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Kemppi customer magazineNewsPR

O2011

EN

Raising PRODUCTIVITY Better results with WIse™-WeLDING PROCesses

Quick and easy WeLDING MeCHANIsATION

Robotic welding to the power of two: TANDeM TCs sYsTeM

www.kemppi.com

Wise decisions create a more productive result

Manage welding skill, productivity and qualityWISE™ products are welding software solutions, enabling levels of welding performance that otherwise would be impossible to achieve with standard MIG/MAG welding process. Use Wise products for enhanced root closure, constant power management, automated arc length control and precise thin sheet welding. Compatible with FastMig synergic and KempArc automation equipment. Order a site demonstration and see the arc di� erence!

3Kemppi ProNews 2011

editorial

Anssi RAntAsAloCEo

ONe Of the best ways tO fOResee the futuRe is tO cReate it

Year 2010 was a big success for Kemppi. We returned to the growth track and made progress in many areas. our new subsidiary in Chennai, india was started and our entry to new areas like tailored arc welding processes (Wise), robotized tandem-welding and automatic Magtrac-welding carriages created a lot of interest around the world. We sincerely thank all our customer and business partners, as well as the Kemppi staff for creating this success with us.

Many important events take place in different parts of the world right now. the tsu-nami and the nuclear disaster that followed in Japan are re-shaping energy policies all over the world. there is unrest and uprising in many Arab countries based on de-mands for democracy. in Europe the main challenge is linked with financial problems of some Euro countries. All this has an impact on the general economic development and growth expectations. Uncertainty about the future is increasing again.

A few years ago i read stephen R. Covey’s book:”7 Habits of Highly Effective People”,. the author advises to focus on things that one can influence (”the Circle of influence”) and to worry less about things that will happen anyway (“the Circle of Concern”). this is a good piece of advice right now, and here at Kemppi we follow it in many ways. We believe that our future competitiveness depends on investments that we make today. We have just finalized a three-year and 25 M€ investment program and taken into use the latest extension to our main assembly plant here in lahti. it was our target to increase the productivity by a minimum of 10% and this target has been reached and in fact exceeded. this year we’ll employ new people to meet the needs of our R&D&i and sales & Marketing activities and the number of our international staff continues to increase, especially on the developing markets in Russia, india and China.

We believe that productivity is the main challenge also for our welding customers when they strive for increased competitiveness on global markets. We want to be a part of this development and actively contribute to increased welding productivity. this is why we have opened a new business unit called Welding Management solutions (WMs). this group of experts will focus on developing and commercialising new tools and service concepts to support further development of welding production.

this year we will also launch exiting new products. the Minarc Evo series introduced in Hannover at the end of last year has entered the market and in september we’ll see a great step forward in compact MiG/MAG equipment. in the meantime our magazine offers interesting reading and also a glimpse to the future…

Enjoy your reading!

4 Kemppi ProNews 2011

Kemppi ProNews. Publisher: Kemppi Oy, P.O. box 13, 15801 Lahti, finland. internet: www.kemppi.com. telephone: +358 3 899 11.editor-in-chief: Minna-Maija Jokisalo. sub-editor: elina suomalainen. Lay-out: tekijätiimi Oy.subscriptions and changes of address: Kemppi Oy. email: [email protected]. Printed by: esa Print Oy, Lahti, finland, 2011. issN 1796-847X.

EditorialOne of the best ways to foresee the future is to create it 3

Briefly 5

InnovationProtrainer trains champions in the virtual world 19

four arc tools every welder should have 22

Viewpointanticipate, innovate and communicate about the future 18

OthertopicsMagtrac never gets tired − even on long longitudinal welds 12

Numerus rerum! New Minarc evo family 13

tandem MiG/MaG welding was reborn 16

welding gave Katja a new life 30

was skating invented in finland? 33

Kemppi Oy subsidiaries 35

Kemppi Oy sales Offices 35

content

27Deltabeam is an internationally recognised and widely used product for many kinds of

construction. several challenges have been overcome in its manufacture.

19one of the most talked-about current topics is virtual welding. it

enables significant savings of time and money in basic welding training.

22 the last few years have seen MiG/MAG welding power

source development create an opportunity to develop more and more multifunctional equipment.

9 light mechanisation delivers efficiency – and better ergonomics.

the cover shows two ship-to-shore cranes belonging to Konecranes company, waiting for transport to the operator. these cranes are manufactured in hanko by Levator, who have also participated in development of the Kemppi Magtrac welding carriages. Mechanised welding is utilised in many stages of manufacturing the main girders of the cranes. Photo by Petri Metsola, Levator Oy..


briefly

Kemppi launches production in india

Kemppi oy, a leading Finnish welding equipment and solution provider, has set up a production facility in Chennai, india, for the

manufacture of devices intended for the local market. the opening ceremony of the new subsidiary and production facility took place on Wednesday 19 January 2011 in local indian style. the new facility is Kemppi’s first production unit outside Finland.

Kemppi have been operating in indian market since the 1970s, and the brand has become well-known and valued over the years. the purpose of establishing a local subsidiary and production facility is to improve and strengthen Kemppi’s position in one of the most rapidly growing markets in the world.

‘We have had good cooperation with local distributors for many years, but local production is also necessary in order to further establish Kemppi in the indian market’, says Anssi Rantasalo, the CEo of Kemppi.

staff from Kemppi’s indian production facility have been in Finland for training, and during spring, the first ever machines to be manufactured at the Chennai factory saw daylight. they were HiArc M400i machines for MiG/MAG welding.

By establishing a sales company and a production facility in india, Kemppi shows that it is seriously competing in this economic region with a huge market potential.

the subsidiary enables local handling of sales, deliveries and service operations.

the office premises are accompanied with modern training facilities, which will be further expanded in the near future.

‘We want to serve our indian customers even better and strengthen our strategic position in the area,’ Rantasalo sums up.

the opening ceremony of Kemppi’s indian subsidiary was held in Chennai on 19 January 2011. the ceremony was based on a traditional Puja ritual used by Hindus, where one shows respect to the Gods and tells them about their hopes and dreams. A Hindu priest played an important role in the opening ceremony.

Kemppi shows that it is seriously competing in this economic region

with a huge market potential.

HiArc MiG welding machines was presented on the opening gala.


NewsPRO

2011ZH

肯倍客户杂志

更高，更快，更强！利用肯倍全新焊接解决方案，可显著提高生产率

· Wise 智能焊接解决方案

· 简易自动焊解决方案

· 机器人双丝焊

NewsPRO

2011ZH

肯倍客户杂志

更高，更快，更强！利用肯倍全新焊接解决方案，可显著提高生产率

· Wise 智能焊接解决方案

· 简易自动焊解决方案

· 机器人双丝焊


the Finnish welding equipment manufacturer Kemppi oy received the national Quality innovation of the Year award for 2010 in the

category for large companies.the winning Kemppi

Datastore concept represents a completely new way of thinking when it comes to the acquisition of welding devices and tailoring them according to customer needs. now the customers can equip their welding machines with exactly those particular welding processes and features that are actually needed in the

welding work. All welding devices at the customer’s site can easily be equipped with

those specific features that are suitable for a particular use or project.

the Kemppi Datastore solution is an online welding Web shop where the user can purchase and download welding processes, welding programs, firmware updates, and validation certificates for welding devices, etc. With this system, all welding equipment can be kept up to date throughout the devices’ service life while still responding to variable needs of use.

the Kemppi DataGun is a small, mobile phone sized tool that is connected to a computer via a UsB cable. it provides a link between the Web and the welding machine, enabling transfer of the purchased software product to the welding machine. in addition, one can use the DataGun to, for instance, duplicate the settings of the welding machine.

this year marks the fourth time that Excellence Finland has granted its Quality innovation of the Year award. this year, two organisations were recognised in the category for large companies.

Kemppi Datastore concept wins the Quality innovation of the year 2010 award

Kemppi communicates in 12 languages

We serve customers in more than 80 countries around the world. We publish operating manuals and customer communications materials in at least twelve languages, in some

cases in as many as fifteen. our customer service follows the principle that customers get clear, easy-to-understand information in their own language.

You can read our Pronews customer magazine in printed form, and the same magazine is also published on our website as a multi-language electronic replica of the print version.

on our website you can also access the Kemppi digital Product Catalogue and browse it on screen. You can easily print any pages you want or even download the whole catalogue in pdf format to your own PC. the Product Catalogue contains basic information about the main Kemppi machines and services.

Kemppi’s newsletter, the Welding issue, features news on Kemppi’s products and activities. on our website you can subscribe to the newsletter and get it delivered direct to your mailbox.

We publish our Pronews customer magazine and Product Catalogue in the following languages: Finnish, English, swedish, norwegian, Danish, German, Dutch, Polish, French, spanish, Portuguese, Russian and Chinese.

briefly

share your experiences – the most surprising ones will be rewarded!

Are you astounded by all the things that can be created through welding? Have you seen an astonishing object that

has been created, joined or fixed through welding?

We have told you, for example, about a wine bottle rack built through welding and about a motorcycle with a trombone as its exhaust pipe. on the next page, you can read how a valuable watch bracelet was repaired through welding.

share the work you have seen or your own experiences with the readers of Kemppi Pronews. send a brief description of the subject along with a few photos and your contact details by email to:[email protected]

the most astounding stories will be rewarded!


Rolex fixed by weldingA norwegian Rolex owner saved a fine sum of money when the wristband of his valuable timepiece was fixed by welding.

After doing some research on the subject, Myhre discovered that the Kemppi Mastertig Mls ACDC and its MicroTack function in combination with the ACs control panel offered a solution for fixing the Rolex wristband.

the wristband and its fastener were dismantled and the components cleaned of old glue and dirt. Myhre also practised with his colleagues in advance by performing welding tests on stainless steel wire with a diameter of 1 mm.

‘in the first welding test we used sunglasses and a lamp equipped with a magnifying glass,’ explained Myhre.

After a few spot welds, we understood that the materials of the wristband and lock behaved slightly differently from those that you normally handle by tack welding.

He said: ‘By increasing the welding current to 135 amperes and adjusting the distance to the welding piece to 0.5 mm, the desired result was attained. the pieces were perfectly connected.’

‘then we continued the welding, at a slightly lower current, of 110 amperes. 6–7 spot welds at the end, and 2–3 spot welds on the side ensured a durable result that would hold for a long time. no damage

the Rolex owner tried to take the watch to various watchmakers in oslo to have it repaired. several attempts were made to fix the

svinndal Gjerde & sveiseverksted is a norwegian company founded in 1978 as a one-man business that focused on welding fences and smaller products. over the years, the company has developed and expanded, and today it occupies facilities of 800 square metres, on two floors. it has five employees, with extensive skills in such fields as automation, pneumatics, hydraulics, and welding.www. svinndalgjerde.no

caused by the heat was noticed on the wristband except for slight discolouration and blackening that could be removed by wiping with your fingers,’ he said.

Myhre finds the result astonishing and sees limitless possibilities for performing similar special tasks with an array of Kemppi’s machines. Understandably, the happy Rolex owner praises the professional skill and flexibility he encountered at svinndal Gjerde & sveiseverksted.

text: Pirjo Kemppinen

wristband by, for instance gluing, but they all failed. one of these craftsmen suggested welding to fix the wristband but did not want to try it himself, in case the heat were to cause even more damage.

A new wristband for the valuable watch would have cost 1,500 euros. A less expensive option was to find a professional with sufficiently high-quality welding equipment.

the watch owner sent e-mail to Øivind Myhre at svinndal Gjerde & sveiseverks-ted, who was attracted by the unusual challenge. He asked to have pictures of the wristband and set out to look for practical solutions for repairing it.


briefly

Valtteri Bottas is contesting the GP3 Championship

tipped to be Finland’s next Formula 1 star, Valtteri Bottas could be seen in action in motor racing’s premier series as early

as next season. He is rapidly building his career in the Williams organisation, which selected him as their official test driver in January 2010.

in addition to his role at Williams, this season Bottas will also contest the GP3 series for the ARt team. He moved up to GP3 from the Formula 3 Euro series, which he contested in the past two seasons.

the GP3 series has been described as GP2’s little brother, and GP2 is regarded as the last stage on the way to Formula 1.

GP3 series races are contested in conjunction with European Formula 1 race weekends, keeping Bottas in constant touch with the Grand Prix circus.

”this has helped to raise my profile and i get to spend time with the Williams team. it’s also important that the series is contested with Pirelli tyres. Pirellis will be introduced to Formula 1 next season and so i’ll get some valuable experience,” Bottas says.

success in the GP3 series will naturally help Bottas to become a Williams driver. His chances are also boosted by the fact that Rubens Barrichello, the team’s Brazilian driver, is already contesting his 19th season in motor racing’s top series and at some stage will make room for new and younger talent.

Bottas does, however, need more experience and is taking things at a steady pace:

”i’ll contest one season in GP3, the next in GP2, and then i hope i can race in Formula 1,” he says.



→

© Pixmac

Light mechanisation delivers

increasing productivity is the target in all areas of industry and other activities involving production.

This self-evident mantra is repeated in all possible situations. The emphasis on efficiency is understandable, of course, because efficiency

is accompanied by a lot of benefits: competitiveness, growth and prosperity. However, it often also involves unfortunate after-effects: job losses, a frenzied pace of work, decreased autonomy for employees.

The demand for increased productiv-ity in welding has been met by the de-velopment of more efficient and versatile welding equipment and the introduction of welding software for different applica-tions. These improvements to equipment and software are increasing the quality and productivity of welding, but by far the best way of raising welding efficiency is through automation and mechanisation. Of these, mechanisation - and light mech-anisation in particular - can be used in a very wide range of applications.

Mechanisation means moving the welding torch mechanically. The welder sets the necessary welding parameters or selects them from the memory channel stored in the welding equipment. When the welding carriage is started it begins to follow the groove and produce a consistent quality weld. The welder’s task is to monitor the progress of the carriage and the quality of the weld.

Light mechanisation is an easy and cost-effective way of improving welding efficiency, and it also has a favourable impact on ergonomics and safety. Exposure to arc radiation and welding fumes is reduced and working positions are improved because the machine does

the physically heavy work while the welder can concentrate on monitoring the process.

As a result light mechanisation of welding can, at least in certain cases, meet the requirement for increased efficiency without unfortunate side-effects for employees. In fact, there are benefits for the welders, as light mechanisation can make their work more enjoyable and safer.

success depends on many factors

Equipment for light mechanisation typically consists of compact and lightweight wheeled tractors and rail carriages. This equipment can deliver a huge increase in welding speed: when manual welding achieves speeds averaging 20 - 40 cm per minute in the long run, light mechanisation makes it possible to reach speeds many times higher – speeds in excess of 100 cm per minute can be realised in horizontal fillet welds, for example.

Welding mechanisation will only result in a clear increase in the efficiency of the production process if welding is the bottleneck that is causing production delays. The basis for successful mechanisation – and automation – is always the ability to understand the production of the workshop as a whole. After all, mechanisation will only result in a genuine increase in productivity if it enables the product lead-through time

– and better ergonomics

efficieNcy


to be shortened by speeding up those work phases that are limiting the entire production capacity.

In principle, light mechanisation is a cost-effective and easy way to improve manufacturing productivity in both large and small workshops. However, light mechanisation could certainly be used in significantly more applications than is the case at present. This is because the switch from manual welding to light mechanisation is often more difficult than anticipated, even though the benefits are fairly well known. The reasons for this are likely to be found in two areas: equipment usability and prejudices on the part of people involved.

A key factor is the working relationship between the plate makers, welders and management: they must work well together with no friction.

When applying mechanisation, the importance of training cannot be over-emphasised. In switching to mechanised welding, both employees and management must share a clear idea of the benefits that can be achieved, the operation of the equipment, and the welding tasks that are suitable. No single mechanised unit is appropriate for all welding tasks, and it is necessary to reserve slightly more time to get the equipment ready for use than is needed in manual welding.

Training can be used to change prejudices and avoid situations where lack of information leads to frustrations with equipment that does not work or is not suitable.

Kemppi has introduced its own welding carriage, the MagTrac F 61, which is featured in this magazine. The leading principle in its development has been ease of use, with the aim of ensuring that users will at least not miss out on the major benefits of light mechanisation just because their equipment is difficult to use.

text: Petteri Jernström Business Manager Welding Management solutions

“when applying mechanisation, the importance of training cannot be over-emphasised. “

SuperSnake makes for easier access in tight spaces.

The strong magnet keeps it on the right track even in demanding jobs.

The quality of the sheet-metal work also plays a major part in the success of a mechanisation project. Poor precision in preparation and fitting work make it difficult to use welding carriages because the welding parameters and torch angle have to be continuously adjusted. This happens, for example, when the air gap varies as a result of fit-up cutting or deformations in the plate.

In addition, if there are shortcomings in the usability of the equipment then it easily gets left in the tool store. When implementing light mechanisation, steps must always be taken to ensure that the quality of the previous work phases meets the demands of mechanisation.


levator oy specialises in the fabrication of steel structures for container cranes. it has succeeded in becoming significantly more competitive by mechanising its production.

with a tractor-type conveyor,’ Viitaniemi explains.

the stiffened panels are assembled to form box girders, with mechanised submerged arc and manual MAG welding being used for the joints.

‘Difficult-to-access position welds are typically done manually. For this reason it’s important that the welding equipment is easy to move around. A lot of welds also have to be done inside the box, so equipment with an extended reach makes access easier and reduces the amount of non-arc time.’

the last steel work phase is to weld equipment mounting brackets and trolley rails to the main girder, and machine the hinge joints. the main girder is then transferred for painting, fitted out with the required equipment and mounted on the crane.

‘Finished cranes are generally transported to the customer on pontoons. this means there is no need to establish a separate construction site at the port and the crane can be got into use quickly.’

Light mechanisation boosts competitiveness

• specialises in manufacturing container, shipyard, and other heavy-duty cranes, as well as wind turbine towers and other heavy steel structures.

• steel production around 5000 tons per year

• 115 employees• 20 hectare factory and storage

area, 9000 m2 workshop and 1200 m2 painting facility

• own harbour, lifting capacity of 200 tons

• Welding processes: MiG/MAG, tiG, submerged arc and laser welding, also laser hybrid applications

• En-iso 9000 and En-iso 3834-2 certified quality system

• Vision: to be the preferred partner in the Baltic sea region

www.levator.fi

The most demanding steel structures for cranes are manufactured in Hanko. The photo shows two STS cranes en route to the customer’s port.

case: levator oy, Hanko, Finland

‘light mechanisation has speeded up our manufacturing processes and improved product quality significantly,’ says Quality and Development Engineer Ilmari Viitaniemi.

He cites the manufacture of main girders for sts (ship-to-shore) cranes as an example of the application of mechanisation in the production of steel structures. these box girders are typically around 50 metres long and weigh 90 tons.

the manufacture of a main girder starts with plate cutting, after which the plates are fabricated into stiffened panels.

‘Welding the panel stiffeners is a typical mechanised application, because the total length to be welded is around 900 metres. At levator the stiffeners are MAG welded and mechanisation has been implemented


Magtrac

When welding large work pieces the seams are often long and straight – leading to boredom

- or have to be welded in stages. They require a lot of arc time and do not really challenge the welder’s skills. It is precisely this type of welding that offers the best potential for mechanisation.

Light welding carriages can significantly improve working conditions and productivity, as they offer almost double the speed of manual welding. In addition, the travel speed and torch position remain constant for a consistent quality weld.

Kemppi’s new MagTrac F 61 welding carriage combines ease of use, accessibility,

quality and efficiency in a completely new way. It has been designed as a basic tool for workshops, especially for horizontal fillet welding.

Features designed for ease of use

Ease of use was the core idea behind the development of the MagTrac F 61 carriage. Welding parameters are transmitted between the carriage and welding equipment via the control cable, which is integrated into the welding gun cable. The carriage gets its operating power through the same cable, so only one cable is needed between the wire feeder and carriage. The fact that separate transformer and control cables are not needed makes for a safe working area and promotes efficiency.

Fixing and adjusting the torch have also been made as easy as possible: the stick-out length and torch angle are adjusted by means of a single fixing handle.

Settings for the wire feed speed, welding voltage and other welding parameters are selected on the carriage control panel. This makes it easier to change the settings while welding is in progress and speeds up work, because the welder does not need to move from the carriage to the power source to make small changes.

The graphical user interface is another feature that promotes ease of use. The functions are arranged in a clear menu structure and can be selected using a multi-function adjustment knob. Wire inch and gas test functions are available for the preparation phase, and an advance

test run can be undertaken without arc ignition to check

the carriage is operating correctly. This ensures successful results.

Valuable data for quality control

The welding parameters and heat input can be read

off the display after welding is finished. The length of the last weld or distance welded during the day can be checked from the carriage display. The carriage display also shows the average heat input during the last weld. This is valuable data for the purposes of quality control and ensuring compliance with the welding procedure specification.

The MagTrac F 61 carriage can be used with an MXF type wire feed unit, which can be placed on a wheeled undercarriage to provide reach. Additional reach can be achieved by using a 15-meter SuperSnake subfeeder, allowing access even to very tight places such as ship block structures and main girders for harbour cranes.

The highest productivity is achieved by maximising the carriage operating time and ensuring that preparation and finishing work is done with purpose-designed equipment such as the Kemppi FitWeld, a MIG/MAG machine developed for tack welding.

− even on long longitudinal welds

‘storing the heat input data provides

valuable information for quality control and carrying out welding

procedure tests.’

NeveR Gets tiReDKemppi’s new Magtrac F 61 welding carriage makes the welder’s work faster and easier. it is a cost-effective and efficient way of increasing welding productivity in large and small metal fabrication workshops.

‘Ease of use was the core idea behind the development of the Magtrac F 61 carriage.’


Numerus Rerum!

→

As a young Kemppi sales person, I was

always keen to describe the circumstances

that influenced my sales figures. Of course

there was success, but also opportunities

missed, and regular ‘if only’ stories were

well-rehearsed in time for the monthly

sales meetings. I would explain that ‘If

only’ we could meet the delivery dates more

quickly, ‘if only’ the sales price was a little

lower, ‘if only’ the product had a slightly

different specification, then my regional

sales figures would be better. I soon realised

that in the world of sales, only one story

really mattered, and that’s number facts.

My sales manager’s retort was always

the same, ‘Stop whining Frost and give

me the numbers, Numerus rerum boy’!

Today, Kemppi’s equipment portfolio has

developed in both width and depth, but in

pure item sales, one specific product family

stands out above all others, and that product

family is Minarc. Now I can honestly say,

‘if only’ I’d had the Minarc family to sell

way back in the ‘90s, then my sales figures

would have been far higher; honestly boss!


Energy e�cient

Establishing a reputation

The first ever Minarc MMA machine was launched at the German Essen welding fair during 2001, and it became an immediate commercial success. In the first full year of production, the original Minarc MMA sold more than 22,000 pieces and claimed a significant market share in the European single phase, portable MMA segment. The success story continued, with new 1ph and 3ph MIG and TIG models entering the market during 2005, 2006 and 2007, and to date the global sales for those models now totals three hundred thousand units.

The success of Minarc family has been truly world wide. All over the world Minarc welding machines have delighted users and provided reliable portable welding solutions to a variety of applications and environments. The current ‘classic Minarc’ models continue their commercial life, however Kemppi have launched a new Minarc Evo Family, offering customers improved specifications, energy efficiency and welding performance, further developing the value of this successful, portable, welding family.

Why Minarc Evo family?

The existing ‘classic’ Minarc family is still extremely popular with customers, so why introduce a new range of machines?Kemppi is committed to ensuring, wherever possible, that our customers have the best product choice on the market, and that choice should conform to all required market conditions and regulations. Whilst the classic Minarc family continues as an outstanding welding performer, we knew that technically, we could offer customers improved technical performance and the all important ‘extra value’ over competitor products that Kemppi customers expect. So Minarc Evo family was developed to deliver performance and efficiency beyond the existing classic Minarc range, and this was achieved largely due to the application of PFC (Power factor correction) technology.

Evolution specification

Has Minarc family gained some weight as it’s got older?Looking at the specification of NEW Minarc Evo family, you will see that the ‘little welding Giants’ have gained a little weight since their first introduction, but for good reason. The application of PFC technology demands a little extra space and therefore weight, but in return you get better welding performance and improved specifications, improved electrical energy utilisation, and in the case of both MIG and TIG models, increased welding output. Plus all Minarc

Evo family models conform to the very latest European EMC

directives, electrical standards and norms for all industrial public supply networks.

Energy efficiency

Compared to the classic Minarc family models, can you save

money using the new PFC Minarc Evo family?Yes,perhaps a little financial

saving. But calculations should be based on welding time and local unit cost of electricity, and perhaps that argument is not so interesting with small, portable welding appliances like Minarc. The real benefit in this argument comes from the utilisation of available electrical energy, the fused electrical supply, and its conversion to welding power output. Classic Minarc family has a power factor at 100% ED of 0.6, where as the new PFC Minarc Evo power sources have a power factor at 100% ED of 0.99 and that’s as good as it gets with existing technology. For example, MinarcMig Evo 200 delivers 200 amps of welding power, at ED 35% from a 16A fused supply, for a weight of 13kg.

New Minarc evo family

Minarc Evo family is designed and manufactured by Kemppi Oy (Finland) and complies with IEC 61000-3-12, EMC class A.


What can you do with the new Minarc Evo models that you can’t do with the old Minarc family?By comparison, the new Minarc Evo family welds at higher welding currents for longer periods of time from the same fused supply. Using the equivalent amount of electrical energy, classic Minarc would achieve less welding current output for the same unit cost. So when evaluating comparable market products, it’s also best to evaluate the machines maximum welding output, and what’s achievable from a standard 16A fused supply or below.

Wherever welding takes you

Can Minarc Evo family be used with power generators?Yes, Minarc Evo family is an excellent performer from both mains and generator power supplies and the PFC technology now allows a minimum power generator size of between 4.2 and 8.0 kW, depending on the model used and the welding current required. Minarc Evo models also tolerate wider input voltage variations and the natural changes in supply from

power generators. In fact, if the supply voltage exceeds fixed limits, the Minarc Evo power source will automatically self protect and safely shut down, notifying its user with a warning LED lamp.

Are there other benefits for site welding environments?Minarc products have always been particularly useful for site working environments, but the new Minarc Evo models are even stronger in specification. For example, in a recent power source performance test, Minarc Evo 150 was evaluated in continuous welding conditions at full power, with 4mm electrodes. The test was completed burning 10 x 4 mm x 450 mm electrodes without any interruption. The fused supply was 16 A and the ambient temperature was 22 °C. Also, the new Lift TIG ignition feature on the Minarc Evo 150, digital meter display and remote control option combine a formidable portable welding tool that weighs less than 6 kg. Plus every Minarc Evo family model can perform perfectly well with power extension cables of up to 100 m in length (2.5 mm²), providing excellent work area coverage at site.

Are there new features and benefits on the MinarcTig Evo?New welding features no, but extra welding power, yes. MinarcTig Evo also employs the new PFC power source technology, so it now delivers 170 A in MMA welding at 35 % duty cycle, and 200 A in DC TIG welding at 35 % duty cycle, so the welding capacity is higher. MinarcTig has always been a little over shadowed by the huge sales numbers of the Minarc MMA and MIG models, but MinarcTig is a superb, professional DC TIG welding solution, that provides extremely refined ignition from 5 amps, offering professional TIG welders the control they need with a variety of remote control options, and even a semi-auto pulse mode.

text: John FrostGroup Product Marketing Manager

Is what you see, what you get?

today there are many variable choices on the market for portable arc welding equipment. Kemppi is a responsible and global equipment provider and we recommend customers to read, test and then decide what best suits their needs. But, when making your choice, it’s always best to check the factual numbers first –

numerus rerum!


was RebORN

In the 1990s and early 21st century, tandem welding was among the processes that were supposed to become a credible competitor for other high-power welding methods. However, this

never happened because the process was cumbersome to use. New technology has now improved the level of usability substantially, and it has become faster and easier for the operator to adjust the welding parameters.

What is actually meant by tandem welding? It belongs to multi-wire welding methods. A MIG/MAG tandem uses two filler wires during welding. This must not be confused with twin-wire MIG/MAG welding that also uses two filler wires. The main characteristics of these processes are the following:

twin wire welding

• Two filler wires are fed into the same weld pool through a shared two-hole contact tip either from the same wire feeder or two separate ones.

• The wires are at the same electric potential.

• There is either a single power source or two power sources connected in parallel.

• The wire feed rate is the only parameter that can be varied between the wires.

• The same welding power has to be used for both filler wires.

tandem welding

• Two filler wires are fed into the same welding pool through two contact tips electrically isolated from each other.

• There is a separate wire feeder and power source for each filler wire.

• The filler wires are at different electric potentials.

• The welding parameters can be adjusted separately for each filler wire (master and slave wires).

There are many process variations for tandem MIG/MAG welding. The issue can be considered from the viewpoint of MIG/MAG arc types or filler materials used. Variations related to the arc type may include pulse-pulse, spray-pulse, spray-spray and in some cases pulse-spray arc welding. The two filler wires may have different properties: they can be of different thickness and alloy, and one can be solid while the other is flux-core wire. The basic idea is that the leading filler wire is used to make the weld penetration, and the trailing one is used to shape the weld surface.

tandem MiG/MAG welding is aimed to provide the following advantages over single-wire welding, for example:

• Welding of small throat thickness (thin sheets) can achieve a higher welding speed compared to single-wire technology.

• Welding of large throat thickness (heavy structures) can achieve a greater melting efficiency compared to single-wire technology.

• The overall quality of the weld is better.

• A longer weld pool makes gases escape more efficiently, which decreases porosity.

• Because the welding energy input is lower in spite of the greater melting efficiency, welding causes less deformations and reduces the need for straightening.

• No special shielding gas is needed for the process.

tandem MiG/MaG welding

the development of welding technology has made giant leaps in recent years with regard to power sources. systems and processes that were considered the cutting edge at the turn of the millennium are now outdated.

the delivery of a KempArc Pulse tCs system typically includes the following components:

• two KempArc Pulse tCs power sources

• two Dt400 wire feeders• the required connecting cables• An efficient KempCool 40 water

cooling unit• A tandem welding torch• two WiseFusion functions• Welding programs acquired by the

customer (MatchCurve)


a b c

Throat thickness 4 mm 6 mm 3 mm

Wire feed speed 14 m/min + 12 m/min 14 m/min + 12 m/min 14 m/min + 14 m/min

Welding speed 1.6 m/min (26.7 mm/s) 0.65 m/min (10.8 mm/s) 1.9 m/min (31.7 mm/s)

Melting efficiency 13.84 kg/h 13.84 kg/h 14.90 kg/h

Tandem welding also has some limitations in comparison with single-wire welding. For example, the welding torch is larger, which imposes limitations on accessibility and small radial motion paths. Due to the torch and the welding power, the process is only suitable for mechanised or automated welding. The impact of magnetic arc blow is also greater compared to single-wire welding but it is possible to diminish its impact through proper grounding of the work piece and possible use of start and end pieces.

It used to be difficult to adjust the parameters for tandem welding. Due to this the parameter window has been narrow, and adjusting the process has required the welding operator to possess great skill. The problem has been excessive mutual synchronisation of the arcs, forcing the welding parameters to be operational within a specific limited range in relation to each other. However, new technology has come to help. The KempArc Pulse TCS equipment developed by Kemppi contains software that actively monitors and controls both welding arcs. The basic idea of control is to freely link the arcs together, making it possible to adjust them independently of each other. The TCS software links the arcs together with intelligent control technology developed by Kemppi. The slave arc continuously monitors the master arc and adjusts itself accordingly, resulting in that

In addition to the new TCS control, the KempArc Pulse TCS system uses the WiseFusion process to make it easier to find welding parameters for different welding applications. This keeps the arc length optimally short and focuses the energy density of the arcs to a narrow area. This results in smaller heat input and a higher welding speed compared to conventional tandem welding systems.

text: Jyri Uusitalo R & D Manager, Welding technology

iMG helped Kemppi develop tandem solution

case:

ingenieurtechnik und Maschinenbau GmbH, or iMG, is a modern and in-novative company based in Rostock, Germany. Among other things, it

specialises in planning and implement-ing automation solutions for shipyards.

For production plants struggling with the challenge of producing quality products in shorter and shorter production times, iMG can offer their expertise to create and implement a comprehensive logistic and technological concept on how to raise the degree of efficiency in modernized or new production departments or entire plants.

iMG has an outstanding expertise

in welding automation, and the company is also a long-time partner and customer of sUt-Rostock, a Kemppi Germany representative. As iMG also has a good knowledge about tandem welding, Kemppi asked them to join the development process of Kemppi’s new solution for mechanised tandem welding, the KempArc Pulse tCs.

the KempArc Pulse tCs utilises Kemppi’s refined tandem control system (tCs) for precise, simultaneous control of the two welding arcs, which act completely individually from each other. the development process of the tCs control system required detailed study and research work in Kemppi

welding laboratory, but also field tests in live industrial environments. local tests were carried out with the help of iMG’s knowledge and the great support from sUt- Rostock.

”it was a great benefit for us to run two-sided tandem test welds in iMG’s gantry system, and the detailed test reports from iMG gave us good support in developing the KempArc Pulse tCs, says Ulrich Hoepfel, Business Area Manager of automated welding at Kemppi.

• thearcsdonotinterferewitheachother

• thearcscanbeadjustedforoptimallengthcompletelyindependentlyofeachother

• welding parameters can beadjusted flexibly, and findingusefulweldingvaluesiseasy.

Welding example: The making of a fillet weld in primed steel was examined using the pulse-pulse variant. The base material was 6-mm steel, the filler material was 1.2-mm G3Si1 solid wire and the shielding gas was Ar+18% CO2. The study demonstrated that the tandem process is also suitable for welding primed steel with solid wire.


view

po

int

aNticiPate, iNNOvate aND cOMMuNicate abOut the futuRe

if past predictions about the world of today had been accurate, we would now be living on the moon or in capsules under the sea, we would fly from place to place using wings attached to our backs, and our food would come

in the form of tablets. Predictions have a bad habit of going wrong, and that’s why we futures researchers openly admit that you can’t predict the future. the fact that it’s not possible to predict the future, however, does not mean that the future isn’t worth thinking about. i personally see three important functions for futures thinking: anticipation, innovation and communication.

so you can never know for sure what tomorrow

will bring. the future is worth anticipating – in other words, it’s worth considering

different possibil-ities in the future.

this is known as scenario thinking.

scenario thinking involves forming imaginary but possible future courses of development linked to a certain period of time. the objective is to

form different futures and then consider what action needs to be taken today if events seem to be leaning towards one of the specific scenarios. scenario thinking may sound exotic, like something to do with business management, but it is in fact the way humans naturally view the world. People who think in this ‘what if ’ way keep an umbrella in their bag, have a few painkillers in their pocket and buy insurance. Because you can never know what will happen in the future...

if anticipation is one way of approaching the future, another is innovation. it is good to realise that every individual, organisation and nation can influence the future and innovate a new and better future. in Finland we naturally tend to play down our own resources: “What can we ever hope to achieve?” However, it’s important to notice that the future is created – even at the individual level. there are plenty of stories about individuals like that in the history books. Even recent history provides examples of Finns who - as individuals - have made a difference: Martti Ahtisaari has brought the message of peace to many different conflicts, linus torvalds developed linux and turned the spotlight on the concept of open source.

A third way of approaching the future is to enter into a dialogue about it with stakeholders. From the corporate point of view this means opening up to the public with regard to speculation about the future. it’s worth bouncing ideas about the future around - with customers, for example. this provides a valuable, external viewpoint for purposes such as product and strategic planning. My favourite example of this type of communication is Finnair’s Departure 2093 project, which presented different images of flying in the future. the project raised a lot of interest both in the press and among ordinary people, who could visit the project’s website to communicate their ideas about the future of flying. Even those behind the project were surprised at the amount of attention it attracted.

We cannot predict the future. that’s a good thing because, i guess, life would be really dull if we knew what tomorrow would bring. My own motto is that in the face of the future you have to be humble, but not overly so. it’s worth preparing for different changes and sequences of events, but it’s also good to keep a firm hold on the reins. Finally: we are the ones who create the future.

”My own motto is that in the face of

the future you have to be humble, but

not overly so.”

Elina HiltunenfuturistWhat’s next Consulting oy and Finpro


→

Protrainer trains

chaMPiONsin the virtual world

Virtual welding training is most beneficial in the early stages of basic training. The ProTrainer teaches its user to move and focus

the welding torch correctly. The motion paths acquired will be consolidated into muscle memory before the student lays his or her hands on the actual tool.

‘This generates significant cost savings in, for example, practice pieces to be welded, filler materials, shielding gas, and energy,’ says JuhaNykänen, welding manager at Kemppi.

The reduction in teaching costs is estimated to be as high as 20–25%. The time saved in basic training and the potential freed for individual teaching also deserve consideration.

strong concentration

The Kemppi ProTrainer is used in a similar way to modern game consoles’ honing of movements. The welding torch works as a joystick does and looks quite real. Ultrasonic technology is used to track and identify the location.

Nykänen emphasises that this device is not a welding simulator. ‘Training concentrates on correct welding technique and control of motion paths. The device helps the user to learn how and at what angle the welding torch should be moved during welding. Welding training can begin in practice when sufficient manual skills have been gained,’ he says.

Training can commence without any preliminary preparations or safety equipment. The learning process is accelerated, for example, by the user’s attention being focused only on the practice.

‘In a traditional learning environment, the beginner finds it difficult to concentrate on only the task given. It takes time just to get accustomed to the overalls, gloves, and welding helmet,’ says Nykänen.

one of the most talked-about current topics is virtual welding. it enables significant savings of time and money in basic welding training. the Kemppi Protrainer virtual welding trainer refines the user’s welding technique to perfection even before the real arc is ignited.

innovation: Kemppi Protrainer


‘Additionally, the first few times, the arc burn, runny weld pool, rattling noise, and spatter are sure to take the attention away from hand positions,’ he attests.

A personal trainer that never ceases to spur one on

The ProTrainer can be used for MMA and MIG/MAG welding practice in flat, horizontal, and vertical positions alike. The device enables one-on-one teaching, as individual exercises can be tailored for each student. The teacher does not need to be present: students can work independently.

Nykänen says: ‘The teacher can use a computer to define personal, password-protected tasks for each student. The results are saved in the device memory and can be reviewed together afterwards.’

The tasks may focus on the steadiness of the motion, speed, or work angles of the welding torch or on its distance from the target piece. The

hardest part for the student generally is to manage all of these elements simultaneously, remaining within the prescribed tolerance levels.

The ProTrainer gives its user constant feedback and instructions.

‘The teacher can also test how well the training has been taken in, by turning off the instructions that guide the user,’ says Nykänen.

The ProTrainer has been developed primarily for basic welding training at educational institutions, but it has also attracted interest from companies.

‘Companies can have welders carry out various kinds of tasks to help them stay in touch with their trade,’ Nykänen says.

The Kemppi ProTrainer was unveiled in Finland in early November 2010, and it has attracted great interest ever since. The device is now also available in Norway, Sweden, and Denmark.

texts: Pirjo Kemppinen

”the Protrainer gives its user constant feedback and instructions.”

Game-like technology

Kemppi’s Pro Trainer is based on CS WAVE, which was developed by French company Diginext and is

already in use in more than 150 educational institutions, around

the world. The product was created through a European-Union-funded project in 2002–2004.

‘An instructor at AFPA, a vocational training

organisation in France, noticed that playing with game consoles

such as the Nintendo Wii effectively developed young people’s co-ordination. He realised that it was possible to use similar technology to refine the motion paths used in welding,’ says CS WAVE Product ManagerLaurentDaDalto.

Thirty months and around a million euros later, the first CS WAVE system was unveiled in March 2004 in Paris. The product and the technology it is based on have been further developed since

then. However, Da Dalto stresses that virtual learning is not intended to replace traditional methods of teaching welding, even in the future.

He explains: ‘The technology provides a new tool for communication between the student and the teacher. It allows making significantly more observations than had previously been possible in a real-world welding situation. For example, in a real welding situation, the teacher is not able to observe the student’s hand movements perfectly.’

‘In addition, virtual practice accelerates learning and helps the student to understand the significance of motion paths,’ he says.

The virtual learning environment is already being used in a number of fields.

‘Our latest applications are used to practise painting, spot welding, and NDT (non-destructive testing),’ Da Dalto explains.

‘the technology provides a new tool for communication

between the student and the teacher.’

21Kemppi ProNews 2011 21Kemppi ProNews 2011

Could I become a welder?

welding manager Juha Nykänen adjusts the Protrainer display panel at a suitable height. When he clicks the options

on the panel menus to choose the parameters for my practice session, the welding torch looks quite real and works like a joystick in a console game.

My first task is probably the easiest possible. i’ll concentrate in keeping the welding torch at the correct distance from a fillet joint for about 30 cm in length. Vertical down welding offers the possibility to stand solidly on my own feet. Because i’m using a virtual training device i don’t need any protective safety equipment.

in practice the welding joint is indicated by green lines in the display panel, and the spot representing the weld pool runs between them. the blue lines indicating the distance of the torch must remain above the green lines. if the tip of the torch wanders too far or too close to the joint, the blue lines become yellow to warn the user or red to give an alarm.

i place the tip of the torch on top of the weld pool and pull the trigger. My eyes are fixed on the spot moving down, hand is sweating when i squeeze the handle an i feel my left index finger shaking while supporting the tip of the torch.

My performance is registered by an indicator that reminds me of an electrocardiogram. two thirds of the way the arc progresses surprisingly steadily, but then it suddenly jumps. that is where i breathed for the first time.

My practice becomes more difficult each time. Eventually the various indicators on the panel show the distance of the welding torch, torch angle, and speed and steadiness of the motion, and give out alarms of these features.

When the trigger is pulled, the weld pool rattles inevitably downwards. i try to keep it at the correct distance compared to the speed, but then the torch angle goes all wrong. the display panel is filled with messages which i cannot even observe at the same time, to say nothing of adjusting my performance according to them. And how to keep my hand steady until the end of the welding joint? should i courtsey or bow to reach the bottom of the joint?

For a first timer, the experience is like an educational game. i get more and more enthusiastic each time, and i’m already wondering who to challenge to a duel.

the positive experiences in the virtual world relieve my tension when i move on to try a real welding situation under guidance of welding instructor Hannu saarivirta. the preparations take a lot more time and effort. My teacher adjusts the welding machine, tapes the weld pieces together, and leaves them to wait until i have put the protective coat, gloves and the welding mask on.

At that time the sweat sticks my hair on my forehead. the view through the visor is dim and the feel through thick gloves is clumsy.

My objective is to weld a similar joint as in the virtual world. i bravely pull the trigger, but at that very instant let it go. the igniting arc, a couple of sparks and

I have always been fascinated by welding. The burning welding arc, scattering sparks, crackling sound and misty smoke create a capturing atmosphere that is controlled by the person behind the mask.For the same reasons, the sight is also awesome. I pulled my courage up and decided to try welding when I was offered the chance to practice with a Kemppi ProTrainer.

The first weld of my life. 1.5 mm thick steel sheets have been joined by a fillet joint created by vertical welding. The MinarcMig 170 Adaptive was an excellent choice for a beginner, as all you need to adjust is the voltage and sheet thickness. Although, I was not able to do even that myself.

a rattling noise make me instinctly back up.

At the second try i keep the trigger pulled and weld all the way to the bottom of the joint. there are no colours, lines or tick marks to guide my movements. if the system should draw a curve of this, it would certainly be far from even. it is however comforting to hear that the joint i managed to create, although it was welded too slowly and burned almost through, is strong.

the experience was lots of fun, and made me appreciate welders even more. they make their work seem so easy and effortless. now i know why: they are true professionals.

− Pirjo Kemppinen

Laurent Da Dalto lists the pluses and minuses of learning welding in a virtual environment:

Benefits:+ Reduces material and

equipment costs.

+ Accelerates learning.

+ improves communication between the teacher and student.

+ Reveals information that cannot be seen with traditional methods.

+ Enhances the image of welding by linking it with new technology and a game-like environment.

+ Boosts and supports self-study.

Challenges:– in some cases there may be

critical attitudes towards the integration of it and high tech-nology in a traditional training process.

22 Kemppi ProNews 201122 Kemppi ProNews 2011

eveRy weLDeR shOuLD

have

Four arc tools


→

Picture 2: Variation in the root gap with the same welding power. Root gaps from the left 2, 4 and 6 mm.

Picture 1: The current waveform of the WISEROOT process when the filler droplet is transmitted to the weld pool. The cycle is composed of the arc and short circuit periods. The dashed line indicates a normal short arc.

the last few years have seen developments in MiG/MaG welding

power sources, creating greater opportunity to increase the

multifunctional aspects of the equipment. both power source and

software technologies have made it possible to further develop

tailored welding processes and improve function, aiding the

welders’ work, quality and productivity.

Kemppi’s wise product family is designed exactly for this purpose.

Wise is a range of software based welding products for use with Kemppi FastMig and

KempArc welding machines. Tailored Wise welding processes and functions are used for root pass work, sheet metal welding, penetration control, and focused arcs, where energy density is concentrated into a narrow area.

the WiseRoot process for root pass welding

Tailored root pass MIG/MAG welding process we consider here is WiseRoot. Patented WiseRoot process controls the power source’s current and voltage parameters digitally. The process monitors the short circuit and ensures correct timing of the filler droplet’s transmission from the filler wire into the weld pool.

The tailored root pass process we consider here is WiseRoot. The patented WiseRoot process controls the power source’s current and voltage parameters digitally. The process monitors the short circuit and ensures correct timing of the filler droplet’s transmission from the filler wire into the weld pool. This is a modified short-arc welding process and as a MIG/MAG welding process it is in category 131, 133, 135 or 138 as defined in the EN ISO 4063 standard.

The principle by which the WiseRoot process operates is that of two different shapes being formed from the welding current. These shapes can be referred to as the short circuit and arc period upslope stages (see picture 1). The WiseRoot process is a modified short-arc process and should not be confused with pulse welding.

In the first upslope stage, the filler material is transmitted in the short circuit phase to the weld pool, while the power of the arc is suddenly increased during the second upslope stage and sustained at the desired level. Before the first upslope

stage, there is a short peak in the welding current, during which the filler material wire contacts the weld pool.

In the first upslope stage, the rapid increase of the current to the desired level generates a so-called pinch force, which allows the droplet to detach from the tip of the filler wire. The detachment is ensured by slowly decreasing the current. Once the droplet has been transmitted to the weld pool, a second stage of increasing current begins and initiates the arc stage. The control system of the device monitors the droplet detachment moment throughout the arc. Correctly timed rise and fall of current guarantees a spatter-free pass–over from the short circuit to the open arc.

The second upslope stage shapes the weld pool and ensures sufficient penetration in the root pass. After the two upslope stages, one following upon the other, the current is reduced to the desired base level. Use of a specified base current level ensures that the next filler droplet will be transmitted during the next short circuit.

Rapid response and correct timing in power source control combine with the correct shape of the current waveform in the process to allow uninterrupted, spatter-free droplet detachment and transmission into the weld pool. This

keeps the arc stable and the welding process easy to control.

The WiseRoot process differs from normal short-arc welding. Picture 1 shows normal short-arc and WiseRoot waveforms. In the normal short-arc process, droplet detachment occurs at a high current value, which depends on voltage control. After that, the current slowly decreases before the arc period ends and the next short circuit begins. In the WiseRoot process, droplet detachment happens at a low current value, which results in soft transmission to the weld pool. After that, in the arc period, the process gives a precisely measured strong boost to the arc and then rapidly cuts the current to the predetermined level before the next short circuit. The WiseRoot process’s highly controlled arc reduces spatter in the droplet detachment phase and decreases the heat input in the arc phase to be comparable with that in a normal short-arc process.

The WiseRoot process allows welding with wider root gaps than usual, with the same welding power settings (see picture 2). Root gaps can range from 1 mm to 10 mm, but the welding power has to be adjusted to match the case. When the welding position changes, the welding power must still be appropriate for the circumstances.

innovation: W

ise meets

the welder


Process v [mm/min]

wfr [m/min]

I [A] U [V] P [W] Q [kj/mm]

Q [%]

WiseThin 800 4 93 16,7 1517 0,091 0

1-MIG 800 4 113 18,3 2028 0,122 25,20

Here is a list of the key benefits of the tailored root pass welding process:

• Wider root gap makes it possible to use a smaller groove angle and decrease groove volume.

• No need to use a backing ring.• It is a highly efficient process:

10 % faster than normal MAG welding, and three times faster than TIG welding.

• It is suitable for position welding• Easy to learn and use.• Less spatter than in normal short

arc.

On the workshop level, the above WiseRoot features can be seen as increased welding quality and decreased need for post-weld rework.

the Wisethin process for sheet metal welding

In sheet metal welding, low heat input is a desirable feature. There are various laser welding applications that have been used for this purpose, but lasers have their limitations.

MIG/MAG welding has developed so that it is now possible to weld with low heat input, especially in the short-arc area. In tailored processes, one can obtain the same heat input as in laser welding.

Kemppi’s WiseThin is a tailored MIG/MAG short-arc process that enables achieving 5–25 % less heat input than with a normal short arc, depending on the welding case. In welding of high-strength steels, this is of great benefit, because the trend is to weld steels of ever higher strengths. This is a driver toward a weld process with low heat input.

Table 1 compares the WiseThin process’s heat input to the heat input of a normal short arc in welding of an overlap joint. The material is structural steel and the plate thickness 1.0 mm.

The principle of the WiseThin process is similar to that of the tailored WiseRoot process for root pass welding. The difference is that the WiseThin is optimised for sheet metal welding.

WiseThin is a modified short-arc welding process and as a MIG/MAG welding process it is in category 131, 133, 135 or 138 as defined in the EN ISO 4063 standard.

Picture 3 shows typical welding applications for tailored sheet metal welding processes.

In sheet metal laser welding applications, the biggest problems arise from the narrow gap tolerances. With MIG/MAG processes the tolerance window is wider, because they are not so sensitive to gap variations. Tailored processes can increase the width of the gap tolerance window, because of the lower heat input. This makes it easier to handle molten metal.

Table 1: WiseThin and synergic MIG heat input comparison

Picture 3: Low heat-input and optimal weld bead geometry are among the benefits of tailored processes.


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the WisePenetration function for guaranteed penetration

In MIG/MAG welding, constant voltage (CV) characteristics are most commonly used. The self-adjusting welding arc is the most important argument for the use of constant voltage characteristics. An increase in stick-out length will cause welding power to drop, because welding current decreases (P = U x I).

Changes in stick-out length have no effect on wire feed speed or arc voltage. Instead, welding current fluctuates according to the changes in stick-out length.

As an example, picture 4 shows you how welding current changes with stick-out length when welding S235 steel with 1.2 mm wire and using Ar + 18% CO2 shielding gas and the following welding parameters: wire feed speed 8.8 m/min, voltage 29 V, travel speed 58.0 cm/min.

Because of using constant voltage characteristics, the welding current

Picture 4: Welding current changes with the stick-out length.

depends on the stick-out length: the greater stick-out length, the lower welding current. This can cause serious welding defects, such as lack of fusion, incomplete penetration, unstable weld quality and spatter.

In manual MIG/MAG welding, the stick-out length always varies more or less, depending on the welder’s skills, and this has an effect on the weld penetration. Sometimes the welder must increase the stick-out length because of limited visibility or accessibility, position welding, difficult joints or weld design problems.

In mechanised and automated welding, dimensional and geometrical deviations of the joints can cause variation of stick-out length. Those deviations can originate from various phases of the joint preparation or fit-up work. Also the welding heat causes distortion, which increases deviations during welding.

Various joint tracking systems can be used to help this, but they are expensive


and do not operate reliably in all welding conditions.

Kemppi offers the unique WisePenetration function for cases where it is difficult to keep a constant stick-out length. This function makes it easy to keep the welding parameters (I, U) within the WPS limits. This guarantees the desired penetration and improves the weld quality.

WisePenetration offers constant welding current with stick-out length within the limits defined in welding procedure specification (WPS). When welding with stick-out lengths within the permitted limits, WisePenetration operates like conventional MIG/MAG process and lets welding current fluctuate with the stick-out length. However, if stick-out length increases above the permitted level, WisePenetration takes the control and ensures that the current remains constant.

Picture 5 shows how WisePenetration keeps the penetration constant while the standard process loses its penetration when stick-out length rises above normal limits.

the WiseFusion focused arc function offers many benefits

In position welding (other than flat or horizontal vertical), the most common problem is how to control the welding arc and the molten weld pool.

This issue is emphasised in MIG/MAG pulse arc and spray arc welding. For example, it is very difficult to find the correct pulse welding parameters when welding aluminium in horizontal overhead position. To meet the needs of all position welding, Kemppi has developed the WiseFusion function, which keeps arc length more constant and prevents the arc from becoming longer as the stick-out length changes.

Picture 6: On the left you can see a weld made with pulsed MIG and WiseFusion function. The weld on the right is made with pulsed MIG without fine tuning the arc. The wire feed rate is 4.6 m/min.

Picture 7: 960 MPa grade steel weld. Plate thickness is 6 mm. I-groove welded with a single pass from one side. Welding energy is only 0.58 kJ/mm.

Picture 5: The upper row of pictures shows normal MAG process without WisePenetration, and lower row shows how WisePenetration affects the weld. Stick-out lengths from left: 25mm, 30 mm, and 35 mm.

‘using the adaptive arc length control brings all kinds of benefits.’

The principle of operation is based on controlled regulation of pulse or spray arc current and voltage waveform. This produces a welding arc that is more focused and has higher energy density than in normal pulse or spray arc welding.

Another benefit of WiseFusion is that a focused arc allows greater welding speeds. The greater welding speed and higher energy density mean less heat input compared to standard pulse or spray arc, and low heat input is a critical factor with certain materials.

Using the adaptive arc length control brings all kinds of benefits, such as excellent weld pool control in all positions, narrow and energy-dense arc, and no need to fine tune the arc length.

WiseFusion is very easy to use. Welding parameters are always right, so you don’t need to adjust them. You can use faster welding speeds and get deeper penetration and stiffer, more focused arc. Low heat input and narrow grooves make it also a very productive and cost-efficient welding function.

27Kemppi ProNews 2011 27Kemppi ProNews 2011

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Deltabeam overcame the

Deltabeam is a hollow beam welded from steel plates with holes in the sides. It is filled with concrete at the construction site.

Once the concrete has hardened, the beam can connect hollow-core, composite, and thin–shell slabs or cast-in-place concrete into an integrated load-bearing structure.

Deltabeam development work is performed by Peikko in Finland. The

beams are manufactured at the company’s facilities in Finland and Slovakia.

Peikko’s beam production facility in Lahti manufactures more than 250 beams weekly, each one tailored to the client’s site-specific requirements. Beam production employs 45 people, 12 of them manual welders.

There are many challenges associated with manufacture.

‘The components of the beam are produced and the required openings

made via plasma or flame cutting and mechanical cutting,’ says Toni Räty, production manager for Deltabeam production at Lahti.

The material is S355J2+N structural steel. The ribbed reinforcement bars are cut mechanically.

The webs are welded onto the bottom and top plates through mechanised submerged arc and MAG welding. Robot assembly welding is used for the connection ends of the beam.

Deltabeam is an internationally

recognised and widely used product for many

kinds of construction. several challenges have

been overcome in its manufacture.

chaLLeNGes Of PRODuctiON

case

: Pei

kko

oy,

laht

i, Fi

nlan

d


© Peikko Oy

The ends, mould plates, spacers, reinforcement bars, and support plate inserts are welded manually by means of the MAG method. Manual welding in Finland is carried out with Kemppi FastMig Pulse 450 equipment with the WisePenetration feature.

‘It ensures the penetration of hard-to-reach welds inside the beam,’ says Räty.

After the beam is assembled, welds have to be made through the web holes. They are only 80 to 150 millimetres in diameter, which means that the visibility of the welding location is poor.

‘Furthermore, because of limited accessibility, the position of the torch changes from pulling to pushing during welding, and the alignment of the arc with respect to the joint cannot be optimal all the time,’ Räty says.

The quality requirement for the beam’s structural welds is level C under the SFS-EN ISO 5817 standard.

After assembly, the lower surface of the beam is protected with alkyd or epoxy primer for storage and transport. ‘Any other painting is subject to case-specific agreement,’ says Räty.

The beams range in weight from 100 to 5,000 kilograms. The longest ones are more than 12 metres long. The most labour-intensive beams take approximately one work day to weld and consume seven kilograms of filler wire.

Toni Paajavuori welding the support plate inserts. They are welded after assembly, through the web holes. The holes are only 80 to 150 millimetres in diameter, which means that both visibility and accessibility are inadequate for traditional approaches.

‘it ensures the penetration of hard-to-reach welds inside the beam.’

facts about Peikko• Peikko Group Corporation,

established in 1965, is a family business specialising in composite beams and joining technology for concrete structures.

• Peikko operates in more than 20 countries, on three continents. it is headquartered in lahti, Finland.

• in addition to Finland, Peikko has production facilities in Great Britain, lithuania, Germany, slovakia, Russia, and the United Arab Emirates.

• since its establishment, Peikko has been developing new technologies and applications for industrial products. For example, the company has developed a standardised foundation structure for the towers of wind power stations.

• the business group’s turnover in 2010 came to €78 million. on average, the company had 700 personnel, approximately 300 of them in Finland.

www.peikko.com

Deltabeam makes a green impactThe results of Peikko’s product development have often been pioneers in their field. The company was among the first to commission research on the carbon footprint of construction. According to an independent study conducted in Great Britain, the use of Deltabeams reduces the carbon footprint over a building’s life span in comparison to I-beams.

‘The use of Deltabeams reduced the carbon footprint of construction materials by 10%. Most of the reduction came from the amount of steel needed: the number of beams required was substantially lower than the equivalent number of I-beams,’ says Toni Räty.

‘There were other savings on materials too – such as

bricks, concrete, and mortar – and in waste, because the use of Deltabeams instead of I-beams reduced the building’s overall height,’ he says.

In all, the use of Deltabeams reduced the carbon footprint over the building’s entire life span by five per cent when compared to I-beam construction.


© Peikko Oy

Karisma combines soft wood with stylish steelBy December this year, Lahti will see a 34,000-square-metre commercial centre completed in the Karisto area. This shopping paradise combining wood and steel in a natural way will be constructed around a frame supplied by Peikko.

The basis for design in the Karisto area in general has been wood construction – something that is appreciated also in the commercial centre. Wood is naturally suitable for this shopping oasis, called ‘Karisma’ (meaning ‘charisma’), which also functions as the entrance to its district of town.

Approximately 22,000 square metres of the roof of the two-storey building has been covered with 12-metre-long, 2.5-metre-wide wooden roofing elements. Also the external panelling will feature wood.

The Karisma commercial centre will rise next to the busy Highway 4. About 26,000 cars per day pass along the highway here, and the new shopping oasis hopes to attract a significant proportion of these. The aim is to offer services to three million customers annually and to reach annual sales of approximately 120 million euros.

The main contractor for the project is SRV. Peikko Finland Oy, Peikko Group’s unit in Finland, is responsible for delivering the steel parts and the installation of the steel and concrete elements of the frame. The company will deliver, in total, 2.2 kilometres of Deltabeams as well as more than 700 tons of other steel structures, such as composite columns and trusses.

The estimate for the total cost of the project is about 90 million euros.

texts: Pirjo Kemppinen

environmentally friendly office facilities being built in Polandoffice facilities totalling 23,000 square metres in floor area are being built in Poland that utilise the latest eco-friendly technologies. the Green towers buildings use Deltabeams manufactured by Peikko, a Finnish company.

Construction work has already begun on the Green towers office blocks, in the city of Wrocław, in south-western Poland. the project’s objective is to produce extremely energy-efficient and sustainable buildings.

the construction project has been awarded lEED certification. leadership in Energy and Environmental Design is an internationally recognised environ-mental certification system.

skanska is Peikko’s customer in this project. in the spring, Peikko delivered 800-metre Deltabeams and several other joint components, such as rebar connections, hidden corbels, and column shoes, from the Peikko plant in slovakia.


welding gave Katja a

For Katja Vironen, welding is not just a job – it has a much deeper meaning. she believes it has changed her life and given her the confidence to realise her dreams. in fact, welding also features in one of her biggest dreams.

When KatjaVironen first picked up a welding gun eleven years ago, she realised

that she had at last found what she’d been looking for. A lot of people tried to discourage her, but she wasn’t put off.

‘I noticed that I could learn quickly and easily. It made welding fun and got me wanting to learn more,’ says Katja, 34, of Riihimäki, Finland.

‘It’s a field where there’s infinite scope to develop your skills. I find there’s always something new, a material or method, for example, that I don’t know yet.’

However, Katja admits with a laugh that she didn’t exactly volunteer when she started training to be a welder.

A career that started at its peak

When she was growing up, Katja enjoyed looking after the horses, sheep and dogs that her family kept at their home in Koria.

With her love of animals, it was only natural that she started an apprenticeship to train as a stable groom when she left school.

Unfortunately, the employment situation in that field was already poor and she couldn’t find a permanent job. She couldn’t think of anything else she wanted to do, either.

‘I’ve always been more interested in doing things with my hands than reading, so I didn’t want to study.’

As time went on she almost completely lost her initiative and self-confidence. Life was hard without a wage and the days were long because all her friends of the same age were studying or working.

Things changed during a visit to the job centre, when a vocational psychologist more or less forced Katja to take a basic course in welding. Katja, who was then 23, decided she would stick out the four-month course to the end.

After a couple of days of theory Katja had the chance to try welding in practice and found her future.

Faces behind the mask: Katja Vironen, Finland

New Life

Four months turned into more than a year of studies. After the basic course Katja wanted to learn more and more about welding, and she did MIG/MAG, MMA, and TIG courses. Her hard work and good level of skills paid off when Kouvola based Steka Oy selected six people from numerous applicants to train as high pressure welders. Katja was one of the successful applicants.

‘I managed to start my career right at the top.’

The job was by no means the easiest way for a beginner to start:

‘TIG welding is a challenge because you have to be able to work with both hands at the same time. In addition to that, as a high pressure welder I had to work in difficult places and uncomfortable positions.’

Monitoring also made the work more demanding. The quality of the weld seams was continuously inspected, both visually and by means of X-ray photography and ultrasound.

‘Sometimes I thought I’d go home and not come back.’


→

Recession dropped down to earth

Katja nevertheless stayed with Steka for six years. She later felt it was time to move away from the area where she was born, and in May 2007 she moved to Tampere and found a good job there.

Her happiness did not last long, though, because the recession had started and she lost her job just over a year later.

‘The bottom fell out of my world.’However, she decided to pay tribute

in her own particular way to the years that had gone by.

Katja had got her first tattoo when she was around twenty, at a time when it was becoming fashionable. She then carried on, and she now has tattoos on about twenty percent of her skin. New art is appearing on her body all the time.

‘My aim is to be a walking picture book of my own life by the time I’m a pensioner.’

On her right arm she’s got the Kemppi logo. Katja asked for the logo to be done in a special way so it looks like the tattoo has been pressed on to her skin with a hot iron.

‘It was a huge thing for me when I found a career and job I liked after years of frustration. I was really happy and felt that I was improving myself.’

‘When I was made redundant I decided to preserve the memory of the new life that welding had helped me to get.’

Katja was in no doubt what image she wanted for the tattoo:

‘Kemppi machines are everywhere – it’s easy to be a fan. They are built to last and they’ve got character. A lot of other equipment builders try to use colours to make their machines stand out, but Kemppi’s orange is unbeatable.’

now seeking success under water

Katja originally liked MMA welding the most because people said it was the most challenging method. She didn’t want to conform to the idea that women should do TIG welding, at least not until she had tried other methods first.

‘I’ve never wanted to go along the road, I always want to tackle the rough ground.’

But she doesn’t think of herself as a feminist.

‘Some people say that metalworking makes women into men, but I don’t think so. Metalworking doesn’t suit all women, but it doesn’t suit all men either.’

At the moment, though, Katja is mainly working as a TIG welder. She found a new job in Riihimäki, first as a security guard and then as a welder. Sometimes when she makes up her mind she’s determined to stick to her decision.

‘When I was on the basic welding course someone said I couldn’t become a welder because I couldn’t lift a gas bottle. I’ve lifted every bottle myself, and without using lifting gear. It’s all about technique, not strength.’

Katja is working on her technique and skills in other areas, too. She is doing a diving course during the spring and plans to use what she learns later.

‘Most people ask me whether I’m going coral reef diving on my holidays. My aim has always been to dive into harbours here in Finland with my welding rods.’

Katja hopes that by building her diving skills she will one day be able to become a professional underwater welder.

But what about the bags of flour?

‘When I was young I spent five years thinking. I’ve decided not to waste any more of my life. I’d rather regret what I’ve done than what I haven’t done,’ Katja explains.

A year ago people couldn’t understand what was happening when they saw Katja packing bags of flour into her backpack every evening. This year she has already become familiar sight, walking along the roads for hours on end with her backpack.

Around the Kemppi logo Katja is having tattoos depicting the Normandy landings.

Katja is both the first female and first TIG welder at Rimera Oy. All the people working at the company have their own nickname, which some get straightaway and others have to wait for. Marko Räty (‘The Pastor’) says that Katja found her own place among the team and got her nickname ‘Putki-Pirkko’ immediately.


© R

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She is practising for summer, when she intends to go hiking with friends.

‘The first time we hiked from Lappeenranta to Hamina along the Salpa Line. We covered 133 kilometres in just over 50 hours. Our next hike will also be along the Salpa Line, but to the north.’

Known officially as Suomen Salpa (Finland’s Bolt), the Salpa Line was a defensive line built close to Finland’s eastern border after the Winter War. Katja had good reasons for choosing it as her hiking route.

‘I was interested in the army when I was young but I was too shy, and after being unemployed for a long time I’d

more or less lost my initiative. Every year I put off applying for military service, and then I had my son.’

For years Katja has been collecting different countries’ army surplus gear. She has already got camouflage suits, boots, bags and hats not only from the Finnish but also German, Swedish, Czech, British, Austrian and Dutch armies. When she goes hiking she naturally wears army gear.

‘I did a course for defence volunteers and I got the chance to run about in the forest with a gas mask on,’ Katja says.There are still some dreams that Katja has not yet been able to realise. Sameli, her son, was born in 2003 and she did a village blacksmith course while on maternity leave.‘If I win the lottery I’ll buy an old house in the middle of the forest and set up my own smithy.’

As well as army gear, Katja also collects material about Kemppi. She particularly wants to find an old poster that says ‘there are no bad welders, it’s just that some have got better machines.’

‘there are still some dreams that Katja has not yet been able to realise.’

Rimera Oy- Designs, manufactures and installs

steel-structured casting moulds for the pre-cast concrete element industry.

- Around 95 percent of production goes for export to more than 40 countries. the main markets are Russia, saudi-Arabia, india and the Philippines.

- the company’s 2 700 m2 production facility is located in Riihimäki. subsidiary company steelform is based in nastola.

- Approx. 40 employees in total.- the company was established in 1980

and has been part of Elematic Group since 1999.

table moulds are used for horizontal casting in the manufacture of panels with a large surface area, such as façades, one at a time.

Hollow core slab moulds, where the concrete is cast by machine, are Rimera’s third main product. Hollow core slab lines are typically 120 metres long and 1.3 metres wide.

Welding represents 90 percent of the work involved in manufacturing casting moulds. Also significant is the fact that the company’s annual consumption of welding wire is almost 30 tons. this is used by 22 Kemppi welding machines.

Annual use of welding wire totals 30 tons

Katja Vironen joined Rimera as a welder in mid 2010. she mainly welds heating tubes for installa-tion in casting moulds manu-

the greatest challenge in manufacturing moulds is to ensure that the surfaces are sufficiently straight.

‘in battery moulds, for example, the permissible deviation is only one millimetre per two metres, and the tolerance for railway sleeper moulds is measured in tenths of a millimetre.’

Right angles and crosswise and external dimensions are also required to be accurate.

‘the welder must have extremely good control over the heat input so that the mould does not change shape while it is being welded,’ Mether says.

texts and pictures: Pirjo Kemppinen

factured for the construction industry.‘Warm water circulating in the

tubes makes the concrete cure faster. in addition, the drying process is controlled when it takes place at a temperature set at a suitable level,’ explains Rimera’s Production Manager Åke Mether.

two main types of mould are used in the construction industry. in the case of battery moulds, the concrete is poured vertically into the mould and about 20 panels can be cast at once.


©P

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ac

Nordic skating tour will generally last from morning until evening.

Roller skating has been regarded as the newest form of skating but it dates back to the 1700s. Nowadays it is popular both as a form of exercise and competitive sport.

the magic of figure skating

Figure skating is one of the most all-round ways of exercising and is probably the most spectacular of the competitive forms of skating. Figure skaters aim for a performance that is technically demanding and artistically high class at the same time. The skaters’ moves, jumps and spins, all executed in time to the music, can be truly breathtaking.

There are four competitive forms of figure skating: singles, pair skating, ice dancing and synchronised skating.

texts: Pirjo Kemppinensources of skating info: Finnish speed skating Association, Finnish Figure skating Association

was skating inventedAccording to recent British

research, the first skates were made from horse bone

4 000 years ago in Finland. in winter people could travel

considerably faster by skating across Finland’s numerous lakes rather than

walking around them.

As far as is known, no stone age skates have been found in Finland to support the results of the British research, but the origin of skating is probably not very significant in any case. Over the millennia, skating across natural ice has developed into a number of recreational and competitive sports that are enjoyed around the world.

the thrill of speed and beautiful scenery

Speed skating has a long history, both as a form of exercise and competitive sport. It is even said that Leonardo da Vinci (1452-1519) wondered how skaters are able to stand on narrow blades.

Speed skaters can use their own strength, speed and skating technique to reach amazing speeds. Only in cycling is it possible to go even faster.

As well as being a competitive sport, speed skating is also an ideal form of exercise for people of all ages and sizes.

Tour and Nordic skating are also effective ways to exercise. Tour skaters use manmade routes across natural ice. Nordic skaters, on the other hand, enjoy the adventure of travelling across free natural ice without manmade tracks. A

A study by researcher Fed-erico Formenti and Pro-fessor Alberto Minetti of Oxford University was published in the Bio-

logical Journal of the Linnean Society of London in 2007.

According to the researchers, skates made of bone thousands of years ago have been found in northern Europe. The large number of lakes in Finland means it is likely that the ancient Finns where those who had the most to gain from the ability to move quickly across ice.

The skates consisted of pieces of bone that were simply bound to the feet with straps. To move across the ice the skaters stood on the bones and pushed themselves along with a stick.

The research team themselves tested copies of the bone skates in the Alps. They found that the skates have good slide characteristics because fat adhering to the bone reduces friction.

The ancient skaters certainly did not set any speed records. The researchers estimated that people could travel around eight kilometres an hour using the bone skates, compared to as much as 60 kilometres per hour achievable by today’s speed skaters.

in FinlAnD?


© P

elic

ans

ice hockey is said to be the world’s fastest-paced team game. During a single game the spectators experience a roller coaster ride of emotions.

ice hockey action with the Pelicansice hockey’s popularity is based on the speed of play and on the sudden, often violent situations that develop during games. A perfect ice hockey game takes the spectator through the whole range of emotions from excitement to despair, from bitterness to joy and jubilation.

”the final result depends on the number of goals and there are usually lots of them. it’s a fast contact sport with plenty of action and body checks to keep the spectators entertained.”

”the speed and intensity of the game keep the audience enthralled,” says Tomi-Pekka Kolu, Marketing Manager of the Pelicans, lahti’s ice hockey team.

He adds that around the world ice hockey games have been built up into all-round events that also feature other types of entertainment and bar and restaurant services.

the Pelicans can trace their roots back to Reipas, a team established in Vyborg in 1891 which went on to win the first ever Finnish ice hockey Championship. the team has changed its name several times over the years, becoming the Pelicans in 1996.

the Pelicans have been playing in the Finnish Championship league continuously since 1999.However, the Pelicans are more than just a team fighting to win the Finnish Championship.

“We are the partner team for Päijät-Häme Central Hospital and we’ve collected almost 50 000 euros for the hospital during the last four years,” he explains.

in fact, the Pelicans are the biggest event organiser in the lahti area, offering around 30-40 opportunities to be entertained at sporting events each year.

”the team also serves as an example for young people in the area who are interested in ice hockey. our Pelicans school tour encourages young people in the Päijät-Häme area to exercise and get fit.”

At the end of the season, Pelicans presented Kemppi with a goaltender’s helmet. the autograph of niko Hovinen, who was the third goaltender of the team that won gold for Finland in the ice Hockey World Championship 2011, was eternalised on the helmet. the helmet was accepted by Chief Executive officer Anssi Rantasalo.

Kemppi oy has been supporting the Pelicans since 2005


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