FABTECH 2011: Welding (Part Two)

The Big Show exhibited the latest advancements in arc, gas, resistance and laser welding for diverse material joining applications, including sheet metal, pipes and tubes, jewelry, plastics and other exotic materials. Now our Show-in-Site brings some more of those welding systems and related equipment to you!

ROBOTIC TUBE CUTTING AND PROFILING
The RAZOR™, a new robotic tube cutting and profiling system from Vernon Tool™ Company (Oceanside, CA) offers features and functions ideal for high-production tube and pipe fabricators in heavy fabrication, agricultural, construction, vehicle and tube frame manufacturing.

The rugged RAZOR improves productivity and quality by consolidating the typical multi-step fabrication process – set-up, layout, manual/CNC machining and end prep – into one easy operation. The capability to take 3D models (CAD) to computer-aided manufacturing (CAM) eliminates the time spent teaching and learning the programming process. Additionally, the system is outfitted with a large pre-loaded cut library, providing maximum tube and pipe configuration flexibility.

The standard configuration for the RAZOR includes a six-axis FANUC® Robotics ARC Mate® 100iC industrial robot; FANUC R-30iA controller; servo-driven two-axis positioning carriage; four-jaw idler; and a plasma cutting unit. The RAZOR can process tubes with cross-sectional dimensions up to 11.5 in (8 x 8, 10 x 4) and overall lengths up to 40 ft. Depending on the material being cut, maximum cutting speeds of up to 320 ipm can be achieved with an optional high-definition plasma cutting equipment.

The WinMPM™ Windows®-based operating system developed by Vernon Tool powers the RAZOR. The unit’s easy-to-use, icon-driven touch screen system interface makes operator training and implementation seamless, allowing fabricators to get up and running within hours, not days. www.vernontool.com

NEW FILTER TECHNOLOGY IN AIR POLLUTION CONTROL
Tri-Mer Corporation (Monroe, OH) a technology company specializing in air pollution control systems, has introduced Tri-Flow, a new filtration concept that delivers HEPA-like performance with a MERV 16 rating. Tri-Flow Compact filters are a higher-performing alternative to bag, cartridge and pocket filters. Service life is 3-5 times longer with zero compromise of filter performance. The unique Tri-Flow design provides in-line pulse jet cleaning and maintains an exceptionally low operating pressure drop. Filter efficiencies of 99.999 percent on 0.5 micron and larger particles (by weight) are typical. www.tri-mer.com

ALTERNATE FUEL OUTFITS, GAS REGULATORS
Smith Equipment (Watertown, SD) plans to display its cutting, heating and welding products, along with various alternate fuel outfits and gas regulators, including:

• Alternate fuel outfits: Designed for use with propane, propylene and natural gases, Smith Equipment alternate fuel outfits are available in medium- and heavy-duty models, as well as an economy version. Each outfit includes a torch and torch handle, regulators, hoses, a toolbox and additional accessories designed to assist in reliable cutting, heating and brazing performance.
• Mizon flowmeter regulator and flowgauge regulators: Smith Equipment designed these regulators to accompany a special shielding gas mixture developed by Linde. The gas eliminates ozone emissions in MIG welding applications, offering greater protection for the welding operator and the environment.
• Specialty gas regulators: Smith Equipment’s specialty gas regulators include its Silverline regulators, which are available in up to 10,000 possible configurations. Each of these specialty gas regulators provides gas purity levels up to 99.999 percent and is available in general-purpose, high purity, analytical and high purity stainless steel corrosion resistant models. Smith Equipment also offers a 3-stage nitrogen transformer blanketing regulator. www.smithequipment.com

TIG TORCHES, ACCESSORIES
Weldcraft (Appleton, WI) announced that it plans to showcase its TIG torches and accessories designed especially to improve quality and performance on fabricating and manufacturing applications. Company representatives will also be available to answer questions from booth visitors and provide product recommendations. www.weldcraft.com

ANGLE GRINDER EXTENDS TOOL AND WHEEL LIFE
Metabo Corporation (West Chester, PA), a leading international manufacturer of professional grade portable electric power tools and abrasives for industrial, construction and welding applications, now offers the 5 in WEPA14-125 Quick angle grinder featuring a unique auto-balance system that extends both tool and wheel life, while making the grinder safer and more comfortable to use.

The WEPA14-125 Quick, ideal for heavy duty cutting and grinding applications, features a long-lasting 12.2 amp motor, 1,450 watts of power, 29.2 in-lb of torque and a no-load speed of 10,000 rpm. Auto-balance technology replaces a traditional backing flange with an auto-balancing flange pressed onto the spindle. Ball bearings automatically offset out-of-balance conditions present in the grinding accessory, while the tool is in use, reducing vibration significantly.

The lower vibration levels in the new grinder decrease the risk of cumulative work related disorders, such as white finger syndrome, minimizing operator fatigue and have the ability to increase the life of a grinding disc by 50 percent. The reduced vibration also extends the grinder’s internal components longevity by up to 50 percent, keeping the tool in service for a far longer period than grinders that do not account for the effects of vibration on internal tool components.

The WEPA14-125 Quick also features a VibraTech (MVT) side handle that reduces vibration up to 60 percent for increased user comfort over an extended work period. The angle grinder’s Quick toolless wheel change system saves time and energy when replacing wheels, making the operator more efficient. Safety features include a non-locking paddle switch, a current interruption switch, a toolless locking wheel guard with seven positions and the “S-Automatic” safety slip clutch to protect against kick-back by absorbing the torque created should the wheel bind or snag.

Further extending the tool’s life span, the WEPA14-125 Quick has an improved and sonically-balanced fan paired with improved venting and more efficient internal ducting that increases air flow over the motor by 15 percent. This new grinder also features one of the most effective dust protection systems on the market. The system includes an encapsulated on/off switch and auto-stop carbon brushes, double-lipped labyrinth sealed bearings, unique dust-deflecting winding protection grid and epoxy coated field coil windings.

Advanced electronic features on the grinder include an electronic winding temperature monitor with LED display, electronic soft start feature and electronic speed stabilization. As with all Metabo grinders, the WEPA14-125 Quick is covered by a free XXL warranty that extends the normal one-year power tool warranty to three. www.metabousa.com

ELECTRO-CLEANING SYSTEM REPLACES HAZARDOUS PICKLING PASTES
Walter Surface Technologies (Montreal, QC) announces new components to the SURFOX weld electro-cleaning system. This latest innovation underscores Walter’s commitment to “Making Green Work.” The new Surfox system is just one more solution that helps create a cleaner, healthier, and safer industrial work environment.

While welding stainless steel often leaves heat discoloration (blueing) on the finished surface, metal fabricators are facing an increased demand for stainless steel that has a clean, fully passivated surface – for a wide range of industries such as food and beverage, pharmaceutical, architectural and transportation. To satisfy customer demand, metal workers must remove these discolorations. But the traditional cleaning methods that use pickling paste or grinding machines have high environmental impact and labor costs.

Grinding is not only time-consuming and labor intensive, but mechanical heat discoloration removal fails to provide a clean, aesthetic finish. Cleaning heat discoloration with pickling paste is the most common chemical method, but the pastes can be difficult to apply evenly, so the worker risks using more than necessary or insufficient amount of paste in some areas.

More importantly, though, pickling pastes are dangerous. Not only are they known carcinogens, but these extremely acidic compounds cause severe chemical burns when in contact with skin; workers must be covered from head to toe in acid-resistant overalls, gloves, and ventilation masks. Finally, the heavy metals in the pastes must be separated from the cleaning residue prior to waste disposal, adding another step to the overall production process.

The Surfox system cleans stainless steel without toxic pickling pastes, saves time for workers, and is easy to use. In a typical application, the worker fills the cleaning unit with an electrolyte cleaning solution. When switched on, the unit pumps the solution through an application pad, which simultaneously cleans and passivates the part. After the electro-cleaning process, the worker applies a neutralizing fluid to remove acid deposits.

The improved Surfox system features a new application pad, which is four times more conductive than the previous one, and can clean surfaces at rates of three fpm to six fpm. The controlled dispersion of the cleaning fluid also prevents waste. The result is a flawless finish on stainless steel – with Surfox, even a mirror-like finish on chrome is possible.

The Surfox system’s new components include:

• Surfox H – the standard electrolyte cleaning solution for regular use cleans up to 3 fpm to 6 fpm.
• Surfox T – the electrolyte cleaning solution for heavy-duty jobs has a higher pH than Surfox H and cleans up to 3 fpm to 6 fpm.
• New application pads for all cleaning units have increased conductivity. With this practical cleaning method, results are visible almost immediately.
• Passivation tester provides numeric values of state of passive layer
• Stainless steel grade ID tester allows customers to instantly identify the grade of stainless steel
• Marking kits electrochemical process to permanently mark stainless steel surfaces (for barcodes, serial numbers, lot and batch numbers, text, company logos, etc.)

Metal fabricators who use the Surfox system save time and money, improve working conditions, and reduce their environmental impact. Surfox system is NSF certified for use in the food industry and ASTM-A967/ASTM-A380 certified for chemical passivation on stainless steel. www.walter.com

DRY AND STORE FLUX
Weld Engineering Co., Inc. (Shrewsbury, MA) has developed the new HTS-700-850 deg Programmable 850 deg F High Temperature Submerged Arc Flux Oven for drying and storing of flux. The high heat range of this Super Oven bakes H2O out of the flux, preventing “hydrogen assisted cracking” of the weld. The oven bakes flux for an adjustable time (3 min to 5 hr) at an adjustable temperature [200 deg F (93 deg C) to 850 deg F (454 deg C)] before resuming to an adjustable storage temperature [175 deg F (79 deg C) to 550 deg F (288 deg C)].  The stationary HTS-700-850 deg holds approximately 700 lb of flux (317 kg). www.weldengineering.com

CABLE CARRIERS FOR DEMANDING ENVIRONMENTS
igus® Inc. (East Providence, RI) will be exhibiting a chip-proof cable carrier, an innovative guide trough system for long-travel applications and a cable carrier for rotary movements.

The RX energy tube is specially designed for the machine-tool industry. It is nearly 100 percent chip-proof and its smooth, domed outer contour ensures all debris, such as metal chips, simply falls off. A series of comprehensive tests – including underwater experiments and tests measuring chip-mass penetration – have been carried out in igus’ test laboratories to confirm the energy tube is nearly 100 percent airtight.  Despite its rugged design, the RX energy tube can be easily opened using a screwdriver to unscrew bolts integrated into the outer radius of each link.

To prevent abrasion and wear in long travel, gliding applications, igus offers Guidelok, a horizontal guiding system designed to keep the upper and lower cable carrier runs apart. The new solution is ideal for machine-tool industry applications up to 164 ft. Since debris and chips can become trapped between a cable carrier’s upper and lower runs as they glide on top of one another, Guidelok keeps the upper and lower runs separate via a spring-loaded roller support. The support is pushed back as the cable carrier passes through, before snapping out again after the radius has passed.

For machine tool applications with limited installation space, igus offers Twisterband, an innovative, compact cable carrier system that can turn through 3,000 deg in a small area. TwisterBand guides energy, data and media with little wear and is extremely cost effective.

Other products on show will include Rol E-Chain^®, a uniquely designed cable carrier with built-in wheels to facilitate travel over long distances, Triflex^® R, a highly flexible cable carrier for applications on multi-axis robots, and DryLin WJRM, a hybrid linear bearing that both rolls and slides. www.igus.com

WELD CLEANING TECHNOLOGIES
The 4½ in Roughneck weld cleaning brush from Weiler Corporation (Cresco, PA) is designed specifically for use on 4½ in mini-grinders. Although 4½ in is the most popular size of small angle grinder, welders and fabricators using this tool have traditionally been limited to 4 in diameter stringer bead wheels for surface preparation, root-pass weld cleaning and inter-pass weld cleaning.

This brush is designed for the greatest cleaning action and longest product life on small angle grinders and features a high knot count and a short trim length. Its design results in a 35 percent improvement in cleaning action, up to 20 percent less wire loss and a 50 percent longer brush life than a comparable 4 in stringer bead brush. The 4½ in Roughneck is available in both carbon steel and Type 302 stainless steel wire with a variety of arbor hole options.

Detailed information on the Saber Tooth line of ceramic abrasives is available by requesting a copy of their 4-page color brochure. The Saber Tooth provides cool, fast-cutting action on aluminum, stainless steel, Inconel, titanium and other hard-to-grind metals, resulting in lower grinding and finishing costs. Saber Tooth ceramic abrasives are fast cutting and have a long life due to an aggressive self-sharpening ceramic grain. A specially formulated grinding aid prevents dulling and glazing of grain and Saber Tooth products are designed to work with heat sensitive materials for cool-cutting – protecting high value parts from heat discoloration.

Weiler’s Saber Tooth flap discs grind and finish in one step, resulting in fewer changeovers and increased productivity – the ideal choice when weld blending, grinding, deburring, deflashing, surface finishing, or edge chamfering on hard to grind metals. Both the standard angled style phenolic back and the high density flat style phenolic back Saber Tooth flap discs are available in 4½ in and 7 in sizes.

In addition, Weiler provides the only ceramic trimmable backed disc in the marketplace. The 4½ in trimmable Saber Tooth’s innovative design enables the operator to reduce the diameter of the backing to extend disc life. The trimmable backing also provides high flexibility, enabling access to hard-to-reach areas. The performance-engineered non-marking trimmable backing will not damage the work-piece, resulting in less re-work and scrap.

In addition to the popular Saber Tooth standard angled style flap disc, Weiler offers ceramic grain high density flap discs, blending discs, resin fiber discs and belts. Saber Tooth blending discs are available in 2 in and 3 in diameter, with metal hub or plastic buttons in grit sizes of 36, 60 and 80. These cloth-backed coated abrasive discs are ideal for a wide range of light fabrication, repair and maintenance applications. The Saber Tooth resin fiber discs are designed for all-purpose weld blending, grinding, surface preparation and finishing.  The resin fiber discs are available in 4½ in, 5 in and 7 in with grit sizes from 24 to 80. Saber Tooth belts are available in many sizes and grits. www.weilerabrasives.com

HEAVY DUTY MOBILE STACKING CONTAINER
Sumner Manufacturing (Houston, TX), an industry leader in pipe and material handling equipment, announces new multi-purpose Tainer Mac heavy duty stacking container. The Tainer Mac is a mobile, compact, stackable, heavy duty container for the contractor. Tainer Macs provide mobile storage for power cords, fittings, fasteners, safety gear, hardware, loose parts, pumps, hoses, rope slings and more.

“Introduction of the Tainer Mac fills a unique void in material handling,” states Rob Collins, the president of Sumner. “Tainer Macs are durable, have an impressive load capacity, and can be stacked with each other or other Stacking Macs such as the Mac Rack, Pipe Mac and Bundle Mac. One of the best features of the Tainer Mac is continued accessibility to items in the lower container when stacked.”

The Tainer Mac features four heavy duty casters that are lockable on one end, a large storage capacity, a steel wire screen and a load capacity of 1,500 lb (680 kg) or 3,000 lb (1,560 kg) when stacked on top of each other. The 32 in width of the Tainer Mac allows it to easily fit through a standard doorway. Tainer Mac storage compartments measure 24 in high, 32 in wide and 56 in long. www.sumner.com

ALL-IN-ONE COIL JOINING
Joining Technologies, Inc. (East Granby, CT), an innovator in industrial laser applications, announces new features and functionality to its innovative Infinite Web® all-in-one coil joiner. The system is noted for its non-contact splicing process that incorporates laser cutting and welding with a single head. The new features will enable the splicing of titanium coils as well as splicing on a 15 degree bias as an alternative to forming perpendicular joints.

The Infinite Web dramatically increases throughput, with some customers reporting a greater than 33 percent increase in plant-wide productivity resulting from improved efficiency and capabilities. With the ability to service multiple converting lines, the Infinite Web is a truly mobile, stand-alone system requiring only an electrical input and minimal operator involvement. The industrial PC-based control system features a touch screen interface, predefined programs for selected alloys, and proprietary self-diagnostics to ensure optimal uptime.

Designed by welders to handle material thicknesses from 0.002 in to 0.040 in, the Infinite Web uses coaxial optics to verify proper positioning and provide precise and accurate splices. Both cutting and welding operations are automatic and non-contact. “It’s a quantum leap from the splicing equipment currently seen in metal converting plants,” said company president Dave Hudson. “The system offers a user friendly, streamlined design with optimal safety features. The Infinite Web automatically prepares the coil ends and delivers the finest weld possible each and every time the Start button is touched, all in less than three minutes.” www.joiningtech.com

PROTECTION AGAINST HEXAVALENT CHROMIUM FUMES
Welders can now obtain affordable protection from harmful particulate contaminants with the new Jackson Safety Brand R60 Airmax Powered Air Purifying Respirator (PAPR) from Kimberly-Clark Corporation (Roswell, GA). The new PAPR features a NIOSH-approved HE filter for particulate contaminants that can be easily set and locked into place.

“The Jackson Safety R60 Airmax PAPR can help provide necessary protection in accordance with new OSHA guidelines on hexavalent chromium fumes,” explains Tami Wenzel, a category manager for Kimberly-Clark Professional. “These fumes may be produced when welding on stainless steel and can cause serious respiratory issues without proper protection.”

The new Jackson Safety R60 Airmax PAPR comes complete with fully adjustable headgear and a welding helmet featuring a Jackson Safety W40 series variable auto-darkening filter. The ADF automatically detects weld arcs and switches to weld shade, which can be adjusted to shade 9-13 with a light shade of 4. The variable ADF is ideal for MIG, TIG and Stick welding. A flame-retardant face seal around the welding helmet protects welders from sparks, and the helmet’s shape helps to prevent embers from sitting on the shell. The unit’s breathing hose is flame-retardant and extends approximately 35 in for maximum flexibility.

Powered by a lightweight, eight-hour lithium ion battery, the compact blower unit has a wide, adjustable waist belt. An audible alarm gives the user a signal when a new filter or battery charge is needed. The unit comes with a “smart” battery charger that indicates when charging is complete to avoid overcharging. An airflow indicator also is included for checking the unit’s airflow prior to use. www.kc-safety.com

ABRASIVES FOR AUTOMATED FINISHING OF STAINLESS, EXOTICS
A line of Type 1 cotton-fiber abrasive wheels that do not change part geometry, making them ideally suited for automated finishing applications, are available from Rex-Cut Products, Inc. (Fall River, MA).

Rex-Cut^® Type 1 Abrasive Wheels feature multiple layers of non-woven cotton fabric impregnated with aluminum oxide or silicon carbide abrasives which are compressed with varying bond hardness. Ideal for automated finishing applications on precision stainless steel parts, they constantly expose fresh abrasives as they work and will not change the part geometry.

Suitable for use on stainless steel, aluminum, steel, and exotic alloys, Rex-Cut^® Type 1 Abrasive Wheels come in sizes from 1 in to 8 in OD and 1/8 in to ½ in thick. They include a wheel with a GFX bond for light deburring and finishing which is comparable to the density of an 8-9 unitized wheel and a Smooth Touch wheel which is equal to a 6-7 density unitized wheel.

Rex-Cut® Type 1 Abrasive Wheels are priced according to size, abrasive grain, bond, and quantity.  Samples and pricing are available upon request. Cotton-Fiber lasts up to 10 times longer than unitized, claims the firm.

A full line of cotton fiber mounted points that are ideally suited for EOAT (end-of-arm-tooling) in automated metal deburring and finishing applications is also available from Rex-Cut Products. Rex-Cut® Mounted Points are made with multiple layers of non-woven cotton fiber and either aluminum oxide or silicon carbide abrasive grains that are pressed and bonded into standard A, B & W-shapes. Ideal for EOAT in robotic finishing operations, they reveal fresh abrasives as they deburr and finish in one step and can be made in custom shapes to match OEM requirements.

Suitable for stainless steel, titanium, Inconel®, exotics, and aluminum, Rex-Cut Cotton Fiber Mounted Points are offered in hard and soft bonds and can be produced in custom shapes and sizes for finishing slots, seams, internal cavities and other applications without changing part geometry. An 80 Grit soft bond is capable of leaving a 16-20 RMS finish on stainless steel. Cotton Fiber Mounted Points for EOAT are often developed to match OEM application and significantly outlast conventional mounted points, claims the firm. They are priced according to shape, size, and quantity. www.rexcut.com