm ) PROCESS 1 mm 12 mm 50 mm

P
SMAW GMAW GTAW SAW LASER EB FRICTION STIR RESISTANCE 35 112 15 57 32 94

S
105 52 40

Total
163 84 130

P
1420 1280

S
1278 277

Total
2698 1557

P
17640

S
13035

Total
30675

1450 454 3230 466 3245 120 120 1100 11 46

864 4268 5283 347

2314 4388 5403 1447

16200

9870

26070

1000 3680

7958 1495

8958 5175

Data from TWI Publication

Total Energy Consumption for making a Weld in KJ P Primary Energy;

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S Secondary Energy
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Friction Stir Welding

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SMAW : Electrode Size from 4 to 5 mm

33% increase in deposition rate

25 % energy saving SAW : Single wire to tandem arc 20% increase in deposition rate TIG : Enhance Penetration Use A-TIG

MIG : Smaller size wire

Increase in deposition rate

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TIG PROCESS

ATIG PROCESS

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70 mm Diameter x 5 mm thick SS Tube welded in 5G position with Activated flux

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CMT Cold Metal Transfer

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Wire feed Forward & Retraction in CMT

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0.8 mm AlMg3 sheets CMT-welded without using any clamping, or backing devices.

1.0 mm Galvanised sheet CMT-brazed joint, filler metal CuSi3.

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Power Factor =

Apparent Power

Real Power
ADVANTAGES OF HIGH POWERACTOR

Increased Power Supply Capacity Reduced Heat Load on Electrical Cables Reduction of kVA Demand Reduction in Electricity Delivery Charge Reduced Voltage Drop on Cables Improved Equipment Operation

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Inverter 6800 kwh/year

Rectifier 8500 kwh/year

Generater 12500 kwh/year

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Energy consumption per year for SMAW welding power sources

14000
Energy Consumption (KWH/year)

12000 10000 8000 6000 4000 2000 0 0 50 100 150 200 250 300

Generator Transformer Inverter

Welding Current - A

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Advantages (Inverter Welding Power Sources)

Compact size Shop floor space free Low weight Highly portable High efficiency energy saving Ripple free Smooth arc and better weld

Multi-process capability

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Recommended Storage for Electrodes

Below 50% relative humidity

Between 20 to 40 degree C

Conditioning of Electrodes before use

Drying at 100 to 300 deg C depending on type of electrode Holding above 100 deg C till use
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Card board carton

40 50 kwh/day

Vacuum sealed packet

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Low velocity candle type burner (Rs. 75/Hr)

Spot burner (Rs. 90/Hr )

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Providing Insulation / hoods to retain heat at the joint

Hood to retain heat at the joint

Dished End and Nozzle covered with Insulation

Forged nozzle Pre-heating

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PID controller

Infra red sensor

Infra red sensor measure preheat temperature

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Large Furnace with Ceramic Fiber Insulation

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Energy Saved is Energy Generated

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Flux Cored Arc Welding

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Flux Cored Arc Welding

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Welding related energy cost as percentage of total energy costs

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Comparison of the total energy consumption of welding processes. (For 250mm length weld)
Material 1 mm thick Process MMAW MIG/MAG GTAW SAW Laser EBW (V) FSW
Primary Energy KJ Secondary Energy KJ Total Energy KJ

Material 12 mm thick
Primary Energy KJ Secondary Energy KJ Total Energy KJ Primary Energy KJ

Material 50 mm thick
Secondary Energy KJ Total Energy KJ

57 32 94 112 -

105 52 40 454 -

162 84 130 566 -

1420 1280 1450 120 120 1100

1278 277 864 4268 5283 347

2698 1557 2314 4388 5403 1447

17640 16200 1000 3680

13035 9870 7958 1495

30675 26070 8958 5175

RSW

35

11

46

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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) Enhance Image of Welding Attract talented youth Improved working environment 4) Knowledge Management in Welding 5) Multiple Qualifications And Certification 6) Use of IT and computer control in welding
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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) Enhance Image of Welding Attract talented youth Improved working environment 4) Knowledge Management in Welding 5) Multiple Qualifications And Certification 6) Use of IT and computer control in welding
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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) Enhance Image of Welding Attract talented youth Improved working environment 4) Knowledge Management in Welding 5) Multiple Qualifications And Certification 6) Use of IT and computer control in welding
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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) Enhance Image of Welding Attract talented youth Improved working environment 4) Knowledge Management in Welding 5) Multiple Qualifications And Certification 6) Use of IT and computer control in welding
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Concerns in Indian Context 1) Energy Optimisation in welding 2) Reduce - Rework, Repair, Rejection Do it Right First Time and Every Time 3) Enhance Image of Welding Attract talented youth Improved working environment 4) Knowledge Management in Welding 5) Multiple Qualifications And Certification 6) Use of IT and computer control in welding
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