Professional Documents
Culture Documents
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Print ISSN 0100-7386
J.Braz.Soc.Mech.Sci.vol.22n.3Campinas2000
doi: 10.1590/S0100-73862000000300002
of a company.
Keywords: Quality, costs, cost sensibility, process
selection, welding
Introduction
The rise of competition has led many companies to
pay more attention in their markets in order to attend
them properly. The first step is to know well the
market in which the company stands, determining
market requirements (what and how much) in terms
of price, quality, product diversity, delivery confidence,
etc. Besides, it is necessary to choose the most
suitable fabrication process to a specific situation,
among them welding, considering technical and
economical viability. The existence of a great number
of welding processes in the market, with their
variances (alternating, direct and pulsed currents,
etc.), makes the best process choice for a specific
situation difficult. Hence, an evaluation method that
helps this task is very important to the final results of
any company market strategy.
A comprehensive and precise analysis to select
correctly a welding process in real situations is very
hard and complex, because of many variables
involved. An important point is that, in market
strategy, Quality and Costs, as the other requirements,
need to be analyzed as a whole. It is not enough
simply to determine that the process "A" is the best in
Quality and the process "B" is the best in Costs. There
are minimum requirements of Quality and Costs that
need to be determined and reached for each case, in
order to be competitive. These requirements depend
mainly on the mix between product and market of the
company. In fact, the best process will be that one
that presents the best overall performance.
One can say that the welding Quality is related to the
bead and the heat affected zone (HAZ) characteristics,
welding [g], tarc is the arc duration time [s], Fwire is the
wire fusion rate [kg/h], is the wire diameter [mm],
fwire is the wire feed rate [m/min], is the steel density
(7.85 x 10-3 g/mm3), Mfcp is the final mass of the test
plate, after welding [g], Micp is the initial mass of the
test plate, before welding [g] and de is the deposition
efficiency [%].
Table 1 presents the Quality criteria adopted for the
welding assessment. As there is no specific standards
for such application and thickness of material (< 3
mm), these criteria were defined according to generic
standards, general recommendations (ANSI/AWS,
1996; ISO, 1992; IIW/IIS, 1984) and the authors
experience, based on the expectation of a dredging
pipe fabricator. In this Quality analysis, three
subjective levels of Quality were adopted, namely
grade A for highest Quality; grade B for an acceptable
Quality for the type of product and service, and grade
C for non-acceptable welds.
Experimental Procedure
To evaluate the proposed approach, a case study was
taken. In this case, dredging pipes are manufactured
by butt welding 2-mm-thick plain carbon steels.
Therefore, welding test plates were prepared using
sheets of plain carbon steel (ABNT 1010), with
Gas Tungsten Arc Welding process (GTAW): 4.0-mmdiameter AWS WTh-2 electrode, 6-mm arc length, tip
electrode angle of 45o, pure Argon shielding gas at 12
l/min, direct current electrode negative (DCEN), torch
angle perpendicular to the test plate and an 1.0-mmdiameter AWS ER70S-6 wire fed from the back of the
torch;
Pulsed Gas Metal Arc Welding process (PGMAW): 1.0mm-diameter AWS ER70S-6 wire, CTWD of 12 mm,
8%CO2-2%O2-Ar ternary mixture shielding gas at 12
l/min, DCEP, torch angle perpendicular to the test
plate.
Quality Analysis
Table 5 shows the outcome from the visual analysis
and geometric measurements in two transverse
sections, based on the proposed criteria presented in
Table 1.
Cost Analysis
The prices for material, labor, equipment, maintenance
and electrical power applied into this analysis are
listed in Table 6, whose figures were practiced on the
Uberlndia-MG market at that time. Table 7 presents
the calculated Total Costs and their components for
each process, which are illustrated by Fig. 2. A value
of 2.5% a month was considered for the interest rate
(Ir) used in the equipment cost calculation. Operating
factor (fop = 30% for SMAW and fop = 65% for the
others) and electrical efficiency (ee = 75%) were
taken based on the current literature, such as
Machado (1995), Canetti (1992), The Lincoln (1973)
and AWS (1987).
Conclusions
From the proposed approach and systematics
presented for the welding process selection, based on
the best global performance of Quality and Cost
analyses (in this case, applied to weld thin sheets of
carbon steel), it is possible to conclude that:
The selection of the best welding process is possible to
a certain industrial activity, considering the best global
performance of Quality and Costs, according to market
requirements of the company. The procedure utilized
in this work showed to be a suitable tool to this aim;
Assuming the data used in this work as representative
and the welding conditions in each process as
adequate, the best process for welding the
manufacturer product in study would be the GMAWC
process (CO2 pure shielding gas) and the worst one
would be the SMAW;
According to the Analysis of Cost Sensitivity, the factor
welder/operator salary, among the analyzed factors,
was the one that most impact causes in the Total
Welding Costs, but this can vary according to the
process and/or welding parameter setting.
Acknowledgements
References
ANSI/AWS D1.1-96, 1996, "AWS Structural Welding
Code Steel", AWS, USA, 440 p.
[ Links ]
AWS, 1987, "Welding Handbook - Vol.1: Welding
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[ Links ]
AWS, 1988, "Guide for the Visual Inspection of Welds",
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F.D.H., Soldagem: processos e metalurgia, Edgard
Blucher, Brazil, chap.11, pp.449-461.
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ISO 5817, 1992,."Arc-welded Joints in Steel: guidance
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[ Links ]
Machado, I.G., 1995, "A Economia da Soldagem",
Anais do XXI Encontro Nacional de Tecnologia da
Soldagem, Vol.II, Caxias do Sul, Brazil, pp.9991013.
[ Links ]
The Lincoln Electric Company, 1973, "The Procedure
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USA.
[ Links ]
abcm@domain.com.br