AUTOMATION AUTOMATION FOR OVERLAY WELDING F
ronius is one of the world’s leading manufacturers of overlay welding systems and repeatedly brings new
innovations to the market, such as the retrofittable SpeedClad 2.0 process. Fronius Welding Automation offers entire systems and the company provides expert, customer-friendly service right from the start and throughout the entire service life of a welding system. Every single user benefits from overlay welding systems that, thanks to update options and retrofitting, will remain state-of-the-art for years to come. From planning, engineering,
manufacturing and commissioning to the maintenance and servicing of overlay welding systems, customers can rely on Fronius Welding Automation to support them with its global service and partner network. Technical commissioning by Fronius experts and the preliminary acceptance by buyers from the oil and gas industry take place at the production site in Steinhaus, Austria. The systems are then delivered, installed on site and finally accepted by international customers in the onshore and offshore sector. The comprehensive Fronius commissioning service includes expert training sessions and process optimisation at the start of production. Every new overlay welding project
begins with feasibility studies and welding tests. Overlay welding is a highly complex process. In addition to the base material of the components to be surfaced, parameters such as amperage, wire speed, welding speed, filler metal, shielding gas, ambient temperature, and humidity also play a decisive role. Even minor deviations can have unwanted effects on the welding result. This is why welding tests should be as realistic as possible—with components, filler metals, and shielding gases that will also be used when the system goes into live operation. If possible, the tests should also be carried out under the same climatic conditions that prevail at the intended place of use. If these conditions cannot be achieved, the welding parameters must be adapted and optimised in line with the production environment during commissioning.
Oil and gas industry Fronius Welding Automation draws on a wealth of experience to devise innovative ideas for new system solutions. Over a period of more than 40 years, the company has developed application- based overlay welding systems that are either used as standard or modified to meet special customer requirements. With a footprint of approximately 6 m²
the Compact Cladding Cell (CCC) mounted on a transportable platform is ‘the’ compact solution for overlay welding. It was developed as a cost-effective inner cladding solution for valve components. The largest bore depth and possible component diameter are 1 m, the maximum component weight is 2,500 kg. Despite its compactness, the system is an extremely powerful overlay welding system. It stands out for its ease
of use, precise movement sequences, and comprehensive data recording options. The ergonomic design includes a wire spool holder at a comfortable user height, welding torch quick-change system, and power sources on a rail. Plus, the CCC boasts innovative software functions, maximum process security, and ultimate reliability in continuous operation. The HMI system controls offer next-level ease of use with a 21-inch touch display, real-time process visualisation, multi-user management, and much more. For applications requiring the highest possible productivity, SpeedClad 2.0 is the process of choice. The Endless Torch Rotation System (ETR)
was developed for larger, more complex components and has been an established solution for many years. Its key feature is an endlessly rotating welding head. This makes it possible to weld components with different bores and bore angles up to an internal diameter of 1 m. The welding torch and the wire feeder rotate together around the bore axis. Components are positioned automatically, which shortens set-up times considerably and saves production costs. If there is a risk of the torch colliding with the component, the electropneumatic collision detection system stops all axes of movement and protects the welding torch against damage. Most recently, Fronius has enhanced its successful ETR system with the even more flexible ETR Ultimate system. In addition to overlay welding tasks, this versatile system also makes it possible to join larger components with challenging geometries and difficult seams.
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