ROBOTICS & AUTOMATION
ROBOTIC WELDING AND THE IMPORTANCE OF THE CORRECT WELDING GAS
a robotic welding system are only as good as the shielding gas and using a gas developed for manual welding will seriously compromise the welding speed. The ultimate question is why would
manufacturers invest heavily in robotic welding systems and then not invest in the best, most suitable shielding gas for their welding applications? Simply put, failing to select the most suitable gas will undoubtedly compromise the overall effectiveness of the robotic welding process.
Ferromaxx® Plus One such gas that has been designed with robotic welding is Ferromaxx® Plus from Air Products. Ferromaxx® Plus has been created for MAG welding carbon steel. The specially formulated mixture increases welding speeds, improves weld quality and reduces rejects, gives excellent penetration characteristics and is tolerant to variations in weld parameter settings. Not only does Ferromaxx® Plus give a smooth and flat weld finish, users see reduced clean-up times due to minimal spatter generation. While the cost of Ferromaxx® Plus may
R
obotic welding has revolutionised the manufacturing industry by
increasing efficiency, precision and consistency in welding processes. It allows manufacturers to streamline operations and maintain high production rates. This automation not only enhances productivity but also reduces human error and improves safety in the workplace. However, as the knowledgeable team at Air Products explain, the effectiveness of robotic welding is heavily influenced by various factors, one of the most critical being the choice of welding gas.
The Role of welding gas Welding (or shielding) gas plays a
pivotal role in the welding process by influencing the quality of the weld. Different types of welding applications require specific gases to achieve optimal results and choosing the correct shielding gas is vital for several reasons:
• Weld quality: The right gas ensures that the weld is free from defects. Inadequate shielding can lead to contamination, resulting in weak joints and poor appearance.
• Process efficiency: Different shielding gases are used depending on the welding process and materials being joined, as they can influence the welding travel speed, mechanical properties and the overall quality of the weld joint.
• Cost-effectiveness: While some gases may be more expensive than others, the long-term savings from increased welding speeds and reduced defects can outweigh initial costs. Selecting the right gas for the application can lead to significant savings in material and labour costs.
Investing in a robotic welding system is a huge financial commitment but one that can significantly enhance production efficiencies, improve weld quality repeatability. The huge advantages of
26 / WELDING WORLD MAGAZINE - ISSUE 05 - SEPTEMBER 2024
be higher per cubic metre than traditional manual welding gases, it accounts for only approximately 5% of the total weld cost. Considering the advantages of Ferromaxx® Plus, manufacturers can maximise their return on investment of the robotic system by using a welding gas specifically design for this application. • Improved welding speed - Ferromaxx® Plus gas increases weld speeds by up to 19% compared to a conventional weld process gas mixture making the overall cost of the weld the same due to the faster welding speeds.
• Fewer rejects – Ferromaxx® gases are easy to use and tolerant to variations in weld parameter settings. This improves the weld quality and means fewer rejects.
• Better working environment – Higher- performing gases like Ferromaxx® Plus ensure that fume levels are reduced resulting in a cleaner and safer working environment.
Ferromaxx® Plus is part of the Maxx® range of gases and is available in high-volume 300 bar cylinders and 300 bar manifolded cylinder packs. Purpose-designed for MAG welding carbon, carbon manganese
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