Kemppi: changing the welding in India

August 12, 2013 12:02 pm

Rashmi Ranjan Mohapatra, National Sales Manager, Kemppi India explains the innovation in the field of welding and Kemppi’s roleBrief us about the latest technology development in the field of welding.Welding is an integral part in manufacturing. Technology has a major impact in this field. Known to be a “blue collar” job it has come a long way shedding its image.
The welding process consists of equipment and consumable to create a fusion. Welding equipment are manufactured based on certain technology. The evolution of technology was in the order of diode-based, thyristor-based, chopper-based, and MOSFET-based.
However, the latest technology in welding equipment is Inverter-based; many of us may say IGBT (Insulated Gate Bipolar Transistor) inverter too. The technology change has impacted the size and ergonomics aspect of the welding machine. The future generation machines from KEMPPI are pretty compact and deliver more than the conventional machine.
Besides the major shift in design, the modern welding equipment are embedded with software to address the challenges faced by the welders and take welding to a different level.
Kemppi has been a pioneer in inverter technology in the field of welding. We have introduced inverter-based welding machine in 1977.
Our latest offering to the welding industry is the “ARC Q” system. This is again a first for the industry. ARC Q is a welding management system which takes the welding to a different domain.
What measures have you taken to make welding process energy efficient?The whole reason of inverter taking prominence in welding is to save power. Secondly, the high power factor, some term it as cos Ø, in inverter-based machines makes these as energy efficient.
All the Kemppi machines are energy efficient. Our machines save 50 per cent cost in power vis-à-vis other conventional machines (Thyristor). Moreover, the high power factor of 0.95 to 0.99 signifies that the whole input power is consumed for welding alone bringing in a high degree of efficiency.
Energy efficient is synonymous to Kemppi machines. But our software help the customers improve their productivity and quality. What are the factors considered while choosing a welding process for a specific process? The selection of the welding process and the welding procedure and technique is as important as the selection of the deposit alloy. Almost all the arc welding processes and several others can be used for the application of hard facing weld metal.
The shielded metal arc welding process is probably the most commonly used of any of the welding processes for hard facing. It can be used in the field and in the shop and can be applied to small and large parts in any position.
Submerged arc welding is also used for many applications but it is restricted to welding in the flat position. Most often it is used for plant operations and not used in the field. It is often used for repeating applications when the same part is surfaced on a routine basis.
Flux-cored arc welding with and without shielding gas is a popular semiautomatic welding process. It can be used in the field or in the shop and is not restricted to the flat position.
The gas tungsten arc welding process is used for many smaller applications, usually for shop work in which the part can be brought to the shop and manipulated and moved for ease of welding. Gas tungsten arc can be used manually or in an automatic mode with automatic wire feeders, oscillators, etc. It is more expensive than the other processes and for this reason is restricted to the more technical type jobs.
Plasma arc welding is also used much in the same manner as gas tungsten arc. It does have a higher temperature and for this reason can be used in certain cases where gas tungsten arc welding is not applicable. It is again restricted to the smaller types of jobs. The electroslag welding process is also used for certain special applications. It has been widely used for rebuilding crusher hammers. These can be rebuilt with special fixturing and done quite rapidly with the electroslag process.
Oxyacetylene welding is also used for certain applications. It is widely used for application of specialised cobalt alloys on relatively thin edges.
In general, the process is selected based on normal process selection factors and modified by some of the above comments. Once the process is selected, the next requirement is the selection of the deposited metal to provide the necessary properties.
What are the initiatives taken to reduce the emission of welding fume during the process?At Kemppi, we are concerned about the occupational hazard of the welder. While it is easier to say that the fume is created by the consumable. For example, the flux or the burning of wire creates the fume in the welding process.

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