Space manufacturing stainless welding electrodes
The Sharp group was started in a very humble manner way back in by the founder Shri KK Ramaswamy in his native village Kalapatti which is about 8 kms from the Manchester of South India - Coimbatore. The Company was started with an initial investment of Rs in a plant area of Square feet with a single lathe and two workmen. A major breakthrough came in the form of an order for spare parts from Vikram Sarabhai Space Research Centre Trivandram. Based on quality and timely supply, a major order for MT Hydraulic Press, came the company way, which was also effectively executed to their entire satisfaction. Our erstwhile Managing Director Shri K Jaganathan Third brother of our founder had played a vital part in executing this order through dedicated hard work spending sleepless nights to deliver the machine of the right quality on time. Ahura Welding Electrode Ltd was in the process of expansion and they wanted to indigenous certain machines for their welding plant.VIDEO ON THE TOPIC: Stainless Steel Welding Electrodes & Welding Manufacturer
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- Welding Electrodes Manufacturer
- US5821500A - Process for manufacturing welding wire - Google Patents
- Welding Electrodes Manufacturer
- Welding - Fumes And Gases
- Welding stainless steel right
- Selectarc Industries
- Orbital welding for space program applications
- Products – Welding Consumables
- Bakery Systems Manufacturer Saves Floor Space With Portable Maxstar TIG Welder
- Gas tungsten arc welding
Welding Electrodes Manufacturer
The propulsion systems for our nation's satellites and launch vehicles, as with every component manufactured for the NASA's Space Program, must meet high quality certification standards.
This means that every weld must pass the highest purity and integrity tests. These are deep-space spacecraft for different planetary and celestial explorations, such as the current Cassini mission to Saturn and the Genesis mission to collect particles of solar wind. This facility designs, fabricates, and tests propellant tanks, feed line tubing, and control systems used to propel a launch vehicle or spacecraft to the proper orbit.
Individual components of the core vehicles that may be found in the plant include the fuel tanks, main engines, electrical harnessing, and black box control units.
Systems integration and testing also are done. For a typical spacecraft, the propulsion system's tubing requires more than welds. The spacecraft and launch vehicles use a variety of tubing, mainly made of stainless steel and titanium materials, with wall thicknesses varying from as thin as 0. Because some of the material used for the tubing is thin and thus is difficult to weld consistently by hand, the facility uses automatic orbital welding.
This process helps to make consistently uniform welds. The products must be defect-free, so the welds must have full penetration and meet Class A X-ray quality standards. Much time and effort are expended on process control to ensure that every weld meets the rigid quality standards. The orbital weld heads do not contaminate the tube, which can cause an internal system leakage problem or a weld defect such as porosity.
The purge gas is maintained clean and free of oxygen or moisture contamination from the supply tank to the weld joint. The weld head maintains part alignment and provides complete inert gas coverage of the weld zone. The orbital welding power supply maintains control over critical welding parameters such as amps, volts, and travel speed, which are necessary for successful welds. For this type of welding, the equipment used must have good arc-starting control.
In addition, it shouldn't deliver welding current unless an arc is established. This helps to prevent burn-through on the thin materials being welded. The facility uses closed-chamber welding heads manufactured for orbital welding in the aerospace and other high-purity industries. These heads are designed specifically for the autogenous welding of the thin stainless steel and titanium tubing.
The protective gas covering made possible by the closed welding head prevents discoloration and embrittlement caused by exposure to oxygen, nitrogen, or hydrogen, all of which are detrimental to the welds. Tubing subassemblies are welded on the bench in a tooling fixture.
In addition to tubes, the weldments consist of other components such as pyro Squibb Taylor valves, latch valves, pressure transducers, regulators, tube reducers, and flow orifices.
When these subassemblies are mounted onto the vehicles, the tubing is interconnected to the fuel tanks and then to the rocket engines. Orbital welding also is used to connect the subassemblies on the main structure.
To do this, the welders bring the equipment to the vehicle and weld in position. The main weld joint is a square butt weld, and socket butt welds also are used. There are instances, however, of close weld head access, such as when two elbow fittings are welded together or a tube is connected to a component inside the spacecraft structure.
The facility always tries to weld equal wall thicknesses, if possible. Occasionally, however, mismatched wall thicknesses are welded. This is not a preferred method of design, but it can be handled when necessary. The facility has one application in which a lap fillet weld is made between two tubes with different outside diameters ODs. A half head is used so that the welders need to clamp on only one side of the weld joint.
When different sizes of tubing are welded, the weld head can be changed with little effort. The second weld head is plugged in, the machine's settings are changed, and the welding is begun. The same power supply is used. Having multiple weld heads available for different tube sizes can save setup time, but weld head inserts can be changed to accomplish the same thing. The company has also found that although the orbital welding process is unique and requires knowledge of metallurgy, detail fit-up, proper part cleaning, and other basics, the time it takes to train someone for automatic welding is less than that for manual welding.
Cleanliness is critical. Material is certified for chemistry, strength, and other criteria before it is accepted. The titanium and stainless steel tubing can have no contamination and must be totally clean. Using the engineering CAD data for proper configuration, the facility first bends the tubes to shape with NC bending equipment. The tube ends are kept square to 0.
The tube then goes through a sequence of cleaning steps to bring it up to the facility's requirements. All of the orbital welding is done in a clean room. The tubes go through a high-level cleaning process in which they are checked for particulate contamination and nonvolatile residue. The work is done in a Class 10, or Class , clean room, depending on program requirements.
Maintaining this cleanliness level requires a controlled-access room with special air filtration, and the welding technicians must wear full clean-room suits, including latex gloves.
Also, detailed procedures are in place for handling the hardware to ensure that no contamination is introduced during the welding process. The welders then fit the tube for welding, ensuring that no gap or mismatch is present at the weld joint. The parts are given a final solvent wipe and visual check before being assembled and welded. The Astronautics Operation is responsible for delivering a certified propulsion system to NASA, which then uses all the test data that the company generated for NASA's acceptance of weld quality and system functionality.
Weld procedures are fully qualified through Lockheed's quality control lab before welding is performed on a vehicle. Once the vehicle is welded, the welds are inspected visually, X-rayed, proof-tested, and helium leak-tested at least once. Sometimes the propulsion system goes through several cycles or different cycles of inspection to ensure system integrity.
During certification, X-ray occasionally finds a lack of penetration indication. This type of defect occurs if the tungsten electrode isn't aligned perfectly over the weld joint. A small portion of the weld might not have been fully penetrated. Typically, a repair reweld cycle is made over that weld.
Argon gas is used to ensure that the welder has a good purge before any welding or rewelding is done. Getting ready to reweld can be a challenge and requires the same setup as for the original weld. A preproduction test sample is hooked up inline with the system being welded. This allows welders to test the welds before the weldments ever go onto the vehicle. The same purge setup used for welding also is used for testing.
This avoids having to break the purge and wondering if the purge was restored to its required level. Welds on space-bound products are critical. Once a vehicle is launched and in orbit, there is no way to fix it. If just one weld fails, a mission can be lost, with catastrophic consequences. Welding applications in the aerospace industries demand high precision, a quality that can be entirely reproduced, and a reject rate that is as low as possible.
Automatic orbital welding is being used to help to meet these requirements. Read more from this issue. View the Digital Edition. The magazine delivers the news, technical articles, and case histories that enable fabricators to do their jobs more efficiently.
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US5821500A - Process for manufacturing welding wire - Google Patents
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Easy-to-read, question-and-answer fact sheets covering a wide range of workplace health and safety topics, from hazards to diseases to ergonomics to workplace promotion. Download the free OSH Answers app. Search all fact sheets:. Welding fumes are a complex mixture of metallic oxides, silicates and fluorides. Fumes are formed when a metal is heated above its boiling point and its vapours condense into very fine, particles solid particulates.
Welding Electrodes Manufacturer
Gas tungsten arc welding GTAW , also known as tungsten inert gas TIG welding , is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area and electrode is protected from oxidation or other atmospheric contamination by an inert shielding gas argon or helium , and a filler metal is normally used, though some welds, known as autogenous welds, do not require it. When helium is used, this is known as heliarc welding. A constant-current welding power supply produces electrical energy, which is conducted across the arc through a column of highly ionized gas and metal vapors known as a plasma. GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminum , magnesium , and copper alloys. The process grants the operator greater control over the weld than competing processes such as shielded metal arc welding and gas metal arc welding , allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and difficult to master, and furthermore, it is significantly slower than most other welding techniques. A related process, plasma arc welding , uses a slightly different welding torch to create a more focused welding arc and as a result is often automated. After the discovery of the short pulsed electric arc in by Humphry Davy   and of the continuous electric arc in by Vasily Petrov ,   arc welding developed slowly. Coffin had the idea of welding in an inert gas atmosphere in , but even in the early 20th century, welding non-ferrous materials such as aluminum and magnesium remained difficult because these metals react rapidly with the air, resulting in porous, dross -filled welds.
Welding - Fumes And Gases
Stan A. Pagini selectate Pagina 8. Pagina iv. Pagina Algorithms for Inverse Analysis of Welding Processes.
Welding fume exposure tends to be highly variable due to several exposure factors. Welding fumes are very small particles that are formed when the vaporized metal rapidly condenses in air. They are typically too small to be seen by the naked eye but collectively form a visible plume. The health effects associated with metal fumes depend on the specific metals present in the fumes; they may range from short-term illnesses, such as metal fume fever i.
Welding stainless steel right
Stick Electrodes are for mild and low alloy steel welding applications. This is designed to provide maximum weld ability for a wide range of applications. Used as a common welding application.SEE VIDEO BY TOPIC: Stick Welding Stainless Steel with 308L-16 Electrodes
The propulsion systems for our nation's satellites and launch vehicles, as with every component manufactured for the NASA's Space Program, must meet high quality certification standards. This means that every weld must pass the highest purity and integrity tests. These are deep-space spacecraft for different planetary and celestial explorations, such as the current Cassini mission to Saturn and the Genesis mission to collect particles of solar wind. This facility designs, fabricates, and tests propellant tanks, feed line tubing, and control systems used to propel a launch vehicle or spacecraft to the proper orbit. Individual components of the core vehicles that may be found in the plant include the fuel tanks, main engines, electrical harnessing, and black box control units. Systems integration and testing also are done.
While there is no such thing as the perfect welding process for stainless steel, keeping some key considerations in mind when selecting the process and filler metal can help ensure success and cost savings. Stainless steel continues to gain popularity in applications across the fabrication industry, mainly thanks to its corrosion resistance, strength, and toughness. Compared to mild steel, however, the material poses some welding challenges, especially for less experienced welders. Stainless steel can be three to five times more expensive than mild steel; any welding mistake can compound the overall costs for rework. Choosing the right welding process is key. There is a give-and-take with every option, and no single process provides a perfect solution. To determine the best option, fabricators need to consider the upfront cost and characteristics of the filler metal, required productivity, equipment complexity, and operator skill set. Stainless steel resists corrosion and maintains strength at extremely hot and cold service temperatures, hence its popularity in the piping and petrochemical industries.
This invention relates to a process for manufacturing flux-cored welding wire for low-hydrogen welding having superior resistance to cracking and primer-proof quality suited for use in the welding of high-tensile steels and other high-grade steels and steel structures subjected to large restraining forces. Dehydrogenation under heat has been applied on wires with small diameters of 2 to 4 mm for the following reasons: 1 There have been no efficient heating dehydrogenating process for large-diameter wires; and 2 Small-diameter wires can be easily formed into coils or loops that are required for shortening the overall length of bell or tunnel furnaces. In addition, the hardness of the outer skin must be controlled to meet the packing ratio and other specifications of individual flux-cored wires to insure good feed efficiency of welding wires varying from 0. Thus, the diameter of wires to be heated must be determined by considering the work hardening of the outer skin that occurs when wires are drawn after softening annealing.
Orbital welding for space program applications
Issue: Update older TIG units with smaller, portable welding machines. Results: Flexible welding cells, less spaces occupied, improved welding performance. Three years ago, tons of stainless steel gleamed in the light of Baxter Manufacturing's warehouse. Rack ovens, deck ovens, proof boxes, donut fryers, bagel boilers, ingredient bins and related bakery systems lined the walls, destined for the world's supermarkets, sub shops, pizza parlors, bakeries and delis.
Products – Welding Consumables
Coating Robustness of the Coated Electrodes. Sensitivity to cracking phenomena. Patent documents cited in the description.
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Bakery Systems Manufacturer Saves Floor Space With Portable Maxstar TIG Welder
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Gas tungsten arc welding
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