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Types of Welding at Cybernetik Technologies
05.19.20

Types of Welding at Cybernetik Technologies

Deep Bonds of Welding

Welding connects materials right down to their molecular level! [1] Plus, the bond is permanent [2]. As a result, continuously welded joints can be as strong as the parent material [3]. This lends remarkable structural integrity to welded joints [3]. A fundamental manufacturing process [4], welding is unsurprisingly popular.

Developments in automation are making robotic welding increasingly useful. Estimates place the international robotic welding market at $5.96 billion by 2023 [4]. Also expected to climb up are the number of operational welding robots [4].

Cybernetik Technologies combines its expertise in robotics and a diligent attitude with the inherently deep approach of welding to deliver customized robotic welding solutions to the Food, Automotive, and Construction industries.

For best results, we prefer robotic welding equipment and systems (i.e. hardware and software) of a single make / brand when making a particular part. Such equipment and systems include robot, software, power source, wire feeder, torch and the like. This ensures seamless compatibility between the different elements of the welding set up.

 

Welding @ Cybernetik Technologies

Cybernetik Technologies provides robotic welding services for the Food, Construction, and Automotive sectors. The types of welding we offer are Spot and MIG (Metal Inert Gas) Welding, utilizing which we fabricate parts and structures made from:

• Carbon Steel (CS)

• Aluminium

• Stainless Steel (SS)

 

ABB, OTC, and Yaskawa are the reputed brands whose robots we employ for welding. Designed for swift operation and high duty cycles for top productivity, these robots are compatible with the complex movements and manoeuvres necessary to deliver weld joints with excellent structural integrity. Run through cabling means these robots have the flexibility for touch orientation.

Parts / components we make via robotic welding are:

• Construction Panels

• Food Industry Vessels such as Cooking Kettles

• Ultra High Pressure Vessels

• Automobile Chassis

• Aluminium Shelters

Construction Panels are made of aluminium. Traditionally, the construction structure comprised of brick work for walls with slabs supported from bottom by wooden poles. Civil engineers have started utilizing aluminium construction panels with scaffolding that are safe and easily set up for construction operations of any scale.

 

Aluminium welding is a challenging operation. Its low melting point of 6600C [5] and hyper heat conductivity means it rapidly transfers heat away from the weld zone. Robotic welding makes it possible to implement the two measures necessary to counter the effects of rapid heat loss [6]:

  1. 1. Use higher voltages and currents.
  2. 2. Speed up the process to prevent the large voltage and currents from fusing out holes in the parent material, a phenomenon called burnthrough.

Power source plays a critical role in aluminium welding and so does its integration with the robot. All parameters have to be set correctly and their values have to be consistent during robotic welding to create a robust joint.  As mentioned, for making one particular part, we use welding hardware and software of only a single brand / make. Such hardware-software includes robot, software, torch, power source, and wire feeder.

 

Cooking Kettles are fundamental food processing equipment [7] and generally made from 316 and 304 stainless steels. Industrial cooking kettles have to be leak proof in order to build up the necessary pressure for rapid cooking, stewing, and mixing of food ingredients. Leak proofing is also important from the point of view of hygiene.

Welding has the capacity to permanently connect parent material(s) through a leak proof joint [8]. Robotic welding further amplifies this natural advantage of welding through precise control over process parameters.

 

Ultra High Pressure Vessels need immensely strong joints to operate uninterrupted and conveniently at extreme pressures. Continuous welding furnishes joints as strong as the parent material itself [3]. Such structural integrity proves invaluable for welding hyper pressure vessels.

 

Robotic welding of stainless steel enables the following conditions needed for producing best quality joints [9]:

• Lower heat input to prevent excessive expansion. Stainless steel expands rapidly when heated.

• Minimal spatter.

That apart, stainless steel is sensitive to contamination. Cybernetik Technologies adheres to excellent workshop practices to prevent impurities from coming in contact with SS parts, before and during welding. Related personnel vigilantly remove the accumulated spatter, slag, and oxides.

 

Automobile Chassis are made from carbon steel or aluminium alloys [10]. Safety holds great importance for automobiles. A properly welded chassis can effectively protect people and goods inside the automobile, particularly in the case of a crash. Here again, the close parameter control of robotic welding is an asset.

Combination of the servo spot gun and the robot assures top class conformity on the life cycle of the weld joint.  Process efficacy depends on the design and ruggedness of the fixture, which must withstand large production requirements. Cybernetik Technologies provides end to end solution from component handling to welding.

 

Strength & Integrity

Welding is very much a part and parcel of the present day world [11]. Cars, trains, high rise buildings, bikes, rockets, roads, ships, pipelines, mobile towers, airplanes, kitchen appliances – all have weld joints inside them. At the root of such broad applicability is the strength and integrity of weld joints.

 

Cybernetik Technologies blends its proficiency in robotic automation and welding to harness all that robotic welding has to offer.

Contact us at +91 20 6790 9600 or sales.automation@cybernetik.com and we will provide weld joints that are as strong as they get.

 


 

References

  1. 1. https://gowelding.org/articles/introduction-welding/
  2. 2. http://www.weldwire.net/3783/welding-is-a-part-of-our-everyday-lives/
  3. 3. http://mechanicalinventions.blogspot.com/2015/06/advantages-and-disadvantages-of-welding.html
  4. 4. https://weldingvalue.com/2019/01/welding-trends-2019/#908f3c46
  5. 5. https://www.onlinemetals.com/en/melting-points
  6. 6. http://www.kemplon.com/for-proactively-stellar-aluminum-welding/
  7. 7. https://www.geegeefoods.com/steam-jacketed-kettle.php
  8. 8. https://www.keyence.com/ss/products/measure/welding/type/pressure.jsp
  9. 9. http://www.kemplon.com/the-peculiarities-of-welding-stainless-steels/
  10. 10. https://www.pressmark.co.uk/chassis-manufacturing-process/
  11. 11. https://www.manufacturing.net/labor/blog/13193137/why-welding-is-an-incredibly-important-industry
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