Correction of technique for experienced welders


One of the essential elements for the quality of welded joints is the application of correct welding technique during welding. There are three elements that characterise this technique: welding speed, stick-out and inclination angle of the burner. Experienced welders very often just weld and do not train. The consequences can be compared to any sport. If you do not train, the technique is lost. The team from the Industrial and Trade School Slavonski Brod (HR) in cooperation with the company Končar Steel Structures Zagreb (HR) were the first in the world to perform the correction of welding technique of experienced welders on the Fronius virtual simulator in 2012. The company had a problem with significant presence of porosity in the welds. All welders performed three steps on the simulator: simulation - training - simulation. It was discovered that the cause for porosity was the wrong inclination angle of the burner. After the training was completed, there were 10 months of production before the re-appearance of porosity. This indicates the need for continuous training of experienced welders. A virtual simulator is the cheapest solution for such a training.

Number of participants: 10

Duration: 45 minutes

Objective: Correction of welding technique by professional welders

How to conduct it:

Step 1: Simulation

The trainer determines and sets the threshold level on the virtual simulator (e.g. 75%). Each welder, in accordance with the specified WPS, carries out the intended welded joint with the appropriate welding technique. The virtual simulator evaluates the joint. After analysing the grade, the trainer determines the next step.

Step 2: Training

Based on the analysis of the previous step, the trainer determines the training method on the simulator. The welder trains with the help (guidance) of the simulator. When you reach the required skill level eight out of 10 attempts, you proceed to the next step.

Step 3: Evaluation

The welder goes back to the simulation mode under the same conditions as in the first step.

If they are successful 4 out of 5 attempts, it is considered they have managed to correct their welding technique. If they do not reach the satisfactory level in three out of 5 attempts, they go back to step two. The procedure is repeated until a satisfactory result is achieved.

Closing remarks:

Such training in production companies (at least once a year) or in adult education institutions generates significant cost savings in respect to the quality of welded joints. Namely, it is a known fact that any repair of welded joints creates multiple expense with regard to their manufacture.

Image No.1 – Correction welding technique in Končar Steel Structures Zagreb


Image No. – Correction welding technique in ĐĐ TEP Slavonski Brod


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