Industry: Power industry
(Can be applied to the oil and gas industry, shipbuilding, aerospace, nuclear power, other power industries, other industries such as food equipment creation industry, etc.)
Customer Challenge:
The customer is a large power equipment manufacturer. The common TIG AC welding process was used for butt welding of the shell-type transformers (large, different aluminum alloys cylinders). This welding process has a high probability of introducing pores and cracks, which seriously affects production efficiency and quality.
Our Solution:
The customer has already invested in costly equipment so they wanted to minimize further investments. As the production task is saturated, the customer did not want to test the new equipment so much that it will affect current production. Therefore, AWT proposed to change the conventional TIG wire feeding to our TIPTIG dynamic wire feeding system based on the customer’s current equipment.
TIPTIG vibration wire feed has the following functions that conventional TIG welding does not have:
- The stirred molten pool effectively destroys the liquid surface tension of the droplets and the molten pool. This will result in finer crystal grains and improve the fusion. It will also better the welding metallurgy and mechanical properties and boost the TIG welding effectiveness.
- Stir away the volatile gas and entrapped air bubbles in the molten pool, and greatly enhance the welding quality.
- The kinetic energy of vibration not only significantly reduces the heat input but also greatly improves the all-position welding ability.
- The reciprocating motion lets the droplet easily leave the welding wire and enter the molten pool.
Results:
This seemingly simple change effectively resolved a multi-year challenge faced by the customer. The qualification rate of the weld improved significantly, reaching almost 100%. After two usage tests, the client was already able to put it into production without change to their existing production equipment. The current welding efficiency and quality greatly exceeded the customer’s expectations.
