Competitive Solutions for Joining Technology

8/2/2019 Competitive Solutions for Joining Technology

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DVS-up to date: Arc Welding


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Competitive solutions or joining technology

Arc Welding

Overview 3EWM Award - Physics o Welding

ABICOR Innovation Award 2010

Research 7Research Association on Welding and

Allied Processes o DVS

Expert Committee 3 Arc Welding

www.dvs-ev.de/v/a3

DFG/IGF Research Cluster

Arc welding - Physics and Tools

Technology 13Technical Committee

Working Group V 2 Arc Welding

www.dvs-at.de/AT/V/V2

IIW-International Institute o WeldingCommission II

Arc Welding and Filler Metals

Commission IXBehaviour o metals subjected to welding

Commission XII

Arc welding processes and production systems

www.iiw-iis.org

Education 18Education Committee

Expert Group 2 Practical Training

Expert Group 3 Theoretical Training

www.dvs-ab.de

DVS-Courses

www.dvs-bildungsuehrer.de

www.dvs-bildungseinrichtungen.de

ContactDipl.-Eng. Wolgang Queren

Phone.: 0211 - 1591-116 Fax: -200

Email: [email protected]

PublisherDVS German Welding SocietyAachener Str. 172

40223 Dsseldor

Credits or illustations

IOT, TU Dresden

ISF, RWTH Aachen

IWF FBT, TU Berlin

Content


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Overview

Arc welding over Time

Fusion welding with an arc was already developed by the end o

the 19th Century but, due to the quality hampering oxidation

processes that went along with, it was only in connection with

the covered electrode and/or gas-shielded that it was able to

rise to its current and signicant stance o technology.

During manual arc

welding, the elect-

rode is melted and

unctions as llermetal. The volatile

fux o the metal

electrode secures

the protection o

the molten bath,

infuences alloy

composition o the

weld metal and

also seam shape. Nowadays, this process is primarily used or

low inrastructure construction operations.

Flux-cored arc welding (FCAW) is now rmly established at

a high perormance process or instance in heavy machinery

construction, in the shipbuilding industry or in large tube pro-

duction. Protection and infuencing o weld seam characteris-

tics is via a mineral-based power that is used up beore the

process.

In modern industrial nations, welding production without MIG/

MAG shielded gas welding processing would be unthinkable

nowadays. Die ersten Schweimaschinen dieser Art kamen in

den nziger Jahren au den Markt. During metal inert gas-and

metal active gas welding, the wire electrode and the moltenbath are shielded by inert or active protective gas. The advan-

tages o this process lie in its comparatively easy handling,

its suitability or all welding positions as well as the process

variants and pro-

tective gases that

have in the mean-

time been develo-

ped to optimally

suit both welding

tasks and materi-

als.

Welding with nonconsumable tungsten electrodes, on the

other hand, is used or those specialist tasks and or mate-

rials that place high demands on weld seam quality. Typical

application areas or these TIG and plasma procedures are the

aerospace industry and chemical plant construction. But even

high-quality bicycle rames are nowadays welded with the TIG

method. A success story in this eld is the automation o TIG

processes with orbit units, which is oten used or the ma-

nuacture o large heat exchangers or when laying premium

piping systems.

For specic requirements, urther welding procedures have

been developed, such as impulse-driven processes or syste-

matic melting o the wire electrode, low-energy procedures or

processing thin or coated metal sheets, or laser hybrid welding

that uses both processes in combination or its advantage.

There is an increasing tendency in arc welding towards au-

tomation. Nowadays, automation tends towards so-called

production cells where handling and joining tasks can be

achieved without outside intererence. To this end, there is

a constant development process concerning sensors or blow-

torch guidance, process stabilisation and weld seam quality

control.

Growing environmental and occupational saety requirements

place ever-higher demands on arc welding processes. The same

applies to duplicability o production quality despite clear im-

provements over the last ew years. This is where research and

development, in Germany, takes both a timely and intensive

approach: Fundamental plasma welding research is one essen-

tial requirement or this; advances in modelling and process

simulation with an eect on deeper understanding o the va-rious processes can already be recognized. Further, research is

going on into the development o welding energy sources with

innate, documentation-suited sensors or stable, low-emission

and even auto-adjusting processes.

Dr.-Ing. Wolgang Scheller

Chairman Expert Committee 3 Arc welding

Salzgitter Mannesmann Forschungsinstitut

(Research Institute) GmbH, Duisburg 3

Welding Arc Materials Transfer

Rotating high-performance arc


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EWM Award - Physics o Welding

On occasion o its 50th anniversary on October 17th, 2008,

the EWM HIGHTEC WELDING GmbH company launched a new

advancement award. This advancement award is intended to

nancially support up-and-coming scientists in research and

development undertakings that will result in a considerably

increased understanding o welding technology processes.

This research and development work can be based on arc

welding processes and combination welding processes (hyb-

rid welding processes).

The EWM Award Physics o Welding is presented bi-annu-

ally.

For each application, one up-and-coming scientist will re-

ceive nancial support o the sum o30.000 or their

research and development work.

Overview

Awards in the Area o Arc Welding

ApplicationInterested parties can apply or the advancement award in

writing. This written application should include a logical

and compelling concept o the planned research and de-

velopment undertaking, outlining content, objectives and

timerame. Submitted applications will be evaluated by an

independent panel o judges.

The written application or the advancement award should

be submitted to the DVS.

The submission deadline or 2008 entries is May 31st, 2009.

The award recipient will be announced in September 2009

at the international trade show SCHWEISSEN & SCHNEIDEN

in Essen.

Contact:

Dr.-Ing. Klaus Middeldor

DVS e.V.

Aachener Strae 172

40223 Dsseldor


Website:

www.ewm-award.de

www.die-verbindungs-spezialisten.de/index.php?id=1261


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Overview

ABICOR Innovation Award 2010

For the lasting support o research and development in

the area o arc welding and cutting, the Alexander Binzel

Schweisstechnik GmbH & Co. KG company, in 1995 on ac-

count o its 50th anniversary, decided to initiate an award

o excellence or this area. The ABICOR Innovation Award, as

it is called or on a bi-annual basis, which happened the last

time on May 7th 2008, and will next be presented in 2010.

The award includes prize money o 10.000 .

Especially considered here are research and development

works related to arc welding and cutting processes, particu-

larly those o undamental signicance that can be expected

to lead to the urthering o automation and mechanisation;

this includes process-relevant control and manuacturing

techniques as well as suitable knowledge transer strate-

gies.

Application ProcedureWorks by junior researchers rom the areas o economy and

science will be primarily considered. Important criteria are

as ollows: scientic advance, technical progress, economic

viability, as well as considerations concerning quality, envi-

ronmental protection and occupational saety. The chances o

eventual implementation and expected end-use are also to be

considered during evaluation

Applications and proposals may be submitted by either indivi-

duals or groups. An independent jury will decide the winners.

Announcement o the award recipients and presentation o the

award will take during the DVS event titled DIE VERBINDUNGSSPEZIALISTEN: Groe Schweitechnische Tagung (The Joining

Specialists Major Welding Technology Conerence)

Contact:Dipl.-Ing. Wolgang Queren-Lieth

DVS e.V.

Aachener Strae 172

40223 Dsseldor


Website:

www.die-verbindungs-spezialisten.de/index.php?id=1298

Award Recipients1st Place o the ABICOR Innovation Award 2008 went to

Dipl.-Eng. Michael Schnick, Dresden University o Applied

Sciences, or his work titled: Current Simulation as a De-

velopment Tool or Arc and Plasma Torches

Motivation

In order to meet the ever-increasing demands o welding

technology, welding tools and arc processes must be urther

developed to ensure sae application in extreme physical

situations. Conventional methods o process and torch de-

velopment, which are based on parameter studies and cost-

intensive prototype construction, are not suitable or this

process as the physically active principles acting on the arc,

the electrode and the molten mass are observed in a simp-

lied Black Box manner, which means that the laboriously

obtained results are ew and ar between and cannot be

generalised. For both timely and localised high-prole de-

scription o the complex physical processes behind process

gas eed, inert gas coverage and in the arc and the electro-

des, a simulation tool or plasma-and arc processes has been

developed, which is based on the base numeric model in thebasic physics equation.


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MethodikThe simulation was systematically applied as a development

tool in order to identiy weaknesses in existing torch con-

cepts and to work out improvements. To this end, certain

eects were visualised that are normally hidden inside the

torch and, due to high radiation and temperature load, are

either not accessible or only with diculty. For the rst

time, numeric sensitive analyses are used to gain a deeper

understanding o physical cause and eect connections bet-

Overview

ween the arc, the workpiece, the torch and the process para-

meters and also to draw conclusions as to process potentials

and restrictions.

This numeric model is suitable or use in PC workstations.

ResultsIn comparison to conventional development methods or

welding and cutting torches, the simulation allows or a

decrease o energy requirement caused by prototype const-

ruction and also o development time while simultaneously

increasing insight. The new process understanding gainedrom modelling leads to new deign and development ap-

proaches or torches. Physically based simulation results

are excellently suited or depicting development results in

a plausible manner. At the same time, they can be used or

knowledge transer, e. g. or actual application or or trai-

ning o expert welding engineers and welders. 3

Optimised Valve for Plasma Arc Welding

Models of the plasma arc

Cathode Sheath

Magneto Hydrodynamics (MHD)

Fluid MechanicsHydrodynamics

ElectromagneticsmElectrodynamics

Maxwell EquationsNavier-Stokes

Equations

InteracesOhms Law

Lorentz Force

Ohmic Heating

Anode Sheath

ArcColumn


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Research

The core activity o the Research Association on Welding and

Allied Processes o DVS is the cooperative industrial research

(IGF) in which companies, corporate bodies and research

institutes rom the various elds o joining technology ac-

tively take part. The Research Association is divided into 13

expert committees (FAs) with specic subject-related main

ocal points. The companies agree upon the need or coope-

rative research and dene main ocal points or pioneering

research which the research institutes involved convert into

concrete research projects without delay. The cooperative

industrial research achieves optimum closeness to the ap-

plication and permits the direct utilisation and implemen-

tation o the results. The collaboration o industry means

that know-how is transerred at an early stage and that the

research work and the utilisation o the results are paral-

lelised. IGF research projects may be promoted rom unds

o the Federal Ministry o Economic Aairs and Technology

(BMWi) via theOtto von Guericke Federation o Industrial

Research Associations (AiF). 3

The Research Association on Welding and Allied Processes o DVS

Further inormation at: www.dvs-ev.de/v

As a new service, DVS is oering its members and all the

interested people bundled technical inormation about va-

rious subject areas in joining technology with the portolio

o services rom DVS. The inormation brochures prepared

in two languages (German/English) include not only de-tailed explanations about the respective main ocal points

including a description o the development potential but

also valuable explanations about the activities and availa-

ble work results o DVS in the elds o research, technology

and education.

The brochures which have been published until now are

available to you or downloading.

www.dvs-ev.de/dvs-aktuell-tb

Printed copies can be requested by e-mail

([email protected]). 3

DVS inormation brochures


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Research

Expert Committee 3 Arc Welding

Fundamental principles

The general goal behind the research works is the urther ad-

vancement o eciency and protability o arc welding pro-

cesses or joining in industrial settings. Under consideration,

especially, are the requirements o small and medium-size

enterprise.

These research undertakings are to take into account such

aspects as boundary and environment conditions like pre-

treatment and ollow-up treatment, tolerance levels, warpage,

emissions, impurities and typical practice quality criteria. The

processes must become clearly understandable.

Economic considerations and estimations also orm part o the

research scope. These are deduced, among others, rom the

technological boundary conditions o the processes.

In the course o the research undertakings, solutions are to be

worked out and documented. Desirable here would be parame-

ter inormation concerning welding tasks that allow or com-

parison to the results o other research projects and practical

applications.

As an overall target, arc welding is to become capable o beingsimulated, as low-emission as possible, easy to monitor, qua-

lity dened and present with production reliability.

Research elds:Optimised arc microstructure and coating processing must be

ound or contemporary materials and combination materials,

or corrosion and acid proo steels, nickel-aluminium-and ma-

gnesium alloys, high-strength steels and or bonding.

The design o process variants (heat-controlled arc processes,

arc soldering, high perormance processes) and hybrid proces-

ses (laser hybrid welding, plasma-MSG welding) must continue

in the direction o operational instrument engineering.

In the eld o instrument engineering and installation engi-

neering, one needs to work on marked improvements in the

areas o torch and tube package technique, suction techno-

logy and especially also torch and energy-source integrated

sensors.

For quality control and easy operation, sensors and sensor sys-

tems or seam detection and tracking as well as or adaptive

welding are to be designed, as well as sensors or process mo-

nitoring, guidance and control; sensor system reliability needs

to be improved.

A new research ocus is on diagnosis, modelling, simulation,

calculation and visualisation o arc welding processes: No-

vel approaches relating to plasma physics and diagnosis, or

modelling and depiction o actual arc welding processes, can

be used in order to obtain a comprehensive and undamental

evaluation and control o eects and infuences o the arc

fash, or visualisation and better understanding o welding

arc process mechanisms. This applies especially also to the

training setting. Direct calculation-based processing o sig-

nals thus generated rom diagnostic methods and modelling

results needs to be integrated, or the purpose o parameter

assessment and denition as well as or process stabilisation

in systems and arc welding equipment. 3

FA 3

Arc Welding

Chairman:Dr.-Ing. Wolgang Scheller

Salzgitter Mannesmann Forschung

GmbH, Duisburg

Vice-Chairman:

Dr.-Ing. Sven-Frithjo Goecke

EWM HIGHTEC WELDING GmbH,

Mndersbach

Secretary:Dipl.-Ing. Wolgang Queren-Lieth

Phone: 0211 / 2591-116 Fax:-200


Website: www.dvs-ev.de/v/FA03

Inert Gas Flow

(Simulation)


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Research

Ongoing research projects

Development o an event-driven control mechanism onthe basis o inverse modelling or robust process opera-tions in complex MSG impulse welding proceduresDVS-Nr.: 03.091 / IGF-Nr.: 15.872 BStart: 01.11.2008 End: 31.10.2011Participating institutes: Pro. Dr. rer. nat. J. Kruscha,FH Lausitz, Sentenberg und Cottbus, IEM Department

Pro. Dr.-Eng. U. Reisgen, RWTH Aachen,Institute o Welding-and Joining Technology

Fluid dynamic design o torch systems or economicaland low-emission arc weldingDVS-Nr.: 03.090 / IGF-Nr.: 15.871 BStart: 01.11.2008 End: 31.10.2011Participating institutes: Pro. Dr.-Eng. habil. U. Fssel,Dresden University o Applied Sciences, Institute oProduction Engineering and Joining Technology

Fully automated welding system or root welding o V- andX joint preparations, with contemporary regulated arc pro-

cedure and digital short circuit resolutionDVS-Nr.: 03.088 / IGF-Nr.: 15.916 NStart: 01.12.2008 End: 30.11.2010Participating institutes: Pro. Dr.-Ing. U. Reisgen,RWTH Aachen, Institute o Welding-and-Joining Technology

Use o novel non-copper materials or weld wire bondingduring MSG welding and soldering processes, especiallyor aluminium and low melting additive materialsDVS-Nr.: 03.087 / IGF-Nr.: 15.914 BStart: 01.12.2008 End: 30.11.2010Participating institutes: Pro. Dr.-Ing. habil. K.-J. Matthes,Chemnitz University o Applied Sciences,

Institute o Production Engineering and Welding TechnologyDeposition welding o nanocrystalline solidiying er-rous-based materials to aluminium substrate via regula-ted short arc techniqueDVS-Nr.: 03.085 / IGF-Nr.: 15.859 NStart: 01.11.2008 End: 31.10.2010Participating institutes: Pro. Dr.-Eng. habil. J. Wilden,Berlin University o Applied Sciences, Institute o MachineTools and Factory Operation, Department o Joining- andCoating Technology

Cause and evaluation o imperections in arc soldered jointsDVS-Nr.: 03.083 / IGF-Nr.: 15.745 B

Start: 01.08.2008 End: 31.07.2010Participating institutes: Pro. Dr.-Ing. habil. K.-J. Matthes,Chemnitz University o Applied Sciences, Institute o Produc-tion Engineering and Welding Technology

Research projects (selection)

Numeric and experimental investigations or systematicinfuencing o arc and molten bath during gas-shieldedwelding through protective gas characteristics and pro-tective gas compositionDVS-Nr.: 03.082 / IGF-Nr.: 15.774 BStart: 01.09.2008 End: 31.08.2010Participating institutes: Pro. Dr.-Eng. habil. U. Fssel,Dresden University o Applied Sciences, Institute o Pro-duction Engineering and Welding Technology

Increase o process saety with simultaneous decreaseo production costs through the use o gaseous fux du-ring arc weldingDVS-Nr.: 03.081 / IGF-Nr.: 15.635 NStart: 01.08.2008 End: 31.07.2010Participating institutes: Pro. Dr.-Eng. W. H. Mller, BerlinUniversity o Applied Sciences, Department o ContinuumMechanics and Materials Theory

Pro. Dr.-Eng. habil. J. Wilden, Berlin University o AppliedSciences, Institute o Machine Tools and Factory Operation,Department o Joining- and Coating Technology

Design o characteristics-and evaluation proles or wel-ding technical use o tungsten electrodesDVS-Nr.: 03.080 / IGF-Nr.: 15.231 NStart: 01.06.2007 End: 31.05.2009Participating institutes:Dr.-Eng. St. Keitel, SLV Duisburg, Section o the GSI mbH

Coecient denition or contemporary gas-shieldedwelding proceduresDVS-Nr.: 03.078 / IGF-Nr.: 15.562 BStart: 01.07.2008 End: 30.06.2010Participating institutes:Pro. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University o

Applied Sciences, Institute o Production Engineering andWelding Technology

Development o a weld head guiding system or automa-ted MSG welding o steel and aluminium alloysDVS-Nr.: 03.076 / IGF-Nr.: 15.296 NStart: 01.08.2007 End: 31.07.2009Participating institutes:Pro. Dr.-Eng. U. Reisgen, RWTH College Aachen, Instituteo Welding-and Joining Technology

Pro. Dr.-Eng. K. Dilger, Braunschweig University o Applied

Sciences, Institute o Welding-and Joining Technology


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Research

Investigation into MSG impulse arc welding with interimimpulse or AC and DC current applicationVorhaben: DVS-Nr.: 03.061 / IGF-Nr.: 13.484 N

Participating institutes: Dipl.-Eng. F. Zech, SLV Munich,Section o the GSI mbH

Investigations into MSG deposition welding with fatwire electrodesVorhaben: DVS-Nr.: 03.057 / IGF-Nr.: 13.408 BParticipating institutes: Dipl.-Eng. F. Zech, SLV Munich,

Section o the GSI mbHDr.-Eng. M. Strer, SLV Halle GmbH

Qualication and use o hybrid synergy eects or highperormance welding o light metalsDVS-Nr.: 03.056 / IGF-Nr.: 13.783 NParticipating institutes: Pro. Dr.-Eng. U. Reisgen, RWTH

Aachen, Institute o Welding-and Joining Technology 3

Concluded research projects

Classication o health hazard levels through the emis-sion o welding umes during modern gas-shielded wel-ding proceduresDVS-Nr.: 03.071 / IGF-Nr.: 14.459 BParticipating institutes: Pro. Dr.-Eng. habil. K.-J. Mat-thes, Chemnitz University o Applied Sciences, Institute oProduction Engineering and Welding Technology

Gas hose infuence on humidity-hydrogen-and oxygenproblematic during gas-shielded weldingDVS-Nr.: 03.068 / IGF-Nr.: 14.426 NParticipating institutes: Pro. Dr.-Eng. U. Reisgen, RWTHAachen, Institute o Welding-and Joining Technology

Investigation into MSG soldering o zinc-coated steelsheet, with impulse arc and or use with impulse-drivingAC and DC current in the base current phaseDVS-Nr.: 03.066 / IGF-Nr.: 14.425 NParticipating institutes: Dipl.-Eng. . Zech, SLV Munich,Section o the GSI mbH

Virtually internal sensor or MIG welding applicationsDVS-Nr.: 03.065 / IGF-Nr.: 13.863 BParticipating institutes: Pro. Dr.-Eng. habil. K.-J. Mat-thes, Chemnitz University o Applied Sciences, Institute oProduction Engineering and Welding Technology

Plasma-MIG technology application during joining ocoated steel materialsDVS-Nr.: 03.064 / IGF-Nr.: 13.862 B

Participating institutes: Pro. Dr.-Eng. habil. K.-J. Matthes,Chemnitz University o Applied Sciences, Institute o Produc-tion Engineering and Welding Technology

Use o fat wire electrodes during ully automated MSGwelding o ne-grained steel with higher yield strengthDVS-Nr.: 03.059 / IGF-Nr.: 13.784 N

Participating institutes: Dr.-Eng. St. Keitel, SLV Duisburg,Section o the GSI mbH

Process-sae MSG welding o high-alloy specialist materi-als with low requency pulsed wire eedDVS-Nr.: 03.062 / IGF-Nr.: 13.787 BParticipating institutes: Pro. Dr.-Eng. I. Martinek,Otto-von-Guericke University at Magdeburg, Faculty oMechanical Engineering, Institute o Joining-and BeamTechnology

MAG-Welding


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this applies especially to the interdisciplinary cooperation

between engineers, physicists, mathematicians/computer

scientists and metallurgists (table 1). The targets are as

outlined in the paragraphs to ollow.

Purpose o the Research

The research cluster strives to signicantly expand both pro-

cess and application boundaries or arc welding procedures.

In the end, we are looking or higher productivity, increased

operational saety and less environmental stress. Further,materials or material combinations that hitherto were consi-

dered dicult to usion weld are to be used with a novel

are welding technology. This technology will be capable o

adapting to changed environmental conditions like higher

tolerance levels and thus lead to a competitive advantage

in the overriding process chain through signicantly aster

laser beam welding process speed.

MethodThe methods supporting the cluster concept are arranged in

such a manner as to allow or examination, via diagnostic

procedures in any basis-oriented project area, o the proces-

ses concerning welding arc or anode and cathode. Material

transer is also under investigation. The purpose here is to

obtain a undamental improvement o knowledge and to make

available or modelling the experimentally obtained data. Mo-

delling then strives or comprehensive denition o the MIG

process, leading to both process behaviour and process va-

riable becoming predictable. In the area o modelling, there

are two undamentally dierent approaches: or one, there is

modelling on the basis o physical undamentals and on the

other, inverse modelling is to serve or obtaining inormation

Research

DFG/IGF Research Cluster

Arc welding - Physics and Tools

SummaryIn this research cluster, based on diagnostic welding arc re-

search, a undamental physical understanding is obtained in

close correlation with modelling applications, so that pro-

cess behaviour can be predicted or estimated via simulation.

Parallel to these works, there are user-oriented projects or

the implementation under technological aspects. Special

emphasis here is placed on a signicant improvement in

process saety. The torch and control concepts to be deve-

loped, synergy-based, also lead to novel metallurgical pos-sibilities (Image 1).

MotivationManuacture o products or all trades, rom tank and con-

tainer to chemical apparatus production, steel-boat-and

railway vehicle construction, and also including vehicle and

aerospace applications, not to mention the manuacture o

athletic devices, urniture or household appliances. All this,

independent o individual usage, calls or technologies that

allow or material-and application riendly joining o semi-

nished products, components or building groups. Among

the rmly bonded joining procedures, welding on account

o its procedure-inherent characteristics has now obtained

a prime position.

Recent developments in arc welding technique, partially

supported by public unds, show completely novel possi-

bilities or energy yield control and open up new elds in

arc technology regarding operational saety, environmental

riendliness and expansion o application elds. A quantum

leap o industrial market relevance, however, can only be

achieved i it becomes possible to both understand and de-

pict via model the undamental physics o welding arcs intheir complexity that is infuenced by process gas fow with

its partial addition o surrounding gases rom the environ-

ment, materials transer o the consumable electrode, me-

tal vapour ormation, emission occurrence etc. This insight

then allows or new metallurgy control possibilities during

solidication that, in turn, leads to control o problematic

hot crack ormation or many materials and their combina-

tions.

Due to the economic signicance and the possibilities ope-

ning up with high innovation potential, there is a big need

or research both undamental and application-oriented

especially in the area o MIG/MAG joining processes and

Image 1: Research Concept Systematic

Diagnostics

Implementation

Experimental analysis oand insight into

process connections

Transer i processunderstanding into

Mathematical-physical

depiction o processconnections

Zero Deect (Process Capability)

Sensor-less Process ControlMetallurgical Eects

Modelling

Process capabilityApplication


12/1912

Research

Image 2: Comparison of Simulation and Experiment; Source: Fssel,

Schnick, Hrtel, Hler, Dresden University of Applies Sciences

about process connections directly rom the process itsel

that are then implemented in a physics-based model. Ater

only 6 o 36 months o project running time, initial results

already showed - through a match o simulation and experi-

ment (Image 2) both the high scientic level and excellent

success chances or actual application signicance.

The undamental works are closely interconnected and si-

multaneously infuence the application-oriented projects.

The arc is to be controlled in such a manner that, on onehand, metallurgy and solidication o molten bath can be

systematically infuenced in order to, or instance, become

better able to handle the problem o hot crack ormation

via a new process-oriented approach. Further, the process-

oriented project area is concerned with working out new

methods by means o which it will become possible to use

the power source itsel as a process sensor and, through

this, nally achieve signicant progress in respect to pro-

cess capability.

Hence, the cluster research allows or an innovation leap in

arc welding technology in respect to both process control

and process capability.

Research Partners

Univ.-Pro. Dr.-Ing. habil. Uwe FsselDepartment o Joining Technology and Assembly

Institute o Surace and Manuacturing Technology

Dresden University o Applied Sciences

Pro. Dr .rer. nat. habil. Johannes KruschaDepartment o Inormation Technology/Electronics/Mecha-

nical Engineering

Lausitz University o Applied Sciences

Pro. Dr.-Ing. Uwe ReisgenInstitute o Welding-and Joining Technology

RWTH Aachen

Pro. Dr.-Ing. Jochen Schein

Institute o Plasma Science and Mathematics (LPT)

University o the German Federal Armed Forces, Munich

Dr. rer. nat. Dirk Uhrlandt

Leibniz Institute or Plasma Science and

Technology e.V. (INP)

Greiswald

Pro. Dr. rer. nat. Klaus-Dieter Weltmann

Leibniz Institute or Plasma Science and

Technology e.V. (INP)

Greiswald

Univ.-Pro. Dr.-Ing. habil. Johannes Wilden

(Coordinator)

Fachgebiet Fge- und Beschichtungstechnik

Institute o Machine Tools and Factory OperationBerlin University o Applies Sciences 3Preamble

Arc Cluster


13/1913

Technology

Secretary and Contact Person or all working groups:

Dipl.-Ing. Wolgang Queren-Lieth

Phone: 0211 - 1591-116 Fax: -200


Working group V 2 Arc welding

Chairman:Pro. Dr.-Ing. Rol Felleisen

Schweitechnische Lehr- und

Versuchsanstalt Mannheim GmbH

Vice-Chairman:

Dr.-Ing. Reinhard Winkler

SLV Duisburg, Section o the GSI mbH

Website: www.dvs-at.de/AT/V/V2

Working groups o the AT

In this central area o welding technology, over 400 ex-

perts are at work, with special and as a rule process-orien-

ted expert ocus, divided into 7 dierent sub-groups and

38 dierent task orces.

Working groups (Selection)

WG V 2.1 Metal arc welding

WG V 2.3 Arc welding with non-consumableelectrode

WG V 2.3.5 Plasma MSG welding

WG V 2.4 Welding with consumable electrode

MIG/MAG

WG V 2.4.6 MSG high perormance processes

WG V 2.4.8 /

WG V 6.8 Arc soldering

WG V 2.5 Submerged arc welding and electro slag

welding

WG V 2.6 Mechanization, automatization and

robotingWG V 2.7 Welding with ller wire

Joint undertakings, contribution to standard DKE 361

Electric Arc Welding Equipment and setting up o the an-

nual arc colloquium together with the Expert Committee 3

Arc Welding are all tasks that are generally coordinated

on an annual basis through the circle o representatives.

The WG V 2 is in correspondence with the ollowing wor-

king units o the International Institute o Welding (IIW)

Commission II Arc Welding and Filler Metals

Commission IX Behaviour o metals subjectedto welding

Commission XII Arc welding processes and production

systems 3Metal arc vertical up seam

Technical Committee (AT) o DVS

The technical-scientic cooperative work o DVS is predo-

minantly determined by the activities o its Technical Com-

mittee (AT) with its working bodies oriented to specic

subjects. Specialists rom the economic and scientic elds,

rom authorities and rom other areas collaborate in them.

The Technical Committee promotes the active exchange o

experience amongst experts, describes the state o the art

by elaborating and contributing to the preparation o a set

o technical rules (DVS technical bulletins, technical codes,

guidelines and standards) and is actively involved in the

technical development o welding and the allied processes

such as brazing/soldering, thermal spraying, adhesive bon-

ding, mechanical joining and plastics joining. Joint commit-

tees with the Standards Committee or Welding Technology

o DIN also exist or this purpose. 3

Further inormation at: www.dvs-at.de


14/1914

Technology

Process and Materials Classication:A Metal arc welding

B TIG plasma welding and process variants

C MIG/MAG welding and process variants

D SAW and ESW welding

E Welding with ller wire

F Instrument engineering, automation, equipment

G Welding o steels

H Welding o NF and light metals

Essential work results

DVS technical bulletins and technical codes (Selection)

DVS technical bulletins and technical codes A B C D E F G H

DVS 0966-1 Plasma-MSG welding Instrument engineering x x x

DVS 0964 Submerged arc double wire welding x x

DVS 0958 Covered electrodes - eciency, metal recovery and

deposition coecient work sheets and calculation aids

x

DVS 0957 Handling o covered electrodes - Transport, storage and

redrying

x

DVS 0955 Welding-based processing o nickel-alloyed steels or

low temperature applications

x x x x x x

DVS 0951 Specialist steel with elevated wear-resistance x x x x x x

DVS 2710 Additional equipment or mechanical TIG and plasma

welding; characteristics and requirements

x x

DVS 0949 Tubular-cored electrodes or MAG- and SAW welding o

erritic steel castings creep resistant at elevated temperatures

x x x

DVS 0948 Submerged arcs welding and its procedure variants x x

DVS 0946 Recommendations or welding o stainless austenitic-

erritic duplex- and super duplex steels

x x x x x

DVS 0945-1 Verication o welded and wearresistant depositions

Abrasive wear

x x

DVS 0943 High-alloy electrodes x x

DVS 0942 Welding with covered electrodes Pore ormation and

avoidance

x

DVS 0941-2 Tubular-cored electrodes or MAG- joint welding

characteristics and application areas

x x x

DVS 0941-1 Tubular-cored electrodes or joint- and deposition

welding principles and terminology

x x x

DVS 0940 Submerged arc deposition welding with strip electrode x x


15/1915

Technology


DVS 0938-1 Arc soldering principles, processes, installation

engineering requirements

x x

DVS 0937 Root protection during gas-shielded welding x x x x x

DVS 0936 Submerged arc narrow-gap welding x x

DVS 0935 Electroslag deposition welding with strip electrode x x

DVS 0934 TIG welding; devices and equipment x x

DVS 2714 Welding devices or manual and ully automated TIG

welding Requirement determination (especially or aerospace

applications)

x x

DVS 0932 MAG set-up practice - Process- and component depen-

dent infuences on seam geometry

x

DVS 0931 MAG welding o non-corrosive, austenitic steels x x

DVS 0928 Submerged arc welding o austenite-errite joints x x

DVS 0926-2 Wire eed, tube package and torch requirements or

gas shielded metal welding

x x x

DVS 0926-1 Energy source requirements or gas shielded metal

welding

x x

DVS 0925 MAG welding o thick sheet metal x x

DVS 0923-1 to -4 Testing o welding powders or weld-related

characteristics in submerged arc welding applications

x

DVS 0921 Load diagrams or rotary tables and rotary tilting

tables

x

DVS 0920 Tungsten inert gas welding (TIG) - principles x x x x

DVS 0919 Tungsten plasma arc welding x x x x

DVS 2707 Plasma arc welding process overview, gas selection

and welding parameters

x x

DVS 0918 Submerged arc welding o ne-grained steels x x

DVS 0917 Submerged arc welding o austenitic steels x x

DVS 0916 Metal gas-shielded welding o ne-grained steels x x

DVS 0915 Submerged arc multiple electrode welding x x

DVS 0914 Processing and storage o welding powders or submer-

ged arc welding

x

DVS 0913-1 to 3 MIG welding o aluminium Material-related

basics / devices, processes, auxiliary materials / application-ori-

ented notes ----------

x x


16/1916

Technology


DVS 0912-1 to 2 Gas-shielded metal arc welding o steel; Guideli-

nes or process execution Prevention o incomplete usion

x x

DVS 0911 Tungsten electrodes or tungsten insert gas welding

Application-oriented notes

x x

DVS 2716 Tungsten electrodes or tungsten insert gas welding

Requirements or aerospace applications

x x

DVS 0909-1 and -2 Principles o MSG high perormance welding

with solid wire electrodes Denition and terminology / Appli-

cation-oriented notes

x x

DVS 0907-1 to 3 Determination o heat input and burn-o or SAW

fux heat input and burn-o lines / Flux diagram / Application

o fux diagram

x

DVS 1502-1 and 2 Manual arc welding o ductile cast iron pipes

Principles o welding engineering / Welding o parts o ductile

cast iron or steel

x x

DVS 0601 Welding o nickel and nickel alloys x x x x

DVS 2713 Welding o titanium materials - Materials, processes,

manuacture, inspection and evaluation o weld joints with sup-

plementary sheet 1: Sample images o heat tinting

x x

Submerged arc welding

ElectrodeContact PiecePowder Funnel

Progress o Weld

Cavern with implied arc

Flux

Liquid

Weld Seam

Heat Aected Zone

Basis Material

Preerred Drop

TranserMelting-solidication

Front

Molten Bath withFlow Direction

Solid Slag


17/1917

Technology

Standards (Selection)

DIN EN ISO 9692-1Welding and allied processes Recommendations or joint

preparation

Part 1: Manual metal-arc welding, gas-shielded metal arc

welding, gas welding, TIG welding and beam welding o

steels

DIN EN ISO 9692-2Welding and allied processes - Joint preparation

Part 2: Submerged arc welding o steel

DIN EN ISO 9692-3Welding and allied processes Recommendations or junc-

ture orms

Part 3: Metal inert gas welding and tungsten insert gas

welding o aluminium and aluminium alloys

DIN EN ISO 15609-1

Specication and qualication o welding procedures or

metallic materials Welding procedure specication

Part 1: Arc welding

DIN EN ISO 15614

Specication and qualication o welding procedures or

metallic materials Welding procedure test

- Part 1: Arc and gas welding o steels and arc welding o

nickel and nickel alloys

- Part 2: Arc welding o aluminium and its alloys

- Part 3: Fusion welding o non-alloyed and low-alloyed

cast irons

- Part 4: Finishing welding o aluminium castings

(with correction)

- Part 5: Arc welding o titanium, zirconium andtheir alloys

- Part 6: Arc and gas welding o copper and its alloys

- Part 7: Overlay welding

- Part 8: Welding o tubes to tube plate joints

DIN EN 1011Welding Recommendations or welding o metallic

materials

- Part 1: General guidance or arc welding

- Part 2: Arc welding o erritic steels

- Part 3: Arc welding o stainless steels

- Part 4: Arc welding o aluminium and aluminium alloys

- Part 5: Welding o clad steel

- Part 8: Welding o cast irons

DIN EN 50504Validation o arc welding equipment

DIN EN 60974 (IEC 60974)

Arc welding equipment

- Part 1: Welding power sources

- Part 2: Liquid cooling systems

- Part 3: Arc striking and stabilizing devices

- Part 4: In-service inspection and testing

- Part 5: Wire eeders

- Part 6: Limited duty manual metal arc welding power

sources

- Part 7: Torches

- Part 8: Gas consoles or welding and plasma cutting

systems

- Part 9: Installation and use

- Part 10: Electromagnetic compatibility (EMC)

requirements

- Part 11: Electrode holders

- Part 12: Coupling devices or welding cables

- Part 13: Return current clamp 3

MAG-Welding


18/1918

Specialist Books (Selection in German only)

Specialist Book Series Welding Techniques Volume 130J. Schuster: Schweien von Eisen-,

Stahl- und Nickelwerkstoen

Specialist Book Series Welding Techniques Volume 76/IR. Killing: Handbuch der Schweiverahren Teil I:

Lichtbogenschweiverahren

Specialist Book Series Welding Techniques Volume 63

P. Mller, L. Wol: Handbuch des Unterpulverschweiens

Part I and Part II:Part I: Verahren, Einstellpraxis, Gerte, Wirtschatlichkeit,

Part II: Schweizustze und Schweipulver

Part III: Draht/Pulver-Kombinationen r Sthle - Schwei-

ergebnisse - Schweiparameter

Part IV: Schweien mit Strip electrode

Part V: Berechnung und Gestaltung von Schweikonstrukti-

onen - Schweitechnologie - Anwendungsbeispiele

Specialist Book Series Welding Techniques Volume 141D. Radaj: Schweiprozesimulation, Grundlagen und

Anwendungen

Specialist Book Series Welding Techniques Volume 84M. Schellhase: Der Schweilichtbogen - ein

technologisches Werkzeug

Specialist Book Series Welding Techniques Volume 133Dipl.-Ing. R. Trillmich, W. Welz: Bolzenschweien -

Grundlagen und Anwendung

Practical Welding Techniques Volume 2

W. Marels, L. Orth: Der Lichtbogenschweier Leitaden

r Ausbildung und Praxis

Practical Welding Techniques Volume 14

Dipl.-Ing. G. Aichele: 140 Arbeitsregeln r das

SchutzgasschweienPractical Welding Techniques Volume 34

L. Baum, S. Pommer: Der Schutzgasschweier -

Teil 1 WIG-/Plasmaschweien

Practical Welding Techniques Volume 35L. Baum, S. Pommer: Der Schutzgasschweier -

Teil 2 MIG/MAG-Schweien

DVS Reports Volume 249

J. Wilden, D. Bartout, F. Homann: Lichtbogengeprozesse

- Stand der Technik und Zukuntspotenzial


C. Lorenz: WIG-Orbitalschweien von Rohr/Rohrverbindungen aus Aluminiumwerkstoen


Schutzgasschweien 3

Education

Education Committee (AB)

Personnel qualication in DVS

The Education Committee (AB) o DVS elaborates and struc-

tures the range o training and urther education oered by

DVS in the elds o joining, cutting and coating. It ollows

tendencies and trends as well as concrete developments in

the education sector and evaluates their eects on society

in general and on the areas o joining, cutting and coatingin particular. AB is oriented to the latest state o the art

and to the needs o the German economy. Due to the close

network o DVS, the structures o the society are used opti-

mally, the latest ndings are exchanged across bodies and

there is eedback about the current needs. DVS thus oers

the expert world o joining technology, members and inte-

rested people a comprehensive range o competitive solu-tions or joining technology. 3

Further inormation at: www.dvs-ab.de

The specied publications can be purchased via DVS Media GmbH:

DVS Media GmbH Aachener Strae 172 D-40223 Dsseldorf Tel.: 0211 / 1591-162 [email protected] www.dvs-media.info


19/19

Education

Practical Training (Selection)

Coordination:K. Andre, SL Magdeburg

Secretary:

Dipl.-Ing. Christoph Esser-Ayerty

Phone: 0211 1591-178 Fax: -200


DVS 1110 DVS Course: Expert vehicle body overhaul -

Supplementary sheet 1: Expert vehicle body overhaul MAG

welding and MSG soldering

DVS/EWF/IIW 1111 International Welder (IW) General

notes, requirements

DVS 1112-2 DVS Course: DVS-FUE1/04 Joining via manual

arc welding and thermal cutting

DVS 1112-3 DVS Course: DVS-FUE2/04 Joining via gas-

shielded welding

DVS 1123 DVS Course: Manual arc welding

DVS 1133 DVS Course: Thin sheet metal welding, MAG

DVS 1133 DVS Course: Thin sheet metal welding, gas-

shielded welding

DVS 1148 Exams or welders, Manual arc welding o duc-

tile cast iron pipes

DVS 1149 DVS Course: Training and certication o cast

iron welders

DVS 1157 DVS Course: DVS Welding Master Specialist

- Supplementary Sheet 3: Manual arc welding in practice

- Supplementary Sheet 4: Tungsten inert gas welding in

practice Steel

- Supplementary Sheet 5: Tungsten inert gas welding in

practice NF metals

- Supplementary Sheet 6: Gas-shielded metal welding in

practice Steel

- Supplementary Sheet 7: Gas-shielded metal welding in

practice NF metals

DVS 1182 DVS Course: Manual arc brazing

Theoretical Training (Selection)

Coordination:

Dipl.-Ing. Ch. Ahrens, SLV-Duisburg

Secretary:

Dipl.-Ing. Michael Metzger

Phone: 0211 1591-177 Fax: -200


DVS/EWF/IIW 1170 Welding Supervisor

International Welding Engineer (SFI/EWE/IWE)

International Welding Technician (ST/EWT/IWT)

International Welding Expert (SFM/EWS/IWS)

International Welding Practitioner (SP/EWP/IWP)

DVS/EWF 1175 Welding Supervision Add-on training or

reinorced steel welding

DVS/EWF/IIW 1178 International Welding Quality Ins-

pection Sta (IWIP)

DVS 1109 Welding Supervisor Sta (WSS) Rail vehicle

construction

DVS 1179 Welding Supervision Add-on training or alu-

minium welding

DVS/EWF 1198 Specialist courses or training or urther

training in laser beam welding or engineers. Technici-

ans, specialists 3

Arc welding is part o any undamental training in welding technology, whether or welders or as part o practice oriented

training or training as a welding supervisor. From the wide range o DVS training courses available, the ollowing list pro-

vides a selection with special arc welding elements:

Competitive Solutions for Joining Technology

Documents

Transcript of Competitive Solutions for Joining Technology