“Hitsauksen kehityksestä
kaasumiehen silmin”
Pauli Toiviainen, AGA Pohjois-Euroopan Regioona
Already the old Egyptians…
Welding by combination of heat and pressure has been used from at least 5000 b.C.
This was the only method until the 1880’s
Milestones in welding from 1880
Electron beam
Plasma welding
Covered
Metal arc TIG MIG
electrodes
Carbon Submerged MAG Laser
Oxy Acetylene
arc arc (CO2) welding
1880 1890 1900 1910 1920 1930 1940 1950 1960 1970
Development 1940’s-1980’s
1940’s : Innovation of TIG and MIG/MAG in the US
1960’s : The methods are spread commercially
1970’s : MAG welding becomes the dominating method in W. Europe (instead of
MMA)
1978 : MISON shielding gases for better working environment
1980’s : Robot welding
Note the drum pack for filler wire (AGA 1960’s)
Development 1990’s
• High deposition rate MAG welding
– RAPID PROCESSINGTM (AGA)
– T.I.M.E. Process (Fronius) RAPID Conventional
PROCESSING MAG
– Twin Arc/Tandem welding
Plate thickness [mm] 3 3
• MIG brazing
Welding speed [cm/min] 120 60
Deposition rate [kg/h] 5 2,5
RAPID Conventional
PROCESSING MAG
RAPID ARC®
• High productivity MAG welding process
• Standard equipment is used
• Mechanized welding
• Shielding gas with low CO2-content
Shielding gas development (steel welding):
• Lower CO2-content (8-10% in Argon)
Conventional MAG, v = 160 cm/min
RAPID ARC®, v = 160 cm/min
Tandem-MAG
• Higher deposition rate
• Higher welding speed
• Accessibility may be limited (bigger welding head)
• More programming due to two arcs
• Difficult to minimize spatter
• More sensitive process
• Harder for operator to fine tune
Shielding gas development (steel welding):
• Lower CO2-content (8-12% in Argon)
• Helium addition
Development during 2000’s
• New variants due to better and faster electronics
– CMT (Fronius)
– Cold Arc (EWM)
”Cold” processes
– AC-MIG/MAG (OTC)
– Etc..
• Hybrid welding
– Laser-MAG
– Plasma-MAG
“Cold” processes - benefits
Welding of thin material:
– Less distortion
– Almost no spatter
– Possible to substitute TIG-welding
– Better gap bridging Stainless steel, 0,5 mm
Overlap
– Suitable for MIG-brazing Filler metal 0,8 mm
Welding speed: 2,0 m/min
Shielding gas development (according to Fronius):
• No influence of shielding gas
– Pure CO2 (steel welding)
– Pure Argon (brazing and Ni-base welding)
Manual MIG-brazing
Filler metal: 1,0 mm CuSi3
Gap: 4 mm
No influence of shielding gas with CMT?
Base material: carbon steel, Filler: alloy 625, cladding
CMT
CMT pulsed
Argon Ar+0,05%CO2+30%He+2%H2
Hybrid welding with laser-MIG/MAG
• Lower laser energy compared to laser welding
– Arc energy is added
– Arc decrease reflection of laser beam
• Higher welding speed
• Lower heat input
• Better tolerance to gap variations
MA
G
Shielding gas development (steel welding):
• “Normal” mixtures works fine
• Optimization still ongoing Lase
r
Laser-
MAG
Trends for shielding gases - MIG/MAG & TIG
Driven by development of power sources
• MAG-welding of carbon steel with pure CO2 or 82/18-mixture
– Fast, reliable electronic control of power sources
Driven by development of construction material
• Nitrogen addition (TIG)
– Duplex and Superduplex
– Lean duplex
• Micro additions of CO2 and O2 in Argon (MAG)
– Ni-base alloys
– Other high alloyed materials
• Helium addition (TIG and MIG/MAG)
– All high alloyed materials
Shielding gas components, TIG
Standard Added value
Ar + NO + He + H2 + N2
Base gas
Work environment
•Ozone reducing
•(Arc stability)
Productivity
•Fluidity
•Wetting
•Penetration
Productivity
•Fluidity
•Wetting
•Penetration Metallurgy
•Reducing •Corrosion
•Strength
Shielding gas components, MAG
Standard Added value
Ar + CO2 + O2 + NO + He
Base gas
Arc stability
Work environment
•Ozone reducing
Productivity
•Fluidity
•Wetting
•Penetration
Trends for shielding gases - Laser
Driven by development of lasers
• CO2 Laser-welding of carbon steel
– Helium replaced by:
– Argon/CO2-mixtures
– Argon/Helium-mixtures
• Diode laser welding of carbon steel
– Argon/CO2-mixtures
Weld Metal consumption 1974-2006
14000
Gross weight 14,400 ktons Gross weight 12,610 ktons
12000
10000
8000
Tons
6000
4000
2000
0
1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006E
Year
MMA MIG/MAG FCAW SAW
•Source: ESAB
Shieding Gases volume development, North
Europe
REN
7 000 000 M3
6 000 000 M3
5 000 000 M3 GAR
CORGON
4 000 000 M3 MISON PURE
MISON 8
3 000 000 M3 MISON 18
MISON 25
2 000 000 M3 Result
1 000 000 M3
0 M3
2004 2005 2006 2007 2008 2009 2010 2011 2012
Gustav Dalen 1904
”Auta asiakasta parantamaan
toimintansa kannattavuutta,
laatua ja turvallisuutta”
