Competitive Solutions for Joining Technology
Content
Competitive solutions for joining technology
DVS-up to date: “Arc Welding”
Research... Technology... Education...
www.the-joining-specialists.de
Content
Competitive solutions for joining technology
Arc Welding
Overview ………………………………… 3
EWM Award - Physics of Welding ABICOR – Innovation Award 2010
Research
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Research Association on Welding and Allied Processes of DVS Expert Committee 3 “Arc Welding“ www.dvs-ev.de/fv/fa3 DFG/IGF Research Cluster Arc welding - Physics and Tools
Technology ……………………………… 13
Technical Committee Working Group V 2 “Arc Welding“ www.dvs-aft.de/AfT/V/V2 IIW-International Institute of Welding Commission II “Arc Welding and Filler Metals“ Commission IX “Behaviour of metals subjected to welding “ Commission XII “Arc welding processes and production systems “ www.iiw-iis.org
Education ……………………………… 18
Education Committee Expert Group 2 “Practical Training“ Expert Group 3 “Theoretical Training“ www.dvs-afb.de DVS®-Courses www.dvs-bildungsfuehrer.de www.dvs-bildungseinrichtungen.de
Contact
Dipl.-Eng. Wolfgang Queren Phone.: 0211 - 1591-116 Fax: -200 Email: [email protected]
Publisher
DVS – German Welding Society Aachener Str. 172 40223 Düsseldorf Credits for illustations IOT, TU Dresden ISF, RWTH Aachen IWF FBT, TU Berlin
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Overview
Arc welding over Time
Fusion welding with an arc was already developed by the end of 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 significant stance of technology. During manual arc welding, the electrode is melted and functions as filler metal. The volatile flux of the metal electrode secures the protection of the molten bath, influences alloy composition of the Welding Arc Materials Transfer weld metal and also seam shape. Nowadays, this process is primarily used for low infrastructure construction operations. Flux-cored arc welding (FCAW) is now firmly established at a high performance process for instance in heavy machinery construction, in the shipbuilding industry or in large tube production. Protection and influencing of weld seam characteristics is via a mineral-based power that is used up before the process. In modern industrial nations, welding production without MIG/ MAG shielded gas welding processing would be unthinkable nowadays. Die ersten Schweißmaschinen dieser Art kamen in den fünfziger Jahren auf den Markt. During metal inert gas-and metal active gas welding, the wire electrode and the molten bath are shielded by inert or active protective gas. The advantages of this process lie in its comparatively easy handling, its suitability for all welding positions as well as the process variants and protective gases that have in the meantime been developed to optimally suit both welding tasks and materials.
Welding with nonconsumable tungsten electrodes, on the other hand, is used for those specialist tasks and for materials that place high demands on weld seam quality. Typical application areas for these TIG and plasma procedures are the aerospace industry and chemical plant construction. But even high-quality bicycle frames are nowadays welded with the TIG method. A success story in this field is the automation of TIG processes with orbit units, which is often used for the manufacture of large heat exchangers or when laying premium piping systems. For specific requirements, further welding procedures have been developed, such as impulse-driven processes for systematic melting of the wire electrode, low-energy procedures or processing thin or coated metal sheets, or laser hybrid welding that uses both processes in combination for its advantage. There is an increasing tendency in arc welding towards automation. Nowadays, automation tends towards so-called production cells where handling and joining tasks can be achieved without outside interference. To this end, there is a constant development process concerning sensors for blowtorch guidance, process stabilisation and weld seam quality control. Growing environmental and occupational safety requirements place ever-higher demands on arc welding processes. The same applies to duplicability of production quality despite clear improvements over the last few years. This is where research and development, in Germany, takes both a timely and intensive approach: Fundamental plasma welding research is one essential requirement for this; advances in modelling and process simulation with an effect on deeper understanding of the various processes can already be recognized. Further, research is going on into the development of welding energy sources with innate, documentation-suited sensors for stable, low-emission and even auto-adjusting processes.
Rotating high-performance arc
Dr.-Ing. Wolfgang Scheller Chairman Expert Committee 3 “Arc welding“ Salzgitter Mannesmann Forschungsinstitut (Research Institute) GmbH, Duisburg
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Overview
Awards in the Area of Arc Welding
EWM Award - Physics of Welding
Application Interested parties can apply for the advancement award in writing. This written application should include a logical and compelling concept of the planned research and development undertaking, outlining content, objectives and timeframe. Submitted applications will be evaluated by an independent panel of judges. The written application for the advancement award should be submitted to the DVS. The submission deadline for 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 Middeldorf DVS e.V. Aachener Straße 172 40223 Düsseldorf Email: [email protected]
On occasion of its 50th anniversary on October 17th, 2008, the EWM HIGHTEC WELDING GmbH company launched a new advancement award. This advancement award is intended to financially support up-and-coming scientists in research and development undertakings that will result in a considerably increased understanding of welding technology processes. This research and development work can be based on arc welding processes and combination welding processes (hybrid welding processes). The EWM Award “Physics of Welding“ is presented bi-annually. For each application, one up-and-coming scientist will receive financial support of the sum of 30.000 € for their research and development work.
Website: www.ewm-award.de www.die-verbindungs-spezialisten.de/index.php?id=1261
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Overview
ABICOR – Innovation Award 2010
viability, as well as considerations concerning quality, environmental protection and occupational safety. The chances of eventual implementation and expected end-use are also to be considered during evaluation Applications and proposals may be submitted by either individuals or groups. An independent jury will decide the winners. Announcement of the award recipients and presentation of the award will take during the DVS event titled DIE VERBINDUNGS SPEZIALISTEN: Große Schweißtechnische Tagung (The Joining Specialists – Major Welding Technology Conference) Contact: Dipl.-Ing. Wolfgang Queren-Lieth DVS e.V. Aachener Straße 172 40223 Düsseldorf Email: [email protected] Website: www.die-verbindungs-spezialisten.de/index.php?id=1298
Award Recipients
For the lasting support of research and development in the area of arc welding and cutting, the Alexander Binzel Schweisstechnik GmbH & Co. KG company, in 1995 on account of its 50th anniversary, decided to initiate an award of excellence for this area. The ABICOR Innovation Award, as it is called for 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 of 10.000 €. Especially considered here are research and development works related to arc welding and cutting processes, particularly those of fundamental significance that can be expected to lead to the furthering of automation and mechanisation; this includes process-relevant control and manufacturing techniques as well as suitable knowledge transfer strategies. Application Procedure Works by junior researchers from the areas of economy and science will be primarily considered. Important criteria are as follows: scientific advance, technical progress, economic 1st Place of the ABICOR Innovation Award 2008 went to Dipl.-Eng. Michael Schnick, Dresden University of Applied Sciences, for his work titled: “Current Simulation as a Development Tool for Arc and Plasma Torches” Motivation In order to meet the ever-increasing demands of welding technology, welding tools and arc processes must be further developed to ensure safe application in extreme physical situations. Conventional methods of process and torch development, which are based on parameter studies and costintensive prototype construction, are not suitable for this process as the physically active principles acting on the arc, the electrode and the molten mass are observed in a simplified Black Box manner, which means that the laboriously obtained results are few and far between and cannot be generalised. For both timely and localised high-profile description of the complex physical processes behind process gas feed, inert gas coverage and in the arc and the electrodes, a simulation tool for plasma-and arc processes has been developed, which is based on the base numeric model in the basic physics equation.
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Overview
Cathode Sheath Arc Column
Fluid Mechanics Hydrodynamics
Electromagneticsm Electrodynamics
Navier-Stokes Equations
Interfaces Ohms Law Lorentz Force Ohmic Heating
Maxwell Equations
Anode Sheath
Magneto Hydrodynamics (MHD)
Models of the plasma arc
Methodik The simulation was systematically applied as a development tool in order to identify weaknesses in existing torch concepts and to work out improvements. To this end, certain effects were visualised that are normally hidden inside the torch and, due to high radiation and temperature load, are either not accessible or only with difficulty. For the first time, numeric sensitive analyses are used to gain a deeper understanding of physical cause and effect connections bet-
ween the arc, the workpiece, the torch and the process parameters and also to draw conclusions as to process potentials and restrictions. This numeric model is suitable for use in PC workstations. Results In comparison to conventional development methods for welding and cutting torches, the simulation allows for a decrease of energy requirement caused by prototype construction and also of development time while simultaneously increasing insight. The new process understanding gained from modelling leads to new deign and development approaches for torches. Physically based simulation results are excellently suited for depicting development results in a plausible manner. At the same time, they can be used for knowledge transfer, e. g. for actual application or for training of expert welding engineers and welders. 3
Optimised Valve for Plasma Arc Welding
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Research
The Research Association on Welding and Allied Processes of DVS
The core activity of the Research Association on Welding and Allied Processes of DVS is the cooperative industrial research (IGF) in which companies, corporate bodies and research institutes from the various fields of joining technology actively take part. The Research Association is divided into 13 expert committees (FAs) with specific subject-related main focal points. The companies agree upon the need for cooperative research and define main focal points for pioneering research which the research institutes involved convert into concrete research projects without delay. The cooperative
industrial research achieves optimum closeness to the application and permits the direct utilisation and implementation of the results. The collaboration of industry means that know-how is transferred at an early stage and that the research work and the utilisation of the results are parallelised. IGF research projects may be promoted from funds of the Federal Ministry of Economic Affairs and Technology (BMWi) via the“Otto von Guericke” Federation of Industrial Research Associations (AiF). 3
Further information at: www.dvs-ev.de/fv
DVS information brochures
As a new service, DVS is offering its members and all the interested people bundled technical information about various subject areas in joining technology with the portfolio of services from DVS. The information brochures prepared in two languages (German/English) include not only detailed explanations about the respective main focal points including a description of the development potential but also valuable explanations about the activities and available work results of DVS in the fields of research, technology and education. The brochures which have been published until now are available to you for downloading. www.dvs-ev.de/dvs-aktuell-ftb Printed copies can be requested by e-mail ([email protected]). 3
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Research
Expert Committee 3 “Arc Welding“
FA 3
Arc Welding
Chairman: Dr.-Ing. Wolfgang Scheller Salzgitter Mannesmann Forschung GmbH, Duisburg Vice-Chairman: Dr.-Ing. Sven-Frithjof Goecke EWM HIGHTEC WELDING GmbH, Mündersbach
Secretary: Dipl.-Ing. Wolfgang Queren-Lieth Phone: 0211 / 2591-116 Fax:-200 Email: [email protected] Website: www.dvs-ev.de/fv/FA03
Fundamental principles The general goal behind the research works is the further advancement of efficiency and profitability of arc welding processes for joining in industrial settings. Under consideration, especially, are the requirements of small and medium-size enterprise. These research undertakings are to take into account such aspects as boundary and environment conditions like pretreatment and follow-up treatment, tolerance levels, warpage, emissions, impurities and typical practice quality criteria. The processes must become clearly understandable. Economic considerations and estimations also form part of the research scope. These are deduced, among others, from the technological boundary conditions of the processes. In the course of the research undertakings, solutions are to be worked out and documented. Desirable here would be parameter information concerning welding tasks that allow for comparison to the results of other research projects and practical applications. As an overall target, arc welding is to become capable of being simulated, as low-emission as possible, easy to monitor, quality defined and present with production reliability. Research fields: Optimised arc microstructure and coating processing must be found for contemporary materials and combination materials, for corrosion and acid proof steels, nickel-aluminium-and magnesium alloys, high-strength steels and for bonding. The design of process variants (heat-controlled arc processes, arc soldering, high performance processes) and hybrid processes (laser hybrid welding, plasma-MSG welding) must continue in the direction of operational instrument engineering.
In the field of instrument engineering and installation engineering, one needs to work on marked improvements in the areas of torch and tube package technique, suction technology and especially also torch and energy-source integrated sensors. For quality control and easy operation, sensors and sensor systems for seam detection and tracking as well as for adaptive welding are to be designed, as well as sensors for process monitoring, guidance and control; sensor system reliability needs to be improved.
Inert Gas Flow (Simulation)
A new research focus is on diagnosis, modelling, simulation, calculation and visualisation of arc welding processes: Novel approaches relating to plasma physics and diagnosis, for modelling and depiction of actual arc welding processes, can be used in order to obtain a comprehensive and fundamental evaluation and control of effects and influences of the arc flash, for visualisation and better understanding of welding arc process mechanisms. This applies especially also to the training setting. Direct calculation-based processing of signals thus generated from diagnostic methods and modelling results needs to be integrated, for the purpose of parameter assessment and definition as well as for process stabilisation in systems and arc welding equipment. 3
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Research
Research projects (selection)
Ongoing research projects
Development of an event-driven control mechanism on the basis of inverse modelling for robust process operations in complex MSG impulse welding procedures DVS-Nr.: 03.091 / IGF-Nr.: 15.872 B Start: 01.11.2008 – End: 31.10.2011 Participating institutes: Prof. Dr. rer. nat. J. Kruscha, FH Lausitz, Senftenberg und Cottbus, IEM Department Prof. Dr.-Eng. U. Reisgen, RWTH Aachen, Institute of Welding-and Joining Technology Fluid dynamic design of torch systems for economical and low-emission arc welding DVS-Nr.: 03.090 / IGF-Nr.: 15.871 B Start: 01.11.2008 – End: 31.10.2011 Participating institutes: Prof. Dr.-Eng. habil. U. Füssel, Dresden University of Applied Sciences, Institute of Production Engineering and Joining Technology Fully automated welding system for root welding of V- and X joint preparations, with contemporary regulated arc procedure and digital short circuit resolution DVS-Nr.: 03.088 / IGF-Nr.: 15.916 N Start: 01.12.2008 – End: 30.11.2010 Participating institutes: Prof. Dr.-Ing. U. Reisgen, RWTH Aachen, Institute of Welding-and-Joining Technology Use of novel non-copper materials for weld wire bonding during MSG welding and soldering processes, especially for aluminium and low melting additive materials DVS-Nr.: 03.087 / IGF-Nr.: 15.914 B Start: 01.12.2008 – End: 30.11.2010 Participating institutes: Prof. Dr.-Ing. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Deposition welding of nanocrystalline solidifying ferrous-based materials to aluminium substrate via regulated short arc technique DVS-Nr.: 03.085 / IGF-Nr.: 15.859 N Start: 01.11.2008 – End: 31.10.2010 Participating institutes: Prof. Dr.-Eng. habil. J. Wilden, Berlin University of Applied Sciences, Institute of Machine Tools and Factory Operation, Department of Joining- and Coating Technology Cause and evaluation of imperfections in arc soldered joints DVS-Nr.: 03.083 / IGF-Nr.: 15.745 B Start: 01.08.2008 – End: 31.07.2010 Participating institutes: Prof. Dr.-Ing. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology
Numeric and experimental investigations for systematic influencing of arc and molten bath during gas-shielded welding through protective gas characteristics and protective gas composition DVS-Nr.: 03.082 / IGF-Nr.: 15.774 B Start: 01.09.2008 – End: 31.08.2010 Participating institutes: Prof. Dr.-Eng. habil. U. Füssel, Dresden University of Applied Sciences, Institute of Production Engineering and Welding Technology Increase of process safety with simultaneous decrease of production costs through the use of gaseous flux during arc welding DVS-Nr.: 03.081 / IGF-Nr.: 15.635 N Start: 01.08.2008 – End: 31.07.2010 Participating institutes: Prof. Dr.-Eng. W. H. Müller, Berlin University of Applied Sciences, Department of Continuum Mechanics and Materials Theory Prof. Dr.-Eng. habil. J. Wilden, Berlin University of Applied Sciences, Institute of Machine Tools and Factory Operation, Department of Joining- and Coating Technology Design of characteristics-and evaluation profiles for welding technical use of tungsten electrodes DVS-Nr.: 03.080 / IGF-Nr.: 15.231 N Start: 01.06.2007 – End: 31.05.2009 Participating institutes: Dr.-Eng. St. Keitel, SLV Duisburg, Section of the GSI mbH Coefficient definition for contemporary gas-shielded welding procedures DVS-Nr.: 03.078 / IGF-Nr.: 15.562 B Start: 01.07.2008 – End: 30.06.2010 Participating institutes: Prof. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Development of a weld head guiding system for automated MSG welding of steel and aluminium alloys DVS-Nr.: 03.076 / IGF-Nr.: 15.296 N Start: 01.08.2007 – End: 31.07.2009 Participating institutes: Prof. Dr.-Eng. U. Reisgen, RWTH College Aachen, Institute of Welding-and Joining Technology Prof. Dr.-Eng. K. Dilger, Braunschweig University of Applied Sciences, Institute of Welding-and Joining Technology
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Research
Concluded research projects
Classification of health hazard levels through the emission of welding fumes during modern gas-shielded welding procedures DVS-Nr.: 03.071 / IGF-Nr.: 14.459 B Participating institutes: Prof. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Gas hose influence on humidity-hydrogen-and oxygen problematic during gas-shielded welding DVS-Nr.: 03.068 / IGF-Nr.: 14.426 N Participating institutes: Prof. Dr.-Eng. U. Reisgen, RWTH Aachen, Institute of Welding-and Joining Technology Investigation into MSG soldering of zinc-coated steel sheet, with impulse arc and for use with impulse-driving AC and DC current in the base current phase DVS-Nr.: 03.066 / IGF-Nr.: 14.425 N Participating institutes: Dipl.-Eng. f. Zech, SLV Munich, Section of the GSI mbH Virtually internal sensor for MIG welding applications DVS-Nr.: 03.065 / IGF-Nr.: 13.863 B Participating institutes: Prof. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Plasma-MIG technology application during joining of coated steel materials DVS-Nr.: 03.064 / IGF-Nr.: 13.862 B Participating institutes: Prof. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Use of flat wire electrodes during fully automated MSG welding of fine-grained steel with higher yield strength DVS-Nr.: 03.059 / IGF-Nr.: 13.784 N Participating institutes: Dr.-Eng. St. Keitel, SLV Duisburg, Section of the GSI mbH Process-safe MSG welding of high-alloy specialist materials with low frequency pulsed wire feed DVS-Nr.: 03.062 / IGF-Nr.: 13.787 B Participating institutes: Prof. Dr.-Eng. I. Martinek, Otto-von-Guericke University at Magdeburg, Faculty of Mechanical Engineering, Institute of Joining-and Beam Technology
Investigation into MSG impulse arc welding with interim impulse for AC and DC current application Vorhaben: DVS-Nr.: 03.061 / IGF-Nr.: 13.484 N Participating institutes: Dipl.-Eng. F. Zech, SLV Munich, Section of the GSI mbH Investigations into MSG deposition welding with flat wire electrodes Vorhaben: DVS-Nr.: 03.057 / IGF-Nr.: 13.408 B Participating institutes: Dipl.-Eng. F. Zech, SLV Munich, Section of the GSI mbH Dr.-Eng. M. Ströfer, SLV Halle GmbH Qualification and use of hybrid synergy effects for high performance welding of light metals DVS-Nr.: 03.056 / IGF-Nr.: 13.783 N Participating institutes: Prof. Dr.-Eng. U. Reisgen, RWTH Aachen, Institute of Welding-and Joining Technology 3
MAG-Welding
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Research
DFG/IGF Research Cluster
Arc welding - Physics and Tools
Summary In this research cluster, based on diagnostic welding arc research, a fundamental physical understanding is obtained in close correlation with modelling applications, so that process behaviour can be predicted or estimated via simulation. Parallel to these works, there are user-oriented projects for the implementation under technological aspects. Special emphasis here is placed on a significant improvement in process safety. The torch and control concepts to be developed, synergy-based, also lead to novel metallurgical possibilities (Image 1). Motivation Manufacture of products for all trades, from tank and container to chemical apparatus production, steel-boat-and railway vehicle construction, and also including vehicle and aerospace applications, not to mention the manufacture of athletic devices, furniture or household appliances. All this, independent of individual usage, calls for technologies that allow for material-and application friendly joining of semifinished products, components or building groups. Among the firmly bonded joining procedures, welding – on account of its procedure-inherent characteristics – has now obtained a prime position. Recent developments in arc welding technique, partially supported by public funds, show completely novel possibilities for energy yield control and open up new fields in arc technology regarding operational safety, environmental friendliness and expansion of application fields. A “quantum leap” of industrial market relevance, however, can only be achieved if it becomes possible to both understand and depict via model the fundamental physics of welding arcs in their complexity that is influenced by process gas flow with its partial addition of surrounding gases from the environment, materials transfer of the consumable electrode, metal vapour formation, emission occurrence etc. This insight then allows for new metallurgy control possibilities during solidification that, in turn, leads to control of problematic hot crack formation for many materials and their combinations. Due to the economic significance and the possibilities opening up with high innovation potential, there is a big need for research – both fundamental and application-oriented – especially in the area of MIG/MAG joining processes and 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 follow. Purpose of the Research The research cluster strives to significantly expand both process and application boundaries for arc welding procedures. In the end, we are looking for higher productivity, increased operational safety and less environmental stress. Further, materials or material combinations that hitherto were considered difficult to fusion weld are to be fused with a “novel“ are welding technology. This technology will be capable of adapting to changed environmental conditions like higher tolerance levels and thus lead to a competitive advantage in the overriding process chain through significantly faster laser beam welding process speed. Method The methods supporting the cluster concept are arranged in such a manner as to allow for examination, via diagnostic procedures in any basis-oriented project area, of the processes concerning welding arc or anode and cathode. Material transfer is also under investigation. The purpose here is to obtain a fundamental improvement of knowledge and to make available for modelling the experimentally obtained data. Modelling then strives for comprehensive definition of the MIG process, leading to both process behaviour and process variable becoming predictable. In the area of modelling, there are two fundamentally different approaches: for one, there is modelling on the basis of physical fundamentals and on the other, inverse modelling is to serve for obtaining information
Diagnostics
Experimental analysis of and insight into process connections
Modelling
Mathematical-physical depiction of process connections
Process capability Application
Transfer if process understanding into
“Zero Defect“ (Process Capability) Sensor-less Process Control Metallurgical Effects
Implementation
Image 1: Research Concept Systematic
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Research
about process connections directly from the process itself that are then implemented in a physics-based model. After only 6 of 36 months of project running time, initial results already showed - through a match of simulation and experiment (Image 2) – both the high scientific level and excellent success chances for actual application significance. The fundamental works are closely interconnected and simultaneously influence the application-oriented projects. The arc is to be controlled in such a manner that, on one hand, metallurgy and solidification of molten bath can be systematically influenced in order to, for instance, become better able to handle the problem of hot crack formation via a new process-oriented approach. Further, the processoriented project area is concerned with working out new methods by means of which it will become possible to use the power source itself as a process sensor and, through this, finally achieve significant progress in respect to process capability. Hence, the cluster research allows for an innovation leap in arc welding technology in respect to both process control and process capability.
Research Partners Univ.-Prof. Dr.-Ing. habil. Uwe Füssel Department of Joining Technology and Assembly Institute of Surface and Manufacturing Technology Dresden University of Applied Sciences Prof. Dr .rer. nat. habil. Johannes Kruscha Department of Information Technology/Electronics/Mechanical Engineering Lausitz University of Applied Sciences Prof. Dr.-Ing. Uwe Reisgen Institute of Welding-and Joining Technology RWTH Aachen Prof. Dr.-Ing. Jochen Schein Institute of Plasma Science and Mathematics (LPT) University of the German Federal Armed Forces, Munich Dr. rer. nat. Dirk Uhrlandt Leibniz Institute for Plasma Science and Technology e.V. (INP) Greifswald Prof. Dr. rer. nat. Klaus-Dieter Weltmann Leibniz Institute for Plasma Science and Technology e.V. (INP) Greifswald Univ.-Prof. Dr.-Ing. habil. Johannes Wilden (Coordinator) Fachgebiet Füge- und Beschichtungstechnik Institute of Machine Tools and Factory Operation Berlin University of Applies Sciences
Preamble Arc Cluster
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Image 2: Comparison of Simulation and Experiment; Source: Füssel, Schnick, Härtel, Häßler, Dresden University of Applies Sciences
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Technology
Technical Committee (AfT) of DVS
The technical-scientific cooperative work of DVS is predominantly determined by the activities of its Technical Committee (AfT) with its working bodies oriented to specific subjects. Specialists from the economic and scientific fields, from authorities and from other areas collaborate in them. The Technical Committee promotes the active exchange of experience amongst experts, describes the state of the art by elaborating and contributing to the preparation of a set
of technical rules (DVS technical bulletins, technical codes, guidelines and standards) and is actively involved in the technical development of welding and the allied processes such as brazing/soldering, thermal spraying, adhesive bonding, mechanical joining and plastics joining. Joint committees with the Standards Committee for Welding Technology of DIN also exist for this purpose. 3
Further information at: www.dvs-aft.de
Working groups of the AfT
Secretary and Contact Person for all working groups: Dipl.-Ing. Wolfgang Queren-Lieth Phone: 0211 - 1591-116 Fax: -200 Email: [email protected] In this central area of welding technology, over 400 experts are at work, with special and as a rule process-oriented expert focus, divided into 7 different sub-groups and 38 different task forces. Working groups (Selection) WG V 2.1 “Metal arc welding“ WG V 2.3 “Arc welding with non-consumable electrode” 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 performance 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 roboting“ WG V 2.7 „Welding with filler wire“ Joint undertakings, contribution to standard DKE 361 “Electric Arc Welding Equipment“ and setting up of the annual arc colloquium together with the Expert Committee 3 “Arc Welding“ are all tasks that are generally coordinated on an annual basis through the circle of representatives. The WG V 2 is in correspondence with the following working units of the International Institute of Welding (IIW) Commission II “Arc Welding and Filler Metals “ Commission IX “Behaviour of metals subjected to welding “ Commission XII “Arc welding processes and production systems “ 3
Working group V 2 „Arc welding“
Chairman: Prof. Dr.-Ing. Rolf Felleisen Schweißtechnische Lehr- und Versuchsanstalt Mannheim GmbH Vice-Chairman: Dr.-Ing. Reinhard Winkler SLV Duisburg, Section of the GSI mbH Website: www.dvs-aft.de/AfT/V/V2
Metal arc vertical up seam
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Technology
Essential work results DVS technical bulletins and technical codes (Selection)
Process and Materials Classification: 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 filler wire F Instrument engineering, automation, equipment G Welding of steels H Welding of NF and light metals
DVS technical bulletins and technical codes DVS 0966-1 Plasma-MSG welding – Instrument engineering DVS 0964 Submerged arc double wire welding DVS 0958 Covered electrodes - efficiency, metal recovery and deposition coefficient – work sheets and calculation aids DVS 0957 Handling of covered electrodes - Transport, storage and redrying DVS 0955 Welding-based processing of nickel-alloyed steels for low temperature applications DVS 0951 Specialist steel with elevated wear-resistance DVS 2710 Additional equipment for mechanical TIG and plasma welding; characteristics and requirements DVS 0949 Tubular-cored electrodes for MAG- and SAW welding of ferritic steel castings creep resistant at elevated temperatures DVS 0948 Submerged arcs welding and its procedure variants DVS 0946 Recommendations for welding of stainless austeniticferritic duplex- and super duplex steels DVS 0945-1 Verification of welded and wearresistant depositions Abrasive wear DVS 0943 High-alloy electrodes DVS 0942 Welding with covered electrodes – Pore formation and avoidance DVS 0941-2 Tubular-cored electrodes for MAG- joint welding – characteristics and application areas DVS 0941-1 Tubular-cored electrodes for joint- and deposition welding – principles and terminology DVS 0940 Submerged arc deposition welding with strip electrode
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DVS technical bulletins and technical codes DVS 0938-1 Arc soldering – principles, processes, installation engineering requirements DVS 0937 Root protection during gas-shielded welding DVS 0936 Submerged arc narrow-gap welding DVS 0935 Electroslag deposition welding with strip electrode DVS 0934 TIG welding; devices and equipment DVS 2714 Welding devices for manual and fully automated TIG welding – Requirement determination (especially for aerospace applications) DVS 0932 MAG set-up practice - Process- and component dependent influences on seam geometry DVS 0931 MAG welding of non-corrosive, austenitic steels DVS 0928 Submerged arc welding of austenite-ferrite joints DVS 0926-2 Wire feed, tube package and torch requirements for gas shielded metal welding DVS 0926-1 Energy source requirements for gas shielded metal welding DVS 0925 MAG welding of thick sheet metal DVS 0923-1 to -4 Testing of welding powders for weld-related characteristics in submerged arc welding applications DVS 0921 Load diagrams for rotary tables and rotary tilting tables DVS 0920 Tungsten inert gas welding (TIG) - principles DVS 0919 Tungsten plasma arc welding DVS 2707 Plasma arc welding – process overview, gas selection and welding parameters DVS 0918 Submerged arc welding of fine-grained steels DVS 0917 Submerged arc welding of austenitic steels DVS 0916 Metal gas-shielded welding of fine-grained steels DVS 0915 Submerged arc multiple electrode welding DVS 0914 Processing and storage of welding powders for submerged arc welding DVS 0913-1 to 3 MIG welding of aluminium – Material-related basics / devices, processes, auxiliary materials / application-oriented notes ----------
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Technology
DVS technical bulletins and technical codes DVS 0912-1 to 2 Gas-shielded metal arc welding of steel; Guidelines for process execution – Prevention of incomplete fusion DVS 0911 Tungsten electrodes for tungsten insert gas welding – Application-oriented notes DVS 2716 Tungsten electrodes for tungsten insert gas welding – Requirements for aerospace applications DVS 0909-1 and -2 Principles of MSG high performance welding with solid wire electrodes – Definition and terminology / Application-oriented notes DVS 0907-1 to 3 Determination of heat input and burn-off for SAW flux – heat input and burn-off lines / Flux diagram / Application of flux diagram DVS 1502-1 and 2 Manual arc welding of ductile cast iron pipes – Principles of welding engineering / Welding of parts of ductile cast iron or steel DVS 0601 Welding of nickel and nickel alloys DVS 2713 Welding of titanium materials - Materials, processes, manufacture, inspection and evaluation of weld joints with supplementary sheet 1: Sample images of heat tinting
A
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x x x
x x x
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Electrode Contact Piece Powder Funnel
Cavern with implied arc Flux
Liquid Solid Slag Molten Bath with Flow Direction Preferred Drop Transfer Weld Seam Melting-solidification Front Heat Affected Zone Basis Material
Progress of Weld
Submerged arc welding
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Technology
Standards (Selection)
DIN EN ISO 9692-1 Welding and allied processes – Recommendations for joint preparation Part 1: Manual metal-arc welding, gas-shielded metal arc welding, gas welding, TIG welding and beam welding of steels DIN EN ISO 9692-2 Welding and allied processes - Joint preparation Part 2: Submerged arc welding of steel DIN EN ISO 9692-3 Welding and allied processes – Recommendations for juncture forms Part 3: Metal inert gas welding and tungsten insert gas welding of aluminium and aluminium alloys DIN EN ISO 15609-1 Specification and qualification of welding procedures for metallic materials – Welding procedure specification Part 1: Arc welding DIN EN ISO 15614 Specification and qualification of welding procedures for metallic materials – Welding procedure test - Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys - Part 2: Arc welding of aluminium and its alloys - Part 3: Fusion welding of non-alloyed and low-alloyed cast irons - Part 4: Finishing welding of aluminium castings (with correction) - Part 5: Arc welding of titanium, zirconium and their alloys - Part 6: Arc and gas welding of copper and its alloys - Part 7: Overlay welding - Part 8: Welding of tubes to tube plate joints
DIN EN 1011 Welding – Recommendations for welding of metallic materials - Part 1: General guidance for arc welding - Part 2: Arc welding of ferritic steels - Part 3: Arc welding of stainless steels - Part 4: Arc welding of aluminium and aluminium alloys - Part 5: Welding of clad steel - Part 8: Welding of cast irons DIN EN 50504 Validation of 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 feeders - Part 6: Limited duty manual metal arc welding power sources - Part 7: Torches - Part 8: Gas consoles for welding and plasma cutting systems - Part 9: Installation and use - Part 10: Electromagnetic compatibility (EMC) requirements - Part 11: Electrode holders - Part 12: Coupling devices for welding cables - Part 13: Return current clamp
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MAG-Welding
17
Education
Specialist Books (Selection – in German only)
Specialist Book Series Welding Techniques Volume 130 J. Schuster: Schweißen von Eisen-, Stahl- und Nickelwerkstoffen Specialist Book Series Welding Techniques Volume 76/I R. Killing: Handbuch der Schweißverfahren Teil I: Lichtbogenschweißverfahren Specialist Book Series Welding Techniques Volume 63 P. Müller, L. Wolff: Handbuch des Unterpulverschweißens Part I and Part II: Part I: Verfahren, Einstellpraxis, Geräte, Wirtschaftlichkeit, Part II: Schweißzusätze und Schweißpulver Part III: Draht/Pulver-Kombinationen für Stähle - Schweißergebnisse - Schweißparameter Part IV: Schweißen mit Strip electrode Part V: Berechnung und Gestaltung von Schweißkonstruktionen - Schweißtechnologie - Anwendungsbeispiele Specialist Book Series Welding Techniques Volume 141 D. Radaj: Schweißprozeßsimulation, Grundlagen und Anwendungen Specialist Book Series Welding Techniques Volume 84 M. Schellhase: Der Schweißlichtbogen - ein technologisches Werkzeug
Specialist Book Series Welding Techniques Volume 133 Dipl.-Ing. R. Trillmich, W. Welz: Bolzenschweißen Grundlagen und Anwendung Practical Welding Techniques Volume 2 W. Marfels, L. Orth: Der Lichtbogenschweißer Leitfaden für Ausbildung und Praxis Practical Welding Techniques Volume 14 Dipl.-Ing. G. Aichele: 140 Arbeitsregeln für das Schutzgasschweißen Practical Welding Techniques Volume 34 L. Baum, S. Pommer: Der Schutzgasschweißer Teil 1 WIG-/Plasmaschweißen Practical Welding Techniques Volume 35 L. Baum, S. Pommer: Der Schutzgasschweißer Teil 2 MIG/MAG-Schweißen DVS Reports Volume 249 J. Wilden, D. Bartout, F. Hofmann: Lichtbogenfügeprozesse - Stand der Technik und Zukunftspotenzial DVS Reports Volume 190 C. Lorenz: WIG-Orbitalschweißen von Rohr/ Rohrverbindungen aus Aluminiumwerkstoffen DVS Reports Volume 87 Schutzgasschweißen 3
The specified publications can be purchased via DVS Media GmbH: DVS Media GmbH ·Aachener Straße 172 · D-40223 Düsseldorf · Tel.: 0211 / 1591-162 · [email protected] · www.dvs-media.info
Education Committee (AfB)
Personnel qualification in DVS
The Education Committee (AfB) of DVS elaborates and structures the range of training and further education offered by DVS in the fields of joining, cutting and coating. It follows tendencies and trends as well as concrete developments in the education sector and evaluates their effects on society in general and on the areas of joining, cutting and coating in particular. AfB is oriented to the latest state of the art and to the needs of the German economy. Due to the close network of DVS, the structures of the society are used optimally, the latest findings are exchanged across bodies and there is feedback about the current needs. DVS thus offers the expert world of joining technology, members and interested people a comprehensive range of competitive solutions for joining technology. 3
Further information at: www.dvs-afb.de 18
Education
Arc welding is part of any fundamental training in welding technology, whether for welders or as part of practice oriented training or training as a welding supervisor. From the wide range of DVS® training courses available, the following list provides a selection with special arc welding elements:
Practical Training (Selection)
Coordination: K. Andreé, SL Magdeburg Secretary: Dipl.-Ing. Christoph Esser-Ayerty Phone: 0211 – 1591-178 Fax: -200 Email: [email protected]
Theoretical Training (Selection)
Coordination: Dipl.-Ing. Ch. Ahrens, SLV-Duisburg Secretary: Dipl.-Ing. Michael Metzger Phone: 0211 – 1591-177 Fax: -200 Email: [email protected]
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 gasshielded 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, gasshielded welding DVS® 1148 Exams for welders, Manual arc welding of ductile cast iron pipes DVS® 1149 DVS Course: Training and certification of 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
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 for reinforced steel welding DVS®/EWF/IIW 1178 International Welding Quality Inspection Staff (IWIP) DVS® 1109 Welding Supervisor Staff (WSS) – Rail vehicle construction DVS® 1179 Welding Supervision – Add-on training for aluminium welding DVS®/EWF 1198 Specialist courses for training or further training in laser beam welding – for engineers. Technicians, specialists – 3
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DVS-up to date: “Arc Welding”
Research... Technology... Education...
www.the-joining-specialists.de
Content
Competitive solutions for joining technology
Arc Welding
Overview ………………………………… 3
EWM Award - Physics of Welding ABICOR – Innovation Award 2010
Research
………………………………… 7
Research Association on Welding and Allied Processes of DVS Expert Committee 3 “Arc Welding“ www.dvs-ev.de/fv/fa3 DFG/IGF Research Cluster Arc welding - Physics and Tools
Technology ……………………………… 13
Technical Committee Working Group V 2 “Arc Welding“ www.dvs-aft.de/AfT/V/V2 IIW-International Institute of Welding Commission II “Arc Welding and Filler Metals“ Commission IX “Behaviour of metals subjected to welding “ Commission XII “Arc welding processes and production systems “ www.iiw-iis.org
Education ……………………………… 18
Education Committee Expert Group 2 “Practical Training“ Expert Group 3 “Theoretical Training“ www.dvs-afb.de DVS®-Courses www.dvs-bildungsfuehrer.de www.dvs-bildungseinrichtungen.de
Contact
Dipl.-Eng. Wolfgang Queren Phone.: 0211 - 1591-116 Fax: -200 Email: [email protected]
Publisher
DVS – German Welding Society Aachener Str. 172 40223 Düsseldorf Credits for illustations IOT, TU Dresden ISF, RWTH Aachen IWF FBT, TU Berlin
2
Overview
Arc welding over Time
Fusion welding with an arc was already developed by the end of 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 significant stance of technology. During manual arc welding, the electrode is melted and functions as filler metal. The volatile flux of the metal electrode secures the protection of the molten bath, influences alloy composition of the Welding Arc Materials Transfer weld metal and also seam shape. Nowadays, this process is primarily used for low infrastructure construction operations. Flux-cored arc welding (FCAW) is now firmly established at a high performance process for instance in heavy machinery construction, in the shipbuilding industry or in large tube production. Protection and influencing of weld seam characteristics is via a mineral-based power that is used up before the process. In modern industrial nations, welding production without MIG/ MAG shielded gas welding processing would be unthinkable nowadays. Die ersten Schweißmaschinen dieser Art kamen in den fünfziger Jahren auf den Markt. During metal inert gas-and metal active gas welding, the wire electrode and the molten bath are shielded by inert or active protective gas. The advantages of this process lie in its comparatively easy handling, its suitability for all welding positions as well as the process variants and protective gases that have in the meantime been developed to optimally suit both welding tasks and materials.
Welding with nonconsumable tungsten electrodes, on the other hand, is used for those specialist tasks and for materials that place high demands on weld seam quality. Typical application areas for these TIG and plasma procedures are the aerospace industry and chemical plant construction. But even high-quality bicycle frames are nowadays welded with the TIG method. A success story in this field is the automation of TIG processes with orbit units, which is often used for the manufacture of large heat exchangers or when laying premium piping systems. For specific requirements, further welding procedures have been developed, such as impulse-driven processes for systematic melting of the wire electrode, low-energy procedures or processing thin or coated metal sheets, or laser hybrid welding that uses both processes in combination for its advantage. There is an increasing tendency in arc welding towards automation. Nowadays, automation tends towards so-called production cells where handling and joining tasks can be achieved without outside interference. To this end, there is a constant development process concerning sensors for blowtorch guidance, process stabilisation and weld seam quality control. Growing environmental and occupational safety requirements place ever-higher demands on arc welding processes. The same applies to duplicability of production quality despite clear improvements over the last few years. This is where research and development, in Germany, takes both a timely and intensive approach: Fundamental plasma welding research is one essential requirement for this; advances in modelling and process simulation with an effect on deeper understanding of the various processes can already be recognized. Further, research is going on into the development of welding energy sources with innate, documentation-suited sensors for stable, low-emission and even auto-adjusting processes.
Rotating high-performance arc
Dr.-Ing. Wolfgang Scheller Chairman Expert Committee 3 “Arc welding“ Salzgitter Mannesmann Forschungsinstitut (Research Institute) GmbH, Duisburg
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3
Overview
Awards in the Area of Arc Welding
EWM Award - Physics of Welding
Application Interested parties can apply for the advancement award in writing. This written application should include a logical and compelling concept of the planned research and development undertaking, outlining content, objectives and timeframe. Submitted applications will be evaluated by an independent panel of judges. The written application for the advancement award should be submitted to the DVS. The submission deadline for 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 Middeldorf DVS e.V. Aachener Straße 172 40223 Düsseldorf Email: [email protected]
On occasion of its 50th anniversary on October 17th, 2008, the EWM HIGHTEC WELDING GmbH company launched a new advancement award. This advancement award is intended to financially support up-and-coming scientists in research and development undertakings that will result in a considerably increased understanding of welding technology processes. This research and development work can be based on arc welding processes and combination welding processes (hybrid welding processes). The EWM Award “Physics of Welding“ is presented bi-annually. For each application, one up-and-coming scientist will receive financial support of the sum of 30.000 € for their research and development work.
Website: www.ewm-award.de www.die-verbindungs-spezialisten.de/index.php?id=1261
4
Overview
ABICOR – Innovation Award 2010
viability, as well as considerations concerning quality, environmental protection and occupational safety. The chances of eventual implementation and expected end-use are also to be considered during evaluation Applications and proposals may be submitted by either individuals or groups. An independent jury will decide the winners. Announcement of the award recipients and presentation of the award will take during the DVS event titled DIE VERBINDUNGS SPEZIALISTEN: Große Schweißtechnische Tagung (The Joining Specialists – Major Welding Technology Conference) Contact: Dipl.-Ing. Wolfgang Queren-Lieth DVS e.V. Aachener Straße 172 40223 Düsseldorf Email: [email protected] Website: www.die-verbindungs-spezialisten.de/index.php?id=1298
Award Recipients
For the lasting support of research and development in the area of arc welding and cutting, the Alexander Binzel Schweisstechnik GmbH & Co. KG company, in 1995 on account of its 50th anniversary, decided to initiate an award of excellence for this area. The ABICOR Innovation Award, as it is called for 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 of 10.000 €. Especially considered here are research and development works related to arc welding and cutting processes, particularly those of fundamental significance that can be expected to lead to the furthering of automation and mechanisation; this includes process-relevant control and manufacturing techniques as well as suitable knowledge transfer strategies. Application Procedure Works by junior researchers from the areas of economy and science will be primarily considered. Important criteria are as follows: scientific advance, technical progress, economic 1st Place of the ABICOR Innovation Award 2008 went to Dipl.-Eng. Michael Schnick, Dresden University of Applied Sciences, for his work titled: “Current Simulation as a Development Tool for Arc and Plasma Torches” Motivation In order to meet the ever-increasing demands of welding technology, welding tools and arc processes must be further developed to ensure safe application in extreme physical situations. Conventional methods of process and torch development, which are based on parameter studies and costintensive prototype construction, are not suitable for this process as the physically active principles acting on the arc, the electrode and the molten mass are observed in a simplified Black Box manner, which means that the laboriously obtained results are few and far between and cannot be generalised. For both timely and localised high-profile description of the complex physical processes behind process gas feed, inert gas coverage and in the arc and the electrodes, a simulation tool for plasma-and arc processes has been developed, which is based on the base numeric model in the basic physics equation.
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Overview
Cathode Sheath Arc Column
Fluid Mechanics Hydrodynamics
Electromagneticsm Electrodynamics
Navier-Stokes Equations
Interfaces Ohms Law Lorentz Force Ohmic Heating
Maxwell Equations
Anode Sheath
Magneto Hydrodynamics (MHD)
Models of the plasma arc
Methodik The simulation was systematically applied as a development tool in order to identify weaknesses in existing torch concepts and to work out improvements. To this end, certain effects were visualised that are normally hidden inside the torch and, due to high radiation and temperature load, are either not accessible or only with difficulty. For the first time, numeric sensitive analyses are used to gain a deeper understanding of physical cause and effect connections bet-
ween the arc, the workpiece, the torch and the process parameters and also to draw conclusions as to process potentials and restrictions. This numeric model is suitable for use in PC workstations. Results In comparison to conventional development methods for welding and cutting torches, the simulation allows for a decrease of energy requirement caused by prototype construction and also of development time while simultaneously increasing insight. The new process understanding gained from modelling leads to new deign and development approaches for torches. Physically based simulation results are excellently suited for depicting development results in a plausible manner. At the same time, they can be used for knowledge transfer, e. g. for actual application or for training of expert welding engineers and welders. 3
Optimised Valve for Plasma Arc Welding
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Research
The Research Association on Welding and Allied Processes of DVS
The core activity of the Research Association on Welding and Allied Processes of DVS is the cooperative industrial research (IGF) in which companies, corporate bodies and research institutes from the various fields of joining technology actively take part. The Research Association is divided into 13 expert committees (FAs) with specific subject-related main focal points. The companies agree upon the need for cooperative research and define main focal points for pioneering research which the research institutes involved convert into concrete research projects without delay. The cooperative
industrial research achieves optimum closeness to the application and permits the direct utilisation and implementation of the results. The collaboration of industry means that know-how is transferred at an early stage and that the research work and the utilisation of the results are parallelised. IGF research projects may be promoted from funds of the Federal Ministry of Economic Affairs and Technology (BMWi) via the“Otto von Guericke” Federation of Industrial Research Associations (AiF). 3
Further information at: www.dvs-ev.de/fv
DVS information brochures
As a new service, DVS is offering its members and all the interested people bundled technical information about various subject areas in joining technology with the portfolio of services from DVS. The information brochures prepared in two languages (German/English) include not only detailed explanations about the respective main focal points including a description of the development potential but also valuable explanations about the activities and available work results of DVS in the fields of research, technology and education. The brochures which have been published until now are available to you for downloading. www.dvs-ev.de/dvs-aktuell-ftb Printed copies can be requested by e-mail ([email protected]). 3
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Research
Expert Committee 3 “Arc Welding“
FA 3
Arc Welding
Chairman: Dr.-Ing. Wolfgang Scheller Salzgitter Mannesmann Forschung GmbH, Duisburg Vice-Chairman: Dr.-Ing. Sven-Frithjof Goecke EWM HIGHTEC WELDING GmbH, Mündersbach
Secretary: Dipl.-Ing. Wolfgang Queren-Lieth Phone: 0211 / 2591-116 Fax:-200 Email: [email protected] Website: www.dvs-ev.de/fv/FA03
Fundamental principles The general goal behind the research works is the further advancement of efficiency and profitability of arc welding processes for joining in industrial settings. Under consideration, especially, are the requirements of small and medium-size enterprise. These research undertakings are to take into account such aspects as boundary and environment conditions like pretreatment and follow-up treatment, tolerance levels, warpage, emissions, impurities and typical practice quality criteria. The processes must become clearly understandable. Economic considerations and estimations also form part of the research scope. These are deduced, among others, from the technological boundary conditions of the processes. In the course of the research undertakings, solutions are to be worked out and documented. Desirable here would be parameter information concerning welding tasks that allow for comparison to the results of other research projects and practical applications. As an overall target, arc welding is to become capable of being simulated, as low-emission as possible, easy to monitor, quality defined and present with production reliability. Research fields: Optimised arc microstructure and coating processing must be found for contemporary materials and combination materials, for corrosion and acid proof steels, nickel-aluminium-and magnesium alloys, high-strength steels and for bonding. The design of process variants (heat-controlled arc processes, arc soldering, high performance processes) and hybrid processes (laser hybrid welding, plasma-MSG welding) must continue in the direction of operational instrument engineering.
In the field of instrument engineering and installation engineering, one needs to work on marked improvements in the areas of torch and tube package technique, suction technology and especially also torch and energy-source integrated sensors. For quality control and easy operation, sensors and sensor systems for seam detection and tracking as well as for adaptive welding are to be designed, as well as sensors for process monitoring, guidance and control; sensor system reliability needs to be improved.
Inert Gas Flow (Simulation)
A new research focus is on diagnosis, modelling, simulation, calculation and visualisation of arc welding processes: Novel approaches relating to plasma physics and diagnosis, for modelling and depiction of actual arc welding processes, can be used in order to obtain a comprehensive and fundamental evaluation and control of effects and influences of the arc flash, for visualisation and better understanding of welding arc process mechanisms. This applies especially also to the training setting. Direct calculation-based processing of signals thus generated from diagnostic methods and modelling results needs to be integrated, for the purpose of parameter assessment and definition as well as for process stabilisation in systems and arc welding equipment. 3
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Research
Research projects (selection)
Ongoing research projects
Development of an event-driven control mechanism on the basis of inverse modelling for robust process operations in complex MSG impulse welding procedures DVS-Nr.: 03.091 / IGF-Nr.: 15.872 B Start: 01.11.2008 – End: 31.10.2011 Participating institutes: Prof. Dr. rer. nat. J. Kruscha, FH Lausitz, Senftenberg und Cottbus, IEM Department Prof. Dr.-Eng. U. Reisgen, RWTH Aachen, Institute of Welding-and Joining Technology Fluid dynamic design of torch systems for economical and low-emission arc welding DVS-Nr.: 03.090 / IGF-Nr.: 15.871 B Start: 01.11.2008 – End: 31.10.2011 Participating institutes: Prof. Dr.-Eng. habil. U. Füssel, Dresden University of Applied Sciences, Institute of Production Engineering and Joining Technology Fully automated welding system for root welding of V- and X joint preparations, with contemporary regulated arc procedure and digital short circuit resolution DVS-Nr.: 03.088 / IGF-Nr.: 15.916 N Start: 01.12.2008 – End: 30.11.2010 Participating institutes: Prof. Dr.-Ing. U. Reisgen, RWTH Aachen, Institute of Welding-and-Joining Technology Use of novel non-copper materials for weld wire bonding during MSG welding and soldering processes, especially for aluminium and low melting additive materials DVS-Nr.: 03.087 / IGF-Nr.: 15.914 B Start: 01.12.2008 – End: 30.11.2010 Participating institutes: Prof. Dr.-Ing. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Deposition welding of nanocrystalline solidifying ferrous-based materials to aluminium substrate via regulated short arc technique DVS-Nr.: 03.085 / IGF-Nr.: 15.859 N Start: 01.11.2008 – End: 31.10.2010 Participating institutes: Prof. Dr.-Eng. habil. J. Wilden, Berlin University of Applied Sciences, Institute of Machine Tools and Factory Operation, Department of Joining- and Coating Technology Cause and evaluation of imperfections in arc soldered joints DVS-Nr.: 03.083 / IGF-Nr.: 15.745 B Start: 01.08.2008 – End: 31.07.2010 Participating institutes: Prof. Dr.-Ing. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology
Numeric and experimental investigations for systematic influencing of arc and molten bath during gas-shielded welding through protective gas characteristics and protective gas composition DVS-Nr.: 03.082 / IGF-Nr.: 15.774 B Start: 01.09.2008 – End: 31.08.2010 Participating institutes: Prof. Dr.-Eng. habil. U. Füssel, Dresden University of Applied Sciences, Institute of Production Engineering and Welding Technology Increase of process safety with simultaneous decrease of production costs through the use of gaseous flux during arc welding DVS-Nr.: 03.081 / IGF-Nr.: 15.635 N Start: 01.08.2008 – End: 31.07.2010 Participating institutes: Prof. Dr.-Eng. W. H. Müller, Berlin University of Applied Sciences, Department of Continuum Mechanics and Materials Theory Prof. Dr.-Eng. habil. J. Wilden, Berlin University of Applied Sciences, Institute of Machine Tools and Factory Operation, Department of Joining- and Coating Technology Design of characteristics-and evaluation profiles for welding technical use of tungsten electrodes DVS-Nr.: 03.080 / IGF-Nr.: 15.231 N Start: 01.06.2007 – End: 31.05.2009 Participating institutes: Dr.-Eng. St. Keitel, SLV Duisburg, Section of the GSI mbH Coefficient definition for contemporary gas-shielded welding procedures DVS-Nr.: 03.078 / IGF-Nr.: 15.562 B Start: 01.07.2008 – End: 30.06.2010 Participating institutes: Prof. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Development of a weld head guiding system for automated MSG welding of steel and aluminium alloys DVS-Nr.: 03.076 / IGF-Nr.: 15.296 N Start: 01.08.2007 – End: 31.07.2009 Participating institutes: Prof. Dr.-Eng. U. Reisgen, RWTH College Aachen, Institute of Welding-and Joining Technology Prof. Dr.-Eng. K. Dilger, Braunschweig University of Applied Sciences, Institute of Welding-and Joining Technology
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Research
Concluded research projects
Classification of health hazard levels through the emission of welding fumes during modern gas-shielded welding procedures DVS-Nr.: 03.071 / IGF-Nr.: 14.459 B Participating institutes: Prof. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Gas hose influence on humidity-hydrogen-and oxygen problematic during gas-shielded welding DVS-Nr.: 03.068 / IGF-Nr.: 14.426 N Participating institutes: Prof. Dr.-Eng. U. Reisgen, RWTH Aachen, Institute of Welding-and Joining Technology Investigation into MSG soldering of zinc-coated steel sheet, with impulse arc and for use with impulse-driving AC and DC current in the base current phase DVS-Nr.: 03.066 / IGF-Nr.: 14.425 N Participating institutes: Dipl.-Eng. f. Zech, SLV Munich, Section of the GSI mbH Virtually internal sensor for MIG welding applications DVS-Nr.: 03.065 / IGF-Nr.: 13.863 B Participating institutes: Prof. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Plasma-MIG technology application during joining of coated steel materials DVS-Nr.: 03.064 / IGF-Nr.: 13.862 B Participating institutes: Prof. Dr.-Eng. habil. K.-J. Matthes, Chemnitz University of Applied Sciences, Institute of Production Engineering and Welding Technology Use of flat wire electrodes during fully automated MSG welding of fine-grained steel with higher yield strength DVS-Nr.: 03.059 / IGF-Nr.: 13.784 N Participating institutes: Dr.-Eng. St. Keitel, SLV Duisburg, Section of the GSI mbH Process-safe MSG welding of high-alloy specialist materials with low frequency pulsed wire feed DVS-Nr.: 03.062 / IGF-Nr.: 13.787 B Participating institutes: Prof. Dr.-Eng. I. Martinek, Otto-von-Guericke University at Magdeburg, Faculty of Mechanical Engineering, Institute of Joining-and Beam Technology
Investigation into MSG impulse arc welding with interim impulse for AC and DC current application Vorhaben: DVS-Nr.: 03.061 / IGF-Nr.: 13.484 N Participating institutes: Dipl.-Eng. F. Zech, SLV Munich, Section of the GSI mbH Investigations into MSG deposition welding with flat wire electrodes Vorhaben: DVS-Nr.: 03.057 / IGF-Nr.: 13.408 B Participating institutes: Dipl.-Eng. F. Zech, SLV Munich, Section of the GSI mbH Dr.-Eng. M. Ströfer, SLV Halle GmbH Qualification and use of hybrid synergy effects for high performance welding of light metals DVS-Nr.: 03.056 / IGF-Nr.: 13.783 N Participating institutes: Prof. Dr.-Eng. U. Reisgen, RWTH Aachen, Institute of Welding-and Joining Technology 3
MAG-Welding
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Research
DFG/IGF Research Cluster
Arc welding - Physics and Tools
Summary In this research cluster, based on diagnostic welding arc research, a fundamental physical understanding is obtained in close correlation with modelling applications, so that process behaviour can be predicted or estimated via simulation. Parallel to these works, there are user-oriented projects for the implementation under technological aspects. Special emphasis here is placed on a significant improvement in process safety. The torch and control concepts to be developed, synergy-based, also lead to novel metallurgical possibilities (Image 1). Motivation Manufacture of products for all trades, from tank and container to chemical apparatus production, steel-boat-and railway vehicle construction, and also including vehicle and aerospace applications, not to mention the manufacture of athletic devices, furniture or household appliances. All this, independent of individual usage, calls for technologies that allow for material-and application friendly joining of semifinished products, components or building groups. Among the firmly bonded joining procedures, welding – on account of its procedure-inherent characteristics – has now obtained a prime position. Recent developments in arc welding technique, partially supported by public funds, show completely novel possibilities for energy yield control and open up new fields in arc technology regarding operational safety, environmental friendliness and expansion of application fields. A “quantum leap” of industrial market relevance, however, can only be achieved if it becomes possible to both understand and depict via model the fundamental physics of welding arcs in their complexity that is influenced by process gas flow with its partial addition of surrounding gases from the environment, materials transfer of the consumable electrode, metal vapour formation, emission occurrence etc. This insight then allows for new metallurgy control possibilities during solidification that, in turn, leads to control of problematic hot crack formation for many materials and their combinations. Due to the economic significance and the possibilities opening up with high innovation potential, there is a big need for research – both fundamental and application-oriented – especially in the area of MIG/MAG joining processes and 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 follow. Purpose of the Research The research cluster strives to significantly expand both process and application boundaries for arc welding procedures. In the end, we are looking for higher productivity, increased operational safety and less environmental stress. Further, materials or material combinations that hitherto were considered difficult to fusion weld are to be fused with a “novel“ are welding technology. This technology will be capable of adapting to changed environmental conditions like higher tolerance levels and thus lead to a competitive advantage in the overriding process chain through significantly faster laser beam welding process speed. Method The methods supporting the cluster concept are arranged in such a manner as to allow for examination, via diagnostic procedures in any basis-oriented project area, of the processes concerning welding arc or anode and cathode. Material transfer is also under investigation. The purpose here is to obtain a fundamental improvement of knowledge and to make available for modelling the experimentally obtained data. Modelling then strives for comprehensive definition of the MIG process, leading to both process behaviour and process variable becoming predictable. In the area of modelling, there are two fundamentally different approaches: for one, there is modelling on the basis of physical fundamentals and on the other, inverse modelling is to serve for obtaining information
Diagnostics
Experimental analysis of and insight into process connections
Modelling
Mathematical-physical depiction of process connections
Process capability Application
Transfer if process understanding into
“Zero Defect“ (Process Capability) Sensor-less Process Control Metallurgical Effects
Implementation
Image 1: Research Concept Systematic
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Research
about process connections directly from the process itself that are then implemented in a physics-based model. After only 6 of 36 months of project running time, initial results already showed - through a match of simulation and experiment (Image 2) – both the high scientific level and excellent success chances for actual application significance. The fundamental works are closely interconnected and simultaneously influence the application-oriented projects. The arc is to be controlled in such a manner that, on one hand, metallurgy and solidification of molten bath can be systematically influenced in order to, for instance, become better able to handle the problem of hot crack formation via a new process-oriented approach. Further, the processoriented project area is concerned with working out new methods by means of which it will become possible to use the power source itself as a process sensor and, through this, finally achieve significant progress in respect to process capability. Hence, the cluster research allows for an innovation leap in arc welding technology in respect to both process control and process capability.
Research Partners Univ.-Prof. Dr.-Ing. habil. Uwe Füssel Department of Joining Technology and Assembly Institute of Surface and Manufacturing Technology Dresden University of Applied Sciences Prof. Dr .rer. nat. habil. Johannes Kruscha Department of Information Technology/Electronics/Mechanical Engineering Lausitz University of Applied Sciences Prof. Dr.-Ing. Uwe Reisgen Institute of Welding-and Joining Technology RWTH Aachen Prof. Dr.-Ing. Jochen Schein Institute of Plasma Science and Mathematics (LPT) University of the German Federal Armed Forces, Munich Dr. rer. nat. Dirk Uhrlandt Leibniz Institute for Plasma Science and Technology e.V. (INP) Greifswald Prof. Dr. rer. nat. Klaus-Dieter Weltmann Leibniz Institute for Plasma Science and Technology e.V. (INP) Greifswald Univ.-Prof. Dr.-Ing. habil. Johannes Wilden (Coordinator) Fachgebiet Füge- und Beschichtungstechnik Institute of Machine Tools and Factory Operation Berlin University of Applies Sciences
Preamble Arc Cluster
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Image 2: Comparison of Simulation and Experiment; Source: Füssel, Schnick, Härtel, Häßler, Dresden University of Applies Sciences
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Technology
Technical Committee (AfT) of DVS
The technical-scientific cooperative work of DVS is predominantly determined by the activities of its Technical Committee (AfT) with its working bodies oriented to specific subjects. Specialists from the economic and scientific fields, from authorities and from other areas collaborate in them. The Technical Committee promotes the active exchange of experience amongst experts, describes the state of the art by elaborating and contributing to the preparation of a set
of technical rules (DVS technical bulletins, technical codes, guidelines and standards) and is actively involved in the technical development of welding and the allied processes such as brazing/soldering, thermal spraying, adhesive bonding, mechanical joining and plastics joining. Joint committees with the Standards Committee for Welding Technology of DIN also exist for this purpose. 3
Further information at: www.dvs-aft.de
Working groups of the AfT
Secretary and Contact Person for all working groups: Dipl.-Ing. Wolfgang Queren-Lieth Phone: 0211 - 1591-116 Fax: -200 Email: [email protected] In this central area of welding technology, over 400 experts are at work, with special and as a rule process-oriented expert focus, divided into 7 different sub-groups and 38 different task forces. Working groups (Selection) WG V 2.1 “Metal arc welding“ WG V 2.3 “Arc welding with non-consumable electrode” 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 performance 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 roboting“ WG V 2.7 „Welding with filler wire“ Joint undertakings, contribution to standard DKE 361 “Electric Arc Welding Equipment“ and setting up of the annual arc colloquium together with the Expert Committee 3 “Arc Welding“ are all tasks that are generally coordinated on an annual basis through the circle of representatives. The WG V 2 is in correspondence with the following working units of the International Institute of Welding (IIW) Commission II “Arc Welding and Filler Metals “ Commission IX “Behaviour of metals subjected to welding “ Commission XII “Arc welding processes and production systems “ 3
Working group V 2 „Arc welding“
Chairman: Prof. Dr.-Ing. Rolf Felleisen Schweißtechnische Lehr- und Versuchsanstalt Mannheim GmbH Vice-Chairman: Dr.-Ing. Reinhard Winkler SLV Duisburg, Section of the GSI mbH Website: www.dvs-aft.de/AfT/V/V2
Metal arc vertical up seam
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Technology
Essential work results DVS technical bulletins and technical codes (Selection)
Process and Materials Classification: 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 filler wire F Instrument engineering, automation, equipment G Welding of steels H Welding of NF and light metals
DVS technical bulletins and technical codes DVS 0966-1 Plasma-MSG welding – Instrument engineering DVS 0964 Submerged arc double wire welding DVS 0958 Covered electrodes - efficiency, metal recovery and deposition coefficient – work sheets and calculation aids DVS 0957 Handling of covered electrodes - Transport, storage and redrying DVS 0955 Welding-based processing of nickel-alloyed steels for low temperature applications DVS 0951 Specialist steel with elevated wear-resistance DVS 2710 Additional equipment for mechanical TIG and plasma welding; characteristics and requirements DVS 0949 Tubular-cored electrodes for MAG- and SAW welding of ferritic steel castings creep resistant at elevated temperatures DVS 0948 Submerged arcs welding and its procedure variants DVS 0946 Recommendations for welding of stainless austeniticferritic duplex- and super duplex steels DVS 0945-1 Verification of welded and wearresistant depositions Abrasive wear DVS 0943 High-alloy electrodes DVS 0942 Welding with covered electrodes – Pore formation and avoidance DVS 0941-2 Tubular-cored electrodes for MAG- joint welding – characteristics and application areas DVS 0941-1 Tubular-cored electrodes for joint- and deposition welding – principles and terminology DVS 0940 Submerged arc deposition welding with strip electrode
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Technology
DVS technical bulletins and technical codes DVS 0938-1 Arc soldering – principles, processes, installation engineering requirements DVS 0937 Root protection during gas-shielded welding DVS 0936 Submerged arc narrow-gap welding DVS 0935 Electroslag deposition welding with strip electrode DVS 0934 TIG welding; devices and equipment DVS 2714 Welding devices for manual and fully automated TIG welding – Requirement determination (especially for aerospace applications) DVS 0932 MAG set-up practice - Process- and component dependent influences on seam geometry DVS 0931 MAG welding of non-corrosive, austenitic steels DVS 0928 Submerged arc welding of austenite-ferrite joints DVS 0926-2 Wire feed, tube package and torch requirements for gas shielded metal welding DVS 0926-1 Energy source requirements for gas shielded metal welding DVS 0925 MAG welding of thick sheet metal DVS 0923-1 to -4 Testing of welding powders for weld-related characteristics in submerged arc welding applications DVS 0921 Load diagrams for rotary tables and rotary tilting tables DVS 0920 Tungsten inert gas welding (TIG) - principles DVS 0919 Tungsten plasma arc welding DVS 2707 Plasma arc welding – process overview, gas selection and welding parameters DVS 0918 Submerged arc welding of fine-grained steels DVS 0917 Submerged arc welding of austenitic steels DVS 0916 Metal gas-shielded welding of fine-grained steels DVS 0915 Submerged arc multiple electrode welding DVS 0914 Processing and storage of welding powders for submerged arc welding DVS 0913-1 to 3 MIG welding of aluminium – Material-related basics / devices, processes, auxiliary materials / application-oriented notes ----------
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Technology
DVS technical bulletins and technical codes DVS 0912-1 to 2 Gas-shielded metal arc welding of steel; Guidelines for process execution – Prevention of incomplete fusion DVS 0911 Tungsten electrodes for tungsten insert gas welding – Application-oriented notes DVS 2716 Tungsten electrodes for tungsten insert gas welding – Requirements for aerospace applications DVS 0909-1 and -2 Principles of MSG high performance welding with solid wire electrodes – Definition and terminology / Application-oriented notes DVS 0907-1 to 3 Determination of heat input and burn-off for SAW flux – heat input and burn-off lines / Flux diagram / Application of flux diagram DVS 1502-1 and 2 Manual arc welding of ductile cast iron pipes – Principles of welding engineering / Welding of parts of ductile cast iron or steel DVS 0601 Welding of nickel and nickel alloys DVS 2713 Welding of titanium materials - Materials, processes, manufacture, inspection and evaluation of weld joints with supplementary sheet 1: Sample images of heat tinting
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Electrode Contact Piece Powder Funnel
Cavern with implied arc Flux
Liquid Solid Slag Molten Bath with Flow Direction Preferred Drop Transfer Weld Seam Melting-solidification Front Heat Affected Zone Basis Material
Progress of Weld
Submerged arc welding
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Technology
Standards (Selection)
DIN EN ISO 9692-1 Welding and allied processes – Recommendations for joint preparation Part 1: Manual metal-arc welding, gas-shielded metal arc welding, gas welding, TIG welding and beam welding of steels DIN EN ISO 9692-2 Welding and allied processes - Joint preparation Part 2: Submerged arc welding of steel DIN EN ISO 9692-3 Welding and allied processes – Recommendations for juncture forms Part 3: Metal inert gas welding and tungsten insert gas welding of aluminium and aluminium alloys DIN EN ISO 15609-1 Specification and qualification of welding procedures for metallic materials – Welding procedure specification Part 1: Arc welding DIN EN ISO 15614 Specification and qualification of welding procedures for metallic materials – Welding procedure test - Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys - Part 2: Arc welding of aluminium and its alloys - Part 3: Fusion welding of non-alloyed and low-alloyed cast irons - Part 4: Finishing welding of aluminium castings (with correction) - Part 5: Arc welding of titanium, zirconium and their alloys - Part 6: Arc and gas welding of copper and its alloys - Part 7: Overlay welding - Part 8: Welding of tubes to tube plate joints
DIN EN 1011 Welding – Recommendations for welding of metallic materials - Part 1: General guidance for arc welding - Part 2: Arc welding of ferritic steels - Part 3: Arc welding of stainless steels - Part 4: Arc welding of aluminium and aluminium alloys - Part 5: Welding of clad steel - Part 8: Welding of cast irons DIN EN 50504 Validation of 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 feeders - Part 6: Limited duty manual metal arc welding power sources - Part 7: Torches - Part 8: Gas consoles for welding and plasma cutting systems - Part 9: Installation and use - Part 10: Electromagnetic compatibility (EMC) requirements - Part 11: Electrode holders - Part 12: Coupling devices for welding cables - Part 13: Return current clamp
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MAG-Welding
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Education
Specialist Books (Selection – in German only)
Specialist Book Series Welding Techniques Volume 130 J. Schuster: Schweißen von Eisen-, Stahl- und Nickelwerkstoffen Specialist Book Series Welding Techniques Volume 76/I R. Killing: Handbuch der Schweißverfahren Teil I: Lichtbogenschweißverfahren Specialist Book Series Welding Techniques Volume 63 P. Müller, L. Wolff: Handbuch des Unterpulverschweißens Part I and Part II: Part I: Verfahren, Einstellpraxis, Geräte, Wirtschaftlichkeit, Part II: Schweißzusätze und Schweißpulver Part III: Draht/Pulver-Kombinationen für Stähle - Schweißergebnisse - Schweißparameter Part IV: Schweißen mit Strip electrode Part V: Berechnung und Gestaltung von Schweißkonstruktionen - Schweißtechnologie - Anwendungsbeispiele Specialist Book Series Welding Techniques Volume 141 D. Radaj: Schweißprozeßsimulation, Grundlagen und Anwendungen Specialist Book Series Welding Techniques Volume 84 M. Schellhase: Der Schweißlichtbogen - ein technologisches Werkzeug
Specialist Book Series Welding Techniques Volume 133 Dipl.-Ing. R. Trillmich, W. Welz: Bolzenschweißen Grundlagen und Anwendung Practical Welding Techniques Volume 2 W. Marfels, L. Orth: Der Lichtbogenschweißer Leitfaden für Ausbildung und Praxis Practical Welding Techniques Volume 14 Dipl.-Ing. G. Aichele: 140 Arbeitsregeln für das Schutzgasschweißen Practical Welding Techniques Volume 34 L. Baum, S. Pommer: Der Schutzgasschweißer Teil 1 WIG-/Plasmaschweißen Practical Welding Techniques Volume 35 L. Baum, S. Pommer: Der Schutzgasschweißer Teil 2 MIG/MAG-Schweißen DVS Reports Volume 249 J. Wilden, D. Bartout, F. Hofmann: Lichtbogenfügeprozesse - Stand der Technik und Zukunftspotenzial DVS Reports Volume 190 C. Lorenz: WIG-Orbitalschweißen von Rohr/ Rohrverbindungen aus Aluminiumwerkstoffen DVS Reports Volume 87 Schutzgasschweißen 3
The specified publications can be purchased via DVS Media GmbH: DVS Media GmbH ·Aachener Straße 172 · D-40223 Düsseldorf · Tel.: 0211 / 1591-162 · [email protected] · www.dvs-media.info
Education Committee (AfB)
Personnel qualification in DVS
The Education Committee (AfB) of DVS elaborates and structures the range of training and further education offered by DVS in the fields of joining, cutting and coating. It follows tendencies and trends as well as concrete developments in the education sector and evaluates their effects on society in general and on the areas of joining, cutting and coating in particular. AfB is oriented to the latest state of the art and to the needs of the German economy. Due to the close network of DVS, the structures of the society are used optimally, the latest findings are exchanged across bodies and there is feedback about the current needs. DVS thus offers the expert world of joining technology, members and interested people a comprehensive range of competitive solutions for joining technology. 3
Further information at: www.dvs-afb.de 18
Education
Arc welding is part of any fundamental training in welding technology, whether for welders or as part of practice oriented training or training as a welding supervisor. From the wide range of DVS® training courses available, the following list provides a selection with special arc welding elements:
Practical Training (Selection)
Coordination: K. Andreé, SL Magdeburg Secretary: Dipl.-Ing. Christoph Esser-Ayerty Phone: 0211 – 1591-178 Fax: -200 Email: [email protected]
Theoretical Training (Selection)
Coordination: Dipl.-Ing. Ch. Ahrens, SLV-Duisburg Secretary: Dipl.-Ing. Michael Metzger Phone: 0211 – 1591-177 Fax: -200 Email: [email protected]
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 gasshielded 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, gasshielded welding DVS® 1148 Exams for welders, Manual arc welding of ductile cast iron pipes DVS® 1149 DVS Course: Training and certification of 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
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 for reinforced steel welding DVS®/EWF/IIW 1178 International Welding Quality Inspection Staff (IWIP) DVS® 1109 Welding Supervisor Staff (WSS) – Rail vehicle construction DVS® 1179 Welding Supervision – Add-on training for aluminium welding DVS®/EWF 1198 Specialist courses for training or further training in laser beam welding – for engineers. Technicians, specialists – 3
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