Beyond human

By Staff Report October 30, 2024 12:53 pm IST

Welding technology has evolved beyond the human touch, achieving exceptional precision and reducing risks. Let’s review the latest advancements in automation and laser technology that are revolutionising welding practices in metal and sheet processing and industrial manufacturing.

The integration of automation in welding technologies has helped advance consistency, productivity, cost reduction, and environmental sustainability. Automated welding systems follow exact specifications for consistent, higher-quality welds. They find specific use in mass production since automation allows for precise repetition of welding tasks. By reducing downtime, automated systems increase the uptime of the manufacturing process. They also operate much faster than manual welding, improving production lines’ efficiency.

In addition to improved productivity, these systems are equipped with sensors and software that monitor welding processes in real time. The data collected is analysed to predict breakdown time, allowing room for pre-emptive measures.

Sunando Kumar Palit, Head – Product Strategy & Customer Experience, Ador Welding Ltd, shares that automation also reduces dependency on skilled labour and minimises human errors, the risk of injuries, and related costs. Optimised welding due to automation also ensures that less welding material is used to reduce waste and cost. Automation in welding technologies also has a positive environmental impact by lowering emissions and waste.

Dissecting production costs and quality

Robotic welding systems in a manufacturing environment positively impact production costs and quality. It comes with the initial investments but eventually reduces the need for manual labour, thus reducing costs. The efficiency is much higher, and the speed at which the welding happens is also much higher than that of manual welding. This increases output and reduces operational costs. The data collection and analysis possible during robotic welding helps predict breakdown and allows for maintenance activity before the actual breakdown. This improves efficiency and reduces costs that would have to be borne due to a breakdown.

Robotic welding systems provide consistent and precise welds, leading to higher-quality products. Automated systems are less prone to human error, reducing the incidence of welding defects. They also lead to lower rejection rates and less need for rework, enhancing overall product quality.

MIG, TIG, and Stick welding processes

Each welding process offers unique applications and advantages tailored to specific needs. MIG Welding (Metal Inert Gas) is well-suited for high productivity and clean welds, making it ideal for automated or high-volume operations. Known for its speed and ability to cover large areas quickly, this method is advantageous for high-volume production. It is also relatively easy to learn, allowing operators of varying skill levels to use it effectively. MIG welding can be applied to a wide range of metals, including steel, aluminium, and stainless steel, with the continuous wire feed enabling long welds without frequent interruptions, thereby reducing downtime. MIG welding produces minimal spatter, resulting in cleaner welds. The process is easily automated, making it a preferred choice in industries like automotive, aerospace, and others that require consistent, high-quality results. Common applications include automotive manufacturing, structural steel fabrication, and metal furniture production.

Rajeev Patki, Senior Product Manager – Marketing, ESAB, shares that TIG (Tungsten Inert Gas) welding, on the other hand, allows the operator great flexibility to meet the needs of precision welds in thin materials and also the root joints for thick materials. High penetration and operator flexibility ensure good gap bridging, apart from delivering aesthetically clean welds in demanding applications like aerospace and energy.

TIG welding is effective on metals like aluminium, magnesium, copper, and stainless steel. Often performed without filler material, this method produces clean welds with no spatter, enhancing the overall quality. It is widely used in applications requiring fine detail and superior finishes, such as aerospace components, automotive exhaust systems, and metal art or sculptures.

Stick Welding (Shielded Metal Arc Welding, SMAW) stands out in outdoor and on-site applications where portability and versatility are essential. It is effective on metals, including steel, cast iron, and stainless steel. The benefit is that it does not require external shielding gas, making it highly practical for outdoor or remote settings. The equipment is typically affordable and easy to maintain, making it a cost-effective solution for smaller operations or repair work. Stick-welding can be performed on less-than-clean metals, making it suitable for maintenance and repair tasks in uncontrolled environments. It is adaptable for welding in any position—whether flat, vertical, horizontal, or overhead. This flexibility makes stick welding a common choice in construction, pipeline work, and shipbuilding.

Latest trends in laser welding and cutting technologies

The adoption of fibre lasers is growing. These lasers offer distinct advantages over traditional CO2 lasers, including better energy efficiency, higher precision, and the ability to cut and weld a broader range of materials. Their faster processing speeds and lower operational costs have contributed to their increasing popularity.

Ultrafast and high-power lasers are also in vogue. Ultrashort pulse lasers are particularly valuable for high-precision applications, such as microfabrication or handling delicate materials. These lasers emit brief bursts of light, delivering exceptional accuracy. High-power lasers excel at cutting and welding thicker and tougher materials with speed and precision.

The industry is also witnessing the growing use of green and blue lasers, which are tailored for specialised applications and perform superiorly when working with specific materials like copper. 3D laser cutting and welding systems are gaining traction, allowing the process of complex geometries and multi-dimensional components. This is especially beneficial in sectors like automotive and aerospace.

Automation and smart manufacturing are becoming increasingly integral to laser cutting and welding. New systems are integrated with robotic arms and automated solutions for high speed and precision. This aligns with the broader shift toward Smart factories and Industry 4.0.

Training and upskilling welders

AR and safety protocols for training and upskilling welders create safer learning environments and enhance the learning curve while reducing costs. Simulated environments allow trainees to learn and practice welding techniques without the risk of injury. It includes understanding the equipment handling and the risks associated with welding, such as burns, electric shocks, and harmful fumes. Training emphasises the importance of personal protective equipment (PPE), covering the correct use and maintenance of items like helmets, gloves, and protective clothing. Emergency procedures enable users to recognise hazards and respond swiftly to accidents or equipment malfunctions.

AR utilisation provides an immersive training environment where trainees can visualise welding techniques and receive real-time feedback on their actions without the dangers of actual welding. It also enables hands-on practice without consuming physical resources like metal or gas, reducing costs and waste while providing nearly identical experiences to welding. AR systems often come with data collection capabilities, tracking the trainees’ performance.

With rapid technological advancements, it has become imperative to upskill welders to meet the demands of a changing work environment. Targeted training programs focus on advanced welding techniques, such as robotic and laser welding and additive manufacturing. Training with new technologies helps welders stay updated. The immersive experience allows for the visualisation of welding techniques. The welders can train on complex processes that might be too risky to practice in real-life scenarios. The educational institutions ensure that advanced welding technologies are integrated into curricula, allowing new welders to enter the workforce with the necessary skills.

Dr. Krishnan Sivaraman, Industrial Welding Expert and Associate Dean – of R&D and Industrial Liaisoning, shares, “Advancements in welding automation are redefining the industry by combining human talent with the precision of robotics and AI. Companies are embracing automated solutions to satisfy production demands and address the skilled labour crisis, investing in technologies that promise unparalleled efficiency and quality. AR for training, AI for quality monitoring, and cobots for collaborative work is a watershed moment in welding. In this era, the modern welder moves beyond the torch to become an intelligent system operator that combines productivity and safety.”

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Sunando Kumar Palit, Head – Product Strategy & Customer Experience, Ador Welding Ltd.

“Welding automation improves consistency and productivity while reducing costs and environmental impact. It reduces the chances of errors and manual exertion for difficult tasks.”

Dr Krishnan Sivaraman, Industrial Welding Expert and Associate Dean – of R&D and Industrial Liaisoning, shares,

“Human talent merged robotics and AI is now assuring the businesses that production demands and the skilled labour crisis is resolved efficiently.”

Rajeev Patki, Senior Product Manager – Marketing, ESAB.

“Advancements in laser welding and cutting have brought versatility across industries, providing higher speeds and improved quality. MIG, TIG, and Stick welding processes offer distinct advantages for specific material types, thicknesses, and operational requirements for diverse applications.”