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By working together you found a new product “Spatter Shield” that has reduced my usage of weld tips by 60%. This product has also taken my arc failures from an average of 40 a day to about 6 a day. This saves us about an hour a day in changing out tips and resetting the robotic weld cell.
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Please consider the below quality improvements which cannot be converted to monetary terms
- Better appearance of the welding beads - due to the smooth feeding of the wire;
- Better weld appearance due to negligible chipping marks on the job. When Spatter Shield is not used the chiseled out spatters make an impression;
- Improved and enhanced robot real arcing time - utilizing the capital equipment even higher;
- Enhanced life of the wire feeder of the robot due to lubricating from inside of the welding gun - resulting in less wear on the feeder rolls;
- Life enhancement of the weld gun and its consumables besides the tip and nozzle - components like
- Contact tip holder
- Nozzle holder
- Gas diffuser
- Swan Neck
- Wire Liner
- Spatter Shield is an inline anti spatter system , which is system dependent, and no manual interference is required. Hence it helps in the automation process bringing in the disciplines in manufacturing processes.
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This engineering firm recently supplied the seating for a cinema complex. The frames of these chairs are fabricated from angle iron and R.H.S. After fabrication of the frames and before painting, it took approximatley 7 minutes per frame to clean weld spatter and check. This has been greatly reduced to 2 minutes because of the reduction of weld spatter to almost NIL. This was a big saving on an order of 2,500 chairs.
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Sheet Metal, Engineering Workshop |
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Lobethal Sheet Metal are proud to have been chosen to test this new welding liquid concept. We have put this through our most vigorous testing procedures conducted at our workshop. This business is a sheet metal, engineering workshop where we use a lot of different types of metals for our fabrication of components eg:
Galvanised Steel
Zinc coated
Stainless Steel
Aluminium
Mild Steel
Hot Dipped Galvanised
Coated Steels
Since starting the tests using our MIG welding machines, we have been able to reduce our gas consumption by 25% due to reducing our gas flow flow rate, we are currently using C.I.G. Argo Shield 50.
Because of minimal spatter the gun nozzle and tip are kept cleaner and does not need constant cleaning as before the testing was started. The fabrication work that we do now requires less clean up time which has increased our production by 30% over the 8 weeks this was tested.
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Case Studies
