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Environmental concerns are driving the development of the welding processes and applications by

This article discusses the development of welding processes and applications driven by environmental concerns, focusing on reducing CO2 and NOX emissions, noise levels, and improving sustainability objectives in aeronautics, space, shipyards, and automotive industries. It explores the impact of weldings on the environment and highlights the shift towards more environmentally conscious practices. Various R&D programs and case studies are presented to showcase sustainable welding innovations in different sectors. The text discusses the influence of environmental awareness on demand, innovation, end-of-life phase, and supply in industries. Examples such as Al-consumption in the car industry and ULSAB AVC consortium demonstrate advancements in sustainable welding practices. Finally, it touches on projects like the EU-shipyard project and Wind Power Stations, emphasizing the importance of sustainable welding for a greener future.

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Environmental concerns are driving the development of the welding processes and applications by

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  1. Environmental concerns are driving the development of the welding processes and applications by Bertil Pekkari ESAB AB, Box 8004, 402 77 Göteborg, Sweden bertil.pekkari@esab.se

  2. ·Reduction of CO2 by 50 % per passenger-km in the long term ·Reduction of NOX-gases by 20 % (80 %) in the short (long) term ·Reduction of external noise by 4-5 dB (10 dB) in the short (long) term Sustainability objectives fordifferent R&D programmesAeronautics & Space

  3. ·Lower weight 40 % by use of high strength steel (690 grade steel) ·Lower running cost 30 % ·Reduction of CO2 emissions 15 % ·Lower manufacturing cost 20 % Sustainability objectives for different R&D programmesShipyards

  4. ·Significantly improved fuel efficiency: 3,2 – 4,5 litre/100km ·Lower CO2 emission: 86 – 108 g/km ·Low environmental impact - 80-85 % recyclable by 2006 Sustainability objectives for different R&D programmesAutomotive

  5. Typical user priorities and opinions today • Functionality and service are the major concerns when buying welding equipment and consumables • Welding is primarly considered a ”health and safety” problem • Welding has a small environmental aspect compared to other manufacturing processes • Packaging is a cause of operational problems • Many have a low degree of environmental awareness JWRI Anniversary 2003-03-14 Bertil Pekkari

  6. Environmentally adapted companies Environmentally conscious companies Law optimizing companies Authority abiding companies Passive companies Increased environmental awareness Companies segregated according to their environmental awareness

  7. INFLUENCE • ON DEMAND • Environmental statements • Eco-labels (ISO type I) • Eco-declarations (ISO type II) • Eco-declarations (ISO type III) • Purchasing and public procurement • Price elements • Product panels • INFLUENCE • ON INNOVATION • Research and development • Life-cycle assessment • Eco-design guidelines • Environmental aspects in product standards • Education and training • Transfer of knowledge • INFLUENCE ON THE • END-OF-LIFE PHASE • Market-driven recycling • Take-back systems • INFLUENCE ON SUPPLY • Codes of conduct • Long-term agreements • Environmental management systems • Supply chain management

  8. Al-consumption in the car industry

  9. Audi A2 completely in Al • YAG- laser welding 30 meter, P = 4 kW, v =5,5 m/min • MIG-welding 20 meter, v = 0,7 m/min • Selfpiercing riveting 1800 st • Number of robots 220 st • Degree of mechanisation 80 %

  10. ULSAB AVC Advanced Vehicle Concepts R&D consortium with 33 steel companies e.g. POSCO, Kobe Steel, Nippon Steel, Corus

  11. ULSABlight weight body 25 % weight reduction Improved crash safety Tailored blanks and tube structures used • Manufacturing processes • Traditional stamping • Hydroforming • Spotwelding • Laserwelding 90 % AHSS Economically feasible

  12. Effective design concepts in AHSS -200 kg lighter High crash safety – meeting year 2004 requirement Low fuel consumption: 3,2/4,5 litre/100 km Low environmental impact: CO2= 86-108 g/km and recyclable Affordable manufacturing costs Achieved resultsULSAB - AVC

  13. Lower weight 40 % - High strength steel (690 grade steel) Lower running cost 30 % Reduction of CO2-emission 15 % Lower manufacturing cost 20 % DEMANDS Development of joining processes Change of maintenance procedures Improvement of corrosion processes EU-shipyard projectObjectives

  14. Annual output 28,7 million GT

  15. Robot welding gantry Robots use growing in shipyards

  16. Tandem MAG welding of Panel Stiffeners Welding data Electrodes = 1.2 mmThroat thickness = 4.5 mmStickout = 20 mm

  17. DockWelder • EU project • Demonstration of flexible modular automation applied to ship building • Automatic welding of ship sections in the dock • Participants • Amrose Denmark • APS Germany • Cybenetix France • Lindö Shipyard Denmark • Ficantieri Shipyard Italy • Inst. For Production Technoolgy

  18. Ship panels 20x16 m welded with the hybrid laser MIG process 4 CO2-laser 12 kW

  19. YAG-laser installation(SHIPYAG planned EU-Project) • Potential participants: • Meyer Shipyard Germany • HDW Shipyard Germany • Chantier de l´Atlantique France • ESAB • Det Norska Veritas Norway • Astilleros Shipyard Spain • Odense Shipyard Denmark • Ficantieri Shipyard Italy • Research centres in the Netherlands, Italy, Germany etc

  20. Wind Power Stations

  21. Typical size and shape of the plate before plate rolling 10 mm 3,25° ~8 m

  22. Typical joint preparation 30° 30° 30° 30° 30°

  23. Ordinary carbon-manganese: Yield strength 350-420 MPa. Impact requirement: 47J at -40ºC Flux: OK Flux 10.71 Wire: OK Autrod 12.20, 12.22, 12.24. Diameter 2.5, 3.0, 4.0 mm. Cored wire: OK Tubrod 15.00S. CTOD-tested with OK Flux 10.71 Tack welding: OK Autrod 12.51. Diameter 1.2-1.6 mm. Plate thickness: 8-50 mm. Filler material consumption: 1.5 tons weld metal/MW Materials

  24. The joint for the foundation flange to the first shell

  25. t=45 mm, X-joint 17 18 19 3 2 1 20 21 22 23 Some welding data

  26. Tapering between shells of different thickness Recommended tapering for reducing the stress concentration at the weld joint. 70° 15° 4

  27. Manipulator with clamping device for the flange

  28. Cu canister for nuclear waste • Length 4830 mm • Diameter 1050 mm • Thickness Cu-lid to be welded 50 mm • Weight 27 tonnes

  29. Deep repository for spent nuclear waste 500 metres deep

  30. Cu-weld made by ”Reduced Pressure” Electron Beam Welding • Pressure 5 mbar • Voltage 200 kV • Amperage 300 mA • Shielding gas He • Beam Diameter 4 mm

  31. Welding of a lid to Cu-canister for nuclear waste with = 50mm in Sweden A transverse metallurgical section through 50 mm thick Cu stir weld The early stages of a Cu canister weld. Note that the tool is operating at read heat A 120 degree weld segment

  32. FSW plant for welding Cu-canister for nuclear waste

  33. 1. Productivity 2.Quality 3.Flexibility 4.Working environment 5.Sustainability        - Reduction of energy consumption        - Use of renewable energy sources        - Safe disposal of waste         - Safety ConclusionsDriving forces behind the development of welding processes and applications

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