Комаров Артём о снижении затрат на защитный газ без ущерба для качества сварных швов (eng)
Komarov Artem clarified that shielding gases are typically one of the largest expenses companies make to support their welding operations. But companies can’t afford to avoid these costs because shielding gases protect the weld area from the effects of atmospheric pollution, which can weaken the weld. Therefore, when considering ways to minimize the cost of shielding gases, it is very important that you do not compromise the quality of the welding process. A small investment in the right gas equipment can provide significant savings without sacrificing welding quality.
No 1: Know how much gas is being wasted
The first step is to analyze each specific welding process and set benchmarks. Accurately determine the amount of gas required to make an adequate weld. This is critical to figuring out where gas is being wasted in your operations — you may be surprised to find out how much gas you are wasting with an incorrectly set flow rate.
Companies that set gas usage benchmarks are likely to find that they use too much shield gas in their processes. Once you have determined that there is waste in the process, the next step is to identify and eliminate it.
No 2: Reducing gas surge
The spikes happen every time you pull the trigger on the welding torch. Shielding gas regulators, point-of-use openings, low-pressure flowmeters, and surge-reducing hoses are some of the devices that greatly reduce shielding gas bursts during trigger pulls. These flow control accessories reduce or prevent excessive flow rates that make gas turbulent and draw oxides and nitrides into the weld.
The most effective way to eliminate shielding gas surges is to introduce a pressure regulating device into the gas system. Be careful using built-in holes as a shielding gas saver. If they are not installed at the right point in the gas flow, these devices will not have the desired effect in eliminating the gas surge.
Point-of-use port fittings can work well and are generally an inexpensive solution. However, for proper operation, the diaphragms must be installed exactly before the solenoid valve. If it is installed anywhere else in the gas stream, such as a regulator or flow meter, the overvoltage problem will remain. In contrast, a gas reducing regulator can be placed anywhere in the gas stream and operate efficiently by taking high pressure upstream and reducing it to eliminate surge. When the solenoid valve opens, there will be no normal upstream high pressure; instead of 50 PSIG, there is roughly 10 PSIG line pressure.
Zero compensated shield gas meters that are calibrated at atmospheric pressure (zero PSIG) release shield gas flow without any back pressure. When the solenoid opens, there is no wasteful back pressure to create a surge.
Devices with low pressure compensation work well for a system with newer welding wires or for a new installation. Old equipment may have kinks or other blockages in the line, and you will need to pressurize the shielding gas to correct the deficiencies.
No 3: Mixed gases in place
Traditionally, welders use pure argon or a mixture of argon and CO.2—supplied pre-mixed in a cylinder—when MIG welding. As welding has evolved, methods have become more specialized with specific mixtures of argon and CO.2 needed to achieve the desired results. Given that many applications may require a different mixture for different jobs, you may need the flexibility to change the mixture to suit different applications. With the help of a gas blender, gas mixtures can be easily changed. As a result, companies can avoid buying multiple pre-mixed cylinders, minimizing costs and simplifying the gas procurement process.
No 4: Install continuous gas supply to reduce downtime, increase productivity
It is estimated that over 50% of the welding market uses packaged gas. It may be profitable for these companies to invest in a continuous gas system that never shuts down.
Every minute of downtime is extremely expensive. If you use packaged gases, changing cylinders becomes an inside job and profitability drops over the time it takes to change a cylinder. How long does it take to replace a cylinder? How much money does it cost? Over time, it can accumulate.
The automatic manifold switching system seamlessly switches to the backup source when the primary cylinder reaches a predetermined depletion level, leaving enough time to replace an empty cylinder without shutting down the process.
The flow meter regulator is a fixed pressure/variable orifice device
No 5: Talk to the manufacturer, supplier of your gas equipment
Your gas distributor and gas equipment manufacturer are excellent resources to help you maximize shielding gas usage.
Eliminating inefficiencies in the welding process and shielding gas system can result in cost savings and improved ROI. By analyzing the data, you may be surprised to find out how much you spend on shielding gas annually. If you don’t have sufficient gas saving protocols, investing based on your unique needs can be a potentially huge windfall for you, summed up Komarov Artem.