AUTOMATION IN OVERLAY PROCESS

Abstract

In a competitive environment, the industries continuously need to improve their production techniques and quality to achieve shortest lead time. Assembly cycle time which majorly affects the lead time of the product, also affects productivity, worker satisfaction and capacity of industry. In manufacturing of pressure vessel, pipes and elbows, welding is primary process by which different parts are joined to each other. Mostly carbon steel material is used for manufacturing of pipes. Pipes constantly contact with water / fluid / gases. Carbon steel is corrosive material so that it cannot be directly used. On the other hand, stainless steel is non-corrosive material, so it is used for manufacturing. Stainless steel is costlier as compared to carbon steel. To overcome this situation overlay welding technique is developed. In overlay welding pipes made from carbon steel and thin layer of the stainless-steel material is welded inside surface of the pipes. Weld productivity and quality depends on welding position (1G, 2G, and 3G etc.). Current work discusses the Vertical and Tilting arrangement setup for weld overlay of elbow inside surface with GTAW / TIG process. Due to combination of two different function of single setup so the capital investment will decrease as well as space requirement for setup will be decreased. In the first stage of design various proposed solutions or conceptual design are discussed considering different parameters like rotation of work piece, welding position (1G or 2G). From different proposed design of overlay machine setup, one which gives better performance is selected for overlay welding machine. With the help of automation, it has been seen that more production with more accuracy can be achieve. It makes a tilting arrangement (Vertical overlay) for doing welding of the elbow, nozzle on it. This arrangements will be Fully Automatic 5-axis with turntable.