SPIRAL WELDING – FLEETFUSION TECHNOLOGY
Spiral Welding Service - Using Fleetfusion Technology
FleetFusion technology is primarily used in the construction of large-diameter pipes, tanks, and pressure vessels, as well as for the repair of existing structures.
FleetFusion welding service is a specialized welding service offered by NESL that utilizes the FleetFusion technology developed by Lincoln Electric. This service is designed for the construction of large-diameter pipes, tanks, and pressure vessels, as well as for the repair of existing structures.
The FleetFusion technology used in this service combines advanced spiral welding equipment, software, and robotics to control the welding process and produce high-quality, consistent welds. The technology allows for the precise control of the welding parameters, such as travel speed, wire feed rate, and welding power, which ensures that the filler metal is added to the joint in a consistent and controlled manner. Additionally, it also allows for the automation of the process, so that less skilled operators can produce consistent results.
One of the main advantages of FleetFusion spiral welding is that it can significantly increase productivity and efficiency in the spiral welding process. The automation of the process allows for faster welding speeds and the ability to weld multiple passes at once, resulting in a faster overall production time. Additionally, the technology also helps to reduce the amount of scrap and rework, which results in cost savings for the company.
FleetFusion welding is particularly useful for use in the oil and gas industry, as well as in the construction of pipelines, chemical plants, and power plants. The service is provided by trained and experienced welders who are skilled in the use of FleetFusion technology and have the necessary certifications.
wide range of application
REPAIR, CLADDING AND BUILDING UP OF:
Rollers Plungers Shafts and axles Pistons and hydraulic cylinders Stocks Propeller shafts Bearing seating and liners Imported components Other cylindrical components
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Advantages of Fleetfusion Technology
High repair quality with metallurgical bondage.
Nonporous and no limitation on deposit thickness.
Low heat input and shallow depth of heat affected zone.
Rebuilding between similar and also between dissimilar materials with extensive range of deposit materials.
Improved properties.
Minimum distortion.
Quick turnaround.
The Process
The procedure starts with setting up the workpiece, which entails cleaning and prepping the surfaces that will be welded. After that, it is aligned and clamped.
The welding device, which is outfitted with FleetFusion technology, is then calibrated and set up. In order to make sure that the filler metal is added to the joint in a reliable and controlled manner, this entails modifying the welding parameters, such as travel speed, wire feed rate, and welding power.
The welding procedure can start after the machine has been calibrated and set up. A robotic arm on the machine directs the filler metal along the joint, while software regulates the welding conditions to produce a consistent, high-quality weld. The software continuously monitors the procedure and modifies the welding parameters as necessary to produce a high-quality weld. As it advances along the joint, the robotic arm constantly welds a spiral and adds filler metal.
After the welding is finished, the workpiece is examined to make sure the weld complies with the necessary requirements. Any flaws or problems are fixed as needed.
After cleaning the workpiece, the FleetFusion welding procedure is finished.
Overall, FleetFusion welding process is an automated process that uses advanced welding equipment, software, and robotics to control the welding process and produce high-quality, consistent welds. The process ensures that the filler metal is added to the joint in a consistent and controlled manner, and continuously monitors the weld to ensure that it meets the required specifications.
Application of Spiral Welding
FleetFusion welding technology is applied in various industries and structures that require consistent and high-quality welds, particularly in the construction of large-diameter pipes, tanks, and pressure vessels, as well as for the repair of existing structures.
Pipeline construction
FleetFusion welding is used in the construction of pipelines for the transport of oil, gas, and water. The technology is particularly useful for the construction of long-distance pipelines, as it allows for faster welding speeds and the ability to weld multiple passes at once, resulting in a faster overall production time.
Tank and pressure vessel construction
FleetFusion welding is used in the construction of large tanks and pressure vessels, such as storage tanks for oil and gas, as well as for chemical storage tanks. The technology ensures that the welds are of high quality and consistent, which is important for the safety and integrity of these structures.
Repair of existing structures
FleetFusion welding is also used for the repair of existing structures, such as pipelines, tanks, and pressure vessels. The technology allows for the precise control of the welding parameters, which ensures that the repair is of high quality and consistent.
Offshore construction
FleetFusion technology is also used in offshore construction, such as the construction of oil platforms, as the precision and automation of the process allows for fast and reliable welds in challenging environments.
Industrial Fabrication
FleetFusion technology is used in the industrial fabrication of large and complex structures like boilers, heat exchangers, and other pressure vessels.
Watch the fleetfusion welding process in this video
- Lower heat input yields controlled microstructure and shallow heat affected zone.
- 1.5 to 5 mm thick weld layer is continuously applied with low heat input and minimum material wastage.
- Weld profile allows achievement of a clean surface with 0.25 mm post weld machining depth of cut which gives high-quality weld with good fusion, controlled penetration, no porosity and minimum dilution.
- Excellent transfer of volatile or readily oxidisable elements across the arc.
- Close to 100% of wire content can be achieved.
- Thickness of deposit can vary without increase in thermally disturbed zone.
Improved properties.
Minimum distortion.
Quick turnaround.
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