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Next generation high productivity submerged arc welding
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.).
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.).
2012 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesisAlternative title
Nästa generations högproduktiva pulverbågssvetsning (Swedish)
Abstract [en]

The task of designing concepts for the next generation of submerged arc welding heads was given by ESAB. ESAB is a global company manufacturing welding equipment for a wide span of industries and uses. In October 2011, ESAB introduced a new technology called Integrated Cold Electrode™, abbreviated and trademarked as ICE™. ICE™ is a technique which utilizes three electrodes in a highly productive and stable process. The current state of the ICE™ technique focuses on welding thick plates with conventional joint types such as x- and v-joints. The next phase in the development of the technique is to be able to weld milled 16/8°-joints which are developed by German company Graebner. This kind of joint determines the requirements of the next generation of ESAB’s equipment for submerged arc welding.Simultaneously as designing the welding torch being able to weld the 16/8°-joint, a concept for a highly customizable modular head was developed enabling the possibility to tailor the submerged arc welding process according to the customer’s precise needs.A progressive conceptual development has been conducted in close collaboration with ESAB. Theoretical models have been developed to evaluate thermal-electric behavior of the welding torches to obtain plausible dimensions for the electric conductors to withstand the effects caused by joule heating. Deliverables for the project has been well defined 3D CAD-models while a prototype was not included in the scope of the project.One concept for the 16/8° joint is presented as the Narrow Joint Concept, NJC, which fulfills the requirements specified. The NJC is developed with focus on smart design with low manufacturing cost as well as ease-of-use for the operator. NJC brings ICE™ into narrow joints.The Modular Head Concept, MHC, presents an idea how to create a fully customizable process with the possibility to emulate the ICE™ technique

Abstract [sv]

Uppdraget att utveckla nästa generation pulverbågsutrustning gavs av företaget ESAB. ESAB är ett globalt företag som tillverkar svetsutrustning för ett brett spann av branscher och användningsområden. I oktober 2011 lanserade ESAB en ny teknik vid namn Integrated Cold Electrode™, ICE™. ICE™ är en teknik som utnyttjar tre stycken elektroder i en högproduktiv och stabil svetsprocess. I dagsläget fokuserar ICE™-tekniken på att svetsa konventionella fogtyper såsom x- och v-fogar i tjocka plåtar. Nästa fas i utvecklingen av tekniken är möjligheten att svetsa frästa 16/8°-fogar som det tyska företaget Graebner utvecklar. Denna typ av foggeometri ger kraven för ESAB’s nästa generation pulverbågsutrustning.Simultant togs koncept fram för att möjliggöra skräddarsydd utrustning efter kunders specifika processbehov.En progressiv konceptutveckling har utförts i nära sammarbete med ESAB. Teoretiska modeller har tagits fram för att utvärdera de termo-elektriska egenskaperna hos de utvecklade svetshuvudena så att dessa kan motstå den resistiva uppvärmningen som sker i de elektriska ledarna. Då en prototypframtagning ej låg inom ramen för arbetet har detaljerade 3D CAD-modeller producerats.Konceptet för 16/8°-fogen kallas Narrow Joint Concept, NJC, och uppfyller de uppställda kraven. NJC är framtaget med fokus på smart konstruktion där låg tillverkningskostnad och enkel användning har premierats. NJC sammanfogar ICE™ och smala fogar.Det modulära konceptet kallat Modular Head Concept, MHC, representerar en idé för att skapa skräddarsydda lösningar efter kunders behov. MHC äger förmågan att fungera som ett ICE™-huvud.

Place, publisher, year, edition, pages
2012.
Series
2012:73 MKN 069
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:kth:diva-148055OAI: oai:DiVA.org:kth-148055DiVA: diva2:734712
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Available from: 2015-03-06 Created: 2014-07-21 Last updated: 2015-03-06Bibliographically approved

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