dssobral97
New Member
- Messages
- 2
- Location
- Portugal
Hello
I work at an exhaust system producing factory for various types of vehicles, in Europe.
We've been having problems with a TIG welding roller forming machine at my work, the photos bellow will show you.
Basically, we have this machine that uses TIG welding on a metal plate that is rolled previously (in the same machine).
The plate, now rolled into a can, goes inside a welding cage, where it's guided by two wheels that press both ends together and moves forward (with the assistance of a mechanical pusher) as the weld is made. The welding torch is stationary, the height is adjustable through a HMI.
Then, the can goes through an expanding device to reach the desired diameter of the rolled plate.
I cannot go into details on the characteristics and model of the machine, as it is one of a kind and confidential, so there isn't anything about it out there.
The problem is (as you can see in the pictures): The weld cracks at the end (sometimes at the beginning too), after it goes through the expanding device.
We are able to adjust the desired diameter, we could put it lower and solve the problem, but then the product isn't compatible with the next procedures, as the diameter isn't enough to produce a good part.
We've tried multiple things: Adjusting welding parameters (lower and higher amperage, lower and higher voltage, distance at which the welding starts and stops, we've switched the TIG torch, we've checked if there's any gas leak and if the gas system is working properly) but nothing seems to work.
We thought it was a problem in the rolling area, as it seems like the plate's end don't meet eachother close enough, but it isn't, as we've adjusted the rolling section to put them as close as possible together, and they only tear apart after the expanding process.
We can't prolong the weld much more, as it creates holes in the end of it, as a result of lack of material I guess.
If you have any idea what might cause this I appreciate the help
I will leave some information that might be useful:
- The welding rod is 3,2mm in diameter and the angle accepted by the machine is 30º
- The welding machine is a Fronius Kuhlgerat FK 4000-R FC
- The usual voltage we use to weld is 10V, it's the only way we can get acceptable penetration
- The amperage is always around 190A-200A
- The protective gas we use is Argon
If you need any other information that I might be able to provide, please ask.
I work at an exhaust system producing factory for various types of vehicles, in Europe.
We've been having problems with a TIG welding roller forming machine at my work, the photos bellow will show you.
Basically, we have this machine that uses TIG welding on a metal plate that is rolled previously (in the same machine).
The plate, now rolled into a can, goes inside a welding cage, where it's guided by two wheels that press both ends together and moves forward (with the assistance of a mechanical pusher) as the weld is made. The welding torch is stationary, the height is adjustable through a HMI.
Then, the can goes through an expanding device to reach the desired diameter of the rolled plate.
I cannot go into details on the characteristics and model of the machine, as it is one of a kind and confidential, so there isn't anything about it out there.
The problem is (as you can see in the pictures): The weld cracks at the end (sometimes at the beginning too), after it goes through the expanding device.
We are able to adjust the desired diameter, we could put it lower and solve the problem, but then the product isn't compatible with the next procedures, as the diameter isn't enough to produce a good part.
We've tried multiple things: Adjusting welding parameters (lower and higher amperage, lower and higher voltage, distance at which the welding starts and stops, we've switched the TIG torch, we've checked if there's any gas leak and if the gas system is working properly) but nothing seems to work.
We thought it was a problem in the rolling area, as it seems like the plate's end don't meet eachother close enough, but it isn't, as we've adjusted the rolling section to put them as close as possible together, and they only tear apart after the expanding process.
We can't prolong the weld much more, as it creates holes in the end of it, as a result of lack of material I guess.
If you have any idea what might cause this I appreciate the help
I will leave some information that might be useful:
- The welding rod is 3,2mm in diameter and the angle accepted by the machine is 30º
- The welding machine is a Fronius Kuhlgerat FK 4000-R FC
- The usual voltage we use to weld is 10V, it's the only way we can get acceptable penetration
- The amperage is always around 190A-200A
- The protective gas we use is Argon
If you need any other information that I might be able to provide, please ask.