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Material Welding procedure Sector Container and apparatus construction Crane construction Mechanical engineering Mechanical engineering supplier Rail vehicle construction Steel: unalloyed and low-alloy forceArc Vehicle construction Reference Page
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Steel and staircase construction Shipbuilding Steel: galvanised Car manufacturer coldArc Automotive supplier Container construction Steel: high-tensile, fine grain Vehicle construction forceArc Crane construction Steel and plant construction coldArc Home appliances manufacturer Automotive supplier Pipe manufacturing Mechanical engineering supplier Aluminium construction
Meiser Meyer Werft VW NEEF CRH Viessmann John Deere Liebherr Manitowoc Plauen Stahl Miele IBG Schller VIS alwitra
CrNi
Steel: high-alloy
Al
Aluminium
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Economic bene ts
The company Scholz has been able to reduce production times by around 50 percent using EWM-forceArc. In the process, the pure productivity gures were increased by 30% using a spray arc instead of the MIG/MAG welding process. The constricted arc achieves very deep fusion penetration. Scholz was also able to reduce its welding times due to the lower number of welding layers and the reduced amount of materials and time required. Further cost savings were achieved via the changeover from cored to solid wire.
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Crane construction
One of the leading innovators in crane manufacturing is Voith-Werke based in Traun, Austria. Andreas Lackner, Managing Director, explains: We deliver quality, something that is clear right from the weld seams. PHOENIX power sources combined with forceArc provide unprecedented levels of efciency and quality. For example, previously the 12 m metal sheet for a beam had to be prewelded with a butt joint manually, with the nal pass being added using an MMA process. We are now using forceArc for all layers. Andreas Brunmair, welding engineer at Voith, adds: On our mechanised welding line, we produce seams of up to 60 metres in length. Thanks to EWM, we can now interconnect two PHOENIX 521 power sources and generate welding current of up to 1,000 amperes. We move along extralong seams requiring up to an hour to weld to 450 amperes on a 100% duty cycle. Andreas Brunmair (left), Welding Engineer Andreas Lackner, Managing Director Voith-Werke, Traun Austria
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Mechanical engineering
After six months of practical experience we are so impressed with the EWM forceArc process combined with the fully digital inverter power source PHOENIX 500 EXPERT PULS that we are going to convert our entire production process to the new process/machine combination, summarised Rudy Day, Production Manager at AMADA in Charleville Mezieres, France, who is delighted with his production accelerator from Mndersbach, Germany. Rudy Day, Production Manager Amada, France
Steel: unalloyed and low-alloy forceArc Manual PHOENIX 500 EXPERT forceArc
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We now manufacture 260 mm metal sheets with 130 layers instead of 180 layers as previously!
Austrian supplier ISW steel components from Ennsdorf builds heavy duty components, weighing up to 80 tonnes, for tool machine manufacturers. Joining technology is the top priority. As owner Gerhard Limberger says: With forceArc, each weld seam can now be produced faster and with less spatter, as well as with considerably less distortion of the work piece and no undercuts. forceArcs short spray arc has such high directional stability that it never deviates from the target, even with free wire ends of 40 mm. With forceArc we save a great number of ller layers, which reduces costs when it comes to ller wire, shielding gas, energy and nishing work.
Steel: unalloyed and low-alloy forceArc Manual PHOENIX 521 PULS forceArc
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ROMVAG
for the production of superstructures for goods wagons and rail tankers
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MEDIAS
Vehicle construction
MEDIAS, Romania
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PHOENIX 521 PULS forceArc power sources are the key to our success, says Gnter Alhuser, Managing Director of steel construction company INKON. INKON is one of the leading providers of modular noise protection walls. Alhuser adds: Thanks to forceArc, production costs were cut by around 35%. For the full connections we weld with forceArc to produce noise protection walls for Deutsche Bahn, no preliminary work is necessary and we can weld the base plate with steel support as a butt joint. Now we only weld two layers rather than three previously, thereby saving on preliminary work, welding time, energy, ller material, shielding gas and nishing work. Following these results we immediately barred all other welding machines from our production site. Eckhard Blcher (left), Dipl.-Ing., SFI Gnter Alhuser, Managing Director INKON GmbH, Hhn
Steel: unalloyed and low-alloy forceArc Manual PHOENIX 521 PULS forceArc
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Involved in a wide range of activities, Hendriks Staalbouw is one of the leading steel and mechanical engineering companies in the Netherlands. The company relies on MIG/MAG welding technologies in a big way and is now convinced that they work about twice as fast with the EWM-forceArc process.
for the production of inner and outer rings for steel-core pipes
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Several equipment suppliers called on us during the offer phase. STM offered us the innovative welding solution from EWM and demonstrated it to us. For our welding tasks, which are carried out completely by hand in 2-shift operation, the forceArc process is a real blessing. With its powerful and directionally stable arc it allows for very deep welding with fusion penetration that we could never achieve with conventional MAG processes. This makes smaller welding joints possible, thereby considerably reducing the amount of welding material required. EWM-forceArc can work with a free wire end of 35 to 40 millimetres and can therefore dip deeply into the narrow joint. In doing so, the arc remains absolutely stable and locked onto the operating point. For the range of goods we manufacture joining large and thick metal sheets, pipes and proles there is no more cost-effective alternative in my opinion. Heinrich Baumgrtel (left), SIBAU Managing Director Olaf Krause, Expert Welding Engineer SIBAU Genthin GmbH & Co. KG, Genthin
Steel: unalloyed and low-alloy forceArc Manual PHOENIX 521 PULS forceArc
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20 Phoenix 521 Puls forceArc power sources as efcient as it is future-proof: No other machine on the market produces such a powerful and exceptionally directionally stable arc; the benets are invaluable, particularly in conned working conditions. Essentially, forceArc produces even seams and practically no spatter reducing cleaning time alone by percent. In addition, forceArc offers a wide range of advantages: for instance, the preparation angle of the welding seam can be signicantly smaller or even eliminated completely even full penetration welds are possible without any preparation angle whatsoever. Furthermore, weld seam backing can often be dispensed with. This saves costs for wages, materials, gas and energy, as well as reducing production times throughout the process chain. From left: Branch manager and authorised representative Dipl.-Ing. Wilfried Handt, Head of production Dipl.-Ing. Werner Meyer P-D Industriegesellschaft mbH, Stahlbau Calbe
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Foto Meiser
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Shipbuilding
The Meyer Werft shipyard of Papenburg, Germany has an excellent reputation around the world. For engineers at Meyer Werft, having access to advanced and e cient production methods is an indispensible part of innovative shipbuilding. Their new laser centre contains an important new development in welding technology: 64 Phoenix-type welding systems with EWM forceArc, likely the most sought-after joining process for these types of welding tasks. Meyer carefully considered the nancial and technological bene ts like those provided by the complete, customised solution. The advanced machines arranged above the workpieces weld more quickly and with greater precision than conventional systems. This is an important advantage, particularly when welding meter-long seams.
for shipbuilding
Manual PHOENIX 521 PULS
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Steel: galvanised, unalloyed and low-alloy coldArc welding Manual PHOENIX 303 PROGRESS PULS coldArc
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Steel: galvanised
coldArc
Automotive supplier
For Berndt Heuter, welding engineer at automotive supplier NEEF, the case is clear: coldArc works extremely well even with exceptionally long free wire ends. This opens up a host of new options when it comes to design. The new EWM welding power sources are also proving their abilities in production because they are fully compatible with welding robots made by KUKA, FANUC and Reis, offering optimum quality in the process. In the past, we had problems with spatter. With coldArc, we are now achieving outstanding seam finish with exceptionally low spatter, adds Heuter. There is also excellent free wire stickout for tight seam openings.
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Automotive suppliers
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Container construction
The current task for EWM-forceArc is welding a full penetration weld on a boiler. The process reduces the welding time for the pronounced seam root required, we only need to carry out one final pass and the amount of work we used to have to do in terms of grinding is also reduced considerably. For a specic welding task and a weld seam opening angle of 30 degrees we have been able to reduce the target time by around 20 percent. This includes a saving of around 75 percent in grinding work, the reduced amount of energy required and lower costs for filler metals. In total the overall savings were over 40 percent! Close contact as well as expert support have ensured rapid success. We have already identied the next application for forceArc and other EWM systems. Dipl.-Ing. Markus Leutloff Technical Production and Welding Manager
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Vehicle construction
As a factory within the factory we have to keep an eye on production costs; high unit volumes are required. 27 robot systems working in 3-shift operation weld up to 250 cabs a day for agricultural and forestry machinery. Each cab has over 300 weld seams, all of which must be perfect. The reliability of the welding power sources is an important productivity factor here: We are able to rely on the PHOENIX from EWM around the clock, and the service provided by our EWM partner is unparalleled. We are completely satised on all counts. For two years now we also have been using the process innovation EWM forceArc at a critical point in the production sequence. The targeted arc has enabled us to reduce lead times considerably. Peter Kapferer Manager, Business Unit Welding John Deere Werke, Bruchsal
for the production of drivers cabs for agricultural and forestry machinery
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Problem solved: the reliable welding process is the decisive factor at Liebherr
forceArc stays on track There are seams on some components that are difcult for the welding torch to reach when using the MAG standard process, in spite of the well thought-out design. The powerful arc provided by forceArc helps us here as well. It burns with a concentrated arc and always follows the joint line, even with a very long free wire end (stick-out up to 40 millimetres). forceArc has provided us with the promised process reliability that we had hoped for, making it clearly superior to the conventional MAG process and signicantly increasing the quality of the welding seams. From right: Dipl.-Ing. Reinhard rtl, Otto Schrode, Sascha Wilde and Thomas Weissenberger
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Powerhouses from Wilhelmshaven forceArc revolutionises welding in the crane construction sector
Crane construction
The Manitowoc Cranes factory in Wilhelmshaven produces mobile and telescopic hydraulic cranes with capacities ranging from 80 to 450 tons (Fig.1). As everywhere in steel construction, welding technology is the key production factor. After having experienced the innovative forceArc welding process for one year, the welding engineer and production manager Dipl.-Ing. Michael Hneke speaks of possibilities that had been considered impossible in welding so far: We are now able to weld full penetration welds with a dened llet weld on the seam root without weld pool backing and chamfering. I am convinced that forceArc will be our future course for further joining applications. Dipl.-Ing. Michael Hneke Production Manager (left). Next to him: Wilfried Nowatzki (master welder), Reinhard Hansemann (quality) and Oliver Tunger (quality)
Crane construction
Manual PHOENIX 521 PULS forceArc
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Our intention with forceArc was to make the MAG joining process even more reliable; we achieved a great leap in quality at the same time. By using it systematically in the root area and for intermediate layers, we save time, lots of time. In the past, the seam root had to be removed by air arc gouging before the backing run could be welded. Looking at the welding process alone, the procedure reduces nonproductive time considerably cleaning and gouging work is minimised, the welder keeps in time, the entire production chain keeps owing. Fillet welds classied as group B according to ISO 5817 are now produced with a dened hollow llet and corresponding overlap and at 3 millimetres, the throat thickness also complies with the value required by the standard. We are aware of what this means for the future of welding technology. It is now possible to weld certain seams from one side only; the backing run is created automatically no joining no welding. Head of process planning and responsible welding engineer (EWE) in the company headquarters in Plauen, Dipl.-Ing. Jrg Neudel Plauen Stahl Technologie GmbH, Plauen
Steel construction for iron and tramway bridges as well as large projects
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CrNi
Steel: high-alloy
coldArc
The production site of big-name brand Miele & Cie. KG in Lehrte, Lower Saxony, is one of the leading global makers of washing machines, tumble dryers and other machines for professional use. The level of vertical integration at this established German company is a high 70%. Welding technology accounts for around just 15% of our production process but plays a major part. This became even clearer to us when we changed over to EWM-coldArc. The fact that we are now achieving a welding speed twice as fast is obviously the icing on the cake, says acting Production Manager Volker Bachmann.
Volker Bachmann, Acting Production Manager Miele & Cie. KG, Lehrte
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CrNi
Steel: high-alloy
microplasma DC
Automotive supplier
Automated microplasma 50
IBG Automation GmbH, Neuenrade
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CrNi
Steel: high-alloy
TIG-DC
Pipe manufacturing
For the mechanised joining of our stainless-steel pipes on almost 100 TIG welding stations we make two key demands of our power sources: High availability during every minute of the three production shifts as well as reproducible weld seams of consistently high quality. The TETRIX type machines meet both demands in full, without compromise. They are reliable, safe and solid. Speed and reliability is also what we expect from the EWM customer service which couldnt be better.
Steel: high-alloy
Jochen Bouschery Electrical Engineering Manager Schoeller Werk GmbH & Co. KG, Hellenthal
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CrNi Al
Since opting for automated joining via robot, we have been able to increase the range of our contract production and thus increase our added value considerably. For our customers primarily from the machine engineering industry we now manufacture complete assemblies. Due to our range of materials from low-alloy and highalloy steels through to aluminium alloy we chose the crucial system components in the shape of the EWM power sources PHOENIX 522 RC PULS forceArc and TETRIX 350 AC/DC activArc: Depending on the material and task, these weld with a robot in the MIG or TIG processes. In the latter process we can also choose between AC and DC welding. Michael Boche Owner, Managing Director VIS - Vetschauer Industrieservice GmbH, Vetschau
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Al
Aluminium
MIG pulse
Aluminium construction
The high-quality, innovative complete at roong systems from medium-sized enterprise alwitra located in Trier are in demand throughout the world. A year ago, the company installed a welding robot system. Since then the robot/power source combination has done exactly what we required of it in the MIG process reliable welding, seam after seam, layer after layer, summarises Albert Thmmes, production manager for aluminium components at alwitra. Christoph Schmidt, assistant to the management: The almost self-explanatory programming method using the control panel made our decision for the Phoenix 422 RC puls power source for our Motoman robot easy. Albert Thmmes, production manager for aluminium components (left) Christoph Schmidt, assistant to the management alwitra GmbH + Co, Trier
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Headquarters
EWM HIGHTEC WELDING GmbH Dr. Gnter-Henle-Strae 8 56271 Mndersbach Germany Tel: +49 2680 181-0 Fax: -244 www.ewm-group.com info@ewm-group.com
Technology centre
EWM HIGHTEC WELDING GmbH Forststr. 7-13 56271 Mndersbach Germany Tel: +49 2680 181-0 Fax: -144 www.ewm-group.com info@ewm-group.com
www.ewm-group.com
EWM HIGHTEC WELDING GmbH EWM Solutions WM.0656.01 08.2011 Subject to change without notice.